water pump YAMAHA FX 2003 Owners Manual

1-16
E
EJU01781
Hazard information

Never start the engine or let it run for any
length of time in an enclosed area.
Exhaust fumes contain carbon monoxide,
a colorless, odorless gas that may cause
loss of consciousness and death within a
short time. Always operate the watercraft
in an open area.

Hot oil tank, muffler, and engine surfaces
can cause serious burns. Do not touch
the oil tank, muffler, or engine immedi-
ately after turning the engine off.
EJU19970
Watercraft characteristics

Jet thrust turns the watercraft. Releasing
the throttle lever completely produces
only minimum thrust. If you are traveling
at speeds above trolling, you will have
rapidly decreasing ability to steer without
throttle. This model has the Yamaha
Engine Management System (YEMS)
that includes an Off-Throttle Steering
(OTS) system. It will activate at planing
speeds should you attempt to steer the
watercraft after releasing the throttle lever.
The OTS system assists in turning by
continuing to supply some thrust while the
watercraft is decelerating, but you can
turn more sharply if you apply throttle
while turning the handlebars. The OTS
system does not function below planing
speeds or when the engine is off. Once
the engine slows down, the watercraft will
no longer turn in response to handlebar
input until you apply throttle again or you
reach trolling speed. Practice turning in
an open area without obstructions until
you have a good feel for this maneuver.

This watercraft is water-jet propelled. The
jet pump is directly connected to the
engine. This means that jet thrust will pro-
duce some movement whenever the
engine is running. There is no “neutral”
position. You are in either “forward” or
“reverse,” depending upon the shift lever
position.

Do not use the reverse function to slow
down or stop the watercraft as it could
cause you to lose control, be ejected, or
impact the handlebars. You could also
damage the shift mechanism.
This could increase the risk of back/spinal
injury (paralysis), facial injuries, and bro-
ken legs, ankles, and other bones.
UF1B71.book Page 16 Tuesday, November 12, 2002 4:17 PM

1-17
E

Reverse can be used to slow down or
stop during low-speed maneuvering, such
as when docking. Once the engine is
idling, shift to reverse and gradually
increase engine speed. Make sure that
there are no obstacles or people behind
you before shifting into reverse.

Keep away from the intake grate 1 while
the 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.

Never insert any object into the jet thrust
nozzle 2 while the engine is running.
Severe injury or death could result from
coming in contact with the rotating parts
of the jet pump.

Stop the engine and remove the clip 3
from the engine shut-off switch 4 before
removing any debris or weeds, which may
have collected around the jet intake.
EJU01863
Water-skiing
You can use the watercraft for water-ski-
ing if it has the seating capacity to carry the
operator, a rearward-facing spotter, and the
water-skier when he or she is not skiing.
The watercraft must also have a cleat 1
designed to pull a ski towrope; do not attach
the towrope to any other location.
It is the watercraft operator’s responsibility
to be alert to the safety of the water-skier
and others. Know and follow all local water-
skiing regulations in effect for the waters in
which you will be operating.
The operator should be comfortable car-
rying passengers before attempting to pull a
skier.
The following are some important consid-
erations for minimizing risks while water-ski-
ing.

The skier should wear an approved PFD,
preferably a brightly colored one so boat
operators can see the skier.

The skier should wear protective clothing.
Severe internal injuries can occur if water
is forced into body cavities as a result of
falling into the water. Normal swimwear
does not adequately protect against
forceful water entry into rectum or vagina.
The skier should wear a wetsuit bottom or
clothing that provides equivalent protec-
tion.
UF1B71.book Page 17 Tuesday, November 12, 2002 4:17 PM

2-2
E
1Fuel tank filler cap
2Stern eye
Use to attach rope for transporting or mooring.
3Intake grate
Prevents debris from getting into the jet pump.
4Reverse gate
Controls direction of jet thrust when in reverse.
5Ride plate
6Jet thrust nozzle
Changes the direction of jet thrust according
to handlebar position.
7Speed sensor8Stern drain plugs
Use to drain water in the bilge when the water-
craft is on dry land.
9Cleat
Use to attach a towrope for pulling water-skier,
or a rope for mooring the watercraft.
0Handgrip
Use for suppor t when boarding the watercraft
or when seated facing rearward and acting as
a spotter for a water-skier.
AElectric bilge pilot outlet
UF1B71.book Page 2 Tuesday, November 12, 2002 4:17 PM

2-19
E
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.
UF1B71.book Page 19 Tuesday, November 12, 2002 4:17 PM

3-2
E

Tighten the filler cap securely after
refueling.

If you should swallow some gasoline,
inhale a lot of gasoline vapor, or get
gasoline in your eyes, get immediate
medical attention.

If any gasoline spills onto your skin,
immediately wash with soap and
water. Change clothing if gasoline
spills on it.
@
CAUTION:@ Use only fresh gasoline that has been
stored in clean containers.
@
EJU01832
Gasohol
There are two types of gasohol: gasohol
containing ethanol and that containing meth-
anol.
Gasohol containing ethanol can be used
if ethanol content does not exceed 10% and
the fuel meets minimum octane ratings.
Gasohol containing methanol is not rec-
ommended by Yamaha because it can
cause fuel system damage or engine perfor-
mance problems.Recommended gasoline:
Regular unleaded gasoline with
a minimum octane rating of
86 (Pump octane number) = (R+M)/2
90 (Research octane number)
UF1B71.book Page 2 Tuesday, November 12, 2002 4:17 PM

3-9
E
EJU01804
Bilge
Check for moisture and fuel residue in the
bilge.
This watercraft is equipped with a conven-
tional jet vacuum bilge draining system and
an electric bilge draining system. The elec-
tric bilge draining system is operated when
the engine is running. When excess water
reaches the water inlet of the electric bilge
pump, the water is discharged from the elec-
tric bilge pilot outlet 1 at the stern.
A small quantity of water will remain in the
bilge and should be removed manually. To
remove any residual water, perform the fol-
lowing procedure.
CAUTION:@ If starting the engine after it has cap-
sized, do not operate the engine at full
open throttle when water is being dis-
charged from the electric bilge pilot out-
let at the stern. Excessive water in the
bilge can splash into the engine which
could cause damage.
To remove water from the bilge:
1. Remove the stern drain plugs.
2. Raise the bow of the watercraft until the
water drains.
3. After the water has drained, wipe the
bilge with dry rags to make sure that the
bilge is thoroughly dry.
4. Install the drain plugs.
CAUTION:@
Make sure that the stern drain plugs
are tightened securely before launch-
ing the watercraft.

Clean any foreign materials, such as
dirt or sand, from the drain plug
threads before installing the drain
plugs.
UF1B71.book Page 9 Tuesday, November 12, 2002 4:17 PM

3-14
E
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.
UF1B71.book Page 14 Tuesday, November 12, 2002 4:17 PM

3-29
E
EJU19960
Turning the watercraft
Steering control depends on the combi-
nation of handlebar position and the amount
of throttle.
Water sucked in through the intake grate
is pressurized by the impeller in the jet
pump. As the pressurized water is expelled
from the pump through the jet thrust nozzle,
it creates thrust to move and steer the
watercraft. The higher the engine speed, the
more thrust produced.
The amount of jet thrust, in addition to the
position of the handlebars, determines how
sharply you turn.
A. More throttle produces higher thrust, so
the watercraft will turn more sharply.
B. Less throttle produces lower thrust, so
the watercraft will turn more gradually.
C. Releasing the throttle lever completely
produces only minimum thrust. If you are
traveling at speeds above trolling, you
will have rapidly decreasing ability to
steer without throttle. You may still have
some turning ability immediately after
releasing the throttle lever, but once the
engine slows down, the watercraft will no
longer respond to handlebar input until
you apply throttle again or you reach
trolling speed.
At trolling speed, the watercraft can be
turned gradually by handlebar position
alone using just the amount of thrust
available at idle.
D. If the engine is stopped while riding,
there is no thrust. The watercraft will go
straight even though the handlebars are
turned.
You need throttle to steer.
UF1B71.book Page 29 Tuesday, November 12, 2002 4:17 PM

4-9
E
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.
PMC-F1B1(
) This mark indicates maintenance that you may do yourself.
(
❍) This mark indicates work to be done by a Yamaha dealer.
MAINTENANCE INTERVAL
INITIALTHEREAFTER
EVERYPA G E
10
hours50
hours100
hours100
hours200
hours
ITEM
6
months12
months12
months24
months
Spark plug Inspect, clean, adjust



4-16
Lubrication points Lubricate


4-18
Intermediate housing Lubricate❍
*1

*2

*2 4-20
Fuel system Inspect❍❍
4-10
Fuel tank Clean❍❍
4-10
Trolling speed Inspect, adjust❍❍❍
4-23
Throttle shaft Inspect❍❍
—
Cooling water passages Flush

*3 4-1
Water inlet strainer Inspect, clean❍❍
—
Bilge strainer Clean❍❍
—
Electric bilge pump strainer Inspect, clean❍❍
—
Impeller Inspect

*4❍❍
—
Jet thrust nozzle angle Inspect


4-14
Steering master Inspect❍❍❍
—
QSTS mechanism Inspect, adjust

*4❍❍
4-15
Shift cable and mechanism Inspect, adjust

*4❍❍
4-14
Throttle lever Check operation

*4 3-12
Throttle cable Inspect, adjust❍❍
4-14
Stern drain plugs Inspect, replace

*4❍❍
3-9
Battery Inspect

*5❍❍
—
Rubber coupling Inspect❍
—
Engine mount Inspect❍
—
Nuts and bolts Inspect❍❍❍
—
Air filter Inspect❍

4-13
Engine oil Replace❍❍❍
4-11
Engine oil filter Replace❍
—
Valve clearance Inspect, adjust❍
—
*1: Grease capacity: 33.0–35.0 cm3 (1.11–1.18 oz)
*2: Grease capacity: 6.0–8.0 cm3 (0.20–0.27 oz)
*3: After every use
*4: Before every use
*5: Inspect fluid level before every use
UF1B71.book Page 9 Tuesday, November 12, 2002 4:17 PM

5-1
E
EJU01116
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
TBC-F0P7ETROUBLE POSSIBLE CAUSE REMEDY PAGE
Engine does not
startStarter motor does not turn over
Engine shut-
off switchClip not in place Install clip
2-8
Fuse Burned out Replace the fuse and
check wiring4-24
Battery Run down Recharge 4-21
Poor terminal connec-
tionsTighten as required
4-21
Terminal corroded Clean 4-5
Starter motor Faulty Have serviced by
Yamaha dealer—
Starter motor turns over
Throttle lever Squeezed Release 2-8
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 dealer4-10
Spark plug Fouled or defective Clean or replace 4-16
Spark plug cap Not connected or loose Connect properly 4-16
Connected to wrong
cylinderConnect properly
4-16
Fuel injection
systemFuel pump faulty Have serviced by
Yamaha dealer—
UF1B71.book Page 1 Tuesday, November 12, 2002 4:17 PM