2003 YAMAHA SUPERJET Owners Manual

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NOTE:@
Wipe off any water on the spark plug or
inside the cap before installing the spark
plug cap. Push the spark plug cap down
until it clicks.

If a torque wrench is not available when
you are fitting a new spark plug, a good
estimate of the correct torque is 1/4 turn
to 1/2 turn past finger tight. Have the
spark plug adjusted to the correct torque
with a torque wrench as soon as possible.
@
WARNING@ Be careful not to damage the insulator
when removing or installing a spark plug.
A damaged insulator could allow sparks
to escape, which could lead to explosion
or fire.
@
EJU01302
Lubrication points
To keep moving parts sliding or rotating
smoothly, coat them with water-resistant
grease.

Throttle cable (carburetor end)

Choke cable (carburetor end)

Throttle cable (handlebar end)
Pull the throttle lever and remove the
seal1. Spray a rust inhibitor into the
outer cable. Refit the seal securely. Recommended water resistant grease:
Yamaha Marine Grease/
Yamaha Grease A
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Steering cable ball joint (handlebar end)

Steering cable inner wire (handlebar end)
1. To access the steering cable and joint,
remove the handle cover by removing
the two bolts.
2. Grease the steering cable ball joints both
on the handlebar end of the cable and on
the jet thrust nozzle end.
3. Extend the steering cable inner wire, and
then apply a thin coat of grease to both
the handlebar end and the jet thrust noz-
zle end.

Steering cable ball joint (nozzle end)

Steering cable inner wire (nozzle end)

Steering handle pivot shaft
Lubrication of the steering handle pivot
shaft requires disassembly of steering
components. Have a Yamaha dealer lubri-
cate it.

Steering nozzle pivot bolts (collars)
UF1N71.book Page 15 Tuesday, June 4, 2002 3:34 PM

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Intermediate housing
Using a grease gun, fill the intermediate
housing with water-resistant grease
through the grease nipple.
Grease capacity:
Initial 10 hours or 1 month:
20.0–22.0 cm
3 (0.67–0.74 oz)
Every 100 hours or 12 months:
3.0–5.0 cm
3 (0.10–0.33 oz)
EJU01261
Adjusting the choke cable
Check that the choke cable is properly
adjusted.
1. Pull the choke knob out until it stops, and
then release the knob. The knob should
not move.
2. If the choke knob moves back on its own,
tighten the choke knob adjusting nut 1
slightly. If the knob is difficult to move,
loosen the adjusting nut slightly.
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EJU01843
Inspecting the battery
Check the level of the battery electrolyte
and make sure that the negative and posi-
tive leads are securely tightened.
WARNING@ Battery electrolyte is poisonous and dan-
gerous, causing severe burns, etc. Elec-
trolyte contains sulfuric acid. Avoid
contact with skin, eyes or clothing.
Antidotes
External: Flush with water.
Internal: Drink large quantities of water
or milk. Follow with milk of magnesia,
beaten egg or vegetable oil. Call physi-
cian immediately.
Eyes: Flush with water for 15 minutes
and get prompt medical attention.
Batteries produce explosive gases. Keep
sparks, flame, cigarettes, etc., well away.
If using or charging the battery in an
enclosed space, make sure that it is well
ventilated. Always shield your eyes when
working near batteries.
KEEP OUT OF THE REACH OF CHIL-
DREN.
@
CAUTION:@
Be careful not to place the battery on
its side.

Be sure to remove the battery from the
battery compartment when adding
electrolyte or charging the battery.

When checking the battery, make sure
that the breather hose is connected to
the battery and that it is not
obstructed.
@
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To replenish the battery:
1. Make sure that the electrolyte level is
between the upper 1 and lower 2 level
marks.
2. Refill the battery with distilled water if
necessary.
CAUTION:@ Normal tap water contains minerals that
are harmful to a battery. Use only dis-
tilled water for replenishing the battery.
@
To recharge the battery:
CAUTION:@ Do not attempt to charge a battery hast-
ily. Battery life could be shortened.
@
It is recommended to have a Yamaha
dealer charge the battery. If you charge the
battery yourself, carefully read the battery
charger instructions before charging and fol-
low the points below.
1. Remove all caps from the battery cell.
2. Add distilled water to the specified level if
the electrolyte level is low.
3. Set the charging rate to 1.9 ampere and
charge the battery slowly until the explo-
sive gases are discharged vigorously
from the battery cells.
To connect the battery terminals:
1. Make sure that the connections are cor-
rect when you insert the battery in the
watercraft.
2. Make sure that the breather hose is
properly connected and that it is not
damaged or obstructed.
3. Make sure that the battery is securely
held in place.
1Positive (+): Red lead
2Negative (–): Black lead
3Breather hose
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EJU01109
Adjusting the carburetor
The carburetor is a vital part of the engine
and requires very sophisticated adjustment.
Most adjusting should be left to a Yamaha
dealer who has the professional knowledge
and experience to perform it. However, the
operator may adjust the trolling speed as
part of the usual maintenance routine.
CAUTION:@ The carburetor was set at the Yamaha
factory after many tests. If the settings
are disturbed by someone who does not
have the necessary technical knowledge,
poor engine performance and damage
may result.
@
EJU01303
Adjusting the trolling speed
1. Put the watercraft in the water.
2. Start the engine and warm it up for 1 or
2 minutes. Using a diagnostic tachome-
ter, adjust the engine speed to specifica-
tion.
3. Turn the throttle stop screw 1 clockwise
to increase engine speed if necessary.
Turn it counterclockwise to decrease
engine speed if necessary.
Trolling speed: 1,250–1,350 r/min
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EJU01263
Replacing the fuse
The fuse is in the electrical box 1.
To replace the fuse:
1. Remove the cap 2, pull out the red lead,
and bring the fuse holder 3 out of the
electrical box.
2. Open the fuse holder and replace the
fuse 4 with one of the correct amper-
age.
WARNING@ Do not use fuses of higher amperage that
those recommended. Substitution of a
fuse of improper rating can cause exten-
sive electrical system damage and possi-
ble fire.
@
Fuse amperage: 10 A
EJU01304
Adjusting the steering friction
The amount of friction in the steering can
be adjusted to suit operator preference.
To adjust the friction:
1. Loosen the four screws, and then
remove the handlebar cover.
2. Turn the handlebars as far as possible to
starboard (right).
3. Loosen the locknut 2.
4. Tighten or loosen the adjusting nut 1
until the desired amount of friction is
reached.
5. Hold the adjusting nut with one wrench
while tightening the locknut with another
wrench.
Tightening torque:
29 N·m (2.9 kgf·m, 21 ft·lb)
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37˚
41˚
45˚
49˚
S1
P1
P1
P2
P2 S2
S1
S2
GM6078a
EJU01305
Adjusting the jet thrust nozzle
angle
The angle of the jet thrust nozzle can be
adjusted to suit operator preference.
1. Loosen the two screws, and then remove
the steering pole cover 1.
2. Select the desired nozzle angle a.
Changing the position of the handlebar
stopper and/or steering cable pivot bolt
changes the nozzle angle as shown in
the following chart.
a
Nozzle angle
b
Handle stopper and steering cable pivot bolt
position
UF1N71.book Page 21 Tuesday, June 4, 2002 3:34 PM