2003 Yamaha GP1300R Waverunner Service Repair Manual.pdf
- 2. E NOTICE This manual has been prepared by Yamaha primarily for use by Yamaha dealers and their trained mechanics when performing maintenance procedures and repairs to Yamaha equipment. It has been written to suit the needs of persons who have a basic understanding of the mechanical and electrical concepts and procedures inherent in the work, for without such knowledge attempted repairs or service to the equipment could render it unsafe or unfit for use. Because Yamaha has a policy of continuously improving its products, models may differ in detail from the descriptions and illustrations given in this publication. Use only the latest edition of this manual. Authorized Yamaha dealers are notified periodically of modifications and significant changes in specifications and procedures, and these are incorporated in successive editions of this manual. A10001-0* WaveRunner GP1300R SERVICE MANUAL ©2003 by Yamaha Motor Corporation, USA 1st Edition, February 2003 All rights reserved. Any reprinting or unauthorized use without the written permission of Yamaha Motor Corporation, USA is expressly prohibited. Printed in USA LIT-18616-02-44
- 3. E HOW TO USE THIS MANUAL MANUAL FORMAT All of the procedures in this manual are organized in a sequential, step-by-step format. The informa- tion has been compiled to provide the mechanic with an easy to read, handy reference that contains comprehensive explanations of all disassembly, repair, assembly, and inspection operations. In this revised format, the condition of a faulty component will precede an arrow symbol and the course of action required will follow the symbol, e.g., • Bearings Pitting/scratches → Replace. To assist you in finding your way through this manual, the section title and major heading is given at the top of every page. ILLUSTRATIONS The illustrations within this service manual represent all of the designated models. CROSS REFERENCES The cross references have been kept to a minimum. Cross references will direct you to the appropri- ate section or chapter.
- 4. E IMPORTANT INFORMATION In this Service Manual particularly important information 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(s), a bystander, or a person inspecting or repairing the watercraft. CAUTION: A CAUTION indicates special precautions that must be taken to avoid damage to the water- craft. NOTE: A NOTE provides key information to make procedures easier or clearer. IMPORTANT: This part has been subjected to change of specification during production.
- 5. E HOW TO USE THIS MANUAL 1 To help identify parts and clarify procedure steps, there are exploded diagrams at the start of each removal and disassembly section. 2 Numbers are given in the order of the jobs in the exploded diagram. 3 Symbols indicate parts to be lubricated or replaced (see “SYMBOLS”). 4 A job instruction chart accompanies the exploded diagram, providing the order of jobs, names of parts, notes in jobs, etc. 5 Dimension figures and the number of parts, are provided for fasteners that require a tightening torque. Example: Bolt or screw size : M10 (D) × 25 mm (L) 6 Jobs requiring more information (such as special service tools and technical data) are described sequentially. 10 × 25 mm D L
- 6. E A50001-1-4 SYMBOLS Symbols 1 to 9 are designed to indicate the content of a chapter. 1 General Information 2 Specifications 3 Periodic Inspection and Adjustment 4 Fuel System 5 Power Unit 6 Jet Pump Unit 7 Electrical System 8 Hull and Hood 9 Trouble Analysis Symbols 0 to E indicate specific data. 0 Special service tool A Specified oil or fluid B Specified engine speed C Specified tightening torque D Specified measurement E Specified electrical value (resistance, voltage, electric current) Symbols F to H in an exploded diagram indi- cate the grade of lubricant and the lubrication point. F Apply Yamaha 2-stroke motor oil G Apply water resistant grease (Yamaha grease A, Yamaha marine grease) H Apply molybdenum disulfide grease Symbols I to N in an exploded diagram indi- cate the type of sealant or locking agent and the application point. I Apply Gasket Maker J Apply Yamabond No. 4 K Apply LOCTITE 271 (red) L Apply LOCTITE 242 (blue) M Apply LOCTITE 572 N Apply silicone sealant NOTE: Additional symbols may be used in this man- ual. 1 2 3 4 5 6 7 8 9 0 A B C D E F G H I J K L M N GEN INFO SPEC INSP ADJ FUEL POWR JET PUMP – + ELEC HULL HOOD TRBL ANLS T R . . E A M GM 4 271 LT 242 LT 572 LT SS
- 7. E INDEX GENERAL INFORMATION 1 GEN INFO SPECIFICATIONS 2 SPEC PERIODIC INSPECTION AND ADJUSTMENT 3 INSP ADJ FUEL SYSTEM 4 FUEL POWER UNIT 5 POWR JET PUMP UNIT 6 JET PUMP ELECTRICAL SYSTEM 7 ELEC HULL AND HOOD 8 HULL HOOD TROUBLE ANALYSIS 9 TRBL ANLS – + A30000-0
- 8. E GEN INFO 1 2 3 4 5 6 7 8 9 CHAPTER 1 GENERAL INFORMATION IDENTIFICATION NUMBERS .........................................................................1-1 PRIMARY l.D. NUMBER ...........................................................................1-1 ENGINE SERIAL NUMBER ......................................................................1-1 JET PUMP UNIT SERIAL NUMBER.........................................................1-1 HULL IDENTIFICATION NUMBER (H.l.N.)...............................................1-1 SAFETY WHILE WORKING......................................................................1-2 FIRE PREVENTION..................................................................................1-2 VENTILATION...........................................................................................1-2 SELF-PROTECTION.................................................................................1-2 PARTS, LUBRICANTS, AND SEALANTS ................................................1-2 GOOD WORKING PRACTICES ...............................................................1-3 DISASSEMBLY AND ASSEMBLY ............................................................1-4 SPECIAL SERVICE TOOLS ...........................................................................1-5 MEASURING AND DIAGNOSIS ...............................................................1-5 REMOVAL AND INSTALLATION..............................................................1-7
- 9. 1-1 E GEN INFO IDENTIFICATION NUMBERS A60700-0* IDENTIFICATION NUMBERS PRIMARY l.D. NUMBER The primary l.D. number is stamped on a label 1 attached inside the engine compartment. Starting primary l.D. number: F1G: 800301 1 ENGINE SERIAL NUMBER The engine serial number is stamped on a label 1 attached to the engine unit. Starting serial number: 60T: 1000001 JET PUMP UNIT SERIAL NUMBER The jet pump unit serial number is stamped on a label attached to the intermediate housing. HULL IDENTIFICATION NUMBER (H.l.N.) The H.l.N. is stamped on a plate 1 attached to the hull on the aft, starboard (right) side.
- 10. 1-2 E GEN INFO SAFETY WHILE WORKING SAFETY WHILE WORKING To prevent and accident or injury and to ensure quality service, follow the safety proce- dures provided below. FIRE PREVENTION Gasoline is highly flammable. Keep gasoline and all flammable products away from heat, sparks, and open flames. VENTILATION Gasoline vapor and exhaust gas are heavier than air and extremely poisonous. If inhaled in large quantities they may cause loss of con- sciousness and death within a short time. When test running an engine indoors (e.g., in a water tank), be sure to do so where adequate ventilation can be maintained. SELF-PROTECTION Protect your eyes by wearing safety glasses or safety goggles during all operation involving drilling and grinding, or when using an air com- pressor. Protect your hands and feet by wearing protec- tive gloves or safety shoes when necessary. PARTS, LUBRICANTS, AND SEALANTS Use only genuine Yamaha parts, lubricants, and sealants or those recommended by Yamaha, when servicing or repairing the watercraft.
- 11. 1-3 E GEN INFO SAFETY WHILE WORKING Under normal conditions, the lubricants men- tioned in this manual should not harm or be hazardous to your skin. However, you should follow these precautions to minimize any risk when working with lubricants. 1. Maintain good standards of personal and industrial hygiene. 2. Change and wash clothing as soon as possible if soiled with lubricants. 3. Avoid contact with skin. Do not, for exam- ple, place a soiled rag in your pocket. 4. Wash hands and any other part of the body thoroughly with soap and hot water after contact with a lubricant or lubricant soiled clothing has been made. 5. To protect your skin, apply a protective cream to your hands before working on the watercraft. 6. Keep a supply of clean, lint-free cloths for wiping up spills, etc. GOOD WORKING PRACTICES 1. The right tools Use the recommended special service tools to protect parts from damage. Use the right tool in the right manner—do not improvise. 2. Tightening torques Follow the tightening torque specifications provided throughout the manual. When tightening nuts, bolts, and screws, tighten the large sizes first, and tighten fasteners starting in the center and moving outward.
- 12. 1-4 E GEN INFO SAFETY WHILE WORKING 3. Non-reusable parts Always use new gaskets, seals, O-rings, oil seals, cotter pins, circlips, etc., when installing or assembling parts. DISASSEMBLY AND ASSEMBLY 1. Use compressed air to remove dust and dirt during disassembly. 2. Apply engine oil to the contact surfaces of moving parts during assembly. 3. Install bearings with the manufacture iden- tification mark in the direction indication in the installation procedure. In addition, be sure to lubricate the bearings liberally. 4. Apply a thin coat of water-resistant grease to the lip and periphery of an oil seal before installation. 5. Check that moving parts operate normally after assembly.
- 13. 1-5 E GEN INFO SPECIAL SERVICE TOOLS SPECIAL SERVICE TOOLS Using the special service tools recommended by Yamaha will aid service and enable accu- rate assembly and tune-up. Improvisations and using improper tools can damage the equipment. NOTE: • For USA and Canada, use the special ser- vice tools starting with part numbers “J-,” “YB-,” “YM-,” “YS-,” “YU-,” or “YW-.” • For all other countries, use the special ser- vice tools starting with part number “90890-.” MEASURING AND DIAGNOSIS 1 Digital multimeter YU-34899-A 2 Digital circuit tester 90890-03174 3 Dial gauge YU-03097 90890-01252 4 Pocket tester YU-03112 90890-03112 5 Fuel pressure gauge adapter YW-06842 90890-06842 6 Fuel pressure gauge YB-06766 90890-06786 7 Cylinder gauge set YU-03017 90890-06759 8 Compression gauge YU-33223-1 90890-03160 1 YU-34899-A 90890-03174 2 3 YU-03097 90890-01252 4 5 YU-03112 90890-03112 YW-06842 90890-06842 6 YB-06766 90890-06786 7 YU-03017 90890-06759 8 YU-33223-1 90890-03160
- 14. 1-6 E GEN INFO SPECIAL SERVICE TOOLS 9 Peak volt meter adapter YU-39991 0 Peak voltage adapter B 90890-03172 A Spark gap tester YM-34487 B Ignition tester 90890-06754 C Lighting coil tester (3 pins) YB-06870 Test harness SMT250-3 (3 pins) 90890-06870 D Air pressure sensor tester (3 pins) YB-06869 Test harness EJ-II-3 (3 pins) 90890-06869 E Test harness (6 pins) YB-06848 Test harness FSW-6A (6 pins) 90890-06848 F Test harness (6 pins) YB-06849 Test harness SM6195021-6 (6 pins) 90890-06849 G Lower unit pressure/vacuum tester YB-35956-A Vacuum/pressure pump gauge set 90890-06756 H Yamaha diagnostic system (CD-ROM only) 60V-WS853-01 G YB-35956-A 90890-06756 9 0 YU-39991 90890-03172 A B YM-34487 90890-06754 C D YB-06870 90890-06870 YB-06869 90890-06869 E F YB-06848 90890-06848 YB-06849 90890-06849 H 60V-WS853-01 60V-2819K-10 YAMAHA DIAGNOSTIC SYSTEM INSTALLATION MANUAL
- 15. 1-7 E GEN INFO SPECIAL SERVICE TOOLS REMOVAL AND INSTALLATION 1 Coupler wrench YW-06551 90890-06551 2 Flywheel holder YW-06550 90890-06550 3 Universal puller YB-06117 4 Flywheel puller 90890-06521 5 Drive shaft holder (impeller) YB-06151 Drive shaft holder 5 (impeller) 90890-06519 6 Slide hammer and adapters (jet pump bearing) YB-06096 7 Stopper guide plate (jet pump bearing) 90890-06501 8 Bearing puller assembly (jet pump bearing) 90890-06535 9 Stopper guide stand (jet pump bearing) 90890-06538 0 Driver rod L3 (jet pump bearing) 90890-06652 A Bearing housing needle bearing remover (jet pump bearing) YB-06112 Drive shaft needle bearing installer and remover (jet pump oil seal) YB-06196 B Needle bearing attachment (jet pump bearing and oil seal) 90890-06614, 90890-06653 1 YW-06551 YW-06550 2 3 YB-06117 90890-06521 4 5 YB-06151 YB-06096 6 7 90890-06501 90890-06535 8 9 90890-06538 90890-06652 0 A YB-06112 90890-06614 B 90890-06551 YB-06196 90890-06653 90890-06550 90890-06519
- 16. 1-8 E GEN INFO SPECIAL SERVICE TOOLS C Outer race installer—forward gear (jet pump oil seal) YB-06085 D Ball bearing attachment (jet pump oil seal) 90890-06634 E Driver handle—large (intermediate shaft and jet pump) YB-06071 F Driver rod LS (intermediate shaft and jet pump) 90890-06606 G Drive shaft needle bearing depth stop (jet pump bearing) YB-34474 H Shaft holder (intermediate shaft) YB-06552 Crankshaft holder 20 (intermediate shaft) 90890-06552 I Drive shaft taper roller bearing cup installer (intermediate shaft) YB-06156 Bearing outer race attachment (intermediate shaft) 90890-06626 C YB-06085 90890-06634 D E YB-06071 90890-06606 F G YB-34474 YB-06552 H I YB-06156 90890-06552 90890-06626
- 17. E SPEC 1 2 3 4 5 6 7 8 9 CHAPTER 2 SPECIFICATIONS GENERAL SPECIFICATIONS .......................................................................2-1 MAINTENANCE SPECIFICATIONS ...............................................................2-3 ENGINE ....................................................................................................2-3 JET PUMP UNIT ......................................................................................2-4 HULL AND HOOD ....................................................................................2-5 ELECTRICAL ............................................................................................2-5 TIGHTENING TORQUES ................................................................................2-8 SPECIFIED TORQUES.............................................................................2-8 GENERAL TORQUE...............................................................................2-14 CABLE AND HOSE ROUTING .....................................................................2-15
- 18. 2-1 E SPEC GENERAL SPECIFICATIONS GENERAL SPECIFICATIONS Item Unit Model GP1300R Model code Hull F1G Engine/jet 60T 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) 297 (653) Maximum capacity Person/kg (lb) 2/160 (353) Performance Maximum output kW (PS) at r/min 121.4 (165) at 7,000 Maximum fuel consumption l/h (US gal/h, lmp gal/h) 63.0 (16.6, 13.9) Cruising range h 0.95 Engine Engine type 2-stroke Number of cylinders 3 Displacement cm3 (cu. in) 1,297 (79.1) Bore × stroke mm (in) 84 × 78 (3.31 × 3.07) Compression ratio #1, #2 5.9:1 #3 5.7:1 Intake system Reed valve Scavenging system Loop charge Exhaust system Wet exhaust/YPVS Lubrication system Variable oil injection Cooling system Water cooled Starting system Electric starter Ignition system Digital CDI Spark plug model (manufacturer) BR8ES-11 (NGK) Spark plug gap mm (in) 1.0–1.1 (0.039–0.043) Battery Voltage, capacity V, Ah 12, 19 Generator output A at r/min 15 at 6,000
- 19. 2-2 E SPEC *1 Pump Octane Number = (Motor Octane Number + Research Octane Number)/2 *2 Research Octane Number *3 YAMALUBE 2-W has been developed for this watercraft and it is available at a Yamaha dealer. CAUTION: Use only YAMALUBE 2-W oil. Using another oil can seriously damage the catalytic converter and other engine components. 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 horizontal angle Degree 23 + 23 Jet thrust nozzle trim angle Degree –5, 0, 5, 10, 15 Trim system Manual 5 positions Reverse system NA Fuel and oil Fuel Regular unleaded gasoline Minimum fuel rating PON*1 86 RON*2 90 Oil YAMALUBE 2-W*3 Fuel-oil ratio (wide open throttle) 30:1 Fuel tank capacity L (US gal, Imp gal) 60 (15.9, 13.2) Oil tank quantity L (US qt, Imp qt) 5.5 (1.5, 1.2) Item Unit Model GP1300R GENERAL SPECIFICATIONS
- 20. 2-3 E SPEC MAINTENANCE SPECIFICATIONS MAINTENANCE SPECIFICATIONS ENGINE Item Unit Model GP1300R Cylinder head Warpage limit mm (in) 0.05 (0.002) Minimum compression pressure*1 kPa (kgf/cm2 , psi) 640 (6.4, 91) Cylinders Bore size mm (in) 84.000–84.018 (3.3071–3.3078) Taper limit mm (in) 0.080 (0.0031) Out-of-round limit mm (in) 0.050 (0.0020) Wear limit mm (in) 84.100 (3.3110) Pistons Piston diameter mm (in) Red: 83.899–83.902 (3.3031–3.3032) Orange: 83.903–83.906 (3.3033–3.3034) Green: 83.907–83.910 (3.3034–3.3035) Purple: 83.911–83.914 (3.3036–3.3037) Measuring point* mm (in) 11 (0.43) Piston-to-cylinder clearance mm (in) 0.100–0.105 (0.0039–0.0041) Wear limit mm (in) 0.155 (0.0061) Piston pin boss inside diameter mm (in) 22.008–22.020 (0.8665–0.8669) Piston rings Top Type Keystone Dimension (B) mm (in) 1.47–1.49 (0.058–0.059) Dimension (T) mm (in) 3.0–3.2 (0.118–0.126) End gap mm (in) 0.45–0.60 (0.018–0.024) Ring groove clearance mm (in) 0.020–0.070 (0.0008–0.0028) 2nd Type Keystone Dimension (B) mm (in) 1.47–1.49 (0.058–0.059) Dimension (T) mm (in) 3.0–3.2 (0.118–0.126) End gap mm (in) 0.45–0.60 (0.018–0.024) Ring groove clearance mm (in) 0.020–0.070 (0.0008–0.0028) Piston pins Outside diameter mm (in) 21.995–22.000 (0.8659–0.8661) Wear limit mm (in) 21.990 (0.8657) Connecting rod Small end inside diameter mm (in) 26.995–27.008 (1.0628–1.0633) *1 Measuring conditions: Engine temperature 48 °C (118 °F), wide open throttle, with spark plugs removed from all cylin- ders. The figures are for reference only.
- 21. 2-4 E SPEC MAINTENANCE SPECIFICATIONS JET PUMP UNIT Crankshaft assembly Crank width A mm (in) 72.95–73.00 (2.872–2.874) Deflection limit B mm (in) 0.05 (0.002) Deflection limit C mm (in) 0.15 (0.006) Big end side clearance D mm (in) 0.250–0.750 (0.0098–0.0295) Maximum small end axial play E mm (in) 2.000 (0.0787) Throttle body Model/quantity 60TA/3 Manufacturer SANSHIN ID mark 60T00 Trolling speed r/min 1,250–1,450 Reed valves Thickness mm (in) 0.6 (0.024) Reed valve stopper height mm (in) 10.5–10.9 (0.413–0.429) Reed valve warpage limit mm (in) 1.5 (0.059) Fuel pump Pump type Electrical Output pressure kPa (kgf/cm2 , psi) 320.8–327.2 (3.21–3.27, 45.62–46.53) Coupling clearance Vertical mm (in) 0–0.5 (0–0.020) Horizontal mm (in) 2–4 (0.079–0.157) Item Unit Model GP1300R Jet pump Impeller material Stainless steel Number of impeller blades 4 Impeller pitch angle Degree 16.3 Impeller clearance mm (in) 0.7–0.9 (0.028–0.035) Impeller clearance limit mm (in) 0.9 (0.035) Drive shaft runout limit mm (in) 0.30 (0.0118) Nozzle diameter mm (in) 85.0–85.6 (3.35–3.37) Item Unit Model GP1300R
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