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.
x
SR230
SRT1000-B/BC Service Manual - 2003
First Edition
©2003 by Yamaha Motor Corporation, U.S.A.
July 2003
All rights reserved. Any reprinting
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.
1
2
3
4
5
6
7
8
9
10 15
10
11
12
13
14
15
16 18
16
17
18
19 24
19
20
21
22
23
24
HULL
DECK
567

INDEX
SPECIFICATIONS
SPEC
GENERAL INFORMATION 1
GEN
INFO
2
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
x

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
RPM
AVE
AVE
DYN
1234
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
21
cmHg
cmHg
25
5
2-t 4-t
5
4035
20
12V
cmHg
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
36
37
38
39
40
41
42
43
44
P
45
46
47
48
49
50
51
52
53
54
55
Pa
P
Pa
1
Pa
2
Pa
3
Pa
4
VacuumMate
®
10

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
11
12
13
14
15
16
17
18
19
20
21
22
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
23
24
25
26
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

1-8
GENERAL INFORMATION
1GEN
INFO REMOVAL AND INSTALLATION TOOLS
1Oil Filter Wrench
P/N YU-38411
90890-01426
2Coupler Wrench
P/N YW-06551
90890-06551
3Sheave Holder
P/N YS-01880-A
90890-01701
4Rotor Puller
P/N YM-01082
90890-01080
5Rotor Holder
P/N YU-01235
90890-01235
6Valve Remover/Installer Kit
P/N YM-45469
90890-04019
7Valve Spring Compressor Attachment
P/N YM-4114 (ø19 mm)
90890-04114 (ø19 mm)
YM-4108 (ø22 mm)
90890-04108 (ø22 mm)
8Valve Guide Remover
P/N YM-04111 (ø4.0 mm)
90890-04111 (ø4.0 mm)
YM-04116 (ø4.5 mm)
90890-04116 (ø4.5 mm)
9Valve Guide Installer
P/N YM-04112 (ø4.0 mm)
90890-04112 (ø4.0 mm)
YM-04117 (ø4.5 mm)
90890-04117 (ø4.5 mm)
Valve Guide Reamer
P/N YM-04113 (ø4.0 mm)
90890-04113 (ø4.0 mm)
YM-04118 (ø4.5 mm)
90890-04118 (ø4.5 mm)
YU-38411
90890-01426 YW-06551
90890-06551
YS-01880-A
90890-01701 YM-01082 90890-01080
YU-01235
90890-01235 YM-45469 90890-04019
YM-4114 (¯19 mm )
90890-04114 (¯19 mm)
YM-4108 (¯22 mm )
90890-04108 (¯22 mm)
YM-04111 (¯ 4.0 mm)
90890-04111 (¯ 4.0 mm)
YM-04116 (¯ 4.5 mm)
90890-04116 (¯ 4.5 mm)
YM-04112 (¯4. 0 mm)
90890-04112 (¯4. 0 mm)
YM-04117 (¯4. 5 mm)
90890-04117 (¯4. 5 mm)
YM-04113 (¯ 4.0 mm)
90890-04113 (¯ 4.0 mm)
YM-04118 (¯ 4.5 mm)
90890-04118 (¯ 4.5 mm)
10

1-9
GENERAL INFORMATIONx1
GEN
INFO
Valve Seat Cutter
Intake
P/N 90890-06813 (60°)
90890-06814 (45°)
90890-06815 (30°)
Exhaust
P/N 90890-06315 (60°)
90890-06312 (45°)
90890-06328 (30°)
Valve Seat Cutter Holder
P/N 90890-06811 (ø4.0 mm)
90890-06812 (ø4.5 mm)
Valve Seat Cutter Set
P/N YM-91043-C
Piston Ring Compressor
P/N YM-08037
90890-05158
Drive Shaft Holder (Impeller)
P/N YB-06151
90890-06519
Slide Hammer Set (jet pump bearing)
P/N YB-06096
Stopper Guide Plate (jet pump bearing)
P/N 90890-06501
Bearing Puller (jet pump bearing)
P/N 90890-06535
Bearing Puller Claw 1 (jet pump bearing)
P/N 90890-06536
Stopper Guide Stand (jet pump bearing)
P/N 90890-06538
Drive Rod L3 (jet pump bearing)
P/N 90890-06652
Needle Bearing Attachment
(jet pump bearing and oil seal)
P/N YB-06112, YB-06196
90890-06614, 90890-06653
11
12
13
14
15
16
17
18
19
20
21
22

GENERAL INFORMATION
1GEN
INFO
1-10

CHAPTER 2
SPECIFICATIONS
GENERAL SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
MAINTENANCE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
JET PUMP UNIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
HULL AND HOOD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
ELECTRICAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
TIGHTENING TORQUES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9
GENERAL TORQUE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-16
CABLE AND HOSE ROUTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-17

GENERAL SPECIFICATIONS
GENERAL SPECIFICATIONSx2
2-1
SPEC
Jet thrust nozzle trim angle Degree +3
Impeller pitch Degree Port 17.3 / Stbd. 16.3
1.72 (5.67 ft)

2-2
GENERAL SPECIFICATIONS
2SPEC