2003 YAMAHA SUV 1200 oil level

2-23
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EJU01228
Engine oil meter
The engine oil meter is provided for con-
venient oil level checking while operating the
watercraft.
The engine oil meter has 3 segments
which show the amount of oil remaining in
the oil tank.
NOTE:@ The indication of the segments differs
depending on your operating condition. Use
the meter as a reference.
@
EJU01984
Clock
A 12-hour clock is provided in this meter.
To show the clock, press the “MODE” but-
ton until the display shows “CLOCK” while
the engine is running.
1. When the display shows “CLOCK,” press
the “MODE” button for at least
3 seconds.
2. The buzzer will sound once. The hour
display and “SET” start blinking. Then
press the “A/SET” button until the
desired hour is displayed.
3. Press the “MODE” button again.
4. The buzzer will sound once. The minute
display and “SET” start blinking. Then
press the “A/SET” button until the
desired minute is displayed.
5. Press the “MODE” button again.
UGU572.book Page 23 Wednesday, August 28, 2002 1:31 PM

2-26
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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.
UGU572.book Page 26 Wednesday, August 28, 2002 1:31 PM

3-1
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EJU01041
Fuel and oil
This engine uses Yamaha’s oil injection
system, which provides superior lubrication
by ensuring the proper oil ratio for all operat-
ing conditions. No fuel premixing is neces-
sary except during the engine break-in
period. Simply pour gasoline into the fuel
tank and oil into the oil tank.
EJU01911
Gasoline
WARNING@ GASOLINE AND ITS VAPORS ARE
HIGHLY FLAMMABLE AND EXPLOSIVE!

Do not smoke when refueling, and
keep away from sparks, flames, or
other sources of ignition.

Stop engine before refueling.

Refuel in a well-ventilated area with
the watercraft in a horizontal position.

Do not stand or sit on the watercraft
while refueling in case of fire.

Take care not to spill gasoline. If gaso-
line spills, wipe it up immediately with
dry rags. Always properly dispose of
gasoline-soaked rags.

Avoid overfilling the fuel tank. Stop fill-
ing when the fuel level just reaches the
bottom of the filler tube. Do not fill up
the filler tube because fuel expands as
it warms up and could overflow. If tem-
porarily leaving the watercraft with a
full fuel tank, do not leave it in direct
sunlight. Leave it in a well-ventilated
area with the watercraft in a horizontal
position.

Tighten the filler cap securely after
refueling.

If you should swallow some gasoline,
inhale a lot of gasoline vapor, or get
gasoline in your eyes, get immediate
medical attention.
UGU572.book Page 1 Wednesday, August 28, 2002 1:31 PM

3-3
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EJU01960
Filling the fuel tank
CAUTION:@ Be careful when refueling. Avoid getting
water or other contaminants in the fuel
tank. Contaminated fuel can cause poor
running or engine damage.
@
1. Remove the rear and front seats. (See
pages 2-4 to 2-5 for seat removal and
installation procedures.)
2. Remove the fuel tank filler cap, and
slowly add fuel to the fuel tank.
3. Stop filling when the fuel level just
reaches the bottom a of the engine oil
tank.
4. Add 15 L (4 US gal, 3.3 Imp gal) to fill the
fuel tank.
WARNING@ Do not add more than 15 L (4 US gal,
3.3 Imp gal) to the fuel tank, otherwise
fuel can overflow when filling the fuel
tank or when it warms up and expands.
@
NOTE:@
The fuel tank is full when the fuel level b
is visible behind the oil tank.

The rear and front seats must be removed
in order to watch the fuel level in the fuel
tank while adding fuel.

Do not fill into the filler tube because gas-
oline could overflow.
@
Fuel tank capacity:
Total: 70 L (18.5 US gal, 15.4 Imp gal)
Reserve: 12 L (3.2 US gal, 2.6 Imp gal)
UGU572.book Page 3 Wednesday, August 28, 2002 1:31 PM

3-4
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EJU01316
Filling the oil tank
WARNING@
Do not add gasoline to the oil tank.
Fire or explosion could result.

Oil in the bilge is a serious fire hazard.
Wipe up any spilled oil immediately.
@
CAUTION:@ Do not allow the oil tank to become com-
pletely empty. If the oil tank becomes
empty the oil injection pump must be
bled to ensure proper oil flow, otherwise
engine damage may occur. If bleeding of
the oil pump is necessary, have a
Yamaha dealer bleed it.
@
1. Remove the rear and front seats to
access the oil filler cap. (See pages 2-4
and 2-5 for seat removal and installation
procedures.)
2. Open the oil tank filler cap, and very
slowly add engine oil to the oil tank.
3. Stop pouring when the oil just reaches
the bottom of the filler tube.
NOTE:@
The rear and front seats must be removed
in order to watch the oil level in the oil
tank while adding oil.

Be careful not to spill oil or overfill the
tank.

Do not fill into the filler tube because oil
could overflow.
@
Oil tank capacity:
5.5 L (1.5 US gal, 1.2 Imp gal)
UGU572.book Page 4 Wednesday, August 28, 2002 1:31 PM

3-5
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EJU01346
Pre-operation checks
EJU01347
Pre-operation check list
Before operating this watercraft, perform the checks in the following check list. See the
accompanying text in this chapter for details on how to perform the checks.
WARNING@ If any item in the pre-operation check list is not working properly, have it inspected
and repaired before operating the watercraft, otherwise an accident could occur.
@
NOTE:@ Pre-operation checks should be made thoroughly each time the watercraft is used. This pro-
cedure can be completed in a short time. It is worth the time spent to assure safety and reli-
ability.
@
ITEM ROUTINE PAGE
Engine compartment Remove all seats to ventilate the engine com-
partment. Check for fuel vapors or loose electri-
cal connections3-6
Bilge Check for water and fuel residue and remove if
necessary3-7
Throttle Check that the throttle lever springs back 3-10
Steering system Check for proper steering system operation 3-10
Shift lever and reverse gate Check for proper operation 3-11
Fuel and oil Check fuel and oil level and add if necessary
Check hoses and tanks for leakage3-6
Water separator Check for water and drain if necessary 3-7
Battery Check electrolyte level and battery condition 3-8
Front and rear seats Check that the seats are properly secured 2-4–2-5
Hull/Deck Check the hull and deck for cracks or other dam-
age—
Jet unit Check for debris and remove if necessary 3-12
Fire extinguisher Check the condition and replace if necessary 3-9
Engine shut-off cord Check condition and replace is frayed or broken 3-12
Switches Check the start switch, engine stop switch and
engine shut-off switch for proper operation when
the watercraft is in the water3-13
Cooling water pilot outlet Check that water is discharged while the engine
is running and the watercraft is in the water3-13
Multifunction meter Check for warning indications and proper opera-
tion3-13
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3-6
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EJU01048
Pre-operation check points
EJU01878
Engine compartment
Ventilate the engine compar tment before
each use.
To ventilate the engine compartment
remove the rear and front seats. (See pages
2-4 and 2-5 for seat removal and installation
procedures.) Allow the engine compartment
to remain open for a few minutes to allow
any fuel vapors to escape. Also, check for
loose electrical connections.
WARNING@ Failure to ventilate the engine compart-
ment could result in fire or explosion. Do
not start the engine if there is a fuel leak
or a loose electrical connection.
@
EJU01318
Fuel and oil systems
Check the fuel system for leakage, cracks
or malfunctions before each use. (See page
4-10 for check points and correct proce-
dures.)
1. Remove the fuel tank filler cap to release
any pressure that might have built up in
the fuel tank.
2. Remove the rear and front seats. (See
pages 2-4 to 2-5 for seat removal and
installation procedures.)
3. Check the fuel and oil levels in the tanks
and replenish if necessary. (See pages
3-3 and 3-4 for filling instructions.)
UGU572.book Page 6 Wednesday, August 28, 2002 1:31 PM

4-9
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EJU01355
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)
*5: After every use
*6: Before every use
*7: Inspect fluid level before every use
MAINTENANCE INTERVAL
INITIALTHEREAFTER
EVERYPA G E
10
hours50
hours100
hours100
hours200
hours
ITEM
6
months12
months12
months24
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, clean, replace❍❍
4-11
Fuel tank Clean❍
4-11
Oil injection system Inspect, clean❍❍
—
Carburetor setting Inspect, adjust❍❍❍
4-22
Trolling speed Inspect, adjust


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

*5 4-1
Water inlet strainer Inspect, clean❍❍
—
Bilge strainer Clean


—
Impeller Inspect

*6❍❍
5-4
Jet thrust nozzle angle Inspect


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

*6❍❍
4-14
Shift cable and mechanism Inspect, adjust

*6❍❍
4-13
Throttle lever Check operation

*6 4-13
Throttle cable Inspect, adjust


4-13
Choke knob Check operation

*6 4-19
Choke cable Inspect, adjust❍❍
4-19
Stern drain plugs Inspect, replace

*6❍❍
3-7
Battery Inspect

*7❍❍
4-20
Rubber coupling Inspect❍
—
Engine mount Inspect❍
—
Nuts and bolts Inspect❍❍❍
—
UGU572.book Page 9 Wednesday, August 28, 2002 1:31 PM