Yamaha XL800 - Manual

1-2 E EJU00631a Emission control information This engine conforms to the U.S. Environ- mental Protection Agency (EPA) regulationsfor marine SI engines for the year 2001. Approval label of Emission control certificate This label is attached to the electrical box and the silencer of the carburetor. 1 ...

1-8 E EJU00686 Safety information The safe use and operation of this watercraft is dependent upon the use ofproper riding techniques, as well as uponthe common sense, good judgment, andexpertise of the operator. Every operatorshould know the following requirementsbefore riding the watercraft. ● Befo...

1-9 E EJU00613 Cruising limitations ● Scan constantly for people, objects, andother watercraft. Be aler t for conditionsthat limit your visibility or block your visionof others. ● Operate defensively at safe speeds andkeep a safe distance away from people,objects, and other watercraft. ● Do not foll...

1-10 E ● This watercraft is not equipped with light-ing required for night operation. Do notoperate the watercraft after sunset orbefore dawn, otherwise you increase therisk of colliding with another boat, whichcould result in severe injury or death. EJU00735a Operation requirements ● All riders mus...

1-16 E EJU00319 Rules of the Road Yamaha watercraft is legally consid- ered a powerboat. Operation of thewatercraft must be in accordance withthe rules and regulations governing thewaterway on which it is used. Just as there are rules that apply when you are driving on streets and highways,there are...

1-18 E Overtaking If you are passing another vessel, you are the give-way vessel. This means that theother vessel is expected to maintain itscourse and speed. You must stay out of itsway until you are clear of it. Likewise, ifanother vessel is passing you, you shouldmaintain your speed and direction...

1-19 E This system uses buoys and signs with distinctive shapes and colors to show regu-latory or advisory information. These mark-ers are white with black letters and orangeborders. They signify speed zones,restricted areas, danger areas, and generalinformation. Remember, markings may vary by geo- ...

1-20 E EJU00320 To get more boating safety information Be informed about boating safety. Addi- tional publications and information can beobtained from many organizations, includingthe following. United States Coast Guard Consumer Affairs Staff (G-BC)Office of Boating, Public, and Consumer Affairs U....

1-21 E EJU00322 Enjoy your watercraft responsibly You share the areas you enjoy when riding your watercraft with others and withnature. So your enjoyment includes aresponsibility to treat these other people,and the lands, waters, and wildlife withrespect and cour tesy. Whenever and wherever you ride...

2-1 E EJU00327 Location of main components 1 HandlebarsUse to control direction. 2 Fuel tank filler cap 3 Rope hole 4 FootwellUse to place feet for balance. 5 FootrestUse for stopping when pulling a water-skier. 6 Front seat latch 7 Rear seat latchLocking and releasing the seat rock. 8 Intake grateP...

2-5 E EJU00328 Operation of controls and other functions EJU00335a 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: Inser t the projections on the front of the seat into the stays on the deck, and thenpush the rear of the seat do...

2-6 E EJU00714 Front seat To remove the front seat:1. Remove the rear seat.2. Pull the front seat latch 2 up, and then pull the seat off. To install the front seat:1. Inser t the projections on the front of the seat into the stays on the deck, and thenpush the rear of the seat down to lock itin plac...

2-7 E EJU00703 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 securedbefore operating the watercraft.

2-8 E EJU00347 Fuel tank filler cap To remove the fuel tank filler cap 1 , turn it counterclockwise. NOTE: Make sure that the fuel tank filler cap isproperly secured before operating the water-craft. EJU00001N Oil tank filler cap To remove the oil tank filler cap:1. Open the hood. (See page 2-7 for ...

2-9 E EJU00704 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 theillustration.OFF: With the fuel cock knob in this position, fuel does not flow. Always turn the fuel cockknob to this position ...

2-10 E EJU00705 Engine stop switch Push this switch 1 (red button) to stop the engine normally. EJU00706 Engine shut-off switch Inser t 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 remov...

2-11 E EJU00351 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. EJU00353 Start switch Push the star t switch 1 (green button) to star t the engine. NOTE: ● The engine will not start when ...

2-13 E EJU00670 Tilt lever The tilt lever 1 is located in front of the glove compar tment and is used to adjust thetilt of the handlebars. To adjust the tilt, pull the tilt lever up, and then move the handlebars up or down to thedesired position. WARNING ● Never touch the tilt lever during opera-tio...

2-14 E EJU00710 Shift lever The shift lever is located on the starboard side of the watercraft and is used to controlthe reverse gate, which allows the watercraftto move into reverse or forward. When in the reverse position, the water- craft can be launched from a trailer, orbacked up out of tight s...

2-18 E EJU00367a Handgrip The handgrip 1 provides a handhold for boarding the watercraft and for a spotterwhen facing rearward. CAUTION: Do not use to tow objects, lift watercraft,or attach tie downs, otherwise damagecould occur.

2-19 E EJU00698b Multifunction meter This meter contains following functions for help and convenience in operating thewatercraft. 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 andTrip tim...

2-20 E EJU00711a 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 situationrequires, much as you would use an ignitionkey in a motor vehicle. If you have previouslychosen “LOCK...

2-21 E 3. Select your four-letter code by pressing the “A/SET,” “B,” or “C” buttons in adesired sequence. NOTE: If you do not press a button for more than10 seconds, the display automatically turnsoff. This cancels the process of setting acode. 4. After code setting is complete, the buzzer will soun...

2-22 E 3. Enter your four-letter code by pressing the “A/SET,” “B,” or “C” buttons in theright sequence. NOTE: If you do not press a button for more than10 seconds, the display automatically turnsoff. This cancels the process of selecting themode. 4. If the code entered is correct, the mode will cha...

2-23 E EJU00384 Speedometer This meter shows the watercraft speed in miles per hour (mph). EJU00386a Fuel meter The fuel meter is provided for convenient fuel level checking while operating thewatercraft. The fuel meter has 4 segments which show the amount of fuel remaining in thefuel tank. NOTE: Th...

2-24 E EJU00387a Engine oil meter The engine oil meter is provided for con- venient oil level checking while operating thewatercraft. The engine oil meter has 3 segments which show the amount of oil remaining inthe oil tank. NOTE: The indication of the segments differsdepending on your operating con...

2-26 E EJU00712 Tripmeter A tripmeter is provided for measuring the approximate distance traveled. To show the tripmeter, press the “MODE” button until the display shows “TRIP” whilethe engine is running. After showing “TRIP,”the display turns to “.MILE.”1. When the display shows “.MILE,” press the ...

2-27 E EJU00717a Oil warning indicator If the oil remaining in the tank drops to about 1.4 L (0.37 US gal, 0.31 Imp gal) orthe oil filter is clogged, the lowest oil levelsegment, the oil warning indicator, “OIL” andthe warning light begin to blink. The buzzeralso starts sounding intermittently. If t...

2-28 E EJU00719 Battery warning indicator If the battery voltage becomes less than 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 batteryand have the char...

2-29 E EJU00672a Storage compartments A front storage compar tment, a glove compar tment, and seat storage compar t-ments are provided. NOTE: ● Make sure that the storage compar tmentsare properly secured before operating thewatercraft. ● The storage compartments are notdesigned to be waterproof. If...

E 3 EJU00410 OPERATION Fuel and oil ................................................ 3-1 Gasoline .................................................. 3-1Filling the fuel tank .................................. 3-32-stroke engine oil................................... 3-3Filling the oil tank ............

3-1 E EJU00411a Fuel and oil This engine uses Yamaha’s oil injection system, which provides superior lubricationby ensuring the proper oil ratio for all operat-ing conditions. No fuel premixing is neces-sary except during the engine break-inperiod. Simply pour gasoline into the fueltank and oil into...

3-2 E CAUTION: Use only fresh gasoline that has beenstored in clean containers. Gasohol There are two types of gasohol: gasohol containing ethanol and that containing meth-anol. Gasohol containing ethanol can be used if ethanol content does not exceed 10 % andthe fuel meets minimum octane ratings. G...

3-3 E EJU00724a Filling the fuel tank CAUTION: Be careful when refueling. Avoid gettingwater or other contaminants in the fueltank. Contaminated fuel can cause poorrunning or engine damage. 1. Open the hood and remove the front storage compartment, to check the fuellevel. (See page 2-29 for front st...

3-4 E EJU00419a 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 hazard.Wipe up any spilled oil immediately. CAUTION: Do not allow the oil tank to become com-pletely empty. If the oil tank becomesempty the oil inj...

3-5 E EJU00422 Pre-operation checks 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 proper...

3-6 E EJU00426 Pre-operation check points Engine compartment Ventilate the engine compar tment before each use. To ventilate the engine compartment, remove all seats and front storage compar t-ment. (See pages 2-5 and 2-6 for front andrear seat, and 2-29 for front storage com-par tment.) Allow the e...

3-7 E EJU00432a Water separator Check the water separator 1 for water. Normally the water separator is empty. Thewater separator retains any water enteringthrough the fuel tank breather hose if thewatercraft is capsized. If water remains in the water separator, drain it by removing the drain screw 2...

3-8 E EJU00435a Battery Check the battery condition and the elec- trolyte level. Check that the battery leads are tightened securely and there is no corrosion on thebattery terminals. WARNING The battery must always be fully chargedand in good condition. Loss of batterypower may leave you stranded. ...

3-9 E F0P03010 EJU00728 Fire extinguisher Check that there is a full fire extinguisher on board. The fire extinguisher container 1 is located in the front storage compar tment. To open the fire extinguisher container cap 2 turn it counterclockwise. After inserting the fire extinguisher make sure tha...

3-10 E EJU00447 Throttle Squeeze and release the throttle lever several times to make sure that there is nohesitation in its travel. It should be smoothover the complete range, and spring back tothe idle position when released. WARNING Before starting the engine, always checkthe operation of the thr...

3-11 E EJU00450 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 shiftlever is pulled up. Also, make sure that the reverse gate goes up to its stopper position when shiftlever is pu...

3-12 E EJU00451a Jet unit Carefully check the jet intake for weeds, debris, or anything else that might restrictthe 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 cool...

3-14 E EJU00676a Operation WARNING Before operating your watercraft,become familiar with all controls. Con-sult your Yamaha dealer about any con-trol or function you do not fullyunderstand. Failure to understand howcontrols work could cause an accident orprevent you from avoiding an accident. CAUTIO...

3-16 E EJU00506 Launching the watercraft Make sure that there are no obstructions behind you. After the watercraft is in the water, star t the engine. Shift into reverse and move thewatercraft back slowly. If there are waves,someone should make sure that the water-craft is not pushed into the traile...

3-18 E 5. If the “LOCK” mode was chosen previ- ously, choose the “START” mode beforestarting the engine. (See pages 2-20 to2-21 for selecting “PADLOC” mode.) NOTE: ● If the initial setting of the PADLOC has notbeen done, the “START” mode is auto-matically selected. ● If you have previously chosen “L...

3-19 E EJU00463a 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 offthe engine can cause you to hit an obsta-cle you are attempting to avoid. A colli-sion could result in severe injury ...

3-20 E EJU00674 Operating your watercraft Getting to know your watercraft Operating your watercraft requires skills acquired through practice over a period oftime. Take the time to learn the basic tech-niques well before attempting more difficultmaneuvers. Operating your new watercraft can be a very...

3-22 E EJU00484 Starting the watercraft WARNING ● Scan constantly for people, objectsand other watercraft. Be alert for con-ditions that limit your visibility or blockyour vision of others. ● Operate defensively at safe speedsand keep a safe distance away frompeople, objects, and other watercraft. ●...

3-23 E EJU00486a Starting and boarding in shallowwater 1. Do not star t the engine in less than 60 cm (2 ft) of water. Put the watercraftin water that is deep enough, and thenboard the watercraft from the side or therear. 2. Attach the engine shut-off cord to your left wrist, and then install the cl...

3-24 E EJU00490a Boarding and starting in deep water WARNING ● Operator and passenger should prac-tice getting on board in shallow waterbefore riding in deep water. Boardingin deep water requires more skill. ● The fatigue and exposure that couldresult after unsuccessful attempts toget back on the wa...

3-25 E EJU00737a Boarding with passengers WARNING Severe internal injuries can occur ifwater is forced into body cavities as aresult of being near the jet thrust nozzle.Do not apply throttle until each passen-ger is seated with his or her feet on thefloor of the footwell and is holding on tothe pers...

3-26 E NOTE: The heavier the total weight of the operatorand passengers, the more difficult it will beto balance the watercraft. Do not operate thewatercraft when the total weight exceeds240 kg (530 lb) including any cargo. If it isdifficult to balance the vehicle at a standstill,proceed as follows:...

3-28 E A B C D EJU00499 Turning the watercraft Steering control depends on the combi- nation of handlebar position and the amountof throttle. Water sucked in through the intake grate is pressurized by the impeller in the jetpump. As the pressurized water is expelledfrom the pump through the jet thru...

3-30 E EJU00621 Stopping the watercraft The watercraft is not equipped with a sep- arate braking system. It is stopped by waterresistance when the throttle lever isreleased. From full speed, the watercraftcomes to a complete stop in approximately105 m (345 ft) after the throttle is releasedand the e...

3-31 E EJU00635 Beaching the watercraft 1. Make sure no obstructions, boats or swimmers are near the beach. Releasethe throttle lever about 105 m (345 ft)before you reach the intended beachingarea. 2. Approach the beach slowly and stop the engine before reaching land. Remem-ber: you need throttle to...

3-32 E EJU00006n Reverse on waterways Reverse can be used for slow speed maneuvering when it is necessary to backup out of tight spots where you cannot turnaround. Reverse can only be used to slowdown or stop during low speed maneuver-ing, such as when docking. Once the engine is idling, shift to re...

3-33 E EJU00691a 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 compar tment for water. To drai...

3-35 E EJU00679 Transporting WARNING Always place the fuel cock knob in the“OFF” position when transporting thewatercraft, otherwise fuel could leak outinto the engine or engine compartment,which would create a fire hazard. When transpor ting the watercraft on a trailer, secure the tie downs to the ...

4-1 E EJU00516a Storage WARNING Always place the fuel cock knob in the“OFF” position when storing the water-craft, otherwise fuel could leak out intothe engine or engine compartment,which would create a fire hazard. Storage for prolonged periods of time, such as winter storage, requires preventa-tiv...

4-3 E EJU00526a Lubrication WARNING To reduce the risk of fire or explosion:Never pour or spray gasoline, or any sub-stance other than engine fogging oilthrough the holes in the carburetorsilencer cover. CAUTION: ● Be sure to replace the caps securelyafter fogging the engine. Otherwisewater could en...

4-4 E 4. Install the cap securely.5. Remove the spark plugs and pour approximately one tablespoon of engineoil into each cylinder. Grease the sparkplug threads and install the spark plugs. 6. Lubricate all cables such as the throttle, choke, and steering cables. NOTE: Use a Yamaha Power Cable Luber ...

4-6 E EJU00535a Maintenance and adjustments Periodic inspection, adjustment and lubri- cation will keep your watercraft in the safestand most efficient condition possible. Safetyis an obligation of the watercraft owner. Themost impor tant points of watercraft inspec-tion, adjustment and lubrication ...

4-8 E EJU00536 Periodic maintenance chart The following char t gives general guidelines for periodic maintenance. However, depend- ing on your operating conditions maintenance may need to be performed more frequently. ( ● ) This mark indicates maintenance that you may do yourself. ( ❍ ) This mark in...

4-9 E EJU00537 Inspecting the fuel system WARNING Gasoline and its vapors are highly flam-mable and explosive. Check the fuel system for leaks, cracks, or malfunctions. If any problem is found, dothe necessary repair or replacement asrequired. If repair is necessary, consult aYamaha dealer.Check: ● ...

4-10 E EJU00538 Fuel filter This watercraft is equipped with a one- piece, disposable fuel filter 1 . The fuel filter should be replaced once a year or afterevery 200 hours of operation, or if water isfound in the filter. Have a Yamaha dealerreplace the fuel filter if necessary. WARNING Do not try t...

4-15 E NOTE: ● Wipe off any water on the spark plug orinside the cap before installing the sparkplug cap. Push the spark plug cap downuntil it clicks. ● If a torque wrench is not available whenyou are fitting a new spark plug, a goodestimate of the correct torque is 1/4 turnto 1/2 turn past finger t...

4-16 E F0D4100 ● Throttle cable (handlebar end)Pull the throttle lever and remove the seal 1 . Spray a rust inhibitor into the outer cable. Refitthe seal securely. ● Steering cable (handlebar end) ● Steering cable (nozzle end) ● Nozzle pivot shaft ● QSTS cable (nozzle end) ● QSTS cables (pulley end)

4-18 E EJU00566a ● Intermediate housingUsing a grease gun, fill the intermediate housing with water-resistant grease throughthe grease nipple 1 . Grease capacity: Initial 10 hours or 1 month: 33.0–35.0 cm 3 (1.11–1.18 oz) Every 100 hours or 6 months: 6.0–8.0 cm 3 (0.20–0.27 oz) EJU00570 Adjusting th...

4-19 E EJU00572 Inspecting the battery Check the level of the battery electrolyte and make sure the leads are secure. WARNING Battery electrolyte is poisonous and dan-gerous, causing severe burns, etc. Elec-trolyte contains sulfuric acid. Avoidcontact with skin, eyes or clothing.AntidotesExternal: F...

4-21 E EJU00573 Adjusting the carburetor The carburetor is a vital part of the engine and requires very sophisticated adjustment.Most adjusting should be left to a Yamahadealer who has the professional knowledgeand experience to perform it. However, theoperator may adjust the trolling speed aspar t ...

4-22 E EJU00578a Replacing the fuse The fuse is in the electrical box 1 . To replace the fuse:1. Remove the cap 2 , pull out the red lead, and bring the fuse holder 3 out of the electrical box. 2. Open the fuse holder and replace the fuse 4 with one of the correct amper- age. WARNING Do not use fuse...

4-23 E EJU00588 Specifications MODEL ITEM Unit XL800 WATERCRAFT CAPACITYMaximum people on board Number of people 3 Maximum load capacity kg (lb) 240 (530) DIMENSIONSLength mm (in) 3,160 (124.4) Width mm (in) 1,220 (48.0) Height mm (in) 1,130 (44.5) Dry weight kg (lb) 314 (693) PERFORMANCEMaximum out...

5-1 E EJU00595 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 se...

5-4 E EJU00597 Emergency procedures EJU00598 Cleaning the jet intake and impeller If weeds or debris get caught in the intake or impeller, cavitation can occur, causing jetthrust to decrease even though enginespeed rises. If this condition is allowed tocontinue, the engine will overheat and mayseize...

5-5 E 2. Remove any weeds or debris from around the drive shaft, impeller, pumphousing, and jet thrust nozzle.If debris is difficult to remove, consultyour Yamaha dealer. CAUTION: Always avoid operating your watercraft inareas where weed growth is thick. If trav-eling in weeded areas is unavoidable,...

5-6 E EJU00600 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. Connect the other end of the negative (–) cable ...

5-7 E EJU00603 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 tow line, the operatorshould ride the watercraft, holding onto thehandlebars. CAUTION: ● Tow the watercraft slowly; water mayente...

5-8 E EJU00604a Submerged watercraft If the watercraft is submerged or flooded with water, follow the procedure below andconsult a Yamaha dealer as soon as possi-ble. Failure to do so may result in seriousengine damage!1. Beach the watercraft and remove the stern drain plugs to drain the water fromt...

E 6 EJU00608 APPENDIX Limited warranty....................................... 6-1 YAMAHA EXTENDED SERVICE (Y.E.S.) ....................................................... 6-3 Index........................................................... 6-4

6-1 E EJU00636 Limited warranty YAMAHA MOTOR CORPORATION, U.S.A.WATER VEHICLE LIMITED WARRANTY Yamaha Motor Cor poration is proud of its heritage and reputation for producing products with high standards of quality and workman-ship. Product excellence provides the cor nerstone for our commitment to ...

6-4 E EJU00609 Index 2-stroke engine oil ................................... 3-3AAdjusting the carburetor ........................ 4-21Adjusting the choke cable ..................... 4-18Adjusting the trolling speed ................... 4-21Approval label of Emission control certificate ................