YAMAHA SUPERJET 2009 Repair Manual

Maintenance and care
54
TIP:
The outermost hole in the steering column
cannot be used.
(5) Connect the steering cable joint to the
steering cable pivot bolt.
(6) Install the steering pole cover, and then
install the two screws.
EJU34361Checking 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.
Squeeze and release the throttle lever. If the
throttle lever does not return smoothly, have a
Yamaha dealer service it.
If the specified throttle lever free play cannot
be obtained as described below, have a
Yamaha dealer make the adjustment.
(1) Remove the four screws, and then re-
move the handlebar cover.
(2) Loosen the locknut.
(3) Adjust the free play by turning the adjust-
er.
1Nozzle angles
1Nozzle angles
2Steering cable pivot bolt positions
Standard steering cable pivot bolt posi-
tion:
P2
Tightening torque:
Steering cable pivot bolt:
5.4 Nm (0.55 kgf-m, 4.0 ft-lb)
1Locknut
2Adjuster
3Throttle lever free play
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Maintenance and care
55
(4) Hold the adjuster with one wrench while
tightening the locknut with another
wrench.
(5) Install the handlebar cover and the four
screws.
EJU34374Cleaning and adjusting the spark
plugs
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.
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.
To remove a spark plug:
(1) Remove the hood. (See page 17 for hood
removal and installation procedures.)
(2) Remove the spark plug cap.(3) Remove the spark plug.
Measure the spark plug gap with a wire
thickness gauge. Replace the spark
plugs or adjust 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) Wipe off any water on the spark plug or
inside the spark plug cap, and then install
the cap. Push the spark plug cap down
until it is securely installed.
TIP:
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 in-
cluded in the tool kit. Have the spark plug ad-
justed to the correct torque with a torque
wrench as soon as possible.
(5) Install the hood. 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 (2.55 kgf-m, 18.4 ft-lb)
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Maintenance and care
56
EJU34401Lubrication 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)

Steering cable inner wire (jet thrust nozzle
end)

Handlebar pivot shaft
Lubrication of the handlebar pivot shaft re-
quires disassembly of steering compo- Recommended water-resistant grease:
Yamaha Marine Grease/Yamaha
Grease A
1Seal
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Maintenance and care
57
nents. Have a Yamaha dealer lubricate the
handlebar pivot shaft.

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
slightly. If the knob is difficult to move,
loosen the adjusting nut slightly.
EJU34452Checking the battery
Check the level of the battery electrolyte and
make sure that the negative (–) and positive
(+) battery leads are tightened securely.
WARNING
EWJ00791
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.
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)
1Choke knob adjusting nut
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Maintenance and care
58
To remove the battery:
Disconnect the negative (–) battery lead first,
then the positive (+) battery lead and breather
hose, and then remove the battery from the
watercraft.
To replenish the battery:
(1) Make sure that the electrolyte level is be-
tween the maximum and minimum level
marks.
(2) If the electrolyte level is low, add distilled
water to raise it to the specified level.
NOTICE: Use only distilled water for
replenishing the battery, otherwise
battery life could be shortened.
[ECJ00241]
To recharge the battery:
NOTICE
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, be sure to read and follow the in-
structions provided with the battery tester and
charger you use.
To install the battery:
(1) Place the battery in the battery compart-
ment. Connect the red lead to the positive
(+) battery terminal, and then connect the
black lead to the negative (–) battery ter-minal. NOTICE: Reversal of the battery
leads will damage the electrical parts.
[ECJ00261]
(2) Connect the breather hose to the battery.
(3) Secure the battery in place. WARNING!
Fire or explosion could result if the
breather hose is damaged, obstruct-
ed, or not connected properly.
[EWJ00451]
EJU34462
Adjusting the carburetor
NOTICE
ECJ00172
If the carburetor settings are disturbed by
someone who does not have the neces-
sary technical knowledge, poor engine
performance and damage may result.
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 rou-
tine.
EJU34470Adjusting the trolling speed
(1) Place the watercraft in the water.
(2) Start the engine and warm it up for 1 to 2
minutes.
1Maximum level mark
2Minimum level mark
1Positive (+) battery terminal: Red lead
2Negative (–) battery terminal: Black lead
3Breather hose
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Maintenance and care
59
(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.
1Throttle stop screw
Trolling speed:
1300 ±50 r/min
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Specifications
60
EJU34542
Specifications
Watercraft capacity:
Maximum people on board:
1 person
Dimensions:
Length:
2240 mm (88.2 in)
Width:
680 mm (26.8 in)
Height:
660 mm (26.0 in)
Dry weight:
139 kg (306 lb)
Performance:
Maximum output (according to ISO 8665/SAE
J1228):
48.50 kW@6250 r/min
Maximum fuel consumption:
29.0 L/h (7.7 US gal/h, 6.4 Imp.gal/h)
Cruising range at full throttle:
0.62 hour
Trolling speed:
1300 ±50 r/min
Engine:
Engine type:
2-stroke
Number of cylinders:
2
Engine displacement:
701 cm³
Bore & stroke:
81.0 × 68.0 mm (3.19 × 2.68 in)
Compression ratio:
7.2 : 1
Lubrication system:
Pre-mixed fuel and oil
Cooling system:
Water
Starting system:
Electric
Ignition system:
C.D.I.
Spark plug:
BR7HS
Spark plug gap:
0.6–0.7 mm (0.024–0.028 in)
Battery capacity:
12 V, 19.0 AhCharging system:
Flywheel magneto
Drive unit:
Propulsion system:
Jet pump
Jet pump type:
Axial flow, single stage
Impeller rotation:
Counterclockwise
Jet thrust nozzle angle:
P1: 14.4+14.4 °
P2: 17.3+17.3 °
Fuel and oil:
Recommended fuel:
Regular unleaded gasoline
Minimum octane rating (PON):
86
Minimum octane rating (RON):
90
Recommended engine oil:
YAMALUBE 2-W or TC-W3 outboard motor
oil or equivalent
Fuel mixing ratio (fuel to oil):
50 :1
Fuel tank total capacity:
18 L (4.8 US gal, 4.0 Imp.gal)
Fuel tank reserve capacity:
5.5 L (1.5 US gal, 1.2 Imp.gal)
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Trouble recovery
61
EJU34560
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.
EJU34571Troubleshooting chart
TROUBLE POSSIBLE CAUSE REMEDY PAGE
Engine does not
start (Starter motor
does not turn over)Engine shut-
off switchClip not in place Install clip
19
Fuse Burned out Replace fuse and
check wiring64
Battery Run down Recharge 57
Poor terminal con-
nectionsTighten as required
57
Terminal corroded Clean 46
Starter motor Faulty Have serviced by
Yamaha dealer—
Engine does not
start (Starter motor
turns over)Fuel cock Turned to “OFF” Turn fuel cock knob to
“ON”18
Fuel Empty Refill as soon as pos-
sible25
Stale or contaminat-
edHave serviced by
Yamaha dealer51
Fuel tank Water or dirt present Have serviced by
Yamaha dealer51
Spark plug Fouled or defective Clean or replace 55
Spark plug
capNot connected or
looseConnect properly
55
Crankcase Filled with water Have serviced by
Yamaha dealer65
Fuel filter Clogged or water
pooledHave serviced by
Yamaha dealer51
Choke Knob moves back on
its ownTighten choke knob
adjusting nut57
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Trouble recovery
62
Engine runs irregu-
larly or stallsFuel Empty Refill as soon as pos-
sible25
Stale or contaminat-
edHave serviced by
Yamaha dealer51
Too much oil in fuel
mixing ratioCorrect fuel-to-oil ra-
tio to 50:124
Choke Knob is left pulled Push fully in 20
Fuel filter Clogged or water
pooledHave serviced by
Yamaha dealer51
Fuel tank Water or dirt present Have serviced by
Yamaha dealer51
Spark plug Fouled or defective Replace 55
Incorrect heat range Replace 55
Gap incorrect Adjust 55
Spark plug
capLoose Connect properly 55
Cracked, torn or dam-
agedHave serviced by
Yamaha dealer—
Electrical wir-
ingLoose electrical con-
nectionsHave serviced by
Yamaha dealer—
Carburetor Incorrect idle adjust-
mentAdjust idle
58
Clogged Have serviced by
Yamaha dealer58
Watercraft slow or
loses powerCavitation Jet intake clogged Clean 63
Impeller damaged or
wornHave serviced by
Yamaha dealer63
Engine over-
heatedJet intake clogged Clean
63
Fuel filter Clogged Have serviced by
Yamaha dealer51
Spark plug Fouled or defective Replace 55
Incorrect heat range Replace 55
Gap incorrect Adjust 55
Spark plug
capsLoose Connect properly
55
Fuel Stale or contaminat-
edHave serviced by
Yamaha dealer51 TROUBLE POSSIBLE CAUSE REMEDY PAGE
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Trouble recovery
63
EJU34620
Emergency procedures EJU34631Cleaning the jet intake and impeller
WARNING
EWJ00780
Before attempting to remove weeds or de-
bris from the jet intake or impeller area,
shut the engine off and remove the clip
from the engine shut-off switch. Severe in-
jury or death could result from coming in
contact with the rotating parts of the jet
pump.
If weeds or debris gets caught in the jet 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.
NOTICE: If weeds or debris gets caught in
the jet intake, do not operate the watercraft
above trolling speed until they have been
removed.
[ECJ00651]
If there is any sign that the jet intake or impel-
ler is clogged with weeds or debris, return to
shore and check the intake and impeller. Al-ways stop the engine before beaching the wa-
tercraft.
(1) Place a suitable clean cloth or carpeting
underneath the watercraft to protect it
from abrasions and scratches. Turn the
watercraft on its side as shown. NOTICE:
Always turn the watercraft over onto
its port (left) side. When turning the
watercraft on its side, support the bow
so that the handlebars are not bent or
damaged.
[ECJ00661]
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