2003 YAMAHA GP1200 fuel cap

3-3
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EJU01045
Filling the fuel tank
CAUTION:@ Be careful when refueling. Avoid getting
water or other contaminants in the fuel
tank. Contaminated fuel can cause poor
running or engine damage.
@
1. Open the hood and remove the front
storage compartment, to check the fuel
level. (See page 2-20 for front storage
compartment.)
2. Open the fuel tank filler cap, and slowly
add fuel to the fuel tank.
3. Stop filling when the fuel just reaches the
bottom of the filler tube on the fuel tank.
Do not fill into the filler tube, because
fuel could spill out.
Fuel tank capacity:
Total: 60 L (15.9 US gal, 13.2 Imp gal)
Reserve: 10 L (2.6 US gal, 2.2 Imp gal)
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Pre-operation check points
EJU01050
Engine compartment
Ventilate the engine compar tment before
each use.
To ventilate the engine compartment,
remove seat and front storage compart-
ment. (See page 2-5 for seat, and 2-20 for
front storage compartment.) Allow the
engine compartment to remain open for a
few minutes to allow any fuel vapors to
escape. Also, check for loose electrical con-
nections.
WARNING@ Failure to ventilate the engine compart-
ment could result in fire or explosion. Do
not start the engine if there is a fuel leak
or a loose electrical connection.
@
EJU01051
Fuel and oil systems
Check the fuel system for leakage, cracks
or malfunctions before each use. (See page
4-9 for check points and correct proce-
dures.)
1. Remove the fuel tank filler cap to release
any pressure that might have built up in
the fuel tank.
2. Remove seat and front storage compart-
ment. (See page 2-5 for seat, and 2-20
for front storage compartment.)
3. Check the fuel and oil levels in the tanks
and replenish if necessary. (See pages
3-3 and 3-4 for filling instructions.)
4. Turn the fuel cock to the “ON” position.
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EJU01961
Water separator
Check the water separator 1 for water.
Normally the water separator is empty. The
water separator retains any water entering
through the fuel tank breather hose if the
watercraft is capsized.
If water remains in the water separator,
drain it by removing the drain screw 2.
Place a drain pan under the water separator
to catch the draining water or use a dry cloth
to soak up any water that could spill into the
watercraft. If any water spills into the water-
craft, be sure to wipe it up with a dry cloth.
Be sure to install the drain screw after drain-
ing the water separator.
EJU01053
Bilge
Check for moisture and fuel residue in the
bilge.
Excessive water in the bilge can splash
into the carburetor and engine which could
cause engine damage.
To remove water from the bilge:
1. Remove the stern drain plugs.
2. Raise the bow of the watercraft until the
water drains.
3. After the water has drained, wipe the
bilge with dry rags to make sure that the
bilge is thoroughly dry.
4. Install the drain plugs.
CAUTION:@
Make sure that the stern drain plugs
are tightened securely before launch-
ing the watercraft.

Clean any foreign materials, such as
dirt or sand, from the drain plug
threads before installing the drain
plugs.
@
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2. Turn the fuel cock knob to the “ON” posi-
tion.
NOTE:@ Before starting the watercraft, after it has
been sitting, remove the fuel tank filler cap
to release any built-up pressure in the tank
due to fuel expansion.
@
3. Attach the clip 1 to the engine shut-off
switch 2. Also, attach the engine shut-
off cord 3 to your left wrist.
WARNING@ Check that the engine shut-off cord is not
frayed or broken, and keep it free from
the handlebars so the engine stops if the
operator falls off. The engine shut-off
cord may not pull free if wrapped around
the handlebars when the operator falls
off, allowing the watercraft to continue to
run and cause an accident.
@
NOTE:@ It is not possible to start the engine with the
clip removed from the engine shut-off
switch.
@
4. Move the choke lever all the way in the
direction of the arrow to start a cold
engine.
NOTE:@ The choke should not be used when the
engine is warm.
@
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4-4
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Avoid overfilling the fuel tank. Stop fill-
ing when the fuel level just reaches the
bottom of the filler tube. Do not fill up
the filler tube because fuel expands as
it warms up and could overflow. If tem-
porarily leaving the watercraft with a
full fuel tank, do not leave it in direct
sunlight. Leave it in a well-ventilated
area with the watercraft in a horizontal
position.

Tighten the filler cap securely after
refueling.

If you should swallow some gasoline,
inhale a lot of gasoline vapor, or get
gasoline in your eyes, get immediate
medical attention.

If any gasoline spills onto your skin,
immediately wash with soap and
water. Change clothing if gasoline
spills on it.
@
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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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-***(
) 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
6
months12
months12
months24
months
Spark plug Inspect, clean, adjust




4-15
Lubrication points Lubricate


4-16
Intermediate housing Lubricate❍
*1

*2

*2 4-18
Fuel system Inspect❍❍
4-10
Fuel filter Check, clean, replace❍❍
4-11
Fuel tank Clean❍
4-11
Oil injection system Inspect, clean❍❍
4-12
Trolling speed Inspect, adjust


4-21
Carburetor throttle shaft Inspect❍❍
—
Cooling water passages Flush

*3 4-1
Water inlet strainer Inspect, clean❍❍
—
Bilge strainer Clean❍❍
—
Impeller Inspect

*4❍❍
—
Jet thrust nozzle angle Inspect


4-13
QSTS mechanism Inspect, adjust

*4❍❍
4-14
Throttle lever Check operation

*4 3-10
Throttle cable Inspect, adjust❍❍
4-13
Choke lever Check operation

*4 2-8
Choke cable Inspect, adjust❍❍
—
Stern drain plugs Inspect, replace

*4❍❍
3-7
Battery Inspect

*5❍❍
4-19
Rubber coupling Inspect❍
—
Engine mount Inspect❍
—
Nuts and bolts Inspect❍❍❍
—
*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)
*3: After every use
*4: Before every use
*5: Inspect fluid level before every use
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Inspecting the fuel system
WARNING@ Gasoline is highly flammable and explo-
sive. A fire or explosion can cause
severe injury or death. Shut off the
engine. Do not smoke. Avoid spilling
gasoline.
@
Check the fuel system for leaks, cracks,
or malfunctions. If any problem is found, do
the necessary repair or replacement as
required. If repair is necessary, consult a
Yamaha dealer.
Check:

Carburetor for leakage.

Fuel pump for malfunction or leakage.

Fuel tank for water or dirt.

Fuel tank for damage, cracks or leakage.

Fuel hose joint for leakage.

Fuel hose for cracks or other damage.

Fuel filter for leakage.

Fuel cock for leakage.

Air vent check valve for leakage.

Fuel tank filler cap for damage.
WARNING@ Failure to check for and repair any fuel
leakage may result in fire or explosion.
@
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Specifications
SPC-***MODEL
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 (1.5, 1.2)
UF0X73.book Page 24 Thursday, July 11, 2002 3:56 PM