spark plugs YAMAHA GP1200 2003 Owners Manual

2-4
E
1Spark plugs/Spark plug caps
2Electrical box
Protects electrical components from water.
3Flush hose connector
Use to flush the engine cooling water pas-
sages.
4Spark plug lead
5Muffler
6Fuel filter
7Fuel tank8Oil tank
9Battery
0Fire extinguisher container
AWater separator
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E
4
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MAINTENANCE AND
CARE
Storage ...................................................... 4-1
Flushing the cooling system .................. 4-1
Lubrication .............................................. 4-3
Fuel system ............................................ 4-3
Battery .................................................... 4-5
Cleaning the watercraft .......................... 4-6
Maintenance and adjustments .............. 4-7
Owner’s/Operator’s Manual and
tool kit ..................................................... 4-8
Periodic maintenance chart ................... 4-9
Inspecting the fuel system ................... 4-10
Inspecting the oil injection system ....... 4-12
Inspecting the jet thrust nozzle
angle ..................................................... 4-13
Inspecting and adjusting the
throttle cable ......................................... 4-13
Inspecting the QSTS mechanism ....... 4-14
Cleaning and adjusting the
spark plugs ........................................... 4-15
Lubrication points ................................. 4-16
Inspecting the battery .......................... 4-19
Adjusting the carburetor ...................... 4-21
Replacing the fuse ............................... 4-22
Bleeding the oil injection pump ............ 4-22
Adjusting the Yamaha Adjustable
Sponson (Y.A.S.) ................................. 4-23
Specifications ........................................ 4-24
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4-3
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Lubrication
1. Remove the spark plugs and pour
approximately one tablespoon of oil into
each cylinder.
2. Grease the spark plug threads and rein-
stall the spark plugs.
3. Crank the engine within 3 seconds using
the start switch.
4. Lubricate all cables such as the throttle,
choke, and steering cables.
NOTE:@ Use a suitable marine grease applicator to
pressure lubricate the cables and purge out
any moisture between the inner and outer
cables.
@
5. Lubricate the areas of the watercraft
specified under Lubrication points on
page 4-16.
EJU01964
Fuel system
Draining the fuel system prevents buildup
of varnishes and other harmful deposits that
result when gasoline sits for a prolonged
period of time.
WARNING@ GASOLINE AND ITS VAPORS ARE
HIGHLY FLAMMABLE AND EXPLOSIVE!

Do not smoke when refueling, and
keep away from sparks, flames, or
other sources of ignition.

Stop engine before refueling.

Refuel in a well-ventilated area with
the watercraft in a horizontal position.

Do not stand or sit on the watercraft
while refueling in case of fire.

Take care not to spill gasoline. If gaso-
line spills, wipe it up immediately with
dry rags. Always properly dispose of
gasoline-soaked rags.
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4-9
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Periodic maintenance chart
The following chart gives general guidelines for periodic maintenance. However, depend-
ing on your operating conditions maintenance may need to be performed more frequently.
PMC-***(
) This mark indicates maintenance that you may do yourself.
(
❍) This mark indicates work to be done by a Yamaha dealer.
MAINTENANCE INTERVAL
INITIALTHEREAFTER
EVERYPA G E
10
hours50
hours100
hours100
hours200
hours
ITEM
6
months12
months12
months24
months
Spark plug Inspect, clean, adjust




4-15
Lubrication points Lubricate


4-16
Intermediate housing Lubricate❍
*1

*2

*2 4-18
Fuel system Inspect❍❍
4-10
Fuel filter Check, clean, replace❍❍
4-11
Fuel tank Clean❍
4-11
Oil injection system Inspect, clean❍❍
4-12
Trolling speed Inspect, adjust


4-21
Carburetor throttle shaft Inspect❍❍
—
Cooling water passages Flush

*3 4-1
Water inlet strainer Inspect, clean❍❍
—
Bilge strainer Clean❍❍
—
Impeller Inspect

*4❍❍
—
Jet thrust nozzle angle Inspect


4-13
QSTS mechanism Inspect, adjust

*4❍❍
4-14
Throttle lever Check operation

*4 3-10
Throttle cable Inspect, adjust❍❍
4-13
Choke lever Check operation

*4 2-8
Choke cable Inspect, adjust❍❍
—
Stern drain plugs Inspect, replace

*4❍❍
3-7
Battery Inspect

*5❍❍
4-19
Rubber coupling Inspect❍
—
Engine mount Inspect❍
—
Nuts and bolts Inspect❍❍❍
—
*1: Grease capacity: 33.0–35.0 cm3 (1.11–1.18 oz)
*2: Grease capacity: 6.0–8.0 cm3 (0.20–0.27 oz)
*3: After every use
*4: Before every use
*5: Inspect fluid level before every use
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4-15
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EJU01106
Cleaning and adjusting the
spark plugs
The spark plug is an important engine
component and is easy to inspect. The con-
dition of the spark plug can indicate some-
thing about the condition of the engine. For
example, if the center electrode porcelain is
very white, this could indicate an intake air
leak or carburetion problem in that cylinder.
Do not attempt to diagnose any problems
yourself. Have a Yamaha dealer service the
watercraft.
Remove and inspect the spark plug peri-
odically; heat and deposits will cause the
spark plug to slowly break down and erode.
If electrode erosion becomes excessive, or if
carbon and other deposits are excessive,
replace the spark plug with the specified
plug.
Measure the spark plug gap a with a
wire thickness gauge before installing the
spark plug. Adjust the gap to specification if
necessary.
To reinstall spark plug:
1. Clean the gasket surface.
2. Wipe any dirt from the threads of the
spark plug.
3. Screw the spark plug to the correct
torque. Standard spark plug: BR8ES-11
Spark plug gap:
1.0–1.1 mm (0.039–0.043 in)
Spark plug torque:
25 N·m (2.5 kgf·m, 18 ft·lb)
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5-8
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EJU01909
Submerged watercraft
If the watercraft is submerged or flooded
with water, follow the procedure below and
consult a Yamaha dealer as soon as possi-
ble. Failure to do so may result in serious
engine damage!
In an emergency:
1. Beach the watercraft and remove the
stern drain plugs to drain the water from
the engine compartment.
2. Turn the fuel cock knob to “OFF.”
3. Remove the spark plugs and dry them
with a cloth.
4. Without reinstalling the spark plugs,
crank the engine until all the water in the
cylinders has been drained.
5. Install the stern drain plugs and the
spark plugs.
6. Turn the fuel cock to “ON.”
7. Launch the watercraft into the water, and
then run the engine for at least
10 minutes. If the engine does not start,
proceed to step 9.
8. Turn the engine off.
9. Turn the fuel cock to “OFF.”
10. Have the watercraft inspected by a
Yamaha dealer as soon as possible.
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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
UF0X73.book Page 1 Thursday, July 11, 2002 3:56 PM