2001 YAMAHA XL 800 fuel cap

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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 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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3-17
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2. Turn the fuel cock knob to the “ON” posi-
tion.
NOTE:
Before starting the watercraft, after it has
been sitting, remove the fuel tank filler cap
to release any built-up pressure in the tank
due to fuel expansion.
3. Attach the clip 1 to the engine shut-off
switch 2. Also, attach the engine shut-
off cord 3 to your left wrist.
WARNING
Check that the engine shut-off cord is not
frayed or broken, and keep it free from
the handlebars so the engine stops if the
operator falls off. The engine shut-off
cord may not pull free if wrapped around
the handlebars when the operator falls
off, allowing the watercraft to continue to
run and cause an accident.
NOTE:
It is not possible to start the engine with the
clip removed from the engine shut-off
switch.
4. Pull and hold the choke knob all the way
out to star t a cold engine.
NOTE:
The choke should not be used when the
engine is warm.
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Periodic maintenance chart
The following chart 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 indicates work to be done by a Yamaha dealer.
*1: Grease capacity: 33.0–35.0 cm3 (1.11–1.18 oz)
*2: Grease capacity: 6.0–8.0 cm3 (0.20–0.27 oz)
MAINTENANCE INTERVAL INITIALTHEREAFTER
EVERYPA G E
10
hours50
hours100
hours100
hours200
hours
ITEM
3
months6
months6
months12
months
Spark plug Inspect, clean, adjust●●●●
4-14
Lubrication points Lubricate●●
4-15
Intermediate housing Lubricate❍
*1●
*2●
*2 4-18
Fuel system Inspect❍❍
4-9
Fuel filter Check, replace❍❍
4-10
Fuel tank Clean❍
4-10
Oil injection system Inspect, clean❍❍
4-11
Trolling speed Adjust●●
4-21
Carburetor throttle shaft Inspect❍❍❍
—
Cooling water passages Flush
●
(after
ever y
use)4-1
Bilge strainer Clean●●●
—
Impeller Inspect●●●
—
Steering cable Inspect●●
4-12
Steering master Inspect❍❍❍
—
QSTS mechanism Inspect●●
4-13
Shift cable and mechanism Inspect, adjust●●
4-12
Throttle cable Inspect, adjust●●
4-12
Choke cable Inspect, adjust●●
4-18
Stern drain plugs Inspect, replace●
3-7
Battery Inspect
●(inspect
fluid level
before
ever y
use)
4-19
Rubber coupling Inspect❍
—
Nuts and bolts Tighten❍❍❍
—
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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, do
the necessary repair or replacement as
required. If repair is necessary, consult a
Yamaha dealer.
Check:
●Carburetor for leakage.
●Fuel pump for malfunction or leakage.
●Fuel tank for water or dirt.
●Fuel tank for damage, cracks or leakage.
●Fuel hose joint for leakage.
●Fuel hose for cracks or other damage.
●Fuel filter for leakage.
●Fuel cock for leakage.
●Air vent check valve for leakage.
●Fuel tank filler cap for damage.
WARNING
Failure to check for and repair any fuel
leakage may result in fire or explosion.
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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
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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