2001 YAMAHA XL 800 fuel

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MAINTENANCE AND
CARE
Storage....................................................... 4-1
Flushing the cooling system ................... 4-1
Lubrication............................................... 4-3
Fuel system............................................. 4-4
Battery ..................................................... 4-4
Cleaning the watercraft........................... 4-5
Maintenance and adjustments............... 4-6
Owner’s/Operator’s Manual and tool
kit ............................................................. 4-7
Periodic maintenance chart .................... 4-8
Inspecting the fuel system ...................... 4-9
Inspecting the oil injection system........ 4-11
Inspecting the steering cable................ 4-12
Inspecting the shift cable ...................... 4-12
Inspecting and adjusting the throttle
cable ...................................................... 4-12
Inspecting the QSTS mechanism ........ 4-13
Cleaning and adjusting the spark
plugs ...................................................... 4-14
Lubrication points .................................. 4-15
Adjusting the choke cable..................... 4-18
Inspecting the battery ........................... 4-19
Adjusting the carburetor ....................... 4-21
Replacing the fuse ................................ 4-22
Bleeding the oil injection pump............. 4-22
Specifications......................................... 4-23
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Storage
WARNING
Always place the fuel cock knob in the
“OFF” position when storing the water-
craft, otherwise fuel could leak out into
the engine or engine compartment,
which would create a fire hazard.
Storage for prolonged periods of time,
such as winter storage, requires preventa-
tive maintenance to ensure against deterio-
ration. It is advisable to have the watercraft
serviced by a Yamaha dealer prior to stor-
age. However, the following procedures can
be performed by the owner.
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Flushing the cooling system
Flushing the cooling system is essential
to prevent the cooling system from being
clogged with salt, sand, or dirt.
CAUTION:
●Do not supply water to the cooling
water passages when the engine is not
running. The water could flow back
through the muffler into the crankcase
causing severe engine damage.
●Do not run the engine for more
15 seconds without supplying water,
otherwise the engine may overheat.
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Fuel system
Draining the fuel system prevents buildup
of varnishes and other harmful deposits that
result when gasoline sits for a prolonged
period of time.
WARNING@Gasoline is highly flammable and explo-
sive. A fire or explosion can cause
severe injury or death. Shut the engine
off. Refuel in well-ventilated areas away
from flames or sparks. Do not smoke.
Avoid spilling gasoline. Wipe up spilled
gasoline immediately.
@
To drain the fuel system:
1. Place the fuel cock knob in the “OFF”
position.
2. Drain the fuel tank using a siphon.
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Battery
When the watercraft is not to be used for
a month or more, remove the battery and
store it in a cool, dark place. Clean the bat-
tery casing using fresh water. Clean the bat-
tery terminals. Apply dielectric grease or
petroleum jelly to the battery terminals and
to all exposed battery leads.
If the battery is to be stored for a longer
period, check the specific gravity of the elec-
trolyte at least once a month and charge the
battery if necessary.
Specific gravity: 1.28 at 20 °C (68 °F)
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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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Fuel filter
This watercraft is equipped with a one-
piece, disposable fuel filter 1. The fuel filter
should be replaced once a year or after
every 200 hours of operation, or if water is
found in the filter. Have a Yamaha dealer
replace the fuel filter if necessary.
WARNING
Do not try to replace the fuel filter your-
self. An incorrectly installed filter can
leak gasoline, which could lead to fire or
explosion. If necessary, have a Yamaha
dealer replace the fuel filter.
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Fuel tank
Check the fuel tank 1 for leakage or
water in the tank. If water is found in the fuel
system or if the fuel tank needs to be
cleaned have a Yamaha dealer service the
watercraft.
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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.
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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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