2003 YAMAHA GP1200 engine overheat

E
2
EJU01007
FEATURES AND
FUNCTIONS
Location of main components .............. 2-1
Operation of controls and other
functions ................................................... 2-5
Seat ........................................................ 2-5
Hood ....................................................... 2-6
Fuel tank filler cap .................................. 2-6
Oil tank filler cap ..................................... 2-6
Fuel cock knob ....................................... 2-7
Engine stop switch ................................. 2-8
Engine shut-off switch ............................ 2-8
Choke lever ............................................ 2-8
Throttle lever .......................................... 2-9
Start switch ............................................. 2-9
Cooling water pilot outlet ..................... 2-10
Steering system ................................... 2-10
Quick Shift Trim System (QSTS)
selector ................................................. 2-11
Handgrip ............................................... 2-12
Engine overheat warning system ........ 2-13
Multifunction information center .......... 2-15
Tachometer .......................................... 2-16
Speedometer ....................................... 2-16
Reset button ......................................... 2-16
Fuel meter ............................................ 2-17
Hour meter ........................................... 2-17
Fuel warning indicator .......................... 2-18
Oil warning indicator ............................ 2-18
Engine overheat warning indicator ...... 2-19
Storage compartments ........................ 2-20
Yamaha Adjustable Sponson
(Y.A.S.) ................................................. 2-21
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2-13
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Engine overheat warning
system
This model is equipped with an engine
overheat warning system.
If the engine starts to overheat, the warn-
ing light and the engine overheat warning
indicator begin to blink, and the buzzer
sounds intermittently.
When this occurs, reduce the engine
speed and beach the watercraft. Check for
water discharge. If there is no discharge of
water at the cooling water pilot outlet, whole
the engine is running, check the intake grate
and impeller for clogging.
WARNING@ Before attempting to remove weeds or
debris from the intake grate or impeller,
shut the engine off and remove the clip
from the engine shut-off switch. Severe
injury or death could result from coming
in contact with the rotating parts of the
jet pump.
@
CAUTION:@
Return to shore at low speed if over-
heat warning indicator and buzzer
come on. If you ignore these signals,
engine will stop running and cannot be
restarted until exhaust system cools
down.

Have your watercraft inspected and
serviced by a Yamaha dealer if engine
stops due to overheating.
@
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If the overheat warning is ignored, engine
and exhaust system heat may increase, par-
ticularly if the watercraft is operated at
higher speeds. When this occurs, the warn-
ing light, the engine overheat warning indi-
cator and the buzzer will change from
intermittently to continuously on, and the
overheat system will stop ignition to the
engine to reduce the risk of severe over-
heating. The engine cannot be started until
it cools down, so it may be necessary to
have the watercraft towed back to the
beach. (See “Towing the watercraft” on page
5-7 for towing procedures.)
NOTE:@ Press the reset button on the multifunction
information center to stop the buzzer.
@
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Multifunction information
center
This meter contains following functions for
the help and convenience of operation.
1
Tachometer
2
Speedometer
3
Fuel meter
4
Hour meter
5
Warning light
6
Oil warning indicator
7
Engine overheat warning indicator
8
Fuel warning indicator
9
Reset button
CAUTION:@
Do not run the engine at full throttle or
more than 15 seconds to check the
meter for operation on land. The
engine could overheat.

Use the specified resistor-type spark
plug and cap, otherwise the meter may
function erratically.
@
NOTE:@ All display light up and the buzzer sounds
twice after the engine starts. Then, the
meter will operate normally after few sec-
onds. The current display will continue to
operate for 30 seconds after the engine
stops.
@
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Engine overheat warning
indicator
If the engine starts to overheat, the warn-
ing light and engine overheat warning indi-
cator begin to blink, and the buzzer sounds
intermittently.
If the watercraft continues to be operated
at higher speeds after the warning system
has been activated, the warning light,
engine overheat warning indicator and the
buzzer will change from intermittently to
continuously on. (See “Engine overheat
warning system” on page 2-13 for further
details.)
The warning signals will turn off when the
engine is started after it has cooled down.
NOTE:@ When the warnings overlap each other, their
priority is as follows:
1. Final overheat warning
2. Fuel level warning
3. Oil level warning
4. Initial overheat warning
@
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3-11
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Jet unit
Carefully check the jet intake for weeds,
debris, or anything else that might restrict
the intake of water. If the intake is clogged,
cavitation could occur, reducing jet thrust,
and possibly damaging the jet pump.
In some cases, the engine may overheat
because of lack of cooling water, and dam-
age to the engine could result. Engine cool-
ing water is fed to the engine by the jet
pump. (See page 5-4 for jet intake cleaning
procedures.)
WARNING@
Keep away from intake grate while
engine is on. Items such as long hair,
loose clothing, or PFD straps can
become entangled in moving parts
resulting in severe injury or drowning.

Stop the engine and remove the clip
from the engine shut-off switch before
removing any debris or weeds, which
may have collected around the jet
intake.
@
EJU01059
Engine shut-off cord (lanyard)
Check that the engine shut-off cord is not
frayed or broken. If the cord is damaged,
replace it; never try to repair it or tie it
together.
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CAUTION:@ Be sure to remove the clip from the
engine shut-off switch, otherwise the
engine will overheat and engine damage
may occur.
@
1. Shut the engine off by removing the clip
from the engine shut-off switch.
2. Swim to the rear of the watercraft. Pull
the watercraft over with left hand on ride
plate while pushing down on the gun-
wale with your right hand/foot.
NOTE:@ If the port (left) side of the capsized water-
craft is tilting upward, first tilt the watercraft
so the port (left) side is down by using your
weight to press down on the gunwale.
@
CAUTION:@ Do not turn the watercraft over counter-
clockwise, otherwise water may leak into
the carburetor and engine and cause
damage.
@
3. Start the engine, and then head for
shore to inspect the engine for water
damage.
CAUTION:@ If the watercraft has been capsized for
5 minutes or more, air may have entered
the oil injection system. Leave the engine
off, or operate only at trolling speed, for
10 minutes after the watercraft has been
turned right-side up. This will allow any
air to bleed off.
@
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Post-operation checks
Always perform the following post-opera-
tion checks after operating the watercraft.
1. Remove the watercraft from the water.
2. Wash down the hull, handlebars, and jet
unit with fresh water.
3. Remove the seat and check the engine
compartment for water. To drain excess
water, remove the stern drain plugs, then
raise the bow of the watercraft enough to
allow water in the bilge to drain out.
NOTE:@ This watercraft is equipped with an auto-
matic bilge-draining system that removes
water from the engine compartment while
you are underway. However, some residual
water will remain.
@
4. Put the watercraft in a horizontal posi-
tion.
5. Flush the cooling system to prevent it
from clogging with salt, sand, or dirt.
(See page 4-1 for flushing the cooling
system procedures.)
6. Drain residual water from the exhaust
system by alternately squeezing and
releasing the throttle lever for 10 to
15 seconds while the engine is running.
CAUTION:@ Do not attempt to run the engine at full
throttle or for more than 15 seconds
while the watercraft is out of the water,
otherwise the engine may overheat or
seize.
@
7. If the watercraft will be stored for a week
or more, lubricate internal engine com-
ponents to help prevent corrosion. (See
page 4-3 for lubrication procedures.)
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