2001 YAMAHA XL 800 check engine

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Filling the fuel tank
CAUTION:
Be careful when refueling. Avoid getting
water or other contaminants in the fuel
tank. Contaminated fuel can cause poor
running or engine damage.
1. Open the hood and remove the front
storage compartment, to check the fuel
level. (See page 2-29 for front storage
compartment.)
2. Open the fuel tank filler cap, and slowly
add fuel to the fuel tank.
3. Stop filling when the fuel just reaches the
top of the fuel tank visible under the
engine oil tank.
EJU00324a
2-stroke engine oil
If YAMALUBE 2-W is not available,
another 2-stroke engine oil with an NMMA-
certified TC-W3 rating may be used.Fuel tank capacity:
Total: 70 L (18.5 US gal, 15.4 Imp gal)
Reserve: 12 L (3.17 US gal, 2.64 Imp gal)
Recommended engine oil:
YAMALUBE 2-W
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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 properly, have it inspected
and repaired before operating the watercraft, otherwise an accident could occur.
NOTE:
Pre-operation checks should be made thoroughly each time the watercraft is used. This pro-
cedure can be completed in a short time. It is worth the time spent to assure safety and reli-
ability.
ITEM ROUTINE PAGE
Engine compartment Remove all seats and front storage compart-
ment to ventilate engine compartment. Check for
fuel vapors or loose electrical connections3-6
Bilge Check for water and fuel residue and remove if
necessary3-7
Throttle Check that the throttle lever springs back 3-10
Steering system Check for proper steering system operation 3-10
Shift lever and reverse gate Check for proper operation 3-11
Fuel and oil Check fuel and oil level and add if necessary
Check hoses and tanks for leakage3-6
Water separator Check for water and drain if necessary 3-7
Battery Check electrolyte level and battery condition 3-8
Front and rear seats Check that the seats are properly secured 2-5, 2-6
Hull/Deck Check the hull and deck for cracks or other dam-
age—
Jet unit Check for debris and remove if necessary 3-12
Fire extinguisher Check the condition and replace if necessary 3-9
Engine shut-off cord Check condition and replace is frayed or broken 3-12
Switches Check the start switch, engine stop switch and
engine shut-off switch for proper operation when
the watercraft is in the water3-13
Cooling water pilot outlet Check that water is discharged while the engine
is running and the watercraft is in the water3-13
Multifunction meter Check for warning indications and proper opera-
tion3-13
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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 compart-
ment. (See pages 2-5 and 2-6 for front and
rear seat, and 2-29 for front storage com-
partment.) Allow the engine compartment to
remain open for a few minutes to allow any
fuel vapors to escape. Also, check for loose
electrical connections.
WARNING
Failure to ventilate the engine compart-
ment could result in fire or explosion. Do
not start the engine if there is a fuel leak
or a loose electrical connection.
EJU00427-30a
Fuel and oil systems
Check the fuel system for leakage, cracks
or malfunctions before each use. (See page
4-9 for check points and correct proce-
dures.)
1. Remove the fuel tank filler cap to release
any pressure that might have built up in
the fuel tank.
2. Remove all seats and front storage com-
partment. (See pages 2-5 and 2-6 for
front and rear seat, and 2-29 for front
storage compartment.)
3. Check the fuel and oil levels in the tanks
and replenish if necessary. (See pages 3-3
and 3-4 for filling instructions.)
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Water separator
Check the water separator 1 for water.
Normally the water separator is empty. The
water separator retains any water entering
through the fuel tank breather hose if the
watercraft is capsized.
If water remains in the water separator,
drain it by removing the drain screw 2.
Install the drain screw again after draining
the water separator.
EJU00433a
Bilge
Check for moisture and fuel residue in the
bilge.
Excessive water in the bilge can splash
into the carburetor and engine which could
cause engine damage.
To remove water from the bilge:
1. Remove the stern drain plugs.
2. Raise the bow of the watercraft until the
water drains.
3. After the water has drained, wipe the
bilge with dry rags to make sure that the
bilge is thoroughly dry.
4. Install the drain plugs.
CAUTION:
●Make sure that the stern drain plugs
are tightened securely before launch-
ing the watercraft.
●Clean any foreign materials, such as
dirt or sand, from the drain plug
threads before installing the drain
plugs.
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Battery
Check the battery condition and the elec-
trolyte level.
Check that the battery leads are tightened
securely and there is no corrosion on the
battery terminals.
WARNING
The battery must always be fully charged
and in good condition. Loss of battery
power may leave you stranded. Never
operate the watercraft if the battery does
not have sufficient power to start the
engine or if it shows any other signs of
decreased power.
Make sure that the breather hose is prop-
erly connected and that it is not damaged or
obstructed.
Make sure that the battery is securely
held in place.
1Positive (+): Red lead
2Negative (–): Black lead
3Breather hose
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Throttle
Squeeze and release the throttle lever
several times to make sure that there is no
hesitation in its travel. It should be smooth
over the complete range, and spring back to
the idle position when released.
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.
EJU00448
Steering system
Check for looseness in the handlebars.
Turn them as far as possible to the right
and left to make sure that operation is
smooth and unrestricted throughout the
whole range. Make sure that the jet thrust
nozzle also changes directions as the han-
dlebars are turned, and that there is no free
play between the handlebars and the jet
thrust nozzle.
Check that the tilt adjustment is locked in
position. (See Tilt lever on page 2-13.)
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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 shift
lever is pulled up.
Also, make sure that the reverse gate
goes up to its stopper position when shift
lever is pushed down.
WARNINGJJ●Make sure that the throttle is com-
pletely released and that the engine is
at idle before shifting into reverse.
●Do not use the reverse function to
slow down or stop the watercraft as it
could cause you to lose control, be
ejected, or impact the handlebars.
●Use reverse for slow-speed maneuver-
ing only.
●Make sure that there are no obstacles
or people behind you before shifting
into reverse.
●Do not touch the reverse gate while the
shift lever is being operated, otherwise
you could be pinched.
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Jet unit
Carefully check the jet intake for weeds,
debris, or anything else that might restrict
the 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 cooling water, and dam-
age to the engine could result. Engine cool-
ing water is fed to the engine by the jet
pump. (See page 5-4 for jet intake cleaning
procedures.)
WARNING
●Keep away from intake grate while
engine is on. Items such as long hair,
loose clothing, or PFD straps can
become entangled in moving parts
resulting in severe injury or drowning.
●Stop the engine and remove the clip
from the engine shut-off switch before
removing any debris or weeds, which
may have collected around the jet
intake.
EJU00004n
Engine shut-off cord (lanyard)
Check that the engine shut-off cord is not
frayed or broken. If the cord is damaged,
replace it; never try to repair it or tie it
together.
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