2003-2007 Honda Aquatrax F-12 ARX1200 Service & Repair Manual

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HOW TO USE THIS MANUAL TNt IWYice manual deaetbs Ihto ~ procedufes lor !he ARXl200T2 Md ARX 1200N2. R*Jw !he t.tanenance ScheduIIo (Section .) r.commendalions to ..ure It\a! !he pt<SOnIIl WI1l8";:IlI11. • In peal< optrallng condition. Pe~iog the fllSl IICheduIed maintenance Is WI)' ImportanL It a:JmP"II&ate& lot the Initial wear thaI occurs oomlllhe break -In period. S«tionII " 4 and S IIPPfV 10 me whole pGfSOnal waterer,lt Sttctiofl 3 ~tn procedu_ lor .....-.cMIWlstallation 01 componentslhat may be I1IQUIf8d 10 pertarm MrVice descrtled In the ~ MCtJons. s.c.ion 61hrough 19 deserIbe pans oIlt1e per$OnIII walercratt, ~ ~ to IDeation. FIf'Id lhIIl*.1ion you want Ot\ this p6g6, then turn 10 the ta~ of contents on !he first page oIlhe section Mo~ MCtiof1s SIan with an aasembly Of system IHlJltration, seNicu InIoImatkln and trouIMshooIlng bI the SIlCIlon. The tubaequen! pages gIW detdtd procedure. " )IOU are no! IamiIIIIr with IhiI moIt>reycIe, read Technical Features In S."",,, n )IOU don' know the .ouroe 01 the \roUbIIf, 00 10 S&ct!Dn 21 T~. Your safely, and 1M nlety 04 0Ih9f11, is very Imponanl To help you maI<e Inbmled decisions wa have provided salllly messa1i/98 and other information Ihrooghoul this manual. 01 courH, ~ • nol paICIicaI Of poujbIe to warn you abcxJ1 •• !he hazards associated wtIh S8tYIc;rIg thiS vehic:Ie. 'ItIu rn.ISI use '/OUI' own good ~l 'ttIu .... fnd important talett W!fom1abOr) In • "'neIY 01 forms irIcIu!ing: • S.laty L.abelll- on the l'8hicle • safely Menage. - preoedGd by II safety .len lymboI If; and one o1lhree signal worm, DANGER, WARNING, or CAUTION. ThetwislgrIal words mean: You Wlu.. be KILLED Of SERIOUSLY !'Il l 1±] nS'i;' HURT W you don~ IoI\OW ..... !I'I.K:tlor .. 'tbu CAN be KILLED Of SERIOUSlY HURT m.,.Wf! ! £lfl • you don't bIIowNuucuons. You CAN be HURT 11 you don~ follow r! Wlnl' J f' ""I\ruCtion •. • IfI5tructiooa - how to 5&rVIce this YIIhicie correctly Ind lately. ,.. you lead this manual, you wi find inlormauon tIlIt '- preceded by e 0i0'Jll::(} symbol. The pI.II"J)(Ite 01 INs ITI8IIIgII '- to help preYMt dImIpe to YOUI YIIhic:Ie. 0!Mr ~Ity, or the erMronment. w z a z w ~ o CD ..J < o ~ ..J W CONTENTS GENERAL INFORMATION TECHNICAL FEATURE HULUHOOD/BODY PANELS MAINTENANCE FLUSHING AND STORAGE LUBRICATION SYSTEM COOLING SYSTEM ====== ENGINE REMOVAL/INSTALLATION CYLINDER HEADNALVE ALTERNATORISTARTER CLUTCH CRANKSHAFTIBALANCER (ARX1200T2)IPISTON PROPULSION SYSTEM STEERING/REVERSE SYSTEM BATTERY/CHARGING SYSTEM IGNITION SYSTEM ELECTRIC STARTER METERISWITCHES WIRING DIAGRAM TROUBLESHOOTING INDEX

SYMBOLS The symbols used throughout this manual show specific service procedures. If supplementary Information is requ ired pertaini ng to these symbol s, it would be explaIned specifically In the text without the use of the symbols. fI Replace the part(s) with new one(5) before assembly. 'I Use the recommended engine oit, unless otherwise specified. 7! Use molybdenum oil solution (mixture of engine oil and molybdenum grease in a ratio of 1 : 1) . . - Use multi-purpose grease (lithium based mutti-purpose grease NLGI #2 or equivalent). ~ Use water resistant grease #0 (Urea based multi-purpose grease NLGI #0 Of equivalent) Example: EXCEUTE EPO manufactured by KYODO YUSHI . Japan). ~ Use water resistant grease #2 (Urea based multi·purpose grease NLGI #2 or equivalent) Example: EXCEUTE EP2 manufactured by KYODO YUSHI , Japan). Use water resistant molybdenum disulfide grease (containing more than 3 "10 molybdenum disulfide, NLGI ...-'i'iiiJI #2 or equivalent) . Example: UNIUTE M No.2 manufactured by KYODO YUSHI, Japan Use molybdenum disulfide grease (containing more than 3"10 molybdenum disulfide, NlGI #2 or equivalent). ~ Example: Molykoteill BR·2 plus manufactured by Dow Corning, U.S.A. Multi-purpose M·2 manufactured by Mitsubishl Oil, Japan Use molybdenum disulfide paste (containing more than 40"10 molybdenum disulfide, NlGI #2 or equivalent). Example: Molykoteill G-n Paste manufactured by Dow Corning, U.S.A. .AWl Honda Moly 60 (U.S.A. only) Rocol ASP manufactured by Rocol Umited, U.K. Rocol Paste manufactured by Sumico lubricant , Japan .AiSlII Use silicone grease. ') MI Apply a locking agent. Use a medium strength locking agent unless otherwise specified . .,('1mI! Apply sealant (engine). 411 Apply silicone sealant (SHIN-ETSU KE45T or equivalent).

1. GENERAL INFORMATION SERVICE RULES ......................................... '-2 MODEL IDENTIFiCATION··· ·· ····················· · '-2 GENERAL SPECIFICATIONS: ARX'200T2 '-5 GENERAL SPECIFICATIONS: ARX,200N2 '-6 LUBRICATION SYSTEM SPECIFICATIONS'-7 FUEL SYSTEM (Programmed Fuel Injection) SPECiFiCATiONS ··· ·· ··································· '-7 CYLINDER HEADIVALVE SPECiFiCATIONS ·· ··············· ·· ···· ······· ·· ·· ··· ·· · '-8 ALTERNATOR/STARTER CLUTCH SPECiFiCATIONS ························· ·· ··· ········· · '-8 CRANKSHAFT/BALANCER (ARX'200T2)/ PISTON SPECIFICATIONS ........................ . '-9 PROPULSION SYSTEM SPECIFICATIONS'-'O BATTERY/CHARGING SYSTEM SPECIFICATIONS ............................... ...... '- '0 IGNITION SYSTEM SPECiFiCATiONS ···· '-'0 ELECTRIC STARTER SPECIFICATIONS ·· '- '0 METER/SWITCHES SPECiFiCATiONS···· '-'0 STANDARD TORQUE VALUES ······· ·· ·· .... ,-" ENGINE & BODY TORQUE VALUES ... .. . ,-" LUBRICATION & SEAL POINTS .............. '-'6 CABLE & HARNESS ROUTING: ARX'200T2 ............................................... '-20 CABLE & HARNESS ROUTING: ARX'200N2 .............................................. '-38 EMISSION CONTROL SYSTEMS ............ ' -54 EMISSION CONTROL INFORMATION LABEL .................... · .......... · .. · .... · .... ·· .......... '-55 1-1

GENERAL INFORMATION SERVICE RULES 1. Use genuine Honda or Honda-recommended parts and lub ricants or their equivalents. Parts that do not meet Honda's design specifications may cause damage to the watercraft. 2. Use the special tools designed for this product to avoid damage and incorrect assembly. 3. Use only metric tools when servicing the watercraft. Metric bolts, nuts and screws are not interchangeable with English fasteners. 4. Install new gaskets, O-rings, cotter pins. and lock plates when reassembling. 5. When tightening bolts or nut s, begin with the larger diameter or inner bolt first. Then tighten to the specified torque diagonally in incremental steps unless 8 particular sequence is specified. 6. Clean parts in cleaning solve nt upon disassembly. lubri cate any slid ing surfaces before reassembly. 7. After reassembly, check all parts for proper installation and operation. 8. Rou te all electrical wires as shown in the Cable and Harness Routing (page 1-20 or 1-38). MODEL IDENTIFICATION This manual covers two types of ARX1200 models: • T2: Turbocharaer model • N2: Standard (no turbocharger) Be sure to refer to the procedure that pertains to the appropriate version of the ARX1200. 1-2

GENERAL INFORMATION The engine serial number and hull identification number are used to register the watercraft. They are unique numbers that distinguish each watercraft from other similar models . If the watercraft is ever stolen these numbers will help identify it. The owner should keep a record of these numbers in a place other than the watercraft. HULL NUMBER IDENTIFICATION OUS-HPS XXXXF1~ O xxx ManufaC1urersI.O. Hull Serial Number (Model type code) Month & Year of Certification Model Year of Watercraft Month code: A '" January, B = February·····L = December Year of certification: 02 '" 2002, 03= 2003; etc. The hull ident ification numbers are located on the rear of the hull. The engine serial number is located on the upper side of the oil tank. The throttle body identification number is stamped on the lower side of the throttle body. HULL IDENTIFICATION NUMBER THROTTLE IDENTIFICATION NUMBER 1-3

GENERAL INFORMATION The color label is attached on the inside of the fr on t hood. When order- ing color-coded parts, always specify the designated col or code. 1-4 • • •

GENERAL INFORMATION GENERAL SPECIFICATIONS: ARX1200T2 SYSTEM Overall Overall height Dry weight Rider capacity I ou t put Maximum torque Maximum fuel consumpt ion Cr uising range at full throttle Fuel tan k capacity Fuel tank reserve type Cylinder arrangement Bore and stroke Displacement Comp ression ratio Intake system Valve train Intake vaive opens closes Exhaust valve ope ns closes Lubrication system Oil pump type Cool ing system dry weight at 1 mm l ift at 1 mm lift at 1 mm lift at 1 mm lift Impeller rotation (viewed from rear) Transmission Steering nozzle angle (horizontal) Steering nozzle trim angle Impeller type Impeller diameter Minimum water level for jet pump Bilge pump type SW03E mm i 1,154mm (45.4 in) 1,036 mm (40.S i n) 338.4 kg (746.0 lbs) 2 pe", on at rpm 191.8 N-m (1S.6 kgf.m) at 5,500 rpm 52.4 liters (13.84 US gal, 11.53 Imp gall/ hour 1.2 hour 63 liters (16.6 US gal, 13.Slmp gal) 12.9lilers (3.41 US I I 4 cylinders in-line, l ongitudinal installed 79.0 X 63.0 mm (3.11 X 2.48 in) 1, 235 cm 3 (75.3 cu- in) 8.5: 1 Turbocharged with intercooler Chain driven, DDHC 10° BTDC 20° ABDC 25° BBDC 5° ATDC Dry su mp Trochoid Water cooled 94.5 kg (208.3 Ibs) 1- 3-4-2 stage, ill Counterclockwise Direct drive fr om engine 23" Upper 0" - Lower 8" (Variable) Stainless steel, 3-blades 154.6 mrn (6.09 in) 90 cm (35 in) Automatic siphon type rru;QFRTCA"L--~~:~~system ;C------------+-;': Electric st~a~rt~e~ '~m ~oITt~o~,di!liU""""""""'''''"'-1 Charging system Triple phase outp ut alterna tor Regulator/rect ifier SeA shorted, triple phase fu l l-wave rectifica- tion 1-5

GENERAL INFORMATION GENERAL SPECIFICATIONS: ARX1200N2 1-6 Overall width Overall height Dry weight Rider capacity Maximum torque Maximum fuel consumption Cruising range at full throttle Fuel tank capacity I I I Cyllncl., arrangement Bore and stroke Displacement Compression ratio Intake system Valve train Intake valve opens closes Exhaust valve opens closes lubrication system Oil pump type Cooling system Engine weight bore pump at 1 mm lift at 1 mm lift at 1 mm lift at 1 mm lift Impeller rotati on (viewed from rearl Tran smission Steering noule angle (horizontal) Steering nozzle trim angle Impeller type Impeller diameter Minimum water level for jet pump Bilge pump type i system Starting system Charging system Regu I ato rlrect ifier mm 1,154mm (45.4 in) 1,036 mm (40.8 in) 324.6 kg (71S.B lbs) 2 person 153.5 'pm 125.5 N·m (12.8 at 7,000 rpm 35 liters (9.2 US gal. 7.7 Imp gal)n-tour 1.8 hour 631;lers (16.6 US 4 cylinders in-line, longitudinal installed 79.0 X 63.0 mm (3.11 X 2. 48 in) 1,235 em] 175.3 cu-in) 11 : 1 Normal aspiration Chain driven, DOHe 10 0 BTDC 30° ABDC 30° BBDC 10° AIDC Dry sump Trochoid Water cooled 80 kg (176Ibs) Direct dri ve from engine 23' Upper 0 0 - Lower eo (Variable) Stainless steel, 3-blades 154.6 mm (6.09 in) 90 em (35 in) Automatic type Electric starter motor phase outpu t alternator shorted, triple phase full-wave rectifica-

2003-2007 Honda Aquatrax F-12 ARX1200 Service & Repair Manual

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