engine YAMAHA XL 700 2005 Repair Manual

5-2
E
Engine runs irregu-
larly or stallsFuel Empty Refill as soon as
possible3-3
Stale or contaminated Have serviced by
Yamaha dealer4-10
Choke Knob pulled Push fully in 2-9
Fuel filter Clogged or water
pooledHave serviced by
Yamaha dealer4-11
Fuel tank Water or dirt present Have serviced by
Yamaha dealer4-11
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
wiringLoose connection Tighten or connect
properly—
Carburetor Incorrect idle adjust-
mentAdjust idle
4-20
Clogged Have serviced by
Yamaha dealer—
Warning light blinksEngine oil level Empty Refill immediately 3-4
Oil filter clogged Clean 4-12 TROUBLE POSSIBLE CAUSE REMEDY PAGE
E_F0M-70.book Page 2 Wednesday, June 23, 2004 4:52 PM

5-3
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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 dealer4-11
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
wiringLoose connection Tighten or connect
properly—
Fuel Stale or contaminated Have serviced by
Yamaha dealer4-10
Bilge Water in bilge Drain 3-8 TROUBLE POSSIBLE CAUSE REMEDY PAGE
E_F0M-70.book Page 3 Wednesday, June 23, 2004 4:52 PM

5-4
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EJU01118
Emergency procedures
EJU01119
Cleaning the jet intake and
impeller
If weeds or debris get caught in the intake
or impeller, cavitation can occur, causing jet
thrust to decrease even though engine
speed rises. If this condition is allowed to
continue, the engine will overheat and may
seize. If there is any sign that the jet intake
or impeller is clogged with weeds or debris,
beach the watercraft and check the intake
and impeller. Always stop the engine before
beaching the watercraft.
WARNING@ Before attempting to remove weeds or
debris from the jet intake or impeller
areas, shut the engine off and remove
the clip from the engine shut-off switch.
Severe injury or death could result from
contact with the rotating parts of the jet
pump.
@
1. Turn the watercraft on its side as shown.
CAUTION:@
Place a suitable clean cloth or carpet-
ing underneath the watercraft to pro-
tect it from abrasions and scratches.

Always turn the watercraft over onto
its port (left) side.

When turning the watercraft on its
side, support the bow so the handle-
bars cannot be bent or damaged.
@
E_F0M-70.book Page 4 Wednesday, June 23, 2004 4:52 PM

5-5
E
2. Remove any weeds or debris from
around the drive shaft, impeller, pump
housing, and jet thrust nozzle.
If debris is difficult to remove, consult
your Yamaha dealer.
CAUTION:@ Always avoid operating your watercraft in
areas where weed growth is thick. If trav-
eling in weeded areas is unavoidable,
operate the engine alternately at partial
throttle and full throttle. Weeds tend to
accumulate more at a steady speed and
at trolling speed. If weeds clog the intake
or impeller area and cause cavitation, fol-
low the cleaning procedure above.
@
EJU01844
Jumping the battery
If the watercraft battery has run down, the
engine can be started using a 12-volt bat-
tery and jumper cables.
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 CHILDREN.
@
E_F0M-70.book Page 5 Wednesday, June 23, 2004 4:52 PM

5-6
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EJU01882
Connecting the jumper cables
1. Connect the positive (+) jumper cable 1
to the positive (+) terminals of both bat-
teries.
2. Connect one end of the negative (–)
jumper cable 2 to the negative (–) termi-
nal of the booster battery 3.
3. Connect the other end of the negative (–)
cable to an unpainted bolt on the cylinder
head.
CAUTION:@ Do not connect the end of the jumper
cable to the negative (–) terminal on the
watercraft battery! Be sure all connec-
tions are secure and correct before
attempting to start the engine. Any
wrong connection may damage the elec-
trical system.
@
4. Start the engine, and then disconnect
the cables by reversing the steps above.
CAUTION:@
Never push the start switch while the
engine is running.

Do not operate the start switch for
more than 5 seconds, otherwise the
battery will be discharged and the
engine will not start. Also, the starter
motor may be damaged. If the engine
does not start in 5 seconds, release
the start switch, wait 15 seconds, and
try again.
@
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5-7
E
EJU01913
Towing the watercraft
If the watercraft becomes inoperative in
the water, it can be towed to shore.
If the watercraft must be towed in an
emergency using a towline, the operator
should ride the watercraft, holding onto the
handlebars.
CAUTION:@
Tow the watercraft at 5 mph (8 km/h) or
less, otherwise water could enter the
engine through the exhaust passages
or through the air intake and flood the
engine compartment if it is towed too
fast.

Tow the watercraft using the bow
eye1 only.

The bow must be kept up out of the
water during towing to prevent water
from entering the engine compart-
ment.
@
WARNING@
The watercraft should only be towed in
an emergency.

The towline should be long enough so
that the watercraft will not collide with
the towing boat when slowing down. A
good rule of thumb is a towline that is
three times the combined length of the
towing boat and the watercraft.

The operator of the towing boat must
keep speed to a minimum and avoid
traffic or obstacles which could be a
hazard to the rider on the watercraft.
@
E_F0M-70.book Page 7 Wednesday, June 23, 2004 4:52 PM

5-8
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EJU01905
Submerged watercraft
If the watercraft is submerged or flooded
with water, follow the procedure below and
consult a Yamaha dealer as soon as possi-
ble. Failure to do so may result in serious
engine damage!
In an emergency:
1. Beach the watercraft and remove the
stern drain plugs to drain the water from
the engine compartment.
2. Turn the fuel cock knob to “OFF.”
3. Remove the spark plugs and dry them
with a cloth.
4. Without reinstalling the spark plugs,
crank the engine until all the water in the
cylinders has been drained.
5. Install the stern drain plugs and the
spark plugs.
6. Turn the fuel cock to “ON.”
7. Launch the watercraft into the water, and
then run the engine for at least
10 minutes. If the engine does not start,
repeat steps 2–7.
8. Turn the engine off.
9. Turn the fuel cock to “OFF,” remove the
silencer cap, and then spray a rust inhib-
itor into the carburetor while cranking the
engine.
10. Have the watercraft inspected by a
Yamaha dealer as soon as possible.
E_F0M-70.book Page 8 Wednesday, June 23, 2004 4:52 PM

6-1
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EJU01125
Index
2-stroke engine oil ................................... 3-2
A
Adjusting the carburetor ........................ 4-20
Adjusting the choke cable ..................... 4-17
Adjusting the trolling speed ................... 4-20
Approval label of Emission control
certificate ................................................. 1-2
B
Battery .............................................. 3-9, 4-5
Beaching the watercraft ........................ 3-32
Bilge ........................................................ 3-8
Bleeding the oil injection pump ............. 4-21
Boarding alone ...................................... 3-24
Boarding and starting in deep water ..... 3-24
Boarding with passengers ..................... 3-25
C
Capsized watercraft .............................. 3-27
Choke knob ............................................. 2-9
Cleaning and adjusting the spark
plugs...................................................... 4-14
Cleaning the jet intake and impeller ........ 5-4
Cleaning the watercraft ........................... 4-6
Connecting the jumper cables................. 5-6
Cooling water pilot outlet .............. 2-11, 3-13
Cruising limitations ................................ 1-10
D
Docking the watercraft .......................... 3-32
E
Emergency procedures ........................... 5-4
Emission control information
(For Canada only) ................................... 1-2
Engine break-in ..................................... 3-14
Engine compartment ............................... 3-6
Engine overheat warning system .......... 2-13
Engine serial number .............................. 1-1
Engine shut-off cord (lanyard) ............... 3-12
Engine shut-off switch ............................. 2-9
Engine stop switch .................................. 2-9
Enjoy your watercraft responsibly ......... 1-17F
Filling the fuel tank .................................. 3-3
Filling the oil tank .................................... 3-4
Finger grip ............................................. 2-12
Fire extinguisher .................................... 3-10
Flushing the cooling system .................... 4-1
Front seat ................................................ 2-5
Front storage compartment ................... 2-15
Fuel and oil.............................................. 3-1
Fuel and oil systems ............................... 3-7
Fuel cock knob ........................................ 2-8
Fuel filter ............................................... 4-11
Fuel system ............................................. 4-4
Fuel tank ............................................... 4-11
Fuel tank filler cap ................................... 2-7
G
Gasohol ................................................... 3-2
Gasoline .................................................. 3-1
Getting to know your watercraft ............ 3-20
Glove compartment ............................... 2-16
H
Handgrip ................................................ 2-12
Hazard information ................................ 1-14
Hood........................................................ 2-6
Hull and deck .......................................... 3-6
Hull Identification Number (HIN).............. 1-1
I
Identification numbers ............................. 1-1
Important labels ....................................... 1-3
Inspecting and adjusting the throttle
cable...................................................... 4-13
Inspecting the battery ............................ 4-18
Inspecting the fuel system ..................... 4-10
Inspecting the jet thrust nozzle angle .... 4-13
Inspecting the oil injection system ......... 4-12
J
Jet unit................................................... 3-12
Jumping the battery ................................. 5-5
L
Label location .......................................... 1-3
Learning to operate your watercraft ...... 3-20
Leaving the watercraft ........................... 3-19
E_F0M-70.book Page 1 Wednesday, June 23, 2004 4:52 PM

6-2
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Limitations on who may operate the
watercraft ................................................ 1-9
Location of main components ................. 2-1
Lubrication............................................... 4-3
Lubrication points .................................. 4-15
M
Maintenance and adjustments ................ 4-7
Manufactured date label.......................... 1-2
O
Oil filter .................................................. 4-12
Oil level warning lamp ........................... 2-14
Oil tank .................................................. 4-12
Oil tank filler cap...................................... 2-7
Operating your watercraft...................... 3-20
Operation .............................................. 3-14
Operation of controls and other
functions .................................................. 2-4
Operation requirements ........................ 1-11
Other labels ............................................. 1-7
Owner’s/Operator’s Manual and
tool kit ...................................................... 4-8
P
Periodic maintenance chart..................... 4-9
Post-operation checks........................... 3-34
Pre-operation check list........................... 3-5
Pre-operation check points ..................... 3-6
Pre-operation checks .............................. 3-5
Primary Identification (PRI-ID)
number .................................................... 1-1
R
Rear seat................................................. 2-4
Recommended equipment .................... 1-13
Replacing the fuse ................................ 4-21
Riding watercraft with passengers ........ 3-21
Rough water operation .......................... 3-33
S
Safe boating rules ................................. 1-17
Safety information ................................... 1-9
Seat storage compartment .................... 2-16
Specifications ........................................ 4-22
Starting and boarding in shallow
water ..................................................... 3-23
Starting from a dock .............................. 3-23Starting the engine ................................ 3-16
Starting the watercraft ........................... 3-22
Start switch............................................ 2-10
Steering system ...........................2-11, 3-11
Stern drain plug ....................................... 3-8
Stopping the engine .............................. 3-19
Stopping the watercraft ......................... 3-31
Storage.................................................... 4-1
Storage compartments .......................... 2-15
Submerged watercraft ............................. 5-8
Switches ................................................ 3-13
T
Throttle .................................................. 3-11
Throttle lever ......................................... 2-10
Towing the watercraft .............................. 5-7
Transporting .......................................... 3-36
Troubleshooting ...................................... 5-1
Troubleshooting chart ............................. 5-1
Turning the watercraft ........................... 3-29
W
Warning labels ........................................ 1-4
Watercraft characteristics ...................... 1-14
Water separator ...................................... 3-7
Water-skiing .......................................... 1-15
E_F0M-70.book Page 2 Wednesday, June 23, 2004 4:52 PM