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Yamaha waverunner gp1200r Assembly Manual
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Yamaha waverunner gp1200r Assembly Manual

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WaveRunnerGP1200R
ASSEMBLY MANUAL
*LIT186660028*
LIT-18666-00-28
F0X-28107-ZA-11

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Summary of Contents for Yamaha waverunner gp1200r

  • Page 1 WaveRunnerGP1200R ASSEMBLY MANUAL *LIT186660028* LIT-18666-00-28 F0X-28107-ZA-11...
  • Page 2 WaveRunner GP1200R ASSEMBLY MANUAL ©2000 Yamaha Motor Co., Ltd. 1st Edition, January 2000 All rights reserved. Any reprinting or unauthorized use without the written permission of Yamaha Motor Co., Ltd. is expressly prohibited. Printed in USA LIT-18666-00-28...
  • Page 3 If any change is introduced into the : Tighten temporarily. specifications or assembly procedures, : Apply locking agent. Yamaha dealers will be notified by a techni- ® LOCTITE ‚ No.242 (BLUE LOCTITE) cal bulletin.
  • Page 4 GENERAL TORQUE SPECIFICATIONS General torque This chart specifies the torques for tighten- Nut A Bolt B specifications ing standard fasteners with standard clean kgf•m lb•ft dry ISO threads at room temperature. 8 mm Torque specifications for special compo- 10 mm nents or assemblies are given in applicable 12 mm sections of this manual.
  • Page 5 NOTE: For USA: If concealed damage is found during uncrating, refer to the Yamaha Warranty Handbook, Chapter 3. Documentation may be required for warranty reimbursement. Do not continue with uncrating or throw the crate away until the requirements in Chapter 3 have been met.
  • Page 6 COMPARTMENT DIAGRAM COMPARTMENT PART CHART Part name Q’ty Part number Grommet F0X-61469-00 Lower handlebar holder EU0-23814-01 Handlebar assembly F0X-U155A-00 Upper handlebar holder EU0-23814-30 Bolt 8 × 55 mm (0.31 × 2.17 in) 90119-089UM Band 90464-32801 Spiral tube 90448-25800 Handlebar cover stay GP7-U142K-00 Screw 6 ×...

  • Page 7: Table Of Contents

    WIRE LEAD AND CABLE ROUTING EXPLODED DIAGRAM INSTALLATION CHART Step Procedure/Part name Q’ty Service points WIRE LEAD AND CABLE Follow “Step” order for installation. ROUTING NOTE: Working from the bow side, open the front hood, and then remove the storage com- partment.

  • Page 8: Installation Chart Step Procedure/Part Name Q'ty

    HANDLEBAR AND THROTTLE CABLE INSTALLATION EXPLODED DIAGRAM INSTALLATION CHART Step Procedure/Part name Q’ty Service points HANDLEBAR AND THROTTLE Follow “Step” order for installation. CABLE INSTALLATION Lower handlebar holder Handlebar assembly NOTE: Upper handlebar holder Align the punched marks a on the handle- bar with the top surface of the lower han- dlebar holders.
  • Page 9 EXPLODED DIAGRAM Step Procedure/Part name Q’ty Service points Band Throttle cable Installation steps: Install the throttle cable end into the throttle lever. Fit the seal into the groove in the bracket. Turn the adjuster 1 in/out until the specified free play is obtained. Throttle lever free play e: 4 ~ 7 mm (0.16 ~ 0.28 in) Turn in...
  • Page 10 CHOKE CABLE INSTALLATION EXPLODED DIAGRAM INSTALLATION CHART Step Procedure/Part name Q’ty Service points CHOKE CABLE INSTALLATION Choke cable Installation steps: Install the choke cable end into the choke lever with the choke lever com- pletely closed. Route the inner choke cable along the choke lever gutter.
  • Page 11 EXPLODED DIAGRAM Step Procedure/Part name Q’ty Service points NOTE: If the inner cable is difficult to make taut using the adjuster 1, 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.

  • Page 12: Choke Cable

    EXPLODED DIAGRAM Step Procedure/Part name Q’ty Service points Make sure that the inner cable has some slack when the choke lever is completely closed. Tighten the locknut 2 to secure the choke cable. Spiral tube NOTE: Be sure to install the spiral tube, containing the throttle cable, choke cable and handle- bar switch lead, at least 50 mm (1.97 in) c into the steering column.

  • Page 13: Note

    HANDLEBAR COVER INSTALLATION EXPLODED DIAGRAM INSTALLATION CHART Step Procedure/Part name Q’ty Service points HANDLEBAR COVER Follow “Step” order for installation. INSTALLATION Handlebar cover stay Screw 6 × 15 mm (0.24 × 0.59 in) Handlebar cover NOTE: Screw 6 × 19 mm (0.24 × 0.75 in) If the handlebar cover is in contact with the steering console cover, adjust the handlebar mount angle so that the clearance a and b...
  • Page 14 WIRING CONNECTION INSTALLATION EXPLODED DIAGRAM INSTALLATION CHART Step Procedure/Part name Q’ty Service points WIRING CONNECTION Follow “Step” order for installation. INSTALLATION Handlebar switch coupler Black coupler (2 pins), natural coupler (2 pins), white coupler (1 pin) Band – 10 –...
  • Page 15 QSTS CABLE INSTALLATION EXPLODED DIAGRAM INSTALLATION CHART Step Procedure/Part name Q’ty Service points QSTS CABLE INSTALLATION Follow “Step” order for installation. NOTE: QSTS cable 1 Set the inner cables length a to 77 mm QSTS cable 2 (3.03 in), using the adjusting nuts 1 when the control grip is in neutral before install- ing the QSTS cables.
  • Page 16 BATTERY INSTALLATION EXPLODED DIAGRAM INSTALLATION CHART Step Procedure/Part name Q’ty Service points BATTERY INSTALLATION Follow “Step” order for installation. NOTE: Battery breather hose Remove the fire extinguisher container for Battery easier removing and installing the battery. Battery positive lead (red) Bolt 6 ×...
  • Page 17 PREDELIVERY CHECK CHECKING CHART Check elements Checking points Reference page Throttle lever Free play Battery Battery condition Oil pump Air bleed Trolling speed Trolling speed Steering system Handlebar and steering nozzle positions QSTS Trim nozzle position BATTERY WARNING Battery electrolyte is poisonous and dan- gerous, causing severe burns, etc.
  • Page 18 1. Fill: Battery electrolyte Filling steps: Remove all the filler caps using pliers. Fill with the specified electrolyte from a jug. After the electrolyte is filled up as far as the UPPER LEVEL a, allow the cell to stand for 20 minutes. If after 20 min- utes, the electrolyte level has dropped, add more electrolyte up to the UPPER LEVEL mark once again.
  • Page 19 OIL PUMP AIR BLEEDING 1. Bleed: Air bleeding steps: Place rags around the air bleed screw 1 to catch any oil that might spill. Fill the oil tank with the recommended engine oil. Recommended engine oil: YAMALUBE 2-W oil only Loosen the air bleed screw 1 two full turns and make sure that both the oil and air bubbles flow out.
  • Page 20 TROLLING SPEED 1. Measure: Trolling speed Out of specification → Adjust. Trolling speed: 1,350 ± 50 r/min Checking steps: (Vehicle on water) Start the engine and allow it to warm up for a few minutes. Attach an engine tachometer to the spark plug lead.
  • Page 21 STEERING CABLE 1. Check: Distance a, b Out of specification → Adjust. Difference of distances a and b: Maximum 5 mm (0.2 in) Checking steps: Turn the handlebar lock to lock. Measure the distances a and b. If the difference of distances a and b is not within specification, adjust the cable joint.
  • Page 22 QSTS CABLE 1. Measure: Nozzle deflector set length a, b Difference → Adjust. Measurement steps: Set the control grip in the neutral posi- tion. Set the jet nozzle in the center posi- tion. Measure nozzle deflector length a and b. If a and b length are not even, adjust the cable joint.
  • Page 23 Imp gal) : Pump Octane Number = (Motor Octane Number + Research Octane Number)/2 : Research Octane Number : YAMALUBE 2-W is developed for this water vehicle and available from a Yamaha water vehicle dealer. CAUTION: Use only YAMALUBE 2-W oil. Using another oil can seriously damage the catalytic converter and other engine components.
  • Page 24 YAMAHA MOTOR CO., LTD. Printed in USA × 1 CR Jan. 2000 – F0X-28107-ZA-11 (GP1200AY) Printed on recycled paper...