cooling YAMAHA FX 2003 Owners Manual

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EJU01007
FEATURES AND
FUNCTIONS
Location of main components .............. 2-1
Operation of controls and other
functions ................................................... 2-5
Rear seat ................................................ 2-5
Front seat ............................................... 2-6
Hood ....................................................... 2-7
Fuel tank filler cap .................................. 2-7
Engine stop switch ................................. 2-7
Engine shut-off switch ............................ 2-8
Throttle lever .......................................... 2-8
Start switch ............................................. 2-9
Cooling water pilot outlet ....................... 2-9
Steering system ................................... 2-10
Tilt lever ................................................ 2-11
Shift lever ............................................. 2-12
Quick Shift Trim System (QSTS)
selector ................................................. 2-13
Handgrip ............................................... 2-14
Yamaha Engine Management System
(YEMS) ................................................. 2-15
Multifunction meter ............................... 2-15
Storage compartments ........................ 2-20
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2-4
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1Air filter case
2Water separator
3Fuel tank
4Battery
5Flush hose connector
Use to flush the engine cooling water pas-
sages.
6Electrical box
Protects electrical components from water.
7Oil tank8Muffler
9Spark plugs/Spark plug caps
0Spark plug lead
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2-9
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EJU01861
Start switch
Push the start switch 1 (green button) to
start the engine.
NOTE:@ The engine will not start when the clip is
removed from the engine shut-off switch or if
the throttle lever is squeezed.
EJU01784
Cooling water pilot outlet
This watercraft is equipped with cooling
water pilot outlets.
When the engine is running, cooling
water is circulated in the engine, and then it
is discharged from the pilot outlets.
To check for proper operation of the cool-
ing system, check that water is being dis-
charged from the port (left) pilot outlet. If
water is not being discharged from this out-
let, cooling water may not be circulating in
the engine. When this occurs, stop the
engine and check for the cause. (See pages
2-19 and 5-3 for further instructions.)
NOTE:@
If the cooling water passages are dry, it
will take about 60 seconds for the water to
reach the outlet after the engine is
started.

Water discharge may not be constant at
idle, therefore, open the throttle a little to
check that water discharges properly.

Water discharge may not be constant at
the starboard (right) pilot outlet, however,
if it is constant at the port (left) pilot outlet,
the cooling system is operating normally.
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2-19
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EJU01794
Engine overheat warning indicator
This model is equipped with an engine
overheat warning system.
If the engine starts to overheat, the over-
heat warning indicator blinks for 5 seconds,
and then it comes on. The buzzer also
begins to sound intermittently, and then it
sounds continuously. At the same time, the
engine speed reduction control is activated
when the engine runs over 3,000 r/min.
If this occurs, immediately reduce the
engine speed and beach the watercraft, and
check for water discharge at the port (left)
cooling water pilot outlet. If there is no dis-
charge of water, check the intake grate and
impeller for clogging.
WARNING@ Before attempting to remove weeds or
debris from the intake grate or impeller,
shut the engine off and remove the clip
from the engine shut-off switch. Severe
injury or death could result from coming
in contact with the rotating parts of the
jet pump.
CAUTION:@ If you cannot locate and correct the
cause of the overheating, consult a
Yamaha dealer. Continuing to operate at
higher speeds could result in severe
engine damage.
NOTE:@ Press any button on the multifunction meter
to stop the buzzer.
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3-5
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EJU01346
Pre-operation checks
EJU01347
Pre-operation check list
Before operating this watercraft, perform the checks in the following check list. See the
accompanying text in this chapter for details on how to perform the checks.
WARNING@ If any item in the pre-operation check list is not working properly, have it inspected
and repaired before operating the watercraft, otherwise an accident could occur.
@
NOTE:@ Pre-operation checks should be made thoroughly each time the watercraft is used. This pro-
cedure can be completed in a short time. It is worth the time spent to assure safety and reli-
ability.
@
ITEM ROUTINE PAGE
Engine compartment Remove all seats to ventilate engine compart-
ment. Check for fuel vapors or loose electrical
connections3-6
Bilge Check for water and fuel residue and remove if
necessary3-9
Throttle Check that the throttle lever springs back 3-12
Steering system Check for proper steering system operation 3-12
Shift lever and reverse gate Check for proper operation 3-13
Fuel Check fuel level and add if necessary
Check hoses and tank for leakage3-6
Engine oil Check oil level and add if necessary 3-7
Water separator Check for water and drain if necessary 3-8
Battery Check electrolyte level and battery condition 3-10
Front and rear seats Check that the seats are properly secured 2-5, 6
Hull/Deck Check the hull and deck for cracks or other dam-
age—
Jet unit Check for debris and remove if necessary 3-14
Fire extinguisher Check the condition and replace if necessary 3-11
Engine shut-off cord Check condition and replace is frayed or broken 3-14
Switches Check the start switch, engine stop switch and
engine shut-off switch for proper operation when
the watercraft is in the water3-15
Cooling water pilot outlet Check that water is discharged while the engine
is running and the watercraft is in the water3-15
Multifunction meter Check for warning indications and proper opera-
tion3-15
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3-14
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EJU01058
Jet unit
Carefully check the jet intake for weeds,
debris, or anything else that might restrict
the intake of water. If the intake is clogged,
cavitation could occur, reducing jet thrust,
and possibly damaging the jet pump.
In some cases, the engine may overheat
because of lack of cooling water, and dam-
age to the engine could result. Engine cool-
ing water is fed to the engine by the jet
pump. (See page 5-3 for jet intake cleaning
procedures.)
WARNING@
Keep away from intake grate while
engine is on. Items such as long hair,
loose clothing, or PFD straps can
become entangled in moving parts
resulting in severe injury or drowning.

Stop the engine and remove the clip
from the engine shut-off switch before
removing any debris or weeds, which
may have collected around the jet
intake.
EJU01059
Engine shut-off cord (lanyard)
Check that the engine shut-off cord is not
frayed or broken. If the cord is damaged,
replace it; never try to repair it or tie it
together.
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3-15
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EJU01835
Switches
Check the start switch 1, the engine stop
switch 2, and the engine shut-off switch 3
for proper operation.
To check these switches, place the water-
craft in the water to provide adequate cooling.
Start the engine, and then pull the engine
shut-off cord 5 to remove the clip 4 from the
engine shut-off switch. Verify that the engine
stops immediately. (See pages 2-7 to 2-9 for
information on proper operation of the start
switch, the engine stop switch and the engine
shut-off switch.)
EJU01806
Cooling water pilot outlet
Check that water comes out from the port
(left) pilot water outlet while the engine is
running and the watercraft is in the water.
(See page 2-9 for further instructions.)
EJU01246
Multifunction meter
Check the operation of the multifunction
meter. (See pages 2-15 to 2-19 for operation
of the meter.)
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EJU01866
Post-operation checks
Always perform the following post-opera-
tion checks after operating the watercraft.
1. Remove the watercraft from the water.
2. Wash down the hull, handlebars, and jet
unit with fresh water.
3. Remove the seat and check the engine
compartment for water. To drain excess
water, remove the stern drain plugs, and
then raise the bow of the watercraft
enough to allow water in the bilge to
drain out.
NOTE:@ This watercraft is equipped with a jet vac-
uum bilge draining system and an electric
bilge draining system that remove water
from the engine compartment while you are
underway. However, some residual water will
remain. (See “Bilge” on page 3-9 for more
information.)
4. Put the watercraft in a horizontal posi-
tion.
5. Flush the cooling system to prevent it
from clogging with salt, sand, or dirt.
(See page 4-1 for flushing procedures.)
6. Drain residual water from the exhaust
system by alternately squeezing and
releasing the throttle lever for 10 to
15 seconds while the engine is running.
CAUTION:@ Do not run the engine for more than
15 seconds on land. The engine could
overheat.
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EJU01086
MAINTENANCE AND
CARE
Storage ...................................................... 4-1
Flushing the cooling system .................. 4-1
Lubrication .............................................. 4-3
Fuel system ............................................ 4-4
Battery .................................................... 4-5
Cleaning the watercraft .......................... 4-6
Maintenance and adjustments .............. 4-7
Owner’s/Operator’s Manual and
tool kit ..................................................... 4-8
Periodic maintenance chart ................... 4-9
Inspecting the fuel system ................... 4-10
Changing the engine oil ....................... 4-11
Checking the air filter element ............. 4-13
Inspecting the jet thrust
nozzle angle ......................................... 4-14
Inspecting the shift cable ..................... 4-14
Inspecting and adjusting the
throttle cable ......................................... 4-14
Inspecting the QSTS mechanism ....... 4-15
Cleaning and adjusting the
spark plugs ........................................... 4-16
Lubrication points ................................. 4-18
Inspecting the battery .......................... 4-21
Adjusting the fuel injection system ...... 4-23
Replacing the fuse ............................... 4-24
Specifications ........................................ 4-25
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4-1
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EJU18121
Storage
WARNING@ Always place the watercraft upright in a
horizontal position when storing it, oth-
erwise fuel could leak out into the engine
or engine compartment, which could
result in a fire hazard.
@
Storage for prolonged periods of time,
such as winter storage, requires preventa-
tive maintenance to ensure against deterio-
ration. It is advisable to have the watercraft
serviced by a Yamaha dealer prior to stor-
age. However, the following procedures can
be performed by the owner.
EJU01813
Flushing the cooling system
Flushing the cooling system is essential
to prevent the cooling system from being
clogged with salt, sand, or dirt.
CAUTION:@
Do not supply water to the cooling
water passages when the engine is not
running. The water could flow back
through the muffler into the crankcase
causing severe engine damage.

Do not run the engine for more 15 sec-
onds without supplying water, other-
wise the engine may overheat.
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