engine YAMAHA XL 700 2004 Owner's Manual

3-4
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EJU01328
Filling the oil tank
WARNING@
Do not add gasoline to the oil tank.
Fire or explosion could result.

Oil in the bilge is a serious 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 injection pump must be
bled to ensure proper oil flow, otherwise
engine damage may occur. If bleeding of
the oil pump is necessary, have a
Yamaha dealer bleed it.
@
1. Open the hood and remove the front stor-
age compartment. Also, remove all seat,
so you can watch the oil level. (See page
2-6 for hood, and pages 2-4 and 2-5 for
seats.)
2. Open the oil tank filler cap, and very
slowly add engine oil to the oil tank.
3. Stop pouring when the oil just reaches
the bottom of the filler tube.
Oil tank capacity:
3.8 L (1.0 US gal, 0.8 Imp gal)
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EJU01346
Pre-operation checks
EJU01347
Pre-operation check list
Before operating this watercraft, perform the checks in the following check list. See the
accompanying text in this chapter for details on how to perform the checks.
WARNING@ If any item in the pre-operation check list is not working properly, have it inspected
and repaired before operating the watercraft, otherwise an accident could occur.
@
NOTE:@ Pre-operation checks should be made thoroughly each time the watercraft is used. This pro-
cedure can be completed in a short time. It is worth the time spent to assure safety and reli-
ability.
@
ITEM ROUTINE PAGE
Engine compartment Remove all seats and the front storage compart-
ment to ventilate the engine compartment.
Check for fuel vapors and loose electrical con-
nections.3-6
Bilge Check for water and fuel and remove if neces-
sary.3-8
Stern drain plugs Check for proper installation. 3-8
Throttle lever Check that the throttle lever springs back
smoothly.3-11
Steering system Check for proper operation. 3-11
Fuel and oil Check fuel and oil levels and add if necessary.
Check the hoses and tanks for leakage.3-7
Water separator Check for water and drain if necessary. 3-7
Battery Check electrolyte level and battery condition. 3-9
Hood Check that the hood is properly secured. 2-6
Front and rear seats Check that the seats are properly secured. 2-4–2-5
Hull and deck Check the hull and deck for cracks or other dam-
age.3-6
Jet unit Check for debris and remove if necessary. 3-12
Fire extinguisher Check condition and replace if necessary. 3-10
Engine shut-off cord Check condition and replace if frayed or broken. 3-12
Switches Check the start switch, engine stop switch, and
engine shut-off switch for proper operation.3-13
Cooling water pilot outlet Check that water is discharged while the engine
is running and the watercraft is in the water.3-12
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EJU01048
Pre-operation check points
EJU01728
Engine compartment
Ventilate the engine compar tment before
each use.
To ventilate the engine compartment,
remove the front seat and front storage com-
partment. (See page 2-5 for front seat, and
2-15 for front storage compartment.) Allow
the engine compartment to remain open for
a few minutes to allow any fuel vapors to
escape. Also, check for loose electrical con-
nections.
WARNING@ Failure to ventilate the engine compart-
ment could result in fire or explosion. Do
not start the engine if there is a fuel leak
or a loose electrical connection.
@
EJU20570
Hull and deck
Check the hull and deck for cracks or
other damage. If any damage is found, have
a Yamaha dealer repair the watercraft.
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EJU10531
Bilge
Check for moisture and fuel residue in the
bilge.
Excessive water in the bilge can splash
into the carburetor and engine which could
cause engine damage.
To remove water from the bilge:
1. Remove the stern drain plugs.
2. Raise the bow of the watercraft until the
water drains.
3. After the water has drained, wipe the
bilge with dry rags to make sure that the
bilge is thoroughly dry.
4. Install the drain plugs.
EJU20581
Stern drain plug
Check the stern drain plugs for proper
installation.
CAUTION:@
Make sure that the stern drain plugs
are tightened securely before launch-
ing the watercraft. Otherwise, water
may flood the engine compartment
and cause the watercraft to submerge.

Clean any foreign materials, such as
dirt or sand, from the drain plug
threads before installing the drain
plugs. Otherwise, the drain plugs may
be damaged and water may enter the
engine compartment.
@
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EJU01969
Battery
Check the battery condition and the elec-
trolyte level.
Check that the battery leads are tightened
securely and there is no corrosion on the
battery terminals.
WARNING@
The battery must always be fully
charged and in good condition. Loss
of battery power may leave you
stranded. Never operate the watercraft
if the battery does not have sufficient
power to start the engine or if it shows
any other signs of decreased power.

Be sure to connect the breather hose
to the battery. Fire or explosion could
result if the breather hose is damaged,
obstructed, or not connected properly.
@
Make sure that the battery is securely
held in place.
1
Positive (+): Red lead
2
Negative (–): Black lead
3
Breather hose
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EJU01834
Throttle
Squeeze and release the throttle lever
several times to make sure that there is no
hesitation in its travel. It should be smooth
over the complete range, and spring back to
the idle position when released.
WARNING@ Before starting the engine, always check
the operation of the throttle lever.
@
EJU01057
Steering system
Check for looseness in the handlebars.
Turn them as far as possible to the right
and left to make sure that operation is
smooth and unrestricted throughout the
whole range. Make sure that the jet thrust
nozzle also changes directions as the han-
dlebars are turned, and that there is no free
play between the handlebars and the jet
thrust nozzle.
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EJU01058
Jet unit
Carefully check the jet intake for weeds,
debris, or anything else that might restrict
the intake of water. If the intake is clogged,
cavitation could occur, reducing jet thrust,
and possibly damaging the jet pump.
In some cases, the engine may overheat
because of lack of cooling water, and dam-
age to the engine could result. Engine cool-
ing water is fed to the engine by the jet
pump. (See page 5-4 for jet intake cleaning
procedures.)
WARNING@
Keep away from intake grate while
engine is on. Items such as long hair,
loose clothing, or PFD straps can
become entangled in moving parts
resulting in severe injury or drowning.

Stop the engine and remove the clip
from the engine shut-off switch before
removing any debris or weeds, which
may have collected around the jet
intake.
@
EJU01059
Engine shut-off cord (lanyard)
Check that the engine shut-off cord is not
frayed or broken. If the cord is damaged,
replace it; never try to repair it or tie it
together.
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EJU18351
Switches
CAUTION:@ Do not run the engine for more than
15 seconds on land without supplying
water. The engine can overheat.
@
Check the start switch, the engine stop
switch, and the engine shut-off switch for
proper operation.
Push the start switch 1 to start the
engine. As soon as the engine starts run-
ning, push the engine stop switch 2 to ver-
ify that the engine stops immediately.
Restart the engine, and then pull the engine
shut-off cord 5 to remove the clip 4 from
the engine shut-off switch 3 to verify that
the engine stops immediately. (See pages
2-9 to 2-10 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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EJU01836
Operation
WARNING@ Before operating your watercraft,
become familiar with all controls. Con-
sult your Yamaha dealer about any con-
trol or function you do not fully
understand. Failure to understand how
controls work could cause an accident or
prevent you from avoiding an accident.
@
CAUTION:@ Make sure that the stern drain plugs are
securely tightened before launching the
watercraft.
@
EJU01888
Engine break-in
The engine break-in period is essential to
allow the various components of the engine
to wear and polish themselves to the correct
operating clearances. This ensures proper
performance and promotes longer compo-
nent life.
CAUTION:@
For the first tankful of operation, pre-
mix a 50:1 mixture of fuel and oil (in
addition to the oil in the oil tank).

After break-in, use straight gasoline
for normal operation.
@
1. Launch the watercraft and start the
engine. (See page 3-16 for engine start-
ing procedures.)
2. Run the engine at the lowest possible
speed for 5 minutes.
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3. Gradually open the throttle to 3/4 or less.
4. Continue operation at 3/4 throttle or less
until the first tankful of fuel has been
used.
5. Fill the tank with straight gasoline, and
then proceed with normal operation.
CAUTION:@ Failure to follow the engine break-in pro-
cedure properly can result in severe
damage to the engine.
@
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