Yamaha WaveRunner XL1200Ltd User manual

LIT186160198

LIT-18616-01-98 F0D-28197-Z9-11

SERVICE

MANUAL

WaveRunner

XL1200Ltd

NOTICE

This manual has been prepared by the Yamaha Motor Company Ltd. primarily for use by

Yamaha dealers and their trained mechanics when performing maintenance procedures and

repairs to Yamaha equipment. It has been written to suit the needs of persons who have a

basic understanding of the mechanical and electrical concepts and procedures inherent in the

work, for without such knowledge attempted repairs or service to the equipment could render

it unsafe or unfit for use.

Because the Yamaha Motor Company, Ltd. has a policy of continuously improving its prod-

ucts, models may differ in detail from the descriptions and illustrations given in this publica-

tion. Use only the latest edition of this manual. Authorized Yamaha dealers are notified

periodically of modifications and significant changes in specifications and procedures, and

these are incorporated in successive editions of this manual.

A10001-0*

WaveRunner XL1200Ltd

SERVICE MANUAL



1999 Yamaha Motor Co., Ltd.

1st Edition, March 1999

No part of this publication may be

reproduced or transmitted in any form or by

any means including photocopying and

recording without the written permission of

the copyright holder.

Such written permission must also be

obtained before any part of this publication

is stored in a retrieval system of any nature.

Printed in USA

LIT-18616-01-98

HOW TO USE THIS MANUAL

MANUAL FORMAT

All of the procedures in this manual are organized in a sequential, step-by-step format. The

information has been compiled to provide the mechanic with an easy to read, handy refer-

ence that contains comprehensive explanations of all disassembly, repair, assembly, and

inspection operations.

In this revised format, the condition of a faulty component will precede an arrow symbol and

the course of action required will follow the symbol, e.g.,

●

Bearings

Pitting/scratches

→

Replace.

To assist you in finding your way through this manual, the section title and major heading is

given at the top of every page.

ILLUSTRATIONS

The illustrations within this service manual represent all of the designated models.

CROSS REFERENCES

The cross references have been kept to a minimum. Cross references will direct you to the

appropriate section or chapter.

IMPORTANT INFORMATION

In this Service Manual particularly important information is distinguished in the following

ways.

The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR SAFETY IS

INVOLVED!

WARNING

Failure to follow WARNING instructions could result in severe injury or death to the machine

operator, a bystander, or a person inspecting or repairing the water vehicle.

CAUTION:

A CAUTION indicates special precautions that must be taken to avoid damage to the water

vehicle.

NOTE:

A NOTE provides key information to make procedures easier or clearer.

IMPORTANT:

This part has been subjected to change of specification during production.

HOW TO USE THIS MANUAL

To help identify parts and clarify procedure steps, there are exploded diagrams at the start

of each removal and disassembly section.

Numbers are given in the order of the jobs in the exploded diagram.

Symbols indicate parts to be lubricated or replaced (see “SYMBOLS”).

A job instruction chart accompanies the exploded diagram, providing the order of jobs,

names of parts, notes in jobs, etc.

Dimension figures and the number of parts, are provided for fasteners that require a tight-

ening torque.

Example:

Bolt or screw size : M10 (D)

25 mm (L)

Jobs requiring more information (such as special tools and technical data) are described

sequentially.

10 ×25 mm

A50001-1-4

SYMBOLS

Symbols

are designed as thumb-

tabs to indicate the content of a chapter.

General Information

Specifications

Periodic Inspection and Adjustment

Fuel System

Power Unit

Jet Pump Unit

Electrical System

Hull and Hood

Trouble-analysis

Symbols

indicate specific data:

Special tool

Specified liquid

Specified engine speed

Specified torque

Specified measurement

Specified electrical value

[Resistance (

Ω

), Voltage (V), Electric current

(A)]

Symbol

in an exploded diagram

indicate the grade of lubricant and the loca-

tion of lubrication point:

Apply YAMALUBE 2-W oil

Apply water resistant grease

(Yamaha grease A, Yamaha marine grease)

Apply molybdenum disulfide grease

Symbols

in an exploded diagram

indicate the grade of the sealing or locking

agent, and the location of the application

point:

Apply Gasket Maker



Apply Yamabond #4

(Yamaha bond number 4)

Apply LOCTITE



No. 271 (Red LOCTITE)

Apply LOCTITE



No. 242 (Blue LOCTITE)

Apply LOCTITE



No. 572

Apply silicone sealant

NOTE:

In this manual, the above symbols may not

be used in every case.

GEN

INFO SPEC

INSP

ADJ FUEL

POWR

JET

PUMP

–+

ELEC

HULL

HOOD

TRBL

ANLS

GM 4

271

242

572

LT LT

INDEX

GENERAL INFORMATION

SPECIFICATIONS

SPEC

PERIODIC INSPECTION AND

ADJUSTMENT

FUEL SYSTEM

FUEL

POWER UNIT

POWR

JET PUMP UNIT

JET

PUMP

ELECTRICAL SYSTEM

ELEC

HULL AND HOOD

HULL

HOOD

TROUBLE-ANALYSIS

GEN

INFO

INSP

ADJ

–+

TRBL

ANLS

A30000-0

GEN

INFO

CHAPTER 1

GENERAL INFORMATION

IDENTIFICATION NUMBERS

......................................................................... 1-1

PRIMARY l.D. NUMBER........................................................................... 1-1

ENGINE SERIAL NUMBER ...................................................................... 1-1

JET PUMP UNIT SERIAL NUMBER ........................................................ 1-1

HULL IDENTIFICATION NUMBER (H.l.N.).............................................. 1-1

SAFETY WHILE WORKING

....................................................................... 1-2

FIRE PREVENTION ................................................................................... 1-2

VENTILATION........................................................................................... 1-2

SELF-PROTECTION.................................................................................. 1-2

OILS, GREASES AND SEALING FLUIDS................................................ 1-2

GOOD WORKING PRACTICES ................................................................ 1-3

DISASSEMBLY AND ASSEMBLY ........................................................... 1-4

SPECIAL TOOLS

............................................................................................. 1-5

MEASURING ............................................................................................ 1-5

REMOVAL AND INSTALLATION ............................................................ 1-6

1-1

GEN

INFO

IDENTIFICATION NUMBERS

A60700-0*

IDENTIFICATION NUMBERS

PRIMARY l.D. NUMBER

The primary l.D. number is stamped on a

label attached to the inside of the engine

compartment.

Starting primary l.D. number:

F0D: 800101 ~

ENGINE SERIAL NUMBER

The engine serial number is stamped on a

label attached to the cylinder head.

Starting serial number:

66V: 000101 ~

JET PUMP UNIT SERIAL NUMBER

The jet pump unit serial number is stamped

on a label attached to the intermediate

housing.

Starting serial number:

66V: 800101 ~

HULL IDENTIFICATION NUMBER

(H.l.N.)

The H.l.N. is stamped on a plate attached to

the aft deck.

1-2

GEN

INFO

SAFETY WHILE WORKING

The procedures given in this manual are

those recommended by Yamaha to be fol-

lowed by Yamaha dealers and their

mechanics.

FIRE PREVENTION

Gasoline (petrol) is highly flammable.

Petroleum vapor is explosive if ignited.

Do not smoke while handling gasoline

(petrol) and keep it away from heat, sparks,

and open flames.

VENTILATION

Petroleum vapor is heavier than air and is

deadly if inhaled in large quantities. Engine

exhaust gases are harmful to breathe.

When test-running an engine indoors,

maintain good ventilation.

SELF-PROTECTION

Protect your eyes with suitable safety spec-

tacles or safety goggles when grinding or

doing any operation which may cause parti-

cles to fly off.

Protect hands and feet by wearing safety

gloves or protective shoes if appropriate to

the work you are doing.

OILS, GREASES AND SEALING

FLUIDS

Use only genuine Yamaha oils, greases,

and sealing fluids or those recommended

by Yamaha.

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