Yamaha EJU00270 manual

LIT -18626-03-86 ● OWNER’S/OPERA TOR’S MANUAL U.S.A.Edition YAMAHA MOTOR CORPORATION, U.S.A. GP800Y W aveRunner GP READ THIS MANUAL CAREFULLY BEFORE OPERATION![...]

EJU00271a EJU00270 TO THE OWNER Thank you for choosing a Yamaha Water Vehicle. This Owner’s Manual contains information you will need for proper oper- ation, maintenance, and care. A thorough understanding of these simple instructions will help you to obtain maximum enjoy- ment from your new Yamaha. If you have any questions about the operation o[...]

EJU00273 CONTENTS 1 2 3 4 5 1 2 3 4 5 GENERAL AND SAFETY INFORMA TION FEA TURE AND FUNCTIONS OPERA TION 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.[...]

1 1 1 2 1 3 1 4 1 5 1 6 EJU00274 Chapter 1 GENERAL AND SAFETY INFORMA TION IDENTIFICATION NUMBER RECORDS ..................................................1-1 PRI-I.D. number ..................................1-1 Hull identification number (H.I.N) ....1-1 Engine number ...................................1-1 EMISSION CONTROL INFORMATION ...1-2 IMPOR[...]

EJU00288a ENGINE NUMBER The engine serial number is stamped on a label 3 attached to the crankcase. 1-1 EJU00699 IDENTIFICA TION NUMBER RECORDS Record your Primary identification (PRI- ID) number, Hull identification number (HIN) and Engine serial number in the spaces provided, to assist you in ordering spare parts from your Yamaha water vehicle de[...]

1-2 q RU0625 w E EJU00631a EMISSION CONTROL INFORMA TION This engine conforms to 2000 U.S. Envi- ronmental Protection Agency (EPA) regu- lation for marine SI engines. 8 Approval label of 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[...]

E 1-3 EJU00293 IMPORT ANT LABELS LOCATION !1 RU063 !5 u RU062 w !3 t !2 r i e o y !0 !4 q RU061*[...]

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[...]

1-5 E i o !0 !1 y GP8-U411A-00 WARNING Do not t ouch or remove electrical parts when starting or running the engine. YAMAHA 6R7-83623-40 Caution labels u[...]

1-6 E Other labels F I R E E X T I N G U I S H E R C O M P A R T M E N T !2 RECOMMENDED OIL YAMALUBE 2-W or an equivalent TC-W3 certified outboard oil. YAMAHA GU0-U418J-00 !3 !4 !5 BR8ES NGK[...]

E 1-7 EJU00686 Q SAFETY INFORMA TION When you operate your Yamaha Water Vehicle, you must know and practice the following for your safety: 8 Before operating the water vehicle, read this entire manual, the Riding Practice Tips, the Riding Instruction card and all warning labels on the water vehicle. Reading these materials should give you an unders[...]

E EJU00613 CRUISING LIMITATIONS EJX24011 8 Do not jump boat wakes or follow another boat or watercraft too closely. You increase your risk of colliding with another boat, which could result in severe injury or death. Do not jump waves, wakes, or any objects. You risk severe impact injuries. Jumping can also cause damage to the water vehicle. EJX250[...]

1-9 E EJU00616a OPERATIONAL REQUIREMENTS EJX16010 8 Operating your water vehicle requires skills acquired only through practice over a period of time. Take the time to learn the basic operating techniques well, before attempting more difficult maneuvers. EJX11211 8 Both operator and a passenger must always wear a U.S. Coast Guard approved personal [...]

1-10 8 For reasons of safety and proper care, always perform the pre-operation checks on page 3-3 before riding. EJX15110 8 The operator and a passenger should always keep both feet on the footrest floor when the vehicle is in motion. If you lift your feet, you increase your chances of losing your balance, and your feet could hit objects outside th[...]

E 1-11 8 To prevent accidental starting of the engine, always remove the lock plate from the engine stop lanyard switch when the engine is not running. 1 Engine stop lanyard switch 2 Engine stop switch lanyard 3 Lock plate 8 Always watch carefully for swimmers. Stay away from swimming areas. Swimmers are hard to see and you could accidentally hit s[...]

E EJU00314a WATER VEHICLE CHARACTERISTICS 8 Jet thrust turns the water vehicle. If you are going faster than trolling speeds (the lowest maneuvering speed), you must use throttle to turn. If you release the throttle completely, you cannot turn-even if you turn the handlebars. Practice turning in an open area without obstructions until you have a go[...]

1-13 E EJU00319 RULES OF THE ROAD Your Yamaha water vehicle is legally con- sidered a power boat. Operation of the water vehicle must be in accordance with the rules and regulations governing the waterway on which it is used. Just as there are rules which apply when you are driving on streets and highways, there are waterway rules which apply when [...]

E In other words, follow the standard rules except when a collision will occur unless both vessels try to avoid each other. If that is the case, both vessels become “Give-Way” vessels. RULES WHEN ENCOUNTERING VESSELS There are three main situations which you may encounter with other vessels which could lead to a collision unless the Steer- ing [...]

E 1-15 Overtaking If you are passing another vessel, you are the “Give-Way” vessel. This means that the other vessel is expected to maintain its course and speed. You must stay out of its way until you are clear of it. Like- wise, if another vessel is passing you, you should maintain your speed and direction so that the other vessel can steer i[...]

E 1-16 tion. These markers are white with black letters and orange boarders. They signify speed zones, restricted areas, danger areas, and general information. Remember, markings may vary by geo- graphic location. Always consult local boating authorities before riding your water vehicle in unfamiliar waters. 1 1 A 1 1 Proceeding toward head of navi[...]

E 1-17 EJU00320 TO GET MORE BOA TING SAFETY INFORMA TION Be informed about boating safety. Addi- tional publications and information can be obtained from many organizations, including the following. United States Coast Guard Consumer Affairs Staff (G-BC) Office of Boating, Public, and Consumer Affairs U.S. Coast Guard Headquaters Washington, D.C. 2[...]

1-18 E EJU00323a FUEL REQUIREMENTS GASOLINE(PETROL) w GASOLINE (PETROL) AND ITS VAPORS ARE HIGHLY FLAMMABLE AND EXPLO- SIVE! 8 Do not smoke when refueling, and keep away from sparks, flames, or other sources of ignition. 8 Stop engine before refueling. 8 Refuel in a well-ventilated area. Do not stand or sit on the water vehicle while refueling in c[...]

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1 1 1 2 1 3 1 4 1 5 1 6 EJU00326 Chapter 2 FEA TURES AND FUNCTIONS LOCATION OF MAIN COMPONENTS .........................................2-1 OPERATION OF CONTROLS AND OTHER FUNCTIONS .......................2-4 Front seat ............................................2-4 Rear seat .............................................2-4 Front hood ............[...]

2-1 EJU00327 EJD10010 LOCA TION OF MAIN COMPONENTS E q w e r t y u i o !1 !0 !2 !3 !4 !5 !6 !7 !8 !9 u TK001A 1 Cooling water pilot outlets Check point of cooling water flowing. 2 Bow eye Rope attachment point for transporting, mooring, or towing the water vehicle in an emergency. 3 Front storage compartment 4 Fire extinguisher compartment 5 Front [...]

q w r t y u e i o !0 o E 2-2 1 Engine stop switch lanyard (Cable) By connecting to the stop switch and opera- tor will stop the engine if the operator falls off the vehicle. 2 Engine stop switch Depress to stop the engine. 3 Engine stop lanyard switch Removing the lock plate makes to stop the engine and disable to start the engine. 4 Lock plate Ins[...]

q r t w y e i u !1 !0 o TK004A E 2-3 1 Fuel tank 2 Water separator To trap water from the air passage to the fuel tank. 3 Fuel filter Prevents dust contained in fuel from 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 t[...]

2-4 EJU00328 OPERA TION OF CONTROLS AND OTHER FUNCTIONS EJU00334 FRONT SEAT There is a seat latch under the rear seat. First remove the rear seat to reach the front seat latch lever, then remove the front seat. Removal Pull the front seat latch lever up, then lift the rear of the seat , and pull back. 1 Front seat latch lever Installation Position [...]

E 2-5 Installation Position the seat on the deck so the front projections on the underside of the seat fits into the stays on the deck. Then push 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 b[...]

E GP7-015 2-6 EJU00345 EJD18010 FUEL TANK FILLER CAP To remove the fuel tank filler cap, turn it counterclockwise. 1 Fuel tank filler cap Be sure to tighten the cap securely before riding. q GP7-013 q GP7-014 EJU00704 FUEL COCK The fuel cock 1 supplies fuel from the fuel tank to the carburetor. The fuel cock has three positions; OFF With the knob i[...]

E 2-7 EJU00705 ENGINE STOP SWITCH The engine can be stopped normally by pressing the red button 1 . EJU00706a ENGINE STOP LANYARD SWITCH The engine can be also stopped if you fall off, or in case of an emergency, when the lock plate 1 attached to the lanyard 2 is pulled out from the engine stop lanyard switch 3 . Should the lock plate be removed fo[...]

2-8 EJU00350a CHOKE KNOB Pulling this knob supplies a rich fuel-air mixture required to start a cold engine. NOTE: Refer to “STARTING THE ENGINE” in the chapter 3 for proper operation. 1 Choke knob q GP7-020 q GP7-021 E EJU00351 THROTTLE LEVER Moving the throttle lever toward the han- dlebar increases engine speed. When the throttle lever is re[...]

2-9 EJU00354a COOLING WATER PILOT OUTLET This watercraft is equipped with a cool- ingwater pilot outlets at left side of the hull. Check that water comes out of the outlets while the engine is running. If you do not see any water at the outlets, cool- ing water may not be circulating in the engine. In that case, stop the engine and check for the ca[...]

E 2-10 GP7-025 q w EJU00360 QUICK SHIFT TRIM SYSTEM (Q.S.T.S.) The trim angle of your water vehicle can be adjusted by operating the Q.S.T.S. Operating the trim shifting grip of the Q.S.T.S. changes the angle of the jet (out- put) nozzle at the rear of the craft. The nozzle angle changes the trim angle of the vehicle to one of five positions : two [...]

E 2-11 Shifting to “Bow Down” “Bow Down” puts more of the bow in the water. This gives the water vehicle more “hook”, which enhances turning perfor- mance. This position will also help the water vehicle get up on plane more quick- ly. At higher speeds, however, the water vehicle will have greater tendency to “bow steer” and follow w[...]

E 2-12 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. c C If you cannot locate and correct the cause of the overheating, consult [...]

2-13 EJU00656a MULTIFUNCTION METER This meter contains following functions for the help and convenience of opera- tion. 1 “MODE” button 2 “SET” button 3 “CODE” setting buttons 4 Tachometer 5 Speedometer 6 Fuel level meter 7 Engine oil level meter 8 Display for Clock, Hour meter, Trip meter and Trip timer 9 Warning lamp (LED) 0 Display f[...]

E 2-14 MODE WARNING m p h 2 1 0 3 4 5 6 7 8 1 000 r/min GP7-036 q GP7-035 A/ SET B C WARNING GP7-037 EJU00657a PADLOC (Programmable digital locking ignition) This feature is provided to deter unautho- rized use. The function allows you to chose either “START” or “LOCK” mode, as the situation requires, much as you would use a main switch key[...]

E 2-15 WARNING WARNING GP7-041* MODE MODE A/ SET B C MODE WARNING GP7-039* 4) After completing code setting, the buzzer will sound 3 times and the dis- play will show “SET”. Lastly, the dis- play turns off and the warning lamp (LED) turns on again. After the meter has displayed this sequence, recon- nect the blue connector. NOTE: 8 Your own cod[...]

E 2-16 WARNING WARNING GP7-041 A/ SET B C WARNING GP7-042 MODE WARNING m p h 2 1 0 3 4 5 6 7 8 1 000 r/min GP7-044 4) If the code entered is correct, the mode will change from the previous mode to either “START” or “LOCK”. Then the mode display and buzzer will operate for 2 seconds. NOTE: 8 Once you select a mode, the mode will not be chang[...]

A/ SET B C WARNING F4 F3 F2 F1 Empty Display Capacity:L(US gal, Imp gal) F4 F3 F2 F1 more than 32 (8.5,7.0) F3 F2 F1 26~32 (6.9,5.7)~(8.5,7.0) F2 F1 17~26 (4.5,3.7)~(6.9,5.7) F1 12~17 (3.2,2.6)~(4.5,3.7) F1 Empty 0~12 (3.2,2.6) ON ON ON ON Blinking GP7-046 2-17 EJU00384 Speedometer The meter shows the vehicle speed in miles per hour (mph). EJU00386[...]

2-18 E EJU00387a Engine oil level meter The engine oil level meter is provided for convenient oil level checking while riding. The engine oil level meter has three seg- ments which show the amount of oil remaining in the oil tank. NOTE: The indication of the segments differs on your operating condition. Use the meter as a reference. EJU00388a Clock[...]

EJU00659 Trip timer The trip timer mode is provided for count- ing the time. To show the trip timer, press the “MODE” button until the display shows “TRIP.T”. 1 Minute unit 2 Second unit 8 Operation 1) When the display shows “TRIP.T”, press the “A/SET” button to start counting. The buzzer will sound once. 2) Press the “A/SET” bu[...]

2-20 E EJU00660a Trip meter A trip meter is provided for measuring the approximate traveled distance in miles. To show the trip meter, press the “MODE” button until the display shows “TRIP”. After showing “TRIP”, the display turns to “MILE”. 1) When the display shows “MILE”, press the “MODE” button for at least 2 seconds. 2)[...]

A/ SET B C WARNING GP7-058 A/ SET B C WARNING GP7-057 2-21 A/ SET B C WARNING GP7-056 E 8 Oil level If the oil remaining in the tank drops to about 1.2 L (0.31 US gal, 0.26 Imp gal) or the oil filter is clogged, the oil level seg- ment, the oil warning indicator, “OIL” and the warning indicator lamp begin to blink. The buzzer also starts soundi[...]

2-22 E q GP7-059 w GP7-060 EJU00909 STORAGE COMPARTMENTS The storage compartment(s) is provided to store the manuals, tools, and other equipment for cruising. Make sure all storage compartments are firmly secured before riding. NOTE: The storage compartment(s) is not designed to be waterproof. If you put the manuals in the compartment(s), store the[...]

GP7-063 t GP7-064 2-23 Grove compartment A grove compartment is provided below the handlebars. Push the latch button to open the lid. To close the lid, push the lid 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 i[...]

2-24 EJU00409 YAMAHA ADJUSTABLE SPONSON (Y.A.S.) The sponsons have adjustable positioning to allow the operator to enhance either straight-line performance or turning 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 acceleratio[...]

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1 1 1 2 1 3 1 4 1 5 1 6 EJU00410 Chapter 3 OPERA TION AND RIDING GASOLINE (PETROL) AND ENGINE OIL FILLING ...............................................3-1 Filling the Gasoline (petrol) tank ......3-1 Filling the oil tank ...............................3-2 PRE-OPERATION CHECKS ......................3-3 Check list ..................................[...]

3-1 EJU00411 GASOLINE (PETROL) AND ENGINE OIL FILLING This engine uses Yamaha’s oil injection system, which provides superior lubrica- tion by ensuring the proper oil ratio for all operating conditions. No fuel premixing is necessary (except during break-in / run- ning-in). Simply pour gasoline (petrol) into the fuel tank and oil into the oil tan[...]

3-2 EJU00419 FILLING THE OIL TANK 1) Remove the rear and front seats, so you can watch the oil level. 2) Open the oil tank filler cap, and very slowly add engine oil to the oil tank. 3) Stop pouring when the oil just reach- es the bottom of the filler tube. c C Do not allow the oil tank to empty com- pletely. The oil injection pump must be bled to [...]

E 3-3 EJU00422 PRE-OPERA TION CHECKS CHECK LIST Before operating this water vehicle, perform the following checks: w If any item in the Pre-Operation check is not working properly, have it inspected and repaired before operating the water vehicle. Otherwise an accident could occur. NOTE: Pre-operation checks should be made each time the vehicle is [...]

E 3-4 EJU00425a CHECK POINT Engine compartment Open the front hood and remove the stor- age compartment, and also remove the front seat for a few minutes to allow any fuel vapors to escape. w Failure to ventilate the engine compart- ment to release fuel vapors could result in fire or explosion. Do not start the engine if you can smell fuel vapors i[...]

3-5 EJU00432a Water separator 1) Check the water separator to see if there is any water in this separator. This water separator retains any water entering through the fuel tank breather pipe if the Vehicle is cap- sized. Normally this water separator is empty. (No water) 2) If water remains in this water separa- tor, drain it by removing the drain [...]

E 3-6 EJU00435a Battery Check the battery condition and the bat- tery electrolyte level. Check that the battery terminals are tight- ened securely and that there is no ero- sion. w The battery must always be fully charged and in good condition. Loss of battery power may leave you stranded. Never operate the water vehicle if the battery does not hav[...]

3-7 GP7-072 E EJU00447 Throttle Operate the throttle lever several times to make sure there is no hesitation in its travel. It should be smooth over the com- plete range, and spring back to the idle position on its own when released. EJU00448 Steering Make sure the handlebars are not loose. Turn them full-right and full-left to make sure operation [...]

E 3-8 EJU00915a Switches First, place the vehicle in the water to pro- vide adequate engine cooling. Push the starter switch 1 and start the engine, then push the engine stop switch 2 . Restart the engine and pull the engine stop switch lanyard on your left wrist to remove the lock plate 3 from the engine stop lanyard switch. Verify that the engine[...]

E 3-9 EJU00455 OPERA TION w Before operating your water vehicle, become familiar with all controls. Consult your Yamaha dealer about any control or function you do not fully understand. Failure to understand how controls work could cause an accident or prevent you from avoiding an accident. c C There are two hull drain plugs near the jet unit on th[...]

E 3-10 1) Launch the vehicle and start the engine. 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. 2) Run the engine at the lowest possible speed for the first five minutes. 3) Gra[...]

E 3-11 EJU00461a STARTING THE ENGINE w This product emits exhaust gases which contain carbon monoxide, a colorless, odorless gas which may cause brain dam- age or death when inhaled. Symptoms include nausea, dizziness, and drowsi- ness. Operate the vehicle in a open area. 1) Always make sure the vehicle is launched and used in waters that are free [...]

E 3-12 3) Attach the lock plate to the engine stop lanyard switch. Also, attach the lanyard to your left wrist. 1 Engine stop lanyard switch 2 Lanyard 3 Lock plate w Check that the lanyard is not frayed or broken, wrapped around the handlebars, or tangled in controls. If the operator falls off, the vehicle could continue to run and cause an acciden[...]

E 3-13 NOTE: 8 If initial setting of the PADLOC has not been done, the “START” mode is auto- matically selected. 8 If you have previously chosen “LOCK” mode, the engine will not start unless the right code is put in to select “START” mode. 6) While lightly squeezing the throttle lever, push the starter switch (green button). w On this v[...]

E 3-14 GP7-082 8) After the engine is warm, push the choke knob in fully, to its original position. NOTE: If the choke knob is left pulled out, the engine will stall. EJU00666a STOPPING THE ENGINE To stop the 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[...]

E 3-15 EJU00466 RIDING YOUR W A TER VEHICLE GETTING TO KNOW YOUR WATER VEHICLE Riding your water vehicle requires skills acquired through practice over a period of time. Take the time to learn the basic techniques well before attempting more difficult maneuvers. Riding your new water vehicle can be a very enjoyable activity, providing you with hour[...]

E 3-16 Wind, water, and glare from the sun may get in your eyes while you operate your water vehicle, reducing your ability to see. You may want to consider wearing eye protection such as sunglasses or goggles while riding. Some may find, however, that eye protection obstructs or distorts their vision, and distracts from operation. Only you know th[...]

E 3-17 EJU00484 STARTING w 8 There may be other water craft, obstructions, or swimmers around you. Check carefully before starting off to avoid an accident. 8 Practice getting on board in shallow water before riding in deep water. 60cm(2 ft) KA021 KA022 EJU00486a Starting in shallow water 1) Do not start your water vehicle in less than 60 cm (2 fee[...]

E 3-18 EJU00490a BOARDING AND STARTING IN DEEP WATER w 8 Operator and passenger should prac- tice getting on board in shallow water before riding in deep water. Reboarding in deep water requires more skill. 8 The fatigue and exposure that could result after unsuccessful attempts to get back on the vehicle may increase the risk of injuries and drown[...]

E 3-19 EJU00492a With a passenger 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 vagina). Do not open the throttle until each passenger is seated with feet on the floor and is holding on to the per- son in front of him or her. 1) Climb up on board as noted earl[...]

E 3-20 EJU00494a LOAD LIMIT The heavier the total weight of the opera- tor and passenger, the more difficult it will be to balance the water vehicle. It is not advisable to ride the vehicle when the total weight exceeds 160 kg (353 lb) including any cargo. If it is difficult to balance the vehicle at a standstill, proceed as follows: 1) The passeng[...]

E 3-21 EJU00497a CAPSIZED WATER VEHICLE 1) Turn off the engine by removing the lock plate from the engine stop lan- yard switch. The engine will overheat when capsized because it has no water to pump as coolant. 2) Swim to the rear side of the vehicle. Pull the vehicle over clockwise with the left hand on the ride plate while pushing down on the gu[...]

E 3-22 c C If the vehicle has been capsized for 5 min- utes or more, air may have entered the oil injection system. Leave the engine off, or operate only at trolling speeds, for 10 minutes after the vehicle has been put right-side up. This will allow any air to bleed off. GU0-083 EJU00499 TURNING Throttle produces thrust from the jet pump. Directio[...]

E 3-23 EJU00634 STOPPING The water vehicle is not equipped with a separate braking system. It is stopped by water resistance when the throttle lever is released. From full speed, the water vehi- cle stops in approximately 115 m (380 feet) after the throttle is released and the engine stopped. The stopping distance varies depending on gross weight, [...]

E 3-24 EJU00505 DOCKING 1) Make sure no obstructions, boats or swimmers are close to the water vehi- cle. Reduce speed about 115 m (380 ft) away from the dock. 2) Slowly approach the dock and stop the engine just before coming along- side it. K2001 EJU00507 ROUGH WATER OPERATION Operating in rough water or jumping waves can crack the vehicle body o[...]

E 3-25 EJU00508a POST -OPERA TION CHECKS 1) After removing the vehicle from the water, put the vehicle in the horizon- tal position. 2) Flush cooling system to prevent the cooling system from clogging up with salt, sand, or dirt. “Refer to pages 4-1 for the cooling system flushing proce- dure”. 3) Lubricate the internal components by performing[...]

E 3-26 6) Raise the bow about 30 cm (12 in.) and remove two hull drain plugs. Allow any water in the bilge to drain out. Rinse the engine compartment with a small amount of fresh water. Be care- ful not to get water on the carburetor or electrical components. After the water has drained, wipe the bilge with dry rags. Reinstall two drain plugs. NOTE[...]

E 3-27 EJU00513 TRANSPORT A TION w Always place the fuel cock in the “OFF” position when transporting the water vehicle. Otherwise, fuel could leak out into the engine or engine compartment, which would create a fire hazard. When transporting the water vehicle on a trailer, lock the bow with a pin to the trail- er and secure the stern with rope[...]

1 1 1 2 1 3 1 4 1 5 1 6 5 5 EJU00515 Chapter 4 MAINTENANCE AND CARE STORAGE ..................................................4-1 Cooling system flushing ...................4-1 Lubrication ..........................................4-3 Fuel system .........................................4-5 Battery .................................................4[...]

4-1 EJU00516 STORAGE EJW42110 w Always place the fuel cock in the “OFF” position when storing the water vehicle. Otherwise, fuel could leak out into the engine or engine compartment, which would create a fire hazard. Water vehicle storage for prolonged peri- ods of time, such as winter storage, requires preventative maintenance to ensure agains[...]

4-2 3) Connect both the garden hose adapter and a water tap using a hose. 4) Start the engine. Then, immediately turn on water supply until the water flows out continually from the cooling water pilot outlet. 5) Run the engine at an idle speed for 10 to 15 minutes watching engine condi- tion. If the engine stopped while flushing, turn off water sup[...]

4-3 q E EJU00526a LUBRICATION w To reduce the risk of fire or explosion: Never pour or spray gasoline, or any other substance except engine fogging oil through the hole(s) in the carburetor silencer cover. c C 8 Be sure to replace the cap(s) securely after fogging the engine. Otherwise water could enter the engine and cause damage. 8 Do not attempt[...]

4-4 4) Remove the spark plugs and pour approximately one tablespoon of oil into each cylinder. 5) Grease the spark plug threads and reinstall the 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 moistu[...]

E 4-5 EJU00528a FUEL SYSTEM Top off the fuel tank with fresh fuel/oil mixture and add one ounce of Yamaha Fuel Stabilizer and Conditioner to each gallon of fuel. NOTE: Use of Yamaha Fuel Stabilizer and Condi- tioner eliminates the need to drain the fuel system. Consult your Yamaha dealer or other qualified mechanic if the fuel sys- tem is to be dra[...]

E 4-6 EJU00531 CLEANING 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. 4) Wax the hull with a non-abrasive wax such as Yama[...]

4-7 E EJU00910 ADJUSTMENT AND MAINTENANCE Periodic inspection, adjustment and lubri- cation will keep your water vehicle in the safest and most efficient condition possi- ble. Safety is an obligation of the vehicle owner. The most important points of vehicle inspection, adjustment and lubri- cation are explained on the following pages. See your Yam[...]

4-8 E NOTE: A service manual is available for purchase through a Yamaha water vehicle dealer for owners who have the mechanical skills, tools, and other equipment neces- sary to perform maintenance not covered by this owner’s/operator’s manual. OWNER’S MANUAL AND TOOL KIT It is advisable always to carry the Owner’s Manual and Tool Kit with [...]

4-9 E EJU00536 PERIODIC INSPECTION CHART Frequency of maintenance operations may be adjusted according to the operating conditions, but the following table gives general guidelines. The mark ( ● ) indicates the checkups which you may do yourself. The mark ( 1 ) indicates work to be done by your Yamaha dealer. Spark plug Greasing points Bearing ho[...]

E 4-10 EJU00537a FUEL SYSTEM INSPECTION w Gasoline (Petrol) and its vapors are highly flammable and explosive. A fire or explo- sion can cause severe injury or death. Shut off the engine. Do not smoke. Avoid spilling gasoline. Do not drain the fuel while the engine is hot. Check the fuel system for leaks, cracks, or malfunctions. If any problem is [...]

4-11 E EJU00539 FUEL FILTER The fuel filter is a one-piece, disposable type. The filter should be replaced once a year or after every 200 hours of operation, or if water is found in the filter, take the water vehicle to your Yamaha dealer if fuel filter replacement is required. 1 Fuel filter w Do not try to change the fuel filter your- self. An inc[...]

E 4-12 EJU00544 OIL INJECTION SYSTEM INSPECTION Check the oil injection system for leaks, cracks, or malfunctions. If any problem is found, do the necessary repair or replace- ment as required. If repair is necessary, consult your nearest Yamaha dealer. Checking points 8 Check the oil tank for damage or cracks. 8 Check for water or dirt in the oil [...]

E 4-13 EJU00547 STEERING CABLE INSPECTION 1) Check the smooth operation of the handlebars and steering (jet) nozzle. 2) Turn the handlebars from lock to lock and check that the distances between rear end of the steering (jet) nozzle and the nozzle at inside of the steer- ing (jet) nozzle are even on both right and left sides. A=B If steering is sti[...]

E 4-14 GP7-099 GP7-100 EJU00551 QUICK SHIFT TRIM SYSTEM MECHANISM INSPECTION 1) Squeeze and release the shift lock release lever. It should move smooth- ly back to the lock position. 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 [...]

E 4-15 EJU00552a SPARK-PLUG CLEANING AND ADJUSTMENT The spark-plug is an important engine component and is easy to inspect. The condition of the spark-plug can indicate something about the condition of the engine. For example, if the centre elec- trode porcelain is very white, this could indicate an intake air leak or carburetion problem in that cy[...]

GU0-105 E 4-16 GU0-102 q GP7-104 EJU00553 GREASING POINTS To keep moving parts sliding or rotating smoothly, coat them with water resistant grease (Yamaha Marine Grease, YAMAHA grease A) or equivalent. Throttle cable and choke cable 1) Grease the carburetor throttle cable and choke cable inner wires. 2) Pull the throttle lever and remove the seal. [...]

GP7-107a E 4-17 EJU00558 Quick Shift Trim System cable joint and inner wire 1) Grease the all joints of the system on the under side of the seat storage com- partment and at the steering nozzle. 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 n[...]

E 4-18 EJU00566a Bearing housing Grease the bearing housing through the grease nipple 1 . This service should 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[...]

E 4-19 GP7-114 q EJU00570a CHOKE CABLE ADJUSTMENT Pull the choke knob out until it stops. Release the knob. The knob should not move. If it moves back on its own, tighten the friction adjustment slightly. If the knob is difficult to move, loosen the friction adjustment slightly. 1 Friction adjustment EJU00572 BATTERY Check the level of the battery [...]

E 4-20 w Battery electrolyte is poisonous and dan- gerous, causing severe burns, etc. Con- tains sulfuric acid. Avoid contact with skin, eyes or clothing. Antidote: EXTERNAL-Flush with water. INTERNAL-Drink large quantities of water or milk. Follow with milk of magnesia, beaten egg or vegetable oil. Call physi- cian immediately. Eyes: Flush with wa[...]

E 4-21 Recharging w 8 When charging the battery keep it well away from sparks and open flames, as it gives off explosive gases. 8 When using a battery charger, connect the battery to the charger before you turn the charger on. This will prevent sparking at the terminals which could ignite battery gases. 1) Remove the caps from the cells. Add distil[...]

4-22 E EJU00573 CARBURETOR ADJUSTMENT The carburetor is a vital part of the engine and requires very sophisticated adjust- ment. Most adjusting should be left to a Yamaha Water Vehicle dealer who has the professional knowledge and experi- ence to do so. However, the following point may be serviced by the owner as part of his usual maintenance routi[...]

4-23 EJU00578 FUSE REPLACEMENT The fuse is in the electrical box. To replace the fuse, remove the cap, pull out the red lead, and bring the fuse box out of the electrical box. Open the fuse box and replace the fuse. 1 Electrical box 2 Cap 3 Fuse (10A) 4 Fuse box w Do not use fuses of higher amperage that those recommended. Substitution of a fuse of[...]

4-24 EJU00587a YAMAHA ADJUSTABLE SPONSON (Y.A.S.) ADJUSTMENT 1) Loosen the cap nuts on both spon- son. 2) Loosen the adjuster lock nut on either sponson. Turn the adjuster to move the sponson up or down to the desired position. 1 Cap nut 2 Lock nut 3 Adjuster 4 Adjustment marks c C Do not attempt to adjust the sponson without loosening the cap nuts[...]

4-25 E GP800 2,860 (112.6) 1,120 (44.1) 970 (38.2) 226 (498) 2 160 (352) 88.2 (120)/ @ 7,000 49 (12.9) 1.0 1,250 ~ 1,350 2-stroke 2 784 (47.84) 80.0 × 78.0 (3.15 × 3.07) 6.6 Oil injection Water-Cooled Electric starter Digital CDI BR-8ES 0.6 ~ 0.7 (0.024 ~ 0.028) 12-19 Flywheel magneto Jet pump Axial flow, single stage Counter clockwise (Rear view[...]

1 1 1 2 1 3 1 4 1 5 1 6 EJU00594 Chapter 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[...]

TROUBLE 5-1 EJU00595 TROUBLESHOOTING If any trouble happens on your water vehicle, use this section to check for the possible case. If you can not find the cause, or if the procedure for replacement or repair is not described on this owner’s manual, ask your Yamaha Water Vehicle dealer or qualified mechanic for the proper service. The trouble sho[...]

E 5-2 8 Fuel 8 Choke 8 Fuel Filter 8 Fuel tank 8 Spark Plug 8 Spark Plug cap 8 Carburetor 8 Fuel level 8 Engine oil level 8 Engine overheat 8 Low battery voltage 8 Cavitation 8 Engine overheat 8 Fuel Filter 8 Spark plug 8 Spark plug caps 8 Fuel 8 Bilge TROUBLE Empty Stale or contaminated Knob is left pulled Clogged or water collected Water or dust [...]

E 5-3 EJU00597 EMERGENCY PROCEDURES EJU00598a CLEANING THE JET INTAKE AND IMPELLER If weeds or debris get caught in the intake or impeller, cavitation can occur, and though the engine speed rises, forward thrust will decrease. If this condition is allowed to continue, the engine will over- heat and may seize. If there is any sign that the jet intak[...]

E 5-4 2) Remove any weeds or debris from around the drive shaft, impeller, pump housing, and steering nozzle. If it is difficult to remove them, con- sult your Yamaha Water Vehicle deal- er. c C Always avoid running your vehicle in areas where weed growth is thick. If trav- eling in weeded areas is unavoidable, run the engine alternately at partial[...]

5-5 E EJU00600a To connect the jumper cables 1) Connect the positive (+) terminals of both batteries with the positive (red) jumper cable. 2) Connect one end of the negative (black) jumper cable to the negative (–) terminal of the booster battery. 3) Connect the other end of the negative (black) cable to an unpainted bolt on the cylinder head. c [...]

E 5-6 EJU00603 TOWING THE WATER VEHICLE If the vehicle becomes inoperative in the water, it can be towed to shore. The bow must be kept up out of the water during towing to prevent water from entering the engine compartment. If the vehicle must be towed in an emer- gency using a tow rope, the operator should ride the vehicle, holding onto the handl[...]

5-7 E EJU00829 SUBMERGED WATER VEHICLE If the water vehicle is submerged or flooded with water, follow the procedure below and consult your Yamaha water vehicle dealer as soon as possible. Failure to do so may result in serious engine damage ! 1) Beach the vehicle and remove the drain plug(s) to drain the water from the engine compartment. 2) Set t[...]

1 1 1 2 1 3 1 4 1 5 1 6 EJU00608 Chapter 6 INDEX INDEX ........................................................6-1 E[...]

6-1 EJU00609 INDEX A Adjustment and maintenance ................4-7 Approval label of emission control certificate...................................................1-2 B Battery ......................................3-6, 4-5, 4-19 Beaching .................................................3-23 Bearing housing .....................................4-[...]

6-2 L Labels ........................................................1-4 Learning to ride your water vehicle .....3-15 Limitations on who may operate the vehicle .......................................................1-7 Load limit ................................................3-20 Location of main components................2-1 Lubrication ......[...]

6-3 Submerged water vehicle .......................5-7 Switches ....................................................3-8 T Tachometer ............................................2-16 Throttle ......................................................3-7 Throttle cable and choke cable.............4-16 Throttle cable inspection and adjustment ............[...]

6-4 EJU00610 LIMITED W ARRANTY YAMAHA MOTOR CORPORATION, U.S.A. WATER VEHICLE LIMITED WARRANTY Yamaha Motor Corporation is proud of its heritage and reputation for producing products with high standards of quality and workman- ship. Product excellence provides the cornerstone for our commitment to customer satisfaction. The Yamaha Water Vehicle Lim[...]

6-5 WARRANTY QUESTIONS AND ANSWERS Q. What costs are my responsibility during the warranty period? A. The customer’s responsibility includes all costs of normal maintenance services, non-warranty repairs, accident and collision damages. Q. What are some examples of “abnormal” strain, neglect, or abuse? A. These terms are general and overlap e[...]

6-6 YAMAHA EXTENDED SERVICE (Y.E.S.) Keep your Yamaha protected even after your warranty expires with genuine Yamaha Extended Service (Y.E.S.). 8 Y.E.S. is designed and administered by Yamaha Motor Corporation to provide maximum owner satisfaction. You get uninterrupted factory-backed coverage for extra peace of mind. 8 Y.E.S. is flexible. You choo[...]

Y AMAHA MOTOR CORPORA TION, USA Printed on recycled paper Printed in U.S.A. Jun. 1999—?.? × 1 CR GU0-F8199-13 (GP800)[...]