Yamaha GP1200R Installation Instruction

Factory Pipe

Bill Of Materials

Yamaha GP1200R

Item Qty Part Number Part Description

1 3 COMASM0690 Yam GP 800/XL1200/GP1200R flange Assy.
2 1 COMASM0840 GP1200R Collector Assy.
3 1 COMASM0821 GP1200R Mag Chamber Assy.
4 1 COMASM0822 GP1200R Center Chamber Assy.
5 1 COMASM0823 GP1200R PTO Chamber Assy.
6 1 COMST12002 Mag Stinger Tailpipe (long S-bend)
7 1 COMST12003 Center Stinger Tailpipe (45 deg. Bend)
8 1 COMST12001 PTO Stinger Tailpipe (short S-Bend)
9 1 COMASM0825 GP1200R/XL1200 Mag Bracket-Mount Assy.
10 1 COMASM0826 GP1200R PTO Upper Bracket-Mount Assy.
11 1 COMASM0827 GP1200R/XL1200 PTO Lower Bracket Assy.
12 1 COMASM0828 GP1200R Filter Block Assy.
13 1 COMASM0829 GP1200R Water Exit Manifold Assy.
14 1 COMASM0844 GP1200R Cylinder Head Exit Waterlines

15 1 COMASM0832 GP1200R Hardware Kit (Consisting of Parts #16-32)

16* 6 COMASM0790 Stainless Steel Exhaust Springs (with clear hose cover)
17* 12 COMFAS0050 10mm x 40mm Hex Head Bolts
18* 6 COMFAS0002 10mm Stainless Steel Spring Hook
19* 9 COMCLP0020 #32 Stainless Steel Hose Clamp
20* 3 COMHOS00703 1-3/4" x 2-1/2" Silicone Coupler
22* 13 COMCLP0010 #6 S.S. Steel Hose Clamp
23* 7 COMFAS0086 3/8" S.S. Flat Washers
24* 6 COMFAS0046 10mm x 30mm Flange Head Bolt
25* 1 COMFAS0280 3/8"-16 x 1" S.S. Hex Head Bolt
26* 5 COMFAS0100 3/8"-16 x 3/4" S.S. Hex Head Bolt
27* 6 COMFAS0040 10mm S.S. Lock Washer
28* 1 COMBRK0214 GP1200R/XL1200 Mag Case Bracket
29* 3 COMGAS0150 7-1/4" long Graphite/Kevlar Sealing Ring
32* 2 COMCLP0085 P-Clamp
33* 1 COMFAS0012 #10 x 1/2" self tapping screw

* Part of Hardware Kit

Required Parts Not Included in Kit: Aftermarket Rev Limiter/Ignition Module, Aftermarket Flame arrestors and
Aftermarket Top Loader Intake Pump Grate and Ride Plate.
<< CHECK CONTENTS AGAINST BILL OF MATERIALS. REPORT ANY SHORTAGES WHERE YOU

PURCHASED YOUR FACTORY PIPE.

<< READ ALL INSTRUCTIONS CAREFULLY BEFORE STARTING INSTALLATION.
<< DO NOT USE THE STOCK IGNITION MODULE, ENGINE DAMAGE WILL OCCUR IF THE STOCK

IGNITION TIMING CURVE IS USED.

<< AN AFTERMARKET INTAKE GRATE AND/OR RIDE PLATE MUST BE USED WITH THIS EXHAUST

SYSTEM. INCREASED SPEEDS WILL RESULT IN DANGEROUS HANDLING WITHOUT THESE
CHANGES.

Page 1

Page 2

Factory Pipe

Instructions

Yamaha GP1200R

Disconnect the battery and remove the power valve servo and cables with the bracket. Completely
remove the stock exhaust/catalytic converter system from the cylinder to the water box and leave the
stock 3/8" waterlines attached to the side squirters. Remove the two studs on the center cylinder.
Retain the stock waterbox rubber coupler and clamp, stock front engine case bracket and stock
exhaust manifold gasket. Remove the stock front air silencer and carburetor flame arrestors. Retain one
of the rubber mounts and bolt. Remove the rear motor mount on the exhaust side of the boat and slide
trim cable, stator wires, starter cable and ground cable under motor. Remove lower cable guide from
hull to allow clearance for exhaust.

Install an aftermarket top loader intake grate and ignition system (or rev limiter/CDI module) as per the
manufacturers instructions.

Install the three graphite/Kevlar sealing rings (Item #29) into the flanges (Item# 1)(Fig. 1) Note:
Kevlar seals should be 7 1/4" in length. Check length before installing. Install the three flanges
on the cylinder using the retained stock manifold gasket, 10mm x 40mm bolts (Item #17) and spring
hooks (Item #18). The barbed hose fittings should point towards the front of the boat and the spring
hooks should be turned outward at a 45 degree angle (Fig. #2). Torque all flange bolts to 30ft. lbs.

Lay the filter block assy. (Item #12) in the left side of the hull in the upper groove centered on the
engine. Connect the front three non-filtered waterlines on the filter block assy. to the fittings on the
exhaust flanges and secure with #6 hose clamps (Item #22) Note: Waterline lengths are left long to
accomodate different setups. Cut to suit your application. Secure the filter assy to the hull using
one of the “P” clamps (Item #32) and the #10 x 1/2" screw (Item #33). Use a 1/8" drill bit to pre-drill
the hole for the screw (Fig. 3). Remove the stock black 5/8" x 4" piece of waterline from the stock
“Y”. Connect the 5/8" waterline from the filter assy. to the “Y” and secure with the supplied clamp.

Remove the air box silencer rubber mount from the left side of the mag cover. Install the Mag case
bracket (Item #28) using the retained rubber mount and 8mm bolt and washer making sure that the
steel collar is on the mag side of the bracket.(Fig #4).

Put the Center chamber (Item #4) in the boat and secure the rubber lord mount on chamber to the Mag
case bracket using a 3/8"-16 x 3/4" bolt and washer (Item #26,23). Do not insert chamber into flange
at this time (Fig. #5).

Page 3