Yamaha XL800 manual

READ THIS MANU AL CAREFULL Y BEFORE OPERA TION! O WNER’S / OPERA T OR’S MANU AL LIT -18626-04-02 U .S.A. E d iti on[...]

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E EJU00270 T o the owner/operator Thank you f or choosing a Y amaha water- craft. This Owner’ s/Operator’ s Manual contains inf or mation you will need for proper opera- tion, maintenance, and care. A thorough understanding of these simp le instructio ns will help you to obtain maximum enjo yment from your ne w Y amaha. If you hav e any questio[...]

E EJU00273 CONTENTS READ THIS O WNER’S/OPERA T OR’S MANU AL CAREFU LL Y BEFORE OPERA TING Y O UR W A TERCRAFT . GENERAL AND SAFETY INFORMA TION 1 FEA TURE AND FUNCTIONS 2 OPERA TION 3 MAINTENANCE AND CARE 4 TR OUBLESHOO TING AND EMERGENCY PR OCEDURES 5 APPENDIX 6[...]

E 1 EJU00274 GENERAL AND SAFETY INFORMA TION Identification numbers ........... .................. 1-1 Primary Identification (PRI-ID) number .. 1-1 Hull Identification Number (HIN)......... .... 1-1 Engine serial number ............... ........... .... 1-1 Emission con trol infor mation ................ . 1-2 Approval label of Emission control cer[...]

1-1 E EJU00699 Identification number s Record your Primar y Identification (PRI- ID) number , Hull Id entification Number (HIN) and engine ser ial number in the spaces pro- vided, to assist you in ordering spare par ts from a Y amaha deal er . Also record and keep these ID numbers in a separate place in case your w atercraft is stolen. EJU00700 Pri[...]

1-2 E EJU00631a Emission control inf ormation This engine conforms to the U .S . Environ- mental Protection Agency (EP A) regulations f or mar ine SI engines for the y ear 2001. Appr ov al label of Emission contr ol cer tificate This label is attach ed to the electri cal box and the silencer of the carburetor . 1 Emission control inf or mation labe[...]

1-3 E EJU00293 Impor tant labels Label location[...]

1-4 E W arning labels 1 2[...]

1-5 E 34 56 7 89 0[...]

1-6 E Caution labels AB C D[...]

1-7 E Other labels F E GH I[...]

1-8 E EJU00686 Safety inf ormation The safe use and operatio n of this watercraft is dependent upon the use of pr oper riding techniq ues, as well as upon the common sense, good judgment, and expertise of the operator . Every operator should kno w the follo wing requirements before riding the water cra ft. ● Bef ore operating th e watercraft, rea[...]

1-9 E EJU00613 Cruising limitations ● Scan constantly for people , objects, and other watercraft. Be aler t for conditions that limit your visibility or bloc k your vision of others . ● Operate def ensively at saf e speeds and keep a saf e di stance aw ay from people , objects, and other w atercraft. ● Do not f ollow directly behind watercraf[...]

1-10 E ● This watercraft is not equipped with light- ing require d f or night ope ration. Do not operate the w atercraft after sunset or bef ore dawn, otherwise you increase the risk of coll iding with another boat, which could result in sev ere injur y or death. EJU00735a Operation requirements ● All riders must we ar a Coast Guard approv ed p[...]

1-11 E ● Helmets meeting Snel l or DO T standard s are required for IJSBA-sanctioned races. Y ou must decide whether to wear a hel - met while you ride f or recreation. Y ou should know that a helmet could help pro- tect you in cer tain kinds of accidents and that it could also injure you in others . A helmet is designed to provide some head prot[...]

1-12 E ● Do not attempt to m odify this watercr aft! Modifications to your w atercraft ma y reduce saf ety and relia bility , and render the watercraft unsaf e or illegal f or use. ● Attach the engine shut-off cord (lanyard) to wrist an d keep it free from the handle- bars so that the engine stops if the opera- tor f alls off . After r iding, r[...]

1-13 E EJU00313 Hazar d inf ormation ● When transpor ting or stor ing your w ater- craft, alwa ys place the fu el cock knob in the “OFF” position, otherwise gasoline ma y ov erflo w from the carburetor . ● Ne ver star t the engine or let it r un f or any length of time in an enclosed area. Exhaust fumes contain carbon mon o xide, a colorles[...]

1-14 E ● Re verse can be used to slow down or stop duri ng slow speed maneuvering, such as when docking. Once the engine is idling, shift to re verse and gr aduall y increase engine speed. Make sure that there are no obstacles or people behind you bef ore shifti ng into re verse. ● K eep aw ay from intake gr ate 1 while the engine is on. Items [...]

1-15 E ● A second person should b e on board as a spotter to watch the skier; in most states it is required by la w . Let the skier direct the operator’ s control of speed and direction with hand signals. The spotter should sit securely on the passenger seat and h old onto the h and- grip with feet firmly on th e f ootrest for proper balance wh[...]

1-16 E EJU00319 Rules of the Road Y amaha watercraft is legall y consid- ered a powerboat. Operation of the watercraft m ust be in accordance with the rules and regulations governing the waterway o n which it is used. Just as there are rules that apply when you are driving on streets an d highwa ys, there are waterwa y r ules that appl y when you a[...]

1-17 E Rules when encountering vessels There are three main situatio ns that you ma y encounter with other vessels which could lead to a col lision unless the Steering Rules are f ollowed: Meeting: you are approaching another vessel head-on Crossing: you are tra veling across another vessel’ s path Overtaking : you are passing or being passed by [...]

1-18 E Overtaking If you are passing another v essel, you are the give-w ay v essel. Th is means that the other ve ssel is expected to maintain its course and speed. Y ou must stay out of its wa y until you are clear of it. Like wise, if another vessel is passing y ou, you should maintain your speed and direction so th at the other vessel can steer[...]

1-19 E This system uses buo ys and signs with distinctive shapes and colors to show regu- lator y or a dvisor y information. These mar k- ers are white with blac k letters and orange borders. The y signify speed zones, restricted areas, danger areas, and general inf or mati on. Remember , marking s ma y vary by geo- graphic location. Alw ays consul[...]

1-20 E EJU00320 T o g et more boating safety inf ormation Be inf or med about boating sa f ety . Addi- tional publications and information can be obtained from many organizations, including the f ollowing. United States Coast Guar d Consumer Aff airs Staff (G-BC) Office of Boating, Public, and Consumer Aff airs U . S. Coast Guard Headquar ters W a [...]

1-21 E EJU00322 Enjo y y our water craft responsibl y Y ou share the areas you enjoy when ridin g your w atercraft with others and with nature. So y our enjo yment includes a responsibility to treat these other people, and the lands, waters , and wildlife with respect and cour tesy . Whene ver and wherev er you r ide, think of yourself as the guest[...]

E 2 EJU00326 FEA TURES AND FUNCTIONS Location of main components ............... 2-1 Operation of co ntrols and othe r functions ................. .................... ............... 2-5 Rear seat...................... ......... ........ ......... . 2-5 Front seat .......... ......... ........ ........ ......... .... 2-6 Hood ............... .....[...]

2-1 E EJU00327 Location of main components 1 Handlebars Use to control direction. 2 Fuel tank filler cap 3 Rope hole 4 Footwell Use to place f eet for balance. 5 Footrest Use for stopping when pulling a water-skier . 6 Front seat latc h 7 Rear seat latch Locking and releasing the seat rock. 8 Intake grate Prev ents debr is from getting into the jet[...]

2-2 E 1 Cooling water pilot outlet Use to verify cooling water flo w . 2 Bow eye Use to attach rope for tr ansporting, moor ing or towing the watercr aft in an emergency . 3 Front storage compartment 4 Hood 5 Fuel cock knob Use to select either nor mal or reser ve fuel flow from the fuel tank to the carburetors, or to shut off fuel flow . 6 Oil tan[...]

2-3 E 1 Engine shut-off cord (lan yar d) Attach to wrist so that the engine stops if the operator f alls off the watercraft. 2 Engine stop switch Push to stop the engine nor mally . 3 Clip Inser t into the engine shut-off switch to enable star ting of the engine. Remov e to stop the engine or prev ent acci- dental star ting of the engine or unautho[...]

2-4 E 1 Spark plugs/Spark plug caps 2 Electrical bo x Protects electrical components fro m water . 3 Flush hose connector Use to flush the engine cooling water pas- sages. 4 Spark plug lead 5 Muffler 6 Fuel filter 7 Fuel tank 8 Oil tank 9 Battery 5 4 3 1 2 F0P02030 6 8 7 F0P02040[...]

2-5 E EJU00328 Operation of contr ols and other functions EJU00335a Rear seat T o remove the rear seat: Pull the rear seat latch 1 up, and then pull the seat off. T o install the rear seat: Inser t the proj ections on the fro nt of the seat into the sta ys on the deck, an d then push the rear of the seat down to lock it in place securely .[...]

2-6 E EJU00714 Fr ont seat T o remove the front seat: 1. Remov e the rear seat. 2. Pull the front seat latch 2 up , and then pull the seat off. T o install the front seat: 1. Inser t the projections on the front of the seat into the stays on the deck, and then push the rear of the seat down to lock it in place. 2. Install the re ar seat. N O TE: Ma[...]

2-7 E EJU00703 Hood T o open the hood, pull the latch 1 up , and then lift the hood up. T o close the hood, p ush the hood down to lock it in plac e. N O TE: Make sure that the hood is properly secured bef ore operating the watercraft.[...]

2-8 E EJU00347 Fuel tank filler cap T o remov e the fuel tank filler cap 1 , tur n it counterclockwise . N O TE: Make sure that the fuel tank filler cap is proper ly secured bef ore operating the water- craft. EJU00001N Oil tank filler cap T o remove the oil tank filler cap: 1. Open the hood. (See page 2-7 for hood.) 2. T u r n the fi ller cap 2 co[...]

2-9 E EJU00704 Fuel cock knob The fuel cock supplies fuel from the fuel tank to the carburetors . The fuel cock knob 1 positions ar e e xplained as f ollows and are shown in the illustration. OFF: With the fuel cock knob in this position, fuel does not flow . Alwa ys tur n the fu el cock knob to this position when the engine is not runn ing. ON: Wi[...]

2-10 E EJU00705 Engine stop switc h Push this s witch 1 (red b utton) to stop the engine nor ma lly . EJU00706 Engine shut-off s witc h Inser t the clip 1 , on the end of the engine shut-off cord 2 , under the engine shut-off s witch 3 (blac k b utton ). The engine will stop automatically when the clip is removed from the s witch, such as if the op[...]

2-11 E EJU00351 Thr ottle lever Squeeze the throttle le ver 1 to increas e engine speed. Release the throttle lev er to decrease engine speed or to retur n it to the idle posi- tion. EJU00353 Star t switc h Push the star t switch 1 (g reen button) to star t the engine. N O TE: ● The engine will not star t when the clip is remov e d from the engin[...]

2-12 E EJU00354 Cooling water pilot outlet This watercraft is equipped with cooling water pilot outlets. When the engin e is r unning, cooling water is circulated in the engine, and then it is discharged from the pilo t outlets. T o chec k for prope r operation of the cool- ing system, check that w ater is being dis- charged from the pilot outlets.[...]

2-13 E EJU00670 Tilt lever The tilt le ver 1 is located in front of the glov e compar tment and is used to adjust the tilt of the handl ebars. T o adjust the tilt, pull the tilt lev er up, and then mov e the handleba rs up or down to the desired position. W A R N I N G ● Never touch the tilt le ver during opera- tion, otherwise th e handlebars ma[...]

2-14 E EJU00710 Shift le ver The shift lev er is located on the sta rboard side of the watercraft and is used to control the re v erse gate, which allows the w atercr aft to mov e into rev erse or f orward. When in the rev erse position, the water- craft can be launched from a tr ailer , or back ed up out of tight spots where you can- not tur n aro[...]

2-15 E EJU00360a Quic k Shift T rim System (QSTS) selector The QSTS selector 1 is located at the left handlebar grip and is used to adjust the tr im angle of the watercraft. Operating the QSTS selector changes the angle of the jet thr ust nozzle ver tically . This changes the trim an gle of the watercraft. There are 5 positions: 2 bow down posi- ti[...]

2-16 E Bow do wn T ur n the grip to A or B and the bow will go down while the watercr aft is on plane. Bow do wn puts more of the bow in the water . This gives the w atercr aft more “hook,” which enhances tur ning perf or mance. This position will also help the watercr aft get up on plane more quickly . At higher speeds, howe ver , the watercra[...]

2-17 E EJU00366 Engine overheat warning system This model is equi pped with an engine ov erheat warning system. If the engine star ts to ov erheat, the warn- ing light, the indicato r for the water tempera- ture symbol, and “W .TEMP” display begin to blink, the b uzzer sounds, and the engine speed will be limited to about 3,000 r/min . When thi[...]

2-18 E EJU00367a Handgrip The handgrip 1 provides a handhold f or boarding the watercraft and f or a spotter when facing rearward. CAUTION : Do not use to to w objects, lift water craft, or attach tie dow ns, otherwise damage could oc cur .[...]

2-19 E EJU00698b Multifunction meter This meter contains f ollowing functions f or help and conv enience in ope rating the watercr aft. 1 “MODE” button 2 “SET” button 3 “CODE” setting buttons 4 T achometer 5 Speedometer 6 Fuel meter 7 Engine oil meter 8 Displa y f or Clock, Hour meter , T r ip meter and T r ip timer 9 W ar ning light 0 [...]

2-20 E EJU00711a P ADLOC (Programmab le digital locking ignition) This f eature is provided to deter unauth o- rized use. The function allows you to choose eith er “ST AR T” or “LOCK” mode, as the situation requires, much as y ou would use an ignition ke y in a m otor v e hicle . If y ou ha ve pre viously chosen “LOCK” mode, the engine [...]

2-21 E 3. Select your f our-letter code by pressing the “A/SET ,” “B,” or “C” buttons in a desired sequence. N O TE: If you do not press a button f or more than 10 seconds, the displa y automatically tur ns off . This cancels the process of setting a code. 4. After code setting is complete, the buzz er will sound 3 times a nd the displa[...]

2-22 E 3. Enter yo ur four-letter code b y pressing the “A/SET ,” “B,” or “C” b uttons in the right sequence. N O TE: If you do not press a button f or more than 10 seconds, the displa y automatically tur ns off. This cancels the process of selecting the mode. 4. If the code entered is correct, the mod e will change from the previous mo[...]

2-23 E EJU00384 Speedometer This meter shows the w atercraft speed in miles per hour (mph). EJU00386a Fuel meter The fuel meter is provided for con venient fuel le vel chec king while ope rating the watercr aft. The fuel meter has 4 segme nts which show the amount of fuel remaining in the fuel tank. N O TE: The indication of the segments differs de[...]

2-24 E EJU00387a Engine oil meter The engine oil meter i s provided f or con- venient oil le vel checking while operating the watercr aft. The engine oil me ter has 3 se gments which show the amount of oil remainin g in the oil tank. N O TE: The indication of the segments differs depending on your operating condition. U se the meter as a ref erence[...]

2-25 E 6. The buzz er will sound twice. The warn- ing light and “SET” blink f or 2 seconds. Then the display turns to “CLOCK” and shows the time . N O TE: If the batter y te r minal is disco nnected, the clock will be reset to 12:00. EJU00390 Hour meter The hour meter is provided to mak e it easy to f ollow the maintenance schedule. The met[...]

2-26 E EJU00712 Tr i p m e t e r A tripmeter is provided f or measur ing the appro ximate distan ce trav eled. T o show the tripmeter , press the “MODE” button until the displa y shows “TRIP” while the engine is ru nning. After showing “TRIP ,” the displa y tur ns to “.MILE.” 1. When the display sho ws “.MILE,” press the “MODE[...]

2-27 E EJU00717a Oil warning indicator If the oil remaining in the tank drops to about 1.4 L (0.37 US gal, 0.31 Imp gal) or the oil filter is clogge d, the lowest oil lev el segment, the oil warning indicator , “OIL” and the warning lig ht begin to blink. The b uzzer also star ts sound ing inter mittentl y . If the oil war ning indi cator begin[...]

2-28 E EJU00719 Battery warning indicator If the batter y voltage becomes less than 11.5 vo lts, the batter y war ning indicator , “V OL T” and the warn ing light begin to blink. The buzzer also star ts sounding. If this happens dur ing operation, beach the watercraft. Then recharge the batter y and hav e the charging system inspected by a Y am[...]

2-29 E EJU00672a Storage compar tments A front storage compar tment, a glov e compar tment, and seat storage compar t- ments are provided. N O TE: ● Make sure that the storage compar tments are proper ly secured before operating the watercr aft. ● The storage compar tments a re not designed to be water proof. If y ou carr y objects that must be[...]

2-30 E Glov e compartment A glov e compar tment 4 is located in front of the seat. T o open the gl ov e compar tment, slide the latch 3 to ward y ou, and then lift up the lid. T o close the glov e compar tment, pu sh the lid down until it locks securely . Glove compartment: Capacity: 1.7 L (0.45 US gal, 0 .37 Imp gal) Load limit: 1 k g (2.2 lb) Sea[...]

E –MEMO–[...]

E 3 EJU00410 OPERA TION Fuel and oil ................... ................... .......... 3-1 Gasoline ............ .................... .................. 3-1 Filling the fuel tank ................ ........... ....... 3-3 2-stroke engine oil........... ........... ............ . 3 -3 Filling the oil tank ..................... ........ ....... 3-4 Pr[...]

3-1 E EJU00411a Fuel and oil This engine uses Y amaha’s oil injection system, which provides superior lubr ication by ensuring the p roper oil ratio for all operat- ing conditions. No fuel p remixing is neces- sar y except during the engine break-in period. Si mply pour gasoli ne into the fuel tank and oil in to the oil tank. Gasoline W A R N I N[...]

3-2 E CAUTION : Use only fresh gasoline that has been stored in clean containers. Gasohol There are two types of gasohol: gasohol containing ethanol and that con taining meth- anol. Gasohol containing ethanol can be used if ethanol content does not exceed 10 % and the fuel meets mini mum octane ra tings . Gasohol containing me thanol is not rec- om[...]

3-3 E EJU00724a Filling the fuel tank CAUTION : Be careful when refueling. A v oid getting water or other contaminants in the fuel tank. Contaminated fuel can cause poor running or eng ine damage. 1. Open the hood and remove the front storage compar tment, to check the fuel le vel. (See page 2-29 f or front storage compar tment.) 2. Open the fuel t[...]

3-4 E EJU00419a Filling the oil tank W A R N I N G ● Do not add gasoline to the oil tank. Fire or e xplosion could result. ● Oil in the bilge is a serio us fire hazard. Wipe up any spilled oil immediately . CAUTION : Do not allow the oil tank to become com- pletely empty . If the oil tank becomes empty the oil injectio n pump must b e bled to e[...]

3-5 E EJU00422 Pre-operation chec ks Pre-operation chec k list Bef ore operating this watercraft, perf or m the checks in the follo wing check list. See the accompanying te xt in this chapter for details on how to perf or m the checks. W A R N I N G If any item in the pre-operation ch eck list is not working pr operly , have it inspected and repair[...]

3-6 E EJU00426 Pre-operation chec k points Engine compar tment V enti late the engine comp ar tme nt before each use. T o v entilate the engine compa r tment, remov e all seats and front storage compar t- ment. (See page s 2-5 and 2-6 for front and rear seat, and 2-29 for front storage com- par tme nt.) Allow the engine compar tment to remain open [...]

3-7 E EJU00432a W ater separator Check the water separator 1 for w a t e r. Nor mally the water separator is empty . The water separator retains any water entering through the fuel tank breather hose if the watercr aft is capsiz ed. If water remains in the water separator , drain it by remo ving the drain screw 2 . Install the drain screw again aft[...]

3-8 E EJU00435a Battery Check the batter y condition and the elec- trolyte le vel. Check that the batter y leads are tightened securely and there is no corrosion on the battery ter minals. W A R N I N G The battery must always be full y charged and in good condition. Lo ss of battery power ma y leave y ou stranded. Never operate the watercraft if t[...]

3-9 E F0P03010 EJU00728 Fire extinguisher Check that there is a full fire e xtin guisher on board. The fire extinguisher container 1 is located in the front storage compar tment. T o open the fire extinguisher container cap 2 turn it counterclockwise. After inser ting the fire extinguisher make sure that the container cap is tightened securely . N [...]

3-10 E EJU00447 Throttle Squeeze and release the throttle lev er se veral times to mak e sure that there is no hesitation in its trav el. It shoul d be smooth ov er the complete range, and spring back to the idle position when released. W A R N I N G Bef ore starting the engine, al ways c heck the operation of the thrott le lever . It should move s[...]

3-11 E EJU00450 Shift lever and re verse gate Check f or proper operation of the shift lev er an d rev erse ga te. Make sure that the re verse gate goes down to its stopper position when the shift lev er is pul led up . Also , make sure that the re verse gate goes up to its stopper position when shift lev er is push ed down. W A R N I N G JJ ● Ma[...]

3-12 E EJU00451a Jet unit Carefully check the jet intake f or weeds, debris, or anything else that might restrict the intake of w ater . If the intake is clogged, cavitation could occur , reducing jet thr ust, and possibly damaging the j et pump . In some cases, the engine ma y ov erheat because of lack of cooling water , and dam- age to the en gin[...]

3-13 E EJU00452a Switches Check the start sw itch 1 , the engine sto p s witch 2 , and the en gine shut-off switch 3 f or proper operation. T o check these s witches place the water- craft in the w ater to provide adequate cooling. Star t the engine, and then pull the engine shut-off cord 5 to remov e the clip 4 from the engine shut-off s witch. V [...]

3-14 E EJU00676a Operation W A R N I N G Before operating y our watercraft, become familiar with all controls. Co n- sult y our Y amaha deal er about an y con- trol or function y ou do not fully understand. F ailure to understan d how controls work could cause an accide nt or prevent y ou from av oiding an accident. CAUTION : Make sure that stern d[...]

3-15 E 3. Gradually open the throttle to 3/4 or less. 4. Continue operation at 3/4 throttle or less until the first tankfu l of fuel has been used. 5. Fill the tank with straight gasoline, and then proceed with nor mal operati on. CAUTION : Fai lure to follo w the engine break-in pr o- cedure properl y can result in severe damage to the engine .[...]

3-16 E EJU00506 Launching the water craft Make sure that there are no obstructions behind you. After the watercr aft is in the water , star t the engine. Shift into re verse and mo ve the watercraft bac k slowly . If there are wav es, someone should make sure that the water- craft is not pushed into the trailer before backing aw ay . EJU00645a Star[...]

3-17 E 2. T u r n the fuel cock knob to the “ON” posi- tion. N O TE: Bef ore star ting the watercraft, after it has been sitting, remov e the fue l tank filler cap to release any b uilt-up pressure in th e tank due to fuel expansion. 3. Attach the clip 1 to the engine shut-off s witch 2 . Also , attach the engine shut- off cord 3 to y our left [...]

3-18 E 5. If the “LOCK” mode was chosen previ- ously , choose the “ST AR T” mode befor e star ting the engine. (See pages 2-20 to 2-21 for selecting “P ADLOC” mo de.) N O TE: ● If the initial setting of the P ADLOC has not been done, the “ST ART” mode is auto- matically selected. ● If you ha ve pre viously chosen “LOCK” mode[...]

3-19 E EJU00463a Stopping the engine T o stop the engine, release the throttle lev er , and then push the engin e stop s witch (red button). W A R N I N G Y ou need throttle to steer . Shutting off the engine can cause y o u to hit an obsta- cle y ou are attempting to av oid. A colli- sion could result in severe injury or death. EJU00005n Leaving t[...]

3-20 E EJU00674 Operating y our water craft Getting to know y our watercraft Operating your w atercraft requires skills acquired through practice over a period of time. T ake the time to lear n the basic tech- niques well before attempting more difficult maneuvers . Operating your ne w watercraft can be a very enjoy able activity , providing you wi[...]

3-21 E W ear protective clothing. Se vere inter nal injuries can occur if water is f o rced into body cavities as result of falling into the wa ter or being near the jet thr ust nozzle. Nor mal s wimwear does not adequate ly protect against forceful w ater entr y into rectum and vagina. All riders must wear a wetsuit bot- tom or clothing that provi[...]

3-22 E EJU00484 Star ting the watercraft W A R N I N G ● Scan constantl y for peop le, objects and other water craft. Be aler t for con- ditions that limit y our visibility or bl oc k y o ur vision of other s. ● Operate defensively at safe speeds and keep a safe distance awa y from people, objects, and other watercraft. ● Do not f ollow direc[...]

3-23 E EJU00486a Starting and boarding in shallo w water 1. Do not star t the e ngine in less than 60 cm (2 ft) of water . Put the watercraft in water that is deep enough, and then board the watercraft from the side or the rear . 2. Attach the engine shu t-off cord to your left wrist, and then instal l the clip to the engine shut-off s witch. 3. Gr[...]

3-24 E EJU00490a Boar ding and star ting in deep water W A R N I N G ● Operator and passeng er should prac- tice getting on board in shallow water before riding in deep water . Boarding in deep water requires more skill. ● The fatigue and exposure that could result after unsuccessful attempts to get back on the water craft may increase the risk[...]

3-25 E EJU00737a Boarding with passengers W A R N I N G Severe internal injuries can occur if water is for ced into body cavities as a result of being near the jet thrust nozzle . Do not apply thr ottle until each passen- ger is seated with his or her feet on the floor of the f ootwell and is holdi ng on to the pers on in front of him or her . 1. C[...]

3-26 E N O TE: The hea vier the total w eight of the oper ator and passengers, the more difficult it wil l be to balance the watercraft. Do not operate the watercraft when the total weight e xceeds 240 kg (530 lb) includi ng any cargo . If it is difficult to balance the vehicle at a standstill, proceed as follows: 1. The passenger must steady the w[...]

3-27 E CAUTION : Be sure to remo ve the clip fr om the shut- off switc h, otherwise the engine will overheat and engine damage ma y occur . 1. Shut the engine off by removing the clip from the engine shut-off switch. 2. Swim to the rear of the watercr aft. Pull the watercraft o ver with left hand on ride plate while pushin g down on the gun- wale w[...]

3-28 E A B C D EJU00499 T urning the watercraft Steering con trol depends on the combi- nation of handlebar position and the amou nt of throttle . W ater suck ed in through the intake grate is pressuriz ed by the impelle r in the jet pump . As the pressurized water is e xpelled from the pump through the je t thrust nozzle, it creates thrust to move[...]

3-29 E W A R N I N G ● Do not release the throttle when trying to steer awa y from objects—y ou need thr ottle to steer . A collision could result in se vere injur y or death. ● When operating at higher speeds, make gradual turns or slow down before t urning. Sharp high-speed turns may cause the water craft to slide side- wa ys or spin, thro [...]

3-30 E EJU00621 Stopping the water craft The watercraft is not equipped with a se p- arate braking system. It is stopped by w ater resistance when the throttle le ver is released. F rom full speed, the watercraft comes to a complete stop in approximately 105 m (345 ft) after the throttle is released and the engin e is stopped, altho ugh this dis- t[...]

3-31 E EJU00635 Beaching the water craft 1. Make sure no obstructions, boats or s wimmers are near the bea ch. Release the throttle lev e r about 105 m (345 ft) bef ore you reach the intended beaching area. 2. Approach the beach slowly and stop the engine before reaching land. Remem- ber : you need throttle to steer . 3. Get off the watercraft and [...]

3-32 E EJU00006n Re ver se on waterways Re verse can be used f or slow speed maneuvering when it is ne cessar y to back up out of tight spots where you cannot tur n around. Rev erse can only be use d to slow down or stop during low speed maneuver- ing, such as when docking. Once the engine is idling, shift to re verse and gradually increase engine [...]

3-33 E EJU00691a P ost-operation chec ks Alwa ys pe rf or m the following post-opera- tion chec ks after operating the wa tercraft. 1. Remov e the watercraft from the w ater . 2. W a sh down the hull, handlebars, and jet unit with fresh water . 3. Remov e the seat and check the engine compar tment for wa ter . T o drain e xcess wat er , remov e the[...]

3-34 E 7. If the watercraft will be stored f o r a week or more, lubricate inter nal en gine com- ponents to help prev ent corrosion. (See page 4-3 f or lubr ication procedures.) 8. Rinse the engine and engine compar t- ment with a small a mount of water . CAUTION : Do not use high pressure wh en rinsing the engine or engine compar tment as seve re[...]

3-35 E EJU00679 T ranspor ting W A R N I N G Alw ays plac e the fuel coc k knob in the “OFF” position when transporting the watercraft, otherwise fuel could leak out into the engi ne or engi ne compar tment, which w ould create a fire hazard. When transpor ting the watercraft on a trailer , secure the tie downs to the trailer through the bow e [...]

E 4 EJU00515 MAINTENANCE AND CARE Storage ...... .................... ................... .......... 4-1 Flushing the cooling system ................... 4-1 Lubrication.................. ................... .......... 4-3 Fuel system ............................................. 4-4 Battery ..................... ................... ............. 4-[...]

4-1 E EJU00516a Storage W A R N I N G Alw ays plac e the fuel coc k knob in the “OFF” position when storing the water- craft, otherwise fuel could leak out into the engine or engine compar tment, which w ould create a fire hazard. Storage f or prolonged per iods of time, such as winter storage, requires pre venta- tive maintenance to ensure aga[...]

4-2 E 1. Put the watercraft on land in a hor izontal position. 2. Open the flush ing hose connector ca p 1 , and then inser t the garden hose ad apter 2 into the flushing hose connector 3 and tur n it until it is securely connected. 3. Connect the garden hose adapter to a water tap using a hose. 4. Star t the e ngine, and then immediately tur n the[...]

4-3 E EJU00526a Lubrication W A R N I N G T o reduce the risk of fire or ex plosion: Never p our or spra y gasoline, or an y su b- stance other th an engine fogging oil thro ugh the holes in the carbu retor silencer cover . CAUTION : ● Be sure to replace the caps securely after fog ging the engine. Otherwise water could enter the engine and cause[...]

4-4 E 4. Install the cap securely . 5. Remov e the spar k plugs and pour approximately one tab lespoon of engine oil into each cylinder . Grease the spar k plug threads and install th e spar k pl ugs. 6. Lubricate all cables such as the throttle , choke , and steer ing cables. N O TE: Use a Y ama ha P ower Cable Luber and Y amaha Lube-Zall to press[...]

4-5 E EJU00530 Battery When the watercr aft is not to be used for a month or more, remov e the batter y and store it in a cool, dark place. Clean the bat- ter y casing using fresh water . Clean the bat- ter y ter minal s. Apply dielectric grease or petroleum jelly to the batter y ter min als and to all e xposed batter y leads. If the batter y is to[...]

4-6 E EJU00535a Maintenance and adjustments P er iodic inspection, adjustme nt and lubri- cation will keep your watercr aft in the saf est and most efficient condition p ossible . Safety is an obligation of the watercraft o wner . The most impor tant points of watercraft inspec- tion, adjustment and lubrication are e xplained on the f ollowing page[...]

4-7 E N O TE: A ser vice manual is a vailable f or purchase through a Y amaha de aler f or owners who hav e the mechanical skills, tools, and other equipment necessar y to perform mainte- nance not covered b y this Owner’ s/Opera- tor’ s Manual. Owner’ s/Operator’ s Manual and tool kit It is advisable alw a ys to carry the Owner’ s/ Opera[...]

4-8 E EJU00536 P eriodic maintenance char t The f ollowing char t gives general guidelines f or per iodic main tenance. Howe ver , depend- ing on your operating conditions maintenance ma y need to be performed more frequently . ( ● ) This mark indicates maintenance that you ma y do yourself . ( ❍ ) This mark indicates work to be done by a Y ama[...]

4-9 E EJU00537 Inspecting the fuel system W A R N I N G Gasoline and its v apors are highl y flam- mable and e xplosive. Check the fuel system f or leaks, crac ks, or malfunctions. If any problem is f o und, do the necessar y repair or replacement as required. If repair is ne cessar y , consult a Y amaha dealer . Check: ● Carb uretor f or leakage[...]

4-10 E EJU00538 Fuel filter This watercraft is equipped with a one- piece, disposab le fuel filter 1 . The fuel filter should be replaced once a year or after e very 200 hours of operati on, or if water is f ound in the filter . Hav e a Y amaha dealer replace the fuel filter if necessar y . W A R N I N G Do not try to replace the fuel filter y our-[...]

4-11 E F0P04040a EJU00544 Inspecting the oil injection system Check the oil injection system f or leakage , crac ks, or malfunctions . If necessar y , hav e a Y amaha dealer repair the oil injection sys- tem. Check: ● Oil tank f or damage, crac ks or leakage. ● Oil tank f or water or dir t. ● Oil hose and joint for damage or cr acks. ● Oil [...]

4-12 E EJU00546a Inspecting the steering cable Check f or smooth operation of the handl e- bars and jet thrust nozzle. T ur n the handl ebars as fa r as possible to the right and left and check that the distance between the jet thrust nozzle and the brack et of the re verse gate are equal on righ t an d left sides. If steering is stiff or misadjust[...]

4-13 E EJU00551 Inspecting the QSTS mechanism Check that the shift loc k lev er mov es back to the lock position smoothly , that the QSTS selector locks and unlocks properly , and that the jet thrust nozzle mo ves up or down. 1. Squeeze and release the shift lock le ver . 2. Chec k that the QSTS selector locks when the lev er is released. 3. Chec k[...]

4-14 E EJU00552a Cleaning and adjusting the spark plugs The spark plug is an impor tan t engine component and is easy to inspe ct. The con- dition of the spar k plug can indica te some- thing about th e condition of the engine. For e xample, if the center e lectrode porcelain is very white, this could indicate an intake air leak or carburetion prob[...]

4-15 E N O TE: ● Wipe off any w ater on the spar k plug or inside the cap before installing the spar k plug cap . Push the spar k plug cap down until it clicks. ● If a torque wrench i s not av ai lable when you are fitting a ne w spar k plug, a good estimate of the correct torque is 1/4 turn to 1/2 tur n past finger tight. Hav e the spark plug [...]

4-16 E F0D4100 ● Throttle cable (handlebar end) Pull the throttle le v er and remov e the seal 1 . Spra y a r ust inhibitor into the outer cab le. Refit the seal secu rely . ● Steering cable (handlebar end) ● Steering cable (nozzle end) ● Nozzle piv ot shaft ● QSTS cable (nozzle end) ● QSTS cables (pulle y end)[...]

4-17 E ● QSTS cables (handlebar end) Remov e the QSTS cable housing. Spra y a rust inhibitor into the ou te r cab le. Reinstall the QSTS cable housing. ● Shift cable (le v er end) ● Shift cable (re verse gate end) ● YPVS cab le[...]

4-18 E EJU00566a ● Intermediate housing Using a grease gun, fill the intermediate housing with water-resistant gr ease through the grease nipple 1 . Grease capaci ty: Initial 10 hours or 1 month: 33.0–35.0 cm 3 (1.11–1.18 oz) Every 100 hours or 6 months: 6.0–8.0 cm 3 (0.20–0.27 oz) EJU00570 Adjusting the choke cab le Check that the choke [...]

4-19 E EJU00572 Inspecting the battery Check the le vel of the batter y electrolyte and make sure the leads are secure. W A R N I N G Battery electrol yte is poisonou s and dan- gerous , causing se vere b urns, etc. Elec - trol yte contains sulfuric acid. Av oid contact with sk in, eyes or c lothi ng. Antidotes External: Flush with water . Internal[...]

4-20 E T o replenish the batter y: 1. Make sure that the electrolyte lev el is between the upper 1 and lower 2 le ve l marks. 2. Refill the batter y with distilled water if necessar y . CAUTION : Normal tap water contains minerals that are harmful to a battery . Use only dis- tilled water f or replenishing th e battery . T o charge the battery: 1. [...]

4-21 E EJU00573 Adjusting the carb uretor The carburetor is a vital par t of th e engine and requires very sophisti cated adjustment. Most adjusting should be left to a Y amaha dealer who has the professional knowledge and experience to perform it. Howe ver , the operator ma y adjust the trolling sp eed as par t of th e usual maintenance routi ne. [...]

4-22 E EJU00578a Replacing the fuse The fuse is in the electrical box 1 . T o replace the fuse: 1. Remov e the cap 2 , pull out the red lead, and bri ng the fuse holder 3 out of the electrical box. 2. Open the fuse holder and re place the fuse 4 with one of the correct amper- age. W A R N I N G Do not use fuses of higher amperage that those recomme[...]

4-23 E EJU00588 Specifications MODEL ITEM Unit XL800 W A TERC RAFT CAP A CITY Maximum pe ople o n bo ard Number of people 3 Maximum load capacity kg (lb) 240 (530) DIMENSIONS Length mm (in) 3,160 (124.4) Width mm (in) 1,220 (48.0) Height mm (in) 1,130 (44.5) Dry weight kg (lb) 314 (693) PERFORMANCE Maximum output kW (PS) @ r/min 88.2 (120)@ 7,000 M[...]

E 5 EJU00594 TR OUBLESHOO TING AND EMERGENCY PR OCEDURES Troubleshooting ............ ................. .......... 5-1 Troubleshooting chart ............................ . 5-1 Emergency procedures ....................... .... 5-4 Cleaning the jet intake and impel ler ....... 5-4 Jumping the battery ................... ............ . 5 -5 Towing the[...]

5-1 E EJU00595 T r oubleshooting If you ha ve an y trouble with your w atercraft, use this section to check f or 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, ha ve a Y amaha dealer perform the nece ssar y ser vice. EJU00596a T roub leshootin[...]

5-2 E Engine runs irregu- larly or stalls Fuel Empty Refill as soon as possi- ble 3-3 Stale or contaminated Hav e ser viced by Y amaha dealer 4-10 Choke Knob pulled Push fully in 2-9 Fuel filter Clogged or wate r pooled Hav e ser viced by Y amaha dealer 4-10 Fuel tank W ater or dir t present Hav e ser viced by Y amaha dealer 4-10 Spark plug Foule d[...]

5-3 E Wa t e r c r a f t s l o w o r loses power Cavitatio n Jet intake clo gged Clean 5-4 Impeller damaged or wor n Hav e ser viced by Y amaha dealer — Engine ov er- heated Jet intak e clogged Clean 5-4 Fuel filter Clogged Hav e ser viced by Y amaha dealer 4-10 Spark plug Foule d or def ective Replace 4-14 Incorrect heat range Replace 4-14 Gap i[...]

5-4 E EJU00597 Emergency pr ocedures EJU00598 Cleaning the jet intake and impeller If weeds or debris get caug ht in the intake or impeller , cavitation can occur , causing jet thrust to decrease ev en though engine speed r ises. If this condition is allowed to continue, the engine will ov erheat and may seize . If there is any sign that the jet in[...]

5-5 E 2. Remov e any weeds or debris from around the drive shaft, impeller , pump housing, and jet thru st nozzle. If debris is difficul t to remov e, consult your Y amaha dealer . CAUTION : Always a v oid op erating your watercraft in areas where weed growth is thick. If trav- eling in weeded areas is unav oidable, operate the engine alternately a[...]

5-6 E EJU00600 Connecting the jumper cables 1. Connect the positive (+) jumper cable 1 to the positive (+) ter minals of both bat- teri es. 2. Connect one end of the negative (–) jumper cable 2 to the negativ e (–) termi- nal of the booster batter y 3 . 3. Connect the other end of the negative (–) cable to an unpainted bolt on the cylinder he[...]

5-7 E EJU00603 T owing the water craft If the watercraft becomes inoper ative in the water , it can be tow ed to shore . If the watercraft must be towed in an emergency using a tow line, the operator should ri de the watercraft, holding onto the handlebars. CAUTION : ● T ow the water craft slowly; water ma y enter the air intake and flood the eng[...]

5-8 E EJU00604a Submerged water craft If the watercr aft is submerged o r flooded with water , follow the procedure below and consult a Y amaha de aler as soon as po ssi- ble . F ailure to do so may result in serious engine damage! 1. Beach the watercr aft and remov e the ster n drain plugs to drain the water from the engine compar tment. 2. T ur n[...]

E –MEMO–[...]

E 6 EJU00608 APPENDIX Limited warranty ............... ................. ....... 6-1 YAMAHA EXTENDED SERVICE (Y.E.S.) ......... ................. ................... .......... 6-3 Index ..................... .................... ................. . 6-4[...]

6-1 E EJU00636 Limited warranty Y AMAHA MOT OR CORPORA TION, U .S.A. W A TER VEHICLE LIMITED W ARRANTY Y amaha Motor Cor poration is pro ud of its heritage and reputation for producin g products with high standa rds of quality and work man- ship. Product e xcellence provides the cor nerstone f or our commitm ent to customer satisf action. The Y ama[...]

6-2 E THIS W ARRA NTY GIVES Y OU SPECIFIC LEGAL RIGHTS, AND Y OU MA Y ALSO HA VE O THER RIGHTS WHICH V ARY FR OM ST A TE TO ST A TE. Y AMAHA MOT OR CORPORA TION, U.S.A. P ost Office Bo x 6555 Cypress, Calif ornia 90630 W A RRANTY QUESTIONS AND ANSW ER S Q. What costs are my responsibility during the warranty period? A. The customer’ s responsibil[...]

6-3 E Y AMAHA EXTENDED SER VICE (Y .E.S.) K eep your Y am aha protected ev en after your warranty expires with genuine Y amaha Ext ended Service (Y .E.S.). ● ● ● ● Y .E.S. is designed and administered by Y amah a Motor Cor poration to provide maximum owner satisf action. Y ou get uninterrup ted factory-backed co verage f o r extr a peace of[...]

6-4 E EJU00609 Index 2-stroke engine oil ................ ................... 3-3 A Adjusting the carburetor .... .................... 4-21 Adjusting the choke cable .... ................. 4-18 Adjusting the trolling speed ................... 4-21 Approval label of Emission control certificate ................... .................... .......... 1-2[...]

6-5 E Inspecting the QSTS mechanism.......... 4-13 Inspecting the shift cable............ ........... 4-12 Inspecting the steering cable ........ ........ 4-12 J Jet unit................. .................... .............. 3-12 Jumping the battery....................... .......... 5-5 L Label location ......... ... .................... ... .. ....[...]

6-6 E T Tachometer ....... ...................... .............. 2-22 Throttle ..... ................. .................... ........ 3-10 Throttle lever ................ ...................... ... 2-11 Tilt lever..................... .................... ........ 2-13 To get more boating safety information ..... ................. ..................[...]

Printed in USA July 2000— 1.5 × 1 CR F0P-F8199-11 (XA800-Z) Printed on recycled paper Y AMAHA MOT OR CORPORA TION, USA[...]