2002 YAMAHA SUV 1200 fuel filter

2-3
E
1Fuel tank
2Water separator
Traps water from the breather hose to the fuel
tank.
3Fuel filter
4Oil tank
5Silencer
Prevents water from getting into the engine
and reduces air intake noise.6Spark plug lead
7Spark plugs/Spark plug caps
8Electrical box
Protects electrical components from water.
9Battery
0Flush hose connector
Use to flush the engine cooling water pas-
sages.
AMuffler
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4-9
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EJU01358
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)
*3: Grease capacity: 8.0 cm3 (0.27 oz)
*4: Grease capacity: 2.0 cm3 (0.07 oz)
MAINTENANCE INTERVAL INITIALTHEREAFTER
EVERYPA G E
10
hours50
hours100
hours100
hours200
hours
ITEM
3
months6
months6
months12
months
Spark plug Inspect, clean, adjust




4-15
Lubrication points Lubricate


4-16
Intermediate housing Lubricate❍
*1

*2

*2 4-19
Starter motor idle gear Lubricate❍
*3

*4

*4 4-19
Fuel system Inspect❍❍
4-10
Fuel filter Check, replace❍❍
4-11
Fuel tank Clean❍
4-11
Oil injection system Inspect, clean❍❍
—
Carburetor setting Inspect, adjust❍❍❍
4-22
Trolling speed Adjust


4-22
Carburetor throttle shaft Inspect❍❍
—
Cooling water passages Flush


(after
ever y
use)4-1
Bilge strainer Clean



—
Impeller Inspect



5-4
Steering cable Inspect


4-13
Steering master Inspect❍❍❍
—
QSTS mechanism Inspect


4-14
Shift cable and mechanism Inspect, adjust


4-13
Throttle cable Inspect, adjust


4-13
Choke cable Inspect, adjust


4-19
Stern drain plugs Inspect, replace

3-7
Battery Inspect


(inspect
fluid level
before
ever y
use)
4-20
Rubber coupling Inspect❍
—
Nuts and bolts Tighten❍❍❍
—
UGU571.book Page 9 Tuesday, July 10, 2001 2:25 PM

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EJU01383
Inspecting the fuel system
WARNING@ Gasoline is highly flammable and explo-
sive. A fire or explosion can cause
severe injury or death. Shut off the
engine. Do not smoke. Avoid spilling
gasoline.
@
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.
@
UGU571.book Page 10 Tuesday, July 10, 2001 2:25 PM

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EJU01098
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.
@
EJU01099
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.
UGU571.book Page 11 Tuesday, July 10, 2001 2:25 PM

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EJU01116
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.
EJU01374
Troubleshooting chart
TROUBLE POSSIBLE CAUSE REMEDY PAGE
Engine does not
startStarter motor does not turn over
Multifunction
meter“LOCK” mode selected Select “START” mode
2-20
Engine shut-
off switchClip not in place Install clip
2-9
Fuse Burned out Replace the fuse and
check wiring4-23
Battery Run down Recharge 4-5
Poor terminal connec-
tionsTighten as required
4-5
Terminal corroded Clean 4-5
Starter motor Faulty Have serviced by
Yamaha dealer—
Starter motor turns over
Fuel cock Turned to “OFF”Turn the fuel cock to
“ON”2-8
Fuel Empty Refill as soon as
possible3-3
Stale or contaminated Have serviced by
Yamaha dealer4-10
Fuel tank Water or dirt present Have serviced by
Yamaha dealer4-11
Spark plug Fouled or defective Clean or replace 4-15
Spark plug cap Not connected or loose Connect properly 4-15
Crankcase Filled with water Crank engine with plug
out until clean5-8
Fuel filter Clogged or water
pooledHave serviced by
Yamaha dealer4-11
Choke Knob moves back on
its ownTighten the choke knob
adjusting nut4-19
UGU571.book Page 1 Tuesday, July 10, 2001 2:25 PM

5-2
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Engine runs irregu-
larly or stallsFuel Empty Refill as soon as
possible3-3
Stale or contaminated Have serviced by
Yamaha dealer4-10
Choke Knob pulled Push fully in 2-9
Fuel filter Clogged or water
pooledHave serviced by
Yamaha dealer4-11
Fuel tank Water or dirt present Have serviced by
Yamaha dealer4-11
Spark plug Fouled or defective Replace 4-15
Incorrect heat range Replace 4-15
Gap incorrect Adjust 4-15
Spark plug cap Loose Connect properly 4-15
Cracked, torn, or dam-
agedReplace
—
Electrical wir-
ingLoose connection Tighten or connect
properly—
Carburetor Incorrect idle adjust-
mentAdjust idle
4-22
Clogged Have serviced by
Yamaha dealer—
Warning light or
indicator blinksFuel level Empty Refill as soon as possi-
ble3-3
Engine oil level Empty Refill immediately 3-4
Oil filter clogged Clean 4-12
Engine over-
heatedJet intake clogged Clean
5-4
Low battery
voltageBattery voltage low Charge 4-21
Battery terminal con-
nected wrongConnect properly
4-21 TROUBLE POSSIBLE CAUSE REMEDY PAGE
UGU571.book Page 2 Tuesday, July 10, 2001 2:25 PM

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Wate rcr af t slow or
loses powerCavitation Jet intake clogged Clean 5-4
Impeller damaged or
wornHave serviced by
Yamaha dealer—
Engine over-
heatedJet intake clogged Clean
5-4
Fuel filter Clogged Have serviced by
Yamaha dealer4-11
Spark plug Fouled or defective Replace 4-15
Incorrect heat range Replace 4-15
Gap incorrect Adjust 4-15
Spark plug
capsLoose Connect properly
4-15
Electrical wir-
ingLoose connection Tighten or connect
properly—
Fuel Stale or contaminated Have serviced by
Yamaha dealer4-10
Bilge Water in bilge Drain 3-7 TROUBLE POSSIBLE CAUSE REMEDY PAGE
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EJU01125
Index
2-stroke engine oil ................................... 3-3
A
Adjusting the carburetor ........................ 4-22
Adjusting the choke cable ..................... 4-19
Adjusting the trolling speed ................... 4-22
Approval label of Emission control
certificate ................................................. 1-2
B
Battery .............................................. 3-8, 4-5
Battery warning indicator....................... 2-27
Beaching the watercraft ........................ 3-31
Bilge ........................................................ 3-7
Bleeding the oil injection pump ............. 4-23
Boarding alone ...................................... 3-24
Boarding and starting in deep water ..... 3-24
Boarding with passengers ..................... 3-25
Bow down.............................................. 2-15
Bow up .................................................. 2-15
C
Capsized watercraft .............................. 3-26
Caution labels ......................................... 1-8
Choke knob ............................................. 2-9
Cleaning and adjusting the spark
plugs...................................................... 4-15
Cleaning the jet intake and impeller ........ 5-4
Cleaning the watercraft ........................... 4-6
Clock ..................................................... 2-23
Connecting the jumper cables................. 5-6
Cooling water pilot outlet .............. 2-11, 3-13
Cruising limitations ................................ 1-11
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 .................................... 2-23
Engine overheat warning indicator ........ 2-26Engine overheat warning system .......... 2-17
Engine serial number .............................. 1-1
Engine shut-off cord (lanyard) ............... 3-12
Engine shut-off switch ............................. 2-9
Engine stop switch .................................. 2-9
Enjoy your watercraft responsibly ......... 1-18
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 ................................................ 2-5
Front storage compartment ................... 2-28
Fuel and oil.............................................. 3-1
Fuel and oil systems ............................... 3-6
Fuel cock knob ........................................ 2-8
Fuel filter ............................................... 4-11
Fuel meter ............................................. 2-22
Fuel system ............................................. 4-4
Fuel tank ............................................... 4-11
Fuel tank filler cap ................................... 2-7
Fuel warning indicator ........................... 2-25
G
Gasohol ................................................... 3-2
Gasoline .................................................. 3-1
Getting to know your watercraft ............ 3-20
Glove compartment ............................... 2-29
H
Handgrip ................................................ 2-16
Hazard information ................................ 1-15
Hood........................................................ 2-6
Hour meter ............................................ 2-24
Hull Identification Number (HIN).............. 1-1
I
Identification numbers ............................. 1-1
Important labels ....................................... 1-3
Inspecting and adjusting the throttle
cable...................................................... 4-13
Inspecting the battery ............................ 4-20
Inspecting the fuel system ..................... 4-10
Inspecting the oil injection system ......... 4-12
Inspecting the QSTS mechanism .......... 4-14
Inspecting the shift cable ....................... 4-13
UGU571.book Page 1 Tuesday, July 10, 2001 2:25 PM