Yamaha Waverunner 3 Manual

5-2
EPOWRENGINE UNIT
EXPLODED DIAGRAM
Step Procedure/Part name Q’ty Service points
3 Electrical box 1
4 Clamp/cooling water hose 1/1 Cooling water pilot outlet
5 Clamp/cooling water hose 1/1 Cooling water pilot outlet
6 Clamp/cooling water hose 1/1 Cooling water outlet
7 Clamp/cooling water hose 1/1 Cooling water outlet
8 Clamp/cooling water hose 1/1 Cooling water inlet
9 Coupler 5
10 Grease hose 1
11 Bolt/collar 1/1
12 Coupling cover 1
4
1011
12
6
3
7
2
8
1
9
5
9 14 91315
LT
271
LTLT
572
LT
7.8 N •
 m...

5-3
EPOWRENGINE UNIT
EXPLODED DIAGRAM
*: As required.Step Procedure/Part name Q’ty Service points
13 Bolt/washer 4/4
14 Shim *
15 Engine unit 1
Reverse the removal steps for installation.
4
1011
12
6
3
7
2
8
1
9
5
9 14 91315
LT
271
LTLT
572
LT
7.8 N •
 m (0.78 kgf • m, 5.6 ft • Ib)
6 × 25 mm
8 × 28 mm
17 N • m (1.7 kgf 
• m, 12 ft 
• Ib)
17 N • m (1.7 kgf 
• m, 12 ft 
• Ib) 8 × 40 mm
17 N • m (1.7 kgf 
• m, 12 ft 
• Ib)
LT
572
LT 

5-4
EPOWRENGINE UNIT
SERVICE POINTS
Compression pressure measurement
The following procedure applies to all of the
cylinders.
NOTE:
Insufficient compression pressure will result in
a loss of performance.
1. Measure:
Valve clearance
Out of specification →
 Adjust.
Refer to “POWER UNIT” in Chapter 3.
2. Warm the engine up, and then put the
watercraft in a horizontal position.
3. Remove:
Air filter case cover 1
 
Air filter element
4. Disconnect:
Spark plug cap
5. Remove:
Spark plug
CAUTION:
Before...

5-5
EPOWRENGINE UNIT
7. Measure:
Compression pressure
Out of specification →
 Refer to steps (b)
and (c).
8. Install:
Spark plug
Minimum compression pressure 
(reference data):
1,080 kPa 
(10.8 kgf/cm
2, 157 psi)
Measurement steps:
a. With the throttle wide open, crank the
engine until the reading on the compres-
sion gauge stabilizes.
 WARNING
To prevent sparking, ground all spark
plug leads before cranking the engine.
NOTE:
The difference in compression pressure
between cylinders should not exceed...

5-6
EPOWRENGINE UNIT
9. Install:
Air filter element
Air filter case cover
T R..
Air filter case cover screw:
2.5 N  m (0.25 kgf  m, 1.8 ft  lb)
LOCTITE
® 572
Oil filter removal and installation
1. Remove:
Oil filter 1
 
NOTE:
Install the oil filter with the same special tool
that was used for removal.
Engine unit removal
1. Remove:
Engine unit
Oil filter wrench 
2:
YU-38411/90890-01426
T R..
Oil filter:
17 N  m (1.7 kgf  m, 12 ft  lb)
Removal steps:
CAUTION:
Lift the engine unit carefully...

5-7
EPOWRENGINE UNIT
Shim removal
1. Remove:
Shims
NOTE:
To ease reassembly and coupling alignment,
remove the shims and organize them in their
respective groups (e.g., front right, rear left)
prior to removing the mounting bolts.
Engine mount inspection
1. Inspect:
Engine mounts
Cracks/damage →
 Replace.
Refer to “ENGINE MOUNT” in Chapter
8.
Coupling clearance inspection
1. Measure:
Clearance a
 
Clearance b
 
(with the rubber damper)
Out of specification →
 Adjust.
NOTE:
Measure the clearances with...

5-8
EPOWREXHAUST PIPE 3
EXHAUST PIPE 3
EXPLODED DIAGRAM
REMOVAL AND INSTALLATION CHART
Step Procedure/Part name Q’ty Service points
EXHAUST PIPE 3 REMOVAL
Follow the left “Step” for removal.
Engine unit Refer to “ENGINE UNIT”.
Air filter case Refer to “FUEL INJECTION SYSTEM” in 
Chapter 4.
1 Clamp/cooling water hose 1/1È
For cooling water outlet on stern side
2 Clamp/cooling water hose 2/1É
For cooling water pilot outlet on port side
3 Clamp/cooling water hose 2/1Ê
From water jacket
4Bolt 2
5...

5-9
EPOWREXHAUST PIPE 3
EXPLODED DIAGRAM
Step Procedure/Part name Q’ty Service points
6 Exhaust joint clamp 2 Slide the outer exhaust joint for exhaust 
manifold side
7 Exhaust joint clamp 2
8Bolt 1
9Bolt 1
10 Bolt 2
11 Collar 1
12 Exhaust pipe 3 1
13 Bolt 3
14 Exhaust pipe end 1
3
6
18
2
717
1610
12
11
8913
14
15 5 4
1
LT
572
LT
572
LT
572
LT
572
LT
242
LT
242
7th   15 N • m (1.5 kgf 
• m, 11 ft 
• Ib) 3rd   2.0 N • m (0.2 kgf 
• m, 1.4 ft 
• Ib)
10 × 45 mm
11th  39 N • m (3.9 kgf 
• m, 28 ft 
• Ib)
LT...

5-10
EPOWREXHAUST PIPE 3
EXPLODED DIAGRAM
Step Procedure/Part name Q’ty Service points
15 Gasket 1
16 Inner exhaust joint 1
17 Exhaust joint seal 1
18 Outer exhaust joint 1
Reverse the removal steps for installation.
3
6
18
2
717
1610
12
11
8913
14
15 5 4
1
LT
572
LT
572
LT
572
LT
572
LT
242
LT
242
7th   15 N • m (1.5 kgf 
• m, 11 ft 
• Ib) 3rd   2.0 N • m (0.2 kgf 
• m, 1.4 ft 
• Ib)
10 × 45 mm
11th  39 N • m (3.9 kgf 
• m, 28 ft 
• Ib)
LT
242
8th   15 N • m (1.5 kgf 
• m, 11 ft 
• Ib) 4th   2.0 N • m...

5-11
EPOWREXHAUST PIPES 1 AND 2
EXHAUST PIPES 1 AND 2
EXPLODED DIAGRAM
REMOVAL AND INSTALLATION CHART
Step Procedure/Part name Q’ty Service points
EXHAUST PIPES 1 AND 2 
REMOVALFollow the left “Step” for removal.
Exhaust pipe 3 Refer to “EXHAUST PIPE 3”.
Generator cover Refer to “GENERATOR AND STARTER 
MOTOR”.
1Bolt 2
2Bolt 1
3 Exhaust pipe stay 1
4Nut 5
5 Exhaust pipe 2 1
6Gasket 1
E
E
E
LT
242LT
242
LT
242
19 48
1012 13
6 7 5 4
4
4
2
3
11È
È
6th   39 N • m (3.9 kgf 
• m, 28 ft 
• Ib) 1st    39 N • m...