check engine YAMAHA SUPERJET 2003 User Guide

3-12
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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 cool-
ing. 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
2-5 to 2-6 for information on proper opera-
tion of the start switch, the engine stop
switch and the engine shut-off switch.)
EJU01320
Cooling water pilot outlet
Check that water comes out from the out-
let while the engine is running and the
watercraft is in the water.
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3. Attach the clip 1 to the engine shut-off
switch 2. Also, attach the engine
shut-off cord 3 to your left wrist.
WARNING@ Check that the engine shut-off cord is not
frayed or broken, and keep it free from
the handlebars so the engine stops if the
operator falls off. The engine shut-off
cord may not pull free if wrapped around
the handlebars when the operator falls
off, allowing the watercraft to continue to
run and cause an accident.
@
NOTE:@ It is not possible to start the engine with the
clip removed from the engine shut-off
switch.
@
4. Pull and hold the choke knob all the way
out to start a cold engine.
NOTE:@ The choke should not be used when the
engine is warm.
@
5. While lightly squeezing the throttle lever,
push the start switch (green button).
WARNING@ On this watercraft, the engine is con-
nected directly to the jet pump. Starting
the engine immediately generates some
thrust. Apply only enough throttle to
keep the engine running.
@
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EJU01068
Operating your watercraft
EJU01285
Getting to know your
watercraft
Operating your watercraft requires skills
acquired through practice over a period of
time. Take the time to learn the basic tech-
niques well before attempting more difficult
maneuvers.
Operating your new watercraft can be a
very enjoyable activity, providing you with
hours of pleasure. However, it is essential to
familiarize yourself with the operation of the
watercraft to achieve the skill necessary to
enjoy riding safely. Before operating this
watercraft, read this Owner’s/Operator’s
Manual, the Riding Practice Guide, and all
warning and caution labels on the water-
craft. Pay particular attention to the safety
information on pages 1-6 to 1-12. These
materials should give you an understanding
of the watercraft and its operation.
Remember: This watercraft is designed to
carry the operator only. Never have more
than one person on the watercraft at any
time.
EJU01286
Learning to operate your
watercraft
Before operating, always perform the
pre-operation checks listed on page 3-5.
The short time spent checking the watercraft
will reward you with added safety and reli-
ability.
Check all local laws before operating your
watercraft.
Operate defensively at safe speeds and
keep a safe distance away from people,
objects and other watercraft. Select a wide
area to learn in, where you have good visi-
bility and light boat traffic.
Use the buddy system—operate with
someone nearby. Scan constantly for peo-
ple, objects and other watercraft. Be alert for
conditions that limit your visibility or block
your vision of others.
Attach the engine shut-off cord (lanyard)
to your wrist and keep it free from the han-
dlebars so that the engine stops if the opera-
tor falls off.
Wear a personal flotation device (PFD).
All riders must wear a PFD that is approved
by the appropriate authorities and suitable
for personal watercraft use.
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EJU01894
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, steering pole, han-
dlebars, and jet unit with fresh water.
3. Remove the hood and check the engine
compartment for water. To drain excess
water, turn the watercraft on its port (left)
side. If necessary, turn the watercraft
upside down to drain water completely.
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 onto its
side or inverting it, support the bow
and secure the steering pole, other-
wise the steering pole and handlebars
could be bent or damaged.
@
NOTE:@ This watercraft is equipped with an auto-
matic bilge-draining system that removes
water from the engine compartment while
you are underway. However, some residual
water will remain.
@
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 the cooling
system 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.
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EJU01090
Fuel system
Draining the fuel system prevents buildup
of varnishes and other harmful deposits that
result when gasoline sits for a prolonged
period of time.
WARNING@ Gasoline is highly flammable and explo-
sive. A fire or explosion can cause
severe injury or death. Shut the engine
off. Drain in well-ventilated areas away
from flames or sparks. Do not smoke.
Avoid spilling gasoline. Wipe up spilled
gasoline immediately.
@
To drain the fuel system:
1. Place the fuel cock knob in the “OFF”
position.
2. Drain the fuel tank using a siphon.
EJU01840
Battery
If the watercraft will not be used for more
than a month, disconnect the negative (–)
lead first, then the positive (+) lead and
breather hose, and then remove the battery
from the watercraft.
Clean the battery casing using fresh
water.
If the battery terminals are dirty or cor-
roded, clean them with a wire brush.
Fully charge the battery, and then store it
in a cool, dark place.
Apply Yamaha marine grease or Yamaha
grease A to the battery terminals.
Check the battery at least every 2 months
and fully charge it if necessary.
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4-6
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CAUTION:@ The battery may not be usable again if
you store it for a long period without
charging it. Charge the battery periodi-
cally.
@
NOTE:@ The condition of the battery can be known
by checking the specific gravity of the elec-
trolyte. However, you can also know the con-
dition of the battery by measuring the
voltage at both battery terminals. Charge the
battery if the voltage is less than 12 volts.
It is recommended to have a Yamaha dealer
check the specific gravity and to charge the
battery. If you maintain the battery yourself,
be sure to read and follow the instructions
provided with the battery tester and charger
you use.
@
EJU01300
Cleaning the watercraft
Clean the watercraft before storing it for a
long period.
1. Wash down the hull, handlebars, and
drive unit with fresh water.
2. Rinse the engine and bilge area with
fresh water. Drain off all water and wipe
up remaining moisture with clean, dry
rags.
3. Spray the engine’s exterior with a rust
inhibitor and lubricant.
4. Wax the hull with a non-abrasive wax.
5. Wipe all vinyl and rubber components,
such as the engine compartment seals,
with a vinyl protectant.
6. Do not use protectant on the riding tray,
because it will make it slippery. Specific gravity (for reference):
1.28 at 20 °C (68 °F)
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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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EJU01383
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.
@
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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
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
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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.
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