Yamaha WaveRunner XL1200Ltd User manual

LIT186160198
LIT-18616-01-98 F0D-28197-Z9-11
SERVICE
MANUAL
WaveRunner
XL1200Ltd

E
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
All rights reserved.
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

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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.

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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.

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HOW TO USE THIS MANUAL
1 To help identify parts and clarify procedure steps, there are exploded diagrams at the start
of each removal and disassembly section.
2 Numbers are given in the order of the jobs in the exploded diagram.
3 Symbols indicate parts to be lubricated or replaced (see “SYMBOLS”).
4 A job instruction chart accompanies the exploded diagram, providing the order of jobs,
names of parts, notes in jobs, etc.
5 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)
6 Jobs requiring more information (such as special tools and technical data) are described
sequentially.
10 ×25 mm
D
L

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A50001-1-4
SYMBOLS
Symbols 1 to 9 are designed as thumb-
tabs to indicate the content of a chapter.
1 General Information
2 Specifications
3 Periodic Inspection and Adjustment
4 Fuel System
5 Power Unit
6 Jet Pump Unit
7 Electrical System
8 Hull and Hood
9 Trouble-analysis
Symbols 0 to E indicate specific data:
0 Special tool
A Specified liquid
B Specified engine speed
C Specified torque
D Specified measurement
E Specified electrical value
[Resistance ( Ω ), Voltage (V), Electric current
(A)]
Symbol F to H in an exploded diagram
indicate the grade of lubricant and the loca-
tion of lubrication point:
F Apply YAMALUBE 2-W oil
G Apply water resistant grease
(Yamaha grease A, Yamaha marine grease)
H Apply molybdenum disulfide grease
Symbols I to N in an exploded diagram
indicate the grade of the sealing or locking
agent, and the location of the application
point:
I Apply Gasket Maker

J Apply Yamabond #4
(Yamaha bond number 4)
K Apply LOCTITE

No. 271 (Red LOCTITE)
L Apply LOCTITE

No. 242 (Blue LOCTITE)
M Apply LOCTITE

No. 572
N Apply silicone sealant
NOTE:
In this manual, the above symbols may not
be used in every case.
12
34
56
78
90
AB
CD
EF
GH
IJ
KL
MN
GEN
INFO SPEC
INSP
ADJ FUEL
POWR
JET
PUMP
–+
ELEC
HULL
HOOD
TRBL
ANLS
T
R
.
.
E
AM
GM 4
271
LT
242
LT
572
LT LT
SS

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INDEX
GENERAL INFORMATION
1
SPECIFICATIONS
2
SPEC
PERIODIC INSPECTION AND
ADJUSTMENT
3
FUEL SYSTEM
4
FUEL
POWER UNIT
5
POWR
JET PUMP UNIT
6
JET
PUMP
ELECTRICAL SYSTEM
7
ELEC
HULL AND HOOD
8
HULL
HOOD
TROUBLE-ANALYSIS
9
GEN
INFO
INSP
ADJ
–+
TRBL
ANLS
A30000-0

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1
2
3
4
5
6
7
8
9
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
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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
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GEN
INFO
SAFETY WHILE WORKING
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.