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