GP800R_F0W-28107-1A-11

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*LIT186660029*

WaveRunner

GP800R

ASSEMBLY MANUAL

F0W-28107-1A-11

LIT-18666-00-29

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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

SYMBOLS U

ASSEMBL

In order to simplify d

bly manuals, the fo

used:

:Coat with wa

(Yamaha gre

grease)

:Tightening to

:Provide clear

:Install so that

upward.

:Frontword of

:Made of rubb

:Tighten temp

:Apply locking

LOCTITE

No

Size:

d/D : Diam

R

: Leng

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GENERAL TORQUE

This chart specifies ting standard fastene

dry ISO threads a

Torque specification

nents or assemblies a

sections of this man

warpage, tighten mu

in a criss-cross fas

stages until the speci

NutA BoltB

General torque

specificationsNm kgfm ftlb

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

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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

Chapter 3. Documentation may be required for warranty reimbursem

with uncrating or throw the crate away until the requirements in Chapt

COMPARTMENT DIAGRAM

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COMPARTMENT DIAGRAM

COMPARTMENT PART CHART

No. Part name Qty Pa

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

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WIRE LEAD AND CABLE ROUTING

EXPLODED DIAGRAM

INSTALLATION CHART

Step Procedure/Part name Qty Service

WIRE LEAD AND CABLEROUTING

Follow Step order fo

NOTE:

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HANDLEBAR AND THROTTLE CABLE INSTALLATION

EXPLODED DIAGRAM

INSTALLATION CHART


HANDLEBAR AND THROTTLECABLE INSTALLATION

Follow Step order fo

1 Lower handlebar holder 2

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EXPLODED DIAGRAM


5 Band 1 Fasten the QSTS cableswitch lead with band a

6 Band 1

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CHOKE CABLE INSTALLATION

EXPLODED DIAGRAM

INSTALLATION CHART


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EXPLODED DIAGRAM


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EXPLODED DIAGRAM


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HANDLEBAR COVER INSTALLATION

EXPLODED DIAGRAM

INSTALLATION CHART


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WIRING CONNECTION INSTALLATION

EXPLODED DIAGRAM

INSTALLATION CHART


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QSTS CABLE INSTALLATION

EXPLODED DIAGRAM

INSTALLATION CHART


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BATTERY INSTALLATION

EXPLODED DIAGRAM

INSTALLATION CHART


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PREDELIVERY CHECK

CHECKING CHARTCheck elements Checking points

Throttle lever Free play

Battery Battery condition

Oil pump Air bleed

Trolling speed Trolling speed

Steering system Handlebar and steering nozzle position

QSTS Trim nozzle position

BATTERY

WARNING

Battery electrolyte

gerous, causing setains sulfuric acid.

Avoid contact with

Antidote: EXTERNA

INTERNAL-Drink lar

or milk. Follow wi

beaten egg or vege

cian immediately. E

for 15 minutes and

attention. Batterie

gases. Keep spark

etc., away. Ventila

using in an enclose

your eyes when wo

KEEP OUT OF REAC

CAUTION:

Be careful not to pla

side. Before adding

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1. Fill:

Battery electrol

2. Initial battery cha

Battery

WARNING

Turn the battery cha

tery is connected to t

The sparking by con

cable to the battery

explosion to the ex

out from the battery

CAUTION:

Always charge the b

trolyte is poured int

first time. Otherwise,

Filling steps:

Remove all the fil Fill with the spec

a jug. After the electroly

the UPPER LEVEL

stand for 20 min

utes, the electrolyadd more electroLEVEL mark once

Charging steps:

Connect the charof the battery ch

terminals correctl

Charge the battewith the rate of 1.

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4. Install:

Filler caps

CAUTION:

Rinse off any electro

case and wipe the

installation.

OIL PUMP AIR BLEED

1. Bleed:

Air

CAUTION:

Do not run the eng

out the air bleed s

Air bleeding steps:

Place rags aroun

1to catch any oi Fill the oil tank w

engine oil.

RecommendYAMALUBequivalent outboard o

Loosen the air blturns and make s

and air bubbles fl When there are

tighten the air ble Wipe up any spilt

T

R.

.

Air bleed scr5 N m (0.5

1

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TROLLING SPEED

1. Measure:

Trolling speed

Out of specifica

Trolling spee1,300 50 r

Checking steps: (Ve

Start the engine up for a few minu Attach an engin

spark plug lead.

Engine tachoYU-8036-A

Measure the engi

2. Adjust:

Trolling speed

Adjustment steps:

Start the engine. Turn the throttle

out until the obtained.

Turn in Incre

Turn out Decr

1

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STEERING CABLE

1. Check:

Distance a, b

and nozzle defle

Out of specifica

Difference of distanMaximum 5 mm (

Checking steps: Set the control gr

tion.

Turn the handleb Measure the dista

If the difference ois not within spe

cable joint.

2. Adjust:

Steering cable j

Adjustment steps:

Loosen the locknu Disconnect the ca

ball joint3. Turn the cable

adjusting the dist

Turn in Dist

Turn out Dist

WARNING

The cable joint mus

than 8 mm (0.31 in)

Connect the cable

1

2

3

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QSTS CABLE

1. Measure:

Nozzle deflecto

Difference A

2. Adjust:

QSTS cable

Measurement steps

Set the control grtion.

Set the jet nozzltion.

Measure the nlengthaandb.

If aand blengththe cable joint.

Adjustment steps:

Set the control gr

tion. Loosen the locknu

Remove the nut2 Set the nozzle de

position. Turn the cable jo

adjusting lengtha

Turn in Leng

Turn out Leng

WARNING

The cable joint mus

than 8 mm (0.31 in)

Connect the cab

pin3and tighten

Nut:4 N m (0 4

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APPENDICES

SERVICE DATA

*1: Pump Octane Number = (Motor Octane Number + Research Octane*2: Research Octane Number

Item Unit GP800

Trolling speed: r/min 1,300

Spark plug:

Type BR8E

Gap mm (in) 0.70.8 (0.02

Fuel and oil:

Fuel Regular unleaded gasoloctane rating of 86 (PO

Engine oil YAMALUBE 2-W or an

certified outb

Fuel tank capacity L (US gal,

Imp gal)

60 (15.9,

Oil tank capacity L (US gal,Imp gal)

5.5 (1.45,

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YAMAHA MOTOR CORPORATION, USA

Printed in USA

Oct. 2000 ?.?1 CR

F0W-28107-1A-11

(GP800A)

GP800R_F0W-28107-1A-11

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