YAMAHA SUPERJET 2012 Repair Manual

Maintenance
55
EJU33768
Maintenance
Periodic checks and lubrication will keep your
watercraft in the safest and most efficient con-
dition possible. Therefore, make sure to carry
out the periodic maintenance. Safety is an ob-
ligation of the watercraft owner. Proper main-
tenance must be carried out to keep the
exhaust emission and sound levels within the
regulated limits. The most important points of
watercraft inspection and lubrication are ex-
plained on the following pages.
See a Yamaha dealer for genuine Yamaha re-
placement parts and optional accessories de-
signed for your watercraft.
Remember, failures that are the result of the
installation of parts or accessories which are
not qualitatively equivalent to genuine
Yamaha parts are not covered by the limited
warranty.
Maintenance, replacement, or repair of the
emission control devices and system may
be performed by any marine SI engine re-
pair establishment or individual. Warranty
repair, however, must be performed at an
authorized Yamaha marine dealership.
WARNING
EWJ00311
Be sure to turn off the engine when you
perform maintenance unless otherwise
specified. If you are not familiar with ma-
chine servicing, this work should be done
by a Yamaha dealer or other qualified me-
chanic.
EJU33802Tool kit
A tool kit is included with this watercraft. Place
the tool kit in a waterproof bag and alwayscarry it with you whenever you use the water-
craft.
EJU34336Adjusting the steering friction
The amount of friction in the steering can be
adjusted to suit operator preference.
To adjust the steering friction:
(1) Lift the steering pole and support it with
the lock pin.
1Tool bag
2Screwdriver
310/12 mm box wrench
4Garden hose adapter
5Spark plug (one included for each cylinder)
614/21 mm box wrench
7Pliers
8Open-end wrench
1Steering pole
2Lock pin
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Maintenance
56
(2) Remove the four screws, and then re-
move the handlebar cover.
(3) Turn the handlebars so that the left han-
dlebar grip is facing down.
(4) Loosen the locknut.
(5) Tighten or loosen the adjusting nut until
the desired amount of friction is obtained.
(6) While holding the adjusting nut with a
wrench, tighten the locknut to the speci-
fied torque.
(7) Securely install the handlebar cover and
four screws in their original positions.(8) While holding the steering pole, move the
lock pin to the stowed position, and then
lower the steering pole.
EJU31288Adjusting the jet thrust nozzle angle
The angle of the jet thrust nozzle can be ad-
justed to two settings to suit operator prefer-
ence.
To adjust the jet thrust nozzle angle:
(1) Remove the two bolts, and then remove
the steering pole cover.
(2) Pull back the outer sleeve of the steering
cable joint, and then disconnect the joint
from the steering cable pivot bolt.
1Handlebar cover
1Adjusting nut
2Locknut
Tightening torque:
Locknut:
29.0 Nm (2.96 kgf-m, 21.4 ft-lb)
1
1Steering pole cover
1Steering cable joint
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Maintenance
57
(3) Remove the steering cable pivot bolt.
(4) Select the nozzle angle, install the steer-
ing cable pivot bolt with the lock washer in
the desired position (P1 or P2) on the
steering column, and then tighten the bolt
to the specified torque.TIP:
The outermost hole in the steering column
cannot be used.
(5) Securely connect the steering cable joint
to the steering cable pivot bolt.
(6) Securely install the steering pole cover
and two bolts in their original positions.
1Steering cable pivot bolt
2Steering column
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)
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Maintenance
58
EJU40830Periodic maintenance chart
The periodic maintenance chart gives general guidelines for periodic maintenance. Have a
Yamaha dealer perform the checks in the following chart. However, maintenance may need to
be performed more frequently depending on your operating conditions. If you have any ques-
tions, consult a Yamaha dealer.
This“” mark indicates maintenance that you may do yourself.
This“” mark indicates items to be checked and serviced by a Yamaha dealer.
Item OperationInitial Thereafter every
Page 10
hours50 hours100
hours200
hours
6
months12
months12
months24
months
Spark plugsCheck, clean, replace 59
Lubrication pointsLubricate 53
Intermediate hous-
ingLubricate 60
Fuel systemCheck—
Fuel filterCheck 60
Check, replace—
Fuel tankCheck, clean—
CarburetorCheck, adjust—
Engine idling
speedCheck, adjust 61
Carburetor throt-
tle shaftCheck—
Bilge strainerClean—
ImpellerCheck—
Jet thrust nozzle
angleCheck, adjust—
Handlebar pivot
shaftCheck, adjust—
Steering frictionCheck, adjust—
Throttle cableCheck, adjust—
Choke cableCheck, adjust 60
BatteryCheck, charge—
Rubber couplingCheck—
Engine mountCheck—
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Maintenance
59
EJU34378Checking 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.
Remove and check the condition of the spark
plugs.
The condition of a spark plug can indicate
something about the condition of the engine.
For example, if the center electrode portion is
very white, this could indicate an intake air
leak or carburetion problem in that cylinder.
Do not attempt to diagnose any problems
yourself. Have a Yamaha dealer service the
watercraft.
To remove a spark plug:
(1) Remove the hood. (See page 23 for hood
removal and installation procedures.)
(2) Remove the spark plug cap.
(3) Remove the spark plug, and then check
the condition of the spark plug and the
spark plug gap. If the electrode portion is
significantly discolored, if electrode ero-
sion becomes excessive, if carbon and
other deposits are excessive, or if the
spark plug gap is not within the specified
range, replace the spark plug.
TIP:
When the engine is operating normally, the
color of the spark plug electrode portion will
be a medium-to-light tan.
To install a spark plug:
(1) Wipe off any dirt from the threads, insula-
tor, and gasket surface of the spark plug.
(2) Install the spark plug, and then tighten it
to the specified torque.
TIP:
If a torque wrench is not available when you
are installing a spark plug, a good estimate of
Nuts and boltsCheck— Item OperationInitial Thereafter every
Page 10
hours50 hours100
hours200
hours
6
months12
months12
months24
months
1Insulator
2Electrode
3Spark plug gap
Specified spark plug:
BR7HS
Spark plug gap:
0.6–0.7 mm (0.024–0.028 in)
Tightening torque:
Spark plug:
25.0 Nm (2.55 kgf-m, 18.4 ft-lb)
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Maintenance
60
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.
(3) Wipe off any water or dirt inside the spark
plug cap.
(4) Install the spark plug cap by pushing it
down until it is securely installed in its
original position.
(5) Securely install the hood in its original po-
sition.
EJU41180Lubrication points
Lubricate moving parts with water-resistant
grease. (See page 53 for information on the
main lubrication points.)
Intermediate housing
Fill the intermediate housing with water-resis-
tant grease through the grease nipple using a
grease gun.
EJU34225Checking the fuel filter
Check the fuel filter. The fuel filter should be
replaced if water or dirt is found in the filter.
Have a Yamaha dealer replace the fuel filter if
necessary.
EJU34441Adjusting the choke cable
Check that the choke cable is properly adjust-
ed.
To adjust the choke cable:
(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. Recommended water-resistant grease:
Yamaha Marine Grease/Yamaha
Grease A
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)
1Fuel filter
1Choke knob adjusting nut
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Maintenance
61
EJU34463Adjusting 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 engine
idling speed as part of the usual maintenance
routine.
EJU34471Adjusting the engine idling 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 idling speed to specification. Turn
the throttle stop screw clockwise to in-
crease the engine idling speed or coun-
terclockwise to decrease the engine
idling speed.
1Throttle stop screw
Engine idling speed:
1300 ±50 r/min
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Specifications
62
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):
48.5 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 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
63
EJU34561
Troubleshooting
If you have any trouble with your watercraft, use the troubleshooting chart to check for the pos-
sible cause.
If you cannot find the cause, consult a Yamaha dealer.
EJU34575Troubleshooting 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
18
Fuse Burned out Replace fuse and
check wiring66
Battery Run down Recharge 50
Poor terminal con-
nectionsTighten as required
50
Terminal corroded Clean or replace 50
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”20
Fuel Empty Refill as soon as pos-
sible28
Stale or contaminat-
edHave serviced by
Yamaha dealer—
Fuel tank Water or dirt present Have serviced by
Yamaha dealer—
Spark plug Fouled or defective Replace 59
Spark plug
capNot connected or
looseConnect properly
59
Crankcase Filled with water Have serviced by
Yamaha dealer67
Fuel filter Clogged or water
pooledHave serviced by
Yamaha dealer60
Choke Knob moves back on
its ownTighten choke knob
adjusting nut60
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Trouble recovery
64
Engine runs irregu-
larly or stallsFuel Empty Refill as soon as pos-
sible28
Stale or contaminat-
edHave serviced by
Yamaha dealer—
Too much oil in fuel
mixing ratioCorrect fuel-to-oil ra-
tio to 50:127
Choke Knob is left pulled Push fully in 20
Fuel filter Clogged or water
pooledHave serviced by
Yamaha dealer60
Fuel tank Water or dirt present Have serviced by
Yamaha dealer—
Spark plug Fouled or defective Replace 59
Incorrect heat range Replace 59
Gap incorrect Replace 59
Spark plug
capNot connected or
looseConnect properly
59
Cracked, torn or dam-
agedHave serviced by
Yamaha dealer—
Electrical wir-
ingLoose electrical con-
nectionsHave serviced by
Yamaha dealer—
Carburetor Incorrect idle adjust-
mentHave serviced by
Yamaha dealer—
Clogged Have serviced by
Yamaha dealer61
Watercraft slow or
loses powerCavitation Jet intake clogged Clean 65
Impeller damaged or
wornHave serviced by
Yamaha dealer65
Engine over-
heatedJet intake clogged Clean
65
Fuel filter Clogged Have serviced by
Yamaha dealer60
Spark plug Fouled or defective Replace 59
Incorrect heat range Replace 59
Gap incorrect Replace 59
Spark plug
capsNot connected or
looseConnect properly
59
Fuel Stale or contaminat-
edHave serviced by
Yamaha dealer— TROUBLE POSSIBLE CAUSE REMEDY PAGE
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