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Yamaha waverunner xlt800 - Service Manual

Yamaha waverunner xlt800
499 pages
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WaveRunner
XLT800
F1F-28197-ZD-C1
SERVICE MANUAL
MANUEL D’ENTRETIEN
WARTUNGSHANDBUCH
MANUAL DE SERVICIO
E
F
D
ES
460077

Table of Contents

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Summary

Important Information

WARNING

Instructions that could result in severe injury or death to the operator, passenger(s), bystander, or inspector.

CAUTION

Special precautions that must be taken to avoid damage to the watercraft.

Symbols

Symbols 1 to 9

Designed as thumb tabs to indicate the content of a chapter.

Symbols 0 to E

Indicate specific data.

Symbols F to H

Indicate the grade of lubricant and the location of lubrication point.

Symbols I to N

Indicate the grade of the sealing or locking agent, and the location of the application point.

Chapter 1 General Information

Safety While Working

Procedures and precautions for safe work.

Safety While Working

Fire Prevention

Handling gasoline safely, avoiding sparks and flames.

Ventilation

Importance of ventilation for gasoline vapor and exhaust gases.

Self-Protection

Protecting eyes, hands, and feet during operations.

Oils, Greases and Sealing Fluids

Use of genuine Yamaha or recommended fluids.

Chapter 2 Specifications

Tightening Torques

Lists specified torques for fasteners.

Chapter 3 Periodic Inspection and Adjustment

Maintenance Interval Chart

Guide to general maintenance intervals based on hours or time.

Periodic Service

Outlines periodic service intervals for various systems.

Control System

Throttle Cable Inspection and Adjustment

Measure and adjust throttle lever free play.

YPVS Cable Adjustment

Check YPVS valve position and adjust cable slack.

Steering Cable Inspection and Adjustment

Inspect and adjust jet thrust nozzle clearance and steering cable joint.

QSTS Cable Inspection and Adjustment

Measure and adjust QSTS cable lengths.

Control System;Fuel System

YPVS Cables 1 and 2 Adjustment

Loosen locknuts, turn adjusters, align holes, and tighten.

Fuel System

Warning about handling fuel system, and fuel line inspection.

Fuel System

Fuel Line Inspection

Inspect fuel filter, hoses, tank, and filler cap.

Oil Injection System;Power Unit

Oil Line Inspection

Inspect oil filter, rubber seal, hoses, tank, filler cap, and check valve.

Power Unit

Spark plug inspection, including electrode condition and insulator color.

Power Unit;Electrical

Spark Plug Inspection

Measure spark gap and tighten spark plug.

Chapter 4 Fuel System

Carburetor Unit

Exploded diagram, removal/installation chart, and service points.

Service Points

Throttle Valve Synchronization Inspection and Adjustment

Check and adjust throttle valve synchronization.

Carburetor Unit

Carburetor

Jet and Carburetor Body Inspection

Inspect main jet, pilot jet, and carburetor body.

Oil Injection Pump Air Bleeding

Oil Injection Pump Air Bleeding

Steps for bleeding air, including notes on recommended oil and cautions.

Chapter 5 Power Unit

Engine Unit

Exploded diagram, removal/installation chart, and service points.

YPVS

Exploded diagram, removal/installation chart, and service points.

Cylinder Head

Exploded diagram, removal/installation chart, and service points.

Engine Unit

YPVS

YPVS Valve Inspection

Eliminate carbon deposits, inspect valve assembly.

YPVS Wiring Diagram

Wiring diagram for the YPVS system.

Cylinder Head

Cylinder Head Removal

Remove cylinder head, referring to exhaust manifold.

Cylinders

Cylinder Removal

Remove cylinder, referring to YPVS and cylinder head sections.

Cylinder Inspection

Eliminate carbon deposits, inspect water jacket, inner surface, and measure bore/taper/roundness.

Pistons

Piston Inspection

Eliminate carbon deposits, inspect piston wall, and measure skirt diameter.

Starter Motor

Starter Motor Disassembly

Exploded diagram for starter motor disassembly.

Crankcase

Crankcase Disassembly

Exploded diagram for crankcase disassembly.

Crankcase Inspection

Inspect mating surfaces and crankcase.

Crankshaft

Crankshaft Removal

Remove crankcase, oil seals, bearings, and crankshaft.

Chapter 6 Jet Pump Unit

Jet Pump Unit

Exploded diagram, removal/installation chart.

Impeller Duct and Drive Shaft

Exploded diagram, removal/installation chart, service points.

Jet Pump Unit

Impeller Duct and Drive Shaft

Drive Shaft Removal

Remove impeller, nut, drive shaft, bearings, and oil seals.

Bearing Housing

Bearing, Intermediate Drive Shaft, and Grease Hose Inspection

Inspect bearings, drive shaft, and grease hose.

Chapter 7 Electrical System

Electrical Analysis

Procedures for digital multimeter, low resistance measurement.

Ignition System

Wiring diagram, spark gap, peak voltage, spark plugs, caps, coil, switches.

Electrical Analysis

Peak Voltage Measurement

Importance of peak voltage, factors affecting it, and consequences of low voltage.

Ignition System Wiring Diagram

Ignition System

Ignition Spark Gap

Warnings and steps for checking spark gap.

Starting System Wiring Diagram

Starting System

Charging System Wiring Diagram

Charging System

Rectifier;Regulator Peak Voltage

Measure peak voltage and replace if out of specification.

YPVS Servomotor

YPVS Cable Removal and Installation

Remove and install YPVS cables.

Indication System Wiring Diagram

Indication System

Chapter 8 Hull and Hood

Remote Control Cables and Speed Sensor Lead

Chapter 9 Trouble Analysis

Trouble Analysis

General checks before consulting the chart.

Trouble Analysis Chart

Chart linking problems to items to be checked.

Trouble Analysis

Items to be Checked

Lists components to check for each problem.

Depannage

Problems

Lists potential problems.

Elements à vérifier

Lists components to check for each problem.

Störungssuche

Probleme

Lists potential problems.

Folgende Punkte müssen überprüft werden

Lists components to check for each problem.

Inspección de Problemas

Problemas

Lists potential problems.

Ítems a comprobar

Lists components to check for each problem.

Summary

Important Information

WARNING

Instructions that could result in severe injury or death to the operator, passenger(s), bystander, or inspector.

CAUTION

Special precautions that must be taken to avoid damage to the watercraft.

Symbols

Symbols 1 to 9

Designed as thumb tabs to indicate the content of a chapter.

Symbols 0 to E

Indicate specific data.

Symbols F to H

Indicate the grade of lubricant and the location of lubrication point.

Symbols I to N

Indicate the grade of the sealing or locking agent, and the location of the application point.

Chapter 1 General Information

Safety While Working

Procedures and precautions for safe work.

Safety While Working

Fire Prevention

Handling gasoline safely, avoiding sparks and flames.

Ventilation

Importance of ventilation for gasoline vapor and exhaust gases.

Self-Protection

Protecting eyes, hands, and feet during operations.

Oils, Greases and Sealing Fluids

Use of genuine Yamaha or recommended fluids.

Chapter 2 Specifications

Tightening Torques

Lists specified torques for fasteners.

Chapter 3 Periodic Inspection and Adjustment

Maintenance Interval Chart

Guide to general maintenance intervals based on hours or time.

Periodic Service

Outlines periodic service intervals for various systems.

Control System

Throttle Cable Inspection and Adjustment

Measure and adjust throttle lever free play.

YPVS Cable Adjustment

Check YPVS valve position and adjust cable slack.

Steering Cable Inspection and Adjustment

Inspect and adjust jet thrust nozzle clearance and steering cable joint.

QSTS Cable Inspection and Adjustment

Measure and adjust QSTS cable lengths.

Control System;Fuel System

YPVS Cables 1 and 2 Adjustment

Loosen locknuts, turn adjusters, align holes, and tighten.

Fuel System

Warning about handling fuel system, and fuel line inspection.

Fuel System

Fuel Line Inspection

Inspect fuel filter, hoses, tank, and filler cap.

Oil Injection System;Power Unit

Oil Line Inspection

Inspect oil filter, rubber seal, hoses, tank, filler cap, and check valve.

Power Unit

Spark plug inspection, including electrode condition and insulator color.

Power Unit;Electrical

Spark Plug Inspection

Measure spark gap and tighten spark plug.

Chapter 4 Fuel System

Carburetor Unit

Exploded diagram, removal/installation chart, and service points.

Service Points

Throttle Valve Synchronization Inspection and Adjustment

Check and adjust throttle valve synchronization.

Carburetor Unit

Carburetor

Jet and Carburetor Body Inspection

Inspect main jet, pilot jet, and carburetor body.

Oil Injection Pump Air Bleeding

Oil Injection Pump Air Bleeding

Steps for bleeding air, including notes on recommended oil and cautions.

Chapter 5 Power Unit

Engine Unit

Exploded diagram, removal/installation chart, and service points.

YPVS

Exploded diagram, removal/installation chart, and service points.

Cylinder Head

Exploded diagram, removal/installation chart, and service points.

Engine Unit

YPVS

YPVS Valve Inspection

Eliminate carbon deposits, inspect valve assembly.

YPVS Wiring Diagram

Wiring diagram for the YPVS system.

Cylinder Head

Cylinder Head Removal

Remove cylinder head, referring to exhaust manifold.

Cylinders

Cylinder Removal

Remove cylinder, referring to YPVS and cylinder head sections.

Cylinder Inspection

Eliminate carbon deposits, inspect water jacket, inner surface, and measure bore/taper/roundness.

Pistons

Piston Inspection

Eliminate carbon deposits, inspect piston wall, and measure skirt diameter.

Starter Motor

Starter Motor Disassembly

Exploded diagram for starter motor disassembly.

Crankcase

Crankcase Disassembly

Exploded diagram for crankcase disassembly.

Crankcase Inspection

Inspect mating surfaces and crankcase.

Crankshaft

Crankshaft Removal

Remove crankcase, oil seals, bearings, and crankshaft.

Chapter 6 Jet Pump Unit

Jet Pump Unit

Exploded diagram, removal/installation chart.

Impeller Duct and Drive Shaft

Exploded diagram, removal/installation chart, service points.

Jet Pump Unit

Impeller Duct and Drive Shaft

Drive Shaft Removal

Remove impeller, nut, drive shaft, bearings, and oil seals.

Bearing Housing

Bearing, Intermediate Drive Shaft, and Grease Hose Inspection

Inspect bearings, drive shaft, and grease hose.

Chapter 7 Electrical System

Electrical Analysis

Procedures for digital multimeter, low resistance measurement.

Ignition System

Wiring diagram, spark gap, peak voltage, spark plugs, caps, coil, switches.

Electrical Analysis

Peak Voltage Measurement

Importance of peak voltage, factors affecting it, and consequences of low voltage.

Ignition System Wiring Diagram

Ignition System

Ignition Spark Gap

Warnings and steps for checking spark gap.

Starting System Wiring Diagram

Starting System

Charging System Wiring Diagram

Charging System

Rectifier;Regulator Peak Voltage

Measure peak voltage and replace if out of specification.

YPVS Servomotor

YPVS Cable Removal and Installation

Remove and install YPVS cables.

Indication System Wiring Diagram

Indication System

Chapter 8 Hull and Hood

Remote Control Cables and Speed Sensor Lead

Chapter 9 Trouble Analysis

Trouble Analysis

General checks before consulting the chart.

Trouble Analysis Chart

Chart linking problems to items to be checked.

Trouble Analysis

Items to be Checked

Lists components to check for each problem.

Depannage

Problems

Lists potential problems.

Elements à vérifier

Lists components to check for each problem.

Störungssuche

Probleme

Lists potential problems.

Folgende Punkte müssen überprüft werden

Lists components to check for each problem.

Inspección de Problemas

Problemas

Lists potential problems.

Ítems a comprobar

Lists components to check for each problem.

Yamaha waverunner xlt800 Specifications

General IconGeneral
ManufacturerYamaha
ModelWaveRunner XLT800
Engine Type2-cylinder, 2-stroke
Fuel TypeGasoline
CategoryPersonal Watercraft
Seating Capacity3

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