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Yamaha XLT800 WaveRunner 2004 Owner's/Operator's Manual

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Summary of Contents for Yamaha XLT800 WaveRunner 2004

  • Page 3 BECOME ALERT! will help you to obtain maximum enjoyment YOUR SAFETY IS INVOLVED! from your new Yamaha. If you have any questions about the operation or mainte- WARNING nance of your watercraft, please consult a Failure to follow WARNING instructions Yamaha dealer.
  • Page 4: Table Of Contents

  • Page 5 EJU00993 GENERAL AND SAFETY INFORMATION Identification numbers ......1-1 Primary Identification (PRI-ID) number ...........1-1 Hull Identification Number (HIN) ....1-1 Engine serial number ......1-1 Emission control information ....1-2 Approval label of Emission control certificate ..........1-2 Manufactured date label ......1-2 Important labels ........1-3 Label location .........1-3 Warning labels ........1-4 Other labels ..........1-5...
  • Page 6: Identification Numbers

    Hull Identification Number (HIN) and engine serial number in the spaces pro- vided for assistance when ordering spare parts from a Yamaha dealer. Also record and keep these ID numbers in a separate place in case your watercraft is stolen.
  • Page 7: Emission Control Information

    EJU01846 Emission control information This engine conforms to 2004 U.S. Envi- ronmental Protection Agency (EPA) regula- tions for marine SI engines. EJU01392 Approval label of Emission control certificate This label is attached to the electrical box and the exhaust side of the crankcase. 1 Emission control information label EJU01393 Manufactured date label...
  • Page 8: Important Labels

    EJU00998 Important labels EJU01351 Label location...
  • Page 9: Warning Labels

    EJU01352 Warning labels...
  • Page 10: Other Labels

    EJU01354 Other labels...
  • Page 12: Safety Information

    Limitations on who may Safety information operate the watercraft The safe use and operation of this Yamaha recommends a minimum opera- watercraft is dependent upon the use of tor age of 16 years old. proper riding techniques, as well as upon Adults must supervise use by minors.
  • Page 13: Cruising Limitations

    Do not operate the watercraft in rough EJU01001 Cruising limitations 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 weather forecasts and the prevailing weather conditions before setting out on your watercraft.
  • Page 14: Operation Requirements

    EJU11603 Operation requirements All riders must wear a Coast Guard approved personal flotation device (PFD) that is suitable for personal watercraft use. Wear protective clothing. Severe internal injuries can occur if water is forced into body cavities as a result of falling into water or being near the jet thrust nozzle.
  • Page 15 Helmets meeting Snell or DOT standards are required for IJSBA-sanctioned races. You must decide whether to wear a hel- met while you ride for recreation. You should know that a helmet could help pro- tect you in certain kinds of accidents and that it could injure you in others.
  • Page 16: Recommended Equipment

    Obey the “Rules of ror can also be used as an emergency the Road,” and be sure to check behind signal. Contact your Yamaha dealer or the you before making a turn. (See Rules of Coast Guard for more information.
  • Page 17: Hazard Information

    EJU01003 EJU01847 Hazard information Watercraft characteristics Jet thrust turns the watercraft. Releasing 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-...
  • Page 18: Water-Skiing

    Reverse can be used to slow down or EJU01899 Water-skiing stop during slow speed maneuvering, You can use the watercraft for water-ski- such as when docking. Once the engine ing if it has the seating capacity to carry the is idling, shift to reverse and gradually operator, a rearward-facing spotter, and the increase engine speed.
  • Page 19 A second person should be on board as a When preparing to pull a skier, operate spotter to watch the skier; in most states it the watercraft at the slowest possible is required by law. Let the skier direct the speed until the watercraft is well away operator’s control of speed and direction from the skier and slack in the towrope is...
  • Page 20: Rules Of The Road

    Rules of the Road Whenever two vessels on the water meet one another, one vessel has the right-of- Yamaha watercraft is legally consid- way; it is called the “stand-on” vessel. The ered a powerboat. Operation of the vessel that does not have the right-of-way is watercraft must be in accordance with called the “give-way”...
  • Page 21: Rules When Encountering Vessels

    Rules when encountering Meeting If you are meeting another power vessel vessels head on, and are close enough to run the There are three main situations that you risk of collision, neither of you has the right- may encounter with other vessels which of-way! Both of you should alter course to could lead to a collision unless the Steering avoid an accident.
  • Page 22: Other Special Situations

    Overtaking Sailing vessel right-of-way If you are passing another vessel, you are Sailing vessels should normally be given the give-way vessel. This means that the the right-of-way. The exceptions to this are: other vessel is expected to maintain its 1. When the sailing vessel is overtaking the course and speed.
  • Page 23 This system uses buoys and signs with Remember, markings may vary by geo- distinctive shapes and colors to show regu- graphic location. Always consult local boat- latory or advisory information. These mark- ing authorities before riding your watercraft ers are white with black letters and orange in unfamiliar waters.
  • Page 24: To Get More Boating Safety Information

    Yamaha is the watercraft industry’s lead- EJU01181 To get more boating ing manufacturer to build awareness and support for boating education. In 1997, safety information Yamaha launched its GET W.E.T. (Water- Be informed about boating safety. Addi- craft Education and Training) initiative and...
  • Page 25: Enjoy Your Watercraft Responsibly

    EJU01006 Enjoy your watercraft responsibly You share the areas you enjoy when riding your watercraft with others and with nature. So your enjoyment includes a responsibility to treat these other people, and the lands, waters, and wildlife with respect and courtesy. Whenever and wherever you ride, think of yourself as the guest of those around you.
  • Page 26 –MEMO–...
  • Page 27: Features And Functions

    EJU01007 FEATURES AND FUNCTIONS Location of main components ....2-1 Operation of controls and other functions ...........2-5 Rear seat ..........2-5 Front seat ..........2-6 Hood ............2-7 Fuel tank filler cap ........2-8 Oil tank filler cap ........2-8 Fuel cock knob ........2-9 Engine stop switch .......2-10 Engine shut-off switch ......2-10 Choke knob ..........2-10 Throttle lever ........2-11...
  • Page 28: Location Of Main Components

    EJU01008 Location of main components 1 Handlebars Use to control direction. 2 Footwell Use to place feet for balance. 3 Footrest To keep proper balance while facing to the rear to watch the skier. 4 Bow eye Use to attach rope for transporting, mooring or towing the watercraft in an emergency.
  • Page 29 1 Fuel tank filler cap 7 Reverse gate 2 Rope holes Controls direction of jet thrust when in reverse. 3 Intake grate 8 Stern drain plugs Prevents debris from getting into the jet pump. Use to drain water in the bilge when the water- 4 Speed sensor craft is on dry land.
  • Page 30 1 Engine stop switch 9 Engine shut-off cord (lanyard) Push to stop the engine normally. Attach to wrist so that the engine stops if the 2 Clip operator falls off the watercraft. 0 Adjustable rearview mirrors Insert into the engine shut-off switch to enable A Multifunction meter starting of the engine.
  • Page 31 1 Spark plugs/Spark plug caps 8 Oil tank 2 Electrical box 9 Battery 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...
  • Page 32: Operation Of Controls And Other Functions

    EJU01009 Operation of controls and other functions EJU01211 Rear seat To remove the rear seat: Pull the rear seat latch 1 up, and then pull the seat off. To install the rear seat: Insert the projections on the front of the seat into the stays on the deck, and then push the rear of the seat down to lock it in place securely.
  • Page 33: Front Seat

    EJU01859 Front seat To remove the front seat: 1. Remove the rear seat. 2. Pull the front seat latch 1 up, and then pull the seat off. To install the front seat: 1. Insert the projections on the front of the seat into the stays on the deck, and then push the rear of the seat down to lock it in place.
  • Page 34: Hood

    EJU01213 Hood To open the hood, pull the latch 1 up, and then lift the hood up. To close the hood, push the hood down to lock it in place. NOTE: Make sure that the hood is properly secured before operating the watercraft.
  • Page 35: Fuel Tank Filler Cap

    EJU01012 Fuel tank filler cap To remove the fuel tank filler cap 1, turn it counterclockwise. NOTE: Make sure that the fuel tank filler cap is properly secured before operating the water- craft. EJU01214 Oil tank filler cap To remove the oil tank filler cap: 1.
  • Page 36: Fuel Cock Knob

    EJU01014 Fuel cock knob The fuel cock supplies fuel from the fuel tank to the carburetors. The fuel cock knob 1 positions are explained as follows and are shown in the illustration. OFF: With the fuel cock knob in this position, fuel does not flow.
  • Page 37: Engine Stop Switch

    EJU01015 Engine stop switch Push this switch 1 (red button) to stop the engine normally. EJU01016 Engine shut-off switch Insert the clip 1, on the end of the engine shut-off cord 2, under the engine shut-off switch 3 (black button). The engine will stop automatically when the clip is removed from the switch, such as if the operator falls off the watercraft.
  • Page 38: Throttle Lever

    EJU01018 Throttle lever Squeeze the throttle lever 1 to increase engine speed. Release the throttle lever to decrease engine speed or to return it to the idle posi- tion. EJU01216 Start switch Push the start switch 1 (green button) to start the engine.
  • Page 39: Cooling Water Pilot Outlet

    EJU10201 Cooling water pilot outlet This watercraft is equipped with cooling water pilot outlets. When the engine is running, cooling water is circulated in the engine, and then it is discharged from the pilot outlets. To check for proper operation of the cool- ing system, check that water is being dis- charged from the pilot outlets.
  • Page 40: Tilt Lever

    EJU01217 Tilt lever The tilt lever 1 is located in front of the glove compartment and is used to adjust the tilt of the handlebars. To adjust the tilt, pull the tilt lever up, and then move the handlebars up or down to the desired position.
  • Page 41: Shift Lever

    EJU01877 Shift lever The shift lever is located on the starboard (right) side of the watercraft and is used to control the reverse gate, which allows the watercraft to move into reverse or forward. When in the reverse position, the water- craft can be launched from a trailer, or backed up out of tight spots where you can- not turn around easily.
  • Page 42: Quick Shift Trim System (Qsts) Selector

    EJU01022 Quick Shift Trim System (QSTS) selector The QSTS selector 1 is located at the left handlebar grip and is used to adjust the trim angle of the watercraft. Operating the QSTS selector changes the angle of the jet thrust nozzle vertically. This changes the trim angle of the watercraft.
  • Page 43: Handgrip

    EJU01023 Bow down Turn the grip to A or B and the bow will go down while the watercraft is on plane. Bow down puts more of the bow in the water. This gives the watercraft more “hook,” which enhances turning performance. This position will also help the watercraft get up on plane more quickly.
  • Page 44: Engine Overheat Warning System

    CAUTION: If you cannot locate and correct the cause of the overheating, consult a Yamaha dealer. Continuing to operate at higher speeds could result in severe engine damage. NOTE: Press any button on the multifunction meter to stop the buzzer.
  • Page 45: Multifunction Meter

    EJU01221 Multifunction meter This meter contains following functions for help and convenience in operating the watercraft. 1 “MODE” button 2 “SET” button 3 “CODE” setting buttons 4 Tachometer 5 Speedometer 6 Fuel meter 7 Engine oil meter 8 Display for Clock, Hour meter, Trip meter and Trip timer 9 Warning light 0 Display for PADLOC and direction of warning...
  • Page 46: Padloc (Programmable Digital Locking Ignition)

    EJU01222 PADLOC (Programmable digital locking ignition) This feature is provided to deter unautho- rized use. The function allows you to choose either “START” or “LOCK” mode, as the situation requires, much as you would use an ignition key in a motor vehicle. If you have previously chosen “LOCK”...
  • Page 47: Selecting "Padloc" Mode

    3. Select your four-letter code by pressing the “A/SET,” “B,” or “C” buttons in a desired sequence. NOTE: If you do not press a button for more than 10 seconds, the display automatically turns off. This cancels the process of setting a code.
  • Page 48: Tachometer

    3. Enter your four-letter code by pressing the “A/SET,” “B,” or “C” buttons in the right sequence. NOTE: If you do not press a button for more than 10 seconds, the display automatically turns off. This cancels the process of selecting the mode.
  • Page 49: Speedometer

    EJU01226 Speedometer The meter shows the watercraft speed against water. EJU01227 Fuel meter The fuel meter is provided for convenient fuel level checking while operating the watercraft. The fuel meter has 4 segments which show the amount of fuel remaining in the fuel tank.
  • Page 50: Engine Oil Meter

    EJU01228 Engine oil meter The engine oil meter is provided for con- venient oil level checking while operating the watercraft. The engine oil meter has 3 segments which show the amount of oil remaining in the oil tank. NOTE: The indication of the segments differs depending on your operating condition.
  • Page 51: Hour Meter

    6. The buzzer will sound twice. The warn- ing light and “SET” blink for 2 seconds. Then the display turns to “CLOCK” and shows the time. NOTE: If the battery terminal is disconnected, the clock will be reset to 12:00. EJU01230 Hour meter The hour meter is provided to make it...
  • Page 52: Tripmeter

    EJU01163 Tripmeter A tripmeter is provided for measuring the approximate distance traveled. To show the tripmeter, press the “MODE” button until the display shows “TRIP” while the engine is running. After showing “TRIP ,” the display turns to “.MILE.” 1. When the display shows “.MILE,” press “MODE”...
  • Page 53: Oil Warning Indicator

    11.5 volts, the battery warning indicator, “VOLT” and the warning light begin to blink. The buzzer also starts sounding. If this happens during operation, beach the watercraft. Then recharge the battery and have the charging system inspected by a Yamaha dealer. 2-26...
  • Page 54: Storage Compartments

    EJU01236 Storage compartments A front storage compartment, a glove compartment, and seat storage compart- ments are provided. NOTE: Make sure that the storage compartments are properly secured before operating the watercraft. The storage compartments are not designed to be waterproof. If you carry objects that must be kept dry, such as the manuals, put them in a waterproof bag.
  • Page 55: Glove Compartment

    EJU20470 Glove compartment A glove compartment 2 is located in front of the seat. To open the glove compartment, slide the latch 1 toward you, and then lift up the lid. To close the glove compartment, push the lid down until it locks securely. Glove compartment: Capacity: 1.7 L (0.45 US gal, 0.37 Imp gal)
  • Page 56 –MEMO–...
  • Page 57: Operation

    EJU01040 OPERATION Fuel and oil ..........3-1 Gasoline ..........3-1 2-stroke engine oil ........3-2 Filling the fuel tank .........3-3 Filling the oil tank ........3-4 Pre-operation checks ......3-5 Pre-operation check list ......3-5 Pre-operation check points ....3-6 Operation ..........3-16 Engine break-in ........3-16 Launching the watercraft .....3-18 Starting the engine .......3-18 Stopping the engine ......3-21 Leaving the watercraft ......3-21...
  • Page 58: Fuel And Oil

    EJU01041 Fuel and oil This engine uses Yamaha’s oil injection system, which provides superior lubrication by ensuring the proper oil ratio for all operat- ing conditions. No fuel premixing is neces- sary except during the engine break-in period. Simply pour gasoline into the fuel tank and oil into the oil tank.
  • Page 59: 2-Stroke Engine Oil

    Gasohol containing ethanol 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. EJU10441...
  • Page 60: Filling The Fuel Tank

    EJU01045 Filling the fuel tank CAUTION: Be careful when refueling. Avoid getting water or other contaminants in the fuel tank. Contaminated fuel can cause poor running or engine damage. 1. Open the hood and remove the front storage compartment, to check the fuel level.
  • Page 61: Filling The Oil Tank

    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.
  • Page 62: Pre-Operation Checks

    EJU01346 Pre-operation checks EJU13470 Pre-operation check list Before operating this watercraft, perform the checks in the following check list. See the accompanying text in this chapter for details on how to perform the checks. WARNING If any item in the pre-operation check list is not working properly, have it inspected and repaired before operating the watercraft, otherwise an accident could occur.
  • Page 63: Pre-Operation Check Points

    EJU20570 Hull and deck Check the hull and deck for cracks or other damage. If any damage is found, have a Yamaha dealer repair the watercraft.
  • Page 64: Fuel And Oil Systems

    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.
  • Page 65: Stern Drain Plug

    EJU10531 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.
  • Page 66 EJU01969 Battery Check the battery condition and the elec- trolyte level. Check that the battery leads are tightened securely and there is no corrosion on the battery terminals. WARNING The battery must always be fully charged and in good condition. Loss of battery power may leave you stranded.
  • Page 67: Fire Extinguisher

    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 obtain one meeting the proper specifications.
  • Page 68 EJU01834 Throttle Squeeze and release the throttle lever several times to make sure that there is no hesitation in its travel. It should be smooth over the complete range, and spring back to the idle position when released. WARNING Before starting the engine, always check the operation of the throttle lever.
  • Page 69: Shift Lever And Reverse Gate

    EJU01245 Shift lever and reverse gate Check for proper operation of the shift lever and reverse gate. Make sure that the reverse gate goes down to its stopper position when the shift lever is pulled up. Also, make sure that the reverse gate goes up to its stopper position when shift lever is pushed down.
  • Page 70: Quick Shift Trim System (Qsts)

    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. 3-13...
  • Page 71: Jet Unit

    EJU01058 Jet unit Carefully check the jet intake for weeds, debris, or anything else that might restrict the intake of water. If the intake is clogged, cavitation could occur, reducing jet thrust, and possibly damaging the jet pump. In some cases, the engine may overheat because of lack of cooling water, and dam- age to the engine could result.
  • Page 72 EJU18351 Switches CAUTION: Do not run the engine for more than 15 seconds on land without supplying water. The engine can overheat. Check the start switch, the engine stop switch, and the engine shut-off switch for proper operation. Push the start switch 1 to start the engine.
  • Page 73: Operation

    Operation WARNING Before operating your watercraft, become familiar with all controls. Con- sult your Yamaha dealer about any con- trol function fully understand. Failure to understand how controls work could cause an accident or prevent you from avoiding an accident.
  • Page 74 3. Gradually open the throttle to 3/4 or less. 4. Continue operation at 3/4 throttle or less until the first tankful of fuel has been used. 5. Fill the tank with straight gasoline, and then proceed with normal operation. CAUTION: Failure to follow the engine break-in pro- cedure properly can result in severe damage to the engine.
  • Page 75: Launching The Watercraft

    EJU01247 Launching the watercraft Make sure that there are no obstructions behind you. After the watercraft is in the water, start the engine. Shift into reverse and move the watercraft back slowly. If there are waves, someone should make sure that the water- craft is not pushed into the trailer before backing away.
  • Page 76 2. Turn the fuel cock knob to the “ON” posi- tion. NOTE: Before starting the watercraft, after it has been sitting, remove the fuel tank filler cap to release any built-up pressure in the tank due to fuel expansion. 3. Attach the clip 1 to the engine shut-off switch 2.
  • Page 77 5. If the “LOCK” mode was chosen previ- ously, choose the “START” mode before starting the engine. (See page 2-20 for selecting “PADLOC” mode.) NOTE: If the initial setting of the PADLOC has not been done, the “START” mode is auto- matically selected.
  • Page 78: Stopping The Engine

    EJU01066 Stopping the engine To stop the engine, release the throttle lever, and then push the engine stop switch (red button). WARNING You need throttle to steer. Shutting off the engine can cause you to hit an obsta- cle you are attempting to avoid. A colli- sion could result in severe injury or death.
  • Page 79: Operating Your Watercraft

    EJU01068 EJU01191 Operating your watercraft Learning to operate your watercraft EJU01165 Getting to know your Before operating the watercraft, always perform the pre-operation checks listed on watercraft page 3-5. The short time spent checking the Operating your watercraft requires skills watercraft will reward you with added safety acquired through practice over a period of and reliability.
  • Page 80: Riding Watercraft With Passengers

    Wear protective clothing. Severe internal The passengers must always wear USCG injuries can occur if water is forced into body approved PFD and wetsuit bottom or equiv- cavities as result of falling into the water or alent. being near the jet thrust nozzle. Normal WARNING swimwear does not adequately protect Do not apply throttle when anyone is at...
  • Page 81: Starting The Watercraft

    EJU01837 Starting the watercraft WARNING Scan constantly for people, objects, and other watercraft. Be alert for con- ditions that limit your visibility or block your vision of others. Operate defensively at safe speeds and keep a safe distance away from people, objects, and other watercraft.
  • Page 82: Starting From A Dock

    EJU01073 Starting and boarding in shallow water 1. Do not start the engine in less than 60 cm (2 ft) of water. Put the watercraft in water that is deep enough, and then board the watercraft from the side or the rear.
  • Page 83: Boarding And Starting In Deep Water

    EJU01075 Boarding and starting in deep water WARNING Operator and passenger should prac- tice getting on board in shallow water before riding in deep water. Boarding in deep water requires more skill. The fatigue and exposure that could result after unsuccessful attempts to get back on the watercraft may increase the risk of injuries and drown- ing.
  • Page 84: Boarding With Passengers

    EJU01849 Boarding with passengers WARNING Severe internal injuries can occur if water is forced into body cavities as a result of being near the jet thrust nozzle. Do not apply throttle until each passen- ger is seated with his or her feet on the floor of the footwell and is holding on to the person in front of him or her.
  • Page 85: Capsized Watercraft

    NOTE: The heavier the total weight of the operator and passengers, the more difficult it will be to balance the watercraft. Do not operate the watercraft when the total weight exceeds 240 kg (530 lb) including any cargo. If it is difficult to balance the watercraft at a stand- still, proceed as follows: 1.
  • Page 86 Watch so you are not hit by the water- craft as it comes over. CAUTION: Be sure to remove the clip from the engine shut-off switch to shut the engine off, otherwise the engine can overheat, which can result in severe engine dam- age.
  • Page 87: Turning The Watercraft

    EJU01839 Turning the watercraft Steering control depends on the combi- nation of handlebar position and the amount of throttle. Water sucked in through the intake grate is pressurized by the impeller in the jet pump. As the pressurized water is expelled from the pump through the jet thrust nozzle, it creates thrust to move and steer the watercraft.
  • Page 88 WARNING Do not release the throttle when trying to steer away from objects—you need throttle to steer. A collision could result in severe injury or death. When operating at higher speeds, make gradual turns or slow down before turning. Sharp high-speed turns may cause the watercraft to slide side- ways or spin, throwing the operator passengers...
  • Page 89: Stopping The Watercraft

    EJU01850 Stopping the watercraft The watercraft is not equipped with a sep- arate braking system. It is stopped by water resistance when throttle lever released. From full speed, the watercraft comes to a complete stop in approximately 105 m (345 ft) after the throttle is released and the engine is stopped, although this dis- tance will vary depending on many factors, including gross weight, water surface condi-...
  • Page 90: Beaching The Watercraft

    EJU01081 Beaching the watercraft 1. Make sure no obstructions, boats or swimmers are near the beach. Release the throttle lever about 105 m (345 ft) before you reach the intended beaching area. 2. Approach the beach slowly and stop the engine before reaching land.
  • Page 91: Reverse On Waterways

    EJU01254 Reverse on waterways Reverse can be used for slow speed maneuvering when it is necessary to back up out of tight spots where you cannot turn around. Reverse can only be used to slow down or stop during low speed maneuver- ing, such as when docking.
  • Page 92: Post-Operation Checks

    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.
  • Page 93 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 compartment to air dry completely before reinstalling the seat.
  • Page 94: Transporting

    EJU01256 Transporting WARNING Always place the fuel cock knob in the “OFF” position when transporting the watercraft, otherwise fuel could leak out into the engine or engine compartment, which would create a fire hazard. When transporting the watercraft on a trailer, secure the tie downs to the trailer through the bow eye and stern rope hole.
  • Page 95: Maintenance And Care

    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 Replacing the fuse .......4-22...
  • Page 96: Storage

    It is advisable to have the watercraft serviced by a Yamaha dealer prior to stor- age. However, the following procedures can be performed by the owner. EJU01088...
  • Page 97 1. Put the watercraft on land in a horizontal position. 2. Open the flushing hose connector cap 1, and then insert the garden hose adapter 2 into the flushing hose con- nector 3 and turn it until it is securely connected.
  • Page 98: Lubrication

    4. Install the cap securely. 5. Lubricate all cables such as the throttle, choke, and steering cables. NOTE: Use a Yamaha Power Cable Luber and Yamaha Lube-Zall to pressure lubricate the cables and purge out any moisture between the inner and outer cables.
  • Page 99: Fuel System

    EJU20600 Fuel system WARNING GASOLINE VAPORS HIGHLY FLAMMABLE AND EXPLOSIVE! Do not smoke when refueling, and keep away from sparks, flames, or other sources of ignition. Stop engine before refueling. Refuel in a well-ventilated area with the watercraft in a horizontal position. Do not stand or sit on the watercraft while refueling in case of fire.
  • Page 100: Battery

    Top off the fuel tank with fresh gasoline and add one ounce of Yamaha Fuel Stabi- lizer and Conditioner to each gallon of fuel. NOTE: Use of Yamaha Fuel Stabilizer and Condi- tioner eliminates the need to drain the fuel system.
  • Page 101: Cleaning The Watercraft

    12 volts. Specific gravity (for reference): 1.28 at 20 °C (68 °F) It is recommended to have a Yamaha dealer check the specific gravity and to charge the battery. If you maintain the battery yourself, be sure to read and follow the instructions provided with the battery tester and charger you use.
  • Page 102: Maintenance And Adjustments

    Remember that failures that are the result of the installation of 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...
  • Page 103: Owner's/Operator's Manual And Tool Kit

    NOTE: A service manual is available for purchase through a Yamaha dealer for owners who have the mechanical skills, tools, and other equipment necessary to perform mainte- nance not covered by this Owner’s/Opera- tor’s Manual. EJU01874 Owner’s/Operator’s Manual and tool kit It is advisable always to carry the Owner’s/Operator’s Manual and tool kit 2...
  • Page 104: Periodic Maintenance Chart

    ) This mark indicates maintenance that you may do yourself. ❍ ) This mark indicates work to be done by a Yamaha dealer. MAINTENANCE INTERVAL THEREAFTER INITIAL...
  • Page 105: Inspecting The Fuel System

    Check the fuel system for leaks, cracks, or malfunctions. If any problem is found, do the necessary repair or replacement as required. If repair is necessary, consult a Yamaha dealer. Check: Carburetor for leakage. Fuel pump for malfunction or leakage.
  • Page 106 10 hours or first month of operation and every 200 hours or 24 months thereafter, or if water is found in the filter. Have a Yamaha dealer replace the fuel filter if necessary. WARNING Do not try to replace the fuel filter your- self.
  • Page 107: Inspecting The Oil Injection System

    Inspecting the oil injection system Check the oil injection system for leakage, cracks, or malfunctions. If necessary, have a Yamaha dealer repair the oil injection sys- tem. Check: Oil tank for damage, cracks or leakage. Oil tank for water or dirt.
  • Page 108: Inspecting The Jet Thrust Nozzle Angle

    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...
  • Page 109: Cleaning And Adjusting The Spark Plugs

    Do not attempt to diagnose any problems yourself. Have a Yamaha dealer service the watercraft. Remove and inspect the spark plug peri- odically; heat and deposits will cause the spark plug to slowly break down and erode.
  • Page 110: Inspecting The Yamaha Power Valve System (Ypvs)

    Since the YPVS is an important part of the engine and requires very sophisticated adjustment, have a Yamaha dealer, who has the necessary professional knowledge and experience, make this adjustment. CAUTION: The YPVS has been set and extensively tested at the Yamaha factory.
  • Page 111: Lubrication Points

    EJU12601 Lubrication points To keep moving parts sliding or rotating smoothly, coat them with water-resistant grease. 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.
  • Page 112 Steering cable (nozzle 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) 4-17...
  • Page 113: Adjusting The Choke Cable

    Shift cable (reverse gate end) YPVS cable Intermediate housing Using a grease gun, fill the intermediate housing with water-resistant grease through the grease nipple 1. Grease quantity: Initial 10 hours or 1 month: 33.0–35.0 cm (1.11–1.18 oz) Every 100 hours or 12 months: 6.0–8.0 cm (0.20–0.27 oz) EJU01261...
  • Page 114: Inspecting The Battery

    EJU01971 Inspecting the battery Check the level of the battery electrolyte and make sure that the negative and posi- tive leads are securely tightened. WARNING Battery electrolyte is poisonous and dangerous, causing severe burns, etc. Electrolyte contains sulfuric acid. Avoid contact with skin, eyes, or cloth- ing.
  • Page 115 CAUTION: Do not attempt to charge a battery hast- ily. Battery life could be shortened. It is recommended to have a Yamaha dealer charge the battery. If you charge the battery yourself, carefully read the battery charger instructions before charging and fol- low the points below.
  • Page 116: Adjusting The Carburetor

    Adjusting the carburetor The carburetor is a vital part of the engine and requires very sophisticated adjustment. Most adjusting should be left to a Yamaha dealer who has the professional knowledge and experience to perform it. However, the operator may adjust the trolling speed as part of the usual maintenance routine.
  • Page 117: Replacing The Fuse

    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 is necessary, have a Yamaha dealer bleed it. 4-22...
  • Page 118: Specifications

    EJU13590 Specifications MODEL Unit XLT800 ITEM WATERCRAFT CAPACITY Maximum people on board Number of people Maximum load capacity kg (lb) 240 (530) DIMENSIONS Length mm (in) 3,160 (124) Width mm (in) 1,220 (48) Height mm (in) 1,130 (45) Dry weight kg (lb) 322 (710) PERFORMANCE...
  • Page 119: Troubleshooting And

    EJU01115 TROUBLESHOOTING AND EMERGENCY PROCEDURES Troubleshooting ........5-1 Troubleshooting chart ......5-1 Emergency procedures ......5-4 Cleaning the jet intake and impeller ..5-4 Jumping the battery .......5-5 Towing the watercraft ......5-7 Submerged watercraft ......5-8...
  • Page 120: Troubleshooting

    If you have any trouble with your watercraft, use this section to check for the possible cause. If you cannot find the cause, or if the procedure for replacement or repair is not described in this Owner’s/Operator’s Manual, have a Yamaha dealer perform the necessary service. EJU13670 Troubleshooting chart...
  • Page 121 PAGE Fuel Empty Refill as soon as possi- Engine runs irregu- larly or stalls Stale or contaminated Have serviced by 4-10 Yamaha dealer Choke Knob pulled Push fully in 2-10 Fuel filter Clogged or water Have serviced by 4-11 pooled...
  • Page 122 REMEDY PAGE Cavitation Jet intake clogged Clean Watercraft slow or loses power Impeller damaged or Have serviced by — worn Yamaha dealer Engine over- Jet intake clogged Clean heated Fuel filter Clogged Have serviced by 4-11 Yamaha dealer Spark plug...
  • Page 123: Emergency Procedures

    EJU01118 Emergency procedures EJU01119 Cleaning the jet intake and impeller If weeds or debris get caught in the intake or impeller, cavitation can occur, causing jet thrust to decrease even though engine speed rises. If this condition is allowed to continue, the engine will overheat and may seize.
  • Page 124: Jumping The Battery

    2. Remove any weeds or debris from around the drive shaft, impeller, pump housing, and jet thrust nozzle. If debris is difficult to remove, consult your Yamaha dealer. CAUTION: Always avoid operating your watercraft in areas where weed growth is thick. If trav-...
  • Page 125: Connecting The Jumper Cables

    EJU01882 Connecting the jumper cables 1. Connect the positive (+) jumper cable 1 to the positive (+) terminals of both bat- teries. 2. Connect one end of the negative (–) jumper cable 2 to the negative (–) termi- nal of the booster battery 3. 3.
  • Page 126: Towing The Watercraft

    EJU01913 Towing the watercraft If the watercraft becomes inoperative in the water, it can be towed to shore. If the watercraft must be towed in an emergency using a towline, the operator should ride the watercraft, holding onto the handlebars. CAUTION: Tow the watercraft at 5 mph (8 km/h) or less, otherwise water could enter the...
  • Page 127: Submerged Watercraft

    EJU01908 Submerged watercraft If the watercraft is submerged or flooded with water, follow the procedure below and consult a Yamaha dealer as soon as possi- ble. Failure to do so may result in serious engine damage! In an emergency: 1. Beach the watercraft and remove the stern drain plugs to drain the water from the engine compartment.
  • Page 128 –MEMO–...
  • Page 129: Appendix

    EJU01124 APPENDIX Limited warranty........6-1 YAMAHA EXTENDED SERVICE (Y.E.S.) ..........6-3 Index ............6-4...
  • Page 130: Limited Warranty

    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.
  • Page 131 If you should move after you have purchased your new watercraft, please advise us of your new address by sending a postcard listing your Yamaha model name, engine number, dealer number [or dealer’s name] as it is shown on your warranty card, your name and new mailing address.
  • Page 132 This excellent Y.E.S. plan coverage is only available to Yamaha owners like you, and only while your Yamaha is still within the Yamaha Limited Warranty period. So visit your authorized Yamaha dealer to get all the facts. He can show you how easy it is to protect your investment with Yamaha Extended Service.
  • Page 133 Engine overheat warning system ..2-17 EJU01125 Index Engine serial number ......1-1 Engine shut-off cord (lanyard) ....3-14 Engine shut-off switch ......2-10 2-stroke engine oil........3-2 Engine stop switch ........ 2-10 Enjoy your watercraft responsibly ..1-20 Adjusting the carburetor ......4-21 Adjusting the choke cable .....
  • Page 134 PADLOC initial setting......2-19 Inspecting the oil injection system..4-12 PADLOC (Programmable digital Inspecting the shift cable....... 4-13 locking ignition) ........2-19 Inspecting the Yamaha Power Periodic maintenance chart..... 4-9 Valve System (YPVS) ......4-15 Post-operation checks......3-35 Pre-operation check list......3-5 Jet unit...........
  • Page 135 Troubleshooting ........5-1 Troubleshooting chart ......5-1 Turning the watercraft ......3-30 United States Coast Guard ....1-19 Warning labels ........1-4 Watercraft characteristics...... 1-12 Watercraft Education and Training..1-19 Water separator ........3-7 Water-skiing .......... 1-13 YAMAHA EXTENDED SERVICE (Y.E.S.)............ 6-3...
  • Page 136 YAMAHA MOTOR CORPORATION, USA Printed in USA Jun. 2003—1.4 × 1 CR F1F-F8199-12 Printed on recycled paper...

This manual is also suitable for:

2004 xlt800 waverunner

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