maintenance YAMAHA SUPERJET 2007 User Guide

Maintenance and care
52
EJU34200Checking the fuel system
WARNING
EWJ00370
Gasoline is highly flammable and explo-
sive. Failure to check for and repair any
fuel leakage could result in a fire or explo-
sion. A fire or explosion can cause severe
injury or death. Shut the engine off. Do not
smoke. Avoid spilling gasoline.
Check the fuel system for leaks, cracks, and
malfunctions. If any problem is found, do the
necessary repair or replacement as required.
If repair is necessary, consult a Yamaha deal-
er.
Check:

Carburetor for leakage.

Fuel pump for malfunction and leakage.

Fuel tank filler cap and seal for damage.

Fuel in fuel tank for water and dirt.

Fuel tank for damage, cracks, and leakage.

Fuel hoses and joints for damage, cracks,
and leakage.

Fuel filter for leakage.

Fuel cock for leakage.

Air vent check valve for leakage.EJU34220Fuel filter
This watercraft is equipped with a one-piece,
disposable fuel filter. The fuel filter should be
replaced after the initial 10 hours or first
month of operation and every 200 hours or 24
months thereafter, or if water is found in the fil-ter. Have a Yamaha dealer replace the fuel fil-
ter if necessary.
WARNING
EWJ00360
Do not try to replace the fuel filter yourself.
An incorrectly installed filter can leak gas-
oline, which could result in a fire or explo-
sion. If necessary, have a Yamaha dealer
replace the fuel filter.
EJU34230Fuel tank
Check the fuel tank for leakage and for water
in the tank. If water is found in the fuel system,
or if the fuel tank needs to be cleaned, have a
Yamaha dealer service the watercraft.
EJU34320Checking the jet thrust nozzle angle
Check the handlebars and jet thrust nozzle for
smooth operation.
1Fuel filter
1Fuel tank
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Maintenance and care
53
Turn the handlebars as far as possible to the
right and left and check that the difference of
distances A and B between the jet thrust noz-
zle and the nozzle is within specification.
If the steering is stiff or misadjusted, have a
Yamaha dealer service it.
EJU34330Adjusting the steering friction
The amount of friction in the steering can be
adjusted to suit operator preference.To adjust the steering friction:
(1) Remove the four screws, and then re-
move the handlebar cover.
(2) Turn the handlebars as far as possible to
the right.
(3) Loosen the locknut.
(4) Tighten or loosen the adjusting nut until
the desired amount of friction is obtained.
(5) Hold the adjusting nut with one wrench
while tightening the locknut with another
wrench.
(6) Install the handlebar cover and the four
screws.
EJU31280Adjusting the jet thrust nozzle angle
The angle of the jet thrust nozzle can be ad-
justed to suit operator preference. Difference of A and B:
Maximum 5 mm (0.20 in)
1Adjusting nut
2Locknut
Tightening torque:
29.0 Nm (21.4 ft-lb) (2.96 kgf-m)
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Maintenance and care
54
(1) Loosen the two screws, and then remove
the steering pole cover.
(2) Select the desired nozzle angle. Chang-
ing the positions of the handlebar stopper
and/or steering cable pivot bolt changesthe nozzle angle as shown in the follow-
ing chart.
1Steering pole cover1Nozzle angles
1Nozzle angles
2Handlebar stopper and steering cable pivot
bolt positions
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Maintenance and care
55
To change the steering cable pivot bolt posi-
tion:
(1) Pull back the outer sleeve, and then dis-
connect the steering cable.
(2) Remove the steering cable joint from the
steering cable pivot bolt.
(3) Loosen the pivot bolt, install it with the
lock washer in the desired position (P1 or
P2), and then tighten it to the specified
torque.
(4) Install the steering cable joint on the
steering cable pivot bolt.
To change the handlebar stopper position:
(1) Loosen the handlebar stopper nut on the
operator’s side of the steering pole.(2) Lift and turn the handlebar stopper to the
desired position (S1 or S2), and then
tighten the handlebar stopper nut to the
specified torque.
(3) Install the steering pole cover securely.
EJU34360Checking and adjusting the throttle
cable
Check that the throttle cable moves back to
the set position smoothly and that the throttle
lever free play is within specification.
(1) Squeeze and release the throttle lever. If
the throttle lever does not return smooth-
ly, have a Yamaha dealer service it.
1Steering cable pivot bolt
Tightening torque:
Steering cable pivot bolt:
5.4 Nm (4.0 ft-lb) (0.55 kgf-m)
1Handlebar stopper nut
Tightening torque:
Handlebar stopper nut:
31.0 Nm (22.9 ft-lb) (3.16 kgf-m)
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Maintenance and care
56
(2) Adjust the free play by loosening the lock-
nut and turning the adjuster.
EJU34370Cleaning and adjusting the spark
plugs
The spark plug is an important engine compo-
nent and is easy to inspect. The condition of
the spark plug can indicate something about
the condition of the engine. For example, if the
center electrode porcelain is very white, this
could indicate an intake air leak or carburetion
problem in that cylinder. Do not attempt to di-
agnose any problems yourself. Have a
Yamaha dealer service the watercraft.
Remove and inspect the spark plugs periodi-
cally; heat and deposits will cause the spark
plugs to slowly break down and erode. If elec-
trode erosion becomes excessive, or if carbon
and other deposits are excessive, replace the
spark plug with the specified plug.Measure the spark plug gap with a wire thick-
ness gauge. Replace the spark plugs or ad-
just the gap to specification if necessary.
To install a spark plug:
(1) Clean the gasket surface.
(2) Wipe any dirt from the threads of the
spark plug.
(3) Install the spark plug, and then tighten it
to the specified torque.
(4) Install the spark plug cap.
NOTE:

Wipe off any water on the spark plug or in-
side the spark plug cap before installing the
cap. Push the spark plug cap down until it is
securely installed.

If a torque wrench is not available when you
are installing a spark plug, a good estimate
of the correct torque is 1/4 turn to 1/2 turn
past finger tight using the spark plug
wrench included in the tool kit. Have the
spark plug adjusted to the correct torque
with a torque wrench as soon as possible.
1Locknut
2Adjuster
3Throttle lever free play
Throttle lever free play:
7.0–10.0 mm (0.28–0.39 in)
Specified spark plug:
BR7HS
1Spark plug gap
Spark plug gap:
0.6–0.7 mm (0.024–0.028 in)
Spark plug tightening torque:
25.0 Nm (18.4 ft-lb) (2.55 kgf-m)
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Maintenance and care
57
WARNING
EWJ00350
Be careful not to damage the insulator
when removing or installing a spark plug.
A damaged insulator could allow sparks to
escape, which could result in a fire or ex-
plosion.
EJU34400Lubrication 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)
Squeeze the throttle lever and remove the
seal. Spray a rust inhibitor into the outer ca-
ble. Refit the seal securely.

Steering cable ball joint (handlebar end)

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

Steering cable ball joint (jet thrust nozzle
end) Recommended water-resistant grease:
Yamaha Marine Grease/Yamaha
Grease A
1Seal
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Maintenance and care
58

Steering cable inner wire (jet thrust nozzle
end)

Handlebar pivot shaft
Lubrication of the handlebar pivot shaft re-
quires disassembly of steering compo-
nents. Have a Yamaha dealer lubricate the
handlebar pivot shaft.

Jet thrust nozzle pivot bolts (collars)

Intermediate housing
Fill the intermediate housing with water-re-
sistant grease through the grease nipple
using a grease gun.
EJU34440Adjusting the choke cable
Check that the choke cable is properly adjust-
ed.
(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
Grease quantity:
Initial 10 hours or 1 month:
20.0–22.0 cm³ (0.68–0.74 US oz)
(0.71–0.78 Imp.oz)
Every 100 hours or 12 months:
3.0–5.0 cm³ (0.10–0.17 US oz)
(0.11–0.18 Imp.oz)
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Maintenance and care
59
slightly. If the knob is difficult to move,
loosen the adjusting nut slightly.
EJU34450Checking the battery
Check the level of the battery electrolyte and
make sure that the negative (–) and positive
(+) battery leads are tightened securely.
WARNING
EWJ00790
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 a physician im-
mediately.
Eyes: Flush with water for 15 minutes and
get prompt medical attention.
Batteries produce explosive gases. Keep
sparks, flames, cigarettes, etc., well away.
If using or charging the battery in an en-
closed space, make sure that it is well ven-
tilated. Always shield your eyes when
working near batteries.
KEEP OUT OF THE REACH OF CHILDREN.
CAUTION:
ECJ00230

Be careful not to place the battery on its
side.

Be sure to remove the battery from the
battery compartment when adding elec-
trolyte or charging the battery.
To replenish the battery:
(1) Make sure that the electrolyte level is be-
tween the maximum and minimum level
marks.
(2) Refill the battery with distilled water if
necessary.
CAUTION:
ECJ00240
Normal tap water contains minerals that
are harmful to a battery. Use only distilled
water for replenishing the battery.
To recharge the battery:
CAUTION:
ECJ00250
Do not attempt to charge a battery hastily.
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 in-
structions before charging and follow the
points below.
1Choke knob adjusting nut
1Maximum level mark
2Minimum level mark
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Maintenance and care
60
(1) Remove all of the battery caps.
(2) If the electrolyte level is low, add distilled
water to raise it to the specified level.
(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 install the battery:
(1) Place the battery in the battery compart-
ment and connect the battery leads to the
battery terminals.
(2) Connect the breather hose to the battery.
(3) Secure the battery in place.
WARNING
EWJ00400
Be sure to connect the breather hose to
the battery. Fire or explosion could result
if the breather hose is damaged, obstruct-
ed, or not connected properly.
CAUTION:
ECJ00260
After installation, make sure that the bat-
tery leads are properly connected to the
battery terminals.
EJU34460Adjusting the carburetor
The carburetor is a vital part of the engine and
requires very sophisticated adjustments.Most adjustments should be left to a Yamaha
dealer who has the professional knowledge
and experience to make them. However, the
operator may adjust the trolling speed as part
of the usual maintenance routine.
CAUTION:
ECJ00170
The carburetor was set at the Yamaha fac-
tory after many tests. If the settings are
disturbed by someone who does not have
the necessary technical knowledge, poor
engine performance and damage may re-
sult.
EJU34470Adjusting the trolling speed
(1) Place the watercraft in the water.
(2) Start the engine and warm it up for 1 to 2
minutes.
(3) While using a diagnostic tachometer, turn
the throttle stop screw to adjust the en-
gine speed to specification. Turn the
throttle stop screw clockwise to increase
the engine speed or counterclockwise to
decrease the engine speed.
1Positive (+) battery terminal: Red lead
2Negative (–) battery terminal: Black lead
3Breather hose
1Throttle stop screw
Trolling speed:
1300 ±50 r/min
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Index
2-stroke engine oil .................................... 25
B
Battery ................................................ 29, 48
Battery, checking...................................... 59
Battery, jumping ....................................... 65
Beaching the watercraft ........................... 43
Bilge ......................................................... 29
Boarding and starting in deep water ........ 39
Boarding and starting in shallow water .... 39
Bow rope hole .......................................... 22
Builder’s plate............................................. 2
C
Capsized watercraft ................................. 40
Carburetor, adjusting................................ 60
Choke cable, adjusting ............................. 58
Choke knob .............................................. 20
Cleaning the watercraft ............................ 48
Cooling water pilot outlet .................... 21, 32
Cruising limitations ..................................... 9
E
Emergency procedures ............................ 64
Engine break-in ........................................ 33
Engine compartment ................................ 28
Engine overheat warning system ............. 23
Engine serial number ................................. 1
Engine shut-off cord ................................. 31
Engine shut-off switch .............................. 20
Engine stop switch ................................... 20
Enjoy your watercraft responsibly ............ 15
F
Filling the fuel tank ................................... 26
Fire extinguisher....................................... 29
Flushing the cooling system ..................... 46
Fuel and oil............................................... 25
Fuel cock knob ......................................... 19
Fuel filter .................................................. 52
Fuel system ........................................ 28, 47
Fuel system, checking.............................. 52
Fuel tank .................................................. 52
Fuel tank filler cap .................................... 19
Fuse, replacing......................................... 66
G
Gasohol .................................................... 25
Gasoline ................................................... 25Getting to know your watercraft ............... 36
H
Hazard information ................................... 13
Hood ......................................................... 18
Hull and deck ........................................... 28
Hull Identification Number (HIN)................. 1
I
Identification numbers ................................ 1
Important labels .......................................... 3
J
Jet intake .................................................. 31
Jet intake and impeller, cleaning .............. 64
Jet thrust nozzle angle, adjusting ............. 53
Jet thrust nozzle angle, checking ............. 52
Jumper cables, connecting ...................... 65
K
Kneeling ................................................... 37
L
Labels, other .............................................. 7
Labels, warning .......................................... 4
Launching the watercraft .......................... 33
Learning to operate your watercraft ......... 36
Leaving the watercraft .............................. 36
Limitations on who may operate the
watercraft ................................................ 8
Lubrication................................................ 47
Lubrication points ..................................... 57
M
Main components, location of .................. 16
Maintenance and adjustments ................. 49
Mixing fuel and oil .................................... 25
Model information....................................... 2
O
Operating positions .................................. 37
Operating your watercraft ......................... 36
Operation ................................................. 33
Operation of controls and other
functions ............................................... 18
Operation requirements ........................... 10
Owner’s/operator’s manual and tool kit .... 49
P
Periodic maintenance chart ...................... 51
Post-operation care .................................. 44
Pre-operation check list ............................ 27
Pre-operation check points ...................... 28
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