2006 Honda Aquatrax Service Manual
This turbocharged AquaTrax can take you on adventures and lead you back to camp again thanks to its on-board GPS navigation system. Features & Benefits New for 2006. Black Hull with White and Bright Blue Upper Deck. Unique features. GPScape® model features built-in GPS unit with easy-to-read LCD display. GPScape is contained within the standard meter assembly and features storage for up to 100 waypoints and a digital compass function indicating travel direction.
When traveling or returning to a designated waypoint, GPScape will tell the rider distance and direction from present location. Folding rear step for easy reboarding. Chrome 3-D turbo emblem. Unique graphics package features exclusive colors and stylized Honda Wing on the hull. Engine/Drivetrain. Lightweight, liquid-cooled, DOHC 16-valve 1235cc dry-sump four-cylinder engine features a one-piece upper-crankcase/cylinder block engineered to withstand the rigors of marine duty. The inherently efficient, low-emissions four-stroke design consumes less fuel than a comparable two-stroke engine and meets all current CARB and Environmental Protection Agency (EPA) emissions standards.
Class-leading performance is provided by a water-cooled IHI turbocharger with water-cooled intercooler. The AquaTrax® turbocharger produces a maximum boost of 13 psi to generate 32 percent more power than a normally aspirated engine. The turbine bearing is an enclosed, ceramic-ball design that withstands sustained high-rpm compressor operation while providing nearly vibration- and friction-free performance.
Water cooling of the turbocharger housing maintains optimum turbine operating efficiency, while the water-cooled intercooler assures a denser intake charge to provide maximum power and combustion efficiency. An electronic control unit (ECU) monitors atmospheric pressure, boost pressure, engine speed, oil and water temperature, intake air temperature and an engine knock sensor to manage an electronic waste gate valve that controls turbocharger boost, protecting vital engine components and maintaining long engine life.
Side-mounted cam chain and ultra-narrow cylinder-sleeve spacing reduce engine size and weight. Crankshaft main bearings feature a micro-grooved bearing surface to improve oil retention and bearing durability as lateral loading occurs throughout a broad range of operating conditions. DOHC-actuated valves use a simple, lightweight and direct cam-over-bucket design. Four-valve cylinder head design with a narrow, 30 degree included valve angle creates a compact combustion chamber for optimum efficiency and power output at all rpm levels. Silent-type cam chain reduces engine noise, while an automatic chain tensioner virtually eliminates maintenance.
Idle screw adjustment conveniently located on front side of engine for ease of adjustment. Unique gear-driven dual engine-balancer system virtually eliminates high-frequency engine vibration.
Oil jets located on the crankcase main journal castings continually cool piston undersides, ensuring consistent operating temperatures and even better engine life under maximum power. Forged pistons and connecting rods are designed to withstand the rigors of turbocharging. The top piston ring land is anodized, and a chrome-plated top ring further enhances durability. Honda Ignition Control System (ICS) protects the engine from abnormal operating conditions. Air intake system features an intake port mounted centrally in the hull and a labyrinth airbox construction with paper air filter.
Together they keep water out of the engine during normal operation and if the craft is accidentally overturned. High-pressure programmed fuel injection (PGM-FI) delivers fuel at 43 psi to four injectors, each mounted in a 38mm throttle body. Fuel is delivered through four laser-drilled nozzle holes in each injector, producing a highly combustible air/fuel charge for maximum combustion efficiency and power. The ECU provides two digital 3-D fuel injection maps for each cylinder, creating the ideal fuel mixture and spark advance settings. A sophisticated throttle sensor and advanced fuel injection mapping combine to produce smooth and linear throttle response, responding precisely to minor throttle and waste gate adjustments to maximize driveability, acceleration and drive pump performance. A unique fast-idling system uses an electric stepping motor to maintain a stable idle speed when the engine is cold.
An automatic fuel-enriching system is integrated into the PGM-FI module, eliminating the need for a manual choke. Four waterproof transistorized direct-ignition coils integrate the spark plug cap and the high-tension lead to produce a high-voltage, long-duration spark, providing maximum performance at high engine-output levels. Iridium-tip spark plugs produce maximum spark performance and minimal carbon build-up for consistent engine operation and long spark plug life. Powerful, compact oil-cooled alternator contributes to the engine's lightweight design. Oil pump is driven by the alternator, further contributing to the engine's lightweight design. Stainless steel oil cooler.
Engine cooling system allows water from the jet pump to circulate through two separate circuits to cool the engine and exhaust manifold, ensuring consistent operating temperatures for each system. Unique three-way coolant coupler and specially designed discharge outlet reduce engine coolant flow during idling and low-speed operation to prevent over-cooling, assuring smooth operation and low emissions. A one-way valve permits simplified coolant system flushing. Dry-sump engine incorporates an oil reservoir mounted adjacent to the cylinder bank. The tank shape and location, together with a specially designed internal multi-baffle system, optimize engine lubrication under a wide variety of marine operating conditions. A uniquely designed crankcase breather system featuring three breather chambers prevents oil from flowing out of the engine or clogging the breather system if the hull is accidentally overturned. Engine-cooling water circulates through the turbocharger housing to enhance compressor life.
Water-cooled cast aluminum exhaust manifold contributes to total heat management and reduces exhaust noise. Output end is directly coupled to the jet pump drive via a rubber damper, providing shock-free, efficient power transfer while minimizing lateral crankshaft load forces. Engine power and pump characteristics are carefully matched for maximum performance without the use of power-robbing gear-reduction systems. Axial-flow single-stage Solas 155mm jet pump with three-blade impeller is matched to the four-stroke power characteristics.
A proprietary Honda impeller design and ECU control of the turbocharger waste gate minimize pump cavitation, resulting in quiet pump operation and extended impeller life. Pump servicing features include easy-to-disassemble pump, driveshaft, and driven coupling, and an easily accessible driveshaft bearing grease fitting. Hull. Unique AquaTrax hull design provides excellent overall stability and exceptional low- and high-speed turning performance without sacrificing the ability to perform low-speed maneuvers.
Dry-sump design allows the engine to be mounted low in the hull, resulting in a very low center of gravity that contributes to the AquaTrax's exceptional handling performance. Raised hull design aids in docking and provides excellent splash protection. Sponson design further contributes to the AquaTrax's low-speed maneuverability and high-speed stability. Strong, lightweight fiberglass reinforced plastic (FRP) hull and deck are joined and permanently sealed at the gunwale, providing the AquaTrax with a distinctive and attractive profile. The liner-type FRP inner hull increases hull rigidity more than 200 percent compared to a single-hull design. AquaTrax hull is designed to be a stable platform for mounting from deep water and to be easily uprighted in case of accidental overturns. Footwell areas have an anti-slip surface to provide sure-footed comfort when mounting, operating and dismounting the AquaTrax.
Forward-located large-capacity, 16.6-gallon polyethylene fuel tank is attached to the hull with rubber-cushioned hold-down straps. A two-way valve is provided to control internal tank pressure and prevent water incursion or fuel leakage if the hull is accidentally overturned.
Abundant storage is available in two sealed compartments, with a large, 23.1-gallon front storage box located under the front hood and a smaller, 2.5-gallon compartment located in front of the rider. Additional Features.
Honda Ignition Control System (ICS) senses low oil-pressure and/or abnormally high coolant temperatures and acts to limit or shut off engine operation as necessary. If oil pressure drops below the optimum level, the ICS limits engine speed to 3000 rpm. Extremely low oil-pressure stops the engine. If high coolant temperature is detected, a warning light and audible alarm are activated.
ICS also shuts off the engine after the hull is accidentally overturned. AquaTrax's selectable Limit Mode provides a lower top-speed setting, ideal for beginning riders, borrowers and rental users. The system displays 'Limit Mode' on the multi-function display when activated, and can be reset with push-button controls. Electronic keyless ignition system (ID mode) allows operator to select from 999 possible identification numbers to effectively deter unauthorized use. Waterproof instruments feature LCD digital displays for GPScape, speed (mph), trip distance (miles), travel time (hours and minutes) clock and engine hourmeter; LCD analog bar graph display for engine speed and fuel level; flashing indicator light and audible alarm for fuel level, battery charge, coolant temperature, oil pressure and fuel injection. Self-diagnosing ECU cycles at start-up and operates continuously during operation to provide immediate troubleshooting and warning functions.
Operational lanyard tethers the ignition button to the operator's wrist or personal flotation device (PFD) and stops the engine if tether comes unplugged. The fully sealed fuel system is leak-free and vapor-free, eliminating the possibility of water contamination. Anti-corrosion treatments for die cast aluminum components include Alodine/Alumite chromate surface plating with an additional Superlac top-coat for exterior components, and epoxy-resin-based primer applied to coolant-exposed parts before Alodine/Alumite treatment. Extensive use of stainless steel, chrome plated and zinc plated stays and fasteners. Waterproof electrical couplers and spark plug/coil caps. Rubber engine-mounts feature two-phase damping to simultaneously minimize engine vibration and engine shock when the AquaTrax is traversing rough water.
Simple and durable mechanical cable steering system directs the jet nozzle's thrust for directional control. Hand-operated controls include right-handlebar-mounted trigger-type throttle control operated by pulling the trigger back to increase engine speed and by releasing the trigger to return engine speed to idle; sealed stop and start buttons on the left handlebar; a reverse lever faired into the upper-left shelter.
Durable, paddle-type speed sensor assembly is flush-mounted on the bottom of the ride plate and provides accurate performance in all riding conditions. Handlebars are equipped with a cushioning pad for extended rider comfort. Dual wide-view color-matched aerodynamic mirrors are both attractive and functional.
Seat cushions are made from urethane foam material and covered with UV-resistant marine-grade vinyl to enhance durability and long-term appearance. Folding rear step for easy reboarding. Seat strap for easier reboarding. Fire extinguisher storage is located underneath the rear passenger seat.
Fully sealed, maintenance-free 18AH battery. Stern-mounted trailer tie-down loops provide convenient points for securing the AquaTrax during transport. Transferable one-year, limited warranty; extended coverage available with a Honda Protection Plan. Ownership includes one-year complimentary membership in the Honda Rider's Club of America™ (HRCA®). Benefits include: discounts, travel benefits, roadside assistance for pwc transport vehicle while pwc is being transported, one year complimentary subscription to Honda Red Rider™ magazine, access to HRCA Clubhouse Web site (www.hrca.honda.com), access online to Honda Common Service Manual. For HRCA details, call 1-800-847-HRCA. For dealers only, please call (310) 783-3958.
Available accessories. Cover.
INTRODUCTION These manuals contains an introductory description on and procedures for the inspection, service and overhaul of its main components. General knowledge information is not included. Please read the GENERAL INFORMATION section to familiarize yourself with basic information concerning your personal watercraft PWC in the manual. Read and refer to the other sections in this manual for information regarding proper inspection and service procedures.
These manuals have been prepared using the latest information available at the time of publication. If a modification has been made since then, differences may exist between the content of these manuals and the actual PWC personal water craft.
Illustrations in these manuals are used to show the basic principles of operation and work procedures of the actual personal watercraft and components in exact detail. These manuals are intended for use by technicians who already possess the basic knowledge and skills to service a personal watercraft motors and components. Persons without such knowledge and skills should attempt with caution to service any component or engine by relying on this manual only.
Never attempt to perform any work with out the assistance of a service manual. Apprentice mechanics or do-it-yourself mechanics that don’t have the proper tools and equipment may or may not be able to properly perform the services described in this manual. Improper repair may result in injury to the mechanic and may render the engine unsafe for the watercraft operator and passengers. 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. Use the special tools designed for this product to avoid damage and incorrect assembly.
Use only metric tools when servicing the watercraft. Metric bolts, nuts and screws are not interchangeable with English fasteners.
Install new gaskets, O-rings, cotter pins, and lock plates when reassembling. 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. Clean parts in cleaning solvent upon disassembly. Lubricate any sliding surfaces before reassembly. After reassembly, check all parts for proper installation and operation. 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.
2006 Honda Aquatrax F12 Service Manual
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.
Connect a garden hose to the flush connector fitting. DO NOT TURN ON THE WATER! Start the engine. Turn on the water to begin flushing. Turn off the water to end flushing. 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.
Service Manual For 2006 Honda Aquatrax F12
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.