2001 Tech Update - LIT-18500-00-01

WaterCraft Technical Update
2001
©2001 by Yamaha Motor Corporation, U.S.A.
February 2001
All rights reserved. Any reprinting

or unauthorized use
without the written permission of
Yamaha Motor Corporation, U.S.A.
is expressly prohibited.
Printed in U.S.A.
Specifications, features and options are subject to
change without notice.
00-311
2001 WaterCraft Technical Update
Welcome
The 2001 year WaterCraft Technical Update
Seminar has been developed to provide
Yamaha dealers with a convenient, one-day
overview of the service needs of newly
released models as well as those models cur-
rently in the marketplace. The seminar is
intended to help you achieve through product
knowledge, an element critical to your efforts to
attain the highest level of customer satisfaction.
This booklet is an important part of the semi-
nar. It provides you with a reference source
your dealership can turn to again and again for
useful information. You’ll find important infor-
mation, significant features and benefits, and
key maintenance and repair points for new
models, as well as updated technical informa-
tion about the units you service every day.
Thank you for your involvement in Yamaha’s
quality service effort. The importance of quality
service to overall customer satisfaction and
your dealership’s growth and profitability can-
not be over emphasized. We hope you’ll find
this booklet to be a useful tool to that end.
Best wishes for a great season!
2001 WATERCRAFT TECHNICAL UPDATE

TABLE OF CONTENTS
WAVERUNNER
1. 2001 Product Information
Model Update Information
XLT1200 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
GP1200R . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
SUV1200 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
XL800 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
GP800R . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
XL700 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
SJ700 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
New Model Information
XLT1200 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6
GP800R . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9
2. 2001 Super Jet / WaveRunner Model Guide
3. 2001 Model Color and Graphics Guide - WaveRunner
XLT1200 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
GP1200R . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
SUV1200 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
XL800 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
GP800R . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7
XL700. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8
SJ700 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9
4. Technical Tips - WaveRunner
Technical Literature Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9
Oil Pump Output Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11
Performance Troubleshooting - “Jet Pump” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-15
Impeller and Impeller Housing Erosion - GP1200R’s, XL1200 Ltd. . . . . . . . . . . . . . . . . 4-17
Performance Troubleshooting “Carburetion” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-18
Carburetor Adjusting Tips . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-21
Catalytic Converter Failure Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-24
Power Valve Improvements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-26
GP1200 Oil Tank Vent Pinched . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-27
Troubleshooting Water Entering the Hull Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-28
Crankshaft Failure Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-30
Parts List Correction: Engine Mounting Spacers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-32
Parts List Correction: Ride Plate Nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-33
Erratic Power-Valve Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-34
Carburetor Settings - 2001 Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-35
Impeller Application Chart - WareRunner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-37
Paint Application Chart - WaveRunner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-39
Paint Color Codes - WaveRunner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-40
Gelcoat Color Codes - WaveRunner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-41
i
TABLE OF CONTENTS (Cont’d.)
5. Technical Bulletins/Tech Exchanges- WaveRunner

6. Service Data - WaveRunner
GP1200R . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
XLT1200 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4
SUV1200 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6
XL800 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8
GP800R . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-10
XL700 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-12
SJ700 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-14
7. WaveRunner Accessory Installation Instructions
XL/WaveVenture Boarding Step Installation Instructions . . . . . . . . . . . . . . . . . . . . . . 7-3
SUV Boarding Step Installation Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-7
XLT1200/XL1200 Ltd./XL800 Boarding Step Installation Instructions . . . . . . . . . . . 7-11
SPORT BOAT
8. 2001 Product Information - Sport Boat

New Model Information
XR1800 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3
LS2000 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3
Model Update Information
XR1800 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-4
LS2000 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-5
9 2001 Model Color and Graphics Guide - Sport Boat
LS2000 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-3
XR800 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-4
10. Technical Tips - Sport Boat
Technical Literature Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-3
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-5
Oil Pump Output Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-7
Performance Troubleshooting “Carburetion” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-11
Carburetion Adjusting Tips . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-14
XR1800 Stalling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-17
Catalytic Converter Failure Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-19
Power-Valve Improvements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-21
Parts List Correction: XR1800 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-22
Parts List Correction: LS2000 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-23
Troubleshooting Water Entering Hull Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-24
Cleanout Hose Sealing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-26
Crankshaft Failure Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-27
Erratic Power-Valve Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-29
Stereo Mounting LS2000 and XR1800 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-30
XR1800 Seat Arm Pad Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-32
Carburetor Settings - 2001 Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-33
Gelcoat Application Chart/Color Code Chart - All Sport Boats . . . . . . . . . . . . . . . . . . 10-34
ii
TABLE OF CONTENTS (Cont’d.)
11. Technical Bulletins/Tech Exchanges - Sport Boat

12. Service Data - Sport Boat
XR1800 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-2
LS2000 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-4
13. Accessory Installation Instructions - Sport Boat
Bimini top Installatin Instructions - XR1800 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-3
AM/FM-CD Stereo Kit Installatin Instructions - XR1800 . . . . . . . . . . . . . . . . . . . . . . . . 13-9
Front Speakers (Optional) Installation Instructions - XR1800 . . . . . . . . . . . . . . . . . . .13-13
Stereo/Receiver Installation Instructions - Exciter 270/LS2000 . . . . . . . . . . . . . . . . . 13-15
Marine Speakers Installation Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-17
Yamaha Billet Aluminum Fuel Cap Installation Instructions . . . . . . . . . . . . . . . . . . . . 13-21
Billet Aluminum Rear Boarding Handles Installation Instructions
- LS2000 & XR1800 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-23
LS2000 Swim Platform Mat Set Installation Instructions . . . . . . . . . . . . . . . . . . . . . . 13-25
Swim Platform or Interior Mat Set Installation Instructions . . . . . . . . . . . . . . . . . . . . . 13-27
Yamaha Aqua Mat Marine Carpet Kit Installation Instructions . . . . . . . . . . . . . . . . . . .13-29
LS2000 Ski Pylon Installation Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-31
Billet Aluminum Gauge Bezel - ’99~’01 LS2000 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-37
Billet Aluminum Steering Wheel Cover - ’99~’01 Sport Boats . . . . . . . . . . . . . . . . . . 13-39
Billet Aluminum Horn Grill - ’99~’01 Sport Boats . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-41
Billet Aluminum Hand Grip - ’99~’01 Sport Boats . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-43
14. Wiring Diagrams - WaveRunner and Sport Boat
WaveRunner:
GP1200R . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-5
SUV1200 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-7
XLT1200 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-9
GP800R . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-11
XL800 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-13
XL700 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-15
SJ700 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-17
Sport Boat:
LS2000 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-21
XR1800 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-23
iii
Section 1
2001 WaveRunner®
Product Information
1-1
1-2
2001 WaterCraft Technical Update - Product Information
2001 Water Vehicles
MODEL UPDATE INFORMATION

XLT1200
New colors for 2001
Focus on rider comfort and towing capabilities
New ride plate and impeller
GP1200R
New Metallic Blue cowling with white deck and hull
Proven winner during 2000 racing season
SUV1200
New colors for 2001 featuring a dark red hull, white deck and red cowlings
Same great handling progressive stepper-draft deep-V hull
1-3
2001 Water Vehicles
XL800
New style graphics with dark green cowlings from last year’s XL1200 Ltd.
White hull and deck for 2001
GP800R
New Model based on the winning GP1200R Hull and XL800 Engine
New Metallic Blue cowling with white deck and hull
New style graphics and blue seat
XL700
80hp two cylinder 701cc engine
Three passenger watercraft
Unchanged for 2001
1-4
2001 Water Vehicles
SJ700
73hp, two cylinder, 701cc engine
Single passenger watercraft
Unchanged for 2001
1-5
WaveRunner XLT1200
NEW MODEL INFORMATION

CONCEPT
1. To develop a high-performance yet versatile
watercraft for multipurpose use.
2. To achieve smoother power delivery, better 2001 XLT1200
maneuverability, higher stability and towing XL1200 Ltd.
capabilities.
Hull:
Multi-chined V-shaped hull. Same as
XL1200 Ltd.
100MM
New style sponson as STD equipment
100mm Longer ride plate for quicker plan-
ing and increased stability
1-6
WaveRunner XLT1200 (Cont’d.)
FEATURE MAP
Deck:
New lighter front lid with limiting strap
allowing lid to open further
Large stepped seat for added comfort
Same multifunction meter as XL1200 Ltd.
with PADLOC system
New air intake design increases air flow

while cruising, for better engine breathing
and engine room ventilation
1-7
WaveRunner XLT1200 (Cont’d.)
Engine:
Sound suppression from the GP1200R is
now used in the intake
Carburetors feature an insulator plate

between the engine and the intake manifold
for improved resistance to heat
Carburetor mounting flange and throttle

shaft boss has been enlarged for increased
rigidity
Jet Pump:
155mm Hyper FlowJet Pump
Newly designed 3-blade, stainless steel
impeller for reduced slip and increased
durability
New impeller housing with a thicker liner for
increased durability
Large redesigned reverse gate no longer
has holes in the center
NEWLY DESIGNED IMPELLER
1-8
WaveRunner GP800R

CONCEPT Hull:
1. To develop a watercraft with good accelera- New semi-V shaped hull from the same
tion, fuel efficiency and a lightweight feel at design as the GP1200R
mid-range speeds.
Deck:
2. Use the proven high-performance engine
found on the WaveRunner GP800, matched New generation styling
with the race winning hull from the
Handlebar mounted choke lever
GP1200R.
“GPR” type multifunction meter design
Engine:
Proven twin cylinder 784cc engine produc-
ing 120hp
“YSSS” (Yamaha Sound Suppression
System)
Jet Pump:
Same 155mm jet pump found on the
GP1200R with an all new 3-blade, stainless
steel impeller.
1-9
WaveRunner GP800R (Cont’d.)
FEATURE MAP
MULTIFUNCTION INFORMATION CENTER

NEW GENERATION STYLING
EASILY ACCESSIBLE CHOKE LEVER ON HANDLEBAR
WINDSCREEN
HIGH-PERFORMANCE
SEMI-V HULL
WITH DOUBLE
SPLASH GUARD LARGE AFT-DECK
FIVE POSITION QSTS
FOAM FILLED
INNER HULL
MULTI-GROOVED
HIGH-PERFORMANCE, TWIN-CYLINDER, 784CM3 TRIM TABS
(47.84 CU. IN) 88.2KW (120PS) ENGINE ADJUSTABLE SPONSONS
1-10
HULL
SMC (Sheet Molded Compound) hull
design with a foam filled inner hull liner to
increase hull strength and rigidity
Same Hull design as the GP1200R INNER HULL
Semi-V shaped design for superior stability

yet a light feel at mid-speed
FLOAT (FILLED WITH
FOAM MATERIAL)
SEMI-V HULL
Yamaha Adjustable Sponsons (YAS)

Two position adjustment to allow tuning of
the watercraft to different riding styles and
conditions
Standard position is up for maximum
speed. Can be easily lowered for increased
stability
With sponsons in the lower position, cor-
nering ability is increased and porpoising is
reduced
Double splash guards (as on the

GP1200R) to suppress splash and improve
rider visibility
Multi-grooved trim tabs (same as
GP1200R)
1-11
DECK
Handlebar mounted choke lever for added
convenience and ease of starting
Bow storage compartment with push button
opening.
Integral windscreen for added protection.
CHOKE LEVER
“GPR” type multifunction meter

Large digital speedometer display with
easy-to-read analog tachometer and eight
bar fuel gauge
Warning indicators for “Low Fuel”, “Low
Oil”, and “Engine Overheat”
Audible alarm can be silenced with the
“Reset” button
RESET BUTTON
(STOPPING THE WARNING BUZZER) HOUR METER
SPEEDOMETER (MPH)
ENGINE R/MIN
FUEL LEVEL METER
YAMAHA
8 MPH HOUR FUEL
7
6
5 MULTI
DISPLAY
4
3 WARNING
2
RESET 1
x1000r/min
FUEL WARNING INDICATOR
OIL WARNING INDICATOR ENGINE OVERHEAT WARNING INDICATOR
1-12
ENGINE
Proven 784cc, 120hp engine using YPVS
technology. Same design as GP800Y.
Two independent ceramic-plated cylinders.
The ceramic plating offers superior durabil-
ity and heat dissipation.
YPVS
The same type of power-valve is used on
the GP1200R. YPVS provides a broader
power curve than can be achieved on a
non-YPVS equipped engine.
A new YPVS map is used to match the
GP800R’s characteristics.
The YPVS is battery driven with an internal

processor that chooses the proper mode
based on the signal from the CDI unit, then
positions the power valves for the maxi-
mum possible performance.
1-13
COOLING SYSTEM
Cooling water is forced from the Jet Pump The pilot outlets even out the volume of
Inlet 1 (through the Cooling Water Inlet water to the exhaust cooling passage
Hose) 2 to the lower part of Exhaust
The remaining water flows through Exhaust
Chamber 1 3
Chamber 2 8, to the Exhaust Outer Cover
Water is then pre-heated as it flows through 9, where part of it exits through the Water
Exhaust Chamber 1 3, to the passages of Bypass Hose 10 and to the Exhaust Outlet
the cylinders 4, and out the Cylinder Head 11
5 The remaining water in the Exhaust Outer
This cooling water is then split between the Cover mixes with the exhaust gases, enters
two Pilot Outlets 6 and the Bypass Hose the Water Lock and12exits the Hull.
7 of Exhaust Chamber 1
BILGE OUTLET HOSE

11 EXHAUST
9 EXHAUST
OUTLET
5 CYLINDER OUTER COVER 10
HEAD BYPASS
HOSE
8 EXHAUST
CHAMBER #2
6 PILOT HOSE 1 JET PUMP

INLET
7 BYPASSHOSE 4
12
CYLINDERS
WATER
LOCK
3
EXHAUST 2
CHAMBER #1 COOLING
WATER
INLET HOSE
PILOT
WATER HOSES
1-14
INTAKE SYSTEM:
Resonator chambers and baffles are used in

the flame arrestor to suppress air intake AIR INTAKE AIR INTAKE CHAMBER
noise.
Intake system chambers are also used to RESONATOR

reduce engine noise as the air enters the
engine compartment through the deck.
AIR INTAKE CHAMBERS
1-15
EXHAUST SYSTEM:
An exhaust resonator system is used to

WATER TANK
reduce noise. The resonator chamber uses
WATER LOCK
sound wave cancellation technology to
reduce exhaust noise.
EXHAUST SYSTEM
JET PUMP:
Same jet pump design as the GP1200R for

increased power and thrust.
Newly designed impeller to match the power
of the 800cc engine to the new hull.
Yamaha’s five position QSTS is used to pro-
vide adjustability under all conditions.
A 5° up nozzle is used. (same as the
GP1200R).
5ß
FIVE-POSITION QSTS
IMPELLER
1-16
ELECTRICAL:
Digital DC CDI, Microcomputer controlled

with five modes of operation and over-rev
protection. Over-rev is activated at 7500
rpm.
Each mode has its own ignition map to vary
the ignition timing.
The overheat protection mode is activated if
the cooling water temperature exceeds
80°C (176°F). The overheat protection map
is activated and the engine rpm is reduced
by 400 rpm per second till 3400 rpm is
reached. This will continue until the water
temperature drops below 70°C (158°F).
During normal operation, one of four ignition
maps are selected based on the engine
speed and the current acceleration ratio.
These are listed on the chart to the right.
SYSTEM DIAGRAM
1-17
1-18
Section 2
2001 SuperJet/ WaveRunner®
Model Guide
2-1
2-2
2001 WaterCraft Technical Update - 2001 Model Guide
2-3
2-4
PURPOSE OF ISSUE
This Model Guide is to provide Yamaha dealers with information about updates to Yamaha s continuing line of
watercrafts for 2001.
The information within this Model Guide may be used by Yamaha dealers to get up-to-date knowledge about
recent changes and modifications to Yamaha s watercrafts line-up.
This guide will also help dealers prepare the parts and service departments for the new model year.
This guide contains information applicable to watercrafts in every market.
NOTE:
● This information was released as of the end of September, 2000.
● Some updated items are not described in this guide. New model information is described in the applicable
Service Guide, Technical Service Information, or Technical Bulletin.
2-5
TABLE OF CONTENTS
CONTENTS AND FORMAT ............................................................2-7

3
STARTING SERIAL NUMBER .......................................................2-7
3
IMPROVED ITEMS..........................................................................2-8 4
IMPROVED ITEMS ......................................................................2-8 4
MODEL APPLICATION TABLE ......................................................2-8 4
DETAIL OF IMPROVED ITEMS ......................................................2-9 5
A-1 Fuel return hose ...............................................................2-9 5
A-2 Fuel suction hose .............................................................2-10 6
A-3 Carburetor body ...............................................................2-11 7
A-4 Pilot water .......................................................................2-12
8
A-5 Flushing attachment .........................................................2-13 9
2-14
COMPONENT INTERCHANGEABILITY....................................... 10
MODEL APPLICATION LIST......................................................... 13
2-17
2-6
CONTENTS AND FORMAT

The Model Guide consists of the following sections:
Starting Serial Number - a detailed list of each model s starting serial number.
Improved Items - detailed updates that were added during the year. The details are categorized from A1 to
A5 .
Component Interchangeability - shows how parts on the updated model relate to equivalent parts on the pre-
vious model.
Model application list - shows the same component part among the updated models.
STARTING SERIAL NUMBER

Starting Serial Number
Model Name Model Code
USA Canada Europe and other
SJ700 GM6 915240 NA 915340
WB800 F0N NA
XL700 F0M 810481 NA 811581
GP760 GP7 816297
XL800 F0P 808001 NA 809001
GP1200R F0X 809301 NA NA
GU5 700101 NA NA
SUV1200
F1D NA
2-7
IMPROVED ITEMS
IMPROVED ITEMS
A-3: Carburetor body
A-1: Fuel return hose A-5: Flushing attachment
A-4: Pilot water
A-2: Fuel suction hose
MODEL APPLICATION TABLE

SuperJet WaveRunner
Item No. SJ700 XL700 XL800 GP1200R SUV1200
GM6 F0M F0P F0X GU5
64V 67E 67A 67X 66G
A-1
A-2
A-3
A-4
A-5
2-8
2-9
2-10
2-11
2-12
A-5 Flushing attachment

Model: XL700, XL800, SUV1200
Modification: The flushing attachment has been Benefit: Easy to store on the watercraft.
made compact.
2000 2001
2-13
COMPONENT INTERCHANGEABILITY
Do not use this list to order spare parts.
This parts interchangeability list is only for referencing the modified components.
Therefore, the information is limited only to the major components. Information about nuts, washers, etc., is
not shown.
When ordering, please use the 2001 model s parts catalog to determine part numbers.
A: Both new and previous parts are interchangeable with both new and previous watercrafts.
Previous parts Previous watercrafts
New parts New watercrafts
B: Only new parts are interchangeable with both new and previous watercrafts.
C: No interchangeability
: Interchangeable as a set
2-14
A-1 Fuel return hose

Model: SJ700
Previous Part
Parts Name New Part Number Interchangeability Remarks
Number
Hose 90445-10MF1 90445-10MF1 A No change
Model: SUV1200
Previous Part
Number
Hose 90445-11M60 90445-11M60 A No change
Model: XL700
Previous Part
Number
Hose 90445-10MA1 90445-10MA1 A No change
Model: XL800
Previous Part
Number
Hose 90445-10MJ0 67A-14298-00 A
A-2 Fuel suction hose

Model: XL700
Previous Part
Number
Hose 90445-10MG0 90445-10MG0 A No change
Model: XL800
Previous Part
Number
Hose 90445-10MH9 67A-14924-00 A
A-3 Carburetor body

Model: XL800
Previous Part
Number
Carburetor 67A-14100-00 67A-14100-01 A
Model: GP1200R
Previous Part
Number
Carburetor 67X-14100-00 67X-14100-01 A Catalyst
2-15
A-4 Pilot water
Model: XL800
Previous Part
Number
Hose 67A-12588-00 90445-14003 B
Hose 67A-12589-00 90445-14M33
Tube 90446-24M94 NA
Tube 90446-24M52 90447-19003
Connection 66E-51142-00 NA
Clamp 90450-14M05 NA
Pilot F0D-6753B-02 F0P-6753B-00
Nut GU0-61652-00 F0X-62733-00
Washer 92990-16200 NA
Model: GP1200R
Previous Part
Number
Hose 66V-12589-00 90445-14M09 B
Hose 67X-12589-00 90445-14M18
Pilot GU0-6753B-00 F0X-6753B-00
Nut GU0-61652-00 F0X-62733-00
Washer 92990-16200 NA
A-5 Flushing attachment

Models: XL700, XL800, SUV1200
Previous Part
Number
Attachment 63M-12590-00 67X-12590-00 A
2-16
MODEL APPLICATION LIST

Fig. 1 CYLINDER/CRANKCASE
Watercraft 2001 Model

MODEL SJ700 XL700 XL800 GP1200R SUV1200
GM6 F0M F0P F0X GU5 REF. NO.
PART NAME 64V 67E 67A 67X 66G
CRANK CYLINDER ASSY 64V-01-8P 62T-02-8P 66E-11-8P 66V-01-8P 65U-01-8P
1
-W0090-
CRANK CASE ASSY 62T-00-94 62T-00-8P 66E-10-8P 66V-00-8P 65U-00-8P
2
-15100-
CYLINDER 1 61X-01-94 62T-00-94 66E-00-94 66V-00-94 65U-00-94
3
-11311-
GASKET CYLINDER 1 63M-01
4
-11351- 6M6-A2 66E-01
HEAD CYLINDER 1 64U-00-94 62T-00-94 66E-00-94 66V-01-94 65U-00-94
5
-11111-
GASKET H/CYLINDER 1 66E-00 66V-00 65U-00
6
-11181- 62T-00
BRACKET 1 66E-21426-10 66V-21426-00 63M-03-94
7
-21415- 6R7-01-94
BRACKET 2 66E-10-8P 66V-00-8P 63M-01-94
8
-21425- 6R7-01-94
MOUNT RUBBER 6R7-00-9M 66V-00-8P 63M-01-5B
9
-44517- 6M6-A1-5B
2-17
Fig. 2 CRANKSHAFT/PISTON

CRANKSHAFT ASSY 64X-03 62T-02 66E-00 66V-00 65U-00
1
-11400-
PISTON (STD) 61X-00-93 62T-00-92 65U-00-89
2
-11631- N/L N/L
PISTON RING SET (STD) 66E-01 66V-00 65U-00
3
-1160*- 61X-00
PIN PISTON 61X-00
-11633- 62T-00 4
66E-00
BEARING CYLINDRICAL
93310- 320U2 5
442U2
BEARING 307U0 000U6 000U4
6
93305- 30601
BEARING
93306- 307U3 7
308U1
CIRCLIP
8
93440- 80023 N/L N/L
WASHER PLATE
90201- 20M04 9
22M04
CIRCLIP
10
93450- 21053 N/L N/L
FLANGE COUPLING 1 63M-01-8P
11
-45813- 6M6-32-8P 66E-10-94
RUBBER SHAFT COUPLING 63M-00
12
-4581J- 61X-00 66E-00
FLANGE COUPLING 2 63M-01-8P
13
-45813- 6M6-22-8P 66E-10-94
2-18
Fig. 3 INTAKE

ELEMENT AIR CLEANER 66E-00 66V-00 65U-00
1
-14451- 62T-00
GASKET MANIFOLD 66E-00 66V-00 65U-00
2
-13556- 62T-00
MANIFOLD INTAKE 65U-00-8P
3
-13555- 62T-00-8P N/L N/L
GASKET 65U-00
4
-13566- 62T-00 N/L N/L
GASKET AIR COOLER 65U-00
5
-13674- 62T-00 66E-13473-00
PLATE REED VALVE 66E-10 66V-00
6
-13624- 62T-00 N/L
REED VALVE ASSY 66E-00 66V-00 (#2) 65U-00
7
-13610- 62T-00 66V-13620-00 (#1, #3)
REED SET 66E-00 66V-00 65U-00

8
-W0004- 62T-00
COVER CARBURETOR 1 66E-14480-10 66V-14480-01 65U-00
9
-14283- 62T-00
COVER CARBURETOR 2 62T-10-8P 62T-01-8P 66E-1441E-0 66V-00 65U-02-8P
10
-14284-
2-19
Fig. 4 CARBURETOR

CARBURETOR ASSY 1 64U-02 62T-02 67A-01 67X-01 66G-01
-14301-
CARBURETOR ASSY 2 64U-02 62T-02 67A-01 67X-01 66G-01
1
-14302-
CARBURETOR ASSY 3 67X-01 66G-01
-14303- N/L N/L N/L
VALVE, CHECK
-24421- 6K8-10 2
N/L 66E-00
BODY 2
-24413- 6M6-01 3
66E-01
DIAPHRAGM
-24411- 6K8-20 4
66E-00
NEEDLE
5
-14916- 61X-15 64T-00
BODY 1
-24412- 6R7-01 6
66E-00
DIAPHRAGM PUMP
7
-14541- 6R7-00
JET MAIN (-1423*-) 3G2-24 (#120) 3G2-30 (#150) 3G2-74 (#117.5) 3G2-27 (#135)
8
3G2-26 (#130)
JET PILOT (-1423*-) 830-14 (#70) 830-64 (#67.5) 830-18 (#90) 1HX-68 (#87.5) 830-20 (#100)
830-19 (#95) 9
830-70 (#97.5)
2-20
Fig. 5 OIL PUMP/OIL TANK

OIL INJ, PUMP ASSY 61X-12 66E-02 66V-00 66G-01
1
-13200- N/L
GASKET PUMP CASE 6R8-A0
2
-13116- N/L 63M-00
VALVE, CHECK
3
-13183- N/L 6R3-00
TANK OIL GJ3-U775B-01 GU5-U775B-01
4
-6775B- N/L F0D-U775B-02
FILTER 6J8-13411-00
5
-6775*- N/L F0D-01
OIL TANK CAP ASSY
6
-67840- N/L GJ3-U778B-00 F0X-0778B-00
ROLL OVER VALVE
7
-67766- N/L FJ0-00
2-21
Fig. 6 EXHAUST

MUFFLER 1 61X-01-9P 62T-10-9P 66E-10-8P 66V-00-8P 63M-00-94
1
-14711-
PROTECTOR MUFFLER 1 6M6-01-9P 63M-00-9P
2
-14718- N/L N/L N/L
GASKET EX, OUTER COVER 6R7-A0 62T-01 66V-00 63M-00
3
-41114- N/L
GASKET EX, INNER COVER 62T-00
4
-41122- N/L N/L N/L N/L
INNER COVER EXHAUST 62T-00-9M 66V-41111-01 63M-00-94
5
-41121- N/L N/L
GASKET EX, OUTER COVER 62T-00 66E-10 66V-00
6
-41124- N/L N/L
OUTER COVER EXHAUST 62T-01-9M 67A-00 67X-00 63M-00-94
7
-41123- N/L
RING JOINT 61L-00-9P 62T-00-9P 66E-10-8P 66V-00-8P 63M-00-9P
8
-14712-
MUFFLER 2 6R7-00-9M 62T-00-94 66E-10-94 66V-00-8P 63M-00-9P
9
-14721-
SILENCER EXHAUST 6R7-00-9M
10
-14753- N/L N/L N/L N/L
DIFFUSER 6R7-00-9M
11
-14785- N/L N/L N/L N/L
2-22
Fig. 6 EXHAUST

OUTER COVER EXHAUST 6R7-00-9M 62T-00-9M 66V-00-8P 63M-00-94
12
-41113- N/L
JOINT EXHAUST 1 61L-A0 62T-01 66E-00 66V-00 63M-00
13
-14615-
JOINT EXHAUST 2 61L-A0
14
-14625- 62T-00 66E-00 66V-00
STAY MUFFLER 1 6M6-00-94 62T-00-94 66V-01-94 63M-00-94
-14771-
66E-01-94
STAY 5 66V-00-94 15
-14782- N/L N/L N/L N/L
STAY MUFFLER 2 66E-10-94
-14781- N/L N/L N/L N/L
CATALYST ASSY 66V-00
16
-14740- N/L N/L N/L N/L
2-23
Fig. 7 FUEL TANK/FUEL

TANK FUEL EW2-01 GH3-00 F0D-00 F0X-00 GU5-00
1
-*7711-
PIPE JOINT
2
-67713- FJ0-00 N/L N/L N/L
CHECK VALVE
3
-67767- EU0-31
FILTER VENT ASSY
4
-62140- EW2-00
CAP FUEL FILLER
-67831- FN8-01 5
GP7-U7831-00
FILTER ASSY
6
-24560- 6K8-10 66V-00
FUEL COCK ASSY 6K8-02
7
-24500- 65U-01 66V-01
2-24
Fig. 8 JET UNIT

SCREEN INTAKE 6R7-00 65R-R1333-00
1
-51333- 66V-00-94 67X-00-94
DUCT INTAKE 6R7-00 65U-R1311-00
2
-51311- 66V-00-94 67X-00-94
HOUSING IMPELLER 6R7-03-94 63M-02-94
3
-51312- 66V-00-94
DUCT IMPELLER 62T-01-94 63M-02-94
4
-51315- 66V-00-94
CAP 62T-00
5
-51326- 65A-R1326-00
SHAFT DRIVE 6R7-01 65R-00
6
-45511- 66V-01
BUSHING DRIVE SHAFT 65V-00
7
-45318- N/L N/L N/L N/L
SPACER 65U-R1348-01
8
-51348- N/L N/L N/L N/L
NOZZLE 6R7-05-94 65R-R1318-00
9
-51318- 66V-00-94 67X-00-94
IMPELLER 6R7-00-94 65R-R1321-10 67A-R1321-00 66V-R1321-00 66G-R1321-00
10
-51321-
2-25
Fig. 8 JET UNIT

NOZZLE, DEFLECTOR 61L-00 65R-R1313-01
11
-51313- 66V-R1313-01
PLATE 2, ASSY EW2-01 GJ3-U273B-00
12
-6273*- F0D-U273B-00 F0X-U273B-00
COVER 61X-00 65R-R1381-00 67A-R1381-00 66V-R1381-00 64Y-00
13
-51381-
SHAFT COUPLER 6R7-02 63N-10
14
-51323- 66V-01
HOUSING BEARING 66G-00-94
15
-45331- N/L N/L N/L N/L
HOUSING BEARING 66G-00-94
16
-45332- 61X-03-94 65U-02-94
GATE REVERSE
17
-51314- N/L N/L 66V-00 N/L
2-26
Fig. 9 ELECTRICAL

ROTOR ASSY 66E-00 66V-00 65U-00
1
-85550- 62T-00
BASE ASSY
-85560- 62T-00 N/L N/L N/L
COIL ASSY
2
-85521- N/L N/L N/L N/L N/L
STATOR ASSY 66E-00 66V-00 65U-01
-85510- N/L N/L
COVER FLYWHEEL 6M6-00-8P 6R8-00-8P 66E-11-8P 66V-02-8P 65U-00-8P
3
-81337-
HOUSING 6M6-01-8P 62L-00-8P 66E-00-94 66V-00 65U-00-5B
4
-8552A-
COVER CASE 66E-00 66V-00 65U-00
5
-8552E- 6M6-01
CDI UNIT ASSY 66E-00 66V-00 65U-00
6
-85540- 62T-01
RECT/REGULATOR ASSY 63M-00 66V-00 6H2-00
7
-81960- 6M6-A0
IGNITION COIL ASSY 62E-00 62E-11 64X-01 66V-00 65U-00
8
-85570- 66G-20
2-27
Fig. 9 ELECTRICAL

THERMO SWITCH ASSY 6R7-00 62T-01 67U-00 66V-85790-00 65U-00
9
-82560-
EXTENSION WIRE LEAD 6R7-01 63N-00 67A-00 67X-00 66G-00
10
-82553-
FUSE HOLDER ASSY 66E-00 66V-00 65U-00
11
-82150- 6K8-01
STARTER RELAY ASSY
12
-81941- 6G1-10
WIRE LEAD
13
-82117- 62E-20 62L-20 6M6-21 67X-20
WIRE LEAD 6R7-11 63N-10 66E-10 67X-10 61L-10
14
-82117-
WIRE LEAD 64V-00 63N-00 61L-00 67X-00 64T-00
15
-82117-
METER ASSY F0M-00 F0P-01 F0X-01 F0D-31
16
-6820A- N/L
SENDER FUEL
17
-6824B- N/L N/L F0D-U824B-01
SENDER OIL GJ8-U824C-00 F0D-U824C-10
18
-6824C- N/L F0D-U824C-00
EXHAUST TEMP, SENSOR 66V-00
19
-85881- N/L N/L N/L N/L
2-28
2-29
YAMAHA MOTOR CORPORATION, USA
Printed in USA
Nov. 2000 0.95 × 1 CR
90894-64650-34
(ALL MODELS)
Printed on recycled paper
2-30
Section 3
2001 WaveRunner® Model Color
and Graphics Guide
3-1
3-2
2001 WaterCraft Technical Update - Color and Graphics Guide
WaveRunner XLT1200
HATCH GRAPHIC
2 1 REAR DECK GRAPHIC
TUNING FORK YAMAHA EMBLEM

(CENTER) (CENTER)
YAMAHA EMBLEM DECK FIN GRAPHIC

HULL GRAPHIC
FRONT DECK GRAPHIC
PAINT AND GRAPHICS:

Ref Color Codes
No. Part Name Color Name Sherwin Williams Color-Rite
1 Lid, Engine Room Light Gray Metallic D TBA 5994U
2 Side Covers Light Gray Metallic D TBA 5994U
3 Deck Pure White 366-51437 5700U
4 Hull Pure White 366-51437 5700U
Part Name Color

Gunwale Black
Gunwale Insert Black
Mats Black
Sponsons Black
Steering Pad Black
Seat Gray
Reverse Lever Black
Mirror Black
Fuel Cap Black
Stern Eye Dark Gray
Rear Hand Grip Black
3-3
WaveRunner GP1200R
YPVS LOGO YAMAHA EMBLEM

(LEFT) REAR DECK GRAPHIC
2
1 1
TUNING FORK
(CENTER) YAMAHA EMBLEM
(CENTER)
FRONT DECK GRAPHIC

REAR HULL GRAPHIC
FRONT HULL GRAPHIC
PAINT AND GRAPHICS:

Ref Color Codes
1 Side Covers Dark Purplish Blue Metallic F TBA TBA
Part Name Color

Gunwale Black
Mats Black
Sponsons Black
Steering Pad Black
Seat Blue
Oil Cap Black
Mirror Black
Fuel Cap White
Stern Eye Black
3-4
WaveRunner SUV1200
YAMAHA EMBLEM
2
1
(CENTER) SIDE DECK GRAPHIC (CENTER)
FRONT DECK GRAPHIC

STORAGE LID GRAPHIC
DECK FIN GRAPHIC
PAINT AND GRAPHICS:

Color Codes
Gelcoat Paint
Ref Sherwin
No. Part Name Color Name Sher-Fab Williams Color-Rite
1 Lid, Engine Room Dark Red Metallic C N/A TBA TBA
2 Side Covers Dark Red Metallic C N/A TBA TBA
3 Deck White Coat 5 SF-498E U7-60694 TBA
4 Hull Dark Red Coat 7 TBA TBA TBA
Part Name Color

Gunwale Black
Mats Black
Sponsons Black
Steering Pad Black
Seat Cranberry
Reverse Lever Black
Mirror Black
Fuel Cap Black
Stern Eye White
3-5
WaveRunner XL800
YAMAHA EMBLEM 1
REAR DECK GRAPHIC
2
(CENTER)
(CENTER)
FRONT DECK GRAPHIC
HULL GRAPHIC DECK FIN GRAPHIC
PAINT AND GRAPHICS:

Ref Color Codes
1 Lid, Engine Room Bluish Black Metallic 3 U7-57689 5950U
2 Side Covers Bluish Black Metallic 3 U7-57689 5950U
Part Name Color

Gunwale Black
Mats Black
Sponsons Black
Steering Pad Black
Seat Dark Green
Reverse Lever Black
Mirror Black
Fuel Cap White
Stern Eye Black
3-6
WaveRunner GP800R
YPVS LOGO
(LEFT) YAMAHA EMBLEM
1 REAR DECK GRAPHIC
YAMAHA EMBLEM
2 (CENTER)
TUNING FORK
(CENTER)
FRONT DECK GRAPHIC
FRONT HULL
GRAPHIC REAR HULL GRAPHIC
PAINT AND GRAPHICS:

Ref Color Codes
1 Side Covers Dark Purplish Blue Metallic F TBA TBA
Part Name Color

Gunwale Black
Mats Black
Sponsons Black
Steering Pad Black
Seat Blue
Oil Cap Black
Mirror Black
Fuel Cap White
Stern Eye Black
3-7
WaveRunner XL700
HATCH GRAPHIC
1 2
REAR DECK GRAPHIC
LID GRAPHIC
SIDE DECK GRAPHIC
YAMAHA EMBLEM
(CENTER)
TUNING FORK
(CENTER)
SIDE COVER GRAPHIC

HULL GRAPHIC
PAINT AND GRAPHICS:

Ref Color Codes
1 Lid, Engine Room Dark Red Metallic C TBA TBA
2 Engine Hatch Cover Dark Red Metallic C TBA TBA
3 Side Covers Dark Red Metallic C TBA TBA
Part Name Color

Gunwale Black
Mats Black
Sponsons Black
Steering Pad Black
Seat Burgundy
Oil Cap Black
Fuel Cap White
Stern Eye Black
3-8
Super Jet SJ700
UPPER POLE GRAPHIC

FRONT HATCH GRAPHIC
SIDE POLE GRAPHIC 2
1
REAR HATCH GRAPHIC
TUNING FORK
(CENTER)
FRONT DECK
GRAPHIC
REAR DECK GRAPHIC
4
HULL GRAPHIC 5 SIDE DECK GRAPHIC
PAINT AND GRAPHICS:

Color Codes
Gelcoat Paint
Ref Sherwin
No. Part Name Color Name Sher-Fab Williams Color-Rite
1 Engine Hatch Dark Purplish Blue Solid M N/A U7-61334 TBA
2 Handle Pole Dark Violet Coat 2 TBA TBA TBA
3 Front Cover Dark purplish Blue Solid M N/A U7-61334 TBA
4 Deck Dark Violet Coat 2 TBA TBA TBA
5 Hull Pure White N/A 366-51437 5700U
Part Name Color

Gunwale Black
Mats Black
Sponsons Black
Steering Pad Blue
Pole Cover Black
Fuel Cap Black
Stern Eye Black
3-9
Section 4
WaveRunner® Technical Tips
4-1
2001 WaterCraft Technical Update - WaveRunner Technical Tips
IMPORTANT!
Yamaha has compiled and included a variety of

useful tips into this WaterCraft Service booklet.
These tips are easy to use and may save you
some diagnostic time while helping dealers
solve problems. In some cases, the tip includes
a change from the factory-emphasizing the
importance of quality input from dealers.
Notice that none of these tips include a blanket
warranty authorization for parts replacement.
In fact, the problem is often related to mainte-
nance or severe operating conditions.
Therefore, warranty would specifically exclude
related failures in most cases. In other cases,
warranty would cover the specific repair, as
long as all other warranty requirements are
met; including a clearly identified defect.
One additional caution: the majority of these
problems occur on very few units. Most units do
not even have the problems described. Use the
tips as intended to help you solve a specific
problem you are experiencing. However, as the
old saying goes, “If it isn’t broken, don’t fix it!”
Yamaha will not pay to replace parts unneces-
sarily and neither should your customer.
“Normal Warranty Applies” means if the unit is
in its normal warranty period and the problem
occurs, repair it and submit a claim. If the unit
is out of warranty, contact your RTA.
4-3
WaveRunner Technical Literature Index
LITERATURE
MODEL YEAR SUBJECT DOCUMENT PART NUMBER
1995 Models 1995 Primary ID Numbers Technical Bulletin WV95-002
1995 Models 1995 Service Literature Technical Bulletin WV95-006
1996 Models 1996 Primary ID Numbers and Service Literature Technical Bulletin WV96-002
1997 Models 1997 New Jet Pump Color Tech Exchange WV96-014
’97~’99 Models 1997~1999 Warranty Flat Rate Revisions Technical Bulletin WR2000-007
1998 Models 1998 Engine Color Change 1998 WV Technical Update Handbook Pg MG-7 LIT-18500-00-98
1999 Models 1999 Essential Tools Technical Bulletin WV99-004
1999 Models 1999 Multifunction Meter Changes 2000 WV Tech. Update Handbook Pg 6-13~6-14 LIT-18500-00-2K
2000 Models 2000 Primary ID Numbers Technical Bulletin WV99-009
2000 Models 2000 Service Literature Technical Bulletin WV99-008B
2000 Models 2000 Technical Update Manual Revisions Technical Bulletin WV2000-001
2001 Models 2001 Carburetor Settings 2001 WV Technical Update Handbook LIT-18500-00-01
2001 Models 2001 Primary ID Numbers Technical Bulletin WR2000-011
2001 Models 2001 Service Literature Technical Bulletin WR2000-010
All 1100cc Models 1995~1997 Peak Voltage Specifications Tech Exchange WV99-006
All 1200cc Models Replacement Oil Pumps 2000 WV Technical Update Handbook Pg 6-17 LIT-18500-00-2K
All 135 HP Models 1997~1999 Hard Starting, Choke Plate Installation 1999 WV Technical Update Handbook Pg 2-3 LIT-18500-00-99
All 135 HP Models 1997~1999 Hard Starting, Choke Plate Installation 1998 WV Technical Update Handbook Pg 42 LIT-18500-00-98
All 135 HP Models 1997~1999 Peak Voltage Manual Correction Tech Exchange WV99-006
All 650cc Models 1990~1994 Hard Starting When Cold 1995 WV Technical Update Handbook Pg 62 LIT-18500-00-95
All 760cc Models 1997~1999 Hard Starting, Choke Plate Installation 1999 WV Technical Update Handbook Pg 2-3 LIT-18500-00-99
All 760cc Models 1997~1999 Hard Starting, Choke Plate Installation 1998 WV Technical Update Handbook Pg 42 LIT-18500-00-98
All 800cc Models Replacement Oil Pumps 2000 WV Technical Update Handbook Pg 6-17 LIT-18500-00-2K
All Models 1995 Manual Bleed Type Oil Pump 1995 WV Technical Update Handbook Pg 63
All Models 1996 High-Altitude Carburation Adjustment Chart Tech Exchange WV96-006
All Models 1997 High-Altitude Carburation Adjustment Chart Tech Exchange WV97-007
All Models 1998 Corrosion Protection 1998 WV Technical Update Handbook Pg MG-9 LIT-18500-00-98
All Models 1987~1995 Paint and Gel-Coat Color Codes & Materials Technical Bulletin WV95-008
All Models 1987~1996 Carburetor Settings Tech Exchange WV96-015
All Models 1987~1996 Impeller Application Chart Tech Exchange WV96-010
All Models 1987~1996 Paint and Gel-Coat Color Codes 1996 WV Service Clinic Handbook Pg 17
All Models 1987~1996 Paint Application Chart 1996 WV Service Clinic Handbook Pg 24~25
All Models 1987~1997 Carburetor Settings Tech Exchange WV97-008B
All Models 1987~1997 Carburetor Settings 1997 WV Technical Update Handbook Pg 81~82 LIT-18500-00-97
All Models 1987~1997 Impeller Application Chart Tech Exchange WV97-006
All Models 1987~1998 Carburetor Settings Technical Bulletin WV98-003
All Models 1987~1998 Impeller Application Chart Technical Bulletin WV98-002
All Models 1987~1998 Impeller Application Chart 1998 WV Tech. Update Handbook Pg 46~48 LIT-18500-00-98
All Models 1987~1999 Carburetor Settings 1999 WV Tech. Update Handbook Pg 2-22~2-23 LIT-18500-00-99
All Models 1987~1999 Impeller Application Chart 1999 WV Tech. Update Handbook Pg 2-24~2-26 LIT-18500-00-99
All Models 1987~2000 Impeller Application Chart 2000 WV Tech. Update Handbook Pg 6-32~6-34 LIT-18500-00-2K
All Models 1993~1997 Paint and Gel-Coat Color Codes 1997 WV Technical Update Handbook Pg 80 LIT-18500-00-97
All Models 1993~1997 Paint Application Chart 1997 WV Tech. Update Handbook Pg 79 LIT-18500-00-97
All Models 1994~1998 Carburetor Settings 1998 WV Tech. Update Handbook Pg 44~45 LIT-18500-00-98
All Models 1994~1998 Gel-Coat Application Chart 1998 WV Tech. Update Handbook Pg 51 LIT-18500-00-98
All Models 1994~1998 Paint Application Chart 1998 WV Tech. Update Handbook Pg 49~50 LIT-18500-00-98
All Models 1994~2000 Carburetor Settings 2000 WV Tech.l Update Handbook Pg 6-30~6-31 LIT-18500-00-2K
All Models 1996~1997 Jet Pump Color/Material Change 1997 WV Tech. Update Handbook Pg 66 LIT-18500-00-97
All Models 1996~2000 Paint Application Chart 2000 WV Tech. Update Handbook Pg 6-35 LIT-18500-00-2K
All Models 1996~2001 Impeller Application Chart 2001 WV Tech. Update Handbook LIT-18500-00-01
All Models 1997~2001 Paint Application Chart 2001 WV Tech. Update Handbook LIT-18500-00-01
All Models 1996 Mikuni BN Carburetor Cutaway Poster Tech Exchange WV96-009
All Models Additional Pliogrip Suppliers 1997 WV Tech. Update Handbook Pg 71 LIT-18500-00-97
All Models Additional Pre-Delivery Service Tech Exchange WV99-005
All Models Basic Hull Repair Video VID-10660-00-43
All Models Battery Maintenance 2000 WV Tech. Update Handbook Pg 6-21~6-22 LIT-18500-00-2K
All Models Battery Tips 1998 WV Tech. Update Handbook Pg 38~41 LIT-18500-00-98
All Models Carburetor Adjusting Tips 2001 WV Tech. Update Handbook LIT-18500-00-01
All Models Control Cable Lock Nuts Missing 1997 WV Technical Update Handbook Pg 67 LIT-18500-00-97
All Models Cooling System Troubleshooting 1995 WV Technical Update Handbook Pg 64 LIT-18500-00-95
All Models Crankshaft Failure Diagnosis 2001 WV Technical Update Handbook LIT-18500-00-01
4-4
WaveRunner Technical Literature Index (Cont’d.)
LITERATURE
All Models Crankshaft Failure Diagnosis 1999 WV Tech. Update Handbook Pg 2-16~2-17 LIT-18500-00-99
All Models Crankshaft Phase Inspection (Twisting) 2000 WV Technical Update Handbook Pg 6-12 LIT-18500-00-2K
All Models Crankshaft Twisting Inspection 1998 WV Technical Update Handbook Pge43 LIT-18500-00-98
All Models Electrical Troubleshooting, Voltage Drop 1995 WV Technical Update Handbook Pg 66~68 LIT-18500-00-95
All Models Essential Tools Technical Bulletin WV96-017
All Models Fuel Pump Changes 2000 WV Technical Update Handbook Pg 6-3 LIT-18500-00-2K
All Models Gasket Removal Tip Tech Exchange WV96-012
All Models Gelcoat Color Codes 2001 WV Technical Update Handbook LIT-18500-00-01
All Models Gelcoat Color Codes 2000 WV Technical Update Handbook Pg 6-37 LIT-18500-00-2K
All Models Gelcoat Color Codes 1999 WV Technical Update Handbook Pg 2-29 LIT-18500-00-99
All Models Gel-Coat Repairs Tech Exchange WV96-011
All Models Gel-Coat Repairs 1995 WV Technical Update Handbook Pg 65 LIT-18500-00-95
All Models Handy Tools Tech Exchange WV96-014
All Models Hot Knife for Cutting Flotation Foam 1998 WV Technical Update Handbook Page 31 LIT-18500-00-98
All Models Lean Running or Flooding carburetors 1999 WV Technical Update Handbook Page 2-4 LIT-18500-00-99
All Models Oil Pump Output Testing Tech Exchange WV96-001
All Models Oil Pump Output Testing 2001 WV Technical Update Handbook LIT-18500-00-01
All Models Oil Pump Output Testing, Handy Tool Tech Exchange WV96-019
All Models Paint Color Codes 2001 WV Technical Update Handbook LIT-18500-00-01
All Models Paint Color Codes 2000 WV Technical Update Handbook Pg 6-36 LIT-18500-00-2K
All Models Paint Color Codes 1999 WV Tech. Update Handbook Pg 2-27~2-28 LIT-18500-00-99
All Models Peak Voltage Testing 1999 WV Technical Update Handbook LIT-18500-00-99
All Models Performance Troubleshooting "Carburetion" 2001 WV Technical Update Handbook LIT-18500-00-01
All Models Performance Troubleshooting "Jet Pump" 2001 WV Technical Update Handbook LIT-18500-00-01
All Models Piston Failure Diagnosis 1999 WV Tech. Update Handbook Pg 2-12~2-15 LIT-18500-00-99
All Models Pop off Pressures Tech Exchange WV96-015
All Models Reformulated Gasoline Tech Exchange WV95-003
All Models SMC Repair Materials 2000 WV Technical Update Handbook Pg 6-18 LIT-18500-00-2K
All Models Special Tools 2001 WV Technical Update Handbook LIT-18500-00-01
All Models Special Tools 2000 WV Technical Update Handbook Pge6-1~6-2 LIT-18500-00-2K
All Models Special Tools 1999 WV Technical Update Handbook Pg 2-1~2-2 LIT-18500-00-99
All Models Special Tools 1995 WV Technical Update Handbook Pg 47~48 LIT-18500-00-95
All Models Speedometer Sensor Service Parts 2000 WV Technical Update Handbook Pg 6-15 LIT-18500-00-2K
All Models Storage Tips 1998 WV Technical Update Handbook Pg 36~37 LIT-18500-00-98
All Models Tip for Removing Fasteners Tech Exchange WV95-009
All Models Tool for Removing Stuck Jet Pump Housings Tech Exchange WV95-012
All Models Troubleshooting Water entering the hull area 2001 WV Technical Update Handbook LIT-18500-00-01
All Models Warranty Information Technical Bulletin WV98-007
All Models Warranty Policies Technical Bulletin WV95-014
All Models Warranty Policies Technical Bulletin WR2000-002
All Models Water Vehicle Carburetor Tuning & Adjust. Video VID-10660-00-34
All Models Winter Storage 2000 WV Tech. Update Handbook Pg 6-19~6-20 LIT-18500-00-2K
All Models Winter Storage Tips and Checklist Tech Exchange WV96-018
All Models Yamaha Drive Train Theory (Watercraft) Video VID-10660-00-64
All Models Yamalube 2-W 1999 WV Techn. Update Handbook Pge2-18~2-19 LIT-18500-00-99
All Models YPAD Flush Kit, Incorrect Hose Clamps Tech Exchange WV95-012
All PADLOC Mdls 1997~ PADLOC Multifunction Meter Troubleshoot. Multifunction Meter Troubleshooting Guide LIT-18556-00-98
All PADLOC Mdls PADLOC Meter Diagnosis Tech Exchange WV98-005
All PADLOC Mdls PADLOC Troubleshooting 1999 WV Tech. Update Handbook Pge2-4~2-11 LIT-18500-00-99
All QSTS Mdls 1997 QSTS Trim Nozzle Adjustment Gauge Tech Exchange WV96-007
All YPVS Mdls 1998~2001 Erratic Powervalve Operation 2001 WV Technical Update Handbook LIT-18500-00-01
All YPVS Mdls 1998~2001 Power-Valve Improvements 2001 WV Technical Update Handbook LIT-18500-00-01
All YPVS Mdls Piston Selection 2000 WV Technical Update Handbook Pg 6-16 LIT-18500-00-2K
FX700 1994~1995 Factory Mod. Campaign, Fuel Tank Damper Technical Bulletin WV95-005
General 1995 Technical Update Seminar Tech Exchange WV95-001
General Fax Tech Form Usage Reminder Tech Exchange WV96-007
General Galvanic Corrosion Tech Exchange WV95-004
General Labor Rate change Request Form Change Tech Exchange WV95-009
General Manual Ordering Procedures Technical Bulletin WR2000-004
General Oxygenated Fuels Tech Exchange WV95-004
General Phone Numbers, Toll-Free Service Assist. Technical Bulletin WV96-022
General Phone Numbers, Toll-Free Service Assist. Technical Bulletin WV95-015
General Phone Numbers, Toll-Free Service Assist. Technical Bulletin WR2000-003
General Technical Education Technical Bulletin WV95-011
General Technical Information Index Technical Bulletin WV96-008
General Water Vehicle Service Clinic Information Tech Exchange WV96-009
4-5
LITERATURE
General Water Vehicle Training Classes Tech Exchange WV96-020
General YPAD Paint and Gel-Coat Part Numbers Tech Exchange WV96-013
GP1200 1997 Bond Line Kits 1998 WV Technical Update Handbook Page 29~30 LIT-18500-00-98
GP1200 1997 Bow Kits 1998 WV Technical Update Handbook Page 24~26 LIT-18500-00-98
GP1200 1997 Carburetor Specification Correction Tech Exchange WV97-010
GP1200 1997 Crate Change Tech Exchange WV97-004
GP1200 1997 Crate Change 1997 WV Technical Update Handbook Page 74 LIT-18500-00-97
GP1200 1997 Handlebar Pad Rubbibg 1998 WV Technical Update Handbook Page 22 LIT-18500-00-98
GP1200 1997 Lighting Coil Specification Correction Tech Exchange WV98-004
GP1200 1997 LongiKits 1998 WV Technical Update Handbook Page 27~28 LIT-18500-00-98
GP1200 1997 Oil Pump Bleeding Procedure Tech Exchange WV97-005
GP1200 1997 PADLOC Programing Technical Bulletin WV97-002
GP1200 1997 PADLOC Troubleshooting 1998 WV Technical Update Handbook Page 20~21 LIT-18500-00-98
GP1200 1997 Parts for Front Lid Not Listed on Microfiche 1998 WV Technical Update Handbook Page 23 LIT-18500-00-98
GP1200 1997 Speedometer Adjustment Tech Exchange WV97-004
GP1200 1997 Sponson Adjustment and Maintenance Tech Exchange WV97-003
GP1200 1997 Steering Cable Ends Tech Exchange WV97-005
GP1200 1997 Steering Cable Stopper Tech Exchange WV97-010
GP1200 1997 Steering Pad Height 1997 WV Technical Update Handbook Page 69 LIT-18500-00-97
GP1200 1997 Velocity Stacks, Loose Tech Exchange WV97-011
GP1200 1998 Engine Color Change 1998 WV Technical Update Handbook Page MG-8 LIT-18500-00-98
GP1200 1999 Fuel Sending Unit End Cap Replacement Technical Bulletin WV99-001
GP1200 1997~1998 Carburetor Specification Correction Tech Exchange WV98-004
GP1200 1997~1999 Oil Tank Vent Pinched 2001 WV Technical Update Handbook LIT-18500-00-01
GP1200A 2000 High Altitude Compensation Program Technical Bulletin WR2000-008
GP1200A 2000~2001 Catalytic Converter Failure Diagnosis 2001 WV Technical Update Handbook LIT-18500-00-01
GP1200A 2000~2001 Impeller and Impeller Housing Burn 2001 WV Technical Update Handbook LIT-18500-00-01
GP1200A 2000~2001 Jet Pump Sealing 2000 WV Technical Update Handbook Page 6-6 LIT-18500-00-2K
GP1200A 2000~2001 Overheat System Troubleshooting 2000 WV Technical Update Handbook Pg 6-6~6-10 LIT-18500-00-2K
GP1200A 2000~2001 Parts List Correction: Ride Plate Nuts 2001 WV Technical Update Handbook LIT-18500-00-01
GP1200A 2000~2001 Water Temperature Sender Tool 2000 WV Technical Update Handbook Page 6-11 LIT-18500-00-2K
GP760 1997 Handlebar Pad Rubbibg 1998 WV Technical Update Handbook Page 22 LIT-18500-00-98
GP760 1997 PADLOC Programing Technical Bulletin WV97-002
GP760 1997 PADLOC Troubleshooting 1998 WV Technical Update Handbook Page 20 LIT-18500-00-98
GP760 1997 Parts for Front Lid Not Listed on Microfiche 1998 WV Technical Update Handbook Page 23 LIT-18500-00-98
GP760 1997 Porpoising (Step Plates) 1998 WV Technical Update Handbook Page 32 LIT-18500-00-98
GP760 1997 Speedometer Adjustment Tech Exchange WV97-004
GP760 1997 Sponson Adjustment and Maintenance Tech Exchange WV97-003
GP760 1997 Steering Cable Ends Tech Exchange WV97-005
GP760 1997 Steering Cable Stopper Tech Exchange WV97-010
GP760 1997 Steering Pad Height 1997 WV Technical Update Handbook Page 69 LIT-18500-00-97
GP760 1998 Engine Color Change 1998 WV Technical Update Handbook Page MG-8 LIT-18500-00-98
GP760 1997~1998 Carburetor Specification Correction Tech Exchange WV98-004
GP800 1998 GP800 Step Plate Installation Instructions Video VID-10660-00-48
GP800 1998 New Special Tools 1998 WV Technical Update Handbook Page 17 LIT-18500-00-98
GP800 1998 Porpoising Technical Bulletin WV98-006
GP800 1998 YPVS Adjustment Procedure Tech Exchange WV98-005
GP800 Piston Selection 1999 WV Tech. Update Handbook Pge2-20~2-21 LIT-18500-00-99
GP800A 2001 Parts List Correction: Ride Plate Nuts 2001 WV Technical Update Handbook LIT-18500-00-01
RA Series 1995~1998 Parts List Correct. Engine Mtg. Spacers 2001 WV Technical Update Handbook LIT-18500-00-01
RA1100 1995 Carburetor Synchronization 1995 WV Technical Update Handbook Pg 50~51 LIT-18500-00-95
RA1100 1995 Crankshaft Twisting Inspection 1996 WV Service Clinic Handbook Page 18
RA1100 1995 Engine Hatch Not Opening 1996 WV Service Clinic Handbook Page 12
RA1100 1995 Kinked Cooling Water Bypass Hose Tech Exchange WV95-007
RA1100 1995 Oil Leaking From Oil Tank Filler Cap 1996 WV Service Clinic Handbook Page 15
RA1100 1995 Oil Pump Driveshaft Breakage Technical Bulletin WV95-013
RA1100 1995 Oil Pump Driveshaft Breakage Tech Exchange WV97-004
RA1100 1995 QSTS Grip Assembly Parts Availability Tech Exchange WV96-006
RA1100 1995 Seat Base Underlocker seal Availability 1996 WV Service Clinic Handbook Page 17
RA1100 1996 Incorrect Wire Color on CDI Unit 1996 WV Service Clinic Handbook Page 22
RA1100 1996 Multifunction Meter Failure 1996 WV Service Clinic Handbook Page 21
RA1100 1996 Splash Guard Component Part Numbers Tech Exchange WV96-011
RA1100 1996 Splash Guard Information Tech Exchange WV96-010
RA1100 1996 Splash Guard Installation Technical Bulletin WV96-003
RA1100 1995~1996 Carburetion Update Kit Technical Bulletin WV96-005
RA1100 1995~1996 Carburetion Update Kit Identification Tech Exchange WV96-012
4-6
LITERATURE
RA1100 1995~1996 Carburetion Update Kit, Additional Info. Tech Exchange WV96-014
RA1100 1995~1996 Carburetion Update Kit, Additional Info. 1997 WV Technical Update Handbook Page 70 LIT-18500-00-97
RA1100 1995~1996 CDI Box Failures 1997 WV Technical Update Handbook Page 72 LIT-18500-00-97
RA1100 1995~1996 Pre-Deliv. Inspec. of Cooling & Bilge Hoses Tech Exchange WV97-001
RA1100 1995~1996 Water Deflectors 1998 WV Technical Update Handbook Page 33 LIT-18500-00-98
RA1100 1995~1996 Water Ingestion Tech Exchange WV97-001
RA700 1994 Carburetor Specification Incorrect 1995 WV Technical Update Handbook Page 53 LIT-18500-00-95
RA700 1994 Engine Hatch Damaged in Crate 1995 WV Technical Update Handbook Page 52 LIT-18500-00-95
RA700 1994 Exhaust Elbow Pipe Change 1995 WV Technical Update Handbook Page 57 LIT-18500-00-95
RA700 1994 Hull Molding Mark 1995 WV Technical Update Handbook Page 54 LIT-18500-00-95
RA700 1994 Incorrect Ignition Coil Part Number 1995 WV Technical Update Handbook Page 58 LIT-18500-00-95
RA700 1994 Loose Sponson Covers Tech Exchange WV95-001
RA700 1994 Seat Base Scratching Engine Hatch 1995 WV Technical Update Handbook Page 56 LIT-18500-00-95
RA700 1994 Seat Cover Corner Protectors Falling Off 1995 WV Technical Update Handbook Page 55 LIT-18500-00-95
RA700 1994 Thermosensor Specification Revised Tech Exchange WV95-001
RA700 1994~1995 Loose Engine Mount Towers 1996 WV Service Clinic Handbook Page 8~11
RA700 1994~1995 QSTS Grip Assembly Parts Availability Tech Exchange WV96-006
RA700/A 1994~1995 Excessive Smoke, Plug Fouling 1997 WV Technical Update Handbook Page 68 LIT-18500-00-97
RA700/A 1994~1995 One Piece Exhaust Elbow 1996 WV Service Clinic Handbook Page 13
RA700/RA700A 1995 Parts Interchangeability Tech Exchange WV95-004
RA700A 1995 Engine Hatch Not Opening 1996 WV Service Clinic Handbook Page 12
RA700A 1995 Oil Leaking From Oil Tank Filler Cap 1996 WV Service Clinic Handbook Page 15
RA700A 1995 Seat Base Underlocker seal Availability 1996 WV Service Clinic Handbook Page 17
RA700A 1996 Multifunction Meter Failure 1996 WV Service Clinic Handbook Page 21
RA700B 1996 Exhaust Outlet Hose Rubbing on Hull Boss 1997 WV Technical Update Handbook Page 75 LIT-18500-00-97
RA760 1996 High-Altitude Impeller Tech Exchange WV96-006
RA760 1996 Splash Guard Component Part Numbers Tech Exchange WV96-011
RA760 1996 Splash Guard Information Tech Exchange WV96-010
RA760 1996 Splash Guard Installation Technical Bulletin WV96-004
SJ650 Impeller Duct Blind Plug Change 1995 WV Technical Update Handbook Page 61 LIT-18500-00-95
SJ650/700 Metton Hull Repair Metton Hull Repair Manual LIT-18616-00-62
SV1200 1999 Front Storage Lid Damper Assy Replace. Technical Bulletin WV99-003
SV1200 1999~2001 Jet Pump Sealing 2000 WV Technical Update Handbook Page 6-6 LIT-18500-00-2K
SV1200 2000~2001 Trailer Warranty Policies Technical Bulletin WR2000-009
WB700 1993~1995 New Water Lock Box Specification 1996 WV Service Clinic Handbook Page 19
WB700 Impeller Duct Blind Plug Change 1995 WV Technical Update Handbook Page 61 LIT-18500-00-95
WB760 1997 Microfiche Error (Jet Pump) Tech Exchange WV97-011
WB760 1996~1997 Seat Graphic Installation 1997 WV Technical Update Handbook Page 76 LIT-18500-00-97
WR/WJ500 1987~1989 Recall Kit Parts Availability 1996 WV Service Clinic Handbook Page 16
WRA650/700 Impeller Duct Blind Plug Change 1995 WV Technical Update Handbook Page 61 LIT-18500-00-95
WRA700 1994 Loss of Power In Turns 1995 WV Technical Update Handbook Page 59 LIT-18500-00-95
WRA700 1994 Ride Plate Casting Mark 1995 WV Technical Update Handbook Page 60 LIT-18500-00-95
WRA700 1994~1995 New Water Lock Box Specification 1996 WV Service Clinic Handbook Page 20
WRB650/700 Impeller Duct Blind Plug Change 1995 WV Technical Update Handbook Page 61 LIT-18500-00-95
WVT Series 1995~1998 Parts List Correction. Engine Mtg.Spacers 2001 WV Technical Update Handbook LIT-18500-00-01
WVT1100 1996 Carburetion Update Kit Technical Bulletin WV96-005
WVT1100 1996 Carburetion Update Kit Identification Tech Exchange WV96-012
WVT1100 1996 Carburetion Update Kit, Additional Info. Tech Exchange WV96-014
WVT1100 1996 Carburetion Update Kit, Additional Info. 1997 WV Technical Update Handbook Page 70 LIT-18500-00-97
WVT1100 1996 CDI Box Failures 1997 WV Technical Update Handbook Page 72 LIT-18500-00-97
WVT1100 1996 Fuel tank Not Venting 1997 WV Technical Update Handbook Page 78 LIT-18500-00-97
WVT1100 1996 Starter Relay Wires, Loose Tech Exchange WV96-019
WVT1100 1996 Underlocker Seals 1998 WV Technical Update Handbook Page 35 LIT-18500-00-98
WVT1100 1996 Underlocker Seals 1997 WV Technical Update Handbook Page 77 LIT-18500-00-97
WVT1100 1996~1997 Midrange Surge Tech Exchange WV96-019
WVT1100 1996~1997 Starter Relay, Intermittant no Start 1998 WV Technical Update Handbook Page 34 LIT-18500-00-98
WVT700 1995 Control Cable End Ship. Location Change Tech Exchange WV95-009
WVT700 1995 Fctry. Modification Campaign, Steering Brckt Technical Bulletin WV95-010
WVT700 1995 Multifunction Meter Operation 1996 WV Service Clinic Handbook Page 14
WVT700 1995 Revised Assembly Manual Tech Exchange WV95-007
WVT700 1995 Smaller Shipping Crate Tech Exchange WV95-009
WVT700 1995 Split Exhaust Outlet Hose 1996 WV Service Clinic Handbook Page 23
WVT700 1996 High-Altitude Impeller Tech Exchange WV96-006
WVT700 1996 Multifunction Meter Failure 1996 WV Service Clinic Handbook Page 21
WVT700 1995~1996 Excessive Smoke, Plug Fouling 1997 WV Technical Update Handbook Page 68 LIT-18500-00-97
WVT700 1995~1996 Fuel tank Not Venting 1997 WV Technical Update Handbook Page 78 LIT-18500-00-97
4-7
LITERATURE
WVT700 1995~1996 Melted Exhaust Outlet Pipes Tech Exchange WV96-020
WVT700 1995~1996 Underlocker Seals 1998 WV Technical Update Handbook Page 35 LIT-18500-00-98
WVT700 1995~1996 Underlocker Seals 1997 WV Technical Update Handbook Page 77 LIT-18500-00-97
WVT700 1995~1996 Water Lock Box Support Foam Availability 1997 WV Technical Update Handbook Page 73 LIT-18500-00-97
WVT700B 1998 Bearing Housing Change 1998 WV Technical Update Handbook Page MG-8 LIT-18500-00-98
WVT760 1997 Impeller Specification Error Tech Exchange WV97-010
XA1200 1999 Assembly Tips Technical Bulletin WV99-007
XA1200 1999 Parts List Correction Spark Plug Tech Exchange WV99-006
XA1200 1999 Parts List Correction: Oil Tank Hose 2000 WV Technical Update Handbook Page 6-4 LIT-18500-00-2K
XA1200 1999 Peak Voltage Specifications Tech Exchange WV99-006
XA1200 1999 Yamalube 2-W Tech Exchange WV99-006
XA1200 1999~2000 Carburetor Cleaning 2000 WV Tech. Update Handbook Pg 6-23~6-29 LIT-18500-00-2K
XA1200 1999~2000 High Altitude Compensation Program Technical Bulletin WR2000-005
XA1200 1999~2000 Impeller and Impeller Housing Burn 2001 WV Technical Update Handbook LIT-18500-00-01
XA1200 1999~2000 Parts List Correction: Ride Plate Nuts 2001 WV Technical Update Handbook LIT-18500-00-01
XA1200 1999~2000 Service Manual Correc. Impeller Clearance 2000 WV Technical Update Handbook Page 6-5 LIT-18500-00-2K
XA1200 1999~2000 Sponson Replacement Technical Bulletin WR2000-006
XA1200 1999~2001 Catalytic Converter Failure Diagnosis 2001 WV Technical Update Handbook LIT-18500-00-01
XA1200 1999~2001 Jet Pump Sealing 2000 WV Technical Update Handbook Page 6-6 LIT-18500-00-2K
XA1200 1999~2001 Overheat System Troubleshooting 2000 WV Technical Update Handbook Pg 6-6~6-10 LIT-18500-00-2K
XA1200 1999~2001 Water Temperature Sender Tool 2000 WV Technical Update Handbook Page 6-11 LIT-18500-00-2K
XA800 2000 High Altitude Compensation Program Technical Bulletin WR2000-008
XA800 2000 Sponson Replacement Technical Bulletin WR2000-006
XA800 2000~2001 Jet Pump Sealing 2000 WV Technical Update Handbook Page 6-6 LIT-18500-00-2K
XA800 2000~2001 Parts List Correction: Ride Plate Nuts 2001 WV Technical Update Handbook LIT-18500-00-01
XL Series 1995~1998 Parts List Correc. Engine Mounting Spacers 2001 WV Technical Update Handbook LIT-18500-00-01
XL1200 1998 Shift Lever Installation Tech Exchange WV98-004
XL760 1998 Shift Lever Installation Tech Exchange WV98-004
XL760 1999 Fuel Sending Unit End Cap Replacement Technical Bulletin WV99-001
4-8
Special Tools
The following charts list some of the more commonly used special tools and their applications:
Kent Moore
Item Part Number Description Application
YW-41528 Flywheel Holder All 1100cc Engines
GP1200V~X, XL1200W,
SV1200X~Z
YW-06550 Flywheel Holder GP800W~Y, GP800AZ

XA800Y~Z, GP1200AY~Z,
XA1200X~Y, XA1200AZ
YW-38741 Coupler Wrench All 650 (except WR650) and

701cc Engines
YW-06546 Coupler Wrench All 1100cc Engines,

GP1200V~X, XL1200W,
SV1200X~Z
YW-06551 Coupler Wrench GP800W~Z, GP800AZ,

XA800Y~Z, GP1200Y~Z,
XA1200X~Y, XA1200AZ
YB-06049 Driveshaft Holder All 650 (except WR650),

701, & 1100cc, GP800W~Y,
GP1200V~X, XL1200W
YB-06151 Driveshaft Holder GP800AZ, XA800Y~Z,

SV1200X~Z, GP1200AY~Z,
XA1200X~Y, XA1200AZ
YW-38742 Intermediate Shaft All 650 (except WR650),

Holder 701, & 1100cc, GP800W~Y,
GP1200V~X, XL1200W
YB-06552 Intermediate Shaft GP800AZ, XA800Y~Z,

Holder SV1200X~Z, GP1200AY~Z,
XA1200X~Y, XA1200AZ
YW-42087 Carburetor Pop Off All Models

Gauge
4-9
Special Tools (Cont'd.)
Kent Moore
YU-33263 Digital Multimeter All Models
YU-39991 Peak Volt Meter Adapter All Models
1. YW-06777 Peak Volt Test Lead All 1100cc Models

GP1200V~X, XL1200W
SV1200X~Z
2. YW-06778 Peak Volt Test Lead GP1200V~X, XL1200W
SV1200X~Z
3. YW-06779 Peak Volt Test Lead All 760cc Engines,

GP800W~Y GP800AZ,
XA800Y~Z
4. YW-06780 Peak Volt Test Lead GP1200AY~Z, XA1200X~Y
XA1200AZ
YU-39951-A Digital Tachometer All Models
YM-34487 Dynamic Spark Tester All Models
J-8037 Inductive Timing Light All Models
4-10
Oil Pump Output Testing
TECHNICAL TIPS
Current service manuals do not provide a Testing:
means for testing oil pumps for correct output.
1. Remove the oil pump feed line from the car-
Follow the steps below to test for proper oil
buretor or carburetor cover on the cylin-
pump output. (See the following page for spec-
der(s) to be tested in the first test.
ifications and an example of test results,) It is
important to follow the procedures precisely to 2. If the oil pump is a variable type, position
obtain proper results. the oil pump lever to the wide open mark.
Setup: 3. With the unit in a test tank or on the flush
kit, start the engine and set the idle speed
You will need a measuring cylinder (or cylin-
to 3000 rpm.
ders) marked in increments of 0.1cc or less.
You may build a tool to perform this test on all FIGURE 1
cylinders at the same time (see Tech Exchange
WV96-019, reprinted following this Tech Tip, for
details).
NOTE: Make sure the oil lines will reach a con-
venient area to locate the measuring cylinder.
Pre-Test Conditions:
CAUTION:
• Make sure you run pre-mixed fuel for the
duration of the test
• Due to differences in viscosity and other NOTE:
characteristics of different oils, the test You may need to warm the engine to obtain a
should be performed using only steady idle speed. Proper Idle speed is imper-
Yamalube 2-W in the oil tank along with ative to the accuracy of this test.
the pre-mixed oil in the fuel tank
4. Position the oil feed line into a clean meas-
• The oil temperature should be between uring cylinder (marked in increments of
10° ~ 30°C (50° ~ 86°F) 0.1cc) and run the engine for 3 minutes.
Make sure the oil line is full when you begin
measuring.
5. Compare the output of each feed line with
the specifications on the following chart.
6. After completion of the test, reattach the oil
line(s), readjust the oil pump cable to the
standard setting (if applicable) and reset
the engine idle speed.
4-11
Oil Pump Output Testing (Cont’d.)
Oil Pump Specification Chart

Engine Oil Pump Oil Pump Output cc’s/
Code Number 3 Min / Per Cylinder at 3,000rpm
Variable Type
Oil Pump Lever Fixed Type
Model Code at WOT Position
XA1200A (01) 68N 66V 13.9 ~16.1
XA1200 (99~00) 66V 66V 13.9 ~16.1
GP1200A (00~01) 67X 66V 13.9 ~16.1
SV1200 66G 66G 7.8 ~ 9.6
XL1200 (98) 66F 65U 7.8 ~ 9.6
GP1200 (97~99) 65U 65U 7.8 ~ 9.6
WVT1100 64T 63M 6.5 ~ 8.3
RA1100 63M 63M 6.5 ~ 8.3
XA800 67A 66E 15.8 ~ 18.2
GP800A (01) 68A 66E 15.8 ~ 18.2
GP800 66E 66E 15.8 ~ 18.2
XL760 66D 62T 7.1 ~ 9.1
WVT760 65R 62T 7.1 ~ 9.1
WB760 64Y 62T 7.1 ~ 9.1
GP760 65V 62T 7.1 ~ 9.1
WVT700 (95~96) 63N 62T 7.1 ~ 9.1
RA700 (94~95) 62T 62T 7.1 ~ 9.1
RA700A (95~96) 62T 62T 7.1 ~ 9.1
XL700 67E 61X 5.4 ~ 7.0
WVT700B (98) 65T 61X 5.4 ~ 7.0
WRA700 64R 61X 5.4 ~ 7.0
WB700 (93~95) 62E 61X 5.4 ~ 7.0
WB700A (96) 64U 61X 5.4 ~ 7.0
RA700B (97) 64R 61X 5.4 ~ 7.0
WRA650 6R8 6R8 4.4 ~ 5.6
Example: XA1200
Test #1 Front Cylinder (3 min): 15.2cc
Test #2 Center Cylinder (3 min): 14.7cc All outputs are within specification
Test #3 Rear Cylinder (3 min): 15.9cc
4-12
4-13
4-14
Performance Troubleshooting “Jet Pump”
TECHNICAL TIPS
Symptom: Remedy:
When accelerating from a stop or from very low The first step in troubleshooting a performance
speeds, the customer may experience a rapid problem is to verify the symptom. Test the unit
increase in engine rpm before the jet pump to be sure you are dealing with a jet pump
“hooks up” (see chart below). related problem and not poor performance due
to an engine, carburetion or ignition problem.
OVERSHOOTING DUE Once it is verified the problem is in the jet pump
TO CAVITATION OR “SLIP” area, follow the steps below to identify the
R/MIN
cause:
1. Measure the impeller to impeller housing
clearance on each blade. If the clearance is
out of specification, replace the impeller.
NORMAL ENGINE
ACCELERATION Inspect the impeller housing for wear and
replace as necessary. You may need to
insert a new impeller to measure this accu-
rately. Wear to the impeller takes place on
THROTTLE ON the outer edge of the impeller. You will typi-
TIME cally see a rounding of the edges on the
outside of the impeller. This will show up
Possible Causes: first on the load or back side of the impeller.
1. Wear to the impeller from sand. This You may also notice a polishing of the sur-
increases the clearance between the face of the impeller from the sand.
impeller and the housing. This acts like a
leaking seal allowing the water to slip past DAMAGE
the impeller instead of being drawn

through.
2. Damage to the impeller from rocks or
debris. This creates cavitation and disrupts
water flow through the jet pump.
3. A leak in the jet pump area allowing air to
enter the jet pump. This also creates cavi-
tation in the jet pump. WEAR
4. Impeller or “Prop” slip. This “slip” also gives

the feeling of reduced acceleration much
like cavitation due to the engine rpm
increasing faster than the vehicle speed. 2. Inspect each blade of the impeller for dam-
age. Damage from rocks will typically be
found on the leading edge of the impeller.
Inspect for nicks or bends in the blades and
replace as necessary.
4-15
Performance Troubleshooting “Jet Pump” (Cont’d.)
3. Inspect the mating surfaces of the jet pump 5. If the symptom is still present after the jet
for evidence of proper sealing. For earlier unit has been inspected and any necessary
design jet pumps, the intake duct is a por- repairs performed, the cause may be “Prop
tion of the jet unit. Inspect for proper seal- Slip.” All water vehicles experience this to
ing where this fits into the hull. Inspect that some degree. This is more apt to occur
the seals, bushing and bushing mounting when the unit is under a heavy load as in a
bolt are in place and in good condition. For towing or with multiple passengers. Under
later style jet units such as XL1200Ltd., these conditions, the unit is harder to plane
XL800 and GP1200R, remove the intake out and the high horsepower of the engine
duct and inspect for proper sealing where will spin the impeller faster than the
this mounts to the hull and contacts the impeller can push the unit. In some cases,
transom plate. Inspect the felt packing for the impeller can be re-pitched or replaced
damage and replace as necessary. with a different style impeller to match the
customers conditions.
GASKET MAKER
SILICONE SEAL
R/MIN “PROP SLIP”
NORMAL ENGINE
ACCELERATION
THROTTLE ON
TIME
4. Remove the transom plate and inspect the

mounting surface for proper sealing. For the XL1200 Ltd. and the GP1200R, a
Inspect the “U” shaped packing for damage new impeller has been developed to
and for proper sealing into the recess of the reduce this slip and thus enhance the feel-
hull. Reseal the transom plate and intake ing of acceleration (see the parts informa-
duct (as necessary) with a marine grade tion below).
silicone sealant.
Impeller
NOTE: Be sure to allow the sealant to fully cure
Old Part Number New Part Number
before the unit is re-tested. The high jet pump
pressures can easily dislodge any sealant that 66V-R1321-00-00 68N-R1321-00-00
has not been allowed to fully cure.
4-16
Impeller and Impeller Housing Erosion GP1200R’s, XL1200 Ltd.
TECHNICAL TIPS
Symptom:
The impeller and impeller housing may have
pre-mature erosion or “Cavitation Burn.” The
impeller may show evidence of burning on the
front side of the blade centered towards the
outer edge.
Cause:
This erosion occurs during extended high-
speed use. The damage, being on the “non-
working” side of the impeller does not effect
performance as long as the clearance to the
housing is correct and the housing is not dam-
aged. In some cases, the liner of the impeller
housing will warp or curl up due to the heat
generated by the cavitation. The liner will then
contact and possibly damage the impeller.
Remedy:
A new Impeller has been developed to greatly
reduce impeller and impeller housing erosion.
The liner of the impeller housing thickness has
been increased from 1mm to 1.5mm to elimi-
nate liner warping. If an impeller or impeller
housing needs replaced due to this problem,
replace them as a set with the parts listed
below.
Parts Information
Old Part Number New Part Number Description
66V-R1321-00-00 68N-R1321-00-00 Impeller
66V-51312-00-94 66V-51312-01-94 Impeller Housing
4-17
Performance Troubleshooting “Carburetion”
TECHNICAL TIPS
The following information has been prepared to
assist in diagnosing performance problems
that may be carburetor based. Use this infor-
mation along with the other performance trou-
bleshooting and carburetor adjusting tips.
I. POOR ACCELERATION
Symptom Possible Cause Remedy
A. Hesitation or Stalling 1. Improper adjustment • Measure the free length of the
needle valve arm spring, the arm
height and the pop off pressure.
R/MIN • Replace it if it is out of specification.
• Inspect the high and low speed fuel
NORMAL ENGINE mixture screws and passages for
ACCELERATION debris or improper adjustment.
• Clean or adjust if out of specification.
*(See Carburetor Adjustment Tips).
2. Carburetor clogged • Check the fuel filter and the small

HESITATION with debris filter in the carburetor. Clean or
replace them if they are clogged with
debris.
• Inspect the needle valve seat and
THROTTLE ON passage in the carburetor and
remove any debris if necessary.
TIME
3. Water in fuel • Check the fuel filter. If water is
present, drain any water from the
separator and the fuel tank. Replace
the fuel filter.
4. Out of sync • Check the carburetor

synchronization and synchronize as
necessary.
5. Increased internal • Loosen the fuel tank cap to release

pressure in the fuel the pressure
tank • Test the fuel tank venting.
6. Improper fuel • Check that the proper octane fuel is

being used.
• High octane fuel used in an engine
designed for 87 octane can cause
hesitation during initial acceleration,
followed by bogging.
4-18
Performance Troubleshooting “Carburetion” (Cont’d.)
I. POOR ACCELERATION (Cont’d.)

B. Bucking or Bogging 1. Low idle rpm • On the water, check the engine idle
rpm after the engine is warm.
Adjust the idle if it is out of
R/MIN specification (see NOTE next page).
NORMAL ENGINE 2. Improper adjustment • Measure the free length of the

ACCELERATION needle valve arm spring, the arm
• Replace it if it is out of specification.
BOGGING mixture screws and passages for
debris or improper adjustment.
• Clean or adjust if out of specification
THROTTLE ON 3. Needle valve stuck • Check whether the needle valve is

with debris (not stuck with debris, and clean or
TIME closing) replace the needle valve as
necessary.
4. Needle valve worn • Inspect the needle valve. If the tip is

worn, replace the needle valve and
seat as a set.
5. Choke valve closed • Check that the choke valve retracts

fully when the choke knob is
returned to its seat. If it does not,
adjust the choke cable.
6. High altitude • Check the altitude the unit is

operated at and change the
carburetor setting to one appropriate
for that elevation. Return the
carburetor to its original settings
when used at sea level.

being used.
• High octane fuel used in 87 octane
designed engines can cause
hesitation during initial acceleration;
4-19
II. SPARK PLUG FOULING
Spark Plugs are Fouled 1. See chart I-B items • See chart I-B items 1~7.
1~7
2. Low to mid-speed • Fully open the throttle for

operation for a long approximately 20 seconds from time
time to time.
3. Improper spark plug • Replace the spark plugs with the

heat range recommended heat range.
III. HARD STARTING

A. The engine fires but does not 1. See chart I-A items • See chart I-A items 1~6.
continue to run. 1~6
2. Idle is set too low. • On the water, check the engine idle
specification (see NOTE below).
B. It takes a while for the engine 1. See chart I-A items • See chart I-A items 1~6.
to start. 1~6. recommended heat range.
2. Needle valve is stuck. • Check whether the needle valve is

stuck, and clean or replace the
needle valve set as necessary.
3. Choke valve not • Check that the choke valve is

completely closed. completely closed when the choke
knob is pulled out. If it is not
completely closed, adjust the choke
cable.
4. Improper starting • Pull the choke knob all the way out.
method. Then, open the throttle about 1/3
and press the start button. Release
the throttle once the engine starts.
5. Weak battery. • Measure the voltage or the specific

gravity of the battery and recharge
the battery if a low reading is
obtained.
NOTE:
Checking and adjusting idle speed:
This operation must be performed on the water.
1. Warm up the engine for five minutes or more at 6000 rpm minimum.
2. Return to idle and operate the engine for two minutes. Check the engine speed and adjust if
out of specification.
4-20
Carburetor Adjusting Tips
TECHNICAL TIPS
Pop Off Pressure Testing 1. Gently depress the needle valve arm to
check for smooth operation and no binding.
Testing pop off pressure has become exceed-
ingly difficult as the standard pressure has 2. Inspect the Needle Valve Arm 1 for dam-
increased on some of the newer models. age.
Because of this increase, the accuracy of this
3. Measure the needle valve arm height. This
test has also diminished.
is measured from the surface of the carbu-
Pop off pressure is a function of two main retor Body b to the top surface of the arm 1.
items:
1
1. Needle seat size a
2. Spring tension on the valve assembly
Perform the following steps to check pop off
pressure: b
1. Remove the carburetor top and diaphragm

to gain access to the needle valve assem-
bly.
Arm height: a
2. Attach the pop off pressure gauge to the 0~0.2mm (0 ~ 0.008 in)
fuel inlet and secure. Make sure your
gauge will operate in the range required for
the model being tested.
3. Block off the fuel return nipple.
b
4. Pressurize the carburetor with the pump
until the needle valve pops. Make sure to
note the pressure. Perform the test 3 times
to assure an accurate reading.
NOTE: When testing, it is very important that
the tip of the needle valve be lubricated. A dry
needle valve tip could stick in the valve seat
causing an inaccurate reading. Use WD-40 or 4. Inspect the spring for proper application
an equivalent to lubricate the needle valve. and measure the free length.
CAUTION: 5. Inspect the needle valve seat size
Do not use gasoline due to the fire hazard. 6. Inspect the needle valve tip for damage or
Always wear eye protection to protect from binding in the valve seat.
spray when the needle pops.
7. Repair or replace these items as neces-
After performing the test, compare your read- sary.
ing to the following chart; based on the specifi-
cations for the model you are testing. If your NOTE: If the pop off pressure changes on a
reading is out of specification, inspect the fol- carburetor, the pressure should not be
lowing items: changed by using different springs or valve
seats. However, the part causing the change
needs to be repaired or replaced.
4-21
Carburetor Adjusting Tips (Cont’d.)
Current Needle Valve Spring Specifications

Identification Spring Pressure
Part Number Free Length (Spring Color) Installed) Arm Set Height
67R-14253-00-00 17.0mm Gold 115 grams 0~0.2mm
63M-14253-00-00 16.1mm Dull Silver 95 grams 0~0.2mm
Control Arm Spring (Color & Strength)

Gold Dull Silver Green Shiny Silver
115 grams 95 grams 80 grams 65 grams*
Needle Valve Size Resulting Pop Off Pressure (+5 psi)
1.2 75 psi 64 psi 54 psi 41 psi
1.5 55 psi 43 psi 38 psi 32 psi
2.0* 32 psi 25 psi 21 psi 18 psi
2.3* 22 psi 20 psi 17 psi 15 psi
2.5* 19 psi 17 psi 14 psi 12 psi
NOTE: Use this as a guideline only, measurements may differ slightly depending on the accuracy of the gauge, test con-
ditions, etc.
* Not original equipment on Yamaha Water Vehicles.
The shaded area of the chart is used for current Yamaha Water Vehicles.
Mixture Screw Adjustment

Specifications: Fig. 1
STANDARD
In the past, carburetor specifications have FUEL FLOW RATE
CARBURETOR
CHARACTERISTICS
been provided with a tolerance of + 1/4 turn. FLOW
This was mistakenly assumed to be the toler- RATE
TOLERANCE TOLERANCE
ance for adjustment in the field. This was actu- UPPER LIMIT
ally the tolerance at the time of being
manufactured. The fuel mixtures are set for
TOLERANCE
total fuel flow rate and the + 1/4 turn is the tol- LOWER LIMIT
erance allowed to achieve the window for
allowable flow.
NUMBER OF TURNS
OUT OF SCREW
In Figure 1, the gray area shows the allowable
fuel flow tolerance. In this example, the carbu- -1/4 +1/4
retor is set to the center of the range.

Fig. 2
The example in Figure 2 shows a carburetor
set at the lower (leaner) edge of the flow rate
window. This is within factory tolerance. If this
carburetor were adjusted in the field to the cor-
rect specification minus 1/4 turn, this would
make the carburetion too lean causing hesita-
tion, hard starting and possibly engine dam- TOLERANCE
LOWER LIMIT
age.
LEANER
NUMBER OF TURNS
1/4 TURN OUT OF SCREW
LEANER
-1/4 +1/4
4-22
The example in Figure 3 shows a carburetor Fig. 3

set at the upper (richer) edge of the flow rate 1/4 TURN
RICHER
window. This is also within factory tolerance. If
this carburetor were adjusted in the field to cor- TOLERANCE
RICHER UPPER LIMIT
rect specification plus 1/4 turn, this would
make the carburetion too rich causing bogging,
plug fouling and poor fuel economy.
Adjustment:
When disassembling carburetors, it is impera- NUMBER OF TURNS

OUT OF SCREW
tive that the position of the fuel mixtures be
-1/4 +1/4
checked before disassembly so they can be
returned to their original position. Perform the
following steps to inspect the fuel mixture
screw settings:
1. Remove the mixture screw cap if applica-
ble.
2. Turn the screw in until it lightly seats, count-
ing the turns as you go. Then record the
number.
3. If the number of turns is within tolerance
this is normal. After carburetor inspection
return the screw to the original setting.
4. If the setting is not within tolerance, the set-

ting may have been changed. Be sure to
thoroughly inspect the carburetor for any
condition that may have caused someone
to change the setting. Set the screw to
specification and test for proper engine
operation.
5. Install a new mixture screw cap, if applica-
ble.
NOTE: With the introduction of the caps over
the mixture screws for emissions purposes, it is
important to use a drill stop when drilling these
for removal. Drilling deeper than 5mm could
allow the drill bit to pass through the cap and
contact the mixture screw. This can drive the
screw into the carburetor, disturbing the origi-
nal setting and possibly damaging the mixture
screw and/or its seat.
4-23
Catalytic Converter Failure Diagnosis
rpm range. No rpm reduction or engine stop-
TECHNICAL TIPS page occurs in this mode.
Symptom:
3. Converter broken loose at the outside of it’s
Loss of top speed, reaching only 40~50 mph.
mounting (Fig. 3). This failure occurs from
Cause: water ingestion. The outer sleeve that
The catalytic converter will cease to function or attaches the honeycomb to the outer case
crack and dislodge from its mount and block corrodes, weakening it until it cracks.
the exhaust system.
The following are four of the most common
catalytic converter failures:
1. Blocked converter due to improper oil (Fig.
1). This will typically show up as an oily car-
bon build-up on the converter. Using the
incorrect oil leaves a chemical coating on
the converter, which (in effect) seals the
surface of the converter. When this hap-
pens, the chemical conversion can no
longer take place. Without this chemical
process, the converter does not heat up
FIG. 1
and this allows the oily residue to accumu-
late, restricting the exhaust and increasing
emissions. This is a slow process and is not
immediately obvious. When the converter
becomes thoroughly coated, it will no
longer generate heat and will trigger an
exhaust warning for the temperature being
too cool.
NOTE: This will activate only after operation
over 4000 rpm or higher, continuously for 2
minutes.
2. Melted converter (Fig. 2). This is most often
seen as a melting of the honeycomb on the FIG. 2
back side of the converter. This is caused
by excessive amounts of unburned fuel in
the exhaust system heating the converter
beyond normal operating temperatures. METAL SLEEVE
The most common causes would be con- RUSTED THROUGH
tinuing to run the unit after fouling a spark
plug, a carburetor malfunction or running
the unit continually with the choke used.
Before the temperature rises to the point
where any damage occurs, the exhaust
overheat warning will activate, alerting the
operator to turn the unit off until it cools.
NOTE: During an exhaust temperature warn- FIG. 3
ing, the engine will still run through the normal
4-24
4. Converter cracked or broken out; 10-20mm

in from the outside housing (Fig. 4 & 5).
This cracking occurs from thermal stress
caused by the rapid expansion and con-
traction of the converter. Some causes
could be: water ingestion while the convert-
er is hot, rapid heating and cooling and
improper warm-up. Caution operators on
proper warm-up procedures, so the engine
is at operating temperature before any
WOT operation occurs.
NOTE: When a converter breaks out or breaks CRACKED
FIG. 4
loose, the pieces will quite often contact the
exhaust temperature sensor. If the sensor is
damaged, this will activate an exhaust temper-
ature warning due to a faulty sensor (tempera-
ture too low.) This will occur only after
operation over 4000 rpm continuously for a
minimum of 2 minutes.
FIG. 5
4-25
Power-Valve Improvements
Problem: PREVIOUS -02 POWER-VALVE

BOLT
The power-valve may contact the piston, dam- 10MM
aging the piston and possibly breaking the
power-valve itself. The power-valve travel is
limited by the stop at the base of its shaft. This
stop bottoms on a machined platform in the
cylinder. In some cases, the stop on the power-
valve may wear, allowing the power-valve to
move further into the cylinder and contact the
piston.
Remedy: 15MM
The power-valve has been improved to elimi-
BUSHING
nate the possibility of contact with the piston.
There is now an additional stop to limit power-
valve travel. The bushing that the power-valve CURRENT POWER-VALVE STOP
shaft rides through is now 2.3mm taller. When
the power-valve is at the bottom of its travel
(fully closed) the lever that operates the power- NEW -03 POWER-VALVE
valve now contacts the top of the bushing pro- 14MM
BOLT
viding an additional limit for power-valve
movement. The bolt that holds the power-valve
bushing in place is now longer due to the addi-
tional height of the bushing. When replacing a LONGER
BOLT
power-valve on a unit that has had a failure,
use the latest power-valve assembly. The
longer bolt must be used with the new power-
valve for it to be properly secured. The new
power-valve will be used starting with models
GP800R and XLT1200. 17.3MM
BUSHING
LEVER NOW CONTACTS BUSHING

FOR ADDITIONAL POWER-VALVE STOP
Old Part Number New Part Number Description Comment

66E-1131S-02-00 66E-1131S-03-00 Valve Ass’y. For models that originally
came with an 02 or earlier
90109-05M95-00 90110-05008-00 Bolt, Hex Head part , these must be replaced
as a set.
Model Application: 2001 models GP800R and XLT1200 will use the -03 power-valve starting with
the beginning of their production. Other power-valve models (GP1200R and XL800) will start using
the -03 power-valve later in production. When ordering replacement parts for one of these models,
be sure to inspect old parts to determine if the longer bolt will be required.
4-26
GP1200 Oil Tank Vent Pinched
Symptom:
Unexplained engine seizure. The oil tank vent
hose can become pinched by the QSTS
cables. In some cases (after engine work, car-
buretor work or cable replacement) the QSTS
cable may be removed from their clamps for
additional clearance. During re-assembly, they
may not be properly reattached. If the QSTS
cables are not clamped in the rear tie in the
engine compartment, the cables can shift for-
ward and fold down and subsequently pinch off
CABLES
the oil tank vent hose. The oil tank will then not IMPROPERLY
be able to vent, starving the engine for oil SECURED
Remedy:
Make sure the QSTS cables are secured in all
three clamps, on the right side of the hull, par-
ticularly the clamp at the rear. Also, check the
cable routing where the QSTS cables go to the
steering area. The QSTS cables must route
behind the steering column mounting bracket.
If the QSTS cables are clamped at the rear and
routed correctly at the steering column, the
cables will not interfere with the oil tank vent.
See the photos for proper QSTS cable routing.
REAR CLAMP
QSTS
CABLES
CLAMP AT ALL 3 LOCATIONS
4-27
Troubleshooting Water Entering the Hull Area
Problem:
Based on the information you have collected,
Water in the engine compartment is often pres- start at the condition below that applies and fol-
ent to a small degree. Under normal condi- low the steps for each:
tions, the bilge system will rapidly remove this. 1. Towing:
If the amount of water present seems to be If the unit is being towed behind anoth-
excessive, use the steps below to diagnose er craft, discuss the method with the
and repair the problem. customer. Watercraft must be towed at
Remedy: trolling speeds only. Higher speeds can
cause two main problems:
1. Collect the following information from the • At higher speeds, the water flowing
customer: through the jet pump will enter the cool-
• When is the water noticed? Is it when ing water inlet and force water into the
sitting, slow speed operation, high engine. Without the engine running, this
speed operation or aggressive riding can enter the cylinders and crankcase
only? through the exhaust causing severe
• How much water is present? engine damage.
• Has the water been noticed at every • A towed vehicle not under its own
outing? power is less stable and sits lower in
• Is the water cool or warm? the water.This could allow excessive
• Is the unit used for skiing or towing? water to wash over the unit entering the
• Is the unit being towed behind another hull .
craft? 2. Water leaks while sitting:
2. Visual inspection: This should be the easiest to diagnose.
• Perform a quick visual inspection After performing a visual inspection, posi-
before lake testing the unit. tion the unit so it can be moved front to
• Inspect the jet pump area, ride plate back and side to side.
and cooling line hoses where they enter • Put enough water in the hull to cover
the hull for loose, damaged or missing the bottom without entering the engine.
items. Watch for water leaking out. Move the
• Inspect the hull for damage that could unit side to side and front to back so the
result in a leak. water will cover the hull to the deck
• Inspect the bilge water pickup for clog- bond line and the jet unit and transom
ging. areas. Inspect for leaks at each step.
• Inspect the cooling hoses, bilge hoses, • Inspect the bilge hose and check valve.
and check the valve for proper connec- A disconnected bilge hose or malfunc-
tions. tioning check valve can allow water to
3. Verify the problem: siphon into the hull while sitting.
• If the information from the customer is • Inspect the bond line around its entire
inconclusive, verify the problem. circumference for leaks. If a bond line
• Some conditions can be duplicated on leak is found, the gunwale may need to
a flush attachment, but others will be removed to identify the exact area of
require a test tank or lake test. the leak. (Water leaking at this seam
may follow the gunwale and exit away
from the actual leak.) For bond line
leaks covering a large area or for spe-
cific details repairing a 1997 GP1200,
4-28

refer to the 1998 Tech Update for repair 4. Warm water leaks
procedures. If the leak is a small area, Run the unit and inspect the following
re-gluing will not be necessary as out- areas:
lined in the update procedure. For a • Cooling water hoses, pilot and bypass
minor leak, simply seal the area with a water hoses and fittings
marine grade silicone. • Engine and exhaust gaskets
• Exhaust hoses, connections and YSSS
3. Cool water leaks while the unit is in use: components
The best way to test this is in a test
tank.Testing on a flush attachment does 5. Aggressive riding or submerging the water
not utilize the entire cooling system.Run craft:
the unit and watch for leaks into the bilge. • There are conditions where due to a
Inspect the following areas: very aggressive riding style, the unit
• Inspect all of the areas in step 2. In can take on water faster than the bilge
some cases, a leak may only show up pump will remove it. In these cases, the
under the higher pressure or operating customer may wish to install an addi-
conditions. tional bilge system such as an electric
• Cooling water hoses from the thru hull pump, which runs all the time the unit is
fitting to the engine (loose connections running.
or hose damage).
• Flush hose and fitting (loose connec-
tions, cracked fittings, loose or missing
cap).
• Drive shaft seals or hoses (possible ski
rope damage).
4-29
Crankshaft Failure Diagnosis
Inspect the following areas:
Crankshaft failures occur in one of the many
A. Inspect the crankshaft for rust. Inspect the
following areas: lower rod bearing, upper rod
undamaged rod surfaces, mains and the
bearing, main bearings rod breakage or crank-
small end of the rod for pitting and evidence
shaft twisting. Lack of oil is generally not the
of rust.
cause of a crankshaft failure due to the fact that
if no oil is present, the piston will generally fail B. Inspect the other rod(s) for excessive play.
first. Most water vehicle crankshaft failures
C. Inspect the CDI unit for modification.
are due to water damage.
FIGURE 1
Often, the clues for failures due to water are
subtle. The example in Figure 1 is an obvious
cause of rust, but an engine with a failed rod
bearing where on the surface it looks clean, is
not. The damage due to water often took place
a number of hours before the crank failure
occurred. This means water will generally not
be present when the technician starts to diag-
nose the failure. Often, the evidence will be on
the parts adjoining the cylinder where the fail-
ure occurred.
Lower Rod Bearing Failure
Lower rod bearing (big end) failure from water FIGURE 2
occurs when the water causes the bearing sur-
face to become pitted (see Figure 3). This pit-
ting creates a rough surface which in turn
wears the rod and rod bearing. Rust on a bear-
ing surface will often be a black pitting or look
like a shadow of the bearing due to the polish-
ing effect that the bearing has (see Figures 2
& 3). This can also take on a grayish appear-
ance after being run in this condition. Once the
bearing becomes loose at high rpm, the bear-
BLACK SHADOW
ing rollers will start to skid, because they lose IS FROM RUST
contact with one side of the outer race. When
the bearing skids, it becomes too hot and will
seize. This same thing can take place due to FIGURE 3
excessive wear.
Excessive rpm from a modified ignition can
also cause this type of failure. This can cause
the lower portion of the rod to stretch, again
causing distortion and the rollers to skid and
seize.
PITTING
FROM RUST
4-30
Crankshaft Failure Diagnosis (Cont’d.)
Upper Rod Bearing: Connecting Rod Breakage:

The upper rod bearing is often accompanied Rod breakage takes place for many reasons.
with a piston seizure. Excess heat from the pis- Most breakages are to due to no fault of the
ton dissipates into the rod and overheats the rod. If the engine hydro-locks due to fuel or
bearing. The lubrication requirements are water in the engine, the force will bend, twist or
much less for the upper bearing, since it only possibly break the rod. A rod can also break on
rocks and does not rotate fully. multi-cylinder engines due to a piston seizure
that continues to run. The crankshaft drives the
A. Inspect the bearing and rod for water dam- seizing piston (applying excessive force on the
age. rod) and breaking it. Excessive heat in the rod
B. Inspect the piston for signs of excessive (from a piston or bearing seizure) can cause
heat or seizure. the rod to overheat, lose its temper and break.
Main Bearings: A. Evidence of hydro-lock, water or fuel pres-

ent distorted or pushed out crankshaft
A main bearing failure is most often caused by seals.
water or debris damage from another or earlier
failure. Main bearings generally do not break or B. Inspect for piston seizure
seize, but typically get loose due to wear. This C. Inspect the connecting rod for evidence of
is due to the lower rotating speed of the bear- excessive heat.
ing rollers.
Crankshaft Twisting:
A. Inspect the bearing and rod for water dam-
age. Crankshaft twisting is most often a result of
hydro-lock. This can also be due to insufficient
B. Inspect for evidence of a previous failure. interference in the fit of the crankshaft compo-
nents. Also, a sudden driveline stoppage can
apply more force than the design of the crank-
shaft causing it to twist.
A. Evidence of hydro-lock
B. Damage to the jet pump bearings or
impeller
C. Modified engine
4-31
Parts List Correction : Engine Mounting Spacers
The parts listing for many models shows the In the example below, this unit uses spacers
incorrect location and/or quantity used for the (Ref. 33) on the starboard side only. Both star-
engine mount spacers. Also a longer bolt is board side mounts would require the longer
used to secure the mount in a location where a bolts (Ref. 34). Both port side mounts would
spacer is used. This listing may also be incor- not use spacers and would require the shorter
rect. Refer to the chart for the proper location of mounting bolts (Ref. 32). The parts fiche incor-
engine mount spacers. rectly shows spacers on both front mounts and
none on the rear.
EXAMPLE OF CORRECTED WVT760 PARTS FICHE
Hull Spacer Location

Molding Port Side Starboard Side
Type Model Name Engine Process Front Rear Front Rear
WVT Series
GJ3 WVT700 63N
GT3 WVT700B 65T
SMC O O
GP3 WVT760 65R
GH3 WVT1100 65A
XL Series
F0M XL700 67E
GU2 XL760 66D SMC O O
GU3 XL1200 66F
RA Series
GH1 RA700 62T HLF O O O O
GH6 RA700A 64B
GJ8 RA700B 64R
SMC O
GP2 RA760 64X
GJ1 RA1100 63M
Spacer Used
O Spacer Not Used
4-32
Parts List Correction: Ride Plate Nuts
TECHNICAL TIPS
The nuts for the ride plate, intake duct and
intake grate are not listed for many models.
See the chart below for an application listing.
Ref. # Part Number Location Used Quantity Used

59 90179-089U7-00 Intake Duct 4
60 90179-06947-00 Intake Grate 2
62 90179-089U7-00 Ride Plate 4
Applicable Models:
XA1200X/Y
XA1200AZ
XA800Y/Z
GP1200AY/Z
GP800AZ
4-33
Erratic Power-Valve Operation
Symptom:
The power-valve may seem to operate errati-
cally, sometimes cycling on its own.
System Description:
The Power Valve System is controlled by a chip
in the servo motor. The servo motor receives a
signal from the CDI unit much like a tachome-
ter signal. The processor in the servo motor
reads this signal, then operates the power-
valve based on the MAP stored in its control-
ling chip. The servo motor has power all the
time and operates based on engine rpm. After
the engine stops, a timer starts in the servo
motor processor. After a few seconds, the
processor will cycle the power-valve for its
CORROSION
cleaning cycle.
Cause:
The block connector for the servo motor may
have corrosion present. With corrosion in the
connector, voltage can short from the battery
side to the signal side simulating an ignition
signal. This will restart the “Engine Off” timer,
and the servo motor will again start a cleaning
cycle. Corrosion may also cause loss of the
signal from the CDI unit during normal opera-
tion, causing the servo motor to operate errati-
cally or not at all.
Remedy:
Clean or replace the servo motor connections.
Use dielectric grease to protect the connection
when reassembling.
4-34
Carburetor Settings - 2001 Models
TECHNICAL TIPS
For information purposes, the factory has released the following list of carburetor settings:
NOTE: High and Low speed screw settings are for reference only. See the previous Tech Tip on
Carburetor Adjustment.
Model SJ700AZ XL700Z GP800AZ XA800Z

Model/
Engine ID GM6/64V F0M/67E F0W/68A F0P/67A
Carb 64U02F 64U02R 62T02F 62T02R 68A011 68A012 67A021 67A022
Stamped Front Rear Front Rear Front Rear Front Rear
I.D. Carb Carb Carb Carb Carb Carb Carb Carb
Throttle Bore 38 mm 38 mm 44 mm 44 mm
Venturi OUT Vent 34 mm 34 mm 40 mm 40 mm
Bore IN Vent 9.0 mm 9.0 mm 10 mm 10 mm
Main Jet 1 1.4 mm 1.5 mm 2.0 mm 2.0 mm
Main Jet 2 #130 #120 #130 #150 #150
High Speed Screw 1-1/8 1-1/2 5/8 1-1/8 1/2 1/2
Main Nozzle 2.5 mm 2.5 mm 3.0 mm 3.0 mm
Low Speed Jet #70 #67.5 #90 #90
Pilot Outlet 0.9 mm 1.0 mm 1.4 mm 1.4 mm
Low Speed Screw 7/8 5/8 1-5/8 1-3/4 1-5/8 1-3/4
Throttle Valve #190 #190 #120 #120
Bypass 1 0.6 mm N/A 0.5 mm 0.5 mm
Bypass 2 0.7 mm 0.6 mm 0.5 mm 0.5 mm
Bypass 3 N/A 0.7 mm 0.7 mm 0.7 mm
Bypass 4 N/A N/A 0.7 mm 0.7 mm
Valve Seat 1.5 mm 1.5 mm 1.2 mm 1.2 mm
Return Jet 0.5 mm 0.5 mm 0.5 mm 0.5 mm
Arm Spring
115 gr/Gold 115 gr/Gold 115 gr/Gold 115 gr/Gold
Set Weight/Color
Arm Spring
17.0 mm 17.0 mm 17.0 mm 17.0 mm
Free Length
4-35
Carburetor Settings - 2001 Models (Cont’d.)
Model GP1200AZ SV1200Z XA1200AZ

Model/
Engine ID F0X/67X GU5/66G F0V/68N
Carb 67X-021 67X-022 67X-023 66G11 66G02 66G03 68N011 68N012 68N013
Stamped Front Center Rear Front Center Rear Front Center Rear
I.D. Carb Carb Carb Carb Carb Carb Carb Carb Carb
Throttle Bore 44 mm 44 mm 44 mm
Venturi OUT Vent 40mm 40 mm 40 mm
Bore IN Vent 10 mm 10 mm 10 mm
Main Jet 1 2.0 mm 2.0 mm 2.0 mm
Main Jet 2 #117.5 #135 #117.5
High Speed Screw 1-1/2 1-3/8 1-1/2 3/4 1.0 3/4 1-1/4 1-1/8 1-3/8
Main Nozzle 3.2 mm 3.2 mm 3.2 mm
Low Speed Jet #95 #100 #95 #97.5 #87.5
Pilot Outlet 1.2 mm 1.2 mm 1.2 mm
Low Speed Screw 1-3/8 1.0 7/8 1-1/8
Throttle Valve #150 #130 #180
Bypass 1 0.6 mm 0.6 mm 0.6 mm
Bypass 4 N/A 1.0 mm N/A
Valve Seat 1.2 mm 1.2 mm 1.2 mm
Return Jet 0.5 mm 0.5 mm 0.5 mm
Arm Spring
115 gr/Gold 95 gr/Gold 115 gr/Gold
Set Weight/Color
Arm Spring
17.0 mm 16.1 mm 17.0 mm
Free Length
4-36
Impeller Application Chart - WaveRunner®
TECHNICAL TIPS
IMPELLER APPLICATION CHART
Pump Type
Model Year (Outer Diameter) Standard Impeller Part Number
SJ700AU ’96 144mm Axial Flow 3 Blade Aluminum 13° ~ 16° 6R7-51321-00-94
WRA650U ’96 144mm Axial Flow 3 Blade Aluminum 13° ~ 16° 6R7-51321-00-94
WB700AU ’96 144mm Axial Flow 3 Blade Stainless 15° ~ 18° 62E-51321-00-00
RA700BU ’96 144mm Axial Flow 3 Blade Aluminum 13° ~ 16° 6R7-51321-00-94
RA1100U ’96 155mm Axial Flow 3 Blade Stainless 16° ~ 19° 63M-51321-A0-00
RA760U ’96 144mm Axial Flow 3 Blade Stainless 17° ~ 20° 62T-51321-B0-00
WVT700U ’96 144mm Axial Flow 3 Blade Stainless 17° ~ 20° 62T-51321-B0-00
WVT1100U ’96 155mm Axial Flow 3 Blade Stainless 16° ~ 19° 63M-51321-A0-00
WB760U ’96 155mm Axial Flow 3 Blade Stainless 13° ~ 16° 64Y-51321-A0-00
SJ700AV ’97 144mm Axial Flow 3 Blade Aluminum 13° ~ 16° 6R7-51321-00-94
RA700BV ’97 144mm Axial Flow 3 Blade Aluminum 13° ~ 16° 6R7-51321-00-94
WRA700V ’97 144mm Axial Flow 3 Blade Aluminum 13° ~ 16° 6R7-51321-00-94
GP760V ’97 144mm Axial Flow 3 Blade Stainless 17° ~ 20° 65V-51321-00-00
WB760V ’97 155mm Axial Flow 3 Blade Stainless 13° ~ 16° 64Y-51321-A0-00
WVT760V ’97 155mm Axial Flow 3 Blade Stainless 11° ~ 14° 65R-R1321-10-00
WVT1100V ’97 155mm Axial Flow 3 Blade Stainless 16° ~ 19° 63M-51321-A0-00
GP1200V ’97 155mm Axial Flow 3 Blade Stainless 15.1° 66F-R1321-00-00
SJ700AW ’98 144mm Axial Flow 3 Blade Aluminum 13° ~ 16° 6R7-51321-00-94
VT700BW ’98 155mm Axial Flow 3 Blade Stainless 11° ~ 14° 65R-R1321-10-00
XL760W ’98 155mm Axial Flow 3 Blade Stainless 11° ~ 14° 65R-R1321-10-00
XL1200W ’98 155mm Axial Flow 3 Blade Stainless 15.1° 66F-R1321-00-00
GP760W ’98 144mm Axial Flow 3 Blade Stainless 17° ~ 20° 65V-51321-00-00
GP800W ’98 144mm Axial Flow 3 Blade Stainless 17.0° 66E-51321-B0-00
GP1200W ’98 155mm Axial Flow 3 Blade Stainless 15.1° 66F-R1321-00-00
SJ700AX ’99 144mm Axial Flow 3 Blade Aluminum 13° ~ 16° 6R7-51321-00-94
XL700X ’99 155mm Axial Flow 3 Blade Stainless 11° ~ 14° 65R-R1321-10-00
XL760X ’99 155mm Axial Flow 3 Blade Stainless 11° ~ 14° 65R-R1321-10-00
GP760X ’99 144mm Axial Flow 3 Blade Stainless 17° ~ 20° 65V-51321-00-00
GP800X ’99 144mm Axial Flow 3 Blade Stainless 17.0° 66E-51321-B0-00
GP1200X ’99 155mm Axial Flow 3 Blade Stainless 15.1° 66F-R1321-00-00
SUV1200X ’99 155mm Axial Flow 3 Blade Stainless 15.2° 66G-R1321-00-00
XA1200X ’99 155mm Axial Flow 3 Blade Stainless 15.6° 66V-R1321-00-00
4-37
Impeller Application Chart - WaveRunner® (Cont’d.)
TECHNICAL TIPS
Pump Type
Model Year (Outer Diameter) Standard Impeller Part Number
SJ700AY ’00 144mm Axial Flow 3 Blade Aluminum 13° ~ 16° 6R7-51321-00-94
XL700Y ’00 155mm Axial Flow 3 Blade Stainless 11° ~ 14° 65R-R1321-10-00
GP760Y ’00 144mm Axial Flow 3 Blade Stainless 17° ~ 20° 65V-51321-00-00
GP800Y ’00 144mm Axial Flow 3 Blade Stainless 17.0° 66E-51321-B0-00
GP1200AY ’00 155mm Axial Flow 3 Blade Stainless 15.6° 66V-R1321-00-00
SUV1200Y ’00 155mm Axial Flow 3 Blade Stainless 15.2° 66G-R1321-00-00
XA800Y ’00 155mm Axial Flow 3 Blade Stainless 13.4° 67A-R1321-00-00
XA1200Y ’00 155mm Axial Flow 3 Blade Stainless 15.6° 66V-R1321-00-00
SJ700AZ ’01 144mm Axial Flow 3 Blade Aluminum 13° ~ 16° 6R7-51321-00-94
XL700Z ’01 155mm Axial Flow 3 Blade Stainless 11° ~ 14° 65R-R1321-10-00
GP800AZ ’01 155mm Axial Flow 3 Blade Stainless 13.2° 68A-R1321-00-00
XA800Z ’01 155mm Axial Flow 3 Blade Stainless 13.5° 67A-R1321-00-00
GP1200AZ ’01 155mm Axial Flow 3 Blade Stainless 15.6° 66V-R1321-00-00
SV1200Z ’01 155mm Axial Flow 3 Blade Stainless 14.6° 66G-R1321-00-00
XA1200AZ ’01 155mm Axial Flow 3 Blade Stainless 15.6° 68N-R1321-00-00
4-38
Paint Application Chart - WaveRunner®
TECHNICAL TIPS
The following chart explains which units have painted surfaces, gelcoated surfaces and the color
used.
PAINT APPLICATION CHART - WaveRunner

Hull Deck Hood Hood Cover/Lid
Year Model Model Name Material Color Material Color Material Color Material Color
’87~’96 See Technical Bulletin WV96-016
’97 RA700BV WaveRaider SMC B SMB B SMB B
SJ700AV SuperJet SMC B HLF DD* SMC B
WRA700V WaveRunner III SMC B SMC B SMC N PC N
WVT760V WaveVenture 760 SMC B SMC B SMC P PC Y
WVT1100V WaveVenture 1100 SMC B SMC B SMC P PC X
GP760V GP760 SMC B SMC B SMC N/A PC Z
GP1200V GP1200 SMC B SMC B SMC N/A PC X
WB760V WaveBlaster II HLF GG* HLF DD* SMC N/A PC TBA
’98 SJ700AW SuperJet SMC B HLF TBA SMC E2
WVT700BW WaveVenture 700 SMC B SMC B SMC W PC Z
XL760W XL760 SMC B SMC B SMC N/A PC A2
XL1200W XL1200 SMC B SMC B SMC N/A PC C2
GP760W GP760 SMC B SMC B SMC N/A PC Z
GP800W GP800 SMC B SMC B SMC N/A PC D2
GP1200W GP1200 SMC B SMC B SMC N/A PC D2
’99 SJ700AX SuperJet SMC B HLF TBA SMC E2
XL700X XL700 SMC B SMC B SMC N/A PC F2
XL760X XL760 SMC B SMC B SMC N/A PC C2
GP760X GP760 SMC B SMC B SMC N/A PC F2
GP800X GP800 SMC B SMC G2 SMC N/A PC D2
GP1200X GP1200 SMC B SMC G2 SMC N/A PC D2
SV1200X SUV1200 HLF HH* HLF HH* SMC L2 SMC L2
XA1200X XL1200 Ltd. SMC B SMC B N/A N/A SMC H2
’00 XJ700AY SuperJet SMC B HLF JJ* SMC U2
XL700Y XL700 SMC B SMC B SMC N/A PC N2
GP760Y GP760 SMC B SMC B SMC N/A PC F2
GP800Y GP800 SMC B SMC B SMC N/A PC P2*1
GP1200AY GP1200R SMC B SMC B N/A N/A PC P2
SV1200Y SUV1200 HLF HH* HLF HH* N/A N/A SMC L2
XL800Y XL800 SMC B SMC T2 N/A N/A SMC S2
XL1200Y XL1200 Ltd. SMC B SMC T2 N/A N/A SMC C2
’01 SJ700AZ SuperJet SMC B HLF JJ* SMC U2 N/A N/A
XL700Z XL700 SMC B SMC B N/A N/A PC N2
GP800AZ GP800R SMC B SMC B N/A N/A PC V2
XA800Z XL800 SMC B SMC B N/A N/A SMC C2
GP1200AZ GP1200R SMC B SMC B N/A N/A PC V2
SV1200Z SUV1200 HLF KK* HLF HH* N/A N/A SMC N2
XA1200AZ XLT1200 SMC B SMC B N/A N/A PC P2
SMC = Sheet Molding Compound (Painted) N/A = Not applicable
HLF = Hand Lay up Fiberglass (gelcoat) *1 Visor Color = R-2
MET = Metton Hood = Engine Hatch
PC = Poly Carbonate Hood Cover = Cover, Engine Hatch
* = Refer to Gelcoat information on next page. Lid = Lid, Engine Room
TBA = To be announced Visor = Insert on Cover, Engine Hatch
4-39
Paint Color Codes - WaveRunner®
TECHNICAL TIPS
The following chart explains which units have painted surfaces, gel-coated surfaces, and their color.
Use this data (with the following charts) to determine your paint or gel-coat repair needs.
Paints
Ref. Factory Sherwin-Williams
Code Color Name Code Base Coat Top Coat Paint Code
A Polar White 0241 * 5705U 366-51436
B Pure White 0240 * 5700U 366-51437
C Greenish Blue Solid 2 (Yamaha Teal) 0263 * 5710U 366-51438
D Deep Purplish Red Metallic 2 (Maroon) 0277 N/A N/A N/A
E Vivid Purplish Red Solid 2 0242 * 5720U N/A
F Blue/Black 0239 N/A N/A 366-51440
G Purplish Blue Solid 1 (Purple) 0396 * 5730U 366-51442-G
H Galactic Blue (Blue/Black Metallic) 00TG * 5672U 366-51444-G
L New Dark Gray 0237 N/A N/A N/A
Dark Grayish Blue Metallic 6
M (Violet Metallic) 0457 * 5740U 366-51443-G
N Violet Solid 6 0440 * 5745U 366-51441-Y
P Deep Purple Solid 1 0123 * 5750U 366-51439-Y
R Violet (Light Violet) GAN5 * 5755U 366-51445
S Vivid Greenish Blue Solid 1 0216 * 5775U 362-52707-G
T Vivid Red Solid C 0503 * 5760U 362-52689
U Pastel Mineral Blue 00T7 * 5770U 362-52688
V Vivid Greenish Yellow Solid 2 0278 * 5562U 362-54883-J
W Dull Cyan Solid 3 0524 * 5765U 362-52687
X Vivid Red Metallic 4 0571 * 5643U U7-54943-T
Dull Greenish Blue Metallic 8
Y (Dull Greenish Metallic 8) 0570 * 5940U U7-54944-Y
Z Calm Yellow 00AL 1555U 5553U U7-54942-T
Dark Purplish Red Metallic 7
A2 (Dark Purplish Red Coctail 2) 0649 * 5990U U7-57687
B2 Black Topcoat N/A N/A U7-57686
Bluish Black Metallic 3
C2 (Camellia Green Metallic) 0636 * 5950U U7-57689
D2 Deep Violet Metallic 9 0624 * 5935U U7-57688
E2 Deep Purplish Blue Solid D 0581 * 5938U U7-60000
F2 Very Dark Red Metallic 1 0696 TBA TBA TBA
G2 Deep Purplish Blue Solid K 0695 TBA TBA U7-60040
H2 Redish Black Metallic 1 0701 TBA TBA U7-60039
L2 Yellowish Gray Metallic 6 0702 * 5971U U7-60038
M2 White Coat 5 GA5E TBA TBA U7-60694
N2 Dark Red Metallic C 0726 TBA TBA TBA
P2 Light Gray Metallic D 0725 * 5994U TBA
R2 Dark Bluish Gray Metallic 6 0733 TBA TBA TBA
S2 Dark Reddish Gray Metallic 3 0739 TBA TBA U7-61331
T2 Yellowish White Solid 3 0728 * 5955U U7-60997
U2 Dark Purplish Blue Solid M 0754 TBA TBA U7-61334
V2 Dark Purplish Blue Metallic F 0770 TBA TBA TBA
W2 Dark Violet Coat 2 GA5D TBA TBA TBA
X2 Dark Red Coat 7 GA5H TBA TBA TBA
Spray Paint YPAD Part Number

W/V Primer PNT-00000-SP-WV
Metallic Marine Silver 00EK PNT-87000-S0-EK
* Not Used
N/A Not Available
TBA To Be Announced
4-40
Gelcoat Color Codes - WaveRunner®
Gel-Coats
Factory
Ref. Code Color Name Code Sher-Fab Part Number
AA Polar White 0241 NF-1031
BB Purplish Blue Solid 1 (Purple) 0396 TF-8303
CC Violet (Light Violet) GAN5 MG30520
DD Pure White 0240 SF2020
EE Vivid Red Solid C 0503 SF9501
FF Vivid Greenish Yellow Solid 2 0278 SF2961
GG New Teal Solid GG30870
HH White Coat 5 GA5E SF498E
JJ Dark Violet Coat 2 GA5D TBA
KK Dark Red Coat 7 GA5H TBA
Note: Gel-Coat was originally used on these models. Some repairers however, may prefer to use paint
instead of Gel-coat during repair. While the color may be slightly different, the following paint
substitutes can be used:
AA Gel-coat = A paint FF Gel-coat = V paint
BB Gel-coat = G paint GG Gel-coat = C paint
CC Gel-coat = R paint HH Gel-coat = M-2 paint
DD Gel-coat = B paint JJ Gel-coat = W-2 paint
EE Gel-coat = T paint KK Gel-coat = X-2 paint
Paint and Gel-coat ordering

Paint
Sherwin Williams paints are available through all Sherwin Williams automotive paint stores nationwide
Color-Rite paints are available directly from Color-Rite

National Sales Office East Coast Sales Office
11603 Groveland Ave. 123 Blaine St.
Whittier, CA 90604 E. Bangor, PA
(562) 947-9796 Information (610) 588-7355 Information
(800) 736-7980 Orders (800) 358-1882 Orders
(562) 902-8068 Fax (610) 588-1570 Fax
On the Web at www.color-rite.com
Gel-Coat
Sher-Fab Gel-coats are availible directly from Sher-Fab
Sher-Fab Unlimited
14629 Carmenita Road
Norwalk, CA 90650
(562) 921-5206
4-41
4-42
Section 5
WaveRunner® Technical Bulletins/
Tech Exchange Review
5-1
5-2
2001 WaterCraft Technical Update - Watercraft Bulletins and Tech Exchanges
WATER VEHICLE 3/17/00 WV2000-001
© 2000 YAMAHA MOTOR CORPORATION, U.S.A.
2000
WaterCraft Technical Update Manual Revisions
The following is a list of revisions that need to be made in the 2000 WaterCraft Technical Update Manual
(LIT-18500-00-2K).
Revisions
Page 1-17
The first line should read: Proven two-stroke, two cylinder, 784cc, 120HP engine. Not three cylinder.
Page 1-33
Mark out the word reverse from the end of the third line.
Page 2-5
Change SJ700A starting serial number to 913467~.
Change GP760 starting serial number to 813697~.
Add SV1200 starting serial number 100101~.
Page 2-16
Under A5, change the part number for ''Valve'' to 65U-24421-00-00.
Page 2-23
This page is a duplication of 2-22. The correct information is as follows:
Water Vehicle 2000 Model
MODEL SJ700A WB800 XL700 GP760 GP800 XA1200 SV1200
GM6 FON FOM GP7 GUO FOD GU5 REF. NO.
PART NAME
64V 67U 67E 65V 66E 66V 67B 66G
JET MAIN (-1423*-) 3G2-26

3G2-74
(#130) 3G2-27
(#117.5)
(#135)
8
1HX-68
N/L N/L NIL N/L (#87.5)
JET MAIN (-1423*-) 830-14 830-64 830-23
(#70) (#64.5) (#115)
9
830-18
(#90) N/L N/L NIL
PAGE 1 of 2
5-3
Revisions (Cont’d.)
Page 4-16
Under Engine, change Ignition Timing to: 15° BTDC~20° BTDC.
Page 4-21
Under Engine, change ignition timing to : 18° BTDC~20° BTDC.
Page 6-34
XA800Y impeller pitch should be 13.5° not 13.4°.
Page 6-36
Under T-2 Yellowish White Solid 3, add U7-60997 for Sherwin Williams Part Number.
PAGE 2 of 2 ROUTE TO: ü SERVICE ü PARTS ü WARRANTY ü SALES
5-4
WAVERUNNER WATERCRAFT 3/29/00 WR2000-002
WAVERUNNER
Warranty Policies
The Yamaha Warranty and Y.E.S. Handbook (LIT-11760-00-95) provides both Motorsport and Marine
Warranty Policies and Procedures, as well as Yamaha Extended Service (Y.E.S.) Policies and
Procedures.
Specific details about each product line’s particular policies and procedures are not in the Yamaha
Warranty and Y.E.S. Handbook. Instead, specific information is provided in “Warranty Policies” Technical
Bulletins like this one for each Yamaha supported product line.
This makes finding information easier. When general Yamaha Warranty policies and procedure informa-
tion is needed, refer to the Handbook. When the policy is known but the specific product details are need-
ed, refer to this quick reference bulletin. This is also an advantage if a policy details changes. Specific
changes can be provided in a new version of this bulletin rather than having the Yamaha Warranty and
Y.E.S. Handbook updated each time.
LIMITED WARRANTY STATEMENT INFORMATION

See Yamaha Warranty and Y.E.S. Handbook, page 1-3 for more information.
Warranty Limited Warranty Statement

Model Period Part Number
Water Vehicle Pleasure use: 1 Year LIT-18792-00-87
Commercial use: 90 days
PRIMARY ID
The Primary ID is on a “PRI-ID” sticker inside the engine compartment. See the appropriate Owner’s or
Service Manual for exact location on each model.
Example:
PRI-ID
MODEL GP1200AY F0X 100101
PRIMARY ID
YAMAHA MOTOR CORPORATION, U.S.A.

ASSEMBLED IN U.S.A. FROM AMERICAN AND JAPANESE PRIMARY ID
COMPONENTS. F0X-100101
ASSEMBLE AUX ETATS-UNIS DE PIECES AMERICAINES ET
JAPONAISES
PAGE 1 of 5
5-5
AUTHORIZATIONS
Warranty repairs* on in-warranty models require authorization only if the total repair cost exceeds the
following:
$750.00 or below Authorization not needed

$750.01 or above Call RTA for authorization
Total repair cost includes:

Warranty Y.E.S.
Parts YCS: Dealer cost + 25% for handling reimbursements Yamaha Suggested Retail
Mail-in Paper form: Dealer Cost + 10%
NOTE: There is a maximum handling
reimbursement of $150.00.
Labor Flat rate time at approved shop labor rate Flat rate time at approved shop labor rate
+ any extra labor claimed and authorized + any extra labor claimed and authorized
*See page 7-5 of the Yamaha Warranty and Y.E.S. Handbook if an accident or fire occurred.
REIMBURSEMENT POLICY
Warranty labor reimbursement is initially set at 80% of your approved labor rate. Participation in Yamaha
technical training programs increases reimbursement.
Base Reimbursement 80% of approved hourly rate

Attendance at annual Service Seminar +10%
Attendance at Yamaha regional school +10%
To get or maintain the full 100% reimbursement, both the annual Service Seminar and technical training
course must be attended each two years, unless Yamaha waives part of the requirement. See the annu-
al Technical Training bulletin for more information.
PAGE 2 of 5
5-6
WARRANTY AND Y.E.S. PHONE NUMBERS

Department Phone Number Purpose Handbook Ref.
Warranty 1-800-227-5963 Registration Questions Chapter 5
Labor Rate Questions Chapter 1
Recall Questions Chapter 8
Concealed Shipping Damage Authorization Chapter 3
Warranty FAX (714) 761-7303 FAXing (rather than mail):
- Registration transfer or correction
documents Chapter 5
- Warranty Appeals Form Chapter 10
- Other Warranty or Y.E.S. documents
Regional Technical See “Toll-Free - Warranty Authorizations Chapter 7
Advisor Service Assistance” - Y.E.S. Authorizations Chapter 7
Technical Bulletin - Out-of-Warranty Authorizations Chapter 7
- Customer Relations Assistance Chapter 7
- Technical Assistance
Y.E.S. 1-800-227-5963 Y.E.S. Questions (except authorizations) Chapters 2, 5
Customer Relations 1-800-635-0736 - Return calls to Customer Relations
(Dealer Calls) - Accidents or fire-related authorizations Chapter 7
Customer Calls:
- Customer Relations 1-800-962-7926 - For customers who insist on talking to Chapter 7
Yamaha instead of letting you help.
- Any recall questions Chapter 8
Distribution 1-800-537-3835 Carrier-Related (visible) Shipping Damage Chapter 3
Assistance
Technical (714) 761-7464 Replacement copies of:
- Technical Bulletins (current)
- Flat Rate Tables (current)
WARRANTY AND Y.E.S. LITERATURE

Water Vehicle Only Forms
Department Part Number Handbook Reference and Usage Notes

Water Vehicle LIT-18161-00-98 See Page 4-2.
Assembly and Checklist for procedures required before delivery to customer.
Predelivery
Inspection Checklist
(25/pkg.)
PAGE 3 of 5
5-7
Warranty and Y.E.S. Forms
Warranty and Y.E.S. Handbook LIT-11760-00-95 Covers warranty and Y.E.S. for all products.
Warranty Request Worksheets LIT-11801-01-02 See Chapter 6.
(15/pkg.) Fill out before submitting warranty or Y.E.S. claim on
YCS.
Warranty Request Forms LIT-11791-01-00 See Chapter 6.
(10/pkg.) Mail-in warranty or Y.E.S. claim form if YCS is not
used.
Transfer of Owner Registration LIT-11790-07-83 See page 5-7.
(10/pkg.) Update registration records with new owner and
transfer any warranty or Y.E.S. coverage.
Warranty Registration LIT-11792-00-00 See page 5-6.
Correction Form (10/pkg.) For correcting warranty or Y.E.S. registration errors.
Warranty Return Envelope LIT-11784-00-01 Pre-addressed envelopes for mailing documents to
(10/pkg.) the Warranty Department.
Warranty Status Chart Pads LIT-11790-00-00 See Chapter 10.
(10/pad) Track status of warranty and Y.E.S. claims.
Warranty Parts Tags LIT-11790-02-00 See page 9-1.
(50/pkg.) Identify parts claimed on warranty requests.
Warranty Document ID Form LIT-11791-00-04 See page 1-7.
(10/pkg.) Identify any supporting documents sent to Warranty.
Recall Reimbursement Request LIT-11790-00-97 See page 8-2.
(5/pkg.) Mail-in form to request reimbursement for Factory
Modification Campaign if YCS is not used.
Warranty Labor Rate Change LIT-11791-02-95 See page 1-5.
Request Request setup or change of the labor rate amount
used to calculate warranty reimbursement.
Service Schedule Pad LIT-11561-00-96 Used to schedule service work. Includes column for
(25/pkg.) warranty request information.
Warranty Error Notification LIT-11791-01-2K See page 10-3.
Explanation Booklet used only if registration and warranty requests are
mailed in on paper forms and errors are present.
PAGE 4 of 5
5-8
Y.E.S. Only Forms

Y.E.S. Plan Highlights Form LIT-11580-00-05 See page 2-2.
for Snowmobile and Sales tool to explain benefits of Y.E.S. plan to
Motorcycle/ATV/Riva/Water customer.
Vehicle (20/pkg.)
Sample Y.E.S. Contract for LIT-11580-00-29 See page 2-2.
Motorcycle, Riva, and ATV Given to each customer at the time of sale. The
actual “live” contract is mailed to the customer
separately by Yamaha.
Y.E.S. Plan Registration Card LIT-11580-00-04 See page 5-5.
(20/pkg.) Used to register Y.E.S. coverage sold after unit
purchase (not needed if YCS is used).
Y.E.S. Lienholder Information LIT-11580-00-08 See page 5-4.
(5/pkg.) Used when lienholder requests additional
documentation about the Y.E.S. coverage.
Y.E.S. Used Unit Registration LIT-11580-00-19 See page 5-5.
(10/pkg.) Used to register Y.E.S. coverage on a used unit sold
from dealer inventory.
Y.E.S. Plan Request to Cancel LIT-11580-00-10 See page 2-5.
(20/pkg.) Required for cancellation of Y.E.S. Plan.
Y.E.S. Hang Tags LIT-11580-00-16 For product display. Lists main customer benefits of
(10/pkg.) coverage for Motorcycle, ATV, Riva, Snowmobile,
WaveRunner, and Sport Boat.
Y.E.S. Price Tags LIT-11580-00-17 For product display. Promotes Y.E.S. coverage with
(20/pkg.) convenient monthly payment information.
Factory Service Brochures LIT-11580-00-18 Sales brochure for Y.E.S. with features and benefits.
(20/pkg.) for Motorcycle, ATV, Riva, Snowmobile, WaveRunner,
and Sport Boat.

Florida Y.E.S. Plan Highlights Call Y.E.S. See page 2-2.
and Contract A “live” contract required when Y.E.S. is sold in
Florida.
Florida Y.E.S. Return LIT-11580-FL-02 Used to mail contracts to Yamaha.
Envelopes (10/pkg.)
Florida Y.E.S. Forms
ROUTE TO: ü SERVICE ü PARTS ü WARRANTY ü SALES PAGE 5 of 5
5-9
5-10
TOLL-FREE SERVICE ASSISTANCE

Phone Numbers
Below are the phone numbers needed for any ser- Dealers (in the various regions shown below)
vice-related assistance. All main assistance num- should call the appropriate region for technical
bers are toll-free. Y.E.S. Authorizations will be assistance.
issued from the affected regional offices.
NORTHERN REGION
WA
MT
ND CUDAHY OFFICE
NORTHERN REGION
MN ME
WI
SD VT
NY NH
OR MI
ID WY MA
IA CT
NE
PA RI
IL IN OH
NJ
NV UT MD
CO KS MO
DE
WV
CA
KY VA
TN NC
OK
AZ NM
AR
GA SC
MS AL
WESTERN REGION
LA
CYPRESSWESTERN
OFFICE REGION TX
FL
AK
HI
SOUTHERN
SOUTHERNREGION
REGION
KENNESAW OFFICE
REGIONAL ASSISTANCE NUMBERS
RTA ASSISTANCE North South West

Tech. Assistance
Warranty Authorizations
Customer Relations Authorizations
Y.E.S. Authorizations
} 1-800-879-0078 1-800-969-9701 1-800-533-4807
Fax Tech: 414-769-9084 770-420-6105 714-761-7303
Warranty/Y.E.S. Administration: 1-800-227-5963

Customer Calls:
Hidden Crate Damage:
Customer Relations Department: (Dealers only)
1-800-962-7926
1-800-227-5963
1-800-635-0736
} ALL REGIONS
PAGE 1 of 3
5-11
RTA ASSISTANCE (TOLL-FREE)
Your Regional Technical Advisor (RTA) is available to help you with the following:
• Technical Assistance - Be sure to check your service library first. Most service problems dealers
encounter are covered in service literature in a Tech Exchange, Technical Bulletin, or seminar pub-
lication. If you still need help solving a technical problem, call your RTA.
• Authorizations - If you need an authorization for an in-warranty repair, out-of-warranty customer

assistance, or Y.E.S., call your RTA.
• Customer Relations Assistance - If you are requesting assistance for a customer, call your RTA.
RTA Assistance: Northern Region 1-800-879-0078 M~F 8:30 am~5:00 pm Central Time
Southern Region 1-800-969-9701 M~F 8:30 am~5:00 pm Eastern Time
Western Region 1-800-533-4807 M~F 8:30 am~5:00 pm Pacific Time
FAX TECH
Many busy dealers enjoy the convenience of Fax Tech for technical assistance requests. Prepare a
Photocopy of a Warranty Authorization Fax form (see next page) and fax it to your RTA. The RTA will
research the problem and send you an answer back - all while you continue with other business at your
dealership.
Fax Tech: Northern Region 414-769-9084 M~F 8:30 am~5:00 pm Central Time
Southern Region 770-420-6105 M~F 8:30 am~5:00 pm Eastern Time
Western Region 714-761-7303 M~F 8:30 am~5:00 pm Pacific Time
WARRANTY/ Y.E.S. ASSISTANCE (TOLL-FREE)
Call the Warranty Department if you need assistance with any of the following:
Labor Rate; Recalls; Transfer of Ownership; Unit Registration; Yamaha Extended Service; Hidden Crate Damage
Warranty Administration: 1-800-227-5963 M~F 8:30 am~5:00 pm Pacific Time
For assistance with carrier-related (visible) shipping damage, call the Distribution Department:
Distribution Department: 1-800-537-3835 M~F 8:30 am~5:00 pm Pacific Time
CUSTOMER RELATIONS ASSISTANCE (TOLL-FREE)
Normally, call your RTA to request assistance with a customer relations problem. However, if you have
been unable to help and the customer wants to call Yamaha, give him/her the toll-free customer num-
ber:
All Customer Calls: 1-800-962-7926 M~F 8:30 am~5:00 pm Pacific Time
If a customer informs you that he/she has contacted Yamaha Customer Relations directly, or you need
to report an accident that allegedly may have been the fault of the product, call the Customer Relations
Dealer hotline:
Dealer Hotline: 1-800-635-0736 M~F 8:30 am~5:00 pm Pacific Time
PAGE 2 of 3
5-12
KENNESAW, GA CYPRESS, CA CUDAHY, WI

(770) 420-6105 (714) 761-7303 (414) 769-9084
5-13
5-14
5-15
5-16
XL1200LTD. (XA1200X/Y)
High Altitude Compensation Program
Due to the high-performance nature of its power-valved engine, the XL1200 Ltd. must be recalibrated
for high-altitude operation if it will be used at 3000 feet or above. This bulletin describes the necessary
recalibration, which includes carburetion adjustments and sending the impeller to a designated vendor
for repitching. This bulletin also explains how to receive the reimbursement provided by this High
Altitude Compensation Program.
Inspect: Inspect the unit for the presence of a modified impeller.
Modify: Recalibrate any unsold affected unit which will be used primarily at 3000 feet or above
during unit setup.
Modify any customer-owned unit that is primarily operated at 3000 feet or above if there
is a concern about high-altitude performance.
Parts
Required: Order the parts necessary for carburetor removal and reinstallation.
Warranty: File a Service-Per-Bulletin (90-code) Warranty Claim.
Any 1999 XL1200 Ltd. (XA1200X) watercraft used primarily at 3000 ft. or above.
Any 2000 XL1200 Ltd. (XA1200Y) watercraft used primarily at 3000 ft. or above.
PAGE 1 of 4
5-17
NOTE: 6. Send the impeller to the vendor for repitch-
Refer to the XL1200 Ltd. Service Manual (LIT- ing. (See Vendor Information later in this bul-
18616-01-98) for details on the following proce- letin). Normal turn-around after the vendor
dures. receives the impeller will be about two days.
Impeller Replacement NOTE:

The recommended vendor, Performance
1. Place the watercraft on a suitable workstand Propellers, is prepared to repitch the impeller to
that will allow access to the jet pump assem- Yamaha's specifications. Repitching by a differ-
bly and the engine compartment. ent vendor could give other results or even
reduced performance. Another vendor's interpre-
2. Inspect the unit to see if the impeller has tation of a 14/18 pitch could be different because
already been modified. See Identification there is no "standard" measurement method.
Procedure later in this bulletin.
7. Reverse this procedure to install the impeller
3. Remove the jet pump assembly from the after the modification has been performed.
watercraft.
CAUTION:
4. Using the driveshaft holding tool, (Kent Install a stock-pitch impeller again if the unit
Moore #YB-06151) remove the impeller from is to be used consistently below 3000 feet.
the driveshaft by turning it clockwise.
Carburetor Adjustments
NOTE:
The impeller uses a left-hand thread pitch. 8. Remove the carburetors to access the high
and low-speed mixture adjustment screws.
5. On customer-owned units, inspect the
impeller for damage. A damaged impeller 9. The mixture adjustment screws are covered
must be repaired or replaced before being with plugs. Remove them by drilling and
repitched: pulling them out with a dent puller.
• If the damage is due to a warrantable CAUTION:

defect, order a new impeller and submit a When drilling the plugs, do not drill deeper
separate warranty claim for the impeller than 5mm. If you drill all the way through the
replacement. Send the new impeller to plug, the drill bit could contact the adjust-
the vendor for repitching. ment screw, forcing it into its seat. This could
cause permanent damage to the carburetor.
• If the damage is not warrantable (such as
impact damage from sand or pebbles), NOTE:
repair must be at the customer's expense See the 2000 Water Vehicle Technical Update
before he or she can take advantage of booklet Tech Tip for "XL1200 Ltd. Carburetor
this High Altitude Program. The vendor Cleaning" (page 6-23) for tips on carburetor and
modifying the impeller may be able to do plug removal.
non-warranty repairs at the same time.
Contact him directly for procedures and
an estimate (see Vendor Information later
in this bulletin).
PAGE 2 of 4
5-18
10. Turn the fuel mixture screws in (clockwise) 11. Reinstall the carburetor plugs to protect the
the specified amount, from their original posi- adjustment screws from corrosion.
tion. See the specification chart for the prop-
er setting based on the elevation where the 12. Reinstall the carburetors. Verify proper car-
unit will be used. buretor synchronization and reset the
trolling speed
CAUTION:
Be sure to readjust carburetor settings if the
unit is to be used at a lower altitude than for
what it was set. Otherwise, severe engine
damage may occur.
Low Speed High Speed

Impeller Pitch Mixture Mixture
Elevation Recommendation (Turns in from STD) (Turns in from STD)
3000 ~ 4500 Ft. 14/18 1/8 1/4
4500 ~ 6000 Ft. 14/18 1/8 3/8
6000 Ft. ~ 14/18 1/8 1/2
Order the following replacement parts for carburetor and jet pump reinstallation.
Description Part Number Qty. Dealer Price
Intake Manifold Gasket 66V-13556-00-00 1 $ 9.65
Jet Pump Clamp 90465-11829-00 1 $ 0.02
Gasket, Muffler 66V-14739-00-00 1 $10.70
Send the impeller to be modified to the following NOTE:

address: Be sure the impeller is packed for shipping so
that no damage will occur. This will be returned
Performance Propellers to you in the same packaging.
Attn: Yamaha HE program
184-B Oxmoor Rd. The charge for repitching and return shipping will
Birmingham, AL 35209 be $42.00. You may enclose payment with the
impeller to save COD charges. If you have any
Phone: (205) 942-4754 special shipping requirements, contact the ven-
dor directly.
Tag the impeller with your Dealer Name, Contact
Name, Dealer's Phone Number, Unit Primary ID The normal turn-around after receipt of your
Number, and "Yamaha High Elevation Program." impeller is two days.
PAGE 3 of 4
5-19
To determine if a unit has already been modified,
look at the impeller through the intake grate.
Modified impellers will have the letters "HE"
(High Elevation) scribed on the face of one of the
impeller blades. You may have to rotate the
impeller to inspect each blade.
If you encounter an unfamiliar unit in high-alti-

tude use, and you are unsure whether or not the
unit has been modified, check for the "HE" mark
on the impeller. You can also check a unit's sta-
tus on YCS or by contacting your Regional
Technical Advisor (RTA)
To receive credit for the modification, submit a standard "Service per Bulletin" warranty request using
problem code 090PB. You will be reimbursed for dealer cost on the parts ($20.37), the cost of impeller
modification ($47.00, which includes a $5.00 allowance for shipping to the vendor) and $50.00 labor
to help offset the labor for performing the adjustments.
If a customer-owned unit required a replacement impeller due to a warrantable failure, submit a sepa-
rate warranty claim for the new impeller itself. Do not include labor, as it is covered by the High Altitude
Compensation Program claim you are submitting.
PAGE 4 of 4 ROUTE TO: üSERVICE ü PARTS üWARRANTY üSALES
5-20
XL1200X/Y; XL800Y (XA1200; XA800)

Sponson Replacement
Newly designed sponsons are installed on later production 2000-model XL1200Ltd. and XL800
WaveRunners. These sponsons reduce the tendency of the deep-Vee hull to tilt slightly to one side or
the other when encountering a cross wind or angling into a current at mid-speeds.
These new sponsons are also available as an option to customers who own 1999-model and early pro-
duction 2000-model XL1200Ltd. and XL800 WaveRunners (see Affected Range below). This bulletin
explains how to install these sponsons under warranty
Modify: Any XL1200Ltd. or XL800 in the Affected Range, if the customer would prefer the han-
dling characteristics of the later production sponsons.
Parts
Required: Yes. Order one sponson kit for each model to be modified.
Warranty: Service-Per-Bulletin (90 Code) for modification.
XL1200X All
XL1200Y F0D-809601 ~ F0D-817700
XL800Y F0P-800101 ~ F0P-806900
PAGE 1 of 2
5-21
1. Secure the watercraft on a suitable work 4. Install the new sponsons using the original
stand. nuts and washers.
2. Remove the four 6mm nuts holding each NEW SPONSON

sponson to the mounting studs (see illustra-
tion below).
FWD
5. Torque the mounting nuts to 4.9~5.8Nm

(3.6~4.2 ft-lb).
OLD SPONSON
3. Remove each sponson leaving the spacers in

place.
NOTE: The spacers are installed with the

flange side in towards the hull.
Part No. Description Qty Dealer Cost

90891-70022-00 Sponson Kit 1 $10.00
The modification of any affected WaveRunner is authorized regardless of warranty status.
To receive credit for parts and labor, file a standard Service-Per-Bulletin Warranty Request using
Problem Code 090PA. The labor allowance for this modification is 0.2 hr.
5-22
1997 ~ 1999 MODELS

Flat Rate Manual Revisions
The following revisions are for the 1997 ~ 1999 WaveRunner Flat Rate Manual (LIT-18750-10-99).
Please add these revisions to your existing manual for use when submitting a Warranty Claim on a
1997~1999 model WaveRunner.
XL1200Ltd.
OPERATION MODEL GP800W,X
(XA1200X)
XL700X
JOB
CODE
INTAKE & FUEL (2100)
2123 Carburetor Cover 2 0.6
EXHAUST & COOLING SYSTEM (4000)
4010 Outer Cover, Exhaust 1.3
4019 Joint Exhaust 3
4020 Stay Muffler 2 0.2 0.3
4025 Catalytic Converter 1.8
HULL (6000)
6009 Mat (Each) 0.2
IGNITION & ELECTRICAL (8000)
8001 Flywheel Magneto Assy./Base Assy. Delete
8022 Switch Box Assy. 1.1
8026 Oil Indicator 0.3
8031 Exhaust Temperature Sensor 0.4
5-23
5-24
GP1200R; XL800 (GP1200AY; XA800Y)

High Altitude Compensation Program
Due to the high-performance nature of the power-valved engine, these models should be recalibrated
for use at higher elevations. This bulletin describes the necessary recalibration, which includes send-
ing the impeller to a designated vendor for repitching and, on the GP1200R only, carburetor adjust-
ments.
High altitude recalibration of the XL800 is recommended only for models primarily used for one or two
person operations without water-skiing or towing. Units primarily used for three person operations,
water-skiing, or towing, use the recommendations listed later in this bulletin. This bulletin also explains
how to receive the reimbursement provided by the High Altitude Compensation Program.
Inspect: Inspect the unit for the presence of a modified impeller.
Modify: Recalibrate, during unit setup, any unsold affected unit which will be primarily used at
higher elevations. Refer to application charts on page 3 for details.
Modify any customer- owned unit that is used at higher elevations if there is a concern
about high altitude performance.
Parts
Required: Order the parts necessary for jet unit and carburetor removal and reinstallation,
depending on the model being recalibrated.
Warranty: File a Service-per-Bulletin (90-code) Warranty Claim.
GP1200AY: All used at elevations over 3000 ft.

XA800Y: All used at elevations over 4500 ft. (If not primarily used for three person operation,
water-skiing, or towing.)
PAGE 1 of 5
5-25
NOTE: Refer to the Service Manual (GP1200R NOTE: The recommended vendor, Performance
LIT-18616-01-98, XL800Y LIT-18616-02-14) for Propellers, is prepared to repitch the impeller to
details on the following procedures. Yamaha's specifications. Repitching by a differ-
ent vendor could give other results or even
Impeller Replacement reduced performance. Another vendor's interpre-
tation of the impeller pitch could be different
1. Place the watercraft on a suitable workstand because there is no "standard" measurement
that will allow access to the jet pump assem- method.
bly and the engine compartment.
7. Reverse this procedure to install the impeller
2. Inspect the unit to see if the impeller has after the modification has been performed.
already been modified. See Identification
Procedure later in this bulletin. CAUTION:
Install a stock-pitch impeller again if the unit
3. Remove the jet pump assembly from the is to be used consistently at lower altitudes.
watercraft.
Carburetor Adjustments (GP1200R Only)
4. Using the driveshaft holding tool, (Kent
Moore #YB-06151) remove the impeller from 8. Remove the carburetors to access the high
the driveshaft by turning it clockwise. and low-speed mixture adjustment screws.
5. On customer-owned units, inspect the 9. The mixture adjustment screws are covered
impeller for damage. A damaged impeller with plugs. Remove them by drilling and
must be repaired or replaced before being pulling them out with a dent puller.
repitched:
CAUTION:
• If the damage is due to a warrantable When drilling the plugs, do not drill deeper
defect, order a new impeller and submit a than 5mm. If you drill all the way through the
separate warranty claim for the impeller plug, the drill bit could contact the adjust-
replacement. Send the new impeller to ment screw, forcing it into its seat. This could
the vendor for repitching. cause permanent damage to the carburetor.
• If the damage is not warrantable (such as NOTE: See the 2000 Water Vehicle Technical
impact damage from sand or pebbles), Update Manual Tech Tip for "XL1200Ltd.
repair must be at the customer's expense Carburetor Cleaning" (page 6-23) for tips on mix-
before he or she can take advantage of ture screw plug removal.
this High Altitude Program. The vendor
modifying the impeller may be able to do 10. Turn the fuel mixture screws in (clockwise)
non-warranty repairs at the same time. the specified amount, from their original posi-
Contact him directly for procedures and tion. See the specification chart for the prop-
an estimate (see Vendor Information later er setting based on the elevation where the
in this bulletin). unit will be used.
6. Send the impeller to the vendor for repitch- NOTE: It is important that the fuel mixtures be
ing. (See Vendor Information later in this bul- set in reference to their original position. Due to
letin). Normal turn-around after the vendor the method used to set the carburetion, each unit
receives the impeller will be about two days. may be slightly different. If it appears that the set-
tings have been previously changed, refer to the
chart later in this bulletin for a reference setting.
PAGE 2 of 5
5-26
CAUTION: 11. Reinstall the carburetor plugs to protect the

adjustment screws from corrosion.
Be sure to readjust carburetor settings if the
unit is to be used at a lower altitude than for 12. Reinstall the carburetors. Verify proper car-
what it was set. Otherwise, severe engine buretor synchronization and reset the
damage may occur. trolling speed.

GP1200AY Impeller Pitch Mixture Mixture
Elevation Recommendation (Turns In from STD) (Turns In from STD)
3000 ~ 4500 Ft. 14/18 1/8 1/4
4500 ~ 6000 Ft. 14/18 1/8 3/8
6000 Ft. ~ 14/18 1/8 1/2

XA800Y Impeller Pitch Mixture Mixture
Elevation Recommendation (Turns In from STD) (Turns In from STD)
3000 ~ 4500 Ft. Stock N/A N/A
4500 ~ 6000 Ft.* 12/16 N/A N/A
6000 Ft. ~* 12/16 N/A N/A
*The stock impeller is recommended for units used primarily for three person operations, towing or ski-
ing,
The following chart lists the approximate starting point (prior to high altitude adjustment) for the fuel
mixture screw settings. These are only for reference if it appears the mixture screws had previously
been changed. If the settings have never been changed, please use the Turns In setting listed above.
Standard Settings
Low Speed Mixture High Speed Mixture
Reference Setting Reference Setting
Model (Turns Out from Lightly Seated) (Turns Out from Lightly Seated)
GP1200R (All Cyls) - 1-3/8 (F) 1-1/2, (C) 1-3/8, (R) 1-1/2
XL800 (F) 1-5/8, (R) 1-3/4 (All Cyls) 1/2
PAGE 3 of 5
5-27
Order the following replacement parts for carburetor and jet pump reinstallation.
GP1200R
Intake Manifold Gasket 66V-13556-00-00 1 $ 9.65
Jet Pump Clamp 90465-11829-00 1 $ 0.02
Gasket, Muffler 66V-14739-00-00 1 $10.70
XL800
Jet Pump Clamp 90465-11829-00 1 $ 0.02
Send the impeller(s) to be modified to the follow- NOTE:

ing address: Be sure the impeller is packed for shipping so
that no damage will occur. This will be returned
Performance Propellers to you in the same packaging.
Attn: Yamaha HE Program
184-B Oxmoor Rd. The charge for repitching and return shipping will
Birmingham, AL 35209 be $42.00. You may enclose payment with the
impeller to save COD charges. If you have any
Phone: (205) 942-4754 special shipping requirements, contact the ven-
dor directly.
Tag the impeller with your Dealer Name, Contact
Name, Dealer's Phone Number, Model, Unit The normal turn-around after receipt of your
Primary ID Number, and "Yamaha High Elevation impeller is two days.
Program."
To determine if a unit has already been modified,

look at the impeller through the intake grate.
Modified impellers will have the letters "HE"
(High Elevation) scribed on the face of one of the
impeller blades. You may have to rotate the
impeller to inspect each blade.
If you encounter an unfamiliar unit in high-

altitude use, and you are unsure whether or not
the unit has been modified, check for the "HE"
mark on the impeller. You can also check a unit's
status on YCS or by contacting your Regional
Technical Advisor (RTA)
PAGE 4 of 5
5-28
5-29
5-30
2000 and 2001 SUV1200 (SV1200Y/Z)

Trailer Warranty Policies
Trailers and trailer components are warranted by their manufacturers. The 2000 and 2001 model
SUV1200 WaveRunners use a Shoreland'r trailer that is manufactured by Midwest Industries Inc. The
trailer manufacturer can be identified by the VIN label located on the inside of the left frame rail,
towards the front of the trailer.
The trailer winch is warranted separately by the winch manufacturer, Dutton-Lainson. Tires are war-
ranted by Duro Tire. This bulletin explains these manufacturers’ warranty policies and provides infor-
mation on who to contact.
Parts requests, warranty related questions or other trailer related questions should be directed to the
trailer manufacturer for all components except the winch and tires.
Trailer information contact:

Midwest Industries, Inc.
Ida Grove, Iowa 51445
(712) 364-3365
Trailer Winch information contact:

Dutton-Lainson Company
Hastings, Nebraska 68902-0729
Customer Service Phone Number
1-800-569-6577
or at dutton-lainson.com
Duro Tire information contact:

Duro Tire Corporation
350 South Pioneer Blvd.
Springboro, OH 45066
1-800-966-8473
SUV1200Y GU5-100101 ~ GU5-102810

SUV1200Z GU5-700101 ~
PAGE 1 of 6
5-31
Warranty Terms
The text of the trailer, trailer winch, and tire warranty statements are included in this bulletin.
• The Shoreland’r Trailer has a One Year Basic Limited Warranty and a Five Year Fabricated Part &
Frame Warranty.
• The Dutton-Lainson Trailer Winch has a Limited Three Year Warranty on most 2000 models. Late
2000 models and all 2001 models have a Limited Five Year Warranty. Check the warranty docu-
ments supplied with the trailer to see which coverage is provided.
• The Duro tire warranty provides a no-cost replacement during the first 15% of useable treadwear
if the tire does not deliver satisfactory service due to a workmanship or material related condition
or six months from the date of purchase warranty, whichever comes first.
To meet dealer obligations under the federal Magnuson-Moss Warranty Act to have the warranty state-
ment available for public inspection, you can either make copies of the warranty statements included
in this bulletin or you can request copies directly from the manufacturer. You should be sure each trail-
er purchaser is provided with the limited warranty statements along with all other literature for the cus-
tomer provided by the manufacturer, such as the Ownership and Operator’s manual.
Warranty Claims
If repairs are necessary under the terms of either warranty, contact the manufacturer at the address,
phone number or web site listed on page 1. Please have Model, VIN, Part and Problem Descriptions
ready to provide as necessary. The manufacturer will instruct you on how to obtain parts or warranty
claim procedures. Do not use YCS Warranty Claim Entry or a Yamaha Warranty Request form for trail-
er or trailer winch claims.
PAGE 2 of 6
5-32
MIDWEST INDUSTRIES, INC “LIMITED 5 YEAR WARRANTY”

FOR SHORELAND’R BOAT AND PWC TRAILERS
Your ShoreLand’r® Limited Warranties
During the terms of the Limited Warranties on your ShoreLand’r trailer, Midwest Industries, Inc. (hereafter
referred to as “Midwest”) covers the cost of all parts and labor needed to repair or replace any Midwest supplied
item (except tires) that proves defective in material, workmanship or factory preparation. These repairs or
replacements (parts and labor) will be made by your dealer at no charge using new or manufactured parts.
Your Legal Rights Under Midwest’s Limited Warranties
All of the midwest Limited Warranties stated in this booklet are the only expressed written warranties made by
Midwest applicable to ShoreLand’r trailers. These Limited Warranties give you specific legal rights and you may
also have other rights which vary from state to state. You may have some implied warranties, depending on the
state in which your trailer is registered. For example, you may have:
1. An “implied warranty of merchantability” (that your trailer is reasonably fit for the general purpose for which
it was sold);
2. An “implied warranty of fitness for a particular purpose,” (that your trailer is suitable for your special purposes;
if your special purposes were specifically disclosed to Midwest itself (not merely to the distributor or dealer)
prior to purchase.
These implied warranties are limited, to the extent allowed by law, to the time period covered by the written
warranties set forth in this publication.
Some states do not allow limitations on how long an implied warranty lasts, so the above limitations may not apply
to you.
Subsequent Buyer/Owner
The Midwest ShoreLand’r Warranty is extended only to the first buyer / owner of the trailer. This is defined as the
first legal owner of a Midwest ShoreLand’r trailer other than an authorized Distributor or Dealer who has bought
the trailer from Midwest for resale to the public.
Things You Should Know About Your Limited Warranty Pre-Delivery Service
Defects in or damage to any components of your trailer may occur at the factory or while it is being transported
to the dealer. Normally, any defect or damage occurring during assembly is detected and corrected at the factory
during the inspection process. In addition, dealers are obliged to inspect each trailer before delivery. They repair
any uncorrected factory defects or damage and any transit damage detected before the trailer is delivered to you.
Trailer Alteration
This warranty does not cover alteration of the trailer, or failure of trailer components caused by such alteration.
Production Changes
Midwest and its distributors / dealers reserve the right to make changes in trailers built and / or sold by them at
any time without incurring any obligation to make the same or similar changes on trailers previously built and/
or sold by them.
YOUR 1-YEAR BASIC LIMITED WARRANTY
What is Covered
The 1-Year “Basic Warranty” covers every Midwest supplied part on your trailer, EXCEPT its tires. (These are
covered by a separate warranty included in your Owner’s Packet.)
The “Basic Warranty” begins on your trailer’s Warranty Start Date. The Warranty Start Date is the earlier of (1)
the date you take delivery of your new trailer, OR (2) the date the trailer was first put into service (for example, as
a dealer “Demo” or as a Midwest company trailer). The “Basic Warranty” lasts for 1 year (12 months) from this
date.
The Basic Warranty covers the cost of all parts and labor needed to repair any item on your trailer that is defective
in material, workmanship, or factory preparation. You pay nothing for these repairs.
PAGE 3 of 6
5-33
YOUR 5-YEAR FABRICATED PART & FRAME WARRANTY
Exceptions
The following items are not covered:
• tires
• paint and/or finish
What is Covered
The “Fabricated Part and Frame Warranty” covers these parts and components of your trailer’s frame for 5 years
counted from the trailer’s Warranty Start Date:
• Fabricated frame weldment, axle weldment, winch stand base, winch holder case, spring bracket, tongue, keel
cradle, keel roller bracket, inline roller pin, roller arm, bunk support channel, front post, winch post.
What Your Midwest Limited Warranties Do Not Cover
Your Midwest limited warranties do not cover the costs of repairing damage caused by environmental factors or
acts of God. “Environmental factors “include such things as airborne fallout, chemicals, tree sap, salt, ocean spray,
road or water hazards. “Acts of Gods” include such things as hailstorms, windstorms, tornadoes, sandstorms,
lightning, floods and earthquakes.
Your Midwest limited warranties do not cover the costs of repairing damage caused by poor or improper
maintenance.
Your Midwest limited warranties do not cover the costs of normal /scheduled maintenance of your trailer. They
do not cover the cost of lubrication, replacing light bulbs, winch straps, fasteners unless done as a result of a
repair covered by your 1-Year “Basic Warranty.”
Your Midwest limited warranties do not cover any “incidental or consequential damages” connected with the failure
of your trailer under warranty. Such damages include lost time, inconvenience; the loss of the use of your trailer;
the cost of rental trailer; gasoline, telephone, travel or lodging; the loss of personal or commercial property; the
loss of revenue, etc. NOTE: Some states do not allow the exclusion or limitation of incidental or consequential
damages , so the above limitations or exclusions may not apply to you.
Your Midwest limited warranties do not cover the cost of repairing damage or conditions caused by fire or accident;
by abuse or negligence; by misuse; by tampering with parts; by improper adjustment or alteration; or by any
changes made to your trailer that do not comply with Midwest specifications.
Your Midwest limited warranties do not cover the cost of adding anything to your trailer once it is delivered to you,
even if parts, components or modifications are changed or added as a production change on other trailers produced
after your trailer was built.
How to Get Warranty Service for Your Trailer
In general, Midwest recommends that you contact the dealer from whom you bought the trailer for warranty
service. Your selling dealer knows you and your trailer best; and he’s the one most interested in making sure that
you get prompt and high quality warranty service.
When contacting your dealer for warranty service, please provide them with your trailer’s model number, vehicle
identification number, date of purchase and the nature of the problem.
Midwest Industries, Inc. • Ida Grove, Iowa 51445 • Ph: 712/364-3365

Printed in U.S.A. 0002246
PAGE 4 of 6
5-34
Trailer Winch Warranty Statement
LIMITED THREE (3) YEAR WARRANTY

Dutton-Lainson Company provides the following three (3) year limited warranty to the original purchaser of
D-L® Rachet Winches, Brake Winches, Worm Gear Winches and Tongue Jacks:
Dutton-Lainson Company will, at its option, repair or replace free-of-charge any part or parts found to be defective in
material or workmanship under normal use for the period of three (3) years from the original purchase date or, if that
date cannot be established, the date of manufacture. This includes a warranty against operational failure for the same
three year period due to rust or corrosion of the TUFFPLATE™ finish. This warranty is void if the product has been
subject to alteration or damage, or is defective due to unauthorized service or repair. This warranty does not assure
that the product shall remain useable for the three (3) year warranty period since the life of the product is dependent
upon the manner and frequency of use.
Repair or replacement is the purchaser’s sole remedy under this or any other warranty on the product, whether express
or implied. Dutton-Lainson Company shall not be liable for any incidental or consequencial damages of any
kind. Dutton-Lainson Company expressly disclaims any implied warranty of merchantability or fitness for par-
ticular purpose after three (3) year warranty period. Some states do not allow the exclusion of incidental or con-
sequencial damages or limitation of an implied warranty so the above exclusion and limitation may not apply to you.
To make a claim, contact Dutton-Lainson Company, Hastings, Nebraska 68902-0729, identify the product, and follow
the instructions for return, which will be provided. Repair or replacement of the product, if found to be defective, will nor-
mally be completed within sixty (60) days after receipt. The purchaser will be responsible for shipping costs to the
Company.
This warranty gives you specific legal rights, and you may have other rights which vary from state-to-state.
This warranty is governed by the laws of the U.S.A. and is void where prohibited.
Date Purchased:___________________________ Winch Date Code: ________________

(located inside front edge of base)
Winch Model Number _______________________
2001 Models
LIMITED FIVE (5) YEAR WARRANTY

Dutton-Lainson Company provides the following five (5) year limited warranty to the original purchaser of D-L® rachet
winches, brake winches, and worm gear winches:
material or workmanship under normal use for the period of five (5) years from the original purchase date or, if that date
cannot be established, the date of manufacture.This includes a warranty against operational failure for the same five year peri-
od due to rust or corrosion of the TUFFPLATE™ finish.This warranty is void if the product is not installed and used in accor-
dance with the operating instructions, has been subject to alteration or damage, or is defective due to unauthorized ser-
vice or repair.This warranty does not assure that the product shall remain useable for the five (5) year warranty period since
the life of the product is dependent upon the manner and frequency of use.
Repair or replacement is the purchaser’s sole remedy under this or any other warranty on the product, whether express or
implied. Dutton-Lainson Company shall not be liable for any incidental or consequencial damages of any kind.
Dutton-Lainson Company expressly disclaims any implied warranty of merchantability or fitness for particular
purpose after five (5) year warranty period. Some states do not allow the exclusion of incidental or consequencial
damages or limitation of an implied warranty so the above exclusion and limitation may not apply to you.
Company.
PAGE 5 of 6
5-35
DURO TIRE CORPORATION
MANUFACTURER OF TIRES AND TUBES
HIGH - SPEED TRAILER TIRE WARRANTY
1. Duro Tire Corporation hereby warrants that it will replace, at its option, the Duro trailer tire or trailer tire and
wheel assembly which proves defective by reasons of improper workmanship and/or materials, without
charge for a period of 6 months or the first 15% of treadwear, whichever comes first.
2. In addition to the above, Duro Tire will replace trailer tires damaged by road hazards and accidents for the
first 6 months or first 15% of treadwear (whichever comes first) at 50% of the suggested retail value.
3. The above warranty is void if the trailer tire is provides unsatisfactory service due to damage from use of
improper inflation pressures, driving more than the maximum speed rating, or overloading the trailer beyond
the maximum load capacity stated on the sidewall.
4. The Duro Trailer Tire Warranty does not cover loss of time, inconvenience, loss of vehicle use, cost of tow-
ing or transportation, or consequential damages of any type or nature.
5. To obtain service under this warranty, you must call Duro Tire Corporation at (800) 966-8473. Also, please
be prepared to submit by mail a copy of your bill of sale for the tire or trailer, and a written statement of what
you believe to be the cause of the tire damage.
6. This warranty gives you specific legal rights, and you may have other rights which vary from state to state.
PAGE 6 of 6
ROUTE TO: ü SERVICE ü PARTS ü WARRANTY ü SALES
5-36
WAVERUNNER WATERCRAFT 10/XX/00 WR2000-010
2001 MODELS
WaveRunner Service Literature
The following is a comprehensive listing of service literature part numbers for 2001 Yamaha
WaveRunners. If the service literature used in prior years is still current, the literature part number will still
be listed, but “Same as . . .” will appear in the appropriate Manual column.
These manuals may be ordered from Crestec Los Angeles, Inc. (ph: 1-888-530-9446). Refer to Technical
Bulletin WR2000-004 for more information. This bulletin also lists other publications related to your deal-
ership operations, which may be ordered from Yamaha Parts and Accessories (see page 2).
Actual Owner’s Assembly Service

Model Displacement Manual Manual Manual
“XLT1200”
XA1200AZ 1176 LIT-18626-04-01 LIT-18666-00-30 LIT-18616-02-27
“SUV1200”
SV1200Z 1131 LIT-18626-04-07 N/A LIT-18616-02-04
Same as
SV1200X~Y
“GP1200R”
GP1200AZ 1176 LIT-18626-04-04 LIT-18666-00-28 LIT-18616-02-15
Same as Same as
GP1200AY GP1200AY
“XL800”
XA800Z 784 LIT-18626-04-02 LIT-18666-00-27 LIT-18616-02-14
Same as Same as
XA800Y XA800Y
“GP800R”
GP800AZ 784 LIT-18626-04-05 LIT-18666-00-29 LIT-18616-02-26
“XL700”
XL700Z 701 LIT-18626-04-03 LIT-18666-00-25 LIT-18616-01-88 (Main)
Same as Same as
XL700X~Y XL700X~Y
LIT-18616-02-00 (Supp)
“Super Jet”
SJ700AZ 701 LIT-18626-04-06 N/A LIT-18616-01-43
Same as
SJ700AU~AY
PAGE 1 of 2
5-37
OTHER PUBLICATIONS PART NUMBER
Water Vehicle Predelivery Checklist LIT-18161-00-98
2000 WaveRunner WaterCraft Flat Rate Manual LIT-18750-10-2K
2000 WV/SB Technical Update Manual LIT-18500-00-2K
Warranty Statement* LIT-18799-00-93
Warranty and Y.E.S. Handbook LIT-11760-00-95
Warranty Labor Rate Change Request LIT-11791-02-95
1998~2000 WV/SB Technical Service Data Booklet LIT-18571-SD-2K
Parts System Handbook LIT-10080-07-01
Basic Hull Repair Video & Workbook VID-10660-00-43
Service Appointment Pad LIT-11561-00-96
2001 WaterCraft Product Brochure LIT-18116-WR-01
WaveRunner Basic Orientation Video VID-10660-00-56
2001 WaterCraft Features & Benefits Video VID-18119-WR-01
2001 WaterCraft Poster Set LIT-18140-WR-01
2001 WaterCraft Salesperson Product Guide
(Available 12/00) LIT-18468-WC-01
Heavy Duty Service Binder LIT-10501-01-80
WaterCraft Drive Train Theory Video & Workbook VID-10660-00-64
Water Vehicle Carburetor Tuning & Adjustment
Video & Workbook VID-10660-00-34
Riding Tips Booklets:
SJ700 LIT-18552-00-41
XL700 LIT-18552-00-42
XA800 LIT-18552-00-43
SUV1200 LIT-18552-00-44
GP800 LIT-18552-00-45
XA1200 LIT-18552-00-46
*The Limited Warranty Statement is also printed in each Owner’s Manual.
5-38
2001 MODELS
WaveRunner Primary I.D. Numbers
For identification purposes, the factory has released the following list of Primary I.D. Numbers.
Production started with the numbers listed below:
Model Model Name Starting Primary I.D. Number

XA1200AZ XLT1200 F0V-800101
SV1200Z SUV1200 GU5-700101
GP1200AZ GP1200R F0X-809301
XA800Z XL800 F0P-808001
GP800AZ GP800R F0W-800101
XL700Z XL700 F0M-810481
SJ700AZ Super Jet GM6-915240
5-39
5-40
Section 6
WaveRunner® Service Data
6-1
GP1200AZ “GP1200R”
2001 Service Data
MODEL:
Model / Model Code GP1200AZ / F0X
Primary ID Starting Number F0X-809301
Fuel Type Unleaded Regular
Total Fuel Tank Capacity 60 L (15.9 gal)
Reserve Capacity 10 L (2.6 gal)
SERVICE LITERATURE:
Owners Manual LIT-18626-04-04
Service Manual (Same as GP1200AY) LIT-18616-02-15
Assembly Manual (Same as GP1200AY) LIT-18666-00-28
Riding Tips N/A
ENGINE:
Engine Type Two-Stroke, Water-Cooled
Engine Number Prefix 67X
Bore / Stroke 80mm / 78mm
Number of Cylinders / Displacement 3 / 1176cc
Cold Cranking Compression at Sea Level (Min) 5.0 kg/cm2 (70 psi)
Piston Skirt Clearance New / Max 0.100 ~ 0.105mm / 0.145mm
Ring End Gap, All New 0.45 ~ 0.60mm (0.018 ~ 0.024 in.)
Lubricant / Mixing Ratio Yamalube 2W / Oil Injection
Oil Tank Capacity 5.5 L (1.45 gal)
CARBURETOR:
Manufacturer / Type Mikuni / Floatless
ID Number (F) 67X-021, (C) 67X-022, (R) 67X-023
Main Jet #117.5
Pilot Jet #95
Needle Valve Assembly d = 1.2
Arm Spring Rate / Color 115 gr / Gold
High Speed Screw Turns Out (F) 1-1/2, (C) 1-3/8, (R) 1-1/2
Low Speed Screw Turns Out 1-3/8
Trolling Speed (Idle) rpm in Water 1350 +50
JET UNIT
Jet Unit / Type Axial Flow / Single Stage
Impeller Pitch Angle / Material 15.6 / Stainless Steel
Impeller Liner Clearance New 0.35 ~ 0.45mm (0.014 ~ 0.018 in)
Impeller Liner Clearance Max 0.6mm (0.024 in)
Impeller Shaft Runout 0.3mm (0.012 in)
Bearing Grease Type Yamaha Marine Grease or Equivalent
6-2
2001 WaterCraft Technical Update - Specifications
GP1200AZ “GP1200R” (Continued)

CHARGING SYSTEM:
Charging System Flywheel Magneto
Battery: Model / Rating YB16CL-B / 12V 19 Amp hr
Maximum Output 9 ~ 11A @ 6,000 rpm
Lighting Coil Color Code / Ω G ~ G / 0.49 ~ 0.59Ω
IGNITION SYSTEM:
Ignition System Battery CDI
Ignition Timing BTDC 18° ~ 24°
Spark Plug Type NGK BR8ES-11
Spark Plug Gap 1.0 ~ 1.1mm (0.039 ~ 0.048 in)
Spark Plug Torque / Cap Ω 2.5 m-kg (18 ft-lb) / ø
Ignition Coil Color Code Pri/Sec BW ~ Body / B/W ~ Plug Wire Terminal
Primary Ω 0.26 ~ 0.36Ω
Secondary Ω 3.5k ~ 4.7kΩ
Ignition Coil Output Spark Gap Test 10mm (0.39 in)
Pulser Coil Color Code / Ω W/R ~ BO / 445 ~ 545Ω
Peak Voltage (Closed Cranking) 2.8V (min)
CDI Box Color Code / Ω BO, B/W, B/Y ~ B
Peak Voltage (Closed Cranking) 180V (min)
Charge Coil Color Code / Ω ø
Peak Voltage (Closed Cranking) ø
HULL / DECK:
Material (Hull / Deck / Hood Cover / Lid) FRP / FRP / PC / PC
Molding Process (Hull / Deck) SMC (all)
Paint (Hull) Pure White #366-51437
Paint (Deck) Pure White #366-51437
Paint (Hood Cover / Lid) Dark Purplish Blue Metallic F TBA
CONTROLS / CABLES:
Throttle Lever Freeplay 4 ~ 7mm (0.16 ~ 0.28 in)
Choke Cable Freeplay Align Marks
YPVS Cable Slack 0.5 ~ 1.5mm (0.02 ~ 0.06 in)
TORQUE VALUES:
Cylinder Head Bolt 1st & 2nd M8: 2.2m-kg (16 ft-lb)
3rd M8: 3.5m-kg (25 ft-lb)
Cylinder Body Bolt 1st M10: 2.2m-kg (16 ft-lb)
2nd M10: 3.9m-kg (28 ft-lb)
Crankcase Bolt 1st / 2nd M8: 1.5m-kg (11 ft-lb) / 2.7m-kg (19 ft-lb)
M6: 1.1m-kg (8 ft-lb)
Engine Mounting Bolt M8: 1.7m-kg (12 ft-lb)
Exhaust Chamber Assembly M10: 3.9m-kg (28 ft-lb)
Muffler Assembly M10: 3.9m-kg (28 ft-lb)
Muffler Stay M10: 3.9m-kg (28 ft-lb)
Flywheel Bolt M10: 7.5m-kg (54 ft-lb)
Jet Unit Mounting Bolt ø
Drive Shaft Nut 7.4m-kg (53 ft-lb)
Impeller (LeftHand Threads) 1.8m-kg (13 ft-lb)
Coupler 3.6m-kg (25 ft-lb)
Transom Plate M10: 2.6m-kg (19 ft-lb)
Ride Plate M8: 1.7m-kg (12 ft-lb)
Intake Grate M6: 0.7m-kg (5.1 ft-lb)
Handlebar Mount M8: 1.6m-kg (11 ft-lb)
6-3
XA1200AZ “XLT1200”
2001 Service Data
MODEL:
Model / Model Code XA1200AZ / F0V
Primary ID Starting Number F0V-8001011
SERVICE LITERATURE:
Service Manual LIT-18616-02-27
Assembly Manual LIT-18666-00-30
Riding Tips LIT-18552-00-46
ENGINE:
Engine Number Prefix 68N
Cold Cranking Compression at Sea Level (Min) 5.0 kg/cm2 (70 psi)
CARBURETOR:
ID Number (F) 68N-011, (C) 68N-012, (R) 68N-013
Main Jet #117.5
Pilot Jet #87.5
High Speed Screw Turns Out (F) 1-1/4 (C) 1-1/8 (R) 13/8
Low Speed Screw Turns Out (F) 7/8 (C) 7/8 (R) 1-1/8
JET UNIT
6-4
XA1200AZ “XLT1200” (Continued)

CHARGING SYSTEM:
IGNITION SYSTEM:
Spark Plug Gap 1.0 ~ 1.1mm (0.039~0.048 in)
Pulser Coil Color Code / Ω W/R ~ BO / 445 ~ 545Ω
Charge Coil Color Code / Ω N/A
Peak Voltage (Closed Cranking) N/A
HULL / DECK:
Material (Hull / Deck / Hood Cover / Lid) FRP / FRP / PC / PC
Paint (Hood Cover / Lid) Light Gray Metallic D TBA
CONTROLS / CABLES:
Throttle Lever Freeplay 4 ~ 7mm (0.16~0.28 in)
Choke Cable Freeplay 1 ~ 6mm (0.039~0.24 in)
YPVS Cable Slack 0.5 ~ 1.5mm (0.02~0.06 in)
TORQUE VALUES:
3rd M8: 3.5m-kg (25 ft-lb)
2nd M10: 3.9m-kg (28 ft-lb)
M6: 1.1m-kg (8 ft-lb)
6-5
SV1200Z “SUV1200”
2001 Service Data
MODEL:
Model / Model Code SV1200Z / GU5
Primary ID Starting Number GU5-700101
SERVICE LITERATURE:
Service Manual (Same as SV1200X~Y) LIT-18616-02-24
Assembly Manual ø
ENGINE:
Engine Number Prefix 66G
Cold Cranking Compression at Sea Level N/A
Ring End Gap, All New 0.2 ~ 0.4mm (0.008~0.016 in.)
CARBURETOR:
ID Number (F) 66G-11, (C) 66G-02, (R) 66G-03
Main Jet #135
Pilot Jet (F) #100, (C) #95, (R) #97.5
Arm Spring Rate / Color 95 gr / Dull Silver
High Speed Screw Turns Out (F) 3/4, (C) 1, (R) 3/4
Low Speed Screw Turns Out 1
JET UNIT
6-6
SV1200Z “SUV1200” (Continued)

CHARGING SYSTEM:
IGNITION SYSTEM:
Ignition System Digital CDI
Ignition Timing BTDC 15°
Spark Plug Type NGK BR8HS
Spark Plug Torque / Cap Ω 2.5 m-kg (18 ft-lb) / 4.0k ~ 6.0kΩ
Ignition Coil Color Code Pri/Sec BW ~ B / High Tension Lead ~ B
Pulser Coil Color Code / Ω W/R, W/B, W/G - B / 248 ~ 372Ω
Charge Coil 1 Color Code / Ω Br - B/R / 172 ~ 258Ω
Charge Coil 2 Color Code / Ω L - B/R / 656 ~ 984Ω
HULL / DECK:
Material (Hull / Deck / Hood Cover / Lid) FRP / FRP / PC / FRP
Molding Process (Hull / Deck) HLF / HLF / SMC
Gelcoat (Hull) / Opt. Paint White Coat 5 #SF498E / #U7-60694
Gelcoat (Deck) / Opt. Paint Dark Red Coat 7 TBA / TBA
Paint (Hood Cover / Lid) Dark Red Metallic C / TBA
CONTROLS / CABLES:
Throttle Lever Freeplay 4~7mm (0.16~0.28 in)
Choke Cable Freeplay 1~6mm (0.039~0.24 in)
YPVS Cable Slack ø
TORQUE VALUES:
Cylinder Head Bolt 1st & 2nd M8: 1.5m-kg (11 ft-lb) / 3.2m-kg (23 ft-lb)
Cylinder Head Cover 1st / 2nd M8: 1.5m-kg (11 ft-lb) / 3.2m-kg (23 ft-lb)
M6: 0.4m-kg (2.9 ft-lb) / 0.8m-kg (5.8 ft-lb)
2nd M10: 4.0m-kg (29 ft-lb)
Exhaust Chamber Assembly to Stay 1st M8: 0.2m-kg (1.4 ft-lb)
3rd M8: 4.7m-kg (34 ft-lb)
Exhaust Chamber Assembly to Cyl 2nd M8: 4.0m-kg (29 ft-lb)
Muffler Stay (to Cyl Head) M10: 4.0m-kg (29 ft-lb)
Impeller 1.8m-kg (13 ft-lb)
6-7
XA800Z “XL800”
2001 Service Data
MODEL:
Model / Model Code XA800Z / F0P
Primary ID Starting Number F0P-808001
SERVICE LITERATURE:
Service Manual (Same as XA800Y) LIT-18616-02-14
Assembly Manual (Same as XA800Y) LIT-18666-00-27
ENGINE:
Engine Number Prefix 67A
Cold Cranking Compression at Sea Level (Min) 5.6kg/cm2 (78 psi)
Piston Skirt Clearance New / Max 0.100~0.105mm / 0.145mm
CARBURETOR:
ID Number (F) 67A-21, (R) 67A-22
Main Jet #150
Pilot Jet #90
High Speed Screw Turns Out 1/2
Low Speed Screw Turns Out (F) 1-5/8, (R) 1-3/4
JET UNIT
6-8
XA800Z “XL800” (Continued)

CHARGING SYSTEM:
Maximum Output 12V 7 ~ 9A @ 6,000 rpm
IGNITION SYSTEM:
Spark Plug Type NGK BR8ES
Spark Plug Torque / Cap Ω 2.5 m-kg (18 ft-lb) / 0Ω
Ignition Coil Color Code Pri/Sec O ~ B / Plug Cap ~ Plug Cap
Pulser Coil Color Code / Ω W/R ~ W/B / 446 ~ 545Ω
CDI Box Color Code / Ω O~B
Charge Coil Color Code / Ω Br ~ L / 299 ~ 365Ω
HULL / DECK:
Material (Hull / Deck / Hood Cover / Lid) FRP / FRP / PC / FRP
Paint (Hood Cover / Lid) Bluish Black Metallic 3 #U7-57689
CONTROLS / CABLES:
Choke Cable Freeplay 1 ~ 6mm (0.039 ~ 0.24 in)
TORQUE VALUES:
Cylinder Head Bolt 1st M8: 1.5m-kg (11 ft-lb)
Cylinder Head Cover 2nd M8: 3.8m-kg (27 ft-lb)
2nd M10: 4.0m-kg (29 ft-lb)
M6: 1.1m-kg (8 ft-lb)
Exhaust System See Service Manual for Procedure
Impeller (Left-Hand Threads) 1.8m-kg (13 ft-lb)
6-9
GP800AZ “GP800R”
2001 Service Data
MODEL:
Model / Model Code GP800AZ / F0W
Primary ID Starting Number F0W-800101
SERVICE LITERATURE:
Service Manual LIT-18616-02-26
Assembly Manual LIT-18666-00-29
ENGINE:
Engine Number Prefix 68A
Cold Cranking Compression at Sea Level (Min) 5.8kg/cm2 (78 psi)
CARBURETOR:
ID Number (F) 68A-11, (R) 68A-12
Main Jet #150
Pilot Jet #90
High Speed Screw Turns Out 1/2 +1/4
Low Speed Screw Turns Out (F) 1-5/8 +1/4, (R) 1-3/4 +1/4
JET UNIT
6-10
GP800AZ “GP800R” (Continued)

CHARGING SYSTEM:
IGNITION SYSTEM:
Spark Plug Type NGK BR8ES
Pulser Coil Color Code / Ω W/R ~ W/B / 446 ~ 545Ω
Charge Coil Color Code / Ω Br ~ L / 299 ~ 365Ω
HULL / DECK:
Material (Hull / Deck / Hood Cover / Lid) FRP / FRP / PC /PC
Paint (Hood Cover / Lid) Dark Purplish Blue Metallic F TBA
CONTROLS / CABLES:
Choke Cable Freeplay Align Marks
TORQUE VALUES:
2nd M10: 4.0m-kg (29 ft-lb)
M6: 1.1m-kg (8 ft-lb)
Exhaust System See Service Manual for Procedure
6-11
XL700Z “XL700”
2001 Service Data
MODEL:
Model / Model Code XL700Z / F0M
Primary ID Starting Number F0M-810481
SERVICE LITERATURE:
Service Manual (Same as XL700X~Y) LIT-18616-02-00
Assembly Manual (Same as XL700X~Y) LIT-18666-00-25
ENGINE:
Engine Number Prefix 67E
Cold Cranking Compression at Sea Level 9.4kg/cm2 (134 psi)
CARBURETOR:
ID Number (F) 62T-02F, (R) 62T-02R
Main Jet (F) #20 (4) #130
Pilot Jet #67.5
High Speed Screw Turns Out (F) 5/8, (R) 1-1/8
Low Speed Screw Turns Out 5/8
JET UNIT
Impeller Pitch Angle / Material 11 ~ 14 / Stainless Steel
Impeller Liner Clearance New 0.3mm (0.012 in)
6-12
XL700Z “XL700” (Continued)

CHARGING SYSTEM:
IGNITION SYSTEM:
Ignition System Capacitor Discharge
Ignition Coil Color Code Pri/Sec O ~ B / Plug Wire ~ Plug Cap
Pulser Coil Color Code / Ω W/R ~ B / 12.6 ~ 15.4Ω
Charge Coil Color Code / Ω Br / W ~ B / 497 ~ 608Ω
HULL / DECK:
Material (Hull / Deck / Hood Cover / Lid) FRP / FRP / PC /PC
Paint (Hood Cover / Lid) Dark Red Metallic C TBA
CONTROLS / CABLES:
YPVS Cable Slack ø
TORQUE VALUES:
2nd M10: 4.0m-kg (29 ft-lb)
2nd M8: 4.7m-kg (34 ft-lb)
Exhaust Chamber Assembly to Cyl M8: 4.0m-kg (29 ft-lb)
Jet Unit Mounting Bolt M10: 3.4m-kg (24 ft-lb)
M6: 0.7m-kg (5.1 ft-lb)
Drive Shaft Nut ø
Transom Plate ø
Intake Grate M6: 1.1m-kg (8 ft-lb)
6-13
SJ700AZ “SJ700”
2001 Service Data
MODEL:
Model / Model Code SJ700AZ / GM6
Primary ID Starting Number GM6-915240
Reserve Capacity 5.5 L (1.5 gal)
SERVICE LITERATURE:
Service Manual (Same as SJ700AU~AY) LIT-18616-01-43
Assembly Manual ø
ENGINE:
Engine Number Prefix 64V
Cold Cranking Compression at Sea Level 9.4kg/cm2 (134 psi)
Lubricant / Mixing Ratio Yamalube 2W / 50:1
Oil Tank Capacity ø
CARBURETOR:
ID Number (F) 64U-02F, (R) 64U-02R
Main Jet #130
Pilot Jet #70
High Speed Screw Turns Out (F) 1-1/8, (R) 1-1/2
Low Speed Screw Turns Out 7/8
JET UNIT
Impeller Pitch Angle / Material 13 ~ 16 / Aluminum
6-14
SJ700AZ “SJ700” (Continued)

CHARGING SYSTEM:
Lighting Coil Color Code / Ω G ~ G /1.14 ~ 1.4Ω
IGNITION SYSTEM:
Ignition System Capacitor Discharge
Spark Plug Torque / Cap Ω 2.5 m-kg (18 ft-lb) / N/A
Pulser Coil Color Code / Ω W/R ~ B / 12.6 ~ 15.4Ω
Charge Coil Color Code / Ω Br / W ~ B / 497 ~ 608Ω
HULL / DECK:
Material (Hull / Deck / Hood Cover / Lid) FRP (all)
Molding Process (Hull / Deck) SMC, HLF, SMC
Gelcoat (Deck) Dark Violet Coat 2 TBA
Paint (Hood Cover / Lid) Dark Purplish Blue Solid M #U7-61334
CONTROLS / CABLES:
YPVS Cable Slack ø
TORQUE VALUES:
2nd M8: 3.6m-kg (26 ft-lb)
2nd M10: 4.0m-kg (29 ft-lb)
Exhaust Chamber Assembly to Stay 1st M10: 2.8m-kg (20 ft-lb)
2nd M10: 5.3m-kg (38 ft-lb)
Muffler Stay (to Cyl. Head) 1st M10: 0.4m-kg (2.9 ft-lb)
2nd M10: 4.0m-kg 929 ft-lb)
Jet Unit Mounting Bolt M10: 1.7m-kg (12 ft-lb)
M6: 1.0m-kg (7.2 ft-lb)
Drive Shaft Nut ø
Transom Plate ø
6-15
6-16
Section 7
WaveRunner®
Installation Instructions
7-1
7-2
2001 WaterCraft Technical Update - Accessory Installation Instructions
XL/WAVE VENTURE BOARDING STEP

INSTALLATION INSTRUCTIONS
MWV-FSTEP-X1-V1
PARTS LIST TOOLS REQUIRED

Item Part Description Qty Item Description Qty
1 Boarding Step 1 1 Drill 1
2 Hardware Package 1 2 1/4” Drill Bit 1
3 Instructions 4 pgs 3 Drill Stop or Equivalent 1
4 Socket Wrench 1
5 Short Extension 1
6 7/16” Socket 1
7 7/16” Box End Wrench 1
8 #3 Phillips Screwdriver 1
9 Marine Grade Silicone Sealant 1
10 Fine Tip Marker 1
BOARDING STEP INSTALLED
December 2000 PAK-FSTEP-X1-V1

PAGE 1 OF 4
7-3
NOTE:
• Read all of these instructions thoroughly
before beginning the installation of the
boarding step.
• Make sure you have all necessary parts and
tools together before you begin.
• A second person will be helpful to hold the
step in position while you mark the mount-
ing location.
• Make sure the rear of the watercraft is clean
and dry. For your comfort, the area under
the rear of the craft (where you will be dur-
ing installation) should also be clean and
dry.
WARNING
Whether on the trailer or a stand, make sure
the craft is on firm, level ground and that it
cannot roll or fall.
1. Remove both sections of the seat. Remove
the rear storage tray to expose the interior of
the hull.
2. Remove the rubber exhaust hose that con-
nects the waterbox to the exhaust outlet.
This will provide much easier access to the
internal step mounting area.
3. Position the step so it is centered in refer-
ence to the centerline of the jet pump. Also,
position the height of the step so the top of
the step is even with the top of the rear deck
(see photo of installed step on page 1).
NOTE: The bottom of the step hinges may be

very close to the drain plugs. This is acceptable
as long as the hinges do not interfere with the
proper operation of the drain plugs.
4. Carefully trace around the hinges. After you

trace the hinges, mark the location of the 6
mounting holes (3 per side). Remove the stp
again and verify that your marks are posi-
tioned properly: the lines should be spaced
correctly and true to the operating direction
of the boarding step.
PAGE 2 OF 4
7-4
5. Place the two aluminum wedges inside the

lines that you traced on the hull. Tape the
wedges to the hull. Make sure the thick side
of the wedge is on the outside (way from the
pump). Carefully recheck the position of the
mounting hole locations.
6. Hold the boarding step back in position with

the brackets carefully aligned with the
wedges. Make absolutely sure the step is
positioned correctly and the marks for the
holes are in the proper location before you
drill.
7. When you have verified correct positioning,

use a 1/4” drill bit with a drill stop at 3/4”
depth to drill the holes. When drilling depth
is correct, finish drilling all 6 holes.
CAUTION:
Use a drill stop to prevent drilling too far and
damaging any internal components.
8. From inside the unit, clear out any debris
that may interfere with hardware installa-
tion. This includes any seam glue (brown
glue) used in production, which may need
to be sanded down.
9. Use acetone or rubbing alcohol to clean the
area around the drilled holes as well as the
mounting surface of the brackets.
10. Apply a bead of silicone sealer around each
bolt hole on the outside of the hull and the
inside of the hull. Be sure to use enough sil-
icone to keep water from seeping in past the
mounting bolts.
PAGE 3 OF 4
7-5
11. Carefully place the wedges on to the brack-
ets and position them onto the hull. Insert
the bolts on each side. Place the stainless
steel backing plates over the screws on the
inside of the hull. Loosely install a washer
and nut on each bolt to hold the bracket in
position while you install the other mount-
ing hardware. After all bolts, washers, and
nuts have been installed, tighten them
securely.
12. Reinstall the rubber exhaust hose. Make sure

both hose clamps are securely tightened.
13. Check operation of the boarding step. It
should fold down and retract smoothly with-
out binding.
14. Place the clear stoppers (split tubing) over
the hinge stop.
15. Replace the storage tray and the seats.
16. Allow 24 hours for the silicone to cure
before placing the watercraft in the water.
17. Next time the craft is in the water, check to
make sure there is no water leakage around
the hinges.
MAINTENANCE:
• Yamaha recommends you hose off the step
after every use to flush out the sand.
Periodically, remove the side caps on the
hinges and spray with lubricant.
CAUTION:
• Do not use the boarding step to attempt to
lift the watercraft. Serious hull damage
could occur.
• Damage due to improper installation or use
is not covered by Yamaha.
PAGE 4 OF 4
7-6
SUV BOARDING STEP

MWV-FSTEP-SU-V1

1 SUV Boarding Step 1 1 Drill 1
4 Socket Wrench 1
5 Short Extension 1
6 7/16” Socket 1
December 2000 PAK-FSTEP-SU-V1

PAGE 1 OF 4
7-7
NOTE:
boarding step.
ing location.
dry.
WARNING
MARK THE POSITION
1. Open the rear storage compartments.
Remove the two round inspection plates
(one on each side). These are each held in
place with 8 Phillips-head Screws.
2. Hold the boarding step assembly in position

with the brackets under the ledge of the hull
to the rear of where the footwell drain plugs
are located.
3. There should be equal distance between the RIDE PLATE

brackets and the edge of the pump cavity on
both sides (see illustration). Mark the hull BOW
with a line on the side edges of both brack-
DRAIN PLUG
ets. Set the step assembly aside. DRAIN PLUG
PUMP CAVITY
BRACKET BRACKET
VIEW
FROM BOTTOM
EQUAL DISTANCE BETWEEN BRACKET AND PUMP CAVITY
PAGE 2 OF 4
7-8
4. Carefully measure back 1-1/8" from the ver-

tical surface where the drain plug is mount-
ed on each side. Mark this measurement
where it intersects the marks you made in
Step 2. This will be the position for the for-
ward-end of the brackets.
1-1/8”
CAUTION:
Measurement is critical to ensure adequate
clearance for drain plug removal and to posi-
tion the aft-end mounting bolts properly. If the
step is placed too far aft, the rear of the hull
might interfere with washer installation. If too
far forward, it could be impossible to remove
the drain plugs.
the brackets carefully aligned with the marks
you made for the sides and the forward-end.
Finish tracing around the bracket and mark
the location of the 6 mounting holes (3 per
side). Remove the step again and verify that
your marks are positioned properly: the lines
should be spaced correctly and true to the
operating direction of the boarding step.
THIRD HOLE IS
6. When you have verified correct positioning, UNDER THRU-HULL
use a 1/4-inch drill bit with a drill stop at FITTING
3/4-inch depth to drill the forward holes.
Because the hull thickness can vary, you
may need to adjust the drill stop position.
When drilling depth is correct, finish drilling
all 6 holes.
CAUTION:

damaging the thru-hull fitting.
PAGE 3 OF 4
7-9
7. From the top, clear out any debris that may 11. Check operation of the boarding step. It
interfere with hardware installation. should fold down and retract smoothly with-
out binding.
area around the drilled holes as well as the 12. Replace the inspection covers on both sides
mounting surface of the brackets. of the storage compartments, using silicone
to reseal them.
bolt hole, on the under side of the hull and 13. Allow 24 hours for the silicone to cure
inside of the hull. Be sure to use enough sil- before placing the watercraft in the water.
mounting bolts.
CAUTION:
10. Carefully place the brackets in position on
the hull, then insert one bolt on each side. • Do not use the boarding step to attempt to
Loosely install a washer and nut on each lift the watercraft. Serious hull damage
bolt to hold the bracket in position while could occur.
you install the other mounting hardware.
After all bolts, washers, and nuts have been
installed, tighten them securely.
PAGE 4 OF 4
7-10
XLT1200/XL1200 LTD./XL800 BOARDING STEP

MWV-FSTEP-XL-LT

1 SUV Boarding Step 1 1 Drill 1
4 Socket Wrench 1
5 Short Extension 1
6 7/16” Socket 1
December 2000 PAK-FSTEP-XL-LT

PAGE 1 OF 5
7-11
NOTE:
boarding step.
ing location.
dry.
WARNING
1. Unlatch and remove the rear section of the
seat. Remove the rear storage tray to expose
the interior of the hull.
2. Remove the plastic resonators and rubber
exhaust hoses that run from the waterbox to
the outlet. This can be done by removing
only the hose clamps that secure the assem-
bly to the waterbox and the exhaust outlet,
and removing the entire assembly. Set the
assembly aside, being careful not to lose the
two hose clamps.
3. You will now have an unobstructed view of

the inside of the stern.
PAGE 2 OF 5
7-12
4. Remove the cast aluminum wedges from the

hardware package. There is a left and a right
wedge. The top of the wedge will have two
holes, and the outside of the wedge (away
from the pump) will be thicker. Hand fit the
wedges to the hull to assure that they are ori-
ented properly.
5. When you have the wedges oriented proper-

ly, tape them to the hinges of the step on MASKING TAPE
both sides. Also open the hinge slightly and
wedge it into place (a wad of masking tape
works well). This will allow the step to line
up into position much easier
6. Next, position the step so it is centered in

reference to the centerline of the jet pump.
Also, position the height of the step so the
top of the step is even with the top of the
rear deck. Make sure the aluminum wedges
are still lined up with the hinges. If you do
not have a helper, it may be easier to zip-tie
the step to the stern eye. Make sure you
have the step in place and are sure it is sta-
bilized in the proper location.
7. Carefully trace around the hinges. After you

trace the hinges, remove the step. Take the
wedges off and use them as templates for the
mounting holes. Be sure to use the correct
wedge (left wedge on the left side, etc.).
Mark the location of the 6 mounting holes (3
per side). After you have your hole locations
marked, hold the step up and verify that
your marks are positioned properly: the lines
should be spaced correctly and true to the
operating direction of the boarding step.
PAGE 3 OF 5
7-13
8. The photo to the right shows the approxi-
mate location of the right side mounting
position.
9. This photo (right) shows the mounting loca-

tions on the stern. This positioning is critical.
Take your time to check and re-check that
the step is positioned properly.

the brackets carefully aligned with the
wedges. Make absolutely sure the step is
positioned correctly and the marks for the
holes are in the proper location before you
drill.
11. When you have verified correct positioning,
use a 1/4-inch drill bit with a drill stop at
3/4-inch depth to drill the holes. When
drilling depth is correct, finish drilling all 6
holes.
CAUTION:

damaging any internal components.
12. From the top, clear out any debris that may
interfere with hardware installation. This
includes any seam glue (brown glue) used in
production, which may need to be sanded
down.
PAGE 4 OF 5
7-14

area around the drilled holes as well as the
mounting surface of the brackets.
bolt hole on the outside of the hull and the
inside of the hull. Be sure to use enough sil-
mounting bolts.
15. Carefully place the wedges on to the hinge
brackets and position them onto the hull.
Using the 1/4" x 2-1/2" pan head screws pro-
vided, insert the screws on each side. Place
the stainless steel backing plates over the
screws, on the inside of the hull. Make sure
the seam glue does not interfere with the
installation of the backing plate. The glue
may need to be sanded down. Loosely
install a flat washer, lock washer, and nut on
each screw to hold the bracket in position
while you install the rest of the mounting
hardware. After all screws, washers, and
nuts have been installed, tighten them
securely.
16. Check the operation of the boarding step. It
should fold down and retract smoothly with-
out binding.
17. Place the clear stoppers (split tubing) over
the hinge stop.
18. Replace the storage tray and the seats.
19. Allow 24 hours for the silicone to cure
before placing the watercraft in the water.
MAINTENANCE:
Yamaha recommends that you hose off the step
after every use to flush out the sand.
Periodically remove the side caps on the
hinges and spray with lubricant.
CAUTION:
• Do not use the boarding step to attempt to

lift the watercraft. Serious hull damage
could occur.
PAGE 5 OF 5
7-15
7-16
Section 8
2001 Sport Boat
Product Information
8-1
8-2
2001 WaterCraft Technical Update - Sport Boat Product Information
2001 Sport Boats
XR1800
New colors for 2001. Smoke Gray bow and engine hatch covers with Smoke Gray/Sky Gray
upholstery.
New under bow cover,
CD player with a back-lit remote and front speakers are standard equipment.
LS2000
New seat and bimini top colors.
New indicator panel like the XR1800.
Beige dash and glove box with XR1800 type finish.
8-3
XR1800 Limited Edition Sport Boat
All new under bow cover for a more finished

look.
In addition to the under dash cover, all

wiring under the bow cover is routed down
the side of the deck through split loom pip-
ing.
45 watt per channel Kenwood CD player
with a backlit remote and front speakers as
standard equipment.
New fastening system for the bucket seat

armrests.
Additional quality control system imple-
mented to increase the QC inspection
points on every unit.
8-4
LS2000 Sport Boat
Standard equipment includes a mooring

cover for 2001.
New style switches are exclusive to the
LS2000.
Meter panel and glove box are beige with a

leather look finish.
The indicator panel introduced on the

XR1800 last year is now standard for the
LS2000.
The indicator panel provides warning indi-
cators for “Low Fuel”, “Low Oil” and
“Overheat” indicatiors for each engine.
With the addition of the low fuel warning

system, the fuel petcocks have been elimi-
nated.
There is a manual shut-off located under
the access panel under the center rear seat
cushion.
8-5
LS2000 Sport Boat

Indicator Panel
LOW FUEL LOW OIL STARBOARD

PORT ENGINE OVERHEAT ENGINE OVERHEAT
The low fuel and low oil warning indicators

Built-in systems check. When both keys are activate when the level reaches approxi-
turned on, all the indicators will light and the mately 20%. The sending unit constantly
audible warning will beep 3 times to verify reads the level and average the readings. If
everything is normal. the level reads low more than 30% of a one
When a warning is sent to the panel, the minute cycle, the warning will be activated,
indicator light will activate and the alarm will sounding the alarm and turning on the
beep for 5-6 seconds. In the case of multi- appropriate indicator.
ple warnings, the alarm will pause 5 sec- Each overheat indicator is independently
onds and repeat for each. The indicator will controlled for port and starboard engines.
stay on until the main switch is turned off or
the fault is corrected. If the engine water temperature exceeds
90°~96°C (194°~205°F) the appropriate
indicator will be activated. This will also
cause the engine to go into rpm reduction.
This will reset when the temperature drops
below 70°~90°C (169°~194°F).
8-6
LS2000 Sport Boat

New Stereo
New Back-lit remote is used for the CD Upgraded 45 watt per channel CD player.
player.
8-7
8-8
Section 9
2001 Sport Boat Model Color
and Graphics Guide
9-1
9-2
2001 WaterCraft Technical Update - Sport Boat Color and Graphics Guide
XR1800 Limited Edition Sport Boat
EMBLEM YAMAHA 2 ENGINE HATCH

GRAPHICS (3)
EMBLEM YAMAHA
1 EMBLEM 310HP
4
EMBLEM YAMAHA
EMBLEM XR1800
HULL GRAPHIC REAR DECK
GRAPHIC
PAINT AND GRAPHICS:

Ref Gel Coat Paint
No. Part Name Color Name Sher-Fab Sherwin Williams
1 Bow Cover Smoke Gray TBA TBA
2 Engine Hatch Smoke Gray TBA TBA
3 Deck White Coat 5 SF498E U7-60694
4 Hull White Coat 5 SF498E U7-60694
Part Name Color

Gunwale White
Seat Smoke Gray/Sky Gray
Seat Lettering Sky Gray
Dash Black
Hand Grips Black
Mirror Black
Fuel Cap White
9-3
LS2000 Sport Boat
EMBLEM LS2000
YAMAHA
DECK GRAPHIC
3
2 EMBLEM YAMAHA
HULL GRAPHIC
PAINT AND GRAPHICS:

Ref Gel Coat Paint
No. Part Name Color Name Sher-Fab Sherwin Williams
1 Engine Hatch White Coat 5 SF498E U7-60694
2 Deck White Coat 5 SF498E U7-60694
3 Hull White Coat 5 SF498E U7-60694
Part Name Color

Gunwale White
Seat Cappuccino/White
Seat Lettering Burgundy
Dash Beige
Hand Grips Black
Mirror Black
Fuel Cap White
9-4
Section 10
Sport Boat Technical Tips
10
10-1
10-2
2001 WaterCraft Technical Update - Sport Boat Technical Tips
Sport Boat Technical Literature Index

LITERATURE
XRT1200 Catalytic Converter Failure Diagnosis 2001 SB Technical Update Handbook
XRT1200 Catalytic Converter Failure Diagnosis 2001 SB Technical Update Handbook
XRT1200 2000~2001 Cleanout Hose Sealing 2001 SB Technical Update Handbook
XRT1200 2000 Dash Assembly Replacement, Pealing Technical Bulletin SB2000-005
XRT1200 2000~2001 Erratic Powervalve Operation 2001 SB Technical Update Handbook
XRT1200 2000 Overheat System Troubleshooting 2000 SB Tech. Update Handbook Page 11-8~11-11 LIT-18500-00-2K
XRT1200 2000 Parts List Correction, Meters & Switches 2001 SB Technical Update Handbook
XRT1200 2000 Piston Selection 2000 SB Technical Update Handbook Page 11-4 LIT-18500-00-2K
XRT1200 Powervalve Improvements 2001 SB Technical Update Handbook
XRT1200 2000 Quality Assurance Inspection Technical Bulletin SB2000-006
XRT1200 2000 Seat Arm Pad Replacement 2001 SB Technical Update Handbook
XRT1200 2000 Seat Slide Assembly Replacement Technical Bulletin SB2000-009
XRT1200 Stalling 2001 SB Technical Update Handbook
XRT1200 2000~2001 Stereo Mounting 2001 SB Technical Update Handbook
XRT1200 2000 Water Temperature Sender Tool 2000 SB Technical Update Handbook Page 11-12 LIT-18500-00-2K
LST1200 2000~2001 Bimini Top Warranty Procedures Technical Bulletin JB99-004
LST1200 2000~2001 Cleanout Hose Sealing 2001 SB Technical Update Handbook
LST1200 2000 Oil Tank Changes 2000 SB Technical Update Handbook Page 11-6 LIT-18500-00-2K
LST1200 2001 Parts List Correction, Meters & Switches 2001 SB Technical Update Handbook
LST1200 1999~2000 Stereo Mounting 2000 SB Technical Update Handbook Page 11-7 LIT-18500-00-2K
LST1200 1999~2001 Stereo Mounting 2001 SB Technical Update Handbook
General Phone Numbers, Toll-Free Service Assist. Technical Bulletin SB2000-003
EXT1200 1998~1999 Parts List correction, Jet Pump 1999 SB Technical Update Handbook Page 5-5 LIT-18500-00-99
EXT1200 1998~1999 Single Engine Operation Tech Exchange JB98-002
EXT1200 1998~1999 Twin Engine Tachometer Variance Tech Exchange JB98-002
EXT1100 1997 Battery Specification Change Tech Exchange JB97-003
EXT1100 1996~1997 Cleanout Tray Hose Inspection/Replace. Technical Bulletin JB97-005
EXT1100 1996~1997 Cleanout Tray Hose Splitting 1998 JB Technical Update Handbook Page 66 LIT-18500-00-98
EXT1100 1996~1997 Drain. Sys. Layout & Cleanout Tray Removal Tech Exchange JB96-005
EXT1100 1996~1997 Engine Hatch Closing Tech Exchange JB97-001
EXT1100 1996~1997 Engine Hatch Latch Breaking 1997 JB Technical Update Handbook Page 18~19
EXT1100 1996~1997 Engine won't Start, Troubleshooting Tech Exchange JB96-004
EXT1100 1997 Fuel System Vent Change 1997 JB Technical Update Handbook Page 22
EXT1100 1996~1997 Gel-Coat Availability Tech Exchange JB97-002
EXT1100 1996~1997 Gel-Coat Availability 1997 JB Technical Update Handbook Page 20
EXT1100 1996~1997 Jet Pump Water Leak 1997 JB Technical Update Handbook Page 23
EXT1100 1996~1997 Normal Tachometer Operation Tech Exchange JB96-004
EXT1100 1997 Oil Pump Bleeding 1997 JB Technical Update Handbook Page 25
EXT1100 1996~1997 Oil Pump Kit Instructions 1998 JB Technical Update Handbook Page 67~69 LIT-18500-00-98
EXT1100 1997 Oil Tank Change, Vented Cap Tech Exchange JB97-003
EXT1100 1996~1997 One Use Only Hose Clamps, Oetiker Tech Exchange JB97-002
EXT1100 1996~1998 Peak Voltage Specifications Tech Exchange JB99-003
EXT1100 1996 Pre-Delivery Setup and Adjustments Technical Bulletin JB96-002
EXT1100 1996 Pri. ID Nmbrs., Service Lit. & Wty. Policies Technical Bulletin JB96-001
EXT1100 1996~1998 Single Engine Operation Tech Exchange JB98-002
EXT1100 1996 Trailer Warranty Policies Technical Bulletin JB96-003
EXT1100 1996~1998 Twin Engine Tachometer Variance Tech Exchange JB98-002
EXT1100 1996~1997 Windshield Cracking at Mounting Holes 1997 JB Technical Update Handbook Page 21
EXS1200 1998 Cleanout Tray Hose Inspection/Replacement Technical Bulletin JB97-005
EXS1200 1998 Cleanout Tray Hose Splitting 1998 JB Technical Update Handbook Page 66 LIT-18500-00-98
EXS1200 1998 Oil Pump Bleeding 1997 JB Technical Update Handbook Page 26
EXS1200 1998 Oil Pump Cable Adjustment 1997 JB Technical Update Handbook Page 24
EXS1200 1998~1999 Parts List correction, Jet Pump 1999 SB Technical Update Handbook Page 5-5 LIT-18500-00-99
All Models Basic Hull Repair Video VID-10660-00-43
All Models Carburetor Adjusting Tips 2001 SB Technical Update Handbook
All Models Crankshaft Failure Diagnosis 2001 SB Technical Update Handbook
All Models Crankshaft Phase Inspection 2000 SB Technical Update Handbook Page 11-13 LIT-18500-00-2K
All Models Essential Tools, Test Harness Technical Bulletin JB99-002
All Models EZ Loader Trailer Warranty Technical Bulletin JB97-004
All Models 1996~1999 GelCoat Application and Color Code Chart 1999 SB Technical Update Handbook Page 5-8 LIT-18500-00-99
All Models 1996~2000 GelCoat Application Chart 2000 SB Technical Update Handbook Page 11-15 LIT-18500-00-2K
All Models 1996~2001 GelCoat Application Chart 2001 SB Technical Update Handbook
All Models Gelcoat Color Codes 2000 SB Technical Update Handbook Page 11-15 LIT-18500-00-2K
All Models Gelcoat Color Codes 2001 SB Technical Update Handbook
All Models 1996~1999 Impeller Application Chart 1999 SB Technical Update Handbook Page 5-7 LIT-18500-00-99
All Models 1996~2000 Impeller Application Chart 2000 SB Technical Update Handbook Page 11-14 LIT-18500-00-2K
Sport Boat Technical Literature Index (Cont’d.)
LITERATURE
All Models 1996~2001 Impeller Application Chart 2001 SB Technical Update Handbook
All Models 1996~1999 Jet Pump Cleanout Procedure Tech Exchange JB98-003
All Models Non-Skid Deck Repair 2000 SB Technical Update Handbook Page 11-5 LIT-18500-00-2K
All Models Oil Pump Output Testing 2001 SB Technical Update Handbook
All Models Peak Voltage Testing 1999 JB Technical Update Handbook LIT-18500-00-99
All Models Performance Troubleshooting "Carburetion" 2001 SB Technical Update Handbook
All Models Replacement Ignition Keys Tech Exchange JB98-001
All Models SAE and Metric Fastener Part Numbers Tech Exchange JB97-001
All Models Special Tools 2000 SB Tech. Update Handbook Page 11-1~11-2 LIT-18500-00-2K
All Models Special Tools 1999 SB Technical Update Handbook Page 5-1~5-2 LIT-18500-00-99
All Models Special Tools 2001 SB Technical Update Handbook
All Models Stalling in Turns, Cleanout Switches 1998 JB Technical Update Handbook Page 70 LIT-18500-00-98
All Models Troubleshtg. - Water Entering the Hull Area 2001 SB Technical Update Handbook
All Models Warranty Information Technical Bulletin JB98-004
All Models Warranty Policies Technical Bulletin SB2000-002
All Models Water Vehicle Carburetor Tuning & Adjust. Video VID-10660-00-34
All Models Yamaha Drive Train Theory (Watercraft) Video VID-10660-00-64
All Exciters 1996~1998 Cleanout Tray Hose Replacement 1999 SB Technical Update Handbook Page 5-4 LIT-18500-00-99
All Exciters 1996~1998 Cracked Windshields Tech Exchange JB98-002
All Exciters Oil Tank Cap Change to Vented Type 1999 SB Technical Update Handbook Page 5-3 LIT-18500-00-99
All Exciters Ski Locker Drain Hose Plugged 1998 JB Technical Update Handbook Page 65 LIT-18500-00-98
All Exciters 1998 Trailer Manufacturer Change 1998 JB Technical Update Handbook Page 71~72 LIT-18500-00-98
All 135 HP Models 1998~2000 Fuel Pump Changes 2000 SB Technical Update Handbook Page 11-3 LIT-18500-00-2K
All 135 HP Models 1998~1999 Hard Starting, Choke Plate Installation 1999 SB Technical Update Handbook Page 5-6 LIT-18500-00-99
2001 Models 2001 Carburetor Settings 2001 SB Technical Update Handbook
2001 Models 2001 Primary ID Numbers and Service Literature Technical Bulletin SB2000-008
2001 Models 2001 Trailer Warranty Policies Technical Bulletin SB2000-007
2000 Models 2000 Primary ID Numbers and Service Literature Technical Bulletin SB2000-004
2000 Models 2000 Service Literature Technical Bulletin JB99-005A
2000 Models Technical Update Manual Revisions Technical Bulletin SB2000-001
2000 Models 2000 Trailer Warranty Policies Technical Bulletin SB2000-007
1999 Models 1999 Peak Voltage Manual Updates Tech Exchange JB99-003
1999 Models 1999 Primary ID Numbers & Service Literature Technical Bulletin JB99-001
10-4
Special Tools
The following charts list some of the more commonly used special tools and their applications:
Kent Moore
EXS1l200, EXT1200
LST1200 (LS2000)
YW-06550 Flywheel Holder XRT1200 (XR1800)
YW-06546 Coupler Wrench All 1100cc Engines,

EXS1200, EXT1200
LST1200 (LS2000)
YW-06551 Coupler Wrench XRT1200 (XR1800)
YB-06049 Driveshaft Holder All 1100cc Engines

EXS1200, EXT1200
LST1200 (LS2000)
YB-06151 Driveshaft Holder XRT1200 (XR1800)
YW-38742 Intermediate Shaft All 1100cc Engines

Holder EXS1200, EXT1200
LST1200 (LS2000)
YB-06552 Intermediate Shaft XRT1200 (XR1800)

Holder
YW-42087 Carburetor Pop Off All Models

Gauge
YU-33263 Digital Multimeter All Models
YU-39991 Peak Volt Meter Adapter All Models
10-5
Special Tools (Cont'd.)
Kent Moore
1. YW-06777 Peak Volt Test Lead All 1100cc Models<
2. YW-06778 EXS1200, EXT1200
LST1200 (LS2000)
YW-06780 Peak Volt Test Leads XRT1200 (XR1800)
YU-39951-A Digital Tachometer All Models
YM-34487 Dynamic Spark Tester All Models
J-8037 Inductive Timing Light All Models
10-6
Oil Pump Output Testing
TECHNICAL TIPS
Current service manuals do not provide a Testing:
means for testing oil pumps for correct output.
1. Remove the oil pump feed line from the car-
Follow the steps below to test for proper oil
buretor or carburetor cover on the cylin-
pump output. (See the following page for spec-
der(s) to be tested in the first test.
ifications and an example of test results.) It is
important to follow the procedures precisely to 2. If the oil pump is a variable type, position
obtain proper results. the oil pump lever to the wide open mark
(see illustration below).
Setup:
FIGURE 1
You will need a measuring cylinder (or cylin-
ders) marked in increments of 0.1cc or less.
You may build a tool to perform this test on all
cylinders at the same time. (See Tech
Exchange WV96-019, reprinted following this
Tech Tip, for details.)
Make sure the oil lines will reach a convenient
area to locate the measuring cylinder.
Pre-Test Conditions:
CAUTION: 3. With the unit in a test tank or on the flush
• Make sure you run pre-mixed fuel for the kit, start the engine and set the idle speed
duration of the test. to 3000 rpm.
• Due to differences in viscosity and other NOTE:

characteristics of different oils, the test You may need to warm the engine to obtain a
should be performed using only steady idle speed. Proper Idle speed is imper-
Yamalube 2-W in the oil tank along with ative to the accuracy of this test.
the pre-mixed oil in the fuel tank.
4. Position the oil feed line into a clean meas-
• The oil temperature should be between uring cylinder (marked in increments of
10 ~ 30°C (50°~ 86°F). 0.1cc) and run the engine for 3 minutes.
Make sure the oil line is full when you begin
measuring.
5. Compare the output of each feed line with
the specifications on the following chart.
6. After completion of the test, reattach the oil
line(s), readjust the oil pump cable to the
standard setting (if applicable) and reset
the engine idle speed.
10-7
Oil Pump Output Testing (Cont’d.)
Oil Pump Specification Chart

Engine Oil Pump Oil Pump Output cc’s/
Code Number 3 Min / Per Cylinder at 3,000rpm
Variable Type
Oil Pump Lever Fixed Type
Model Code at WOT Position
XRT1200 (00~01) 68Y 66V 13.9 ~16.1
LST1200 (99~01) 67V 66H 7.8 ~ 9.6
EXT1200 (98~99 66H 66H 7.8 ~ 9.6
EXS1200 (98~99) 66H 66H 7.8 ~ 9.6
EXT1100 (97~98) 65B 65B 6.7 ~ 8.1
EXT1100 (96) 65B 63M 6.5 ~ 8.3
Example: XRT1200
Test #1 Front Cylinder (3 min): 15.2cc
Test #2 Center Cylinder (3 min): 14.7cc All outputs are within specification
Test #3 Rear Cylinder (3 min): 15.9cc
10-8
10-9
10-10
Performance Troubleshooting “Carburetion”
TECHNICAL TIPS
The following information has been prepared to
assist in diagnosing performance problems
that may be carburetor based. Use this infor-
mation along with the other performance trou-
bleshooting and carburetor adjusting tips.
I. POOR ACCELERATION
A. Hesitation or Stalling 1. Improper adjustment • Measure the free length of the
needle valve arm spring, the arm
R/MIN • Replace it if it is out of specification.
NORMAL ENGINE mixture screws and passages for
ACCELERATION debris or improper adjustment.
• Clean or adjust if out of specification.
2. Carburetor clogged • Check the fuel filter and the small

HESITATION with debris filter in the carburetor. Clean or
replace them if they are clogged with
debris.
• Inspect the needle valve seat and
THROTTLE ON passage in the carburetor and
remove any debris if necessary.
TIME
3. Water in fuel • Check the fuel filter. If water is
present, drain any water from the
fuel tank. Replace the fuel filter.
4. Out of sync • Check the carburetor

synchronization and synchronize as
necessary.
5. Increased internal • Loosen the fuel tank cap to release

pressure in the fuel the pressure
tank • Test the fuel tank venting.

being used.
• High octane fuel used in an engine
designed for 87 octane can cause
hesitation during initial acceleration,
10-11
I. POOR ACCELERATION (Cont’d.)

B. Bucking or Bogging 1. Low idle rpm • On the water, check the engine idle
R/MIN specification (see NOTE next page).
NORMAL ENGINE 2. Improper adjustment • Measure the free length of the

ACCELERATION needle valve arm spring, the arm
• Replace it if it is out of specification.
BOGGING mixture screws and passages for
debris or improper adjustment.
• Clean or adjust if out of specification
THROTTLE ON 3. Needle valve stuck • Check whether the needle valve is

with debris (not stuck with debris, and clean or
TIME closing) replace the needle valve as
necessary.
4. Needle valve worn • Inspect the needle valve. If the tip is

worn, replace the needle valve and
seat as a set.
5. Choke valve closed • Check that the choke valve retracts

fully when the choke knob is
returned to its seat. If it does not,
adjust the choke cable.
6. High altitude • Check the altitude the unit is

operated at and change the
carburetor setting to one appropriate
for that elevation. Return the
carburetor to its original settings
when used at sea level.

being used.
• High octane fuel used in 87 octane
designed engines can cause
hesitation during initial acceleration;
10-12

II. SPARK PLUG FOULING
Spark Plugs are Fouled 1. See chart I-B items • See chart I-B items 1~7.
1~7
2. Low to mid-speed • Fully open the throttle for

operation for a long approximately 20 seconds from time
time to time.
3. Improper spark plug • Replace the spark plugs with the

heat range recommended heat range.
III. HARD STARTING

A. The engine fires but does not 1. See chart I-A items • See chart I-A items 1~6.
continue to run. 1~6
2. Idle is set too low. • On the water, check the engine idle
specification (see NOTE below).
B. It takes a while for the engine 1. See chart I-A items • See chart I-A items 1~6.
to start. 1~6. recommended heat range.
2. Needle valve is stuck. • Check whether the needle valve is

stuck, and clean or replace the
needle valve set as necessary.
3. Choke valve not • Check that the choke valve is

completely closed. completely closed when the choke
knob is pulled out. If it is not
completely closed, adjust the choke
cable.
4. Improper starting • Pull the choke knob all the way out.
method. Then, open the throttle about 1/3
and press the start button. Release
the throttle once the engine starts.
5. Weak battery. • Measure the voltage or the specific

gravity of the battery and recharge
the battery if a low reading is
obtained.
NOTE:
Checking and adjusting idle speed:
This operation must be performed on the water.
1. Warm up the engine for five minutes or more at 6000 rpm minimum.
2. Return to idle and operate the engine for two minutes. Check the engine speed and adjust if
out of specification.
10-13
Carburetor Adjusting Tips
TECHNICAL TIPS
Pop Off Pressure Testing 1. Gently depress the needle valve arm to
check for smooth operation and no binding.
Testing pop off pressure has become exceed-
ingly difficult as the standard pressure has 2. Inspect the Needle Valve Arm 1 for dam-
increased on some of the newer models. age.
Because of this increase, the accuracy of this
3. Measure the needle valve arm height. This
test has also diminished.
is measured from the surface of the carbu-
Pop off pressure is a function of two main retor Body b to the top surface of the arm 1.
items:
1
1. Needle seat size a
2. Spring tension on the valve assembly
Perform the following steps to check pop off
pressure: b
1. Remove the carburetor top and diaphragm

to gain access to the needle valve assem-
bly.
Arm height: a
2. Attach the pop off pressure gauge to the 0~0.2mm (0 ~ 0.008 in)
fuel inlet and secure. Make sure your
gauge will operate in the range required for
the model being tested.
3. Block off the fuel return nipple.
b
4. Pressurize the carburetor with the pump
until the needle valve pops. Make sure to
note the pressure. Perform the test 3 times
to assure an accurate reading.
NOTE: When testing, it is very important that
the tip of the needle valve be lubricated. A dry
needle valve tip could stick in the valve seat
causing an inaccurate reading. Use WD-40 or 4. Inspect the spring for proper application
an equivalent to lubricate the needle valve. and measure the free length.
CAUTION: 5. Inspect the needle valve seat size
Do not use gasoline due to the fire hazard. 6. Inspect the needle valve tip for damage or
Always wear eye protection to protect from binding in the valve seat.
spray when the needle pops.
7. Repair or replace these items as neces-
After performing the test, compare your read- sary.
ing to the chart on the following page; based on
the specifications for the model you are testing. NOTE: If the pop off pressure changes on a
If your reading is out of specification, inspect carburetor, the pressure should not be
the following items: changed by using different springs or valve
seats. However, the part causing the change
needs to be repaired or replaced.
10-14

Current Needle Valve Spring Specifications
Identification Spring Pressure
Part Number Free Length (Spring Color) Installed) Arm Set Height
67R-14253-00-00 17.0mm Gold 115 grams 0~0.2mm
63M-14253-00-00 16.1mm Dull Silver 95 grams 0~0.2mm
Control Arm Spring (Color & Strength)

Gold Dull Silver Green Shiny Silver
115 grams 95 grams 80 grams 65 grams*
Needle Valve Size Resulting Pop Off Pressure (+5 psi)
1.2 75 psi 64 psi 54 psi 41 psi
1.5 55 psi 43 psi 38 psi 32 psi
2.0* 32 psi 25 psi 21 psi 18 psi
2.3* 22 psi 20 psi 17 psi 15 psi
2.5* 19 psi 17 psi 14 psi 12 psi
NOTE: Use this as a guideline only, measurements may differ slightly depending on the accuracy of the gauge, test con-
ditions, etc.
* Not original equipment on Yamaha Sport Boats.
The shaded area of the chart is used for current Yamaha Sport Boats.
Mixture Screw Adjustment

Specifications:
Fig. 1
STANDARD
In the past, carburetor specifications have FUEL FLOW RATE
CARBURETOR
been provided with a tolerance of + 1/4 turn. CHARACTERISTICS
FLOW
This was mistakenly assumed to be the toler- RATE
TOLERANCE
ance for adjustment in the field. This was actu- TOLERANCE
UPPER LIMIT
ally the tolerance at the time of being
manufactured. The fuel mixtures are set for
total fuel flow rate and the + 1/4 turn is the tol- TOLERANCE
LOWER LIMIT
erance allowed to achieve the window for
allowable flow.
NUMBER OF TURNS
In Figure 1, the gray area shows the allowable OUT OF SCREW
fuel flow tolerance. In this example, the carbu- -1/4 +1/4

retor is set to the center of the range.
Fig. 2
The example in Figure 2 shows a carburetor
set at the lower (leaner) edge of the flow rate
window. This is within factory tolerance. If this
carburetor were adjusted in the field to the cor-
rect specification minus 1/4 turn, this would
make the carburetion too lean causing hesita-
tion, hard starting and possibly engine dam- TOLERANCE
LOWER LIMIT
age.
LEANER
NUMBER OF TURNS
1/4 TURN OUT OF SCREW
LEANER
-1/4 +1/4
10-15
The example in Figure 3 shows a carburetor Fig. 3

set at the upper (richer) edge of the flow rate 1/4 TURN
window. This is also within factory tolerance. If RICHER
this carburetor were adjusted in the field to cor- TOLERANCE

RICHER UPPER LIMIT
rect specification plus 1/4 turn, this would
make the carburetion too rich causing bogging,
plug fouling and poor fuel economy.
Adjustment:
NUMBER OF TURNS
When disassembling carburetors, it is impera- OUT OF SCREW
tive that the position of the fuel mixtures be -1/4 +1/4
checked before disassembly so they can be

returned to their original position. Perform the
following steps to inspect the fuel mixture
screw settings:
1. Remove the mixture screw cap if applica-
ble.
2. Turn the screw in until it lightly seats, count-
ing the turns as you go. Then record the
number.
3. If the number of turns is within tolerance
this is normal. After carburetor inspection
return the screw to the original setting.
4. If the setting is not within tolerance, the set-

ting may have been changed. Be sure to
thoroughly inspect the carburetor for any
condition that may have caused someone
to change the setting. Set the screw to
specification and test for proper engine
operation.
5. Install a new mixture screw cap, if applica-
ble.
NOTE: With the introduction of the caps over
the mixture screws for emissions purposes, it is
important to use a drill stop when drilling these
for removal. Drilling deeper than 5mm could
allow the drill bit to pass through the cap and
contact the mixture screw. This can drive the
screw into the carburetor, disturbing the origi-
nal setting and possibly damaging the mixture
screw and/or its seat.
10-16
XR1800 Stalling
TECHNICAL TIPS 7. Disassemble the fuel chamber, needle and

Symptom: seat and body 1.
When the throttles are applied from idle to full
throttle, the engine(s) may stall.
Remedy:
This condition is generally due to lean carbure-
tion. Follow the steps below to inspect the fuel
system and determine the cause:
1. Inspect the fuel system for any restrictions.
2. Check the fuel line for proper routing or
possible kinks. Make sure the hoses are
not routed over the fuel tank ribs. This is
very close to the seat base and could pinch 8. Inspect the check valve on body 1 1 and
the fuel hose. replace the assembly if this is frayed or not
3. Inspect the fuel filters for debris or contam- sealing. Inspect the needle tip 2 and seat
ination and replace as necessary. o-ring 3 for wear or damage. Measure the
free length of the needle valve arm spring.
4. Inspect the carburetors for proper idle Be sure to set the arm height during
speed, synchronization and throttle syn- reassembly.
chronization.
5. Remove and disassemble the carburetors. 1
6. Remove the carburetor top and inspect the

diaphragm for wear, distortion or damage.
3
9. Disassemble the fuel pumps. Inspect the

check valves and diaphragms for pinholes
or other damage.
CHECK VALVE
DIAPHRAGM
10-17
XR1800 Stalling (Cont’d.)
10. Inspect and clean the small fuel filter, 12. The fuel mixture screws are pre set at the
diaphragm, gasket and o-ring. factory so you will need to verify where they
are set. Lightly turn each screw in until it
lightly seats and note the number of turns.
Refer to the previous carburetor adjusting
Technical Tip for more information
13. If the fuel mixture setting appear to have
been changed or are set excessively lean,
set them to specification.
Mixture Screw Setting (Turns out)
FILTER
High Speed (F) 1-1/4, (C) 1-1/8, (R)1-3/8
Low Speed (F) 7/8, (C) 7/8, (R)1-1/8
NOTE: A fuel mixture screw cap must be rein-

11. Remove the caps over the fuel mixture stalled after the carburetor work is completed.
screws using a 1/8" drill bit and a drill stop. This will keep water from corroding the screws
(a spacer over the drill bit can be used) Set into the carburetor body.
the stop to 5mm. This will insure that the
drill will not go all the way through the plug NOTE: The high and low speed screws are not
and contact the fuel mixture screw. Drill the the same. Make sure they are re-installed at
cap to the specified depth. Using a dent their proper location. For easy identification,
puller (or slide hammer with a sheet metal the high-speed screw is brass colored and the
screw attached) screw it into the cap and low speed screw is silver.
pull out to remove the plug. Clean any
remaining shavings away.
HIGH SPEED (BRASS COLOR & SHORTER
LOW SPEED (SILVER COLOR & LONGER
14. After completing the carburetor inspection,

be sure to set the idle speed and synchro-
CAUTION: nize the carburetors and the throttles.
If the drill bit contacts the Fuel mixture
screw, it may drive the screw into the seat.
This can severely damage the carburetor so
that it will need to be replaced.
10-18

NOTE: During an exhaust temperature warn-
TECHNICAL TIPS ing, the engine will still run through the normal
Symptom: rpm range. No rpm reduction or engine stop-
Loss of top speed. page occurs in this mode.
Cause: 3. Converter broken loose at the outside of it’s
The catalytic converter will cease to function or mounting (Fig. 3). This failure occurs from
crack and dislodge from its mount and block water ingestion. The outer sleeve that
the exhaust system. attaches the honeycomb to the outer case
corrodes, weakening it until it cracks.
The following are four of the most common cat-
alytic converter failures:
1. Blocked converter due to improper oil (Fig.
1). This will typically show up as an oily car-
bon build-up on the converter. Using the
incorrect oil leaves a chemical coating on
the converter, which (in effect) seals the
surface of the converter. When this hap-
pens, the chemical conversion can no
longer take place. Without this chemical
process, the converter does not heat up
and this allows the oily residue to accumu- Fig. 1
late, restricting the exhaust and increasing
emissions. This is a slow process and is not
immediately obvious. When the converter
becomes thoroughly coated, it will no
longer generate heat and will trigger an
exhaust warning for the temperature being
too cool.
NOTE: This will activate only after operation
over 4000 rpm or higher, continuously for 2
minutes.
2. Melted converter (Fig. 2). This is most often
seen as a melting of the honeycomb on the Fig. 2
back side of the converter. This is caused
by excessive amounts of unburned fuel in
the exhaust system heating the converter
beyond normal operating temperatures. METAL SLEEVE
The most common causes would be con- RUSTED
tinuing to run the unit after fouling a spark
plug, a carburetor malfunction or running
the unit continually with the choke used.
Before the temperature rises to the point
where any damage occurs, the exhaust
overheat warning will activate, alerting the
operator to turn the unit off until it cools.
Fig. 3
10-19
4. Converter cracked or broken out; 10-20mm

in from the outside housing (Figs. 4 & 5).
This cracking occurs from thermal stress
caused by the rapid expansion and con-
traction of the converter. Some causes
could be: water ingestion while the convert-
er is hot, rapid heating and cooling and
improper warm-up. Caution operators on
proper warm-up procedures, so the engine
is at operating temperature before any
WOT operation occurs.
NOTE: When a converter breaks out or breaks CRACKED
Fig. 4
loose, the pieces will quite often contact the
exhaust temperature sensor. If the sensor is
damaged, this will activate an exhaust temper-
ature warning due to a faulty sensor (tempera-
ture too low.) This will occur only after
operation over 4000 rpm continuously for a
minimum of 2 minutes.
Fig. 5
10-20
Power-Valve Improvements
Problem: PREVIOUS -02 POWER-VALVE

BOLT
The power-valve may contact the piston, dam- 10MM
aging the piston and possibly breaking the
power-valve itself. The power-valve travel is
limited by the stop at the base of its shaft. This
stop bottoms on a machined platform in the
cylinder. In some cases, the stop on the power-
valve may wear, allowing the power-valve to
move further into the cylinder and contact the
piston.
Remedy:
15MM
The power-valve has been improved to elimi-
BUSHING
nate the possibility of contact with the piston.
There is now an additional stop to limit power-
valve travel. The bushing that the power-valve CURRENT POWER-VALVE STOP
shaft rides through is now 2.3mm taller. When
the power-valve is at the bottom of its travel
(fully closed) the lever that operates the power- NEW -03 POWER-VALVE
valve now contacts the top of the bushing pro- 14MM
BOLT
viding an additional limit for power-valve
movement. The bolt that holds the power-valve
bushing in place is now longer due to the addi-
tional height of the bushing. When replacing a LONGER
BOLT
power-valve on a unit that has had a failure,
use the latest power-valve assembly. The
longer bolt must be used with the new power-
valve for it to be properly secured.
17.3MM
BUSHING
LEVER NOW CONTACTS BUSHING

FOR ADDITIONAL POWER-VALVE STOP
Old Part Number New Part Number Description Comment

66E-1131S-02-00 66E-1131S-03-00 Valve Ass’y. For models that originally
came with an 02 or earlier
90109-05M95-00 90110-05008-00 Bolt, Hex Head part , these must be replaced
as a set.
Model Application: 2001 XR1800 will use the -03 power-valve starting late in production. When
ordering replacement parts for one of these models, be sure to inspect old parts to determine if the
longer bolt will be required.
10-21
Parts List Correction XR1800
The parts list for the 2000 model XR1800 lists the incorrect part numbers for the meters and key
switch assembly. Some early lists also do not list the part number for the indicator assembly. Please
make note of these changes until updated listings are issued.
Quantity
Ref. # Part Number Description Used Comments
7 F0C-U8241-00-00 Fuel Gauge 1
22 F0C-U822N-00-00 Speedometer 1
25 F0C-U8245-00-00 Tachometer 2
27 F0C-U830B-00-00 Indicator Assembly 1
(27) F0C-U8131-00-00 Body, Light 1 Included with indicator assembly.
(27) F0C-U8132-00-00 Gasket, Light 1 Not shown separately on the
illustration.
(27) F0C-U8142-00-00 Lens, Light 1
(27) F0C-U8144-00-00 Cover, Light 1
(27) F0C-U8126-00-00 Lamp, Indicator 5
33 GP1-68037-00-00 Key, Switch Assy 2
10-22
Parts List Correction LS2000

Some versions of the parts list for the 2001 model LS2000 lists the incorrect part numbers for the
switches on the instrument panel, the key switch and the fuel gauge. Please make note of these
changes until updated listings are issued.
Quantity
Ref. # Part Number Description Used Comments
16 F0R-U8241-10-00 Fuel Gauge 1 No oil light
19 F0R-U8353-00-00 Switch Assembly (Stereo) 1
20 F0R-U8026-10-00 Switch Assembly, Light 1 Courtesy Light
21 F0R-U8029-00-00 Switch Assembly, Lights 1 Navigation Lights
22 F0R-U8022-00-00 Switch Assembly, Blower 1
23 F0R-U8012-00-00 Switch Assembly, Bilge Pump 1
24 F0R-U8011-00-00 Switch Assembly, Horn 1
25 GP1-68037-00-00 Key Switch Assembly 2
10-23
Problem: Based on the information you have collected,

start at the condition below that applies and fol-
Water in the bilge area is often present to a
low the steps for each:
small degree. Under normal conditions the
bilge system will rapidly remove this. If the 1. Towing the unit or running on only one of
amount of water present seems to be exces- two engines:
sive, use the steps below to diagnose and If the unit is being towed behind another
repair the problem. craft, discuss the method with the cus-
tomer. Sport Boats must be towed at
Remedy: trolling speeds only.
1. Collect the following information from the • At higher speeds the water flowing
customer: through the jet pump will enter the cool-
• Discuss with the operator when they ing water inlet and force water into the
noticed the water. Is it when sitting, engine. Without the engine running this
slow speed operation, high speed oper- can enter the cylinders and crankcase
ation or aggressive riding only? through the exhaust causing severe
• How much water is present? engine damage.
• Was the bilge pump turned on? 2. Water leaks while sitting:
• Has the water been noticed at every After performing a visual inspection, posi-
outing? tion the unit so it can be inspected from the
• Is the water cool or warm? top and bottom. Remove the cleanout tray
• Is the unit used for skiing or towing? so that the bilge area can be inspected.
• Is the unit being towed behind another • Put enough water in the bilge area to
craft? cover the jet pump, bilge area compo-
2. Visual inspection nents and fittings. Watch for water leak-
• Perform a quick visual inspection ing out.
before lake testing the unit. • Inspect the exhaust thru hull mounting,
• Inspect the jet pump area, intake duct speedometer pickup mounting and
and cooling line hoses where they enter around the thru hull fitting and hose for
the hull for loose, damaged or missing the deck drain.
items. • Inspect the cleanout tray drain hose
• Inspect the hull for damage that could and the thru hull fitting it attaches to
result in a leak. 3. Cool water leaks while the unit is in use:
• Inspect the bilge pump for proper oper-
ation and debris clogging the inlet. The best way to test this is a lake test.
• Inspect the cooling hoses and bilge Testing on a flush attachment does not uti-
hoses for proper connections. lize the entire cooling system. Make sure
the engine compartment drains are in
3. Verify the problem
place to isolate any leaks in that area.
• If the information from the customer is
Remove the cleanout tray so the bilge can
inconclusive, verify the problem. be inspected. Run the unit and watch for
• Some conditions can be duplicated by
leaks. Inspect the following areas:
spraying or filling the unit with water. • Inspect all of the areas in step 2. In
Others will require running on a flush
some cases a leak may only show up
attachment or a lake test.
under the higher pressure or operating
conditions.
10-24

• Cooling water hoses from the thru hull 4. Warm water leaks
fitting to the engine. (loose connections Run the unit and inspect the following areas
or hose damage) • Cooling water hoses, pilot and bypass
• Flush hose and fitting. (loose connec- water hoses and fittings
tions, cracked fittings, loose or missing • Engine and exhaust gaskets
cap) • Exhaust hoses, connections and YSSS
• Drive shaft seals or hoses. (possible components
ski rope damage) 5. Aggressive riding, submerging the bow:
• Inspect the sealing of the gunwale Based on the information you have collect-
around its entire circumference for ed, start at the condition below that
gaps that could allow a leak. If a leak applies, and follow the steps for each:
is found, simply seal the area with a
marine grade silicone. There are conditions where due to a very
NOTE: Yamaha Sport Boats are not glued or aggressive riding style, the unit can take on
sealed at the bond line. The lower side of the water faster than the bilge pump will
gunwale is sealed to the hull so that water can- remove it. Caution the customer on improp-
not enter. Spraying water at the top of the gun- er operation, such as high speed use of
wale or at the bond line from inside the craft reverse. This is for trolling speed maneu-
will show a leak. This is normal. vering only. Make sure the bilge pump is
being turned on when ever the unit is in the
water, whether the engine is running or not.
10-25
Cleanout Hose Sealing
Symptom:
Remedy:
A small amount of water collects on the top of Early straight hose on LS2000
the cleanout plugs during operation. If the bot-
• Inspect the placement of the hose over the
tom of the hose from the cleanout tray to the
cleanout housing. If the alignment or latch-
housing is not properly sealed, this water may
ing holes are exposed below the hose or
leak into the bilge.
the hose clamp, this will need to be
Two situations may exist: repaired. If the hose cannot be positioned
to cover these holes, replace the hose with
• In early 2000 model LS2000’s, the hose the newer style, cut at an angle. Clean and
was cut straight across the bottom and dry the new hose and the housing. Remove
clamped in place. The hose may not have any flashing of the glue in this area that
completely covered the alignment or latch- many not allow the hose to fully seat.
ing holes for the cleanout plug.
• Later model LS2000 (2000 and 2001) have CAUTION:
an angled hose that is sealed in place. All Do not remove too much material as it may
XR1800’s also use the angled hose. If the weaken the mounting or cause a leak.
cleanout tray is removed for any reason,
the hose could become dislodged, break- • Glue the hose in place with a marine grade
ing the seal. silicone sealant. The hose clamp will not be
reused.
Later units and XR1800 with the angled hose:
• If a leak is found or the hose becomes dis-
lodged during a repair, remove the hose
and clean off the old sealant. Reinstall the
hose using marine grade silicone sealant.
HOSE MUST BE
BELOW THIS LEVEL
NO CLAMP USED
SEAL THIS AREA
10-26
Crankshaft Failure Diagnosis

Crankshaft failures occur in one of the many
A. Inspect the crankshaft for rust. Inspect the
following areas: lower rod bearing, upper rod
undamaged rod surfaces, mains and the
bearing, main bearings rod breakage or crank-
small end of the rod for pitting and evidence
shaft twisting. Lack of oil is generally not the
of rust.
cause of a crankshaft failure due to the fact that
if no oil is present, the piston will generally fail B. Inspect the other rod(s) for excessive play.
first. Most watercraft crankshaft failures are
C. Inspect the CDI unit for modification.
due to water damage.
FIGURE 1
Often, the clues for failures due to water are
subtle. The example in Figure 1 is an obvious
cause of rust, but an engine with a failed rod
bearing where on the surface it looks clean, is
not. The damage due to water often took place
a number of hours before the crank failure
occurred. This means water will generally not
be present when the technician starts to diag-
nose the failure. Often, the evidence will be on
the parts adjoining the cylinder where the fail-
ure occurred.
Lower Rod Bearing Failure
Lower rod bearing (big end) failure from water FIGURE 2
occurs when the water causes the bearing sur-
face to become pitted (see Figure 3). This pit-
ting creates a rough surface which in turn
wears the rod and rod bearing. Rust on a bear-
ing surface will often be a black pitting or look
like a shadow of the bearing due to the polish-
ing effect that the bearing has (see Figures 2
& 3). This can also take on a grayish appear-
ance after being run in this condition. Once the
bearing becomes loose at high rpm, the bear-
BLACK SHADOW
ing rollers will start to skid, because they lose IS FROM RUST
contact with one side of the outer race. When
the bearing skids, it becomes too hot and will
seize. This same thing can take place due to FIGURE 3
excessive wear.
Excessive rpm from a modified ignition can
also cause this type of failure. This can cause
the lower portion of the rod to stretch, again
causing distortion and the rollers to skid and
seize.
PITTING
FROM RUST
10-27
Crankshaft Failure Diagnosis (Cont’d.)
Upper Rod Bearing: Connecting Rod Breakage:

The upper rod bearing is often accompanied Rod breakage takes place for many reasons.
with a piston seizure. Excess heat from the pis- Most breakages are to due to no fault of the
ton dissipates into the rod and overheats the rod. If the engine hydro-locks due to fuel or
bearing. The lubrication requirements are water in the engine, the force will bend, twist or
much less for the upper bearing, since it only possibly break the rod. A rod can also break on
rocks and does not rotate fully. multi-cylinder engines due to a piston seizure
that continues to run. The crankshaft drives the
A. Inspect the bearing and rod for water dam- seizing piston (applying excessive force on the
age. rod) and breaking it. Excessive heat in the rod
B. Inspect the piston for signs of excessive (from a piston or bearing seizure) can cause
heat or seizure. the rod to overheat, lose its temper and break.
Main Bearings: A. Evidence of hydro-lock, water or fuel pres-

ent distorted or pushed out crankshaft
A main bearing failure is most often caused by seals.
water or debris damage from another or earlier
failure. Main bearings generally do not break or B. Inspect for piston seizure
seize, but typically get loose due to wear. This C. Inspect the connecting rod for evidence of
is due to the lower rotating speed of the bear- excessive heat.
ing rollers.
Crankshaft Twisting:
A. Inspect the bearing and rod for water dam-
age. Crankshaft twisting is most often a result of
hydro-lock. This can also be due to insufficient
B. Inspect for evidence of a previous failure. interference in the fit of the crankshaft compo-
nents. Also, a sudden driveline stoppage can
apply more force than the design of the crank-
shaft causing it to twist.
A. Evidence of hydro-lock
B. Damage to the jet pump bearings or
impeller
C. Modified engine
10-28
Erratic Power-Valve Operation
Symptom:
The power-valve may seem to operate errati-
cally, sometimes cycling on its own.
System Description:
The Power Valve System is controlled by a chip
in the servo motor The servo motor receives a
signal from the CDI unit much like a tachome-
ter signal. The processor in the servo motor
reads this signal, then operates the power-
valve based on the MAP stored in its control-
ling chip. The servo motor has power all the
time and operates based on engine rpm. After
the engine stops, a timer starts in the servo
motor processor. After a few seconds, the
processor will cycle the power-valve for its
CORROSION
cleaning cycle.
Cause:
The block connector for the servo motor may
have corrosion present. With corrosion in the
connector, voltage can short from the battery
side to the signal side simulating an ignition
signal. This will restart the “Engine Off” timer,
and the servo motor will again start a cleaning
cycle. Corrosion may also cause loss of the
signal from the CDI unit during normal opera-
tion, causing the servo motor to operate errati-
cally or not at all.
Remedy:
Clean or replace the servo motor connections.
Use dielectric grease to protect the connection
when reassembling.
10-29
Stereo Mounting LS2000 and XR1800
Symptom: XR1800 —
Under harsh operating conditions, the stereo The XR1800 has always used the stereo spac-
could come loose from its mount allowing the er for the factory installed stereos and the
stereo to fall. accessory installation kit contains this part.
Later 2001 model XR1800’s also have the
Remedy: updated support bracket installed. If you have
Two changes have been made to the mounting an XR1800 that is experiencing mounting
system for the stereo. problems, make sure the updated support
bracket is in place.
LS2000 — Support Bracket Installation:
An additional mounting plate (stereo spacer) 1. Mount the bracket to the wood block (lami-
has been used on the factory installed stereos nated into the underside of the dash) and
starting in the middle of the 2000 model year. to the chassis of the stereo.
This is used to ensure a tight fit into the glove 2. Align the bracket to the back of the glove
box mount. During the 2001 model year, the box. (Slight bending may be required for a
rear support strap was changed to a more rigid flush fit) Mark and drill the lower hole and
part that now mounts in two locations. When attach with a 1/4-20 x 3/4 screw and lock-
installing an accessory stereo, order and install nut.
these two new components. If you have an
LS2000 with a factory installed stereo that is Part No. Description
experiencing mounting problems, make sure F0R-U8169-00-00 Spacer, Stereo
the newest components are in place. The rear
F0C-U826C-00-00 Bracket, (Stereo)
mounting strap comes as a straight piece and
will need to be bent to shape. 90149-14SB3-00 Screw, 1/4-20 x 3/4 PTH
90185-14S00-00 Nut, 1/4-20 Nyloc
Support Bracket Installation:
1. Bend the bracket to the dimensions shown LS2000 Shown
in the following illustration.
2. Mount the bracket to the wood block lami-
nated into the port pod and to the chassis
of the stereo.
3. Align the bracket to the back of the glove
box. Mark and drill the lower hole and
attach with a 1/4-20 x 3/4 screw and lock-
nut.
LS2000 Shown
10-30
Stereo Mounting LS2000 and XR1800 (Cont’d.)
LS2000 (Bend to these dimensions.) XR1800 (Use as supplied.)
TOP TOP
5-1/4”
MOUNT AT
STEREO
STEREO MOUNT
MOUNT AT
GLOVE BOX
8-1/4”
MOUNT AT
GLOVE BOX
2”
10-31
XR1800 Seat Arm Pad Replacement
The arm pads (on the driver and passenger

seats for the XR1800) have been updated. The
new part has an additional clip added to better
secure the pads to the body of the seat. If a
seat arm pad requires replacement, modify the
seat using the following simple modification:
1. Remove the arm pad from the seat base.
2. Measure up from the edge of the arm pad
relief 3/4" and draw a line.
5. Be sure the pins are properly aligned.

Place a towel over the pad for protection,
then starting with the front, seat the pad
with a rubber mallet.
3. Draw a vertical line up from the existing

hole, intersecting your 1st line.
4. Drill a 1-1/2" hole centered over this mark.
NOTE: It is important that the pad is properly

installed the first try. If the plastic pins are
pushed into the holes a second time, they lose
some of their gripping power
Parts Information
Part No. Description
F0C-U375A-01-00 Pad, Seat 1 (port)
F0C-U375B-01-00 Pad, Seat 2 (stbd)
NOTE: When drilling the hole, do not let the
plug fall into the seat. This may be difficult to
remove and could cause a rattle. When pulling
the hole saw out, you can push on the plastic
plug (through the upper hole in the seat) to pre-
vent it from falling. Install the new pad by start-
ing the clip into the hole while aligning the
upper pins.
10-32
Carburetor Settings - 2001 Models
TECHNICAL TIPS
For information purposes, the factory has released the following list of carburetor settings:
NOTE: High and Low speed screw settings are for reference only. See the previous Tech Tip on
Carburetor Adjustment.
Model LST1200Z XRT1200Z

Model/
Engine ID F0R/66HV F0C/68Y
Carb 66H-21 66H-12 66H-13 68Y-021 68Y-022 68Y-023
Stamped Front Center Rear Front Center Rear
I.D. Carb Carb Carb Carb Carb Carb
Throttle Bore 44 mm 44 mm
Venturi OUT Vent 40 mm 40 mm
Bore IN Vent 10 mm 10 mm
Main Jet 1 2.0 mm 2.0 mm
Main Jet 2 #135 #117.5
High Speed Screw 3/4 1.0 3/4 1-1/4 1-1/8 1-3/8
Main Nozzle 3.2 mm 3.2 mm
Low Speed Jet #100 #95 #97.5 #87.5
Pilot Outlet 1.2 mm 1.2 mm
Low Speed Screw 1.0 7/8 1-1/8
Throttle Valve #130 #180
Bypass 1 0.6 mm 0.6 mm
Bypass 4 1.0 mm N/A
Valve Seat 1.2 mm 1.2 mm
Return Jet 0.5 mm 0.5 mm
Arm Spring
95 gr/Dull Silver 115 gr/Gold
Set Weight/Color
Arm Spring
16.1 mm 17.0 mm
Free Length

Model Year Pump Type Standard Impeller Part Number
EXT1100 ’96 ~ ’98 155mm Axial Flow 3 Blade Stainless 16° ~ 19° 63M-51321-A0-00
EXS1200 ’98 ~ ‘99 155mm Axial Flow 3 Blade Stainless 15.1° 66F-R1321-00-00
EXT1200 ’98 ~ ‘99 155mm Axial Flow 3 Blade Stainless 15.1° 66F-R1321-00-00
LST1200 ’99 ~ ‘01 155mm Axial Flow 3 Blade Stainless 15.1° 66F-R1321-00-00
XRT1200 ’00 ~ ‘01 155mm Axial Flow 3 Blade Stainless 15.6° 66V-R1321-00-00
10-33
Gelcoat Application and Color Code Charts - All Sport Boats
GELCOAT APPLICATION CHART

Year Model Hull Color Code Deck Color Code Hatch Color Code
1996 EXT1100U 1A 1A
Deck Stripe 2A 1A
1997 EXT1100V 1A 1A
Deck Stripe 2A 1A
1998 EXT1100W 6A 6A 6A
1998 EXS1200W 6A 6A 3A
1998 EXT1200W 6A 6A 4A
1999 EXS1200X 6A 6A 5A
1999 EXT1200X 6A 6A 5A
1999 LST1200X 6A 6A 6A
2000 LST1200Y 6A 6A 6A
2000 XRT1200Y 6A 6A 7A
Bow Cover 7A
2001 LST1200Z 6A 6A 6A
2001 XRT1200Z 6A 6A 8A
Bow Cover 8A
GELCOAT COLOR CODE CHART

Code Color Name Sher-Fab Part Number Sherwin Williams Part No.
1A Arctic White LLY5W-1 N/Z
2A Purple SF9701 N/A
3A Teal SF198E U7-60696
4A Red SF298E U7-60697
5A Blue TBA TBA
6A White SF498E U7-60694
7A Silver Crystal TBA TBA
8A Smoke Gray TBA TBA
10-34
Section 11
Sport Boat Technical Bulletins/
Tech Exchange Review
11
11-1
11-2
2001 WaterCraft Technical Update - Sport Boat Bulletins and Tech Exchanges
SPORT BOAT 3/29/00 SB2000-001
2000 MODELS
WaterCraft Technical Update Manual Revisions
The following is a list of revisions that need to be made in the Sport Boat section of the 2000 WaterCraft
Technical Update Manual (LIT-18500-00-2K).
Revisions
Page 8-8
The shape of the XR1800 Air Intake System and Exhaust System have changed on production mod-
els (see illustrations below for the correct shapes).
AIR INTAKE
SYSTEM
EXHAUST
SYSTEM
Page 9-1
Change the XR1800 Engine Model Code to 68Y.
Mark out the reference to reserve capacity. This unit has no reserve.
Page 9-3
Under Carburetor, change the following XR1800 engine specifications:
Change ID from 67X to 68Y.
Change pilot jet to value to #87.5.
Change throttle valve value to #180.
11-3
11-4
SPORT BOAT 3/29/00 SB2000-002
SPORT BOAT
Warranty Policies
The Yamaha Warranty and Y.E.S. Handbook (LIT-11760-00-95) provides both Motorsport and Marine
Warranty Policies and Procedures, as well as Yamaha Extended Service (Y.E.S.) Policies and
Procedures.
Specific details about each product line’s particular policies and procedures are not in the Yamaha
Warranty and Y.E.S. Handbook. Instead, specific information is provided in “Warranty Policies” Technical
Bulletins like this one for each Yamaha supported product line.
This makes finding information easier. When general Yamaha Warranty policies and procedure informa-
tion is needed, refer to the Handbook. When the policy is known but the specific product details are need-
ed, refer to this quick reference bulletin. This is also an advantage if a policy details changes. Specific
changes can be provided in a new version of this bulletin rather than having the Yamaha Warranty and
Y.E.S. Handbook updated each time.
LIMITED WARRANTY STATEMENT INFORMATION

See Yamaha Warranty and Y.E.S. Handbook, page 1-3 for more information.
Warranty Limited Warranty Statement
Model Period Remarks Part Number
Sport Boat Hull and Deck: Hull and deck LIT-18790-JB-96
(Jet Boat) Pleasure use: 5 years warranty against
Commercial use: 1 year major structural
defects only.
All other components:

Pleasure use: 1 year
Commercial use: 90 days
PRIMARY ID
The Primary ID is on a “PRI-ID” sticker inside the engine compartment. See the appropriate Owner’s or
Service Manual for exact location on each model.
PAGE 1 of 5
11-5
NOTE: The serial number part of the Primary ID label has an extra beginning “0” label which should
be ignored.
IGNORE
Example:
PRI-ID
MODEL XRT1200Y 0100101
F0C
PRIMARY ID
YAMAHA MOTOR CORPORATION, U.S.A.
ASSEMBLED IN U.S.A. FROM AMERICAN AND JAPANESE PRIMARY ID
COMPONENTS. F0C-100101
ASSEMBLE AUX ETATS-UNIS DE PIECES AMERICAINES ET
JAPONAISES
AUTHORIZATIONS
Warranty repairs* on on-warranty units require authorization only if the total repair cost exceeds the
following:
$750.00 or below Authorization not needed

$750.01 or above Call RTA for authorization
Total repair cost includes:

Warranty Y.E.S.
Parts YCS: Dealer cost + 25% for handling reimbursements Yamaha Suggested Retail
Mail-in Paper form: Dealer Cost + 10%
NOTE: There is a maximum handling
reimbursement of $150.00.
Labor Flat rate time at approved shop labor rate Flat rate time at approved shop labor rate
+ any extra labor claimed and authorized + any extra labor claimed and authorized
*See page 7-5 of the Yamaha Warranty and Y.E.S. Handbook if an accident or fire occurred.
REIMBURSEMENT POLICY
Warranty labor reimbursement is initially set at 80% of your approved labor rate. Participation in
Yamaha technical training programs increases reimbursement.
Base Reimbursement 80% of approved hourly rate

Attendance at annual Service Seminar +10%
Attendance at Yamaha regional school +10%
To get or maintain the full 100% reimbursement, both the annual Service Seminar and technical
training course must be attended each two years, unless Yamaha waives part of the requirement.
See the annual Technical Training bulletin for more information.
PAGE 2 of 5
11-6
WARRANTY AND Y.E.S. PHONE NUMBERS

Department Phone Number Purpose Handbook Ref.
Warranty 1-800-227-5963 Registration Questions Chapter 5
Labor Rate Questions Chapter 1
Recall Questions Chapter 8
Concealed Shipping Damage Authorization Chapter 3
Warranty FAX (714) 761-7303 FAXing (rather than mail):
- Registration transfer or correction
documents Chapter 5
- Warranty Appeals Form Chapter 10
- Other Warranty or Y.E.S. documents
Regional Technical See “Toll-Free - Warranty Authorizations Chapter 7
Advisor Service Assistance” - Y.E.S. Authorizations Chapter 7
Technical Bulletin - Out-of-Warranty Authorizations Chapter 7
- Customer Relations Assistance Chapter 7
- Technical Assistance
Y.E.S. 1-800-227-5963 Y.E.S. Questions (except authorizations) Chapters 2, 5
Customer Relations 1-800-635-0736 - Return calls to Customer Relations
(Dealer Calls) - Accidents or fire-related authorizations Chapter 7
Customer Calls:
- Customer Relations 1-800-962-7926 - For customers who insist on talking to Chapter 7
Yamaha instead of letting you help.
- Any recall questions Chapter 8
Distribution 1-800-537-3835 Carrier-Related (visible) Shipping Damage Chapter 3
Assistance
Technical (714) 761-7464 Replacement copies of:
Publications - Technical Bulletins (current)
- Flat Rate Tables (current)
WARRANTY AND Y.E.S. LITERATURE

Sport Boat-Only Forms
Jet Boat Predelivery LIT-18161-00-97 See page 4-2.
Checklist Checklist for procedures required before
delivery to customer.
PAGE 3 of 5
11-7
Warranty and Y.E.S. Forms
Warranty and Y.E.S. Handbook LIT-11760-00-95 Covers warranty and Y.E.S. for all products.
Warranty Request Worksheets LIT-11801-01-02 See Chapter 6.
(15/pkg.) Fill out before submitting warranty or Y.E.S. claim on
YCS.
Warranty Request Forms LIT-11791-01-00 See Chapter 6.
(10/pkg.) Mail-in warranty or Y.E.S. claim form if YCS is not
used.
Transfer of Owner Registration LIT-11790-07-83 See page 5-7.
(10/pkg.) Update registration records with new owner and
transfer any warranty or Y.E.S. coverage.
Warranty Registration LIT-11792-00-00 See page 5-6.
Correction Form (10/pkg.) For correcting warranty or Y.E.S. registration errors.
Warranty Return Envelope LIT-11784-00-01 Pre-addressed envelopes for mailing documents to
(10/pkg.) the Warranty Department.
Warranty Status Chart Pads LIT-11790-00-00 See Chapter 10.
(10/pad) Track status of warranty and Y.E.S. claims.
Warranty Parts Tags LIT-11790-02-00 See page 9-1.
(50/pkg.) Identify parts claimed on warranty requests.
Warranty Document ID Form LIT-11791-00-04 See page 1-7.
(10/pkg.) Identify any supporting documents sent to Warranty.
Recall Reimbursement Request LIT-11790-00-97 See page 8-2.
(5/pkg.) Mail-in form to request reimbursement for Factory
Modification Campaign if YCS is not used.
Warranty Labor Rate Change LIT-11791-02-95 See page 1-5.
Request Request setup or change of the labor rate amount
used to calculate warranty reimbursement.
Service Schedule Pad LIT-11561-00-96 Used to schedule service work. Includes column for
(25/pkg.) warranty request information.
Warranty Error Notification LIT-11791-01-2K See page 10-3.
Explanation Booklet used only if registration and warranty requests are
mailed in on paper forms and errors are present.
PAGE 4 of 5
11-8
Y.E.S. Only Forms

Sample Y.E.S. Contract for LIT-11580-00-35 See page 2-2.
Sport Boat (10/pkg.) Given to each customer at the time of sale. The
actual “live” contract is mailed to the customer
separately by Yamaha.
Y.E.S. Plan Registration Card LIT-11580-00-04 See page 5-5.
(20/pkg.) Used to register Y.E.S. coverage sold after unit
purchase (not needed if YCS is used).
Y.E.S. Lienholder Information LIT-11580-00-08 See page 5-4.
(5/pkg.) Used when lienholder requests additional
documentation about the Y.E.S. coverage.
Y.E.S. Used Unit Registration LIT-11580-00-19 See page 5-5.
(10/pkg.) Used to register Y.E.S. coverage on a used unit sold
from dealer inventory.
Y.E.S. Plan Request to Cancel LIT-11580-00-10 See page 2-5.
(20/pkg.) Required for cancellation of Y.E.S. Plan.
Y.E.S. Hang Tags LIT-11580-00-16 For product display. Lists main customer benefits of
(10/pkg.) coverage for Motorcycle, ATV, Riva, Snowmobile,
WaveRunner, and Sport Boat.
Y.E.S. Price Tags LIT-11580-00-17 For product display. Promotes Y.E.S. coverage with
(20/pkg.) convenient monthly payment information.
Factory Service Brochures LIT-11580-00-18 Sales brochure for Y.E.S. with features and benefits.
(20/pkg.) for Motorcycle, ATV, Riva, Snowmobile, WaveRunner,
and Sport Boat.
Florida Y.E.S. Forms

Florida Y.E.S. Plan Highlights Call Y.E.S. See page 2-2.
and Contract A “live” contract required when Y.E.S. is sold in
Florida.
Florida Y.E.S. Return LIT-11580-FL-02 Used to mail contracts to Yamaha.
Envelopes (10/pkg.)
11-9
11-10
SPORT BOAT 3/29/00 SB2000-003
TOLL-FREE SERVICE ASSISTANCE

Phone Numbers
Below are the phone numbers needed for any ser- Dealers (in the various regions shown below)
vice-related assistance. All main assistance num- should call the appropriate region for technical
bers are toll-free. Y.E.S. Authorizations will be assistance.
issued from the affected regional offices.
NORTHERN REGION
WA
MT
ND CUDAHY OFFICE
NORTHERN REGION
MN ME
WI
SD VT
NY NH
OR MI
ID WY MA
IA CT
NE
PA RI
IL IN OH
NJ
NV UT MD
CO KS MO
DE
WV
CA
KY VA
TN NC
OK
AZ NM
AR
GA SC
MS AL
WESTERN REGION
LA
CYPRESSWESTERN
OFFICE REGION TX
FL
AK
HI
SOUTHERN
SOUTHERNREGION
REGION
KENNESAW OFFICE
REGIONAL ASSISTANCE NUMBERS
RTA ASSISTANCE North South West

Tech. Assistance
Warranty Authorizations
Customer Relations Authorizations
Y.E.S. Authorizations
} 1-800-879-0078 1-800-969-9701 1-800-533-4807
Fax Tech: 414-769-9084 770-420-6105 714-761-7303
Warranty/Y.E.S. Administration: 1-800-227-5963

Customer Calls:
Hidden Crate Damage:
Customer Relations Department: (Dealers only)
1-800-962-7926
1-800-227-5963
1-800-635-0736
} ALL REGIONS
PAGE 1 of 3
11-11
RTA ASSISTANCE (TOLL-FREE)
Your Regional Technical Advisor (RTA) is available to help you with the following:
• Technical Assistance - Be sure to check your service library first. Most service problems dealers
encounter are covered in service literature in a Tech Exchange, Technical Bulletin, or seminar pub-
lication. If you still need help solving a technical problem, call your RTA.
• Authorizations - If you need an authorization for an in-warranty repair, out-of-warranty customer

assistance, or Y.E.S., call your RTA.
• Customer Relations Assistance - If you are requesting assistance for a customer, call your RTA.
RTA Assistance: Northern Region 1-800-879-0078 M~F 8:30 am~5:00 pm Central Time
Southern Region 1-800-969-9701 M~F 8:30 am~5:00 pm Eastern Time
Western Region 1-800-533-4807 M~F 8:30 am~5:00 pm Pacific Time
FAX TECH
Many busy dealers enjoy the convenience of Fax Tech for technical assistance requests. Prepare a
Photocopy of a Warranty Authorization Fax form (see next page) and fax it to your RTA. The RTA will
research the problem and send you an answer back - all while you continue with other business at your
dealership.
Fax Tech: Northern Region 414-769-9084 M~F 8:30 am~5:00 pm Central Time
Southern Region 770-420-6105 M~F 8:30 am~5:00 pm Eastern Time
Western Region 714-761-7303 M~F 8:30 am~5:00 pm Pacific Time
WARRANTY/ Y.E.S. ASSISTANCE (TOLL-FREE)
Call the Warranty Department if you need assistance with any of the following:
Labor Rate; Recalls; Transfer of Ownership; Unit Registration; Yamaha Extended Service; Hidden Crate Damage
Warranty Administration: 1-800-227-5963 M~F 8:30 am~5:00 pm Pacific Time
For assistance with carrier-related (visible) shipping damage, call the Distribution Department:
Distribution Department: 1-800-537-3835 M~F 8:30 am~5:00 pm Pacific Time
CUSTOMER RELATIONS ASSISTANCE (TOLL-FREE)
Normally, call your RTA to request assistance with a customer relations problem. However, if you have
been unable to help and the customer wants to call Yamaha, give him/her the toll-free customer num-
ber:
All Customer Calls: 1-800-962-7926 M~F 8:30 am~5:00 pm Pacific Time
If a customer informs you that he/she has contacted Yamaha Customer Relations directly, or you need
to report an accident that allegedly may have been the fault of the product, call the Customer Relations
Dealer hotline:
Dealer Hotline: 1-800-635-0736 M~F 8:30 am~5:00 pm Pacific Time
PAGE 2 of 3
11-12
KENNESAW, GA CYPRESS, CA CUDAHY, WI

(770) 420-6105 (714) 761-7303 (414) 769-9084
11-13
11-14
SPORT BOAT 6/09/00 SB2000-004
2000 MODELS
Sport Boat Primary ID Numbers & Service Literature
This bulletin contains a comprehensive listing of Service Literature Part Numbers for 2000 models.
If the service literature used in prior years is still current, the literature part number will still be listed,
but “Same as . . .” will appear in the appropriate Manual column.
Production started with the numbers listed below.
Model Actual Starting Primary Owner’s Assembly Service

Model Name Displ. I.D. Number Manual Manual Manual
XRT1200Y XR1800 1176 F0C-000101 LIT-18626-03-92 N/A LIT-18616-02-25
LST1200Y LS2000 1131 F0R-100101 LIT-18626-03-91 N/A LIT-18616-02-06 (Main)
Same as
LST1200X
LIT-18616-02-23 (Suppl.)
Other Publications Part Number

Limited Warranty Statement* LIT-18790-JB-96
Jet Boat Y.E.S. Sample Contract LIT-11580-00-35
1997-1999 WV/JB Service Data Booklet LIT-18571-SD-99
Jet Boat Poster Set LIT-18140-SB-2K
2000 Jet Boat Product Brochure LIT-18116-SB-2K
2000 Jet Boat Features & Benefits Video VID-18199-SB-2K
LS2000 TV Commercial Video (Beta Format) VID-18199-SB-00
2000 Jet Boat Flat Rate Manual LIT-18750-SB-2K
11-15
11-16
SPORT BOAT 8/04/00 SB2000-005
XR1800 (XRT1200Y)
Dash Assembly Replacement
XR1800 dash components have a modern, luxury look that is highlighted by a vinyl covering. However,
on affected units, the vinyl may separate from its backing, adversely affecting the appearance of the
boat. Improved dash components are now available that were manufactured with a new process for a
quality finish. To ensure the highest customer satisfaction possible, dash components, on affected
units, should be replaced whether or not the vinyl has begun separating. This bulletin will explain how
to identify and replace affected components, as well as the proper steps required to obtain reim-
bursement.
Inspect: All affected units for the new dash components.
Modify: Any unit in the affected range with the older dash components, whether or not the vinyl
is separating.
Parts
Required: Yes. Order the parts necessary to repair any affected unit.
XRT1200Y: F0C-000101 ~ F0C-000348
1. Disconnect the battery leads.
2. Remove the two hex nuts, lock washers and

flat washers holding the center cover in
place. Remove the center cover.
PAGE 1 of 10
11-17
3. Remove the three screws, from the back of 5. Remove the panel covering the harnesses
the steering wheel (see photo below), hold- on the left side of the meter panel (see photo
ing the steering wheel cover in place. below).
Remove the cover.
SCREWS
6. Remove the choke knob set screws, choke
4. Remove the nut and washer holding the knobs, friction nuts and the choke cable
steering wheel in place (See photo below). retaining nuts (see photo below). Slide the
Remove the steering wheel by pulling cables out of the meter panel and let them
sharply back on the wheel. You may need to hang at this time. Mark the cables for instal-
strike the shaft with a soft faced hammer, lation (e.g., port/stbd).
while pulling back on the wheel, to break it
loose.
27~36 Nm (19.5~26 FT LB)
LOCTITE 242
NOTE: Be careful not to lose the key that posi-

tions the steering wheel on the shaft. The key
way will be in the 6 o'clock position when
installing the steering wheel.
PAGE 2 of 10
11-18
7. From behind the dash, disconnect the three

block connectors leading to the meter panel
and the three wire connector (purple, gray,
black wires) at each key switch (see photo
below). Remove the zip tie securing the har-
nesses to each other. Remove the key
switches and let them hang.
NOTE: During re-assembly, note the three wash-

ers (A) on the lower mounting studs (see photo
above) go between the meter panel and the
mount.
11. Remove the wiring from the meters.
8. Disconnect the courtesy light at the connec- 12. Remove the nuts holding the breakers to the
tor near the lamp, and free the wires back to meter panel.
the meter panel. Remove the hose from the
back of the speedometer 13. Remove the switches by depressing each
locking tab and working the switches out the
9. Open the starboard windscreen for access to front of the panel. The switches can then be
the upper mounting screws (see photo separated and fed back through the panel
below). Working from below, remove the without removing the wiring.
three upper nuts and washers, then the nuts,
lock washers and flat washers from the lower
3 mounting studs. Remove the three upper
mounting screws.
MOUNTING SCREWS
NOTE: For easier installation, leave the wires
connected to the breakers and switches.
10. Starting from the left, pull the meter panel

away from the mount. Remove the instru-
ment panel and place it on a soft cloth for
protection.
PAGE 3 of 10
11-19
14. Remove the two screws holding the indicator 15. Remove the meters and indicator lens (see
panel socket (see photo below). Remove the illustration below) and install them into the
panel, switches, harness assembly and new instrument panel assembly.
breakers as a set.
PAGE 4 of 10
11-20
NOTE: Make sure to check meter alignment 17. Reconnect all wiring to the meters and install
before tightening the meters. You can use the the indicator panel socket. Secure the IPA
vertical line of the panel for a reference (see controller to the instrument harness. (Refer to
photo below). This line is vertical when the panel the wiring diagrams on page 10).
is installed.
IPA
TIE
NOTE: Use Loctite 242 on the meter mounting

16. Install the breakers and switches into the nuts.
meter panel. Note the proper order of the
switches. 18. Temporarily connect the panel and the bat-
tery. Test all lights and meters before
installing the panel.
19. After a successful test, disconnect the bat-

tery and panel wiring. Set the meter panel in
place. Hold the upper edge of the meter
panel assembly tight against the lip of the
dash mount. Due to manufacturing changes
in these parts, the mounting holes may not
line up. If not, mark the new mounting loca-
tions, remove the meter panel and drill the
new mounting holes. Install the new meter
panel using Loctite 242 on the mounting
NOTE: Place masking tape on the dash surface screws.
around the breaker retaining nuts to protect the
finish when tightening the breakers (see photo
above).
PAGE 5 of 10
11-21
20. Mount the key switches in the meter panel. 22. Connect the wires behind the meter panel.
Clean the area above the key switches with Loop the harnesses, except the key switch
isopropyl alcohol and install the new labels wires, up into the hollow of the dash and
(see photo below). secure it on each side to the main dash har-
ness (see photo below). Loop the key switch
wires in the same fashion, and tie them
above and below the connectors to the other
harnesses. Now, connect the courtesy light
wires.
NOTE: Be sure the key switch plate (behind the

meter panel) is properly positioned so the keys
point in the proper direction. If not, turn the plate
over. SECURE HERE
21. Attach the speedometer hose and install a

zip tie to secure it (see photo below). 23. Reinstall the harness cover panel, steering
wheel and steering wheel cover. Next, rein-
stall the choke cables.
NOTE: Place masking tape on the dash surface

(around the choke cable retaining nuts) to protect
the finish when tightening the cables.
24. If the unit is equipped with the optional

stereo, disconnect the stereo connector,
remote control connector and antenna lead
at the back of the stereo. Remove the rear
mounting strap from the stereo and slide the
stereo out using the special tools provided
with the stereo (see the Kenwood Operator’s
Manual for details). Straighten the mounting
tabs on the mounting shell and remove it.
PAGE 6 of 10
11-22
25. Disconnect the wires to the accessory outlet 27. Remove the left dash panel and set the new
and remove the outlet and breaker (see one in place. Hold the upper edge of the
photo below). glove box assembly tight against the lip of the
dash mount. If the mounting holes do not line
up, mark the dash mount, remove the glove
box and drill the new mounting holes.
28. Reverse the procedure to finish the left dash

panel replacement.
NOTE: Use Loctite 242 on the dash panel

mounting nuts.
29. The Center Dash panel needs to be drilled to

accept an additional screw to hold it in place.
Protect the panel with masking tape.
NOTE: When reassembling the wires to the Measure 1'' back from the leading edge of
accessory outlet, be sure the polarity is correct. the panel and mark the panel on the tape
The terminals are each marked with a "+" or "-". (see photo below). Measure in from each for-
The Purple/Red wire goes to the "+" (positive) ward tip (equal distance) to mark the center.
terminal. Place the panel over a block of wood and
using a 7/32'' bit, drill a hole at the mark.
26. Remove the three upper mounting screws,
nuts and washers for the left dash panel
(glove box assembly) and the two lower
mounting nuts, washers and lock washers
(see photo below).
MOUNTING SCREWS
PAGE 7 of 10
11-23
30. Press the panel in place and align it 31. Install the new Center Dash panel by press-
between the two sides of the dash. Mark the ing it firmly in place and securing it with the
hole location on the fiberglass dash mount. black phillips head screw, flat washer and
Remove the panel and using the same lock nut (see photo below).
7/32'' bit, drill the dash mount (see photo
below).
CAUTION:
Do not overtighten the screw or the panel
may be distorted or damaged.
PAGE 8 of 10
11-24
The new style dash components can be identified by their textured surface and rounded corners. The
older components have a smooth surface, sharper edges and a seam running right to left across the
top of each piece (see photos below).
Old Style New Style
Order the following replacement parts for each unit to be repaired.

Description Part Number Quantity Dealer Cost (Each)
Panel Meter, Twin F0C-U8223-01-00 1 $325.96
Cover, Center F0C-U5554-01-00 1 $ 42.42
Glove Box Hatch Assy F0C-U1708-01-00 1 $221.50
Indicator, Key Switch F0R-U4144-00-00 2 $ 0.84
Screw, #10-24 x 1-3/4'' PTH Black 90149-10SB7-00 1 $ 0.20
Washer, 1/4'' Flat 90201-14S00-00 1 $ 0.04
Nut, 10-24 Locking 90185-10S00-00 1 $ 0.04
Zip Tie 6" (Speedometer Hose) 90601-200U1-00 1 $ 0.04
Zip Tie 8" GP1-U7253-00-00 5 $ 0.05
The repair of all affected units is authorized regardless of warranty status. To receive credit for parts
and labor after completion replacement of the dash components, submit a standard Service-Per-
Bulletin Warranty Request. The labor allowance is 2.3 hours using the Problem Code 90PE.
For YCS Dealers, refer to the YCS Operator's Manual page 4-4 and 4-5 for instructions to enter your
on-screen request.
PAGE 9 of 10
11-25
METER WIRING (REAR VIEW)
SWITCH WIRING (REAR VIEW)
PAGE 10 of 10
11-26
SPORT BOAT 8/04/00 SB2000-006
XR1800 (XRT1200Y)
Quality Assurance Inspection
In our continuing effort to maintain the highest possible quality and customer satisfaction, there are
some items on the 2000 Model XR1800 that require modification. The following areas relating to the
quality of the fit and finish have been identified on the XR1800 Sport Boat:
- Securing Bow Area Wiring

- Windscreen Inspection/Adjustment
- Glove Box Seal Replacement
- Seat Pivot Adjustment
- Clean-out Hatch Switch Inspection/Reinstallation
- Hand Grip Cap Reinstallation
The modifications described in this bulletin are to be performed to any sold or unsold units. This bul-
letin describes the necessary steps to perform these modifications and how to obtain reimbursement.
Inspect: All affected units for evidence of the modifications having been performed.
Modify: Any unit in the affected range that has not been previously modified.
Parts
Required: Order the parts necessary to repair any affected unit.
XRT1200Y: F0C-000101 ~ F0C-000651

F0C-000663 ~ F0C-000685
PAGE 1 of 7
11-27
Preparation
Secure the boat in a suitable work area.
11/2''
Bow Area Wiring
1. Under the bow cover area, disconnect the
courtesy light. Remove all of the tie wraps
securing the courtesy light, bow light and
antenna wiring to the white wire hangers.
2. Remove all of the white wire hangers and

clean any remaining glue residue from the
bow cover.
Stereo Harness and Antenna Wire
Tie Wrap Location
3. Mark the location for mounting each tie wrap (Above Glove Box w/Tie Wrap Pointing Down)
(refer to the following photos on this page
and page 3).
NOTE: Locate each mounting hole 1'' down from

the underside of the bow cover.
7'' 4''
7''
5'' 71/2'' 71/2''
1''
BACK
1'
FROM
CROSS Courtesy Light and Antenna Wire Tie Wrap
BRACE
EDGE. Locations (Starboard Side)
8''
Antenna Wire Tie Wrap Locations
(Port Side)
1''
10''
10''
10'' 10''
Bow Light Wire Tie Wrap Locations
(Starboard Side)
PAGE 2 of 7
11-28
6. Continue running the antenna to the port

side, tying it loosely at each tie wrap. The end
of this antenna pole is to be at a hanger so it
1'' will not hang down. Adjust the wire position
as necessary and tighten all the tie wraps
(see photo below).
10'' 7'' 7''

Bow Light and Courtesy Light Tie
Wrap Locations (Cont’d.)
4. Predrill each mounting hole using a 1/8'' drill

bit. Then, install a tie wrap in each hole with
the tie wrap pointed up from the screws.
5. Start with the antenna wire. Tie it loosely to 7. Attach the end of the wrapped harness to the
the first tie wrap on the port side of the cour- new tie wrap above the glove box. Loop the
tesy light. The “T” connector should be just to end of the antenna with the loose stereo har-
the starboard side of the tie wrap, with one ness and secure these to the wrapped har-
pole of the antenna going to the starboard ness above them (see photo below).
side and the other pole following the main
lead back to the port side (see photo below.)
“T” CONNECTOR
NEW
SECURE TO
HARNESS TIE WRAP
PAGE 3 of 7
11-29
8. Starting at the bow light, run the wires 10. Secure the courtesy light wires and the
through the split loom and down the right remaining antenna pole with the tie wraps
side of the under bow area till the cross brace installed on the front aft side of the cross
is reached. Secure this loosely with the tie brace. At the point they intersect the bow light
wraps as you go (see photo below). wires, include the antenna and courtesy light
wires in the split wrap (see photo below).
NOTE: The wires should fit in the recess

between the deck and bow cover with the tie 11. Continue both sets of wires in the split wrap
wraps pointing up (see photo below). until they reach the connectors behind the
dash. Be sure all the wires are free of slack
then tighten each tie wrap. Secure the split
wrap bundle to the main harness (behind the
meter panel) and tie any extra wire to the
meter panel harnesses.
SECURE WITH
TIE WRAP
9. Go back to the front and tighten the tie

wraps. Be sure there is no droop in the wires.
Windscreen Inspection/Adjustment
1. Inspect each windscreen for three items:

- Remnants of the plastic shipping protector
- Proper latching
- Adjustment.
2. If there is plastic wrap left around the latch,

remove the latch assembly, clear the wrap
away and reinstall the latch.
PAGE 4 of 7
11-30
11-31
8. Pull each corner loose and glue the corners 2. Measure the set height of the switch and
together using Super Glue or an equivalent. adjust to 1/2” (12.5mm), if necesary.
Hold the pieces together until the glue sets.
1/2'' (12.5mm)
9. Adjust the position of the packing as neces-
sary, then press it firmly in place.
Seat Pivot Adjustment
1. Loosen the pivot adjustment handle and the

locking nut below it until each is loose.
2. Using light pressure, grasp the seat and gen-

tly rock it while inspecting the seat slide for
movement on the pedestal.
3. After the switch height is set, reach through
NOTE: There will be some movement at the slide the inspection hole and pull a few inches of
mechanism. Do not mistake this for movement at the slack in the switch wiring out through the
the pivot. hole. This will keep the switch from falling
down when it is removed.
3. Tighten the pivot adjustment locking nut until
the rocking movement is gone. Tighten the 4. Remove the top nut and pull the switch out
handle until it seats, then tighten an addition- through the inspection hole, being careful not
al one turn (see photo below). to rotate the lower nut. Apply a drop of Super
Glue (or an equivalent) to the lower nut at
each flat side of the switch. Rotate the nut 1/4
turn, then back to its original position to dis-
tribute the glue.
5. Reinstall the switch and install the top nut fin-

ger tight. Apply a drop of Super Glue to the
flat sides of each switch (see photo below).
4. Sit in the seat and test that the seat pivots

properly and that the locking pin engages in
both the forward and rear facing positions.
5. Repeat steps 1~4 above for the other seat.
Cleanout Hatch Switch Inspection/ APPLY SUPER GLUE AT THESE FLAT SIDES
Reinstallation
CAUTION:
1. Open the cleanout hatch and remove the Do not allow any of the Super Glue into the
black inspection plug below the switches, plunger area of the switch. If this occurs, the
switch will need to be replaced.
PAGE 6 of 7
11-32
NOTE: Due to Super Glue being an anaerobic- Hand Grip Cap Reinstallation
type chemical, when used in this manner, will
require 24 hours to reach a proper cure. 1. Remove each cap that covers the mounting
bolt for the passenger hand grips. Apply a
6. Holding the switch through the inspection few drops of Super Glue (or equivalent) to
hole, torque the top nut to 25 in-lb. Re-check each cap and reinstall as shown in the photo
the adjustment. below.
7. Repeat steps 2~6 for the other switch, then

reinstall the inspection plug.
8. Start each engine and open the hatch to test

that the engine stops and will not re-start with
the hatch open.

Pipe, Wiring 1 (6’x3/8'' Split Loom) F0C-U8271-00-00 1 $1.96
Screw, #8 x 3/4'' PPH 90167-08S12-00 15 $0.04
Clamp, Cable (Tie Wrap 8'' with Eye) 90601-200U4-00 18 $0.05
Packing, Glove Box F0C-U266C-00-00 1 $2.08
The repair of all affected units is authorized regardless of warranty status. To receive credit for parts
and labor after completion, submit a standard Service-Per-Bulletin Warranty Request using Problem
Code 90PG. The labor allowance is 1.5 hours.
For YCS Dealers, refer to the YCS Operator’s manual (pages 4-4 and 4-5) for instructions to enter your
screen request.
11-33
11-34
SPORT BOAT 10/03/00 SB2000-007
2000 and 2001 MODELS

Trailer Warranty Policies
Trailers and trailer components are warranted by their manufacturers. The 2000 and 2001 model Sport
Boats use a Shoreland'r trailer that is manufactured by Midwest Industries Inc. The trailer manufactur-
er can be identified by the VIN label located on the inside of the left frame rail, towards the front of the
trailer.
The trailer winch is warranted separately by the winch manufacturer, Dutton-Lainson. Tires are war-
ranted by Goodyear. This bulletin explains these warranty policies and provides information on who to
contact.
Parts requests, warranty related questions or other trailer related questions should be directed to the
trailer manufacturer for all components except the winch and tires.
Trailer information contact:

Midwest Industries, Inc.
Ida Grove, Iowa 51445
Phone Number (712) 364-3365
Trailer Winch information contact:

Dutton-Lainson Company
Hastings, Nebraska 68902-0729
Customer Service Phone Number
1-800-569-6577
or at dutton-lainson.com
Goodyear Tire information contact:
Nearest Goodyear Tire outlet
or
Goodyear Assistance Center
Phone Number 1-800-321-2136
or write to:
Goodyear Consumer Relations Department
1144 East Market Street
Akron, Ohio 44316-0001
PAGE 1 of 7
11-35
Warranty Terms
The text of the trailer, trailer winch, and tire warranty statements are included in this bulletin.
• The Shoreland’r Trailer has a One Year Basic Limited Warranty and a Five Year Fabricated Part &
Frame Warranty.
• The Dutton-Lainson Trailer Winch has a Limited Three Year Warranty on most 2000 models. Late
2000 models and all 2001 models have a Limited Five Year Warranty. Check the warranty docu-
ments supplied with the trailer to see which coverage is provided.
• The Goodyear tire warranty provides no-cost replacement during the first 10% of useable tread-
wear if the tire does not deliver satisfactory service due to a workmanship or material related con-
dition, and pro-rated replacement for the balance of the useable treadwear.
To meet dealer obligations under the federal Magnuson-Moss Warranty Act to have the warranty state-
ment available for public inspection, you can either make copies of the warranty statements included
in this bulletin or you can request copies directly from the manufacturer. You should be sure each trail-
er purchaser is provided with the limited warranty statements along with all other literature for the cus-
tomer provided by the manufacturer, such as the Ownership and Operator’s manual.
Warranty Claims
If repairs are necessary under the terms of either warranty, contact the manufacturer at the address,
phone number or web site listed above. Please have Model, VIN, Part and Problem Descriptions ready
to provide as necessary. The manufacturer will instruct you on how to obtain parts or warranty claim
procedures. Do not use YCS Warranty Claim Entry or a Yamaha Warranty Request form for trailer or
trailer winch claims.
PAGE 2 of 7
11-36
MIDWEST INDUSTRIES, INC. “LIMITED 5 YEAR WARRANTY”

FOR SHORELAND’R BOAT AND PWC TRAILERS
Your ShoreLand’r® Limited Warranties
During the terms of the Limited Warranties on your ShoreLand’r trailer, Midwest Industries, Inc. (hereafter
referred to as “Midwest”) covers the cost of all parts and labor needed to repair or replace any Midwest supplied
item (except tires) that proves defective in material, workmanship or factory preparation. These repairs or
replacements (parts and labor) will be made by your dealer at no charge using new or manufactured parts.
Your Legal Rights Under Midwest’s Limited Warranties
All of the midwest Limited Warranties stated in this booklet are the only expressed written warranties made by
Midwest applicable to ShoreLand’r trailers. These Limited Warranties give you specific legal rights and you may
also have other rights which vary from state to state. You may have some implied warranties, depending on the
state in which your trailer is registered. For example, you may have:
1. An “implied warranty of merchantability” (that your trailer is reasonably fit for the general purpose for which
it was sold);
2. An “implied warranty of fitness for a particular purpose,” (that your trailer is suitable for your special purposes;
if your special purposes were specifically disclosed to Midwest itself (not merely to the distributor or dealer)
prior to purchase.
These implied warranties are limited, to the extent allowed by law, to the time period covered by the written
warranties set forth in this publication.
Some states do not allow limitations on how long an implied warranty lasts, so the above limitations may not apply
to you.
Subsequent Buyer/Owner
The Midwest ShoreLand’r Warranty is extended only to the first buyer / owner of the trailer. This is defined as the
first legal owner of a Midwest ShoreLand’r trailer other than an authorized Distributor or Dealer who has bought
the trailer from Midwest for resale to the public.
Things You Should Know About Your Limited Warranty Pre-Delivery Service
Defects in or damage to any components of your trailer may occur at the factory or while it is being transported
to the dealer. Normally, any defect or damage occurring during assembly is detected and corrected at the factory
during the inspection process. In addition, dealers are obliged to inspect each trailer before delivery. They repair
any uncorrected factory defects or damage and any transit damage detected before the trailer is delivered to you.
Trailer Alteration
This warranty does not cover alteration of the trailer, or failure of trailer components caused by such alteration.
Production Changes
Midwest and its distributors / dealers reserve the right to make changes in trailers built and / or sold by them at
any time without incurring any obligation to make the same or similar changes on trailers previously built and/
or sold by them.
YOUR 1-YEAR BASIC LIMITED WARRANTY
What is Covered
The 1-Year “Basic Warranty” covers every Midwest supplied part on your trailer, EXCEPT its tires. (These are
covered by a separate warranty included in your Owner’s Packet.)
The “Basic Warranty” begins on your trailer’s Warranty Start Date. The Warranty Start Date is the earlier of (1)
the date you take delivery of your new trailer, OR (2) the date the trailer was first put into service (for example, as
a dealer “Demo” or as a Midwest company trailer). The “Basic Warranty” lasts for 1 year (12 months) from this
date.
The Basic Warranty covers the cost of all parts and labor needed to repair any item on your trailer that is defective
in material, workmanship, or factory preparation. You pay nothing for these repairs.
PAGE 3 of 7
11-37
YOUR 5-YEAR FABRICATED PART & FRAME WARRANTY
Exceptions
The following items are not covered:
• tires
• paint and/or finish
What is Covered
The “Fabricated Part and Frame Warranty” covers these parts and components of your trailer’s frame for 5 years
counted from the trailer’s Warranty Start Date:
• Fabricated frame weldment, axle weldment, winch stand base, winch holder case, spring bracket, tongue, keel
cradle, keel roller bracket, inline roller pin, roller arm, bunk support channel, front post, winch post.
What Your Midwest Limited Warranties Do Not Cover
Your Midwest limited warranties do not cover the costs of repairing damage caused by environmental factors or
acts of God. “Environmental factors” include such things as airborne fallout, chemicals, tree sap, salt, ocean spray,
road or water hazards. “Acts of God” include such things as hailstorms, windstorms, tornadoes, sandstorms, light-
ning, floods and earthquakes.
Your Midwest limited warranties do not cover the costs of repairing damage caused by poor or improper
maintenance.
Your Midwest limited warranties do not cover the costs of normal /scheduled maintenance of your trailer. They
do not cover the cost of lubrication, replacing light bulbs, winch straps, fasteners unless done as a result of a
repair covered by your 1-Year “Basic Warranty.”
Your Midwest limited warranties do not cover any “incidental or consequential damages” connected with the failure
of your trailer under warranty. Such damages include lost time, inconvenience; the loss of the use of your trailer;
the cost of rental trailer; gasoline, telephone, travel or lodging; the loss of personal or commercial property; the
loss of revenue, etc. NOTE: Some states do not allow the exclusion or limitation of incidental or consequential
damages, so the above limitations or exclusions may not apply to you.
Your Midwest limited warranties do not cover the cost of repairing damage or conditions caused by fire or accident;
by abuse or negligence; by misuse; by tampering with parts; by improper adjustment or alteration; or by any
changes made to your trailer that do not comply with Midwest specifications.
Your Midwest limited warranties do not cover the cost of adding anything to your trailer once it is delivered to you,
even if parts, components or modifications are changed or added as a production change on other trailers produced
after your trailer was built.
How to Get Warranty Service for Your Trailer
In general, Midwest recommends that you contact the dealer from whom you bought the trailer for warranty
service. Your selling dealer knows you and your trailer best; and he’s the one most interested in making sure that
you get prompt and high quality warranty service.
When contacting your dealer for warranty service, please provide them with your trailer’s model number, vehicle
identification number, date of purchase and the nature of the problem.
Midwest Industries, Inc. • Ida Grove, Iowa 51445 • Ph: 712/364-3365

Printed in U.S.A. 0002246
PAGE 4 of 7
11-38
Trailer Winch Warranty Statement

2000 Models
LIMITED THREE (3) YEAR WARRANTY

Dutton-Lainson Company provides the following three (3) year limited warranty to the original purchaser of
D-L® Rachet Winches, Brake Winches, Worm Gear Winches and Tongue Jacks:
material or workmanship under normal use for the period of three (3) years from the original purchase date or, if that
date cannot be established, the date of manufacture. This includes a warranty against operational failure for the same
three year period due to rust or corrosion of the TUFFPLATE™ finish. This warranty is void if the product has been
subject to alteration or damage, or is defective due to unauthorized service or repair. This warranty does not assure
that the product shall remain useable for the three (3) year warranty period since the life of the product is dependent
upon the manner and frequency of use.
Repair or replacement is the purchaser’s sole remedy under this or any other warranty on the product, whether express
or implied. Dutton-Lainson Company shall not be liable for any incidental or consequencial damages of any
kind. Dutton-Lainson Company expressly disclaims any implied warranty of merchantability or fitness for par-
ticular purpose after three (3) year warranty period. Some states do not allow the exclusion of incidental or con-
sequencial damages or limitation of an implied warranty so the above exclusion and limitation may not apply to you.
Company.

2001 Models
LIMITED FIVE (5) YEAR WARRANTY

Dutton-Lainson Company provides the following five (5) year limited warranty to the original purchaser of D-L® rachet
winches, brake winches, and worm gear winches:
material or workmanship under normal use for the period of five (5) years from the original purchase date or, if that date
cannot be established, the date of manufacture.This includes a warranty against operational failure for the same five year peri-
od due to rust or corrosion of the TUFFPLATE™ finish.This warranty is void if the product is not installed and used in accor-
dance with the operating instructions, has been subject to alteration or damage, or is defective due to unauthorized ser-
vice or repair.This warranty does not assure that the product shall remain useable for the five (5) year warranty period since
the life of the product is dependent upon the manner and frequency of use.
Repair or replacement is the purchaser’s sole remedy under this or any other warranty on the product, whether express or
implied. Dutton-Lainson Company shall not be liable for any incidental or consequencial damages of any kind.
Dutton-Lainson Company expressly disclaims any implied warranty of merchantability or fitness for particular
purpose after five (5) year warranty period. Some states do not allow the exclusion of incidental or consequencial
damages or limitation of an implied warranty so the above exclusion and limitation may not apply to you.
Company.
PAGE 5 of 7
11-39
GOODYEAR LIMITED WARRANTY
AUTO AND LIGHT TRUCK (EXCLUDES
UNISTEEL RADIAL LIGHT TRUCK)
HIGHWAY TIRE ADJUSTMENT POLICY
ELIGIBILITY material-related condition will be replaced with com-
You are eligible for the benefits of this policy if you are parable new Goodyear tires on a pro rata basis. The
the owner or authorized agent of the owner of new replacement price will be calculated by multiplying the
Goodyear highway auto and light truck tires (including current Goodyear “predetermined price for adjust-
mud and snow and on/off-road tires, but excluding ment” or current advertised at adjustment location
Unisteel radial light truck tires, motorcycle, antique, (whichever is lower) by the percentage of useable
and classic tires) bearing Department of original tread that has been worn off at the time of the
Transportation prescribed tire identification numbers, adjustment. You pay for mounting, balancing, and an
and if your tires have been used only on the vehicle amount equal to the full current Federal Excise Tax
on which they were originally installed according to applicable to the comparable new replacement tire.
the vehicle manufacturer’s or Goodyear’s recommen-
dations. Light truck tires are defined as all tires identi- EXAMPLE: If your disabled tire had an original
fied with the “LT” designation in the sidewall stamping 8/32nd of useable treadwear and is worn to 4/32nd
plus the 8-19.5 and 8R19.5 sizes which do not carry useable tread remaining, you have used 50% of the
the “LT” designation. predetermined price for adjustment or advertised
price of the comparable tire plus an amount equal to
COVERAGE (REPLACEMENT FREE) the full current Federal Excise Tax applicable to the
RADIAL AUTO AND RADIAL LIGHT TRUCK TIRES comparable new replacement tire at time of adjust-
Any new Goodyear highway radial auto tire or radial ment. if the price of the new comparable tire is $80.00
light truck tire, except Unisteel radial light truck tires, and FET is $2.00, the cost to you would be $42.00.
covered by this policy, that does not deliver satisfac-
tory highway service due to a workmanship or mater- The “predetermined price for adjustment,” available at
ial-related condition (see Adjustment Policy all Goodyear Auto Service Centers and participating
Limitations) during the first 25% of useable treadwear, dealers, fairly represents the actual regular retail sell-
or twelve months from date of purchase, whichever ing price of the comparable tire at the time of adjust-
comes first, will be replaced with a comparable new ment. If a “predetermined price for adjustment” is not
Goodyear tire without charge. Mounting and balanc- available, adjustment will be based on the price at
ing are included. which you are entitled to buy at the time of adjust-
ment.
ALL OTHER HIGHWAY TIRES
Any new Goodyear highway auto or light truck tire, A tire has delivered its full original tread life and this
other than radial auto, radial light truck tire, or Unisteel warranty ends when the treadwear indicators become
radial light truck tire, that does not deliver satisfactory visible regardless of age or mileage.
highway service, due to a workmanship or material-
related condition (see Adjustment Policy Limitations), DEFINITION OF COMPARABLE TIRE
during the first 10% of useable treadwear will be A “comparable” new Goodyear tire may either be the
replaced with a comparable new Goodyear tire with- same line of tire or, in the event the disabled tire is out
out charge. Mounting and balancing are included. of production, the same basic construction and quali-
ty with different sidewall or tread configuration.
Any Goodyear temporary spare tire does not deliver
satisfactory service due to a workmanship or material- If a higher priced tire is accepted as replacement, the
related condition during the first 50% of useable tread difference in price will be additional.
depth (1/32 of an inch) will be replaced with a compa-
rable new Goodyear temporary spare tire without Any tire replacement under this warranty will be cov-
charge. Mounting is included. After the first 50% of ered by the Goodyear Warranty in effect at time of
useable treadwear you pay only an adjustment charge replacement.
for the treadwear received, plus any mounting charge.
ADJUSTMENT POLICY LIMITATION
COVERAGE (PRORATED ADJUSTMENT) This limited warranty is applicable only in the United
Tires not eligible for no charge adjustment that do not States and Canada. For countries other than the
deliver satisfactory service due to a workmanship or United States and Canada , consult your local
PAGE 6 of 7
11-40
Goodyear dealer or distributor. OWNER’S OBLIGATIONS

A. You must present the tire to be adjusted to a
No representative or dealer has authority to make any Goodyear Auto Service Center or goodyear Tire
representation, promise, or agreement on behalf of Dealer. (Please consult your telephone directory
Goodyear, except as stated herein. for locations.) Tires replaced on an adjustment
basis become the property of the Goodyear Tire
The folllowing are not covered by this policy: & Rubber Company.
• Goodyear does not warrant and will not give cred-
it in any adjustment transaction for any kind of B. You must pay for taxes or any additional service
material added to the tire after leaving a you order at the time of adjustment.
Goodyear factory, nor will it adjust any tire which
has failed as a result of adding any such materi- C. No claim will be recognized unless submitted on
al. (Example: Tire fillers, sealants, or balancing a Goodyear claim form (supplied by Goodyear
substances.) Dealer or Auto Service Center) completely filled
out and signed by you, the owner of the tire pre-
• Irregular wear or tire damage due to: sented for adjustment or your authorized agent.
• Road hazards (including punctures, cuts,
snags, impact breaks, etc.) TIRE ROTATION
The purpose for regular rotation is to achieve more
• Wreck, collision, or fire.
uniform wear for all tires on the vehicle. The first rota-
• Improper inflation, overloading, high speed tion is the most important. Before rotating tires,
spinup, misapplication, misuse, negligence, always consult your vehicle owner‘s manual for rec-
racing, chain damage, or improper mounting ommended rotation patterns and intervals. Tires
or demounting. should be inspected every 6,000 to 8,000 miles
• Mechanical condition of the vehicle. (10,000 to 13,000 km) for any signs of unusual wear.
If unusual wear is present, rotate your tires as soon as
• Ride disturbance after the first 25% of useable possible and check wheel alignment.
treadwear or due to damaged wheels or any vehi-
cle condition. LEGAL RIGHTS
• Temporary spare tires used on vehicles used in This warranty gives you specific legal rights, and you
racing and on passenger cars in special applica- may also have other which vary from state to state.
tions such as police pursuit service.
SAFETY WARNING
• Any tire intentionally altered after leaving a Serious injury may result from:
Goodyear factory to change its appearance.
(Example: White inlay on a black tire.) • Tire failure due to underinflation/overloading---
follow owner’s manual or tire placard in vehicle.
• Tires with weather cracking which were pur-
chased more than four (4) years prior to the pre- • Explosion of tire/rim assembly due to improper
sentation for adjustment. If you have no proof of mounting--only specially trained persons should
purchase date, tires manufactured four (4) or mount tires.
more years prior to presentation are not covered. Radial tires must be mounted on approved rims.
• Loss of time, inconvenience, loss of use of the
vehicle, or consequential damage. TIRE SPINNING
CAUTION:
Some states do not allow the exclusion or limitation of
On slippery surfaces such as snow, mud, ice, etc.
incidental or consequential damages so the above
do not spin tires in excess of 35 MPH as indicated
limitation or exclusion may not apply to you.
on the speedometer. Personal injury and severe
damage may result from excessive wheel spin-
Any tire no matter how well constructed may fail in
ning, including tire disintegration or axle failure.
service or otherwise become unserviceable due to
conditions beyond the control of the manufacturer.
This warranty is not intended as a representation that
a tire failure cannot occur.
11-41
11-42
SPORT BOAT 10/23/00 SB2000-008
2001 MODELS
Sport Boat Primary ID Numbers & Service Literature
This bulletin contains a comprehensive listing of Service Literature Part Numbers for 2001 models. If
the service literature used in prior years is still current, the literature part number will still be listed, but
“Same as . . . “ will appear in the appropriate Manual column.
Production started with the numbers listed below:
NOTE: Sport Boat literature is ordered through Yamaha Parts and Accessories not Crestec Los
Angeles, Inc.
Model Actual Starting Primary Owner’s Assembly Service

Model Name Displ. I.D. Number Manual Manual Manual
XRT1200Z XR1800 1176 F0C-700101 LIT-18626-04-09 N/A LIT-18616-02-25
LIT-18616-02-30*
(Z Supplement)
LST1200Z LS2000 1131 F0R-700101 LIT-18626-04-08 N/A LIT -18616-02-06
Same as
LST1200 X~Y
LIT-18616-02-23
(Y Supplement)
LIT-18616-02-29
(Z Supplement)
*The XR1800 Service Manual Supplement (LIT-18616-02-30) will be available in late 2000.
PAGE 1 of 2
11-43
Other Publications Part Number
Sport Boat Predelivery Checklist LIT-18616-00-97
2001 Sport Boat Flat Rate Manual LIT-18750-SB-01
2000 WV/SB Technical Update Handbook LIT-18500-00-2K
1998-2000 WV/JB Service Data Booklet LIT-18571-SD-2K
2001 Sport Boat Product Brochure LIT-18116-SB-01
2001 Sport Boat Features & Benefits Video VID-18199-SB-01
2001 Sport Boat Poster Set LIT-18140-SB-01
2001 WaterCraft Salesperson Product Guide (available 12/00) LIT-18468-WC-01
WaterCraft Drive Train Theory Video & Workbook VID-10660-00-64
Water Vehicle Carburetor Tuning & Adjustment Video & Workbook VID-10660-00-34
Limited Warranty Statement* LIT-18790-JB-96
Sport Boat Y.E.S. Sample Contract LIT-11580-00-35
11-44
SPORT BOAT 11/13/00 SB2000-009
XR1800 (XRT1200Y)
Seat Slide Assembly Replacement
The seat slide on the XR1800 may flex somewhat during sharp turns. A new seat slide has been devel-
oped which has increased rigidity. This bulletin describes the replacement procedure for the seat slide
with an inspection of the seat pivot surface, and how to receive reimbursement for the procedures.
Inspect: Inspect the unit for the presence of the updated seat slide assembly.
Modify: Modify all units in the affected range. Contact the customer of any sold unit to schedule
the repair to the unit.
Parts
Required: Yes. Order one port and one starboard seat slide assembly for any affected unit.
All 2000 model XRT1200Y
1. Secure the unit to prevent movement during 4. Place the seat assembly on an appropriate
the repair procedure. work surface to avoid any damage to the
seat. Remove the eight pan head screws
2. Loosen the seat pivot adjustment till the seat holding the seat slide assembly to the seat.
pivots freely.
5. Install the new seat slide assembly onto the
3. Raise the seat pivot lock lever, rotate the seat seat base using the same hardware.
slightly and lift the seat assembly off the seat
pedestal.
PAGE 1 of 3
11-45
6. Inspect the seat pedestal for sharp edges 8. Install the seat assembly onto the pedestal.
where the pivot bushing rides (see photo
below). If the top of the pivot area or the out- 9. Using light pressure, grasp the seat and gen-
side of the locking pin hole have sharp edges, tly rock it while inspecting the seat slide for
these may damage the pivot bushing. movement on the pedestal. Tighten the pivot
adjustment handle until the rocking movement
is gone. Tighten the handle an additional 1/2
turn.
7. Use a sanding block (medium grit 80-120) to

put a 1-2mm radius on these edges and
smooth any roughness on the top of the 10. Sit in the seat and test that the seat will pivot
pedestal (see photo below). properly and that the locking pin will engage in
both the forward and rear facing positions.
Rotate the adjusting handle as necessary for
any final adjustment.
11. Repeat the procedure for the other seat.
NOTE: Remove only high spots on the top of the

pedestal pivot surface. Removing too much mate-
rial could lower the seat and interfere with the
locking pin operation.
PAGE 2 of 3
11-46
Inspect the unit for the new seat slide assembly. The new part can be identified by the single adjustment
lever. The original part has a U-bolt with an adjustment lever and nut. You can also check the status on
YCS or call your RTA for assistance.
Old Seat Slide Assembly New Seat Slide Assembly

Slider, Seat (Port) F0C-U3715-02-00 1 $ 62.50
Slider, Seat (Stbd) F0C-U3715-12-00 1 $ 62.50
The repair of all affected units is authorized regardless of warranty status. To receive credit for parts and
labor after completion of the replacement of the seat base slides and pedestal modification, submit a
standard Service-Per-Bulletin Warranty Request. The labor allowance is 1.0 hour using the Problem
Code 090PF.
For YCS Dealers, refer to the YCS Operator's Manual page 4-4 and 4-5 for instructions to enter your on-
screen request.
11-47
11-48
Section 12
Sport Boat Service Data
12
12-1
XRT1200Z “XR1800”
2001 Service Data
MODEL:
Model / Model Code XRT1200Z / F0C
Primary ID Starting Number F0C-700101 ~
Total Fuel Tank Capacity 155 L (41 gal)
Reserve Capacity ø
SERVICE LITERATURE:
Service Manual (Supplement) LIT-18616-02-30
(Main, Same as XRT1200Y) LIT-18616-02-25
ENGINE:
Engine Type Two-Stroke, Water-Cooled / 2
Engine Number Prefix 68Y
Cold Cranking Compression at Sea Level 5.0 kg/cm2 (70 psi)
Oil Tank Capacity 10 L (2.6 gal)
CARBURETOR:
ID Number (F) 68Y-021, (C) 68Y-022, (R) 68Y-023
Main Jet #117.5
Pilot Jet #87.5
High Speed Screw Turns Out (F) 1-1/4, (C) 1-1/8, (R) 1-3/8
Low Speed Screw Turns Out (F) 7/8, (C) 7/8, (R) 1-1/8
JET UNIT
12-2
2001 WaterCraft Technical Update - Sport Boat Service Data
XRT1200Z “XR1800” (Continued)

CHARGING SYSTEM:
Battery: Model / Rating Marine Group 24 / 12V 100 Amp hr
IGNITION SYSTEM:
Pulser Coil Color Code / Ω W/R ~ B/O / 445 ~ 545Ω
Charge Coil Color Code / Ω ø
Peak Voltage (Closed Cranking) ø
HULL / DECK:
Material (Hull / Deck / Engine Hatch) FRP (all)
Molding Process (Hull / Deck / Engine Hatch)) HLF (all)
Gelcoat (Hull) White #SF498E (Paint) U7-60694
Gelcoat (Deck) White #SF498E (Paint) U7-60694
Gelcoat (Engine Hatch) Smoke Gray TBA
CONTROLS / CABLES:
Throttle Stop Clearance (WOT) 0.025 ~ 2.0mm (0.001 ~ 0.079 in)
Choke Cable Freeplay 1 ~ 6mm (0.04 ~ in)
TORQUE VALUES:
3rd M8: 3.5m-kg (25 ft-lb)
2nd M10: 3.9m-kg (28 ft-lb)
M6: 1.1m-kg (8 ft-lb)
Transom Plate M10: 3.7 ~ 4.2m-kg (27.8 ~ 30.4 ft-lb)
Ride Plate M8: 1.2 ~ 1.5m-kg (9 ~ 11 ft-lb)
Intake Grate M8: 1.2 ~ 1.5m-kg (9 ~ 11 ft-lb)
12-3
LST1200Z “LS2000Z”
2001 Service Data
MODEL:
Model / Model Code LST1200Z / F0R
Primary ID Starting Number F0R-700101 ~
Total Fuel Tank Capacity 155 L (41 gal)
Reserve Capacity 27 L (7 gal)
SERVICE LITERATURE:
Service Manual (Supplement) LIT-18616-02-29
(Main, Same as LST1200X) LIT-18616-02-06
ENGINE:
Engine Type Two-Stroke, Water-Cooled / 2
Engine Number Prefix 66H
Cold Cranking Compression at Sea Level N/A
Oil Tank Capacity 10 L (2.6 gal)
CARBURETOR:
ID Number (F) 66H-21, (C) 66H-12, (R) 66H-13
Main Jet #135
Pilot Jet (F) #100, (C) #95, (R) #97.5
High Speed Screw Turns Out (F) 3/4, (C) 1, (R) 3/4
Low Speed Screw Turns Out 1
JET UNIT
12-4
2001 WaterCraft Technical Update - Sport Boat Service Data
LST1200Z “LS2000Z” (Continued)

CHARGING SYSTEM:
Battery: Model / Rating Marine Group 24 / 12V 100 Amp hr
IGNITION SYSTEM:
Ignition Timing BTDC 15°
Spark Plug Torque / Cap Ω 2.5 m-kg (18 ft-lb) / 4.0 ~ 6.0kΩ
Ignition Coil Color Code Pri/Sec BW ~ B / High Tension Lead ~ B
Pulser Coil Color Code / Ω W/R, W/B, W/G ~ B / 248 ~ 372Ω
CDI Box Color Code / Ω B/O, B/W, B/Y ~ B
Charge Coil 1 Color Code / Ω Br ~ B/R / 172 ~ 258Ω
Charge Coil 2 Color Code / Ω L ~ B/R / 656 ~ 984Ω
HULL / DECK:
Material (Hull / Deck / Engine Hatch) FRP (all)
Molding Process (Hull / Deck / Engine Hatch)) HLF (all)
Gelcoat (Hull) White #SF498E (Paint) U7-60694
Gelcoat (Deck) White #SF498E (Paint) U7-60694
Gelcoat (Engine Hatch) White #SF498E (Paint) U7-60694
CONTROLS / CABLES:
Throttle Stop Clearance (WOT) 0.025 ~ 2.0mm (0.001 ~ 0.079 in)
YPVS Cable Slack ø
TORQUE VALUES:
Cylinder Head Bolt 1st & 2nd M8: 1.5m-kg (11 ft-lb) / 3.2m-kg (23 ft-lb)
Cyl Head cover 1st / 2nd M8: 1.5m-kg (11 ft-lb) / 3.2m-kg 23 ft-lg)
M6: 0.4m-kg (2.9 ft-lb) / 0.8m-kg (5.8 ft-lb)
2nd M10: 4.0m-kg (29 ft-lb)
3rd M8: 4.7m-kg (34 ft-lb)
Exhaust Chamber Assembly to Cyl 2nd M8: 4.0m-kg (29 ft-lb)
Jet Unit Mounting Bolt M8: 1.8 ~ 2.2m-kg (12.8 ~ 15.6 ft-lb)
Impeller 1.8m-kg (13 ft-lb)
Transom Plate M8: 1.8 ~ 2.2m-kg (12.8 ~ 15.6 ft-lb)
Intake Duct M8: 1.9m-kg (13.7 ft-lb)
12-5
12-6
Section 13
Sport Boat
Installation Instructions
13
13-1
13-2
2001 WaterCraft Technical Update - Sport Boat Installation Instructions
BIMINI TOP
MAR-XR180-BT-OP
XR1800 SPORT BOAT
INTRODUCTION
Please read and understand these instructions DEALER: These instructions contain important
completely (before installation) to avoid any information for future reference and must be
possible injury to yourself or damage to your given to the customer.
boat or the Bimini Top.
PARTS LIST
Item Part Description Qty
1 Bimini Top 1
2 Hardware Package 1
• Mounts 4
• Strap Eyes 2
• #8 X 1-5/8” Phillips Oval Head Screws 4
• 10-24 X 1-1/4” Phillips Oval Head Bolts 8
• #10 Flat Washers 8
• 10-24 Nylon Lock “Nyloc” Nuts 8
TOOLS REQUIRED
1 - Drill 1 - Short Extension 1 - 3mm Allen Wrench
1 - 1/8” Drill Bit 1 - 3/8” Deep Well Socket 1 - Marine Grade Silicone Sealant - White
1 - 3/16” Drill Bit 1 - #2 Phillips Screwdriver 1 - Fine Tip Erasable Marker
1 - Socket Wrench 1 - #2 Phillips Bit
BIMINI TOP INSTALLED
May 2000 PAK-XR180-BP-OP

PAGE 1 OF 6
13-3
BIMINI MOUNT LOCATIONS
c
a b
2”
1-3/4”
2”
49-13/16” 38-3/16”
WARNING 3. Look from inside the engine compartment

to be sure no wiring will be damaged by
Failure to follow the installation and operating drilling. Drill the mounting holes with a
instructions could result in personal injury or 3/16" drill bit. Countersink the holes with a
death. blunt object such as a Phillips bit to prevent
the gelcoat from chipping.
CAUTION:
REAR MOUNT
Improper installation, operation, or care could
damage the Bimini Top. Such damage would
not be covered by the limited warranty.
PREPARATION
before beginning the installation of the 2”
Bimini Top.
• A second person is recommended to help
with the installation procedure.
4. Secure the mount with the #10-24 x 1-1/4"
• Make sure the trailer is on firm, level Phillips Oval Head bolts, using the flat
ground, that it is blocked against move- washers and nyloc nuts on the inside of the
ment, and that the boat is properly secured deck.
to it.
INSTALLATION
1. Using the back edge of the rear seat cushion
as the starting point, measure and mark the
mounting positions “a”, “b”, “c” on both
sides of the boat (see the illustration above).
The marked positions are the center point of
the mounting brackets.
2. The holes for the rear mounting bracket are
positioned 2" in from the deck edge (see
illustration). Using the bracket as a tem-
plate, be sure the bracket fitting is angled to
the inboard side of the boat. Mark the
mounting holes.
PAGE 2 OF 6
13-4
5. To secure the middle Mounts, first use a 8. Secure the mount on each side with the
3mm Allen wrench to unscrew the 4 screws #10-24 X 1-1/4" Phillips Oval Head bolts,
holding the cup holders on each side. using the flat washers and nyloc nuts on the
Remove the cup holders from the box, then inside of the deck.
remove the box.
FRONT STRAP EYE
2”
REMOVE HOLDER
9. After mounting the middle mounts, reinstall

6. The holes for the middle Mounting Bracket the cup holder boxes using Loctite® 242 on
are positioned 1-3/4" in from the deck edge the bolts. Seal the outer edge of the cup
(see illustration below). Using the bracket as holder boxes to the deck with white silicone
a template, be sure the bracket fitting is sealant. Also, apply sealant to the underside
angled to the inboard side of the boat, then of the cup holder lips and install them.
mark the mounting holes.
10. The front Strap Eye is positioned 2" out from
MIDDLE MOUNT
the deck edge at the bow cover. Drill the
front Strap Eye holes with a 1/8" Drill Bit.
Mount the Strap Eyes with the #8 X 5/8"
Phillips Oval Head Screws.
CAUTION:
Do not overtighten the mounting screws. The
fiberglass could be damaged, allowing the
mount to pull loose.
11. With the Bimini Top in its fully collapsed
1-3/4”
position, install the middle support poles to
the middle brackets with the lock pins. The
adjustable support pole goes to the stern
7. Inspect the area inside the deck for any when installing the Bimini Top. Refer to
wiring that may be damaged during drilling Operating Instructions to raise the Bimini to
and move to the side, if necessary. Drill the the upright position.
mounting holes with a 3/16" drill bit, and
countersink the holes as before.
PAGE 3 OF 6
13-5
YAMAHA XR1800 BIMINI TOP
OPERATING INSTRUCTIONS
Raising from the fully collapsed storage 4. Unfold the top by pulling toward the bow of
position: the Sport Boat.
CAUTION:
Do not exceed 45 miles per hour with the
Bimini top in the open position.
1. Release the hook and loop strap securing

the rear support poles.
5. Check that the rear support poles are at the

highest position.
6. Attach the snap hooks to the strap eyes.
7. Lower the rear support poles to the lower
position.
2. With an assistant, raise the top and secure

the rear support poles to the rear support
pole mounts with the lock pins.
8. The top should be snug and wrinkle free. If

the top is too loose or too tight, adjust the
front straps as needed by sliding the buckle
up or down the strap.
3. Unzip and remove the storage cover.
PAGE 4 OF 6
13-6
Storing In the Upright Position: CAUTION:

1. Raise the rear support poles to the highest Do not trailer the boat with the Bimini Top in
position. the fully extended or upright storage positions.
2. Unhook the front straps and pull the top to Put the cover in the fully collapsed position to
the back. avoid damage.
3. Roll the fabric around the frames and zip
the storage cover in place. Removing the Bimini Top:
1. Follow the steps for storing in the fully col-
Storing in the Fully Collapsed Position: lapsed position.
1. Follow the steps for storing in the upright 2. Remove the lock pins holding the Bimini
position. Top to the mounting brackets.
2. Remove the snap pins holding the rear sup- 3. The top can now be removed from your
port poles to the mounting brackets. Sport Boat.
3. Lower the top onto the rear deck/hatch.

4. Secure the rear support poles to the main Reinstalling the Bimini Top:
poles with the hook and loop straps. Simply reverse the removal steps making sure
the lock pins are fully engaged.
Trailering with the Bimini Top: NOTE: The adjustable support pole goes to the
stern when reinstalling the Bimini Top.
The Bimini Top must be secured to the boat
when it is being trailered. When trailered with a
Genuine Yamaha Cover, simply store the Bimini
Top in the fully collapsed position and install
the cover. If a cover is not used, wrap an elastic
cord around the top and secure the ends to the
ski tow hook to restrict movement.
PAGE 5 OF 6
13-7
YAMAHA XR1800 BIMINI TOP
CANVAS CARE AND CLEANING
The canvas supplied with your Bimini Top is 4. Under no circumstances should the boat be
manufactured from top quality materials to pro- transported with the boat top in the upright
vide you years of trouble-free service. The fol- position
lowing information on the care, cleaning, and
proper storage of the fabric and fasteners that
make up your marine canvas is being provided
CLEANING INSTRUCTIONS
to help you maintain its appearance and ease of Fabric should be cleaned regularly before sub-
operation. We will also explain the performance stances such as dirt, roof particles, etc. are
characteristics you should expect from your allowed to accumulate on and become embed-
canvas. ded in the fabric.
Light Cleaning
FABRIC CHARACTERISTICS The fabric can be cleaned without being
Sunbrella is a woven fabric made of 100% solu- removed from the installation. Simply brush off
tion-dyed acrylic fiber with the following char- any loose dirt, etc., hose down and clean with a
acteristics: mild solution of natural soap (such as Ivory or
Lux) in lukewarm water (no more than 100° F).
1. It is very colorfast and will withstand long Do not use detergents. Rinse thoroughly to
term exposure to the sun (ultra-violet) with- remove all of the soap. Allow the fabric to air
out excessive fading or deterioration. dry completely
2. Because Sunbrella is a woven fabric, some Heavily Soiled Fabric
“misting” through the fabric is typical even The Sunbrella fabric may be hand-washed or
though it is treated with water repellency. dry-cleaned after removing the top from the
3. With a new canvas, the greatest potential frame.
for leakage is through the sewn seams. Hand Washing
Because Sunbrella and the long-term Prepare a solution of 1/2 cup of Clorox bleach
threads that are used are synthetic, the fab- and 1/2 cup of Ivory or Lux soap (liquid or
ric will not swell and seal the holes as cot- flakes) per each gallon of lukewarm water (no
ton does when wet. Usually, the movement more than100° F). Allow the fabric to soak until
of the fabric during use will move the fibers the bleach has killed any mildew. Brush out
enough to seal the holes. stains with a common nylon kitchen scrub
4. The fit will normally be tight when the fab- brush. Rinse the fabric thoroughly in cold water
ric is new. It is designed this way because to remove all of the soap - incomplete rinsing
Sunbrella stretches as it ages. Its initial tight can cause deterioration of the sewing threads
fit allows for a suitable fit for the life of the and prohibit the fabric from being retreated
canvas. The fit with Sunbrella will vary properly. Allow the fabric to air dry completely.
slightly in heat, cold, or rain. Sunbrella fabric is thermoplastic or heat sensi-
tive. Do not steam press or dry in an electric or
gas dryer. Excessive heat can damage and shrink
CARE INSTRUCTIONS
the fabric.
1. Never store the canvas wet or in an unven- Retreatment
tilated moist area. Cleaning may remove part of the water and
2. Roll the top carefully around the bows, and stain repellency that was applied to the fabric
cover it with the storage boot provided. during its manufacture. When necessary, apply
an air-curing treatment such as “303 High Tech
3. Do not exceed 45 miles per hour with the Fabric Guard.”
Bimini Top in the open position.
PAGE 6 OF 6
13-8
AM/FM-CD STEREO KIT

MAR-XR180-ST-KT
XR1800 SPORT BOAT
INTRODUCTION
Please read and understand these instructions DEALER: These instructions contain important
completely before installation to avoid any pos- information for future reference and must be
sible injury to yourself or damage to your boat or given to the customer.
the stereo system
PARTS LIST
1 Installation Kit
• Stereo Mounting Plate 1
• #10 x 3/4” Phillips Truss Head Screw 1
• Installation Instructions 1
2 KDC-35MRCCY AM/FM CD Player (hardware included) 1
3 KFC-1650MR 6-1/2” Speakers (rear) * 1 pr.
4 KCA-RC900MRY Remote Control Keypad (hardware included) 1
*Order front speakers separately (MAR-SPEAK-ER-00).
TOOLS REQUIRED
1 - Razor Knife 1 - Marking Pen 1 - 7/64” Drill Bit
1 - Small Flat Screwdriver 1 - Center Punch 1 - 1” Hole Saw
1 - #2 Phillips Screwdriver 1 - Drill 1 - 5” Hole Saw
1 - #2 Phillips Bit 1 - 3/8” Drill Bit
OPTIONAL
FRONT SPEAKER
LOCATION
NOTE: Refer to the Sport Boat Tech Tip “Stereo Mounting LS2000 and XR1800” for undated instal-
lation information. This can be found in Chapter 11 of the handbook.
May 2000 PAK-XR180-ST-KT

PAGE 1 OF 5
13-9
WARNING 3. Using the tools provided in the stereo kit,
remove the stereo chassis from the sleeve.
Failure to follow the installation and operating
instructions could result in shock, electrical
fire, or personal injury.
CAUTION:
Improper installation or operation could dam-
age the stereo components. Such damage
would not be covered by the limited warranty
on the product.
REMOVAL TOOL
PREPARATION
• Read all of these instructions thoroughly 4. Insert the stereo mounting sleeve through
before beginning the installation of the the mounting plate and into the stereo open-
stereo. ing in the glove box. Bend out the tabs on
• Read the installation instructions supplied in the mounting sleeve to secure it to the glove
the stereo package from Kenwood for box. Refer to the Kenwood Installation
details pertaining specifically to the stereo. Instructions to install the stereo.
• Make sure you have all necessary parts and MOUNTING SLEEVE
• Make sure the trailer is on firm, level ground
that it is blocked against movement, and
that the boat is properly secured to it.
INSTALLATION
1. Disconnect the battery.
2. Remove the stereo panel blank inside the MOUNTING PLATE
glove box. This panel can be easily cut out
with a razor knife by following the groove in 5. Bend the rear mounting strap 90° at the
the panel. Trim the edges as close to the upper mounting hole. Test fit the strap by
opening in the glove box as possible to holding it up against the wood block lami-
ensure a proper fit. nated into the deck. Lift the back of the
stereo enough to relieve the weight on the
mounting sleeve, then check to see if the
hole in the back of the stereo aligns with a
hole in the strap. Re-bend the strap as nec-
essary for proper hole alignment.
WOOD BLOCK
MOUNTING
CUT OUT
STRAP
CAUTION:
Be careful not to enlarge the opening when cut-
ting out the blank panel. Otherwise, the stereo
will fit too loosely.
13-10
CAUTION: 9. Mark the center of the hole for the Remote

Control Panel using the dimensions on the
Be sure the mounting strap has a sharp bend
illustration below. Center the gasket over
near the upper mounting hole. If it is bent in an
this mark, and then use the gasket as a tem-
arc, it may straighten with use and allow the
plate to mark the holes for the two mount-
stereo to loosen.
ing studs.
6. Secure the mounting strap to the wood
block in the deck with the #10 X 3/4"
Phillips Truss Head Screw. Secure the
Mounting Strap to the back of the Stereo
with the bolt provided.
7. Plug the Stereo Harness Adapter into the
back of the Stereo and then into the existing
harness. Plug the antenna and remote con- 2-9/16”
trol leads into the appropriate connectors.
Secure all wires to the wire harness located
along the bottom of deck.
8. Remove the throttle assembly and cover
plate to provide access for the Remote 10. Use a 1/4" bit to drill the two holes for the
Control Unit installation. Lift the controls mounting studs. Use a 1" hole saw to drill a
out and lay them to the side. 1" hole in the center for the wires.
NOTE:
Before drilling holes, punch the center of the
location with a center punch. This will prevent
the drill bit from walking on the gel coat.
11. Insert the Remote Control Panel’s wiring
through the hole, then install the Remote
Control Panel in place. Install flat washers,
then split lock washers, and finally the nuts
onto the studs. Make connections to the
existing Wiring Harness.
CAUTION:
CONNECT REMOTE TO
WIRE HARNESS
CAUTION:
Place a shop towel under the throttle assembly
to protect the deck finish.
REMOTE CONTROL
PANEL
NOTE:
Do not reinstall the throttle controls yet.
PAGE 3 OF 5
13-11
12. Mark the location for the center of the rear 14. Reach into the speaker opening and locate
speakers using the dimensions in the illus- the speaker wires. Pull the wires through the
tration below (starboard side shown). Center opening until there is some slack, then plug
punch the marks, then cut 5" diameter holes the connectors onto the speakers.
for each rear speaker.
7”
12-3/16”
15. Install the speakers with the screws provid-

ed.
CAUTION:
Be careful when drilling the holes. Wires for
the speakers are already in place behind the
panel.
13. Position the speaker into the opening, mak-
ing sure the speaker is level. Use the speak-
er as a template to mark each mounting
hole. Center punch each hole location, then
drill the holes using a 7/64" drill bit.
Countersink the holes with a Phillips Bit in
the drill.
16. Refer to the procedure on the following

page if you are installing the optional front
speakers.
17. Connect the battery, then turn on power to
the stereo with the switch on the Instrument
Panel. Check operation with the Remote
Control Unit. If all operates normally, rein-
stall the Throttle and Shift Control.
NOTE:
Refer to the operating instructions provided with
each component.
CARE AND CLEANING

Refer to your Owner’s Manual.
PAGE 4 OF 5
13-12
FRONT SPEAKERS (OPTIONAL)

MAR-SPEAK-ER-00
XR1800
1. Measure and mark the location of the front NOTE:
speakers per the illustration (starboard side Before drilling holes, punch the center of the
shown). location with a center punch. This will prevent
the drill bit from walking on the gel coat.
3. Position the speaker into the opening, mak-
ing sure the speaker is level. Use the speak-
er as a template to mark each mounting
hole.
8 1/4" 4. Center punch each hole location, then drill
the holes using a 7/64” drill bit. Countersink
12 3/16" the holes with a Phillips bit in the drill.
5. The wires for the speakers are already in
place. Reach inside of deck and locate these
wires. Pull the wires through the opening
until enough slack is obtained. Plug the
connectors onto the speakers and install the
2. Use a 5”-diameter hole saw to cut a hole for speakers with the screws provided.
each speaker.
PAGE 5 OF 5
13-13
13-14
STEREO/RECEIVER
EXCITER 270 AND LS2000
PARTS LIST
1 AM/FM Stereo Receiver/Player with Remote Connector (CD or Cassette) 1
2 Wiring Harness Pigtail 1
3 Instructions 1
Additional:
1 Kenwood 165MRW, 6-1/2” Speakers (Optional) 2
NOTE: For Exiter 135 & 220 installations, 6. Reach into the deck, locate the antennae
please refer to the Installation Instructions, and plug it into the back of the stereo.
which are included with the Exciter 135 and
7. Re-install the Access Cover.
220 Installation Kits.
EXCITER 270 INSTALLATION LS2000 INSTALLATION

1. Remove the Stereo Chassis from the sleeve
1. Remove the White Access Cover to the left with the tools provided with the Stereo
of the Stereo Housing to gain access to the Kit*. Insert the stereo sleeve into the rec-
back of the Stereo. tangular hole in the glove box and bend
2. Remove the Stereo Chassis from the sleeve down the tabs to secure*.
with the tools provided with the Stereo 2. Attach one end of the securing strap to the
Kit*. Insert stereo sleeve into the Radio back of the stereo, and the other end to the
Enclosure, and bend down tabs to secure*. wood block above the back of the stereo,
3. Connect the harnesses as follows: using a #10 x 1/2" screw (not provided).
• Plug the wiring harness pigtail into the 3. Connect the harnesses as follows:
back of the stereo. • Plug the wiring harness pigtail into the
• Plug the two 6-pin connectors into the back of the stereo.
two mating connectors on the pigtail. • Plug the two 6-pin connectors into the
• Plug the remote control connector into two mating connectors on the pigtail.
the mating connector on the pigtail. • Plug the remote control connector into
4. Insert the Stereo Chassis into the sleeve the mating connector on the pigtail.
until properly seated. • Plug the antennae coax into the back of
the stereo.
5. Bend the securing strap so one end of the
strap will attach onto the back of the Stereo (*Refer to Kenwood Installation Instructions
and the other end onto the wood block on for details).
the top of the deck. Mount one end of the
NOTE: Refer to the Sport Boat Tech Tip "Stereo
strap to the back of the Stereo, and the
Mounting LS2000 and XR1800" for updated
other end of the strap to the wood block
installation information. This can be found in
using a #10 x 1/2" screw (not provided).
Chapter 11.
PAGE 1 OF 1
13-15
13-16
MARINE SPEAKERS
MAR-SPEAK-ER-00
PARTS LIST
1 KFC1650MR 6-1/2” Speakers (hardware included) 1
2 Installation Instructions 1
TOOLS REQUIRED
Item Description Qty
2 #2 Phillips Bit 1
3 Marking Pen 1
4 Center punch 1
5 Drill 1
6 7/64” Drill Bit 1
7 5” Hole Saw 1
Installation:
WARNING
Failure to follow the installation and operating 1. Measure and mark the location of the speak-
instructions could result in personal injury. ers per the attached illustration pages.
Using a 5" hole saw, cut (2) 5" diameter
NOTE: Improper installation or operation could holes for the speakers.
damage the stereo components and effect the
warranty status of the product. NOTE: Before drilling holes, be sure to punch
the center of the location with a center punch.
This will prevent the drill bit from walking on
the gel coat.
NOTE: The Exciter 135 and 220 speaker loca-
2. Place each speaker into the hole, making
tion information is included for reference only.
sure the speaker is level. Mark each mount-
These units require an optional installation kit to
ing hole, then drill each hole using a 7/64"
provide the necessary wiring that may no longer
drill bit.
be available.
3. The wires for the speakers are already in
Preparation:
place. Reach inside of the deck and locate
• Read all of these instructions thoroughly these wires. Pull the wires through the open-
before beginning the installation of the ing until enough slack is obtained. Plug the
speakers. connectors onto the speakers and install the
speakers with the screws provided.
tools together before you begin. NOTE: Before installing screws into a gel coat-
ed surface, be sure to countersink the holes with
WARNING a Phillips Bit installed in a drill. This will prevent
Make sure the boat is on firm, level ground and the gel coat from chipping.
secured against movement.
PAGE 1 OF 4
13-17
XR1800 SPEAKER INSTALLATION ILLUSTRATION
8-1/4”
7”
12-3/16”
12-3/16”
REAR SPEAKER LOCATION (STARBOARD) FRONT SPEAKER LOCATION (STARBOARD)
PAGE 2 OF 4
13-18
LS2000 FRONT SPEAKER INSTALLATION ILLUSTRATION
FACTORY INSTALLED SPEAKER
SEE DETAIL E
DETAIL E
117.5MM 95.3MM
(4.625 IN.) (3.75 IN.)
PAGE 3 OF 4
13-19
EXCITER FRONT/REAR SPEAKER INSTALLATION INSTRUCTIONS
SEE DETAIL C
SEE DETAIL A
SEE DETAIL B
SEE DETAIL D
DETAIL A: LEFT FRONT DETAIL B: RIGHT FRONT

(OPTIONAL) (OPTIONAL)
DETAIL C: LEFT FRONT DETAIL D: RIGHT FRONT
PAGE 4 OF 4
13-20
YAMAHA BILLET ALUMINUM FUEL CAP

MAR-BLTFU-EL-CP / MAR-BLTFU-EL-BL
Fits All WaveRunners and Sport Boats
PARTS LIST
1 Billet Aluminum Fuel Cap with Stainless Steel Split Ring 1
2 Instruction Sheet 1
INSTRUCTIONS
1. Unscrew the fuel cap from the water-
craft.
2. Remove the Phillips screw holding the

retention chain to the cap. If the reten-
tion chain happens to slip inside the
filler neck, it can be retrieved with your
finger.
3. Remove the rubber gasket from the orig-

inal fuel cap, and place it on the new
cap.
4. Attach the stainless steel split ring to the

retention chain.
5. Screw the cap back on the watercraft.
MAINTENANCE AND CARE:

Clean with a mild detergent or marine
cleaner (avoid harsh detergents or abra-
sives).
PAGE 1 OF 1
13-21
13-22
BILLET ALUMINUM REAR BOARDING HANDLES

MAR-REARH-ND-SV
Fits All LS2000 and XR1800 Yamaha Sport Boats
PARTS LIST
1 Billet Aluminum Rear Boarding Handle 2
TOOLS REQUIRED
#2 Phillips Screwdriver 1
Medium Straight Slot Screwdriver 1
10mm Box End Wrench 1
INSTALLATION
1. Open the cleanout door and remove the
screws that attach the hinge to the hull of
the boat. Set aside the cleanout door and
screws.
2. Remove all of the screws that secure the

cleanout tray to the boat. Do not tamp-
er with the safety switches.
3. Carefully pry the tray up to expose the

drain hose connection. Use a screwdriv-
er to loosen the hose clamp and remove
the hose from the nipple. Carefully set
the tray aside leaving the safety switch
wires attached and undisturbed.
PAGE 1 OF 2
13-23
4. Using the appropriate size wrench, hold
the nut inside the hull while loosening
the two Phillips screws that hold on each
handle. Remove the plastic handles, and
(utilizing the existing hardware), replace
them with the aluminum handles. Note
that one side of the aluminum handle is
countersunk. This side should face up.
5. Tighten both handles securely. To com-

plete the installation, be sure the wiring
to the safety switches is free and clear.
Attach the drain hose and tighten the
hose clamp. Carefully fit the tray into
place, making sure it is seated properly
around the cleanout ports, as well as
around the perimeter of the tray.
Replace all screws.
6 Test the operation of both cleanout safe-

ty switches before continuing. Do not
proceed until you are satisfied the safety
switches are working properly!
CAUTION:
If either switch fails to operate properly,
have them inspected by your Yamaha
Dealer before operating your Sport Boat.
MAINTENANCE AND CARE

Clean with a mild detergent or marine
cleaner (avoid harsh detergents or abra-
sives).
PAGE 2 OF 2
13-24
LS2000 SWIM PLATFORM MAT SET

PARTS LIST
1 3 Pieces of Traction Mat 1
2 Stainless Steel Hinge 1
3 8 oz. Can of Contact Cement 2
4 2” Brush 1
TOOLS REQUIRED
1 Pencil 1
2 Sheet of Sandpaper (80~100 grit) 1
3 Masking Tape 1
5 Flathead Screwdriver 1
6 Tack Rag 1
7 Cleaning Solvent (Acetone, Goof Off™, etc.) 1
PREPARATION 4 Remove the other 8 Phillips Screws that

hold the hinge to the boat and note
Prepare the area to be padded by making
exactly how the hinge is oriented.
sure the surface is smooth, dry and free from
dirt and grease. 5 Replace the hinge with the stainless steel
hinge provided in the kit and make sure
CAUTION: it is oriented correctly. The countersunk
Be sure to work in a properly ventilated side of the hinge should face out away
area when using solvents or adhesives. from the mounting surfaces.
Refer the manufacturer’s instructions for
6 Using the original screws, mount the
proper use and cautions.
new hinge to the deck. Snug the screws
but do not fully tighten at this time.
INSTALLATION INSTRUCTIONS 7 Position the cleanout door and install
the remaining 8 screws; attaching the
1 Make sure you have all of the necessary cleanout door. Snug the screws, but do
tools and parts together before you not tighten.
begin.
8 Check the door for a smooth opening
2 Open the cleanout tray door on the and closing and make sure it fits flush as
swim platform of the boat. before.
3 Remove the 8 Phillips Screws that hold 9 If any fit problems are encountered, try
the hinge to the cleanout door and removing the hinge and reinstalling it
remove the door. rotated 180°, so the top is now the bot-
tom.
PAGE 1 OF 2
13-25
10 After properly fitting the hinge carefully, 17 Lightly sand inside the areas you traced.
tighten the screws being careful not to It is not necessary to sand the textured
strip them. areas flat. This will give the contact
cement a good bonding surface.
11 Test the operation of both cleanout
switches before continuing. Do not pro- 18 Wipe the swim platform and cleanout
ceed until you are satisfied the door is door clean of any sanding dust with a
installed properly and the safety switch- tack rag.
es are working properly!
19 Shake the can of contact cement well.
CAUTION: Open the contact cement with a screw-
driver.
If either switch fails to operate properly,
have them inspected by your Yamaha 20 Working with one piece at a time, brush
Dealer before operating your Sport Boat. a thin, even layer of contact cement to
the back of the mat and to the corre-
12 Before using any glue, lay out the mats sponding area traced on the swim plat-
to make sure you have all the pieces in form.
the correct location. The grooved side
should face upward when installed. 21 Allow both sides to dry for 5-10 minutes
before putting together. NOTE: Line up
13 Match each piece of mat to the textured each piece carefully, as it will be very
areas on the swim platform. As some of difficult to move once the two surfaces
the pieces have a similar shape, you of glue make contact. Once pieces are
may have to move them around until positioned, press firmly starting in the
you find their correct location. When center and working outwards.
properly positioned, all textured areas
will be neatly covered with a mat. If this 22 Remove any excess glue from your mats
is not the case, keep rotating the pieces and swim platform with solvent. Apply
and trying different locations until you only a small amount to the tip of a rag
are sure you have all of the mats in the and work carefully around the outer
correct location. edge of the mat. Do not allow solvent to
get under the mat, as it may cause the
14 Leaving the mats in their correct loca- mats to lift up.
tion, trace the outline of all the pieces
with a pencil. 23 Allow mats 24 hours to dry before using
your Sport Boat.
15 Mark each mat as to its location with
tape for easier identification during
installation.
16 Remove the mats and mask around the
outside of the traced line with masking
tape. This will help protect the finish
during sanding and speed cleanup.
PAGE 2 OF 2
13-26
SWIM PLATFORM OR INTERIOR MAT SET

PARTS LIST
1 Traction Mat Set
2 8 oz. Can of Contact Cement Varies w/kit 2 to 4
3 2” Brush 1
TOOLS REQUIRED
1 Pencil 1
2 Sheet of Sandpaper (80~100 grit) 1
3 Masking Tape 1
4 Flathead Screwdriver 1
5 Tack Rag 1
6 Cleaning Solvent (Acetone, Goof Off™, etc.) 1
PREPARATION rotating the pieces and trying different loca-
tions until you are sure you have all of the
Prepare the area to be padded by making sure
mats in the correct location.
the surface is smooth, dry and free from dirt and
grease. 4. Leaving the mats in their correct location,
trace the outline of all the pieces with a pen-
CAUTION: cil.
Be sure to work in a properly ventilated area
5. Mark each mat as to its location with tape
when using solvents or adhesives. Refer to the
for easier identification during installation.
manufacturer’s instructions for proper use and
cautions. 6. Remove the mats and mask around the out-
side of the traced line with masking tape.
INSTALLATION INSTRUCTIONS This will help protect the finish during sand-
1. Make sure you have all of the necessary ing and speed cleanup.
tools and parts together before you begin. 7. Lightly sand inside the areas you traced. It
2. Before using any glue, lay out the mats to is not necessary to sand the textured areas
make sure you have all the pieces in the cor- flat. This will give the contact cement a
rect location, (the grooved side should face good bonding surface.
upward when installed). 8. Wipe the textured areas clean of any sand-
3. Match each piece of mat to the textured por- ing dust with the tack rag.
tion of the area being covered. As some of 9. Shake the can of contact cement well. Open
the pieces have a similar shape, you may the contact cement with screwdriver.
have to move them around until you find
their correct location. When properly posi-
tioned, all textured areas will be neatly cov-
ered with a mat. If this is not the case, keep
PAGE 1 OF 2
13-27
10. Working with one piece at a time, brush a 12. Remove any excess glue from your mats and
thin, even layer of contact cement to the the deck with solvent. Apply only a small
back of the mat and to the corresponding amount to the tip of a rag and work careful-
area previously traced. ly around the outer edge of the mat. Do not
allow solvent to get under the mat as it may
11. Allow both sides to dry for 5-10 minutes
cause the mats to lift up.
before putting together. Note: Line up each
piece carefully, as it will be very difficult to 13. Allow mats 24 hours to dry before using
move once the two surfaces of glue make your Sport Boat.
contact. Once pieces are positioned, press
Yamaha Motor Corp. U.S.A.
firmly starting in the center and working out-
Parts and Accessories Division
wards.
6555 Katella Ave. Cypress, CA. 90630
LS2000 SWIM PLATFORM
XR1800 SWIM PLATFORM EXCITER INTERIOR MATS
EXCITER SWIM PLATFORM
PAGE 2 OF 2
13-28
YAMAHA AQUA MAT

MARINE CARPET KIT
PARTS LIST
1 Carpet Set 1
2 3M Scotchmate™ Hook and Loop Industrial Fasteners (on carpet) 1
3 Instructions 1
gage the loop strip from the hook strip.

Next, FIRMLY press the loop strip adhesive
Your AQUA MAT is engineered with a hook and onto the floor of the boat by pressing from
loop fastener system which secures the mat to the carpet side of the mat. Make sure the
the floor of your boat. The first installation entire surface of the adhesive is FIRMLY
requires that you follow these instructions care- pressed down. Repeat this process until all
fully. Once properly installed, your mat can be hook and loop systems are in place. FOR
removed and replaced easily. BEST RESULTS, THE MAT SHOULD
REMAIN IN PLACE UNUSED FOR 12
1 Locate the strategically placed "hook and HOURS.
loop" fastener system sewn into the binding
on the underside of the mat. Note the black 4. Leave mat in position for 24 hours or more
"hook" strip is permanently sewn into the before attempting to remove. The water-
binding and a white “loop” strip is fastened proof adhesive on the loop strip will contin-
to the hook strip. DO NOT SEPARATE ue to “cure” for 24 hours. 50% of its ability
THESE TWO PIECES UNTIL THE INSTALLA- to stick to the floor of the boat is immediate
TION IS COMPLETE. and continues to cure with time. After 24
hours, the mat can be removed, if necessary,
2 Place the mat into position in the boat, not- leaving the loop strips firmly attached to the
ing the areas where the hook and loop sys- floor of the boat for reattachment to the
tems are located. hook strips, permanently sewn into the
IMPORTANT NOTE: It is mandatory that the binding of the mat.
floor surface be free of dust, lint and oils
prior to attempting to adhere the adhesive
side of the “loop” fastener to the floor. STORAGE & CARE
Thoroughly clean directly below and sur-
• For storage, always roll the carpet with the
rounding the hook and loop system applica-
carpet facing out. Never fold and do not roll
tion areas with a residue-free cleaner. Also,
while wet.
wiping the area to receive the adhesive strip
with Isopropyl Alcohol is highly recom- • Vacuum or hose off for regular cleaning. If
mended to achieve proper adhesion. the carpet becomes soiled, use a standard
type carpet cleaner.
3. Once the adhesive contact areas are clean,
check that the mats are in the desired posi- • Always dry carpet face-up (or facing out if
tion. Kneel on the mat surface to keep the hanging) to ensure the carpet face dries ade-
mat from shifting, lift the mat edge and quately.
remove the adhesive protector sheet from
the “loop” strip, being careful not to disen-
PAGE 1 OF 1
13-29
13-30
LS2000 SKI PYLON

MAR-LS2SK-PY-LN
PARTS LIST
Item Part Number Part Description Qty
1 N/A Ski Pylon Assembly
2 90152-14S32-00 Screw, 1/4-20 x 2” P Oval Head 4
3 90209-14SA9-00 Washer, 1/4” x 3/4” O.D. 4
4 90185-14S00-00 Nut, 1/4-20 Nylon Lock 6
5 90157-14S48-00 Screw, 1/4-20 x 3” P Truss Head 2
6 N/A Spacer 2
TOOLS REQUIRED
Drill 3/4” Wrench or Socket
2-1/4” Hole Saw 7/16” Wrench or Socket
3/4” Hole Saw or Drill Bit 1/8” Allen Wrench
9/32” Drill Bit Medium Screwdriver
Tape Measure Medium File
#2 Phillips Screwdriver
PREPARATION
1. Unpack the Ski Pylon and confirm that

the proper components were supplied.
2. Remove the large locking nut and UPPER
washer from the bottom of the Ski MOUNT
Pylon Assembly and set aside for later LARGE SET SCREW
use.
3. Using a 1/8" Allen wrench, loosen the
set screw for the lower mount. Remove SMALL SET LOWER MOUNT
the mount and set aside. SCREW
4. For ease of installation remove the large

set screw and pull the Ski Pylon Shaft
INNER SHAFT LARGE NUT
from the upper mount assembly. AND WASHER
PAGE 1 OF 5
13-31
1. Open the engine hatch and remove the stor-

age tray.
2. From inside the engine compartment, locate
and remove the four (4) nuts securing the
rear seat backrest to the deck. Lift the back-
rest to disengage the mounting hooks and
set aside.
MOUNTING NUTS
3. On the deck area between the seat back and

the engine compartment opening, locate the
center by measuring between the two sides
of the engine hatch opening and mark this
point (see adjacent illustration).
CENTER
POINT
4. Measure back from the upper edge of the

bulkhead (seat back support) 1-13/16"
(46mm). Mark this point. This is your center
point for the Ski Pylon Mounting Hole. 1-13/16”
5-1/2”
BULKHEAD
PAGE 2 OF 5
13-32
5. Measure from this center point to the right 1-

3/16" (30mm). This is your center point for 1-3/4”
the clearance hole (A). Mark this point.
6. Using a 3/4" drill bit or hole, saw drill the
clearance hole.
B
7. Using a 2-1/4" hole saw, drill the mounting 2-3/4”

hole at center point (B).
1-3/16”
8. File the sides straight where the two holes
intersect.
9. Insert the Ski Pylon Upper Mount into the
upper hole and mark the four (4) mounting 1-13/16”
holes. A
BOW
10. Remove the pylon and drill the four (4) holes
with a 9/32" drill bit.
11. Insert the upper mount through the hole in

the deck and install the lower mounting
bracket on the upper mount. Insert the UPPER MOUNT
upper bolts for alignment.
12. Position the two (2) spacers provided
between the lower mount and the bulkhead.
Mark the bulkhead and remove both BULKHEAD
mounts. Drill the lower two (2) 9/32" mount-
ing holes through the bulkhead.
MARK AND DRILL
SPACER
LOWER MOUNT
PAGE 3 OF 5
13-33
13. Reinstall the upper and lower mounts.
Secure the upper mount to the deck using
the four (4) "1/4-20 x 2" Oval Head Screws,
washers and locking nuts. Do not fully tight-
en at this time.
14. Insert the two (2) 1/4"-20 x 3" Truss Head
Screws from the front, through the two spac-
ers and the lower mount. Secure this with
the two (2) locking nuts. Do not fully tight-
en.
15. Loosen the set screw on the lower bracket.
Align the lower bracket so it is fully seated
on the flange and against the bulkhead.
Tighten the set screw and finish tightening
the upper and lower mounting bolts.
16. Reinstall the Ski Pylon Shaft. Install the large
set screw making sure that it is in the slot.
Tighten the large set screw until it bottoms,
then back off 1/8 to _ turns. Install the large
washer and nut on the bottom of the shaft
and tighten.
17. Move the shaft through its travel to check
operation and for proper clearance.
18. Move the shaft to its fully lowered of storage
position.
19. Reinstall the backrest assembly and storage
tray.
20. Attach a copy of Operating Instructions to
the Sport Boat owners manual.
PAGE 4 OF 5
13-34
OPERATING INSTRUCTIONS
The Sky Pylon has 2 positions, one for storage

and one for use. When in the storage position,
the Ski Pylon should be fully lowered. When the
LARGE SET SCREW
Ski Pylon is in use, it should be fully raised and
locked.
To rise the pylon from the stored position, per-
form the following steps:
1. Lift the pylon until it reaches its limit, rotate
counterclockwise 1/4 turn and then lower it
until it bottoms (about 1/2”).
VIEW FROM RIGHT
(STARBOARD)
CAUTION: SIDE
When the Ski Pylon is in the raised position,

DO NOT sit in the center rear seat.
To store the Ski Pylon, perform the following
steps:
1. Lift the pylon until it reaches its limit (about
1/2”). rotate clockwise 1/4 turn and then
lower it until it bottoms.
Maintenance:
Periodically lubricate the Ski Pylon Shaft with
silicone spray protectant to protect it from the
elements and ensure smooth operation. The
Large set screw can be turned to adjust the ten-
sion on the shaft.
NOTE: Do not exceed 1/2 turn out from bot-
tomed on the set screw.
PAGE 5 OF 5
13-35
13-36
BILLET ALUMINUM GAUGE BEZEL

MAR-LSBZL-SV-LG / MAR-LSBZL-SV-SM
Fits 1999~2001 LS2000 SPORT BOATS
PARTS LIST
1 Billet Aluminum Gauge Bezel 1
INSTRUCTIONS
1. Clean the gauge that will receive the billet

aluminum bezel with a mild cleaner that
will not attack the clear plastic face.
2. Rub a small amount of soapy water on the
inside of the aluminum bezel. This will
make it easier to pop the bezel onto the
gauge.
3. Place one side of the bezel onto the gauge
and carefully push the bezel onto the gauge
until it snaps into place. There is a lip on the
inside of the bezel that should hold the
bezel securely in place.
4. Make sure the bezel is secure. Once the
bezel is snapped into place, it should not be
possible to pull it off by hand. If you can pull
it off, it is too loose. You may need to re-
clean the parts and apply a few drops of
clear silicone sealant to the inside of the
bezel. Be extremely careful not to get any on
the face of the gauge. Re-install the bezel
without using the soapy water. Allow sili-
cone sealant to cure.
MAINTENANCE AND CARE:

Clean the bezel with a mild detergent or marine
cleaner, (avoid harsh detergents or abrasives).
PAGE 1 OF 1
13-37
13-38
BILLET ALUMINUM STEERING WHEEL COVER

MAR-BTHRN-BU-TN
Fits All 1999~2001 YAMAHA SPORT BOATS
PARTS LIST
1 Billet Aluminum Steering Wheel Cover 1
2 Button Head Cap Screws 3
INSTRUCTIONS
1. Using a stubby Phillips Screwdriver, remove
the 3 screws that attach the plastic steering
wheel cover. Keep these screws separate,
they will not be re-used.
2. Remove the plastic steering wheel cover.
3. Install the Yamaha emblem (sold separately,

part #F0R-U411H-00-00) onto the alu-
minum steering wheel cover.
4. Install the aluminum wheel cover using the

buttonhead cap screws provided. Tighten
the cap screws with a 2.5mm Allen Key.
5. Check for a secure fit.
Clean with a mild detergent or marine cleaner.
(avoid harsh detergents or abrasives).
PAGE 1 OF 1
13-39
13-40
BILLET ALUMINUM HORN GRILL

MAR-BTHRN-GR-SV
PARTS LIST
1 Billet Aluminum Horn Grill 1
INSTRUCTIONS
1. LS2000 - Open the driver side hatch, and LS2000
remove the storage tray.
2. XR1800 - Remove the driver’s side drink
holder.
NOTE: Seal with silicone sealer to secure during
installation.
3. Reach into the hull and support the horn, XR1800

while you remove the two screws that attach
the grill to the hull on the outside of the
boat. The horn will become loose as you
remove the screws. Save the screws as they
will be reused.
4. Place the Billet Aluminum Horn Grill over

the existing plastic white grill. Replace the
two screws, re-align the horn and tighten the
screws. Be careful not to cross thread the
screws.
5. Make sure the horn is secure. Test the horn for
proper operation.
Clean with a mild detergent or marine cleaner
PAGE 1 OF 1
13-41
13-42
BILLET ALUMINUM HAND GRIP

MAR-GRABH-ND-SV
PARTS LIST
1 Billet Aluminum Hand Grip 1
2 3/16” Stainless Steel Cap Screws 2
INSTRUCTIONS
1. Open rubber caps to expose mounting
screws. Remove both mounting screws and
the plastic hand grip.
2. Position the aluminum hand grip in place

and start the 3/16" cap head screws that are
provided.
3. Tighten the 3/16" cap head screws with an

Allen Wrench.
NOTE: Torque to 5 Nm (0.5m/kg , 4 ft/lb.)
4. Check to make sure the hand grip is secure.

Clean with a mild detergent or marine cleaner
PAGE 1 OF 1
13-43
13-44
Section 14
SuperJet/Waverunner®
& Sport Boat
Wiring Diagrams
14
14-1
14-2
2001 WaterCraft Technical Update - WaveRunner Wiring Diagrams
WaveRunner
Wiring Diagrams
14-3
14-4
WIRING DIAGRAM GP1200R
COLOR CODE
B
Br
Ch
:
:
:
Black
Brown
Chocolate
B/Y : Black/yellow
Gy/B : Gray/black
Gy/R : Gray/red
G : Green Gy/Y : Gray/yellow
Gy : Gray L/B : Blue/black
1 Lighting coil
L : Blue L/R : Blue/red
O : Orange R/L : Red/blue
R : Red R/W : Red/white
W : White R/Y : Red/yellow
2 Pickup Y : Yellow W/L : White/blue
coil 3 CDI unit B/O
B/W
:
:
Black/orange
Black/white
W/R : White/red
G G W/R B/O B
Gy/B
B/O Gy/Y
W/R Gy Br
G B/Y
B B/W
O
B/O
B/O
B
G W L
W/R B/Y
Gy/R Br R L
L
W/R
G
B/O B/Y Br Gy/B Gy W B/W B Br R 4 Oil level sensor B
B
B B
B
B/O W/R O Gy/R G Gy/Y B/O B/Y
B
B/O
W/L
B B/O
G G W/R B
5 Fuel level sensor

Gy/Y W/L W/L
W/L
W
B/O O
W W
B/Y B/O Gy/Y Gy/Y

B/O
G G
B/Y O G
B/O Gy Gy
K Rectifier/regulator 6 Buzzer
Gy/B
G G G B L/R R
R/W
B/Y O R B Gy/R
G Gy/R Gy Gy/Y
B/O Gy/B L/R R
B/O
R/W Gy/Y L/B
B G B
Gy/B Gy/B Gy/B G L/B B
R B/Y B/O O B/O Gy/R Gy/R
J Water temperature sensor

Gy/R R
7 Multi-function meter
Gy/B B Gy/Y
G G B
Gy/R
R/Y
B B/Y
B/Y R/W B
I Exhaust B B/O
Br Br
R/Y R/W
0 Engine stop A
B B B/Y B/O Y Y
temperature sensor B/O
Br Br
B/Y B
W
W O
8 Speed sensor Y Start
9 Engine stop
R R
R R
lanyard switch switch Ch
R/W R/L W B R Br
G Ignition coil
B B/O R/W R/Y SET
B
O
R/W R/W switch PULL
Ch
W Br
W B
R R
W W
#1 Br
B/W B/O
F Fuse (20A,10A) B B
H Spark plug G Ignition coil

B B
B
#2
R R/W
D Starter motor R/Y
R
Br Br
N Br R
B/W B/W
H Spark plug G Ignition coil B R M

S
R/Y
Br Br
Br
R
#3 B
B/W B/Y R
H Spark plug
B R
R R
B R/L
+ –
B YPVS servomotor
Br
R/L R
E Starter relay
B B B
Gy Gy
B C Battery B
Gy
B
B
B B
B
B
14-5
14-6
WIRING
WIRING DIAGRAM SV1200
DIAGRAM
1 Thermo switch
2 Ignition coil
3 Lighting coil
W/R W/G W/G W/R B/R B/R R R R/Y R L L R/B
4 Pulser coil
5 Charge coil
W/B B B W/B Br L L Br
Br Br Br Br B B
6 CDI unit
7 Starter motor
Gy B B R L/R B/Y R/Y R/W B W W B R R B 8 Stop switch
9 Engine stop switch
W/L W/L B L/B B B
P G G P 0 Start switch
A
Y Y
Battery
B Fuse
C Starter relay
W B R Br
D Rectifier/regulator
E
SET
PULL
Fuel level switch
F
W Br
B
Multi-function meter
RR
G Oil level switch
H Speed sensor
B/W B B/W B B/W B
L L
I Buzzer
B B Gy R/B
B : Black
W/L W/L
Br : Brown
3 2 1
R R/Y
B B G : Green
R
Br
R
Br Gy : Gray
B R Br Br
B/Y B/W B/O
R
L : Blue
B
3 2 1
P
W
B
P : Pink
W
W
P
B B R : Red
P
W/G W/R Br L
W/B B B/R
R
P
R W : White
B B
G G Y : Yellow
P P Br
W B/O : Black/Orange
W/G W/R Br L R/Y
Y
R/W
Y
B/R : Black/Red
W/B B B/R
G G
B/Y B
B/W : Black/White
G
G
G
G B/Y : Black/Yellow
R
L/R L/B : Blue/Black
L/B
N
R L/R : Blue/Red
B B
H
B
R/B : Red/Black
S
R R/W : Red/White
B
R/Y : Red/Yellow
W/B W/B : White/Black
W/G
W/R
W/G : White/Green
B W/L : White/Blue
W/R : White/Red
14-7
14-8
WIRING DIAGRAM XLT1200
COLOR CODE
B
Br
Ch
:
:
:
Black
Brown
Chocolate
B/Y : Black/yellow
Gy/B : Gray/black
Gy/R : Gray/red
G : Green Gy/Y : Gray/yellow
Gy : Gray L/B : Blue/black
L : Blue L/R : Blue/red
1 Lighting coil O : Orange R/B : Red/black
R : Red R/L : Red/blue
W : White R/W : Red/white
2 Pickup Y : Yellow R/Y : Red/yellow
coil B/O : Black/orange W/L : White/blue
3 CDI unit
B/W : Black/white W/R : White/red
G G W/R B/O B
Gy/B
B/O Gy/Y
W/R Gy Br
G B/Y
B B/W
O
B/O
B/O
B
G W L
W/R B/Y
Gy/R Br R L
L
G
W/R
B/O B/Y Br Gy/B Gy W B/W B Br R 4 Oil level sensor B B
W/R O Gy/R G Gy/Y B/O B/Y B B B
B/O
B
B/O
W/L
B B/O
G G W/R B
Gy/Y W/L W/L
W/L
W 5 Fuel level sensor
B/O O
W W
B/Y B/O Gy/Y Gy/Y

B/O R/B
G G
B/Y O G
B/O Gy Gy Gy
Gy/B
G
K Rectifier/regulator G G B R/W
B
Gy R/B
B/Y O R Gy/R
G Gy/R Gy Gy/Y
B/O B/O
R/W
Gy/B L/R R 6 Buzzer
B G Gy/Y
Gy/B Gy/B Gy/B G L/R R
R B/Y B/O O B/O Gy/R Gy/R R L/B B
Gy/R
Gy/B B Gy/Y
B L/B B
J Water temperature sensor G Gy/R G
R
R/Y R/Y
B B/Y
B/Y R/W B 7 Multi-function meter
B B/O
I Exhaust B B B/Y B/O
Br Br
R/Y
Y
R/W
Y
Br Br
temperature sensor B/O
B/Y B
W
W O
Y Engine shut-
R R
8 Speed sensor
R
R/W
R
R/L
9 Engine stop off switch A Start switch
B B/O R/W R/Y switch SET
W B R Br
Ch
B R/W R/W
G Ignition coil O PULL Ch
W W Br
B
B
R R
W W
#1 Br
B/W B/O B B
F Fuse (20A,10A) B
B
H Spark plug
G Ignition coil
R R/W R/Y Br
D Starter motor Br R/Y Br
#2 R
N Br R R/Y R
B/W B/W
B R M R/Y Br Br Br
H Spark plug Br Br R
G Ignition coil S
R
#3 B
B/W B/Y R
B R
R R
B R/L
H Spark plug Br + – R/L R
B B B
Gy Gy B YPVS servomotor
E Starter relay B B
B C Battery Gy
B
B B
B
B
14-9
14-10
COLOR CODE
WIRING DIAGRAM GP800R

B : Black
Br : Brown
G : Green
Y : Yellow
B/Y : Black/yellow
L/B : Blue/black
Gy : Gray L/R : Blue/red
L : Blue R/W : Red/white
O : Orange R/Y : Red/yellow
P : Pink W/B : White/black
R : Red W/L : White/blue
W : White W/R : White/red
3 Lighting coil
C Oil level sensor
4 Pickup G G
W/B
L L
coil W/R
Br 5 Charge coil B L B
B
L B
W/L B
B
W/L B W /L
W/L
7 Starter motor D Fuel level sensor

6 CDI unit M
1 Thermoswitch L Br B R R B
E Multifunction L/R L/B R
B O Gy
G
meter L/R R
J Buzzer
R
L/B B
B P P B
W/R W G
B
W/B P
Gy P G G P
W/R W R/W
R B G R P B
B O B/Y R/Y B
2 Ignition coil L
G
F Speed R/Y
Y
R/W
Y
W/B Br B Br sensor B/Y B
G G W/R L
Y Y
B Br W/B P
H Engine stop
G Engine stop switch lanyard switch I Start switch
L W/R O W
B O G G W B R Br
SET
PULL
Gy W Br
B W W B
G B
O W W W
B
P P P R R B B
P P
B B B
R R
R
R R Br Br
R R Br R R Br
8 Rectifier/
Br
B
regulator B Br
R R
0 Fuse (10A) R
B
R
B R
R
R
R
Gy
B
R
Gy
B
B YPVS servomotor
9 Starter relay A Battery
Gy
14-11
14-12
WIRING DIAGRAM XL800
A P W/B B W/B P C G Gy D Gy G E B R F R B G W H W I R J R K L L L
W W/R W/R W
O B B O B B Br Br B B
P G G P
Br L L Br
M B N B OB R/W PR/W B Q R/Y R R S R T L/R U R/B V Gy W X B

B R R
W/L W/L Y Y Br Br B L/B Gy Gy
G L
G 3 G
L
KL
W/B
W/R
4 B B
B
W L
Br MN
L
5 B
W/L
B
7 E
M
1 Gy
VU
R/B
R B
F
G G
B P
R EF R L/R TS R
P P L/B B
6
B B R
R/Y I
A C
2 G W/R L
B D
H
R/W
Y
OP R/W
Y
G W/B Br B B B
35
L W/R O W
B Br W/B P
B 8 9
G G W B R Br
SET
PULL
Gy W Br
G B
O O W
B W GH W
P P P R R
P P B B
B B B
R
R R
R
R IJ R R/Y QR R
Br Br Br Br Br Br
B
D B B
R
R
R B R XW R
B
R
R R
Gy
B
Gy
B
J
C A
1 Thermo switch 8 Stop switch E Fuel level switch B : Black P : Pink R/B : Red/black
2 Ignition coil 9 Engine stop switch F Multifunction meter Br : Brown R : Red R/W : Red/white
3 Lighting coil Start switch G Oil level switch G : Green W : White R/Y : Red/yellow
4 Pulser coil A Battery H Speed sensor Gy : Gray Y : Yellow W/B : White/black
5 Charge coil B Fuse (10 A) I Buzzer L : Blue L/B : Blue/black W/L : White/blue
6 CDI unit C Starter relay J YPVS servomotor O : Orange L/R : Blue/red W/R : White/red
7 Starter motor D Rectifier/regulator
14-13
14-14
WIRING DIAGRAM XL700
14-15
14-16
WIRING DIAGRAM SJ700 G
G 3
4
W/R
5
Br / W
B
7
1
B P
2 Br/W 6
G
W/R B B
G G
B W
Br/W
8 9
G G W B R Br
SET
W/R B PULL
W Br
O O W
A B B
B B B W W
P P P
B B
B B
R R
R R
G G R
Br Br Br Br
B
R
C D
R
R
B R
A W B W C R D R 1 Thermo switch 8 Stop switch B : Black R : Red

2 Ignition coil 9 Engine stop switch Br : Brown W : White
B B Br Br 3 Lighting coil Start switch G : Green Br /W : Brown/White
4 Pulser coil Battery O : Orange W/R : White/red
5 Charge coil Fuse P : Pink
6 CDI unit Starter relay
7 Starter motor Rectifier/regulator
14-17
14-18
2001 WaterCraft Technical Update - Sport Boat Wiring Diagrams
Sport Boat
Wiring Diagrams
14-19
14-20
12V
BATTERY 20A RED/BLACK
WIRING DIAGRAM LS2000 CLEANOUT
RED/BLACK
ENGINE SHUT-OFF SWITCH KEY SWITCH

ASSEMBLY (RIGHT)
HATCH SWITCH (RIGHT) BLK WHT BLK WHT
WHT BLK RED YEL BRN
BRN BRN BLK WHT SHIFTER (RIGHT) SET
OFF
FREE (OFF)
RED PULL
ON OPTIONAL FRONT SPEAKERS
PUSH (ON)
START
BRN BRN
BLK
BLK RF SPEAKER
GRY/WHT 4 OHM
BRN
BLK
BRN
ENGINE CDI WHT BLK
(RIGHT) (RIGHT) RED LF SPEAKER
GRN WHT 4 OHM
RED/BLK
TACHOMETER (RIGHT)
BLK GRY PUR PUR BLK
POWER ON RR SPEAKER
BLK LIGHT (-) LIGHT (+) BLU LIGHT PUR/YEL 4 OHM
RIGHT ENGINE 6 PIN RIGHT OVERHEAT LIGHT
TAN PUR
BLK
KEY SWITCH ASSEMBLY (LEFT) LR SPEAKER
CLEANOUT HATCH SWITCH (LEFT) GRN/YEL
WHT BLK RED YEL BRN 4 OHM
BRN BRN BLK WHT SHIFTER (LEFT)
OFF
FREE (OFF)
ON
PUSH (ON)
RED BRN BRN START
BRN
BLK
BRN
ENGINE CDI WHT
(LEFT) (LEFT) RED
GRN RED/BLK
TACHOMETER (LEFT)
BLK GRY PUR PUR
BLK LIGHT(-) LIGHT(+) BLUE

LEFT ENGINE 6 PIN TAN/WHT LEFT OVERHEAT LIGHT PUR
BLK/WHT
LOW FUEL SWITCH PINK/BLK LOW FUEL LIGHT PUR
BLK BLUE
LIGHT(-) LIGHT(+) ANTENNA
SPEEDOMETER
BLK BLUE
FUEL SENDER LIGHT(-) LIGHT(+) STEREO
BLK PNK PURPLE
40Wx4
YEL RED BLK
FUEL GAUGE
BLK TAN/BLU 5A STEREO SWITCH
RED/BLK RED/BLK
COURTESY LIGHT OIL WARNING LIGHT RED/BLK
5A ORG
BLK OIL SENDER BLU COURTESY LIGHT SWITCH ORG RED/BLK REMOTE CONTROL KEYPAD
10A BRN
BLK PUR/RED
5A
HORN ORG HORN SWITCH ORG RED/BLK
ACCESSORY
RECEPTACLE 3A MAX, 12V BLK BLOWER 5A
BLK BLOWER YEL SWITCH ORG RED/BLK
2.7A, 12V
BILGE SWITCH 5A
BLK BILGE PUMP BRN ORG RED/BLK
1.9A, 12V RED
5A
ORG RED/BLK 3A
STERN LIGHT BOW LIGHT
1A, 12V
BLK GRY/BLU NAVIGATION LIGHTS SWITCH GRY/GRN
BLK BLK
14-21
14-22
BLACK - 102"
LIGHT
BOW
GREY/GREEN - 90"
STEREO
PRPL/YLLW 139" BL K 139"

GREY/WHT 91"
BLK 91"
COURTESY
LIGHT
BLUE - 78"
BLACK - 78"
BLACK 15"
GREEN/YLLW 15"
PURPLE 12"
GREY 15" GREY/YLLW 19"

BLACK 14" TAN 19" TAN 160"
12V ACC
OUTLET
YELLOW 64"
GREY 19"
TAN/BLUE 19" TAN/WHT 19" TAN/WHT 160"
BLACK 15"
PINK/BLK 19" PINK/BLK 145"

PINK 19"
BLK 27" BLACK 12"
YLLW 25" YLLW 160"
PURPLE 9"
BLACK 10"
BRN 25" BROWN 160"

GREY 11"
PRPL 15" YLLW 28" YLLW 12"

PURPLE/RED 4"
PRPL 10" RED/BLK 28" RED/BLK 59"

ORANGE 48"
BLACK 4"
START
BL 13" BLK 13" GREY/BLUE 33" GREY/BLUE 176"

WHITE 15"
ORANGE 30"
TACH
OFF
ON
GREY/GRN 34" GREY/GRN 90"

BLACK 64"
BL 7" BL 11" BLACK - 29" 10 AWG

TACH PRPL 9" RED/BLK - 31" 10 AWG
GREY 160"
BLK 11"
PINK 145"
FUEL
SPEEDO
ORANGE 111"
10
FORWARD
BL
STBD
SPKR
15"
PURPLE/RED 59"
GREY/YLLW 160"
TAN/BLUE 160"
BLACK 59"
START
RED/BLACK 4"
OFF
ON
PURPLE/RED 46"
BROWN 111"
PORT SPEAKER
NEUTRAL
SWITCH
FORWARD
BLACK 43"
HORN
LANYARD
SWITCH
WHITE 54"
BLACK 54"
14-23
BLACK/WHITE 137"
CONTROL
REMOTE
STEREO
GREEN/YLLW 82"
BLACK 82"
RED/BLK 160"
AFT STBD
SPEAKER
AFT PORT
SPEAKER
BLK 124"
SENDER
YLLW 160" BRN 160"

FUEL
SENDER
BLK 157"
OIL
BRN A
BLK/WHT 137"
GREY/RED TAN/WHT - 160"
GREY/BLK
GREY - 160"
PORT
GREY/YLLW
CDR
RED RED/BLK 160"

GRN BRN 108"
BLK GRN 160"
WHT BLK 60"
BRN WHT 160"
WHT
BLK
WHT
BROWN
A
WIRING DIAGRAM XR1800
GREY/RED TAN 160"

GREY/BLK
GREY/YLLW 160"
STBD
GREY/YLLW
CDI
RED RED/BLK 160"
GREEN BRN 108"
BLK GRN 160"
WHT BLK 160" WHT 160"
WHT BRN
WHT
BLK
BLOWER
MOTOR
YLLW 1900"
BLK 1900"
STBD ENGINE
PORT ENGINE
KILL SWITCH
KILL SWITCH
STERN
LIGHT
GREY/BLUE 176"
BLK 140"
BILDGE
PUMP
BILGE
BRN 1250"
PUMP
BLK 1250"
LIT-18500-00-01

2001 Tech Update - LIT-18500-00-01

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2001 Tech Update - LIT-18500-00-01

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WaterCraft Technical Update

©2001 by Yamaha Motor Corporation, U.S.A.

All rights reserved. Any reprinting

2001 WATERCRAFT TECHNICAL UPDATE

5. Technical Bulletins/Tech Exchanges- WaveRunner

8. 2001 Product Information - Sport Boat

TABLE OF CONTENTS (Cont’d.)

11. Technical Bulletins/Tech Exchanges - Sport Boat

2001 Water Vehicles

MODEL UPDATE INFORMATION

NEW MODEL INFORMATION

New air intake design increases air flow

Carburetors feature an insulator plate

Carburetor mounting flange and throttle

NEWLY DESIGNED IMPELLER

NEW MODEL INFORMATION

MULTIFUNCTION INFORMATION CENTER

FIVE POSITION QSTS

WaveRunner GP800R (Cont’d.)

Semi-V shaped design for superior stability

Yamaha Adjustable Sponsons (YAS)

Double splash guards (as on the

“GPR” type multifunction meter

FUEL LEVEL METER

FUEL WARNING INDICATOR

OIL WARNING INDICATOR ENGINE OVERHEAT WARNING INDICATOR

WaveRunner GP800R (Cont’d.)

The YPVS is battery driven with an internal

BILGE OUTLET HOSE

6 PILOT HOSE 1 JET PUMP

WaveRunner GP800R (Cont’d.)

Resonator chambers and baffles are used in

Intake system chambers are also used to RESONATOR

AIR INTAKE CHAMBERS

An exhaust resonator system is used to

Same jet pump design as the GP1200R for

WaveRunner GP800R (Cont’d.)

Digital DC CDI, Microcomputer controlled

This guide contains information applicable to watercrafts in every market.

CONTENTS AND FORMAT ............................................................2-7

CONTENTS AND FORMAT

STARTING SERIAL NUMBER

A-3: Carburetor body

A-1: Fuel return hose A-5: Flushing attachment

A-4: Pilot water

A-2: Fuel suction hose

MODEL APPLICATION TABLE

A-5 Flushing attachment

Previous parts Previous watercrafts

New parts New watercrafts

Previous parts Previous watercrafts

New parts New watercrafts

Previous parts Previous watercrafts

New parts New watercrafts

A-1 Fuel return hose

A-2 Fuel suction hose

A-3 Carburetor body

A-5 Flushing attachment

MODEL APPLICATION LIST

Watercraft 2001 Model

Watercraft 2001 Model

Watercraft 2001 Model

REED SET 66E-00 66V-00 65U-00