2001 YAMAHA XL 800 steering

4-8
E
EJU00536
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❍❍❍
—
E_F0P71-4.fm Page 8 Tuesday, July 18, 2000 7:17 PM

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

4-16
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

6-1
E
EJU00609
Index
2-stroke engine oil ................................... 3-3
A
Adjusting the carburetor ........................ 4-21
Adjusting the choke cable ..................... 4-18
Adjusting the trolling speed ................... 4-21
Approval label of Emission control
certificate ................................................. 1-2
B
Battery .............................................. 3-8, 4-4
Battery warning indicator....................... 2-28
Beaching the watercraft ........................ 3-31
Bilge ........................................................ 3-7
Bleeding the oil injection pump ............. 4-22
Boarding alone ...................................... 3-24
Boarding and starting in deep water ..... 3-24
Boarding with passengers ..................... 3-25
Bow down.............................................. 2-16
Bow up .................................................. 2-16
C
Capsized watercraft .............................. 3-26
Caution labels ......................................... 1-7
Choke knob ........................................... 2-10
Cleaning and adjusting the spark
plugs...................................................... 4-14
Cleaning the jet intake and impeller ........ 5-4
Cleaning the watercraft ........................... 4-5
Clock ..................................................... 2-24
Connecting the jumper cables................. 5-6
Cooling water pilot outlet .............. 2-12, 3-13
Cruising limitations ................................ 1-10
D
Docking the watercraft .......................... 3-31
E
Emergency procedures ........................... 5-4
Emission control information ................... 1-2
Engine break-in ..................................... 3-14
Engine compartment ............................... 3-6
Engine oil meter .................................... 2-24
Engine overheat warning indicator ........ 2-27
Engine overheat warning system .......... 2-17Engine serial number .............................. 1-1
Engine shut-off cord (lanyard) ............... 3-12
Engine shut-off switch ........................... 2-10
Engine stop switch ................................ 2-10
Enjoy your watercraft responsibly ......... 1-17
F
Filling the fuel tank .................................. 3-3
Filling the oil tank .................................... 3-4
Fire extinguisher ...................................... 3-9
Flushing the cooling system .................... 4-1
Front seat ................................................ 2-6
Front storage compartment ................... 2-29
Fuel and oil .............................................. 3-1
Fuel and oil systems ............................... 3-6
Fuel cock knob ........................................ 2-9
Fuel filter ............................................... 4-10
Fuel meter ............................................. 2-23
Fuel system ............................................. 4-4
Fuel tank ............................................... 4-10
Fuel tank filler cap ................................... 2-8
Fuel warning indicator ........................... 2-26
G
Gasohol ................................................... 3-2
Gasoline .................................................. 3-1
Getting to know your watercraft ............ 3-20
Glove compartment ............................... 2-30
H
Handgrip ................................................ 2-18
Hazard information ................................ 1-13
Hood........................................................ 2-7
Hour meter ............................................ 2-25
Hull Identification Number (HIN).............. 1-1
I
Identification numbers ............................. 1-1
Important labels ....................................... 1-3
Inspecting and adjusting the throttle
cable...................................................... 4-12
Inspecting the battery ............................ 4-19
Inspecting the fuel system ....................... 4-9
Inspecting the oil injection system ......... 4-11
Inspecting the QSTS mechanism .......... 4-13
Inspecting the shift cable ....................... 4-12
Inspecting the steering cable ................ 4-12
E_F0P71IX.fm Page 1 Tuesday, July 18, 2000 7:19 PM

6-2
E
J
Jet unit................................................... 3-12
Jumping the battery................................. 5-5
L
Label location .......................................... 1-3
Launching the watercraft ....................... 3-16
Learning to operate your watercraft ...... 3-20
Leaving the watercraft ........................... 3-19
Limitations on who may operate the
watercraft ................................................ 1-9
Location of main components ................. 2-1
Lubrication............................................... 4-3
Lubrication points .................................. 4-15
M
Maintenance and adjustments ................ 4-6
Multifunction meter ....................... 2-19, 3-13
O
Oil filter .................................................. 4-11
Oil tank .................................................. 4-11
Oil tank filler cap...................................... 2-8
Oil warning indicator.............................. 2-27
Operating your watercraft...................... 3-20
Operation .............................................. 3-14
Operation of controls and other
functions .................................................. 2-5
Operation requirements ........................ 1-11
Other labels ............................................. 1-8
Owner’s/Operator’s Manual and tool kit .. 4-7
P
PADLOC initial setting........................... 2-20
PADLOC (Programmable digital locking
ignition).................................................. 2-20
Periodic maintenance chart..................... 4-8
Post-operation checks........................... 3-33
Pre-operation check list........................... 3-5
Pre-operation check points ..................... 3-6
Pre-operation checks .............................. 3-5
Primary Identification (PRI-ID) number ... 1-1
Q
Quick Shift Trim System (QSTS)
selector.................................................. 2-15
R
Rear seat................................................. 2-5Replacing the fuse ................................ 4-22
Reverse on waterways .......................... 3-32
Riding watercraft with passengers ........ 3-21
Rough water operation .......................... 3-32
S
Safe boating rules ................................. 1-16
Safety information ................................... 1-9
Seat storage compartment .................... 2-30
Selecting “PADLOC” mode ................... 2-21
Shift lever .............................................. 2-14
Shift lever and reverse gate .................. 3-11
Specifications ........................................ 4-23
Speedometer......................................... 2-23
Starting and boarding in shallow
water ..................................................... 3-23
Starting from a dock .............................. 3-23
Starting the engine ................................ 3-16
Starting the watercraft ........................... 3-22
Start switch............................................ 2-11
Steering system ...........................2-12, 3-10
Stopping the engine .............................. 3-19
Stopping the watercraft ......................... 3-30
Storage.................................................... 4-1
Storage compartments .......................... 2-29
Submerged watercraft ............................. 5-8
Switches ................................................ 3-13
T
Tachometer ........................................... 2-22
Throttle .................................................. 3-10
Throttle lever ......................................... 2-11
Tilt lever ................................................. 2-13
Towing the watercraft .............................. 5-7
Transporting .......................................... 3-35
Tripmeter ............................................... 2-26
Trip timer ............................................... 2-25
Troubleshooting ...................................... 5-1
Troubleshooting chart ............................. 5-1
Turning the watercraft ........................... 3-28
W
Warning labels ........................................ 1-4
Watercraft characteristics ...................... 1-14
Water separator ...................................... 3-7
Water-skiing .......................................... 1-15
E_F0P71IX.fm Page 2 Tuesday, July 18, 2000 7:19 PM