Yamaha WaveRunner GP1200R User manual

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

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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

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PREFACE
This Assembly Manual contains the infor-
mation needed to assemble the Yamaha
water vehicle correctly prior to delivery to
the customer. Since some external parts of
the water vehicle have not been assemblied
at the Yamaha factory for convenience of
packing, assembly by the Yamaha dealer is
required. It should be noted that the reas-
sembled water vehicle should be thor-
oughly cleaned, inspected, and adjusted
prior to delivery to the customer.
NOTICE
Because Yamaha constantly strives for
product improvement, the service specifica-
tions may be subject to change in the
future. If any change is introduced into the
specifications or assembly procedures,
Yamaha dealers will be notified by a techni-
cal bulletin.
IMPORTANT MANUAL INFORMATION:
Particularly important information is distin-
guished in this manual by the following
notations.
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, a bystander, or a person
inspecting or repairing the water vehicle.
CAUTION:
A CAUTION indicates special precautions
that must be taken to avoid damage to the
water vehicle.
NOTE:
A NOTE provides key information to make
procedures easier or cleaner.
SYMBOLS USED IN THIS
ASSEMBLY MANUAL
In order to simplify descriptions in assem-
bly manuals, the following symbols are
used:
:Coat with water resistant grease.
(Yamaha grease A, Yamaha marine
grease)
:Tightening torque.
:Provide clearance.
:Install so that the arrow mark faces
upward.
:Frontword of the water vehicle.
:Made of rubber or plastics.
:Tighten temporarily.
:Apply locking agent.
LOCTITE

‚ No.242 (BLUE LOCTITE)
Size:
d/D : Diameter of part.
R : Length of part.

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GENERAL TORQUE SPECIFICATIONS
This chart specifies the torques for tighten-
ing standard fasteners with standard clean
dry ISO threads at room temperature.
Torque specifications for special compo-
nents or assemblies are given in applicable
sections of this manual. To avoid causing
warpage, tighten multi-fastener assemblies
in a criss-cross fashion, in progressive
stages until the specified torque is reached.
Nut ABolt B
General torque
specifications
Nm kgf•m lb•ft
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

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UNPACKING AND CHECKING
Carefully uncrate unit and inventory any missing or damaged parts.
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.
COMPARTMENT DIAGRAM
COMPARTMENT PART CHART
No. Part name Q’ty Remarks
1 Water vehicle body 1
2 Carton box 1

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COMPARTMENT DIAGRAM
COMPARTMENT PART CHART
No. Part name Q’ty Part number
1 Grommet 1 F0X-61469-00
2 Lower handlebar holder 2 EU0-23814-01
3 Handlebar assembly 1 F0X-U155A-00
4 Upper handlebar holder 2 EU0-23814-30
5 Bolt 8 × 55 mm (0.31 × 2.17 in) 4 90119-089UM
6 Band 1 90464-32801
7 Spiral tube 1 90448-25800
8 Handlebar cover stay 1 GP7-U142K-00
9 Screw 6 × 15 mm (0.24 × 0.59 in) 4 90159-069U1
10 Handlebar cover 1 GP7-U142A-11
11 Screw 6 × 19 mm (0.24 × 0.75 in) 4 90149-069U9
12 Band 1 90601-200U2
13 Flashing conduction fitting 1 67X-12590-00
14 Tool kit 1 EU0-65986-00
15 Vinyl bag 1 EU0-65901-01
16 Spark plug 3 94702-00396
17 Owner’s/Operator’s manual 1 F0X-F8199-10
18 Riding practice tips 1 F0X-F819T-10
19 Riding instruction card 1 FN8-U595B-02
20 Basic orientation video 1 F0D-U595A-00

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WIRE LEAD AND CABLE ROUTING
EXPLODED DIAGRAM
INSTALLATION CHART
Step Procedure/Part name Q’ty Service points
WIRE LEAD AND CABLE
ROUTING
Follow “Step” order for installation.
NOTE:
Working from the bow side, open the front
hood, and then remove the storage com-
partment.
1 Choke cable 1
2 Throttle cable 1
3 Handlebar switch lead 1
4 Grommet 1 NOTE:
Apply soapy water to the grommet for eas-
ier installation.
5 QSTS cable 2

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HANDLEBAR AND THROTTLE CABLE INSTALLATION
EXPLODED DIAGRAM
INSTALLATION CHART
Step Procedure/Part name Q’ty Service points
HANDLEBAR AND THROTTLE
CABLE INSTALLATION
Follow “Step” order for installation.
1 Lower handlebar holder 2
2 Handlebar assembly 1
3 Upper handlebar holder 2 NOTE:
●
Align the punched marks a on the handle-
bar with the top surface of the lower han-
dlebar holders.
●
The upper handlebar holder should be
installed with the punched mark b forward.
4 Bolt (with washer)
8 × 55 mm (0.31 × 2.17 in)
4NOTE:
Tighten the bolts so that the front clearance
c of the upper handlebar holder is smaller
than the rear clearance d .

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EXPLODED DIAGRAM
Step Procedure/Part name Q’ty Service points
5 Band 1
6 Throttle cable 1 Installation steps:
●Install the throttle cable end into the
throttle lever.
●Fit the seal into the groove in the
bracket.
●Turn the adjuster 1in/out until the
specified free play is obtained.
Throttle lever free play e:
4 ~ 7 mm (0.16 ~ 0.28 in)
Turn in Free play is increased.
Turn out Free play is decreased.
●Tighten the locknut 2.

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CHOKE CABLE INSTALLATION
EXPLODED DIAGRAM
INSTALLATION CHART
Step Procedure/Part name Q’ty Service points
CHOKE CABLE INSTALLATION
1 Choke cable 1 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.
●Install the choke cable and screw the
adjuster 1fully into the bracket.
●Align the choke lever end awithin the
line marks b.
●Turn out the adjuster 1until the inner
cable is taut.

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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
ais positioned within the line marks b.
Reset the adjuster if necessary.
●Make sure that the choke lever moves
back slightly when it is fully opened.

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EXPLODED DIAGRAM
Step Procedure/Part name Q’ty Service points
2 Spiral tube 1 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.
●Make sure that the inner cable has
some slack when the choke lever is
completely closed.
●Tighten the locknut 2to secure the
choke cable.

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HANDLEBAR COVER INSTALLATION
EXPLODED DIAGRAM
INSTALLATION CHART
Step Procedure/Part name Q’ty Service points
HANDLEBAR COVER
INSTALLATION
Follow “Step” order for installation.
1 Handlebar cover stay 1
2 Screw
6 × 15 mm (0.24 × 0.59 in)
4
3 Handlebar cover 1
4 Screw
6 × 19 mm (0.24 × 0.75 in)
4NOTE:
If the handlebar cover is in contact with the
steering console cover, adjust the handlebar
mount angle so that the clearance a and b
are equal.

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WIRING CONNECTION INSTALLATION
EXPLODED DIAGRAM
INSTALLATION CHART
Step Procedure/Part name Q’ty Service points
WIRING CONNECTION
INSTALLATION
Follow “Step” order for installation.
1 Handlebar switch coupler 3Black coupler (2 pins), natural coupler (2 pins),
white coupler (1 pin)
2 Band 1

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QSTS CABLE INSTALLATION
EXPLODED DIAGRAM
INSTALLATION CHART
Step Procedure/Part name Q’ty Service points
QSTS CABLE INSTALLATION Follow “Step” order for installation.
1 QSTS cable 1 1 NOTE:
●
Set the inner cables length a to 77 mm
(3.03 in), using the adjusting nuts 1 when
the control grip is in neutral before install-
ing the QSTS cables.
●
Tighten the locknuts 2 to secure the QSTS
cables.
●
QSTS cable 2 is marked with white tape
b .
2 QSTS cable 2 1

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BATTERY INSTALLATION
EXPLODED DIAGRAM
INSTALLATION CHART
Step Procedure/Part name Q’ty Service points
BATTERY INSTALLATION Follow “Step” order for installation.
1 Battery breather hose 1 NOTE:
●Remove the fire extinguisher container for
easier removing and installing the battery.
●Charge the battery before installing it.
Refer to “PREDELIVERY CHECK”.
CAUTION:
Make sure that the battery breather hose is
not pinched.
2 Battery 1
3 Battery positive lead (red) 1
4 Bolt 6 ×12 mm (0.24 ×0.47 in) 1
5 Battery negative lead (black) 1
6 Bolt 6 ×12 mm (0.24 ×0.47 in) 1
7 Band 1

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PREDELIVERY CHECK
CHECKING CHART
Check elements Checking points Reference page
Throttle lever Free play 5
Battery Battery condition 13
Oil pump Air bleed 15
Trolling speed Trolling speed 16
Steering system Handlebar and steering nozzle positions 17
QSTS Trim nozzle position 18
BATTERY
WARNING
●Battery electrolyte is poisonous and dan-
gerous, causing severe burns, etc. Con-
tains sulfuric acid.
●Avoid contact with skin, eyes or clothing.
●Antidote: EXTERNAL-Flush with water.
●INTERNAL-Drink large quantities of water
or milk. Follow with milk of magnesia,
beaten egg or vegetable oil. Call a physi-
cian immediately. Eyes: Flush with water
for 15 minutes and get prompt medical
attention. Batteries produce explosive
gases. Keep sparks, flame, cigarettes,
etc., away. Ventilate when charging or
using in an enclosed space. Always shield
your eyes when working near batteries.
●KEEP OUT OF REACH OF CHILDREN.
CAUTION:
Be careful not to place the battery on its
side. Before adding the battery fluid or
recharging, be sure to bring it out of the
battery compartment. When checking the
battery, make sure the breather hose is
connected to the battery and is not pinched
shut anywhere in the battery compart-
ment.

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1. Fill:
●Battery electrolyte
2. Inspect:
●Battery fluid specific gravity
Out of specification →Charge.
3. Install:
●Filler caps
CAUTION:
Rinse off any electrolyte from the battery
case and wipe the battery dry prior to
installation.
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.
Specific gravity at 20˚C (68˚F):
1.28
Charging current:
68.4 kC (1.9 Amps ×10 Hrs)

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OIL PUMP AIR BLEEDING
1. Bleed:
●Air
CAUTION:
●Do not run the engine if oil does not flow
out the air bleed screw. Inspect the oil
lines for proper routing and make sure
there are no restrictions in the line.
●Fill the fuel tank with 50:1 premixed fuel
using the recommended engine oil during
the first full tank of operation.
●Use only YAMALUBE 2-W oil. Using
another oil can seriously damage the cat-
alytic converter and other engine compo-
nents.
Air bleeding steps:
●Place rags around the air bleed screw
1to 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 1two full
turns and make sure that both the oil
and air bubbles flow out.
●When there are no air bubbles left,
tighten the air bleed screw.
●Wipe up any spilt oil.
T
R
.
.
Air bleed screw:
3 Nm (0.3 kgf • m, 2.2 lb • ft)

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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.
Engine tachometer:
YU-8036-A/90890-06760
●Measure the engine trolling speed.
2. Adjust:
●Trolling speed
Adjustment steps:
●Start the engine.
●Turn the remote throttle stop screw 1
in or out until the specified speed is
obtained.
Turn in Increase trolling speed.
Turn out Decrease trolling speed.