2001 YAMAHA XL 800 Owners Manual

4-12
E
EJU00546a
Inspecting the steering cable
Check for smooth operation of the handle-
bars and jet thrust nozzle.
Turn the handlebars as far as possible to
the right and left and check that the distance
between the jet thrust nozzle and the
bracket of the reverse gate are equal on
right and left sides.
If steering is stiff or misadjusted, have a
Yamaha dealer service it.
EJU00549a
Inspecting the shift cable
Place the shift lever in the reverse posi-
tion.
Make sure the gate makes contact with the
stopper 1 on the bracket, and the arm 2
makes contact with the reverse gate.
If the reverse gate does not reach the cor-
rect positions, have a Yamaha dealer ser-
vice it.
EJU00550
Inspecting and adjusting the
throttle cable
Check that the throttle cable moves back
to the set position smoothly and that free
play is within specification.
1. Squeeze and release the throttle lever. If
the lever does not return smoothly, have
a Yamaha dealer service it.
2. Adjust free play a by loosening the lock-
nut 1 and turning the adjuster 2. Distance A and B: A=B
Throttle lever free play:
4.0–7.0 mm (0.16–0.26 in)
E_F0P71-4.fm Page 12 Tuesday, July 18, 2000 7:17 PM

4-13
E
EJU00551
Inspecting the QSTS
mechanism
Check that the shift lock lever moves back
to the lock position smoothly, that the QSTS
selector locks and unlocks properly, and that
the jet thrust nozzle moves up or down.
1. Squeeze and release the shift lock lever.
2. Check that the QSTS selector locks
when the lever is released.
3. Check that the selector turns smoothly
when the lever is squeezed and held in
place.
4. Check that the angle of the jet thrust
nozzle changes when the selector is
shifted from neutral to bow-up or bow-
down.
If the mechanism does not work properly,
have a Yamaha dealer service it.
E_F0P71-4.fm Page 13 Tuesday, July 18, 2000 7:17 PM

4-14
E
EJU00552a
Cleaning and adjusting the
spark plugs
The spark plug is an important engine
component and is easy to inspect. The con-
dition of the spark plug can indicate some-
thing 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. Have a Yamaha dealer service the
watercraft.
Remove and inspect the spark plug peri-
odically; heat and deposits will cause the
spark plug to slowly break down and erode.
If electrode erosion becomes excessive, or if
carbon and other deposits are excessive,
replace the spark plug with the specified
plug.
Measure the spark plug gap a with a
wire thickness gauge before installing the
spark plug. Adjust the gap to specification if
necessary.
To reinstall spark plug:
1. Clean the gasket surface.
2. Wipe any dirt from the threads of the
spark plug.
3. Screw the spark plug to the correct
torque. Standard spark plug: BR8ES
Spark plug gap:
0.6–0.7 mm (0.024–0.028 in)
Spark plug torque:
25 Nm (2.5 m·kg, 18 ft·lb)
E_F0P71-4.fm Page 14 Tuesday, July 18, 2000 7:17 PM

4-15
E
NOTE:
●Wipe off any water on the spark plug or
inside the cap before installing the spark
plug cap. Push the spark plug cap down
until it clicks.
●If a torque wrench is not available when
you are fitting a new spark plug, a good
estimate of the correct torque is 1/4 turn
to 1/2 turn past finger tight. Have the
spark plug adjusted to the correct torque
with a torque wrench as soon as possible.
WARNING
Be careful not to damage the insulator
when removing or installing a spark plug.
A damaged insulator could allow sparks
to escape, which could lead to explosion
or fire.
EJU00553a
Lubrication points
To keep moving parts sliding or rotating
smoothly, coat them with water-resistant
grease.
Recommended water-resistant grease:
Yamaha Marine Grease/
Yamaha Grease A
●Throttle cable (carburetor end)
●Oil pump cable
●Choke cable (carburetor end)
E_F0P71-4.fm Page 15 Tuesday, July 18, 2000 7:17 PM

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. Refit
the seal securely.
●Steering cable (handlebar end)
●Steering cable (nozzle end)
●Nozzle pivot shaft
●QSTS cable (nozzle end)
●QSTS cables (pulley end)
E_F0P71-4.fm Page 16 Tuesday, July 18, 2000 7:17 PM

4-17
E
●QSTS cables (handlebar end)
Remove the QSTS cable housing. Spray
a rust inhibitor into the outer cable.
Reinstall the QSTS cable housing.
●Shift cable (lever end)
●Shift cable (reverse gate end)
●YPVS cable
E_F0P71-4.fm Page 17 Tuesday, July 18, 2000 7:17 PM

4-18
E
EJU00566a
●Intermediate housing
Using a grease gun, fill the intermediate
housing with water-resistant grease through
the 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 the choke cable
Check that the choke cable is properly
adjusted.
1. Pull the choke knob out until it stops, and
then release the knob. The knob should
not move.
2. If the choke knob moves back on its own,
tighten the choke knob adjusting nut 1
slightly. If the knob is difficult to move,
loosen the adjusting nut slightly.
E_F0P71-4.fm Page 18 Tuesday, July 18, 2000 7:17 PM

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. Avoid
contact with skin, eyes or clothing.
Antidotes
External: Flush with water.
Internal: Drink large quantities of water
or milk. Follow with milk of magnesia,
beaten egg or vegetable oil. Call physi-
cian immediately.
Eyes: Flush with water for 15 minutes
and get prompt medical attention.
Batteries produce explosive gases. Keep
sparks, flame, cigarettes, etc., well away.
If using or charging the battery in an
enclosed space, make sure that it is well
ventilated. Always shield your eyes when
working near batteries.
KEEP OUT OF THE REACH OF CHIL-
DREN.
CAUTION:
Be careful not to place the battery on its
side.
Make sure to remove the battery from the
battery compartment when adding bat-
tery electrolyte or charging the battery.
When checking the battery, make sure
the breather hose is connected to the
battery and not obstructed.
E_F0P71-4.fm Page 19 Tuesday, July 18, 2000 7:17 PM