Yamaha WaveRunner XL1200 Manuals

Manuals and User Guides for Yamaha WaveRunner XL1200. We have 1 Yamaha WaveRunner XL1200 manual available for free PDF download: Service Manual

Yamaha WaveRunner XL1200 Service Manual (253 pages)

Brand: Yamaha | Category: Boat | Size: 11.8 MB

How to Use this Manual
3
Model Indication
3
Warnings, Cautions and Notes
4
How to Read Descriptions
5
Symbols
6
Index
7
General Information
8
Engine Serial Number
9
Hull Identification Number (HIN)
9
Primary ID Number
9
Pump Serial Number
9
Fire Prevention
10
Safety While Working
10
Self-Protection
10
Ventilation
10
Good Working Practices
11
Safe Disassembly and Assembly
12
Special Tools
13
Specifications
15
General Specifications
16
Engine Data
18
Maintenance Specifications
18
Jet Unit Data
19
Electrical Data
20
Hull and Hood Data
20
Tightening Torque
21
Fuel Line Routing
23
Cable Line Routing
27
Periodic Inspection and Adjustment
31
Maintenance Interval Chart
32
Control System Periodic Service
33
Pivot Shaft Bearing Inspection
33
Steering Cable Inspection and Adjustment
33
Throttle Cable Inspection and Adjustment
34
Choke Cable Inspection and Adjustment
35
Shift Cable Inspection and Adjustment
36
Fuel Filter Inspection
37
Fuel System Maintenance
37
Trolling Speed Inspection and Adjustment
37
Oil Pump Cable Inspection and Adjustment (XL 1200)
39
Oil Injection System Maintenance
39
Oil Filter Inspection
39
Carburetor Adjustment
39
Oil Injection Pump Air Bleeding
40
Power Unit Maintenance
41
Spark Plug Inspection
41
Battery Inspection
42
Electrical System Maintenance
42
Filling the Battery
43
Bilge Strainer Inspection
44
Impeller Inspection
44
Jet Pump Unit Maintenance
44
Drain Plug Inspection
45
Fuel System
47
Fuel Line Exploded Diagram
49
Fuel Line - Removal and Installation Chart
49
Fuel Cock Inspection
51
Oil Tank - Removal and Installation Chart
52
Oil Tank Exploded Diagram
52
Check Valve Inspection
53
Oil Tank Inspection
53
Fuel Tank - Removal and Installation Chart
54
Fuel Tank Removal - Exploded Diagram
54
Fuel Tank Exploded Diagram
55
Fuel Tank Inspection
56
Pipe Joint Inspection
56
Pipe Joint Installation
56
Carburetor Unit Removal - Exploded Diagram
57
Carburetor Removal - Exploded Diagram
59
Throttle Valve Synchronization Inspection and Adjustment
60
Carburetor Exploded Diagram
62
Body Assembly Inspection
63
Diaphragm Inspection
63
Float Arm Inspection
63
Needle Valve Inspection
63
Carburetor Assembly
64
High and Low Screws Adjustment
64
High and Low Speed Screws Inspection
64
Jet and Carburetor Body Inspection
64
Fuel Pump Exploded Diagram
65
Filter Inspection
66
Fuel Pump Inspection
66
Oil Line Exploded Diagram
67
Oil Pump Exploded Diagram
68
Oil Hose Inspection
69
Oil Pump Inspection
69
Ring Rubber Inspection
69
Ring Rubber Installation
69
Power Unit
70
Engine Unit Removal - Exploded Diagram
73
Coupling Clearance Inspection
75
Mount Bracket Inspection
75
Shim Removal
75
Reed Valve Exploded Diagram
76
Reed Valve Inspection
78
Exhaust Ring Exploded Diagram
79
Exhaust Chamber Removal
81
Exhaust Chamber Exploded Diagram
83
Muffler Exploded Diagram
85
Cylinder Head Exploded Diagram
87
Cylinder Head Inspection
89
Cylinder Exploded Diagram
90
Cylinder Inspection
92
Piston Exploded Diagram
93
Piston Inspection
94
Piston Pin Clip Removal and Installation
94
Piston Pin and Bearing Inspection
95
Piston Ring Inspection
95
Flywheel Magneto and Base Exploded Diagram
97
Flywheel Magneto Inspection
99
Flywheel Magneto Removal and Installation
99
Coupling Flange Removal and Installation
99
Coupling Flange Inspection
99
Idle Gear Assembly Inspection
100
Electrical Unit Exploded Diagram
101
Starter Motor Exploded Diagram
103
Armature Inspection
104
Pinion Inspection
104
Brush Holder Inspection
105
Cover Inspection
105
Crankcase Exploded Diagram
106
Crankcase Inspection
108
Crankcase Installation
108
Crankshaft Exploded Diagram
109
Crankshaft Inspection
111
Intermediate Housing Removal - Exploded Diagram
113
Bearing Inspection/Coupling Inspection
115
Bearing Installation
115
Bearing Removal
115
Coupling Removal and Installation
115
Oil Seal Installation
116
Jet Pump Unit
117
Jet Pump Unit Removal - Exploded Diagram
118
Nozzle Deflector and Reverse Gate Exploded Diagram
119
Nozzle, Duct and Intake Exploded Diagram
120
Housing Installation
121
Impeller and Drive Shaft Exploded Diagram
122
Drive Shaft Removal
123
Drive Shaft Inspection
123
Bearing Inspection
123
Drive Shaft Installation
124
Intake Duct Exploded Diagram
126
Bushing and Oil Seal Installation
127
Housing Inspection
127
Oil Seal and Bushing Removal
127
Seal Rubber Inspection
127
Cooling and Bilge System Exploded Diagram
128
Electrical System
129
Electrical Components Diagram
131
Harness Installation
133
Electrical Unit Diagram
134
Electrical Diagram
136
Electrical Analysis
138
Low Resistance Measurement
138
Ignition System Wiring Diagram
139
Ignition Spark Gap
141
Ignition Coil Inspection
142
Spark Plug Cap Inspection
142
Charge Coil Inspection
143
Engine Stop Switch Check
143
Pulser Coil Inspection
144
Thermo Switch Inspection
144
CDI Unit Inspection
145
Starting System Wiring Diagram
146
Starter Switch
147
Wiring Connection
147
Starter Relay
147
Fuse
147
Charging System Wiring Diagram
149
Lighting Coil
150
Rectifier Regulator
150
Indication System Wiring Diagram
151
Fuel Level Sensor
152
Oil Level Sensor
152
Multi-Function Meter - Instrument Indicating Function
153
Multi-Function Meter - Security Function
154
Multi-Function Meter - Display Function
155
Hull and Hood
158
Engine Hood Removal - Exploded Diagram
161
Handlebar Removal - Exploded Diagram
162
Handlebar Assembly Installation
163
Handlebar Exploded Diagram
164
Handlebar Inspection
165
Handlebar Switch Installation
165
Steering Column Exploded Diagram
166
Bushing Inspection
167
Bushing Joint Installation
167
Steering Column Inspection
167
Shift Lever Exploded Diagram
168
Engine Hood Exploded Diagram
169
Steering Cable Exploded Diagram
171
Jet Pump Side Cable Joint Installation
172
Steering Cable Inspection
172
Throttle Cable and Choke Cable Exploded Diagram
173
Throttle Cable and Choke Cable Inspection
174
Cable Installation
174
Shift Cable Exploded Diagram
175
Shift Cable Inspection
176
Seat and Storage Box Exploded Diagram
177
Battery Case Exploded Diagram
178
Exhaust System Exploded Diagram
179
Exhaust System Inspection
180
Deck Exploded Diagram
181
Ventilation System Inspection
182
Gunwale Exploded Diagram
183
Mat Exploded Diagram
184
Hull Exploded Diagram
185
Hull Repair - Deep Scratching
186
Hull Repair - Light Scratching
186
Hull Damage (Punctured)
187
Applying a Graphic
190
Removing a Graphic
190
Trouble Analysis
191
Trouble Analysis Chart
192
Supplementary Service Manual: Waverunner XL700
194
Table of Contents
196
XL700: Contents
196
XL700 Engine Serial Number
199
XL700 Identification Numbers
199
XL700 Primary ID Number
199
XL700 Pump Serial Number/Hull Identification Number (HIN)
199
Primary I.D. Number
199
Hull Identification Number (H.I.n)
199
XL700 - Special Tools
200
Measuring
200
Removal and Installation
200
- XL700 General Specifications
  201
- XL700 Maintenance Specifications
  202
Engine
202
Jet Unit
203
Electrical
203
XL700 Tightening Torque
204
Specified Torque
204
- Fuel Line Routing (XL700)
  205
- Cable Line Routing (XL700)
  207
- Maintenance Interval Chart (XL700)
  209
- XL700 Periodic Service
  210
- Fuel System Service (XL700)
  210
- Trolling Speed Inspection and Adjustment (XL700)
  210
- Carburetor Adjustment (XL700)
  210
- Fuel Line Diagram (XL700)
  211
Exploded Diagram
211
Removal and Installation Chart
211
Carburetor Unit Removal Exploded Diagram (XL700)
212
Removal and Installation Chart
212
Carburetor Exploded Diagram (XL700)
214
Removal and Installation Chart
214
- High and Low Speed Screws Adjustment (XL700)
  215
- Throttle Valve Synchronization Inspection and Adjustment (XL700)
  215
Service Points
215
Removal and Installation Chart
217
Reed Valve Exploded Diagram (XL700)
219
Removal and Installation Chart
219
Exhaust Ring Exploded Diagram (XL700)
220
Removal and Installation Chart
220
Exhaust Chamber Removal Exploded Diagram (XL700)
221
Removal and Installation Chart
221
Exhaust Chamber Exploded Diagram (XL700)
222
Removal and Installation Chart
222
Cylinder Head Exploded Diagram (XL700)
223
Cylilnder Head

223
- Removal and Installation Chart
  223
- Cylinder Exploded Diagram (XL700)
  224
- Removal and Installation Chart
  224
- Cylinder Inspection (XL700)
  225
- Service Point
  225
- Piston Exploded Diagram (XL700)
  226
- Removal and Installation Chart
  226
- Piston Inspection (XL700)
  227
- Service Point
  227
- Flywheel Magneto and Base Exploded Diagram (XL700)
  228
- Removal and Installation Chart
  228
  - Coupling Flange Removal and Installation (XL700)
    230
  - Flywheel Magneto Removal and Installation (XL700)
    230
- Service Points
  230
- Electrical Unit Exploded Diagram (XL700)
  231
- Removal and Installation Chart
  231
- Intermediate Housing Exploded Diagram (XL700)
  233
Intermediate Shaft Housing

233
- Removal and Installation Chart
  233
- Coupling Removal and Installation (XL700)
  234
- Service Point
  234
  - Electrical Components (XL700)
    235
  - Electrical Diagram (XL700)
    236
  - Electrical Analysis (XL700)
    237
  - Peak Voltage Measurement (XL700)
    237
  - Ignition System Wiring Diagram (XL700)
    239
  - Peak Voltage
    240
- Charge Coil
  242
- Pulser Coil
  242
- Thermo Switch
  242
- CDI Unit
  243
- Starting System Wiring Diagram (XL700)
  244
Charging System

245

Yamaha Categories

Motorcycle Musical Instrument Electronic Keyboard Receiver Amplifier

More Yamaha Manuals

Yamaha WaveRunner XL1200 Manuals

Yamaha WaveRunner XL1200 Service Manual (253 pages)

Table of Contents

Cylilnder Head

Intermediate Shaft Housing

Charging System

Related Products

Yamaha Categories