2003 YAMAHA GP800R battery

4-6
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NOTE:@ The condition of the battery can be known
by checking the specific gravity of the elec-
trolyte. However, you can also know the con-
dition of the battery by measuring the
voltage at both battery terminals. Charge
the battery if the voltage is less than
12 volts.
It is recommended to have a Yamaha dealer
check the specific gravity and to charge the
battery. If you maintain the battery yourself,
be sure to read and follow the instructions
provided with the battery tester and charger
you use.
@
EJU01093
Cleaning the watercraft
Clean the watercraft before storing it for a
long period.
1. Wash down the hull, handlebars, and
drive unit with fresh water.
2. Rinse the engine and bilge area with
fresh water. Drain off all water and wipe
up remaining moisture with clean, dry
rags.
3. Spray the engine’s exterior with a rust
inhibitor and lubricant.
4. Wax the hull with a non-abrasive wax.
5. Wipe all vinyl and rubber components,
such as the seat and engine compart-
ment seals, with a vinyl protectant. Specific gravity (for reference):
1.28 at 20 °C (68 °F)
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4-9
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EJU01355
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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4-19
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EJU01971
Inspecting the battery
Check the level of the battery electrolyte
and make sure that the negative and posi-
tive leads are securely tightened.
WARNING@
Battery electrolyte is poisonous and
dangerous, causing severe burns, etc.
Electrolyte contains sulfuric acid.
Avoid contact with skin, eyes, or cloth-
ing.
Antidotes
External: Flush with water.
Internal: Drink large quantities of water
or milk. Follow with milk of magnesia,
beaten egg, or vegetable oil. Call phy-
sician 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 bat-
tery in an enclosed space, make sure
that it is well ventilated. Always shield
your eyes when working near batter-
ies.
KEEP OUT OF THE REACH OF CHIL-
DREN.

Be sure to connect the breather hose
to the battery. Fire or explosion could
result if the breather hose is damaged,
obstructed, or not connected properly.
@
CAUTION:@
Be careful not to place the battery on
its side.

Be sure to remove the battery from the
battery compartment when adding
electrolyte or charging the battery.
@
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4-20
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To replenish the battery:
1. Make sure that the electrolyte level is
between the upper 1 and lower 2 level
marks.
2. Refill the battery with distilled water if
necessary.
CAUTION:@ Normal tap water contains minerals that
are harmful to a battery. Use only dis-
tilled water for replenishing the battery.
@
To recharge the battery:
CAUTION:@ Do not attempt to charge a battery hast-
ily. Battery life could be shortened.
@
It is recommended to have a Yamaha
dealer charge the battery. If you charge the
battery yourself, carefully read the battery
charger instructions before charging and fol-
low the points below.
1. Remove all caps from the battery cell.
2. Add distilled water to the specified level if
the electrolyte level is low.
3. Set the charging rate to 1.9 ampere and
charge the battery slowly until the explo-
sive gases are discharged vigorously
from the battery cells.
To connect the battery terminals:
1. Make sure that the connections are cor-
rect when you install the battery in the
watercraft.
2. Make sure that the breather hose is
properly connected and that it is not
damaged or obstructed.
3. Make sure that the battery is securely
held in place.
1Positive (+): Red lead
2Negative (–): Black lead
3Breather hose
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4-24
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EJU01359
Specifications
SPC-***MODEL
ITEMUnit GP800R
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) 268 (591)
PERFORMANCE
Maximum output kW (PS) @ r/min 88.3 (118.3)@ 7,000
Maximum fuel consumption L/h (US gal/h, Imp gal/h) 49.0 (12.9, 10.8)
Cruising range at full throttle hr. 1.2
Trolling speed r/min 1,250–1,350
ENGINE
Engine type 2-stroke
Number of cylinders 2
Engine displacement
cm
3 (cu in)784 (47.8)
Bore & stroke mm (in) 80.0 ×
78.0 (3.15 ×
3.07)
Compression ratio 6.6:1
Lubrication system Variable oil injection
Cooling system Water cooled
Starting system Electric starter
Ignition system Digital CDI
Spark plug BR8ES (NGK)
Spark plug gap mm (in) 0.7–0.8 (0.028–0.031)
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)
UF0W72.book Page 24 Thursday, August 22, 2002 1:27 PM

E
5
EJU01115
TROUBLESHOOTING
AND EMERGENCY
PROCEDURES
Troubleshooting ...................................... 5-1
Troubleshooting chart ............................ 5-1
Emergency procedures .......................... 5-4
Cleaning the jet intake and impeller ...... 5-4
Jumping the battery ............................... 5-5
Towing the watercraft ............................ 5-7
Submerged watercraft ........................... 5-8
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EJU01116
Troubleshooting
If you have any trouble with your watercraft, use this section to check for the possible
cause.
If you cannot find the cause, or if the procedure for replacement or repair is not described
in this Owner’s/Operator’s Manual, have a Yamaha dealer perform the necessary service.
EJU01367
Troubleshooting chart
TBC-F0X7ETROUBLE POSSIBLE CAUSE REMEDY PAGE
Engine does not
startStarter motor does not turn over
Engine shut-
off switchClip not in place Install clip
2-8
Fuse Burned out Replace the fuse and
check wiring4-22
Battery Run down Recharge 4-19
Poor terminal connec-
tionsTighten as required
4-19
Terminal corroded Clean—
Starter motor Faulty Have serviced by
Yamaha dealer—
Starter motor turns over
Fuel cock Turned to “OFF”Turn the fuel cock to
“ON”2-7
Fuel Empty Refill as soon as possi-
ble3-3
Stale or contaminated Have serviced by
Yamaha dealer4-10
Fuel tank Water or dirt present Have serviced by
Yamaha dealer4-11
Spark plug Fouled or defective Clean or replace 4-15
Spark plug cap Not connected or loose Connect properly 4-15
Crankcase Filled with water Crank engine with plug
out until clean5-8
Fuel filter Clogged or water
pooledHave serviced by
Yamaha dealer4-11
Choke Choke valve can not be
closed surely by lever
operationHave serviced by
Yamaha dealer—
UF0W72.book Page 1 Thursday, August 22, 2002 1:27 PM

5-2
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Engine runs irregu-
larly or stallsFuel Empty Refill as soon as possi-
ble3-3
Stale or contaminated Have serviced by
Yamaha dealer4-10
Choke Lever is moved to on Move back to original
position2-8
Fuel filter Clogged or water
pooledHave serviced by
Yamaha dealer4-11
Fuel tank Water or dirt present Have serviced by
Yamaha dealer4-11
Spark plug Fouled or defective Replace 4-15
Incorrect heat range Replace 4-15
Gap incorrect Adjust 4-15
Spark plug cap Loose Connect properly 4-15
Cracked, torn, or dam-
agedReplace
—
Electrical wir-
ingLoose connection Tighten or connect
properly—
Carburetor Incorrect idle adjust-
mentAdjust idle
4-21
Clogged Have serviced by
Yamaha dealer—
Warning light or
indicator blinksFuel level Empty Refill as soon as possi-
ble3-3
Engine oil level Empty Refill immediately 3-4
Oil filter clogged Clean 4-12
Engine over-
heatedJet intake clogged Clean
5-4
Low battery
voltageBattery voltage low Charge 4-19
Battery terminal con-
nected wrongConnect properly
4-19 TROUBLE POSSIBLE CAUSE REMEDY PAGE
UF0W72.book Page 2 Thursday, August 22, 2002 1:27 PM