cooling YAMAHA XL 1200 2001 Owners Manual

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2
EJU00326
FEATURES AND
FUNCTIONS
Location of main components............... 2-1
Operation of controls and other
functions.................................................... 2-5
Rear seat................................................. 2-5
Front seat ................................................ 2-6
Hood ........................................................ 2-7
Fuel tank filler cap ................................... 2-8
Oil tank filler cap...................................... 2-8
Fuel cock knob........................................ 2-9
Engine stop switch ................................ 2-10
Engine shut-off switch........................... 2-10
Choke knob ........................................... 2-10
Throttle lever ......................................... 2-11
Start switch............................................ 2-11
Cooling water pilot outlet ...................... 2-12
Steering system .................................... 2-12
Tilt lever ................................................. 2-13
Shift lever .............................................. 2-14
Quick Shift Trim System (QSTS)
selector .................................................. 2-15
Engine overheat warning system ......... 2-17
Handgrip................................................ 2-19
Multifunction meter................................ 2-20
PADLOC (Programmable digital locking
ignition) .................................................. 2-21
Tachometer ........................................... 2-23
Speedometer ........................................ 2-24
Fuel meter ............................................. 2-24
Engine oil meter .................................... 2-25
Clock ..................................................... 2-25
Hour meter ............................................ 2-26
Trip timer ............................................... 2-26
Tripmeter ............................................... 2-27
Fuel warning indicator........................... 2-27
Oil warning indicator ............................. 2-28
Engine overheat warning indicator....... 2-28
Battery warning indicator ...................... 2-29
Storage compartments ......................... 2-30

2-4
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1Spark plugs/Spark plug caps
2Electrical box
Protects electrical components from water.
3Flush hose connector
Use to flush the engine cooling water pas-
sages.
4Spark plug lead
5Muffler
6Fuel filter
7Fuel tank8Oil tank
9Battery

2-12
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EJU00354
Cooling water pilot outlet
This watercraft is equipped with cooling
water pilot outlets.
When the engine is running, cooling
water is circulated in the engine, and then it
is discharged from the pilot outlets.
To check for proper operation of the cool-
ing system, check that water is being dis-
charged from the pilot outlets. If water is not
being discharged from the outlets, cooling
water may not be circulating in the engine.
When this occurs, stop the engine and check
for the cause. (See pages 2-17 and 5-4 for
further instructions.)
NOTE:
If the cooling water passages are dry, it will
take about 20 seconds for the water to reach
the outlets after the engine is started.
EJU00356
Steering system
Your watercraft can be steered by turning
the handlebars 1 the same direction you
wish to travel.
When the handlebars are turned, the
angle of the jet thrust nozzle 2 is changed,
and the direction of the watercraft is
changed accordingly. Since the strength of
the jet thrust determines the speed and
direction of a turn, the throttle must always
be open when attempting a turn, except at
trolling speed.

2-17
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EJU00366
Engine overheat warning
system
The model has an overheat warning
device. If the engine starts to overheat, the
warning light, indicator and “W.TEMP” on
the meter begin to blink and the buzzer
sounds intermittently. If this happens,
reduce the engine speed and return to
beach at low speed. If there is no water dis-
charge at the cooling water pilot outlet while
the engine is running, check the jet intake
and impeller for clogging.
WARNING
Before attempting to remove weeds or
debris from the intake grate or impeller,
shut the engine off and remove the clip
from the engine shut-off switch. Severe
injury or death could result from coming
in contact with the rotating parts of the
jet pump.
CAUTION:
●Return to shore at low speed if the
overheat warning indicator and buzzer
are on, and the display shows
“W.TEMP.” If you ignore these signals,
the engine will stop running and can-
not be restarted until the exhaust sys-
tem cools.
●Have your watercraft inspected and
serviced by a Yamaha dealer if the
engine stopped due to overheating.

3-5
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EJU00422
Pre-operation checks
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 front storage compart-
ment to ventilate engine compartment. Check for
fuel vapors or loose electrical connections3-6
Bilge Check for water and fuel residue and remove if
necessary3-7
Throttle Check that the throttle lever springs back 3-10
Steering system Check for proper steering system operation 3-10
Shift lever and reverse gate Check for proper operation 3-11
Fuel and oil Check fuel and oil level and add if necessary
Check hoses and tanks for leakage3-6
Water separator Check for water and drain if necessary 3-7
Battery Check electrolyte level and battery condition 3-8
Front and rear seats Check that the seats are properly secured 2-5, 2-6
Hull/Deck Check the hull and deck for cracks or other dam-
age—
Jet unit Check for debris and remove if necessary 3-12
Fire extinguisher Check the condition and replace if necessary 3-9
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 when
the watercraft is in the water3-13
Cooling water pilot outlet Check that water is discharged while the engine
is running when the watercraft is in the water3-13
Multifunction meter Check for warning indications and proper opera-
tion3-13

3-12
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EJU00451a
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.
EJU00004n
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.

3-13
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EJU00452a
Switches
Check the start switch 1, the engine stop
switch 2, and the engine shut-off switch 3
for proper operation.
To check these switches place the water-
craft in the water to provide adequate cooling.
Start the engine, and then pull the engine
shut-off cord 5 to remove the clip 4 from the
engine shut-off switch. Verify that the engine
stops immediately. (See pages 3-16 to 3-19
for information on proper operation of the
start switch, the engine stop switch and the
engine shut-off switch.)
EJU00453
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.
EJU00454
Multifunction meter
Check the operation of the multifunction
meter. (See pages 2-20 to 2-29 for operation
of the meter.)

3-33
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EJU00691a
Post-operation checks
Always perform the following post-opera-
tion checks after operating the watercraft.
1. Remove the watercraft from the water.
2. Wash down the hull, handlebars, and jet
unit with fresh water.
3. Remove the seat and check the engine
compartment for water. To drain excess
water, remove the stern drain plugs, then
raise the bow of the watercraft enough to
allow water in the bilge to drain out.
NOTE:
This watercraft is equipped with an auto-
matic bilge-draining system that removes
water from the engine compartment while
you are underway. However, some residual
water will remain.
4. Put the watercraft in a horizontal posi-
tion.
5. Flush the cooling system to prevent it
from clogging with salt, sand, or dirt.
(See page 4-1 for flushing the cooling
system procedures.)
6. Drain residual water from the exhaust
system by alternately squeezing and
releasing the throttle lever for 10 to
15 seconds while the engine is running.
CAUTION:
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 or
seize.

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4
EJU00515
MAINTENANCE AND
CARE
Storage....................................................... 4-1
Flushing the cooling system ................... 4-1
Lubrication............................................... 4-3
Fuel system............................................. 4-3
Battery ..................................................... 4-4
Cleaning the watercraft........................... 4-5
Maintenance and adjustments............... 4-6
Owner’s/Operator’s Manual and tool
kit ............................................................. 4-7
Periodic maintenance chart .................... 4-8
Inspecting the fuel system ...................... 4-9
Inspecting the oil injection system........ 4-11
Inspecting the steering cable................ 4-12
Inspecting the shift cable ...................... 4-12
Inspecting and adjusting the throttle
cable ...................................................... 4-12
Inspecting the QSTS mechanism ........ 4-13
Cleaning and adjusting the spark
plugs ...................................................... 4-14
Lubrication points .................................. 4-15
Adjusting the choke cable..................... 4-18
Inspecting the battery ........................... 4-19
Adjusting the carburetor ....................... 4-21
Replacing the fuse ................................ 4-22
Bleeding the oil injection pump............. 4-22
Specifications......................................... 4-23

4-1
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EJU00516a
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.
EJU00913a
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 seconds without supplying water,
otherwise the engine may overheat.