2001 YAMAHA XL 800 water pump

4-11
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F0P04040a
EJU00544
Inspecting the oil injection
system
Check the oil injection system for leakage,
cracks, or malfunctions. If necessary, have a
Yamaha dealer repair the oil injection sys-
tem.
Check:
●Oil tank for damage, cracks or leakage.
●Oil tank for water or dirt.
●Oil hose and joint for damage or cracks.
●Oil filter for dirt.
●Oil pump for leakage.
Oil tank
Check the oil tank for leakage or water in
the tank. If water is found in the oil injection
system or if the oil tank needs to be cleaned
have a Yamaha dealer service the water-
craft.
Oil filter
Check the oil filter for dirt and clogs. If the
oil filter is clogged, remove it from the oil
tank together with the oil level sender and
clean it.
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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)
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EJU00588
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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5-4
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EJU00597
Emergency procedures
EJU00598
Cleaning the jet intake and
impeller
If weeds or debris get caught in the intake
or impeller, cavitation can occur, causing jet
thrust to decrease even though engine
speed rises. If this condition is allowed to
continue, the engine will overheat and may
seize. If there is any sign that the jet intake
or impeller is clogged with weeds or debris,
beach the watercraft and check the intake
and impeller. Always stop the engine before
beaching the watercraft.
WARNING
Before attempting to remove weeds or
debris from the jet intake or impeller
areas, shut the engine off and remove
the clip from the engine shut-off switch.
Severe injury or death could result from
contact with the rotating parts of the jet
pump.
1. Turn the watercraft on its side as shown.
CAUTION:
●Place a suitable clean cloth or carpet-
ing underneath the watercraft to pro-
tect it from abrasions and scratches.
●Always turn the watercraft over onto
its port (left) side.
●When turning the watercraft on its
side, support the bow so the handle-
bars cannot be bent or damaged.
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2. Remove any weeds or debris from
around the drive shaft, impeller, pump
housing, and jet thrust nozzle.
If debris is difficult to remove, consult
your Yamaha dealer.
CAUTION:
Always avoid operating your watercraft in
areas where weed growth is thick. If trav-
eling in weeded areas is unavoidable,
operate the engine alternately at partial
throttle and full throttle. Weeds tend to
accumulate more at a steady speed and
at trolling speed. If weeds clog the intake
or impeller area and cause cavitation, fol-
low the cleaning procedure above.
EJU00599
Jumping the battery
If the watercraft battery has run down, the
engine can be started using a 12-volt bat-
tery and jumper cables.
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 give off explosive gases. Keep
sparks, flame, cigarettes, etc. well away.
If using or charging the battery in an
enclosed area, make sure that it is well
ventilated. Always shield your eyes when
working near batteries.
KEEP OUT OF THE REACH OF CHILDREN.
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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
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