Fuel/Intake System

PERSONAL WATER CRAFT

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 INTRODUCTION

More than 20 years have elapsed since our personal watercraft (hereinafter the “PWC”)
first appeared on the market, and now the PWC has become a product that occupies a
major place in the world of marine pleasure just like outboards and motorboats.
The increasing opportunities for the use of the PWC by people are accompanied by the
increasing needs for more of the product knowledge of the PWC and its servicing
techniques and skills. And we, who handle our own PWC, should commit ourselves to
enhancing the product reliability through improved servicing skills and user
enlightenment of safety.
This book has been produced as a textbook for those PWC servicemen who receive
Marine YTA training. The text contains important basics that are required to better
understand the engines, propellers, hulls, and so on that are involved in the PWC.
Therefore, you are requested to carefully read and understand the contents of this
textbook so you will be knowledgeable enough to win customer reliance. Also if,
together with this book, you use the CAI (Computer Aided Instructions) containing
animation, we assure you that you will be able to get further and more effective learning
and knowledge.

Marine Business Operations

Yamaha Motor Co., Ltd.

YTA PWC Text

Issued in December 2008

All rights reserved
memo Compiled and issued by:
Marine Business Operations
Yamaha Motor Co., Ltd.
 WHAT WE LEARN IN VOLUME
INTRODUCTION
In this volume we will learn about PWC fuel and
intake system. We will learn about the basics of air-
fuel intake including the PWC intake device, fuel
feed device creating an air-fuel mixture, and its
control, which are all critical for engine performance.

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 CHAPTER 1
INTAKE SYSTEM
INTRODUCTION……….………………....…1-1
WHAT WE LEARN IN CHAPTER 1…....1-1
FUNCTIONS OF INTAKE SYSTEM….…...1-2
COMBUSTION AND INTAKE………..…1-2
SUPERCHARGING DEVICE……….…..1-2

CHAPTER 2
FUEL SYSTEM
INTRODUCTION ………………………...…2-1
WHAT WE LEARN IN CHAPTER 2.…...2-1
FUNCTIONS OF FUEL SYSTEM.………...2-2
OUTLINE OF FUEL…………….……....2-2
FUNCTIONS OF FUEL SYSTEM.……..2-4

CHAPTER 3
FUEL/ INTAKE SYSTEM FOR
PWC
INTRODUCTION………………………....…3-1
WHAT WE LEARN IN CHAPTER 3.…...3-1
ROLE OF EACH PART IN FUEL
SYSTEM…………………....………………3-2
FUEL TANK………………………………3-2
FUEL FILTER….…………………………3-2
FUEL PUMP….…………………………3-3
CARBURETOR.…………………………3-3
ROLE OF EACH PART IN INTAKE
SYSTEM…………………………………...…3-9
VENTILATION.…………………………3-9
INTAKE COVER.…………………………3-9
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FILTER……..….…………………………3-9
FLAME ARRESTER……………………3-9
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 INTRODUCTION
CHAPTER 1. INTAKE SYSTEM
INTRODUCTION
WHAT WE LEARN IN CHAPTER 1
In this chapter we will learn about the role of fuel
intake in relation to engine operation.This chapter
also introduces the latest mechanism involved in
natural intake, supercharge, and so forth.

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 FUNCTIONS OF INTAKE SYSTEM
FUNCTIONS OF INTAKE SYSTEM
COMBUSTION AND INTAKE
Air (oxygen) is a prerequisite for burning a fuel in
the engine. In the engine's intake process, the
intake port in the cylinder opens as the piston goes
down creating vacuum which in turn allows a fresh
mixture of air and fuel to enter the cylinder. The
intensity of burning is proportionate to the amount
of the air-fuel mixture drawn into the cylinder, so
the cylinder is designed to take in the largest
amount of the mixture. When a small amount of
energy is required as for deceleration or idling, the
intake amount of air is adjusted with the throttle
valve.
SUPERCHARGING DEVICE
Air intake amount may be increased if more energy
is to be obtained from a cylinder of the same
volume, but an ordinary engine cannot take in air at
a pressure higher than the atmospheric one.Thus, a
device is contrived that collects more air and forces
it into the cylinder with the rotation of vanes of a so-
called turbine. This device is called a supercharger.

In Yamaha FX-SHO, the open air is forced to be

collected by the turning force of the crankshaft. The
temperature of the collected air rises with the
increasing pressure, so an air cooler is used to
lower the temperature of the air, which is then fed
into the cylinder.

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 INTRODUCTION
CHAPTER 2. FUEL SYSTEM
INTRODUCTION
WHAT WE LEARN IN CHAPTER 2
In this chapter we will learn about the role of the
fuel system.

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 FUNCTIONS OF FUEL SYSTEM
FUNCTIONS OF FUEL SYSTEM
OUTLINE OF FUEL
General internal combustion engines use gasoline,
light oil, heavy oil, etc. for fuel. However, small
engines as for PWC or Motor cycle mainly use
gasoline, which is easy to handle and can produce
high power with ease.

1. Knocking
While a combustion engine is operated, the fuel
may self-ignite and if abnormal combustion takes
place, a sharp noise as if hitting the cylinder with a
hammer is heard, causing a drop in power,
piston/cylinder damage, etc.This phenomenon is
referred to as 'knock' and the resistance to knock is
referred to as antiknock property.A larger octane
number is effective in enhancing the antiknock
property.

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 FUNCTIONS OF FUEL SYSTEM
2. Octane number
Resistance of a fuel to knocking is indicated by an
octane number. Octane number is compared with
the isooctane number as 100 and normal heptane
number as 0.

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 FUNCTIONS OF FUEL SYSTEM
FUNCTIONS OF FUEL SYSTEM
It is important that a proper fuel completely free of
impurities be used for an internal combustion
engine so as to be capable of feeding a proper air-
fuel mixture to the engine.

1. Proper fuel
Gasoline comes in regular gasoline and premium
gasoline according to the difference in the octane
number. All Yamaha PWC use unleaded gasoline.
( Currently, leaded gasoline is not sold except in
some areas.)

2. Fuel free of impurities

Purchased fuel contains moisture and dirt in it. If
such a fuel is used as is, the moisture and dirt will
clog each of the fuel passages with the eventual
engine malfunction. Thus, they will be filtered out.

3. Appropriate air-fuel mixture

Engine requires an air-fuel mixture suited to its
operation and surrounding environment. It is
important that the engine be provided with an
optimum mixture.

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 INTRODUCTION
CHAPTER 3. FUEL/ INTAKE
SYSTEM FOR PWC
INTRODUCTION
WHAT WE LEARN IN CHAPTER 3
In this chapter we will learn about the PWC fuel and
the outline and characteristics of its intake system.

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 ROLE OF EACH PART IN FUEL SYSTEM
ROLE OF EACH PART IN FUEL
SYSTEM
FUEL TANK
The fuel tank is securely fixed to the hull front. Its
capacity is 18 to 70 liters. The tank is secured so as
not to allow the fuel in it to leak out inside or outside
the PWC when it turns over.

FUEL FILTER
For the carburetor model, the fuel filter is located
between the fuel tank and the carburetor.

The FI model uses an electric fuel pump, which is

kept operating while the engine is running.

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 ROLE OF EACH PART IN FUEL SYSTEM
FUEL PUMP
The carburetor model uses a diaphragm type of fuel
pump, which is integrated into the carburetor. Since
the carburetor model is only for the 2-stroke engine,
the diaphragm is operated with the crankcase
pressure.

The FI model uses an electric fuel pump, which is

kept operating while the engine is running.

CARBURETOR
The carburetor and FI types are available for
creation of an air-fuel mixture.

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 ROLE OF EACH PART IN FUEL SYSTEM
1. Floatless carburetor
The PWC carburetor is of a special structure that
has no float.

1) For starting

2) At idling or trolling

3) At intermediate speeds

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 ROLE OF EACH PART IN FUEL SYSTEM

4) At higher speed running

2. FI
FI stands for Fuel Injector, which is a device that
forces by pressure the fuel drawn in the intake port
to jet out in the form of fine particles. The injector
has fuel fed to it with constant pressure and when
an electric current flows in it, the generated
magnetic force causes the valve to open, thereby
allowing the fuel to jet out.

FI feeds a proper air-fuel mixture at the signal from

ECU.

1) For starting
At starting, an air-fuel mixture is controlled in a
manner different from what it is in normal cruising.
Signals from the pickup coil indicate that the engine
is still starting, thereby causing a richer mixture to
jet out according to the values that the temperature
and throttle position sensors show respectively.

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 ROLE OF EACH PART IN FUEL SYSTEM

2) At idling or trolling
Normal cruising control is carried out by a
combination of a speed density method and a
throttle speed method. At lower running while the
throttle is not open, a speed density method, which
is based on signals from the intake pressure and
engine speed, is used for control. Also a warm-up
operation is further controlled depending on the
engine temperatures and speeds.

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 ROLE OF EACH PART IN FUEL SYSTEM

3) Normal cruising
Normal cruising control is carried out by a
combination of the speed density and throttle speed
methods. The speed density method is used for
control at a throttle opening of 12 deg. or less and
the throttle speed method at an opening of 12 deg.
or more. At an opening of 14 deg. or less, both are
used.

4) At higher speed running

The relationship between the throttle position
sensor voltage and the engine speed is memorized
beforehand. As the throttle valve is opened, the
fuel injection amount is increased, at the same time
increasing the fuel amount by means of additional
injection.

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 ROLE OF EACH PART IN FUEL SYSTEM

5) Deceleration
In the 4-stroke engine, if the throttle valve is closed
abruptly, the ISC valve opens immediately before
full close, thereby preventing the engine from
stalling.

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 ROLE OF EACH PART IN INTAKE SYSTEM
ROLE OF EACH PART IN INTAKE
SYSTEM
VENTILATION
The PWC is always used for travel on the water, so
its engine room is designed to be watertight. This
design is called ventilation.

INTAKE COVER
In some of the engines a cover is provided for the
intake system for protection against water being
drawn in during the intake process

FILTER
The intake portion is provided with a large filter.
This filter removes moisture, salt, tiny particles of
dust, and so on.

FLAME ARRESTER
Flame arrester is designed such that if a backfire
should break out in an enclosed engine room, no
flame will take place in it. This arrester is of a
honeycomb structure allowing sufficient air to pass
through it but not the flame at all.

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 ROLE OF EACH PART IN INTAKE SYSTEM

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