Yamaha SR230 2004 Service Manual

Service ManualSR2302004

3. Avoid skin contact with lubricants; do not,for example, place a soiled wiping-rag inone’s pocket.4. Hands, and any other part of the bodywhich have

5-5POWER UNIT x5POWR

5-6POWER UNIT5POWRCAUTION:

5-7POWER UNIT x5POWR

5-8POWER UNIT5POWRUNIT.”

5-9POWER UNIT x5POWREXHAUST PIPE 3 (Cont’d.)

5-10POWER UNIT5POWREXHAUST PIPE 3 (Cont’d.)

5-11POWER UNIT x5POWRPIPE 3.”MOTOR.”

5-12POWER UNIT5POWREXHAUST PIPES 1 AND 2 (Cont’d.)

5-13POWER UNIT x5POWRAND 2.”

5-14POWER UNIT5POWREXHAUST MANIFOLD (Cont’d.)

DISASSEMBLY AND ASSEMBLY1. Clean parts with solvent and compressed-air on disassembling them.2. Oil the contact surfaces of moving parts onassembly.3.

5-15POWER UNIT x5POWRUNIT.”“THERMOSTAT.”

5-16POWER UNIT5POWROIL TANK (Cont’d.)

5-17POWER UNIT x5POWROIL TANK (Cont’d.)

5-18POWER UNIT5POWROIL TANK (Cont’d.)

5-19POWER UNIT x5POWROIL TANK (Cont’d.)

5-20POWER UNIT5POWROIL TANK (Cont’d.)

5-21POWER UNIT x5POWROIL TANK (Cont’d.)

5-22POWER UNIT5POWR

5-23POWER UNIT x5POWR

5-24POWER UNIT5POWR

SPECIAL TOOLSUse of the correct special tools recommendedby Yamaha will aid the work and enable accu-rate assembly and tune-up. Improvisations anduse

5-25POWER UNIT x5POWR

5-26POWER UNIT5POWRTANK.”

5-27POWER UNIT x5POWROIL PUMP (Cont’d.)

5-28POWER UNIT5POWROIL PUMP (Cont’d.)

5-29POWER UNIT x5POWR

5-30POWER UNIT5POWR

5-31POWER UNIT x5POWR

5-32POWER UNIT5POWRMOTOR.”PUMP.”

5-33POWER UNIT x5POWRREDUCTION DRIVE GEAR (Cont’d.)

5-34POWER UNIT5POWRREDUCTION DRIVE GEAR (Cont’d.)

SPECIAL TOOLSFuel Pressure GaugeP/N YB-0676690890-06786Compression Gauge ExtensionP/N 90890-06582Cylinder Gauge SetP/N YU-0301790890-06759Compre

5-35POWER UNIT x5POWRREDUCTION DRIVE GEAR (Cont’d.)

5-36POWER UNIT5POWRREDUCTION DRIVE GEAR (Cont’d.)

5-37POWER UNIT x5POWR

5-38POWER UNIT5POWR

5-39POWER UNIT x5POWRUNIT.”

5-40GENERATOR AND STARTER MOTOR (Cont’d.)POWER UNIT5POWR

5-41GENERATOR AND STARTER MOTOR (Cont’d.)POWER UNIT x5POWR

5-42GENERATOR AND STARTER MOTOR (Cont’d.)POWER UNIT5POWRMake sure not to pinch the pulser coilleads between the washers and projec-tions on the case

5-43GENERATOR AND STARTER MOTOR (Cont’d.)POWER UNIT x5POWR

5-44POWER UNIT5POWR

1-7GENERAL INFORMATIONx1GENINFOSPECIAL TOOLSTest Harness (3 pins)P/N YB-0676990890-06769Vacuum/Pressure Pump Gauge SetP/N YB-35956-A90890-06756Yam

5-45POWER UNIT x5POWR

5-46POWER UNIT5POWRCAUTION:washer. Always replace them with new ones.

5-47POWER UNIT x5POWR

5-48POWER UNIT5POWRCAMSHAFTS (Cont’d.)

5-49POWER UNIT x5POWRCAMSHAFTS (Cont’d.)GEAR.”

5-50POWER UNIT5POWRCAMSHAFTS (Cont’d.)

5-51POWER UNIT x5POWRCAMSHAFTS (Cont’d.)

5-52POWER UNIT5POWR

5-53POWER UNIT x5POWR

5-54POWER UNIT5POWR

1-8GENERAL INFORMATION1GENINFOREMOVAL AND INSTALLATION TOOLS1 Oil Filter WrenchP/N YU-3841190890-014262 Coupler WrenchP/N YW-0655190890-065513 She

5-55POWER UNIT x5POWR

5-56POWER UNIT5POWRCAUTION:

5-57POWER UNIT x5POWR

5-58POWER UNIT5POWR

5-59POWER UNIT x5POWRTighten the cylinder head cover bolts in a criss-cross pattern.

5-60POWER UNIT5POWRUNIT.”PIPE 3.”AND 2.”TANK.”“CAMSHAFTS.”

5-61CYLINDER HEAD (Cont’d.)POWER UNIT x5POWR

5-62POWER UNIT5POWR

5-63POWER UNIT x5POWR

5-64POWER UNIT5POWR

1-9GENERAL INFORMATIONx1GENINFOValve Seat CutterIntakeP/N 90890-06813 (60°)90890-06814 (45°)90890-06815 (30°)ExhaustP/N 90890-06315 (60°)90890-06312 (

5-65POWER UNIT x5POWRHEAD.”

5-66POWER UNIT5POWRVALVES AND VALVE SPRINGS (Cont’d.)

5-67POWER UNIT x5POWR

5-68POWER UNIT5POWR

5-69POWER UNIT x5POWRBefore checking the valve guide, make surethe valve stem diameter is within specifica-tion.

5-70POWER UNIT5POWR

5-71POWER UNIT x5POWR

5-72POWER UNIT5POWR

5-73POWER UNIT x5POWRCAUTION:

5-74POWER UNIT5POWR

GENERAL INFORMATION1GENINFO1-10

5-75POWER UNIT x5POWRCAUTION:

5-76POWER UNIT5POWR

5-77POWER UNIT x5POWRUNIT.”PIPE 3.”AND 2.”MOTOR.”TANK.”MANIFOLD.”

5-78POWER UNIT5POWRCRANCASE (Cont’d.)PUMP.”GEAR.”“CAMSHAFTS.”

5-79POWER UNIT x5POWRCRANCASE (Cont’d.)

5-80POWER UNIT5POWRCRANCASE (Cont’d.)

5-81POWER UNIT x5POWRCRANCASE (Cont’d.)“CRANKSHAFT.”

5-82POWER UNIT5POWRTap on one side of the crankcase with asoft-face hammer. Tap only on rein-forced portions of the crankcase, not onthe crankcase mat

5-83POWER UNIT x5POWR

5-84POWER UNIT5POWR

CHAPTER 2SPECIFICATIONSGENERAL SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1MAINT

5-85POWER UNIT x5POWRCAUTION:

5-86POWER UNIT5POWR

5-87POWER UNIT x5POWR“CRANKCASE.”

5-88POWER UNIT5POWRCONNECTING RODS AND PISTONS (Cont’d.)

5-89POWER UNIT x5POWRCAUTION:

5-90POWER UNIT5POWRpistons:

5-91POWER UNIT x5POWRformula:

5-92POWER UNIT5POWR

5-93POWER UNIT x5POWR

5-94POWER UNIT5POWRCAUTION:

GENERAL SPECIFICATIONSGENERAL SPECIFICATIONSx22-1SPECJet thrust nozzle trim angle Degree +3Impeller pitch Degree Port 17.3 / Stbd. 16.31.72 (5.67 ft)

5-95POWER UNIT x5POWRLubricate the bolt threads and nut seatsinstallation.”removal.”

5-96POWER UNIT5POWR

5-97POWER UNIT x5POWR

5-98POWER UNIT5POWR

5-99POWER UNIT x5POWRprocedure.”CAUTION:

5-100POWER UNIT5POWR“CRANKCASE.”PISTONS.”

5-101POWER UNIT x5POWR

5-102POWER UNIT5POWRCAUTION:

5-103POWER UNIT x5POWR“CRANKCASE.”

5-104POWER UNIT5POWR

PREFACEThis manual has been prepared by Yamaha primarily for use by Yamaha dealers and their trainedmechanics when performing maintenance procedures a

2-2GENERAL SPECIFICATIONS2SPEC

5-105POWER UNIT x5POWRFWD

5-106POWER UNIT5POWRTHERMOSTAT (Cont’d.)FWD

5-107POWER UNIT x5POWRDoes not open at 50~60°C (123~

5-108POWER UNIT5POWRMANIFOLD.”

5-109POWER UNIT x5POWRPRESSURE CONTROL VALVE (Cont’d.)

5-110POWER UNIT5POWRPRESSURE CONTROL VALVE (Cont’d.)

5-111POWER UNIT x5POWRPRESSURE CONTROL VALVE (Cont’d.)

5-112POWER UNIT5POWR

CHAPTER 6JET PUMP UNITINTAKE GRATING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

JET PUMP x66-1JETPUMPINTAKE GRATINGEXPLODED DIAGRAMLT242LT24212345LT242Step Procedure / Part Name Q’ty (ea) Service PointsINTAKE GRATING Follow the l

2-3MAINTENANCE SPECIFICATIONSx2SPEC

6-2JET PUMP6JETPUMPApply clear silicone as shown before installingDuct into hull. Install Duct and torque screws to15Nm (1.5m-kg, 11 ft-lb).FILL GAPS

6-3JET PUMP x6JETPUMPPUMP UNITEXPLODED DIAGRAMStep Procedure / Part Name Q’ty (ea.) Service PointsPUMP UNIT REMOVAL Follow the “Step” order for remova

JET PUMP6JETPUMPStep Procedure / Part Name Q’ty (ea) Service PointsREVERSE GATE AND NOZZLE Follow the “Step” order for removal.DEFLECTOR REMOVAL1 Bolt

6-5JET PUMP x6JETPUMPIMPELLER AND DRIVE SHAFTEXPLODED DIAGRAMStep Procedure / Part Name Q’ty (ea) Service PointsIMPELLER DUCT AND DRIVE Follow the “St

JET PUMP6JETPUMP6-6JET PUMP CLEAN-OUT PORTSEXPLODED DIAGRAMREMOVAL AND INSTALLATION CHARTLT242Step Procedure / Part Name Qty (ea.) Service PointsJET P

JET PUMP x6JETPUMP6-7

JET PUMP6JETPUMP6-8 10 11 2

JET PUMP x6JETPUMP6-9

JET PUMP6JETPUMP6-10

xCHAPTER 7ELECTRICAL SYSTEMELECTRICAL COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1ELE

2-4MAINTENANCE SPECIFICATIONS2SPEC

THERMOSWITCH (EXHAUST) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-31SLANT DETECTION SWITCH . . . . . . . . .

7-1ELECTRICAL SYSTEM x7ELECELECTRICAL COMPONENTSStereoSpeakerRunning Light 23 24 112233445566778899Bow lightFuel pumpsFuel sender 19 22 23

7-2ELECTRICAL SYSTEM7ELECELECTRICAL BOX AND IGNITION COIL BOXEXPLODED DIAGRAM 2Step Procedure / Part Name Qty Service PointsELECTRICAL BOX REMOVA

7-3ELECTRICAL BOX AND IGNITION COIL BOX (Cont’d.)EXPLODED DIAGRAM 2ELECTRICAL SYSTEM x7ELECStep Procedure / Part Name Qty Service Points9 Bolt

7-4ELECTRICAL SYSTEM7ELECELECTRICAL BOX AND IGNITION COIL BOX (Cont’d.)EXPLODED DIAGRAM 2Step Procedure / Part Name Q’ty Service Points17 Gaske

7-5ELECTRICAL SYSTEM x7ELECELECTRICAL BOX AND IGNITION COIL BOX (Cont’d.)EXPLODED DIAGRAM

7-6ELECTRICAL SYSTEM7ELECELECTRICAL BOX AND IGNITION COIL BOX (Cont’d.)EXPLODED DIAGRAM

7-7ELECTRICAL SYSTEM x7ELECELECTRICAL BOX AND IGNITION COIL BOX (Cont’d.)EXPLODED DIAGRAMStep Procedure / Part Name Q’ty Service Points19Tapping sc

7-8ELECTRICAL SYSTEM7ELECELECTRICAL BOX AND IGNITION COIL BOX (Cont’d.)EXPLODED DIAGRAM

7-9ELECTRICAL SYSTEM x7ELECELECTRICAL BOX AND IGNITION COIL BOX (Cont’d.)EXPLODED DIAGRAMHigh tension code

2-5MAINTENANCE SPECIFICATIONSx2SPEC

7-10ELECTRICAL SYSTEM7ELECELECTRICAL BOX AND IGNITION COIL BOX (Cont’d.)

7-11ELECTRICAL SYSTEM x7ELECThroughout this chapter, the digital tester’s partnumber has been omitted. Refer to the followingpart number.“O O” indi

7-12ELECTRICAL SYSTEM7ELEC• When checking the condition of the ignitionsystem, it is vital to know the peak voltage.• Cranking speed is dependant on m

7-13ELECTRICAL SYSTEM x7ELEC• Throughout this chapter, the peak voltageadaptor’s part number has been omitted.Refer to the following part number.tests

7-14ELECTRICAL SYSTEM7ELECIGNITION SYSTEMWIRING DIAGRAMFREEPUSHWBFREEPUSHBrBWBrP/WP/WP/WR/YB/WB/WOB/OP/GRL/RR/Y R/YB/OB/OB/YB/OB/OB/OB/OB/WRBB/OR/YL/R

7-15ELECTRICAL SYSTEM x7ELECIGNITION SYSTEMWIRING DIAGRAMFREEPUSHWBFREEPUSHBrBWBrP/WP/WP/WR/YB/WB/WOB/OP/GRL/RR/Y R/YB/OB/OB/YB/OB/OB/OB/OB/WRBB/OR/YL

7-16ELECTRICAL SYSTEM7ELEC

7-17ELECTRICAL SYSTEM x7ELEC• If there is no spark or the spark is weak, con-tinue with the ignition system test.• If a good spark is obtained, the pr

7-18ELECTRICAL SYSTEM7ELEC

7-19ELECTRICAL SYSTEM x7ELECSYSTEM.”

2-6MAINTENANCE SPECIFICATIONS2SPECPort 17.3 Stbd. 16.3Marine Group 24Dual Purpose 675 CCA100 (12/68.4)

7-20ELECTRICAL SYSTEM7ELECmeasurement.”Lanyard Clip White BlackInstalled O ORemoved O O

7-21ELECTRICAL SYSTEM x7ELEC

7-22ELECTRICAL SYSTEM7ELEC

7-23ELECTRICAL SYSTEM x7ELEC

7-24ELECTRICAL SYSTEM7ELEC

7-25ELECTRICAL SYSTEM x7ELEC

7-26ELECTRICAL SYSTEM7ELEC

7-27ELECTRICAL SYSTEM x7ELECFUEL CONTROL SYSTEMWIRING DIAGRAMThermoswitch (exhaust)Thermoswitch (engine) 6 7 8 9 10 11 12 13 12

7-28ELECTRICAL SYSTEM7ELECFUEL CONTROL SYSTEMWIRING DIAGRAM12 9 10 11 6 7 8 13

7-29ELECTRICAL SYSTEM x7ELEC12VDCPurpleFUEL GAUGE, LOW FUELLED AND WIRING CHECK1. Open the fuel hatch and locate the three wireconnector for the Fuel

2-7MAINTENANCE SPECIFICATIONSx2SPEC

7-30ELECTRICAL SYSTEM7ELEC2. Put the black lead of a voltmeter on theBlack/White wire of the harness. Then usethe red lead of the voltmeter to measure

7-31ELECTRICAL SYSTEM x7ELEC43218765R/Y718R/YL/RBrLYR/Y R/YBR/YR/YYRBrBrBrBrR/BR/BBrRBBR43216R/YR/YRPPORRRRRR1 2 3 4 5 6 7 8 BBB5BrBBB87OFFONSTAR

7-32ELECTRICAL SYSTEM7ELECKEY SWITCH1. Check:• ContinuityOut of specification →→Replace.1. Disconnect switch at harness.2. Turn key to function to be

7-33ELECTRICAL SYSTEM x7ELEC

7-34ELECTRICAL SYSTEM7ELEC

7-35ELECTRICAL SYSTEM x7ELECSTARTER MOTOR (Cont’d.)

7-36ELECTRICAL SYSTEM7ELECSTARTER MOTOR (Cont’d.)

7-37ELECTRICAL SYSTEM x7ELEC

7-38ELECTRICAL SYSTEM7ELEC

7-39ELECTRICAL SYSTEM x7ELEC

2-8MAINTENANCE SPECIFICATIONS2SPECMain (At Battery)Starter (At each engine)B

7-40ELECTRICAL SYSTEM7ELECSYSTEM.”SYSTEM.”SYSTEM.”

7-41ELECTRICAL SYSTEM x7ELECBBBBr BrBrBrELECTRIC BILGE PUMPWIRING DIAGRAMB: BlackBr: Brown

7-42ELECTRICAL SYSTEM7ELEC

7-43ELECTRICAL SYSTEM x7ELECMAIN COMPONENT LOCATIONEXPLODED DIAGRAM12345678910111.Battery2.Fuel Level Sensor3.Bow Light4.Stern Light Connector5.Blower

7-44ELECTRICAL SYSTEM7ELECSWITCH LOCATIONWIRING DIAGRAM123451.Key Switches2.Lanyard Switch3.Neutral Switch4.Hatch Interlock Switches5.Engine Harness #

7-45ELECTRICAL SYSTEM x7ELECMETER PANEL BACK VIEWWIRING DIAGRAMDEUTSCH6 PINPLUG 52506WEDGE 52508SOC 52518STB TACH PWR 2STB TACH 1STB LO OIL 4STB OVERH

7-46ELECTRICAL SYSTEM7ELECELECTRICAL COMPONENTSStep Procedure / Part Name Qty (ea.) Service PointsMETER PANEL DISASSEMBLY Follow the “Step” order for

7-47ELECTRICAL SYSTEM x7ELECSWITCH AND COMPONENTWIRING DIAGRAM1 Circuit Breaker2 Stereo Switch3 Courtesy Light Switch4 Navigation Light Switch5 Bilge

7-48ELECTRICAL SYSTEM7ELEC

7-49ELECTRICAL SYSTEM x7ELEC

2-9MAINTENANCE SPECIFICATIONSx2SPEC1/4-208-3210-24Part To Be Tightened

CHAPTER 8HULL AND DECKENGINE COMPARTMENT LAYOUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1EXPLODED DIAG

GUNWALE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-24EXPLODED DIAGRAM

8-1HULL AND DECK x8HULLDECKENGINE COMPARTMENT LAYOUTEXPLODED DIAGRAM12345671. Engine 5. Battery2. Water Lock 6. Blowers3. Jet Pump 7. Bilge Pump4. Fue

8-2HULL AND DECK 8HULLDECKVENTILATION SYSTEM EXPLODED DIAGRAM

8-3Step Procedure / Part Name Q’ty Service PointsVENTILATION SYSTEM Follow the “Step” order for removal.DISASSEMBLY1 Hose Clamp 11 Snap type2 Screw, O

8-4HULL AND DECK 8HULLDECKCOOLING SYSTEMEXPLODED DIAGRAM282829293027273025

8-5Step Procedure / Part Name Q’ty Service PointsCOOLING SYSTEM ANDWATER LOCK REMOVAL Follow the “Step” order for removal.1 Band, Hose 18 22 Clip 23 H

8-6STEERING SYSTEMEXPLODED DIAGRAMHULL AND DECK 8HULLDECK123413AAASSSS11 12 1 2 3 4 5 6 7 8 9 10 NOTE: See REMO

8-7Step Procedure / Part Name Q’ty Service PointsSTEERING HELM REMOVAL Follow the “Step” order for removal.1 Cover 12 Nut 1 1/2"-13, Nylon lock,

8-8REMOTE CONTROL SYSTEMEXPLODED DIAGRAMHULL AND DECK 8HULLDECK

2-10MAINTENANCE SPECIFICATIONS2SPECTIGHTENING TORQUESPart To Be Tightened

8-9Step Procedure / Part Name Q’ty Service PointsREMOTE CONTROL UNIT Follow the “Step” order for removal.REMOVAL1 Throttle Lever Plugs (red) 2 sets Sc

8-10ENGINE HATCHEXPLODED DIAGRAMHULL AND DECK 8HULLDECK

8-11Step Procedure / Part Name Q’ty Service PointsENGINE HATCH REMOVAL Follow the “Step” order for removal.AND DISASSEMBLY1 Support, Engine Hatch 2Sup

8-12HATCH FITTINGS/BOW COVEREXPLODED DIAGRAMHULL AND DECK 8HULLDECK

8-13Step Procedure / Part Name Q’ty Service PointsBOW LOCKER Follow the “Step”DISASSEMBLY order for removal.1 Screw, Tapping 16 #8 x 5/8”2 Hinge 13 Ha

8-14HULL AND DECK 8HULLDECKSEAT FITTINGSEXPLODED DIAGRAM

8-15HULL AND DECK x8HULLDECKStep Procedure / Part Name Q’ty Service PointsSEAT FITTING DISASSEMBLY Follow the “Step” order for removal.DRIVER’S BUCKET

DECK FITTINGSEXPLODED DIAGRAMHULL AND DECK 8HULLDECK8-16

8-17Step Procedure / Part Name Q’ty Service PointsSTERN LIGHT Follow the “Step” order for removal.1 Stern Light Assembly 12 Lens 13 Bulb 1 ML1004 obta

8-18HULL AND DECK 8HULLDECKDECK FITTINGS (Continued)EXPLODED DIAGRAMStep Procedure / Part Name Q’ty Service PointsTABLE39 Table 1 Optional Accy40 S

2-11MAINTENANCE SPECIFICATIONSx2SPECTIGHTENING TORQUESPart To Be Tightened

8-19REMOVAL AND INSTALLATION CHART (Continued)HULL AND DECK x8HULLDECKStep Procedure / Part Name Q’ty Service PointsBIMINI TOP BRACKETS48 Nut, 10-24

8-20DECK FITTINGS (Continued)EXPLODED DIAGRAMHULL AND DECK 8HULLDECK

8-21HULL AND DECK x8HULLDECKREMOVAL AND INSTALLATION CHART (Continued)Step Procedure / Part Name Q’ty Service PointsWINDSHIELD58 Nut, 10-24 Nylon Loc

8-22THROUGH HULL AND DRAIN FITTINGSEXPLODED DIAGRAMQty 3 for Bilge HoseHULL AND DECK 8HULLDECK

8-23Step Procedure / Part Name Q’ty Service PointsTHROUGH HULL AND DRAIN Follow the “Step” order for removal.FITTINGS1 Drain Plug 1 Apply silicone to

8-24GUNWALEEXPLODED DIAGRAM12345Step Procedure / Part Name Q’ty Service PointsGUNWALE Follow the “Step” order for removal.1 Screw, 310 x 2” POH 2 Tor

8-25HULL AND DECK x8HULLDECKHULL CONSTRUCTIONAND CAREThe SRT1000 hull is built of a material calledFRP. This is then finished with a very hardproduct

TROUBLE ANALYSIS x9TRBLANLSWINDOWS®95, WINDOWS®98, WINDOWS®ME,WINDOWS®2000,®OR WINDOWS®XP ... 9-3UPDATING THE D

Operating procedure... 9-41Data display item selection...

9-1TROUBLE ANALYSIS x9TRBLANLSIf this software is run on Microsoft Windows®95, Windows®98, Windows®Me, Windows®2000, orWindows®XP, the information can

HOW TO USE THIS MANUALMANUAL FORMATAll of the procedures in this manual are organized in a sequential, step-by-step format. The infor-mation has been

2-12MAINTENANCE SPECIFICATIONS2SPECTIGHTENING TORQUESPart To Be Tightened

9-2TROUBLE ANALYSIS9TRBLANLSMake sure your computer meets the following requirements before using this software.RS232C (Dsub-9 pin) port, USB portj

TROUBLE ANALYSIS x9TRBLANLS9-3INSTALLING THE YAMAHA DIAGNOSTIC SYSTEM UNDER WINDOWS 95, WINDOWS 98, WINDOWS ME, WINDOWS 2000, OR WINDOWS XP9-2.

9-4TROUBLE ANALYSIS9TRBLANLS

9-5TROUBLE ANALYSIS x9TRBLANLS

9-6TROUBLE ANALYSIS9TRBLANLSInstall the Database file before using the Yamaha Diagnostic System, otherwise, the program will notoperate correctly. For

9-7TROUBLE ANALYSIS x9TRBLANLSAfter about three seconds, the display will automatically go to the first menu display, or you can clickor press any key

9-8TROUBLE ANALYSIS9TRBLANLSDo not click the Starting service tool [Enter] button or press the Enter key on your keyboard untilthe database has been u

9-9TROUBLE ANALYSIS x9TRBLANLS

9-10TROUBLE ANALYSIS9TRBLANLSWhen the database is updated, a confirmation screen is displayed.

9-11TROUBLE ANALYSIS x9TRBLANLS

2-13MAINTENANCE SPECIFICATIONSx2SPECTIGHTENING TORQUESPart To Be Tightened6M83202.014

9-12TROUBLE ANALYSIS9TRBLANLS12

9-13TROUBLE ANALYSIS x9TRBLANLSOpen the Yamaha Diagnostic System window. (Fig. 20) After about three seconds, the display willautomatically go to the

9-14TROUBLE ANALYSIS9TRBLANLS

9-15TROUBLE ANALYSIS x9TRBLANLS

9-16TROUBLE ANALYSIS9TRBLANLSEight commands appear in the main Menu. Select a command in any of the following three ways:

9-17TROUBLE ANALYSIS x9TRBLANLS

9-18TROUBLE ANALYSIS9TRBLANLS

9-19TROUBLE ANALYSIS x9TRBLANLStop.

9-20TROUBLE ANALYSIS9TRBLANLS

9-21TROUBLE ANALYSIS x9TRBLANLS

2-14MAINTENANCE SPECIFICATIONS2SPECTIGHTENING TORQUESThread Tightening torquePart To Be Tightened Part Name size Qty N•m kgf•m ft•lb RemarksWater inle

9-22TROUBLE ANALYSIS9TRBLANLS

9-23TROUBLE ANALYSIS x9TRBLANLS.

9-24TROUBLE ANALYSIS9TRBLANLSCheck that the items deleted are normal in the Diagnosis Record. If the items remain irregular, theywill appear as irregu

9-25TROUBLE ANALYSIS x9TRBLANLSClick the OK button or press the Enter key on your keyboard (Fig. 35): The selected item is deleted.To cancel deleting

9-26TROUBLE ANALYSIS9TRBLANLSDo not use the Engine Monitor function to check the engine condition while operating a water-craft, otherwise, you could

9-27TROUBLE ANALYSIS x9TRBLANLSin the scroll bar or press the up or down(Fig. 38).keyboard

9-28TROUBLE ANALYSIS9TRBLANLSAvoid clicking the Execute and Cancel buttons repeatedly, otherwise, the ECM or PC will notwork properly and they could b

9-29TROUBLE ANALYSIS x9TRBLANLSkeys on your keyboard (Fig. 39).(Spark Gap Tester YM-34487/90890-06754) is needed.keyboard (Fig. 39).

9-30TROUBLE ANALYSIS9TRBLANLSkeyboard (Fig. 42).

9-31TROUBLE ANALYSIS x9TRBLANLSIf the engine is running an error message is displayed, follow the instructions that appear (Fig. 44).instructions in t

2-15MAINTENANCE SPECIFICATIONSx2SPECTIGHTENING TORQUESThread Tightening TorquePart To Be Tightened Part Name size Qty N•m kgf•m ft•lb RemarksMain and

9-32TROUBLE ANALYSIS9TRBLANLSselected (Fig. 46).displayed (Fig. 47).

9-33TROUBLE ANALYSIS x9TRBLANLSkeyboard (Fig. 48).Make sure that there is fuel in the fuel tank, otherwise, an error will occur and the test cannot be

9-34TROUBLE ANALYSIS9TRBLANLSkeyboard (Fig. 49).

9-35TROUBLE ANALYSIS x9TRBLANLSselected (Fig. 51).Do not test the same cylinder three or more times, otherwise, the spark plug insulator could bedamag

9-36TROUBLE ANALYSIS9TRBLANLSSelect the test to be performed, then click the Select button or press the Enter key on your keyboard(Fig. 52).Make sure

9-37TROUBLE ANALYSIS x9TRBLANLSkeyboard (Fig. 53).selected (Fig. 54).

9-38TROUBLE ANALYSIS9TRBLANLSAvoid clicking the Execute and Cancel buttons repeatedly, otherwise, the ECM or PC will notwork properly and they could b

9-39TROUBLE ANALYSIS x9TRBLANLSFor the first ten seconds, operate all four cylinders, then stop one cylinder for five seconds. For the lastfive second

9-40TROUBLE ANALYSIS9TRBLANLSIf the engine is not running, an error message is displayed. Follow the instructions that appear (Fig. 57).displayed (Fig

9-41TROUBLE ANALYSIS x9TRBLANLSboard (Fig. 59).Press the Enter key on your keyboard. The window of the selected item is displayed(Fig. 59).

2-16GENERAL TORQUEThis chart specifies the torques for tighteningstandard fasteners with standard clean dry ISOthreads at room temperature. Torque spe

9-42TROUBLE ANALYSIS9TRBLANLSbar (Fig. 60).displayed (See fig. 61).

9-43TROUBLE ANALYSIS x9TRBLANLSaxis (Fig. 61).value at the time the Enter key on your keyboard was pressed in the Monitor item selection.

9-44TROUBLE ANALYSIS9TRBLANLS(Fig. 62).Although the engine is running, the displayed time refers to the added hours until the Data loggerstarts.

9-45TROUBLE ANALYSIS x9TRBLANLSdisplayed (Fig. 63).

9-46TROUBLE ANALYSIS9TRBLANLS(Fig. 65).

9-47TROUBLE ANALYSIS x9TRBLANLSPrograms (Fig. 66).(Fig. 67).

9-48TROUBLE ANALYSIS9TRBLANLSbutton (see Figs. 68~70).

9-49TROUBLE ANALYSIS x9TRBLANLS

9-50TROUBLE ANALYSIS9TRBLANLStest,

9-51TROUBLE ANALYSIS x9TRBLANLSDisplay (Fig. 73).slider (Fig. 74)..

2-17MAINTENANCE SPECIFICATIONSx2SPECCABLE AND HOSE ROUTING

9-52TROUBLE ANALYSIS9TRBLANLSbutton (see Figs. 75~76).

9-53TROUBLE ANALYSIS x9TRBLANLSconsulted:

9-54TROUBLE ANALYSIS9TRBLANLS

9-55TROUBLE ANALYSIS x9TRBLANLS

LIT-18616-02-52©2003 YAMAHA MOTOR CORPORATION, U.S.A. Printed in U.S.A.

2-18MAINTENANCE SPECIFICATIONS2SPECCABLE AND HOSE ROUTING

2-19MAINTENANCE SPECIFICATIONSx2SPECCABLE AND HOSE ROUTING

2-20MAINTENANCE SPECIFICATIONS2SPECCABLE AND HOSE ROUTING

2-21MAINTENANCE SPECIFICATIONSx2SPECCABLE AND HOSE ROUTING

HOW TO READ DESCRIPTIONS1. A disassembly/installation job instruction mainly consists of the exploded diagram 11.2. The numerical figures represented

CHAPTER 3PERIODIC INSPECTION AND ADJUSTMENTMAINTENANCE INTERVAL CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-1PERIODIC INSPECTION AND ADJUSTMENT x3INSPADJ

PERIODIC SERVICECONTROL SYSTEMSteering helm inspection1. Check:●FrictionExcessively heavy ➔Replace the steering helm unit.2. Check:●Free playExcessive

1 Cable Wheel2 Locknuts3 Throttle CableREMOTE CONTROL UNIT1. Check throttle:●Throttle lever at Wide-Open-Throttle(W.O.T.) position.Throttle cable whee

Shift cable inspection and adjustmentThe cable joints must have more than 8mm(0.31 in) engagement after adjustment iscomplete.3. Check:●Mechanical int

3-5PERIODIC INSPECTION AND ADJUSTMENT x3INSPADJ

3-6PERIODIC INSPECTION AND ADJUSTMENT 3INSPADJ•Valve clearance adjustment should be madeon a cold engine at room temperature.• When the valve clearanc

3-7PERIODIC INSPECTION AND ADJUSTMENT x3INSPADJ

3-8PERIODIC INSPECTION AND ADJUSTMENT 3INSPADJ

3-9PERIODIC INSPECTION AND ADJUSTMENT x3INSPADJMake a note of the position of each valvelifter 3 and valve pad 4 so they can beinstalled in the correc

SYMBOLSSymbols 1 to 9 are designed as thumb-tabsto indicate the content of a chapter:General InformationSpecificationsPeriodic Inspection and Adjustme

3-10PERIODIC INSPECTION AND ADJUSTMENT 3INSPADJ

3-11PERIODIC INSPECTION AND ADJUSTMENT x3INSPADJ

3-12PERIODIC INSPECTION AND ADJUSTMENT 3INSPADJCAUTION:

3-13PERIODIC INSPECTION AND ADJUSTMENT x3INSPADJCAUTION:Place the craft in water, and then

3-14PERIODIC INSPECTION AND ADJUSTMENT 3INSPADJIf the oil temperature is low, the reading onthe dipstick will be low. If the temperature ishigh, the r

3-15PERIODIC INSPECTION AND ADJUSTMENT x3INSPADJCAUTION:

3-16PERIODIC INSPECTION AND ADJUSTMENT 3INSPADJWhen starting the engine, make sure the dip-stick is securely fitted into the oil tank.CAUTION:

3-17PERIODIC INSPECTION AND ADJUSTMENT x3INSPADJMake sure the air filter element is installedin the filter case properly.If cleaning the air filter el

3-18PERIODIC INSPECTION AND ADJUSTMENT 3INSPADJ

3-19PERIODIC INSPECTION AND ADJUSTMENT x3INSPADJ

INDEXSPECIFICATIONSSPECGENERAL INFORMATION1GENINFO2PERIODIC INSPECTION AND ADJUSTMENT3INSPADJFUEL SYSTEM4FUELPOWER UNIT5POWRJET PUMP6JETPUMPELECTRICAL

PERIODIC INSPECTION AND ADJUSTMENT 3INSPADJ3-20CAUTION:Be sure the cap is properly positioned andlocked in place. Otherwise, the cap could loosenand b

3-21PERIODIC INSPECTION AND ADJUSTMENT x3INSPADJDisconnect the bilge strainer from the bilgestrainer holder.BILGE PUMP1. Remove inspection cover in pu

3-22PERIODIC INSPECTION AND ADJUSTMENT 3INSPADJ

3-23PERIODIC INSPECTION AND ADJUSTMENT x3INSPADJGENERALDrain plug inspection1. Inspect:●Drain plugCrack/Damage ➔ Replace.●O-RingCrack/Wear ➔ Replace.●

3-24PERIODIC INSPECTION AND ADJUSTMENT 3INSPADJLubrication points1. Lubricate:●Throttle cable (throttle body end)NOTE:Before lubricating the QSTS cont

PERIODIC INSPECTION AND ADJUSTMENT x3INSPADJ4.3-25

xCHAPTER 4FUEL SYSTEMFUEL TANK AND FUEL PUMP MODULEEXPLODED DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

FUEL SYSTEM x4FUEL4-128282828282828282812345101211131613151813171920262524232721221413986729292830Step Procedure / Part Name Q’ty Service PointsFUEL T

4-2FUEL SYSTEM4FUELFUEL TANK AND FUEL PUMP MODULE (Cont’d.)28282828282828282812345101211131613151813171920262524232721221413986729292830Step Procedure

4-3FUEL SYSTEM x4FUELFUEL TANK AND FUEL PUMP MODULE (Cont’d.)28282828282828282812345101211131613151813171920262524232721221413986729292830Step Procedu

CHAPTER 1GENERAL INFORMATIONIDENTIFICATION NUMBERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1PRIM

4-4FUEL SYSTEM4FUELSYSTEM.”ScrewsLoosen the screws in the sequence shown.

4-5FUEL SYSTEM x4FUELSYSTEM.”Screws4.9 Nm (0.49 kgf-m)7.9 Nm (0.8 kgf-m)

4-6FUEL SYSTEM4FUEL

4-7FUEL SYSTEM x4FUELFUEL INJECTION SYSTEM (Cont’d.)

4-8FUEL SYSTEM4FUELFUEL INJECTION SYSTEM (Cont’d.)

4-9FUEL SYSTEM x4FUELFUEL INJECTION SYSTEM (Cont’d.)

4-10FUEL SYSTEM4FUELFUEL INJECTION SYSTEM (Cont’d.)

4-11FUEL SYSTEM x4FUELFUEL INJECTION SYSTEM (Cont’d.)

4-12FUEL SYSTEM4FUELFUEL INJECTION SYSTEM (Cont’d.)Qty

4-13FUEL SYSTEM x4FUELFUEL INJECTION SYSTEM (Cont’d.)

A60700-0*IDENTIFICATION NUMBERSPRIMARY I.D. NUMBERThe primary I.D. number is stamped on a labelattached to the deck under the rear seat.ENGINE SERIAL

4-14FUEL SYSTEM4FUELFUEL INJECTION SYSTEM (Cont’d.)

4-15FUEL SYSTEM x4FUELCAUTION:

4-16FUEL SYSTEM4FUELCAUTION:Disconnect the fuel hose 1 directly from thefuel pipe 2.

4-17FUEL SYSTEM x4FUELCAUTION:If free play is not obtained, disconnect the fuelhose, check the O-ring for damage and that it isproperly installed.

4-18FUEL SYSTEM4FUELCAUTION:

4-19FUEL SYSTEM x4FUELCAUTION:Blow out all passages with compressed air.

4-20FUEL SYSTEM4FUELCAUTION:Only butterfly valve #2 should be fullyclosed. The other valves should be halfwayclosed.

4-21FUEL SYSTEM x4FUEL

4-22FUEL SYSTEM4FUELCAUTION:

4-23FUEL SYSTEM x4FUEL

SAFETY WHILE WORKINGThe procedures given in this manual are thoserecommended by Yamaha to be followed byYamaha dealers and their mechanics.FIRE PREVEN

4-24FUEL SYSTEM4FUEL

4-25FUEL SYSTEM x4FUEL“Fuel hose disconnection.”“Fuel hose connection.”)nection.”)connection.”

POWER UNIT x5POWR5-1Refer to “ENGINE HATCH” in Chapter 8.

5-2ENGINE UNITEXPLODED DIAGRAMPOWER UNIT5POWR

5-3POWER UNIT x5POWR

5-4POWER UNIT5POWRCAUTION: