warning YAMAHA GP1200 2003 Service Manual

4-16
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NOTE:@
Wipe off any water on the spark plug or
inside the cap before installing the spark
plug cap. Push the spark plug cap down
until it clicks.

If a torque wrench is not available when
you are fitting a new spark plug, a good
estimate of the correct torque is 1/4 turn
to 1/2 turn past finger tight. Have the
spark plug adjusted to the correct torque
with a torque wrench as soon as possible.
@
WARNING@ Be careful not to damage the insulator
when removing or installing a spark plug.
A damaged insulator could allow sparks
to escape, which could lead to explosion
or fire.
@
EJU01107
Lubrication points
To keep moving parts sliding or rotating
smoothly, coat them with water-resistant
grease.
Recommended water resistant grease:
Yamaha Marine Grease/
Yamaha Grease A

Throttle cable (carburetor end)

Oil pump cable

Choke cable (carburetor end)
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EJU01971
Inspecting the battery
Check the level of the battery electrolyte
and make sure that the negative and posi-
tive leads are securely tightened.
WARNING@
Battery electrolyte is poisonous and
dangerous, causing severe burns, etc.
Electrolyte contains sulfuric acid.
Avoid contact with skin, eyes, or cloth-
ing.
Antidotes
External: Flush with water.
Internal: Drink large quantities of water
or milk. Follow with milk of magnesia,
beaten egg, or vegetable oil. Call phy-
sician immediately.
Eyes: Flush with water for 15 minutes
and get prompt medical attention.
Batteries produce explosive gases.
Keep sparks, flame, cigarettes, etc.,
well away. If using or charging the bat-
tery in an enclosed space, make sure
that it is well ventilated. Always shield
your eyes when working near batter-
ies.
KEEP OUT OF THE REACH OF CHIL-
DREN.

Be sure to connect the breather hose
to the battery. Fire or explosion could
result if the breather hose is damaged,
obstructed, or not connected properly.
@
CAUTION:@
Be careful not to place the battery on
its side.

Be sure to remove the battery from the
battery compartment when adding
electrolyte or charging the battery.
@
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EJU01111
Replacing the fuse
The fuse is attached to the electrical box.
To replace the fuse:
1. Remove the cap 1, and then pull out the
defective fuse 3 by using the fuse
puller2.
2. Install the spare fuse 4 of the correct
amperage.
WARNING@ Do not use fuses of higher amperage that
those recommended. Substitution of a
fuse of improper rating can cause exten-
sive electrical system damage and possi-
ble fire.
@
EJU01112
Bleeding the oil injection
pump
If the oil tank becomes completely empty,
or any hose connected to the oil pump has
been disconnected, the oil pump must be
bled to ensure proper oil flow.
If bleeding of the oil pump is necessary,
have a Yamaha dealer bleed it.Fuse amperage: 10 A, 20 A
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5-2
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Engine runs irregu-
larly or stallsFuel Empty Refill as soon as possi-
ble3-3
Stale or contaminated Have serviced by
Yamaha dealer4-10
Choke Lever is moved to on Move back to original
position2-8
Fuel filter Clogged or water
pooledHave serviced by
Yamaha dealer4-11
Fuel tank Water or dirt present Have serviced by
Yamaha dealer4-11
Spark plug Fouled or defective Replace 4-15
Incorrect heat range Replace 4-15
Gap incorrect Adjust 4-15
Spark plug cap Loose Connect properly 4-15
Cracked, torn, or dam-
agedReplace
—
Electrical wir-
ingLoose connection Tighten or connect
properly—
Carburetor Incorrect idle adjust-
mentAdjust idle
4-21
Clogged Have serviced by
Yamaha dealer—
Warning light or
indicator blinksFuel level Empty Refill as soon as possi-
ble3-3
Engine oil level Empty Refill immediately 3-4
Oil filter clogged Clean 4-12
Engine over-
heatedJet intake clogged Clean 5-4
Water temperature
sensor is failedHave serviced by
Yamaha dealer2-13
Low battery
voltageBattery voltage low Charge 4-19
Battery terminal con-
nected wrongConnect properly
4-19 TROUBLE POSSIBLE CAUSE REMEDY PAGE
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EJU01118
Emergency procedures
EJU01119
Cleaning the jet intake and
impeller
If weeds or debris get caught in the intake
or impeller, cavitation can occur, causing jet
thrust to decrease even though engine
speed rises. If this condition is allowed to
continue, the engine will overheat and may
seize. If there is any sign that the jet intake
or impeller is clogged with weeds or debris,
beach the watercraft and check the intake
and impeller. Always stop the engine before
beaching the watercraft.
WARNING@ Before attempting to remove weeds or
debris from the jet intake or impeller
areas, shut the engine off and remove
the clip from the engine shut-off switch.
Severe injury or death could result from
contact with the rotating parts of the jet
pump.
@
1. Turn the watercraft on its side as shown.
CAUTION:@
Place a suitable clean cloth or carpet-
ing underneath the watercraft to pro-
tect it from abrasions and scratches.

Always turn the watercraft over onto
its port (left) side.

When turning the watercraft on its
side, support the bow so the handle-
bars cannot be bent or damaged.
@
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5-5
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2. Remove any weeds or debris from
around the drive shaft, impeller, pump
housing, and jet thrust nozzle.
If debris is difficult to remove, consult
your Yamaha dealer.
CAUTION:@ Always avoid operating your watercraft in
areas where weed growth is thick. If trav-
eling in weeded areas is unavoidable,
operate the engine alternately at partial
throttle and full throttle. Weeds tend to
accumulate more at a steady speed and
at trolling speed. If weeds clog the intake
or impeller area and cause cavitation, fol-
low the cleaning procedure above.
@
EJU01844
Jumping the battery
If the watercraft battery has run down, the
engine can be started using a 12-volt bat-
tery and jumper cables.
WARNING@ Battery electrolyte is poisonous and dan-
gerous, causing severe burns, etc. Elec-
trolyte contains sulfuric acid. Avoid
contact with skin, eyes or clothing.
Antidotes
External: Flush with water.
Internal: Drink large quantities of water
or milk. Follow with milk of magnesia,
beaten egg or vegetable oil. Call physi-
cian immediately.
Eyes: Flush with water for 15 minutes
and get prompt medical attention.
Batteries produce explosive gases. Keep
sparks, flame, cigarettes, etc. well away.
If using or charging the battery in an
enclosed space, make sure that it is well
ventilated. Always shield your eyes when
working near batteries.
KEEP OUT OF THE REACH OF CHILDREN.
@
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5-7
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EJU01913
Towing the watercraft
If the watercraft becomes inoperative in
the water, it can be towed to shore.
If the watercraft must be towed in an
emergency using a towline, the operator
should ride the watercraft, holding onto the
handlebars.
CAUTION:@
Tow the watercraft at 5 mph (8 km/h) or
less, otherwise water could enter the
engine through the exhaust passages
or through the air intake and flood the
engine compartment if it is towed too
fast.

Tow the watercraft using the bow
eye1 only.

The bow must be kept up out of the
water during towing to prevent water
from entering the engine compart-
ment.
@
WARNING@
The watercraft should only be towed in
an emergency.

The towline should be long enough so
that the watercraft will not collide with
the towing boat when slowing down. A
good rule of thumb is a towline that is
three times the combined length of the
towing boat and the watercraft.

The operator of the towing boat must
keep speed to a minimum and avoid
traffic or obstacles which could be a
hazard to the rider on the watercraft.
@
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EJU01125
Index
2-stroke engine oil ................................... 3-2
A
Adjusting the carburetor ........................ 4-21
Adjusting the trolling speed ................... 4-21
Adjusting the Yamaha Adjustable
Sponson (Y.A.S.) .................................. 4-23
B
Battery .............................................. 3-8, 4-5
Beaching the watercraft ........................ 3-30
Bilge ........................................................ 3-7
Bleeding the oil injection pump ............. 4-22
Boarding alone ...................................... 3-23
Boarding and starting in deep water ..... 3-23
Boarding with a passenger.................... 3-24
Bow down.............................................. 2-12
Bow up .................................................. 2-12
C
Capsized watercraft .............................. 3-25
Choke lever ............................................. 2-8
Cleaning and adjusting the
spark plugs ............................................ 4-15
Cleaning the jet intake and impeller ........ 5-4
Cleaning the watercraft ........................... 4-6
Connecting the jumper cables................. 5-6
Cooling water pilot outlet .............. 2-10, 3-12
Cruising limitations .................................. 1-8
D
Docking the watercraft .......................... 3-30
E
Emergency procedures ........................... 5-4
Engine break-in ..................................... 3-13
Engine compartment ............................... 3-6
Engine overheat warning indicator ........ 2-19
Engine overheat warning system .......... 2-13
Engine serial number .............................. 1-1
Engine shut-off cord (lanyard) ............... 3-11
Engine shut-off switch ............................. 2-8
Engine stop switch .................................. 2-8
Enjoy your watercraft responsibly ......... 1-14F
Filling the fuel tank .................................. 3-3
Filling the oil tank .................................... 3-4
Fire extinguisher ...................................... 3-9
Flushing the cooling system .................... 4-1
Front storage compartment ................... 2-20
Fuel and oil.............................................. 3-1
Fuel and oil systems ............................... 3-6
Fuel cock knob ........................................ 2-7
Fuel filter ............................................... 4-11
Fuel meter ............................................. 2-17
Fuel system ............................................. 4-3
Fuel tank ............................................... 4-11
Fuel tank filler cap ................................... 2-6
Fuel warning indicator ........................... 2-18
G
Gasohol ................................................... 3-2
Gasoline .................................................. 3-1
Getting to know your watercraft ............ 3-19
Glove compartment ............................... 2-21
H
Handgrip ................................................ 2-12
Hazard information ................................ 1-12
Hood........................................................ 2-6
Hour meter ............................................ 2-17
Hull Identification Number (HIN).............. 1-1
I
Identification numbers ............................. 1-1
Important labels ....................................... 1-2
Inspecting and adjusting the
throttle cable.......................................... 4-13
Inspecting the battery ............................ 4-19
Inspecting the fuel system ..................... 4-10
Inspecting the jet thrust nozzle angle .... 4-13
Inspecting the oil injection system ......... 4-12
Inspecting the QSTS mechanism .......... 4-14
J
Jet unit................................................... 3-11
Jumping the battery ................................. 5-5
L
Label location .......................................... 1-2
Learning to operate your watercraft ...... 3-19
Leaving the watercraft ........................... 3-18
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6-2
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Limitations on who may operate the
watercraft ................................................ 1-7
Location of main components ................. 2-1
Lubrication............................................... 4-3
Lubrication points .................................. 4-16
M
Maintenance and adjustments ................ 4-7
Multifunction information center ... 2-15, 3-12
O
Oil filter .................................................. 4-12
Oil tank .................................................. 4-12
Oil tank filler cap...................................... 2-6
Oil warning indicator.............................. 2-18
Operating your watercraft...................... 3-19
Operation .............................................. 3-13
Operation of controls and other
functions .................................................. 2-5
Operation requirements .......................... 1-9
Other labels ............................................. 1-6
Owner’s/Operator’s Manual and
tool kit ...................................................... 4-8
P
Periodic maintenance chart..................... 4-9
Post-operation checks........................... 3-31
Pre-operation check list........................... 3-5
Pre-operation check points ..................... 3-6
Pre-operation checks .............................. 3-5
Primary Identification (PRI-ID) number ... 1-1
Q
Quick Shift Trim System (QSTS)
selector.................................................. 2-11
R
Recommended equipment .................... 1-11
Replacing the fuse ................................ 4-22
Reset button .......................................... 2-16
Riding watercraft with a passenger ....... 3-20
Rough water operation .......................... 3-30
S
Safe boating rules ................................. 1-13
Safety information ................................... 1-7
Seat ......................................................... 2-5
Specifications ........................................ 4-24
Speedometer......................................... 2-16Starting and boarding in shallow
water ..................................................... 3-22
Starting from a dock .............................. 3-22
Starting the engine ................................ 3-15
Starting the watercraft ........................... 3-21
Start switch.............................................. 2-9
Steering system ...........................2-10, 3-10
Stopping the engine .............................. 3-18
Stopping the watercraft ......................... 3-29
Storage.................................................... 4-1
Storage compartments .......................... 2-20
Submerged watercraft ............................. 5-8
Switches ................................................ 3-12
T
Tachometer ........................................... 2-16
Throttle .................................................. 3-10
Throttle lever ........................................... 2-9
Towing the watercraft .............................. 5-7
Transporting .......................................... 3-33
Troubleshooting ...................................... 5-1
Troubleshooting chart ............................. 5-1
Turning the watercraft ........................... 3-27
W
Warning labels ........................................ 1-3
Watercraft characteristics ...................... 1-12
Water separator ...................................... 3-7
Y
Yamaha Adjustable Sponson
(Y.A.S.).................................................. 2-21
UF0X73.book Page 2 Thursday, July 11, 2002 3:56 PM