2003 YAMAHA GP800R maintenance

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To the owner/operator
Thank you for choosing a Yamaha water-
craft.
This Owner’s/Operator’s Manual contains
information you will need for proper opera-
tion, maintenance, and care. A thorough
understanding of these simple instructions
will help you to obtain maximum enjoyment
from your new Yamaha. If you have any
questions about the operation or mainte-
nance of your watercraft, please consult a
Yamaha dealer.
Because Yamaha has a policy of continu-
ing product improvement, this product may
not be exactly as described in this Owner’s/
Operator’s Manual. Specifications are sub-
ject to change without notice.
This manual should be considered a per-
manent part of this watercraft and should
remain with it even if the watercraft is subse-
quently sold.EJU00990
Important manual information:
In this manual, information of particular
importance is distinguished in the following
ways:
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, passenger, a
bystander, or a person inspecting or
repairing the watercraft.
@
CAUTION:@ A CAUTION indicates special precau-
tions that must be taken to avoid damage
to the watercraft.
@
NOTE:@ A NOTE provides key information to make
procedures easier or clearer.
@
EJU00991
WaveRunner GP800R
OWNER’S/OPERATOR’S MANUAL
©2002 by Yamaha Motor Co., Ltd.
1st Edition, August 2002
All rights reserved.
Any reprinting or unauthorized use
without the written permission of
Yamaha Motor Co., Ltd.
is expressly prohibited.
Printed in USA
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EEJU00992
CONTENTS
READ THIS OWNER’S/OPERATOR’S MANUAL CAREFULLY BEFORE
OPERATING YOUR WATERCRAFT.
GENERAL AND SAFETY
INFORMATION
1
FEATURES AND FUNCTIONS2
OPERATION3
MAINTENANCE AND CARE4
TROUBLESHOOTING AND
EMERGENCY PROCEDURES
5
APPENDIX6
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2-16
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Fuel meter
The fuel meter is provided for convenient
fuel level checking while riding. The fuel
meter has eight segments which show the
amount of fuel remaining in the fuel tank.
NOTE:@ The indication of the segments differs on
your operating condition. Use the meter as a
reference.
@
EJU01032
Hour meter
The hour meter is provided to make it
easy to follow the maintenance schedule.
The meter shows the hours of engine opera-
tion that have elapsed since the watercraft
was new.
NOTE:@
The elapsed time will be kept even if the
battery terminals have been discon-
nected.

If the hour meter malfunctions, “_ _ _ _”
display and the warning light will blink.
@
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MAINTENANCE AND
CARE
Storage ...................................................... 4-1
Flushing the cooling system .................. 4-1
Lubrication .............................................. 4-3
Fuel system ............................................ 4-4
Battery .................................................... 4-5
Cleaning the watercraft .......................... 4-6
Maintenance and adjustments .............. 4-7
Owner’s/Operator’s Manual and
tool kit ..................................................... 4-8
Periodic maintenance chart ................... 4-9
Inspecting the fuel system ................... 4-10
Inspecting the oil injection system ....... 4-12
Inspecting the jet thrust nozzle
angle ..................................................... 4-13
Inspecting and adjusting the
throttle cable ......................................... 4-13
Inspecting the QSTS mechanism ....... 4-14
Cleaning and adjusting the
spark plugs ........................................... 4-15
Lubrication points ................................. 4-16
Inspecting the battery .......................... 4-19
Adjusting the carburetor ...................... 4-21
Replacing the fuse ............................... 4-22
Bleeding the oil injection pump ............ 4-22
Adjusting the Yamaha Adjustable
Sponson (Y.A.S.) ................................. 4-23
Specifications ........................................ 4-24
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4-1
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Storage
WARNING@ Always place the fuel cock knob in the
“OFF” position when storing the water-
craft, otherwise fuel could leak out into
the engine or engine compartment,
which would create a fire hazard.
@
Storage for prolonged periods of time,
such as winter storage, requires preventa-
tive maintenance to ensure against deterio-
ration. It is advisable to have the watercraft
serviced by a Yamaha dealer prior to stor-
age. However, the following procedures can
be performed by the owner.
EJU01088
Flushing the cooling system
Flushing the cooling system is essential
to prevent the cooling system from being
clogged with salt, sand, or dirt.
CAUTION:@
Do not supply water to the cooling
water passages when the engine is not
running. The water could flow back
through the muffler into the crankcase
causing severe engine damage.

Do not run the engine for more
15 seconds without supplying water,
otherwise the engine may overheat.
@
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4-7
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Maintenance and
adjustments
Periodic inspection, adjustment and lubri-
cation will keep your watercraft in the safest
and most efficient condition possible. Safety
is an obligation of the watercraft owner. The
most important points of watercraft inspec-
tion, adjustment and lubrication are
explained on the following pages.
See your Yamaha dealer for genuine
Yamaha replacement parts and optional
accessories designed for your watercraft.
Remember that failures that are the result
of the installation of parts or accessories
which are not qualitatively equivalent to gen-
uine Yamaha parts are not covered by the
limited warranty.
WARNING@
Be sure to turn off the engine when
you perform maintenance unless oth-
erwise specified, otherwise an acci-
dent or injury could result from
unexpected operation, moving parts,
or electric shock. If the owner is not
familiar with watercraft servicing, this
work should be done by a Yamaha
dealer. Improperly serviced compo-
nents could fail or stop operating cor-
rectly, which could result in an
accident.

Modifications to this watercraft not
approved by Yamaha may cause loss
of performance or excessive noise, or
render it unsafe for use. Consult a
Yamaha dealer before attempting any
changes.
@
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4-8
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Owner’s/Operator’s Manual
and tool kit
It is advisable always to carry the
Owner’s/Operator’s Manual and tool kit2
with you whenever you use the watercraft.
For your convenience, a storage compart-
ment 1 is provided on the watercraft for the
manual and tool kit.
NOTE:@ To protect these materials from water dam-
age, it would be a good idea to put them in a
waterproof bag.
@
The service information included in this
manual is intended to provide you with the
necessary information for completing your
own preventive maintenance and minor
repairs. The tools provided in the tool kit are
sufficient for this purpose.
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4-9
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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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