Yamaha GP800Y WaveRunner GP Owner'S/Operator'S Manual Download | Manualshive

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EJU00515

Chapter 4

MAINTENANCE

AND CARE

STORAGE

..................................................4-1

Cooling system flushing ...................4-1
Lubrication ..........................................4-3
Fuel system.........................................4-5
Battery .................................................4-5
Cleaning ..............................................4-6

ADJUSTMENT AND MAINTENANCE

....4-7

Owner‘s manual and tool kit.............4-8
Periodic inspection chart...................4-9
Fuel system inspection....................4-10
Fuel filter ...........................................4-11
Fuel tank............................................4-11
Oil injection system inspection ......4-12
Steering cable inspection................4-13
Throttle cable inspection and
adjustment........................................4-13
Quick shift trim system mechanism
inspection .........................................4-14
Spark-plug cleaning and
adjustment........................................4-15
Greasing points ................................4-16
Choke cable adjustment..................4-19
Battery ...............................................4-19
Carburetor adjustment ....................4-22
Fuse replacement.............................4-23
Bleeding the oil injection pump .....4-23
YAMAHA adjustable sponson (Y.A.S.)
adjustment........................................4-24

SPECIFICATIONS

...................................4-25

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Summary of Contents for GP800Y WaveRunner GP

Page 1: ...LIT 18626 03 86 OWNER S OPERATOR S MANUAL U S A Edition YAMAHA MOTOR CORPORATION U S A GP800Y WaveRunner GP READ THIS MANUAL CAREFULLY BEFORE OPERATION ...

Page 2: ... and should remain with it even if the vehicle is subsequently sold IMPORTANT MANUAL INFORMATION In this manual information of particular importance is distinguished in the follow ing ways Q The Safety Alert Symbol means ATTENTION BECOME ALERT YOUR SAFETY IS INVOLVED w Failure to follow WARNING instructions could result in severe injury or death to the machine operator a bystander or a person insp...

Page 3: ... 3 4 5 GENERAL AND SAFETY INFORMATION FEATURE AND FUNCTIONS OPERATION AND RIDING MAINTENANCE AND CARE TROUBLESHOOTING AND EMERGENCY PROCEDURE 5 6 INDEX READ THIS OWNER S OPERATOR S MANUAL CAREFULLY BEFORE OPERATING YOUR WATER VEHICLE ...

Page 4: ...TY INFORMATION 1 7 Limitations on who may operate the vehicle 1 7 Cruising limitations 1 8 Operational requirements 1 9 Hazard information 1 11 Water vehicle characteristics 1 12 RULES OF THE ROAD 1 13 Steering and sailing rules and sound signals 1 13 Rules when encountering vessels 1 14 Other special situations 1 15 TO GET MORE BOATING SAFETY INFORMATION 1 17 ENJOY YOUR WATER VEHICLE RESPONSIBLY ...

Page 5: ...ded to assist you in ordering spare parts from your Yamaha water vehicle dealer Also record and keep these ID numbers in a separate place in case your water vehicle is stolen EJU00281a PRI I D NUMBER The PRI ID number is stamped on a label 1 attached to the deck under the rear seat EJU00286a HULL IDENTIFICATION NUMBER H I N The H I N is stamped on a plate 2 attached to the stern q w e E YAMAHA MOT...

Page 6: ...Emission control certificate This label is attached to the electrical box 1 Emission control information label 8 Manufactured date label This label is attached to the muffler box 2 Manufactured date label EMISSION CONTROL INFORMATION ENGINE FAMILY THIS ENGINE CONFORMS TO 2000 U S EPA REGULATIONS FOR MARINE SI ENGINES FELs TROLLING SPEED rpm SPARK PLUG GAP mm g kw hr Manufactured ...

Page 7: ...E 1 3 EJU00293 IMPORTANT LABELS LOCATION 1 RU063 5 u RU062 w 3 t 2 r i e o y 0 4 q RU061 ...

Page 8: ...1 4 E LABELS Warning labels r WARNING Do not add gasoline to the oil tank Fire or explosion could result YAMAHA GD0 U418F 00 t w e q GP8 U411A 00 ...

Page 9: ...1 5 E i o 0 1 y GP8 U411A 00 WARNING Do not touch or remove electrical parts when starting or running the engine YAMAHA 6R7 83623 40 Caution labels u ...

Page 10: ...1 6 E Other labels FIRE EXTINGUISHER COMPARTMENT 2 RECOMMENDED OIL YAMALUBE 2 W or an equivalent TC W3 certified outboard oil YAMAHA GU0 U418J 00 3 4 5 BR8ES NGK ...

Page 11: ...ly for operators 16 and older with a valid motor vehicle license Even though a motor vehicle operator s license is not required for water vehicle operation in most states it is one indi cator that the operator has previously demonstrated a reasonable degree of maturity responsibility and good judg ment A responsible adult must supervise operation of this vehicle by minors Many states have minimum ...

Page 12: ...ater vehicle without some one else near by If you ride further than swimming distance from shore you should be accompanied by another boat or watercraft It s good common sense EJX22010 1 8 8 Never ride in water that is less than 60 cm 2 feet deep You increase your chance of hitting an underwater obsta cle You could be injured EJX21010 8 Do not operate water vehicle after sun set or before dawn It ...

Page 13: ...s from abrasions EJX11911 8 Wind water and glare from the sun may get in your eyes while you operate your water vehicle reducing your abili ty to see You may want to consider wearing eye protection such as sun glasses or goggles while riding Some may find however that eye protection obstructs or distorts their vision and distracts from operation Only you know the circumstances in which you operate...

Page 14: ...r or tangled in the controls which would prevent the lan yard from pulling away EJX71110 E A helmet may have potential safety haz ard as well A helmet could catch the water during a fall into the water This is commonly called bucketing The resulting strain on your neck could cause choking severe and permanent neck injuries or death A helmet could also increase the risk of an accident if it reduces...

Page 15: ...ance from other boats or watercraft and also watch for boat s ski ropes or fishing lines Obey the Rules of the Road see page 1 13 1 16 and be sure to check behind you before making a turn EJX15020 8 This water vehicle is included in the Class A inboard boat classification of the U S Coast Guard A water craft of this type MUST carry a fire extinguisher of a B 1 classification with a capacity of two...

Page 16: ...engine is run ning There is no neutral position 8 Boats including your water vehicle do not have brakes Release the throttle or stop the engine to slow down Remem ber however that you have no steering control without throttle EJX79011 1 12 8 Keep hands feet hair and all other parts of your body and clothing away from jet intake on the bottom of the hull while engine is running because they could b...

Page 17: ...r boat which could cause injury or death STEERING AND SAILING RULES AND SOUND SIGNALS Whenever two vessels on the water meet one another one vessel has the right of way it is called the stand on vessel The vessel which does not have the right of way is called the give way or bur dened vessel These rules determine which vessel has the right of way and what each vessel should do Stand On Vessel The ...

Page 18: ...ay ves sels Both you and the meeting vessel must alter course to avoid each other 1 14 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 doesn t apply if both of you will clear one another ...

Page 19: ... right of way regardless of position Fishing vessels cannot howev er 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 fishing ves...

Page 20: ... N E L M A I N C H A N N E L old new 2 2 2 A L L Odd number increasing toward head of naviga MAIN CHANNEL BUOYS 1 3 5 7 tion Leave to port left proceeding upstream LIGHTED BUOY Port Hand White Light Green Light old new old new old new LIGHTED BUOY Starboard Hand 2 4 6 Even number increasing toward head of naviga tion Leave to starboard right proceeding up stream White Light Red Light A LIGHTED SAF...

Page 21: ...enever and wherever you ride think of yourself as the guest of those around you Remember for example that the sound of your Water Vehicle may be music to you but it could be just noise to others And the exciting splash of your wake can make waves others wont enjoy Avoid riding close to shoreline homes and waterfowl nesting areas or other wildlife areas and keep a respect ful distance from fisherme...

Page 22: ...swallow some gasoline petrol inhale a lot of gasoline petrol vapor or get gasoline petrol in your eyes get immediate medical attention 8 If any gasoline petrol spills onto your skin immediately wash with soap and water Change clothing if gasoline petrol spills on it cC Use only fresh gasoline petrol that has been stored in clean containers Gasohol There are two types of gasohol gasohol containing ...

Page 23: ...E MEMO ...

Page 24: ...uel tank filler cap 2 6 Fuel cock 2 6 Engine stop switch 2 7 Engine stop lanyard switch 2 7 Choke knob 2 8 Throttle lever 2 8 Starter switch 2 8 Cooling water pilot outlet 2 9 Steering 2 9 Quick shift trim system Q S T S 2 10 Overheat warning system 2 11 Handgrips 2 12 Bow eye Rope holes and Cleat 2 12 Multifunction meter 2 13 Storage compartments 2 22 Yamaha adjustable sponson Y A S 2 24 ...

Page 25: ...ing a cold engine 7 Rope hole Rope attachment point for transporting mooring 8 Fuel tank filler cap 9 Fuel cock Select fuel flow from normal or reserve area of the fuel tank or shut off fuel flow 0 Handlebars Control steering direction q Footrest floor To place feet for balance w Cleat Rope attachment point for mooring only e Intake grille Prevents debris from getting into the jet pump r Speed sen...

Page 26: ...ed Remove the plate to stop the engine or prevent it from starting 5 Quick Shift Trim System QSTS controller Controls thrust trim for different operating conditions 6 Starter switch Depress to start the engine 7 Multifunction meter Shows engine speed and vehicle speed and some other conditions on the vehicle 8 Throttle lever Controls the engine speed when accelerat ing and decelerate 9 Drain plugs...

Page 27: ...om getting into the engine 4 Oil tank 5 Silencer To help prevent water from getting into the engine and reduce the air intake noise 6 High tension cord Deliver electrical current to the spark plug 7 Spark plug Spark plug cap 8 Electrical box Contains most electrical components included fuse in this water resistant box 9 Battery 0 Flush hose connector q Muffler box ...

Page 28: ...at latch lever Installation Position the seat on the deck so the front projection of the seat fits under the stay on the deck Then push the rear of the seat down until the seat locks latch 2 Stay NOTE Make sure the seat is firmly secured before riding q GP7 005 w GU0 006 GP7 007 q GP7 008 E EJU00335 EJD13510 REAR SEAT There is a seat latch lever at the rear of the seat to remove the rear seat Remo...

Page 29: ... the rear of the seat down until the seat lock latches NOTE Make sure the seat is firmly secured before riding GP7 009 GP7 010 GP7 012 GP7 011 q EJU00343a EJD15710 FRONT HOOD The front food is secured by the latch 1 Pull up the latch lever and lift the food to open it NOTE Make sure the front food is firmly secured with the latch before riding ...

Page 30: ...has three positions OFF With the knob in this position fuel does not flow Always turn the knob to this position when the engine is not running ON With the knob in this position fuel flows to the carburetor Normal running is done with the knob in this position RES If you run out of fuel in the ON posi tion turn the knob to this position to be able to continue for a short time Remember to FILL THE T...

Page 31: ...d switch 3 Should the lock plate be removed for any reason the engine stops by itself w 8 Always attach the engine stop switch lanyard cable to your left wrist BEFORE starting the engine 8 To prevent accidental starting of the engine always remove the lock plate from the stop switch when the engine is not running NOTE When the red button on the engine stop switch is pushed without removing the loc...

Page 32: ...turn spring w Before starting the engine always check the operation of the throttle lever It should move smoothly through its full range of operation and should spring back to the idle position when released 1 Throttle lever q GP7 022 EJU00353a STARTER SWITCH To start the engine push the starter switch green button NOTE 8 The engine will not start when the lock plate is removed from the engine sto...

Page 33: ...l take about 20 seconds to reach water at the outlet after starting the engine GU0 023 q GP7 024 E EJU00356a STEERING Your water vehicle can be steered by turning the handlebars the same direction you wish to travel to the right or left When the handlebars are turned the angle of the jet output nozzle at the stern is changed and the change in direction of the nozzle changes the direction of the ve...

Page 34: ... the throttle lever to half open 3000 r min or less 2 Squeeze and hold the shift lock release lever Then turn the trim shift ing grip to the desired position 8 Turning the grip to A or B from N Bow will go down while the vehicle is on plane 8 Turning the grip to C or D from N Bow will go up while the vehicle is on plane 3 Release the shift lock release lever to lock the position cC Do not turn the...

Page 35: ...acceleration when on plane and top speed are enhanced In some conditions however the vehicle may tend to porpoise hop in the water If the vehicle is porpoising choose Neutral or Bow Down trim A SET B C MODE W A R N I N G mph 2 1 0 3 4 5 6 7 8 1000 r min GP7 028 EJU00366a OVERHEAT WARNING SYSTEM The engine has an overheat warning device If the engine starts to overheat the overheat warning symbol i...

Page 36: ... speeds could result in severe engine damage NOTE The buzzer will stop sounding if any but ton on the multifunction meter is pressed q w e GP7 031 q GP7 030 GP7 029 EJU00367 HANDGRIPS Handgrips provide a handhold to use while boarding the vehicle 1 Handgrips cC Do not use to tow objects lift vehicle or attach tie downs Damage could occur EJU00368 BOW EYE ROPE HOLES AND CLEAT The bow eye rope holes...

Page 37: ... operation of this meter Otherwise the engine could overheat 8 Use the specified resistor type spark plug and cap otherwise the meter may function erratically MODE W A R N I N G mph 2 1 0 3 4 5 6 7 8 1000 r min q r t o GP7 033 A SET B C W A R N I N G 1 1 0 i w e u y GP7 034 E A SET B C MODE W A R N I N G mph 2 1 0 3 4 5 6 7 8 1000 r min GP7 032 NOTE After starting the engine the demonstra tion mod...

Page 38: ... code is put in to select START mode NOTE If you do not use the PADLOC system it is unnecessary to perform the initial setting of PADLOC If so the START mode is automatically selected 8 Initial setting 1 Disconnect the blue connector 1 behind the front storage compart ment 2 After the warning lamp LED lights press the MODE button for at least 3 seconds until the display shows COdE You are ready to...

Page 39: ...tting procedure again from the beginning 8 Selecting START or LOCK mode Selecting the desired mode can only be done after the Initial setting has been done and while the display is not lighting 1 Press the MODE button until the meter displays the current mode START or LOCK 2 With START or LOCK displayed press the MODE button continu ously for about 3 seconds until the display changes to COdE 3 Ent...

Page 40: ... LOCK Then the mode display and buzzer will operate for 2 seconds NOTE 8 Once you select a mode the mode will not be changed unless you perform this mode selection again 8 If the wrong code has been put in the mode display shows ERROR for 2 seconds and the buzzer will sound 5 times Then the display turns back to COdE EJU00383 Tachometer The engine speed r min is displayed by segments Each segment ...

Page 41: ...17 EJU00384 Speedometer The meter shows the vehicle speed in miles per hour mph EJU00386a Fuel level meter The fuel level meter is provided for con venient fuel level checking while riding The fuel level meter has four segments which show the amount of fuel remaining in the fuel tank NOTE The indication of the segments differs on your operating condition Use the meter as a reference E MODE W A R N...

Page 42: ...tting the time 1 When the display shows CLOCK press the mode button for at least 3 seconds 2 The buzzer will sound once The dis play of hour unit and SET start blinking Then press the A SET but ton until desired hour is displayed 3 Press MODE button again 4 The buzzer will sound once The dis play of minute unit and SET start blinking Then press the A SET but ton until desired minute is displayed 5...

Page 43: ... dis play of time and TRIP T blinks for 2 seconds Now it is ready to start counting A SET B C W A R N I N G GP7 052 A SET B C MODE W A R N I N G q w GP7 051 2 19 A SET B C W A R N I N G GP7 050 E EJU00390 Hour meter The hour meter is provided to make it easy to follow the maintenance schedule The meter shows the hours of engine operation that have elapsed since the vehicle was new To show the hour...

Page 44: ...hen the trip meter begins measur ing the traveled distance the to the left of MILE on the display will blink When the watercraft is stopped the will no longer be dis played NOTE Measured distance may vary depending on the water surface conditions and wind direction The measured distance should be used for a reference A SET B C MODE W A R N I N G GP7 053 A SET B C MODE W A R N I N G GP7 054 A SET B...

Page 45: ...l filter for clogging 8 Overheat If the engine starts to overheat the over heat warning indicator W TEMP and the warning lamp LED begin to blink The buzzer also starts sounding Refer to Overheat warning system on page 2 11 8 Low battery voltage If the battery voltage becomes less than 11 5 volts the low battery voltage indica tor VOLT and the warning lamp LED begin to blink The buzzer also starts ...

Page 46: ...m water damage If your owner s manual becomes dam aged order a replacement from a Yamaha water vehicle dealer Front storage compartment A front storage compartment is provided under the front hood 8 Opening Pull up the latch lever to open the front hood NOTE The front storage compartment can be removed to access the engine room 1 Latch lever 2 Front storage compartment Capacity 16 5 L 4 4 US gal 3...

Page 47: ...id down to lock it securely 3 Latch button 4 Storage compartment Capacity 1 L 0 26 US gal 0 22 Imp gal Load limit 1 kg 2 2 lb Seat storage compartment A seat storage compartment is provided under the rear seat Refer to REAR SEAT for removal and installation 5 Seat storage compartment Capacity 21 2 L 5 6 US gal 4 7 Imp gal Load limit 9 kg 19 8 lb E e r GP7 062 ...

Page 48: ...ing per formance according to the preference and operating conditions 1 Sponson Adjusting to upward A There will be less water resistance in this position so straight ahead acceleration when on plane and top speed will be enhanced Adjusting to downward B This position will give the water vehicle more hook which will enhance turning performance A B 1 GP7 065 E ...

Page 49: ...E MEMO ...

Page 50: ...in Running in procedure 3 9 Starting the engine 3 11 Stopping the engine 3 14 RIDING YOUR WATER VEHICLE 3 15 Getting to know your water vehicle 3 15 Learning to ride your water vehicle 3 15 Riding with a passenger 3 16 Starting 3 17 Boarding and starting in deep water 3 18 Load limit 3 20 Capsized water vehicle 3 21 Turning 3 22 Stopping 3 23 Beaching 3 23 Docking 3 24 Rough water operation 3 24 P...

Page 51: ...OL TANK 1 Remove the rear and front seats so you can watch the fuel level 2 Open the fuel tank filler cap and slowly add fuel to the fuel tank Be careful not to spill fuel or overfill the tank 3 Stop filling when the fuel just reaches the bottom of the filler tube on the top of the fuel tank Do not fill into the filler tube because gasoline petrol could spill out cC Be careful when refueling Avoid...

Page 52: ...om of the filler tube cC Do not allow the oil tank to empty com pletely The oil injection pump must be bled to ensure proper oil flow after the tank empties Otherwise engine damage may occur If bleeding of the oil pump is necessary take the water vehicle to your nearest Yamaha dealer w Oil in the bilge is a serious fire hazard Wipe up any spilled oil immediately GP7 067 E Oil tank capacity 4 0 lit...

Page 53: ...ration STEERING Check for proper steering operation FUEL AND OIL Check fuel and oil level add as necessary Check for leaks WATER SEPARATOR Check retaining water drain it if retaining BATTERY Check fluid level and charge condition Check the terminal securely FRONT HOOD Check the front food securely SEAT Check that the seats are securely fastened to the deck HULL DECK Check the hull and deck for dam...

Page 54: ...ou can smell fuel vapors in the engine compartment EJU00427 Fuel system Refer to page 4 10 FUEL SYSTEM INSPECTION for correct procedure EJU00430a Fuel and engine oil 1 Remove the fuel tank filler cap to release any pressure which might have built up in the tank because of fuel expansion 2 Remove the rear and front seats 3 Check the fuel and oil level oil injec tion model in the tank and add as nec...

Page 55: ...Drain screw EJU00433a Bilge Excessive water in the engine compart ment bilge can splash into the carburetor and engine This could cause engine dam age If there is any moisture in the bilge raise the bow about 30 cm 12 in and remove the hull drain plugs After the water has drained wipe the bilge with dry rags Reinstall the drain plugs cC Tighten two hull drain plugs securely before launching the Wa...

Page 56: ... instructions supplied by the fire extinguisher manufacturer to determine proper indication of condition Always keep the extinguisher in the fire extinguisher compartment Always carry a fire extinguisher on board The fire extinguisher compartment 1 is in the front storage compartment Open the front hood and turn the fire extinguisher compartment cap 2 counterclockwise to open it Reinstall the cap ...

Page 57: ...en the handlebars and the jet nozzle GP7 029 GU0 073 EJU00451a Jet intake 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 jet pump parts In some cases the engine may overheat because of lack of cooling water and damage could result Engine cooling water ...

Page 58: ...k plate remove from the engine stop lanyard switch Be sure the lanyard is in good condition with no frayed or broken parts A damaged lanyard must be replaced it should never be repaired or tied together q e w GP7 074 EJU00453a Cooling water pilot outlet Check that water comes out from the out let s while engine is running in the water Refer to page 2 9 for correct operation of the device EJU00454 ...

Page 59: ...in plugs near the jet unit on the stern side Be sure they are securely tightened before launching the Water Vehicle EJU00459 BREAK IN RUNNING IN PROCEDURE The engine and other components require a break in running in period to allow surfaces of moving parts to wear in even ly This ensures proper performance and promotes longer component life cC 8 During first tankful of operation use 50 1 premix f...

Page 60: ...ater free of under water obstacles 2 Run the engine at the lowest possible speed for the first five 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 up 5 Fill the tank with a straight gasoline and proceed with normal operation cC Failure to follow the break in running in procedure properly can result in ...

Page 61: ...0 cm 2 feet w Never ride in water that is less than 60 cm 2 feet deep You increase your chance of hitting an underwater obstacle You could be injured Operate at higher speeds only in deep water free of under water obstacles cC Never ride in water that is less than 60cm 2 feet deep Pebbles or sand could be sucked into the jet intake causing impeller damage or engine overheating 2 Turn the fuel cock...

Page 62: ...nt The operator would also be unable to rebound the vehicle which increases the chance of being hit by another boat and the risk of exposure NOTE It is not possible to start the engine with the lock plate removed from the engine stop lanyard switch 4 Pull the choke knob all the way out to start a cold engine NOTE The choke should not be used when the engine is warm 5 If the LOCK mode was chosen pr...

Page 63: ...nly enough throttle should be applied to keep the engine at a fast enough idle to stay running 7 As soon as the engine starts to run release the starter button at once The starter button returns to its home position automatically cC 8 Never push the starter switch while the engine is running 8 Do not keep the starter motor running for more than five seconds The battery will be quickly discharged a...

Page 64: ...he engine release the throttle lever then push and hold the engine stop switch red button with your left hand When the red button is pushed the igni tion stops which stops the engine NOTE If leaving the water vehicle choose the LOCK mode on multifunction meter by setting PADLOC and remove the engine stop switch lanyard to deter unauthorized use To set the mode refer to PADLOC of MULTIFUNCTION METE...

Page 65: ...ecks listed on page 3 3 The short time spent checking the machines condition will reward you with added safety and a more reliable water vehicle Check state and local laws before operat ing your water vehicle Read the Boat Handling Instructions issued by the U S Coast Guard for basic safe boating infor mation Select a wide area to learn in where visi bility is good and other boat traffic is light ...

Page 66: ...its Normal swimming attire may not adequately pro tect you A wetsuit will help protect against internal injuries to orifices rectum and vagina from strong jet streams and from impact with the water surface Wet suits also help protect against hypother mia low body temperature and abra sions Both operator and a passenger should wear water shoes to help protect feet from objects hidden under water We...

Page 67: ... deep enough then board the vehicle from the side or the rear 2 Attach the lanyard to your left wrist then install the lock plate to the engine stop lanyard switch 3 Grip the handlebars with both hands place both feet on the footrest floor start the engine and start off Starting from a landing jetty 1 Board the vehicle from the side 2 Attach the lanyard to your left wrist then install the lock pla...

Page 68: ...mpts to get back on the vehicle may increase the risk of injuries and drowning Solo 1 Swim to the rear of the vehicle and place both hands on the footrest floor Pull yourself up on the floor and kneel down K1041 K1042 K1043 2 Move to the seat and sit astride 3 Attach the lanyard to your left wrist then install the lock plate to the engine stop lanyard switch 4 Grip the handlebars firmly with both ...

Page 69: ...left wrist then install the lock plate to the engine stop lan yard switch 2 The passenger should move to the rear of the vehicle 3 Next let the passenger get on board and sit on the rear portion of the seat NOTE When letting the passenger get on board both he and operator should try to bal ance the vehicle 4 The operator should check to see that the passenger has his feet on the footrest floor and...

Page 70: ...ances the vehicle 2 Attach the lanyard to your left wrist then install the lock plate to the engine stop lanyard switch Start the engine and keep it at idle 3 The passenger pulls himself up on the floor kneels down then crawls onto the seat as the vehicle acceler ates w Strong streams of water from the jet noz zle can be dangerous and can result in injury when directed at body orifices rec tum and...

Page 71: ...eak into the car buretor and engine NOTE If the right side of the capsized vehicle view from rear of the vehicle tilts upward first tilt the vehicle so the right side is down by pressing down on the gunwale with your weight Then turn the vehicle over as described 3 Start the engine using normal proce dure then head for shore to inspect engine for water damage w IMPROPER UPRIGHTING CAN CAUSE INJURY...

Page 72: ...shift your weight in the desired direction and apply enough throt tle to make your turn High thrust turns the vehicle sharply low thrust turns less sharply Releasing the throttle completely causes the vehicle to go straight TURNS CANNOT BE MADE WITHOUT APPLYING THROTTLE w 8 You need engine power to turn Do not release the throttle completely Releas ing the throttle lever can cause you to hit an ob...

Page 73: ...a distance before fully stopping If you are not sure you can stop in time before hitting an obstacle apply throttle and turn in anoth er direction w Allow adequate stopping distance Fail ure to begin slowing soon enough could cause you to hit an obstacle you are approaching Do not shut off the engine when slowing down in case you need engine power to steer away from a boat or other obstacle that c...

Page 74: ...ct on both the water vehicle and the opera tor It is possible for the operator to hit his chest or jaw on the vehicle body or han dlebars and be injured Do not ride with your chin right above the handlebars or with your feet outside the vehicle Avoid riding in rough water or bad weather con ditions w Operating in rough water or jumping waters can lead to injury It may also damage the vehicle 3 Get...

Page 75: ... performing LUBRICATION at page 4 3 if storing the water vehicle for more than a week 4 Drain residual water from the exhaust system by alternately pulling and releasing the throttle lever for a peri od of 10 to 15 seconds while the engine is running cC Do not attempt to run the engine at full throttle or for more than 15 seconds while the vehicle is out of the water The engine may overheat and or...

Page 76: ...ipe the bilge with dry rags Reinstall two drain plugs NOTE This vehicle is equipped with an automat ic bilge draining device that removes water from the engine compartment while you are underway However some residual water remains that must be drained by removing two drain plugs w Always properly dispose of gasoline petrol soaked rags They can sponta neously ignite 7 Spray a rust inhibitor such as...

Page 77: ...nsporting the water vehicle on a trailer lock the bow with a pin to the trail er and secure the stern with ropes or tie downs through the rope hole s on the rear footrest floor cC Do not route ropes or tie downs over the seat as they may leave permanent marks on the seats surface Also wrap the ropes or tie downs with towels or rags where they touch the body of the water vehicle to avoid scratching...

Page 78: ... inspection 4 10 Fuel filter 4 11 Fuel tank 4 11 Oil injection system inspection 4 12 Steering cable inspection 4 13 Throttle cable inspection and adjustment 4 13 Quick shift trim system mechanism inspection 4 14 Spark plug cleaning and adjustment 4 15 Greasing points 4 16 Choke cable adjustment 4 19 Battery 4 19 Carburetor adjustment 4 22 Fuse replacement 4 23 Bleeding the oil injection pump 4 23...

Page 79: ...e performed by the owner with a minimum of tools GP7 086 GP7 088 q w e E EJU00913 COOLING SYSTEM FLUSHING Cooling system flushing is essential in order to prevent the cooling system from being clogged with salt sand or dirt cC 8 Do not supply the water into the cool ing water passages when the engine is not running The water could flow back through the muffler into the crankcase causing severe eng...

Page 80: ... the engine at an idle speed for 10 to 15 minutes watching engine condi tion If the engine stopped while flushing turn off water supply immediately Repeat above steps 6 Turn off the water supply Then force the remaining water out from the cooling passages by quickly opening and closing the throttle several times within 10 to 15 seconds 7 Stop the engine 8 Remove the garden hose adapter and secure ...

Page 81: ...e engine at full throttle or for more than 15 seconds while the vehicle is out of the water The engine may overheat and or seize 1 Open the cap 1 on the carburetor silencer by turning counterclockwise 2 With the water vehicle in a well venti lated area start the engine 3 With the engine running at a fast idle quickly spray as much Yamaha Stor Rite Fogging Oil or an equivalent as possible into the ...

Page 82: ...spark plugs 6 Lubricate all cables such as the throt tle choke and steering cables NOTE Use a Yamaha Power Cable Luber and Yamaha Lube Zall to pressure lubricate the cables and purge out any moisture between the inner and outer cables 7 Grease the areas of the water vehicle specified in Grease Points in the ADJUSTMENT AND MAINTENANCE section E ...

Page 83: ...ad EJU00530a BATTERY 1 When the machine is not to be used for a month or more remove the bat tery and store it in a cool dark place Clean the battery s casing and termi nals using a mixture of baking soda and water one tablespoon of baking soda to one cup of water Apply dielectric grease or petroleum jelly to the battery terminals and to all exposed connectors 2 If the battery is to be stored for ...

Page 84: ... off all water and wipe up remaining moisture with clean dry rags 3 Spray the engine s exterior with Yamaha Silicone Protectant and Lubricant 4 Wax the hull with a non abrasive wax such as Yamaha Silicone Wax 5 Wipe all vinyl and rubber compo nents such as the seat and engine compartment seals with a vinyl pro tectant such as Yamaha Protectant ...

Page 85: ...alitatively equiva lent to genuine Yamaha parts are not cov ered by the limited warranty w 8 Be sure to turn off the engine when you perform maintenance unless otherwise specified Otherwise accident or injury could result from unexpected opera tion moving parts or electric shock If the owner is not familiar with machine servicing this work should be done by a Yamaha water vehicle dealer or other q...

Page 86: ... user a storage space is pro vided on the vehicle Refer to STORAGE CONTAINER STORAGE COMPART MENT To protect these materials from water it would be a good idea to put them in a vinyl bag The service information included in this manual is intended to provide you the owner with the necessary information for completing your own preventive mainte nance and minor repairs The tools pro vided in the owne...

Page 87: ...QSTS Drain plugs Battery Rubber coupling Bolts and nuts Maintenance interval Item 10 hours 50 hours 100 hours 100 hours 200 hours 3 months 6 months 6 months 12 months Page Initial Thereafter every Inspection Cleaning Adjustment Greasing Greasing Inspection Checking Replacement Cleaning Inspection Cleaning Inspection Adjustment Adjustment Inspection Cleaning Flushing Cleaning Inspection Inspection ...

Page 88: ... for leaks cracks or malfunctions If any problem is found do the necessary repair or replacement as required If repair is necessary consult your nearest Yamaha Water Vehicle deal er Checking points 8 Carburetor leakage 8 Fuel pump malfunction or leakage 8 Fuel tank leakage 8 Fuel hose joint leakage 8 Fuel hose cracks or other damage 8 Fuel filter leakage 8 Fuel cock leakage 8 Air vent check valve ...

Page 89: ... replacement is required 1 Fuel filter w Do not try to change the fuel filter your self An incorrectly installed filter can leak gasoline petrol which could lead to fire or explosion Take the water vehicle to your Yamaha dealer for fuel filter replace ment GP7 093 q q GU0 094 EJU00540 FUEL TANK When the fuel tank needs to be cleaned or when any water is found in the fuel sys tem take the water veh...

Page 90: ... oil tank for damage or cracks 8 Check for water or dirt in the oil tank 8 Check the oil hose and joint 8 Check the oil filter Oil tank Check for oil tank damage or cracks Check the oil hose and joint When the oil tank need to be cleaned or when any water or dirt is found in the oil tank take the water vehicle to your Yamaha dealer for service Oil filter cleaning If the filter is clogged remove it...

Page 91: ... Yamaha dealer to service it A A GP7 096 B B GP7 097 q w A GP7 098 EJU00550 THROTTLE CABLE INSPECTION AND ADJUSTMENT 1 By pulling or releasing the throttle lever check that it moves back to the set position smoothly If not ask your Yamaha Water Vehicle dealer for ser vice 2 Throttle lever free play should be within specification If it is not adjust it by loosening the lock nut and turn ing the adj...

Page 92: ...Check that the trim shifting grip is locked with the lever released 2 Squeeze and hold the lever Check that the grip turns smoothly 3 Check that the angle of the output nozzle changes to up or down from the middle position when the grip is shifted from neutral to bow up or bow down If the mechanism does not work properly ask your Yamaha Water Vehicle dealer to service it GP7 101 ...

Page 93: ...stalling the spark plug measure the electrode gap with a wire thickness gauge adjust the gap to specification if necessary When fitting the plug always clean the gasket surface and use a new gasket Wipe off any dirt from the threads and screw in the spark plug to the correct torque NOTE Before installing the spark plug cap be sure to wipe off any water on the spark plug or inside the cap Push the ...

Page 94: ...nner wires 2 Pull the throttle lever and remove the seal Spray a rust inhibitor into the outer cable Refit the seal securely 1 Seal EJU00554 Oil pump cable Grease the oil pump cable inner wire GP7 106 EJU00555 Steering cable ball joints and inner wire 1 Grease the steering cable ball joints both on the handlebar side and on the steering nozzle side 2 Extend the steering cable inner wire and apply ...

Page 95: ...2 Extend the inner wire of the trim shift cable under the seat storage compart ment Apply a thin coat of grease to the exposed wire Repeat at the jet nozzle end EJU00562 Steering handle pivot shaft After removing the front storage compart ment grease the handle pivot shaft and bushing If the steering shaft becomes loose tight en the band until a satisfactory feel is obtained 1 Band q GP7 108 ...

Page 96: ...be done first after 10 hours or 1 month by your YAMAHA deal er Fill the bearing housing with water resis tant grease through the grease nipple After first service Every 100 hours or 6 months you may do this yourself q Grease capacity 33 0 35 0 cm3 1 11 1 18 oz Grease capacity 6 0 8 0 cm3 0 20 0 27 oz GU0 111 ...

Page 97: ...ment slightly 1 Friction adjustment EJU00572 BATTERY Check the level of the battery fluid and see if the terminals are tight Add distilled water if the fluid level is low cC Be careful not to place the battery on its side When adding the battery fluid or recharg ing be sure to bring it out of the battery compartment When checking the battery make sure the breather pipe is connected to the bat tery...

Page 98: ...es produce explosive gases Keep sparks flame cigarettes etc away Ventilate when charging or using in enclosed space Always shield eyes when working near batteries KEEP OUT OF REACH OF CHILDREN Replenishing the battery fluid A poorly maintained battery will deterio rate quickly The battery fluid should be checked before every ride 1 The level should be between the upper and lower level marks If ref...

Page 99: ...e cells Add distilled water if necessary to top up the electrolyte to the proper level 2 Connect the battery to a charger Set the charging rate at 1 9 amps and charge it for 10 hours Connecting the battery terminals Always make sure the connections are cor rect when you insert the battery in the water vehicle Make sure that the breather pipe is properly connected and that it is not dam aged or obs...

Page 100: ...rformance and damage may result EJU00577 Trolling speed Place the water vehicle afloat Start the engine and warm it up for one or two minutes Using a diagnostic tachometer or if necessary the tachometer in the multifunction meter adjust the engine speed to specification Turn the throttle stop screw clockwise to increase engine speed or counterclockwise to decrease engine speed 1 Throttle stop scre...

Page 101: ...ot 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 EJU00580 BLEEDING THE OIL INJECTION PUMP If the oil tank becomes completely empty or any hose connected to oil pump has been disconnected the oil pump must be bled to ensure proper oil flow If bleeding of the oil pump is necessary take th...

Page 102: ...rks cC Do not attempt to adjust the sponson without loosening the cap nuts The adjuster mechanism can be damaged 3 Tighten the adjuster lock nut Check the number of marks showing on the shaft of the adjuster then repeat the adjustment procedure on the other sponson Both sponsons should be adjusted to the same level 4 Tighten the cap nuts on both sponson securely Do not overtighten e q GP7 121 e w ...

Page 103: ...mended engine oil Fuel tank capacity L US gal lmp gal Oil tank capacity L US gal Imp gal DIMENSIONS VEHICLE CAPACITY PERFORMANCE Length mm in Width mm in Height mm in Dry Weight kg lb Maximum people on board Number of people Maximum load capacity kg lb Maximum output kw PS r min Maximum fuel consumption L h US gal h lmp gal h Cruising range at full throttle hr Trolling speed r min ENGINE Engine ty...

Page 104: ... 5 TROUBLESHOOTING AND EMERGENCY PROCEDURE TROUBLESHOOTING 5 1 Troubleshooting chart 5 1 EMERGENCY PROCEDURES 5 3 Cleaning the jet intake and impeller 5 3 Connecting jumper cables 5 4 Towing the water vehicle 5 6 Submerged water vehicle 5 7 E ...

Page 105: ... mode is selected Lock plate is not in place Burned out Run down Poor terminal connections Terminal is eroded Faulty OFF position Empty Stale or contaminated Water or dust collected Built up pressure Fouled or defective Not fitted or loose Filled with water Clogged or water collected Knob automatically return 8Select START mode Install lock plate 8Replace the fuse and Check wiring 8Recharge 8Tight...

Page 106: ...ntaminated Water is accumulated in the vehicle POSSIBLE CAUSE REMEDY Refer Page The engine runs irregularly or stalls Warning indicator symbol blinks The water vehicle speeds too slow or loses power 8Refill as soon as possible 1 8Have a service at Yamaha dealer 8 Push it in fully 8Have service at Yamaha dealer 8Have service at Yamaha dealer 8Replace 8Replace 8Adjust 8Fit properly 8Tighten or conne...

Page 107: ...ways stop the engine before beaching the vehi cle w Before attempting to remove weeds or debris from the jet intake or impeller areas shut off the engine and remove the lock plate from the engine stop lanyard switch Severe injury or death could result from coming in contact with the rotating parts of the jet pump 1 Turn the vehicle on its side as shown cC Place a suitable clean cloth or carpeting ...

Page 108: ... procedure EJU00599 CONNECTING JUMPER CABLES If the vehicle battery has run down the engine can be started using a 12 volt bat tery and jumper cables w Battery electrolyte is poisonous and dan gerous It contains sulfuric acid which can cause severe burns Avoid contact with skin eyes or clothing Antidote EXTERNAL Flush with water INTERNAL Drink large quantities of water or milk follow with milk of ...

Page 109: ... vehicle battery Be sure all connections are secure and correct before attempting to start the engine Any wrong connec tion may damage the electrical system 4 Start the engine then disconnect the cables by reversing the above steps cC Do not turn the starter motor for more than 5 seconds The battely will be quick ly discharged which may be impossible to start the engine Also the starter motor may ...

Page 110: ...vehicle is towed too fast 8 Tow the vehicle using the bow eye only 1 Bow eye w If the water vehicle is towed using a rope 8 The water vehicle should only be towed in an emergency The towing rope should be long enough so that the water vehicle will not collide with the towing boat when slowing down A good rule of thumb is a tow rope which is three times the combined length of the towing boat and th...

Page 111: ...oth 4 Without reinstalling the spark plugs crank the engine until all the water in the cylinders has been drained 5 Reinstall the drain plug s and the spark plugs 6 Set the fuel cock to ON 7 Launch the vehicle into the water again and run the engine for at least 10 minutes If the engine will not start repeat above steps 8 Turn the engine off Set the fuel cock to OFF 9 Remove the cap s on the silen...

Page 112: ...1 1 1 2 1 3 1 4 1 5 1 6 EJU00608 Chapter 6 INDEX INDEX 6 1 E ...

Page 113: ...sion control information 1 2 Engine compartment 3 4 Engine number 1 1 Engine oil 1 18 Engine oil level meter 2 18 Engine stop lanyard switch 2 7 Engine stop switch 2 7 Enjoy your water vehicle responsibly 1 17 F Filling the gasoline petrol tank 3 1 Filling the oil tank 3 2 Fire extinguisher 3 6 Fishing vessel right of way 1 15 Front hood 2 5 Front seat 2 4 Front storage compartment 2 22 Fuel and e...

Page 114: ...Q Quick shift trim system Q S T S 2 10 Quick shift trim system cable joint and inner wire 4 17 Quick shift trim system mechanism inspection 4 14 R Reading buoys and other markers 1 15 Rear seat 2 4 Recharging 4 21 Removal 2 4 Replenishing the battery fluid 4 20 Riding with a passenger 3 16 Riding your water vehicle 3 15 Rough water operation 3 24 Rules of the road 1 13 Rules when encountering vess...

Page 115: ... 5 5 To get more boating safety information 1 17 Towing the water vehicle 5 6 Transportation 3 27 Trip meter 2 20 Trip timer 2 19 Trolling speed 4 22 Troubleshooting 5 1 Troubleshooting chart 5 1 Turning 3 22 U United states coast guard 1 17 W Warning indicators 2 20 Warning labels 1 4 Water separator 3 5 Water vehicle characteristics 1 12 With a passenger 3 19 Y Yamaha adjustable sponson Y A S 2 ...

Page 116: ...e notice to an authorized Yamaha water vehicle dealer of any and all apparent defects within ten 10 days of discovery and make the vehicle 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 a result of abuse or neglect of the product Examples of abuse and neglect inc...

Page 117: ...r satisfation at the time of sale and upon your request at any later date In addition each Yamaha water vehicle 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 upon request The unit has to be inspected and re registered by an authorized Yamaha water vehicle deal...

Page 118: ... 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 cov erage 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 8 Y E S coverage is honored at any authorized Yamaha dealer nationwide 8 Y E...

Page 119: ...YAMAHA MOTOR CORPORATION USA Printed on recycled paper Printed in U S A Jun 1999 1 CR GU0 F8199 13 GP800 ...

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