maintenance YAMAHA GP800R 2002 Owners Manual

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EJU00989
To the owner/operator
Thank you for choosing a Yamaha water-
craft.
This Owner’s/Operator’s Manual contains
information you will need for proper opera-
tion, maintenance, and care. A thorough
understanding of these simple instructions
will help you to obtain maximum enjoyment
from your new Yamaha. If you have any
questions about the operation or mainte-
nance of your watercraft, please consult a
Yamaha dealer.
Because Yamaha has a policy of continu-
ing product improvement, this product may
not be exactly as described in this Owner’s/
Operator’s Manual. Specifications are sub-
ject to change without notice.
This manual should be considered a per-
manent part of this watercraft and should
remain with it even if the watercraft is subse-
quently sold.EJU00990
Important manual information:
In this manual, information of particular
importance is distinguished in the following
ways:
The Safety Alert Symbol means
ATTENTION! BECOME ALERT!
YOUR SAFETY IS INVOLVED!
WARNING@ Failure to follow WARNING instructions
could result in severe injury or death to
the machine operator, passenger, a
bystander, or a person inspecting or
repairing the watercraft.
@
CAUTION:@ A CAUTION indicates special precau-
tions that must be taken to avoid damage
to the watercraft.
@
NOTE:@ A NOTE provides key information to make
procedures easier or clearer.
@
EJU00991
WaveRunner GP800R
OWNER’S/OPERATOR’S MANUAL
©2001 by Yamaha Motor Co., Ltd.
1st Edition, August 2001
All rights reserved.
Any reprinting or unauthorized use
without the written permission of
Yamaha Motor Co., Ltd.
is expressly prohibited.
Printed in USA
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EEJU00992
CONTENTS
READ THIS OWNER’S/OPERATOR’S MANUAL CAREFULLY BEFORE
OPERATING YOUR WATERCRAFT.
GENERAL AND SAFETY
INFORMATION
1
FEATURES AND FUNCTIONS2
OPERATION3
MAINTENANCE AND CARE4
TROUBLESHOOTING AND
EMERGENCY PROCEDURES
5
APPENDIX6
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2-16
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Fuel meter
The fuel meter is provided for convenient
fuel level checking while riding. The fuel
meter has eight segments which show the
amount of fuel remaining in the fuel tank.
NOTE:@ The indication of the segments differs on
your operating condition. Use the meter as a
reference.
@
EJU01032
Hour meter
The hour meter is provided to make it
easy to follow the maintenance schedule.
The meter shows the hours of engine opera-
tion that have elapsed since the watercraft
was new.
NOTE:@
The elapsed time will be kept even if the
battery terminals have been discon-
nected.

If the hour meter malfunctions, “_ _ _ _”
display and the warning light will blink.
@
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MAINTENANCE AND
CARE
Storage ...................................................... 4-1
Flushing the cooling system .................. 4-1
Lubrication .............................................. 4-3
Fuel system ............................................ 4-4
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 steering cable ............... 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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4-1
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Storage
WARNING@ Always place the fuel cock knob in the
“OFF” position when storing the water-
craft, otherwise fuel could leak out into
the engine or engine compartment,
which would create a fire hazard.
@
Storage for prolonged periods of time,
such as winter storage, requires preventa-
tive maintenance to ensure against deterio-
ration. It is advisable to have the watercraft
serviced by a Yamaha dealer prior to stor-
age. However, the following procedures can
be performed by the owner.
EJU01088
Flushing the cooling system
Flushing the cooling system is essential
to prevent the cooling system from being
clogged with salt, sand, or dirt.
CAUTION:@
Do not supply water to the cooling
water passages when the engine is not
running. The water could flow back
through the muffler into the crankcase
causing severe engine damage.

Do not run the engine for more 15 sec-
onds without supplying water, other-
wise the engine may overheat.
@
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4-5
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Battery
If the watercraft is not used for a month or
more, disconnect the (–) battery cable first,
and then the (+) cable and breather pipe,
and next remove the battery from the craft.
Clean the battery casing using fresh
water.
If the battery terminals are dirty or cor-
roded, clean the mating surfaces on the ter-
minals for the battery cables using the wiring
brush or equivalents.
Recharge the battery, and then store it in
a cool and dark place.
Apply the Yamaha marine grease/Yamaha
grease A to the battery terminals.
Recharge the battery periodically at least
2 months because a battery will discharge
electricity by itself while storing.
CAUTION:@ The battery may be impossible to use
again if you store it for a longer time
without recharging. Recharge the battery
periodically.
@
NOTE:@ The battery condition can be found by
checking the specific gravity of the electro-
lyte. However, you can also know the battery
condition roughly by measuring the voltage
at both battery terminals. Recharge the bat-
tery if the voltage is 12 volts or less.
Yamaha recommend checking the specific
gravity of the electrolyte and charging bat-
tery by a Yamaha dealer or a battery dealer.
If you maintain the battery yourself, read
carefully the instructions for the tool and
machine before maintenance.
@
Specific gravity of electrolyte
(for reference):
1.28 at 20 °C (68 °F)
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4-7
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Maintenance and
adjustments
Periodic inspection, adjustment and lubri-
cation will keep your watercraft in the safest
and most efficient condition possible. Safety
is an obligation of the watercraft owner. The
most important points of watercraft inspec-
tion, adjustment and lubrication are
explained on the following pages.
See your Yamaha dealer for genuine
Yamaha replacement parts and optional
accessories designed for your watercraft.
Remember that failures that are the result
of the installation of parts or accessories
which are not qualitatively equivalent to gen-
uine Yamaha parts are not covered by the
limited warranty.
WARNING@
Be sure to turn off the engine when
you perform maintenance unless oth-
erwise specified, otherwise an acci-
dent or injury could result from
unexpected operation, moving parts,
or electric shock. If the owner is not
familiar with watercraft servicing, this
work should be done by a Yamaha
dealer. Improperly serviced compo-
nents could fail or stop operating cor-
rectly, which could result in an
accident.

Modifications to this watercraft not
approved by Yamaha may cause loss
of performance or excessive noise, or
render it unsafe for use. Consult a
Yamaha dealer before attempting any
changes.
@
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4-8
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Owner’s/Operator’s Manual
and tool kit
It is advisable always to carry the
Owner’s/Operator’s Manual and tool kit 2
with you whenever you use the watercraft.
For your convenience, a storage compart-
ment 1 is provided on the watercraft for the
manual and tool kit.
NOTE:@ To protect these materials from water dam-
age, it would be a good idea to put them in a
waterproof bag.
@
The service information included in this
manual is intended to provide you with the
necessary information for completing your
own preventive maintenance and minor
repairs. The tools provided in the tool kit are
sufficient for this purpose. However, a torque
wrench may also be necessary to tighten
nuts and bolts.
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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-F0X7E(
) 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
3
months6
months6
months12
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, replace❍❍
4-11
Fuel tank Clean❍
4-11
Oil injection system Inspect, clean❍❍
4-12
Trolling speed Adjust


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

(after
ever y
use)4-1
Bilge strainer Clean



—
Impeller Inspect



—
Steering cable Inspect


4-13
QSTS mechanism Inspect


4-14
Throttle cable Inspect, adjust


4-13
Stern drain plugs Inspect, replace

3-7
Battery Inspect



(inspect
fluid level
before
ever y
use)
4-19
Rubber coupling Inspect❍
—
Nuts and bolts Tighten❍❍❍
—
*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)
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4-21
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Adjusting the carburetor
The carburetor is a vital part of the engine
and requires very sophisticated adjustment.
Most adjusting should be left to a Yamaha
dealer who has the professional knowledge
and experience to perform it. However, the
operator may adjust the trolling speed as
part of the usual maintenance routine.
CAUTION:@ The carburetor was set at the Yamaha
factory after many tests. If the settings
are disturbed by someone who does not
have the necessary technical knowledge,
poor engine performance and damage
may result.
@
EJU01344
Adjusting the trolling speed
1. Put the watercraft in the water.
2. Start the engine and warm it up for 1 or 2
minutes. Using a diagnostic tachometer
or, if necessary, the tachometer in the
multifunction information center, adjust
the engine speed to specification.
3. Turn the throttle stop screw 1 clockwise
to increase engine speed if necessary.
Turn it counterclockwise to decrease
engine speed if necessary.
Trolling speed: 1,250–1,350 r/min
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