JetSki Solutions - Installation Instructions >
Electrical Box Battery Stud Kit Installation
BATTERY STUD KIT INSTALLATION
Positive battery studs for Yamaha electric box
The Positive Battery Stud kit comes assembled. Note the aluminum bushings have an X marked on them. This area is where the rubber grommet will be, captured by the glass fiber plate below and the large washer and nut on top.
Disassemble the unit, noting the order the parts are in. Test-fit the unit and be sure the washer on top (outside the box) will be crushed or will sit very tight against the rubber grommet. If it does not sandwich the grommet tight, file or sand down the height of the aluminum bushing and test again until a very tight fit is achieved.
Also while test fitting, decide what position you want to have the wires lead off in so a easy connection to the starter solenoid can be had. The wire is heavy gauge and stiff, so planning your fit and assembly is important.
We recommend cutting out the plastic "rim" that trims out the fuse access hole flush with the inside cover. We also recommend removing the fuse. This is easy since the connectors are male / female, just remove the piece and put the two red wire together. We have yet to hear of blown fuses on Super Jets.
Once all dry fitting is complete, assemble the unit onto the grommets with the parts in the proper order and use red Loctite on the plain nut that tightens against the large washer. Tighten very tight, as you do not want the assemble to spin when tightening the Nyloc nut that will hold the positive cable terminal on the outside of the box. You should also soak some super glue around the top and bottom of the grommet, around the bushing, to lock it in place, and prevent any possible water intrusion.
Once the assembly is in place, you can connect the lugs to the terminals on the solenoid and assemble the electric box.
Once the box is back in the craft, mock up the positive cables and cut them to the correct length and install lugs on them (not provided). Remove the Nyloc nut, ensure the small washer is in place, install the lug onto the stud, and install Nyloc nut and tighten. Do not over tighten!
The two primary places water enters the electric box have now been eliminated, and you will find the electric box easier to work with. If you install a connector for the stator wires, you could remove the box easily and work on it somewhere besides the top of your motor or ski!
Please contact us if you do not understand these instructions, or need clarification.
