Intermediate Shaft assembly

[Marcio Fazzio Martins]

2004 AR230

I am reassembling the Intermediate shaft and the Service Manual is very confusing about the specs. If anyone could confirm if my conclusion is correct, I would appreciate.

Apparently, the edge of the shaft must be 0.37~0.41 in (9.5~10.5mm) from the rear side of the Housing. This distance shows as "B" but on page 6-8, but on page 6=10 it says "Shaft" Distance "a".

See file attached!

Let me know if anyone knows if it is right.

Thanks

 

[Acard7]

So you had to change the intermediate bearing? Just trying to figure out why you had to reassemble!

 

[Marcio Fazzio Martins]

So you had to change the intermediate bearing? Just trying to figure out why you had to reassemble!

I had no choice other than cutting the shaft, and the bearings on the housing ere completely destroyed. Actually I will change the whole assembly on the Impeller housing as well.
The boat is 2004 and I took really good care since I bought in 07, but one thing I neglected is lubricating the bearings on the jet unit.

I already have all parts, just waiting for the EPNOC AP#0 today to start reassembling. I know many people (and dealers) say I could use regular marine grease, but it doesn't hurt to follow Yamaha's specs.

So, now... replace engine mounts, change all old clamps, reassemble Impeller housing, Intermediate shaft and put engine back!

After summer I will do the same to the other engine. Bearings bust be in bad shape as well, and I don't wanna risk that the engine mounts brake as this one did.

About the question on this thread, newer AR230 have the same pages for the specs (Check my friend's 2011) and the references are wrong as well.

 

[Brad_Ct]

Page 6-10 is misprinted as far as letter designation. The end of the shaft should be 0.37-0.41” from the backside of the assembly.

 

[Marcio Fazzio Martins]

Yes, that is what I thought. This part is done. Waiting for the parts to rebuilt the other side of the Jet Pump. Bearings, seals...
I've got a shop press that made it easier. Lots of "jigs" needed without the Yamaha tools.