2003 Yamaha GP800R Waverunner Service Repair Manual

*LIT186160226*
WaveRunner
GP800R
SERVICEMANUAL
F0W-28197-1A-11LIT-18616-02-26

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 equip-
ment. 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 edi-
tion of this manual. Authorized Yamaha dealers are notified periodically of modifications and
significant changes in specifications and procedures, and these are incorporated in succes-
sive editions of this manual.
A10001-0*
WaveRunner GP800R
SERVICE MANUAL
©2000 by Yamaha Motor Corporation, USA
1st Edition, November 2000
All rights reserved.
Any reprinting or unauthorized use
without the written permission of
Yamaha Motor Corporation, USA
is expressly prohibited.
Printed in USA
LIT-18616-02-26

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
information has been compiled to provide the mechanic with an easy to read, handy refer-
ence 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.,
q 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
appropriate section or chapter.

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 deathto the machine
operator, 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.

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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 tight-
ening torque.
Example:
Bolt or screw size : M10 (D) × 25 mm (L)
6 Jobs requiring more information (such as special tools and technical data) are described
sequentially.
10 × 25 mm
D
L

E
A50001-1-4
SYMBOLS
Symbols 1 to 9 are designed as thumb-
tabs 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 tool
A Specified liquid
B Specified engine speed
C Specified torque
D Specified measurement
E Specified electrical value
[Resistance (Ω), Voltage (V), Electric current
(A)]
Symbol F to H in an exploded diagram
indicate the grade of lubricant and the loca-
tion of lubrication point:
F Apply YAMALUBE 2-W oil or TC-W3 cirtified
outboard 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
indicate the grade of the sealing or locking
agent, and the location of the application
point:
I Apply Gasket Maker®
J Apply Yamabond #4
(Yamaha bond number 4)
K Apply LOCTITE® No. 271 (Red LOCTITE)
L Apply LOCTITE® No. 242 (Blue LOCTITE)
M Apply LOCTITE® No. 572
N Apply silicone sealant
NOTE:
In this manual, the above symbols may not
be used in every case.
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
LTSS

E
INDEX
GENERAL INFORMATION 1GEN
INFO
SPECIFICATIONS 2SPEC
PERIODIC INSPECTION AND
ADJUSTMENT 3INSP
ADJ
FUEL SYSTEM 4FUEL
POWER UNIT 5POWR
JET PUMP UNIT 6JET
PUMP
ELECTRICAL SYSTEM 7ELEC
HULL AND HOOD 8HULL
HOOD
TROUBLE ANALYSIS 9TRBL
ANLS
– +
A30000-0

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1
2
3
4
5
6
7
8
9
GEN
INFO
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
OILS, GREASES AND SEALING FLUIDS................................................ 1-2
GOOD WORKING PRACTICES................................................................ 1-3
DISASSEMBLY AND ASSEMBLY........................................................... 1-4
SPECIAL TOOLS............................................................................................. 1-5
MEASURING ............................................................................................ 1-5
REMOVAL AND INSTALLATION ............................................................ 1-6

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 attached to the inside of the engine
compartment.
Starting primary l.D. number:
F0W: 800101–
ENGINE SERIAL NUMBER
The engine serial number is stamped on a
label attached to the cylinder head.
Starting serial number:
68A: 000101–
JET PUMP UNIT SERIAL NUMBER
The jet pump unit serial number is stamped
on a label attached to the intermediate
housing.
Starting serial number:
68A: 800101–
HULL IDENTIFICATION NUMBER
(H.l.N.)
The H.l.N. is stamped on a plate attached to
the aft deck.

1-2
E
GEN
INFO SAFETY WHILE WORKING
SAFETY WHILE WORKING
The procedures given in this manual are
those recommended by Yamaha to be fol-
lowed by Yamaha dealers and their
mechanics.
FIRE PREVENTION
Gasoline (petrol) is highly flammable.
Gasoline vapor is explosive if ignited.
Do not smoke while handling gasoline
(petrol) and keep it away from heat, sparks,
and open flames.
VENTILATION
Gasoline vapor is heavier than air and is
deadly if inhaled in large quantities. Engine
exhaust gases are harmful to breathe.
When test-running an engine indoors,
maintain good ventilation.
SELF-PROTECTION
Protect your eyes with suitable safety spec-
tacles or safety goggles when grinding or
doing any operation which may cause parti-
cles to fly off.
Protect hands and feet by wearing safety
gloves or protective shoes if appropriate to
the work you are doing.
OILS, GREASES AND SEALING
FLUIDS
Use only genuine Yamaha oils, greases,
and sealing fluids or those recommended
by Yamaha.

1-3
E
GEN
Under normal conditions of use there
should be no hazards from the use of the
lubricants mentioned in this manual, but
safety is all-important, and by adopting
good safety practises any risk is minimized.
A summary of the most important precau-
tions is as follows:
1. While working, maintain good stan-
dards of personal and industrial
hygiene.
2. Clothing which has become contami-
nated with lubricants should be
changed as soon as practicable and
laundered before further use.
3. Avoid skin contact with lubricants (e.g.,
do not place a soiled rag in your
pocket).
4. Hands and any other part of the body
which have been in contact with lubri-
cants or lubricant-contaminated cloth-
ing should be thoroughly washed with
hot water and soap as soon as practica-
ble.
5. To protect the skin, the application of a
suitable barrier cream to the hands
before working is recommended.
6. A supply of clean lint-free cloths should
be available for wiping purposes.
GOOD WORKING PRACTICES
1. The right tools
Use the recommended special tools to
protect parts from damage. Use the
right tool in the right manner – do not
improvise.
2. Tightening torque
Follow the tightening torque instruc-
tions. When tightening bolts, nuts and
screws, tighten the larger sizes first and
tighten inner-positioned fixings before
outer-positioned ones.

1-4
E
GEN
3. Non-reusable items
Always use new gaskets, packings, O-
rings, oil seals, split-pins, circlips, etc.,
on reassembly.
DISASSEMBLY AND ASSEMBLY
1. Clean parts with compressed air when
disassembling.
2. Oil the contact surfaces of moving parts
during assembly.
3. After assembly, check that moving parts
operate normally.
4. Install bearings with the manufacturer’s
markings on the side exposed to view
and liberally oil the bearings.
CAUTION:
Do not spin bearings with compressed air
because this will damage their surfaces.
5. When installing oil seals, apply a light
coat of water-resistant grease to the
outside diameter.

1-5
E
GEN
INFO SPECIAL TOOLS
SPECIAL TOOLS
Using the correct special tools recom-
mended by Yamaha, will aid the work and
enable accurate assembly and tune-up.
Improvisations and using improper tools
can damage the equipment.
NOTE:
q For U.S.A. and Canada, use part numbers
starting with “J-”, “YB-”, “YM-”, “YU-” or
“YW-”.
q For other countries, use part numbers
starting with “90890-”.
MEASURING
1 Engine tachometer
P/N. YU-8036-A
90890-06760
2 Dial gauge and stand
P/N. YU-03097, YU-01256
90890-01252
3 Pocket tester
P/N. YU-03112
90890-03112
4 Cylinder gauge set
P/N. YU-03017
90890-06759
5 Compression gauge
P/N. YU-33223
90890-03160
6 Digital tester
P/N. J-39299
90890-06752
7 Peak voltage adapter
P/N. YU-39991
90890-03169
8 Peak voltage test harness
P/N. YW-06779
90890-06779
9 Spark gap tester
P/N. YM-34487
90890-06754
43
1
2
5
6
87
9
YU-8036-A 90890-06760
YU-03097
YU-01256
90890-01252
YU-03112
90890-03112
YU-03017
90890-06759
YU-33223 90890-03160
J-39299 90890-06752
YU-39991
90890-03169
YW-06779
90890-06779
YM-34487 90890-06754

1-6
E
GEN
INFO SPECIAL TOOLS
REMOVAL AND INSTALLATION
1 Coupler wrench
P/N. YW-06551
90890-06551
2 Flywheel holder
P/N. YW-06550
90890-06550
3 Flywheel puller
P/N. YB-06117
90890-06521
4 Drive shaft holder (impeller)
P/N. YB-06151
90890-06519
5 Slide hammer set (jet pump bearing)
P/N. YB-06096
6 Stopper guide plate (jet pump bearing)
P/N. 90890-06501
7 Bearing puller (jet pump bearing)
P/N. 90890-06535
8 Bearing puller claw 1 (jet pump bearing)
P/N. 90890-06536
9 Stopper guide stand (jet pump bearing)
P/N. 90890-06538
0 Drive rod L3 (jet pump bearing)
P/N. 90890-06652
A Needle bearing attachment
(jet pump bearing and oil seal)
P/N. YB-06112, YB-06196
90890-06614, 90890-06653
B Ball bearing attachment
(jet pump oil seal)
P/N. YB-06156
90890-06634
C Driver rod
(intermediate shaft and jet pump)
P/N. YB-06071
90890-06606
D Bearing inner/outer race attachment
(jet pump bearing)
P/N. YB-34474
E Shaft holder (intermediate shaft)
P/N. YB-06552
90890-06552
F Bearing outer race attachment
(intermediate shaft)
P/N. YB-06016
90890-06626
21
3
54
76
98
A0
B
DC
E
YW-06551
90890-06551
YW-06550 90890-06550
YB-06117 90890-06521
YB-06151 90890-06519
90890-06501 90890-06535
90890-06536 90890-06538
90890-06652 YB-06112
YB-06196
90890-06614
90890-06653
YB-06156 90890-06634
YB-06071 90890-06606 YB-34474
YB-06552 YB-06016 90890-06626
90890-06552
F
YB-06096

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1
2
3
4
5
6
7
8
9
SPEC
CHAPTER 2
SPECIFICATIONS
GENERAL SPECIFICATIONS.......................................................................... 2-1
MAINTENANCE SPECIFICATIONS................................................................ 2-3
ENGINE..................................................................................................... 2-3
JET PUMP UNIT....................................................................................... 2-4
HULL AND HOOD .................................................................................... 2-4
ELECTRICAL ............................................................................................. 2-5
TIGHTENING TORQUES................................................................................ 2-7
SPECIFIED TORQUES.............................................................................. 2-7
GENERAL TORQUE ............................................................................... 2-10
CABLE AND HOSE ROUTING...................................................................... 2-11

2-1
SPEC EGENERAL SPECIFICATIONS
GENERAL SPECIFICATIONS
Item Unit
Model
GP800R
MODEL CODE
Hull F0W
Engine 68A
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) 268 (591)
Watercraft capacity 2
PERFORMANCE
Maximum output kW (PS) @ r/min 88.2 (120) @ 7,000
Maximum fuel consumption R/h (US gal/h,
lmp gal/h)
49 (12.9, 10.8)
Cruising range h 1.2
ENGINE
Engine type 2-stroke
Number of cylinders 2
Displacement cm3 (cu. in) 784 (47.8)
Bore × stroke mm (in) 80.0 × 78.0 (3.15 × 3.07)
Compression ratio 6.6:1
Intake system Reed valve
Carburetor model
(manufacturer) × quantity
BN44 (Mikuni) × 2
Enrichment control Choke valve
Scavenging system Loop charge
Lubrication system Oil injection
Cooling system Water
Starting system Electric
Ignition system Digital CDI
Ignition timing Degree 15 BTDC–20 BTDC
Spark plug model
(manufacturer)
BR8ES (NGK)
Battery capacity V/Ah (kC) 12/19 (68.4)
Lighting coil max. A @ r/min 8 @ 6,000
Propulsion system Jet pump
DRIVE UNIT
Jet pump type Axial flow, single stage
Impeller rotation (from rear) Counterclockwise
Transmission Direct drive from engine
Nozzle angle (horizontal) Degree 23 + 23
Nozzle angle (vertical) Degree –5, 0, 5, 10, 15
Trim system Manual 5 positions

2-2
SPEC E
PON*: Pump Octane Number = (Motor Octane Number + Research Octane Number)/2
RON*: Research Octane Number
FUEL AND OIL
Fuel Regular unleaded gasoline
Fuel rating PON* 86
RON* 90
Oil YAMALUBE 2-W or an equivalent TC-W3
certified outboard oil
Fuel/oil mixing ratio
(wide open throttle)
30:1
Fuel tank capacity R(US gal,
Imp gal)
60 (15.9, 13.2)
Fuel tank reserve capacity R(US gal,
Imp gal)
10 (2.6, 2.2)
Oil tank capacity R(US gal,
Imp gal)
5.5 (1.45, 1.21)
Item Unit
Model
GP800R
GENERAL SPECIFICATIONS

2-3
SPEC EMAINTENANCE SPECIFICATIONS
MAINTENANCE SPECIFICATIONS
ENGINE
Item Unit
Model
GP800R
CYLINDER HEAD
Warpage limit mm (in) 0.1 (0.004)
Compression pressure*1
kPa (kg/cm2) 560 (5.6)
CYLINDERS
Bore size mm (in) 80.000–80.018 (3.1496–3.1503)
Taper limit mm (in) 0.08 (0.003)
Out-of-round limit mm (in) 0.05 (0.002)
Wear limit mm (in) Original cylinder bore + 0.04 (0.0016)
PISTONS
Diameter mm (in) Red: 79.899–79.902 (3.1456–3.1457)
Orange: 79.903–79.906 (3.1458–3.1459)
Green: 79.907–79.910 (3.1459–3.1461)
Purple: 79.911–79.914 (3.1461–3.1462)
Measuring point* mm (in) 22 (0.87)
Piston-to-cylinder clearance mm (in) 0.100–0.105 (0.0039–0.0041)
Wear limit mm (in) Cylinder bore – 0.105 (0.0041)
Piston pin bore inside
diameter
mm (in) 22.004–22.025 (0.8663–0.8671)
PISTON RINGS
Top
Type Keystone
Dimensions (B) mm (in) 1.2 (0.05)
Dimensions (T) mm (in) 2.85 (0.112)
End gap mm (in) 0.30–0.45 (0.012–0.018)
Ring groove clearance mm (in) 0.03–0.05 (0.001–0.002)
2nd*2
Type Keystone
Dimensions (B) mm (in) 1.2 (0.05)
Dimensions (T) mm (in) 2.85 (0.112)
End gap mm (in) 0.30–0.45 (0.012–0.018)
Ring groove clearance mm (in) 0.03–0.05 (0.001–0.002)
PISTON PINS
Diameter mm (in) 21.995–22.000 (0.8659–0.8661)
Wear limit mm (in) 21.990 (0.8657)
*1: At 760 mmHg and 20 ˚C (68 ˚F)
*2: The top ring and 2nd ring are of the same type.

2-4
JET PUMP UNIT
HULL AND HOOD
CRANKSHAFT ASSEMBLY
Crank width A mm (in) 72.95–73.00 (2.872–2.874)
Deflection limit B mm (in) 0.05 (0.002)
Big end side clearance C mm (in) 0.25–0.75 (0.010–0.030)
Maximum small end axial
play D
mm (in) 2.0 (0.08)
CARBURETORS
Type Floatless
Identification mark #1: 68A-01, #2: 68A-02
Main nozzle mm (in) 3.0 (0.12)
Main jet 150
Pilot jet 90
Throttle valve 120
Valve seat size mm (in) 1.2 (0.05)
Trolling speed r/min 1,300 ± 50
REED VALVES
Thickness mm (in) 0.52 (0.020)
Reed valve stopper height mm (in) 10.8–11.4 (0.43–0.45)
Reed valve warpage limit mm (in) 0.2 (0.01)
Item Unit
Model
GP800R
JET PUMP
Impeller material Stainless steel
Number of impeller blades 3
Impeller pitch angle Degree 13.2
Impeller clearance mm (in) 0.35–0.45 (0.014–0.018)
Impeller clearance limit mm (in) 0.6 (0.024)
Drive shaft runout limit mm (in) 0.3 (0.012)
Nozzle diameter mm (in) 86.8 (3.42)
Item Unit
Model
GP800R
FREE PLAY
YPVS cable slack mm (in) 0.5–1.5 (0.02–0.06)
Throttle lever free play mm (in) 4–7 (0.16–0.28)
Item Unit
Model
GP800R

2-5
ELECTRICAL
Item Unit
Model
GP800R
BATTERY
Type Fluid
Capacity V/Ah (kC) 12/19 (68.4)
CDI UNIT (O – B)
Output peak voltage lower
limit
@cranking 1 V 85
@cranking 2 V 110
@2,000 r/min V 205
@3,500 r/min V 200
STATOR
Charge coil (Br – L)
Output peak voltage
lower limit
@cranking 1 V 90
@cranking 2 V 120
@2,000 r/min V 220
@3,500 r/min V 210
Pickup coil (W/R – W/B)
Output peak voltage
lower limit
@cranking 1 V 5
@cranking 2 V 3
@2,000 r/min V 7
@3,500 r/min V 11
Lighting coil (G – G)
Output peak voltage
lower limit
@cranking 1 V 8.5
@cranking 2 V 8.5
@2,000 r/min V 13
@3,500 r/min V 13
Charge coil resistance Ω (color) 299–365 (Br – L)
Pickup coil resistance Ω (color) 446–545 (W/R – W/B)
Lighting coil resistance Ω (color) 0.86–1.06 (G – G)
Minimum charging current A @ r/min 9 @ 6,000
IGNITION COIL
Minimum spark gap mm (in) 10 (0.39)
Primary coil resistance Ω (color) 0.078–0.106 (O – B)
Secondary coil resistance kΩ 14.3–30.5
(#1 Spark plug cap – #2 Spark plug cap)
Cranking 1: unloaded
Cranking 2: loaded

2-6
RECTIFIER/REGULATOR
(R – B)
Output peak voltage lower
limit (unloaded)
@cranking V 7.5
@2,000 r/min V 12.5
@3,500 r/min V 12.5
THERMO SWITCH
On temperature ˚C (˚F) 80 (177)
Off temperature ˚C (˚F) 70 (159)
STARTER MOTOR
Brush length mm (in) 12.5 (0.49)
Wear limit mm (in) 6.5 (0.26)
Commutator undercut mm (in) 0.7 (0.03)
Limit mm (in) 0.2 (0.01)
Commutator diameter mm (in) 28.0 (1.10)
Limit mm (in) 27.0 (1.06)
FUSE
Rating V/A 12/10
Item Unit
Model
GP800R

2-7
SPEC ETIGHTENING TORQUES
TIGHTENING TORQUES
SPECIFIED TORQUES
Part to tightened Part name
Thread
size
Q’ty
Tightening torque
Remarks
N•m kgf•m ft•lb
ENGINE UNIT
Engine unit – engine mount Bolt M8 4 17 1.7 12
572
LT
Exhaust chamber
assembly – muffler stay 1
– muffler stay 3
1st
Bolt M10 2
2 0.2 1.4
271
LT
4th 51 5.1 37
2nd
Bolt M10 4
2 0.2 1.4
6th 39 3.9 28
3rd
Nut M10 2
2 0.2 1.4
5th 51 5.1 37
7th
Bolt M10 1
2 0.2 1.4
9th 49 4.9 35
8th
Bolt M10 1
2 0.2 1.4
10th 49 4.9 35
Exhaust chamber –
muffler
1st
Nut M8 2
15 1.5 11
271
LT
2nd 39 3.9 28
1st
Bolt M8 3
15 1.5 11
2nd 33 3.3 24
1st
Nut M10 1
15 1.5 11
2nd 51 5.1 37
Exhaust chamber joint –
exhaust manifold
1st
Bolt M8 5
17 1.7 12
271
LT
2nd 34 3.4 24
Exhaust chamber joint –
muffler stay
1st
Bolt M10 1
2 0.2 1.4
271
LT
3rd 49 4.9 35
2nd
Bolt M8 2
2 0.2 1.4
271
LT
4th 37 3.7 27
Exhaust manifold –
cylinder
1st
Bolt M10 8
23 2.3 17 271
LT
2nd 51 5.1 37
Reed valve – reed valve seat Screw M3 16 0.8 0.08 0.58
242
LT
YPVS cable bracket – YPVS cover
– cylinder
Bolt M6 2 10 1.0 7.2
572
LT
YPVS cover – cylinder Bolt M6 6 10 1.0 7.2
572
LT
YPVS valve assembly – cylinder Bolt M5 2 4 0.4 2.9
271
LT
YPVS valve lever – shaft Bolt M4 2 3 0.3 2.2
242
LT
Spark plug – cylinder head Spark plug M14 2 25 2.5 18
Cylinder head – cylinder
1st
Bolt M8 10
15 1.5 11
572
LT
2nd 37 3.7 27
Cylinder – crankcase
1st
Bolt M10 8
22 2.2 16
572
LT
2nd 39 3.9 28
Starter motor lead – starter
motor
Nut M6 1 5 0.5 3.6
Flywheel magneto – crankshaft
assembly
Bolt M10 1 74 7.4 53
E

2-8
Drive coupling – crankshaft
assembly
Drive
coupling
M27 1 36 3.6 25
572
LT
Generator cover –
crankcase
1st
Bolt M8 8
15 1.5 11
271
LT
2nd 27 2.7 19
Pickup coil – generator cover Bolt M5 2 5 0.5 3.6
242
LT
Cable holder – generator cover Bolt M6 2 14 1.4 10
242
LT
Stator coil – generator cover Bolt M6 3 14 1.4 10
242
LT
Lower crankcase – upper
crankcase
1st
Bolt
M8 13
15 1.5 11
572
LT
2nd 27 2.7 19
M6 7 11 1.1 8.0
Mount bracket –
crankcase
1st
Bolt M8 6
15 1.5 11
271
LT
2nd 27 2.7 19
JET PUMP UNIT
Steering cable joint – nozzle
deflector
Nut M6 1 7 0.7 5.1
242
LT
Ride plate – hull Bolt M8 4 17 1.7 12
572
LT
Intake duct – hull Bolt M8 4 17 1.7 12
572
LT
Intake grate – hull Bolt M6 4 7 0.7 5.1
572
LT
Speed sensor – ride plate Screw M5 4 4 0.4 2.9
242
LT
Nozzle ring – nozzle Bolt M8 2 15 1.5 11
271
LT
Nozzle deflector – nozzle ring Bolt M8 2 15 1.5 11
271
LT
Water inlet cover – water inlet
strainer – impeller duct
Bolt M6 4 7 0.7 5.1
572
LT
Drive shaft nut – drive shaft Nut M16 1 74 7.4 53
Impeller (left-hand threads) –
drive shaft
Impeller M22 1 18 1.8 13
572
LT
Transom plate – hull Nut M10 4 26 2.6 19
Bilge strainer holder – bulkhead Screw M5 1 4 0.4 2.9
Intermediate housing – bulkhead Bolt M8 3 17 1.7 12
572
LT
Driven coupling – shaft
Driven
coupling
M27 1 36 3.6 25
572
LT
Grease nipple – intermediate
housing
Nipple — 1 5 0.5 3.6
572
LT
HULL AND HOOD
Handlebar cover – handlebar
cover stay
Screw M6 4 1.1 0.11 0.8
Handlebar cover stay – steering
column
Screw M6 4 2.9 0.29 2.1
Upper handlebar holder/lower
handle holder – steering column
Bolt M8 4 16 1.6 11
QSTS converter – hull Nut M6 2 5 0.5 3.6
QSTS cable 1, 2 locknut Nut M8 2 16 1.6 11
Throttle lever assembly –
handlebar
Screw M5 2 3 0.3 2.2
Thread
size
Q’ty
Tightening torque
Remarks

2-9
Handlebar switch assembly –
handlebar
Screw M5 2 3 0.3 2.2
QSTS grip assembly – handlebar Screw M6 1 3 0.3 2.2
Grip end – handlebar Bolt M5 2 1 0.1 0.7
Choke lever assembly –
handlebar
Screw M5 2 3 0.3 2.2
QSTS cable housing – cover Screw M4 1 1 0.1 0.7
Plate/steering column assembly
– deck
Nut M8 2 16 1.6 11
Steering column assembly – deck Nut M8 2 16 1.6 11
Steering arm – steering column Nut M8 1 16 1.6 11
Steering cable ball joint –
steering arm
Nut M6 1 5 0.5 3.6
Handlebar stopper – steering
column housing
Nut M10 1 26 2.6 19
QSTS cable locknut
(nozzle ring side)
Nut M5 1 3 0.3 2.2
QSTS cable – hull Nut — 1 6 0.6 4.3
QSTS cable end – pin – QSTS
converter
Nut M6 1 4 0.4 2.9
Steering cable locknut
(nozzle deflector side)
Nut M6 1 6 0.6 4.3
Steering cable – hull Nut — 1 6 0.6 4.3
Steering cable holder – bracket Bolt M6 1 6 0.6 4.3
Speed sensor lead – hull Nut — 1 6 0.6 4.3
Hinge assembly – front hood Bolt M6 2 12 1.2 8.7
Wind shield – front hood Screw M5 8 1 0.1 0.7
Hood lock – front hood Bolt M6 2 5 0.5 3.6
Hinge assembly – deck Nut M8 2 16 1.6 11
Steering console cover assembly
– deck
Nut M6 2 5 0.5 3.6
Bolt M6 4 3 0.3 2.2
Screw M5 2 2 0.2 1.4
Nut M8 2 16 1.6 11
Multifunction meter – holder Nut M5 2 2 0.2 1.4
Steering console cover – side
cover
Screw M6 4 3 0.3 2.2
Steering console cover – glove
compartment
Screw M5 4 1 0.1 0.7
Steering cable bracket – deck Bolt M6 1 6 0.6 4.3
Buzzer bracket – deck – steering
cable bracket
Bolt M6 2 6 0.6 4.3
Hood lock assembly – deck Nut M6 2 6 0.6 4.3
Seat lock assembly – seat Bolt M6 2 6 0.6 4.3
572
LT
Bracket/deck – notch Nut M10 1 26 2.6 19
Bracket/deck – hand grip Bolt M8 2 5 0.5 3.6
Thread
size
Q’ty
Tightening torque
Remarks

2-10
Hand grip – deck Nut M8 2 5 0.5 3.6
Seat bracket – deck Nut M8 2 15 1.5 11
Battery box/stay – holder Nut M6 2 9 0.9 6.5
Battery box – bracket/deck Nut M8 2 13 1.3 9.4
Battery box – electrical box Bolt M8 3 15 1.5 11
Extension bolt – battery negative
terminal
Bolt M6 1 6 0.6 4.3
Exhaust outlet – hull Bolt M6 3 6 0.6 4.3
Sponson – hull Bolt M8 6 18 1.8 13
Spout – hull Nut M24 1 5 0.5 3.6
Rope hole – hull Nut M24 2 5 0.5 3.6
Bow eye – hull Bolt M6 2 13 1.3 9.4
Flap – hull Bolt M6 8 6 0.6 4.3
Drain plug/packing – hull Nut M5 4 2 0.2 1.4
Engine mount – hull Bolt M8 8 17 1.7 12
572
LT
Engine damper – hull Bolt M6 2 6 0.6 4.3
Thread
size
Q’ty
Tightening torque
Remarks
GENERAL TORQUE
This chart specifies tightening torques for
standard fasteners with a standard ISO
thread pitch. Tightening torque specifica-
tions for special components or assemblies
are provided in applicable sections of this
manual. To avoid warpage, tighten multi-
fastener assemblies in a crisscross fashion
and progressive stages until the specified
tightening torque is reached. Unless other-
wise specified, tightening torque specifica-
tions require clean, dry threads.
Components should be at room tempera-
ture.
Nut A Bolt B
General torque
specifications
8 mm M5 5.0 0.5 3.6
10 mm M6 8.0 0.8 5.8
12 mm M8 18 1.8 13
14 mm M10 36 3.6 25
17 mm M12 43 4.3 31

2-11
SPEC ECABLE AND HOSE ROUTING
CABLE AND HOSE ROUTING
20˚
5
6
7
G-G
4
H-H
8
F-F
D-D
E-E
A
C
B12
2
2 2
3
2
4
K-K
9
B
0
L
I-I
9
0
J-J
A
9
9
0
A
B
L
C
K
K K
J J
E
E
K
D D
F
E
E
F
I I H H
J J
G G
C
D
E
F
K
G
H
I
J
A
F
1 Fuel filter
2 Fuel tank breather hose
3 Fuel hose
4 Cooling water hose
5 Choke cable
6 Throttle cable
7 Oil return hose
8 Bilge hose
9 Speed sensor lead
0 Electrical box lead
A YPVS cables
B Cooling water pilot outlet
C Battery negative lead
D Battery
E Steering cable
F QSTS cable
G Battery breather hose
H Battery positive lead
I Starter motor lead
J Generator lead
K YPVS servomotor

2-12
SPEC ECABLE AND HOSE ROUTING
A
A
B
C
F
I
J
J
B C
D E
J-J
G-G
48
H-HI F
9F
F
G
A
A
E
E
0
1
2 3
EE
BCD 7
6 5
4
G G
H H
H
K
I
J2
5
L
M
4GE FA 7
D
D
1 Oil delivery hose
2 Fuel return hose
3 Fuel suction hose
4 Speed sensor lead
5 QSTS cable
6 Cooling water hose
7 Steering cable
8 Flushing hose
9 Bilge hoses
0 To multifunction meter
A To stator assembly
B To cylinder #1
C To cylinder #2
D To battery positive terminal
E To starter motor positive
terminal
F To thermoswitch
G Battery negative lead
H Buzzer lead
I Choke cable
J YPVS servomotor
K YPVS cables
L Battery positive lead
M Battery breather hose

2003 Yamaha GP800R Waverunner Service Repair Manual

E
1
2
3
4
5
6
7
8
9
INSP
ADJ
CHAPTER 3
PERIODIC INSPECTION AND ADJUSTMENT
MAINTENANCE INTERVAL CHART.............................................................. 3-1
PERIODIC SERVICE ........................................................................................ 3-2
CONTROL SYSTEM ................................................................................. 3-2
Steering column inspection ............................................................. 3-2
Steering cable inspection and adjustment ..................................... 3-2
Throttle cable inspection and adjustment ...................................... 3-3
Choke cable inspection and adjustment ......................................... 3-4
QSTS cable inspection and adjustment.......................................... 3-5
YPVS cable adjustment .................................................................... 3-6
FUEL SYSTEM.......................................................................................... 3-7
Fuel line inspection........................................................................... 3-7
Trolling speed check and adjustment ............................................. 3-8
OIL INJECTION SYSTEM......................................................................... 3-9
Oil line inspection ............................................................................. 3-9
POWER UNIT............................................................................................ 3-9
Spark plug inspection....................................................................... 3-9
ELECTRICAL ........................................................................................... 3-10
Battery inspection ........................................................................... 3-10
JET PUMP UNIT..................................................................................... 3-13
Impeller inspection ......................................................................... 3-13
Water inlet strainer inspection....................................................... 3-14
Bilge strainer inspection................................................................. 3-14
GENERAL................................................................................................ 3-14
Drain plug inspection...................................................................... 3-14
Lubrication points ........................................................................... 3-15

3-1
INSP
ADJ EMAINTENANCE INTERVAL CHART
MAINTENANCE INTERVAL CHART
The following chart should be considered strictly as a guide to general maintenance intervals.
Depending on operating conditions, the intervals of maintenance should be changed.
*1: After every ride
*2: Inspect fluid level before every ride
*3: Grease capacity 33.0–35.0 cm3 (1.11–1.18 oz)
*4: Grease capacity 6.0–8.0 cm3 (0.20–0.27 oz)
Item Remarks
Initial Every
Refer to
page10 hours
(Break-in)
50 hours
(3 months)
100 hours
(6 months)
200 hours
(1 year)
CONTROL SYSTEM
Steering cable Inspect/adjust 3-2
Steering column Inspect 3-2
Throttle cable Inspect/adjust 3-3
Carburetor throttle shaft Inspect/adjust —
Choke cable Inspect/adjust 3-4
QSTS cable Inspect/adjust 3-5
YPVS cable Inspect/adjust 3-6
FUEL SYSTEM
Fuel tank Clean 4-9
Fuel filter Clean/replace 3-7
Fuel line Inspect 3-7
Trolling speed Check/adjust 3-8
Carburetor setting Inspect/adjust 4-18
OIL INJECTION SYSTEM
Oil injection system Check/clean 3-9
Oil pump cable Inspect/adjust 4-30
POWER UNIT
Spark plugs Inspect/clean/adjust 3-9
Cooling water passage Inspect/clean *1 —
Rubber coupling Inspect —
ELECTRICAL
Battery Inspect *2 3-10
JET PUMP UNIT
Impeller Inspect 3-13
Water inlet strainer Clean 3-14
Bilge strainer Clean 3-14
GENERAL
Bolts and nuts Retighten —
Drain plugs Inspect/replace 3-14
Lubrication points Grease 3-15
Intermediate housing Grease *3 *4 3-17

3-2
INSP
ADJ ECONTROL SYSTEM
PERIODIC SERVICE
CONTROL SYSTEM
Steering column inspection
1. Inspect:
q Steering column
Excessive play → Replace the steer-
ing column.
Refer to “STEERING COLUMN” in
chapter 8.
Steering cable inspection and adjustment
1. Inspect:
q Distance a, b (between the nozzle
and nozzle deflector)
Out of specification → Adjust.
2. Adjust:
q Steering cable joint
(steering column side)
Inspection steps:
q Move the handlebar up and down and
back and forth.
q Check the excessive play of the han-
dlebar.
Inspection steps:
q Set the control grip in the neutral posi-
tion.
q Turn the handlebar from lock to lock.
q Measure distances a and b.
q If the difference is not within specifica-
tion, adjust the cable joint.
Difference of distances a and b:
Maximum 5 mm (0.2 in)
Adjustment steps:
q Loosen the locknut 1.
q Disconnect the steering cable joint 2
from the ball joint 3.
q Turn the cable joint in or out for adjust-
ing the distances a and b.
Turn in Distance a is increased.
Turn out Distance b is increased.
1
2
3

3-3
INSP
ADJ ECONTROL SYSTEM
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. Refer to
“REMOTE CONTROL CABLES AND SPEED
SENSOR LEAD” in chapter 8.
Throttle cable inspection and adjustment
NOTE:
Before adjusting the throttle lever free play,
adjust the trolling speed.
1. Measure:
q Throttle lever free play a
2. Adjust:
q Throttle lever free play
WARNING
The cable joint must be screwed in more
than 8 mm (0.31 in).
q Connect the cable joint and tighten the
locknut.
T
R
.
.
Locknut:
6 N • m (0.6 kgf • m, 4.3 ft • lb)
Throttle lever free play:
4–7 mm (0.16–0.28 in)
Adjustment steps:
q Turn the adjuster 2 in or out until the
specified free play is obtained.
Turn in Free play is increased.
Turn out Free play is decreased.
q Tighten the locknut.

3-4
INSP
ADJ ECONTROL SYSTEM
WARNING
After adjusting the free play, turn the han-
dlebar to the right and left and make sure
that the trolling speed does not increase.
Choke cable inspection and adjustment
1. Check:
q Choke lever operation
Incorrect operation → Adjust.
2. Adjust:
q Choke lever operation
Checking steps:
q Check that the choke lever moves back
slightly when it is fully opened.
q Check that the inner cable has some
slack when the choke lever is com-
pletely closed.
Adjustment steps:
q Screw the adjuster 2 fully into the
bracket.
q Align the choke lever end a within the
line marks b.
q Turn out the adjuster 2 until the inner
cable is taut.
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.
q Tighten the locknut 1.

3-5
INSP
ADJ ECONTROL SYSTEM
QSTS cable inspection and adjustment
1. Measure:
q Nozzle deflector set length a, b
Difference → Adjust.
Measurement steps:
tion.
q Measure the nozzle deflector set
length a and b.
q If a and b length are not even, adjust
the cable joint.
2. Adjust:
q QSTS cable
Adjustment steps:
tion.
q Remove the nut 2 and pivot pin 3.
q Set the nozzle deflector in the center
position.
q Turn the cable joint 4 for adjusting.
Turn in Length b is increased.
Turn out Length a is increased.
WARNING
The cable joint must be screwed in more
than 8 mm (0.31 in).
q Connect the cable joint 4 and pivot
pin 3 and tighten the nut 2.
T
R
.
.
Nut:
4 N • m (0.4 kgf • m, 2.9 ft • lb)
q Tighten the locknut 1.
T
R
.
.
Locknut:
4 N • m (0.4 kgf • m, 2.9 ft • lb)

3-6
INSP
ADJ ECONTROL SYSTEM
NOTE:
If the QSTS cable cannot be properly
adjusted at the QSTS converter side, make
sure the QSTS cable at the jet pump side is
set to the specified length.
Refer to “REMOTE CONTROL CABLES AND
SPEED SENSOR LEAD” in chapter 8.
YPVS cable adjustment
1. Check:
q YPVS valve position
Incorrect position → Adjust the YPVS
cable.
Checking steps:
q Start the engine and then stop it.
NOTE:
When the engine has been stopped for 3
seconds, the YPVS valve assembly will
retract and extend one time.
q Check that the hole a in the pulley is
aligned with the hole in the cylinder
when the YPVS valve is fully closed.
2. Measure:
q YPVS cable slack a
YPVS cable slack:
0.5–1.5 mm (0.02–0.06 in)

3-7
INSP
ADJ ECONTROL SYSTEM/FUEL SYSTEM
3. Adjust:
q YPVS cables 1 and 2
FUEL SYSTEM
WARNING
q Stop the engine, set the fuel cock to
“OFF” before servicing the fuel system.
q When removing fuel system parts, wrap
them in a cloth and take care that no fuel
spills into the engine compartment.
Fuel line inspection
1. Inspect:
q Fuel filter 1
Contaminants → Replace.
Cracks/damage → Replace.
Water contamination → Replace and
check the fuel tank.
q Fuel hoses
q Fuel tank
q Fuel hoses through part
q Fuel filler cap
Cracks/damage → Replace.
Adjustment steps:
q Loosen locknuts 1 and 2.
q Turn in adjusters 3 and 4 until there
is slack in the cables.
q Align the hole a in the pulley with the
hole in the cylinder.
q Insert a 4-mm-diameter pin through
the holes in the pulley and cylinder.
q Turn adjusters 3 and 4 in or out until
the specified slack is obtained.
Turn in Slack is increased.
Turn out Slack is decreased.
q Finger tighten locknuts 1 and 2.
q Remove the pin.
q Start and stop the engine.
q Recheck the hole alignment.
q If the hole alignment is correctly,
tighten the locknuts.
q If the hole alignment is incorrect,
repeat the above steps.
4 1
3 2

3-8
INSP
ADJ EFUEL SYSTEM
2. Inspect:
q Water separator 1
Water accumulation → Drain.
NOTE:
If need the water draining, remove the drain
plug 2.
Trolling speed check and adjustment
1. Check:
q Trolling speed
Trolling speed:
1,300 ± 50 r/min
Checking steps (with the watercraft in
the water):
q Start the engine and allow it to warm
up for several minutes.
q Attach the engine tachometer to the
spark plug lead.
Engine tachometer:
YU-8036-A/90890-06760
q Measure the engine trolling speed.
2. Adjust:
q Trolling speed
Adjustment steps:
q Start the engine and allow it to warm
up for several minutes.
q Attach the engine tachometer to the
spark plug lead.
Engine tachometer:
YU-8036-A/90890-06760
q Turn the throttle stop screw 1 in or
out until the specified trolling speed is
obtain.
1

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2003 Yamaha GP800R Waverunner Service Repair Manual