Yamaha SR230 2004 User manual

Service Manual
SR230
2004

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

2-3
MAINTENANCE SPECIFICATIONSx2
SPEC

2-4
MAINTENANCE SPECIFICATIONS
2SPEC

2-5
MAINTENANCE SPECIFICATIONSx2
SPEC

2-6
MAINTENANCE SPECIFICATIONS
2SPEC
Port 17.3 Stbd. 16.3
Marine Group 24
Dual Purpose 675 CCA
100 (12/68.4)