285/325 TurboJet Service Manual

Service Manual

285/325 TurboJet
MY23 Service Manual
Revision. 1.0 Document No. WI.158

Page 1 of 59 MY23
 285/325 TurboJet Service Manual

Contents
Service Manual ............................................................................................ 1

Contents ...................................................................................................... 2
Meaning of safety symbols and signal words ........................................................................ 4
Important safety messages ...................................................................................................... 4

Routine Maintenance ................................................................................... 5

1. Wash The Tender .............................................................................................................. 5
2. Raw Water Filter Clean .................................................................................................... 5
3. Engine Oil Level Check .................................................................................................... 6
4. Check Coolant Level ....................................................................................................... 7
5. Flush Open Loop Cooling System ................................................................................... 8
6. Grease and Corrosion Guard ......................................................................................... 9
7. Check Bilges .................................................................................................................... 10
8. Check Anodes ................................................................................................................ 10
9. Tube Inspection .............................................................................................................. 10

Engine ....................................................................................................... 11
A. Maintenance .................................................................................................................. 12
B. Engine Management System ........................................................................................ 13
C. Engine Replacement 903............................................................................................... 15

Helm and Fuel System ............................................................................... 21

A. Helm Removal................................................................................................................. 22
B. Fuel Tank Replacement ................................................................................................. 24

Steering and Helm Control ........................................................................ 25

A. Reverse Cable Replacement........................................................................................ 26
B. Steering Cable Replacement ....................................................................................... 29
C. Jet Pump Removal .......................................................................................................... 31

Electrical Systems ..................................................................................... 33

A. Battery Replacement ..................................................................................................... 34
B. Engine Control Unit Replacement ................................................................................ 35
C. Voltage Regulator Replacement ................................................................................. 37
D. Bilge Blower Replacement ............................................................................................ 38
E. Tether Switch Replacement .......................................................................................... 39
F. Ignition Switch Replacement ........................................................................................ 40
G. Helm Switches Replacement ........................................................................................ 41
H. Cluster Replacement ..................................................................................................... 42
I. Engine Fuse Box .............................................................................................................. 44
J. Boat Harness Fuse Box .................................................................................................... 45
K. Starter Relay Replacement ........................................................................................... 46

Exhaust System ......................................................................................... 48

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 285/325 TurboJet Service Manual

Ancillaries ................................................................................................. 49
A. Tube Replacement ........................................................................................................ 50
B. Tube Valves Replacement ............................................................................................ 54
C. Fire Extinguisher Replacement...................................................................................... 55
D. Heat Exchanger Replacement ..................................................................................... 56

BUDS Diagnostic ........................................................................................ 58

A. Cluster Coding ................................................................................................................ 58

Contact Details .......................................................................................... 59

Page 3 of 59 MY23
 285/325 TurboJet Service Manual

Meaning of safety symbols and signal words

This safety alert symbol appears throughout the Service Manual. It means attention, be alert, your safety is involved! Please read and
abide by the message that follows the safety alert symbol.

DANGER - indicates a hazardous situation which, if not avoided, will result in death or serious injury. WARNING -

indicates a hazardous situation which, if not avoided, could result in death or serious injury. CAUTION - indicates a

hazardous situation which, if not avoided, could result in minor or moderate injury.

NOTICE - indicates important information which although not considered hazardous, may potentially cause damage to property. The
safety alert symbol may not always be used with this signal word.

Important safety messages

Fuel System - fuel and fuel vapours are

highly flammable. Do not smoke when refuelling
or when servicing any part of the fuel system.

Engine exhaust gases - engine exhaust

gases contain carbon monoxide (CO). Only operate
the engine in well ventilated areas.

Hot engine surfaces - the engine and its

external surfaces can be extremely hot during
operation. Do not touch any of these surfaces and allow
to cool fully before carrying out any servicing tasks.

Electrical system - never work on a “live”

electrical system. This should be disconnected from the
battery before completing any servicing work.

Page 4 of 59 MY23
 Engine 285/325 TurboJet Service Manual

Routine Maintenance
To ensure a long service life and to maintain the tender in a safe and reliable condition, please follow these routine
maintenance instructions. Williams cannot accept any responsibility for damage or injury resulting from incorrect
maintenance or improper adjustment carried out by the owner.

1. Wash The Tender

Wash the tender regularly with fresh water to remove salt deposits.

2. Raw Water Filter Clean

Ensure the raw water filter is clean and clear of any debris. Open up and clean out the internal filter.

This part is a service item and must be emptied multiple times during the life of the working life of the Tender.

It is important to ensure a thin smear of Vaseline is added to the O-ring and it is not overtightened when installed.

Page 5 of 59 MY23
 Engine 285/325 TurboJet Service Manual

3. Engine Oil Level Check

Check engine oil level. When topping up, follow the engine manufacturer’s recommendations.
Engine must be at running temperature when checking oil level.

I. IMPORTANT: Boat must be levelled. Oil level can be checked either with the boat in the
water or out of the water.

A. If the boat is out of the water and on a trailer, block the wheels and raise the bow
slightly with the trailer jack (if so equipped) until the bumper rail is level.
Install a garden hose to the flushing connector. Do not open water tap at this time.
a) Never run the engine longer than 2 minutes. The drive line seals have no
cooling when the boat is out of the water.
b) Start engine and immediately open the water tap.
c) Continue to run the engine for 90 seconds at idle speed.
d) Close the water tap.
e) Run the engine at 5000 RPM for 5 seconds then stop the engine.
f) Wait at least 30 seconds. Pull the dipstick out and wipe clean.
g) Reinstall the dipstick and push in completely.
h) Remove the dipstick and read the oil level. It should be between the marks
shown below.

B. If the boat is in the water, it is of the utmost importance to follow this procedure in
order to obtain an accurate reading of the engine oil level.
a) Ensure engine is at normal operating temperature.
b) Let the engine idle for 30 seconds before stopping.
c) Stop Engine. Wait at least 30 seconds. Pull the dipstick out and wipe clean.
d) Reinstall the dipstick and push in completely.
e) Remove the dipstick and read the oil level. It should be between the marks
shown below.

XPS 4-Stroke Synthetic Blend Oil (Summer) or XPS 4-StrokeSynthetic Oil (All Climate). If XPS engine oil is not available
use for 903 engine 5W40 or 10W40 API SERVICE SN synthetic oil.

The engine oil and the engine filter must be replaced at the same time. 903 Engine Oil Capacity 1.8L.

First replacement after 50 hours then every 100 hours or 1 year

For more details refer to the 903 Engine Service Manual.

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 Engine 285/325 TurboJet Service Manual

4. Check Coolant Level

I. Always use Long Life Antifreeze, P/N 460777. If the recommended coolant is not available,
use a low silicate, extended life ethylene-glycol premixed coolant (50%-50%) specifically
formulated for internal combustion aluminium engines.
II. To prevent antifreeze deterioration, always use the same brand and grade. Never mix
different brands or grades unless the cooling system completely flushed and refilled.
III. Replace the engine coolant every 200 hours or 2 years, whichever occurs first. Coolant
filling quantity 903 engine 3L

For more details refer to the 903 or 1603 Engine Service Manual.

Page 7 of 59 MY23
 Engine 285/325 TurboJet Service Manual

5. Flush Open Loop Cooling System

I. Flush the open loop water circuit to remove salt, sand, shells, and other contaminants that
may be trapped in the raw water-cooling circuit. Daily flushing in salt water or foul water
use.
II. Failure to carry out flushing will significantly reduce the life of engine components and may
invalidate the warranty.
III. Flushing the exhaust system with fresh water is essential to neutralise corroding effects of
salt and other chemical products present in water.
IV. Exhaust system flushing should be performed when the boat is not expected to be used again
the same day or when it is stored for an extended period of time.
WARNING. Perform the flushing procedure in a well-ventilated area. Certain components in the engine
compartment may be very hot. Direct contact with hot components may result in skin burns. Do not touch any
electrical part or the jet pump area when the engine is running.
A. Wash the jet pump area with fresh water before commencing the flushing procedure.
B. Ensure the raw water filter is clean and clear of any debris. Open up and clean out the
internal filter.
C. Connect a water hose to the flushing point inside the helmsman’s footwell. Do not
open water tap at this time.
D. Start engine and immediately open the water tap.
CAUTION. Always start the engine before opening the water tap. Open the water tap immediately after the engine is
started to prevent overheating. Never run the engine without supplying water to the exhaust system when the boat
is out of the water.

E. Continue to run the engine for 90 seconds at idle speed.

CAUTION. Never run the engine for more than 2 minutes while the boat is out of the water. The driveline seal has no
cooling when the boat is out of the water.
F. Ensure there is water flowing out of the jet pump while flushing.
G. Close the water tap. Run the engine at 5000 RPM for 5 seconds then stop the engine.
CAUTION. Always close the water tap before stopping the engine.

H. Disconnect the hose from the flushing attachment.

• For better result we recommend using Stopsel product for flushing.

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 Engine 285/325 TurboJet Service Manual

6. Grease and Corrosion Guard

I. Apply a good quality marine grease containing Teflon (eg Quicksilver 101) to all control
cables, both under the helm and at the pump. Every 10 hours in water.
A. Grease all control cables at both ends and exercise to ensure good coverage.
a) Revers cable. For Reverse Cable Replacement see below.
b) Steering cable. For Steering Cable Replacement see below
c) Throttle cable.

II. Corrosion protection (spray an anticorrosion lubricant to metallic components in engine

compartment and under helm).

III. Lightly grease the extending running light pole base using white grease or similar.
Check all plugs and connections in the engine bay and under the helm. Ensure all plugs and
connections are lubricated and if required add more lubrication and re-connect.
Apply a bit of corrosion bock (recommended for electronic equipment) in the ignition key
switch.

Page 9 of 59 MY23
 Engine 285/325 TurboJet Service Manual

7. Check Bilges
I. Check bilges for water ingress, oil or fuel contamination and clean if necessary.

8. Check Anodes
I. Check the condition of all anodes. Inspect each month (every two weeks in salt water) and
change when necessary
A. At Jet Pump

9. Tube Inspection
I. Loss of tube pressure over 24 hours is not unusual. Temperature and atmospheric pressure
will affect tube pressures. Check pressures regularly. Tube pressure will fluctuate with
temperature. Inflate tubes in sequence to 24.80 kPa/ 250mB/3.6 psi. Failure to observe this
will compromise the sea-keeping ability and watertight integrity of the boat. Inflation valves
are fitted with quarter-turn locks to enable rapid deflation.
II. For replacing a valve see instruction below Tube Valve Replacement.

Page 10 of 59 MY23
 Engine 285/325 TurboJet Service Manual

Coolant tank
Engine Valve cover 903 Engine

Intake manifold

Oil filter

ECM
Rectifier
regulator Oil cooler
Throttle body
Air filter Water pump Magneto cover

Connecting socket Throttle plates Flame arrestor

Electric Catalytic
Spark plugs converter
starter

Page 11 of 59 MY23
 Engine - Maintenance 285/325 TurboJet Service Manual

A. Maintenance

First 50 hrs. or 1 year After 100 hours or 1 year After 200 hours or 2 year

Engine oil and filter Replace Replace

Coolant Inspect Inspect Replace

Throttle body Inspect Inspect

Spark plugs Inspect Inspect Replace

Flame arrestor Inspect

Spark plugs / Throttle Body / Connecting socket / Flame arrestor / PTO seal and sleeve

Spark plugs • Visually inspect condition of the spark plug.

Throttle body connecting socket • Visually inspect the throttle body connecting
socket for cracks or other damages and
replace if necessary.

Throttle body • Clean the throttle plates and the throttle bores
using the Pulley Flange Cleaner, P/N 460798.

Flame arrestor • Check for any debris that may be clogging the
flame arrestor.

• Clean the flame arrestor.

PTO seal and sleeve • Replace PTO oil seal and sleeve

Page 12 of 59 MY23
 Engine – Engine Management System 285/325 TurboJet Service Manual

B. Engine Management System 903 Engine

Ignition coils
TPS

CAPS

MAPTS

ETA CTS
Fuel injectors O2

KS OPS

CPS

Page 13 of 59 MY23
 Engine – Engine Management System 285/325 TurboJet Service Manual

Page 14 of 59 MY23
 Engine - Engine Replacement 903 285/325 TurboJet Service Manual

C. Engine Replacement 903

1) Depress tube valves and 1/4 turn anti- 4) Open the helm around 100 degrees, using a
clockwise to deflate the tubes. This will box and for safety, tie the steering wheel to
provide better access to the engine bay. bow eye.
Switch off the isolator (power).

2) To open fully the helm, follow the next

steps. Unplug the helm seat cushion on the
5) Now, there is access to the engine bay to
rear and top then remove it.
remove the engine.

3) Unclip and retain the locking pins from the

top or bottom end of both gas struts at the 6) Disconnect all the cables from the battery.
helm. You need a help as the helm is heavy.

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 Engine - Engine Replacement 903 285/325 TurboJet Service Manual

7) Disconnect the battery cables from the starter 10) Unscrew the towing valve and its bracket
relay. from the PPS bracket.

8) Unscrew and remove the engine fuse box 11) Loosen the hose clamp and disconnect the
and its base from the hull. raw water outlet hose from the towing valve.
Use heat gun for easy removing.

12) Disconnect the fuel pump power supply and

9) Remove the water strainer hoses. the fuel line.

Page 16 of 59 MY23
 Engine - Engine Replacement 903 285/325 TurboJet Service Manual

13) Locate the engine to boat harness connector 16) Unhook the fuel tank straps. Unscrew and
and disconnect by pulling the red tab retain all the hex head bolts from the battery
outwards and pressing the sides of the grey and heat exchanger bracket to allow the heat
sleeve inwards. exchanger to be lifted out with the engine.

14) Disconnect both plugs from the voltage 17) Remove the cat cooling raw water outlet
regulator. hoses and disconnect the exhaust
temperature sensor.

15) Unplug both of the connections from the

ECU or remove the ECU.
18) Remove the exhaust hose from cat-housing.

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 Engine - Engine Replacement 903 285/325 TurboJet Service Manual

19) Remove the Jet Pump by following the ‘Jet 22) Remove the security c-clip by pulling back
Pump Removal’ instruction below. the floating ring.

23) Or you can order a ‘Carbon Seal C-Clip

20) Remove and discard the aft PTO Oetiker Removal Tool’
clamp.

During assembly don’t use grease on the floating ring,

21) Remove the driver’s seat and base. but P-80 GRIP-IT Quick Drying Lubricant or equivalent.
To get clear access to the carbon seal C-clip
you might need to remove couple of hose
and cables. 24) Remove the drive shaft.

Page 18 of 59 MY23
 Engine - Engine Replacement 903 285/325 TurboJet Service Manual

28) If no lifting eyes place suitable lifting strops

25) Unscrew and retain each of the 8x nuts
around the port fwd and aft starboard lifting
securing the top of the engine mount feet.
feet. NOTE - keep the lifting strop to the port
side of the oil dipstick to prevent possible
damage.

26) Remove and retain the 4x mount feet plates.

Keep the bottom plates unmoved because the 29) Slowly lift the engine out of the bay
engine alignment. checking for any obstructions or trapped
cables/hoses.

27) Place suitable lifting strops in the engine

lifting eyes if they are fitted.

* Engine install is the reverse of removal.

The following points should be noted, however.

Page 19 of 59 MY23
 Engine - Engine Replacement 903 285/325 TurboJet Service Manual

a. Engine mount conical washers should be

oriented with the ‘T’ facing up.

b. Before fitting the drive shaft, a new Oetiker

clamp should be placed onto the PTO rubber
boot and then tightened once the driveshaft
has been installed.

c. Make sure the engine alignment is correct

and the drive shaft moves freely.

Page 20 of 59 MY23
 Fuel System 285/325 TurboJet Service Manual

Helm and Fuel System

Page 21 of 59 MY23
 Fuel System – Helm Removal 285/325 TurboJet Service Manual

A. Helm Removal
4) Open the helm around 100 degrees, using a
1) Depress tube valves and 1/4 turn anti- box and for safety, tie the steering wheel to
clockwise to deflate the tubes. This will bow eye.
provide better access to the engine bay.
Switch off the isolator (power).

5) Disconnect the steering cable from the

2) To open fully the helm, follow the next steering column. Remove the 2 locking nuts.
steps. Unplug the helm seat cushion on the
rear and top then remove it.

6) Remove the reverse cable from the

3) Unclip and retain the locking pins from the throttle/shift control unit by cutting the cable
top or bottom end of both gas struts at the tie and removing the split pin.
helm. You need a help as the helm is heavy.

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 Fuel System – Helm Removal 285/325 TurboJet Service Manual

7) Disconnect the throttle cable by removing 10) When the helm is disconnected from
the security pin and the split pin. electrics and cables, you need some help to
remove the helm from the hinges. Use a bit
of clear silicone under the hinge at
installation.

8) Disconnect the harness from the switches 11) Remove the helm carefully.
and units. Cut cable ties to free up the helm.

a) Helm install is the reverse of removal.

b) During the installation grease the cables and
spray corrosion guard over metal parts.

9) To remove the fuse box, first the back rest

needs to be removed.

c) Use white grease or similar on connections.

Page 23 of 59 MY23
 Fuel System – Fuel Tank Replacement 285/325 TurboJet Service Manual

B. Fuel Tank Replacement

1) Follow the steps 1-4 on the ‘Helm Removal’ 4) Disconnect the breathing and fuel filler hoses
instruction, then continue with the next step then unscrew the fuel filler.
here.

5) Lift out carefully the fuel tank.

2) Disconnect the fuel pump power supply and
the fuel line.
DANGER: Fuel in the system

a) Installation is the reverse of removal.

Follow the steps also at the Helm Removal
instruction to finish your job.
3) Unhook the straps and secure the straps on
that position to allow the fuel tank removal. b) During the installation use some grease and
corrosion guards on metal and electric parts
according to maintenance guide to extend the
life of the components.

c) Use white grease or similar on connections.

Page 24 of 59 MY23
 Steering and Helm Control 285/325 TurboJet Service Manual

Steering and Helm Control

Page 25 of 59 MY23
 Steering and Helm Control – Reverse Cable Replacement 285/325 TurboJet Service Manual

A. Reverse Cable Replacement

4) The other end of the cable is attached to the
1) Disconnect the cable from bucket, removing throttle under the helm.
the rod end, locking nut and rubber seals.

2) Using a box spanner remove the nut from the

5) Remove the split pin and the brass fitting.
base of the cable.

Remove split pin

6) Remove the cable by cutting the cable tie

3) Try to push the cable into the boat. If it
and feed in the new cable. Attach back all
doesn’t move, try to remove the black
the fittings. Fit the cable to the throttle and
polyurethan seal from the other side of the
use some grease on the moving part of the
cable.
cable.

Page 26 of 59 MY23
 Steering and Helm Control – Reverse Cable Replacement 285/325 TurboJet Service Manual

7) Put the nut and washer on the cable, set the 10) Move the throttle handle fully reverse.
nut almost to the end of the thread and use
black polyurethan seal under the washer.

11) Check to ensure before tightening the lock

nut that enough thread is in the Rod End. A
8) Put the washer and nut then tide it. minimum of 5 threads must be engaged.
Refit the rubber seal and locking nut.

9) Seal the cable inside over the nut. 12) Measure distance from pump face to centre
of bucket cable pivot bolt is as shown.

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 Steering and Helm Control – Reverse Cable Replacement 285/325 TurboJet Service Manual

13) Check measurement as shown above. Pull 16) Cover the moving part of the cable with
cable fully rearwards and adjust length to some grease to protect it.
the recommended mm to centre of Rod-End
and tighten locknut.

312mm (+, - 2mm)

a) Triple Guard Grease

14) Check the throttle movement and bucket

opening (fully opened or closed it should
have a little play, if not, it needs a bit of
adjusting, in this case the Rod-End can be
adjusted out of tolerance.

15) Then check bucket is clear of nozzle

assembly.

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 Steering and Helm Control – Steering Cable Replacement 285/325 TurboJet Service Manual

B. Steering Cable Replacement

5) Open the helm. Disconnect the steering cable
2) Disconnect the cable from the pump nozzle,
1)

remove the rod end, locking nut and rubber from the steering column. Remove the 2
seals. locking nuts and fittings.

6) Swap the old cable to the new one.

3) Using a box spanner remove the nut from the 7) Fit all the fittings back on the new cable and
base of the cable. use some grease on the moving part to
protect it from corrosion.

4) Try to push the cable into the boat. If it

doesn’t move, try to remove the black
polyurethan seal from the other side of the 8) Put the nut and washer on the cable, set the
cable. nut almost to the end of the thread and use
black polyurethan seal under the washer.

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 Steering and Helm Control – Steering Cable Replacement 285/325 TurboJet Service Manual

9) Outside of the boat put the washer and nut on 13) Check to ensure before tightening the lock
the cable, then tide it. nut that enough thread is in the Rod End. A
minimum of 5 threads must be engaged.
10) Refit the rubber seals (use grease under),
locking nut and the rod-end.

14) Adjust the rod-end to the straight nozzle

11) Seal the cable inside over the nut. bracket’s hole and fit the cable to the pump
nozzle.

12) Set the steering wheel straight. 15) Test the steering to both sides.

Page 30 of 59 MY23
 Steering and Helm Control – Jet Pump removal 285/325 TurboJet Service Manual

C. Jet Pump Removal

1) Remove the bucket by disconnecting the 3) Remove the steering cable bolt and
reverse cable. Don’t remove the rod end as it remember to put the washers back to their
is set up with measurement. Remove the bolt place when assemble. Don’t remove the rod
and remember to put the washers back to end as it is synchronized with the steering
their place when assemble. wheel.

4) Remove 4 x jet nozzle bolts (red circle) and

2) Remove bucket swivel bolt on both sides. washers and remove brackets.
Caution bucket will drop if not held. Caution nozzle will drop if not held.

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 Steering and Helm Control – Jet Pump removal 285/325 TurboJet Service Manual

5) During the assembly use gasket compound 8) If you need to remove the impeller, use the
between the nozzle and jet pump around the following work instruction ‘WI.114 Jet
contact area. Pump Impeller Removal’

6) Remove 4 x nuts and washers (yellow

circle), then remove pump by pulling
rearwards
Caution pump is heavy

9) Replacement is the reverse of the removal.

When sliding the pump back on it may
require the assistance of another person to
guide the pump onto the driveshaft from
below, and at the same time turning the
impeller from the rear to engage the
driveshaft splines
Note orientation of any O-rings

7) Remove the jet pump.

10) If you removed the rod ends from the cables

you need to follow the setup in the next
instructions: Reverse Cable Change and
Steering Cable Change Turbojet or Sportjet
version.

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 Electrical System 285/325 TurboJet Service Manual

Electrical Systems

Page 33 of 59 MY23
 Electrical System – Battery Replacement 285/325 TurboJet Service Manual

A. Battery Replacement

1) Unscrew and remove all the wires from the negative terminal first, followed by the positive wire.

2) Unhook the strap. Unscrew the 2x retaining bolts located at the base of the battery bracket.

3) Remove the existing battery ensuring that you clean up any areas of corrosion or battery leakage.

Fit the new battery in the reverse of removal ensuring that all the wires are
reconnected to the negative terminal.

Page 34 of 59 MY23
 Electrical System – Engine Control Unit Replacement 285/325 TurboJet Service Manual

B. Engine Control Unit Replacement

5) Unlock the 2x plugs by pressing in the small
plastic button on the latch and then rotating
1) Unscrew the 2x Cap Head Screws from the the assembly anti-clockwise.
top of the Towing Valve Bracket.

6) Completely remove both of the plugs.

2) Pull the Towing Valve and its bracket away
from the ECU.
3) Unscrew the 3x M6 Nylock nuts and washers
from the ECU Bracket.

7) Swap out the ECU and then reconnect both

of the plugs. Check these are locked in place
4) Remove the ECU from its bracket. by rotating the locking bracket clockwise.

Page 35 of 59 MY23
 Electrical System – Engine Control Unit Replacement 285/325 TurboJet Service Manual

8) Refit the ECU back onto the bracket using

the M6 Nylock nuts and washers.

9) Apply a small amount of Loctite 243 to the

screw threads of the Towing Valve Bracket.

10) Reassemble the Towing Valve onto its

bracket and attach using the 2x Hex Head
Screws.

Page 36 of 59 MY23
 Electrical System – Voltage Regulator Replacement 285/325 TurboJet Service Manual

C. Voltage Regulator Replacement

1) The voltage regulator unit is located next to 4) Remove the voltage regulator and replace
the Power limit key switch in the engine bay. with the new unit.
Remove the water strainer to get access.

2) Unplug both the electrical connections from 5) Reconnect both of the electrical plugs and fit
the side of the voltage regulator unit. back the water strainer.

3) Unscrew and remove both screws. Behind a) Lightly grease the plugs with white grease or
the regulator there are 2 spacer rings, ensure similar.
they are not going to be lost.

Page 37 of 59 MY23
 Electrical System – Bilge Blower Replacement 285/325 TurboJet Service Manual

D. Bilge Blower Replacement

1) Bilge Blower is located behind the engine in 4) Switch the isolator off. Disconnect the Bilge
the engine bay. Blower at the electrical plug.

2) Remove the driver’s seat. Disconnect the 5) Remove the two screws.
blower hose from the blower by cutting the
cable tie.
Air flow direction

6) Install in the reverse process as removal.

3) Remove the hose.

NOTE - once installed checked operation to
ensure that air flow is in the correct direction
(out of vent).

Reverse polarity in the plug can change the air

flow direction. Check the arrow on the blower
for the correct air flow direction.

a) Lightly grease the plugs with white grease or

similar.

Page 38 of 59 MY23
 Electrical System – Tether Switch Replacement 285/325 TurboJet Service Manual

E. Tether Switch Replacement

1) Open the helm. Switch the isolator off. 5) Attach the front locking nut and fully tighten
2) From the underside of the helm, disconnect using the 22mm box spanner. Do not over
both of the terminal spades. Ensure that you tighten the nut as it is plastic.
pull from the terminal housing and not the
cable to prevent damage to the terminal
connection.

6) A bead of clear silicone should be placed

around the base of the switch in order to
prevent any water ingress.
3) Using a 22mm box spanner, unscrew the
front locking nut.

4) Remove the tether switch. Attach the new 7) Reattach the terminal connections.
tether switch ensuring that the terminals are Lightly grease the plugs with white grease or
oriented as per the figure. similar.

Page 39 of 59 MY23
 Electrical System – Ignition Switch Replacement 285/325 TurboJet Service Manual

F. Ignition Switch Replacement

1) Open the helm. Switch the isolator off. 5) Attach the front locking nut and fully
tighten. Do not over tighten the nut as it is
plastic. Attach the new ignition switch
2) From the underside of the helm, disconnect ensuring that the terminals are oriented as
the plug. per the figure.

3) Using a spanner or similar tool, unscrew the

front locking nut. Do not scratch the gel. 6) Reattach the electric plug.

*Lightly grease the plug with white grease or

similar.

4) Remove the ignition switch. Use some

polyurethan sealant but do not cover the
drain water hole with it. See next image.

Page 40 of 59 MY23
 Electrical System – Helm Switches Replacement 285/325 TurboJet Service Manual

G. Helm Switches Replacement

5) Push the switch out, while pushing the
1) To remove one of the switches below, follow switch’ locking shoulder with a flat
the next steps. screwdriver.

2) Switch the isolator off.

3) Cut supporting cable ties is necessary for
unplugging the connector.

6) Insert the replacement switch by pushing it

down into the housing.

7) Reattach the electric plugs.

*Lightly grease the plug with white grease or
similar.
4) Disconnect the plugs from the relevant
switch like below.

Page 41 of 59 MY23
 Electrical System – Cluster Replacement 285/325 TurboJet Service Manual

H. Cluster Replacement
1) Open the helm. Switch the isolator off. 5) Remove plastic cluster surround.
2) Unlock plug by pulling right, a flat blade
screwdriver may help.

6) Remove as much clear silicone as possible to

3) Unscrew 4 x nylon nuts. enable removal.

4) Or if fitted 4 x M5 screws, refit using the

7) Push in Tabs (blue arrows) and remove
same amount of packing washers in the same
cluster
location

Page 42 of 59 MY23
 Electrical System – Cluster Replacement 285/325 TurboJet Service Manual

8) On the new cluster remove the 2 x black lugs 11) Once the cluster is in position add silicone to
using wire snips. seal the void between the aluminium panel
and the moulding.

Note: The silicone needs to be hidden under the

bezel.

9) Removed lugs.

12) Refit cluster and tighten down using the

fixings from the rear.

10) Lower new Cluster into the opening, square

to the aluminium panel. The cluster will
lock into position with a click (blue arrows) 13) Reattach the electrical plug. Lightly grease
the plugs with white grease or similar.

a) Code Cluster using BUDS if required.

See ‘Cluster Coding’ instruction.

Page 43 of 59 MY23
 Electrical System – Engine Fuse Box 285/325 TurboJet Service Manual

I. Engine Fuse Box

1) Fuse box location. 4) You can follow the ‘BRP Relay Diagnosis-
Hot Wire’ instruction below to make sure
the relays are faulty or something else.

2) 10A Relays:
‘0’ is a spare relay to replace a faulty one. 5) Remove ECU relay and bridge jumper wire
‘1’ is for ECU (Power Shutdown). across the 2 pin-outs highlighted and check
‘2’ is for engine and 12v accessory engine start on the key switch.

6) Remove Engine relay and bridge jumper

3) Fuse locations. wire across the 2 pin-outs highlighted and
check engine start on the key switch.

Page 44 of 59 MY23
 Electrical System – Boat Harness Fuse Box 285/325 TurboJet Service Manual

J. Boat Harness Fuse Box

1) Fuse box location under the helm. 4) Plugs under the helm, labelled with the
corresponding fuses

2) Fuse box power flow. 5) Fuses.

Bottom red line is the 12v supply to fuse box
with isolator ‘ON’
Top blue line is the signal to device.

3) Fuse locations.

Page 45 of 59 MY23
 Electrical System – Starter Relay Replacement 285/325 TurboJet Service Manual

K. Starter Relay Replacement

1) Starter relay location is next to the engine 4) Disconnect the signal plug.
fuse box.

2) Switch off the isolator, which located under

the driver’s seat. 5) Push down the security lock.

3) Disconnect the two battery cables and the

charging wire from relay. Make a note where 6) Pull out the relay.
the wires were fitted.

Page 46 of 59 MY23
 Electrical System – Starter Relay Replacement 285/325 TurboJet Service Manual

7) Remove the relay. 10) Slide in the whole relay until clicks on.

8) Fit the new relay.

11) Push the security lock up if necessary.

9) First push in the inside shoulder then the 12) Refit all the wiring. Make sure you fit all the
other one. wires to the same place as were before.

Page 47 of 59 MY23
 Exhaust System 285/325 TurboJet Service Manual

Exhaust System

Page 48 of 59 MY23
 Ancillaries 285/325 TurboJet Service Manual

Ancillaries

Page 49 of 59 MY23
 Ancillaries - Tube Replacement 285/325 TurboJet Service Manual

A. Tube Replacement
4) Fully unscrew and remove the laser plate
1) Inflate the new tube for inspection. which holding the tube.

2) Spray washing up liquid mixed with water 5) Fully unscrew and remove the bolts in the
around the valves to find out air leaks. If front of the boat.
necessary tight more the valves or check if it
fitted correctly.

6) Open the front stowage hatch to get access to

the bolts and nuts.
3) Deflate all chambers of the old tube by
depressing the central core of the inflation
valve.

Page 50 of 59 MY23
 Ancillaries - Tube Replacement 285/325 TurboJet Service Manual

7) Unhook the front of the stowage bag 10) Clean the luffing track and spray some
washing up liquid mixed with water all the
way of luffing track and tube’s boltrope.

8) Use a 10mm ratchet socket or spanner to 11) Feed the tube’s boltrope into the luffing track
remove the bolts. You might need some help both sides.
to do that.

12) Pull the tube on evenly both sides of the

9) Pull off the tube from the boat. boat.

Page 51 of 59 MY23
 Ancillaries - Tube Replacement 285/325 TurboJet Service Manual

13) Someone else could help with feeding the 16) Put some air in the tube and line it up again.
tube during the pulling on.

14) If necessary, spray some more soapy water

on the luffing track for easier move. 17) Drill out the tube’s tag in the front lined up
the previous holes on the deck.

15) At the end of pull line up the front of the

tube to the boat. 18) Fit the bolts, washers and nuts to secure the
tube.

Page 52 of 59 MY23
 Ancillaries - Tube Replacement 285/325 TurboJet Service Manual

19) Pull the tube fully and inflate it, then 22) Screw down the back of the tube to the deck.
measure both side for even fitting.

23) Inflate the tube.

20) Mark the tube tag according to the holes for
screws.

21) Screw the laser plate to the tube’s tag.

Page 53 of 59 MY23
 Ancillaries - Tube Valves Replacement 285/325 TurboJet Service Manual

B. Tube Valves Replacement

1) Deflate all chambers of the tube by 4) Clean the Valve Gasket with a damp cloth to
depressing the central core of the inflation remove any dust and debris.
valve.

2) Use an A6 & A7 Tube Spanner to loosen the

upper section of the valve body. 5) Screw the new valve into the existing body.

3) Fully unscrew and remove the valve body. 6) Fully tighten using the A6 & A7 Valve
NOTE - take care that the internal section of Spanner.
the valve body does not fall down into the
tube.

Page 54 of 59 MY23
 Ancillaries - Fire Extinguisher Replacement 285/325 TurboJet Service Manual

C. Fire Extinguisher Replacement

1) Fire Extinguisher Replacement 4) Sub-assemble the new thermal head onto the
new extinguisher ensuring that a small cable
tie is secured to the release pin to prevent
accidental activation. Hand tide the thermal
head to the extinguisher.

2) Loosen the fire extinguisher bracket.

5) Insert the new unit ensuring that the coded

date is visible with the helm lid open.

3) Slide the existing fire extinguisher

6) Re-tighten the bracket to the point at the
rightwards and out from its bracket.
extinguisher is not moving under a bit of
force. Do not over tight.

Page 55 of 59 MY23
 Ancillaries – Heat Exchanger Replacement 285/325 TurboJet Service Manual

D. Heat Exchanger Replacement

1) Heat exchanger location is next to the 4) Remove the heat exchanger bracket by
battery. removing the 2 bolts.

5) One bolt is next to battery.

2) Unhook the fuel tank strap and disconnect
the raw water hose from strainer.

6) Some coolant will come out, so some tissue

or rug placed around the heat exchanger
would be useful.
3) Take out as much as possible from coolant. 7) For easier access the coolant tank can be
removed but not necessary.

Page 56 of 59 MY23
 Ancillaries – Heat Exchanger Replacement 285/325 TurboJet Service Manual

8) To keep more coolant in the heat exchanger, 11) Coolant flow. There is a coolant drain plug,
loosen the hose clamps on the top of the however it is hard to reach.
hoses.

9) The top hose clamp is under the coolant tank.

12) Once the heat exchanger is released, remove
the raw water outlet hose.

10) The other clamp is on the heat exchanger

outlet hose.
13) Replacement is the reverse of the removal.

Page 57 of 59 MY23
 BUDS Diagnostic – Cluster Coding 285/325 TurboJet Service Manual

BUDS Diagnostic
A. Cluster Coding
1) Connect BUDS to the boat. 5) Select ‘Learn’.
2) In BUDS select:
‘Module, Cluster, Security Coding’

6) Select ‘OK

3) Highlight ‘ECM’ cell, select ‘Copy’ or

‘Ctrl+C’

*If the boat has INR option or the boat needs metric
settings these can be set up under ‘Settings’ tab.

4) Paste into ‘Cluster’ cell.

Page 58 of 59 MY23
 285/325 TurboJet Service Manual

Contact Details

Williams Jet Tenders Ltd

Vogue Business Park, Berinsfield, Oxfordshire OX10 7LN, United
Kingdom T: +44 (0)1865 341134 F: +44 (0)1865 341234
E: [email protected]

Page 59 of 59 MY23