HOW TO USE THIS MANUAL CONTENTS

This service manual describes the service procedures for the

ARX1500T3, ARX1500T3D GENERAL INFORMATION
--

Follow the Maintenance Schedule (Section 4) recommendations to

ensure that the personal watercraft is in peak operating condition TECHNICAL FEATURES
I
Performing the first scheduled maintenance is very important It
compensates for the initial wear that occurs during the break-in period
I
HULUHOODIBODY PANELS I
Sections 1, 4 and 5 apply to the whole personal watercraft Section 3
illustrates procedures for removal/installationof components that may be
required to perform service described in the following sections
1 MAINTENANCE
Section 6 through 19 describe parts of the personal watercraft, grouped
according to location
FLUSHING AND STORAGE
P

Find the section you want on this page, then turn to the table of contents
on the first page of the section
LUBRICATION SYSTEM
Most sections start with an assembly or system illustration, service
information and troubleshooting for the section. The subsequent pages
COOLING SYSTEM
give detailed procedures
FUEL SYSTEM
If you are not familiar with this personal watercraft, read Technical (Programmed Fuel Injection)
Features in Section 2.
If vou do not know the source of vehicle trouble, a0 to section 21 ENGINE REMOVAUINSTALLATION

CYLINDER HEADNALVE
Your safety, and the safety of others, is very important. To help you
make informed decisions we have provided safety messages and
other information throughout this manual Of course, it is not
practical or possible to warn you about all the hazards associated
1 ALTERNATORISTARTER CLUTCH I
with servicing this vehicle
You must use your own good judgement
You will find important safety information in a variety of forms
including
Safety Labels - on the vehicle
1 EXHAUST SYSTEMITURBOCHARGER I
Safety Messages - preceded by a safety alert symbol A and
one of three signal words, DANGER, WARNING, or CAUTION.
These signal words mean Q PROPULSION SYSTEM
You WILL be KILLED or SERIOUSLY STEERINGIREVERSE SYSTEM
HURT if you don't follow instructions

You CAN be KILLED or SERIOUSLY HURT BATTERYICHARGING SYSTEM

if you don't follow instructions
a
You CAN be HURT if you don't follow 2 IGNITION SYSTEM
instructions a
I-
Instructions - how to service thisvehicle correctly and safely ELECTRIC STARTER
$
_1

As you read this manual, you will find information that is preceded by a
METERISWITCHES
m ) symbol The purpose of this message is to help prevent
damage to your vehicle, other property, or the environment. WIRING DIAGRAM

TROUBLESHOOTING
ALL INFORMATION, ILLUSTRATIONS, DIREC-
TIONS AND SPECIFICATIONS INCLUDED IN
THIS PUBLICATION ARE BASED ON THE LAT-
INDEX
EST PRODUCT INFORMATION AVAILABLE AT
THE TIME OF APPROVAL FOR PRINTING.
Honda Motor Co., Ltd. RESERVES THE RIGHT
TO MAKE CHANGES AT ANY TIME WITHOUT
NOTICE AND WITHOUT INCURRING ANY OBLI-
GATION WHATSOEVER. NO PART OF THIS
PUBLICATION MAY BE REPRODUCED WITH-
OUT WRITTEN PERMISSION. THIS MANUAL IS
WRITTEN FOR PERSONS WHO HAVE
ACQUIRED BASIC KNOWLEDGE OF MAINTE-
NANCE ON Honda MOTORCYCLES, MOTOR

1 SCOOTERS, ATVS OR PERSONAL WATER

CRAFT.

Honda Motor Co., Ltd.

SERVICE PUBLICATION OFFICE

Date of Issue:April, 2008

@ Honda Motor Co., M g e : 2 2008 Honda Aquatrax ARX1500 ARX 500 - www.ReadManuals.com
SYMBOLS
The symbols used throughout this manual show specific service procedures. If supplementary information is required pertaining to
these symbols, it would be explained specifically in the text without the use of the symbols.

a*
*# Replace the part(s) with new one(s) before assembly.

1 Use the recommended engine oil, unless otherwise specified.

I Use molybdenum oil solution (mixture of engine oil and molybdenum grease in a ratio of 1 : 1).
3 ,
Use multi-purpose grease (lithium based multi-purpose grease NLGI #2 or equivalent).

Use water resistant grease #0 (Urea based multi-purpose grease NLGI #0 or equivalent).
Example: EXCELITE EPO manufactured by KYODO YUSHI, Japan

Use water resistant grease #2 (Urea based multi-purpose grease NLGI #2 or equivalent).
Example: EXCELITE EP2 manufactured by KYODO YUSHI, Japan

Use water resistant molybdenum disulfide grease (containing more than 3% molybdenum disulfide, NLGI
#2 or equivalent).
Example: UNILITE M No.2 manufactured by KYODO YUSHI, Japan

Use molybdenum disulfide grease (containing more than 3% molybdenum disulfide, NLGI #2 or
equivalent).
Example: MolykoteB BR-2 plus manufactured by Dow Corning, U.S.A.
Multi-purpose M-2 manufactured by Mitsubishi Oil, Japan

Use molybdenum disulfide paste (containing more than 40% molybdenum disulfide, NLGI #2 or
equivalent).
Example: MolykoteB G-n Paste manufactured by Dow Corning, U.S.A.
Honda Moly 60 (U.S.A. only)
Rocol ASP manufactured by Rocol Limited, U.K.
Rocol Paste manufactured by Sumico Lubricant, Japan

Use silicone grease.

Apply a locking agent. Use a medium strength locking agent unless otherwise specified.

Apply sealant (engine).

- - - -

Apply silicone sealant (SHIN-ETSU KE45T or equivalent).

- -- -

Page: 3 2008 Honda Aquatrax ARX1500 ARX 500 - www.ReadManuals.com

 GENERAL INFORMATION
SERVICE RULES
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 i n 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 1-19 ).

ABBREVIATION
Throughout this manual, the following abbreviations are used to identify the respective parts or systems.
Abbrev. term Full term
PGM-FI Programmed Fuel Injection
MAP sensor Manifold Absolute Pressure sensor
TCP sensor Turbo Charged Pressure sensor
TP sensor Throttle Position sensor
ECT sensor Enaine Coolant Temoerature sensor

1- CMP sensor
Intake Air Temperature sensor
Engine Oil Temperature sensor
Camshaft Position sensor
CKP sensor Crankshaft Position sensor
EOP (High) switch 1 Engine Oil pressure (High) switch
EOP (Low) switch 1 Enaine Oil pressure (Low) switch
IACV idle Air control Valve
-I MST switch Manifold Surface Temperature switch
1 WMT sensor 1 Water Muffler Temoerature sensor 1
ECM Engine Control ~ o d u l e
EEPROM 1 Electrically Erasable Programmable Read Only Memory
DLC 1 Data Link Connector
SCS connector 1 Service Check Short connector
HDS Honda Diagnostic System
DTC Diagnostic Trouble Code
MIL Malfunction Indicator Lamp
FP Fuel Pump
OTS Off-Throttle Steering

1-2 Page: 5 2008 Honda Aquatrax ARX1500 ARX 500 - www.ReadManuals.com

 GENERAL INFORMATION
MODEL IDENTIFICATION
"^n.
This manual covers two types of ARX1500 models:
T3: Turbocharger model
T3D: Turbocharger model equipped with GPS receiver and boarding step
Be sure to refer to the procedure that pertains t o the appropriate version of the ARX1500.

Page: 6 2008 Honda Aquatrax ARX1500 ARX 500 - www.ReadManuals.com 1-3

GENERAL DWFORMAT10N
SERIAL NUMBERS
The engine serial number, hull identification number are used to register the watercraft. They are unique numbers that dis-
tinguish each watercraft from other similar models.
If the watercraft is ever stolen these numbers will help identify it. The owner should keep a record of these numbers in a
place other than the watercraft.

HULL NUMBER IDENTIFICATION

d
~anufactirers
I.D. 1 ierial
Number
(Model type code)
Month year of
Certification
h o d e l Year of
Watercraft

Month code: A = January, B = February-.-!- = December

Year of certification: 08 = 2008; etc.
The hull identification number is located on the rear of the hull.
rn

I
I
\
HULL IDENTIFICATION NUMBER 1
I

The registration identification number is located on both sides of the

watercraft.

REGISTRATION
IDENTIFICATION NUMBER

The engine serial number is located on the upper side of the oil tank.
ENGINE SERIAL NUMBER 1

1-4 Page: 7 2008 Honda Aquatrax ARX1500 ARX 500 - www.ReadManuals.com

 GENERAL INFORMATION
The throttle body identification number is stamped on the lower side
of the throttle body.

LABELS
The color label is attached on the inside of the front hood. When order-
ing color-coded parts, always specify the designated color code.

The Emission Control Information Label is located on the cylinder head

cover as shown. It gives basic emissions certification information.
EMISSION CONTROL INFORMATION LABEL

Canada model only:

-- -
EMISSION CONTROL INFORMATION LABEL

Page: 8 2008 Honda Aquatrax ARX1500 ARX 500 - www.ReadManuals.com 1-5

GENERAL INFORMATION
GENERAL SPECIFICATIONS
ITEM SPECIFICATIONS
MODEL CODE 1 Hull 1 ARXI 500T3/T3D (SW05) I
1 Engine SW05E
DIMENSIONS 1 Overall length 3,400 m m (133.9 in)
Overall width 1,245 m m (49.0 in)
Overall height 1,075 m m (42.3 in)
Curb weight ARXI BOOT3 433 kg (955 Ibs)
ARXI 500T3D 435 kg (959 Ibs)
Rider capacity 3 person
1 Maximum weight capacity - - 238.5 kg (525 Ibs)
PERFORMANCE 1 Maximum output 147.1 kW (197.3 PS) at 6,500 rpm
Maximum torque 230.0 N - m (23.5 kgf-m) at 5,000 rpm
Fuel consumption at full throttle 64.6 liters (17.07 US gal, 14.21 Imp gal)/hour
Cruising range at full throttle 1 hour 5 minute
Fuel tank capacity 70.0 liters (18.49 US gal, 15.40 Imp gal)
Fuel tank reserve capacity 15.5 liters (4.10 US gal, 3.41 Imp gal)
HULL Hull type Deep V
Hull material FRP
ENGINE Engine type 4 stroke
Cylinder arrangement 4 cylinders in-line, longitudinal installed
Bore and stroke 79.0 X 75.0 m m (3.11 X 2.95 in)
Displacement 1,470 cm3 (89.7 cu-in)
Compression ratio 8.5 : 1
Intake system Turbocharged with intercooler
Valve train Chain driven, DOHC
Intake valve opens at 1 m m lift - 5' BTDC
closes at 1 m m lift 30ÂABDC
Exhaust valve opens at 1 m m lift 30' BBDC
closes at 1 m m lift - 5' ATDC
Lubrication system Dry sump
Oil pump type Trochoid
Cooling system Water cooled
Engine dry weight 100.5 kg (221.6 lbs)
Firing order 1-3-4-2
FUEL DELIVERY Type PGM-FI (Programmed Fuel Injection)
SYSTEM Throttle bore 54 m m (2.1 in)
PROPULSION Jet pump type Single stage, axial flow
Impeller rotation (viewed from rear) Counterclockwise
Transmission Direct drive from engine
Steering nozzle angle (horizontal) 23'
Impeller type Stainless steel, 3-blades
Minimum water level for jet pump 90.0 cm (3.54 in)
Bilge pump type Automatic siphon type
1 Reverse system Reverse bucket type
1 Ignition system Computer-controlled digital transistorized
starting system Electric starter motor
Charging system Triple phase output alternator
Regulator/rectifier SCR shorted, triple phase full-wave rectifica-

1-6 Page: 9 2008 Honda Aquatrax ARX1500 ARX 500 - www.ReadManuals.com


LUBRICATION SYSTEM SPECIFICATIONS
ITEM
Engine oil capacity
Recommended engine oil
Oil pressure (At EOP (Low) switch)
GENERAL INFORMATION
Unit: m m (in
STANDARD SERVICE LIMIT
After draining 4.2 liters (4.4 US qt, 3.7 Imp qt)
After draininglfilter 4.3 liters (4.5 US qt, 3.8 Imp qt)
change
After disassemblv 5.3 liters (5.6 US qt, 4.7 Imp qt)
Pro Honda GN4 4-stroke oil (U.S.A and
Canada) or equivalent motor oil
API service classification: SG or Higher
JASO T 903 standard: M A
Viscosity: SAE 10W-30
294 kPa (3.0 kgf/cm2, 43 psi)

Oil pump rotor Tip clearance

Bodv clearance
1 Side clearance
s

FUEL SYSTEM (Programmed Fuel Injection) SPECIFICATIONS

I
ITEM SPECIFICATIONS
Throttle body identification number AC54 - 954
Idle speed 1,200 Â 100 rpm
Throttle lever free play 3 - 5 m m (118-3116in)
ECT sensor resistance at 20°C/680 2.2 - 2.8 kQ
at 100°C/22OF 0.1 - 0.2 k!2
EOT sensor resistance at 20°C/680 2.5 - 2.8 kt2
at 100°C/2120 0.2 - 0.3 kt2
WMT sensor resistance at 20°C/680 2.5 - 2.8 kf2
at 100°C/2120 0.2 - 0.3 kt2
Fuel injector resistance (at 20°C/680F 9.9 - 11.1 a
CMP sensor peak voltage (at 20°C/680F 0.7 V minimum
CKP sensor ~ e a voltaae
k " .(at 20°C/680F I
0.7 V minimum -
Fuel pressure at idle 294 kPa (3.0 kgf/cm2, 43 psi)

Page: 10 2008 Honda Aquatrax ARX1500 ARX 500 - www.ReadManuals.com 1-7

 GENERAL INFORMATION
TORQUE VALUES
STANDARD TORQUE VALUES
TORQUE TORQUE
FASTENER TYPE N - m (kgfm, Ibf.ft)
FASTENER TYPE N - m (kgf-m, Ibf-ft)
5 m m hex bolt and nut 4.9 (0.5, 3.6) 5 m m screw 3.9 (0.4, 2.9)
1 6 m m hex bolt and nut
8 m m hex bolt and nut
9.8 (1.0, 7)
22 (2.2, 16)
6 m m screw
6 m m flange bolt
10 m m hex bolt and nut 34 (3.5, 25) (8 m m head, small flange)
12 m m hex bolt and nut 54 (5.5,40) 6 m m flange bolt
(8 m m head, large flange)
6 m m flange bolt
(10 m m head) and nut
8 m m flange bolt and nut
10 m m flange bolt and nut
Torque specifications listed below are for main fasteners.
Other fasteners should be tightened to standard torque values listed above.

s
HULLIHOODIBODY PANELS
THREAD
REMARKS
DIA. (mm)
Sponson bolt 8 Apply locking agent
to the threads
Pilot water nozzle nut See page 3-6

, Bow eye nut

Side panel socket bolt
Passenger grab rail socket bolt
See page 3-7
Apply locking agent
t o the threads
Stern eyelet plate nut
Noise reduction damper nut
Side cover socket bolt (small) Apply locking agent
to the threads
Side cover socket bolt (large)
Reverse lever rail socket bolt
Post cover bolt
Hood hinge mounting nut
Coupler cover bolt
Boarding step pipe screw Apply locking agent
(ARX1500T3D only) to the threads
Boarding step bracket bolt Apply locking agent
(ARX1500T3D only) to the threads
Hood catch stud nut Self-lock nut.
Hood catch nut Self-lock nut.
Hood damper rod ball stud
Seat catch stud nut (front and rear) Self-lock nut
Seat catch bolt (front and rear)
Tow hook nut Apply locking agent
t o the threads

7-10 Page: 13 2008 Honda Aquatrax ARX1500 ARX 500 - www.ReadManuals.com

 GENERAL INFORMATION
MAINTENANCE
THREAD TORQUE
ITEM Q'TY REMARKS
DIA. (mm)
Throttle cable lock nut 2 6
Spark plug 4 10
Engine oil filter cartridge 1 20 Apply engine oil to
the threads and seat-
ing surface
Anode (turbocharger) 1 8 Apply locking agent
to the threads
Anode cap (turbocharger) 1 18
Anode cap (oil tank cover) 1 36 Apply multi-purpose
grease to the threads
Reverse cable joint lock nut 2 5
Steering cable joint lock nut 2 6
Bearing housing grease nipple 1 6
Bearing housing grease nipple joint 1 10
LUBRICATION SYSTEM
THREAD TORQUE
ITEM Q'TY REMARKS
-
DIA. (mm) N - m (kgf-m, Ibf-ft)
Oil filter boss (oil tank side) 20 See page 6-7
Oil tanklfront crankcase cover bolt 8 22 (2.2, 16)
(8 m m )
Oil pumptfront crankcase cover bolt 8
(8 m m )
Front crankcase cover bolt (6 x 40 m m ) 6
Front crankcase cover bolt (6 x 90 m m ) 6
Front crankcase cover bolt (6 x 100 m m ) 6
Front crankcase cover bolt (6 x 75 m m ) 6
Oil cooler bolt 6
Oil thermostat cap 38
Oil pump driven joint bolt 6 Apply locking agent
to the threads
18 m m sealing bolt (front crankcase 18 Apply locking agent
cover) to the threads
Crankcase breather hose clamp bolt 6
(oil tank side) -

Page: 14 2008 Honda Aquatrax ARX1500 ARX 500 - www.ReadManuals.com 1-11

 GENERAL INFORMATION
FUEL SYSTEM (Programmed Fuel Injection)
r-
ITEM THREAD TORQUE
DIA. (mm) REMARKS 4s
N.m (kgf-m, Ibf-ft)
Fuel pump lock nut 1 - 93 (9.5, 69)
Airbox mounting bolt 1 6 8 (0.82, 5.9)
Airbox band screw 1 - 0.69 (0.07, 0.5)
Airbox connecting hose band screw
Pressure regulator mounting bolt
1
2
-
6
0.69 (0.07,0.5) I
9.8 (1.00, 7.2)
Fuel hose joint mounting bolt 2 6 9.8 (1.00, 7.2)
Fuel feed pipe mounting bolt 4 5 5.4 (0.55, 4.0)
Throttle body mounting bolt 4 8 19.6 (2.0, 14)
Intake manifold mounting socket bolt
EOP (Low) switch
8
1
8
PT 118
22 (2.2, 16)
12 (1.2,9) Apply sealant to the
I1
threads
EOP (High) switch 1 10 22 (2.2, 16)
MAP sensor mounting bolt 1 5 5.4 (0.55, 4.0)
ECT sensor 1 10 12 (1.2,9)
EOT sensor 1 10 15 (1.5, 11)
IAT sensor mounting screw 2 5 5.4 (0.55, 4.0)
Knock sensor 1 12 32 (3.3, 24) Apply sealant to the
threads
ECM mounting bolt
OTS limit switch
Throttle cable stay mounting screw
(intake manifold side)
2
1
2
6
20
6
8 (0.82, 5.9)
2.2 (0.22, 1.6)
5.4 (0.55, 4.0) I
Maintenance port cap chain 1 5 5.4 (0.55, 4.0)
mounting screw I

ENGINE MOUNTING

ITEM
THREAD
DIA. (mm)
TORQUE
N-m (kgfm,
REMARKS 1
Engine mounting bolt 4 12 60 (6.1, 44)
the threads and seat-
ing surface
1 Engine mounting bolt (with rubber
mount)
Apply engine oil to
the threads and seat-
ina surface
CYLINDER HEADIVALVE

ITEM
Cylinder head cover bolt
1 Q*m
4
I THREAD
DIA. (mm)
6
TORQUE
N-m (kqf-m, Ibf-ft)
REMARKS

1 Camshaft holder bolt 20 6 Apply engine oil to

the threads and seat-
ing surface
Cylinder head mounting bolt 10 Apply molybdenum
oil solution to the
threads and seating
surface
1 Cam chain tensioner pivot bolt Apply locking agent
to the threads
1
1 Cam chain t e s o n e r lifter socket bolt
Cam sprocket bolt
2
4 Apply locking agent
to the threads
1 CMP sensor rotor bolt 2 6 12 (1.2, 9) Apply locking agent
I to the threads

1-12 Page: 15 2008 Honda Aquatrax ARX1500 ARX 500 - www.ReadManuals.com

 GENERAL INFORMATION
ALTERNATORSTARTER CLUTCH
THREAD TORQUE
ITEM Q'TY REMARKS
DIA. (mm) N - m (kgf-m, Ibfftl
Alternator stator mounting bolt 4 6 10 (1.0,7)
Alternator wire clamp bolt 1 6 12 (1.2, 9)
Starter clutch outer torx bolt 6 6 16 (1.6, 12) Apply locking agent
to the threads
Flywheel bolt 1 12 Apply engine oil to
the threads and seat-
ing surface; Left-hand
threads
Drive coupler 1 24

THREAD TORQUE
ITEM Q'TY REMARKS
DIA. (mm) N-rn (kcif-m, IbfW
Turbocharger oil feed pipe oil filter bolt 1
Turbocharger oil return pipe mounting 2
bolt
Crankcase bolt (9 mm) 14 Apply engine oil to
the threads and seat-
ing surface
(8 mm) 14
Oil drain pipe guide bolt 1
Drive coupler bolt 1 Apply engine oil t o
the threads and seat-
ing surface
Connecting rod bearing cap nut 8 Apply engine oil to
the threads and seat-
ing surface
Balancer reduction gear shaft sealing cap 1
20 m m sealing bolt 1 Apply locking agent
to the threads
45 m m sealing cap (upper crankcase) 1 Apply multi-purpose
grease to the threads

Win

Page: 16 2008 Honda Aquatrax ARX1500 ARX 500 - www.ReadManuals.com 1-13

GENERAL INFORMATION
EXHAUST SYSTEM/TURBOCHARGER
THREAD TORQUE
ITEM REMARKS
DIA. (mm) N - m (kgf-m, Ibf-ft)
1 12 28 (2.9, 21)
charger)
Oil feed pipe oil orifice bolt
(upper of turbocharger)
Water hose joint bolt (turbocharger) 4 6 12 (1.2, 9) Apply locking agent
to the threads
1 Turbocharaer stud bolt 4 8 - See page 13-11
PROPULSION SYSTEM

I ITEM
Water jet nozzle bolt
TORQUE
N-m (kgf-m, Ibf-ft)
22 (2.2, 16)
REMARKS
Apply locking agent
to the threads
Jet pump mounting bolt Apply locking agent
to the threads
Cooling water pipe bolt Apply locking agent
to the threads
Stator cap socket bolt Apply locking agent
to the threads
Impeller Apply water resistant
molybdenum
disulfide grease to
the threads
Thrust plate bolt Apply locking agent
to the threads
Bearing housing boot band screw
Bearing housing mounting nut
Driven coupler bolt Apply engine oil to
the threads and seat-
ing surface
Intake grate bolt Apply locking agent
to the threads
Ride plate bolt Apply locking agent
to the threads

1-14 Page: 17 2008 Honda Aquatrax ARX1500 ARX 500 - www.ReadManuals.com

 GENERAL INFORMATION
STEERING/REVERSE SYSTEM
THREAD TORQUE
ITEM Q'TY REMARKS
DIA. (mm) N-m (kgf-m, Ibf-ft)
Handlebar holder bolt 8 22 (22, 16)
Left handlebar switch housing screw
Throttle lever pivot bolt Apply locking agent
to the threads
Throttle lever holder screw
Steering shaft holder nut Self-lock nut
Steering shaft retainer nut Apply locking agent
to the threads
Steering cable bracket mounting nut Self-lock nut
Steering cable bracket holder bolt Apply locking agent
to the threads
Steering cable arm holder nut Self-lock nut,
Apply locking agent
t o the threads
Steering cable joint pivot nut
(cable arm and steering nozzle)
Steering cable joint pivot lock nut Self-lock nut
(cable arm and steering nozzle)
Steering cable setting nut (thrust plate)
Steering nozzle pivot bolt Apply locking agent
to the threads
Reverse lever holder mounting nut Apply locking agent
to the threads
Reverse lever pivot socket bolt
Reverse cable setting nut (thrust plate)
Reverse bucket pivot bolt Apply locking agent
to the threads
Reverse bucket guide nut Self-lock nut
Reverse bucket arm pivot bolt Apply locking agent
to the threads
Reverse bucket catch bolt (bucket arm) Apply locking agent
to the threads
Reverse lever pivot link bolt
Reverse cable joint stud (bucket arm) Apply locking agent
to the threads
ELECTRIC STARTER
THREAD TORQUE
ITEM Q'TY
A mm) 1 N - m (kgf-m, Ibf-ft)
REMARKS
Starter motor case mounting bolt 2
Starter motor brush mounting screw 1

1 Starter relay switch box cover mounting

bolt
4

I Starter relay switch box cover connector

stav bolt

Page: 18 2008 Honda Aquatrax ARX1500 ARX 500 - www.ReadManuals.com 1-15

GENERAL INFORMATION
LUBRICATION & SEAL POINTS
ENGINE
MATERIAL
Sealant
Silicone sealant
Molybdenum disulfide oil
(a mixture of engine oil
and molybdenum
disulfide grease in a ratio
Engine oil
Multi-purpose grease
Locking agent
SHIN-ETSU KS613 grease
or Dow Corning SC102
1-16 Page: 19 2008 Honda Aquatrax ARX1500 ARX 500
LOCATION REMARKS
Crankcase mating surface See page 12-21
Oil pan mating surface
EOP (Low) switch threads See page 8-89
Knock sensor threads
Crankcase mating surface (front crankcase cover side) See page 6-14
Front crankcase cover wire grommet seating areas See page 6-14
Cylinder head semi-circular area edges See page 10-26
Valve stem sliding surface
Valve lifter outer surface
Camshaft cam lobes, journals and thrust surfaces
Starter reduction gear shaft outer surface
Piston pin outer surface
Crankshaft main journal bearing sliding surface and
thrust surface
Balancer journal bearing sliding surface
Crankpin bearing sliding surface
Piston and piston ring sliding surface
Starter sprag clutch contacting surfaces
Each gear tooth and rotating surface
Each bearing rotating area
Each O-ring
Other rotating and sliding areas
Each oil seal lip
Oil cooler spacer O-ring
20 m m sealing bolt (lower crankcase) Coat 6.5 m m from tip
MST switch setting plate bolt threads Coat 6.5 m m from tip
Oil pump driven joint bolt threads Coat 6.5 m m from tip
Anode threads (turbocharger) Coat 6.5 m m from tip
Anode tightening screw threads Coat 6.5 m m from tip
Water hose joint bolt threads (turbocharger lower side) Coat 6.5 rnm from tip
Cam sprocket bolt threads Coat 6.5 m m from tip
~ t a r t e clutch
r outer torx bolt threads Coat 6.5 m m from tip
MST switch outer surface 1.4 cm3 (page 8-88)
- www.ReadManuals.com
 GENERAL INFORMATION
BODY
MATERIAL LOCATION REMARKS
Silicone sealant Flushing connector seating surface and screw holes Apply 0.5 g (0.02 oz)

Pilot water nozzle threads and seating surface See page 3-6
Exhaust outlet screw holes (hull side) See page 13-16
Bow eye stud plate mounting areas See page 3-6
Stern eyelet plate mounting areas See page 3-8
Drain plug base screw holes See page 3-4
Ride plate front end fitting area See page 14-21
Thrust plate seating surface See page 14-24
Equal mixture of two Cable retaining base seating surface Apply 0.5 g (0.02 oz)
component urethane
based adhesives
(LOAD 7542 or equivalent)

Hull identification number plate Apply 0.5 - 1.0 g

(0.02 - 0.04 02)
5 m m (0.2 in)

-I '
92 m m (3.6 in)
Starter relay switch box base (bottom side) Apply 10 g (0.4 oz)

-
Drive shaft guide seating surface
5 m m (0.2 in) maximum
Does not overflow t o end
surface.

Noise reduction damper bracket seating area Apply 0.5 - 1.0 g

(0.02 - 0.04 02)

5 m m (0.2 in)
maximum
Intake lip fitting area See page 14-25
Thrust plate bolt washer seating surface See oaae 14-24

Page: 20 2008 Honda Aquatrax ARX1500 ARX 500 - www.ReadManuals.com 1-17

GENERAL INFORMATION
MATERIAL
Water resistant grease #0
Water resistant grease #2
Water resistant molybde-
num disulfide grease
1-18 Page: 21
LOCATION REMARKS
Impeller shaft bearing rotating area
Impeller shaft water seal lips
Impeller shaft O-ring
Cooling water pipe O-ring
Stator cap O-ring
Stator cap inside 40 g (1.4 oz)
Drive shaft bearing housing oil seal lips
Drive shaft bearing rotating area
Drive shaft bearing housing (between bearings)
Drive shaft bearing housing (between seals)
Drive shaft bearing housing grease nipple See page 4-20
Front hood hinge pin
OTS limit switch lever sliding area and pivot
Throttle cable (Each end) Apply 0.5 g (0.02 oz)
Driveldriven coupler splines
Impeller shaft threads
Impeller splines Fill u p 2 g (0.1 oz)
Steering shaft sliding surfaces
Steering shaft retainer sliding area
Steering cable joint pivot (each end)
Steering nozzle pivot collar
Reverse lever pivot sliding area
Reverse cable joint pivot (each end)
Reverse bucket arm pivot and bushings See page 15-17
Reverse bucket arm guide groove See page 4-21
Reverse bucket pivots
2008 Honda Aquatrax ARX1500 ARX 500 - www.ReadManuals.com
 GENERAL INFORMATION
CABLE & HARNESS ROUTING
w

HANDLEBAR SWITCH WIRE

Upper side

WARNING BUZZER

CABLE

1 WARNING
BUZZER WIRE
HANDLEBAR SWITCH WIRE
The cord length from the point of the
warning buzzer case end to steering
shaft is about 210 mm (8.3 in)

COMBINATION METER

GPS
(ARXI 500T3D only) CONNECTOR (ARXI5 0 0 ~ only)
3~

Page: 22 2008 Honda Aquatrax ARX1500 ARX 500 - www.ReadManuals.com 1-19

GENERAL INFORMATION

FUEL TANK
BREATHER HOSE

FUELTANK AIR VENT

HOSE 2-WAY JOINT WARNING

II - Meter 8P (Gray) and 10P (Gray)

- Handlebar switch 4P (Black)
THROTTLE CABLE -Warning buzzer 2 P (White)
- OTS limit switch 2P (Red)
- JUNCTION BOX 24P

1-20 Page: 23 2008 Honda Aquatrax ARX1500 ARX 500 - www.ReadManuals.com

 GENERAL INFORMATION

FUEL PUMPILEVEL SENSOR 5P

(GRAY) CONNECTOR

THROTTLE CAB

MAIN WIRE HARNESS

FUEL RETURN HOSE FUEL FEED HOSE

FUEL FEED HOSE CLIP \ /
BAND

TANK

Page: 24 2008 Honda Aquatrax ARX1500 ARX 500 - www.ReadManuals.com 1-21

GENERAL INFORMATION

FUEL FEED HOSE

CRANKCASE BREATHER HOSE

CRANKCASE BREATHER HOSE
(CYLINDER HEAD TO OIL TANK)
(OIL TANK TO AIRBOX PIPE)

SIDE

/ / AIRBOX PIPE
/ CRANKCASE BREATHER HOSE
EOP (HIGH) SWITCH 2P (Gray) (OIL TANK TO AIRBOX PIPE)
CONNECTOR

1-22 Page: 25 2008 Honda Aquatrax ARX1500 ARX 500 - www.ReadManuals.com

 GENERAL INFORMATION

WATER HOSE (P)

No.1 DIRECT IGNITION

3P (Black) CONNECTOR
PILOT WATER

RIGHT

WATER HOSE
\ 1 POSITION MARK
NO.I FUEL INJECTOR 2~
(Black) CONNECTOR
MAP SENSOR
a
\ 3~
1
WATER(Facing
HOSE up)

Page: 26 2008 Honda Aquatrax ARX1500 ARX 500 - www.ReadManuals.com 1-23

GENERAL INFORMATION

SENSOR WIRE

THROTTLE CABLE

JUNCTION BOX
24P CONNECTOR

SENSOR WIRE

GROUND CABLE
TERMINAL

IAT SENSOR 2P
ECT SENSOR 2P (Black) CONNECTOR
(Black) CONNECTOR

KNOCK SENSOR IP EOT SENSOR 2~

(Brown) CONNECTOR (Black) CONNECTOR

1-24 Page: 27 2008 Honda Aquatrax ARX1500 ARX 500 - www.ReadManuals.com

 GENERAL INFORMATION

\
BYPASS WATER WATER HOSE REGULATORIRECTIFIER
HOSE (D) POSITION MARK 5P (Gray) CONNECTOR
(Facing out)

CMP SENSOR 2P (Black) EOP (LOW) SWITCH IP (Gray)

EOP (LOW) SWITCH CONNECTOR CONNECTOR
CONNECTOR BO

ALTERNATOR 5P (Black) \
CONNECTOR EOP (HIGH) SWITCH
WIRE

Page: 28 2008 Honda Aquatrax ARX1500 ARX 500 - www.ReadManuals.com 1-25

GENERAL INFORMATION

WATE

HOSE (C)

1-26 Page: 29 2008 Honda Aquatrax ARX1500 ARX 500 - www.ReadManuals.com

Thank you very much
for your reading.
Please Click Here
Then Get More
Information.