Yamaha WaveRunner GP1200R Manuals

Manuals and User Guides for Yamaha WaveRunner GP1200R. We have 2 Yamaha WaveRunner GP1200R manuals available for free PDF download: Service Manual, Assembly Manual

Yamaha WaveRunner GP1200R Service Manual

Yamaha WaveRunner GP1200R Service Manual (245 pages)

Brand: Yamaha | Category: Boat | Size: 7 MB

Table of Contents

Info Chapter 1 General Information

8
- How to Use this Manual
  3
- Periodic Inspection and
  6
- Table of Contents
  8
- Chapter 1
  9
- Engine Serial Number
  9
- HULL IDENTIFICATION NUMBER (H.l.n.)
  9
- Identification Numbers
  9
- Jet Pump Unit Serial Number
  9
- PRIMARY L.D. NUMBER
  9
- Safety While Working
  10
  - Fire Prevention
    10
  - Ventilation
    10
  - Self-Protection
    10
  - Oils, Greases and Sealing Fluids
    10
  - Good Working Practices
    11
  - Disassembly and Assembly
    12
- Special Tools
  13
  - Measuring
    13
  - Removal and Installation
    14
Specifications

15
- Chapter 2 Specifications
  16
- General Specifications
  16
- Maintenance Specifications
  18
  - Engine
    18
  - Jet Pump Unit
    19
  - Hull and Hood
    19
  - Electrical
    20
- Tightening Torques
  22
  - Specified Torques
    22
  - General Torque
    25
- Cable and Hose Routing
  26
Table of Contents

28
- Chapter 3
  29
- Maintenance Interval Chart
  29
- Periodic Service
  30
  - Control System
    30
    
    Steering Column Inspection
    30
    
    Steering Cable Inspection and Adjustment
    30
    
    Throttle Cable Inspection and Adjustment
    31
    
    Choke Cable Inspection and Adjustment
    32
    
    QSTS Cable Inspection and Adjustment
    33
    
    YPVS Cable Adjustment
    34
  - Fuel System
    35
    
    Fuel Line Inspection
    35
    
    Trolling Speed Check and Adjustment
    36
  - Oil Injection System
    37
    
    Oil Line Inspection
    37
  - Power Unit
    37
    
    Spark Plug Inspection
    37
  - Electrical
    38
    
    Battery Inspection
    38
  - Jet Pump Unit
    41
    
    Impeller Inspection
    41
    
    Water Inlet Strainer Inspection
    42
    
    Bilge Strainer Inspection
    42
  - General
    42
    
    Drain Plug Inspection
    42
    
    Lubrication Points
    43
Table of Contents

46
- Chapter 4
  49
- Fuel Cock Inspection
  49
- Fuel Filter Inspection
  49
- Service Points
  49
- Oil Tank
  50
  - Exploded Diagram
    50
  - Removal and Installation Chart
    50
  - Service Points
    52
    
    Oil Line Inspection
    52
    
    Oil Level Switch Inspection
    52
    
    Oil Tank Inspection
    52
- Fuel Tank
  53
  - Exploded Diagram
    53
  - Removal and Installation Chart
    53
  - Service Points
    56
    
    Check Valve Inspection
    56
    
    Fuel Level Switch Inspection
    56
    
    Fuel Tank Inspection
    56
    
    Pipe Joint Inspection
    56
- Intake Duct and Silencer
  57
  - Exploded Diagram
    57
  - Removal and Installation Chart
    57
- Carburetor Unit
  59
- Carburetor
  65
  - Removal and Installation Chart
    65
  - Service Points
    68
    
    Diaphragm Inspection
    68
    
    Accelerator Pump Body Inspection
    68
    
    Arm Inspection
    68
    
    Regulator Body Inspection
    69
    
    Needle Valve Inspection
    69
    
    Jet and Carburetor Body Inspection
    69
    
    Carburetor Assembly
    69
- Fuel Pump
  70
  - Exploded Diagram
    70
  - Removal and Installation Chart
    70
  - Service Points
    72
    
    Fuel Pump Inspection
    72
    
    Fuel Filter Inspection
    72
- Oil Pump
  73
  - Exploded Diagram
    73
  - Removal and Installation Chart
    73
  - Service Points
    75
    
    Oil Pump Inspection
    75
    
    Oil Hose Inspection
    75
    
    Check Valve Inspection
    75
    
    Oil Pump Cable Adjustment
    76
    
    Oil Injection Pump Air Bleeding
    77
Power Unit

78
- Chapter 5
  80
- Exploded Diagram
  80
- Muffler Assembly
  80
- Removal and Installation Chart
  80
- Service Point
  86
  - Catalyst Inspection
    86
- Exhaust Chamber Assembly
  87
  - Exploded Diagram
    87
  - Removal and Installation Chart
    87
- Engine Unit
  90
  - Exploded Diagram
    90
  - Removal and Installation Chart
    90
  - Service Points
    92
    
    Shim Removal
    92
    
    Engine Mount Inspection
    92
    
    Coupling Clearance Inspection
    92
- Exhaust Manifold
  93
  - Exploded Diagram
    93
  - Removal and Installation Chart
    93
  - Removal and Installation Chart
    94
  - Service Points
    96
    
    Reed Valve Inspection
    96
- Ypvs
  97
  - Exploded Diagram
    99
  - Service Points
    100
    
    YPVS Valve Inspection
    100
    
    YPVS Valve Installation
    100
- Cylinder Head
  101
  - Exploded Diagram
    101
  - Removal and Installation Chart
    101
  - Service Points
    103
    
    Cylinder Head Inspection
    103
- Cylinders
  104
  - Exploded Diagram
    104
  - Removal and Installation Chart
    104
  - Service Points
    105
    
    Cylinder Inspection
    105
- Pistons
  106
  - Exploded Diagram
    106
  - Removal and Installation Chart
    106
  - Service Points
    108
    
    Piston Pin Clip Removal and Installation
    108
    
    Piston Inspection
    108
    
    Cylinder and Piston Combination
    109
    
    Piston Ring Inspection
    109
    
    Piston Pin and Bearing Inspection
    110
- Generator and Starter Motor
  112
  - Exploded Diagram
    112
  - Removal and Installation Chart
    112
  - Service Points
    119
    
    Drive Coupling Removal and Installation
    119
    
    Flywheel Magneto Removal and Installation
    119
    
    Drive Coupling Inspection
    120
    
    Flywheel Magneto Inspection
    120
    
    Starter Clutch Assembly Inspection
    120
- Crankcase
  121
  - Exploded Diagram
    121
  - Removal and Installation Chart
    121
  - Crankcase Exploded Diagram
    121
  - Service Points
    123
    
    Crankcase Inspection
    123
    
    Crankcase Installation
    123
- Crankshaft
  124
  - Exploded Diagram
    124
  - Service Points
    125
    
    Crankshaft Inspection
    125
Pump Chapter 6 Jet Pump Unit

127
- Chapter 6
  130
- Exploded Diagram
  130
- Jet Pump Unit
  130
- Nozzle Deflector and Nozzle Ring
  131
  - Exploded Diagram
    131
- Removal and Installation Chart
  131
- Impeller Duct, Impeller Housing, and Intake Duct
  132
  - Exploded Diagram
    132
  - Removal and Installation Chart
    132
- Impeller Duct and Drive Shaft
  134
  - Exploded Diagram
    134
  - Service Points
    136
    
    Drive Shaft Removal
    136
    
    Impeller Inspection
    137
    
    Drive Shaft Inspection
    137
    
    Drive Shaft Installation
    137
- Transom Plate and Hoses
  140
  - Exploded Diagram
    140
  - Removal and Installation Chart
    140
  - Service Points
    142
    
    Bilge Strainer Inspection
    142
    
    Bilge Hose Inspection
    142
- Bearing Housing
  143
  - Exploded Diagram
    143
  - Removal and Installation Chart
    143
  - Service Points
    146
    
    Driven Coupling Removal and Installation
    146
    
    Intermediate Drive Shaft Removal
    146
    
    Bearing Removal
    146
    
    Bearing, Driven Coupling Shaft, and Grease Hose Inspection
    147
    
    Driven Coupling Inspection
    147
    
    Bearing Installation
    147
    
    Oil Seal Installation
    147
    
    Intermediate Housing Installation
    148
Table of Contents

149
- Chapter 7
  151
- Electrical Components
  151
- Electrical Box
  152
  - Exploded Diagram
    152
  - Removal and Installation Chart
    152
- Electrical Analysis
  157
  - Inspection
    157
    
    Digital Circuit Tester
    157
    
    Low Resistance Measurement
    158
    
    Peak Voltage Measurement
    158
    
    Peak Voltage Adaptor
    158
    
    Test Harness
    159
- Ignition System
  160
  - Wiring Diagram
    160
  - Ignition Spark Gap
    161
  - Ignition System Peak Voltage
    162
  - Battery
    164
  - Fuse
    164
  - Spark Plugs
    164
  - Spark Plug Lead Assembly
    164
  - Ignition Coil
    165
  - Engine Stop Switch
    165
  - Water Temperature Sensor
    166
  - Exhaust Temperature Sensor
    166
- Starting System
  167
  - Wiring Diagram
    167
  - Battery
    168
  - Wiring Connections
    168
  - Fuse
    168
  - Starter Switch
    169
  - Starter Relay
    169
- Starter Motor
  170
  - Service Points
    173
    
    Armature Inspection
    173
    
    Brush Holder Inspection
    174
    
    Starter Motor Front Cover Inspection
    174
- Charging System
  175
  - Wiring Diagram
    175
  - Fuse
    176
  - Battery
    176
  - Lighting Coil
    176
  - Rectifier/Regulator
    176
- Ypvs
  177
  - Wiring Diagram
    177
  - Fuse
    178
  - Battery
    178
  - Pickup Coil
    178
  - CDI Unit
    178
  - Lighting Coil
    178
  - Rectifier/Regulator
    178
- Ypvs Servomotor
  180
  - Service Points
    180
    
    YPVS Cable Removal and Installation
    180
    
    YPVS Cable Inspection
    180
    
    YPVS Servomotor Inspection
    180
    
    YPVS Cable Adjustment
    181
- Indication System
  182
  - Wiring Diagram
    182
  - Fuse
    183
  - Battery
    183
  - Lighting Coil
    183
  - Rectifier/Regulator
    183
  - CDI Unit
    183
  - Water Temperature Sensor
    183
  - Exhaust Temperature Sensor
    183
  - Buzzer
    183
  - Oil Level Sensor
    183
  - Fuel Level Sensor
    184
  - Multi-Function Meter
    184
  - Multi-Function Meter Removal
    184
    
    Display Function
    185
    
    Fuel Level Gauge
    186
    
    Oil Level Gauge
    187
    
    Overheat Warning Indicator
    188
    
    Speed Meter
    190
    
    Speed Sensor
    190
    
    Fuel Filter
    242

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Yamaha WaveRunner GP1200R Assembly Manual

Yamaha WaveRunner GP1200R Assembly Manual (24 pages)

Brand: Yamaha | Category: Boat | Size: 2 MB

Table of Contents

Table of Contents
7
INSTALLATION CHART Step Procedure/Part Name Q'ty
8
- Choke Cable
  12
Note
12
Service Points
12
Note
13

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