2002 YAMAHA GP1200 oil

E
4
EJU01086
MAINTENANCE AND
CARE
Storage ...................................................... 4-1
Flushing the cooling system .................. 4-1
Lubrication .............................................. 4-3
Fuel system ............................................ 4-3
Battery .................................................... 4-4
Cleaning the watercraft .......................... 4-5
Maintenance and adjustments .............. 4-6
Owner’s/Operator’s Manual and
tool kit ..................................................... 4-7
Periodic maintenance chart ................... 4-8
Inspecting the fuel system ..................... 4-9
Inspecting the oil injection system ....... 4-11
Inspecting the steering cable ............... 4-12
Inspecting and adjusting the
throttle cable ......................................... 4-12
Inspecting the QSTS mechanism ....... 4-13
Cleaning and adjusting the
spark plugs ........................................... 4-14
Lubrication points ................................. 4-15
Inspecting the battery .......................... 4-18
Adjusting the carburetor ...................... 4-20
Replacing the fuse ............................... 4-21
Bleeding the oil injection pump ............ 4-21
Adjusting the Yamaha Adjustable
Sponson (Y.A.S.) ................................. 4-22
Specifications ........................................ 4-23
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4-3
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Lubrication
1. Remove the spark plugs and pour
approximately one tablespoon of oil into
each cylinder.
2. Grease the spark plug threads and rein-
stall the spark plugs.
3. Crank the engine within 3 seconds using
the start switch.
4. Lubricate all cables such as the throttle,
choke, and steering cables.
NOTE:@ Use a suitable marine grease applicator to
pressure lubricate the cables and purge out
any moisture between the inner and outer
cables.
@
5. Lubricate the areas of the watercraft
specified under Lubrication points on
pages 4-15 to 4-17.
EJU01090
Fuel system
Draining the fuel system prevents buildup
of varnishes and other harmful deposits that
result when gasoline sits for a prolonged
period of time.
WARNING@ Gasoline is highly flammable and explo-
sive. A fire or explosion can cause
severe injury or death. Shut the engine
off. Drain in well-ventilated areas away
from flames or sparks. Do not smoke.
Avoid spilling gasoline. Wipe up spilled
gasoline immediately.
@
To drain the fuel system:
1. Place the fuel cock knob in the “OFF”
position.
2. Drain the fuel tank using a siphon.
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4-8
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Periodic maintenance chart
The following chart gives general guidelines for periodic maintenance. However, depend-
ing on your operating conditions maintenance may need to be performed more frequently.
PMC-F0X7E(
) This mark indicates maintenance that you may do yourself.
(
❍) This mark indicates work to be done by a Yamaha dealer.
MAINTENANCE INTERVAL INITIALTHEREAFTER
EVERYPA G E
10
hours50
hours100
hours100
hours200
hours
ITEM
3
months6
months6
months12
months
Spark plug Inspect, clean, adjust




4-14
Lubrication points Lubricate


4-15
Intermediate housing Lubricate❍
*1

*2

*2 4-17
Fuel system Inspect❍❍
4-9
Fuel filter Check, replace❍❍
4-10
Fuel tank Clean❍
4-10
Oil injection system Inspect, clean❍❍
4-11
Trolling speed Adjust


4-20
Carburetor throttle shaft Inspect❍❍
—
Cooling water passages Flush

(after
ever y
use)4-1
Bilge strainer Clean



—
Impeller Inspect



—
Steering cable Inspect


4-12
QSTS mechanism Inspect


4-13
Throttle cable Inspect, adjust


4-12
Stern drain plugs Inspect, replace

3-7
Battery Inspect



(inspect
fluid level
before
ever y
use)
4-18
Rubber coupling Inspect❍
—
Nuts and bolts Tighten❍❍❍
—
*1: Grease capacity: 33.0–35.0 cm3 (1.11–1.18 oz)
*2: Grease capacity: 6.0–8.0 cm3 (0.20–0.27 oz)
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4-11
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Inspecting the oil injection
system
Check the oil injection system for leakage,
cracks, or malfunctions. If necessary, have a
Yamaha dealer repair the oil injection sys-
tem.
Check:

Oil tank for damage, cracks or leakage.

Oil tank for water or dirt.

Oil hose and joint for damage or cracks.

Oil filter for dirt.

Oil pump for leakage.
EJU01101
Oil tank
Check the oil tank for leakage or water in
the tank. If water is found in the oil injection
system or if the oil tank needs to be cleaned
have a Yamaha dealer service the water-
craft.
EJU01102
Oil filter
Check the oil filter 1 for dirt and clogs. If
the oil filter is clogged, remove it from the oil
tank together with the oil level sender and
clean it.
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4-15
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NOTE:@
Wipe off any water on the spark plug or
inside the cap before installing the spark
plug cap. Push the spark plug cap down
until it clicks.

If a torque wrench is not available when
you are fitting a new spark plug, a good
estimate of the correct torque is 1/4 turn
to 1/2 turn past finger tight. Have the
spark plug adjusted to the correct torque
with a torque wrench as soon as possible.
@
WARNING@ Be careful not to damage the insulator
when removing or installing a spark plug.
A damaged insulator could allow sparks
to escape, which could lead to explosion
or fire.
@
EJU01107
Lubrication points
To keep moving parts sliding or rotating
smoothly, coat them with water-resistant
grease.
Recommended water resistant grease:
Yamaha Marine Grease/
Yamaha Grease A

Throttle cable (carburetor end)

Oil pump cable

Choke cable (carburetor end)
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Inspecting the battery
Check the level of the battery electrolyte
and make sure the leads are secure.
WARNING@ Battery electrolyte is poisonous and dan-
gerous, causing severe burns, etc. Elec-
trolyte contains sulfuric acid. Avoid
contact with skin, eyes or clothing.
Antidotes
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 water for 15 minutes
and get prompt medical attention.
Batteries produce explosive gases. Keep
sparks, flame, cigarettes, etc., well away.
If using or charging the battery in an
enclosed space, make sure that it is well
ventilated. Always shield your eyes when
working near batteries.
KEEP OUT OF THE REACH OF CHILDREN.
@
CAUTION:@ Be careful not to place the battery on its
side.
Make sure to remove the battery from the
battery compartment when adding bat-
tery electrolyte or charging the battery.
When checking the battery, make sure
the breather hose is connected to the
battery and not obstructed.
@
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Replacing the fuse
The fuse is attached to the electrical box.
To replace the fuse:
1. Remove the cap 1, and then pull out the
defective fuse 3 by using the fuse
puller2.
2. Install the spare fuse 4 of the correct
amperage.
WARNING@ Do not use fuses of higher amperage that
those recommended. Substitution of a
fuse of improper rating can cause exten-
sive electrical system damage and possi-
ble fire.
@
EJU01112
Bleeding the oil injection
pump
If the oil tank becomes completely empty,
or any hose connected to the oil pump has
been disconnected, the oil pump must be
bled to ensure proper oil flow.
If bleeding of the oil pump is necessary,
have a Yamaha dealer bleed it.Fuse amperage: 10 A, 20 A
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4-23
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Specifications
SPC-F0X7EMODEL
ITEMUnit GP1200R
WATERCRAFT CAPACITY
Maximum people on board Number of people 2
Maximum load capacity kg (lb) 160 (353)
DIMENSIONS
Length mm (in) 2,930 (115.4)
Width mm (in) 1,150 (45.3)
Height mm (in) 1,020 (40.2)
Dry weight kg (lb) 306 (675)
PERFORMANCE
Maximum output kW (PS) @ r/min 114.0 (155)@ 7,000
Maximum fuel consumption L/h (US gal/h, Imp gal/h) 64.0 (16.9, 14.1)
Cruising range at full throttle hr. 0.9
Trolling speed r/min 1,300–1,400
ENGINE
Engine type 2-stroke
Number of cylinders 3
Engine displacement
cm
3 (cu in)1,176 (71.7)
Bore & stroke mm (in) 80.0 ×
78.0 (3.15 ×
3.07)
Compression ratio 5.9:1
Lubrication system Variable oil injection
Cooling system Water cooled
Starting system Electric starter
Ignition system Digital CDI
Spark plug BR8ES-11 (NGK)
Spark plug gap mm (in) 1.0–1.1 (0.039–0.043)
Battery capacity V-AH 12-19
Charging system Flywheel magneto
DRIVE UNIT
Propulsion system Jet pump
Jet pump type Axial flow, single stage
Impeller rotation Counterclockwise (viewed from rear)
Transmission Direct drive from engine
Jet thrust nozzle angle Degree 23 + 23
Trim nozzle angle Degree -5, 0, 5, 10, 15
FUEL AND OIL
Recommended fuel Regular unleaded gasoline
Minimum octane rating PON
RON86
90
Recommended engine oil YAMALUBE 2-W, or an equivalent NMMA-
certified TC-W3 marine oil
Fuel tank capacity
Total L (US gal, Imp gal) 60 (15.9, 13.2)
Reserve L (US gal, Imp gal) 10 (2.6, 2.2)
Oil tank capacity L (US gal, Imp gal) 5.5 (1.45, 1.21)
UF0X72.book Page 23 Friday, August 3, 2001 11:13 AM