Yamaha SR230 2004 User manual

Service Manual

SR230

2004

PREFACE

This manual has been prepared by Yamaha primarily for use by Yamaha dealers and their trained

mechanics when performing maintenance procedures and repairs to Yamaha equipment. It is not

possible to put an entire mechanic’s education into one manual, so it is assumed that persons using

this book to perform maintenance and repairs on Yamaha machines have a basic understanding of

the mechanical concepts and procedures inherent in machine repair technology. Without such

knowledge, attempted repairs or service to this model may render it unfit to use and/or unsafe.

Because Yamaha has a policy of continuously improving its products, models may differ in detail

from the descriptions and illustrations given in this publication. Use only the latest edition of this

manual. Authorized Yamaha dealers are notified periodically of modifications and significant

changes in specifications and procedures, and these are incorporated in successive editions of this

manual.

SR230

SRT1000-B/BC Service Manual - 2003

First Edition

July 2003

or unauthorized use

without the written permission of

Yamaha Motor Corporation, U.S.A.

is expressly prohibited.

Printed in U.S.A.

Specifications, features and options are subject to

change without notice.

03-187

HOW TO USE THIS MANUAL

MANUAL FORMAT

All of the procedures in this manual are organized in a sequential, step-by-step format. The infor-

mation has been compiled to provide the mechanic with an easy-to-read, handy reference that con-

tains comprehensive explanations of all disassembly, repair, assembly, and inspection operations.

In this revised format, the condition of a faulty component will precede an arrow symbol and the

course of action required will follow the symbol, e.g.:

●Bearings

Pitting/Damage ➔Replace.

To assist you in finding your way about this manual, the Section Title and Major Heading is given

at the head of every page.

An index to contents is provided on the first page of each section.

THE ILLUSTRATIONS

Some illustrations in this manual may differ from the model you have. This is because a procedure

described may relate to several models, though only one may be illustrated. (The name of model

described will be mentioned in the description).

REFERENCES

These have been kept to a minimum, however, when you are referred to another section of the man-

ual, you are told the page number.

WARNINGS, CAUTIONS AND NOTES

Attention is drawn to the various Warnings, Cautions, and Notes which distinguish important infor-

mation in this manual in the following ways:

The SafetyAlert Symbol meansATTENTION! BECOME ALERT! YOUR SAFETY IS INVOLVED!

Failure to follow WARNING instructions could result in severe injury or death to the machine

operator, a bystander, or a person inspecting or repairing the jet boat.

ACAUTION indicates special precautions that must be taken to avoid damage to the jet boat.

NOTE: ________________________________________________________________________

ANOTE provides key information to make procedures easier or clearer.

IMPORTANT: __________________________________________________________________

This part has been subjected to change of specification during production.

WARNING

CAUTION:

HOW TO READ DESCRIPTIONS

1. A disassembly/installation job instruction mainly consists of the exploded diagram 11.

2. The numerical figures represented by the number 22indicates the order of the job steps.

3. The symbols represented by the number 33indicates the contents and notes of the job.

For the meanings of the symbols, refer to the next page(s).

4. The REMOVAL AND INSTALLATION CHART 44is attached to the exploded diagram and

explains the job steps, part names, notes for the jobs, etc.

5. The SERVICE POINTS, other than the exploded diagram, explains in detail the items difficult to

explain in the exploded diagram of REMOVALAND INSTALLATION CHART, the Service Points

requiring the detailed description 55, etc.

SYMBOLS

Symbols 1to 9are designed as thumb-tabs

to indicate the content of a chapter:

General Information

Specifications

Periodic Inspection and Adjustment

Fuel System

Power Unit

Jet Pump Unit

Electrical System

Hull and Deck

Trouble Analysis

Symbols to indicate specific data:

Special Tool

Specified Liquid

Specified Engine Speed

Specified Torque

Specified Measurement

Specified Electrical Valve

[Resistance (Ω), Voltage (V),

Electric Current (A)]

Symbol to in an exploded diagram indi-

cate grade of lubricant and location of lubrica-

tion point:

Apply Yamaha 2-stroke outboard motor oil

Apply water resistant grease (Yamaha

grease A, Yamaha marine grease)

Apply molybdenum disulfide grease

Symbols to in an exploded diagram indi-

cate grade of sealing or locking agent and loca-

tion of application point:

Apply Gasket Maker®

Apply Yamabond #4 (Yamaha Bond No. 4)

Apply LOCTITE® No. 271 (Red LOCTITE)

Apply LOCTITE® No. 242 (Blue LOCTITE)

Apply LOCTITE® No. 567 (PST)

Apply Silicone Sealant

NOTE: ______________________________

In this manual, the above symbols may not be

used in every case.

10 15

16 18

19 24

HULL

DECK

567

INDEX

SPECIFICATIONS

SPEC

GENERAL INFORMATION 1

GEN

INFO

PERIODIC INSPECTION AND ADJUSTMENT 3

INSP

ADJ

FUEL SYSTEM 4

FUEL

POWER UNIT 5

POWR

JET PUMP 6

JET

PUMP

ELECTRICAL SYSTEM 7

ELEC

HULL AND DECK 8

HULL

DECK

TROUBLE ANALYSIS 9

TRBL

ANLS

CHAPTER 1

GENERAL INFORMATION

IDENTIFICATION NUMBERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

PRIMARY I.D. NUMBER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

ENGINE SERIAL NUMBER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

HULL IDENTIFICATION NUMBER (H.I.N.) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

SAFETY WHILE WORKING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

FIRE PREVENTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

VENTILATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

SELF-PROTECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

OILS, GREASES AND SEALING FLUIDS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

GOOD WORKING PRACTICES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3

DISASSEMBLY AND ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4

SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5

MEASURING TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5

SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-6

REMOVAL AND INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8

A60700-0*

IDENTIFICATION NUMBERS

PRIMARY I.D. NUMBER

The primary I.D. number is stamped on a label

attached to the deck under the rear seat.

ENGINE SERIAL NUMBER

The engine serial number is stamped on a label

attached to the crankcase.

HULL IDENTIFICATION NUMBER

(H.I.N.)

The H.I.N. is stamped into the hull on the star-

board side of the stern.

GENERAL INFORMATION x1

1-1

GEN

INFO

Starting Primary I.D. Number:

F1C-700101~

Starting Engine Serial Number:

6B5: 700101~

SAFETY WHILE WORKING

The procedures given in this manual are those

recommended by Yamaha to be followed by

Yamaha dealers and their mechanics.

FIRE PREVENTION

Gasoline (petrol) is highly flammable.

Petroleum vapor is explosive if ignited. Do not

smoke while handling gasoline (petrol), and

keep it away from heat, sparks, and open

flames.

VENTILATION

Petroleum vapor is heavier than air and if

inhaled in large quantities will not support life.

Engine exhaust gases are harmful to breathe.

When test-running an engine indoors, maintain

good ventilation.

SELF-PROTECTION

Protect your eyes with suitable safety specta-

cles or safety goggles when using compressed

air, when grinding or when doing any operation

which may cause particles to fly off.

Protect hands and feet by wearing safety

gloves and protective shoes if appropriate to

the work you are doing.

OILS, GREASES AND SEALING FLUIDS

Use only Genuine Yamaha oils, greases and

sealing fluids or those recommended by

Yamaha.

Under normal conditions of use, there should

be no hazards from the use of the lubricants

mentioned in this manual. However, safety is

all-important, and by adopting good safety

practices, any risk is minimized. A summary of

the most important precautions is as follows:

1. While working, maintain good standards of

personal and industrial hygiene.

2. Clothing which has become contaminated

with lubricants should be changed as soon

as practicable and laundered before further

use.

GENERAL INFORMATION

1-2

1GEN

INFO

3. Avoid skin contact with lubricants; do not,

for example, place a soiled wiping-rag in

one’s pocket.

4. Hands, and any other part of the body

which have been in contact with lubricants

or lubricant-contaminated clothing, should

be thoroughly washed with hot water and

soap as soon as practicable.

5. To protect the skin, the application of a suit-

able barrier cream to the hands before

working is recommended.

6. A supply of clean lint-free cloths should be

available for wiping purposes.

GOOD WORKING PRACTICES

1. The right tools

Use the special tools that are designed to

protect parts from damage. Use the right

tool in the right manner – don’t improvise.

2. Tightening torque

Follow the torque tightening instructions.

When tightening bolts, nuts and screws,

tighten the larger sizes first, and tighten

inner-positioned fasteners before outer-

positioned ones.

3. Non-reusable items

Always use new gaskets, packings,o-rings,

oil seals, split-pins and circlips, etc. on

reassembly.

GENERAL INFORMATIONx1

1-3

GEN

INFO

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