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

E
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.

E
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.

E
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

E
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

E
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

E
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
E
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
E
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.

1-3
E
GEN
INFO
SAFETY WHILE WORKING
Under normal conditions of use there
should be no hazards from the use of the
lubricants mentioned in this manual, but
safety is all-important, and by adopting
good safety practises any risk is minimized.
A summary of the most important precau-
tions is as follows:
1. While working, maintain good stan-
dards of personal and industrial
hygiene.
2. Clothing which has become contami-
nated with lubricants should be
changed as soon as practicable and
laundered before further use.
3. Avoid skin contact with lubricants (e.g.,
do not place a soiled rag in your
pocket).
4. Hands and any other part of the body
which have been in contact with lubri-
cants or lubricant-contaminated cloth-
ing should be thoroughly washed with
hot water and soap as soon as practica-
ble.
5. To protect the skin, the application of a
suitable barrier cream to the hands
before working is recommended.
6. A supply of clean lint-free cloths should
be available for wiping purposes.
GOOD WORKING PRACTICES
1. The right tools
Use the recommended special tools to
protect parts from damage. Use the
right tool in the right manner – do not
improvise.
2. Tightening torque
Follow the tightening torque instruc-
tions. When tightening bolts, nuts and
screws, tighten the larger sizes first and
tighten inner-positioned fixings before
outer-positioned ones.

1-4
E
GEN
INFO
SAFETY WHILE WORKING
3. Non-reusable items
Always use new gaskets, packings, O-
rings, oil seals, split-pins, circlips, etc.,
on reassembly.
DISASSEMBLY AND ASSEMBLY
1. Clean parts with compressed air when
disassembling.
2. Oil the contact surfaces of moving parts
during assembly.
3. After assembly, check that moving parts
operate normally.
4. Install bearings with the manufacturer’s
markings on the side exposed to view
and liberally oil the bearings.
CAUTION:
Do not spin bearings with compressed air
because this will damage their surfaces.
5. When installing oil seals, apply a light
coat of water-resistant grease to the
outside diameter.

1-5
E
GEN
INFO
SPECIAL TOOLS
SPECIAL TOOLS
Using the correct special tools recom-
mended by Yamaha, will aid the work and
enable accurate assembly and tune-up.
Improvisations and using improper tools
can damage the equipment.
NOTE:
●
For U.S.A. and Canada, use part numbers
starting with “YB-”, “YM-”, “YU-” or
“YW-”.
●
For other countries, use part numbers
starting with “90890-”.
MEASURING
1. Dial gauge and stand
P/N. YU-03097, YU-01256
90890-01252
2. Digital multimeter
P/N. YU-34899-A
90890-06752
3. Pocket tester
P/N. YU-03112
90890-03112
4. Cylinder gauge set
P/N. YU-03017
90890-06759
5. Compression gauge
P/N. YU-33223
90890-03160
6. Engine tachometer
P/N. YU-08036-A
90890-06760
7. Spark gap tester
P/N. YM-34487
90890-06754
8. Peak voltage test harness
P/N. YW-06780
90890-06780
1
7
6
4
5
3
2
YU-03097
YU-01256
90890-01252
YU-34899-A 90890-06752
YU-03112
YU-33223 90890-03160
YU-03017
YU-08036-A 90890-06760
YM-34487 90890-06754
90890-03112 90890-06759
8YW-06780
90890-06780

1-6
E
GEN
INFO
SPECIAL TOOLS
REMOVAL AND INSTALLATION
1. Coupler wrench
P/N. YW-06551
90890-06551
2. Flywheel holder
P/N. YW-06550
90890-06550
3. Flywheel puller
P/N. YB-06117
90890-06521
4. Shaft holder (intermediate shaft)
P/N. YB-06552
90890-06552
5. Driver rod
(intermediate shaft and jet pump)
P/N. YB-06071, YB-06229
90890-06602, 90890-06605,
90890-06606
6. Bearing outer race attachment
(intermediate shaft)
P/N. YB-06016
90890-06626
7. Drive shaft holder (impeller)
P/N. YB-06151
90890-06519
8. Slide hammer set (jet pump bearing)
P/N. YB-06096
90890-06523, 90890-06531
9. Ball bearing attachment
(jet pump oil seal)
P/N. YB-06156
90890-06634
10. Bearing inner race attachment
(jet pump bearing)
P/N. YB-34474
90890-06662
12
3
4
5
67
8
90
YW-06551
90890-06551
YW-06550 90890-06550
YB-06117 90890-06521
YB-06552
90890-06552
YB-06071
YB-06229
90890-06602
90890-06605
90890-06606
YB-06016 90890-06626 YB-06151 90890-06519
YB-06096 90890-06523
90890-06531
YB-06156 90890-06634 YB-34474 90890-06662

E
1
2
3
4
5
6
7
8
9
SPEC
CHAPTER 2
SPECIFICATIONS
GENERAL SPECIFICATIONS .......................................................................... 2-1
MAINTENANCE SPECIFICATIONS ................................................................ 2-3
ENGINE..................................................................................................... 2-3
JET PUMP UNIT....................................................................................... 2-4
HULL AND HOOD .................................................................................... 2-4
ELECTRICAL ............................................................................................. 2-5
TIGHTENING TORQUES ................................................................................ 2-7
SPECIFIED TORQUES .............................................................................. 2-7
GENERAL TORQUE ................................................................................. 2-9
CABLE AND HOSE ROUTING ...................................................................... 2-10

2-1
SPEC
E
GENERAL SPECIFICATIONS
GENERAL SPECIFICATIONS
Item Unit Model
XL1200Ltd
MODEL CODE
Hull F0D
Engine 66V
DIMENSIONS
Length mm (in) 3,160 (124.4)
Width mm (in) 1,220 (48.0)
Height mm (in) 1,130 (44.5)
Dry weight kg (lb) 354 (780)
Vehicle capacity 3
PERFORMANCE
Maximum output kW (PS) @ r/min 114.0 (155) @ 7,000
Maximum fuel consumption R /h (US gal/h,
lmp gal/h)
64.0 (16.9, 14.1)
Cruising range hr 1.1
ENGINE
Engine type 2-stroke
Number of cylinders 3
Displacement cm
3
(cu. in) 1,176 (71.7)
Bore × stroke mm (in) 80.0 × 78.0 (3.15 × 3.07)
Compression ratio 5.9:1
Intake system Reed valve
Carburetor model
(manufacturer) × quantity
BN44 (MIKUNI) × 3
Enrichment control Choke valve
Scavenging system Loop charge
Lubrication system Variable oil injection
Cooling system Water cooled
Starting system Electric starter
Ignition system Digital CDI
Ignition timing Degree 18 BTDC ~ 24 BTDC
Spark plug model
(manufacturer)
BR8ES-11 (NGK)
Battery capacity V-Ah (kC) 12 - 19 (68.4)
Lighting coil A @ r/min 9 ~ 11 @ 6,000
DRIVE UNIT
Propulsion system Jet pump
Jet pump type Axial flow, single stage
Impeller rotation
(from rear)
Counterclockwise
Transmission Direct drive from engine
Nozzle angle (horizontal) Degree 24 + 24
Nozzle angle (vertical) Degree –7, –2, 3, 8, 13
Trim system Manual 5 positions
Reverse system Reverse gate

2-2
SPEC
E
PON*: Pump Octane Number
RON*: Research Octane Number
YAMALUBE 2-W*: YAMALUBE 2-W is developed for this water vehicle and available from a
Yamaha water vehicle dealer.
CAUTION:
Use only YAMALUBE 2-W oil. Using another oil can seriously damage the catalytic converter
and other engine components.
FUEL AND OIL
Fuel Regular unleaded gasoline
Minimum fuel rating PON* 86
RON* 90
Oil YAMALUBE 2-W*
Fuel/oil mixing ratio
(wide open throttle)
30:1
Fuel tank capacity R (US gal,
Imp gal)
70 (18.5, 15.4)
Fuel tank reserve capacity R (US gal,
Imp gal)
12 (3.17, 2.64)
Oil tank capacity R (US gal,
Imp gal)
5.5 (1.45, 1.21)
Item Unit Model
XL1200Ltd
GENERAL SPECIFICATIONS

2-3
SPEC
E
MAINTENANCE SPECIFICATIONS
MAINTENANCE SPECIFICATIONS
ENGINE
Item Unit Model
XL1200Ltd
CYLINDER HEAD
Warpage limit mm (in) 0.1 (0.004)
Compression pressure
*1
KPa (kg/cm
2
) 500 (5.0)
CYLINDERS
Bore size mm (in) 80.000 ~ 80.018 (3.1496 ~ 3.1503)
Taper limit mm (in) 0.08 (0.003)
Out-of-round limit mm (in) 0.05 (0.002)
Wear limit mm (in) Original cylinder bore + 0.04 (0.0016)
PISTONS
Diameter mm (in) Red: 79.899 ~ 79.902 (3.1456 ~ 3.1457)
Orange: 79.903 ~ 79.906 (3.1458 ~ 3.1459)
Green: 79.907 ~ 79.910 (3.1459 ~ 3.1461)
Purple: 79.911 ~ 79.914 (3.1461 ~ 3.1462)
Measuring point* mm (in) 22 (0.87)
Piston-to-cylinder clearance mm (in) 0.100 ~ 0.105 (0.0039 ~ 0.0041)
Wear limit mm (in) Cylinder bore – 0.105 (0.0041)
Piston pin bore inside
diameter
mm (in) 22.004 ~ 22.025 (0.8663 ~ 0.8671)
PISTON RINGS
Top
Type Keystone
Dimensions (B) mm (in) 1.47 ~ 1.49 (0.058 ~ 0.059)
Dimensions (T) mm (in) 2.8 ~ 2.9 (0.110 ~ 0.114)
End gap mm (in) 0.45 ~ 0.60 (0.018 ~ 0.024)
Ring groove clearance mm (in) 0.02 ~ 0.07 (0.001 ~ 0.003)
2nd
Type Keystone
Dimensions (B) mm (in) 1.47 ~ 1.49 (0.058 ~ 0.059)
Dimensions (T) mm (in) 2.8 ~ 2.9 (0.110 ~ 0.114)
End gap mm (in) 0.45 ~ 0.60 (0.018 ~ 0.024)
Ring groove clearance mm (in) 0.02 ~ 0.07 (0.001 ~ 0.003)
PISTON PINS
Diameter mm (in) 21.995 ~ 22.000 (0.8659 ~ 0.8661)
Wear limit mm (in) 21.990 (0.8657)
*1: At 760 mmHg and 20 ˚C (68 ˚F).

2-4
SPEC
E
MAINTENANCE SPECIFICATIONS
JET PUMP UNIT
HULL AND HOOD
CRANKSHAFT ASSEMBLY
Crank width A mm (in) 72.95 ~ 73.00 (2.872 ~ 2.874)
Deflection limit B mm (in) 0.05 (0.002)
Deflection limit C mm (in) 0.15 (0.006)
Big end side clearance D mm (in) 0.25 ~ 0.75 (0.010 ~ 0.030)
Maximum small end axial
play E
mm (in) 2.0 (0.08)
CARBURETORS
Type Floatless
Identification mark #1: 66V-01, #2: 66V-02, #3: 66V-03
Main nozzle mm (in) 3.2 (0.13)
Main jet 117.5
Pilot jet 87.5
Throttle valve 180
Valve seat size mm (in) 1.2 (0.05)
Trolling speed r/min 1,350 ± 50
REED VALVES
Thickness mm (in) 0.6 (0.024)
Reed valve stopper height mm (in) 10.4 ~ 11.0 (0.41 ~ 0.43)
Reed valve warpage limit mm (in) 0.2 (0.01)
Item Unit Model
XL1200Ltd
JET PUMP
Impeller material Stainless steel
Number of impeller blades 3
Impeller pitch angle Degree 15.6
Impeller clearance mm (in) 0.8 (0.031)
Impeller clearance limit mm (in) 0.9 (0.035)
Drive shaft runout limit mm (in) 0.3 (0.012)
Nozzle diameter mm (in) 86.8 (3.42)
Item Unit Model
XL1200Ltd
FREE PLAY
YPVS cable slack mm (in) 0.5 ~ 1.5 (0.02 ~ 0.06)
Throttle lever free play mm (in) 4 ~ 7 (0.16 ~ 0.28)
Item Unit Model
XL1200Ltd

2-5
SPEC
E
MAINTENANCE SPECIFICATIONS
ELECTRICAL
Item Unit Model
XL1200Ltd
BATTERY
Type Fluid
Capacity V-Ah (kC) 12 - 19 (68.4)
CDI UNIT (B/W – B)
Output peak voltage lower
limit
@cranking 1 V 200
@cranking 2 V 180
@2,000 r/min V 190
@3,500 r/min V 180
STATOR
Pickup coil (W/R – B/O)
Output peak voltage
lower limit
@cranking 1 V 5
@cranking 2 V 2.8
@2,000 r/min V 7.9
@3,500 r/min V 11
Lighting coil (G – G)
Output peak voltage
lower limit
@cranking 1 V 9
@cranking 2 V 9
@2,000 r/min V 14
@3,500 r/min V 14
Pickup coil resistance Ω (color) 445 ~ 545 (W/R – B/O)
Lighting coil resistance Ω (color) 0.49 ~ 0.59 (G – G)
Minimum charging current A @ r/min 9 @ 6,000
IGNITION COIL
Minimum spark gap mm (in) 10 (0.39)
Primary coil resistance Ω (color) 0.26 ~ 0.36 (B/W – Ground)
Secondary coil resistance k Ω (color) 3.5 ~ 4.7 (B/W – Spark plug lead terminal)
Spark plug lead resistance
#1 k Ω 6.1 ~ 14.3
#2 k Ω 4.6 ~ 11.1
#3 k Ω 3.1 ~ 7.7
Cranking 1: unloaded
Cranking 2: loaded