WaveRunner XL1200Ltd OWNER’S/OPERATOR’S MANUAL READ THIS MANUAL CAREFULLY BEFORE OPERATION! U.S.A.Edition YAMAHA MOTOR CORPORATION, U.S.A.
E EJU00270a TO THE OWNER Thank you for choosing a Yamaha water vehicle. This owner’s/operator’s manual contains information you will need for proper operation, maintenance, and care. A thorough understanding of these simple instructions will help you to obtain maximum enjoyment from your new Yamaha. If you have any questions about the operation or maintenance of your water vehicle, please consult a Yamaha water vehicle dealer. YAMAHA MOTOR CO., LTD.
EJU00273 CONTENTS E GENERAL AND SAFETY INFORMATION 1 FEATURE AND FUNCTIONS 2 OPERATION AND RIDING 3 MAINTENANCE AND CARE 4 TROUBLESHOOTING AND EMERGENCY PROCEDURE 5 INDEX 6 READ THIS OWNER’S / OPERATOR’S MANUAL CAREFULLY BEFORE OPERATING YOUR WATER VEHICLE.
E EJU00274 Chapter 1 GENERAL AND SAFETY INFORMATION IDENTIFICATION NUMBER RECORDS ............................................. 1-1 Primary identification (PRI-ID) number ............................................... 1-1 Hull identification number (H.I.N) ....... 1-1 Engine serial number ......................... 1-1 EMISSION CONTROL INFORMATION......................................1-2 IMPORTANT LABELS .......................... 1-3 Location.............................................. 1-3 Labels.......
E EJU00275a IDENTIFICATION NUMBER RECORDS Record your Primary identification (PRI-ID) number, Hull identification number (H.I.N) and Engine serial number in the spaces provided, to assist you in ordering spare parts from your Yamaha water vehicle dealer. Also record and keep these ID numbers in a separate place in case your water vehicle is stolen. EJU00276a PRIMARY IDENTIFICATION (PRI-ID) NUMBER The PRI-ID number is stamped on a label 1 attached to the inside of the engine compartment.
E EJU00631a EMISSION CONTROL INFORMATION This engine conforms to 2000 U.S. Environmental Protection Agency (EPA) regulation for marine SI engines. ● Approved label of Emission control certificate This label is attached to the electrical box. 1 Emission control information label ● Manufactured date label This label is attached to the electrical box.
E EJU00293 IMPORTANT LABELS LOCATION 1-3
E LABELS Warning labels 1 2 3 4 5 6 1-4
E 7 8 9 @ A B 1-5
E Caution labels C D E G F H I 1-6
E Other labels J K L 1-7
E A responsible adult must supervise operation of this vehicle by minors. Many states have minimum age and education requirements. Always check states and all applicable local boating laws that apply to you before you operate the vehicle.
E EJU00613a CRUISING LIMITATIONS ● ● ● ● Do not jump boat wakes or follow another boat or watercraft too closely. You increase your risk of colliding with another boat, which could result in severe injury or death. Do not jump waves, wakes, or any objects. You risk severe impact injuries. Jumping can also cause damage to the vehicle. Do not operate the vehicle in rough water, bad weather or when visibility is poor; this may lead to an accident causing injury or death.
E ● Both operator and passengers must always wear a U.S. Coast Guard approved personal flotation device (vesttype) because of the drowning hazards associated with water sports. ● ● 1 U.S. Coast Guard-approved personal flotation device 2 Wet suit 3 Water shoes 4 Gloves 5 Eye protection ● ● ● Strong streams of water from the jet nozzle, or impact with the water surface can be dangerous. Both operator and passengers must wear wet suits. Normal swimming attire may not adequately protect you.
E ● How should you decide if a helmet’s potential safety benefits outweigh its potential risks for you? Consider your particular riding conditions. Consider factors such as your riding environment and your riding style and ability. Also consider the likelihood of traffic congestion, and the water surface conditions. If you decide to wear a helmet based upon your riding circumstances, choose one carefully. Look for a helmet designed for personal watercraft use, if possible.
E ● ● ● Always watch carefully for swimmers. Stay away from swimming areas. Swimmers are hard to see and you could accidentally hit someone in the water. Avoid being hit by another boat! You should always take the responsibility to watch for traffic, other boaters may not be watching for you. If they don’t see you, or you maneuver more quickly than other boaters expect, you risk a collision. Maintain a safe distance from other boats or watercraft, and also watch for boat’s ski ropes or fishing lines.
E ● EJU00315a WATER VEHICLE CHARACTERISTICS ● ● ● ● Jet thrust turns the vehicle. If you are going faster than trolling speeds (the lowest maneuvering speed), you must use throttle to turn. If you release the throttle completely, you cannot turn-even if you turn the handlebars. Practice turning in an open area without obstructions until you have a good feel for this maneuver. Yamaha water vehicles are water-jet propelled. The jet pump is directly connected to the engine.
E EJU00655a WATER SKIING You can use this water vehicle to pull a water skier. Keep the following in mind when using the vehicle for skiing. ● Because this water vehicle does not have the size or thrust of a traditional ski boat, pulling a skier can affect steering and handling. ● Your control while pulling a skier is affected by the skier’s ability, as well as water and weather conditions. ● The operator should be comfortable carrying passengers before attempting to pull a skier.
E STEERING AND SAILING RULES AND SOUND SIGNALS EJU00319a RULES OF THE ROAD Your Yamaha water vehicle is legally considered a power boat. Operation of this water vehicle must be in accordance with the rules and regulations governing the waterway on which it is used. Just as there are rules which apply when you are driving on streets and highways, there are waterway rules which apply when you are riding your water vehicle.
E In other words, follow the standard rules except when a collision will occur unless both vessels try to avoid each other. If that is the case, both vessels become “Give-Way” vessels.
E Overtaking If you are passing another vessel, you are the “Give-Way” vessel. This means that the other vessel is expected to maintain its course and speed. You must stay out of its way until you are clear of it. Likewise, if another vessel is passing you, you should maintain your speed and direction so that the other vessel can steer itself around you. OTHER SPECIAL SITUATIONS There are three other rules you should be aware of when riding your water vehicle around other vessels.
E This system uses buoys and signs with distinctive shapes and colors to show regulatory or advisory information. These markers are white with black letters and orange boarders. They signify speed zones, restricted areas, danger areas, and general information. Remember, markings may vary by geographic location. Always consult local boating authorities before riding your water vehicle in unfamiliar waters.
E EJU00320a EJU00322a TO GET MORE BOATING SAFETY INFORMATION ENJOY YOUR WATER VEHICLE RESPONSIBLY Be informed about boating safety. Additional publications and information can be obtained from many organizations, including the following. United States Coast Guard Consumer Affairs Staff (G-BC) Office of Boating, Public, and Consumer Affairs U.S. Coast Guard Headquarters Washington, D.C. 20593-0001 Boating Safety Hotline: 1-800-368-5647 ● ● Personal Watercraft Industry Association (PWIA) 401 N.
E EJU00323a Recommended gasoline: Unleaded regular gasoline with a minimum octane rating of: 86 (Pump octane number)=(R+M)/2 90 (Research octane number) FUEL REQUIREMENTS GASOLINE (PETROL) WARNING GASOLINE (PETROL) AND ITS VAPORS ARE HIGHLY FLAMMABLE AND EXPLOSIVE! ● Do not smoke when refueling, and keep away from sparks, flames, or other sources of ignition. ● Stop the engine before refueling. ● Refuel in a well-ventilated area. Do not stand or sit on the vehicle while refueling in case of fire.
E – MEMO –
E EJU00326 Chapter 2 FEATURES AND FUNCTIONS LOCATION OF MAIN COMPONENTS . 2-1 OPERATION OF CONTROLS AND OTHER FUNCTIONS............................. 2-5 Front seat ........................................... 2-5 Rear seat............................................ 2-5 Front hood.......................................... 2-6 Fuel and oil tank filler caps................. 2-7 Fuel cock............................................ 2-7 Engine stop switch .............................
E EJU00327 LOCATION OF MAIN COMPONENTS 1 Handlebars Control steering direction 2 Fuel tank filler cap Unscrew counterclockwise to add fuel Tighten securely clockwise 3 Rope hole Rope attachment point for transporting, mooring 4 Footrest floor To place feet for balance 5 Foot steps To be used by the observer as a footrest when pulling a water skier 6 Front seat latch 7 Rear seat latch Locking and releasing the seat rock 8 Intake grille Prevents debris from getting into the jet pump 9 Speed sensor 2-1
E 1 Cooling water pilot outlet Check point of cooling water flowing 2 Bow eye Rope attachment point for transporting, mooring or towing the water vehicle in an emergency 3 Front storage compartment 4 Front hood 5 Fuel cock Select fuel flow from normal or reserve area of the fuel tank, or shut off fuel flow 6 Oil tank filler cap Unscrew counterclockwise to add oil Tighten securely clockwise 7 Choke Knob Pull knob when starting a cold engine 8 Fire extinguisher container 9 Cleat Rope attachment point for pul
E 1 Engine stop switch lanyard (Cable) By connecting to the engine stop lanyard switch and operator will stop the engine If the operator falls off the vehicle 2 Engine stop switch Depress to stop the engine 3 Lock-plate Insert the lock-plate in the engine stop lanyard switch to allow the engine to be started Remove the lock-plate to stop the engine or prevent it from starting 4 QSTS (Quick Shift Trim System) controller Controls thrust trim for different operating conditions 5 Engine stop lanyard switch Rem
E 1 Spark plug / spark plug cap 2 Electrical box Contains most electrical components in this water resistant box 3 Flush hose connector To flush the engine cooling water passages 4 High tension cord Deliver electrical current to the spark plug 5 Muffler box 6 Fuel filter Prevents dust contained in fuel from getting into the carburetor 7 Fuel tank 8 Oil tank 9 Battery 2-4
E EJU00328 OPERATION OF CONTROLS AND OTHER FUNCTIONS EJU00714 FRONT SEAT There is a seat latch lever 1 at the rear of the seat to remove the front seat. Removal Pull the front seat latch lever up, then lift the rear of the seat, and pull back. Installation Position the seat on the deck so the front projections on the underside of the seat fits into the stays on the deck. Then push the rear of the seat down until the seat locks latch securely.
E Installation Position the seat on the deck so the front projections on the underside of the seat fits into the stays on the deck. Then push the rear of the seat down until the seat locks latch securely. EJU00703 FRONT HOOD The front hood is secured at the rear by one latch. Pull the latch lever 1 up and lift the hood, to open it. NOTE: Make sure the front hood is firmly secured with the latch before riding.
E EJU00347 FUEL AND OIL TANK FILLER CAPS To remove the fuel or oil tank filler cap, turn it counterclockwise. 1 Fuel tank filler cap 2 Oil tank filler cap Be sure to tighten the caps securely before riding. EJU00704 FUEL COCK The fuel cock 1 supplies fuel from the fuel tank to the carburetor. The fuel cock has three positions; OFF With the knob in this position, fuel does not flow. Always turn the knob to this position when the engine is not running.
E EJU00705 ENGINE STOP SWITCH The engine can be stopped normally by pressing the red button 1. EJU00706a ENGINE STOP LANYARD SWITCH The engine can be also stopped if you fall off, or in case of an emergency, when the lock plate 1 attached to the lanyard 2 is pulled out from the engine stop lanyard switch 3. Should the lock-plate be removed for any reason, the engine stops by itself. EWJ00048 WARNING ● ● Always attach the engine stop switch lanyard (cable) to your left wrist BEFORE starting the engine.
E EJU00707 THROTTLE LEVER Moving the throttle lever 1 toward the handlebar increases engine speed. When the throttle lever is released, it returns to its closed (idle) position through the action of a return spring. EWJ00049 WARNING Before starting the engine, always check the operation of the throttle lever. It should move smoothly through its full range of operation, and should spring back to the idle position when released.
E EJU00709 COOLING WATER PILOT OUTLET This engine is equipped with a cooling-water pilot outlet at both sides of the deck. Check that water comes out of the outlet while the engine is running. If you do not see any water at the outlet, cooling water may not be circulating in the engine. In that case, stop the engine and check for the cause (Refer to overheat warning system). NOTE: If water cooling passages on the engine are dry it will take about 20 seconds to reach water at the outlet after starting.
E EJU00670 TILT HANDLE LEVER Tilt handle lever 1 is located in front of the glove compartment to adjust the tilt position of the handle. Adjusting the handle position 1) Pull up the tilt handle lever. 2) Move the handle up or down in an appropriate position you desire. 3) Push the lever and put force on the handle up and down to make sure that it is securely fastened. WARNING ● ● 2-11 Never touch the tilt handle lever during operation.
E EJU00710 SHIFT LEVER This water vehicle is equipped with a shift lever. By placing the shift lever in “Forward” or “Reverse”, the direction of the jet thrust can be changed. Use “Reverse” for slowspeed maneuvering only. It is useful when launching the vehicle from a trailer, or when it is necessary to back up out of tight spots where you cannot turn around. To shift in Reverse, close the throttle and pull the shift lever up using your right hand.
E EJU00360a QUICK SHIFT TRIM SYSTEM(Q.S.T.S.) The trim angle of your water vehicle can be adjusted by operating the Q.S.T.S. Operating the trim shifting grip 1 changes the angle of the jet (output) nozzle at the stern. The nozzle angle changes the trim angle of the vehicle to one of five positions. NOTE: There are two positions A and B for bow down, neutral “N”, and two positions C and D for bow up. Changing the trim angle of the vehicle 1) Set the throttle lever to half open (3,000 r/min) or less.
E Shifting to “Bow Down” “Bow Down” puts more of the bow in the water. This gives the water vehicle more “hook,” which enhances turning performance. This position will also help the water vehicle get up on plane more quickly. At higher speeds, however, the water vehicle will have greater tendency to “bow steer” and follow waves and wakes in the water. Fuel economy and maximum speed are also reduced. Shifting to “Bow Up” “Bow Up” puts less of the bow in the water.
E EJU00696a OVERHEAT WARNING SYSTEM The engine has an overheat warning device. If the engine starts to overheat, the warning lamp(LED), indicator and “W.TEMP” on the meter begin to blink and the buzzer sounds intermittently. If this happens, reduce the engine speed and return to beach at low speed. If there is no water discharge at the cooling water pilot outlet while the engine is running, check the jet intake and impeller for clogging.
E If the initial overheat warning is ignored, engine and exhaust system heat can increase, particularly if the vehicle continues to be operated at higher speed. If so, the warning indicators and buzzer will change from intermittent to constantly on and the overheat system will stop ignition to the engine to reduce the risk of severe overheating. The engine cannot be restarted until it cools down, so it may be necessary to have the vehicle towed back to the beach.
E CAUTION: This model is equipped with a catalytic converter. Return to shore at low speed (below 4000 r/min) if the warning indicator and buzzer are on, and the display shows “EXHST.” Have your vehicle inspected and serviced by a Yamaha water vehicle dealer if the engine stopped due to overheating. NOTE: ● The buzzer stops sounding if any button on the meter is pressed. ● Ask a Yamaha water vehicle dealer to inspect the vehicle if there is no apparent reason for overheating.
E EJU00698 MULTIFUNCTION METER This meter contains following functions for the help and convenience of operation.
E EJU00711a PADLOC (Programmable digital locking ignition) This feature is provided to deter unauthorized use. The function allows you to chose either “START” or “LOCK” mode, as the situation requires, much as you would use a main switch key in a motor vehicle. If you have previously chosen “LOCK” 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.
E 3) Select your 4-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 of a code. 4) After completing code setting, the buzzer will sound 3 times and the display will show “SET”. Lastly, the display turns off and the warning lamp (LED) turns on again. After the meter has displayed this sequence, reconnect the blue connector.
E 3) Enter your 4-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. 4) If the code entered is correct, the mode will change from the previous mode to either “START” or “LOCK”. Then the mode display and buzzer will operate for 2 seconds.
E EJU00384 Speedometer The meter shows the vehicle speed in miles per hour (mph). EJU00386a Fuel meter The fuel meter is provided for convenient fuel level checking while riding. The fuel meter has four segments which show the amount of fuel remaining in the fuel tank. NOTE: The indication of the segments differs on your operating condition. Use the meter as a reference.
E EJU00387a Engine oil meter The engine oil meter is provided for convenient oil level checking while riding. The engine oil meter has three segments which show the amount of oil remaining in the oil tank. NOTE: The indication of the segments differs on your operating condition. Use the meter as a reference. EJU00388a Clock A 12-hour clock is provided in this meter. To show the clock, press the “MODE” button until the display shows “CLOCK”.
E 6) The buzzer will sound twice. The warning lamp (LED) and “SET” blinks for two seconds. Then the display turns to “CLOCK” and shows the time. NOTE: After the battery terminal is disconnected, the clock will be reset to 12:00. EJU00390 Hour meter The hour meter is provided to make it easy to follow the maintenance schedule. The meter shows the hours of engine operation that have elapsed since the vehicle was new. To show the hour meter, press the “MODE” button until the display shows “HOUR.M”.
E EJU00712 Trip meter A trip meter is provided for measuring the approximate traveled distance in miles. To show the trip meter, press the “MODE” button until the display shows “TRIP”. After showing “TRIP”, the display turns to “MILE”. 1) When the display shows “.MILE”, press the “MODE” button for at least 2 seconds. 2) The buzzer will sound twice. The warning lamp(LED) and “.MILE” blink for 2 seconds, and “000” is displayed. Now the meter will start to measure the distance you will travel.
E EJU00717 Oil warning indicator If the oil remaining in the tank drops to about 1.4 L (0.37 US gal, 0.31 Imp gal) or the oil filter is clogged, the oil level segment, the oil warning indicator, “OIL” and the warning lamp(LED) begin to blink. The buzzer also starts sounding intermittently. If the oil warning indicator begins to blink, refill with engine oil as soon as possible. NOTE: If the warning indicator blinks with adequate oil in the tank, check the oil filter for clogging.
E EJU00720a Exhaust temperature warning indicator If the exhaust system becomes too hot, the exhaust temperature warning indicator will come on. Also, the warning lamp (LED) will blink and the buzzer will start sounding intermittently. Refer to “Exhaust temperature warning system” on page 2-16. EJU00719 Battery warning indicator If the battery voltage becomes less than 11.5 volts, the battery warning indicator, “VOLT” and the warning lamp(LED) begin to blink. The buzzer also starts sounding.
E EJU00721a STORAGE COMPARTMENTS The storage compartment(s) is provided to store the manuals, tools, and other equipment for cruising. Make sure all storage compartments are firmly secured before riding. NOTE: The storage compartment(s) is not designed to be waterproof. If you put the manuals in the compartment(s), store them in a waterproof bag to protect them from water damage. If your owner’s manual becomes damaged, order a replacement from a Yamaha water vehicle dealer.
E Grove compartment A grove compartment is provided below the handle bars. Slide the latch 3 to open the compartment. To close the lid, push it down until it locks securely. NOTE: Grove compartment 4 Capacity: 1.7 L (0.45 US gal, 0.37 Imp gal) Load limit: 1 kg (2.2 lb) Seat storage compartment A seat storage compartment is provided under the rear seat. Refer to “REAR SEAT” for removal and installation. NOTE: Seat storage compartment 5 Capacity: 30 L (8 US gal, 6.6 Imp gal) Load limit: 9 kg (19.
E EJU00410 Chapter 3 OPERATION AND RIDING GASOLINE (PETROL) AND ENGINE OIL FILLING .......................................... 3-1 Filling the gasoline (petrol) tank ......... 3-1 Filling the oil tank ............................... 3-2 PRE-OPERATION CHECKS ................. 3-3 Check point ........................................ 3-4 OPERATION........................................ 3-10 Break-in (running-in) procedure ....... 3-10 Starting the engine ........................... 3-12 Stopping the engine ..
E EJU00411 GASOLINE (PETROL) AND ENGINE OIL FILLING This engine uses Yamaha’s oil injection system, which provides superior lubrication by ensuring the proper oil ratio for all operating conditions. No fuel premixing is necessary (except during break-in / running-in). Simply pour gasoline (petrol) into the fuel tank and oil into the oil tank. EJU00722 FILLING THE GASOLINE (PETROL) TANK 1) Open the front hood and remove the front storage compartment, to check the fuel level.
E EJU00723a FILLING THE OIL TANK 1) Open the front hood to access the oil filler cap and remove the front storage compartment, so you can watch the oil level. 2) Open the oil tank filler cap, and very slowly add engine oil to the oil tank. 3) Stop pouring when the oil just reaches the bottom of the filler tube. ECJ00060 CAUTION: Do not allow the oil tank to empty completely. The oil injection pump must be bled to ensure proper oil flow after the tank empties. Otherwise, engine damage may occur.
E EJU00422 PRE-OPERATION CHECKS CHECK LIST Before operating this water vehicle, perform the following checks: WARNING If any item in the pre-operation check is not working properly, have it inspected and repaired before operating the vehicle. Otherwise an accident could occur.
E EJU00725 CHECK POINT Engine compartment Remove the rear and front seats and the front storage compartment to ventilate the engine compartment for a few minutes to allow any fuel vapors to escape. EWJ00053 WARNING Failure to ventilate the engine compartment to release fuel vapors could result in fire or explosion. Do not start the engine if you can smell fuel vapors in the engine compartment. EJU00427a Fuel system Check the fuel system. Refer to page 4-9 “FUEL SYSTEM INSPECTION” for correct procedure.
E EJU00726 Water separator 1) Check the water separator 1 to see if there is any water in the separator. The water separator retains any water entering through the fuel tank breather pipe if the vehicle is capsized. Normally, this water separator is empty (no water). 2) If water remains in the water separator, drain it by loosening the drain plug 2. Do not forget to tighten the drain plug. EJU00727 Bilge Excessive water in the engine compartment bilge can splash into the carburetor and engine.
E EJU00435a Battery Check the battery condition and the battery electrolyte level. Check if the battery terminals are tightened securely and that there is no erosion. EWJ00055 WARNING The battery must always be fully charged and in good condition. Loss of battery power may leave you stranded. Never operate the water vehicle if the battery does not have sufficient power to start the engine or if it shows any other signs of decreased power.
E EJU00447 Throttle Operate the throttle lever several times to make sure there is no hesitation in its travel. It should be smooth over the complete range, and spring back to the idle position on its own when released. EJU00448a Steering Make sure the handlebar is not loose. Turn it full-right and full-left to make sure operation is smooth and unrestricted throughout the whole range.
E EWJ00056 WARNING ● ● ● ● Shifting to “REVERSE” will not slow down or stop the vehicle from higher speed. Reverse is for slow speed maneuvering only. There is no “neutral” position. The vehicle will produce some forward or reverse thrust whenever the engine is running. Shift only with the engine idling or off. Do not shift when applying throttle. Make sure there are no obstacles or people behind you before shifting into reverse.
E EJU00452a Switches First, place the vehicle in the water to provide adequate engine cooling. Push the starter switch 1 and start the engine, then push the engine stop switch 2. Restart the engine and pull the lanyard on your left wrist to remove the lock-plate 3 from the engine stop lanyard switch. Verify that the engine stops immediately, when the engine stop switch pushed or the lock-plate remove from the engine stop lanyard switch.
E EJU00455a OPERATION EWJ00057 WARNING Before operating your water vehicle, become familiar with all controls. Consult your Yamaha water vehicle dealer about any control or function you do not fully understand. Failure to understand how controls work could cause an accident or prevent you from avoiding an accident. ECJ00064 CAUTION: Tighten two hull drain plugs securely before launching the vehicle. Clean any foreign material, such as dirt or sand, from the threads before reinstalling the drain plugs.
E 1) Launch the vehicle and start the engine. EWJ00058 WARNING Never ride in water that is less than 60 cm (2 feet) deep. You increase your chance of hitting an underwater obstacle. You could be injured. Operate at higher speeds only in deep water free of under water obstacles. 2) Run the engine at the lowest possible speed for the first five minutes. 3) Gradually open the throttle and run the engine at 5,000 r/min or less.
E EJU00645a STARTING THE ENGINE WARNING This product emits exhaust gases which contain carbon monoxide, a colorless, odorless gas which may cause brain damage or death when inhaled. Symptoms include nausea, dizziness, and drowsiness. Operate the vehicle in an open area. 1) Always make sure the vehicle is launched and used in waters that are free from weeds and debris, and in depths of at least 60 cm (2 feet). WARNING Never ride in water that is less than 60 cm (2 feet) deep.
E 3) Attach the lock-plate 1 to the engine stop lanyard switch 2. Also attach the lanyard 3 to your left wrist. WARNING Check that the lanyard is not frayed or broken, wrapped around the handlebar, or tangled in controls. If the operator falls off, the vehicle could continue to run and cause an accident. The operator and passenger(s) would also be unable to reboard the vehicle, which increases the chance of being hit by another boat and the risk of the exposure.
E 6) While lightly squeezing the throttle lever, push the starter switch (green button). WARNING On this water vehicle, the engine is connected directly to the drive unit. Starting the engine immediately generates some thrust. Only enough throttle should be applied to keep the engine at a fast enough idle to stay running. 7) As soon as the engine starts to run, release the starter button at once. The starter button returns to its home position automatically.
E EJU00463a STOPPING THE ENGINE To stop the engine, release the throttle lever, and then push and hold the engine stop switch (red button) with your left hand. When the red button is pushed the ignition stops, which stops the engine. EWJ00047 NOTE: If leaving the vehicle, choose the “LOCK” mode on multifunction meter by setting PADLOC, and remove the engine stop switch lanyard to reduce the chance of unauthorized use or theft. To set the mode, refer to “PADLOC” of “MULTIFUNCTION METER”.
E EJU00468a RIDING YOUR WATER VEHICLE GETTING TO KNOW YOUR WATER VEHICLE Riding your water vehicle requires skills acquired through practice over a period of time. Take the time to learn the basic techniques well before attempting more difficult maneuvers. Riding your new water vehicle can be a very enjoyable activity, providing you with hours of pleasure. But it is essential to familiarize yourself with the operation of the water vehicle to achieve the skill necessary to enjoy riding safely.
E You should grip the handlebars firmly and keep both feet on the footrest floor. Do not attempt to ride with passengers until your riding skills are fully developed. cumstances in which you operate your water vehicle, so only you can decide if the benefits of eye protection outweigh the potential hazards. EJU00482a Never exceed the weight capacity (240 kg, 530 lb) nor allow more than three person (or two persons with a skier) to ride this water vehicle at one time.
E EJU00484 STARTING WARNING ● ● There may be other water craft, obstructions, or swimmers around you. Check carefully before starting off to avoid an accident. Practice getting on board in shallow water before riding in deep water. EJU00486a Starting in shallow water 1) Do not start your water vehicle in less than 60 cm (2 feet) of water. Put it in an area that is deep enough, then board the vehicle from the side or the rear.
E EJU00490a BOARDING AND STARTING IN DEEP WATER EWJ00068 WARNING ● ● Operator and passenger should practice getting on board in shallow water before riding in deep water. Reboarding in deep water requires more skill. The fatigue and exposure that could result after unsuccessful attempts to get back on the vehicle may increase the risk of injuries and drowning. Solo 1) Swim to the rear of the vehicle and place both hands on the footrest floor. Pull yourself up on the floor and kneel down.
E EJU00493a With passengers WARNING Strong streams of water from the jet nozzle can be dangerous, and can result in injury when directed at body orifices (rectum and vagina). Do not open the throttle until each passenger is seated with feet on the floor and is holding on to the person in front of him or her. 1) Climb up on board as noted earlier, and sit astride the seat. Attach the lanyard to your left wrist, then install the lock-plate on the lanyard to the engine stop lanyard switch.
E EJU00494a LOAD LIMIT The heavier the total weight of the operator and passenger, the more difficult it will be to balance the vehicle. It is not advisable to ride the vehicle when the total weight exceeds 240 kg (530 lb) including any cargo. If it is difficult to balance the vehicle at a standstill, proceed as follows: 1) The passenger must steady the water vehicle while the operator is boarding. The operator pulls himself up onto the footrest floor into a seating position, then balances the vehicle.
E EJU00497a CAPSIZED WATER VEHICLE 1) Turn off the engine by removing the lock-plate from the engine stop lanyard switch. The engine will overheat when capsized because it has no water to pump as coolant. 2) Swim to the rear side of the vehicle. Pull the vehicle over clockwise with the left hand on the jet pump cover while pushing down on the gunwale with your right hand/foot. Do not turn the vehicle counterclockwise, or water may leak into the carburetor and engine.
E ECJ00071 CAUTION: If the vehicle has been capsized for five minutes or more, air may have entered the oil injection system. Leave the engine off, or operate only at trolling speeds, for 10 minutes after the vehicle has been put right-side up. This will allow any air to bleed off. EJU00499 TURNING Throttle produces thrust from the jet pump. Directional control is provided by opening the throttle and turning the handlebars.
E EJU00621a STOPPING The vehicle is not equipped with a separate braking system. It is stopped by water resistance when the throttle lever is released. From full speed, the vehicle stops in approximately 120 m (395 feet) after the throttle is released and the engine stopped. The stopping distance varies depending on gross weight, water surface conditions, and wind direction. The stated stopping distance should be used for a reference.
E EJU00635a BEACHING 1) Make sure no obstructions, boats or swimmers are near the beach. Release the throttle lever about 120 m (395 feet) before the intended landing area. 2) Approach the beach slowly and stop the engine before reaching landing point. Remember: turning is impossible with the engine stopped. 3) Get off the vehicle and pull it up on the beach. CAUTION: Small pebbles, sand, seaweed, and other debris can be ingested into the jet intake and impair or damage the impeller.
E EJU00506 LAUNCHING Make sure there are no obstructions behind you. When the vehicle is in the water, start the engine. Shift into reverse and move the vehicle back slowly. If there are waves, someone should watch to make sure the vehicle is not pushed into the trailer before backing away. 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.
E EJU00508a POST-OPERATION CHECKS 1) After removing the vehicle from the water, put the vehicle in the horizontal position. 2) Flush cooling system to prevent the cooling system from clogging up with salt, sand, or dirt. (Refer to page 4-1 for the cooling system flushing procedure.) 3) Lubricate the internal components by performing “LUBRICATION” at page 4-3, if storing the vehicle for more than a week.
E 6) Raise the bow of the vehicle slightly and remove two hull drain plugs. Allow any water in the bilge to drain out. Rinse the engine compartment with a small amount of fresh water. Be careful not to get water on the carburetor or electrical components. After the water has drained, wipe the bilge with dry rags. Reinstall two drain plugs securely. NOTE: This water vehicle is equipped with an automatic bilge-draining device that removes water from the engine compartment while you are underway.
E EJU00514a TRANSPORTATION WARNING Always place the fuel cock in the “OFF” position when transporting the vehicle. Otherwise, fuel could leak out into the engine or engine compartment, which would create a fire hazard. When transporting the vehicle on a trailer, lock the bow with a pin to the trailer and secure the stern with ropes or tie downs through the rope hole(s) on the rear footrest floor.
E EJU00515 Chapter 4 MAINTENANCE AND CARE STORAGE ............................................. 4-1 Cooling system flushing ..................... 4-1 Lubrication.......................................... 4-3 Fuel system........................................ 4-4 Battery................................................ 4-4 Cleaning ............................................. 4-5 ADJUSTMENT AND MAINTENANCE .. 4-6 Owner’s / operator’s manual and tool kit.................................................
E EJU00516a STORAGE EWJ00079 WARNING Always place the fuel cock in the “OFF” position when storing the vehicle. Otherwise, fuel could leak out into the engine or engine compartment, which would create a fire hazard. Storage for prolonged periods of time, such as winter storage, requires preventative maintenance to ensure against deterioration. It is advisable to have the water vehicle serviced by an authorized Yamaha water vehicle dealer prior to storage.
E 1) Put the vehicle without lowering the bow on land. 2) Open the cap 1. Press the flush kit garden hose adapter 2 into the flush hose connector 3 and turn it until it is securely connected. 3) Connect both the garden hose adapter and a water tap using a hose. 4) Start the engine. Then, immediately turn on water supply until the water flows out continually from the cooling water pilot outlet. 5) Run the engine at an idle speed for 10 to 15 minutes watching engine condition.
E EJU00528a LUBRICATION WARNING Do not spray flammable rust inhibitor products on engine surfaces while the engine is hot. The sprayed substance or propellants could catch fire. 1) Remove the spark plugs and pour approximately one tablespoon of oil into each cylinder. 2) Grease the spark plug threads and reinstall the spark plugs. 3) Crack the engine within 3 seconds using the starter switch. 4) Lubricate all cables such as the throttle, choke, and steering cables.
E EJU00528b FUEL SYSTEM WARNING Gasoline is highly flammable and explosive. A fire or explosion can cause severe injury or death. Shut off the engine. Do not smoke. Avoid spilling gasoline. 1) Place the fuel cock in the OFF position. 2) Drain the fuel tank by using a siphon. EJU00530a BATTERY 1) When the vehicle is not to be used for a month or more, remove the battery and store it in a cool, dark place. Clean the battery’s casing and terminals using a mixture of baking soda and water (one tablespoon.
E EJU00531a CLEANING 1) Wash down the hull, handlebar, 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. WARNING Do not spray flammable rust inhibitor products on engine surfaces while the engine is hot. The sprayed substance or propellants could catch fire.
E EJU00962 ADJUSTMENT AND MAINTENANCE Periodic inspection, adjustment and lubrication will keep your water vehicle in the safest and most efficient condition possible. Safety is an obligation of the vehicle owner. The most important points of vehicle inspection, adjustment and lubrication are explained on the following pages. See your Yamaha dealer for genuine Yamaha replacement parts and optional accessories designed for your watercraft.
E NOTE: A service manual is available for purchase through a Yamaha water vehicle dealer for owners who have the mechanical skills, tools, and other equipment necessary to perform maintenance not covered by this owner’s/operator’s manual. OWNER’S / OPERATOR’S MANUAL AND TOOL KIT It is advisable always to carry the Owner’s/ Operator’s manual and tool kit with you whenever you use the vehicle. For the convenience of the user, a storage space is provided on the vehicle.
E EJU00536a PERIODIC INSPECTION CHART Frequency of maintenance operations may be adjusted according to the operating conditions, but the following table gives general guidelines. The mark (●) indicates the checkups which you may do yourself. The mark (❍) indicates work to be done by your Yamaha water vehicle dealer.
E EJU00537a FUEL SYSTEM INSPECTION EWJ00084 WARNING Gasoline is highly flammable and explosive. A fire or explosion can cause severe injury or death. Shut off the engine. Do not smoke. Avoid spilling gasoline. Do not drain the fuel while the engine is hot. 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 your nearest Yamaha water vehicle dealer. Checking points ● Carburetor leakage.
E EJU00538a FUEL FILTER The fuel filter 1 is a one-piece, disposable type. The filter should be replaced once a year or after every 200 hours of operation, or if water is found in the filter, take the vehicle to your Yamaha water vehicle dealer if fuel filter replacement is required. EWJ00086 WARNING Do not try to change the fuel filter yourself. An incorrectly installed filter can leak gasoline (petrol), which could lead to fire or explosion.
E EJU00544a OIL INJECTION SYSTEM INSPECTION Check the oil injection system for leaks, cracks, or malfunctions. If any problem is found, do the necessary repair or replacement as required. If repair is necessary, consult your nearest Yamaha water vehicle dealer. Checking points ● Check the oil tank for damage or cracks. ● Check for water or dirt in the oil tank. ● Check the oil hose and joint for damage or crack. ● Check the oil filter for clogging. Oil tank Check the oil tank for damage or cracks.
E EJU00546a STEERING CABLE INSPECTION 1) Check the smooth operation of the handlebar and steering (jet) nozzle. 2) Turn the handlebar from lock to lock and check that the clearances between the steering (jet) nozzle and the bracket of the reverse gate are even on both right and left sides. A=B If steering is stiff or maladjusted, ask your Yamaha water vehicle dealer to service it. EJU00549a SHIFT CABLE INSPECTION Place the shift lever in the “REVERSE” position.
E EJU00551a QUICK SHIFT TRIM SYSTEM (Q.S.T.S) MECHANISM INSPECTION 1) Squeeze and release the shift lock release lever. It should move smoothly back to the lock position. Check that the trim shifting grip is locked with the lever released. 2) Squeeze and hold the lever. Check that the grip turns smoothly. 3) Check that the angle of the output nozzle changes to up or down from the middle position when the grip is shifted from neutral to bow-up or bow-down.
E EJU00552a SPARK PLUG CLEANING AND ADJUSTMENT The spark plug is an important engine component and is easy to inspect. The condition of the spark plug can indicate something about the condition of the engine. For example, if the center electrode porcelain is very white, this could indicate an intake air leak or carburetion problem in that cylinder. Do not attempt to diagnose any problems yourself. Instead, take the vehicle to a Yamaha water vehicle dealer.
E NOTE: ● Before installing the spark plug cap, be sure to wipe off any water on the spark plug or inside the cap. Push the spark plug cap down until it clicks. ● If a torque wrench is not available when fitting a new spark plug, good estimate of the correct torque is 1/4 to 1/2 a turn past finger-tight. Have the spark plug adjusted to the correct torque as soon as possible with a torque wrench. EWJ00088 WARNING When removing or installing a spark plug, be careful not to damage the insulator.
E ● Steering cable (handlebar side) ● ● Steering cable (nozzle side) Nozzle pivot shaft QSTS cable (nozzle side) ● QSTS cables (pulley side) ● ● QSTS cables (handlebar side) Remove the QSTS cable housing. Spray a rust-inhibitor into the outer cable. Reinstall the QSTS cable housing.
E ● Shift cable (lever side) ● Shift cable (reverse gate side) ● YPVS cable 4-17
E EJU00566a ● Bearing housing grease nipple This service should be done first after 10 hours or 1 month by your Yamaha water vehicle dealer. Fill the bearing housing with water resistant grease through the grease nipple. Grease capacity: 33.0 ~ 35.0 cm3 (1.11 ~ 1.18 oz.) After first service: Every 100 hours or 6 months (you may do this yourself) Grease capacity: 6.0 ~ 8.0 cm3 (0.20 ~ 0.27 oz.) EJU00570 CHOKE CABLE ADJUSTMENT Pull the choke knob out until it stops. Release the knob.
E EJU00572a BATTERY Check the level of the battery fluid and see if the terminals are tight. Add distilled water if the fluid level is low. EWJ00089 WARNING Battery electrolyte is poisonous and dangerous. It contains sulfuric acid which can cause severe burns. Avoid contact with skin, eyes or clothing. Antidote: EXTERNAL-Flush with water. INTERNALDrink large quantities of water or milk; follow with milk of magnesia, beaten egg or vegetable oil. Call physician immediately.
E 1) The level should be between the upper 1 and lower 2 level marks. If refilling is necessary, use only distilled water. ECJ00084 CAUTION: Normal tap water contains minerals which are harmful to a battery, therefore, refill only with distilled water. Recharging EWJ00090 WARNING ● ● When charging the battery keep it well away from sparks and open flames, as it gives off explosive gases. When using a battery charger, connect the battery to the charger before you turn the charger on.
E EJU00573a CARBURETOR ADJUSTMENT The carburetor is a vital part of the engine and requires very sophisticated adjustment. Most adjusting should be left to a Yamaha water vehicle dealer who has the professional knowledge and experience to do so. However, the following point may be serviced by the owner as part of his usual maintenance routine. ECJ00085 CAUTION: The carburetor was set at the Yamaha factory after many tests.
E EJU00578a FUSE REPLACEMENT The fuse(s) is in the electrical box. Remove the hose band a and avoid the duct hose b from the electrical box. Remove the cap on the electrical box. Remove the fuse using the fuse puller. Replace the fuse to correct ampere one. 1 2 3 4 5 Electrical box Cap Fuse Spare fuse Fuse puller EWJ00091 WARNING Do not use fuses of higher amperage that those recommended. Substitution of a fuse of improper rating can cause extensive electrical system damage and possible fire.
E EJU00588 SPECIFICATIONS Model Item Unit XL1200Ltd VEHICLE CAPACITY Maximum people on board Number of people Maximum load capacity kg (lb) DIMENSIONS Length mm (in) Width mm (in) Height mm (in) Dry weight kg (lb) PERFORMANCE Maximum output kW(PS) @ r/min Maximum fuel consumption L/h (US gal/h, lmp gal/h) Cruising range/at full the throttle hr. Trolling speed r/min ENGINE Engine type Number of cylinder Displacement cm3 (cu.
E EJU00594 Chapter 5 TROUBLESHOOTING AND EMERGENCY PROCEDURE TROUBLESHOOTING........................... 5-1 Troubleshooting chart ........................5-1 EMERGENCY PROCEDURES.............. 5-3 Cleaning the jet intake and impeller ... 5-3 Connecting jumper cables.................. 5-4 Towing the water vehicle.................... 5-6 Submerged water vehicle...................
E EJU00595a TROUBLESHOOTING If any trouble happens with your water vehicle, 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, ask your Yamaha water vehicle dealer or qualified mechanic for the proper service. The troubleshooting chart contains “TROUBLE”, “POSSIBLE CAUSE”, “REMEDY”, “REFER PAGE”.
E TROUBLE The engine runs irregularly or stalls Warning indicator / symbol blinks or light POSSIBLE CAUSE Empty ● ● Choke ● Fuel Filter ● Fuel tank ● Spark plug ● Spark plug cap ● Carburetor ● Fuel level ● Engine oil level ● Engine overheat ● ● The water vehicle speeds too slow or loses power Fuel Exhaust gas temperature Low battery voltage ● Cavitation ● Engine overheat ● Fuel Filter ● Spark plug ● Spark plug caps ● Fuel ● Bilge REMEDY Refill as soon as possible ●
E EJU00597 EMERGENCY PROCEDURES EJU00598a CLEANING THE JET INTAKE AND IMPELLER If weeds or debris get caught in the intake or impeller, cavitation can occur, and though the engine speed rises, forward thrust will decrease. If this condition is allowed to continue, the engine will overheat and may seize. If there is any sign that the jet intake or impeller is clogged with weeds or debris, beach the vehicle and check the intake and impeller. Always stop the engine before beaching the vehicle.
E 2) Remove any weeds or debris from around the drive shaft, impeller, pump housing, and steering nozzle. If it is difficult to remove them, consult your Yamaha water vehicle dealer. ECJ00090 CAUTION: Always avoid running your vehicle in areas where weed growth is thick. If traveling in weeded areas is unavoidable, run the engine alternately at partial-throttle and full-throttle. Weeds tend to accumulate more at a steady speed and at trolling speed.
E EJU00600a To connect the jumper cables 1) Connect the positive (+) terminals of both batteries with the positive (+) jumper cable. 2) Connect one end of the negative (–) jumper cable to the negative (–) terminal of the booster battery. 3) Connect the other end of the negative (–) cable to an unpainted bolt on the cylinder head. ECJ00091 CAUTION: Do not connect the end of the jumper cable to the negative (–) terminal on the vehicle battery.
E EJU00603a TOWING THE WATER VEHICLE If the vehicle becomes inoperative in the water, it can be towed to shore. The bow must be kept up out of the water during towing to prevent water from entering the engine compartment. If the vehicle must be towed in an emergency using a tow rope, the operator should ride the vehicle, holding onto the handlebar. ECJ00094 CAUTION: ● ● Tow the water vehicle slowly; water may enter the air intake and flood the engine compartment if the vehicle is towed too fast.
E EJU00828 SUBMERGED WATER VEHICLE If the vehicle is submerged or flooded with water, follow the procedure below and consult your Yamaha water vehicle dealer as soon as possible. Failure to do so may result in serious engine damage! 1) Beach the vehicle and remove the drain plug(s) to drain the water from the engine compartment. 2) Set the fuel cock to “OFF”. 3) Remove the spark plugs and dry them with a cloth.
E EJU00608 Chapter 6 INDEX INDEX ....................................................
E EJU00609 INDEX A Adjusting the handle position ............... 2-11 Adjustment and maintenance ................ 4-6 B Battery ................................. 3-6, 4-4, 4-19 Battery warning indicator ..................... 2-27 Beaching .............................................. 3-25 Bilge ....................................................... 3-5 Bleeding the oil injection pump ............ 4-22 Boarding and starting in deep water .... 3-19 Bow eye, rope holes, and cleat ............
E Learning to ride your water vehicle ...... 3-16 Limitations on who may operate the vehicle .............................................. 1-8 Load limit ............................................. 3-21 Location ................................................. 1-3 Location of main components ................ 2-1 Lubrication ............................................. 4-3 Lubrication points ................................. 4-15 M Meeting ................................................
E Throttle cable inspection and adjustment ........................................... 4-12 Throttle lever .......................................... 2-9 Tilt handle lever ................................... 2-11 To connect the jumper cables ................ 5-5 To get more boating safety information ........................................... 1-19 Towing the water vehicle ....................... 5-6 Transportation ...................................... 3-29 Trip meter ......................................
E – MEMO –
EJU00636 LIMITED WARRANTY YAMAHA MOTOR CORPORATION, U.S.A. WATER VEHICLE LIMITED WARRANTY Yamaha Motor Corporation is proud of its heritage and reputation for producing products with high standards of quality and workmanship. Product excellence provides the cornerstone for our commitment to customer satisfaction. The Yamaha Water Vehicle Limited Warranty is your assurance of this commitment.
THIS WARRANTY GIVES YOU SPECIFIC LEGAL RIGHTS, AND YOU MAY ALSO HAVE OTHER RIGHTS WHICH VARY FROM STATE TO STATE. YAMAHA MOTOR CORPORATION, U.S.A. Post Office Box 6555 Cypress, California 90630 WARRANTY QUESTIONS AND ANSWERS Q. What costs are my responsibility during the warranty period? A. The customer’s responsibility includes all costs of normal maintenance services, non-warranty repairs, accident and collision damages. Q. What are some examples of “abnormal” strain, neglect, or abuse? A.
YAMAHA EXTENDED SERVICE (Y.E.S.) Keep your Yamaha protected even after your warranty expires with genuine Yamaha Extended Service (Y.E.S.). ● Y.E.S. is designed and administered by Yamaha Motor Corporation to provide maximum owner satisfaction. You get uninterrupted factory-backed coverage for extra peace of mind. ● Y.E.S. is flexible. You choose the plan that’s right for you: 12 months, 24 months, or 36 months beyond your warranty period. ● Y.E.S.
YAMAHA MOTOR CORPORATION, USA Printed in U.S.A. Sep.
