YAMAHA SUV 1200 2003 Owners Manual

3-34
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7. If the watercraft will be stored for a week
or more, lubricate internal engine com-
ponents to help prevent corrosion. (See
page 4-3 for lubrication procedures.)
8. Rinse the engine and engine compart-
ment with a small amount of water.
CAUTION:@ Do not use high pressure when rinsing
the engine or engine compartment as
severe engine damage could result.
@
9. Wipe the engine and engine compart-
ment dry with a clean cloth (repeat
step 3, if necessary).
10. Wipe the hull, handlebars, and jet unit
dry with a clean cloth.
11. Spray a rust inhibitor on metallic parts to
minimize corrosion.
12. Allow the engine compartment to air dry
completely before reinstalling the seat.
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EJU01256
Transporting
WARNING@ Always place the fuel cock knob in the
“OFF” position when transporting the
watercraft, otherwise fuel could leak out
into the engine or engine compartment,
which would create a fire hazard.
@
When transporting the watercraft on a
trailer, secure the tie downs to the trailer
through the bow eye and stern rope hole.
CAUTION:@
Do not route ropes or tie downs over
the seat, as they may leave permanent
marks on the seat’s surface. Also,
wrap the ropes or tie downs with tow-
els or rags where they touch the body
of the watercraft to avoid scratching or
damage.

Before putting the watercraft on the
trailer or transporting it, be sure to put
the shift lever in the forward position,
otherwise the reverse gate may hit an
obstruction, which may cause dam-
age.
@
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E
4
EJU01086
MAINTENANCE AND
CARE
Storage ...................................................... 4-1
Flushing the cooling system .................. 4-1
Lubrication .............................................. 4-3
Fuel system ............................................ 4-4
Battery .................................................... 4-5
Cleaning the watercraft .......................... 4-6
Maintenance and adjustments .............. 4-7
Owner’s/Operator’s Manual and
tool kit ..................................................... 4-8
Periodic maintenance chart ................... 4-9
Inspecting the fuel system ................... 4-10
Inspecting the oil injection system ....... 4-12
Inspecting the jet thrust nozzle
angle ..................................................... 4-13
Inspecting the shift cable ..................... 4-13
Inspecting and adjusting the throttle
cable ..................................................... 4-13
Inspecting the QSTS mechanism ....... 4-14
Cleaning and adjusting the spark
plugs ..................................................... 4-15
Lubrication points ................................. 4-16
Adjusting the choke cable .................... 4-19
Inspecting the battery .......................... 4-20
Adjusting the carburetor ...................... 4-22
Replacing the fuse ............................... 4-23
Bleeding the oil injection pump ............ 4-23
Specifications ........................................ 4-24
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EJU01087
Storage
WARNING@ Always place the fuel cock knob in the
“OFF” position when storing the water-
craft, otherwise fuel could leak out into
the engine or engine compartment,
which would create a fire hazard.
@
Storage for prolonged periods of time,
such as winter storage, requires preventa-
tive maintenance to ensure against deterio-
ration. It is advisable to have the watercraft
serviced by a Yamaha dealer prior to stor-
age. However, the following procedures can
be performed by the owner.
EJU01088
Flushing the cooling system
Flushing the cooling system is essential
to prevent the cooling system from being
clogged with salt, sand, or dirt.
CAUTION:@
Do not supply water to the cooling
water passages when the engine is not
running. The water could flow back
through the muffler into the crankcase
causing severe engine damage.

Do not run the engine for more 15 sec-
onds without supplying water, other-
wise the engine may overheat.
@
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1. Put the watercraft on land in a horizontal
position.
2. Open the flushing hose connector
cap1, and then insert the garden hose
adapter 2 into the flushing hose con-
nector 3 and turn it until it is securely
connected.
3. Connect the garden hose adapter to a
water tap using a hose.
4. Start the engine, and then immediately
turn the water supply on until water flows
out continually from the cooling water
pilot outlet.
5. Run the engine at idling speed for about
3 minutes watching the engine condition.
If the engine stops while flushing, turn
the water supply off immediately and
repeat the above steps.
6. Turn the water supply off, and then force
the remaining water out from the cooling
passages by alternately squeezing, and
releasing the throttle lever for 10 to
15 seconds.
7. Stop the engine.
8. Remove the garden hose adapter and
secure the cap.
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EJU01325
Lubrication
WARNING@ To reduce the risk of fire or explosion:
Never pour or spray gasoline, or any sub-
stance other than engine fogging oil
through the holes in the carburetor
silencer cover.
@
CAUTION:@
Be sure to replace the caps securely
after fogging the engine. Otherwise
water could enter the engine and
cause damage.

Do not attempt to run the engine at full
throttle or for more than 15 seconds
while the watercraft is out of the water,
otherwise the engine may overheat
and/or seize.
@
1. Open the silencer caps 1 on the
silencer.
2. Start the engine with the watercraft in a
well-ventilated area.
3. With the engine running at a fast idle,
quickly spray as much fogging oil as pos-
sible through the holes in the silencer
cover. Keep spraying until the engine
stalls (or a maximum of 15 seconds).
4. Install the caps securely.
5. Lubricate all cables such as the throttle,
choke, and steering cables.
NOTE:@ Use a suitable marine grease applicator to
pressure lubricate the cables and purge out
any moisture between the inner and outer
cables.
@
6. Lubricate the areas of the watercraft
specified under Lubrication points on
page 4-16.
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EJU01964
Fuel system
Draining the fuel system prevents buildup
of varnishes and other harmful deposits that
result when gasoline sits for a prolonged
period of time.
WARNING@ GASOLINE AND ITS VAPORS ARE
HIGHLY FLAMMABLE AND EXPLOSIVE!

Do not smoke when refueling, and
keep away from sparks, flames, or
other sources of ignition.

Stop engine before refueling.

Refuel in a well-ventilated area with
the watercraft in a horizontal position.

Do not stand or sit on the watercraft
while refueling in case of fire.

Take care not to spill gasoline. If gaso-
line spills, wipe it up immediately with
dry rags. Always properly dispose of
gasoline-soaked rags.

Avoid overfilling the fuel tank. Stop fill-
ing when the fuel level just reaches the
bottom of the filler tube. Do not fill up
the filler tube because fuel expands as
it warms up and could overflow. If tem-
porarily leaving the watercraft with a
full fuel tank, do not leave it in direct
sunlight. Leave it in a well-ventilated
area with the watercraft in a horizontal
position.

Tighten the filler cap securely after
refueling.

If you should swallow some gasoline,
inhale a lot of gasoline vapor, or get
gasoline in your eyes, get immediate
medical attention.

If any gasoline spills onto your skin,
immediately wash with soap and
water. Change clothing if gasoline
spills on it.
@
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To drain the fuel system:
1. Place the fuel cock knob in the “OFF”
position.
2. Drain the fuel tank using a siphon.
EJU01970
Battery
If the watercraft will not be used for more
than a month, disconnect the negative (–)
lead first, then the positive (+) lead and
breather hose, and then remove the battery
from the watercraft.
Clean the battery casing using fresh
water.
If the battery terminals are dirty or cor-
roded, clean them with a wire brush.
Fully charge the battery, and then store it
in a cool, dark place.
Apply Yamaha marine grease or Yamaha
grease A to the battery terminals.
Check the battery at least every 2 months
and fully charge it if necessary.
WARNING@ 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.
@
CAUTION:@ The battery may not be usable again if
you store it for a long period without
charging it. Charge the battery periodi-
cally.
@
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4-6
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NOTE:@ The condition of the battery can be known
by checking the specific gravity of the elec-
trolyte. However, you can also know the con-
dition of the battery by measuring the
voltage at both battery terminals. Charge
the battery if the voltage is less than
12 volts.
It is recommended to have a Yamaha dealer
check the specific gravity and to charge the
battery. If you maintain the battery yourself,
be sure to read and follow the instructions
provided with the battery tester and charger
you use.
@
EJU01093
Cleaning the watercraft
Clean the watercraft before storing it for a
long period.
1. Wash down the hull, handlebars, and
drive unit with fresh water.
2. Rinse the engine and bilge area with
fresh water. Drain off all water and wipe
up remaining moisture with clean, dry
rags.
3. Spray the engine’s exterior with a rust
inhibitor and lubricant.
4. Wax the hull with a non-abrasive wax.
5. Wipe all vinyl and rubber components,
such as the seat and engine compart-
ment seals, with a vinyl protectant. Specific gravity (for reference):
1.28 at 20 °C (68 °F)
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EJU01094
Maintenance and
adjustments
Periodic inspection, adjustment and lubri-
cation will keep your watercraft in the safest
and most efficient condition possible. Safety
is an obligation of the watercraft owner. The
most important points of watercraft inspec-
tion, adjustment and lubrication are
explained on the following pages.
See your Yamaha dealer for genuine
Yamaha replacement parts and optional
accessories designed for your watercraft.
Remember that failures that are the result
of the installation of parts or accessories
which are not qualitatively equivalent to gen-
uine Yamaha parts are not covered by the
limited warranty.
WARNING@
Be sure to turn off the engine when
you perform maintenance unless oth-
erwise specified, otherwise an acci-
dent or injury could result from
unexpected operation, moving parts,
or electric shock. If the owner is not
familiar with watercraft servicing, this
work should be done by a Yamaha
dealer. Improperly serviced compo-
nents could fail or stop operating cor-
rectly, which could result in an
accident.

Modifications to this watercraft not
approved by Yamaha may cause loss
of performance or excessive noise, or
render it unsafe for use. Consult a
Yamaha dealer before attempting any
changes.
@
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