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Yamaha XLT800 WaveRunner 2003 Owner's/operator's Manual

Summary of XLT800 WaveRunner 2003

  • Page 1

    2003 waverunner xlt800 owner’s/operator’s manual lit-18626-05-16 u.S.A. Edition read this manual carefully before operation! Printed in usa aug. 2002—1.3 × 1 cr f1f-f8199-11 (e) printed on recycled paper yamaha motor corporation, usa.

  • Page 3: To The Owner/operator

    E eju00989 to the owner/operator thank you for choosing a yamaha water- craft. This owner’s/operator’s manual contains information you will need for proper opera- tion, maintenance, and care. A thorough understanding of these simple instructions will help you to obtain maximum enjoyment from your ne...

  • Page 4

    Uf1f11.Book page 2 monday, june 10, 2002 11:54 am.

  • Page 5: Contents

    E eju00992 contents read this owner’s/operator’s manual carefully before operating your watercraft. General and safety information 1 features and functions 2 operation 3 maintenance and care 4 troubleshooting and emergency procedures 5 appendix 6 uf1f11.Book page 3 monday, june 10, 2002 11:54 am.

  • Page 6

    Uf1f11.Book page 4 monday, june 10, 2002 11:54 am.

  • Page 7: General and

    E 1 eju00993 general and safety information identification numbers ............................1-1 primary identification (pri-id) number ...................................................1-1 hull identification number (hin) ............1-1 engine serial number .............................1-1 emis...

  • Page 8: Identification Numbers

    1-1 e eju01830 identification numbers record the primary identification (pri-id) number, hull identification number (hin) and engine serial number in the spaces pro- vided for assistance when ordering spare parts from a yamaha dealer. Also record and keep these id numbers in a separate place in case...

  • Page 9: Emission Control

    1-2 e eju01846 emission control information this engine conforms to 2003 u.S. Envi- ronmental protection agency (epa) regula- tions for marine si engines. Eju01392 approval label of emission control certificate this label is attached to the electrical box and the exhaust side of the crankcase. 1 emi...

  • Page 10: Important Labels

    1-3 e eju00998 important labels eju01351 label location uf1f11.Book page 3 monday, june 10, 2002 11:54 am.

  • Page 11: Warning Labels

    1-4 e eju01352 warning labels 1 2 3 4 uf1f11.Book page 4 monday, june 10, 2002 11:54 am.

  • Page 12: Other Labels

    1-5 e eju01354 other labels 7 5 6 8 9 uf1f11.Book page 5 monday, june 10, 2002 11:54 am.

  • Page 13

    1-6 e b 0 c a uf1f11.Book page 6 monday, june 10, 2002 11:54 am.

  • Page 14: Safety Information

    1-7 e eju01177 safety information the safe use and operation of this watercraft is dependent upon the use of proper riding techniques, as well as upon the common sense, good judgment, and expertise of the operator. Every operator should know the following requirements before riding the watercraft. ●...

  • Page 15: Cruising Limitations

    1-8 e eju01001 cruising limitations ● scan constantly for people, objects, and other watercraft. Be alert for conditions that limit your visibility or block your vision of others. ● operate defensively at safe speeds and keep a safe distance away from people, objects, and other watercraft. ● do not ...

  • Page 16: Operation Requirements

    1-9 e ● this watercraft is not equipped with light- ing required for night operation. Do not operate the watercraft after sunset or before dawn, otherwise you increase the risk of colliding with another boat, which could result in severe injury or death. Eju01160 operation requirements ● all riders ...

  • Page 17

    1-10 e ● helmets meeting snell or dot standards are required for ijsba-sanctioned races. You must decide whether to wear a hel- met while you ride for recreation. You should know that a helmet could help pro- tect you in certain kinds of accidents and that it could injure you in others. A helmet is ...

  • Page 18: Recommended Equipment

    1-11 e ● do not attempt to modify this watercraft! Modifications to your watercraft may reduce safety and reliability, and render the watercraft unsafe or illegal for use. ● attach the engine shut-off cord (lanyard) to wrist and keep it free from the handle- bars so that the engine stops if the oper...

  • Page 19: Hazard Information

    1-12 e eju01003 hazard information ● when transporting or storing your water- craft, always place the fuel cock knob in the “off” position, otherwise gasoline may overflow from the carburetor. ● never start the engine or let it run for any length of time in an enclosed area. Exhaust fumes contain ca...

  • Page 20: Water-Skiing

    1-13 e ● reverse can be used to slow down or stop during slow speed maneuvering, such as when docking. Once the engine is idling, shift to reverse and gradually increase engine speed. Make sure that there are no obstacles or people behind you before shifting into reverse. ● keep away from intake gra...

  • Page 21

    1-14 e ● a second person should be on board as a spotter to watch the skier; in most states it is required by law. Let the skier direct the operator’s control of speed and direction with hand signals. The spotter should sit securely on the passenger seat and hold onto the hand- grip 2 with feet firm...

  • Page 22: Rules of The Road

    1-15 e eju01180 rules of the road yamaha watercraft is legally consid- ered a powerboat. Operation of the watercraft must be in accordance with the rules and regulations governing the waterway on which it is used. Just as there are rules that apply when you are driving on streets and highways, there...

  • Page 23: Rules When Encountering

    1-16 e rules when encountering vessels there are three main situations that you may encounter with other vessels which could lead to a collision unless the steering rules are followed: meeting: you are approaching another vessel head-on crossing: you are traveling across another vessel’s path overta...

  • Page 24: Other Special Situations

    1-17 e overtaking if you are passing another vessel, you are the give-way vessel. This means that the other vessel is expected to maintain its course and speed. You must stay out of its way until you are clear of it. Likewise, if another vessel is passing you, you should maintain your speed and dire...

  • Page 25

    1-18 e this system uses buoys and signs with distinctive shapes and colors to show regu- latory or advisory information. These mark- ers are white with black letters and orange borders. They signify speed zones, restricted areas, danger areas, and general information. Remember, markings may vary by ...

  • Page 26: To Get More Boating

    1-19 e eju01181 to get more boating safety information be informed about boating safety. Addi- tional publications and information can be obtained from many organizations, including the following. United states coast guard consumer affairs staff (g-bc) office of boating, public, and consumer affairs...

  • Page 27: Enjoy Your Watercraft

    1-20 e eju01006 enjoy your watercraft responsibly you share the areas you enjoy when riding your watercraft with others and with nature. So your enjoyment includes a responsibility to treat these other people, and the lands, waters, and wildlife with respect and courtesy. Whenever and wherever you r...

  • Page 28: –Memo–

    E –memo– uf1f11.Book page 21 monday, june 10, 2002 11:54 am.

  • Page 29: Features and

    E 2 eju01007 features and functions location of main components ..............2-1 operation of controls and other functions ...................................................2-5 rear seat ................................................2-5 front seat ...............................................2...

  • Page 30: Location of Main Components

    2-1 e eju01008 location of main components 1 handlebars use to control direction. 2 footwell use to place feet for balance. 3 footrest to keep proper balance while facing to the rear to watch the skier. 4 bow eye use to attach rope for transporting, mooring or towing the watercraft in an emergency. ...

  • Page 31

    2-2 e 1 fuel tank filler cap 2 rope holes 3 intake grate prevents debris from getting into the jet pump. 4 speed sensor 5 cleat use to attach a towrope for pulling water-skier, or a rope for mooring the watercraft. 6 handgrip use for support when boarding the watercraft or when seated facing rearwar...

  • Page 32

    2-3 e 1 engine stop switch push to stop the engine normally. 2 clip insert into the engine shut-off switch to enable starting of the engine. Remove to stop the engine or prevent acci- dental starting of the engine or unauthorized use of the watercraft. 3 quick shift trim system (qsts) selector use t...

  • Page 33

    2-4 e 1 spark plugs/spark plug caps 2 electrical box protects electrical components from water. 3 flush hose connector use to flush the engine cooling water pas- sages. 4 spark plug lead 5 muffler 6 fuel filter 7 fuel tank 8 oil tank 9 battery uf1f11.Book page 4 monday, june 10, 2002 11:54 am.

  • Page 34: Operation of Controls and

    2-5 e eju01009 operation of controls and other functions eju01211 rear seat to remove the rear seat: pull the rear seat latch 1 up, and then pull the seat off. To install the rear seat: insert the projections on the front of the seat into the stays on the deck, and then push the rear of the seat dow...

  • Page 35: Front Seat

    2-6 e eju01859 front seat to remove the front seat: 1. Remove the rear seat. 2. Pull the front seat latch 1 up, and then pull the seat off. To install the front seat: 1. Insert the projections on the front of the seat into the stays on the deck, and then push the rear of the seat down to lock it in ...

  • Page 36: Hood

    2-7 e eju01213 hood to open the hood, pull the latch 1 up, and then lift the hood up. To close the hood, push the hood down to lock it in place. Note: @ make sure that the hood is properly secured before operating the watercraft. @ uf1f11.Book page 7 monday, june 10, 2002 11:54 am.

  • Page 37: Fuel Tank Filler Cap

    2-8 e eju01012 fuel tank filler cap to remove the fuel tank filler cap 1, turn it counterclockwise. Note: @ make sure that the fuel tank filler cap is properly secured before operating the water- craft. @ eju01214 oil tank filler cap to remove the oil tank filler cap: 1. Open the hood. (see page 2-7...

  • Page 38: Fuel Cock Knob

    2-9 e eju01014 fuel cock knob the fuel cock supplies fuel from the fuel tank to the carburetors. The fuel cock knob 1 positions are explained as follows and are shown in the illustration. Off: with the fuel cock knob in this position, fuel does not flow. Always turn the fuel cock knob to this positi...

  • Page 39: Engine Stop Switch

    2-10 e eju01015 engine stop switch push this switch 1 (red button) to stop the engine normally. Eju01016 engine shut-off switch insert the clip 1, on the end of the engine shut-off cord 2, under the engine shut-off switch 3 (black button). The engine will stop automatically when the clip is removed ...

  • Page 40: Throttle Lever

    2-11 e eju01018 throttle lever squeeze the throttle lever 1 to increase engine speed. Release the throttle lever to decrease engine speed or to return it to the idle posi- tion. Eju01216 start switch push the start switch 1 (green button) to start the engine. Note: @ ● the engine will not start when...

  • Page 41: Cooling Water Pilot Outlet

    2-12 e eju01020 cooling water pilot outlet this watercraft is equipped with a 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 ...

  • Page 42: Tilt Lever

    2-13 e eju01217 tilt lever the tilt lever 1 is located in front of the glove compartment and is used to adjust the tilt of the handlebars. To adjust the tilt, pull the tilt lever up, and then move the handlebars up or down to the desired position. Warning @ ● never touch the tilt lever during opera-...

  • Page 43: Shift Lever

    2-14 e eju01877 shift lever the shift lever is located on the starboard (right) side of the watercraft and is used to control the reverse gate, which allows the watercraft to move into reverse or forward. When in the reverse position, the water- craft can be launched from a trailer, or backed up out...

  • Page 44: Quick Shift Trim System

    2-15 e eju01022 quick shift trim system (qsts) selector the qsts selector 1 is located at the left handlebar grip and is used to adjust the trim angle of the watercraft. Operating the qsts selector changes the angle of the jet thrust nozzle vertically. This changes the trim angle of the watercraft. ...

  • Page 45: Handgrip

    2-16 e eju01023 bow down turn the grip to a or b and the bow will go down while the watercraft is on plane. Bow down puts more of the bow in the water. This gives the watercraft more “hook,” which enhances turning performance. This position will also help the watercraft get up on plane more quickly....

  • Page 46: Engine Overheat Warning

    2-17 e eju01220 engine overheat warning system this model is equipped with an engine overheat warning system. If the engine starts to overheat, the warn- ing light, the indicator for the water tempera- ture symbol, and “w.Temp” display begin to blink, the buzzer sounds, and the engine speed will be ...

  • Page 47: Multifunction Meter

    2-18 e eju01221 multifunction meter this meter contains following functions for help and convenience in operating the watercraft. 1 “mode” button 2 “set” button 3 “code” setting buttons 4 tachometer 5 speedometer 6 fuel meter 7 engine oil meter 8 display for clock, hour meter, trip meter and trip ti...

  • Page 48: Padloc (Programmable

    2-19 e eju01222 padloc (programmable digital locking ignition) this feature is provided to deter unautho- rized use. The function allows you to choose either “start” or “lock” mode, as the situation requires, much as you would use an ignition key in a motor vehicle. If you have previously chosen “lo...

  • Page 49

    2-20 e 3. Select your four-letter code by pressing the “a/set,” “b,” or “c” buttons in a desired sequence. Note: @ if you do not press a button for more than 10 seconds, the display automatically turns off. This cancels the process of setting a code. @ 4. After code setting is complete, the buzzer w...

  • Page 50: Tachometer

    2-21 e 3. Enter your four-letter code by pressing the “a/set,” “b,” or “c” buttons in the right sequence. Note: @ if you do not press a button for more than 10 seconds, the display automatically turns off. This cancels the process of selecting the mode. @ 4. If the code entered is correct, the mode ...

  • Page 51: Speedometer

    2-22 e eju01226 speedometer the meter shows the watercraft speed against water. Eju01227 fuel meter the fuel meter is provided for convenient fuel level checking while operating the watercraft. The fuel meter has 4 segments which show the amount of fuel remaining in the fuel tank. Note: @ the indica...

  • Page 52: Engine Oil Meter

    2-23 e eju01228 engine oil meter the engine oil meter is provided for con- venient oil level checking while operating the watercraft. The engine oil meter has 3 segments which show the amount of oil remaining in the oil tank. Note: @ the indication of the segments differs depending on your operating...

  • Page 53: Hour Meter

    2-24 e 6. The buzzer will sound twice. The warn- ing light and “set” blink for 2 seconds. Then the display turns to “clock” and shows the time. Note: @ if the battery terminal is disconnected, the clock will be reset to 12:00. @ eju01230 hour meter the hour meter is provided to make it easy to follo...

  • Page 54: Tripmeter

    2-25 e eju01163 tripmeter a tripmeter is provided for measuring the approximate distance traveled. To show the tripmeter, press the “mode” button until the display shows “trip” while the engine is running. After showing “trip,” the display turns to “.Mile.” 1. When the display shows “.Mile,” press t...

  • Page 55: Oil Warning Indicator

    2-26 e eju01233 oil warning indicator if the oil remaining in the tank drops to about 1.4 l (0.37 us gal, 0.31 imp gal) or the oil filter is clogged, the lowest oil level segment, the oil warning indicator, “oil” and the warning light begin to blink. The buzzer also starts sounding intermittently. I...

  • Page 56: Storage Compartments

    2-27 e eju01236 storage compartments a front storage compartment, a glove compartment, and seat storage compart- ments are provided. Note: @ ● make sure that the storage compartments are properly secured before operating the watercraft. ● the storage compartments are not designed to be waterproof. I...

  • Page 57

    2-28 e eju01038 glove compartment a glove compartment 2 is located in front of the seat. To open the glove compartment, slide the latch 1 toward you, and then lift up the lid. To close the glove compartment, push the lid down until it locks securely. Glove compartment: capacity: 1.7 l (0.45 us gal, ...

  • Page 58: –Memo–

    E –memo– uf1f11.Book page 33 monday, june 10, 2002 11:54 am.

  • Page 59: Operation

    E 3 eju01040 operation fuel and oil ...............................................3-1 gasoline .................................................3-1 2-stroke engine oil ..................................3-2 filling the fuel tank .................................3-3 filling the oil tank ................

  • Page 60: Fuel and Oil

    3-1 e eju01041 fuel and oil this engine uses yamaha’s oil injection system, which provides superior lubrication by ensuring the proper oil ratio for all operat- ing conditions. No fuel premixing is neces- sary except during the engine break-in period. Simply pour gasoline into the fuel tank and oil ...

  • Page 61: Caution:

    3-2 e ● if any gasoline spills onto your skin, immediately wash with soap and water. Change clothing if gasoline spills on it. @ caution: @ use only fresh gasoline that has been stored in clean containers. @ eju01832 gasohol there are two types of gasohol: gasohol containing ethanol and that contain...

  • Page 62: Filling The Fuel Tank

    3-3 e eju01045 filling the fuel tank caution: @ be careful when refueling. Avoid getting water or other contaminants in the fuel tank. Contaminated fuel can cause poor running or engine damage. @ 1. Open the hood and remove the front storage compartment, to check the fuel level. (see page 2-27 for f...

  • Page 63: Filling The Oil Tank

    3-4 e eju01240 filling the oil tank warning @ ● do not add gasoline to the oil tank. Fire or explosion could result. ● oil in the bilge is a serious fire hazard. Wipe up any spilled oil immediately. @ caution: @ do not allow the oil tank to become com- pletely empty. If the oil tank becomes empty th...

  • Page 64: Pre-Operation Checks

    3-5 e eju01346 pre-operation checks eju01349 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 wor...

  • Page 65: Pre-Operation Check Points

    3-6 e eju01048 pre-operation check points eju01893 engine compartment ventilate the engine compartment before each use. To ventilate the engine compartment, remove all seats and front storage compart- ment. (see pages 2-5 to 2-6 for front and rear seat, and 2-27 for front storage com- partment.) all...

  • Page 66: Caution:

    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...

  • Page 67: Warning

    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 stra...

  • Page 68

    3-9 e f0p03010 eju01164 fire extinguisher check that there is a full fire extinguisher on board. The fire extinguisher container 1 is located in the front storage compartment. To open the fire extinguisher container cap 2 turn it counterclockwise. After inserting the fire extinguisher make sure that...

  • Page 69: Warning

    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 t...

  • Page 70: Warning

    3-11 e eju01245 shift lever and reverse gate check for proper operation of the shift lever and reverse gate. Make sure that the reverse gate goes down to its stopper position when the shift lever is pulled up. Also, make sure that the reverse gate goes up to its stopper position when shift lever is ...

  • Page 71: Warning

    3-12 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 co...

  • Page 72

    3-13 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 cli...

  • Page 73: Operation

    3-14 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....

  • Page 74: Caution:

    3-15 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 ca...

  • Page 75: Launching The Watercraft

    3-16 e eju01247 launching the watercraft make sure that there are no obstructions behind you. After the watercraft is in the water, start the engine. Shift into reverse and move the watercraft back slowly. If there are waves, someone should make sure that the water- craft is not pushed into the trai...

  • Page 76: Warning

    3-17 e 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 en...

  • Page 77: Warning

    3-18 e 5. If the “lock” mode was chosen previ- ously, choose the “start” mode before starting the engine. (see page 2-20 for selecting “padloc” mode.) note: @ ● if the initial setting of the padloc has not been done, the “start” mode is auto- matically selected. ● if you have previously chosen “lock...

  • Page 78: Stopping The Engine

    3-19 e eju01066 stopping the engine to stop the engine, release the throttle lever, and then push the engine stop switch (red button). Warning @ you need throttle to steer. Shutting off the engine can cause you to hit an obsta- cle you are attempting to avoid. A colli- sion could result in severe in...

  • Page 79: Operating Your Watercraft

    3-20 e eju01068 operating your watercraft eju01165 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 c...

  • Page 80: Riding Watercraft With

    3-21 e wear protective clothing. Severe internal injuries can occur if water is forced into body cavities as result of falling into the water or being near the jet thrust nozzle. Normal swimwear does not adequately protect against forceful water entry into rectum and vagina. All riders must wear a w...

  • Page 81: Starting The Watercraft

    3-22 e eju01837 starting the watercraft warning @ ● scan constantly for people, objects, and other watercraft. Be alert for con- ditions that limit your visibility or block your vision of others. ● operate defensively at safe speeds and keep a safe distance away from people, objects, and other water...

  • Page 82

    3-23 e eju01073 starting and boarding in shallow water 1. Do not start the engine in less than 60 cm (2 ft) of water. Put the watercraft in water that is deep enough, and then board the watercraft from the side or the rear. 2. Attach the engine shut-off cord to your left wrist, and then install the ...

  • Page 83: Water

    3-24 e eju01075 boarding and starting in deep water warning @ ● operator and passenger should prac- tice getting on board in shallow water before riding in deep water. Boarding in deep water requires more skill. ● the fatigue and exposure that could result after unsuccessful attempts to get back on ...

  • Page 84: Warning

    3-25 e 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 t...

  • Page 85: Capsized Watercraft

    3-26 e note: @ the heavier the total weight of the operator and passengers, the more difficult it will be to balance the watercraft. Do not operate the watercraft when the total weight exceeds 240 kg (530 lb) including any cargo. If it is difficult to balance the watercraft at a stand- still, procee...

  • Page 86: Caution:

    3-27 e caution: @ be sure to remove the clip from the engine shut-off switch, otherwise the engine will overheat and engine damage may occur. @ 1. Shut the engine off by removing the clip from the engine shut-off switch. 2. Swim to the rear of the watercraft. Pull the watercraft over with left hand ...

  • Page 87: Turning The Watercraft

    3-28 e eju01839 turning the watercraft steering control depends on the combi- nation of handlebar position and the amount of throttle. Water sucked in through the intake grate is pressurized by the impeller in the jet pump. As the pressurized water is expelled from the pump through the jet thrust no...

  • Page 88: Warning

    3-29 e warning @ ● do not release the throttle when trying to steer away from objects—you need throttle to steer. A collision could result in severe injury or death. ● when operating at higher speeds, make gradual turns or slow down before turning. Sharp high-speed turns may cause the watercraft to ...

  • Page 89: Stopping The Watercraft

    3-30 e eju01850 stopping the watercraft the watercraft is not equipped with a sep- arate braking system. It is stopped by water resistance when the throttle lever is released. From full speed, the watercraft comes to a complete stop in approximately 105 m (345 ft) after the throttle is released and ...

  • Page 90: Beaching The Watercraft

    3-31 e eju01081 beaching the watercraft 1. Make sure no obstructions, boats or swimmers are near the beach. Release the throttle lever about 105 m (345 ft) before you reach the intended beaching area. 2. Approach the beach slowly and stop the engine before reaching land. Remember: you need throttle ...

  • Page 91: Reverse On Waterways

    3-32 e eju01254 reverse on waterways reverse can be used for slow speed maneuvering when it is necessary to back up out of tight spots where you cannot turn around. Reverse can only be used to slow down or stop during low speed maneuver- ing, such as when docking. Once the engine is idling, shift to...

  • Page 92: Post-Operation Checks

    3-33 e eju01384 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 drai...

  • Page 93: Caution:

    3-34 e 7. If the watercraft will be stored for a week or more, lubricate internal engine com- ponents to help prevent corrosion. (see page 4-3 for lubrication procedures.) 8. Rinse the engine and engine compart- ment with a small amount of water. Caution: @ do not use high pressure when rinsing the ...

  • Page 94: Transporting

    3-35 e eju01256 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 ...

  • Page 95: Maintenance and

    E 4 eju01086 maintenance and care storage ......................................................4-1 flushing the cooling system ..................4-1 lubrication ..............................................4-3 fuel system ............................................4-4 battery .......................

  • Page 96: Storage

    4-1 e eju01087 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 preve...

  • Page 97

    4-2 e 1. Put the watercraft on land in a horizontal position. 2. Open the flushing hose connector cap 1, and then insert the garden hose adapter 2 into the flushing hose con- nector 3 and turn it until it is securely connected. 3. Connect the garden hose adapter to a water tap using a hose. 4. Start...

  • Page 98: Lubrication

    4-3 e eju01152 lubrication warning @ to reduce the risk of fire or explosion: never pour or spray gasoline, or any sub- stance other than a rust inhibitor through the hole in the carburetor silencer cover. @ caution: @ ● make sure to replace the cap securely after fogging the engine, otherwise water...

  • Page 99: Fuel System

    4-4 e eju01962 fuel system warning @ gasoline and its vapors are highly flammable and explosive! ● do not smoke when refueling, and keep away from sparks, flames, or other sources of ignition. ● stop engine before refueling. ● refuel in a well-ventilated area with the watercraft in a horizontal posi...

  • Page 100: Battery

    4-5 e top off the fuel tank with fresh gasoline and add one ounce of yamaha fuel stabi- lizer and conditioner to each gallon of fuel. Note: @ use of yamaha fuel stabilizer and condi- tioner eliminates the need to drain the fuel system. If the fuel system is to be drained instead, consult a yamaha de...

  • Page 101: Cleaning The Watercraft

    4-6 e 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 h...

  • Page 102: Maintenance and

    4-7 e eju01170 maintenance and adjustments periodic inspection, adjustment and lubri- cation will keep your watercraft in the safest and most efficient condition possible. Safety is an obligation of the watercraft owner. The most important points of watercraft inspec- tion, adjustment and lubricatio...

  • Page 103: And Tool Kit

    4-8 e note: @ a service manual is available for purchase through a yamaha dealer for owners who have the mechanical skills, tools, and other equipment necessary to perform mainte- nance not covered by this owner’s/opera- tor’s manual. @ eju01874 owner’s/operator’s manual and tool kit it is advisable...

  • Page 104: Periodic Maintenance Chart

    4-9 e eju01357 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 ind...

  • Page 105: Inspecting The Fuel System

    4-10 e 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...

  • Page 106: Warning

    4-11 e eju01953 fuel filter this watercraft is equipped with a one- piece, disposable fuel filter 1. The fuel filter should be replaced after the initial 10 hours or first month of operation and every 200 hours or 24 months thereafter, or if water is found in the filter. Have a yamaha dealer replace...

  • Page 107: Inspecting The Oil Injection

    4-12 e eju01100 inspecting the oil injection system check the oil injection system for leakage, cracks, or malfunctions. If necessary, have a yamaha dealer repair the oil injection sys- tem. Check: ● oil tank for damage, cracks or leakage. ● oil tank for water or dirt. ● oil hose and joint for damag...

  • Page 108: Angle

    4-13 e eju01897 inspecting the jet thrust nozzle angle check for smooth operation of the handle- bars and jet thrust nozzle. Turn the handlebars as far as possible to the right and left and check that the distance between the jet thrust nozzle and the bracket of the reverse gate are equal on right a...

  • Page 109: Inspecting The Qsts

    4-14 e eju01842 inspecting the qsts mechanism check that the shift lock lever moves back to the lock position smoothly, that the qsts selector locks and unlocks properly, and that the jet thrust nozzle moves up or down. 1. Squeeze and release the shift lock lever. 2. Check that the qsts selector loc...

  • Page 110: Cleaning and Adjusting The

    4-15 e eju01341 cleaning and adjusting the spark plugs the spark plug is an important engine component and is easy to inspect. The con- dition of the spark plug can indicate some- thing about the condition of the engine. For example, if the center electrode porcelain is very white, this could indica...

  • Page 111: Warning

    4-16 e note: @ ● wipe off any water on the spark plug or inside the cap before installing the spark plug cap. Push the spark plug cap down until it clicks. ● if a torque wrench is not available when you are fitting a new spark plug, a good estimate of the correct torque is 1/4 turn to 1/2 turn past ...

  • Page 112

    4-17 e f0d4100 ● throttle cable (handlebar end) pull the throttle lever and remove the seal 1. Spray a rust inhibitor into the outer cable. Refit the seal securely. ● steering cable (handlebar end) ● steering cable (nozzle end) ● nozzle pivot shaft ● qsts cable (nozzle end) ● qsts cables (pulley end...

  • Page 113

    4-18 e ● qsts cables (handlebar end) remove the qsts cable housing. Spray a rust inhibitor into the outer cable. Reinstall the qsts cable housing. ● shift cable (lever end) ● shift cable (reverse gate end) ● ypvs cable uf1f11.Book page 18 monday, june 10, 2002 11:54 am.

  • Page 114: Adjusting The Choke Cable

    4-19 e ● intermediate housing using a grease gun, fill the intermediate housing with water-resistant grease through the grease nipple 1. Grease capacity: initial 10 hours or 1 month: 33.0–35.0 cm 3 (1.11–1.18 oz) every 100 hours or 12 months: 6.0–8.0 cm 3 (0.20–0.27 oz) eju01261 adjusting the choke ...

  • Page 115: Inspecting The Battery

    4-20 e eju01971 inspecting the battery check the level of the battery electrolyte and make sure that the negative and posi- tive leads are securely tightened. Warning @ ● battery electrolyte is poisonous and dangerous, causing severe burns, etc. Electrolyte contains sulfuric acid. Avoid contact with...

  • Page 116: Caution:

    4-21 e to replenish the battery: 1. Make sure that the electrolyte level is between the upper 1 and lower 2 level marks. 2. Refill the battery with distilled water if necessary. Caution: @ normal tap water contains minerals that are harmful to a battery. Use only dis- tilled water for replenishing t...

  • Page 117: Adjusting The Carburetor

    4-22 e eju01109 adjusting the carburetor the carburetor is a vital part of the engine and requires very sophisticated adjustment. Most adjusting should be left to a yamaha dealer who has the professional knowledge and experience to perform it. However, the operator may adjust the trolling speed as p...

  • Page 118: Replacing The Fuse

    4-23 e eju01263 replacing the fuse the fuse is in the electrical box 1. To replace the fuse: 1. Remove the cap 2, pull out the red lead, and bring the fuse holder 3 out of the electrical box. 2. Open the fuse holder and replace the fuse 4 with one of the correct amper- age. Warning @ do not use fuse...

  • Page 119: Specifications

    4-24 e eju01719 specifications model item unit xlt800 watercraft capacity maximum people on board number of people 3 maximum load capacity kg (lb) 240 (530) dimensions length mm (in) 3,160 (124) width mm (in) 1,220 (48) height mm (in) 1,130 (45) dry weight kg (lb) 322 (710) performance maximum outpu...

  • Page 120: –Memo–

    E –memo– uf1f11.Book page 25 monday, june 10, 2002 11:54 am.

  • Page 121: Troubleshooting

    E 5 eju01115 troubleshooting and emergency procedures troubleshooting ......................................5-1 troubleshooting chart ............................5-1 emergency procedures ..........................5-4 cleaning the jet intake and impeller ......5-4 jumping the battery ...................

  • Page 122: Troubleshooting

    5-1 e 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 se...

  • Page 123

    5-2 e engine runs irregu- larly or stalls fuel empty refill as soon as possi- ble 3-3 stale or contaminated have serviced by yamaha dealer 4-10 choke knob pulled push fully in 2-10 fuel filter clogged or water pooled have serviced by yamaha dealer 4-11 fuel tank water or dirt present have serviced b...

  • Page 124

    5-3 e watercraft slow or loses power cavitation jet intake clogged clean 5-4 impeller damaged or worn have serviced by yamaha dealer — engine over- heated jet intake clogged clean 5-4 fuel filter clogged have serviced by yamaha dealer 4-11 spark plug fouled or defective replace 4-15 incorrect heat r...

  • Page 125: Emergency Procedures

    5-4 e 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 s...

  • Page 126: Caution:

    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 unavo...

  • Page 127: Caution:

    5-6 e 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 ...

  • Page 128: Towing The Watercraft

    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) ...

  • Page 129: Submerged Watercraft

    5-8 e eju01908 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 d...

  • Page 130: –Memo–

    E –memo– uf1f11.Book page 9 monday, june 10, 2002 11:54 am.

  • Page 131: Appendix

    E 6 eju01124 appendix limited warranty.................................... 6-1 yamaha extended service (y.E.S.) .................................................. 6-3 index ...................................................... 6-4 uf1f11.Book page 1 monday, june 10, 2002 11:54 am.

  • Page 132: Limited Warranty

    6-1 e eju01172 limited warranty yamaha motor corporation, u.S.A. Watercraft limited warranty yamaha motor corporation is proud of its heritage and reputation for producing products with high standards of quality and workman- ship. Product excellence provides the cornerstone for our commitment to cus...

  • Page 133

    6-2 e this warranty gives you specific legal rights, and you may also have other rights which vary from state to state. Yamaha motor corporation, u.S.A. Post office box 6555 cypress, california 90630 warranty questions and answers q. What costs are my responsibility during the warranty period? A. Th...

  • Page 134

    6-3 e eju01201 yamaha extended service (y.E.S.) keep your yamaha protected even after your warranty expires with genuine yamaha extended service (y.E.S.). ● ● ● ● y.E.S. Is designed and administered by yamaha motor corporation to provide maximum owner satisfaction. You get uninterrupted factory-back...

  • Page 135: Index

    6-4 e eju01125 index 2-stroke engine oil................................... 3-2 a adjusting the carburetor ........................ 4-22 adjusting the choke cable ..................... 4-19 adjusting the trolling speed ................... 4-22 approval label of emission control certificate.............

  • Page 136

    6-5 e inspecting the jet thrust nozzle angle ..................................................... 4-13 inspecting the oil injection system......... 4-12 inspecting the qsts mechanism.......... 4-14 inspecting the shift cable....................... 4-13 j jet unit.......................................

  • Page 137

    6-6 e storage.................................................... 4-1 storage compartments.......................... 2-27 submerged watercraft............................. 5-8 switches................................................ 3-13 t tachometer ........................................... 2-21 ...

  • Page 138

    Uf1f11.Book page 7 monday, june 10, 2002 11:54 am.

  • Page 140: 2003

    2003 waverunner xlt800 owner’s/operator’s manual lit-18626-05-16 u.S.A. Edition read this manual carefully before operation! Printed in usa aug. 2002—1.3 × 1 cr f1f-f8199-11 (e) printed on recycled paper yamaha motor corporation, usa.