Yamaha XLT800 WaveRunner 2004 Owner'S/Operator'S Manual Download

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4-17

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Steering cable (nozzle end)

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Nozzle pivot shaft

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QSTS cable (nozzle end)

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QSTS cables (pulley end)

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QSTS cables (handlebar end)
Remove the QSTS cable housing. Spray
a rust inhibitor into the outer cable.
Reinstall the QSTS cable housing.

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Shift cable (lever end)

E_F1F-10-4.fm Page 17 Friday, May 30, 2003 2:30 PM

Summary of Contents for XLT800 WaveRunner 2004

Page 1: ...2004 WaveRunner XLT800 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: ...arine 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 Emission control information label EJU01393 Manufactured date label This label is attached to the electrical box and the exhaust side of the crankcase 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 3 4 ...

Page 10: ...1 5 E EJU01354 Other labels 7 5 6 8 9 ...

Page 11: ...1 6 E B 0 C A ...

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: ...ors 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 engaging in closed cours...

Page 16: ...e Road 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...

Page 17: ... 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 trolling speed Prac tice turning in an open area without obstructions until you have a good feel for this maneuver This watercraft is water jet propelled The jet pump is directly connected to th...

Page 18: ...g capacity to carry the operator a rearward facing spotter and the water skier when he or she is not skiing The watercraft must also 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 effe...

Page 19: ...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 the skier at least 50 m 150 ft about...

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: ...ling water pilot outlet 2 12 Steering system 2 12 Tilt lever 2 13 Shift lever 2 14 Quick Shift Trim System QSTS selector 2 15 Handgrip 2 16 Engine overheat warning system 2 17 Multifunction meter 2 18 PADLOC Programmable digital locking ignition 2 19 Tachometer 2 21 Speedometer 2 22 Fuel meter 2 22 Engine oil meter 2 23 Clock 2 23 Hour meter 2 24 Trip timer 2 24 Tripmeter 2 25 Fuel warning indicat...

Page 28: ...rection 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 5 Hood 6 Front seat 7 Rear seat 8 Sponsons 9 Gunwale ...

Page 29: ... the watercraft 6 Handgrip Use for support when boarding the watercraft or when seated facing rearward and acting as a spotter for a water skier 7 Reverse gate Controls direction of jet thrust when in reverse 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 to handlebar position 0 Ride plate ...

Page 30: ...d dis able it from starting 6 Start switch Push to start the engine 7 Fuel cock knob Use to select either normal or reserve fuel flow from the fuel tank to the carburetors or to shut off fuel flow 8 Choke knob Use to start a cold engine 9 Engine shut off cord lanyard Attach to wrist so that the engine stops if the operator falls off the watercraft 0 Adjustable rearview mirrors A Multifunction mete...

Page 31: ... 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 ...

Page 32: ...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 33: ... 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 place 2 Install the rear seat NOTE Make sure that the seats are properly secured before operating the watercraft ...

Page 34: ...01213 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 ...

Page 35: ... 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 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 36: ...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 37: ...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 38: ... 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 the clip is removed from the engine shut off switch The engine will not start if the LOCK mode of the multifunction meter has been selected See page 2 20 for PADLOC mode selection procedures ...

Page 39: ...curs stop the engine and check for the cause See pages 2 17 and 5 4 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 je...

Page 40: ...hen move the handlebars up or down to the desired position WARNING Never touch the tilt lever during opera tion otherwise the handlebars may suddenly change position which may lead to an accident Be sure to fasten the tilt lever properly after adjusting the handlebar position If the handlebars are not properly fas tened they may suddenly change position which may lead to an acci dent ...

Page 41: ...e shift lever toward you WARNING Make sure that the throttle is com pletely released and that the engine is at idle before shifting into reverse Do not use the reverse function to slow down or stop the watercraft as it could cause you to lose control be ejected or impact the handlebars Use reverse for slow speed maneuver ing only Make sure that there are no obstacles or people behind you before sh...

Page 42: ...and B neutral N and 2 bow up positions C and D To change the trim angle 1 Reduce engine speed to 3 000 r min or less 2 Squeeze the shift lock lever 2 and then turn the QSTS selector to the desired position 3 Release the shift lock lever to lock the QSTS selector CAUTION Do not turn the QSTS selector while operating the watercraft at full throttle otherwise damage could occur to the QSTS The neutra...

Page 43: ...speed are also reduced EJU01024 Bow up Turn the grip to C or D and the bow will go up while the watercraft is on plane Bow up puts less of the bow in the water There is less water resistance so straight ahead acceleration when on plane and top speed are enhanced In some conditions however the water craft may tend to porpoise hop in the water If the watercraft is porpoising choose neutral or bow do...

Page 44: ...charge of water reduce the engine 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 canno...

Page 45: ...ator B Engine overheat warning indicator C Fuel warning indicator D Oil warning indicator CAUTION Do not run the engine at full throttle or more than 15 seconds to check the meter for operation on land The engine could overheat Use the specified resistor type spark plugs and caps otherwise the meter may function erratically NOTE The demonstration mode display starts showing after the engine starts...

Page 46: ...OCK mode the engine will not start unless the right code is put in to select START mode NOTE If you do not use the PADLOC system it is unnecessary to perform the initial setting of the PADLOC In this case the START mode is automatically selected EJU01223 PADLOC initial setting 1 Disconnect the blue connector 1 behind the front storage compartment 2 After the warning light turns on press the MODE b...

Page 47: ...eter has displayed this sequence connect the blue connector again NOTE Your own code is kept even if the battery terminal is disconnected If you forget your own code or if you want to change the code do this initial setting procedure again from the beginning EJU01224 Selecting PADLOC mode Selecting the desired mode can only be done after the initial setting has been done and while the display is n...

Page 48: ...e will change from the previous mode to either START or LOCK Then the mode display and buzzer will operate for 2 seconds NOTE Once you select a mode the mode will not change unless you perform this mode selection sequence again If the wrong code is entered the mode display shows ERROR for 2 seconds and the buzzer will sound 5 times Then the display returns to COdE EJU01225 Tachometer The engine sp...

Page 49: ...eter 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 indication of the segments differs depending on your operating condition Use the meter as a reference ...

Page 50: ...k A 12 hour clock is provided in this meter To show the clock press the MODE but ton until the display shows CLOCK while the engine is running 1 When the display shows CLOCK press the MODE button for at least 3 sec onds 2 The buzzer will sound once The hour display and SET start blinking Then press the A SET button until the desired hour is displayed 3 Press the MODE button again 4 The buzzer will...

Page 51: ... button until the display shows HOUR M while the engine is running EJU01231 Trip timer The trip timer is provided for counting the time traveled on a given trip To show the trip timer press the MODE button until the display shows TRIP T while the engine is running 1 Minutes 2 Seconds 1 When the display shows TRIP T press the A SET button to start counting The buzzer will sound once 2 Press the A S...

Page 52: ...ds and 000 is displayed Now the meter will start to measure the distance you travel 3 When the tripmeter begins measuring the distance traveled the to the left of MILE on the display will blink NOTE Measured distance may vary depending on the water surface conditions and wind direc tion The measured distance should be used for a reference EJU01232 Fuel warning indicator If the fuel remaining in th...

Page 53: ...il in the tank check the oil filter for clog ging EJU01234 Engine overheat warning indicator If the engine starts to overheat the over heat warning indicator W TEMP and the warning light begin to blink The buzzer also starts sounding intermittently Refer to Engine overheat warning sys tem on page 2 17 EJU01235 Battery warning indicator If the battery voltage becomes less than 11 5 volts the batter...

Page 54: ...hat must be kept dry such as the manuals put them in a waterproof bag EJU01237 Front storage compartment The front storage compartment 2 is 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 front storage compartment can be removed to acc...

Page 55: ...lid down until it locks securely Glove compartment Capacity 1 7 L 0 45 US gal 0 37 Imp gal 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 5 for rear seat removal and installation procedures Seat storage compartment Capacity 30 L 8 US gal 6 6 Imp gal Load limi...

Page 56: ...E MEMO ...

Page 57: ...topping the engine 3 21 Leaving the watercraft 3 21 Operating your watercraft 3 22 Getting to know your watercraft 3 22 Learning to operate your watercraft 3 22 Riding watercraft with passengers 3 23 Starting the watercraft 3 24 Boarding and starting in deep water 3 26 Capsized watercraft 3 28 Turning the watercraft 3 30 Stopping the watercraft 3 32 Beaching the watercraft 3 33 Docking the watercr...

Page 58: ...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 59: ...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 EJU10441 2 stroke engine oil If YAMALUBE 2 W oil is not available another 2 stroke engine oil with an NMMA certified TC W3 rating may be used Recommended gasoline Regular unleaded ga...

Page 60: ...ove the front storage compartment to check the fuel level See page 2 27 for front storage compartment 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 70 L 18 5 US gal 15 5 Imp gal Reserve 12 L 3 2 US gal...

Page 61: ...pump 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 to access the oil tank filler cap Also remove all seats to watch the oil level See page 2 7 for hood and 2 5 and 2 6 for rear and front seat 2 Open the oil tank filler cap and very slowly add engine oil to the oil tank 3 Stop pouring w...

Page 62: ...e lever springs back smoothly 3 11 Steering system Check for proper operation Check that the handlebars are securely locked 3 11 Shift lever and reverse gate Check for proper operation 3 12 QSTS Check for proper operation 3 13 Fuel and oil Check fuel and oil levels and add if necessary Check the hoses and tanks for leakage 3 7 Water separator Check for water and drain if necessary 3 7 Battery Chec...

Page 63: ...storage com partment Allow the engine compartment to remain open for a few minutes to allow any fuel vapors to escape Also check for loose electrical connections WARNING Failure to ventilate the engine compart ment could result in fire or explosion Do not start the engine if there is a fuel leak or a loose electrical connection EJU20570 Hull and deck Check the hull and deck for cracks or other dam...

Page 64: ...sh if necessary See pages 3 3 and 3 4 for filling instructions EJU01961 Water separator Check the water separator 1 for water Normally the water separator is empty The water separator retains any water entering through the fuel tank breather hose if the watercraft is capsized If water remains in the water separator drain it by removing the drain screw 2 Place a drain pan under the water separator ...

Page 65: ...h dry rags to make sure that the bilge is thoroughly dry 4 Install the drain plugs EJU20581 Stern drain plug Check the stern drain plugs for proper installation CAUTION Make sure that the stern drain plugs are tightened securely before launch ing the watercraft Otherwise water may flood the engine compartment and cause the watercraft to submerge Clean any foreign materials such as dirt or sand fro...

Page 66: ... 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 67: ...tainer cap is tightened securely 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 have one contact a Yamaha dealer or a fire extinguisher dealer to obta...

Page 68: ...on of the throttle lever EJU01848 Steering system Check for looseness in the handlebars Turn them as far as possible to the right and left to make sure that operation is smooth and unrestricted throughout the whole range Make sure that the jet thrust nozzle also changes directions as the han dlebars are turned and that there is no free play between the handlebars and the jet thrust nozzle Check th...

Page 69: ...ed down WARNING Make sure that the throttle is com pletely released and that the engine is at idle before shifting into reverse Do not use the reverse function to slow down or stop the watercraft as it could cause you to lose control be ejected or impact the handlebars Use reverse for slow speed maneuver ing only Make sure that there are no obstacles or people behind you before shifting into rever...

Page 70: ...heck that they oper ate properly 2 Check that the QSTS selector locks when the lever is released 3 Check that the selector turns smoothly when the lever is squeezed and held in place 4 Check that the angle of the jet thrust nozzle changes when the selector is shifted from neutral to bow up or bow down If the mechanism does not work properly have a Yamaha dealer service it ...

Page 71: ... engine by the jet pump See page 5 4 for jet intake cleaning procedures WARNING Keep away from intake grate while engine is on Items such as long hair loose clothing or PFD straps can become entangled in moving parts resulting in severe injury or drowning Stop the engine and remove the clip from the engine shut off switch before removing any debris or weeds which may have collected around the jet ...

Page 72: ...ps immediately Restart the engine and then pull the engine shut off cord 5 to remove the clip 4 from the engine shut off switch 3 to verify that the engine stops immediately See pages 2 10 to 2 11 for information on proper opera tion of the start switch the engine stop switch and the engine shut off switch EJU01061 Cooling water pilot outlet Check that water comes out from the out lets while the e...

Page 73: ...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 74: ...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 75: ...n an enclosed area Exhaust fumes contain carbon monox ide a colorless odorless gas that may cause loss of consciousness and death within a short time Always operate the watercraft in an open area 1 Launch the watercraft in water free from weeds and debris and at least 60 cm 2 ft deep WARNING Never operate in water that is less than 60 cm 2 ft deep otherwise you increase your chance of hitting a su...

Page 76: ...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 77: ...ine is con nected directly to the jet pump Starting the engine immediately generates some thrust Apply only enough throttle to keep the engine running 7 Release the start switch as 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 s...

Page 78: ...u to hit an obsta cle you are attempting to avoid A colli sion could result in severe injury or death EJU01249 Leaving the watercraft If leaving the watercraft choose the LOCK mode on the multifunction meter by setting PADLOC and remove the engine shut off cord to reduce the chance of acci dental starting or unauthorized use by chil dren or others To set the mode see PADLOC under Mul tifunction me...

Page 79: ...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 80: ...re 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 equiv alent WARNING Do...

Page 81: ...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 82: ...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 83: ...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 84: ...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 85: ...or 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 EJU18831 Capsized watercraft If th...

Page 86: ...OTE If the port left side of the capsized watercraft is tilting up push down on the gunwale so that the port left side is down before turning the watercraft clockwise CAUTION Do not turn the watercraft over counter clockwise otherwise water can leak into the carburetor and engine which can result in severe damage 3 Start the engine and operate the water craft to discharge any water remaining in th...

Page 87: ...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 88: ...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 89: ...t 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 speeds and keep a safe distance away from people objects and other watercra...

Page 90: ...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 105 m 345 ft away fr...

Page 91: ...people behind you before shifting to reverse EJU01255 Rough water operation The force of landing after jumping can cause a strong impact on both the watercraft and the operator and passengers It is pos sible for the operator to hit his or her chest or jaw on the watercraft body or handlebars and be injured Do not operate the water craft with your chin right above the handle bars or with your feet ...

Page 92: ...ith an auto matic bilge draining system that removes water from the engine compartment while you are underway However some residual water will remain 4 Put the watercraft in a horizontal posi tion 5 Flush the cooling system to prevent it from clogging with salt sand or dirt See page 4 1 for flushing the cooling system procedures 6 Drain residual water from the exhaust system by alternately squeezi...

Page 93: ...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 with a clean cloth repeat step 3 if necessary 10 Wipe the hull handlebars and jet unit dry with a clean cloth 11 Spray a rust inhibitor such as Yamaha Silicone Protectant and Lubricant on metallic parts to minimize corrosion 12 Allow the engine compartm...

Page 94: ...ns 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 fo...

Page 95: ... fuel system 4 10 Inspecting the oil injection system 4 12 Inspecting the jet thrust nozzle angle 4 13 Inspecting the shift cable 4 13 Inspecting and adjusting the throttle cable 4 13 Cleaning and adjusting the spark plugs 4 14 Inspecting the Yamaha Power Valve System YPVS 4 15 Lubrication points 4 16 Adjusting the choke cable 4 18 Inspecting the battery 4 19 Adjusting the carburetor 4 21 Replacin...

Page 96: ...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 97: ...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 98: ...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 99: ...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 100: ...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 101: ...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 102: ...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 103: ...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 104: ...spect clean adjust 4 14 Lubrication points Lubricate 4 15 Intermediate housing Lubricate 1 2 2 4 18 Fuel system Inspect 4 10 Fuel filter Inspect clean replace 4 11 Fuel tank Inspect clean 4 11 Oil injection system Inspect clean 4 12 Trolling speed Inspect adjust 4 21 Carburetor throttle shaft Inspect Cooling water passages Flush 3 4 1 Water inlet strainer Inspect clean Bilge strainer Clean Impelle...

Page 105: ...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 106: ...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 107: ...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 108: ...posi tion Make sure that the reverse gate makes contact with the stopper 1 on the bracket and that the arm 2 makes contact with the reverse gate If the reverse gate does not reach the cor rect positions have a Yamaha dealer ser vice it 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 specificatio...

Page 109: ...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 110: ...o escape which could lead to explosion or fire EJU20630 Inspecting the Yamaha Power Valve System YPVS Yamaha Power Valve System YPVS boosts engine performance and efficiency by means of a variable valve in the exhaust port The YPVS valve is constantly adjusted in accordance with the engine speed by a computer controlled servomotor Since the YPVS is an important part of the engine and requires very...

Page 111: ...ease Recommended water resistant grease Yamaha Marine Grease Yamaha Grease A Throttle cable carburetor end Oil pump cable Choke cable carburetor end 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 ...

Page 112: ...zle end Nozzle pivot shaft QSTS cable nozzle end QSTS cables pulley end 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 ...

Page 113: ...th 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 oz EJU01261 Adjusting the choke cable Check that the choke cable 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 adjusti...

Page 114: ...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 115: ...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 116: ... 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 EJU01262 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 or if necessary the tachometer in the multifunction meter adjust the engine speed to sp...

Page 117: ... 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 118: ...m Variable oil injection Cooling system Water cooled Starting system Electric starter Ignition system Digital CDI Spark plug BR8ES NGK Spark plug gap mm in 0 7 0 8 0 028 0 031 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 Direct drive from engi...

Page 119: ...ESHOOTING 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 5 5 Towing the watercraft 5 7 Submerged watercraft 5 8 ...

Page 120: ...ace the fuse and check wiring 4 22 Battery Run down Recharge 4 19 Poor terminal connec tions Tighten as required 4 19 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 9 Fuel Empty Refill as soon as possi ble 3 3 Stale or contaminated Have serviced by Yamaha dealer 4 10 Fuel tank Water or dirt...

Page 121: ...ncorrect Adjust 4 14 Spark plug cap Loose Connect properly 4 14 Cracked torn or dam aged Replace Electrical wir ing Loose connection Tighten or connect properly Carburetor Incorrect idle adjust ment Adjust idle 4 21 Clogged Have serviced by Yamaha dealer Warning light or indicator blinks Fuel level Empty Refill as soon as possi ble 3 3 Engine oil level Empty Refill immediately 3 4 Oil filter clogg...

Page 122: ...lter Clogged Have serviced by Yamaha dealer 4 11 Spark plug Fouled or defective Replace 4 14 Incorrect heat range Replace 4 14 Gap incorrect Adjust 4 14 Spark plug caps Loose Connect properly 4 14 Electrical wir ing Loose connection Tighten or connect properly Fuel Stale or contaminated Have serviced by Yamaha dealer 4 10 Bilge Water in bilge Drain 3 8 TROUBLE POSSIBLE CAUSE REMEDY PAGE ...

Page 123: ...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 124: ...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 125: ...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 126: ...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 127: ...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 128: ...E MEMO ...

Page 129: ...E 6 EJU01124 APPENDIX Limited warranty 6 1 YAMAHA EXTENDED SERVICE Y E S 6 3 Index 6 4 ...

Page 130: ...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 131: ...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 132: ...to 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 coverag...

Page 133: ...6 Engine compartment 3 6 Engine oil meter 2 23 Engine overheat warning indicator 2 26 Engine overheat warning system 2 17 Engine serial number 1 1 Engine shut off cord lanyard 3 14 Engine shut off switch 2 10 Engine stop switch 2 10 Enjoy your watercraft responsibly 1 20 F Filling the fuel tank 3 3 Filling the oil tank 3 4 Fire extinguisher 3 10 Fishing vessel right of way 1 17 Flushing the coolin...

Page 134: ...7 Overtaking 1 17 Owner s Operator s Manual and tool kit 4 8 P PADLOC initial setting 2 19 PADLOC Programmable digital locking ignition 2 19 Periodic maintenance chart 4 9 Post operation checks 3 35 Pre operation check list 3 5 Pre operation check points 3 6 Pre operation checks 3 5 Primary Identification PRI ID number 1 1 Q Quick Shift Trim System QSTS 3 13 Quick Shift Trim System QSTS selector 2...

Page 135: ...1 Tilt lever 2 13 To get more boating safety information 1 19 Towing the watercraft 5 7 Transporting 3 37 Tripmeter 2 25 Trip timer 2 24 Troubleshooting 5 1 Troubleshooting chart 5 1 Turning the watercraft 3 30 U United States Coast Guard 1 19 W Warning labels 1 4 Watercraft characteristics 1 12 Watercraft Education and Training 1 19 Water separator 3 7 Water skiing 1 13 Y YAMAHA EXTENDED SERVICE ...

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Yamaha XLT800 WaveRunner 2004, Owner'S/Operator'S Manual

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