engine overheat YAMAHA GP800R 2003 Owners Manual

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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
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2-13
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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.
@
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2-14
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EJU01027
Multifunction information
center
This meter contains following functions for
the help and convenience of operation.
1
Tachometer
2
Speedometer
3
Fuel meter
4
Hour meter
5
Warning light
6
Oil warning indicator
7
Engine overheat warning indicator
8
Fuel warning indicator
9
Reset button
CAUTION:@
Do not run the engine at full throttle or
more than 15 seconds to check the
meter for operation on land. The
engine could overheat.

Use the specified resistor-type spark
plug and cap, otherwise the meter may
function erratically.
@
NOTE:@ All display light up and the buzzer sounds
twice after the engine starts. Then, the
meter will operate normally after few sec-
onds. The current display will continue to
operate for 30 seconds after the engine
stops.
@
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2-17
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EJU01033
Fuel warning indicator
If the fuel remaining in the tank drops to
about 13 L (3.4 US gal, 2.9 Imp gal), the
lowest two fuel level segments, the fuel
warning indicator and the warning light
begin to blink. The buzzer also starts sound-
ing intermittently.
The warning signals will be cleared when
the engine restarts after refilling fuel.
EJU01034
Oil warning indicator
If the oil remaining in the tank drops to
about 1.7 L (0.45 US gal, 0.37 Imp gal) or
the oil filter is clogged, the oil warning indi-
cator and the warning light begin to blink.
The buzzer also starts sounding intermit-
tently.
If the oil warning indicators begin to blink,
refill with engine oil as soon as possible.
The warning signals will be cleared when
the engine restarts after refilling engine oil.
NOTE:@ If the warning indicators blink with adequate
oil in the tank, check the oil filter for clog-
ging.
@
EJU01340
Engine overheat warning
indicator
If the engine starts to overheat, the warn-
ing light and the engine overheat warning
indicator begin to blink, and the buzzer
sounds intermittently.
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3-11
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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.
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3-26
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CAUTION:@ Be sure to remove the clip from the
engine shut-off switch, otherwise the
engine will overheat and engine damage
may occur.
@
1. Shut the engine off by removing the clip
from the engine shut-off switch.
2. Swim to the rear of the watercraft. Pull
the watercraft over with left hand on ride
plate while pushing down on the gun-
wale with your right hand/foot.
NOTE:@ If the port (left) side of the capsized water-
craft is tilting upward, first tilt the watercraft
so the port (left) side is down by using your
weight to press down on the gunwale.
@
CAUTION:@ Do not turn the watercraft over counter-
clockwise, otherwise water may leak into
the carburetor and engine and cause
damage.
@
3. Start the engine, and then head for
shore to inspect the engine for water
damage.
CAUTION:@ If the watercraft has been capsized for
5 minutes or more, air may have entered
the oil injection system. Leave the engine
off, or operate only at trolling speed, for
10 minutes after the watercraft has been
turned right-side up. This will allow any
air to bleed off.
@
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3-31
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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 page 4-1 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.)
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4-1
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EJU01087
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 seconds without supplying water,
otherwise the engine may overheat.
@
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4-3
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EJU01299
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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5-4
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EJU01118
Emergency procedures
EJU01119
Cleaning the jet intake and
impeller
If weeds or debris get caught in the intake
or impeller, cavitation can occur, causing jet
thrust to decrease even though engine
speed rises. If this condition is allowed to
continue, the engine will overheat and may
seize. If there is any sign that the jet intake
or impeller is clogged with weeds or debris,
beach the watercraft and check the intake
and impeller. Always stop the engine before
beaching the watercraft.
WARNING@ Before attempting to remove weeds or
debris from the jet intake or impeller
areas, shut the engine off and remove
the clip from the engine shut-off switch.
Severe injury or death could result from
contact with the rotating parts of the jet
pump.
@
1. Turn the watercraft on its side as shown.
CAUTION:@
Place a suitable clean cloth or carpet-
ing underneath the watercraft to pro-
tect it from abrasions and scratches.

Always turn the watercraft over onto
its port (left) side.

When turning the watercraft on its
side, support the bow so the handle-
bars cannot be bent or damaged.
@
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