fuel filter YAMAHA GP800R 2003 Owners Manual

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
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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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EJU01355
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-***(
) 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
6
months12
months12
months24
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, clean, replace❍❍
4-11
Fuel tank Clean❍
4-11
Oil injection system Inspect, clean❍❍
4-12
Trolling speed Inspect, adjust


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

*3 4-1
Water inlet strainer Inspect, clean❍❍
—
Bilge strainer Clean


—
Impeller Inspect

*4❍❍
—
Jet thrust nozzle angle Inspect


4-13
QSTS mechanism Inspect, adjust

*4❍❍
4-14
Throttle lever Check operation

*4 3-10
Throttle cable Inspect, adjust❍❍
4-13
Choke lever Check operation

*4 2-8
Choke cable Inspect, adjust❍❍
—
Stern drain plugs Inspect, replace

*4❍❍
3-7
Battery Inspect

*5❍❍
4-19
Rubber coupling Inspect❍
—
Engine mount Inspect❍
—
Nuts and bolts Inspect❍❍❍
—
*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)
*3: After every use
*4: Before every use
*5: Inspect fluid level before every use
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EJU01383
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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EJU01953
Fuel filter
This watercraft is equipped with a one-
piece, disposable fuel filter 1. The fuel filter
should be replaced after the initial 10 hours
or first month of operation and every
200 hours or 24 months thereafter, 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.
@
EJU01841
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.
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EJU01116
Troubleshooting
If you have any trouble with your watercraft, use this section to check for the possible
cause.
If you cannot find the cause, or if the procedure for replacement or repair is not described
in this Owner’s/Operator’s Manual, have a Yamaha dealer perform the necessary service.
EJU01367
Troubleshooting chart
TBC-F0X7ETROUBLE POSSIBLE CAUSE REMEDY PAGE
Engine does not
startStarter motor does not turn over
Engine shut-
off switchClip not in place Install clip
2-8
Fuse Burned out Replace the fuse and
check wiring4-22
Battery Run down Recharge 4-19
Poor terminal connec-
tionsTighten as required
4-19
Terminal corroded Clean—
Starter motor Faulty Have serviced by
Yamaha dealer—
Starter motor turns over
Fuel cock Turned to “OFF”Turn the fuel cock to
“ON”2-7
Fuel Empty Refill as soon as possi-
ble3-3
Stale or contaminated Have serviced by
Yamaha dealer4-10
Fuel tank Water or dirt present Have serviced by
Yamaha dealer4-11
Spark plug Fouled or defective Clean or replace 4-15
Spark plug cap Not connected or loose Connect properly 4-15
Crankcase Filled with water Crank engine with plug
out until clean5-8
Fuel filter Clogged or water
pooledHave serviced by
Yamaha dealer4-11
Choke Choke valve can not be
closed surely by lever
operationHave serviced by
Yamaha dealer—
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Engine runs irregu-
larly or stallsFuel Empty Refill as soon as possi-
ble3-3
Stale or contaminated Have serviced by
Yamaha dealer4-10
Choke Lever is moved to on Move back to original
position2-8
Fuel filter Clogged or water
pooledHave serviced by
Yamaha dealer4-11
Fuel tank Water or dirt present Have serviced by
Yamaha dealer4-11
Spark plug Fouled or defective Replace 4-15
Incorrect heat range Replace 4-15
Gap incorrect Adjust 4-15
Spark plug cap Loose Connect properly 4-15
Cracked, torn, or dam-
agedReplace
—
Electrical wir-
ingLoose connection Tighten or connect
properly—
Carburetor Incorrect idle adjust-
mentAdjust idle
4-21
Clogged Have serviced by
Yamaha dealer—
Warning light or
indicator blinksFuel level Empty Refill as soon as possi-
ble3-3
Engine oil level Empty Refill immediately 3-4
Oil filter clogged Clean 4-12
Engine over-
heatedJet intake clogged Clean
5-4
Low battery
voltageBattery voltage low Charge 4-19
Battery terminal con-
nected wrongConnect properly
4-19 TROUBLE POSSIBLE CAUSE REMEDY PAGE
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Wate rcr af t slow or
loses powerCavitation Jet intake clogged Clean 5-4
Impeller damaged or
wornHave serviced by
Yamaha dealer—
Engine over-
heatedJet intake clogged Clean
5-4
Fuel filter Clogged Have serviced by
Yamaha dealer4-11
Spark plug Fouled or defective Replace 4-15
Incorrect heat range Replace 4-15
Gap incorrect Adjust 4-15
Spark plug
capsLoose Connect properly
4-15
Electrical wir-
ingLoose connection Tighten or connect
properly—
Fuel Stale or contaminated Have serviced by
Yamaha dealer4-10
Bilge Water in bilge Drain 3-7 TROUBLE POSSIBLE CAUSE REMEDY PAGE
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Index
2-stroke engine oil ................................... 3-2
A
Adjusting the carburetor ........................ 4-21
Adjusting the trolling speed ................... 4-21
Adjusting the Yamaha Adjustable
Sponson (Y.A.S.) .................................. 4-23
B
Battery .............................................. 3-8, 4-5
Beaching the watercraft ........................ 3-30
Bilge ........................................................ 3-7
Bleeding the oil injection pump ............. 4-22
Boarding alone ...................................... 3-23
Boarding and starting in deep water ..... 3-23
Boarding with a passenger.................... 3-24
Bow down.............................................. 2-12
Bow up .................................................. 2-12
C
Capsized watercraft .............................. 3-25
Choke lever ............................................. 2-8
Cleaning and adjusting the
spark plugs ............................................ 4-15
Cleaning the jet intake and impeller ........ 5-4
Cleaning the watercraft ........................... 4-6
Connecting the jumper cables................. 5-6
Cooling water pilot outlet .............. 2-10, 3-12
Cruising limitations .................................. 1-8
D
Docking the watercraft .......................... 3-30
E
Emergency procedures ........................... 5-4
Engine break-in ..................................... 3-13
Engine compartment ............................... 3-6
Engine overheat warning indicator ........ 2-17
Engine overheat warning system .......... 2-13
Engine serial number .............................. 1-1
Engine shut-off cord (lanyard) ............... 3-11
Engine shut-off switch ............................. 2-8
Engine stop switch .................................. 2-8
Enjoy your watercraft responsibly ......... 1-14F
Filling the fuel tank .................................. 3-3
Filling the oil tank .................................... 3-4
Fire extinguisher ...................................... 3-9
Flushing the cooling system .................... 4-1
Front storage compartment ................... 2-18
Fuel and oil.............................................. 3-1
Fuel and oil systems ............................... 3-6
Fuel cock knob ........................................ 2-7
Fuel filter ............................................... 4-11
Fuel meter ............................................. 2-16
Fuel system ............................................. 4-4
Fuel tank ............................................... 4-11
Fuel tank filler cap ................................... 2-6
Fuel warning indicator ........................... 2-17
G
Gasohol ................................................... 3-2
Gasoline .................................................. 3-1
Getting to know your watercraft ............ 3-19
Glove compartment ............................... 2-19
H
Handgrip ................................................ 2-12
Hazard information ................................ 1-12
Hood........................................................ 2-6
Hour meter ............................................ 2-16
Hull Identification Number (HIN).............. 1-1
I
Identification numbers ............................. 1-1
Important labels ....................................... 1-2
Inspecting and adjusting the
throttle cable.......................................... 4-13
Inspecting the battery ............................ 4-19
Inspecting the fuel system ..................... 4-10
Inspecting the jet thrust nozzle angle .... 4-13
Inspecting the oil injection system ......... 4-12
Inspecting the QSTS mechanism .......... 4-14
J
Jet unit................................................... 3-11
Jumping the battery ................................. 5-5
L
Label location .......................................... 1-2
Learning to operate your watercraft ...... 3-19
Leaving the watercraft ........................... 3-18
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