Yamaha XL700 WaveRunner 2003 Owner'S/Operator'S Manual Download

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EJU01115

TROUBLESHOOTING

AND EMERGENCY

PROCEDURES

Troubleshooting

......................................5-1

Troubleshooting chart ............................5-1

Emergency procedures

..........................5-3

Cleaning the jet intake and impeller ......5-3
Jumping the battery  ...............................5-4
Towing the watercraft  ............................5-6
Submerged watercraft  ...........................5-7

UF0M14.book Page 1 Wednesday, July 31, 2002 2:30 PM

Summary of Contents for XL700 WaveRunner 2003

Page 1: ...2003 WaveRunner XL700 OWNER S OPERATOR S MANUAL ...

Page 2: ......

Page 3: ...h it even if the watercraft is subse quently sold EJU01204 Important manual information In this manual information of particular importance is distinguished in the following ways The Safety Alert Symbol means ATTENTION BECOME ALERT YOUR SAFETY IS INVOLVED WARNING Failure to follow WARNING instructions could result in severe injury or death to the machine operator passengers a bystander or a person...

Page 4: ...AD 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 ...

Page 5: ... 5 Safety information 1 7 Limitations on who may operate the watercraft 1 7 Cruising limitations 1 8 Operation requirements 1 9 Recommended equipment 1 11 Hazard information 1 12 Watercraft characteristics 1 12 Water skiing 1 13 Rules of the Road 1 15 Steering and sailing rules 1 15 Rules when encountering vessels 1 16 Other special situations 1 17 Reading buoys and other markers 1 17 To get more ...

Page 6: ...er Also record and keep these ID numbers in a separate place in case your watercraft is stolen EJU01831 Primary Identification PRI ID number The PRI ID number is stamped on a label 1 attached inside the engine compart ment EJU01205 Hull Identification Number HIN The HIN is stamped on a plate 2 attached to the aft deck EJU00997 Engine serial number The engine serial number is stamped on a label 3 a...

Page 7: ...ncy EPA regula tions for marine SI engines EJU01126 Approval label of Emission control certificate This label is attached to the electrical box and muffler 1 Emission control information label EJU01127 Manufactured date label This label is attached to the electrical box and muffler 2 Manufactured date label ...

Page 8: ...1 3 E EJU00998 Important labels EJU01351 Label location ...

Page 9: ...1 4 E EJU01352 Warning labels 1 2 ...

Page 10: ...1 5 E 5 3 7 6 4 ...

Page 11: ...1 6 E EJU01354 Other labels 8 9 0 A B C ...

Page 12: ... the information contained in these materials EJU01159 Limitations on who may operate the watercraft Yamaha recommends a minimum opera tor age of 16 years old Adults must supervise use by minors Know the operator age and training requirements for your state A boating safety course is recommended and may be required in your state You can find local rules by contacting the United States Coast Guard ...

Page 13: ...rmance boat not a toy Sharp turns or jumping wakes or waves can increase the risk of back spinal injury paralysis facial injuries and bro ken legs ankles and other bones Do not jump wakes or waves Do not operate the watercraft in rough water bad weather or when visibility is poor this may lead to an accident caus ing injury or death Be alert to the possi bility of adverse weather Take note of weat...

Page 14: ...lling into water or being near the jet thrust nozzle Normal swimwear does not adequately protect against forceful water entry into rectum or vagina All riders must wear a wetsuit bottom or clothing that provides equivalent protection Such clothing includes thick tightly woven sturdy and snug fitting apparel such as denim but does not include spandex or similar fab rics like those used in bicycle s...

Page 15: ...tions Consider factors such as your riding environment and your riding style and ability Also consider the likelihood of traffic congestion and the water surface conditions If you decide to wear a helmet based upon your riding cir cumstances choose one carefully Look for a helmet designed for personal water craft use if possible Consider a helmet meeting Snell or DOT standards If you will be engag...

Page 16: ...ad and be sure to check behind you before making a turn See Rules of the Road on pages 1 15 to 1 18 This watercraft is included in the Class A inboard boat classification of the U S Coast Guard A watercraft of this type MUST carry a fire extinguisher of a B 1 classification with a capacity of two pounds or more when navigating in waters under Coast Guard jurisdiction In addition most state and loc...

Page 17: ...eleasing the throttle completely produces only min imum thrust If you are traveling at speeds above trolling you will have rapidly decreasing ability to steer without throttle You may still have some turning ability immediately after releasing the throttle but once the engine slows down the watercraft will no longer respond to han dlebar input until you open the throttle again or you reach a troll...

Page 18: ...so have a cleat 1 designed to pull a ski tow rope do not attach the tow rope to any other location It is the watercraft operator s responsibility to be alert to the safety of the water skier and others Know and follow all state and local water skiing regulations in effect for the waters in which you will be operating The operator should be comfortable car rying passengers before attempting to pull...

Page 19: ...ble speed until the watercraft is well away from the skier and slack in the towrope is taken up Make sure that the rope is not looped around anything After checking that the skier is ready and that there is no traffic or other obstacles apply enough throttle to raise the skier Make smooth wide turns The watercraft is capable of very sharp turns which could exceed the abilities of the skier Keep th...

Page 20: ...er meet one another one vessel has the right of way it is called the stand on vessel The vessel that does not have the right of way is called the give way or burdened vessel These rules determine which vessel has the right of way and what each vessel should do Stand on vessel The vessel with the right of way has the duty to continue its course and speed except to avoid an immediate collision When ...

Page 21: ...each other Meeting If you are meeting another power vessel head on and are close enough to run the risk of collision neither of you has the right of way Both of you should alter course to avoid an accident You should keep the other vessel on your port left side This rule does not apply if both of you will clear one another if you continue on your set course and speed Crossing When two power driven...

Page 22: ...ve the right of way regardless of position Fishing vessels can not however impede the passage of other vessels in narrow channels Sailing vessel right of way Sailing vessels should normally be given the right of way The exceptions to this are 1 When the sailing vessel is overtaking the power driven vessel the power driven vessel has the right of way 2 Sailing vessels should keep clear of any fishi...

Page 23: ...isory 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 geo graphic location Always consult local boat ing authorities before riding your watercraft in unfamiliar waters ...

Page 24: ...s a free 50 question learning course available to the public Upon successful completion of 80 percent or better the user can request a certificate of completion by mail or can download one immediately The Online Boating Safety Course provided by the Boat US Foundation is approved by the National Association of State Boating Law Administrators NASBLA and recognized by the United States Coast Guard ...

Page 25: ...riding close to shoreline homes and waterfowl nesting areas or other wildlife areas and keep a respectful distance from fishermen other boats swimmers and populated beaches When travel in areas like these is unavoid able ride slowly and obey all laws Remember that pollution can be harmful to the environment Do not refuel or add oil where a spill could cause damage to nature Remove your watercraft ...

Page 26: ...E MEMO ...

Page 27: ...2 5 Hood 2 6 Fuel tank filler cap 2 7 Oil tank filler cap 2 7 Fuel cock knob 2 8 Engine stop switch 2 9 Engine shut off switch 2 9 Choke knob 2 9 Throttle lever 2 10 Start switch 2 10 Cooling water pilot outlet 2 11 Steering system 2 11 Handgrip 2 12 Engine overheat warning system 2 13 Oil level warning lamp 2 14 Storage compartments 2 15 ...

Page 28: ... direction 7 Fuel tank filler cap 8 Rope hole Use to attach a rope for mooring only 9 Oil tank filler cap 0 Choke knob Use to start a cold engine A Footwell Use to place feet for balance B Footrest To keep proper balance while facing to the rear to watch the skier C Fire extinguisher container Use to store the fire extinguisher D Intake grate Prevents debris from getting into the jet pump E Handgr...

Page 29: ...ne or unauthorized use of the watercraft 4 Engine shut off switch Remove the clip to stop the engine and dis able it from starting 5 Start switch Push to start the engine 6 Oil level warning lamp 7 Throttle lever Use to accelerate and decelerate 8 Stern drain plugs Use to drain water in the bilge when the water craft is on dry land 9 Jet thrust nozzle Changes the direction of jet thrust according ...

Page 30: ...gine and reduces air intake noise 2 Spark plugs caps 3 Electrical box Protects electrical components from water 4 Spark plug lead 5 Muffler 6 Fuel tank 7 Oil tank 8 Fuel filter 9 Flush hose connector Use to flush the engine cooling water pas sages 0 Battery ...

Page 31: ...211 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 down to lock it in place securely ...

Page 32: ...ull the front seat latches 1 on both sides up and then lift the seat and pull it off To install the front seat 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 place securely ...

Page 33: ...1011 Hood To open the hood push the latch 1 down 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 ...

Page 34: ... before operating the water craft EJU01214 Oil tank filler cap To remove the oil tank filler cap 1 Open the hood See page 2 6 for hood 2 Turn the filler cap 2 counterclockwise To install the oil tank filler cap Install the filler cap and then close the hood NOTE Make sure that the oil tank filler cap and hood are properly secured before operating the watercraft ...

Page 35: ...ion when the engine is not running ON With the fuel cock knob in this position fuel flows to the carburetors Turn the fuel cock knob to this position when starting the engine and operating the watercraft RES This indicates reserve With the fuel cock knob in this position the fuel reserve is made available Turn the fuel cock knob to this position if you run out of fuel while oper ating the watercra...

Page 36: ...e operator falls off the watercraft WARNING Always attach the engine shut off cord to your wrist and the clip to the engine shut off switch BEFORE starting the engine To prevent accidental starting of the engine or unauthorized use by chil dren or others always remove the clip from the shut off switch when the engine is not running EJU01215 Choke knob Starting a cold engine requires a richer air f...

Page 37: ...e engine speed Release the throttle lever to decrease engine speed or to return it to the idle posi tion EJU01019 Start switch Push the start switch 1 green button to start the engine NOTE The engine will not start when the clip is removed from the engine shut off switch ...

Page 38: ...urs stop the engine and check for the cause See pages 2 13 and 5 3 for further instructions NOTE If the cooling water passages are dry it will take about 20 seconds for the water to reach the outlet after the engine is started EJU01021 Steering system Your watercraft can be steered by turning the handlebars 1 the same direction you wish to travel When the handlebars are turned the angle of the jet...

Page 39: ...ARNING Do not use the handgrip to lift the water craft The watercraft could fall which could result in severe injury EJU01981 Finger grip The finger grip 1 provides a handhold for a spotter when facing rearward WARNING Do not use the finger grip to lift the watercraft The watercraft could fall which could result in severe injury ...

Page 40: ...ngine speed and beach the watercraft and then check the intake grate and impeller for clogging WARNING Before attempting to remove weeds or debris from the intake grate or impeller shut the engine off and remove the clip from the engine shut off switch Severe injury or death could result from coming in contact with the rotating parts of the jet pump CAUTION If you cannot locate and correct the cau...

Page 41: ...lter is clogged the oil level warning lamp begins to blink If the oil level warning lamp begins to blink refill with engine oil as soon as possi ble NOTE The lamp will light up for 2 seconds after starting the engine to check the lamp operation If the warning lamp blinks with adequate oil in the tank check for a clogged oil fil ter ...

Page 42: ... are located at the bow To open the front storage compartment pull the hood latch 1 up and then open the hood To close the front storage compartment push down on the rear of the hood until it latches securely NOTE The lower storage compartment 3 is pro vided under the upper storage compart ment 2 To access the lower storage compartment remove the upper storage compartment CAUTION Store only soft l...

Page 43: ...own until it locks securely Glove compartment Capacity 1 7L 0 45USgal 0 37Impgal Load limit 1 kg 2 2 lb EJU01797 Seat storage compartment The seat storage compartment 1 is located under the rear seat To open the seat storage compartment remove the rear seat See page 2 4 for rear seat removal and installation procedures Seat storage compartment Capacity 21 2 L 5 6 US gal 4 7 Imp gal Load limit 9 kg...

Page 44: ...E MEMO ...

Page 45: ...pping the engine 3 18 Leaving the watercraft 3 18 Operating your watercraft 3 19 Getting to know your watercraft 3 19 Learning to operate your watercraft 3 19 Riding watercraft with passengers 3 20 Starting the watercraft 3 21 Boarding and starting in deep water 3 23 Capsized watercraft 3 25 Turning the watercraft 3 27 Stopping the watercraft 3 29 Beaching the watercraft 3 30 Docking the watercraf...

Page 46: ...a horizontal position Do not stand or sit on the watercraft while refueling in case of fire Take care not to spill gasoline If gaso line spills wipe it up immediately with dry rags Always properly dispose of gasoline soaked rags Avoid overfilling the fuel tank Stop fill ing when the fuel level just reaches the bottom of the filler tube Do not fill up the filler tube because fuel expands as it warm...

Page 47: ...can be used if ethanol content does not exceed 10 and the fuel meets minimum octane ratings Gasohol containing methanol is not rec ommended by Yamaha because it can cause fuel system damage or engine perfor mance problems EJU01044 2 stroke engine oil If YAMALUBE 2 W is not available another 2 stroke engine oil with an NMMA certified TC W3 rating may be used Recommended gasoline Regular unleaded ga...

Page 48: ...ge compartment Also remove all seats so you can watch the fuel level See page 2 6 for hood and pages 2 4 and 2 5 for seats 2 Open the fuel tank filler cap and slowly add fuel to the fuel tank 3 Stop filling when the fuel just reaches the bottom of the filler tube on the fuel tank Do not fill into the filler tube because fuel could spill out Fuel tank capacity Total 50 L 13 2 US gal 11 Imp gal Rese...

Page 49: ...p must be bled to ensure proper oil flow otherwise engine damage may occur If bleeding of the oil pump is necessary have a Yamaha dealer bleed it 1 Open the hood and remove the front storage compartment Also remove all seat so you can watch the oil level See page 2 6 for hood and pages 2 4 and 2 5 for seats 2 Open the oil tank filler cap and very slowly add engine oil to the oil tank 3 Stop pourin...

Page 50: ... fuel residue and remove if necessary 3 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 leakage 3 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 sec...

Page 51: ...he 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 9 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 Rem...

Page 52: ...th 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 draine...

Page 53: ... 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 Po...

Page 54: ...tightened securely Install the fire extinguisher container on the seat and secure it with the bands 3 NOTE See the instructions supplied by the fire extinguisher manufacturer for checking the fire extinguisher Always keep the extinguisher in the fire extinguisher con tainer Always carry a fire extinguisher on board A fire extinguisher is not standard equip ment with this watercraft If you do not h...

Page 55: ...fore 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 ...

Page 56: ... engine by the jet pump See page 5 3 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 ...

Page 57: ...t 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 wat...

Page 58: ...atercraft 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 strai...

Page 59: ...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 ...

Page 60: ...s 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...

Page 61: ...eck 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...

Page 62: ...soon as the engine starts to run 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 7 After the engine has warmed up push the...

Page 63: ...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 injury or death EJU01067 Leaving the watercraft If leaving the watercraft remove the engine shut off cord to reduce the chance of accidental starting or unauthorized use by children or others ...

Page 64: ...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 EJU01191 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 state...

Page 65: ...cluding the oper ator are on board the watercraft handles differently and is not as easy to maneuver so operating it requires a higher degree of skill Before attempting to operate the water craft with passengers on board the operator must practice operating the watercraft alone enough to be able to acquire the necessary skills The passengers must always wear USCG approved PFD and wetsuit bottom or...

Page 66: ...ctly behind water craft or other boats Do not go near others to spray or splash them with water Avoid sharp turns or other maneuvers that make it hard for others to avoid you or understand where you are going Avoid areas with sub merged objects or shallow water Take early action to avoid collisions Remember watercraft and other boats do not have brakes Do not release the throttle when trying to st...

Page 67: ...ll the clip to the engine shut off switch 3 Grip the handlebars with both hands place both feet on the floor of the foot well start the engine and start off EJU01074 Starting from a dock 1 Board the watercraft from the side 2 Attach the engine shut off cord to your left wrist and then install the clip to the engine shut off switch 3 Push the watercraft away from the dock grip the handlebars with b...

Page 68: ...rear of the watercraft and place both hands on the boarding plat form pull yourself up and then grasp the handgrip with one hand 2 Pull yourself up to a kneeling position on the platform and then move to the seat and sit astride 3 Attach the engine shut off cord to your left wrist and then install the clip to the engine shut off switch 4 Grip the handlebars firmly with both hands place both feet o...

Page 69: ...he 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...

Page 70: ...The operator attaches the engine shut off cord to his or her left wrist and then installs the clip to the engine shut off switch 3 The operator starts the engine and lets it run at idle 4 The passenger pulls him or herself up to a kneeling position and then crawls onto the seat as the watercraft accelerates 5 The operator gradually increases speed to balance the watercraft EJU01883 Capsized waterc...

Page 71: ... craft is tilting upward first tilt the watercraft so the port left side is down by using your weight to press down on the gunwale CAUTION Do not turn the watercraft over counter clockwise otherwise water may leak into the carburetor and engine and cause damage 3 Start the engine and then head for shore to inspect the engine for water damage CAUTION If the watercraft has been capsized for 5 minute...

Page 72: ...sharply B Less throttle produces lower thrust so the watercraft will turn more gradually C Releasing the throttle completely pro duces only minimum thrust If you are traveling at speeds above trolling you will have rapidly decreasing ability to steer without throttle You may still have some turning ability immediately after releasing the throttle but once the engine slows down the watercraft will ...

Page 73: ...rottle 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 slide side ways or spin throwing the operator and passengers overboard which could cause an injury ...

Page 74: ... The watercraft slows down as soon as the throttle lever is released but will coast for a distance before fully stopping If you are not sure you can stop in time before hitting an obstacle apply throttle and turn in another direction WARNING Allow adequate stopping distance Take early action to avoid collisions Remember watercraft and other boats do not have brakes Operate defensively at safe spee...

Page 75: ...e to steer 3 Get off the watercraft and pull it up on the beach CAUTION Small pebbles sand seaweed and other debris can be pulled into the jet intake and impair or damage the impeller Always stop the engine and get off before beaching the watercraft EJU01082 Docking the watercraft 1 Make sure that no obstructions boats or swimmers are close to the watercraft Reduce speed about 95 m 310 ft away fro...

Page 76: ...age internal parts Avoid operating in rough water or bad weather conditions 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 drain excess water remove the stern drain plu...

Page 77: ... seize 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 engine or engine compartment as severe engine damage could result 9 Wipe the engine and engine compart ment dry w...

Page 78: ...hich 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 holes 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 towels or rags where they touch the body of the water craft to avoid scratching or damage ...

Page 79: ...odic maintenance chart 4 9 Inspecting the fuel system 4 10 Inspecting the oil injection system 4 12 Inspecting the jet thrust nozzle angle 4 13 Inspecting and adjusting the throttle cable 4 13 Cleaning and adjusting the spark plugs 4 14 Lubrication points 4 15 Adjusting the choke cable 4 17 Inspecting the battery 4 18 Adjusting the carburetor 4 20 Replacing the fuse 4 21 Bleeding the oil injection...

Page 80: ...have the watercraft serviced by a Yamaha dealer prior to stor age However the following procedures can be performed by the owner EJU01088 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 throug...

Page 81: ...ly turn the water supply on until water flows out continually from the cooling water pilot outlet 5 Run the engine at idling speed for about 3 minutes watching the engine condition If the engine stops while flushing turn the water supply off immediately and repeat the above steps 6 Turn the water supply off and then force the remaining water out from the cooling passages by alternately squeezing a...

Page 82: ...ze 1 Open the silencer cap 1 on the silencer 2 Start the engine with the watercraft in a well ventilated area 3 With the engine running at a fast idle quickly spray as much rust inhibitor as possible through the hole in the silencer cover Use Yamaha Stor Rite Fogging Oil or an equivalent Keep spraying until the engine stalls or a maximum of 15 sec onds 4 Install the cap securely 5 Lubricate all ca...

Page 83: ...soline soaked rags Avoid overfilling the fuel tank Stop fill ing when the fuel level just reaches the bottom of the filler tube Do not fill up the filler tube because fuel expands as it warms up and could overflow If tem porarily leaving the watercraft with a full fuel tank do not leave it in direct sunlight Leave it in a well ventilated area with the watercraft in a horizontal position Tighten th...

Page 84: ...emove the battery from the watercraft Clean the battery casing using fresh water If the battery terminals are dirty or cor roded clean them with a wire brush Fully charge the battery and then store it in a cool dark place Apply Yamaha marine grease or Yamaha grease A to the battery terminals Check the battery at least every 2 months and fully charge it if necessary WARNING Be sure to connect the b...

Page 85: ...ded with the battery tester and charger you use EJU01169 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 Yamaha Silicone Protectant and Lubricant ...

Page 86: ...parts or accessories which are not qualitatively equivalent to gen uine Yamaha parts are not covered by the limited warranty WARNING Be sure to turn off the engine when you perform maintenance unless oth erwise specified otherwise an acci dent or injury could result from unexpected operation moving parts or electric shock If the owner is not familiar with watercraft servicing this work should be d...

Page 87: ...enever you use the watercraft For your convenience a storage compart ment 1 is provided on the watercraft for the manual and tool kit NOTE To protect these materials from water dam age it would be a good idea to put them in a waterproof bag If your Owner s Operator s Manual is damaged order a replacement from a Yamaha dealer The service information included in this manual is intended to provide yo...

Page 88: ... 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 Ins...

Page 89: ...e 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 damag...

Page 90: ...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 EJU01841 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 ne...

Page 91: ...dirt Oil hose and joint for damage or cracks Oil filter for dirt Oil pump for leakage EJU01101 Oil tank Check the oil tank for leakage or water in the tank If water is found in the oil injection system or if the oil tank needs to be cleaned have a Yamaha dealer service the water craft EJU01102 Oil filter Check the oil filter 1 for dirt and clogs If the oil filter is clogged remove it from the oil ...

Page 92: ...s If steering is stiff or misadjusted have a Yamaha dealer service it Distance A and B A B EJU01104 Inspecting and adjusting the throttle cable Check that the throttle cable moves back to the set position smoothly and that free play is within specification 1 Squeeze and release the throttle lever If the lever does not return smoothly have a Yamaha dealer service it 2 Adjust free play a by loosenin...

Page 93: ...t Remove and inspect the spark plug peri odically heat and deposits will cause the spark plug to slowly break down and erode If electrode erosion becomes excessive or if carbon and other deposits are excessive replace the spark plug with the specified plug Measure the spark plug gap a with a wire thickness gauge before installing the spark plug Adjust the gap to specification if necessary To reins...

Page 94: ...e the spark plug adjusted to the correct torque with a torque wrench as soon as possible WARNING Be careful not to damage the insulator when removing or installing a spark plug A damaged insulator could allow sparks to escape which could lead to explosion or fire EJU01139 Lubrication points To keep moving parts sliding or rotating smoothly coat them with water resistant grease Recommended water re...

Page 95: ...ot shaft If the steering pivot shaft becomes loose tighten the band 1 until a satisfactory feel is obtained Steering cable nozzle end Nozzle pivot shaft 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 cm3 1 11 1 18 oz Every 100 hours or 12 months 6 0 8 0 cm3 0 20 0 27...

Page 96: ... is properly adjusted 1 Pull the choke knob out until it stops and then release the knob The knob should not move 2 If the choke knob moves back on its own tighten the choke knob adjusting nut 1 slightly If the knob is difficult to move loosen the adjusting nut slightly ...

Page 97: ...hy sician 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 bat tery in an enclosed space make sure that it is well ventilated Always shield your eyes when working near batter ies KEEP OUT OF THE REACH OF CHIL DREN Be sure to connect the breather hose to the battery...

Page 98: ...ourself carefully read the battery charger instructions before charging and fol low the points below 1 Remove all caps from the battery cell 2 Add distilled water to the specified level if the electrolyte level is low 3 Set the charging rate to 1 9 ampere and charge the battery slowly until the explo sive gases are discharged vigorously from the battery cells To connect the battery terminals 1 Mak...

Page 99: ...as set at the Yamaha factory after many tests If the settings are disturbed by someone who does not have the necessary technical knowledge poor engine performance and damage may result EJU01303 Adjusting the trolling speed 1 Put the watercraft in the water 2 Start the engine and warm it up for 1 or 2 minutes Using a diagnostic tachome ter adjust the engine speed to specifica tion 3 Turn the thrott...

Page 100: ... age WARNING Do not use fuses of higher amperage that those recommended Substitution of a fuse of improper rating can cause exten sive electrical system damage and possi ble fire EJU01112 Bleeding the oil injection pump If the oil tank becomes completely empty or any hose connected to the oil pump has been disconnected the oil pump must be bled to ensure proper oil flow If bleeding of the oil pump...

Page 101: ...ression ratio 7 2 1 Lubrication system Oil injection Cooling system Water cooled Starting system Electric starter Ignition system C D I Spark plug BR8HS NGK Spark plug gap mm in 0 6 0 7 0 024 0 028 Battery capacity V AH 12 19 Charging system Flywheel magneto DRIVE UNIT Propulsion system Jet pump Jet pump type Axial flow single stage Impeller rotation Counterclockwise Viewed from rear Transmission ...

Page 102: ...E MEMO ...

Page 103: ...ESHOOTING AND EMERGENCY PROCEDURES Troubleshooting 5 1 Troubleshooting chart 5 1 Emergency procedures 5 3 Cleaning the jet intake and impeller 5 3 Jumping the battery 5 4 Towing the watercraft 5 6 Submerged watercraft 5 7 ...

Page 104: ... Battery Run down Recharge 4 18 Poor terminal connec tions Tighten 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 possible 3 3 Stale or contaminated Have serviced by Yamaha dealer 4 10 Fuel tank Water or dirt present Have serviced by Yamaha de...

Page 105: ...Carburetor Incorrect idle adjust ment Adjust idle 4 20 Clogged Have serviced by Yamaha dealer Warning light blinks Engine oil level Empty Refill immediately 3 4 Oil filter clogged Clean 4 12 Watercraft slow or loses power Cavitation Jet intake clogged Clean 5 3 Impeller damaged or worn Have serviced by Yamaha dealer Engine over heated Jet intake clogged Clean 5 3 Fuel filter Clogged Have serviced ...

Page 106: ...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 car...

Page 107: ...ry 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 veg...

Page 108: ...e 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 w...

Page 109: ...artment if it is towed too fast Tow the watercraft using the bow eye 1 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...

Page 110: ...em 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 min utes If the engine does not start repeat steps 2 7 8 Turn the engine off 9 Turn the fuel cock to OFF remove the ...

Page 111: ...E 6 EJU01124 APPENDIX Limited warranty 6 1 YAMAHA EXTENDED SERVICE Y E S 6 3 Index 6 4 ...

Page 112: ...ified in the applicable Owner s Operator s Manual The owner of the watercraft shall give notice to an authorized Yamaha dealer of any and all apparent defects within ten 10 days of dis covery and make the watercraft available at that time for inspection and repairs at the dealer s place of business GENERAL EXCLUSIONS FROM WARRANTY This warranty will not cover the repair of damage if the damage is ...

Page 113: ...letely set up each new watercraft before sale 2 Explain the operation maintenance and warranty requirements to your satisfaction at the time of sale and upon your request at any later date In addition each Yamaha dealer is held responsible for his setup service and warranty repair work Q Is the warranty transferable to second owners A Yes The remainder of the existing warranty can be transferred u...

Page 114: ...150 reimbursement per occurrence for any reasonable expenses you incur because your Yamaha needs covered service replacement vehicle rental emergency towing phone calls even food and lodging when you are away from home This superb cover age goes into effect when you purchase Y E S so it applies to any warranty repairs as well as covered repairs during your entire Y E S plan period Y E S coverage i...

Page 115: ...ial number 1 1 Engine shut off cord lanyard 3 11 Engine shut off switch 2 9 Engine stop switch 2 9 Enjoy your watercraft responsibly 1 20 F Filling the fuel tank 3 3 Filling the oil tank 3 4 Fire extinguisher 3 9 Fishing vessel right of way 1 17 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 6 Fuel cock knob 2 8 Fuel filter 4 1...

Page 116: ...mmended equipment 1 11 Replacing the fuse 4 21 Riding watercraft with passengers 3 20 Rough water operation 3 31 Rules of the Road 1 15 Rules when encountering vessels 1 16 S Safety information 1 7 Sailing vessel right of way 1 17 Seat storage compartment 2 16 Specifications 4 22 Stand on vessel 1 15 Starting and boarding in shallow water 3 22 Starting from a dock 3 22 Starting the engine 3 15 Sta...

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