Yamaha WaveRunner GP800R User manual

*LIT186660029*

WaveRunner

GP800R

ASSEMBLY MANUAL

YAMAHA MOTOR CORPORATION, USA

Printed in USA

Oct. 2000 — ?.? ×1 CR

F0W-28107-1A-11

(GP800A) F0W-28107-1A-11LIT-18666-00-29

WaveRunner GP800R

ASSEMBLY MANUAL

1st Edition, October 2000

Any reprinting or unauthorized use

without the written permission of

Yamaha Motor Corporation, USA

is expressly prohibited.

Printed in USA

P/N LIT-18666-00-29

PREFACE

This Assembly Manual contains the infor-

mation needed to assemble the Yamaha

water vehicle correctly prior to delivery to

the customer. Since some external parts of

the water vehicle have not been assemblied

at the Yamaha factory for convenience of

packing, assembly by the Yamaha dealer is

required. It should be noted that the reas-

sembled water vehicle should be thor-

oughly cleaned, inspected, and adjusted

prior to delivery to the customer.

NOTICE

Because Yamaha constantly strives for

product improvement, the service specifica-

tions may be subject to change in the

future. If any change is introduced into the

specifications or assembly procedures,

Yamaha dealers will be notified by a techni-

cal bulletin.

IMPORTANT MANUAL INFORMATION:

Particularly important information is distin-

guished in this manual by the following

notations.

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, a bystander, or a person

inspecting or repairing the water vehicle.

CAUTION:

A CAUTION indicates special precautions

that must be taken to avoid damage to the

water vehicle.

NOTE:

A NOTE provides key information to make

procedures easier or cleaner.

SYMBOLS USED IN THIS

ASSEMBLY MANUAL

In order to simplify descriptions in assem-

bly manuals, the following symbols are

used:

:Coat with water resistant grease.

(Yamaha grease A, Yamaha marine

grease)

:Tightening torque.

:Provide clearance.

:Install so that the arrow mark faces

upward.

:Frontword of the water vehicle.

:Made of rubber or plastics.

:Tighten temporarily.

:Apply locking agent.

LOCTITE



‚ No.242 (BLUE LOCTITE)

Size:

d/D : Diameter of part.

: Length of part.

GENERAL TORQUE SPECIFICATIONS

This chart specifies the torques for tighten-

ing standard fasteners with standard clean

dry ISO threads at room temperature.

Torque specifications for special compo-

nents or assemblies are given in applicable

sections of this manual. To avoid causing

warpage, tighten multi-fastener assemblies

in a criss-cross fashion, in progressive

stages until the specified torque is reached.

Nut ABolt B

General torque

specifications

N•m kgf•m ft•lb

8 mm M5 5.0 0.5 3.6

10 mm M6 8.0 0.8 5.8

12 mm M8 18 1.8 13

14 mm M10 36 3.6 25

17 mm M12 43 4.3 31

– 1 –

UNPACKING AND CHECKING

Carefully uncrate unit and inventory any missing or damaged parts.

NOTE:

For USA:

If concealed damage is found during uncrating, refer to the Yamaha Warranty Handbook,

Chapter 3. Documentation may be required for warranty reimbursement. Do not continue

with uncrating or throw the crate away until the requirements in Chapter 3 have been met.

COMPARTMENT DIAGRAM

COMPARTMENT PART CHART

No. Part name Q’ty Remarks

1 Water vehicle body 1

2 Carton box 1

– 2 –

COMPARTMENT DIAGRAM

COMPARTMENT PART CHART

No. Part name Q’ty Part number

1 Grommet 1 F0X-61469-00

2 Lower handlebar holder 2 EU0-23814-01

3 Handlebar assembly 1 F0W-U155A-00

4 Upper handlebar holder 2 EU0-23814-30

5 Bolt 8

55 mm (0.31

2.17 in) 4 90119-089UM

6 Band 2 90601-200U2

7 Band 1 90464-32801

8 Spiral tube 1 90448-25800

9 Handlebar cover stay 1 GP7-U142K-00

10 Screw 6

15 mm (0.24

0.59 in) 4 90159-069U1

11 Handlebar cover 1 GP7-U142A-11

12 Screw 6

19 mm (0.24

0.75 in) 4 90149-069U9

13 Terminal extension 1 F0W-68239-01

14 Flashing conduction fitting 1 67X-12590-00

15 Tool kit 1 EU0-65986-00

16 Vinyl bag 1 EU0-65901-01

17 Spark plug 2 94702-00204

18 Owner’s/Operator’s manual 1 F0W-F8199-10

19 Riding practice tips 1 F0W-F819T-10

20 Riding instruction card 1 FN8-U595B-02

21 Basic orientation video 1 F0D-U595A-00

– 3 –

WIRE LEAD AND CABLE ROUTING

EXPLODED DIAGRAM

INSTALLATION CHART

Step Procedure/Part name Q’ty Service points

WIRE LEAD AND CABLE

ROUTING

Follow “Step” order for installation.

NOTE:

Before starting work open the front hood

and remove the storage compartment, and

remove the seat.

1 Choke cable 1

2 Throttle cable 1

3 Handlebar switch lead 1

4 Grommet 1 NOTE:

Apply soapy water to the grommet for eas-

ier installation.

5 QSTS cable 2

– 4 –

HANDLEBAR AND THROTTLE CABLE INSTALLATION

EXPLODED DIAGRAM

INSTALLATION CHART

Step Procedure/Part name Q’ty Service points

HANDLEBAR AND THROTTLE

CABLE INSTALLATION

Follow “Step” order for installation.

1 Lower handlebar holder 2

2 Handlebar assembly 1

3 Upper handlebar holder 2 NOTE:

●

Align the punched marks

on the handle-

bar with the top surface of the lower han-

dlebar holders.

●

The upper handlebar holder should be

installed with the punched mark

forward.

4 Bolt (with washer)

55 mm (0.31

2.17 in)

4NOTE:

Tighten the bolts so that the front clearance

of the upper handlebar holder is smaller

than the rear clearance

– 5 –

EXPLODED DIAGRAM

Step Procedure/Part name Q’ty Service points

5 Band 1 Fasten the QSTS cables and handlebar

switch lead with band at the handlebar.

6 Band 1

7 Throttle cable 1 Installation steps:

●Install the throttle cable end into the

throttle lever.

●Fit the seal into the groove in the

bracket.

●Turn the adjuster 1in/out until the

specified free play is obtained.

Throttle lever free play e:

4–7 mm (0.16–0.28 in)

Turn in Free play is increased.

Turn out Free play is decreased.

●Tighten the locknut 2.

– 6 –

CHOKE CABLE INSTALLATION

EXPLODED DIAGRAM

INSTALLATION CHART

Step Procedure/Part name Q’ty Service points

CHOKE CABLE INSTALLATION

1 Choke cable 1 Installation steps:

●Install the choke cable end into the

choke lever with the choke lever com-

pletely closed.

●Route the inner choke cable along the

choke lever gutter.

●Install the choke cable and screw the

adjuster 1fully into the bracket.

●Align the choke lever end awithin the

line marks b.

●Turn out the adjuster 1until the inner

cable is taut.

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