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2001 2005 yamaha xlt1200 waverunner service repair manual

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2001 2005 yamaha xlt1200 waverunner service repair manualIn doing so, no representation of affiliation, association or the like is intended, unless otherwise stated. Moreover, we are in fact owners of intellectual property, property that is a valuable asset to our business. The following items require some mechanical knowledge. Consult an authorized Yamaha dealer. Consult an authorized Yamaha PWC dealer for recommendations applicable to your individual needs and use. Also, check that the clamp is installed on the oil tank securely. Check the fuel tank for cracks or leakage and that the tank is installed securely with the straps and replace if necessary. Check that the throttle opens and automatically closes in all steering positions. Check for any deterioration or damage to the throttle cable. Apply a water-displacement corrosion-proof lubricant (without Teflon or molybdenum additives, such as CRC 6-56 or an equivalent) to the throttle cable upper end. Release the rubber shield, and apply a water-displacement corrosion-proof lubricant (without Teflon or molybdenum additives, such as CRC 6-56 or an equivalent) to the throttle cable lower end (throttle drum rolling area) and to the throttle screw tip. With the engine idling, turn the handlebar all the way to the right and left to ensure that the idle speed does not change. If idle speed increases, check the throttle lever free play and the throttle cable connection. Install the joint hoses into the clip(s) properly. The spark plug cap and ignition coil are integrated. Remove the seats. Disconnect the ignition coil connectors. Remove the bolts and the direct ignition coils. Clean around the spark plug bases with compressed air before removing the plugs, and be sure that no debris is allowed to enter the combustion chamber and remove the spark plugs. Replace the plug if necessary. Make sure the 1.0 mm (0.04 in) wire-type feeler gauge cannot be inserted into the gap. If the gauge can be inserted into the gap, replace the plug with a new one.

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Screw the spark plug in the cylinder head by hand to prevent cross-threading. Tighten the spark plug to the specified torque. Install the removed parts in the reverse order of removal. Replace the air filter in accordance with the maintenance schedule or any time it is excessively dirty or damaged. Install a new air filter into the housing base properly. Be sure the rubber seal in the cover is in good condition and install the airbox cover. Secure the cover with the retainers Install the seats. Follow the following procedures to determine if the proper amount of oil is in the engine. Remove the rear tray. Remove the dipstick and check the oil level. Reinstall the drain pipe cap and tighten it. Remove the rear tray. Warm up the engine for a few minutes according to the flushing procedure. Turn off the water and stop the engine. Pump out the engine oil with a commercially available Fluid Evacuator from the oil filler hole and drain pipe, to drain the oil tank and oil pan. After draining the oil completely, install the drain pipe cap and pour the recommended oil into the oil tank through the filler hole. Check the oil level. Place a shop towel around the oil filter cartridge to avoid spilling the engine oil. Remove the oil filter cartridge and discard it. Clean any oil from the cartridge seating surface of the engine and the oil filter tray. Apply engine oil to the O-ring and threads of a new oil filter cartridge and install the filter using the filter wrench. Fill the oil tank with the recommended oil. Remove the seats. Remove the rear tray. Connect a tachometer. Warm up the engine with the watercraft in the water and check the idle speed. Adjust the idle speed by turning the throttle stop screw as required. Check the jet stator inner wall for scratches. Check the impeller seal for cracks or damage. Measure the clearance between each impeller blade and the jet stator, using a feeler gauge 12-inches long. Impeller clearance is critical for proper performance. If the clearance is out of specification, disassemble and inspect the impeller and impeller housing area. These can be diagnosed by a compression test, or by tracing top-end noise with a sounding rod or stethoscope. Compression too low, hard starting or poor performance at low speed. Apply battery voltage to the starter motor directly. Does the starter motor turn? Check the ground line of the starter relay switch. Is the ground line normal? Is the power input line normal.Does the starter relay switch function properly. Our payment security system encrypts your information during transmission. We don’t share your credit card details with third-party sellers, and we don’t sell your information to others. Please try again.Please try again.Please try again. Then you can start reading Kindle books on your smartphone, tablet, or computer - no Kindle device required. Register a free business account To calculate the overall star rating and percentage breakdown by star, we don’t use a simple average. Instead, our system considers things like how recent a review is and if the reviewer bought the item on Amazon. It also analyzes reviews to verify trustworthiness. It has been written to suit the needs of persons who have a basic understanding of the. 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. The Safety Alert Symbol means ATTENTION.Starting primary l.D. number: F0V: 800101 ENGINE SERIAL NUMBER The engine serial number is stamped on a label attached to the cylinder head. FIRE PREVENTION Gasoline (petrol) is highly flammable. Gasoline vapor is explosive if ignited. Do not smoke while handling gasoline (petrol) and keep it away from heat, sparks, and open flames. A summary of the most important precau- tions is as follows: 1. Improvisations and using improper tools can damage the equipment. NOTE: For U.S.A.http://www.familyreunionapp.com/family/events/devonthink-manual-20 and Canada, use part numbers starting with “J-”, “YB-”, “YM-”, “YU-”. CAUTION: Use only YAMALUBE 2-W oil. Using another oil can seriously damage the catalytic converter. ATTENTION: N’utilisez que l’huile YAMALUBE 2-W. L’utilisation de toute autre huile peut gravement endommager le convertisseur cata-. Depending on operating conditions, the intervals of maintenance should be changed. Initial Every Refer to Item Remarks 10 hours 50 hours 100 hours 200 hours. Je nach Betriebsbedingungen kann es erforderlich sein, die Wartungsintervalle anzupassen. Anfang Alle Siehe Bezeichnung Anmerkungen 10 Stunden 50 Stunden 100 Stunden 200 Stunden Seite (Einfahrzeit) (3 Monate) (6 Monate) Refer to “STEERING MASTER” in Chapter 8. Inspection steps: Move the handlebar up and down and back and forth. Check the excessive play of the han- dlebar. Turn out Free play is decreased. Tighten the locknut. Install the handlebar cover. WARNING After adjusting the free play, turn the han- dlebar to the right and left and make sure that the trolling speed does not increase. Loosen the locknut 1. Remove the nut 2 and pivot pin 3. Set the jet thrust nozzle in the center position. Turn the cable joint 4 for adjusting. Length b is increased. Checking steps: Set the shift lever to the reverse posi- tion. Check that the reverse gate 1 contacts the stopper 2 on the bracket and the lever 3 contacts the reverse gate. Checking steps: Start the engine and then stop it. NOTE: When the engine has been stopped for 3 seconds, the YPVS valve assembly will retract and extend one time. Align the hole a in the pulley with the hole in the cylinder. CAUTION: Do not allow the oil tank to become com- pletely empty. Keep sparks, flame, cigarettes, etc., well away. If using or charging the battery in an enclosed space, make sure that it is well ventilated. Always shield your eyes when working near batteries.Von Funken, offenem Feuer, sifs.Filling steps: Remove each filler cap. Add distilled water. When the electrolyte level reaches the upper level mark, allow the cell to stand for 20 minutes. Make sure the battery leads are con- nected properly. Reversing the leads can seriously damage the electrical system. Inspection steps: Remove the ride plate. Refer to “JET PUMP UNIT” in Chapter Remove the water inlet cover 1. Inspect the water inlet strainer mesh Install the water inlet cover. Recommended grease: Yamaha marine grease, Yamaha grease A (Water resistant grease) 6. Fill: Intermediate housing Recommended grease: Yamaha marine grease, Yamaha grease A. REMOVAL Screw Knob Washer Fuel cock assembly Fuel hose Holder Fuel filter. Screw Knob Friction adjusting nut Choke cable Reverse the removal steps for installation. Engine unit Refer to “ENGINE UNIT” in Chapter 5. Hose clamp Disconnect the oil filler hose from the oil filler neck. Oil hose Bolt Tank belt Oil tank assembly Hose clamp Oil filler hose Oil level sensor Reverse the removal steps for installation. Oil level sensor inspection Refer to “INDICATION SYSTEM”. Oil tank Refer to “OIL TANK”. Hose clamp Disconnect the fuel filler hose from the fuel filler neck. Fuel breather hose Fuel tank assembly Hose clamp Fuel filler hose Hose clamp Fuel sensor assembly. Checking steps: Connect a hose to the end of check valve “A” and blow into it. Air should come out from end “B”. Connect the hose to the end of check valve “B”. Silencer plate Refer to “INTAKE DUCT AND SILENCER”. NOTE: Oil pump cable Before removing the oil pump cable, mark the cable’s installation position for reference when installing the oil pump cable. SEPARATION Hose Fuel suction Hose Fuel return Accelerator pump hose Remote throttle stop screw assembly Bolt Cable holder 4-15. Checking steps: Loosen the remote throttle stop screw 1 until untouched the screw end from the throttle lever. Check the each throttle valve is fully closed. Checking steps: Turn the choke lever 1 and check the each choke valve is fully closed. 2. Adjust: Choke valve synchronization Adjustment steps: Loosen the screws 1, 2. DISASSEMBLY Screw Stay Spring Spring seat Screw Accelerator pump cover assembly Spring Diaphragm Accelerator pump body Reverse the disassembly steps for assembly. CAUTION: Do not use steel wire for cleaning the jets. This may enlarge the jet diameters and seriously affect performance. CAUTION: Do not use a steel wire to clean the jets. This may enlarge the jet diameters and seriously affect performance. Carburetor assembly NOTE: Before assembling the carburetor, make. Carburetors Refer to “CARBURETOR”. Screw Fuel pump cover Gasket Not reusable Diaphragm O-ring Diaphragm body 4-26. Exhaust chamber assembly Refer to “EXHAUST CHAMBER ASSEMBLY” in Chapter 5. Intake duct Refer to “INTAKE DUCT AND SILENCER”. REMOVAL Bleed hose Air bleed screw Gasket Bleed hose stay Oil delivery hose 1 Oil delivery hose 2 Check valve Oil pump cable. DE POMPE A HUILE Flexible de purge Vis de purge d’air Joint Sangle du flexible de purge. CAUTION: If the oil delivery hoses are not full of oil, fill them up. Checking steps: Fully close the carburetor throttle valves. Check that the mark a on the oil pump lever is aligned with the mark b on the oil pump body. Fill the oil tank with the recommended oil. NOTE: If the oil pump is replaced or the oil suc- tion hose is reinstalled, bleed air from the oil suction hose by removing it from the oil pump. DISASSEMBLY Bolt Bolt Exhaust chamber joint Gasket Not reusable Exhaust chamber Reverse the disassembly steps for assembly. Exhaust chamber assembly Refer to “EXHAUST CHAMBER ASSEMBLY”.Bolt Intermediate housing grease hose NOTE: Remove the spark plug before removing the eye, and reinstall it to make removing the muffler assembly easier. Reverse the removal steps for installation. Exhaust temperature sensor Water temperature sensor Bolt Muffler stay Bolt Cover Gasket Not reusable Catalyst housing. LEADS REMOVAL Battery lead Refer to “ELECTRICAL BOX” in Chapter (negative and positive) Exhaust chamber assembly Refer to “EXHAUST CHAMBER. Gasket Not reusable Bolt 5-12. Reverse the removal steps for installation. Engine mount inspection 1. Carburetor unit Refer to “CARBURETOR UNIT” in Chapter 4. Bolt NOTE: Tighten the bolts in the proper sequence Reed valve plate as shown. Exhaust chamber assembly Refer to “EXHAUST CHAMBER ASSEMBLY”.Shaft 3 Shaft 2 Shaft 1 YPVS valve arm 5-21. Reverse the removal steps for installation. 5-22. YPVS valve installation 1. Muffler assembly Refer to “MUFFLER ASSEMBLY”. Spark plug NOTE: Bolt Tighten the bolts in the proper sequence Ground lead as shown and in three stages. YPVS Refer to “YPVS”. Cylinder head Refer to “CYLINDER HEAD”. NOTE: Bolt Tighten the bolts in a crisscross pattern and in two stages. Cylinders Refer to “CYLINDERS”. Piston pin clip CAUTION: Do not align the open end of the clip with the piston pin slot a. Reverse the removal steps for installation. 5-30. Piston pin and bearing inspection 1. REMOVAL NOTE: Bolt This washer holds the pickup coil lead. Washer Make sure to not pinch the lead between Cable holder the projection and the washer when Bolt. DE LA BOBINE EXPLORATRICE N.B.: Boulon. STARTER MOTOR REMOVAL Drive coupling Flywheel magneto bolt Flywheel magneto Woodruff key Starter clutch assembly Bolt Starter motor Reverse the removal steps for installation. DISASSEMBLY Clip Not reusable Clip stopper Spring seat Spring Washer Idle gear Circlip 5-39. Pinion gear Reverse the disassembly steps for assembly. 5-40. Flywheel magneto removal and installation 1. Pistons Refer to “PISTONS”. Generator cover and starter Refer to “GENERATOR AND STARTER motor MOTOR”. Bolt Mount bracket Bolt Bolt Bolt. Boulon Support de montage Goupille. Bolt Lower crankcase Crankshaft assembly Upper crankcase Reverse the disassembly steps for assembly. 5-44. Crankcase Refer to “CRANKCASE”. Oil seal Bearing Oil seal Crankshaft assembly CAUTION: Install the bearing locating pins into the gloves in the crankcase body. NOTE: Before inspection, thoroughly clean the bearings.Bolt Bolt Intake grate Bolt Intake duct Screw NOTE: Speed sensor Route the speed sensor lead between the jet pump unit and the bilge hose. PROPULSION Boulon Boulon. Paddle wheel set Not reusable Speed sensor housing Reverse the disassembly steps for assembly. NOZZLE RING REMOVAL Jet pump unit Refer to “JET PUMP UNIT”. HOUSING REMOVAL Nozzle ring Refer to “JET THRUST NOZZLE AND NOZZLE RING”. Impeller inspection Refer to “JET PUMP UNIT”. REMOVAL Exhaust system Refer to “EXHAUST SYSTEM” in Chapter 8. Jet pump unit Refer to “JET PUMP UNIT”. Engine unit Refer to “ENGINE UNIT” in Chapter 5. Rubber coupling Bolt Intermediate housing assembly NOTE: Shim Install the shims in their original locations. DISASSEMBLY Grease hose Grease nipple Grease nipple stay Nipple Driven coupling Washer Intermediate drive shaft 6-21. Intermediate drive shaft removal 1. Measure the clearance a at each bolt hole. Install the suitable shim from the table below.Ventilation hose, water Refer to “MUFFLER ASSEMBLY” in temperature sensor coupler Chapter 5. Exhaust temperature sensor Refer to “EXHAUST CHAMBER coupler. Damaged or mis- handled instruments will not measure properly. On an instrument powered by dry batter- ies, check the battery’s voltage periodi- cally replace batteries. To obtain the correct value, subtract the internal resistance from the displayed measurement. NOTE: Make sure that the adaptor leads are properly installed in the digital tester.When performing the spark gap test, take special care not to let sparks leak out of the removed spark plug cap. NOTE: If there is no spark, or the spark is weak, continue with the ignition system test. If a good spark is obtained, the problem is not with the ignition system, but possibly with the spark plug(-s) or another compo-. Fuse holder continuity: Between 1 and 2 Between 2 and 3 2. DISASSEMBLY Starter motor Refer to “GENERATOR AND STARTER MOTOR” in Chapter 5. O-ring Not reusable Bolt Starter motor front cover O-ring. BATTERY Refer to “ELECTRICAL” in Chapter 3. LIGHTING COIL Refer to “IGNITION SYSTEM”.BATTERY Refer to “ELECTRICAL” in Chapter 3. PICKUP COIL Refer to “IGNITION SYSTEM”. CDI UNIT Refer to “IGNITION SYSTEM”. LIGHTING COIL Refer to “IGNITION SYSTEM”.Bolt YPVS cable bracket YPVS servomotor coupler Bolt YPVS servomotor Spacer YPVS cable Slide the cover. NOTE: Make sure the pulley operates three sec- onds after the jumper lead is removed. CAUTION: Do not disassemble the YPVS servomotor unit. It is a sealed unit and if it is faulty it must be replaced. BATTERY Refer to “ELECTRICAL” in Chapter 3. LIGHTING COIL Refer to “IGNITION SYSTEM”. CDI UNIT Refer to “IGNITION SYSTEM”. WATER TEMPERATURE SENSOR Refer to “IGNITION SYSTEM”. EXHAUST TEMPERATURE SENSOR Refer to “IGNITION SYSTEM”. REMOVAL Multifunction meter coupler Holder Multifunction meter Reverse the removal steps for installation. 7-37. Disconnect the blue one-pin connector 1 and make sure the “WARNING”. Disconnect the white two-pin connec- tor (blue and black leads). Screw Handlebar cover Band Bolt NOTE: Handlebar cover stay Position the corrugated tube for the throt- Throttle cable tle cable as shown in the illustration so that the tube attaches to the end of the. QSTS cable (to jet thrust nozzle) Refer to “REMOTE CONTROL CABLES AND SPEED SENSOR LEAD”. Bolt QSTS converter with white tape a QSTS cable 2 QSTS cable 1. Handlebar Reverse the disassembly steps for assembly. Handlebar switch inspection Refer to “STARTING SYSTEM” in Chapter 7. Handlebar assembly installation 1. Install: Bands 1 NOTE: After inserting the QSTS cables, buzzer lead, handlebar switch lead and throttle cable into the grommets, tie the end of grommets with the bands. QSTS grip assembly Refer to “HANDLEBAR”.Steering console cover Refer to “STEERING CONSOLE COVER”. Steering cable end Refer to “REMOTE CONTROL CABLES AND SPEED SENSOR LEAD”. AND SPEED SENSOR LEAD REMOVAL Speed sensor coupler Screw. This could deform or loosen the cable end due to extreme angles and or pressure. Always hold the cables by the outer cover below the crimp. Remote control cables adjustment Refer to “CONTROL SYSTEM”. Circlip Pin (long) Pin (short) Wire Spacer Spacer Damper Hinge Reverse the disassembly steps for assembly. 8-23. REMOVAL Handlebar assembly Refer to “HANDLEBAR”. Fuel cock assembly Refer to “FUEL COCK AND FUEL FILTER” in Chapter 4. Steering console cover Refer to “STEERING CONSOLE COVER”. Band Ventilation hose Band Check valve Oil tank breather hose Fuel tank breather hose 8-26. Checking steps: Connect a hose to the end of check valve “A” and blow into it. Air should come out from end “B”. Connect the hose to the end of check valve “B”. Steering console cover Refer to “STEERING CONSOLE COVER”. Shift cable Refer to “REMOTE CONTROL CABLES AND SPEED SENSOR LEAD”. Install the shaft 3 to the base so that it come in contact with the stopper 4 as shown. Jet pump unit assembly Refer to “JET PUMP UNIT” in Chapter 6. Band Hose clamp Exhaust joint Hose clamp. Resonator assembly Rubber hose Hose clamp Water tank Rubber hose Plate Reverse the removal steps for installation. 8-37. Exhaust component parts sub-assembly 1. Engine assembly Refer to “ENGINE UNIT” in Chapter 5. Bolt Damper Bolt Engine mount Reverse the removal steps for installation. 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