Yamaha WaveRunner GP800R User manual

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

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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

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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
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.,
● 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.

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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, 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

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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
®
JApply Yamabond #4
(Yamaha bond number 4)
KApply LOCTITE®No. 271 (Red LOCTITE)
LApply LOCTITE®No. 242 (Blue LOCTITE)
MApply LOCTITE®No. 572
NApply silicone sealant
NOTE:
In this manual, the above symbols may not
be used in every case.
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
AM
GM 4
271
LT
242
LT
572
LT 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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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
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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
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GEN
INFO SAFETY WHILE WORKING
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
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GEN
INFO SAFETY WHILE WORKING
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:
●For U.S.A. and Canada, use part numbers
starting with “J-”, “YB-”, “YM-”, “YU-” or
“YW-”.
●For other countries, use part numbers
starting with “90890-”.
MEASURING
1Engine tachometer
P/N. YU-8036-A
90890-06760
2Dial gauge and stand
P/N. YU-03097, YU-01256
90890-01252
3Pocket tester
P/N. YU-03112
90890-03112
4Cylinder gauge set
P/N. YU-03017
90890-06759
5Compression gauge
P/N. YU-33223
90890-03160
6Digital tester
P/N. J-39299
90890-06752
7Peak voltage adapter
P/N. YU-39991
90890-03169
8Peak voltage test harness
P/N. YW-06779
90890-06779
9Spark 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
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GEN
INFO SPECIAL TOOLS
REMOVAL AND INSTALLATION
1Coupler wrench
P/N. YW-06551
90890-06551
2Flywheel holder
P/N. YW-06550
90890-06550
3Flywheel puller
P/N. YB-06117
90890-06521
4Drive shaft holder (impeller)
P/N. YB-06151
90890-06519
5Slide hammer set (jet pump bearing)
P/N. YB-06096
6Stopper guide plate (jet pump bearing)
P/N. 90890-06501
7Bearing puller (jet pump bearing)
P/N. 90890-06535
8Bearing puller claw 1 (jet pump bearing)
P/N. 90890-06536
9Stopper guide stand (jet pump bearing)
P/N. 90890-06538
0Drive rod L3 (jet pump bearing)
P/N. 90890-06652
ANeedle bearing attachment
(jet pump bearing and oil seal)
P/N. YB-06112, YB-06196
90890-06614, 90890-06653
BBall bearing attachment
(jet pump oil seal)
P/N. YB-06156
90890-06634
CDriver rod
(intermediate shaft and jet pump)
P/N. YB-06071
90890-06606
DBearing inner/outer race attachment
(jet pump bearing)
P/N. YB-34474
EShaft holder (intermediate shaft)
P/N. YB-06552
90890-06552
FBearing 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 E
GENERAL 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 E
MAINTENANCE 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.