Yamaha gp800r waverunner owners manual

Needle valve inspection 1. NOTE: Always replace the needle valve and needle valve seat as a set. Fuel filter inspection 1. Oil hose inspection 1. Adjust: Oil pump cable Adjustment steps: Loosen the locknut 1 and the adjust- ing nut 2.

Fully close the carburetor throttle valves. Adjust the oil pump cable so that the mark a on the oil pump lever is aligned with the mark b on the oil pump body. Inspect the oil pump hoses for proper routing and make sure there are no restrictions in the line. Reverse the removal steps for installation. Remove: Shims NOTE: To ease reassembly and coupling align- ment, remove the shims and organize them in their respective groups e. Engine mount inspection 1. Bolt Thermoswitch Hose clamp Slide the outer exhaust joint.

Hose clamp Bolt Bolt Bolt Exhaust chamber assembly Outer exhaust joint Inner exhaust joint Reverse the removal steps for installation. YPVS valve installation 1. Eliminate: Carbon deposits with a rounded scraper 1 CAUTION: Do not use a sharp instrument to avoid damaging or scratching the cylinder head or spark plug bore threads.

Eliminate: Carbon deposits with a rounded scraper 1 2. Remove and install: Piston pin clip NOTE: Before removing or installing the piston pin clip, cover the crankcase opening with a clean rag to prevent the piston pin clip from falling into the crankcase.

End gap: 0. Piston pin and bearing inspection 1. Bolt Bolt Generator cover Pinion gear Reverse the disassembly steps for assembly. Flywheel magneto removal and installation 1. Flywheel magneto inspection 1. Starter clutch assembly inspection 1. Bolt Mount bracket 1 Bolt Mount bracket Bolt Lower crankcase Crankshaft assembly Upper crankcase Reverse the disassembly steps for assembly.

Crankcase installation 1. Crank width: NOTE: Before inspection, thoroughly clean the bearings. Immediately after inspection, lubricate the bearings to prevent rust. Dowel pin When installing the jet pump unit, align the drive shaft spline male with the intermediate drive shaft spline female. Bolt Collar Nozzle deflector Turn the impeller clockwise to loosen it. Bilge hose inspection 1.

Intermediate drive shaft removal 1. Inspect: Bearing Rotate the inner race by hand. Driven coupling inspection 1. Install: Intermediate drive shaft Distance a: 9. Oil the contact surfaces of moving parts during assembly. When installing oil seals, apply a light coat of water-resistant grease to the outside diameter. Improvisations and using improper tools can damage the equipment.

YM YB Red: Drive coupling — crankshaft assembly 1st Generator cover — crankcase 2nd Pickup coil — generator cover Cable holder — generator cover Stator coil — generator cover 1st Lower crankcase — upper 2nd crankcase. This chart specifies tightening torques for standard fasteners with a standard ISO thread pitch.

Tightening torque specifications for special components or assemblies are provided in applicable sections of this manual. To avoid warpage, tighten multifastener assemblies in a crisscross fashion and progressive stages until the specified tightening torque is reached. Unless otherwise specified, tightening torque specifications require clean, dry threads.

Components should be at room temperature. Bilge hoses To multifunction meter To stator assembly To cylinder 1 To cylinder 2 To battery positive terminal To starter motor positive terminal Depending on operating conditions, the intervals of maintenance should be changed.

Steering cable inspection and adjustment 1. Difference of distances a and b: Maximum 5 mm 0. NOTE: If the steering cable cannot be properly adjusted at the steering column side, make sure the steering cable at the jet pump side is set to the specified length. Throttle cable inspection and adjustment NOTE: Before adjusting the throttle lever free play, adjust the trolling speed. Throttle lever free play: 4—7 mm 0. Fill the oil tank with the recommended oil. Five minutes of idling is sufficient.

Connect a tachometer. Warm up the engine with the watercraft in the water and check the idle speed. Adjust the idle speed by turning the throttle stop screw as required. Check the impeller for deep scratches, pitting or nicks by looking from both the water outlet and inlet sides.

Check the jet stator inner wall for scratches. Check the impeller seal for cracks or damage. Measure the clearance between each impeller blade and the jet stator, using a feeler gauge inches long. Impeller clearance is critical for proper performance. If the clearance is out of specification, disassemble and inspect the impeller and impeller housing area. Poor performance driveability and poor fuel economy. Engine top-end problems usually affect engine performance.

These can be diagnosed by a compression test, or by tracing top-end noise with a sounding rod or stethoscope. Compression too low, hard starting or poor performance at low speed. Starter motor does not turn 1. Fuse Inspection 2. Battery Inspection 3. Starter Relay Switch Operation Inspection 4. Starter Motor Inspection Remove the safety lanyard switch from the engine stop switch.

Apply battery voltage to the starter motor directly. Does the starter motor turn? Check the ground line of the starter relay switch. Throttle cable inspection and adjustment NOTE: Before adjusting the throttle lever free play, adjust the trolling speed. Turn in Free play is increased. Turn out Free play is decreased. Choke cable inspection and adjustment 1. Adjust: q Choke lever operation Checking steps: q Check that the choke lever moves back slightly when it is fully opened.

Adjustment steps: q Loosen the locknut 1. NOTE: If the inner cable is difficult to make taut using the adjuster 2, adjust the choke lever so that the cable is taut. The cable must be taut when the choke lever end a is positioned within the line marks b.

Reset the adjuster if necessary. Measurement steps: q Set the control grip in the neutral posi- tion. Turn in Length b is increased. Turn out Length a is increased. YPVS cable adjustment 1. Checking steps: q Start the engine and then stop it. YPVS cable slack: 0. Fuel line inspection 1. Adjustment steps: q Loosen locknuts 1 and 2. Turn in Slack is increased. Turn out Slack is decreased. NOTE: If need the water draining, remove the drain plug 2.

Trolling speed check and adjustment 1. Adjust: q Trolling speed Adjustment steps: q Start the engine and allow it to warm up for several minutes. Thank you very much for your reading.

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