Yamaha WaveRunner XL1200 Service Manual
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Yamaha WaveRunner XL1200 Service Manual

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  • Page 194 Marine WaveRunner XL700 SUPPLEMENTARY SERVICE MANUAL LIT-18616-02-00 F0M-28197-Z8-1X...
  • Page 195 For what is not mentioned in this manual, please refer to the descriptions for XL760 in the above SERVICE MANUAL. A10001-0* XL700 SUPPLEMENTARY SERVICE MANUAL 1998 Yamaha Motor Co., Ltd. 1st Edition, September 1998 All rights reserved. No part of this publication may be reproduced or transmitted in any from or...
  • Page 196 GENERAL INFORMATION IDENTIFICATION NUMBERS ........PRIMARY I.D. NUMBER .
  • Page 197 POWER UNIT ENGINE UNIT REMOVAL ........EXPLODED DIAGRAM .
  • Page 198 ELECTRICAL SYSTEM ELECTRICAL COMPONENTS ........ELECTRICAL DIAGRAM .

  • Page 199: Identification Numbers

    IDENTIFICATION NUMBERS INFO A80700-0* IDENTIFICATION NUMBERS PRIMARY I.D. NUMBER The primary I.D. number is stamped on a plate attached to the hull on the front of the engine hood. Starting primary I.D. number: F0M: 800101 – ENGINE SERIAL NUMBER The engine serial number is stamped on a plate attached to the crankcase.

  • Page 200: Special Tools

    SPECIAL TOOLS INFO SPECIAL TOOLS Use of the correct special tools recom- mended by Yamaha will aid the work and en- able accurate assembly and tune-up. Impro- visations and use of improper tools can cause damage to the equlpment. MEASURING 1.

  • Page 201: General Specifications

    SPEC GENERAL SPECIFICATIONS GENERAL SPECIFICATIONS Item Unit XL700 MODEL CODE: Hull Engine DIMENSIONS: Length mm (in) 3,150 (124.0) Width mm (in) 1,250 (49.2) Height mm (in) 1,100 (43.3) Dry weight kg (lb) 245 (54.0) PERFORMANCE: Maximum speed km/ h (mph) 74 (46) Maximum output kW (hp) / rpm...

  • Page 202: Maintenance Specifications

    SPEC MAINTENANCE SPECIFICATIONS MAINTENANCE SPECIFICATIONS ENGINE Item Unit XL700 Cylinder head: Warpage limit mm (in) 0.1 (0.004) Cylinder: Bore size mm (in) 81.00 – 81.02 (3.189 – 3.190) Wear limit mm (in) 81.1 (3.193) Taper limit mm (in) 0.08 (0.003) Out of round limit mm (in) 0.05 (0.002)
  • Page 203 SPEC MAINTENANCE SPECIFICATIONS JET UNIT Item Unit XL700 Jet pump: Impeller clearance mm (in) 0.25 – 0.35 (0.010 – 0.014) Service limit mm (in) 0.6 (0.024) Impeller shaft run out mm (in) 0.3 (0.012) ELECTRICAL Item Unit XL700 Ignition system: Type CDI magneto Ignition timing...

  • Page 204: Tightening Torque

    SPEC TIGHTENING TORQUE TIGHTENING TORQUE SPECIFIED TORCUE Tightening torque Part Part to be tightened h e e Size Q’ Q’ty Remark name m kg ft lb ENGINE: Electric box Bolt Mounting bolt Bolt Reed valve Screw Exhaust ring Bolt Exhaust chamber Bolt Muffler stay Bolt...

  • Page 205: Fuel Line Routing

    SPEC FUEL LINE ROUTING FUEL LINE ROUTING Pilot water hose Fuel cock Fuel return hose Fuel filter Battery breather hose Pass the oil hose out of belt...
  • Page 206 SPEC FUEL LINE ROUTING Align mark Align mark Fuel hose (Fuel cock- Fuel return hose fuel filter) (Carburetor-fuel tank) A – A Fuel hose (Fuel cock- fuel filter) B – B Align mark Fuel hose (Fuel cock- 10 mm Fuel hose fuel filter) (Fuel filter-engine) C –...
  • Page 207 SPEC CABLE LINE ROUTING CABLE LINE ROUTING Throttle cable Choke cable Battery positive lead Battery negative lead To themo switch lead Steering cable To starting motor To starting motor negative terminal positibve terminal...
  • Page 208 SPEC CABLE LINE ROUTING Pilot water hose Electric equipment box Oil level warning lamp lead Handlebar switch lead D – D Choke cable Throttle cable A – A Electric equipment box lead Handlebar E – E Electric equi- Handlebar switch switch lead pment box lead Handlber switch...
  • Page 209 INSP MAINTANCE INTERVAL CHART MAINTANCE INTERVAL CHART The following chart should be considered strictly as a guide to general maintenance intervals. Depending on operating conditions, the intervals of maintenance should be changed. Initial Every Refer Item Remarks 10 hours 10 h 50 hours 50 h 100 hours 200 hours...

  • Page 210: Periodic Service

    INSP PERIODIC SERVICE PERIODIC SERVICE FUEL SYSTEM Trolling speed inspection and adjustment 1. Check: Trolling speed Out of specification Adjust. Trolling speed: 1,250 50 r/min Checking steps: (vehicle on water) Start the engine and allow it to warm up for a few minutes. Attach the engine tachometer to the spark plug lead.
  • Page 211 FUEL FUEL LINE FUEL LINE Gasoline (Petrol) is highly flammable and explosive. Handle with special care. EXPLODED DIAGRAM REMOVAL AND INSTALLATION CHART Step Procedure/Part name Q’ty Service points AIR VENTILATION HOSE, Follow the left “Step” for removal. FUEL COCK AND FUEL FILTER REMOVAL Hose tie Clamp...
  • Page 212 FUEL CARBURETOR UNIT REMOVAL CARBURETOR UNIT REMOVAL EXPLODED DIAGRAM 2 Nm (0.2 m kg, 1.4 ft lb) 9 Nm (0.9 m kg, 6.5 ft lb) REMOVAL AND INSTALLATION CHART Step Procedure/Part name Q’ty Service points CARBURETOR REMOVAL Follow the left “Step” for removal. NOTE: Fuel cock Turn the fuel cock to “OFF”.
  • Page 213 FUEL CARBURETOR UNIT REMOVAL 2 Nm (0.2 m kg, 1.4 ft lb) 9 Nm (0.9 m kg, 6.5 ft lb) Step Procedure/Part name Q’ty Service points Cover gasket Choke cable Cable guide set position Throttle calbe 17 mm (0.67 in) Between cable guide top and plate top.
  • Page 214 FUEL CARBURETOR CARBURETOR EXPLODED DIAGRAM 1 Nm (0.1 m kg, 0.7 ft lb) 4 Nm (0.4 m kg, 2.9 ft lb) 2 Nm (0.2 m kg, 1.4 ft lb) 2 Nm (0.2 m kg, 1.4 ft lb) 1 Nm (0.1 m kg, 0.7 ft lb) 5 Nm (0.5 m kg, 3.6 ft lb) REMOVAL AND INSTALLATION CHART Step...
  • Page 215 FUEL CARBURETOR SERVICE POINTS High and low speed screws adjustment 1. Adjust: High speed screw Low speed screw Adjustment steps: Screw in the high speed screw 1 or lower speed screw 2 until it is lightly seated. Back out by the specified number of turns.
  • Page 216 FUEL CARBURETOR Choke valve synchronization inspection and adjustment 1. Check: Choke valve synchronization Out of specification Adjust. Checking steps: While turning the choke lever, check the opening of all choke valves. 2. Adjust: Choke valve synchronization Adjustment steps: a. Turn in or out the synchronization screw 1 to bring all the choke valves into a fully closed position when the choke lever is turned on the closed...
  • Page 217 POWR ENGINE UNIT REMOVAL ENGINE UNIT REMOVAL EXPLODED DIAGRAM 7 Nm (0.7 m kg, 5.1 ft lb) 1 Nm (0.1 m kg, 0.7 ft lb) 17 Nm (1.7 m kg, 12 ft lb) 4 Nm (0.4 m kg, 2.9 ft lb) REMOVAL AND INSTALLATION CHART Step Procedure/Part name...
  • Page 218 POWR ENGINE UNIT REMOVAL 7 Nm (0.7 m kg, 5.1 ft lb) 1 Nm (0.1 m kg, 0.7 ft lb) 17 Nm (1.7 m kg, 12 ft lb) 4 Nm (0.4 m kg, 2.9 ft lb) Step Procedure/Part name Q’ty Service points Clamp Fuel hose...
  • Page 219 POWR REED VALVE REED VALVE EXPLODED DIAGRAM 1 Nm (0.1 m kg, 0.7 ft lb) REMOVAL AND INSTALLATION CHART Step Procedure/Part name Q’ty Service points REED VALVE REMOVAL Follow the left “Step” for removal. Carburetor assembly Refer to the “CARBURETOR REMOVAL”...
  • Page 220 POWR EXHAUST RING EXHAUST RING EXPLODED DIAGRAM 2 Nm (0.2 m kg, 1.4 ft lb) 2 Nm (0.2 m kg, 1.4 ft lb) 30 Nm (3.0 m kg, 22 ft lb) REMOVAL AND INSTALLATION CHART Step Procedure/Part name Q’ty Service points EXHAUST RING REMOVAL Follow the left “Step”...
  • Page 221 POWR EXHAUST CHAMBER REMOVAL EXHAUST CHAMBER REMOVAL EXPLODED DIAGRAM 40 Nm (4.0 m kg, 29 ft lb) 2 Nm (0.2 m kg, 1.4 ft lb) 47 Nm (4.7 m kg, 34 ft lb) 40 Nm (4.0 m kg, 29 ft lb) 4 Nm (0.4 m kg, 2.9 ft lb) REMOVAL AND INSTALLATION CHART Step...
  • Page 222 POWR EXHAUST CHAMBER EXHAUST CHAMBER EXPLODED DIAGRAM REMOVAL AND INSTALLATION CHART Step Procedure/Part name Q’ty Service points CHAMBER DISASSEMBLY Follow the left “Step” for removal. Exhaust chamber assembly Refer to “EXHAUST CHAMBER REMOVAL”. Bolt (with washer) Exhaust outer cover 1 Gasket Exhaust inner cover Seal...
  • Page 223 POWR CYLINDER HEAD CYLINDER HEAD EXPLODED DIAGRAM 25 Nm (2.5 m kg, 18 ft lb) 15 Nm (1.5 m kg, 11 ft lb) 36 Nm (3.6 m kg, 25 ft lb) REMOVAL AND INSTALLATION CHART Step Procedure/Part name Q’ty Service points CYLINDER HEAD REMOVAL Follow the left “Step”...
  • Page 224 POWR CYLINDER CYLINDER EXPLODED DIAGRAM 23 Nm (2.3 m kg, 17 ft lb) 40 Nm (4.0 m kg, 29 ft lb) REMOVAL AND INSTALLATION CHART Step Procedure/Part name Q’ty Service points CYLINDER REMOVAL Follow the left “Step” for removal. Cylinder head Refer to “CYLINDER HEAD”...
  • Page 225 POWR CYLINDER SERVICE POINTS Cylinder inspection 1. Eliminate: Carbon deposits Use a rounded scraper 1 . 2. Inspect: Cylinder water jacket Mineral deposits/Corrosion Clean. Cylinder inner surface Score marks Repair or replace. Use #600 800 grit wet sandpaper. 3. Measure: Cylinder bore “D”...
  • Page 226 POWR PISTON PISTON EXPLODED DIAGRAM REMOVAL AND INSTALLATION CHART Step Procedure/Part name Q’ty Service points PISTON REMOVAL Follow the left “Step” for removal. Cylinder Refer to “CYLINDER”. CAUTION: Piston pin clip Do not allow the clip open ends to meet Piston pin the piston pin slot NOTE:...
  • Page 227 POWR PISTON SERVICE POINT Piston inspection 1. Eliminate: Carbon deposits From the piston crown and ring groove. 2. Inspect: Piston wall Score marks Repair or replace. Use #600 – 800 grit wet sandpaper. NOTE: Sand in a criss-cross pattern. Do not sand ex- cessively.
  • Page 228 POWR FLYWEEL MAGNETO AND BASE FLYWEEL MAGNETO AND BASE EXPLODED DIAGRAM 37 Nm (3.7 m kg, 27 ft lb) 70 Nm (7.0 m kg, 50 ft lb) REMOVAL AND INSTALLATION CHART Step Procedure/Part name Q’ty Service points FLYWHEEL MAGNETO AND BASE Follow the left “Step”...
  • Page 229 POWR FLYWHEEL MAGNETO AND BASE 37 Nm (3.7 m kg, 27 ft lb) 70 Nm (7.0 m kg, 50 ft lb) Step Procedure/Part name Q’ty Service points NOTE: Idle gear assembly Fill the flywheel cover groove with water resistant grease. NOTE: Base assembly Align the punch mark on the crankcase...
  • Page 230 POWR FLYWHEEL COVER AND FLYWHEEL MAGNETO SERVICE POINTS Coupling flange removal and installation 1. Remove and install: Coupling flange Coupler wrench: YW-38741/90890-06425 Flywheel holder: YB-06139/90890-06522 Flywheel magneto removal and installation 1. Remove and install: Bolt Flywheel holder: YB-06139/90890-06522 2. Remove: Flywheel magneto Flywheel puller: YB-06117/90890-06521...
  • Page 231 POWR ELECTRICAL UNIT ELECTRICAL UNIT EXPLODED DIAGRAM 5 Nm (0.5 m kg, 3.6 ft lb) 4 Nm (0.4 m kg, 2.9 ft lb) 4 Nm (0.4 m kg, 2.9 ft lb) 4 Nm (0.4 m kg, 2.9 ft lb) REMOVAL AND INSTALLATION CHART Step Procedure/Part name Q’ty...
  • Page 232 POWR ELECTRICAL UNIT 5 Nm (0.5 m kg, 3.6 ft lb) 4 Nm (0.4 m kg, 2.9 ft lb) 4 Nm (0.4 m kg, 2.9 ft lb) 4 Nm (0.4 m kg, 2.9 ft lb) Step Procedure/Part name Q’ty Service points ELECTRICAL UNIT DISASSEMBLY Screw Case cover...
  • Page 233 POWR INTERMEDIATE HOUSING INTERMEDIATE HOUSING EXPLODED DIAGRAM 6 Nm (0.6 m kg, 4.3 ft lb) 37 Nm (3.7 m kg, 27 ft lb) REMOVAL AND INSTALLATION CHART Step Procedure/Part name Q’ty Service points INTERMEDIATE HOUSING Follow the left “Step” for removal. DISASSEMBLY Bearing housing assembly Refer to “INTERMEDIATE HOUSING...
  • Page 234 POWR INTERMEDIATE SHAFT AND HOUSING SERVICE POINT Coupling removal and installation 1. Remove and install: Coupling Coupler wrench: YW-38741/90890-06425 Shaft holder: YW-38742/90890-06069...

  • Page 235: Electrical Components

    ELEC ELECTRICAL COMPONENTS ELECTRICAL COMPONENTS 1 Throttle cable 9 CDI magneto lead 2 Oil level sensor lead 10 Choke cable 3 Battery lead (positive) 11 Steering cable 4 Battery lead (negative) 12 Sterter motor lead (nagative) 5 Oil level warning lamp lead 13 Grease nipple hose 6 Handlebar switch lead 14 Electrical box...
  • Page 236 Thermo switch Ignition coil Lighting coil Pulser coil Charge coil CDI unit Starter motor Stop switch Engine stop switch Starter switch Battery Fuse Starter relay Rectifier regulator Oil level sensor Oil level warning lamp : Black : Brown Br/W : Brown/White : Green : Blue : Orange...

  • Page 237: Electrical Analysis

    ELEC ELECTRICAL ANALYSIS ELECTRICAL ANALYSIS PEAK VOLTAGE MEASUREMENT NOTE: If the spark produces no sparks, check the wiring for any disconnection, looseness, in- sufficient contact, etc. Then measure the peak voltage. The peak voltages are listed for the loaded and the circuit state. The “loaded value” is used for measuring a normally operating system and the “circuit valve”...
  • Page 238 ELEC ELECTRICAL ANALYSIS Set the digital tester dial at the DCV posi- tion. Connect the peak voltage adaptor leads b to the correct terminals to be mea- sured. NOTE: The peak voltage leads have no polarity connection of either lead to either termi- nal c for measurement will result in the same measurement.
  • Page 239 ELEC IGNITION SYSTEM IGNITION SYSTEM WIRING DIAGRAM 1 Pulser coil : Black 2 Charge coil Br/ W : Brown / White 3 CDI unit : Orange 4 Stop switch : Pink 5 Engine stop switch : White 6 Thermo switch W / R : White / Red 7 Ignition coil...
  • Page 240 ELEC IGNITION SYSTEM IGNITION SYSTEM Peak voltage When checking the peak voltage do not touch any of the connections of the digital tester lead wires. NOTE: If there is no spark or the spark is weak, con- tinue with the ignition system test. If a good spark is obtained, the problem is not with the ignition system, but possibly with the spark plug(s) or another compo-...
  • Page 241 ELEC IGNITION SYSTEM 3. Measure: Pulser coil output peak voltage Above specification Replace the CDI unit. Below specification Replace the pulser coil. Pulser coil output peak voltage White/red (W/R) – Black (B) Circuit Loaded r/min Cranking 1,500 3,500 17.0 29.5...
  • Page 242 ELEC IGNITION SYSTEM CHARGE COIL 1. Measure: Charge coil resistance Out of specification Replace. Charge coil resistance: Brown/White (Br/W) – Black (B) 497.7 – 608.3 Ω at 20 C (68 F) PULSER COIL 1. Measure: Pulser coil resistance Out of specification Replace.
  • Page 243 ELEC IGNITION SYSTEM CDI UNIT 1. Measure: CDI unit resistance Out of specification Replace. Pocket tester: YU-03112/90890-03112 NOTE: The resistance values will vary from meter to meter, especially with electronic digital meters. For some testers, the polarity of the leads is reversed. The needle swings once to the ”...

  • Page 244: Starting System

    ELEC STARTING SYSTEM STARTING SYSTEM WIRING DIAGRAM 1 Fuse : Black 2 Engine stop switch : Brown 3 Starter switch : Red 4 Battery 5 Starter motor 6 Starter relay...

  • Page 245: Charging System

    ELEC CHARGING SYSTEM CHARGING SYSTEM WIRING DIAGRAM 1 Fuse : Black 2 Battery : Green 3 Lighting coil : Red 4 Rectifier regulator...
  • Page 246 ELEC CHARGING SYSTEM RECTIFIER/REFULATOR OUTPUT PEAK VOLTAGE 1. Measure: Rectifier/regulator output peak voltage Below specification Check the lighting coil. Rectifier/regulator output peak voltage Red (R) – Black (B) Circuit Loaded r/min Cranking 1,500 3,500 – – 12.6 12.5 NOTE: Before measuring the rectifier/regulator output peak voltage, disconnect the lighting coil coupler and remove the fuses.

  • Page 247: Indication System

    ELEC INDICATION SYSTEM INDICATION SYSTEM WIRING DIAGRAM : Black 1 Oil level sensor : Grren 2 Lighting coil : Blue 3 Oil levle warning lamp : Red 4 Rectifier regulator...
  • Page 248 ELEC INDICATION SYSTEM OIL LEVEL SENSOR 1. Meadure: Oil level sensor continuity Out of specifi- cation Replace. Checing leads Float position Max. 2.5 mm (0.010 in.) Float length a : 37,0 – 41,0 mm (1,46 – 1,61 in) OIL LEVEL WARNING LAMP 1.
  • Page 249 HULL THORTTLE CABLE AND CHOKE CABLE HOOD THROTTLE CABLE AND CHOKE CABLE EXPLODED DIAGRAM 8 Nm (0.8 m kg, 6.0 ft lb) REMOVAL AND INSTALLATION CHART Step Procedure/Part name Q’ty Service points THROTTLE CABLE REMOVAL Follow the left “Step” fot removal. Spiral tube Throttle cable lock nut Throttle cable adjusting...

  • Page 250: Exhaust System

    HULL EXHAUST SYSTEM HOOD EXHAUST SYSTEM EXPLODED DIAGRAM 4 Nm (0.4 m kgf, 2.9 ft lb) 3 Nm (0.3 m kgf, 2.2 ft lb) 4 Nm (0.4 m kgf, 2.9 ft lb) 7 Nm (0.7 m kgf, 5.1 ft lb) 4 Nm (0.4 m kgf, 2.9 ft lb) REMOVAL AND INSTALLATION CHART Step...
  • Page 251 HULL HULL HOOD HULL EXPLODED DIAGRAM 7 Nm (0.7 m kgf, 5.1 ft lb) REMOVAL AND INSTALLATION CHART Step Procedure/Part name Q’ty Service points HULL DISASSEMBLY Follow the left “Step” for removal. Plate washer Packing Sponson Reverse the removal steps for installation.
  • Page 252 Printed on ohlorine-free paper...

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