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Table of Contents
Related Manuals for Yamaha WaveRunner GP800R
Summary of Contents for Yamaha WaveRunner GP800R
- Page 1 WaveRunner GP800R ASSEMBLY MANUAL *LIT186660029* LIT-18666-00-29 F0W-28107-1A-11...
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Page 2: Assembly Manual
WaveRunner GP800R ASSEMBLY MANUAL ©2000 by Yamaha Motor Corporation, USA 1st Edition, October 2000 All rights reserved. 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... -
Page 3: Important Manual Information
If any change is introduced into the : Tighten temporarily. specifications or assembly procedures, : Apply locking agent. Yamaha dealers will be notified by a techni- ® LOCTITE ‚ No.242 (BLUE LOCTITE) cal bulletin. -
Page 4: General Torque Specifications
GENERAL TORQUE SPECIFICATIONS General torque This chart specifies the torques for tighten- Nut A Bolt B specifications ing standard fasteners with standard clean N•m kgf•m ft•lb dry ISO threads at room temperature. 8 mm Torque specifications for special compo- 10 mm nents or assemblies are given in applicable 12 mm sections of this manual. -
Page 5: Unpacking And Checking
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. - Page 6 COMPARTMENT DIAGRAM COMPARTMENT PART CHART Part name Q’ty Part number Grommet F0X-61469-00 Lower handlebar holder EU0-23814-01 Handlebar assembly F0W-U155A-00 Upper handlebar holder EU0-23814-30 Bolt 8 × 55 mm (0.31 × 2.17 in) 90119-089UM Band 90601-200U2 Band 90464-32801 Spiral tube 90448-25800 Handlebar cover stay GP7-U142K-00 Screw 6 ×...
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Page 7: Installation Chart
WIRE LEAD AND CABLE ROUTING EXPLODED DIAGRAM INSTALLATION CHART Step Procedure/Part name Q’ty Service points WIRE LEAD AND CABLE Follow “Step” order for installation. ROUTING NOTE: Before starting work open the front hood and remove the storage compartment, and remove the seat. Choke cable Throttle cable Handlebar switch lead... - Page 8 HANDLEBAR AND THROTTLE CABLE INSTALLATION EXPLODED DIAGRAM INSTALLATION CHART Step Procedure/Part name Q’ty Service points HANDLEBAR AND THROTTLE Follow “Step” order for installation. CABLE INSTALLATION Lower handlebar holder Handlebar assembly NOTE: Upper handlebar holder Align the punched marks a on the handle- bar with the top surface of the lower han- dlebar holders.
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Page 9: Exploded Diagram
EXPLODED DIAGRAM Step Procedure/Part name Q’ty Service points Band Fasten the QSTS cables and handlebar switch lead with band at the handlebar. Band Throttle cable Installation steps: Install the throttle cable end into the throttle lever. Fit the seal into the groove in the bracket. -
Page 10: Choke Cable Installation
CHOKE CABLE INSTALLATION EXPLODED DIAGRAM INSTALLATION CHART Step Procedure/Part name Q’ty Service points CHOKE CABLE INSTALLATION Choke cable 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. - Page 11 EXPLODED DIAGRAM Step Procedure/Part name Q’ty Service points NOTE: If the inner cable is difficult to make taut using the adjuster 1, adjust the choke lever so that the cable is taut. The cable must be taut when the choke lever end a is positioned within the line marks b.
- Page 12 EXPLODED DIAGRAM Step Procedure/Part name Q’ty Service points Make sure that the inner cable has some slack when the choke lever is completely closed. Tighten the locknut 2 to secure the choke cable. Spiral tube NOTE: Be sure to install the spiral tube, containing the throttle cable, choke cable and handle- bar switch lead, at least 50 mm (1.97 in) c into the steering column.
- Page 13 HANDLEBAR COVER INSTALLATION EXPLODED DIAGRAM INSTALLATION CHART Step Procedure/Part name Q’ty Service points HANDLEBAR COVER Follow “Step” order for installation. INSTALLATION Handlebar cover stay Screw 6 × 15 mm (0.24 × 0.59 in) Handlebar cover NOTE: Screw 6 × 19 mm (0.24 × 0.75 in) If the handlebar cover is in contact with the steering console cover, adjust the handlebar mount angle so that the clearance a and b...
- Page 14 WIRING CONNECTION INSTALLATION EXPLODED DIAGRAM INSTALLATION CHART Step Procedure/Part name Q’ty Service points WIRING CONNECTION Follow “Step” order for installation. INSTALLATION Speed sensor coupler White coupler (3 pins) Fuel level sensor coupler Green coupler (2 pins) Oil level sensor coupler White coupler (2 pins) Multifunction meter coupler White coupler (4 pins)
- Page 15 QSTS CABLE INSTALLATION EXPLODED DIAGRAM INSTALLATION CHART Step Procedure/Part name Q’ty Service points QSTS CABLE INSTALLATION Follow “Step” order for installation. NOTE: QSTS cable 1 Set the inner cables length a to 77 ± 0.5 QSTS cable 2 mm (3.03 ± 0.02 in), using the adjusting nuts 1 when the control grip is in neutral before installing the QSTS cables.
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Page 16: Battery Installation
BATTERY INSTALLATION EXPLODED DIAGRAM INSTALLATION CHART Step Procedure/Part name Q’ty Service points Follow “Step” order for installation. BATTERY INSTALLATION Battery breather hose NOTE: Charge the battery before installing it. Refer Battery to “PREDELIVERY CHECK”. Battery positive lead (red) Bolt 6 × 12 mm (0.24 × 0.47 in) Terminal extension Battery negative lead (black) Bolt 6 ×... - Page 17 PREDELIVERY CHECK CHECKING CHART Check elements Checking points Reference page Throttle lever Free play Battery Battery condition Oil pump Air bleed Trolling speed Trolling speed Steering system Handlebar and steering nozzle positions QSTS Trim nozzle position BATTERY WARNING Battery electrolyte is poisonous and dan- gerous, causing severe burns, etc.
- Page 18 1. Fill: Battery electrolyte Filling steps: Remove all the filler caps using pliers. Fill with the specified electrolyte from a jug. After the electrolyte is filled up as far as the UPPER LEVEL a, allow the cell to stand for 20 minutes. If after 20 min- utes, the electrolyte level has dropped, add more electrolyte up to the UPPER LEVEL mark once again.
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Page 19: Oil Pump Air Bleeding
4. Install: Filler caps CAUTION: Rinse off any electrolyte from the battery case and wipe the battery dry prior to installation. OIL PUMP AIR BLEEDING 1. Bleed: Air bleeding steps: Place rags around the air bleed screw 1 to catch any oil that might spill. Fill the oil tank with the recommended engine oil. - Page 20 TROLLING SPEED 1. Measure: Trolling speed Out of specification → Adjust. Trolling speed: 1,300 ± 50 r/min Checking steps: (Vehicle on water) Start the engine and allow it to warm up for a few minutes. Attach an engine tachometer to the spark plug lead.
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Page 21: Steering Cable
STEERING CABLE 1. Check: Distance a, b (between the nozzle and nozzle deflector) Out of specification → Adjust. Difference of distances a and b: Maximum 5 mm (0.2 in) Checking steps: Set the control grip in the neutral posi- tion. Turn the handlebar lock to lock. - Page 22 QSTS CABLE 1. Measure: Nozzle deflector set length a, b Difference → Adjust. Measurement steps: Set the control grip in the neutral posi- tion. Set the jet nozzle in the center posi- tion. Measure the nozzle deflector length a and b. If a and b length are not even, adjust the cable joint.
- Page 23 APPENDICES SERVICE DATA Item Unit GP800R 1,300 ± 50 Trolling speed: r/min Spark plug: Type BR8ES mm (in) 0.7–0.8 (0.028–0.031) Fuel and oil: Fuel Regular unleaded gasoline with a minimum octane rating of 86 (PON ) or 90 (RON Engine oil YAMALUBE 2-W or an equivalent TC-W3 certified outboard oil Fuel tank capacity...
- Page 24 YAMAHA MOTOR CORPORATION, USA Printed in USA × 1 CR Oct. 2000 — F0W-28107-1A-11 (GP800A)