Yamaha WaveRunner GP800R User manual

*LIT186660029*
WaveRunner
GP800R
ASSEMBLY MANUAL
YAMAHA MOTOR CORPORATION, USA
Printed in USA
Oct. 2000 — ?.? ×1 CR
F0W-28107-1A-11
(GP800A) F0W-28107-1A-11LIT-18666-00-29

E
WaveRunner GP800R
ASSEMBLY MANUAL
©2000 by Yamaha Motor Corporation, USA
1st Edition, October 2000
All rights reserved.
Any reprinting or unauthorized use
without the written permission of
Yamaha Motor Corporation, USA
is expressly prohibited.
Printed in USA
P/N LIT-18666-00-29

E
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.

E
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
N•m kgf•m ft•lb
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

– 1 –
E
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

– 2 –
E
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 F0W-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 2 90601-200U2
7 Band 1 90464-32801
8 Spiral tube 1 90448-25800
9 Handlebar cover stay 1 GP7-U142K-00
10 Screw 6 × 15 mm (0.24 × 0.59 in) 4 90159-069U1
11 Handlebar cover 1 GP7-U142A-11
12 Screw 6 × 19 mm (0.24 × 0.75 in) 4 90149-069U9
13 Terminal extension 1 F0W-68239-01
14 Flashing conduction fitting 1 67X-12590-00
15 Tool kit 1 EU0-65986-00
16 Vinyl bag 1 EU0-65901-01
17 Spark plug 2 94702-00204
18 Owner’s/Operator’s manual 1 F0W-F8199-10
19 Riding practice tips 1 F0W-F819T-10
20 Riding instruction card 1 FN8-U595B-02
21 Basic orientation video 1 F0D-U595A-00

– 3 –
E
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:
Before starting work open the front hood
and remove the storage compartment, and
remove the seat.
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

– 4 –
E
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 .

– 5 –
E
EXPLODED DIAGRAM
Step Procedure/Part name Q’ty Service points
5 Band 1 Fasten the QSTS cables and handlebar
switch lead with band at the handlebar.
6 Band 1
7 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.

– 6 –
E
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.