fuel YAMAHA XL 800 2001 Owner's Manual

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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 stern drain plugs are
securely tightened before launching the
watercraft.
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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 pages 3-16 to 3-18 for
engine starting procedures.)
2. Run the engine at the lowest possible
speed for 5 minutes.
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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.
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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 star t a cold engine.
NOTE:
The choke should not be used when the
engine is warm.
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Transporting
WARNING
Always place the fuel cock knob in the
“OFF” position when transporting the
watercraft, otherwise fuel could leak out
into the engine or engine compartment,
which would create a fire hazard.
When transporting the watercraft on a
trailer, secure the tie downs to the trailer
through the bow eye and stern rope hole.
CAUTION:
●Do not route ropes or tie downs over
the seat, as they may leave permanent
marks on the seat’s surface. Also,
wrap the ropes or tie downs with tow-
els or rags where they touch the body
of the watercraft to avoid scratching or
damage.
●Before putting the watercraft on the
trailer or transporting it, be sure to put
the shift lever in the forward position,
otherwise the reverse gate may hit an
obstruction, which may cause dam-
age.
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MAINTENANCE AND
CARE
Storage....................................................... 4-1
Flushing the cooling system ................... 4-1
Lubrication............................................... 4-3
Fuel system............................................. 4-4
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
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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.
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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.
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Fuel system
Draining the fuel system prevents buildup
of varnishes and other harmful deposits that
result when gasoline sits for a prolonged
period of time.
WARNING@Gasoline is highly flammable and explo-
sive. A fire or explosion can cause
severe injury or death. Shut the engine
off. Refuel in well-ventilated areas away
from flames or sparks. Do not smoke.
Avoid spilling gasoline. Wipe up spilled
gasoline immediately.
@
To drain the fuel system:
1. Place the fuel cock knob in the “OFF”
position.
2. Drain the fuel tank using a siphon.
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Battery
When the watercraft is not to be used for
a month or more, remove the battery and
store it in a cool, dark place. Clean the bat-
tery casing using fresh water. Clean the bat-
tery terminals. Apply dielectric grease or
petroleum jelly to the battery terminals and
to all exposed battery leads.
If the battery is to be stored for a longer
period, check the specific gravity of the elec-
trolyte at least once a month and charge the
battery if necessary.
Specific gravity: 1.28 at 20 °C (68 °F)
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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.
*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)
MAINTENANCE INTERVAL INITIALTHEREAFTER
EVERYPA G E
10
hours50
hours100
hours100
hours200
hours
ITEM
3
months6
months6
months12
months
Spark plug Inspect, clean, adjust●●●●
4-14
Lubrication points Lubricate●●
4-15
Intermediate housing Lubricate❍
*1●
*2●
*2 4-18
Fuel system Inspect❍❍
4-9
Fuel filter Check, replace❍❍
4-10
Fuel tank Clean❍
4-10
Oil injection system Inspect, clean❍❍
4-11
Trolling speed Adjust●●
4-21
Carburetor throttle shaft Inspect❍❍❍
—
Cooling water passages Flush
●
(after
ever y
use)4-1
Bilge strainer Clean●●●
—
Impeller Inspect●●●
—
Steering cable Inspect●●
4-12
Steering master Inspect❍❍❍
—
QSTS mechanism Inspect●●
4-13
Shift cable and mechanism Inspect, adjust●●
4-12
Throttle cable Inspect, adjust●●
4-12
Choke cable Inspect, adjust●●
4-18
Stern drain plugs Inspect, replace●
3-7
Battery Inspect
●(inspect
fluid level
before
ever y
use)
4-19
Rubber coupling Inspect❍
—
Nuts and bolts Tighten❍❍❍
—
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Inspecting the fuel system
WARNING
Gasoline and its vapors are highly flam-
mable and explosive.
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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Fuel filter
This watercraft is equipped with a one-
piece, disposable fuel filter 1. The fuel filter
should be replaced once a year or after
every 200 hours of operation, or if water is
found in the filter. Have a Yamaha dealer
replace the fuel filter if necessary.
WARNING
Do not try to replace the fuel filter your-
self. An incorrectly installed filter can
leak gasoline, which could lead to fire or
explosion. If necessary, have a Yamaha
dealer replace the fuel filter.
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Fuel tank
Check the fuel tank 1 for leakage or
water in the tank. If water is found in the fuel
system or if the fuel tank needs to be
cleaned have a Yamaha dealer service the
watercraft.
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