Yamaha SR230 2004 Service Manual 354pg marginmod printme1

PERIODIC INSPECTION AND ADJUSTMENT x INSP 3 ADJ Make a note of the position of each valve lifter 3 and valve pad 4 so they can be installed in the correct place. lowing table: 3-9

3 INSP PERIODIC INSPECTION AND ADJUSTMENT ADJ 3-10

PERIODIC INSPECTION AND ADJUSTMENT x INSP 3 ADJ 3-11

3 INSP PERIODIC INSPECTION AND ADJUSTMENT ADJ CAUTION: 3-12

PERIODIC INSPECTION AND ADJUSTMENT x INSP 3 ADJ Place the craft in water, and then CAUTION: 3-13

3 INSP PERIODIC INSPECTION AND ADJUSTMENT ADJ If the oil temperature is low, the reading on the dipstick will be low. If the temperature is high, the reading on the dipstick will be high. CAUTION: Do not run the engine for more than 15 sec- onds without supplying water when check- ing the oil level on land. The engine could overheat. craft in a horizontal position. 3-14

PERIODIC INSPECTION AND ADJUSTMENT x INSP 3 ADJ CAUTION: 3-15

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

PERIODIC INSPECTION AND ADJUSTMENT x INSP 3 ADJ CAUTION: Make sure the air filter element is installed in the filter case properly. If cleaning the air filter element, use cold or lukewarm water and let it air dry complete- ly. Do not use detergent or a solvent to clean the air filter element, or dry it with heat or compressed air, otherwise it could be damaged. CAUTION: 3-17

3 INSP PERIODIC INSPECTION AND ADJUSTMENT ADJ 3-18

PERIODIC INSPECTION AND ADJUSTMENT x INSP 3 ADJ 3-19

3 INSP PERIODIC INSPECTION AND ADJUSTMENT ADJ Clean-out cap 1 by pressing Release A Bottom A and lift the cap out of the Port. 1 Align the grooved recess on the clean-out cap with the projection in the clean-out opening. CAUTION: A Be sure the cap is properly positioned and locked in place. Otherwise, the cap could loosen and be forced out of the access ports by water pressure, causing loss of performance and pos- sible damage. 3-20

PERIODIC INSPECTION AND ADJUSTMENT x INSP 3 ADJ BILGE PUMP 1. Remove inspection cover in pump clean-out tray. 2. Inspect: • Bilge strainer Contaminants → Clean. Cracks/damage → Replace. Inspection Steps: • Install the coupling cover. Disconnect the bilge strainer from the bilge strainer holder. 3-21

3 INSP PERIODIC INSPECTION AND ADJUSTMENT ADJ 3-22

PERIODIC INSPECTION AND ADJUSTMENT x INSP 3 ADJ GENERAL Drain plug inspection 1. Inspect: ● Drain plug Crack/Damage ➔ Replace. ● O-Ring Crack/Wear ➔ Replace. ● Screw threads Dirt/Sand ➔ Clean. Greasing points 1. Apply: ● Throttle cable inner wire ● Shift control cable ● Cable joint ● Steering cable Recommended Grease: Water resistant grease NOTE: Remove the cable joint and apply a small amount of grease to the following parts. ● Nozzle pivot shaft collar ● Bearing housing Recommended Grease: Water resistant grease NOTE: ● Fill in the bearing housing with water resis- tant grease from a nipple. ● Fill the grease slowly and carefully, as it can damage the hose and the joints. ● Refer to the “MAINTENANCE INTERVAL CHART” section. 3-23

3 INSP PERIODIC INSPECTION AND ADJUSTMENT ADJ Lubrication points 1. Lubricate: ● Throttle cable (throttle body end) Recommended lubricant: Yamaha marine grease, Yamaha grease A (Water resistant grease) NOTE: Before lubricating the QSTS control cables, remove the QSTS cable housing cover. Spray the rust inhibitor into the outer cables, and apply grease to the inner cables. 2. Lubricate: ● Nozzle pivot shaft ● Steering cable (nozzle end) ● QSTS cable (nozzle end) Recommended grease: Yamaha marine grease, Yamaha grease A (Water resistant grease) 3. Lubricate: ● Steering cable ● Steering cable joint ● Shift cable ● Shift cable joint NOTE: Disconnect the joints and apply a small amount of grease. Recommended grease: Yamaha marine grease, Yamaha grease A (Water resistant grease) 3-24

PERIODIC INSPECTION AND ADJUSTMENT x INSP 3 ADJ 4. 3-25

x CHAPTER 4 FUEL SYSTEM FUEL TANK AND FUEL PUMP MODULE EXPLODED DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1 REMOVAL AND INSTALLATION CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1 SERVICE POINTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4 Fuel hose disconnection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4 Fuel pump module removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4 Check valve inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4 Fuel tank inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4 Fuel hose inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4 Fuel pump filter inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5 Fuel strainer inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5 Fuel pump module installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5 Fuel hose connect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5 FUEL INJECTION SYSTEM EXPLODED DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6 REMOVAL AND INSTALLATION CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6 SERVICE POINTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-15 Hose clamps removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-15 Hose clamps installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-15 Fuel hose disconnection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-15 Fuel line inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-16 Fuel hose installation (replacing with new fuel hose) . . . . . . . . . . . . . . . . . . . . . . 4-17 Fuel hose connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-17 Throttle body removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-17 Fuel injector inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-18 Throttle body inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-18 Throttle body installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-19 Throttle bodies synchronization . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-20 Fuel pressure measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-25

FUEL SYSTEM x FUEL 4 6 1 3 7 2 4.9~7.9 Nm (50~80 kgf-cm) 54 See Note 28 10 28 28 8 12 28 29 11 228 28 28 29 28 9 15 13 18 16 14 13 13 13 17 30 19 20 26 21 27 25 22 23 24 REMOVAL AND INSTALLATION CHART Q’ty Service Points Follow the “Step” order for removal. Step Procedure / Part Name FUEL TANK PUMP MODULE NOTE: Apply Loctite, torque in 2 steps see page 4-4 Pump Module Removal, 1 Connector, harness 2 4-5 Installation 2 Cover 2 3 Screw, Machine 2 Apply Loctite, 2.9 Nm (30 kgf-cm) 4 Clamp 2 5 Fuel hose 2 6 Screw 16 7 Plate 2 8 Fuel Pump Assembly 2 9 Seal 2 10 Screw 5 4-1

4 FUEL FUEL SYSTEM FUEL TANK AND FUEL PUMP MODULE (Cont’d.) 6 1 7 3 2 54 28 10 28 8 29 12 28 11 28 28 28 29 228 9 28 15 13 18 16 14 13 13 13 17 30 19 20 26 21 27 25 22 23 24 Step Procedure / Part Name Q’ty Service Points 11 Fuel Level Sender 1 12 Gasket 1 13 Clamp 4 14 Hose, Vent 1 15 Hose, Vent 1 16 Valve, Check 1 17 Nut 1 18 Washer, Star 1 19 Washer 1 20 Vent, Fuel 1 21 Clamp 4 4.2 Nm (0.42 kgf-m, 3.0 ft-lbs) 22 Hose, Fuel Filler See detail on clamp installation 23 Nut, #8-32 Nylon Lock 1 24 Washer, #8 Flat 6 25 Screw, #8-32 6 6 4-2

FUEL SYSTEM x FUEL 4 FUEL TANK AND FUEL PUMP MODULE (Cont’d.) 6 1 7 3 2 54 28 10 28 8 29 12 28 11 28 28 28 29 228 9 28 15 13 18 16 14 13 13 13 17 30 19 20 26 21 27 25 22 23 24 Step Procedure / Part Name Q’ty Service Points 1 26 Filler Cap Assembly 1 27 Gasket Note: Deck must be cut at outline to FUEL TANK access fuel tank for removal 8 4.9~7.9 Nm (50~80 kgf-cm) 28 Screw, Machine 1/4” - 20 x 1” 2 29 Fix, Fuel Tank 1 30 Fuel Tank Assembly Reverse the removal steps for installation. 4-3

4 FUEL FUEL SYSTEM SYSTEM.” Screws Loosen the screws in the sequence shown. 4-4

FUEL SYSTEM x FUEL 4 Screws 4.9 Nm (0.49 kgf-m) 7.9 Nm (0.8 kgf-m) SYSTEM.” 4-5

4 FUEL FUEL SYSTEM 4-6

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

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

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

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

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

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

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

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

FUEL SYSTEM x FUEL 4 CAUTION: 4-15

4 FUEL FUEL SYSTEM CAUTION: Disconnect the fuel hose 1 directly from the fuel pipe 2. 4-16

FUEL SYSTEM x FUEL 4 If free play is not obtained, disconnect the fuel hose, check the O-ring for damage and that it is properly installed. CAUTION: 4-17

4 FUEL FUEL SYSTEM CAUTION: 4-18

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

4 FUEL FUEL SYSTEM CAUTION: Only butterfly valve #2 should be fully closed. The other valves should be halfway closed. 4-20

FUEL SYSTEM x FUEL 4 4-21

4 FUEL FUEL SYSTEM CAUTION: 4-22

FUEL SYSTEM x FUEL 4 4-23

4 FUEL FUEL SYSTEM 4-24

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











POWER UNIT x POWR 5 Refer to “ENGINE HATCH” in Chapter 8. 5-1

5 POWR POWER UNIT ENGINE UNIT EXPLODED DIAGRAM 5-2