Yamaha XLT1200 WaveRunner 2003 Operator's Manual

2003WaveRunnerXLT1200OWNER’S/OPERATOR’SMANUALLIT-18626-05-17U.S.A. EditionREAD THIS MANUALCAREFULLY BEFORE OPERATION!Printed in USAAug. 2002—1.6 × 1

1-5EEJU01352 Warning labels 1234E_F0V-12-1.fm Page 5 Wednesday, July 10, 2002 5:10 PM

4-5ETop off the fuel tank with fresh gasolineand add one ounce of Yamaha Fuel Stabi-lizer and Conditioner to each gallon of fuel.NOTE:@ Use of Yamaha

4-6ENOTE:@ The condition of the battery can be knownby checking the specific gravity of the elec-trolyte. However, you can also know the con-dition of

4-7EEJU01197 Maintenance and adjustments Periodic inspection, adjustment and lubri-cation will keep your watercraft in the safestand most efficient c

4-8ENOTE:@ A service manual is available for purchasethrough a Yamaha dealer for owners whohave the mechanical skills, tools, and otherequipment neces

4-9EEJU01357 Periodic maintenance chart The following chart gives general guidelines for periodic maintenance. However, depend-ing on your operating

4-10EEJU01199 Inspecting the fuel system WARNING@ Gasoline is highly flammable and explo-sive. A fire or explosion can causesevere injury or death. S

4-11EEJU01953Fuel filter This watercraft is equipped with a one-piece, disposable fuel filter 1. The fuel filtershould be replaced after the initial 1

4-12EEJU01100 Inspecting the oil injection system Check the oil injection system for leakage,cracks, or malfunctions. If necessary, have aYamaha deal

4-13EEJU01897Inspecting the jet thrust nozzle angle Check for smooth operation of the handle-bars and jet thrust nozzle. Turn the handlebars as far as

4-14EEJU01842Inspecting the QSTS mechanism Check that the shift lock lever moves backto the lock position smoothly, that the QSTSselector locks and un

1-6EEJU01354 Other labels 785690E_F0V-12-1.fm Page 6 Wednesday, July 10, 2002 5:10 PM

4-15EEJU01106 Cleaning and adjusting the spark plugs The spark plug is an important enginecomponent and is easy to inspect. The con-dition of the spa

4-16ENOTE:@ ●Wipe off any water on the spark plug orinside the cap before installing the sparkplug cap. Push the spark plug cap downuntil it clicks. ●

4-17EF0D4100●Throttle cable (handlebar end) Squeeze the throttle lever and remove theseal 1. Spray a rust inhibitor into theouter cable. Refit the se

4-18E●QSTS cables (handlebar end) Remove the QSTS cable housing. Spraya rust inhibitor into the outer cable. Reinstall the QSTS cable housing. ●Shift

4-19E●Intermediate housing Using a grease gun, fill the intermediatehousing with water-resistant greasethrough the grease nipple 1.Grease capacity: In

4-20EEJU01971 Inspecting the battery Check the level of the battery electrolyteand make sure that the negative and posi-tive leads are securely tighte

4-21ETo replenish the battery: 1. Make sure that the electrolyte level isbetween the upper 1 and lower 2 levelmarks. 2. Refill the battery with distil

4-22EEJU01109 Adjusting the carburetor The carburetor is a vital part of the engineand requires very sophisticated adjustment.Most adjusting should b

4-23EEJU01702 Replacing the fuse The fuses are in the electrical box 1. To replace the fuse: 1. Remove the hose band a and keep theduct hose b away f

4-24EEJU01364 Specifications MODELITEMUnit XLT1200WATERCRAFT CAPACITYMaximum people on board Number of people 3Maximum load capacity kg (lb) 240 (53

1-7EABDECE_F0V-12-1.fm Page 7 Wednesday, July 10, 2002 5:10 PM

E–MEMO–UF0V12.book Page 25 Friday, June 21, 2002 2:23 PM

E5EJU01115 TROUBLESHOOTING AND EMERGENCY PROCEDURESTroubleshooting ...5-1Troubleshooting chart ...

5-1EEJU01116 Troubleshooting If you have any trouble with your watercraft, use this section to check for the possiblecause. If you cannot find the ca

5-2EEngine runs irregu-larly or stallsFuel Empty Refill as soon as possi-ble3-3Stale or contaminated Have serviced by Yamaha dealer4-10Choke Knob pull

5-3EWatercraft slow or loses powerCavitation Jet intake clogged Clean 5-4Impeller damaged or wornHave serviced by Yamaha dealer—Engine over-heatedJet

5-4EEJU01118 Emergency procedures EJU01119 Cleaning the jet intake and impeller If weeds or debris get caught in the intakeor impeller, cavitation ca

5-5E2. Remove any weeds or debris fromaround the drive shaft, impeller, pumphousing, and jet thrust nozzle. If debris is difficult to remove, consulty

5-6EEJU01882Connecting the jumper cables 1. Connect the positive (+) jumper cable 1to the positive (+) terminals of both bat-teries. 2. Connect one en

5-7EEJU01913Towing the watercraft If the watercraft becomes inoperative inthe water, it can be towed to shore. If the watercraft must be towed in anem

5-8EEJU01909Submerged watercraft If the watercraft is submerged or floodedwith water, follow the procedure below andconsult a Yamaha dealer as soon as

1-8EEJU01177 Safety information The safe use and operation of thiswatercraft is dependent upon the use ofproper riding techniques, as well as uponthe

E–MEMO–UF0V12.book Page 9 Friday, June 21, 2002 2:23 PM

E6EJU01124 APPENDIXLimited warranty ...6-1YAMAHA EXTENDED SERVICE(Y.E.S.) ...

6-1EEJU01200 Limited warranty YAMAHA MOTOR CORPORATION, U.S.A.WATERCRAFT LIMITED WARRANTYYamaha Motor Corporation is proud of its heritage and reputa

6-2ETHIS WARRANTY GIVES YOU SPECIFIC LEGAL RIGHTS, AND YOU MAY ALSO HAVE OTHER RIGHTS WHICH VARY FROM STATE TOSTATE.YAMAHA MOTOR CORPORATION, U.S.A.Po

6-3EEJU01986YAMAHA EXTENDED SERVICE (Y.E.S.) Keep your Yamaha protected even after your warranty expires with genuine Yamaha ExtendedService (Y.E.S.).

6-4EEJU01125 Index2-stroke engine oil... 3-3AAdjusting the carburetor... 4-22Adjusting the choke

6-5EIIdentification numbers... 1-1Important labels... 1-4Inspecting and adjusting the th

6-6EStarting the engine ... 3-16Starting the watercraft ...3-22Start switch...

2003WaveRunnerXLT1200OWNER’S/OPERATOR’SMANUALLIT-18626-05-17U.S.A. EditionREAD THIS MANUALCAREFULLY BEFORE OPERATION!Printed in USAAug. 2002—1.6 × 1

1-9EEJU01001 Cruising limitations ●Scan constantly for people, objects, andother watercraft. Be alert for conditionsthat limit your visibility or blo

1-10E●This watercraft is not equipped with light-ing required for night operation. Do notoperate the watercraft after sunset orbefore dawn, otherwise

1-11E●Helmets meeting Snell or DOT standardsare required for IJSBA-sanctioned races.You must decide whether to wear a hel-met while you ride for recre

1-12E●Do not attempt to modify this watercraft! Modifications to your watercraft mayreduce safety and reliability, and renderthe watercraft unsafe or

1-13EEJU01202 Hazard information ●When transporting or storing your water-craft, always place the fuel cock knob inthe “OFF” position, otherwise gas

1-14E●Reverse can be used to slow down orstop during slow speed maneuvering,such as when docking. Once the engineis idling, shift to reverse and gradu

1-15E●A second person should be on board as aspotter to watch the skier; in most states itis required by law. Let the skier direct theoperator’s contr

1-16EEJU01180 Rules of the Road Yamaha watercraft is legally consid-ered a powerboat. Operation of thewatercraft must be in accordance withthe rules

1-17ERules when encountering vessels There are three main situations that youmay encounter with other vessels whichcould lead to a collision unless t

1-18EOvertaking If you are passing another vessel, you arethe give-way vessel. This means that theother vessel is expected to maintain itscourse and

1-19EThis system uses buoys and signs withdistinctive shapes and colors to show regu-latory or advisory information. These mark-ers are white with bla

1-20EEJU01181 To get more boating safety information Be informed about boating safety. Addi-tional publications and information can beobtained from m

1-21EEJU01006 Enjoy your watercraft responsibly You share the areas you enjoy whenriding your watercraft with others and withnature. So your enjoymen

E2EJU01007 FEATURES AND FUNCTIONSLocation of main components ...2-1Operation of controls and other functions ...

2-1EEJU01008 Location of main components 1HandlebarsUse to control direction.2FootwellUse to place feet for balance.3FootrestTo keep proper balance wh

2-2E1Fuel tank filler cap2Rope holes3Intake gratePrevents debris from getting into the jet pump.4Speed sensor5CleatUse to attach a towrope for pulling

EEJU00989 To the owner/operator Thank you for choosing a Yamaha water-craft. This Owner’s/Operator’s Manual containsinformation you will need for prop

2-3E1Engine stop switchPush to stop the engine normally.2ClipInsert into the engine shut-off switch to enablestarting of the engine.Remove to stop the

2-4E1Spark plugs/Spark plug caps2Electrical boxProtects electrical components from water.3Flush hose connectorUse to flush the engine cooling water pa

2-5EEJU01009 Operation of controls and other functions EJU01211 Rear seat To remove the rear seat: Pull the rear seat latch 1 up, and thenpull the se

2-6EEJU01859Front seat To remove the front seat:1. Remove the rear seat. 2. Pull the front seat latch 1 up, and thenpull the seat off.To install the f

2-7EEJU01213 Hood To open the hood, pull the latch 1 up,and then lift the hood up. To close the hood, push the hood down tolock it in place. NOTE:@ M

2-8EEJU01012 Fuel tank filler cap To remove the fuel tank filler cap 1, turn itcounterclockwise. NOTE:@ Make sure that the fuel tank filler cap ispro

2-9EEJU01014 Fuel cock knob The fuel cock supplies fuel from the fueltank to the carburetors. The fuel cock knob 1 positions areexplained as follows

2-10EEJU01015 Engine stop switch Push this switch 1 (red button) to stopthe engine normally.EJU01016 Engine shut-off switch Insert the clip 1, on th

2-11EEJU01018 Throttle lever Squeeze the throttle lever 1 to increaseengine speed. Release the throttle lever to decreaseengine speed or to return it

2-12EEJU01020 Cooling water pilot outlet This watercraft is equipped with a coolingwater pilot outlets. When the engine is running, coolingwater is c

EEJU00992 CONTENTSREAD THIS OWNER’S/OPERATOR’S MANUAL CAREFULLY BEFORE OPERATING YOUR WATERCRAFT.GENERAL AND SAFETY INFORMATION1FEATURES AND FUNCTIONS

2-13EEJU01217 Tilt lever The tilt lever 1 is located in front of theglove compartment and is used to adjust thetilt of the handlebars. To adjust the

2-14EEJU01877Shift lever The shift lever is located on the starboard(right) side of the watercraft and is used tocontrol the reverse gate, which allow

2-15EEJU01022Quick Shift Trim System (QSTS) selector The QSTS selector 1 is located at theleft handlebar grip and is used to adjust thetrim angle of t

2-16EEJU01023 Bow down Turn the grip to A or B and the bow willgo down while the watercraft is on plane. Bow down puts more of the bow in thewater. T

2-17EEJU01329 Engine overheat warning system The model has an overheat warningdevice. If the engine starts to overheat, thewarning light, indicator a

2-18EIf the initial overheat warning is ignored,engine and exhaust system heat canincrease, particularly if the watercraft contin-ues to be operated a

2-19EEJU01331 Exhaust temperature warning system This model has an exhaust temperaturewarning device. If the exhaust temperaturegets too hot, the war

2-20EEJU01332 Multifunction meter This meter contains following functions forhelp and convenience in operating thewatercraft. 1“MODE” button 2“SET” b

2-21EEJU01222 PADLOC (Programmable digital locking ignition) This feature is provided to deter unautho-rized use. The function allows you to choose e

2-22E3. Select your four-letter code by pressingthe “A/SET,” “B,” or “C” buttons in adesired sequence. NOTE:@ If you do not press a button for more

E1EJU00993 GENERAL AND SAFETY INFORMATIONIdentification numbers ...1-1Primary Identification (PRI-ID) number ...

2-23E3. Enter your four-letter code by pressingthe “A/SET,” “B,” or “C” buttons in theright sequence. NOTE:@ If you do not press a button for more t

2-24EEJU01226 Speedometer The meter shows the watercraft speedagainst water.EJU01227 Fuel meter The fuel meter is provided for convenientfuel level

2-25EEJU01228 Engine oil meter The engine oil meter is provided for con-venient oil level checking while operating thewatercraft. The engine oil mete

2-26E6. The buzzer will sound twice. The warn-ing light and “SET” blink for 2 seconds.Then the display turns to “CLOCK” andshows the time. NOTE:@ If t

2-27EEJU01163 Tripmeter A tripmeter is provided for measuring theapproximate distance traveled. To show the tripmeter, press the “MODE”button until t

2-28EEJU01233 Oil warning indicator If the oil remaining in the tank drops toabout 1.4 L (0.37 US gal, 0.31 Imp gal) orthe oil filter is clogged, the

2-29EEJU01334 Exhaust temperature warning indicator If the exhaust system becomes too hot,the exhaust temperature warning indicator,“EXHST” and warni

2-30EEJU01236 Storage compartments A front storage compartment, a glovecompartment, and seat storage compart-ments are provided. NOTE:@ ●Make sure th

2-31EEJU01038Glove compartment A glove compartment 2 is located in frontof the seat. To open the glove compartment, slide thelatch 1 toward you, and t

E3EJU01040 OPERATIONFuel and oil ...3-1Gasoline ...3-12-stro

1-1EEJU01830Identification numbers Record the Primary Identification (PRI-ID)number, Hull Identification Number (HIN)and engine serial number in the s

3-1EEJU01041 Fuel and oil This engine uses Yamaha’s oil injectionsystem, which provides superior lubricationby ensuring the proper oil ratio for all

3-2E●If any gasoline spills onto your skin,immediately wash with soap andwater. Change clothing if gasolinespills on it. @CAUTION:@ ●Do not use leaded

3-3EEJU01187 2-stroke engine oil CAUTION:@ Use only YAMALUBE 2-W oil. Usinganother oil can seriously damage the cat-alytic converter and other engine

3-4EEJU01240 Filling the oil tank WARNING@ ●Do not add gasoline to the oil tank.Fire or explosion could result. ●Oil in the bilge is a serious fire h

3-5EEJU01346 Pre-operation checks EJU01349 Pre-operation check list Before operating this watercraft, perform the checks in the following check list.

3-6EEJU01048 Pre-operation check points EJU01893Engine compartment Ventilate the engine compartment beforeeach use. To ventilate the engine compartmen

3-7EEJU01961Water separator Check the water separator 1 for water.Normally the water separator is empty. Thewater separator retains any water entering

3-8EEJU01969 Battery Check the battery condition and the elec-trolyte level. Check that the battery leads are tightenedsecurely and there is no corros

3-9EF0P03010EJU01164 Fire extinguisher Check that there is a full fire extinguisheron board. The fire extinguisher container 1is located in the front

3-10EEJU01834Throttle Squeeze and release the throttle leverseveral times to make sure that there is nohesitation in its travel. It should be smoothov

1-2EEJU00997 Engine serial number The engine serial number is stamped ona label 3 attached to the engine unit.E_F0V-12-1.fm Page 2 Wednesday, July 1

3-11EEJU01245 Shift lever and reverse gate Check for proper operation of the shiftlever and reverse gate. Make sure that the reverse gate goesdown to

3-12EEJU01058 Jet unit Carefully check the jet intake for weeds,debris, or anything else that might restrictthe intake of water. If the intake is clo

3-13EEJU01835Switches Check the start switch 1, the engine stopswitch 2, and the engine shut-off switch 3for proper operation. To check these switches

3-14EEJU01836Operation WARNING@ Before operating your watercraft,become familiar with all controls. Con-sult your Yamaha dealer about any con-trol or

3-15E3. Gradually open the throttle and run theengine at 5,000 r/min or less. 4. Continue operation at 5,000 r/min or lessuntil the first tankful of f

3-16EEJU01247 Launching the watercraft Make sure that there are no obstructionsbehind you. After the watercraft is in the water, startthe engine. Shi

3-17E2. Turn the fuel cock knob to the “ON” posi-tion.NOTE:@ Before starting the watercraft, after it hasbeen sitting, remove the fuel tank filler cap

3-18E5. If the “LOCK” mode was chosen previ-ously, choose the “START” mode beforestarting the engine. (See page 2-22 forselecting “PA D L OC ” mode.)N

3-19EEJU01066 Stopping the engine To stop the engine, release the throttlelever, and then push the engine stop switch(red button). WARNING@ You need

3-20EEJU01068 Operating your watercraft EJU01165 Getting to know your watercraft Operating your watercraft requires skillsacquired through practice o

1-3EEJU01846Emission control information This engine conforms to 2003 U.S. Envi-ronmental Protection Agency (EPA) regula-tions for marine SI engines.E

3-21EWear protective clothing. Severe internalinjuries can occur if water is forced into bodycavities as result of falling into the water orbeing near

3-22EEJU01837Starting the watercraft WARNING@ ●Scan constantly for people, objects,and other watercraft. Be alert for con-ditions that limit your visi

3-23EEJU01073 Starting and boarding in shallowwater 1. Do not start the engine in less than60 cm (2 ft) of water. Put the watercraftin water that is

3-24EEJU01075 Boarding and starting in deep water WARNING@ ●Operator and passenger should prac-tice getting on board in shallow waterbefore riding in

3-25EEJU01849Boarding with passengers WARNING@ Severe internal injuries can occur ifwater is forced into body cavities as aresult of being near the je

3-26ENOTE:@ The heavier the total weight of the operatorand passengers, the more difficult it will beto balance the watercraft. Do not operate thewate

3-27ECAUTION:@ Be sure to remove the clip from theengine shut-off switch, otherwise theengine will overheat and engine damagemay occur. @1. Shut the e

3-28EEJU01839Turning the watercraft Steering control depends on the combi-nation of handlebar position and the amountof throttle. Water sucked in thro

3-29EWARNING@ ●Do not release the throttle when tryingto steer away from objects—you needthrottle to steer. A collision couldresult in severe injury o

3-30EEJU01850Stopping the watercraft The watercraft is not equipped with a sep-arate braking system. It is stopped by waterresistance when the throttl

1-4EEJU00998 Important labels EJU01351 Label location E_F0V-12-1.fm Page 4 Wednesday, July 10, 2002 5:10 PM

3-31EEJU01081 Beaching the watercraft 1. Make sure no obstructions, boats orswimmers are near the beach. Releasethe throttle lever about 110 m (360 f

3-32EEJU01254 Reverse on waterways Reverse can be used for slow speedmaneuvering when it is necessary to backup out of tight spots where you cannot t

3-33EEJU01193 Post-operation checks Always perform the following post-opera-tion checks after operating the watercraft. WARNING@ Stay away from stern

3-34E7. If the watercraft will be stored for a weekor more, lubricate internal engine com-ponents to help prevent corrosion. (Seepage 4-3 for lubricat

3-35EEJU01256 Transporting WARNING@ Always place the fuel cock knob in the“OFF” position when transporting thewatercraft, otherwise fuel could leak o

E4EJU01086 MAINTENANCE AND CAREStorage ...4-1Flushing the cooling system ...4-1Lubri

4-1EEJU01087 Storage WARNING@ Always place the fuel cock knob in the“OFF” position when storing the water-craft, otherwise fuel could leak out intoth

4-2E1. Put the watercraft on land in a horizontalposition. 2. Open the flushing hose connectorcap 1, and then insert the garden hoseadapter 2 into th

4-3EEJU01195 Lubrication WARNING@ Do not spray flammable rust inhibitorproducts on engine surfaces while theengine is hot. The sprayed substance orpr

4-4EEJU01962Fuel system WARNING@ GASOLINE AND ITS VAPORS AREHIGHLY FLAMMABLE AND EXPLOSIVE! ●Do not smoke when refueling, andkeep away from sparks, fl