Target Audience:
Recreational riders and families seeking a three-seat personal watercraft with touring capability
Market Segment:
Mid-size three-passenger PWC class
Key Advantage:
Yamaha marine engine and jet drive reliability with low maintenance requirements compared to competitors
Competitors:
Sea-Doo GTX and Kawasaki STX class models
Seating:
Three-passenger capacity
Engine:
Two-cylinder 800cc two-stroke marine engine
Hull Design:
Deep-V hull for open water stability
General Information:
Model identification, specifications, torque values, special tools
Fuel System:
Carburetor removal, disassembly, inspection and tuning
Engine:
Cylinder head, cylinders, pistons, crankshaft disassembly and reassembly
Lubrication System:
Oil injection pump service and adjustment
Cooling System:
Water passages, cooling flow inspection and flushing
Jet Pump:
Impeller removal, inspection, wear ring and housing service
Electrical System:
Ignition, starting charging, gauges and wiring diagrams
Hull and Deck:
Hull inspection, seat, grips and hardware
Steering and Handlepole:
Steering cable, handlebar and reverse gate service
Suspension and Ride Tray:
Bolts, inserts and hardware torque checks
Step-by-Step Repair:
Complete teardown and rebuild procedures with torque specifications
Maintenance:
Scheduled service, adjustments, lubrication points
Diagnostics:
Troubleshooting charts for engine, electrical and fuel systems
Inspection:
Measurement tables with service limits for wear items
Reassembly:
Assembly sequences, gasket and seal replacement procedures
Detail Level:
Factory-level service data written for technicians and DIY owners
Illustrations:
Exploded views and diagrams for component identification
Specifications:
Full torque specs, clearances and service limits
Special Tools:
Listed where required with part references
Parts Data:
Component identification in exploded diagrams for correct part selection
Fastener Data:
Torque specifications throughout each procedure
File Format:
PDF (searchable, bookmarked, zoomable)
Compatibility:
Windows, macOS, Linux, iOS, and Android — any device with a PDF reader
Requirements:
A PDF reader application (e.g. Adobe Acrobat Reader, free)
Searchability:
Fully text searchable for fast lookup of any topic
Print Quality:
High-resolution digital pages, printable at full clarity
Binding Type:
N/A — digital download, no physical binding
Paper Type:
N/A — digital download, no physical paper
Engine Type:
Two-cylinder two-stroke, in-line
Displacement:
760cc (marketed as 800 class)
Cooling:
Water-cooled, open loop
Lubrication:
Oil injection (Yamaha Variable Ratio Oil Injection)
Induction:
Reed valve with twin carburetors
Rated Output:
Approximately 110 hp
Fuel Delivery:
Dual carburetors
Fuel Type:
Regular unleaded gasoline, 87 octane minimum
Fuel Capacity:
Approximately 41 liters (10.8 US gal)
Overall Length:
Approximately 3.26 m (128.0 in)
Overall Width:
Approximately 1.17 m (46.1 in)
Overall Height:
Approximately 1.14 m (44.9 in)
Dry Weight:
Approximately 290 kg (639 lb)
Load Capacity:
Three persons (approximately 240 kg / 529 lb)
Off-Throttle Steering:
YEMS (Yamaha Engine Management System) off-throttle steering assist
Reverse Gate:
Manual reverse for low-speed maneuvering
Lanyard:
Engine stop switch lanyard
Boarding Step:
Reboarding step and grab handle
Hull Material:
Fiberglass-reinforced plastic (FRP) SMC hull
Fire Extinguisher:
Onboard storage compartment
Bilge System:
Automatic siphon bilge drainage
Crash Test Rating:
N/A - personal watercraft are not crash-tested like road vehicles
Gauges:
Analog speedometer, tachometer, fuel level and oil level gauges
Warning System:
Low oil and engine warning indicators
Infotainment and Driver Assistance
Audio System:
N/A - this model year has no factory audio system
Driver Assistance:
N/A - no electronic driver assistance features on 2002 PWC
After First 10 Hours:
Initial break-in inspection and spark plug check
Every 50 Hours:
Spark plugs, carburetor synchronization, oil injection inspection
Annually or 100 Hours:
Jet pump inspection, cooling system flush, grease points, compression test
Engine Oil:
Yamaha 2-stroke injection oil (Yamalube 2-W or equivalent API TC)
Fuel:
Regular unleaded, 87 octane minimum
Impeller and Wear Ring:
Inspect for debris damage and clearance; common wear point
Spark Plugs:
Replace at 50-hour intervals; fouling common with extended idle
Carburetors:
Rebuild recommended after storage or ethanol fuel exposure
Cooling Passages:
Flush after every saltwater use to prevent corrosion blockage
Manufacturer:
Yamaha Motor Company, a Japanese manufacturer of marine and powersports products since 1955
PWC History:
Yamaha introduced the WaveRunner line in 1986 and became a leading PWC manufacturer
XLT800 Introduction:
Introduced in 2002 as a three-seat, mid-size touring-oriented WaveRunner
Position in Range:
Sat between the smaller XL800 and flagship XLT1200
Assembly:
Manufactured in Japan
