YAMAHA GP800R 2002 Manual Online

4-2
E
1. Put the watercraft on land in a horizontal
position.
2. Open the flushing hose connector
cap1, and then insert the garden hose
adapter 2 into the flushing hose con-
nector 3 and turn it until it is securely
connected.
3. Connect the garden hose adapter to a
water tap using a hose.
4. Start the engine, and then immediately
turn the water supply on until water flows
out continually from the cooling water
pilot outlet.
5. Run the engine at idling speed for about
3 minutes watching the engine condition.
If the engine stops while flushing, turn
the water supply off immediately and
repeat the above steps.
6. Turn the water supply off, and then force
the remaining water out from the cooling
passages by alternately squeezing, and
releasing the throttle lever for 10 to 15
seconds.
7. Stop the engine.
8. Remove the garden hose adapter and
secure the cap.
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4-3
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Lubrication
WARNING@ To reduce the risk of fire or explosion:
Never pour or spray gasoline, or any sub-
stance other than a rust inhibitor through
the hole in the carburetor silencer cover.
@
CAUTION:@
Make sure to replace the cap securely
after fogging the engine, otherwise
water could enter the engine and
cause damage.

Do not attempt to run the engine at full
throttle or for more than 15 seconds
while the watercraft is out of the water,
otherwise the engine may overheat
and/or seize.
@
1. Open the silencer cap 1 on the silencer.
2. Start the engine with the watercraft in a
well-ventilated area.
3. With the engine running at a fast idle,
quickly spray as much rust inhibitor as
possible through the hole in the silencer
cover. Keep spraying until the engine
stalls (or a maximum of 15 seconds).
4. Install the cap securely.
5. 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.
@
6. Lubricate the areas of the watercraft
specified under Lubrication points on
page 4-16.
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4-4
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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 is highly flammable and explo-
sive. A fire or explosion can cause
severe injury or death. Shut the engine
off. Drain in well-ventilated areas away
from flames or sparks. Do not smoke.
Avoid spilling gasoline. Wipe up spilled
gasoline immediately.
@
To drain the fuel system:
1. Place the fuel cock knob in the “OFF”
position.
2. Drain the fuel tank using a siphon.
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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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4-6
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Cleaning the watercraft
Clean the watercraft before storing it for a
long period.
1. Wash down the hull, handlebars, and
drive unit with fresh water.
2. Rinse the engine and bilge area with
fresh water. Drain off all water and wipe
up remaining moisture with clean, dry
rags.
3. Spray the engine’s exterior with a rust
inhibitor and lubricant.
4. Wax the hull with a non-abrasive wax.
5. Wipe all vinyl and rubber components,
such as the seat and engine compart-
ment seals, with a vinyl protectant.
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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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4-10
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Inspecting the fuel system
WARNING@ Gasoline is highly flammable and explo-
sive. A fire or explosion can cause
severe injury or death. Shut off the
engine. Do not smoke. Avoid spilling
gasoline.
@
Check the fuel system for leaks, cracks,
or malfunctions. If any problem is found, do
the necessary repair or replacement as
required. If repair is necessary, consult a
Yamaha dealer.
Check:

Carburetor for leakage.

Fuel pump for malfunction or leakage.

Fuel tank for water or dirt.

Fuel tank for damage, cracks or leakage.

Fuel hose joint for leakage.

Fuel hose for cracks or other damage.

Fuel filter for leakage.

Fuel cock for leakage.

Air vent check valve for leakage.

Fuel tank filler cap for damage.
WARNING@ Failure to check for and repair any fuel
leakage may result in fire or explosion.
@
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4-11
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Fuel filter
This watercraft is equipped with a one-
piece, disposable fuel filter 1. The fuel filter
should be replaced once a year or after
every 200 hours of operation, or if water is
found in the filter. Have a Yamaha dealer
replace the fuel filter if necessary.
WARNING@ Do not try to replace the fuel filter your-
self. An incorrectly installed filter can
leak gasoline, which could lead to fire or
explosion. If necessary, have a Yamaha
dealer replace the fuel filter.
@
EJU01099
Fuel tank
Check the fuel tank 1 for leakage or
water in the tank. If water is found in the fuel
system or if the fuel tank needs to be
cleaned have a Yamaha dealer service the
watercraft.
UF0W71.book Page 11 Thursday, August 30, 2001 3:46 PM