Yamaha SR230 2004 User manual

Service Manual

SR230

2004

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

DISASSEMBLY AND ASSEMBLY

1. Clean parts with solvent and compressed-

air on disassembling them.

2. Oil the contact surfaces of moving parts on

assembly.

3. After assembly, check that moving parts

operate normally.

4. Install bearings with the manufacturer’s

markings on the side exposed to view and

liberally oil the bearings.

Do not use compressed air to spin the bear-

ings dry. This causes damage to the bearing

surfaces.

5. When installing oil seals, apply a light coat-

ing of water-resistant grease to the outside

diameter.

GENERAL INFORMATION

1-4

1GEN

INFO

CAUTION:

SPECIAL TOOLS

Use of the correct special tools recommended

by Yamaha will aid the work and enable accu-

rate assembly and tune-up. Improvisations and

use of improper tools can cause damage to the

equipment.

NOTE:

• For U.S.A. and Canada, use part numbers

starting with “J-”, “YB-”, “YM-”,“YS-”, “YU-” or

“YW-”.

• For other countries, use part numbers starting

with “90890-.”

MEASURING TOOLS

1Dial Gauge

P/N YU-03097-B

90890-01252

2Dial Gauge Stand

P/N 90890-06583

3Dial Gauge Needle

P/N 90890-06584

4Dial Gauge Stand Set

P/N YW-06585

90890-06585

5Pocket Tester

P/N YU-03112-C

90890-03112

6Digital Circuit Tester

P/N YU-A1927

90890-03174

7Vacuum Synchronizer

P/N YU-44456

8Vacuum Gauge

P/N 90890-03094

Vacuum attachment

P/N 90890-03060

9Test Connector

P/N YW-06862

90890-06862

Fuel Pressure Gauge Adapter

P/N YW-06842

90890-06842

GENERAL INFORMATIONx1

1-5

GEN

INFO

YU-03097-B 90890-01252

90890-06583 90890-06584

YW-06585

90890-06585

YU-03112-C

90890-03112 YU-A1927

90890-03174

YU-44456 90890-03094 90890-03060

YW-06862

90890-06862 YW-06842

90890-06842

VAC

DYN

600

700

800

900

1000

1100

1200

1300

1400

1500

1600

1700

1800

1900

2000

2100

2200

2300

2400

2500

RPM

AVE

DYN

1234

cmHg

2-t 4-t

4035

12V

cmHg

VacuumMate

SPECIAL TOOLS

Fuel Pressure Gauge

P/N YB-06766

90890-06786

Compression Gauge Extension

P/N 90890-06582

Cylinder Gauge Set

P/N YU-03017

90890-06759

Compression Gauge

P/N YU-33223-1

90890-03160

Peak Voltage Adapter

P/N YU-39991

90890-03172

Spark Gap Tester

P/N YM34487

90890-06754

Test Harness (2 pins)

P/N YB-06792

90890-06792

Test Harness (3 pins)

P/N YB-06791

90890-06791

Test Harness (3 pins)

P/N YB-06770

90890-06770

Test Harness (6 pins)

P/N YB-06790

90890-06790

Test Harness (3 pins)

P/N YB-06793

90890-06793

Test Harness ( 3 pins)

P/N YB-0677

90890-06777

1-6

GENERAL INFORMATION

1GEN

INFO

1-7

GENERAL INFORMATIONx1

GEN

INFO

SPECIAL TOOLS

Test Harness (3 pins)

P/N YB-06769

90890-06769

Vacuum/Pressure Pump Gauge Set

P/N YB-35956-A

90890-06756

Yamaha Diagnostic System for Watercraft

P/N LIT-YDIS1-21-00

Yamaha Diagnostic System Connector

for Watercraft

P/N 60V-WS850-00-00 USB Cable

P/N 68F-WS850-00-00 Serial Cable

YB-06769

90890-06769 YB-35956-A

90890-06756

60V

YW-06862

90890-06862

-WS853-01

60V-85300-01

YAMAHA DIAGNOSTIC SYSTEM

for Watercraft

INSTALLATION MANUAL

60E-2819K-10

LIT-YDIS1-21-00

60V-WS850-00-00 USB Cable /

68F-WS850-00-00 Serial Cable

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