Yamaha GP1200 Manuals

Manuals and User Guides for Yamaha GP1200. We have 1 Yamaha GP1200 manual available for free PDF download: Service Manual

Yamaha GP1200 Service Manual (182 pages)

Brand: Yamaha | Category: Boat | Size: 3.04 MB

Manual Format/Indication
2
The Illustrations
2
References
2
How to Read Descriptions
3
Warning, Cautions and Notes
4
Symbols
5
Index
6
General Information/Contents
7
Primary ID/Hull Identification Number
8
Engine/Pump Serial Number
8
Safety While Working
9
Fire Prevention and Ventilation
9
Self-Protection
9
Oils,Greases and Sealing Fluids
9
Good Working Practices
10
Disassembly and Assembly
11
Special Tools
12
Measuring
12
Removal and Installation
13
Specifications/Contents
14
General Specifications
15
Maintenance Specifications/Engine
17
Maintenance Specifications/Jet Unit
18
Maintenance Specifications/Hull and Hood
19
Maintenance Specifications/Electrical
19
Specified Torque
20
General Torque
21
Periodic Inspection and Adjustment/Contents
22
Maintenance Interval Chart
23
Pivot Shaft Bearing Inspection
24
Steering Cable Inspection and Adjustment
24
Throttle Cable Inspection and Adjustment
25
Throttle Lever Free Play
25
Choke Cable Inspection and Adjustment
26
Choke Cable Free Play
26
Trim Cable Inspection and Adjustment
27
Wheel Free Play
27
Fuel Filter Inspection
29
Trolling Speed Inspection and Adjustment
29
Carburetor Adjustment
31
Oil Filter Inspection
31
Oil Pump Cable Inspection and Adjustment
31
Oil Injection Pump Air Bleeding
32
Spark Plug Inspection/Gap
33
Color Guide
33
Battery Inspection
34
Filling Steps
35
Jet Pump Unit
36
Impeller/Bilge Strainer Inspection
36
Drain Plug Inspection
37
Greasing Point
37
Recommended Grease
37
Fuel System/Contents
39
Fuel Line Exploded Diagram (GP760)
41
Removal and Installation Chart
41
Fuel Hose Removal
41
Fuel Line Exploded Diagram (GP1200)
42
Fuel Filter/Cock Inspection
43
Oil Tank Exploded Diagram
44
Oil Tank Removal
44
Check Valve Inspection
45
Oil Filter/Tank Inspection
45
Oil Level Sensor Inspection
45
Fuel Tank Removal Exploded Diagram
46
Fuel Tank Exploded Diagram
47
Fuel Tank Disassembly
47
Fuel Tank/Level Sensor Inspection
48
Pipe Joint Inspection/Installation
48
Carburetor Unit Removal Exploded Diagram (GP760)
49
Carburetor Removal
49
Cable Guide Set Position
49
Carburetor Unit Removal Exploded Diagram (GP1200)
50
Choke/Throttle Cable Guide Set Position
50
Carburetor Removal Exploded Diagram
51
Throttle Valve Synchronization Inspection and Adjustment
52
Choke Valve Synchronization Inspection and Adjustment (GP760)
53
Carburetor Assembly
53
Carburetor Exploded Diagram
54
Carburetor Disassembly
54
Diaphragm/Body Assembly/Needle Valve Inspection
55
Float Arm Inspection/Height
55
Jet and Carburetor Body Inspection
56
High and Low Speed Screws Inspection/Adjustment
56
High/Low Speed Screw
56
Fuel Pump Exploded Diagram
57
Fuel Pump Disassembly
57
Fuel Pump/Filter Inspection
58
Oil Line Exploded Diagram
59
Oil Pump Removal
59
Oil Pump Exploded Diagram
60
Oil Pump/Hose Inspection
61
Ring Rubber Inspection/Installation
61
Power Unit/Contents
62
Engine Unit Removal Exploded Diagram (GP760)
65
Engine Unit Removal Exploded Diagram (GP1200)
66
Shim Removal
67
Mount Bracket Inspection
67
Coupling Clearance Inspection
67
Pilot Water Hose Installation
67
Reed Valve Exploded Diagram (GP760)
68
Reed Valve Removal
68
Reed Valve Exploded Diagram (GP1200)
69
Reed Valve Inspection
70
Valve Bending Limit
70
Valve Stopper Height
70
Exhaust Ring Exploded Diagram (GP760)
71
Exhaust Ring Removal
71
Exhaust Ring Exploded Diagram (GP1200)
72
Exhaust Chamber Removal Exploded Diagram (GP760)
73
Exhaust Chamber Removal
73
Exhaust Chamber Removal Exploded Diagram (GP1200)
74
Exhaust Chamber Exploded Diagram (GP760)
75
Chamber Disassembly
75
Exhaust Chamber Exploded Diagram (GP1200)
76
Muffler Exploded Diagram (GP760)
77
Muffler Removal
77
Muffler Exploded Diagram (GP1200)
78
Cylinder Head Exploded Diagram (GP760)
79
Cylinder Head Removal
79
Cylinder Head Exploded Diagram (GP1200)
80
Cylinder Head Inspection
81
Warpage Limit
81
Warpage Measurement and Resurfacing Steps
81
Cylinder Exploded Diagram (GP760)
82
Cylinder Removal
82
Cylinder Exploded Diagram (GP1200)
83
Cylinder Inspection
84
Piston Exploded Diagram
85
Piston Removal
85
Piston Pin Clip Removal and Installation
86
Piston Inspection/Clearance
86
Piston Ring/Pin and Bearing Inspection
87
Piston Pin Outside Diameter
88
Flywheel Magneto and Base Exploded Diagram (GP760)
89
Flywheel Magneto and Base Disassembly
89
Flywheel Magneto and Base Exploded Diagram (GP1200)
90
Coupling Flange Removal/Installation/Inspection
91
Flywheel Magneto Removal/Installation/Inspection
91
Coupler Wrench
91
Flywheel Holder/Puller
91
Idle Gear Assembly Inspection
92
Electrical Unit Exploded Diagram (GP760)
93
Electrical Unit Removal
93
Electrical Unit Exploded Diagram (GP1200)
94
Starter Motor Exploded Diagram
95
Starter Motor Disassembly
95
Pinion/Armature Inspection
96
Commutator Diameter/Undercut
96
Brush Holder Inspection/Continuity
97
Armature Coil Continuity
97
Cover Inspection
97
Brush Length
97
Crankcase Exploded Diagram (GP760)
98
Crankcase Disassembly
98
Crankcase Exploded Diagram (GP1200)
99
Crankcase Inspection/Installation
100
Crankshaft Exploded Diagram (GP760)
101
Crankshaft Removal
101
Crankshaft Exploded Diagram (GP1200)
102
Crankshaft Inspection
103
Crank Width
103
Maximum Deflection
103
Big End Side Clearance
103
Intermediate Housing Removal Exploded Diagram
105
Intermediate Housing Exploded Diagram
106
Intermediate Housing Disassembly
106
Coupling Removal/Installation/Inspection
107
Bearing Removal/Installation/Inspection
107
Oil Seal Installation
108
Jet Pump Unit/Contents
109
Jet Pump Unit Removal Exploded Diagram
110
Deflector and Trim Ring Exploded Diagram
111
Deflector and Trim Ring Removal
111
Nozzle, Duct and Intake Exploded Diagram
112
Nozzle, Duct and Intake Removal
112
Housing Installation
113
Water Resistant Grease
113
Impeller and Drive Shaft Exploded Diagram
114
Impeller and Drive Shaft Disassembly
114
Drive Shaft Removal/Inspection
115
Impeller/Bearing Inspection
115
Drive Shaft Holder
115
Slide Hammer Set
115
Drive Shaft Installation
116
Bearing Inner Race Attachment
116
Intake Duct Exploded Diagram
117
Intake Duct Disassembly
117
Oil Seal and Bushing Removal
118
Housing/Seal Rubber Inspection
118
Bushing and Oil Seal Installation
118
Cooling and Bilge System Exploded Diagram
119
Cooling and Bilge System Removal
119
Bilge Strainer/Hose Inspection
119
Electrical System/Contents
120
Electrical Components GP760
122
Electrical Components GP1200
123
Spiral Tube Installation
124
Electrical Unit GP760
125
Electrical Unit GP1200
126
Electrical Analysis Inspection
127
Low Resistance Measurement
127
Ignition System Wiring Diagram (GP760)
128
Ignition System Wiring Diagram (GP1200)
129
Ignition Spark Gap
130
Spark Gap Tester
130
Spark Plug/Plug Cap
131
Ignition Coil
131
Primary Coil Resistance
131
Engine Stop Switch/Continuity
132
Charge Coil/Coil Resistance
132
Secondary Coil Resistance
132
Pulser Coil/Coil Resistance
133
Thermo Switch
133
Thermo Switch Continuity Temperature
133
CDI Unit
134
Starting System Wiring Diagram
135
Battery
136
Starter Motor/Switch/Relay
136
Wiring Connection
136
Fuse
136
Charging System Wiring Diagram
138
Lighting Coil
139
Rectifier Regulator
139
Indication System Wiring Diagram
140
Oil/Fuel Level Sensor
141
Multi-Function Meter
142
Instrument Indicating Function
142
Security Function
143
Hull and Hood/Contents
144
Handle Removal Exploded Diagram
147
Handlebar Assembly Installation
148
Nozzle Control Cable Length
149
Handle Exploded Diagram
150
Handlebar Disassembly
150
Handle Inspection
151
Handle Switch Inspection/Installation
151
Trim Grip and Control Cable Exploded Diagram
152
Trim Grip and Control Cable Removal
152
Trim Control Cable Inspection
153
Grim Guide Inspection
153
Engine Hood Cover Exploded Diagram
154
Engine Hood Cover Removal
154
Handle Column Exploded Diagram
155
Handle Column Removal
155
Bushing Inspection
156
Handle Column Inspection
156
Bushing Joint Installation
156
Adjustable Mirror and Engine Hood Removal Exploded Diagram
157
Adjustable Mirror/Engine Hood Removal
157
Engine Hood Exploded Diagram
158
Engine Hood Disassembly
158
Steering Cable Exploded Diagram
159
Steering Cable Removal
159
Cable Inspection
160
Jet Pump Side Cable Joint Installation
160
Cable Stopper Installation
160
Steering Cable Adjustment
160
Throttle Cable and Choke Cable Exploded Diagram
161
Throttle/Choke Cable Removal
161
Cable Inspection/Installation
162
Throttle/Choke Cable Adjustment
162
Trim Cable Exploded Diagram
163
Trim Cable Removal
163
Trim Cable Adjustment
164
Seat, Storage Box and Battery Case Exploded Diagram
165
Seat, Storage Box and Battery Case Removal
165
Seat/Storage Box/Battery Case Inspection
166
Exhaust System Exploded Diagram
167
Exhaust System Removal
167
Exhaust System Inspection
168
Deck Exploded Diagram
169
Deck Disassembly
169
Ventilation System Inspection
170
Gunwale Exploded Diagram
171
Gunwale Removal
171
Mat Exploded Diagram
172
Mat Removal/Installation
172
Hull Exploded Diagram
173
Hull Disassembly
173
Hull Repair
174
Light/Deep Scratching
174
Hull Damage (Punctured)
175
Insert Nut
176
Removing/Applying a Graphic
178
Trouble Analysis/Contents
179
Trouble Analysis Chart
180

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