Yamaha Waverunner 3 Manual
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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 (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
5-3 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 removing the spark plugs, use com- pressed air to blow away any dirt accumu- lated in the spark plug wells to prevent it from falling into the cylinders. 6. Install: Compression gauge extension 1 Compression gauge 2 Compression gauge extension: 90890-06582 Compression gauge: YU-33223-1/90890-03160 2 1
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 100 kPa (1 kgf/cm2, 14 psi). b. If the compression pressure is extremely high, check the cylinder head, valve sur- faces and piston crown for carbon depos- its. Carbon deposits → Eliminate. c. If the compression pressure is below the minimum specification, squirt a few drops of oil into the cylinder and measure again. Refer to the following table. Compression pressure (with oil applied into the cylinder) Reading Diagnosis Higher than without oilPiston wear or damage → Repair. Same as without oilPiston ring(s), valves, cylinder head gasket or pis- ton possibly defec- tive → Repair. T R.. Spark plug: 13 N m (1.3 kgf m, 9.4 ft lb)
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 trying not to hit it on the deck or letting it fall hard on the hull. Suspend the engine unit using all three engine hangers, and then separate the unit from the engine mount. Remove the hoist cable from the front engine hanger and use the two rear engine hangers to suspend the engine unit. Lift the engine unit out vertically while turning it clockwise. 1 2
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 a straightedge and thickness gauge. Clearance a: 0–0.5 mm (0–0.020 in) Clearance b: 2–4 mm (0.079–0.157 in) 2. Adjust: Clearance a and b Adjustment steps: Adjust the clearance a by adding or removing shims. Adjust the clearance b by moving the engine unit position.
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 Thermoswitch (exhaust) 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 242 8th 15 N • m (1.5 kgf • m, 11 ft • Ib) 4th 2.0 N • m (0.2 kgf • m, 1.4 ft • Ib) 10 × 45 mm 12th 39 N • m (3.9 kgf • m, 28 ft • Ib) 7.6 N • m (0.76 kgf • m, 5.5 ft • Ib) 6 × 16 mm 5th 15 N • m (1.5 kgf • m, 11 ft • Ib) 1st 2.0 N • m (0.2 kgf • m, 1.4 ft • Ib) 10 × 35 mm 9th 39 N • m (3.9 kgf • m, 28 ft • Ib)6th 15 N • m (1.5 kgf • m, 11 ft • Ib) 2nd 2.0 N • m (0.2 kgf • m, 1.4 ft • Ib) 10 × 35 mm 10th 39 N • m (3.9 kgf • m, 28 ft • Ib) 2nd 4.4 N • m (0.44 kgf • m, 3.2 ft • Ib) 1st 4.4 N • m (0.44 kgf • m, 3.2 ft • Ib) 6 × 16 mm 2nd 7.6 N • m (0.76 kgf • m, 5.5 ft • Ib) 1st 3.7 N • m (0.37 kgf • m, 2.7 ft • Ib) È É Ê
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 242 8th 15 N • m (1.5 kgf • m, 11 ft • Ib) 4th 2.0 N • m (0.2 kgf • m, 1.4 ft • Ib) 10 × 45 mm 12th 39 N • m (3.9 kgf • m, 28 ft • Ib) 7.6 N • m (0.76 kgf • m, 5.5 ft • Ib) 6 × 16 mm 5th 15 N • m (1.5 kgf • m, 11 ft • Ib) 1st 2.0 N • m (0.2 kgf • m, 1.4 ft • Ib) 10 × 35 mm 9th 39 N • m (3.9 kgf • m, 28 ft • Ib)6th 15 N • m (1.5 kgf • m, 11 ft • Ib) 2nd 2.0 N • m (0.2 kgf • m, 1.4 ft • Ib) 10 × 35 mm 10th 39 N • m (3.9 kgf • m, 28 ft • Ib) 2nd 4.4 N • m (0.44 kgf • m, 3.2 ft • Ib) 1st 4.4 N • m (0.44 kgf • m, 3.2 ft • Ib) 6 × 16 mm 2nd 7.6 N • m (0.76 kgf • m, 5.5 ft • Ib) 1st 3.7 N • m (0.37 kgf • m, 2.7 ft • Ib) È É Ê
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 (0.2 kgf • m, 1.4 ft • Ib) 10 × 45 mm 12th 39 N • m (3.9 kgf • m, 28 ft • Ib) 7.6 N • m (0.76 kgf • m, 5.5 ft • Ib) 6 × 16 mm 5th 15 N • m (1.5 kgf • m, 11 ft • Ib) 1st 2.0 N • m (0.2 kgf • m, 1.4 ft • Ib) 10 × 35 mm 9th 39 N • m (3.9 kgf • m, 28 ft • Ib)6th 15 N • m (1.5 kgf • m, 11 ft • Ib) 2nd 2.0 N • m (0.2 kgf • m, 1.4 ft • Ib) 10 × 35 mm 10th 39 N • m (3.9 kgf • m, 28 ft • Ib) 2nd 4.4 N • m (0.44 kgf • m, 3.2 ft • Ib) 1st 4.4 N • m (0.44 kgf • m, 3.2 ft • Ib) 6 × 16 mm 2nd 7.6 N • m (0.76 kgf • m, 5.5 ft • Ib) 1st 3.7 N • m (0.37 kgf • m, 2.7 ft • Ib) È É Ê Not reusable
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 (3.9 kgf • m, 28 ft • Ib) 2nd 22 N • m (2.2 kgf • m, 16 ft • Ib) 1st 22 N • m (2.2 kgf • m, 16 ft • Ib) 8 × 75 mm 3rd 35 N • m (3.5 kgf • m, 25 ft • Ib) 8 × 45 mm 2nd 42 N • m (4.2 kgf • m, 30 ft • Ib) 1st 15 N • m (1.5 kgf • m, 11 ft • Ib) 10 × 35 mm 2nd 42 N • m (4.2 kgf • m, 30 ft • Ib) 1st 15 N • m (1.5 kgf • m, 11 ft • Ib) 9th 39 N • m (3.9 kgf • m, 28 ft • Ib) 4th 39 N • m (3.9 kgf • m, 28 ft • Ib) 7th 39 N • m (3.9 kgf • m, 28 ft • Ib) 2nd 39 N • m (3.9 kgf • m, 28 ft • Ib) 10th 39 N • m (3.9 kgf • m, 28 ft • Ib) 5th 39 N • m (3.9 kgf • m, 28 ft • Ib) 2nd 22 N • m (2.2 kgf • m, 16 ft • Ib) 1st 22 N • m (2.2 kgf • m, 16 ft • Ib) 8 × 125 mm 3rd 35 N • m (3.5 kgf • m, 25 ft • Ib) 8th 39 N • m (3.9 kgf • m, 28 ft • Ib) 3rd 39 N • m (3.9 kgf • m, 28 ft • Ib) Not reusable