2002 YAMAHA SUV 1200 oil 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
UGU571.book Page 3 Tuesday, July 10, 2001 2:25 PM

2-26
E
EJU01233
Oil warning indicator
If the oil remaining in the tank drops to
about 1.4 L (0.37 US gal, 0.31 Imp gal) or
the oil filter is clogged, the lowest oil level
segment, the oil warning indicator, “OIL” and
the warning light begin to blink. The buzzer
also starts sounding intermittently.
If the oil warning indicator begins to blink,
refill with engine oil as soon as possible.
NOTE:@ If the warning indicator blinks with adequate
oil in the tank, check the oil filter for clog-
ging.
@
EJU01234
Engine overheat warning
indicator
If the engine starts to overheat, the over-
heat warning indicator, “W. T E M P” and the
warning light begin to blink. The buzzer also
starts sounding intermittently.
Refer to “Engine overheat warning sys-
tem” on page 2-17.
UGU571.book Page 26 Tuesday, July 10, 2001 2:25 PM

4-9
E
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

4-12
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EJU01100
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.
EJU01101
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.
EJU01102
Oil filter
Check the oil filter 1 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.
UGU571.book Page 12 Tuesday, July 10, 2001 2:25 PM

5-2
E
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

6-1
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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

6-2
E
Inspecting the steering cable ................ 4-13
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 .............................................. 1-10
Location of main components ................. 2-1
Lubrication............................................... 4-3
Lubrication points .................................. 4-16
M
Maintenance and adjustments ................ 4-7
Multifunction meter ....................... 2-18, 3-13
O
Oil filter .................................................. 4-12
Oil tank .................................................. 4-12
Oil tank filler cap...................................... 2-7
Oil warning indicator.............................. 2-26
Operating your watercraft...................... 3-20
Operation .............................................. 3-14
Operation of controls and other
functions .................................................. 2-4
Operation requirements ........................ 1-12
Other labels ............................................. 1-9
Owner’s/Operator’s Manual and
tool kit ...................................................... 4-8
P
PADLOC initial setting........................... 2-19
PADLOC (Programmable digital
locking ignition) ..................................... 2-19
Periodic maintenance chart..................... 4-9
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.................................................. 2-14R
Rear seat................................................. 2-4
Rear storage compartments .................. 2-30
Recommended equipment .................... 1-14
Replacing the fuse ................................ 4-23
Reverse on waterways .......................... 3-32
Riding watercraft with passengers ........ 3-21
Rough water operation .......................... 3-32
S
Safe boating rules ................................. 1-18
Safety information ................................. 1-10
Selecting “PADLOC” mode ................... 2-20
Shift lever .............................................. 2-13
Shift lever and reverse gate .................. 3-11
Side grips .............................................. 2-16
Specifications ........................................ 4-24
Speedometer......................................... 2-22
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............................................ 2-10
Steering system ...........................2-11, 3-10
Stopping the engine .............................. 3-19
Stopping the watercraft ......................... 3-30
Storage.................................................... 4-1
Storage compartments .......................... 2-28
Submerged watercraft ............................. 5-8
Switches ................................................ 3-13
T
Tachometer ........................................... 2-21
Throttle .................................................. 3-10
Throttle lever ......................................... 2-10
Tilt lever ................................................. 2-12
Towing the watercraft .............................. 5-7
Transporting .......................................... 3-35
Tripmeter ............................................... 2-25
Trip timer ............................................... 2-24
Troubleshooting ...................................... 5-1
Troubleshooting chart ............................. 5-1
Turning the watercraft ........................... 3-28
UGU571.book Page 2 Tuesday, July 10, 2001 2:25 PM