2003 YAMAHA SUPERJET check engine

4-9
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EJU01355
Periodic maintenance chart
The following chart gives general guidelines for periodic maintenance. However, depend-
ing on your operating conditions maintenance may need to be performed more frequently.
*1: Grease capacity: 20.0–22.0 cm3 (0.68–0.74 oz)
*2: Grease capacity: 3.0–5.0 cm3 (0.10–0.17 oz)
*3: After every use
*4: Before every use
*5: Inspect fluid level before every use
(
) This mark indicates maintenance that you may do yourself.
(
❍) This mark indicates work to be done by a Yamaha dealer.
MAINTENANCE INTERVAL INITIALTHEREAF-
TER EVERYPA G E
10
hours50
hours100
hours 100
hours 200
hours
ITEM
6
months12
months12
months24
months
Spark plug Inspect, clean, adjust




4-13
Lubrication points Lubricate


4-14
Intermediate housing Lubricate❍
*1

*2

*2 4-16
Fuel system Inspect❍❍
4-10
Fuel filter Check, clean, replace❍❍
4-11
Fuel tank Clean❍
4-11
Carburetor setting Inspect, adjust❍❍❍
4-19
Trolling speed Inspect, adjust


4-19
Carburetor throttle shaft Inspect❍❍
—
Cooling water passages Flush

*34-1
Bilge strainer Clean


—
Impeller Inspect

*4❍❍
—
Jet thrust nozzle angle Inspect


4-12
Steering pivot Inspect❍❍❍
—
Steering friction Inspect, adjust



4-20
Throttle lever Check operation

*44-12
Throttle cable Inspect, adjust


4-12
Choke knob Check operation

*44-16
Choke cable Inspect, adjust ❍❍
4-16
Battery Inspect

*5❍❍
4-17
Rubber coupling Inspect❍
—
Engine mount Inspect❍
—
Nuts and bolts Inspect❍❍❍
—
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Inspecting the fuel system
WARNING@ Gasoline is highly flammable and explo-
sive. A fire or explosion can cause
severe injury or death. Shut off the
engine. Do not smoke. Avoid spilling
gasoline.
@
Check the fuel system for leaks, cracks,
or malfunctions. If any problem is found, do
the necessary repair or replacement as
required. If repair is necessary, consult a
Yamaha dealer.
Check:

Carburetor for leakage.

Fuel pump for malfunction or leakage.

Fuel tank for water or dirt.

Fuel tank for damage, cracks or leakage.

Fuel hose joint for leakage.

Fuel hose for cracks or other damage.

Fuel filter for leakage.

Fuel cock for leakage.

Air vent check valve for leakage.

Fuel tank filler cap for damage.
WARNING@ Failure to check for and repair any fuel
leakage may result in fire or explosion.
@
UF1N71.book Page 10 Tuesday, June 4, 2002 3:34 PM

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Troubleshooting
If you have any trouble with your watercraft, use this section to check for the possible
cause.
If you cannot find the cause, or if the procedure for replacement or repair is not described
in this Owner’s/Operator’s Manual, have a Yamaha dealer perform the necessary service.
EJU01367
Troubleshooting chart
TROUBLE POSSIBLE CAUSE REMEDY PAGE
Engine does not
startStarter motor does not turn over
Engine shut-
off switch Clip not in place Install clip
2-5
Fuse Burned out Replace fuse and check
wiring4-20
Battery Run down Recharge 4-17
Poor terminal connec-
tionsTighten as required
4-17
Starter motor Faulty Have serviced by
Yamaha dealer—
Starter motor turns over
Fuel cock Turned to “OFF”Turn fuel cock knob to
“ON”2-4
Fuel Empty Refill as soon as possi-
ble3-4
Stale or contaminated Have serviced by
Yamaha dealer4-10
Fuel tank Water or dirt present Have serviced by
Yamaha dealer4-11
Spark plug Fouled or defective Clean or replace 4-13
Spark plug cap Not connected or loose Connect properly 4-13
Crankcase Filled with water Crank engine with plug
out until clean5-7
Fuel filter Clogged or water
pooledHave serviced by
Yamaha dealer4-11
Choke Knob moves back on
its ownTighten choke knob
adjusting nut4-16
UF1N71.book Page 1 Tuesday, June 4, 2002 3:34 PM

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EJU01118
Emergency procedures
EJU01119
Cleaning the jet intake and
impeller
If weeds or debris get caught in the intake
or impeller, cavitation can occur, causing jet
thrust to decrease even though engine
speed rises. If this condition is allowed to
continue, the engine will overheat and may
seize. If there is any sign that the jet intake
or impeller is clogged with weeds or debris,
beach the watercraft and check the intake
and impeller. Always stop the engine before
beaching the watercraft.
WARNING@ Before attempting to remove weeds or
debris from the jet intake or impeller
areas, shut the engine off and remove
the clip from the engine shut-off switch.
Severe injury or death could result from
contact with the rotating parts of the jet
pump.
@
1. Turn the watercraft on its side as shown.
CAUTION:@
Place a suitable clean cloth or carpet-
ing underneath the watercraft to pro-
tect it from abrasions and scratches.

Always turn the watercraft over onto
its port (left) side.

When turning the watercraft on its
side, support the bow so the handle-
bars cannot be bent or damaged.
@
2. Remove any weeds or debris from
around the drive shaft, impeller, pump
housing, and jet thrust nozzle.
If debris is difficult to remove, consult
your Yamaha dealer.
UF1N71.book Page 3 Tuesday, June 4, 2002 3:34 PM

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Operation requirements .......................... 1-8
Other labels ............................................. 1-5
Owner’s/Operator’sManualandtoolkit ...... 4-8
P
Periodic maintenance chart..................... 4-9
Post-operation checks........................... 3-31
Pre-operation check list........................... 3-5
Pre-operation check points ..................... 3-6
Pre-operation checks .............................. 3-5
Primary Identification (PRI-ID) number ... 1-1
R
Recommended equipment .................... 1-10
Replacing the fuse ................................ 4-20
Rough water operation .......................... 3-30
S
Safe boating rules ................................. 1-12
Safety information ................................... 1-6
Specifications ........................................ 4-23
Standing ................................................ 3-25
Starting the engine ................................ 3-15
Starting the watercraft ........................... 3-21
Start switch.............................................. 2-6
Steering pole .................................. 2-8, 3-10
Steering system ............................. 2-7, 3-10
Stopping the engine .............................. 3-18
Stopping the watercraft ......................... 3-29
Storage.................................................... 4-1
Storage pouch ....................................... 2-10
Submerged watercraft ............................. 5-7
Switches ................................................ 3-12
T
Throttle .................................................. 3-10
Throttle lever ........................................... 2-6
Towing the watercraft .............................. 5-6
Transporting .......................................... 3-33
Troubleshooting ...................................... 5-1
Troubleshooting chart ............................. 5-1
Turning the watercraft ........................... 3-27
W
Warning labels ................................. 1-2, 1-3
Watercraft characteristics...................... 1-11
Water separator ...................................... 3-7
UF1N71.book Page 2 Tuesday, June 4, 2002 3:34 PM