YAMAHA XL 1200 2001 Owners Manual

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EJU00566a
●Intermediate housing
Using a grease gun, fill the intermediate
housing 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 6 months:
6.0–8.0 cm
3 (0.20–0.27 oz)
EJU00570
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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EJU00572
Inspecting the battery
Check the level of the battery electrolyte
and make sure the leads are secure.
WARNING
Battery electrolyte is poisonous and dan-
gerous, causing severe burns, etc. Elec-
trolyte contains sulfuric acid. Avoid
contact with skin, eyes or clothing.
Antidotes
External: Flush with water.
Internal: Drink large quantities of water
or milk. Follow with milk of magnesia,
beaten egg or vegetable oil. Call physi-
cian 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 battery in an
enclosed space, make sure that it is well
ventilated. Always shield your eyes when
working near batteries.
KEEP OUT OF THE REACH OF CHIL-
DREN.
CAUTION:
Be careful not to place the battery on its
side.
Make sure to remove the battery from the
battery compartment when adding bat-
tery electrolyte or charging the battery.
When checking the battery, make sure
the breather hose is connected to the
battery and not obstructed.

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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 may be shorter.
Yamaha recommend charging battery by
a Yamaha dealer or a battery dealer. If you
charge the battery yourself, read the battery
charger instructions carefully before charg-
ing and follow 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 become coming out vigor-
ously from battery cells.
To connect the battery terminals:
1. Make sure that the connections are correct
when you insert 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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EJU00573
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.
EJU00577a
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: 1,300–1,400 r/min

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EJU00578a
Replacing the fuse
The fuses are in the electrical box 1.
To replace the fuse:
1. Remove the hose band a and keep the
duct hose b away from the electrical
box.
2. Remove the cap 2 on the electrical box.
3. Remove the fuse using the fuse puller3.
4. Replace the fuse with one of the correct
amperage.
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.
EJU00580
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, 20 A

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Specifications
MODEL
ITEMUnit XLT1200
WATERCRAFT CAPACITY
Maximum people on board Number of people 3
Maximum load capacity kg (lb) 240 (530)
DIMENSIONS
Length mm (in) 3,160 (125)
Width mm (in) 1,220 (48)
Height mm (in) 1,130 (45)
Dry weight kg (lb) 364 (803)
PERFORMANCE
Maximum output kW (PS) @ r/min 114 (155)@ 7,000
Maximum fuel consumption L/h (US gal/h, Imp gal/h) 64 (17, 14)
Cruising range at full throttle hr. 1.09
Trolling speed r/min 1,300–1,400
ENGINE
Engine type 2-stroke, L3
Engine displacement
cm
3 (cu in)1,176 (71.8)
Bore & stroke mm (in) 80.0 ×
78.0 (3.15 ×
3.07)
Compression ratio 5.9:1
Lubrication system Variable oil injection
Cooling system Water cooled
Starting system Electric starter
Ignition system Digital CDI
Spark plug BR8ES-11 (NGK)
Spark plug gap mm (in) 1.0–1.1 (0.039–0.043)
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 horizontal angle Degree 24 + 24
Jet thrust nozzle trim 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, 15.5)
Reserve L (US gal, Imp gal) 12 (3.2, 2.7)
Oil tank capacity L (US gal, Imp gal) 5.5 (1.5, 1.3)

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EJU00594
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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EJU00595
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.
EJU00596a
Troubleshooting chart
TROUBLE POSSIBLE CAUSE REMEDY PAGE
Engine does not
startStarter motor does not turn over
Multifunction
meter“LOCK” mode selected Select “START” mode
2-22
Engine shut-
off switchClip not in place Install clip
2-10
Fuse Burned out Replace the fuse and
check wiring4-22
Battery Run down Recharge 4-20
Poor terminal connec-
tionsTighten as required
4-20
Terminal corroded Clean 4-4
Starter motor Faulty Have serviced by
Yamaha dealer—
Starter motor turns over
Fuel cock Turned to “OFF” Turn the fuel cock to
“ON”2-9
Fuel Empty Refill as soon as possi-
ble3-3
Stale or contaminated Have serviced by
Yamaha dealer4-10
Fuel tank Water or dirt present Have serviced by
Yamaha dealer4-10
Spark plug Fouled or defective Clean or replace 4-14
Spark plug cap Not connected or loose Connect properly 4-14
Crankcase Filled with water Crank engine with plug
out until clean5-8
Fuel filter Clogged or water
pooledHave serviced by
Yamaha dealer4-10
Choke Knob moves back on
its ownTighten the choke knob
adjusting nut4-18
Water
temperature
sensorFailed Have serviced by
Yamaha dealer —

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Engine runs irregu-
larly or stallsFuel Empty Refill as soon as possi-
ble3-3
Stale or contaminated Have serviced by
Yamaha dealer4-10
Choke Knob pulled Push fully in 2-10
Fuel filter Clogged or water
pooledHave serviced by
Yamaha dealer4-10
Fuel tank Water or dirt present Have serviced by
Yamaha dealer4-10
Spark plug Fouled or defective Replace 4-14
Incorrect heat range Replace 4-14
Gap incorrect Adjust 4-14
Spark plug cap Loose Connect properly 4-14
Cracked, torn, or dam-
agedReplace
—
Electrical wir-
ingLoose connection Tighten or connect
properly—
Carburetor Incorrect idle adjust-
mentAdjust idle
4-21
Clogged Have serviced by
Yamaha dealer—
Warning light or
indicator blinksFuel level Empty Refill as soon as possi-
ble3-3
Engine oil level Empty Refill immediately 3-4
Oil filter clogged Clean 4-11
Engine over-
heatedJet intake clogged Clean 5-4
Water temperature
sensor failedHave serviced by
Yamaha dealer—
Low battery
voltageBattery voltage low Charge 4-20
Battery terminal con-
nected wrongConnect properly
4-20 TROUBLE POSSIBLE CAUSE REMEDY PAGE

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Wate rcr af t slow or
loses powerCavitation Jet intake clogged Clean 5-4
Impeller damaged or
wornHave serviced by
Yamaha dealer—
Engine over-
heatedJet intake clogged Clean
5-4
Fuel filter Clogged Have serviced by
Yamaha dealer4-10
Spark plug Fouled or defective Replace 4-14
Incorrect heat range Replace 4-14
Gap incorrect Adjust 4-14
Spark plug
capsLoose Connect properly
4-14
Electrical wir-
ingLoose connection Tighten or connect
properly—
Fuel Stale or contaminated Have serviced by
Yamaha dealer4-10
Bilge Water in bilge Drain 3-7 TROUBLE POSSIBLE CAUSE REMEDY PAGE