1998 Yamaha GP800 WaveRunner GP Service Manual

Covers jet pump unit, 2-stroke engine, carburetor systems with spec torques—impeller clearance 0.32–0.40 mm, compression ratio 6.6:1. Technical reference LIT-18616-01-93.

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Document Details

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Document Number / Seller:
24871 / Rebecca Henry
File Size:
13.05 MB
File Type:
PDF
Language:
English
Pages:
218
Printable:
Yes
Category:
Personal Watercraft (PWC)
Last updated / verified
Feb 2, 2025

Models Covered & Key Technical Specifications

Yamaha GP800 WaveRunner GP — 1998 Consolidated Mechanical Primer & Mechanical Vault Kit.

  • Certified Installation Footprint: 784 cm³ (47.8 cu. in) corresponds to the engine displacement Architecture.
  • Measured Maximum Resolution: For optimal performance, 88.3 kW (120 hp) at 7,000 r/min is calibrated to the peak power output Norms.
  • Design Twist Specifications: The compression chamber determines 6.6:1 as the established combustion ratio Bounds.
  • Engineered Deviation Limits: Cylinder bore-to-stroke geometry requires 80.0 × 78.0 mm (3.15 × 3.07 in) set as dimensional Topology.
  • Verified Operating Temps: Fuel capacity defines 50 L (13.2 US gal) as the system reservoir Matrix.
  • Factory Gross Dimensions: Battery voltage rating is specified to 12 V / 68.4 kC (19 Ah) Standards.

Professional Workshop Service Manual & Technical Specifications

Operational Assembly Manual: Yamaha GP800 WaveRunner GP (1998) OEM-Documentation

Documentation-Type: GP800 (1998) // Operational-Scope: Engine and Power Plant Systems / Fuel-Delivery Architecture // Repair-Classification: Service-Focused Technical Reference.

System Category Coverage Area Reference
Engine Specifications Complete dimensional and performance data for 784cc 2-stroke power plant Chapter 2: General Specifications
Fuel System Architecture Carburetor configuration, tank capacity, and fuel routing documentation Chapter 4: Fuel System Components
Electrical Framework Ignition, charging, and starting system specifications with wiring diagrams Chapter 7: Complete System Reference

Following OEM groupings, the manual includes engine specifications and drivetrain architecture, details fuel injection and carburetor systems, examines jet pump operational parameters, covers control system mechanics, and presents electrical component configuration alongside service point reference material.

Structured Interface

Drivetrain specifications are addressed in comprehensive detail, documenting the direct-drive transmission configuration and axial-flow jet pump propulsion system. The document references torque specifications for mounting bolts and fasteners, providing component assembly data for technicians performing disassembly and reassembly operations.

Advanced Logic-Path

Reassembly procedures are specified for major subassemblies including the engine unit, intermediate housing, and jet pump components. The manual captures exploded diagrams paired with sequential installation charts, showing numbered part identification and assembly order. Removal procedures mirror installation steps in reverse sequence, with annotations regarding component orientation and alignment requirements.

Systematic Topology

Service intervals are documented for routine maintenance tasks, including spark plug inspection, fuel filter replacement, and bilge system cleaning. The document includes maintenance interval scheduling based on operating hours (10, 50, 100, and 200-hour intervals), with corresponding reference pages for each service category. Cable adjustment procedures and bearing clearance measurements are presented with visual diagrams and dimensional specifications.

Precise Topology

Component locations are identified for all major systems through detailed exploded diagrams and wiring schematics. The electrical system section features complete wiring diagrams for the ignition, starting, charging, and indication circuits, with color-coded lead identification and component connectivity documentation. Oil hose routing, cooling water passages, and electrical harness paths are illustrated with reference to chapter locations for related service procedures.

Precise Benchmarks

Service procedures are documented for electrical testing including resistance measurements, continuity checks, and voltage verification using specified test equipment. The manual provides comprehensive charts for CDI unit resistance values, coil measurements, and circuit continuity testing across all electrical subassystems. Bolt tightening torque tables organize fastener specifications by component group, with sequential tightening patterns illustrated for multi-bolt assemblies requiring progressive stages to specification.

The manual documents torque specifications for the crankshaft mounting bolts to ensure proper axial load stability, with reference values provided in both metric and imperial units. Service points throughout identify areas requiring specific gasket compounds (Gasket Maker®, Yamabond #4, LOCTITE varieties, and silicon sealant) and lubrication types (water-resistant grease, 2-stroke motor oil, molybdenum disulfide compounds).

FAQ

What procedures are **necessary** to maintain electrical values? keyboard_arrow_down

12V/68.4 kC battery capacity with 8A maximum at 6,000 r/min charging current ensures proper electrical system operation. Battery maintenance includes checking electrolyte levels between upper and lower marks, verifying specific gravity at 1.28 (20°C), and replacing filler caps before charging. Regular inspection prevents electrical system failures and ensures reliable starting.

Determine the **recommended** calibration settings for the engine. keyboard_arrow_down

6.6:1 compression ratio with 18 BIDC at 1,300 r/min and 20 BIDC at 5,500 r/min provides optimal ignition timing. The 2-stroke engine requires spark plug gap adjustment to 0.6 ~ 0.7 mm and trolling speed calibration to 1,300 + 50 r/min for proper performance. Both settings must be verified during initial inspection and 50-hour maintenance intervals.

What specifications are **calibrated** for clearance measurements? keyboard_arrow_down

0.32 ~ 0.40 mm impeller clearance with 0.6 mm maximum limit maintains jet pump efficiency. Nozzle diameter standard is 82.0 mm (3.228 in). Drive shaft runout limit of 0.3 mm (0.012 in) ensures proper alignment. Piston-to-cylinder clearance of 0.100 ~ 0.105 mm (0.0039 ~ 0.0041 in) prevents excessive wear while maintaining sealing integrity.

Check the **applicable** torque specifications for assembly. keyboard_arrow_down

115 Nm (dry specification) applies to the crankcase when tightening in sequential stages. Cylinder head bolts require 38 Nm second stage, muffler assembly 53 Nm, and flywheel magneto 70 Nm (7.0 m·kgf, 50 ft·lb). All multi-fastener assemblies must be tightened in crisscross pattern with progressive stages to prevent warpage and ensure structural integrity.

What does the **exact** emergency procedure require before service work? keyboard_arrow_down

220 ml (7.4 oz) of distilled water for battery electrolyte replacement represents critical safety preparation. Stop the engine, set fuel cock to OFF, loosen filler cap, and drain fuel from tank before servicing any system. Remove the battery to prevent acid loss during impeller service. Ventilate work areas when handling gasoline and petroleum vapors, with fire extinguisher access required for all maintenance procedures.

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