TYPICAL CHAPTERS IN A HONDA AQUATRAX SERVICE MANUAL:
(Chapters may differ in each manual depending on year and model)
GENERAL INFORMATION
MAINTENANCE
FLUSHING AND STORAGE
LUBRICATION SYSTEM
COOLING SYSTEM
FUEL SYSTEM
ENGINE REMOVAL/INSTALLATION
CYLINDER HEAD/VALVE
ALTERNATOR/STARTER CLUTCH
CRANKSHAFT/BALANCER
PISTON
EXHAUST SYSTEM/
TURBOCHARGER
PROPULSION SYSTEM
STEERING/REVERSE SYSTEM
BATTERY/CHARGING SYSTEM
IGNITION SYSTEM
ELECTRIC STARTER
METER/SWITCHES
WIRING DIAGRAMS
TROUBLESHOOTING
ELECTRICAL BODY
HULL/HOOD/BODY PANELS
TECHNICAL FEATURES
ENGINE
INDEX
SERVICE RULES
1. Use genuine Honda or Honda-recommended parts and lubricants or their equivalents. Parts that do not meet Honda's design specifications may cause damage to the watercraft.
2. Use the special tools designed for this product to avoid damage and incorrect assembly.
3. Use only metric tools when servicing the watercraft. Metric bolts, nuts and screws are not interchangeable with English fasteners.
4. Install new gaskets, O-rings, cotter pins, and lock plates when reassembling.
5. When tightening bolts or nuts, begin with the larger diameter or inner bolt first. Then tighten to the specified torque diagonally in incremental steps unless a particular sequence is specified.
6. Clean parts in cleaning solvent upon disassembly. Lubricate any sliding surfaces before reassembly.
7. After reassembly, check all parts for proper installation and operation.
8. Route all electrical wires as shown in the Cable and Harness Routing (page 1-31 or 1-52).
DRY-SUMP SYSTEMS (ENGINE LUBRICATION)
This dry sump system consists of an external oil tank on the front of the engine, and a dual rotor oil pump (scavenge and feed) located within the oil tank. The feed pump draws oil from the oil tank and supplies it to various engine components. The scavenge pump transfers oil from the sump to the oil tank. This engine can be positioned lower than conventional engines, because the oil is not stored in the lower portion of the crankcase. This dry sump design incorporates an oil cooler that lowers the oil temperature.
OIL PRESSURE SWITCH
The watercraft incorporates a fail-safe function in the event that the engine oil pressure drops. If the high oil pressure switch detects an engine oil pressure below 216 kPa (2.2 kg/cm2, 31 psi), the engine control module lights the oil pressure warning light and limits the engine speed to 3,000 rpm to prevent engine damage. However, if the low oil pressure switch detects an engine oil pressure below 20 kPa (0.2, kg/cm2, 3 psi), the fail-safe function stops the engine.
OVERHEAT WARNING LIGHT
The watercraft incorporates a fail-safe function in the event that the engine overheats. If the engine coolant temperature (ECT) sensor detects an engine temperature above 85°C (185°F), the fail-safe function allows the engine to continue to operate. However, if the manifold surface temperature (MST) switch and/or the ECT sensor detects an engine temperature above 95°C (203°F), the fail-safe function stops the engine.
SERVICE INFORMATION GENERAL
Never clean fiberglass and plastic components with strong chemicals or cleaning detergents. These products will damage the gel-coat finish.
• This section covers removal and installation of the body covers.
• The bodywork is made up of two basic materials: the hull and deck are FRP with a Gel coat finish and the hood, mirrors and upper covers are made of plastic.
• Honda strongly recommends that any body damage (e.g., cuts, scratches, holes) be repaired by a qualified boat repair facility.
• After washing the watercraft, consider using a commercially-available spray cleaner/polish or quality fiberglass marine polish wax to finish the job. Use only a non-abrasive polish or wax made specifically for marine watercraft. Apply the polish or wax to the hull and deck according to the instructions on the container.
FLUSHING AND STORAGE
FLUSHING AND STORAGE SERVICE INFORMATION GENERAL
IMPORTANT SAFETY PRECAUTIONS
• Flushing must be performed in a well ventilated area. Never run the engine in an enclosed area. The exhaust contains poisonous carbon monoxide gas that may cause loss of consciousness and lead to death.
• Keep hands, feet, and loose clothing away from the jet pump when running the engine. Never touch any electrical parts.
• Do not turn over the engine when cleaning the jet pump area. Remove the safety lanyard and disconnect the negative battery cable to prevent accidental engine starting.
THE IMPORTANCE OF FLUSHING
• Flushing the cooling system with fresh water is essential to neutralize corroding effects of salt or other chemical products present in water. The flushing water will help to flush out any sand, salt, shells or other particles in water jackets (engine, exhaust components, turbocharger) and/or hoses.
• Clean the watercraft thoroughly and flush the cooling system with only fresh water after each use, or before storage. Also, use the flushing procedure to provide engine cooling when running the engine out of the water for service purposes.
• A flush connector fitting (water outlet joint) is located near the reverse bucket to attach a garden hose for flushing. Failure to properly flush the cooling system after riding will severely damage the engine and/or exhaust system.
FLUSHING PROCEDURE
It is extremely important to perform the following procedure when flushing. If you do not follow this procedure, water will flow into the exhaust and possibly enter the cylinder head and engine, resulting in damage, contamination, or hard starting. Flush for approximately 5 minutes.
1. Connect a garden hose to the flush connector fitting. DO NOT TURN ON THE WATER!
2. Start the engine.
3. Turn on the water to begin flushing.
4. Turn off the water to end flushing.
5. Stop the engine.
THE IMPORTANCE OF PROPER STORAGE
• A watercraft that is not properly prepared prior to storage, may result in component damage or corrosion.
• During the winter, or whenever the watercraft will not be in use for an extended period, proper storage is essential. Proper storage consists of checking the entire watercraft for damage or broken parts; lubricating parts to ensure that they do not become rusted; and, in general, preparing the watercraft so that when the time comes to use it again, it will be in top condition.
• If the watercraft will be stored outside, cover it with an appropriate cover.
LUBRICATION SYSTEM
SERVICE INFORMATION GENERAL
• This section covers service of the oil tank, oil pump and oil cooler.
• The service procedures in this section must be performed with the engine removed.
• For oil level check, oil change and filter replacement, refer to section 4 (page 4-12).
• If the high oil pressure switch detects an engine oil pressure below 216 kPa (2.2 kg/cm2, 31 psi), the ECM lights the oil pressure warning light and limits the engine speed to 3,000 rpm to prevent the engine damage. However, if the low oil pressure switch detects an engine oil pressure below 20 kPa (0.2, kg/cm2, 3 psi), the fail-safe function stops the engine.
SERVICE INFORMATION GENERAL
• Be sure to release the fuel pressure while the engine is off.
• Bending or twisting the control cables will impair smooth operation and could cause the cables to stick or bind, resulting in loss of vehicle control.
• Work in a well ventilated area. Smoking or allowing flames or sparks in the work area or where gasoline is stored can cause a fire or explosion.
• Do not apply commercially available carburetor cleaners to the inside of the throttle bore.
• Do not snap the throttle valve from full open to full close after the throttle cable has been removed, it may cause incorrect idle operation.
• Seal the cylinder head intake ports with tape or a clean cloth to keep dirt and debris from entering the intake ports after the throttle body has been removed.
• Do not apply excessive force to the fuel rail on the throttle body while removing or installing the throttle body.
• Do not damage the throttle body. A damaged throttle body may cause incorrect throttle and idle valve synchronization.
• Prevent dirt and debris from entering the throttle bore, fuel hose and return hose, clean them using compressed air.
• The throttle body is factory pre-set. Do not disassemble in a way other than shown in this manual.
• The programmed fuel injection system is equipped with the Self-Diagnostic System described on page 8-10. If the malfunction indicator lamp (MIL) blinks, follow the Self-Diagnostic Procedures to remedy the problem.
• When checking the PGM-FI, always follow the steps in the troubleshooting flow chart.
• The PGM-FI system is provided with a fail-safe function to secure a minimum running capability even when there is no trouble in the system. When any abnormality is detected by the self-diagnosis function, running capability is secured by using the preset value in advance in the simulated program MAP. It must be remembered, however, that when any abnormality is detected in the four injectors, the ignition pulse generator and/or camshaft position sensor, the fail safe function stops the engine to protect it.
• A faulty PGM-FI system is often related to poorly connected or corroded connectors. Check those connections before proceeding.
• When disassembling the fuel system parts, note the location of the O-rings. Replace them with new ones upon reassembly.
• Before disconnecting the fuel feed hose, open the fuel fill cap to release the pressure in the fuel tank and release the fuel pressure by loosening the fuel feed hose joint nut at the fuel rail.
• Always replace the sealing washers when the fuel feed hose joint nut is removed or loosened.
• Use a digital tester for PGM-FI system inspection.
ENGINE REMOVAL/INSTALLATION
SERVICE INFORMATION
GENERAL
• Whenever the engine is removed from the watercraft, engine-to-jet pump alignment must be checked with the special tools.
• The following components require engine removal for service.
– oil pump
– alternator/starter clutch
– crankshaft/piston/cylinder
– exhaust manifold
• When removing and installing the engine, take care not to damage the deck, cables and hoses.
• The engine-to-jet pump alignment is necessary to eliminate possible vibration and/or damage to components.
• Tighten the engine mounting bolts after adjusting the engine-to-jet pump alignment.
• The following illustration is for a suggested engine stand, for after removing the engine.
CYLINDER HEAD/VALVE
SERVICE INFORMATION GENERAL
• This section covers service of the camshafts, cylinder head and valves. The camshafts can be serviced with the engine installed in the hull. To service the cylinder head components, the engine must be removed.
• When disassembling, mark and store the disassembled parts to ensure that they are reinstalled in their original locations.
• Clean all disassembled parts with cleaning solvent and dry them by blowing them off with compressed air before inspection.
• Camshaft lubricating oil is fed through oil passages in the cylinder head. Clean the oil passages before assembling the cylinder head.
• Be careful not to damage the mating surfaces when removing the cylinder head cover and cylinder head.
ALTERNATOR/STARTER CLUTCH
SERVICE INFORMATION GENERAL
• This section covers service of the alternator stator, flywheel and starter clutch.
• The service procedures in this section must be performed with the engine removed.
• Refer to service manual for alternator stator inspection.
• Refer to service manual for starter motor servicing.
CRANKSHAFT/BALANCER PISTON
SERVICE INFORMATION GENERAL
• This section covers service of the crankcase, crankshaft, balancer and pistons/connecting rods. The balancer gear service is included in section 10.
• Be careful not to damage the crankcase mating surfaces when servicing.
• Prior to assembling the crankcase halves and oil pan, apply sealant to their mating surfaces. Wipe off excess sealant thoroughly.
• Mark and store the connecting rods, bearing caps, pistons and bearing inserts to be sure of their correct locations for reassembly.
• The crankpin and main journal bearing inserts are select fit and are identified by color codes. Select replacement bearings from the code tables. After selecting new bearings, recheck the oil clearance with plastigauge. Incorrect oil clearance can cause major engine damage.
• Clean the oil jets in the upper crankcase with compressed air before installing the crankshaft.
PROPULSION SYSTEM
SERVICE INFORMATION GENERAL
• Remove the safety lanyard and disconnect the negative battery cable to prevent accidental engine starting when working on the propulsion system.
• Keep hands, feet, and loose clothing away from the jet pump when running the engine.
• ARX1200T3,/T3D and ’04 ARX1200N3: The pump is a 3-blades impeller with a six vein mixed-flow pump.
After ’04 ARX1200N3: The pump is a 3-blades impeller with a seven vein mixed-flow pump.
• Be sure to inspect the drive shaft seals at the recommended intervals to guard against driveline damage and leaks.
• Everytime the drive shaft bearing holder or thrust plate is removed, check the engine-to-jet pump alignment using the special tool. The alignment is necessary to eliminate possible vibration and/or damage to components.
• Always inspect the impeller for signs of cavitation or other damage; replace if necessary.
• Refer to the following table for impeller information.
SERVICE INFORMATION GENERAL
• Always remove the safety lanyard clip from the engine stop switch before servicing the starter motor. The motor could suddenly start, causing serious injury.
• When checking the starter system, always follow the steps in the troubleshooting flow chart.
• A weak battery may be unable to turn the starter motor quickly enough, or supply adequate ignition current.
• If the current is kept flowing through the starter motor to turn it while the engine is not cranking over, the starter motor may be damaged.
• Refer to service manual for the starter clutch servicing.
• Refer to service manual for engine stop switch and starter switch inspection.
• Refer to service repair manual for main relay inspection.
• Refer to service shop manual for combination meter information.
METER/SWITCHES
SERVICE INFORMATION GENERAL
• Use an electric heating element to heat the coolant mixture for the engine coolant temperature sensor inspection. Keep flammable materials away from the electric heating element. Wear protective clothing, insulated gloves and eye protection.
• Check the battery condition before performing any inspection that requires proper battery voltage.
• A continuity test can be made with the switches installed on the watercraft.
• The following color codes are used throughout this section.
SPECIFICATIONS
Bu = Blue G = Green Lg = Light Green R = Red
Bl = Black Gr = Gray O = Orange W = White
Br = Brown Lb = Light Blue P = Pink Y = Yellow
