Yamaha GP800R WaveRunner 2003 Owner'S/Operator'S Manual Download Page 98

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4-17

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Steering cable (nozzle end)

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Nozzle pivot shaft

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QSTS cable (nozzle end)

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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.

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YPVS cable

UF0W13.book Page 17 Tuesday, July 8, 2003 9:09 AM

Summary of Contents for GP800R WaveRunner 2003

Page 1: ...2004 WaveRunner GP800R OWNER S OPERATOR S MANUAL ...

Page 2: ......

Page 3: ...h it even if the watercraft is subse quently sold EJU00990 Important manual information In this manual information of particular importance is distinguished in the following ways The Safety Alert Symbol means ATTENTION BECOME ALERT YOUR SAFETY IS INVOLVED WARNING Failure to follow WARNING instructions could result in severe injury or death to the machine operator passenger a bystander or a person ...

Page 4: ...AD THIS OWNER S OPERATOR S MANUAL CAREFULLY BEFORE OPERATING YOUR WATERCRAFT GENERAL AND SAFETY INFORMATION 1 FEATURES AND FUNCTIONS 2 OPERATION 3 MAINTENANCE AND CARE 4 TROUBLESHOOTING AND EMERGENCY PROCEDURES 5 APPENDIX 6 ...

Page 5: ... labels 1 5 Safety information 1 7 Limitations on who may operate the watercraft 1 7 Cruising limitations 1 8 Operation requirements 1 9 Recommended equipment 1 12 Hazard information 1 12 Watercraft characteristics 1 13 Rules of the Road 1 14 Steering and sailing rules 1 14 Rules when encountering vessels 1 15 Other special situations 1 16 Reading buoys and other markers 1 16 To get more boating s...

Page 6: ...d and keep these ID numbers in a separate place in case your watercraft is stolen EJU01831 Primary Identification PRI ID number The PRI ID number is stamped on a label 1 attached inside the engine compartment EJU01884 Hull Identification Number HIN The HIN is stamped on a plate 2 attached to the hull on the aft starboard right side EJU00997 Engine serial number The engine serial number is stamped ...

Page 7: ...arine SI engines EJU01392 Approval label of Emission control certificate This label is attached to the electrical box and the exhaust side of the crankcase 1 Emission control information label EJU01393 Manufactured date label This label is attached to the electrical box and the exhaust side of the crankcase 2 Manufactured date label ...

Page 8: ...1 3 E EJU00998 Important labels EJU01351 Label location ...

Page 9: ...1 4 E EJU01352 Warning labels 1 ...

Page 10: ...1 5 E 4 6 5 2 3 ...

Page 11: ...1 6 E EJU01354 Other labels 7 8 9 0 B C A ...

Page 12: ...he video may help rein force the information contained in these materials EJU01178 Limitations on who may operate the watercraft Yamaha recommends a minimum opera tor age of 16 years old Adults must supervise use by minors Know the operator age and training requirements for your state A boating safety course is recommended and may be required in your state You can find local rules by contacting th...

Page 13: ...rmance boat not a toy Sharp turns or jumping wakes or waves can increase the risk of back spinal injury paralysis facial injuries and bro ken legs ankles and other bones Do not jump wakes or waves Do not operate the watercraft in rough water bad weather or when visibility is poor this may lead to an accident caus ing injury or death Be alert to the possi bility of adverse weather Take note of weat...

Page 14: ...lling into water or being near the jet thrust nozzle Normal swimwear does not adequately protect against forceful water entry into rectum or vagina All riders must wear a wetsuit bottom or clothing that provides equivalent protection Such clothing includes thick tightly woven sturdy and snug fitting apparel such as denim but does not include spandex or similar fab rics like those used in bicycle s...

Page 15: ...iding conditions Consider factors such as your riding environment and your riding style and ability Also consider the likelihood of traffic congestion and the water surface conditions If you decide to wear a helmet based upon your riding cir cumstances choose one carefully Look for a helmet designed for personal water craft use if possible Consider a helmet meeting Snell or DOT standards If you wi...

Page 16: ...You should always take the responsibility to watch for traffic other boaters may not be watching for you If they do not see you or you maneuver more quickly than other boaters expect you risk a collision Maintain a safe distance from other boats or watercraft and also watch for boats ski ropes or fishing lines Obey the Rules of the Road and be sure to check behind you before making a turn See Rule...

Page 17: ...al Contact your Yamaha dealer or the Coast Guard for more information Watch A watch is helpful so you will know how long you have been operating Towline A towline can be used to tow a disabled watercraft in an emergency EJU01003 Hazard information When transporting or storing your water craft always place the fuel cock knob in the OFF position otherwise gasoline may overflow from the carburetor Ne...

Page 18: ...ave a good feel for this maneuver This watercraft is water jet propelled The jet pump is directly connected to the engine This means that jet thrust will pro duce some movement whenever the engine is running There is no neutral position Keep away from intake grate 1 while the engine is on Items such as long hair loose clothing or PFD straps can become entangled in moving parts resulting in severe ...

Page 19: ...er meet one another one vessel has the right of way it is called the stand on vessel The vessel that does not have the right of way is called the give way or burdened vessel These rules determine which vessel has the right of way and what each vessel should do Stand on vessel The vessel with the right of way has the duty to continue its course and speed except to avoid an immediate collision When ...

Page 20: ...each other Meeting If you are meeting another power vessel head on and are close enough to run the risk of collision neither of you has the right of way Both of you should alter course to avoid an accident You should keep the other vessel on your port left side This rule does not apply if both of you will clear one another if you continue on your set course and speed Crossing When two power driven...

Page 21: ...ve the right of way regardless of position Fishing vessels can not however impede the passage of other vessels in narrow channels Sailing vessel right of way Sailing vessels should normally be given the right of way The exceptions to this are 1 When the sailing vessel is overtaking the power driven vessel the power driven vessel has the right of way 2 Sailing vessels should keep clear of any fishi...

Page 22: ...isory information These mark ers are white with black letters and orange borders They signify speed zones restricted areas danger areas and general information Remember markings may vary by geo graphic location Always consult local boat ing authorities before riding your watercraft in unfamiliar waters ...

Page 23: ...s a free 50 question learning course available to the public Upon successful completion of 80 percent or better the user can request a certificate of completion by mail or can download one immediately The Online Boating Safety Course provided by the Boat US Foundation is approved by the National Association of State Boating Law Administrators NASBLA and recognized by the United States Coast Guard ...

Page 24: ...riding close to shoreline homes and waterfowl nesting areas or other wildlife areas and keep a respectful distance from fishermen other boats swimmers and populated beaches When travel in areas like these is unavoid able ride slowly and obey all laws Remember that pollution can be harmful to the environment Do not refuel or add oil where a spill could cause damage to nature Remove your watercraft ...

Page 25: ...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...

Page 26: ...ocation of main components 1 Handlebars Use to control direction 2 Fuel tank filler cap 3 Rope hole 4 Footwell Use to place feet for balance 5 Intake grate Prevents debris from getting into the jet pump 6 Speed sensor ...

Page 27: ...o verify cooling water flow 2 Bow eye Use to attach rope for transporting mooring or towing the watercraft in an emergency 3 Front storage compartment 4 Hood 5 Jet intake 6 Handgrip 7 Seat 8 Glove compartment 9 Yamaha Adjustable Sponson Y A S ...

Page 28: ... Shift Trim System QSTS selector Use to select the trim angle of the watercraft 5 Engine shut off switch Remove the clip to stop the engine and dis able it from starting 6 Start switch Push to start the engine 7 Multifunction information center Use to check watercraft operation 8 Throttle lever Use to accelerate and decelerate 9 Choke lever 0 Oil tank filler cap A Fuel cock knob B Stern drain plug...

Page 29: ...rical box Protects electrical components from water 3 Flush hose connector Use to flush the engine cooling water pas sages 4 Spark plug lead 5 Muffler 6 Fuel filter 7 Fuel tank 8 Oil tank 9 Battery 0 Fire extinguisher container A Water separator ...

Page 30: ...move the seat To remove the seat Pull the seat latch up and then pull the seat off To install the seat Insert the projection on the front of the seat into the stay on the deck and then push the rear of the seat down to lock it in place securely NOTE Make sure that the seat is properly secured before operating the watercraft ...

Page 31: ...perating the watercraft EJU01012 Fuel tank filler cap To remove the fuel tank filler cap 1 turn it counterclockwise NOTE Make sure that the fuel tank filler cap is properly secured before operating the water craft EJU01013 Oil tank filler cap To remove the oil tank filler cap 2 turn it counterclockwise NOTE Make sure that the oil tank filler cap is prop erly secured before operating the watercraft...

Page 32: ...ion when the engine is not running ON With the fuel cock knob in this position fuel flows to the carburetors Turn the fuel cock knob to this position when starting the engine and operating the watercraft RES This indicates reserve With the fuel cock knob in this position the fuel reserve is made available Turn the fuel cock knob to this position if you run out of fuel while oper ating the watercra...

Page 33: ...lls off the watercraft WARNING Always attach the engine shut off cord to your wrist and the clip to the engine shut off switch BEFORE starting the engine To prevent accidental starting of the engine or unauthorized use by chil dren or others always remove the clip from the shut off switch when the engine is not running EJU01017 Choke lever Starting a cold engine requires a richer air fuel mixture ...

Page 34: ...e engine speed Release the throttle lever to decrease engine speed or to return it to the idle posi tion EJU01019 Start switch Push the start switch 1 green button to start the engine NOTE The engine will not start when the clip is removed from the engine shut off switch ...

Page 35: ...curs 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 je...

Page 36: ...and B neutral N and 2 bow up positions C and D To change the trim angle 1 Reduce engine speed to 3 000 r min or less 2 Squeeze the shift lock lever 2 and then turn the QSTS selector to the desired position 3 Release the shift lock lever to lock the QSTS selector CAUTION Do not turn the QSTS selector while operating the watercraft at full throttle otherwise damage could occur to the QSTS The neutra...

Page 37: ...economy and maximum speed are also reduced EJU01024 Bow up Turn the grip to C or D and the bow will go up while the watercraft is on plane Bow up puts less of the bow in the water There is less water resistance so straight ahead acceleration when on plane and top speed are enhanced In some conditions however the water craft may tend to porpoise hop in the water If the watercraft is porpoising choo...

Page 38: ... 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 t...

Page 39: ... 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 cu...

Page 40: ... by segments Each segment indicates a 250 r min increment EJU01029 Speedometer The meter shows the watercraft speed against water NOTE If the speedometer malfunctions _ _ dis play will blink EJU01030 Reset button Pushing the reset button stops sounding the buzzer ...

Page 41: ...ts differs on your operating condition Use the meter as a reference EJU01032 Hour meter The hour meter is provided to make it easy to follow the maintenance schedule The meter shows the hours of engine opera tion that have elapsed since the watercraft was new NOTE The elapsed time will be kept even if the battery terminals have been discon nected If the hour meter malfunctions _ _ _ _ display and ...

Page 42: ... 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 have...

Page 43: ... dry such as the manuals put them in a waterproof bag EJU01037 Front storage compartment The front storage compartment 2 is located at the bow To open the front storage compartment push the hood latch 1 down and then open the hood NOTE The front storage compartment can be removed to access the engine compart ment Front storage compartment Capacity 16 L 4 2 US gal 3 5 Imp gal Load limit 5 kg 11 lb ...

Page 44: ... 2 lb EJU10391 Yamaha Adjustable Sponson Y A S The sponsons 1 have adjustable posi tioning to allow the operator to enhance either straight line performance or turning performance according to the preference and operating conditions See page 4 23 for adjustment procedures Up position A There will be less water resistance in this position so straight ahead acceleration when on plane and top speed w...

Page 45: ...pping the engine 3 20 Leaving the watercraft 3 20 Operating your watercraft 3 21 Getting to know your watercraft 3 21 Learning to operate your watercraft 3 21 Riding watercraft with a passenger 3 22 Starting the watercraft 3 23 Boarding and starting in deep water 3 25 Capsized watercraft 3 27 Turning the watercraft 3 29 Stopping the watercraft 3 31 Beaching the watercraft 3 32 Docking the watercra...

Page 46: ...a horizontal position Do not stand or sit on the watercraft while refueling in case of fire Take care not to spill gasoline If gaso line spills wipe it up immediately with dry rags Always properly dispose of gasoline soaked rags Avoid overfilling the fuel tank Stop fill ing when the fuel level just reaches the bottom of the filler tube Do not fill up the filler tube because fuel expands as it warm...

Page 47: ...be used if ethanol content does not exceed 10 and the fuel meets minimum octane ratings Gasohol containing methanol is not rec ommended by Yamaha because it can cause fuel system damage or engine perfor mance problems EJU10441 2 stroke engine oil If YAMALUBE 2 W oil is not available another 2 stroke engine oil with an NMMA certified TC W3 rating may be used Recommended gasoline Regular unleaded ga...

Page 48: ...ove the front storage compartment to check the fuel level See page 2 18 for front storage compartment 2 Open the fuel tank filler cap and slowly add fuel to the fuel tank 3 Stop filling when the fuel just reaches the bottom of the filler tube on the fuel tank Do not fill into the filler tube because fuel could spill out Fuel tank capacity Total 60 L 15 9 US gal 13 2 Imp gal Reserve 10 L 2 6 US gal...

Page 49: ...If the oil tank becomes empty the oil injection pump must be bled to ensure proper oil flow otherwise engine damage may occur If bleeding of the oil pump is necessary have a Yamaha dealer bleed it 1 Remove the seat to watch the oil level See page 2 5 for seat 2 Open the oil tank filler cap and very slowly add engine oil to the oil tank 3 Stop filling when the oil just reaches the top of oil tank v...

Page 50: ...per installation 3 9 Throttle lever Check that the throttle lever springs back smoothly 3 11 Steering system Check for proper operation 3 11 QSTS Check for proper operation 3 12 Fuel and oil Check fuel and oil levels and add if necessary Check the hoses and tanks for leakage 3 7 Water separator Check for water and drain if necessary 3 7 Battery Check electrolyte level and battery condition 3 9 Hoo...

Page 51: ...tment Allow the engine compartment to remain open for a few minutes to allow any fuel vapors to escape Also check for loose electrical con nections WARNING Failure to ventilate the engine compart ment could result in fire or explosion Do not start the engine if there is a fuel leak or a loose electrical connection EJU20570 Hull and deck Check the hull and deck for cracks or other damage If any dam...

Page 52: ...3 4 for filling instructions 4 Turn the fuel cock to the ON position EJU01961 Water separator Check the water separator 1 for water Normally the water separator is empty The water separator retains any water entering through the fuel tank breather hose if the watercraft is capsized If water remains in the water separator drain it by removing the drain screw 2 Place a drain pan under the water sepa...

Page 53: ...h dry rags to make sure that the bilge is thoroughly dry 4 Install the drain plugs EJU20581 Stern drain plug Check the stern drain plugs for proper installation CAUTION Make sure that the stern drain plugs are tightened securely before launch ing the watercraft Otherwise water may flood the engine compartment and cause the watercraft to submerge Clean any foreign materials such as dirt or sand fro...

Page 54: ... Loss of battery power may leave you stranded Never operate the watercraft if the battery does not have sufficient power to start the engine or if it shows any other signs of decreased power 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 Make sure that the battery is securely held in place 1 Po...

Page 55: ...the container cap is tightened securely NOTE See the instructions supplied by the fire extinguisher manufacturer for checking the fire extinguisher Always keep the extinguisher in the fire extinguisher con tainer Always carry a fire extinguisher on board A fire extinguisher is not standard equip ment with this watercraft If you do not have one contact a Yamaha dealer or a fire extinguisher dealer ...

Page 56: ...fore starting the engine always check the operation of the throttle lever EJU01057 Steering system Check for looseness in the handlebars Turn them as far as possible to the right and left to make sure that operation is smooth and unrestricted throughout the whole range Make sure that the jet thrust nozzle also changes directions as the han dlebars are turned and that there is no free play between ...

Page 57: ...heck that they oper ate properly 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 ...

Page 58: ... 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 ...

Page 59: ...start the engine and then pull the engine shut off cord 5 to remove the clip 4 from the engine shut off switch 3 to verify that the engine stops immediately See pages 2 8 to 2 9 for information on proper opera tion 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 an...

Page 60: ...ure that the stern drain plugs are securely tightened before launching the watercraft EJU01888 Engine break in The engine break in period is essential to allow the various components of the engine to wear and polish themselves to the correct operating clearances This ensures proper performance and promotes longer compo nent life CAUTION For the first tankful of operation pre mix a 50 1 mixture of ...

Page 61: ...peed for 5 minutes 3 Gradually open the throttle to 3 4 or less 4 Continue operation at 3 4 throttle or less until the first tankful of fuel has been used 5 Fill the tank with straight gasoline and then proceed with normal operation CAUTION Failure to follow the engine break in pro cedure properly can result in severe damage to the engine ...

Page 62: ...s operate the watercraft in an open area 1 Launch the watercraft in water free from weeds and debris and at least 60 cm 2 ft deep WARNING Never operate in water that is less than 60 cm 2 ft deep otherwise you increase your chance of hitting a submerged object which could result in injury CAUTION Never operate in water that is less than 60 cm 2 ft deep otherwise pebbles or sand could be sucked into...

Page 63: ...the engine shut off cord is not frayed or broken and keep it free from the handlebars so the engine stops if the operator falls off The engine shut off cord may not pull free if wrapped around the handlebars when the operator falls off allowing the watercraft to continue to run and cause an accident NOTE It is not possible to start the engine with the clip removed from the engine shut off switch 4...

Page 64: ...on as the engine starts to run CAUTION Never push the start switch while the engine is running Do not operate the start switch for more than 5 seconds otherwise the battery will be discharged and the engine will not start Also the starter motor may be damaged If the engine does not start in 5 seconds release the start switch wait 15 seconds and try again 7 After the engine has warmed up move the c...

Page 65: ...You need throttle to steer Shutting off the engine can cause you to hit an obsta cle you are attempting to avoid A colli sion could result in severe injury or death EJU01067 Leaving the watercraft If leaving the watercraft remove the engine shut off cord to reduce the chance of accidental starting or unauthorized use by children or others ...

Page 66: ...y the operator and one passenger Never exceed the maximum load limit or allow more than 2 persons to ride the water craft at one time EJU01191 Learning to operate your watercraft Before operating the watercraft always perform the pre operation checks listed on page 3 5 The short time spent checking the watercraft will reward you with added safety and reliability Check state and local laws before o...

Page 67: ...the footwell Do not attempt to ride with passengers until your operating skills are fully developed EJU01192 Riding watercraft with a passenger When a passenger is on board with the operator the watercraft handles differently and is not as easy to maneuver so operat ing it requires a higher degree of skill Before attempting to operate the watercraft with a passenger on board the operator must prac...

Page 68: ...ctly behind water craft or other boats Do not go near others to spray or splash them with water Avoid sharp turns or other maneuvers that make it hard for others to avoid you or understand where you are going Avoid areas with sub merged objects or shallow water Take early action to avoid collisions Remember watercraft and other boats do not have brakes Do not release the throttle when trying to st...

Page 69: ...ll the clip to the engine shut off switch 3 Grip the handlebars with both hands place both feet on the floor of the foot well start the engine and start off EJU01074 Starting from a dock 1 Board the watercraft from the side 2 Attach the engine shut off cord to your left wrist and then install the clip to the engine shut off switch 3 Push the watercraft away from the dock grip the handlebars with b...

Page 70: ...rear of the watercraft and place both hands on the boarding plat form pull yourself up and then grasp the handgrip with one hand 2 Pull yourself up to a kneeling position on the platform and then move to the seat and sit astride 3 Attach the engine shut off cord to your left wrist and then install the clip to the engine shut off switch 4 Grip the handlebars firmly with both hands place both feet o...

Page 71: ...wrist and then install the clip to the engine shut off switch 2 Have the passenger move to the rear of the watercraft 3 Have the passenger get on board and sit on the seat NOTE When a passenger is getting on board both the passenger and the operator should try to balance the watercraft 4 The operator should check to see that the passenger has his or her feet on the floor of the footwell and that h...

Page 72: ... then install the clip on the lanyard to the engine shut off switch Start the engine and keep it at idle 3 The passenger pulls himself up on the platform kneels down then crawls onto the seat as the watercraft accelerates 4 The watercraft can now be accelerated to planing speed then the operator can reduce the throttle to the desired running speed EJU18831 Capsized watercraft If the watercraft cap...

Page 73: ...TE If the port left side of the capsized water craft is tilting up push down on the gunwale so that the port left side is down before turning the watercraft clockwise CAUTION Do not turn the watercraft over counter clockwise otherwise water can leak into the carburetor and engine which can result in severe damage 3 Start the engine and operate the water craft to discharge any water remaining in th...

Page 74: ...sharply B Less throttle produces lower thrust so the watercraft will turn more gradually C Releasing the throttle completely pro duces only minimum thrust If you are traveling at speeds above trolling you will have rapidly decreasing ability to steer without throttle You may still have some turning ability immediately after releasing the throttle but once the engine slows down the watercraft will ...

Page 75: ...rottle to steer A collision could result in severe injury or death When operating at higher speeds make gradual turns or slow down before turning Sharp high speed turns may cause the watercraft to slide side ways or spin throwing the operator and passengers overboard which could cause an injury ...

Page 76: ... The watercraft slows down as soon as the throttle lever is released but will coast for a distance before fully stopping If you are not sure you can stop in time before hitting an obstacle apply throttle and turn in another direction WARNING Allow adequate stopping distance Take early action to avoid collisions Remember watercraft and other boats do not have brakes Operate defensively at safe spee...

Page 77: ...he watercraft 1 Make sure that no obstructions boats or swimmers are close to the watercraft Reduce speed about 110 m 360 ft away from the dock 2 Slowly approach the dock and stop the engine just before coming alongside it EJU01083 Rough water operation The force of landing after jumping can cause a strong impact on both the watercraft and the operator and passenger It is possi ble for the operato...

Page 78: ...artment 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 ru...

Page 79: ...e damage could result 9 Wipe the engine and engine compart ment dry with a clean cloth repeat step 3 if necessary 10 Wipe the hull handlebars and jet unit dry with a clean cloth 11 Spray a rust inhibitor such as Yamaha Silicone Protectant and Lubricant on metallic parts to minimize corrosion 12 Allow the engine compartment to air dry completely before reinstalling the seat ...

Page 80: ...hich would create a fire hazard When transporting the watercraft on a trailer secure the tie downs to the trailer through the bow eye and stern rope holes CAUTION Do not route ropes or tie downs over the seat as they may leave permanent marks on the seat s surface Also wrap the ropes or tie downs with towels or rags where they touch the body of the water craft to avoid scratching or damage ...

Page 81: ...ng the fuel system 4 10 Inspecting the oil injection system 4 12 Inspecting the jet thrust nozzle angle 4 13 Inspecting and adjusting the throttle cable 4 13 Cleaning and adjusting the spark plugs 4 14 Inspecting the Yamaha Power Valve System YPVS 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 Adju...

Page 82: ... 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 throu...

Page 83: ...ly 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 a...

Page 84: ...ze 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 Use Yamaha Stor Rite Fogging Oil or an equivalent Keep spraying until the engine stalls or a maximum of 15 sec onds 4 Install the cap securely 5 Lubricate all ca...

Page 85: ...soline soaked rags Avoid overfilling the fuel tank Stop fill ing when the fuel level just reaches the bottom of the filler tube Do not fill up the filler tube because fuel expands as it warms up and could overflow If tem porarily leaving the watercraft with a full fuel tank do not leave it in direct sunlight Leave it in a well ventilated area with the watercraft in a horizontal position Tighten th...

Page 86: ...emove the battery from the watercraft Clean the battery casing using fresh water If the battery terminals are dirty or cor roded clean them with a wire brush Fully charge the battery and then store it in a cool dark place Apply Yamaha marine grease or Yamaha grease A to the battery terminals Check the battery at least every 2 months and fully charge it if necessary WARNING Be sure to connect the b...

Page 87: ...ded with the battery tester and charger you use EJU01169 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 Yamaha Silicone Protectant and Lubricant ...

Page 88: ...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 d...

Page 89: ...enever 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 If your Owner s Operator s Manual is damaged order a replacement from a Yamaha dealer The service information included in this manual is intended to provide yo...

Page 90: ...iate housing Lubricate 1 2 2 4 18 Fuel system Inspect 4 10 Fuel filter Inspect clean replace 4 11 Fuel tank Inspect 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 Jet thrust nozzle angle Inspect adjust 4 13 QSTS mechani...

Page 91: ...e 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 damag...

Page 92: ...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 ne...

Page 93: ...dirt Oil hose and joint for damage or cracks Oil filter for dirt Oil pump for leakage EJU01101 Oil tank Check the oil tank for leakage or water in the tank If water is found in the oil injection system or if the oil tank needs to be cleaned have a Yamaha dealer service the water craft EJU01102 Oil filter Check the oil filter 1 for dirt and clogs If the oil filter is clogged remove it from the oil ...

Page 94: ...ering is stiff or misadjusted have a Yamaha dealer service it Difference of A and B Maximum 5 mm 0 20 in EJU01104 Inspecting and adjusting the throttle cable Check that the throttle cable moves back to the set position smoothly and that free play is within specification 1 Squeeze and release the throttle lever If the lever does not return smoothly have a Yamaha dealer service it 2 Adjust free play...

Page 95: ...t 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 reins...

Page 96: ...o escape which could lead to explosion or fire EJU20630 Inspecting the Yamaha Power Valve System YPVS Yamaha Power Valve System YPVS boosts engine performance and efficiency by means of a variable valve in the exhaust port The YPVS valve is constantly adjusted in accordance with the engine speed by a computer controlled servomotor Since the YPVS is an important part of the engine and requires very...

Page 97: ...ease Recommended water resistant grease Yamaha Marine Grease Yamaha Grease A Throttle cable carburetor end Oil pump cable Choke cable carburetor end Throttle cable handlebar end Pull the throttle lever and remove the seal 1 Spray a rust inhibitor into the outer cable Refit the seal securely Steering cable handlebar end ...

Page 98: ...le nozzle end Nozzle pivot shaft QSTS cable nozzle end QSTS cables pulley end QSTS cables handlebar end Remove the QSTS cable housing Spray a rust inhibitor into the outer cable Reinstall the QSTS cable housing YPVS cable ...

Page 99: ...the outer cable Intermediate housing Using a grease gun fill the intermediate housing with water resistant grease through the grease nipple 1 Grease quantity Initial 10 hours or 1 month 33 0 35 0 cm3 1 11 1 18 oz Every 100 hours or 12 months 6 0 8 0 cm3 0 20 0 27 oz ...

Page 100: ...hy 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...

Page 101: ...ourself 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 Mak...

Page 102: ... 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 tachometer or if necessary the tachometer in the multifunction information center adjust the engine speed...

Page 103: ... 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...

Page 104: ...rence 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 ...

Page 105: ...Lubrication system Variable oil injection Cooling system Water cooled Starting system Electric starter Ignition system Digital CDI Spark plug BR8ES NGK Spark plug gap mm in 0 7 0 8 0 028 0 031 Battery capacity V AH 12 19 Charging system Flywheel magneto DRIVE UNIT Propulsion system Jet pump Jet pump type Axial flow single stage Impeller rotation Counterclockwise viewed from rear Transmission Direc...

Page 106: ...E MEMO ...

Page 107: ...ESHOOTING AND EMERGENCY PROCEDURES Troubleshooting 5 1 Troubleshooting chart 5 1 Emergency procedures 5 4 Cleaning the jet intake and impeller 5 4 Jumping the battery 5 5 Towing the watercraft 5 7 Submerged watercraft 5 8 ...

Page 108: ...tery Run down Recharge 4 19 Poor terminal connec tions Tighten 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 ble 3 3 Stale or contaminated Have serviced by Yamaha dealer 4 10 Fuel tank Water or dirt present Have serviced by Yamaha dealer 4 ...

Page 109: ...e 4 14 Gap incorrect Adjust 4 14 Spark plug cap Loose Connect properly 4 14 Cracked torn or dam aged Replace Electrical wir ing Loose connection Tighten or connect properly Carburetor Incorrect idle adjust ment Adjust idle 4 21 Clogged Have serviced by Yamaha dealer Warning light or indicator blinks Fuel level Empty Refill as soon as possi ble 3 3 Engine oil level Empty Refill immediately 3 4 Oil ...

Page 110: ...lter Clogged Have serviced by Yamaha dealer 4 11 Spark plug Fouled or defective Replace 4 14 Incorrect heat range Replace 4 14 Gap incorrect Adjust 4 14 Spark plug caps Loose Connect properly 4 14 Electrical wir ing Loose connection Tighten or connect properly Fuel Stale or contaminated Have serviced by Yamaha dealer 4 10 Bilge Water in bilge Drain 3 8 TROUBLE POSSIBLE CAUSE REMEDY PAGE ...

Page 111: ...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 car...

Page 112: ...ry If the watercraft battery has run down the engine can be started using a 12 volt bat tery and jumper cables WARNING Battery electrolyte is poisonous and dan gerous causing severe burns etc Elec trolyte contains sulfuric acid Avoid contact with skin eyes or clothing Antidotes External Flush with water Internal Drink large quantities of water or milk Follow with milk of magnesia beaten egg or veg...

Page 113: ...e terminal on the watercraft battery Be sure all connec tions are secure and correct before attempting to start the engine Any wrong connection may damage the elec trical system 4 Start the engine and then disconnect the cables by reversing the steps above CAUTION Never push the start switch while the engine is running Do not operate the start switch for more than 5 seconds otherwise the battery w...

Page 114: ...artment if it is towed too fast Tow the watercraft using the bow eye 1 only The bow must be kept up out of the water during towing to prevent water from entering the engine compart ment WARNING The watercraft should only be towed in an emergency The towline should be long enough so that the watercraft will not collide with the towing boat when slowing down A good rule of thumb is a towline that is...

Page 115: ...em with a cloth 4 Without reinstalling the spark plugs crank the engine until all the water in the cylinders has been drained 5 Install the stern drain plugs and the spark plugs 6 Turn the fuel cock to ON 7 Launch the watercraft into the water and then run the engine for at least 10 minutes If the engine does not start repeat steps 2 7 8 Turn the engine off 9 Turn the fuel cock to OFF remove the s...

Page 116: ...E MEMO ...

Page 117: ...E 6 EJU01124 APPENDIX Limited warranty 6 1 YAMAHA EXTENDED SERVICE Y E S 6 3 Index 6 4 ...

Page 118: ...ified in the applicable Owner s Operator s Manual The owner of the watercraft shall give notice to an authorized Yamaha dealer of any and all apparent defects within ten 10 days of dis covery and make the watercraft available at that time for inspection and repairs at the dealer s place of business GENERAL EXCLUSIONS FROM WARRANTY This warranty will not cover the repair of damage if the damage is ...

Page 119: ...letely set up each new watercraft before sale 2 Explain the operation maintenance and warranty requirements to your satisfaction at the time of sale and upon your request at any later date In addition each Yamaha dealer is held responsible for his setup service and warranty repair work Q Is the warranty transferable to second owners A Yes The remainder of the existing warranty can be transferred u...

Page 120: ...to 150 reimbursement per occurrence for any reasonable expenses you incur because your Yamaha needs covered service replacement vehicle rental emergency towing phone calls even food and lodging when you are away from home This superb cover age goes into effect when you purchase Y E S so it applies to any warranty repairs as well as covered repairs during your entire Y E S plan period Y E S coverag...

Page 121: ...2 17 Engine overheat warning system 2 13 Engine serial number 1 1 Engine shut off cord lanyard 3 13 Engine shut off switch 2 8 Engine stop switch 2 8 Enjoy your watercraft responsibly 1 19 F Filling the fuel tank 3 3 Filling the oil tank 3 4 Fire extinguisher 3 10 Fishing vessel right of way 1 16 Flushing the cooling system 4 1 Front storage compartment 2 18 Fuel and oil 3 1 Fuel and oil systems 3...

Page 122: ...k list 3 5 Pre operation check points 3 6 Pre operation checks 3 5 Primary Identification PRI ID number 1 1 Q Quick Shift Trim System QSTS 3 12 Quick Shift Trim System QSTS selector 2 11 R Reading buoys and other markers 1 16 Recommended equipment 1 12 Replacing the fuse 4 22 Reset button 2 15 Riding watercraft with a passenger 3 22 Rough water operation 3 32 Rules of the Road 1 14 Rules when enco...

Page 123: ...5 1 Turning the watercraft 3 29 U United States Coast Guard 1 18 W Warning labels 1 4 Watercraft characteristics 1 13 Watercraft Education and Training 1 18 Water separator 3 7 Y Yamaha Adjustable Sponson Y A S 2 19 YAMAHA EXTENDED SERVICE Y E S 6 3 ...

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Yamaha GP800R WaveRunner 2003, Owner'S/Operator'S Manual

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