check engine YAMAHA XL 700 2003 User Guide

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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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EJU01835
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 cool-
ing. 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
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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2. Turn the fuel cock knob to the “ON” posi-
tion.
NOTE:@ Before starting the watercraft, after it has
been sitting, remove the fuel tank filler cap
to release any built-up pressure in the tank
due to fuel expansion.
@
3. Attach the clip 1 to the engine shut-off
switch 2. Also, attach the engine shut-
off cord 3 to your left wrist.
WARNING@ Check that the engine shut-off cord is not
frayed or broken, and keep it free from
the handlebars so the engine stops if the
operator falls off. The engine shut-off
cord may not pull free if wrapped around
the handlebars when the operator falls
off, allowing the watercraft to continue to
run and cause an accident.
@
NOTE:@ It is not possible to start the engine with the
clip removed from the engine shut-off
switch.
@
4. Pull and hold the choke knob all the way
out to start a cold engine.
NOTE:@ The choke should not be used when the
engine is warm.
@
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EJU01068
Operating your watercraft
EJU01250
Getting to know your
watercraft
Operating your watercraft requires skills
acquired through practice over a period of
time. Take the time to learn the basic tech-
niques well before attempting more difficult
maneuvers.
Operating your new watercraft can be a
very enjoyable activity, providing you with
hours of pleasure. However, it is essential to
familiarize yourself with the operation of the
watercraft to achieve the skill level neces-
sary to enjoy riding safely. Before operating
this watercraft, read this Owner’s/Operator’s
Manual, the Riding Practice Guide, and all
warning and caution labels on the water-
craft. Pay particular attention to the safety
information on pages 1-7 to 1-14. These
materials should give you an understanding
of the watercraft and its operation.
Remember: This watercraft is designed to
carry the operator and up to 2 passengers.
Never exceed the maximum load limit or
allow more than 3 persons (or 2 persons if a
water-skier is being pulled) to ride the water-
craft at one time.
EJU01070
Learning to operate your
watercraft
Before operating the watercraft, always
perform the pre-operation checks listed on
page 3-5. The short time spent checking the
watercraft will reward you with added safety
and reliability.
Check all local laws before operating your
watercraft.
Operate defensively at safe speeds and
keep a safe distance away from people,
objects, and other watercraft. Select a wide
area to learn in, where you have good visi-
bility and light boat traffic.
Use the buddy system—operate with
someone nearby. Scan constantly for peo-
ple, objects, and other watercraft. Be alert
for conditions that limit your visibility or block
your vision of others.
Attach the engine shut-off cord (lanyard)
to your wrist and keep it free from the han-
dlebars so that the engine stops if the opera-
tor falls off.
Wear a personal flotation device (PFD).
All riders must wear an authority-approved
PFD that is suitable for personal watercraft
use. Maximum load: 240 kg (530 lb)
Load is the total weight of cargo,
operator and passengers.
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EJU01849
Boarding with passengers
WARNING@ Severe internal injuries can occur if
water is forced into body cavities as a
result of being near the jet thrust nozzle.
Do not apply throttle until each passen-
ger is seated with his or her feet on the
floor of the footwell and is holding on to
the person in front of him or her.
@
1. Climb on board as noted in the previous
section, and sit astride the seat. Attach
the engine shut-off cord to your left wrist,
and then install the clip to the engine
shut-off switch.
2. Have the passenger move to the rear of
the watercraft.
3. Have the passenger get on board and sit
on the seat. If a second passenger is
getting on, have him or her follow the
same procedure.
NOTE:@ When a passenger is getting on board, both
he and the operator should try to balance
the watercraft.
@
4. The operator should check to see that
the passengers have their feet on the
floor of the footwell and that they are
securely holding on to the person in front
of them.
5. Start the engine, look in all directions,
and then accelerate to planing speed.
WARNING@ Before starting off, make sure that there
are no boats, obstructions, or swimmers
around you.
@
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EJU01084
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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4-6
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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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EJU01355
Periodic maintenance chart
The following chart gives general guidelines for periodic maintenance. However, depend-
ing on your operating conditions maintenance may need to be performed more frequently.
(

) This mark indicates maintenance that you may do yourself.
(
❍) This mark indicates work to be done by a Yamaha dealer.
MAINTENANCE INTERVAL
INITIALTHEREAFTER
EVERYPA G E
10
hours50
hours100
hours100
hours200
hours
ITEM
6
months12
months12
months24
months
Spark plug Inspect, clean, adjust




4-14
Lubrication points Lubricate


4-15
Intermediate housing Lubricate❍
*1

*2

*2 4-16
Fuel system Inspect❍❍
4-10
Fuel filter Check, clean, replace❍❍
4-11
Fuel tank Clean❍
4-11
Oil injection system Inspect, clean❍❍
—
Carburetor setting Inspect, adjust❍❍❍
4-20
Trolling speed Inspect, adjust


4-20
Carburetor throttle shaft Inspect❍❍
—
Cooling water passages Flush

*3 4-1
Bilge strainer Clean


—
Impeller Inspect

*4❍❍
—
Jet thrust nozzle angle Inspect


4-13
Throttle lever Check operation

*4 4-13
Throttle cable Inspect, adjust


4-13
Choke knob Check operation

*4 4-17
Choke cable Inspect, adjust❍❍
4-17
Stern drain plugs Inspect, replace

*4❍❍
3-7
Battery Inspect

*5❍❍
4-18
Rubber coupling Inspect❍
—
Engine mount Inspect❍
—
Nuts and bolts Inspect❍❍❍
—
*1: Grease capacity: 33.0–35.0 cm3 (1.11–1.18 oz)
*2: Grease capacity: 6.0–8.0 cm3 (0.20–0.27 oz)
*3: After every use
*4: Before every use
*5: Inspect fluid level before every use
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EJU01383
Inspecting the fuel system
WARNING@ Gasoline is highly flammable and explo-
sive. A fire or explosion can cause
severe injury or death. Shut off the
engine. Do not smoke. Avoid spilling
gasoline.
@
Check the fuel system for leaks, cracks,
or malfunctions. If any problem is found, do
the necessary repair or replacement as
required. If repair is necessary, consult a
Yamaha dealer.
Check:

Carburetor for leakage.

Fuel pump for malfunction or leakage.

Fuel tank for water or dirt.

Fuel tank for damage, cracks or leakage.

Fuel hose joint for leakage.

Fuel hose for cracks or other damage.

Fuel filter for leakage.

Fuel cock for leakage.

Air vent check valve for leakage.

Fuel tank filler cap for damage.
WARNING@ Failure to check for and repair any fuel
leakage may result in fire or explosion.
@
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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
TBC-F0P7ETROUBLE POSSIBLE CAUSE REMEDY PAGE
Engine does not
startStarter motor does not turn over
Engine shut-
off switchClip not in place Install clip
2-9
Fuse Burned out Replace the fuse and
check wiring4-21
Battery Run down Recharge 4-18
Poor terminal connec-
tionsTighten as required
4-18
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 4-14
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 dealer4-11
Choke Knob moves back on
its ownTighten the choke knob
adjusting nut4-17
UF0M74.book Page 1 Wednesday, July 31, 2002 2:45 PM