Yamaha GP1200R Owners Manual

WaveRunnerGP1200R

ASSEMBLY MANUAL

*LIT186660028*

LIT-18666-00-28 F0X-28107-ZA-11

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WaveRunner GP1200R

ASSEMBLY MANUAL

©2000 Yamaha Motor Co., Ltd.

1st Edition, January 2000

All rights reserved. Any reprinting

or unauthorized use without

the written permission of

Yamaha Motor Co., Ltd.
is expressly prohibited.

Printed in USA

LIT-18666-00-28

R

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PREFACE

This Assembly Manual contains the infor­mation 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 reas­sembled water vehicle should be thor­oughly cleaned, inspected, and adjusted
prior to delivery to the customer.

NOTICE

Because Yamaha constantly strives for
product improvement, the service specifica­tions 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 techni­cal bulletin.

IMPORTANT MANUAL INFORMATION:

Particularly important information is distin­guished in this manual by the following
notations.

SYMBOLS USED IN THIS

ASSEMBLY MANUAL

In order to simplify descriptions in assem­bly 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

Size:

d/D : Diameter of part.



‚ No.242 (BLUE LOCTITE)

: Length of part.

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
machine operator, a bystander, or a person
inspecting or repairing the water vehicle.

to the

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.

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General torque

Nut A Bolt B

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

specifications

Nm kgf•m lb•ft

GENERAL TORQUE SPECIFICATIONS

This chart specifies the torques for tighten­ing standard fasteners with standard clean
dry ISO threads at room temperature.
Torque specifications for special compo­nents 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.

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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

– 1 –

COMPARTMENT DIAGRAM

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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 F0X-U155A-00
4 Upper handlebar holder 2 EU0-23814-30
5 Bolt 8
6 Band 1 90464-32801
7 Spiral tube 1 90448-25800
8 Handlebar cover stay 1 GP7-U142K-00

9 Screw 6 × 15 mm (0.24 × 0.59 in) 4 90159-069U1
10 Handlebar cover 1 GP7-U142A-11
11 Screw 6 × 19 mm (0.24 × 0.75 in) 4 90149-069U9
12 Band 1 90601-200U2
13 Flashing conduction fitting 1 67X-12590-00
14 Tool kit 1 EU0-65986-00
15 Vinyl bag 1 EU0-65901-01
16 Spark plug 3 94702-00396
17 Owner’s/Operator’s manual 1 F0X-F8199-10
18 Riding practice tips 1 F0X-F819T-10
19 Riding instruction card 1 FN8-U595B-02
20 Basic orientation video 1 F0D-U595A-00

×

55 mm (0.31

×

2.17 in) 4 90119-089UM

– 2 –

WIRE LEAD AND CABLE ROUTING

EXPLODED DIAGRAM

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INSTALLATION CHART

Step Procedure/Part name Q’ty Service points

WIRE LEAD AND CABLE
ROUTING

1 Choke cable 1

2 Throttle cable 1

3 Handlebar switch lead 1

4 Grommet 1

5 QSTS cable 2

Follow “Step” order for installation.

NOTE:

Working from the bow side, open the front
hood, and then remove the storage com­partment.

NOTE:

Apply soapy water to the grommet for eas­ier installation.

– 3 –

c

HANDLEBAR AND THROTTLE CABLE INSTALLATION

EXPLODED DIAGRAM

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INSTALLATION CHART

Step Procedure/Part name Q’ty Service points

HANDLEBAR AND THROTTLE
CABLE INSTALLATION

1 Lower handlebar holder 2
2 Handlebar assembly 1
3 Upper handlebar holder 2

4 Bolt (with washer)

8

×

55 mm (0.31

×

2.17 in)

Follow “Step” order for installation.

NOTE:

Align the punched marks a on the handle-

●

bar with the top surface of the lower han­dlebar holders.
The upper handlebar holder should be

●

installed with the punched mark b forward.

NOTE:

4

Tighten the bolts so that the front clearance

of the upper handlebar holder is smaller

than the rear clearance d .

– 4 –