Yamaha WaveRunner GP1300R Manual

SUPPLEMENTARY
SERVICE MANUAL
GP1300R
WaveRunner
F1G-28197-1G-1XLIT-18616-02-90
*LIT186160290*

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NOTICE
This Supplementary Service Manual has been prepared to introduce new service and new data
information for the GP1300R which are based on the 2003 GP1300R. For complete information on
service procedures, it is necessary to use this Supplementary Service Manual together with the fol-
lowing manual.
GP1300R SERVICE MANUAL: F1G-28197-1F-11 (LIT-18616-02-44)
A10001-0*
WaveRunner GP1300R
SUPPLEMENTARY SERVICE MANUAL
©2004 by Yamaha Motor Corporation, USA
1st Edition, October 2004
All rights reserved.
Any reprinting or unauthorized use
without the written permission of
Yamaha Motor Corporation, USA
is expressly prohibited.
Printed in USA
LIT-18616-02-90

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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.

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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.

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HOW TO USE THIS MANUAL
1To help identify parts and clarify procedure steps, there are exploded diagrams at the start of
each removal and disassembly section.
2Numbers are given in the order of the jobs in the exploded diagram.
3Symbols indicate parts to be lubricated or replaced (see “SYMBOLS”).
4A job instruction chart accompanies the exploded diagram, providing the order of jobs, names of
parts, notes in jobs, etc.
5Dimension 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)
6Jobs requiring more information (such as special service tools and technical data) are described
sequentially.
10 ×25 mm
D
L

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A50001-1-4
SYMBOLS
Symbols 1to 9are designed to indicate the
content of a chapter.
1General Information
2Specifications
3Periodic Inspection and Adjustment
4Fuel System
5Power Unit
6Jet Pump Unit
7Electrical System
8Hull and Hood
9Trouble Analysis
Symbols 0to Eindicate specific data.
0Special service tool
ASpecified oil or fluid
BSpecified engine speed
CSpecified tightening torque
DSpecified measurement
ESpecified electrical value
(resistance, voltage, electric current)
Symbols Fto Hin an exploded diagram indi-
cate the grade of lubricant and the lubrication
point.
FApply Yamaha 2-stroke motor oil
GApply water resistant grease
(Yamaha grease A, Yamaha marine grease)
HApply molybdenum disulfide grease
Symbols Ito Nin an exploded diagram indi-
cate the type of sealant or locking agent and
the application point.
IApply Gasket Maker
JApply Yamabond No. 4
KApply LOCTITE 271 (red)
LApply LOCTITE 242 (blue)
MApply LOCTITE 572
NApply silicone sealant
NOTE:
Additional symbols may be used in this man-
ual.
12
34
56
78
90
AB
CD
EF
GH
IJ
KL
MN
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

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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

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GENERAL INFORMATION
IDENTIFICATION NUMBERS ............................................................................ 1
PRIMARY l.D. NUMBER .............................................................................. 1
ENGINE SERIAL NUMBER ......................................................................... 1
JET PUMP UNIT SERIAL NUMBER ............................................................ 1
HULL IDENTIFICATION NUMBER (H.l.N.).................................................. 1
SPECIAL SERVICE TOOLS .............................................................................. 2
REMOVAL AND INSTALLATION................................................................. 3
SPECIFICATIONS
GENERAL SPECIFICATIONS .......................................................................... 4
MAINTENANCE SPECIFICATIONS .................................................................. 6
ENGINE ....................................................................................................... 6
JET PUMP UNIT ......................................................................................... 7
HULL AND HOOD ....................................................................................... 8
ELECTRICAL ............................................................................................... 8
TIGHTENING TORQUES ................................................................................. 11
SPECIFIED TORQUES.............................................................................. 11
GENERAL TORQUE .................................................................................. 16
CABLE AND HOSE ROUTING ........................................................................ 17
PERIODIC INSPECTION AND ADJUSTMENT
MAINTENANCE INTERVAL CHART ............................................................... 26

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JET PUMP UNIT
IMPELLER DUCT AND IMPELLER HOUSING 1 ............................................ 27
EXPLODED DIAGRAM .............................................................................. 27
REMOVAL AND INSTALLATION CHART ................................................. 27
IMPELLER DUCT AND DRIVE SHAFT ........................................................... 29
EXPLODED DIAGRAM .............................................................................. 29
REMOVAL AND INSTALLATION CHART ................................................. 29
SERVICE POINTS ..................................................................................... 31
Drive shaft removal .............................................................................. 31
Impeller inspection ............................................................................... 33
Drive shaft inspection........................................................................... 33
Drive shaft installation.......................................................................... 33
ELECTRICAL SYSTEM
ELECTRICAL COMPONENTS......................................................................... 36
IGNITION SYSTEM .......................................................................................... 37
WIRING DIAGRAM .................................................................................... 37
SENSOR ASSEMBLY ................................................................................ 39
SLANT DETECTION SWITCH ................................................................... 39
OFF THROTTLE STEERING SYSTEM............................................................ 40
WIRING DIAGRAM .................................................................................... 40
STEERING SENSOR ................................................................................. 41
HULL AND HOOD
STEERING COLUMN....................................................................................... 42
EXPLODED DIAGRAM .............................................................................. 42
REMOVAL AND INSTALLATION CHART ................................................. 42
SERVICE POINTS ..................................................................................... 46
Steering column assembly................................................................... 46
EXHAUST SYSTEM ......................................................................................... 47
SERVICE POINTS ..................................................................................... 47
Exhaust component parts assembly .................................................... 47

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TROUBLE ANALYSIS
TROUBLE ANALYSIS...................................................................................... 48
SELF-DIAGNOSIS ..................................................................................... 48
WIRING DIAGRAM

1
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GEN
INFO IDENTIFICATION NUMBERS
A60700-0*
IDENTIFICATION NUMBERS
PRIMARY l.D. NUMBER
The primary l.D. number is stamped on a label
1attached inside the engine compartment.
Starting primary l.D. number:
F1G: 809601
1
ENGINE SERIAL NUMBER
The engine serial number is stamped on a
label 1attached to the engine unit.
Starting serial number:
60T: 1009801
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 1attached to
the hull on the aft, starboard (right) side.

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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-.”
1
2
3
4
5
6
7
8
9

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GEN
INFO
REMOVAL AND INSTALLATION
1Drive shaft holder (impeller)
YB-06151
Drive shaft holder 5 (impeller)
90890-06519
2Slide hammer and adapters
(jet pump bearing)
YB-06096
3Stopper guide plate (jet pump bearing)
90890-06501
4Bearing puller assembly
(jet pump bearing)
90890-06535
5Stopper guide stand (jet pump bearing)
90890-06538
6Driver rod L3 (jet pump bearing)
90890-06652
7Bearing housing needle bearing remover
(jet pump bearing)
YB-06112
Drive shaft needle bearing installer
(jet pump oil seal)
YB-06196
8Needle bearing attachment
(jet pump bearing and oil seal)
90890-06614
9Outer race installer—forward gear
(jet pump oil seal)
YB-06085
0Ball bearing attachment (jet pump oil seal)
90890-06631
ADriver handle—large
(jet pump bearing)
YB-06071
BDriver rod LS
(jet pump oil seal)
90890-06606
CDrive shaft needle bearing depth stop
(jet pump bearing)
YB-34474
1YB-06151 YB-06096
2
390890-06501 90890-06535
4
590890-06538 90890-06652
6
7YB-06112 90890-06614
8
YB-06196
90890-06519
9YB-06085 90890-06631
0
AYB-06071 90890-06606
B
CYB-34474
SPECIAL SERVICE TOOLS

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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 (655)
Maximum capacity Person/kg (lb) 2/160 (353)
Performance
Maximum output kW (PS) at r/min 125.0 (170) at 7,000
Maximum fuel consumption l/h (US gal/h,
lmp gal/h)
57.0 (15.1, 12.5)
Cruising range h 1.05
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, #3 6.0:1
Intake system Reed valve
Scavenging system Loop charge
Exhaust system Wet exhaust
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
1
2
3
4
5
6
7
8
9

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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 –10, –5, 0, 5, 10
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)
27:1
Fuel tank capacity L (US gal,
Imp gal)
60 (15.9, 13.2)
Oil tank quantity L (US gal,
Imp gal)
5.5 (1.5, 1.2)
Item Unit Model
GP1300R
GENERAL SPECIFICATIONS

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SPEC MAINTENANCE SPECIFICATIONS
MAINTENANCE SPECIFICATIONS
ENGINE
Item Unit Model
GP1300R
Cylinder head
Warpage limit mm (in) 0.10 (0.004)
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 (0.0032)
Out-of-round limit mm (in) 0.050 (0.0020)
Wear limit mm (in) 84.100 (3.3110)
Pistons
Piston diameter mm (in) Red: 83.889–83.892 (3.3027–3.3028)
Orange: 83.893–83.896 (3.3029–3.3030)
Green: 83.897–83.900 (3.3030–3.3031)
Purple: 83.901–83.904 (3.3032–3.3033)
Measuring point*mm (in) 11 (0.43)
Piston-to-cylinder clearance mm (in) 0.110–0.115 (0.0043–0.0045)
Wear limit mm (in) 0.165 (0.0065)
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)
*1Measuring conditions:
Engine temperature 48 °C (118 °F), wide open throttle, with spark plugs removed from all cylin-
ders.
The figures are for reference only.

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SPEC MAINTENANCE SPECIFICATIONS
JET PUMP UNIT
Crankshaft assembly
Crank width Amm (in) 72.95–73.00 (2.872–2.874)
Deflection limit Bmm (in) 0.05 (0.002)
Deflection limit Cmm (in) 0.15 (0.006)
Big end side clearance Dmm (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
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) 0.2 (0.079)
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 3
Impeller pitch angle Degree 15.0
Impeller clearance mm (in) 0.35–0.45 (0.0138–0.0177)
Impeller clearance limit mm (in) 0.6 (0.024)
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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SPEC MAINTENANCE SPECIFICATIONS
HULL AND HOOD
ELECTRICAL
Item Unit Model
GP1300R
Free play
Throttle lever free play mm (in) 4–7 (0.16–0.28)
Item Unit Model
GP1300R
Battery
Type Fluid
Voltage, capacity V, Ah 12, 19
Specific gravity 1.27
ECM unit
(B/R –Ground for cylinder #1)
(B/W –Ground for cylinder #2)
(B/Y –Ground for cylinder #3)
Output peak voltage lower
limit
at cranking V 0.8
at 2,000 r/min V 174
at 3,500 r/min V 156
Stator
Pickup coil
(W/R, W/B, W/Y –B)
Output peak voltage
at cranking 1 V 6.0
at cranking 2 V 6.0
at 2,000 r/min V 24
at 3,500 r/min V 40
Pickup coil resistance 1
(W/R –B)
Ω459–561
Pickup coil resistance 2
(W/B –B)
Ω459–561
Pickup coil resistance 3
(W/Y –B)
Ω459–561
Lighting coil (G –G)
Output peak voltage
at cranking 1 V 9.0
at cranking 2 V 7.5
at 2,000 r/min V 12.5
at 3,500 r/min V 12.5
Lighting coil resistance
(G –G)
Ω0.54–0.66
Cranking 1: unloaded
Cranking 2: loaded

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SPEC MAINTENANCE SPECIFICATIONS
Ignition coil
Minimum spark gap mm (in) 10–11 (0.39–0.43)
Primary coil resistance
(B/W –body)
Ω0.26–0.36
Secondary coil resistance
(B/W –spark plug lead
terminal)
kΩ3.5–4.7
Spark plug lead resistance
#1 kΩ6.1–14.3
#2 kΩ4.5–10.9
#3 kΩ3.3–8.2
Rectifier/regulator (R –B)
Output peak voltage
(unloaded)
at 3,500 r/min V 14.5
Starter motor
Type Bendix
Output kW 0.8
Rating Seconds 30
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)
Starter relay
Rating Seconds 30
Engine temperature sensor
Engine temperature sensor
resistance (B/Y –B/Y)
at 20 °C (68 °F) kΩ54.2–69.0
at 100 °C (212 °F) kΩ3.12–3.48
Exhaust temperature sensor
resistance
at 300 °C (572 °F) kΩ 73–241
at 600 °C (1,112 °F) kΩ 0.86–1.58
at 900 °C (1,652 °F) Ω 64–90
Cooling water temperature
sensor resistance
at 0 °C (32 °F) kΩ 24.0–37.1
at 100 °C (212 °F) kΩ 0.87–1.18
at 200 °C (392 °F) Ω 104–153
Item Unit Model
GP1300R

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SPEC MAINTENANCE SPECIFICATIONS
*1 The figures are for reference only.
Speed sensor
Output voltage (on pulse) V 11.6
Output pulse/one full turn 2
Throttle position sensor
Output voltage (P –B/O)
at trolling speed V 0.793–0.807
Fuel sender
Fuel sender resistance
Position A Ω 133.5–136.5
Position B Ω 5–7
Fuel injector
Fuel injector resistance*1 Ω13.8
Oil level sensor
Oil level sensor resistance
Position A Ω 292–308
Position B Ω 97–103
Position C Ω 0–3
Fuse
Rating
Main V/A 12/20
Multifunction meter V/A 12/3
Electrical bilge pump V/A 12/3
Item Unit Model
GP1300R