Yamaha WaveRunner GP800R User manual

*LIT186160226*

WaveRunner

GP800R

SERVICE MANUAL

F0W-28197-1A-11LIT-18616-02-26

NOTICE

This manual has been prepared by Yamaha primarily for use by Yamaha dealers and their

trained mechanics when performing maintenance procedures and repairs to Yamaha equip-

ment. It has been written to suit the needs of persons who have a basic understanding of the

mechanical and electrical concepts and procedures inherent in the work, for without such

knowledge attempted repairs or service to the equipment could render it unsafe or unfit for

use.

Because Yamaha has a policy of continuously improving its products, models may differ in

detail from the descriptions and illustrations given in this publication. Use only the latest edi-

tion of this manual. Authorized Yamaha dealers are notified periodically of modifications and

significant changes in specifications and procedures, and these are incorporated in succes-

sive editions of this manual.

A10001-0*

WaveRunner GP800R

SERVICE MANUAL

1st Edition, November 2000

Any reprinting or unauthorized use

without the written permission of

Yamaha Motor Corporation, USA

is expressly prohibited.

Printed in USA

LIT-18616-02-26

HOW TO USE THIS MANUAL

MANUAL FORMAT

All of the procedures in this manual are organized in a sequential, step-by-step format. The

information has been compiled to provide the mechanic with an easy to read, handy refer-

ence that contains comprehensive explanations of all disassembly, repair, assembly, and

inspection operations.

In this revised format, the condition of a faulty component will precede an arrow symbol and

the course of action required will follow the symbol, e.g.,

●

Bearings

Pitting/scratches

→

Replace.

To assist you in finding your way through this manual, the section title and major heading is

given at the top of every page.

ILLUSTRATIONS

The illustrations within this service manual represent all of the designated models.

CROSS REFERENCES

The cross references have been kept to a minimum. Cross references will direct you to the

appropriate section or chapter.

IMPORTANT INFORMATION

In this Service Manual particularly important information 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, a bystander, or a person inspecting or repairing the watercraft.

CAUTION:

A CAUTION indicates special precautions that must be taken to avoid damage to the water-

craft.

NOTE:

A NOTE provides key information to make procedures easier or clearer.

IMPORTANT:

This part has been subjected to change of specification during production.

HOW TO USE THIS MANUAL

To help identify parts and clarify procedure steps, there are exploded diagrams at the start

of each removal and disassembly section.

Numbers are given in the order of the jobs in the exploded diagram.

Symbols indicate parts to be lubricated or replaced (see “SYMBOLS”).

A job instruction chart accompanies the exploded diagram, providing the order of jobs,

names of parts, notes in jobs, etc.

Dimension figures and the number of parts, are provided for fasteners that require a tight-

ening torque.

Example:

Bolt or screw size : M10 (D)

25 mm (L)

Jobs requiring more information (such as special tools and technical data) are described

sequentially.

10 ×25 mm

A50001-1-4

SYMBOLS

Symbols

are designed as thumb-

tabs to indicate the content of a chapter.

General Information

Specifications

Periodic Inspection and Adjustment

Fuel System

Power Unit

Jet Pump Unit

Electrical System

Hull and Hood

Trouble analysis

Symbols

indicate specific data:

Special tool

Specified liquid

Specified engine speed

Specified torque

Specified measurement

Specified electrical value

[Resistance (

Ω

), Voltage (V), Electric current

(A)]

Symbol

in an exploded diagram

indicate the grade of lubricant and the loca-

tion of lubrication point:

Apply YAMALUBE 2-W oil or TC-W3 cirtified

outboard oil

Apply water resistant grease

(Yamaha grease A, Yamaha marine grease)

Apply molybdenum disulfide grease

Symbols

in an exploded diagram

indicate the grade of the sealing or locking

agent, and the location of the application

point:

Apply Gasket Maker

JApply Yamabond #4

(Yamaha bond number 4)

KApply LOCTITE®No. 271 (Red LOCTITE)

LApply LOCTITE®No. 242 (Blue LOCTITE)

MApply LOCTITE®No. 572

NApply silicone sealant

NOTE:

In this manual, the above symbols may not

be used in every case.

GEN

INFO SPEC

INSP

ADJ FUEL

POWR

JET

PUMP

–+

ELEC

HULL

HOOD

TRBL

ANLS

GM 4

271

242

572

LT LT

INDEX

GENERAL INFORMATION 1

GEN

INFO

SPECIFICATIONS 2

SPEC

PERIODIC INSPECTION AND

ADJUSTMENT 3

INSP

ADJ

FUEL SYSTEM 4

FUEL

POWER UNIT 5

POWR

JET PUMP UNIT 6

JET

PUMP

ELECTRICAL SYSTEM 7

ELEC

HULL AND HOOD 8

HULL

HOOD

TROUBLE ANALYSIS 9

TRBL

ANLS

–+

A30000-0

GEN

INFO

CHAPTER 1

GENERAL INFORMATION

IDENTIFICATION NUMBERS......................................................................... 1-1

PRIMARY l.D. NUMBER........................................................................... 1-1

ENGINE SERIAL NUMBER ...................................................................... 1-1

JET PUMP UNIT SERIAL NUMBER ........................................................ 1-1

HULL IDENTIFICATION NUMBER (H.l.N.).............................................. 1-1

SAFETY WHILE WORKING ...................................................................... 1-2

FIRE PREVENTION................................................................................... 1-2

VENTILATION........................................................................................... 1-2

SELF-PROTECTION.................................................................................. 1-2

OILS, GREASES AND SEALING FLUIDS................................................ 1-2

GOOD WORKING PRACTICES................................................................ 1-3

DISASSEMBLY AND ASSEMBLY........................................................... 1-4

SPECIAL TOOLS............................................................................................. 1-5

MEASURING ............................................................................................ 1-5

REMOVAL AND INSTALLATION ............................................................ 1-6

1-1

GEN

INFO IDENTIFICATION NUMBERS

A60700-0*

IDENTIFICATION NUMBERS

PRIMARY l.D. NUMBER

The primary l.D. number is stamped on a

label attached to the inside of the engine

compartment.

Starting primary l.D. number:

F0W: 800101–

ENGINE SERIAL NUMBER

The engine serial number is stamped on a

label attached to the cylinder head.

Starting serial number:

68A: 000101–

JET PUMP UNIT SERIAL NUMBER

The jet pump unit serial number is stamped

on a label attached to the intermediate

housing.

Starting serial number:

68A: 800101–

HULL IDENTIFICATION NUMBER

(H.l.N.)

The H.l.N. is stamped on a plate attached to

the aft deck.

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