2001 YAMAHA XL 800 Owners Manual

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To replenish the battery:
1. Make sure that the electrolyte level is
between the upper 1 and lower 2 level
marks.
2. Refill the battery with distilled water if
necessary.
CAUTION:
Normal tap water contains minerals that
are harmful to a battery. Use only dis-
tilled water for replenishing the battery.
To charge the battery:
1. Remove the caps from the battery cells.
If the level is low, add distilled water if
necessary.
2. Connect the battery to a charger. Set the
charging rate at 1.9 A, and then charge
the battery for 10 hours.
WARNING
●The battery gives off explosive gases.
When charging the battery, keep it well
away from sparks and open flames.
●When using a battery charger, connect
the battery to the charger before you
turn the charger on. This will prevent
sparking at the terminals, which could
ignite battery gases.
Specific gravity: 1.28 at 20 °C (68 °F)
To connect the battery terminals:
1. Make sure that the connections are correct
when you insert the battery in the watercraft.
2. Make sure that the breather hose is
properly connected and that it is not
damaged or obstructed.
3. Make sure that the battery is securely
held in place.
1Positive (+): Red lead
2Negative (–): Black lead
3Breather hose
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Adjusting the carburetor
The carburetor is a vital part of the engine
and requires very sophisticated adjustment.
Most adjusting should be left to a Yamaha
dealer who has the professional knowledge
and experience to perform it. However, the
operator may adjust the trolling speed as
part of the usual maintenance routine.
CAUTION:
The carburetor was set at the Yamaha
factory after many tests. If the settings
are disturbed by someone who does not
have the necessary technical knowledge,
poor engine performance and damage
may result.
EJU00577a
Adjusting the trolling speed
1. Put the watercraft in the water.
2. Start the engine and warm it up for 1 or
2 minutes. Using a diagnostic tachome-
ter or, if necessary, the tachometer in the
multifunction meter, adjust the engine
speed to specification.
3. Turn the throttle stop screw 1 clockwise
to increase engine speed if necessary.
Turn it counterclockwise to decrease
engine speed if necessary.
Trolling speed: 1,250–1,350 r/min
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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
fuse4 with one of the correct amper-
age.
WARNING
Do not use fuses of higher amperage that
those recommended. Substitution of a
fuse of improper rating can cause exten-
sive electrical system damage and possi-
ble fire.
EJU00580
Bleeding the oil injection
pump
If the oil tank becomes completely empty,
or any hose connected to the oil pump has
been disconnected, the oil pump must be
bled to ensure proper oil flow.
If bleeding of the oil pump is necessary,
have a Yamaha dealer bleed it.Fuse amperage: 10 A
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Specifications
MODEL
ITEMUnit XL800
WATERCRAFT CAPACITY
Maximum people on board Number of people 3
Maximum load capacity kg (lb) 240 (530)
DIMENSIONS
Length 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)
PERFORMANCE
Maximum output kW (PS) @ r/min 88.2 (120)@ 7,000
Maximum fuel consumption L/h (US gal/h, Imp gal/h) 49.0 (12.9, 10.8)
Cruising range at full throttle hr. 1.4
Trolling speed r/min 1,250–1,350
ENGINE
Engine type 2-stroke
Number of cylinders 2
Engine displacement
cm
3 (cu in)784 (47.84)
Bore & stroke mm (in) 80.0 × 78.0 (3.15 × 3.07)
Compression ratio 6.6:1
Lubrication system Variable oil injection
Cooling system Water cooled
Starting system Electric starter
Ignition system Digital CDI
Spark plug BR8ES (NGK)
Spark plug gap mm (in) 0.7–0.8 (0.028–0.031)
Battery capacity V-AH 12 - 19
Charging system Flywheel magneto
DRIVE UNIT
Propulsion system Jet pump
Jet pump type Axial flow, single stage
Impeller rotation Counterclockwise (viewed from rear)
Transmission Direct drive from engine
Jet thrust nozzle angle Degree 24 + 24
Trim nozzle angle Degree -7, -2, 3, 8, 13
FUEL AND OIL
Recommended fuel Regular unleaded gasoline
Minimum octane rating PON
RON86
90
Recommended engine oil YAMALUBE 2-W, or an equivalent NMMA-
certified TC-W3 marine oil
Fuel tank capacity
Total L (US gal, Imp gal) 70 (18.5, 15.4)
Reserve L (US gal, Imp gal) 12 (3.12, 2.64)
Oil tank capacity L (US gal, Imp gal) 5.5 (1.45, 1.21)
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TROUBLESHOOTING
AND EMERGENCY
PROCEDURES
Troubleshooting....................................... 5-1
Troubleshooting chart ............................. 5-1
Emergency procedures........................... 5-4
Cleaning the jet intake and impeller ....... 5-4
Jumping the battery ................................ 5-5
Towing the watercraft ............................. 5-7
Submerged watercraft ............................ 5-8
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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 service.
EJU00596a
Troubleshooting chart
TROUBLE POSSIBLE CAUSE REMEDY PAGE
Engine does not
startStarter motor does not turn over
Multifunction
meter“LOCK” mode selected Select “START” mode
2-21
Engine shut-
off switchClip not in place Install clip
2-10
Fuse Burned out Replace the fuse and
check wiring4-22
Battery Run down Recharge 4-20
Poor terminal connec-
tionsTighten as required
4-20
Terminal corroded Clean 4-4
Starter motor Faulty Have serviced by
Yamaha dealer—
Starter motor turns over
Fuel cock Turned to “OFF” Turn the fuel cock to
“ON”2-9
Fuel Empty Refill as soon as possi-
ble3-3
Stale or contaminated Have serviced by
Yamaha dealer4-10
Fuel tank Water or dirt present Have serviced by
Yamaha dealer4-10
Spark plug Fouled or defective Clean or replace 4-14
Spark plug cap Not connected or loose Connect properly 4-14
Crankcase Filled with water Crank engine with plug
out until clean5-8
Fuel filter Clogged or water
pooledHave serviced by
Yamaha dealer4-10
Choke Knob moves back on
its ownTighten the choke knob
adjusting nut4-18
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Engine runs irregu-
larly or stallsFuel Empty Refill as soon as possi-
ble3-3
Stale or contaminated Have serviced by
Yamaha dealer4-10
Choke Knob pulled Push fully in 2-9
Fuel filter Clogged or water
pooledHave serviced by
Yamaha dealer4-10
Fuel tank Water or dirt present Have serviced by
Yamaha dealer4-10
Spark plug Fouled or defective Replace 4-14
Incorrect heat range Replace 4-14
Gap incorrect Adjust 4-14
Spark plug cap Loose Connect properly 4-14
Cracked, torn, or dam-
agedReplace
—
Electrical wir-
ingLoose connection Tighten or connect
properly—
Carburetor Incorrect idle adjust-
mentAdjust idle
4-21
Clogged Have serviced by
Yamaha dealer—
Warning light or
indicator blinksFuel level Empty Refill as soon as possi-
ble3-3
Engine oil level Empty Refill immediately 3-4
Oil filter clogged Clean 4-11
Engine over-
heatedJet intake clogged Clean
5-4
Low battery
voltageBattery voltage low Charge 4-20
Battery terminal con-
nected wrongConnect properly
4-20 TROUBLE POSSIBLE CAUSE REMEDY PAGE
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Watercraft slow or
loses powerCavitation Jet intake clogged Clean 5-4
Impeller damaged or
wornHave serviced by
Yamaha dealer—
Engine over-
heatedJet intake clogged Clean
5-4
Fuel filter Clogged Have serviced by
Yamaha dealer4-10
Spark plug Fouled or defective Replace 4-14
Incorrect heat range Replace 4-14
Gap incorrect Adjust 4-14
Spark plug
capsLoose Connect properly
4-14
Electrical wir-
ingLoose connection Tighten or connect
properly—
Fuel Stale or contaminated Have serviced by
Yamaha dealer4-10
Bilge Water in bilge Drain 3-7 TROUBLE POSSIBLE CAUSE REMEDY PAGE
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