FLJetBoater
Jet Boat Junkie
- Messages
- 740
- Reaction score
- 280
- Points
- 127
- Boat Make
- Yamaha
- Year
- 2020
- Boat Model
- 242 Limited S E-Series
- Boat Length
- 24
For anyone who is having starter issues, it's a relatively simple job to do. This is the 3rd one I've done now and start to finish is under an hour and a half.
I wanted to document it better but it was getting dark and my pictures didn't come out very well. I'll add some after with close ups of the bolts/wires/etc to remove.
I would suggest making it part of your maintenance that you reach down under the manifold and wiggle the long bolts on the starter to make sure that they haven't come loose. You might be able to save it vs having to replace it if you catch it early enough.
Tools -
ratchet with 12mm socket (all manifold bolts and starter bolts are 12mm, I think the rear exhaust pipe bolt was 11mm)
torque wrench w/12mm socket
pliers for hose clamps
242 (blue) loctite for manifold bolts and rear exhaust pipe bolt
marine grease
Step0 - make sure batteries/power are turned off/disconnected
Step1 - Remove the bolt on the connection from the exhaust pipe to the rear of the motor. It's hidden down below the rectifier. Very important to remove this bolt first, if you don't and you remove all the exhaust manifold bolts you could shear this one off. It was a b%!*# to remove - very tight and difficult to get leverage.
Step2 - Remove all the exhaust manifold bolts. There are 8 shorter bolts along the top and 3 longer ones below them. There are 2 bolts on each end one above the other they're easy to miss if you don't look for them. The top bolt to the back of the engine doesn't come out all the way because the rectifier is in the way. I just loosened it and let it sit there
Step3 - Pull back exhaust manifold from engine
Step4 - Loosen hose clamp and remove big black hose coming from back of engine. Loosen hose clamp and remove hose coming up from below engine (it's directly in front of the starter bolts and much easier to work if it's disconnected, although you may not HAVE to do this one). Disconnect the 2 quick-connect connectors that come from the engine to the rectifier. On mine one was grey and one was black. Once this is done you should be able to push the exhaust manifold back far enough to clear the oil filter and rest it there.
Step5 - Remove starter bolts. This parts fun - prepare to scrape the you know what out of your knuckles/forearm on the corners of the exhaust manifold as you reach down there.
Step6 - Pull starter out. Collect all the pieces when it completely falls apart because the long bolts backed out. See picture. Disconnect positive power from the top of the starter piece that you can still grab and hasn't fallen into the bottom of the engine bay.
FYI this is a 3 year old OEM yamaha starter.
Step7 - Install new starter (grease the o-ring and metal part that slides in). Connect starter bolts (make sure ground wire is attached to bottom bolt) and reconnect positive wire to top of starter.
Step8 - Reconnect the hoses you disconnected in step 4. Reposition exhaust manifold closer to engine. Reconnect wires to rectifier.
Step9 - Install new exhaust manifold gasket and re-attach manifold. I put the center long bolt in first and semi-tighten it. Put in all the rest of the bolts and semi-tighten. In the older manuals there was a specific order to install/tighten the bolts but it seems in the newer manuals they have changed to phase 1 - tighten all bolts to 14.8ft-lb, phase 2 - tighten all bolts to 25.8 ft-lb.
tada!
I wanted to document it better but it was getting dark and my pictures didn't come out very well. I'll add some after with close ups of the bolts/wires/etc to remove.
I would suggest making it part of your maintenance that you reach down under the manifold and wiggle the long bolts on the starter to make sure that they haven't come loose. You might be able to save it vs having to replace it if you catch it early enough.
Tools -
ratchet with 12mm socket (all manifold bolts and starter bolts are 12mm, I think the rear exhaust pipe bolt was 11mm)
torque wrench w/12mm socket
pliers for hose clamps
242 (blue) loctite for manifold bolts and rear exhaust pipe bolt
marine grease
Step0 - make sure batteries/power are turned off/disconnected
Step1 - Remove the bolt on the connection from the exhaust pipe to the rear of the motor. It's hidden down below the rectifier. Very important to remove this bolt first, if you don't and you remove all the exhaust manifold bolts you could shear this one off. It was a b%!*# to remove - very tight and difficult to get leverage.
Step2 - Remove all the exhaust manifold bolts. There are 8 shorter bolts along the top and 3 longer ones below them. There are 2 bolts on each end one above the other they're easy to miss if you don't look for them. The top bolt to the back of the engine doesn't come out all the way because the rectifier is in the way. I just loosened it and let it sit there
Step3 - Pull back exhaust manifold from engine
Step4 - Loosen hose clamp and remove big black hose coming from back of engine. Loosen hose clamp and remove hose coming up from below engine (it's directly in front of the starter bolts and much easier to work if it's disconnected, although you may not HAVE to do this one). Disconnect the 2 quick-connect connectors that come from the engine to the rectifier. On mine one was grey and one was black. Once this is done you should be able to push the exhaust manifold back far enough to clear the oil filter and rest it there.
Step5 - Remove starter bolts. This parts fun - prepare to scrape the you know what out of your knuckles/forearm on the corners of the exhaust manifold as you reach down there.
Step6 - Pull starter out. Collect all the pieces when it completely falls apart because the long bolts backed out. See picture. Disconnect positive power from the top of the starter piece that you can still grab and hasn't fallen into the bottom of the engine bay.
FYI this is a 3 year old OEM yamaha starter.
Step7 - Install new starter (grease the o-ring and metal part that slides in). Connect starter bolts (make sure ground wire is attached to bottom bolt) and reconnect positive wire to top of starter.
Step8 - Reconnect the hoses you disconnected in step 4. Reposition exhaust manifold closer to engine. Reconnect wires to rectifier.
Step9 - Install new exhaust manifold gasket and re-attach manifold. I put the center long bolt in first and semi-tighten it. Put in all the rest of the bolts and semi-tighten. In the older manuals there was a specific order to install/tighten the bolts but it seems in the newer manuals they have changed to phase 1 - tighten all bolts to 14.8ft-lb, phase 2 - tighten all bolts to 25.8 ft-lb.
tada!
