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WAVERUNNER

WATERCRAFT

4/10/08 WR2008-001R

Yamaha Motor Corporation, U.S.A. has determined

that a possible defect which relates to safety may

exist in all 2003 through 2007 and certain 2008 model

GP1300 (GP1300R) WaveRunners and also in all 2005

through 2007 and certain 2008 model VX1100 (VX)

WaveRunners. In the affected units, there is a possibility

that the outer throttle cable could corrode and become

cracked or kinked. If the outer cable is damaged in this

way, it could cause the inner cable (throttle wire) to fray

over time from wear. If the frayed inner cable catches

on the damaged outer cable, throttle movement can be

increasingly impaired which may eventually lead to the

throttle being incapable of returning to the idle position.

This could result in an accident with the potential of

personal injury or death to the operator, passenger, or

bystanders.

To correct this defect, Yamaha is initiating a Factory Modification Campaign. Affected watercraft must have

the throttle cable replaced with one of a new material.

Yamaha is notifying all registered owners of affected units by first-class mail. A copy of this letter is included in

this bulletin. The customer should take the letter along with the affected unit to an authorized Yamaha dealer

for throttle cable replacement.

A computer report listing all affected units invoiced to your dealership is included in this bulletin. Use the list

to help ensure all units are modified. All sold units that have been registered with Yamaha will show the cus-

tomer’s name and address. Your dealership must notify the owner of any affected unit that was actually sold

but is listed as “unsold” on the report.

You must correct all affected units in your inventory, as well as all customer-owned units brought to you for this

service. Before modifying a unit, check for a black circle mark under the Primary ID label inside the engine

compartment (see Identification Procedure in this bulletin) which indicates a unit has already been modified.

If you purchase an affected unit from another dealer in the future, check for this black circle mark and then

perform the procedures in this bulletin if no mark is present before you sell the unit.

Affected WaveRunners should not be operated until they are modified. It is a violation of federal law and

Yamaha policy for your dealership to deliver any new affected units to customers until the procedures in this

bulletin are performed.

When the modification on each unit has been performed, follow the Warranty information section of this

bulletin to receive reimbursement. Be sure to use the Factory Modification Campaign procedures in

Chapter 8 of the Warranty and Y.E.S. Handbook (LIT-11760-00-05).

PAGE 1 of 20

2003~2008 GP1300 and 2005~2008 VX1100

FACTORY MODIFICATION CAMPAIGN – Throttle Cable Corrosion

RECALL

This modification has top priority. This bulletin must be

performed immediately to ensure customer safety.

NOTE: Bulletins that announce a recall will have an “R” at the end of the bulletin number from now on.

GP1300 SHOWN

Summary of content (20 pages)

PAGE 1
WAVERUNNER® WATERCRAFT 4/10/08 WR2008-001R ©2008 YAMAHA MOTOR CORPORATION, U.S.A. RECALL This modification has top priority. This bulletin must be performed immediately to ensure customer safety. NOTE: Bulletins that announce a recall will have an “R” at the end of the bulletin number from now on. 2003~2008 GP1300 and 2005~2008 VX1100 FACTORY MODIFICATION CAMPAIGN – Throttle Cable Corrosion Yamaha Motor Corporation, U.S.A.
PAGE 2
Sold Units: Modify all watercraft in the affected range. Before modifying a unit, check to be sure it has not already been performed. See “Identification Procedure” in this bulletin. Unsold Units Modify all affected units during unit set up and pre-delivery inspection. Parts Required: Yes. Order the appropriate Throttle Wire Kit for each unit Warranty: Factory Modification Campaign. See the Warranty Information section of this bulletin. Notify Customers: Yes.
PAGE 3
Exhaust System Removal 1. Remove the seat and disconnect the battery. 2. Remove all the spark plug caps. 3. Disconnect the exhaust temperature sensor coupler and the cooling water temperature sensor coupler from the side of the box. 6. Remove the 3 exhaust cover retaining bolts and remove the exhaust cover. NOTE: During reassembly, replace the bolt covers and the gasket on the underside of the exhaust cover with the new ones in the kit.
PAGE 4
8. Remove the cooling water pipe from below the outer exhaust joint and loosen the 2 screw clamp. 10. Remove the exhaust muffler assembly as shown in the illustration. CAUTION: Be careful not to damage the watercraft while removing the exhaust muffler assembly. 2 3 1 4 2 5 1 11. Remove the 3 plastic ties on the inside of the watercraft at the port side, and place the wiring harness aside, inside the watercraft. 9. Slide the outer exhaust joint forward.
PAGE 5
13. Remove the exhaust chamber assembly as shown in the illustration. NOTE: To remove the bolt from the exhaust chamber assembly, use a socket with an overall length of 65mm (2.6 in). Intake Silencer Removal 1. Loosen the 2 intake silencer pipe screw clamps and remove the intake silencer pipe. 2. Remove the plastic tie from above the intake duct and place the fuel hose aside. Then, loosen the intake duct retaining bolt and pull out the intake duct upward. 65mm (2.6 in) SOCKET 14. Remove the gasket.
PAGE 6
3. Disconnect the engine temperature sensor coupler and remove the plastic tie at the top of the throttle body assembly. CAUTION: Put a clean cloth between the throttle body and cylinder head to protect them. Also put a clean cloth over the throttle body assembly and the throttle body joint to keep out dust and foreign objects Throttle Cable Replacement 1. Disconnect the throttle cable from the throttle body assembly. 4.
PAGE 7
4. Remove the steering pad. 7. Pull up the 2 QSTS cables from the handlebar side of the grommet. NOTE: Pull out the QSTS cables until their sponge portions are out of the grommet. 5. Disconnect the throttle cable from the throttle lever. 8. From the inside of the watercraft, pull the throttle cable and take it out of the grommet on the inside of the watercraft. 6. From the inside of the watercraft, remove the plastic tie of the grommet on the inside the watercraft.
PAGE 8
9. Replace the throttle cable with the new throttle cable. NOTE: Identify the part by its part number. 12. Replace the sponges of the 2 QSTS cables with new parts and insert the sponges until they are inside the grommet. Install the cables so that their sponge portions are placed 300 mm (11.8 in) from the base of the QSTS grip. 300mm (11.8 in) Previous: 60T5200 New: 60T5201 10. From the inside of the watercraft, insert the throttle cable into the grommet and pull it out to the handlebar side. 11.
PAGE 9
14. Measure the installation length “A” of the throttle cable. Adjust it if this measurement is out of specification. Apply grease to the throttle cable end, then connect the throttle cable to the throttle body assembly. Tighten the throttle cable locknut 1 and adjustment nut 2 to the specified torque. WARNING After adjusting free play, turn the handlebar side to side to make sure the free play does not change. Throttle cable installation length “a:” 18.5±1 mm (0.728±0.
PAGE 10
18. Pull the throttle lever to its fully open position and adjust the clearance of the oil pump. Adjust the positions of the locknut for the oil pump cable and the adjustment nut so that the oil pump has the specified amount of clearance a. After attaining the specified amount of clearance, tighten the locknut and the adjustment nut to the specified torque. Intake duct retaining bolt: 1st stage 9.0 Nm (0.9 kgf-m, 6.5 ft-lb) 2nd stage 18 Nm (1.
PAGE 11
4. Replace the gasket with a new part. 5. Install the muffler assembly as shown in the illustration and install the 1 cooling water pipe. 4 3 5 2 4 NEW GASKET 1 5 No. 1 Bolt, No. 2 Bolt, No. 3 Bolt, No. 4 Bolt, No. 5 bolt: 1st stage 2.0 Nm (0.2 kgf-m 1.5 ft-lb) 2nd stage 39 Nm (4.0 kgf-m 28.8 ft-lb) Loctite® 271 6. Secure the wiring harness to the watercraft with 3 new plastic ties from the kit. 7. Tighten the 1 screw clamp for the inner exhaust joint to the specified torque.
PAGE 12
9. Install the exhaust cover. Tighten the 3 bolts to the specified torque. Exhaust cover retaining bolt: 12 Nm (1.2 kgf-m, 8.7 ft-lb) Loctite® 242 10. Tighten the screw clamp for the exhaust joint to the specified torque. 15. Install the seat. 16. Start the engine, and use the multifunction meter or YDIS to measure the trolling speed of the engine. Trolling speed: 1250~1450 r/min 17. To prevent the replaced throttle cable from being reused inadvertently, break it with pliers to render it unusable.
PAGE 13
VX1100 Refer to the VX1100 Service Manual (LIT-18616-02-91), if necessary, when performing these procedures. 4. Remove the upper handlebar cover; then, disconnect the throttle cable from the throttle lever. 1. Remove the seat and disconnect the battery terminals. 2. Open the front hood, remove the 4 plastic rivets, and remove the storage compartment panel. NOTE: To remove a rivet, push the rivet pin until it is below the top surface of the rivet and makes a sound.
PAGE 14
6. Remove the grommet from the steering column, and pull the throttle cable inboard. NOTE: Do not reuse the grommet that has been removed. 9. Apply water resistant grease to the throttle cable end. Connect the throttle cable to the accelerator position sensor assembly. Before doing so, measure the installation length “A” of the throttle cable. Adjust it if this measurement is out of specification. Throttle cable installation length “A”: 18.4±1 mm (0.72±0.04 in) Throttle cable locknut: 6.5 Nm (0.
PAGE 15
10. Route the throttle cable and the lead for the handlebar switch assembly through the cutout in the new grommet, which is included in the kit. Then, install the grommet in the steering column with its cutout facing starboard side as shown. 11. Tighten the upper handlebar holders to the specified torque and secure the handlebar in place. Install each upper handlebar holder with its punch mark a facing forward as shown in the illustration.
PAGE 16
12. Connect the cable end to the throttle lever. Then, adjust the throttle lever free play. Throttle lever free play “A:” 4~7 mm (0.16~0.28 in) WARNING After adjusting free play, turn the handlebar side to side to make sure the free play does not change. a NOTE: As shown in the illustration, install the seal 1 into the groove in the bracket. Pull the throttle cable 2 in the direction of the arrow, and install the seal end 3 around the inner cable.
PAGE 17
13. Install the pad. NOTE: Before installing the long pad a, cut off 57.8mm (2.3 in) from its lower end, thus setting its overall length to 139.4mm (5.5 in). Install the short pad b as is. 14. Install the upper handlebar cover and the storage compartment panel. 15. Connect the battery terminals and start the engine. Use the multifunction meter or YDIS to measure the trolling speed of the engine. Trolling speed: 1550~1750 r/min b a 16.
PAGE 18
When the modification is complete, put a black circle with permanent marker under the Primary ID label which will make it easy to identify a modified unit. If you encounter an unfamiliar unit, check first for this mark before performing the procedures in this bulletin.
PAGE 19
The owner of each warranty-registered unit will receive a letter announcing this campaign. The letter has a label which includes the Primary ID and Recall Number. The modification is authorized for all affected WaveRunners, both sold and unsold, regardless of ownership or warranty status. You do not need the customer’s letter to perform the modification or to file for reimbursement. After modification, submit a Recall Request using Recall Number 990046. Choose the status “M.
PAGE 20
SAFETY RECALL NOTICE April 10, 2008 Dear Yamaha WaveRunner® Owner: Yamaha Motor Corporation, U.S.A. has determined that a possible defect which relates to safety may exist in all 2003 through 2007 and certain 2008 model GP1300 (GP1300R) WaveRunners and also in all 2005 through 2007 and certain 2008 model VX1100 (VX) WaveRunners. Our records indicate that you own one of these watercraft.