Yamaha R-2000 Wartungshandbuch

*LIT186160215* SERVICE MANUAL LIT-18616-02-15 F0X-28197-ZA-11 WaveRunnerGP1200R

1-2 EGENINFO SAFETY WHILE WORKING SAFETY WHILE WORKING The procedures given in this manual arethose recommended by Yamaha to be fol-lowed by Yamah

5-21POWRESERVICE POINTSYPVS valve inspection1. Eliminate:● Carbon deposits(with a rounded scraper 1)CAUTION:Do not use a sharp instrument to avoiddama

5-22POWRECYLINDER HEADCYLINDER HEADEXPLODED DIAGRAMREMOVAL AND INSTALLATION CHART Step Procedure/Part name Q’ty Service pointsCYLINDER HEAD REMOVAL Fo

5-23POWRECYLINDER HEADEXPLODED DIAGRAMStep Procedure/Part name Q’ty Service points7 Cylinder head cover 18 Gasket 19 Cylinder head 110 Gasket 111 Clam

5-24POWRECYLINDER HEADSERVICE POINTSCylinder head inspection1. Eliminate:● Carbon deposits(with a rounded scraper 1)CAUTION:Do not use a sharp instrum

5-25POWRECYLINDERSCYLINDERSEXPLODED DIAGRAMREMOVAL AND INSTALLATION CHARTStep Procedure/Part name Q’ty Service pointsCYLINDER REMOVAL Follow the left

5-26POWRECYLINDERSSERVICE POINTSCylinder inspection1. Eliminate:● Carbon deposits(with a rounded scraper 1)2. Inspect:● Cylinder water jacketCorrosion

5-27POWREPISTONSPISTONSEXPLODED DIAGRAMREMOVAL AND INSTALLATION CHARTStep Procedure/Part name Q’ty Service pointsPISTON REMOVAL Follow the left “Step”

5-28POWR E PISTONS EXPLODED DIAGRAM Step Procedure/Part name Q’ty Service points5 Bearing 16 Piston ring 2CAUTION: Align each end gap with its respec

5-29POWREPISTONSSERVICE POINTSPiston pin clip removal and installation1. Remove and install:● Piston pin clipNOTE:Before removing or installing the pi

5-30POWREPISTONS4. Calculate:● Piston-to-cylinder clearanceOut of specification → Replace thepiston, piston rings and cylinder as aset. Cylinder and p

1-3 EGENINFO SAFETY WHILE WORKING Under normal conditions of use thereshould be no hazards from the use of thelubricants mentioned in this manual, b

5-31POWREPISTONS2. Measure:● End gap(with a thickness gauge 1)Out of specification → Replace thepiston rings as a set.NOTE:Push the piston ring into t

5-32POWREPISTONS4. Check:● Piston-pin-to-connecting-rod free play(with the piston pin in the small endof the connecting rod as shown)Free play/small e

5-33POWREGENERATOR AND STARTER MOTORGENERATOR AND STARTER MOTOREXPLODED DIAGRAMREMOVAL AND INSTALLATION CHART Step Procedure/Part name Q’ty Service po

5-34POWREGENERATOR AND STARTER MOTOREXPLODED DIAGRAMStep Procedure/Part name Q’ty Service points6 Spring 17 Packing 18 Pin 29 Bolt 210 Bolt 211 Bracke

5-35POWREEXPLODED DIAGRAMREMOVAL AND INSTALLATION CHART Step Procedure/Part name Q’ty Service pointsSTATOR COIL AND PICKUP COIL REMOVALFollow the left

5-36POWREGENERATOR AND STARTER MOTOREXPLODED DIAGRAMREMOVAL AND INSTALLATION CHART Step Procedure/Part name Q’ty Service pointsGENERATOR ROTOR AND STA

5-37POWREGENERATOR AND STARTER MOTOREXPLODED DIAGRAMStep Procedure/Part name Q’ty Service points8 Nut/washer 1/19 Starter motor lead 110 Starter motor

5-38POWREGENERATOR AND STARTER MOTOREXPLODED DIAGRAM REMOVAL AND INSTALLATION CHARTStep Procedure/Part name Q’ty Service pointsSTARTER CLUTCH DISASSEM

5-39POWREGENERATOR AND STARTER MOTOREXPLODED DIAGRAM Step Procedure/Part name Q’ty Service points8 Weight 39 Spring ring 110 Pinion gear 1Reverse the

5-40POWRESERVICE POINTSDrive coupling removal and installation 1. Remove:● Drive couplingNOTE:Install the drive coupling with the samespecial tools th

1-4 EGENINFO SAFETY WHILE WORKING 3. Non-reusable items Always use new gaskets, packings, O-rings, oil seals, split-pins, circlips, etc.,on reassemb

5-41POWREGENERATOR AND STARTER MOTORDrive coupling inspection1. Inspect:● Drive coupling Damage/wear → Replace.Flywheel magneto inspection1. Inspect:●

5-42POWRECRANKCASECRANKCASEEXPLODED DIAGRAMREMOVAL AND INSTALLATION CHARTStep Procedure/Part name Q’ty Service pointsCRANKCASE DISASSEMBLY Follow the

5-43POWRECRANKCASEEXPLODED DIAGRAMStep Procedure/Part name Q’ty Service points7 Bolt 1NOTE:Tighten the bolts in sequence as shown.8 Bolt 169 Lower cra

5-44POWRECRANKCASESERVICE POINTSCrankcase inspection1. Inspect:● Mating surfacesScratches → Replace the crankcase.● CrankcaseCracks/damage → Replace.C

5-45POWRECRANKSHAFTCRANKSHAFTEXPLODED DIAGRAMREMOVAL AND INSTALLATION CHARTStep Procedure/Part name Q’ty Service pointsCRANKSHAFT REMOVAL Follow the l

5-46POWRECRANKSHAFTSERVICE POINTSCrankshaft inspection1. Measure:● Crank width A Out of specification → Replace.Crank width:72.95 ~ 73.00 mm (2.872 ~

5-47POWRECRANKSHAFT5. Inspect:● BearingsDamage/pitting → Replace.NOTE:● Before inspection, thoroughly clean thebearings.● Immediately after inspection

E 6 JETPUMP CHAPTER 6JET PUMP UNIT JET PUMP UNIT ...

6-1 EJETPUMP JET PUMP UNITJET PUMP UNIT EXPLODED DIAGRAMREMOVAL AND INSTALLATION CHART Step Procedure/Part name Q’ty Service points JET PUMP UNIT REM

6-2 EJETPUMP JET PUMP UNIT EXPLODED DIAGRAM Step Procedure/Part name Q’ty Service points8 Bolt 49 Ride plate 110 QSTS cable joint 111 Bilge hose 112

1-5 EGENINFO SPECIAL TOOLSSPECIAL TOOLS Using the correct special tools recom-mended by Yamaha, will aid the work andenable accurate assembly and tun

6-3 EJETPUMP JET PUMP UNIT EXPLODED DIAGRAM Step Procedure/Part name Q’ty Service points17 Jet pump unit assembly 1NOTE: ● Pull the jet pump unit str

6-4 EJETPUMP NOZZLE DEFLECTOR AND NOZZLE RINGNOZZLE DEFLECTOR AND NOZZLE RING EXPLODED DIAGRAMREMOVAL AND INSTALLATION CHART Step Procedure/Part name

6-5 EJETPUMP IMPELLER DUCT, IMPELLER HOUSING, AND INTAKE DUCTIMPELLER DUCT, IMPELLER HOUSING, AND INTAKE DUCT EXPLODED DIAGRAMREMOVAL AND INSTALLATIO

6-6 EJETPUMP IMPELLER DUCT, IMPELLER HOUSING, AND INTAKE DUCT EXPLODED DIAGRAM Step Procedure/Part name Q’ty Service points7 Bolt 48 Water inlet cove

6-7 EJETPUMP IMPELLER DUCT AND DRIVE SHAFTIMPELLER DUCT AND DRIVE SHAFT EXPLODED DIAGRAMREMOVAL AND INSTALLATION CHART *1 : EPNOC grease AP #0Step Pr

6-8 EJETPUMP IMPELLER DUCT AND DRIVE SHAFT EXPLODED DIAGRAM *1 : EPNOC grease AP #0Step Procedure/Part name Q’ty Service points8 Drive shaft 19 Rear

6-9 EJETPUMP IMPELLER DUCT AND DRIVE SHAFT SERVICE POINTS Drive shaft removal 1. Remove: ● Impeller NOTE: The impeller has left-hand threads. Turn th

6-10 EJETPUMP IMPELLER DUCT AND DRIVE SHAFT 5. Remove: ● Front bearingNOTE: Remove the front bearing with a press.6. Remove: ● Oil sealNOTE: Remove t

6-11 EJETPUMP IMPELLER DUCT AND DRIVE SHAFT 2. Install: ● Front bearing ● Drive shaftNOTE: Install the front bearing and drive shaft with a press.3.

6-12 EJETPUMP IMPELLER DUCT AND DRIVE SHAFT 6. Add: ● EPNOC grease AP #0 (into the cap)Quantity:Approximately 1/3 of capacity7. Install:● Nut● Impell

1-6 EGENINFO SPECIAL TOOLS REMOVAL AND INSTALLATION 1. Coupler wrenchP/N. YW-06551 90890-065512. Flywheel holderP/N. YW-0655090890-065503. Flywheel p

6-13EJETPUMPTRANSOM PLATE AND HOSESTRANSOM PLATE AND HOSESEXPLODED DIAGRAMREMOVAL AND INSTALLATION CHARTStep Procedure/Part name Q’ty Service pointsTR

6-14EJETPUMPTRANSOM PLATE AND HOSESEXPLODED DIAGRAMStep Procedure/Part name Q’ty Service points4 Hose 1 Cooling water inlet5 Nut/washer 4/46 Transom p

6-15EJETPUMPTRANSOM PLATE AND HOSESSERVICE POINTSBilge strainer inspectionRefer to “JET PUMP UNIT” in chapter 3.Bilge hose inspection1. Inspect:● Bilg

6-16EJETPUMPBEARING HOUSINGBEARING HOUSINGEXPLODED DIAGRAMREMOVAL AND INSTALLATION CHARTStep Procedure/Part name Q’ty Service pointsBEARING HOUSING RE

6-17EJETPUMPBEARING HOUSINGEXPLODED DIAGRAMREMOVAL AND INSTALLATION CHARTStep Procedure/Part name Q’ty Service pointsBEARING HOUSING DISASSEMBLYFollow

6-18EJETPUMPBEARING HOUSINGEXPLODED DIAGRAMStep Procedure/Part name Q’ty Service points8 O-ring 29 Oil seal 110 Oil seal 111 Oil seal 112 Circlip 113

6-19EJETPUMPBEARING HOUSINGSERVICE POINTSDriven coupling removal and installation1. Remove and install:● Driven coupling NOTE:Install the driven coupl

6-20EJETPUMPBEARING HOUSINGBearing, driven coupling shaft, and grease hose inspection1. Inspect:● BearingRotate the inner race by hand.Damage/rough mo

6-21EJETPUMPBEARING HOUSING2. Install:● Intermediate drive shaft NOTE:Support the intermediate housing withsteel blocks 1 and press the driven cou-pli

E–+ELEC CHAPTER 7 ELECTRICAL SYSTEM ELECTRICAL COMPONENTS ... 7-1 ELECTRICAL BO

E 2 SPEC CHAPTER 2SPECIFICATIONS GENERAL SPECIFICATIONS ... 2-1 MAINTE

E 7 –+ELEC CHARGING SYSTEM ... 7-25WIRING DIAGRAM...

7-1 E–+ELEC ELECTRICAL COMPONENTSELECTRICAL COMPONENTS1234567DCBA9>81 Buzzer2 Fuel level sensor3 Multi-function meter4 YPVS servomotor5 Spark plug

7-2 E–+ELEC ELECTRICAL BOXELECTRICAL BOX EXPLODED DIAGRAM REMOVAL AND INSTALLATION CHART Step Procedure/Part name Q’ty Service points ELECTRICAL BOX

7-3 E–+ELEC ELECTRICAL BOX EXPLODED DIAGRAM REMOVAL AND INSTALLATION CHART Step Procedure/Part name Q’ty Service points ELECTRICAL BOX DISASSEMBLY Fo

7-4 E–+ELEC ELECTRICAL BOX EXPLODED DIAGRAM Step Procedure/Part name Q’ty Service points11 Ignition coil 312 Ignition coil lead 313 Spark plug lead/

7-5 E–+ELEC ELECTRICAL BOX EXPLODED DIAGRAM Step Procedure/Part name Q’ty Service points23 Lead holder 124 Fuse lead 525 Screw 226 Fuse holder 127 L

7-6 E–+ELEC ELECTRICAL BOX1 Ignition coil2 CDI unit3 Rectifier/regulator4 Fuse holder5 Starter relay6 Tape7 Clear tube8 Red tube9 White tapeÅ To batt

7-7 E–+ELEC ELECTRICAL ANALYSISELECTRICAL ANALYSIS INSPECTIONCAUTION: ● All measuring instruments should be han-dled with special care. Damaged or mi

7-8 E–+ELEC ELECTRICAL ANALYSIS Low resistance measurementNOTE: ● When measuring a resistance of 10 Ω orless with the digital tester, the correctme

7-9E–+ELECELECTRICAL ANALYSIS● When measuring the peak voltage, con-nect the peak voltage adaptor to the digi-tal tester and switch the selector to th

2-1SPEC E GENERAL SPECIFICATIONSGENERAL SPECIFICATIONS Item UnitModelGP1200RMODEL CODEHull F0XEngine 67XDIMENSIONSLength mm (in) 2,930 (115.4)Width

7-10E–+ELECIGNITION SYSTEMIGNITION SYSTEMWIRING DIAGRAM1 Engine stop switch2 Engine stop lanyard switch3 Lighting coil4 Pickup coil5 CDI unit6 Ignitio

7-11E–+ELECIGNITION SYSTEMIGNITION SPARK GAPWARNING● When checking the spark gap, do nottouch any of the connections of the sparkgap tester lead wires

7-12E–+ELECIGNITION SYSTEMIGNITION SYSTEM PEAK VOLTAGEWARNINGWhen checking the electrical components,do not touch any of the connections of thedigital

7-13E–+ELECIGNITION SYSTEM2. Measure:● Pickup coil output peak voltageBelow specification → Replace thepickup coil. NOTE:The starter motor will not op

7-14E–+ELECIGNITION SYSTEM4. Measure:● Rectifier/regulator output peak voltageBelow specification → Replace therectifier/regulator.NOTE:Make sure the

7-15E–+ELECIGNITION COIL1. Measure:● Primary coil resistanceOut of specification → Replace.NOTE:When measuring a resistance of 10 Ω orless with the di

7-16E–+ELECWATER TEMPERATURE SENSOR1. Measure:● Water temperature sensor resistance(at the specified temperature)Out of specification → Replace. Water

7-17E–+ELECSTARTING SYSTEMSTARTING SYSTEMWIRING DIAGRAM1 CDI unit2 Engine stop lanyard switch3 Starter switch4 Fuse (10A)5 Fuse (20A)6 Starter relay7

7-18E–+ELECSTARTING SYSTEMBATTERYRefer to “ELECTRICAL” in chapter 3.WIRING CONNECTIONS1. Check:● Wiring connectionsPoor connections → Properly connect

7-19E–+ELECSTARTING SYSTEMSTARTER SWITCH1. Check:● ContinuityOut of specification → Replace.Starter continuity(natural color coupler)Lock plate Positi

2-2SPEC EPON*: Pump Octane Number = (Motor Octane Number + Research Octane Number)/2RON*: Research Octane NumberYAMALUBE 2-W*: YAMALUBE 2-W is develo

7-20E–+ELECSTARTER MOTORSTARTER MOTOREXPLODED DIAGRAMREMOVAL AND INSTALLATION CHART Step Procedure/Part name Q’ty Service pointsSTARTER MOTOR DISASSEM

7-21E–+ELECSTARTER MOTOREXPLODED DIAGRAMStep Procedure/Part name Q’ty Service points8 Starter motor rear cover 19 O-ring 110 Shim * t = 0.2 mm, 0.8 mm

7-22E–+ELECSTARTER MOTOREXPLODED DIAGRAMStep Procedure/Part name Q’ty Service points18 Spacer 119 Holder 120 Starter motor yoke 1Reverse the disassemb

7-23E–+ELECSTARTER MOTORSERVICE POINTSArmature inspection1. Inspect:● Armature shaft 1 Damage/wear → Replace.12. Inspect:● CommutatorDirt → Clean with

7-24E–+ELECSTARTER MOTOR6. Inspect:● Armature coil continuityOut of specification → Replace.Armature coil continuity:Commutator segments 1 ContinuityS

7-25E–+ELECCHARGING SYSTEMCHARGING SYSTEMWIRING DIAGRAM1 Lighting coil2 Battery3 Fuse (20A)4 Rectifier/regulatorB : BlackG : GreenR : RedG/W : Green/w

7-26E–+ELECCHARGING SYSTEMFUSERefer to “STARTING SYSTEM”.BATTERYRefer to “ELECTRICAL” in chapter 3.LIGHTING COILRefer to “IGNITION SYSTEM”.RECTIFIER/R

7-27E–+ELECYPVSYPVSWIRING DIAGRAM1 Lighting coil2 Pickup coil3 CDI unit4 YPVS servomotor5 Fuse (10A)6 Fuse (20A)7 Battery8 Rectifier/regulatorB : Blac

7-28E–+ELECYPVSFUSERefer to “STARTING SYSTEM”.BATTERYRefer to “ELECTRICAL” in chapter 3.PICKUP COILRefer to “IGNITION SYSTEM”.CDI UNITRefer to “IGNITI

7-29E–+ELECYPVS SERVOMOTORYPVS SERVOMOTOREXPLODED DIAGRAMREMOVAL AND INSTALLATION CHARTStep Procedure/Part name Q’ty Service pointsYPVS SERVOMOTOR REM

2-3SPEC E MAINTENANCE SPECIFICATIONSMAINTENANCE SPECIFICATIONS ENGINE Item UnitModelGP1200RCYLINDER HEADWarpage limit mm (in) 0.1 (0.004)Compression

7-30E–+ELECYPVS SERVOMOTORSERVICE POINTSYPVS cable removal and installation1. Remove:● YPVS cables 1 and 2NOTE:● There is a white paint mark a on YPVS

7-31E–+ELECYPVS SERVOMOTORCAUTION:Do not disassemble the YPVS servomotorunit. It is a sealed unit and if it is faulty itmust be replaced.YPVS cable ad

7-32E–+ELECINDICATION SYSTEMINDICATION SYSTEMWIRING DIAGRAM1 CDI unit2 Fuel level sensor3 Oil level sensor4 Buzzer5 Multi-function meter6 Speed sensor

7-33E–+ELECINDICATION SYSTEMFUSERefer to “STARTING SYSTEM”.BATTERYRefer to “ELECTRICAL” in chapter 3.LIGHTING COILRefer to “IGNITION SYSTEM”.RECTIFIER

7-34E–+ELECINDICATION SYSTEMFUEL LEVEL SENSOR1. Measure:● Fuel level sensor resistanceOut of specification → Replace.White/blue (W/L) – Black (B)Float

7-35E–+ELECINDICATION SYSTEMDisplay function1. Check:● Display functionNot operate → Replace the multi-function meter.1 Oil level sensor2 Fuel level s

7-36E–+ELECINDICATION SYSTEMFuel level gauge1. Check:● Fuel level gaugeNot operating → Replace the multi-function meter. Checking steps:● Supply DC 12

7-37E–+ELECINDICATION SYSTEMOil level gauge1. Check:● Oil level gaugeNot operating → Replace the multi-function meter. Checking steps:● Supply DC 12 v

7-38E–+ELECINDICATION SYSTEMOverheat warning indicator1. Check:● Overheat 1 warning indicatorNot operating → Replace the multi-function meter. Checkin

7-39E–+ELECINDICATION SYSTEM● Make sure the water temperature sym-bol 3 display and “WARNING” lamp4 on, and the buzzer sounds continu-ity.WARNINGYAMA

2-4SPEC E MAINTENANCE SPECIFICATIONS JET PUMP UNIT HULL AND HOOD CRANKSHAFT ASSEMBLYCrank width A mm (in) 72.95 ~ 73.00 (2.872 ~ 2.874)Deflection

7-40E–+ELECINDICATION SYSTEMSpeed meter1. Check:● Speed meter output voltageWithin specification → Check the speedsensor output voltage and pulses.Out

EHULLHOOD CHAPTER 8HULL AND HOOD HANDLEBAR ... 8-1EXP

E 8 HULLHOOD BUZZER AND HOOD LOCK ... 8-27EXPLODED DIAGRAM...

8-1 EHULLHOOD HANDLEBARHANDLEBAR EXPLODED DIAGRAMREMOVAL AND INSTALLATION CHART Step Procedure/Part name Q’ty Service points HANDLEBAR COVER REMOVAL

8-2 EHULLHOOD HANDLEBAR EXPLODED DIAGRAM Step Procedure/Part name Q’ty Service points7 Throttle cable 18 Choke cable 19 Bolt 410 Upper handlebar hold

8-3 EHULLHOOD HANDLEBAR EXPLODED DIAGRAMREMOVAL AND INSTALLATION CHART Step Procedure/Part name Q’ty Service points HANDLEBAR REMOVAL Follow the left

8-4 EHULLHOOD HANDLEBAR EXPLODED DIAGRAM Step Procedure/Part name Q’ty Service points4 QSTS cable 1 1NOTE: Route the QSTS cables behind of the oil fi

8-5 EHULLHOOD HANDLEBAR EXPLODED DIAGRAMREMOVAL AND INSTALLATION CHART Step Procedure/Part name Q’ty Service points HANDLEBAR DISASSEMBLY Follow the

8-6 EHULLHOOD HANDLEBAR EXPLODED DIAGRAM Step Procedure/Part name Q’ty Service points10 Screw 211 Throttle lever assembly 112 Screw 213 Choke lever a

8-7 EHULLHOOD HANDLEBAR SERVICE POINTS Handlebar inspection 1. Inspect: ● HandlebarBends/cracks/damage → Replace. Handlebar switch inspection Refer

E NOTICE This manual has been prepared by the Yamaha Motor Company Ltd. primarily for use byYamaha dealers and their trained mechanics when performin

2-5SPEC E MAINTENANCE SPECIFICATIONS ELECTRICAL Item UnitModelGP1200RBATTERYType FluidCapacity V-Ah (kC) 12 - 19 (68.4)CDI UNIT(B/O – B for cylinder

8-8 EHULLHOOD HANDLEBAR 3. Install: ● Throttle cableNOTE: Fit the seal into the glove in the bracket. 4. Install: ● Band 1 NOTE: After inserting the

8-9 EHULLHOOD HANDLEBAR 7. Adjust: ● Choke lever operationRefer to “CONTROL SYSTEM” in chapter 3.8. Adjust: ● Throttle cable free playRefer to “CONTR

8-10 EHULLHOOD QSTS GRIPQSTS GRIP EXPLODED DIAGRAMREMOVAL AND INSTALLATION CHART Step Procedure/Part name Q’ty Service points QSTS GRIP DISASSEMBLY F

8-11 EHULLHOOD QSTS GRIP EXPLODED DIAGRAM Step Procedure/Part name Q’ty Service points7 Screw/washer 2/28 Collar 19 QSTS shift lock lever 110 Spring

8-12 EHULLHOODQSTS GRIPSERVICE POINTSQSTS cable inspection1. Inspect:● QSTS cablesFrays/kinks/rough movement → Replace.QSTS grip inspection1. Inspect

8-13EHULLHOODSTEERING COLUMNSTEERING COLUMNEXPLODED DIAGRAMREMOVAL AND INSTALLATION CHARTStep Procedure/Part name Q’ty Service pointsSTEERING COLUMN R

8-14EHULLHOODSTEERING COLUMNEXPLODED DIAGRAMREMOVAL AND INSTALLATION CHART*: Be sure to install the same number of shim(s) as installed originally at

8-15EHULLHOODSTEERING COLUMNEXPLODED DIAGRAMStep Procedure/Part name Q’ty Service points5 Washer 16 Steering column 17 Bushing 28 Steering column hous

8-16EHULLHOODSTEERING COLUMNSERVICE POINTSSteering column bushing inspection1. Inspect:● BushingsDamage/wear → Replace.2. Inspect:● Steering column in

8-17EHULLHOODREMOTE CONTROL CABLES AND SPEED SENSOR LEADREMOTE CONTROL CABLES AND SPEED SENSOR LEADEXPLODED DIAGRAMREMOVAL AND INSTALLATION CHARTStep

2-6SPEC E MAINTENANCE SPECIFICATIONS RECTIFIER/REGULATOR(R – B)Output peak voltage lower limit (unloaded)@cranking V 7@2,000 r/min V 12.6@3,500 r/min

8-18EHULLHOODREMOTE CONTROL CABLES AND SPEED SENSOR LEADEXPLODED DIAGRAMStep Procedure/Part name Q’ty Service points8 Cap 19 Nut 110 Steering cable 11

8-19EHULLHOODREMOTE CONTROL CABLES AND SPEED SENSOR LEADSERVICE POINTSWARNINGWhen routing the cables, do not grasp thecable by the outer crimped sheat

8-20EHULLHOODREMOTE CONTROL CABLES AND SPEED SENSOR LEADQSTS cable (jet pump side) installation1. Install:● QSTS cable (jet pump side) a WARNINGThe QS

8-21EHULLHOODFRONT HOODFRONT HOODEXPLODED DIAGRAMREMOVAL AND INSTALLATION CHARTStep Procedure/Part name Q’ty Service pointsFRONT HOOD REMOVAL Follow t

8-22EHULLHOODEXPLODED DIAGRAMStep Procedure/Part name Q’ty Service points7 Hood lock 18 Front hood 19 Nut 210 Plate 111 Hinge assembly 1Reverse the re

8-23EHULLHOODSTEERING CONSOLE COVERSTEERING CONSOLE COVEREXPLODED DIAGRAMREMOVAL AND INSTALLATION CHARTStep Procedure/Part name Q’ty Service pointsSTE

8-24EHULLHOODSTEERING CONSOLE COVEREXPLODED DIAGRAMStep Procedure/Part name Q’ty Service points6 Plate 17 Nut/washer 2/28 Bolt/square-ring 2/29 Steeri

8-25EHULLHOODSTEERING CONSOLE COVEREXPLODED DIAGRAMREMOVAL AND INSTALLATION CHARTStep Procedure/Part name Q’ty Service pointsSTEERING CONSOLE COVER DI

8-26EHULLHOODSTEERING CONSOLE COVEREXPLODED DIAGRAMStep Procedure/Part name Q’ty Service points6 Screw 47 Glove compartment 18 Pop nut 49 Steering con

8-27EHULLHOODBUZZER AND HOOD LOCKBUZZER AND HOOD LOCKEXPLODED DIAGRAMREMOVAL AND INSTALLATION CHARTStep Procedure/Part name Q’ty Service pointsBUZZER

2-7SPEC E TIGHTENING TORQUESTIGHTENING TORQUES SPECIFIED TORQUES Part to tightened Part nameThread sizeQ’tyTightening torqueRemarksNm m•kgf ft•lb ENG

8-28EHULLHOODBUZZER AND HOOD LOCKEXPLODED DIAGRAMStep Procedure/Part name Q’ty Service points6 Nut 27 Bolt 28 Hood lock assembly 19 Grommet 1Reverse t

8-29EHULLHOODBUZZER AND HOOD LOCKEXPLODED DIAGRAMREMOVAL AND INSTALLATION CHARTStep Procedure/Part name Q’ty Service pointsHOOD LOCK DISASSEMBLY Follo

8-30EHULLHOODHOSESHOSESEXPLODED DIAGRAMREMOVAL AND INSTALLATION CHARTStep Procedure/Part name Q’ty Service pointsHOSES REMOVAL Follow the left “Step”

8-31EHULLHOODHOSESEXPLODED DIAGRAMStep Procedure/Part name Q’ty Service points4 Band 15 Check valve 16 Oil tank breather hose 17 Fuel tank breather ho

8-32EHULLHOODHOSESSERVICE POINTSCheck valve inspection1. Check:● Check valveFaulty → Replace.Checking steps:● Connect a hose to the end of checkvalve

8-33EHULLHOODSEATS AND HAND GRIPSEATS AND HAND GRIPEXPLODED DIAGRAMREMOVAL AND INSTALLATION CHARTStep Procedure/Part name Q’ty Service pointsSEATS AND

8-34EHULLHOODSEATS AND HAND GRIPEXPLODED DIAGRAMStep Procedure/Part name Q’ty Service points7 Rubber ring 18 Nut/washer 2/29 Bolt 210 Bolt 211 Hand gr

8-35EHULLHOODSEATS AND HAND GRIPSERVICE POINTSSeat lock inspection1. Inspect:● Seat lockDamage/wear → Replace.

8-36EHULLHOODBATTERY BOXBATTERY BOXEXPLODED DIAGRAMREMOVAL AND INSTALLATION CHARTStep Procedure/Part name Q’ty Service pointsBATTERY BOX REMOVAL Follo

8-37EHULLHOODBATTERY BOXEXPLODED DIAGRAMStep Procedure/Part name Q’ty Service points12 Holder 113 Cap nut/washer 2/214 Nut/washer 4/415 Electrical box

2-8SPEC E TIGHTENING TORQUES Cylinder – crankcase1stBolt M10 1222 2.2 16572LT 2nd 39 3.9 28Generator cover – crankcase1stBolt M10 715 1.5 11271LT 2nd

8-38EHULLHOODEXHAUST SYSTEMEXHAUST SYSTEMEXPLODED DIAGRAMREMOVAL AND INSTALLATION CHARTStep Procedure/Part name Q’ty Service pointsEXHAUST SYSTEM REMO

8-39EHULLHOODEXHAUST SYSTEMEXPLODED DIAGRAMStep Procedure/Part name Q’ty Service points9 Hose clamp 2NOTE:Remove parts 9 to 12 as a set.10 Water tank

8-40EHULLHOODEXHAUST SYSTEMSERVICE POINTSExhaust system inspection1. Inspect:● Water lock bandCracks/damage → Replace.2. Inspect:● Rubber hosesBurns/c

8-41EHULLHOODDECK AND HULLDECK AND HULLEXPLODED DIAGRAMREMOVAL AND INSTALLATION CHARTStep Procedure/Part name Q’ty Service pointsDECK AND HULL DISASSE

8-42EHULLHOODDECK AND HULLEXPLODED DIAGRAMStep Procedure/Part name Q’ty Service points8 Sponson 2NOTE:Make sure install the starboard and portside spo

8-43EHULLHOODENGINE MOUNTENGINE MOUNTEXPLODED DIAGRAMREMOVAL AND INSTALLATION CHARTStep Procedure/Part name Q’ty Service pointsENGINE MOUNT REMOVAL Fo

8-44EHULLHOODENGINE MOUNTHULL REPAIRShallow scratches1. Sand the scratches with 400 grit sand-paper (either wet or dry) until thescratches are smooth.

8-45EHULLHOODENGINE MOUNTCracks and puncturesNOTE:Before attempting to repair any cracks orpunctures, refer to “WATER VEHICLE FRPREPAIR MANUAL”.1. Rem

8-46EHULLHOODENGINE MOUNTInsert nutNOTE:Use the insert nut when:● A pop nut which was attached to the hullslipped off or,● When a bolt which was faste

8-47EHULLHOODENGINE MOUNT4. First, apply tape 1 to the inner surfaceof the hull and then laminate fiberglassmats over the tape with resin.NOTE:When it

2-9SPECETIGHTENING TORQUESGrip end – handlebar Bolt M5 2 1 0.1 0.7Choke lever assembly – handlebarScrew M5 2 3 0.3 2.2QSTS cable housing – cover Scre

8-48EHULLHOODENGINE MOUNT2. To prevent water from entering the ure-thane foam, apply silicone sealant tothe inside of the hole as shown.3. Install the

E 9 TRBLANLS CHAPTER 9TROUBLE ANALYSIS TROUBLE ANALYSIS ...

9-1TRBLANLS E TROUBLE ANALYSISTROUBLE ANALYSISNOTE: The following items should be checked before the “Trouble analysis” chart is consulted.1. The bat

9-2TRBLANLS E TROUBLE ANALYSIS Rubber coupling 5Pilot water hose 5Water hose 5Water passage 5JET PUMP UNITDuct 6Impeller 6Intake screen 6Bearings 6I

Printed on recycled paperPrinted in USAFeb. 2000 – × 1 CR F0X-28197-ZA-11 (GP1200AY)YAMAHA MOTOR CO., LTD.

WB RBrSETPULL+–NSMGW/RW/RB/OGBB/YB/OW/RGy/RGy/YGBrGyWOGy/BB/WB/OB/YBrRBB/YB/OB/YB/OB/OOGy/YWGGyGy/RGy/BB/YB/OB/OOR/WGy/YRGy/RGBGy/BBGBWBR/YBrR/LRB

2-10SPECETIGHTENING TORQUESEngine mount – hull Bolt M8 6 17 1.7 12572LTEngine mount/plate – hull Bolt M8 2 17 1.7 12572LTEngine damper – hull Bolt M6

2-11SPECECABLE AND HOSE ROUTINGCABLE AND HOSE ROUTINGI-IH-HJD-DE-EF-FG-GACB20˚ABCEEGJGDDEEIIGGHHFFGGC22DEFC6IHAIBA678901223245671 Fuel filter2 Fuel br

2-12SPECECABLE AND HOSE ROUTINGAHDGAGE-EF-FDBCI-IHIIIIFFCEEIIBI15790ABCDEF8FDGHGDFF9254GJH61223458K1 Choke cable2 Steering cable3 Cooling water hose4

E 3 INSPADJ CHAPTER 3PERIODIC INSPECTION AND ADJUSTMENT MAINTENANCE INTERVAL CHART ...

3-1INSPADJ E MAINTENANCE INTERVAL CHARTMAINTENANCE INTERVAL CHART The following chart should be considered strictly as a guide to general maintenance

E HOW TO USE THIS MANUAL MANUAL FORMAT All of the procedures in this manual are organized in a sequential, step-by-step format. Theinformation has be

3-2INSPADJ E CONTROL SYSTEMPERIODIC SERVICE CONTROL SYSTEM Steering column inspection 1. Inspect: ● Steering columnExcessive play → Replace the ste

3-3INSPADJ E CONTROL SYSTEMNOTE: If the steering cable cannot be properlyadjusted at the steering column side, makesure the steering cable at the jet

3-4INSPADJ E CONTROL SYSTEMWARNING After adjusting the free play, turn the han-dlebar to the right and left and make sure that the trolling speed doe

3-5INSPADJECONTROL SYSTEMQSTS cable inspection and adjustment1. Measure:● Nozzle deflector set length a, b Difference → Adjust.Measurement steps:● Set

3-6INSPADJECONTROL SYSTEMNOTE:If correct adjustment by using the cablejoint at the wheel end is not obtained,adjust the cable joint on the trim nozzle

3-7INSPADJECONTROL SYSTEM/FUEL SYSTEM3. Adjust:● YPVS cables 1 and 2FUEL SYSTEMWARNING● Stop the engine, set the fuel cock to“OFF” before servicing th

3-8INSPADJEFUEL SYSTEM2. Inspect:● Water separator 1 Water accumulation → Drain.NOTE:If need the water draining, remove the drainplug 2.Trolling speed

3-9INSPADJEOIL INJECTION SYSTEM/POWER UNITOIL INJECTION SYSTEMOil line inspectionRefer to “OIL TANK” in chapter 4.POWER UNITSpark plug inspection1. In

3-10INSPADJEPOWER UNIT/ELECTRICAL4. Tighten:● Spark plugNOTE:● Before installing the spark plug, clean thegasket surface and spark plug surface.Also,

3-11INSPADJEELECTRICALBatteries generate explosive, hydrogengas. Always follow these preventive mea-sures:● Charge batteries in a well-ventilated area

E IMPORTANT INFORMATION In this Service Manual particularly important information is distinguished in the followingways.The Safety Alert Symbol means

3-12INSPADJEELECTRICAL2. Inspect:● Electrolyte levelLow → Add distilled water.The electrolyte level should bebetween the upper a and lower blevel mark

3-13INSPADJEELECTRICAL/JET PUMP UNIT5. Install:● Battery breather hose 1 ● Battery ● Battery positive lead 2 ● Battery negative lead 3 ● BandCAUTION:●

3-14INSPADJEJET PUMP UNIT/GENERALWater inlet strainer inspection1. Inspect:● Water inlet strainerContaminants → Clean.Cracks/damage → Replace.Inspecti

3-15INSPADJEGENERALLubrication points1. Lubricate:● Throttle cable (handlebar side)NOTE:Before lubricating the throttle cable,squeeze the throttle lev

3-16INSPADJEGENERAL4. Lubricate:● Throttle cable (carburetor side)● Oil pump cable● QSTS cables (pulley side)● YPVS cablesRecommended grease:Yamaha ma

3-17INSPADJEGENERAL6. Lubricate:● Steering cable ● Steering cable jointNOTE:Disconnect the joints and apply a smallamount of grease.Recommended grease

EFUEL CHAPTER 4FUEL SYSTEM FUEL COCK AND FUEL FILTER ... 4-1EXPLODED DIAGRAM...

E 4 FUEL CARBURETOR ... 4-18EXPLODED DIAGRAM...

4-1FUEL E FUEL COCK AND FUEL FILTERFUEL COCK AND FUEL FILTER EXPLODED DIAGRAMREMOVAL AND INSTALLATION CHART Step Procedure/Part name Q’ty Service poi

4-2FUEL E FUEL COCK AND FUEL FILTER SERVICE POINTS Fuel filter inspection Refer to “FUEL SYSTEM” in chapter 3. Fuel cock inspection 1. Check: ● Fuel

E HOW TO USE THIS MANUAL1 To help identify parts and clarify procedure steps, there are exploded diagrams at the startof each removal and disassembly

4-3FUEL E OIL TANKOIL TANK EXPLODED DIAGRAMREMOVAL AND INSTALLATION CHART Step Procedure/Part name Q’ty Service points OIL TANK REMOVAL Follow the le

4-4FUEL E OIL TANK EXPLODED DIAGRAM Step Procedure/Part name Q’ty Service points6 Breather hose 17 Oil hose 18 Bolt 29 Tank belt 210 Oil tank assembl

4-5FUEL E OIL TANK SERVICE POINTS Oil line inspection 1. Inspect: ● Oil filterContaminants → Clean.Frays/tears → Replace. ● Rubber sealCracks/wea

4-6FUEL E FUEL TANKFUEL TANK EXPLODED DIAGRAMREMOVAL AND INSTALLATION CHART Step Procedure/Part name Q’ty Service points FUEL TANK REMOVAL Follow the

4-7FUEL E FUEL TANK EXPLODED DIAGRAM Step Procedure/Part name Q’ty Service points7 Fuel hose 18 Fuel return hose 1 Red mark a 9 Fuel breather hose 1

4-8FUEL E FUEL TANK EXPLODED DIAGRAM Step Procedure/Part name Q’ty Service points15 One way valve 116 Screw/washer 1/117 Filter 118 Screw/washer 1/11

4-9FUEL E FUEL TANK SERVICE POINTS Check valve inspection 1. Check: ● Check valveFaulty → Replace. Fuel level switch inspection Refer to “INDICATIO

4-10FUEL E INTAKE DUCT AND SILENCERINTAKE DUCT AND SILENCER EXPLODED DIAGRAMREMOVAL AND INSTALLATION CHART Step Procedure/Part name Q’ty Service poin

4-11FUEL E INTAKE DUCT AND SILENCER EXPLODED DIAGRAM Step Procedure/Part name Q’ty Service points6 Bolt/collar/grommet 1/1/17 Intake duct 18 Silencer

4-12FUEL E CARBURETOR UNITCARBURETOR UNIT EXPLODED DIAGRAMREMOVAL AND INSTALLATION CHART Step Procedure/Part name Q’ty Service points CARBURETOR UNIT

E A50001-1-4 SYMBOLS Symbols 1 to 9 are designed as thumb-tabs to indicate the content of a chapter.1 General Information2 Specifications3 Periodi

4-13FUEL E CARBURETOR UNIT EXPLODED DIAGRAM Step Procedure/Part name Q’ty Service points5 Fuel return hose 1 Red mark a 6 Oil delivery hose 37 Clamp

4-14FUEL E CARBURETOR UNIT EXPLODED DIAGRAMREMOVAL AND INSTALLATION CHART Step Procedure/Part name Q’ty Service points CARBURETOR UNIT SEPARATION Fol

4-15FUEL E CARBURETOR UNIT EXPLODED DIAGRAM Step Procedure/Part name Q’ty Service points7 Bolt 38 Cable holder 19 Bolt 610 Carburetor 311 Gasket 312

4-16FUEL E CARBURETOR UNIT SERVICE POINTS Throttle valve synchronization inspection and adjustment 1. Check: ● Throttle valve synchronizationNot sync

4-17FUELECARBURETOR UNITChoke cable and throttle cable installation1. Install:● Choke cable 1 ● Throttle cable 2 Choke cable guide installation positi

4-18FUELECARBURETORCARBURETOREXPLODED DIAGRAMREMOVAL AND INSTALLATION CHARTStep Procedure/Part name Q’ty Service pointsCARBURETOR DISASSEMBLY Follow t

4-19FUELECARBURETOREXPLODED DIAGRAMStep Procedure/Part name Q’ty Service points10 Pilot jet 111 Screw 112 Arm 113 Arm pin 114 Spring 115 Screw 116 Nee

4-20FUELECARBURETOREXPLODED DIAGRAMREMOVAL AND INSTALLATION CHARTStep Procedure/Part name Q’ty Service pointsACCELERATOR PUMP DISASSEMBLYFollow the le

4-21FUELECARBURETORSERVICE POINTSCAUTION:Do not use steel wire for cleaning the jets.This may enlarge the jet diameters andseriously affect performanc

4-22FUELERegulator body inspection1. Inspect:● Regulator bodyContaminants → Clean.Damage → Replace.● Valve (clear film) 1 Damage → Replace.Needle valv

EINDEXGENERAL INFORMATION1 SPECIFICATIONS2 SPECPERIODIC INSPECTION AND ADJUSTMENT3 FUEL SYSTEM4 FUELPOWER UNIT5 POWRJET PUMP UNIT6 JETPUMPELECTRICAL S

4-23FUELEFUEL PUMPFUEL PUMPEXPLODED DIAGRAMREMOVAL AND INSTALLATION CHARTStep Procedure/Part name Q’ty Service pointsFUEL PUMP DISASSEMBLY Follow the

4-24FUELEFUEL PUMPEXPLODED DIAGRAMStep Procedure/Part name Q’ty Service points7 Rubber diaphragm 18 Diaphragm 19 Packing 110 Fuel filter 1Reverse the

4-25FUELEFUEL PUMPSERVICE POINTSFuel pump inspection1. Inspect:● Diaphragm● Rubber diaphragm● Diaphragm body Damage → Replace.Fuel filter inspection1.

4-26FUELEOIL PUMPOIL PUMPEXPLODED DIAGRAMREMOVAL AND INSTALLATION CHARTStep Procedure/Part name Q’ty Service pointsOIL PUMP REMOVAL Follow the left “S

4-27FUELEOIL PUMPEXPLODED DIAGRAMREMOVAL AND INSTALLATION CHARTStep Procedure/Part name Q’ty Service pointsOIL PUMP HOSES AND CABLE REMOVALFollow the

4-28FUELEOIL PUMPSERVICE POINTSOil pump inspection1. Inspect:● Oil pumpContaminants → Clean.Damage/wear → Replace. ● Oil pump joint pieceDamage/wear →

4-29FUELEOIL PUMPOil pump cable adjustment1. Check:● Oil pump lever positionIncorrect → Adjust. Checking steps:● Fully close the carburetor throttleva

4-30FUELEOIL PUMPOil injection pump air bleeding1. Bleed:● AirAir bleeding steps:● Place rags around the air bleed screw1 to catch any oil that might

EPOWR CHAPTER 5POWER UNIT MUFFLER ASSEMBLY ... 5-1EXPLODED DIAGRAM...

E 5 POWR CYLINDERS ... 5-25EXPLODED DIAGRAM..

E 1 GENINFO CHAPTER 1GENERAL INFORMATION IDENTIFICATION NUMBERS ... 1-1

5-1POWR E MUFFLER ASSEMBLY EXPLODED DIAGRAM REMOVAL AND INSTALLATION CHART Step Procedure/Part name Q’ty Service points WATER HOSES AND LEADS REMOVAL

5-2POWR E MUFFLER ASSEMBLY EXPLODED DIAGRAM Step Procedure/Part name Q’ty Service points4 AC magneto coupler 15 Cap/bolt 3/36 Cover 17 Water hose/cl

5-3POWR E MUFFLER ASSEMBLY EXPLODED DIAGRAM Step Procedure/Part name Q’ty Service points8 Hose clamp 2 Slide the outer exhaust joint.9 Hose clamp 21

5-4POWR E MUFFLER ASSEMBLY EXPLODED DIAGRAM Step Procedure/Part name Q’ty Service points16 Bolt 217 Bolt 118 Bolt 119 Bolt 120 Muffler stay 2 121 Mu

5-5POWR E MUFFLER ASSEMBLY EXPLODED DIAGRAM REMOVAL AND INSTALLATION CHART Step Procedure/Part name Q’ty Service points MUFFLER DISASSEMBLY Follow th

5-6POWR E MUFFLER ASSEMBLY EXPLODED DIAGRAM Step Procedure/Part name Q’ty Service points9 Gasket 110 Catalyst 111 Gasket 112 Pin 213 Bolt 614 Mixing

5-7POWR E MUFFLER ASSEMBLY SERVICE POINT Catalyst inspection 1. Inspect: ● CatalystCracks/damage → Replace.

5-8POWR E EXHAUST CHAMBER ASSEMBLYEXHAUST CHAMBER ASSEMBLY EXPLODED DIAGRAM REMOVAL AND INSTALLATION CHART Step Procedure/Part name Q’ty Service poin

5-9POWR E EXHAUST CHAMBER ASSEMBLY EXPLODED DIAGRAM Step Procedure/Part name Q’ty Service points8 Exhaust chamber assembly 1NOTE: Before installing

5-10POWR E EXHAUST CHAMBER ASSEMBLY EXPLODED DIAGRAM REMOVAL AND INSTALLATION CHART Step Procedure/Part name Q’ty Service points EXHAUST CHAMBER DISA

1-1 EGENINFO IDENTIFICATION NUMBERS A60700-0* IDENTIFICATION NUMBERS PRIMARY l.D. NUMBER The primary l.D. number is stamped on alabel attached to the

5-11POWR E ENGINE UNITENGINE UNIT EXPLODED DIAGRAMREMOVAL AND INSTALLATION CHART Step Procedure/Part name Q’ty Service points ENGINE UNIT REMOVAL Fol

5-12POWR E ENGINE UNIT EXPLODED DIAGRAM Step Procedure/Part name Q’ty Service points6 Coupling cover 17 Bolt/washer 4/48 Engine assembly 19 Shim * In

5-13POWR E ENGINE UNIT SERVICE POINTS Shim removal 1. Remove: ● ShimsNOTE: To ease reassembly and coupling align-ment, remove the shims and organize

5-14POWREEXHAUST MANIFOLDEXHAUST MANIFOLDEXPLODED DIAGRAM REMOVAL AND INSTALLATION CHARTStep Procedure/Part name Q’ty Service pointsEXHAUST MANIFOLD A

5-15POWREEXHAUST MANIFOLDEXPLODED DIAGRAM REMOVAL AND INSTALLATION CHARTStep Procedure/Part name Q’ty Service pointsEXHAUST MANIFOLD DISASSEMBLYFollow

5-16POWREREED VALVESREED VALVESEXPLODED DIAGRAMREMOVAL AND INSTALLATION CHARTStep Procedure/Part name Q’ty Service pointsREED VALVE REMOVAL Follow the

5-17POWREREED VALVESSERVICE POINTSReed valve inspection1. Inspect:● Reed valvesCracks/damage → Replace.2. Measure:● Valve bending a Out of specificati

5-18POWREYPVSYPVSEXPLODED DIAGRAMREMOVAL AND INSTALLATION CHARTStep Procedure/Part name Q’ty Service pointsYPVS REMOVAL Follow the left “Step” for rem

5-19POWREYPVSEXPLODED DIAGRAMStep Procedure/Part name Q’ty Service points7 Washer 58 Bolt 3NOTE:During installation, align the hole a inthe YPVS shaft

5-20POWREYPVSEXPLODED DIAGRAMStep Procedure/Part name Q’ty Service points13 Bolt 314 YPVS valve assembly 315 Oil seal 6NOTE:If the YPVS shaft is remov