engine YAMAHA XL 700 2003 Owner's Manual

3-5
E
EJU01346
Pre-operation checks
EJU01347
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
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
Hood Check hood for secure 2-6
Front and rear seats Check that the seats are properly secured 2-4–2-5
Hull/Deck Check the hull and deck for cracks or other dam-
age—
Jet unit Check for debris and remove if necessary 3-11
Fire extinguisher Check the condition and replace if necessary 3-9
Engine shut-off cord Check condition and replace is frayed or broken 3-11
Switches Check the start switch, engine stop switch and
engine shut-off switch for proper operation when
the watercraft is in the water3-12
Cooling water pilot outlet Check that water is discharged while the engine
is running and the watercraft is in the water3-12
UF0M74.book Page 5 Wednesday, July 31, 2002 2:45 PM

3-6
E
EJU01048
Pre-operation check points
EJU01728
Engine compartment
Ventilate the engine compar tment before
each use.
To ventilate the engine compartment,
remove the front seat and front storage com-
partment. (See page 2-5 for front seat, and
2-15 for front storage compartment.) Allow
the engine compartment to remain open for
a few minutes to allow any fuel vapors to
escape. Also, check for loose electrical con-
nections.
WARNING@ Failure to ventilate the engine compart-
ment could result in fire or explosion. Do
not start the engine if there is a fuel leak
or a loose electrical connection.
@
EJU01242
Fuel and oil systems
Check the fuel system for leakage, cracks
or malfunctions before each use. (See page
4-10 for check points and correct proce-
dures.)
1. Remove the fuel tank filler cap to release
any pressure that might have built up in
the fuel tank.
2. Remove all seats and front storage com-
partment. (See pages 2-4 and 2-5 for
front and rear seat, and 2-15 for front
storage compartment.)
3. Check the fuel and oil levels in the tanks
and replenish if necessary. (See pages
3-3 and 3-4 for filling instructions.)
UF0M74.book Page 6 Wednesday, July 31, 2002 2:45 PM

3-7
E
EJU01961
Water separator
Check the water separator 1 for water.
Normally the water separator is empty. The
water separator retains any water entering
through the fuel tank breather hose if the
watercraft is capsized.
If water remains in the water separator,
drain it by removing the drain screw 2.
Place a drain pan under the water separator
to catch the draining water or use a dry cloth
to soak up any water that could spill into the
watercraft. If any water spills into the water-
craft, be sure to wipe it up with a dry cloth.
Be sure to install the drain screw after drain-
ing the water separator.
EJU01053
Bilge
Check for moisture and fuel residue in the
bilge.
Excessive water in the bilge can splash
into the carburetor and engine which could
cause engine damage.
To remove water from the bilge:
1. Remove the stern drain plugs.
2. Raise the bow of the watercraft until the
water drains.
3. After the water has drained, wipe the
bilge with dry rags to make sure that the
bilge is thoroughly dry.
4. Install the drain plugs.
CAUTION:@
Make sure that the stern drain plugs
are tightened securely before launch-
ing the watercraft.

Clean any foreign materials, such as
dirt or sand, from the drain plug
threads before installing the drain
plugs.
@
UF0M74.book Page 7 Wednesday, July 31, 2002 2:45 PM

3-8
E
EJU01969
Battery
Check the battery condition and the elec-
trolyte level.
Check that the battery leads are tightened
securely and there is no corrosion on the
battery terminals.
WARNING@
The battery must always be fully
charged and in good condition. Loss
of battery power may leave you
stranded. Never operate the watercraft
if the battery does not have sufficient
power to start the engine or if it shows
any other signs of decreased power.

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.
@
Make sure that the battery is securely
held in place.
1
Positive (+): Red lead
2
Negative (–): Black lead
3
Breather hose
UF0M74.book Page 8 Wednesday, July 31, 2002 2:45 PM

3-10
E
EJU01834
Throttle
Squeeze and release the throttle lever
several times to make sure that there is no
hesitation in its travel. It should be smooth
over the complete range, and spring back to
the idle position when released.
WARNING@ Before starting the engine, always check
the operation of the throttle lever.
@
EJU01057
Steering system
Check for looseness in the handlebars.
Turn them as far as possible to the right
and left to make sure that operation is
smooth and unrestricted throughout the
whole range. Make sure that the jet thrust
nozzle also changes directions as the han-
dlebars are turned, and that there is no free
play between the handlebars and the jet
thrust nozzle.
UF0M74.book Page 10 Wednesday, July 31, 2002 2:45 PM

3-11
E
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.
UF0M74.book Page 11 Wednesday, July 31, 2002 2:45 PM

3-12
E
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.
UF0M74.book Page 12 Wednesday, July 31, 2002 2:45 PM

3-13
E
EJU01836
Operation
WARNING@ Before operating your watercraft,
become familiar with all controls. Con-
sult your Yamaha dealer about any con-
trol or function you do not fully
understand. Failure to understand how
controls work could cause an accident or
prevent you from avoiding an accident.
@
CAUTION:@ Make sure that the stern drain plugs are
securely tightened before launching the
watercraft.
@
EJU01888
Engine break-in
The engine break-in period is essential to
allow the various components of the engine
to wear and polish themselves to the correct
operating clearances. This ensures proper
performance and promotes longer compo-
nent life.
CAUTION:@
For the first tankful of operation, pre-
mix a 50:1 mixture of fuel and oil (in
addition to the oil in the oil tank).

After break-in, use straight gasoline
for normal operation.
@
1. Launch the watercraft and start the
engine. (See page 3-15 for engine start-
ing procedures.)
2. Run the engine at the lowest possible
speed for 5 minutes.
UF0M74.book Page 13 Wednesday, July 31, 2002 2:45 PM

3-14
E
3. Gradually open the throttle to 3/4 or less.
4. Continue operation at 3/4 throttle or less
until the first tankful of fuel has been
used.
5. Fill the tank with straight gasoline, and
then proceed with normal operation.
CAUTION:@ Failure to follow the engine break-in pro-
cedure properly can result in severe
damage to the engine.
@
UF0M74.book Page 14 Wednesday, July 31, 2002 2:45 PM

3-15
E
EJU01137
Starting the engine
WARNING@ Never start the engine or let it run for any
length of time in an enclosed area.
Exhaust fumes contain carbon monox-
ide, a colorless, odorless gas that may
cause loss of consciousness and death
within a short time. Always operate the
watercraft in an open area.
@
1. Launch the watercraft in water free from
weeds and debris and at least 60 cm
(2 ft) deep.
WARNING@ Never operate in water that is less than
60 cm (2 ft) deep, otherwise you increase
your chance of hitting a submerged
object, which could result in injury.
@
CAUTION:@ Never operate in water that is less than
60 cm (2 ft) deep, otherwise pebbles or
sand could be sucked into the jet intake,
causing impeller damage or engine over-
heating.
@
UF0M74.book Page 15 Wednesday, July 31, 2002 2:45 PM