cooling YAMAHA GP800R 2002 Owners Manual

E
2
EJU01007
FEATURES AND
FUNCTIONS
Location of main components .............. 2-1
Operation of controls and other
functions ................................................... 2-5
Seat ........................................................ 2-5
Hood ....................................................... 2-6
Fuel tank filler cap .................................. 2-6
Oil tank filler cap ..................................... 2-6
Fuel cock knob ....................................... 2-7
Engine stop switch ................................. 2-8
Engine shut-off switch ............................ 2-8
Choke lever ............................................ 2-8
Throttle lever .......................................... 2-9
Start switch ............................................. 2-9
Cooling water pilot outlet ..................... 2-10
Steering system ................................... 2-10
Quick Shift Trim System (QSTS)
selector ................................................. 2-11
Handgrip ............................................... 2-12
Engine overheat warning system ........ 2-13
Multifunction information center .......... 2-14
Tachometer .......................................... 2-15
Speedometer ....................................... 2-15
Reset button ......................................... 2-15
Fuel meter ............................................ 2-16
Hour meter ........................................... 2-16
Fuel warning indicator .......................... 2-17
Oil warning indicator ............................ 2-17
Engine overheat warning indicator ...... 2-17
Storage compartments ........................ 2-18
Yamaha Adjustable Sponson
(Y.A.S.) ................................................. 2-19
UF0W71.book Page 1 Thursday, August 30, 2001 3:46 PM

2-2
E
1Cooling water pilot outlet
Use to verify cooling water flow.
2Bow eye
Use to attach rope for transporting, mooring or
towing the watercraft in an emergency.
3Front storage compartment
4Hood
5Jet intake
6Handgrip
7Seat
8Glove compartment
9Yamaha Adjustable Sponson (Y.A.S.)
UF0W71.book Page 2 Thursday, August 30, 2001 3:46 PM

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
UF0W71.book Page 4 Thursday, August 30, 2001 3:46 PM

2-10
E
EJU01020
Cooling water pilot outlet
This watercraft is equipped with a cooling
water pilot outlets.
When the engine is running, cooling
water is circulated in the engine, and then it
is discharged from the pilot outlets.
To check for proper operation of the cool-
ing system, check that water is being dis-
charged from the pilot outlets. If water is not
being discharged from the outlets, cooling
water may not be circulating in the engine.
When this occurs, stop the engine and
check for the cause. (See pages 2-13 and
5-4 for further instructions.)
NOTE:@ If the cooling water passages are dry, it will
take about 20 seconds for the water to reach
the outlet after the engine is started.
@
EJU01021
Steering system
Your watercraft can be steered by turning
the handlebars 1 the same direction you
wish to travel.
When the handlebars are turned, the
angle of the jet thrust nozzle 2 is changed,
and the direction of the watercraft is
changed accordingly. Since the strength of
the jet thrust determines the speed and
direction of a turn, the throttle must always
be open when attempting a turn, except at
trolling speed.
UF0W71.book Page 10 Thursday, August 30, 2001 3:46 PM

2-13
E
EJU01140
Engine overheat warning
system
This model is equipped with an engine
overheat warning system.
If the engine starts to overheat, the warn-
ing light and the engine overheat warning
indicator begin to blink, the buzzer sounds,
and the engine speed will be limited to about
3,400 r/min.
When this occurs, check for water dis-
charge at the cooling water pilot outlet. If
there is no discharge of water, reduce the
engine speed and beach the watercraft, and
then check the intake grate and impeller for
clogging.
WARNING@ Before attempting to remove weeds or
debris from the intake grate or impeller,
shut the engine off and remove the clip
from the engine shut-off switch. Severe
injury or death could result from coming
in contact with the rotating parts of the
jet pump.
@
CAUTION:@ If you cannot locate and correct the
cause of the overheating, consult a
Yamaha dealer. Continuing to operate at
higher speeds could result in severe
engine damage.
@
NOTE:@ Press the reset button on the multifunction
information center to stop the buzzer.
@
UF0W71.book Page 13 Thursday, August 30, 2001 3:46 PM

3-5
E
EJU01346
Pre-operation checks
EJU01047
Pre-operation check list
Before operating this watercraft, perform the checks in the following check list. See the
accompanying text in this chapter for details on how to perform the checks.
WARNING@ If any item in the pre-operation check list is not working properly, have it inspected
and repaired before operating the watercraft, otherwise an accident could occur.
@
POC-F0X7E
NOTE:@ Pre-operation checks should be made thoroughly each time the watercraft is used. This pro-
cedure can be completed in a short time. It is worth the time spent to assure safety and reli-
ability.
@
ITEM ROUTINE PAGE
Engine compartment Remove the seat and front storage compartment
to ventilate engine compartment. Check for fuel
vapors or loose electrical connections3-6
Bilge Check for water and fuel residue and remove if
necessary3-7
Throttle Check that the throttle lever springs back 3-10
Steering system Check for proper steering system operation 3-10
Fuel and oil Check fuel and oil level and add if necessary
Check hoses and tanks for leakage3-6
Water separator Check for water and drain if necessary 3-7
Battery Check electrolyte level and battery condition 3-8
Hood Check that the hood is properly secured 2-6
Seat Check that the seat is properly secured 2-5
Hull/Deck Check the hull and deck for cracks or other dam-
age—
Jet unit Check for debris and remove if necessary 3-11
Fire extinguisher Check the condition and replace if necessary 3-9
Engine shut-off cord Check condition and replace is frayed or broken 3-11
Switches Check the start switch, engine stop switch and
engine shut-off switch for proper operation when
the watercraft is in the water3-12
Cooling water pilot outlet Check that water is discharged while the engine
is running and the watercraft is in the water3-12
Multifunction information center Check for warning indications and proper opera-
tion3-12
UF0W71.book Page 5 Thursday, August 30, 2001 3:46 PM

3-11
E
EJU01058
Jet unit
Carefully check the jet intake for weeds,
debris, or anything else that might restrict
the intake of water. If the intake is clogged,
cavitation could occur, reducing jet thrust,
and possibly damaging the jet pump.
In some cases, the engine may overheat
because of lack of cooling water, and dam-
age to the engine could result. Engine cool-
ing water is fed to the engine by the jet
pump. (See page 5-4 for jet intake cleaning
procedures.)
WARNING@
Keep away from intake grate while
engine is on. Items such as long hair,
loose clothing, or PFD straps can
become entangled in moving parts
resulting in severe injury or drowning.

Stop the engine and remove the clip
from the engine shut-off switch before
removing any debris or weeds, which
may have collected around the jet
intake.
@
EJU01059
Engine shut-off cord (lanyard)
Check that the engine shut-off cord is not
frayed or broken. If the cord is damaged,
replace it; never try to repair it or tie it
together.
UF0W71.book Page 11 Thursday, August 30, 2001 3:46 PM

3-12
E
EJU01060
Switches
Check the start switch 1, the engine stop
switch 2, and the engine shut-off switch 3
for proper operation.
To check these switches place the water-
craft in the water to provide adequate cooling.
Start the engine, and then pull the engine
shut-off cord 5 to remove the clip 4 from the
engine shut-off switch. Verify that the engine
stops immediately. (See pages 3-15 to 3-18
for information on proper operation of the
start switch, the engine stop switch and the
engine shut-off switch.)
EJU01061
Cooling water pilot outlet
Check that water comes out from the out-
lets while the engine is running and the
watercraft is in the water.
EJU01062
Multifunction information center
Check the operation of the multifunction
information center. (See pages 2-14 to 2-17
for multifunction information center.)
UF0W71.book Page 12 Thursday, August 30, 2001 3:46 PM

3-31
E
EJU01084
Post-operation checks
Always perform the following post-opera-
tion checks after operating the watercraft.
1. Remove the watercraft from the water.
2. Wash down the hull, handlebars, and jet
unit with fresh water.
3. Remove the seat and check the engine
compartment for water. To drain excess
water, remove the stern drain plugs, then
raise the bow of the watercraft enough to
allow water in the bilge to drain out.
NOTE:@ This watercraft is equipped with an auto-
matic bilge-draining system that removes
water from the engine compartment while
you are underway. However, some residual
water will remain.
@
4. Put the watercraft in a horizontal posi-
tion.
5. Flush the cooling system to prevent it
from clogging with salt, sand, or dirt.
(See pages 4-1 to 4-2 for flushing the
cooling system procedures.)
6. Drain residual water from the exhaust
system by alternately squeezing and
releasing the throttle lever for 10 to 15
seconds while the engine is running.
CAUTION:@ 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 or
seize.
@
7. If the watercraft will be stored for a week
or more, lubricate internal engine com-
ponents to help prevent corrosion. (See
page 4-3 for lubrication procedures.)
UF0W71.book Page 31 Thursday, August 30, 2001 3:46 PM

E
4
EJU01086
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
UF0W71.book Page 1 Thursday, August 30, 2001 3:46 PM