YAMAHA GP800R 2003 Owners Manual

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EJU01842
Inspecting the QSTS
mechanism
Check that the shift lock lever moves back
to the lock position smoothly, that the QSTS
selector locks and unlocks properly, and that
the jet thrust nozzle moves up or down.
1. Squeeze and release the shift lock lever.
2. Check that the QSTS selector locks
when the lever is released.
3. Check that the selector turns smoothly
when the lever is squeezed and held in
place.
4. Check that the angle of the jet thrust
nozzle changes when the selector is
shifted from neutral to bow up or bow
down.
If the mechanism does not work properly,
have a Yamaha dealer service it.
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EJU01341
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
Spark plug gap:
0.7–0.8 mm (0.028–0.031 in)
Spark plug torque:
25 N·m (2.5 kgf·m, 18 ft·lb)
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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.
@
EJU01141
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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Throttle cable (handlebar end)
Pull the throttle lever and remove the
seal1. Spray a rust inhibitor into the
outer cable. Refit the seal securely.

Steering cable (handlebar end)

Steering cable (nozzle end)

Nozzle pivot shaft

QSTS cable (nozzle end)

QSTS cables (pulley end)
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QSTS cables (handlebar end)
Remove the QSTS cable housing. Spray
a rust inhibitor into the outer cable.
Reinstall the QSTS cable housing.

YPVS cable

Choke cable (handlebar side)
Spray the rust inhibitor into the outer
cable.

Intermediate housing
Using a grease gun, fill the intermediate
housing with water-resistant grease
through the grease nipple 1.
Grease capacity:
Initial 10 hours or 1 month:
33.0–35.0 cm
3 (1.11–1.18 oz)
Every 100 hours or 12 months:
6.0–8.0 cm
3 (0.20–0.27 oz)
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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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To replenish the battery:
1. Make sure that the electrolyte level is
between the upper 1 and lower 2 level
marks.
2. Refill the battery with distilled water if
necessary.
CAUTION:@ Normal tap water contains minerals that
are harmful to a battery. Use only dis-
tilled water for replenishing the battery.
@
To recharge the battery:
CAUTION:@ Do not attempt to charge a battery hast-
ily. Battery life could be shortened.
@
It is recommended to have a Yamaha
dealer charge the battery. If you charge the
battery yourself, carefully read the battery
charger instructions before charging and fol-
low the points below.
1. Remove all caps from the battery cell.
2. Add distilled water to the specified level if
the electrolyte level is low.
3. Set the charging rate to 1.9 ampere and
charge the battery slowly until the explo-
sive gases are discharged vigorously
from the battery cells.
To connect the battery terminals:
1. Make sure that the connections are cor-
rect when you install the battery in the
watercraft.
2. Make sure that the breather hose is
properly connected and that it is not
damaged or obstructed.
3. Make sure that the battery is securely
held in place.
1Positive (+): Red lead
2Negative (–): Black lead
3Breather hose
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EJU01109
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 tachome-
ter 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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EJU01263
Replacing the fuse
The fuse is in the electrical box 1.
To replace the fuse:
1. Remove the cap 2, pull out the red lead,
and bring the fuse holder 3 out of the
electrical box.
2. Open the fuse holder and replace the
fuse 4 with one of the correct amper-
age.
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
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EJU01113
Adjusting the Yamaha
Adjustable Sponson (Y.A.S.)
The Yamaha Adjustable Sponsons can be
adjusted to enhance watercraft performance
according to operator preference and oper-
ating conditions. (See page 2-19 for an
explanation of various positions.)
To adjust the Y.A.S.:
1. Remove the bolts 1 on both sponsons.
2. Remove both sponsons, and then install
them in the desired position.
NOTE:@ Be sure to install both sponsons to the same
level.
@
3. Tighten the bolts on both sponsons to
the correct torque.
Tightening torque:
18 N·m (1.8 kgf·m, 13 ft·lb)
UF0W72.book Page 23 Thursday, August 22, 2002 1:27 PM