YAMAHA SUV 1200 2003 Owners Manual

4-18
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QSTS cables (handlebar end)
Remove the QSTS cable housing. Spray
a rust inhibitor into the outer cable.
Reinstall the QSTS cable housing.

Shift cable (lever end)

Shift cable (reverse gate end)
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4-19
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Intermediate housing
Using a grease gun, fill the intermediate
housing with water-resistant grease
through the grease nipple 1.

Starter motor idle gear
Using a grease gun, fill the starter motor
idle gear with water-resistant grease
through the grease nipple 1. Grease capacity:
Initial 10 hours or 1 month:
33.0–35.0 cm
3 (1.11–1.18 oz)
Every 100 hours or 12 months:
6.0–8.0 cm
3 (0.20–0.27 oz)
Grease capacity:
Initial 10 hours or 1 month:
8.0 cm
3 (0.27 oz)
Every 100 hours or 12 months:
2.0 cm
3 (0.07 oz)
EJU01261
Adjusting the choke cable
Check that the choke cable is properly
adjusted.
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 1
slightly. If the knob is difficult to move,
loosen the adjusting nut slightly.
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EJU01971
Inspecting the battery
Check the level of the battery electrolyte
and make sure that the negative and posi-
tive leads are securely tightened.
WARNING@
Battery electrolyte is poisonous and
dangerous, causing severe burns, etc.
Electrolyte contains sulfuric acid.
Avoid contact with skin, eyes, or cloth-
ing.
Antidotes
External: Flush with water.
Internal: Drink large quantities of water
or milk. Follow with milk of magnesia,
beaten egg, or vegetable oil. Call phy-
sician immediately.
Eyes: Flush with water for 15 minutes
and get prompt medical attention.
Batteries produce explosive gases.
Keep sparks, flame, cigarettes, etc.,
well away. If using or charging the bat-
tery in an enclosed space, make sure
that it is well ventilated. Always shield
your eyes when working near batter-
ies.
KEEP OUT OF THE REACH OF CHIL-
DREN.

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:@
Be careful not to place the battery on
its side.

Be sure to remove the battery from the
battery compartment when adding
electrolyte or charging the battery.
@
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To replenish the battery:
1. Make sure that the electrolyte level is
between the upper 1 and lower 2 level
marks.
2. Refill the battery with distilled water if
necessary.
CAUTION:@ Normal tap water contains minerals that
are harmful to a battery. Use only dis-
tilled water for replenishing the battery.
@
To recharge the battery:
CAUTION:@ Do not attempt to charge a battery hast-
ily. Battery life could be shortened.
@
It is recommended to have a Yamaha
dealer charge the battery. If you charge the
battery yourself, carefully read the battery
charger instructions before charging and fol-
low the points below.
1. Remove all caps from the battery cell.
2. Add distilled water to the specified level if
the electrolyte level is low.
3. Set the charging rate to 1.9 ampere and
charge the battery slowly until the explo-
sive gases are discharged vigorously
from the battery cells.
To connect the battery terminals:
1. Make sure that the connections are cor-
rect when you install the battery in the
watercraft.
2. Make sure that the breather hose is
properly connected and that it is not
damaged or obstructed.
3. Make sure that the battery is securely
held in place.
1Positive (+): Red lead
2Negative (–): Black lead
3Breather hose
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EJU01109
Adjusting the carburetor
The carburetor is a vital part of the engine
and requires very sophisticated adjustment.
Most adjusting should be left to a Yamaha
dealer who has the professional knowledge
and experience to perform it. However, the
operator may adjust the trolling speed as
part of the usual maintenance routine.
CAUTION:@ The carburetor was set at the Yamaha
factory after many tests. If the settings
are disturbed by someone who does not
have the necessary technical knowledge,
poor engine performance and damage
may result.
@
EJU01262
Adjusting the trolling speed
1. Put the watercraft in the water.
2. Start the engine and warm it up for 1 or
2 minutes. Using a diagnostic tachome-
ter or, if necessary, the tachometer in the
multifunction meter, adjust the engine
speed to specification.
3. Turn the throttle stop screw 1 clockwise
to increase engine speed if necessary.
Turn it counterclockwise to decrease
engine speed if necessary.
Trolling speed: 1,250–1,350 r/min
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EJU01263
Replacing the fuse
The fuse is in the electrical box 1.
To replace the fuse:
1. Remove the cap 2, pull out the red lead,
and bring the fuse holder 3 out of the
electrical box.
2. Open the fuse holder and replace the
fuse 4 with one of the correct amper-
age.
WARNING@ Do not use fuses of higher amperage that
those recommended. Substitution of a
fuse of improper rating can cause exten-
sive electrical system damage and possi-
ble fire.
@
EJU01112
Bleeding the oil injection
pump
If the oil tank becomes completely empty,
or any hose connected to the oil pump has
been disconnected, the oil pump must be
bled to ensure proper oil flow.
If bleeding of the oil pump is necessary,
have a Yamaha dealer bleed it.Fuse amperage: 10 A
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EJU01359
Specifications
MODEL
ITEMUnit SUV1200
WATERCRAFT CAPACITY
Maximum people on board Number of people 4
Maximum load capacity kg (lb) 300 (662)
DIMENSIONS
Length mm (in) 3,850 (151.6)
Width mm (in) 1,510 (59.4)
Height mm (in) 1,140 (44.9)
Dry weight kg (lb) 370 (816)
PERFORMANCE
Maximum output kW (PS) @ r/min 99.3 (135)@ 6,750
Maximum fuel consumption L/h (US gal/h, Imp gal/h) 53.0 (14.0, 11.7)
Cruising range at full throttle hr. 1.3
Trolling speed r/min 1,250–1,350
ENGINE
Engine type 2-stroke
Number of cylinders 3
Engine displacement
cm
3 (cu in)1,131 (69.01)
Bore & stroke mm (in) 84 ×
68 (3.31 ×
2.68)
Compression ratio 6.0:1
Lubrication system Oil injection
Cooling system Water cooled
Starting system Electric starter
Ignition system Digital CDI
Spark plug BR8HS (NGK)
Spark plug gap mm (in) 0.6–0.7 (0.024–0.028)
Battery capacity V-AH 12-19
Charging system Flywheel magneto
DRIVE UNIT
Propulsion system Jet pump
Jet pump type Axial flow, single stage
Impeller rotation Counterclockwise (viewed from rear)
Transmission Direct drive from engine
Jet thrust nozzle angle Degree 26 + 26
Trim nozzle angle Degree -7, -2, 3, 8, 13
FUEL AND OIL
Recommended fuel Regular unleaded gasoline
Minimum octane rating PON
RON86
90
Recommended engine oil YAMALUBE 2-W, or an equivalent NMMA-
certified TC-W3 marine oil
Fuel tank capacity
Total L (US gal, Imp gal) 70 (18.5, 15.4)
Reserve L (US gal, Imp gal) 12 (3.2, 2.6)
Oil tank capacity L (US gal, Imp gal) 5.5 (1.5, 1.2)
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–MEMO–
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5
EJU01115
TROUBLESHOOTING
AND EMERGENCY
PROCEDURES
Troubleshooting ...................................... 5-1
Troubleshooting chart ............................ 5-1
Emergency procedures .......................... 5-4
Cleaning the jet intake and impeller ...... 5-4
Jumping the battery ............................... 5-5
Towing the watercraft ............................ 5-7
Submerged watercraft ........................... 5-8
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EJU01116
Troubleshooting
If you have any trouble with your watercraft, use this section to check for 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, have a Yamaha dealer perform the necessary service.
EJU01367
Troubleshooting chart
TROUBLE POSSIBLE CAUSE REMEDY PAGE
Engine does not
startStarter motor does not turn over
Multifunction
meter“LOCK” mode selected Select “START” mode
2-20
Engine shut-
off switchClip not in place Install clip
2-9
Fuse Burned out Replace the fuse and
check wiring4-23
Battery Run down Recharge 4-5
Poor terminal connec-
tionsTighten as required
4-5
Terminal corroded Clean 4-5
Starter motor Faulty Have serviced by
Yamaha dealer—
Starter motor turns over
Fuel cock Turned to “OFF”Turn the fuel cock to
“ON”2-8
Fuel Empty Refill as soon as
possible3-3
Stale or contaminated Have serviced by
Yamaha dealer4-10
Fuel tank Water or dirt present Have serviced by
Yamaha dealer4-11
Spark plug Fouled or defective Clean or replace 4-15
Spark plug cap Not connected or loose Connect properly 4-15
Crankcase Filled with water Crank engine with plug
out until clean5-8
Fuel filter Clogged or water
pooledHave serviced by
Yamaha dealer4-11
Choke Knob moves back on
its ownTighten the choke knob
adjusting nut4-19
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