Yamaha Waverunner 3 Manual
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5-32 EPOWRREDUCTION DRIVE GEAR EXPLODED DIAGRAM *1: EPNOC grease AP #0 Step Procedure/Part name Q’ty Service points 9 Circlip 2 10 Driven gear 1 11 Washer 2 12 Circlip 1 13 Oil seal 2 14 Bearing 1 NOTE: Remove parts 12 to 15 as a set. 15 Drive shaft 1 16 Circlip 1 17 Circlip 1 E EE E E 15 13 14 16 18 17 12 9 11 10 11 9 8 7 61 2 34521 20 19 E E E *1 AA *1 5 × 10 mm 10 N m (1.0 kgf m, 7.2 ft Ib) 6 × 16 mm8 × 40 mm 2nd 28 N m (2.8 kgf m, 20 ft Ib) 1st 15 N m (1.5 kgf m, 11 ft Ib) E Not reusable Not reusable Not reusable Not reusable Not reusable Not reusable
5-33 EPOWRREDUCTION DRIVE GEAR EXPLODED DIAGRAM *1: EPNOC grease AP #0 Step Procedure/Part name Q’ty Service points 18 Bearing 1 19 Circlip 1 20 Bearing 1 21 Reduction drive gear case 1 Reverse the disassembly steps for assembly. E EE E E 15 13 14 16 18 17 12 9 11 10 11 9 8 7 61 2 34521 20 19 E E E *1 AA *1 5 × 10 mm 10 N m (1.0 kgf m, 7.2 ft Ib) 6 × 16 mm8 × 40 mm 2nd 28 N m (2.8 kgf m, 20 ft Ib) 1st 15 N m (1.5 kgf m, 11 ft Ib) E Not reusable Not reusable Not reusable
5-34 EPOWRREDUCTION DRIVE GEAR SERVICE POINTS Drive coupling removal 1. Remove: Drive coupling 1 NOTE: While holding the flywheel magneto 2 with the sheave holder 3, loosen the drive coupling with coupler wrench 4. Coupler wrench: YW-06551/90890-06551 Sheave holder: YS-01880-A/90890-01701 1 4 23 Drive shaft removal 1. Remove: Circlip Drive shaft NOTE: Press in the direction of the arrow. Oil pump driven gear inspection 1. Check: Oil pump driven gear 1 Cracks/damage/wear → Replace. 1 Relief valve inspection 1. Check: Relief valve 1 Spring 2 Damage/wear → Replace the defective part(s).1 2
5-35 EPOWRREDUCTION DRIVE GEAR Drive shaft installing 1. Install: Drive shaft NOTE: Press in the direction of the arrow. 2. Install: Oil seals 1 Distance a: 8.9–9.3 mm (0.35–0.37 in) 1 a Drive coupling installation 1. Install: Drive coupling 1 NOTE: While holding the flywheel magneto 2 with the sheave holder 3, tighten the drive coupling with coupler wrench 4. Coupler wrench: YW-06551/90890-06551 Sheave holder: YS-01880-A/90890-01701 1 4 23
5-36 EPOWRGENERATOR AND STARTER MOTOR GENERATOR AND STARTER MOTOR EXPLODED DIAGRAM REMOVAL AND INSTALLATION CHART Step Procedure/Part name Q’ty Service points GENERATOR COVER AND FLYWHEEL MAGNET REMOVALFollow the left “Step” for removal. Engine unit Refer to “ENGINE UNIT”. 1 Nut/washer 1/1 2 Starter motor lead 1 3Bolt 2 4 Battery negative lead 1 5 Starter motor 1 6 Band 1 7 Lighting coil coupler 1 8 Pulser coil coupler 1 4 3 2 1 5 6 8 7 10 9 111214 13 19 17182021 22 16 15 AA E E E LT 572 LT 572 AA AA 8 × 30 mm 18 N m (1.8 kgf m, 13 ft Ib) 4.9 N m (0.49 kgf m, 3.5 ft Ib) 10 × 47 mm 75 N m (7.5 kgf m, 54 ft Ib) 5 × 10 mm 8 × 20 mm 24 N m (2.4 kgf m, 17 ft Ib) 10 × 60 mm 2nd 50 N m (5.0 kgf m, 36 ft Ib) 1st 15 N m (1.5 kgf m, 11 ft Ib)
5-37 EPOWRGENERATOR AND STARTER MOTOR EXPLODED DIAGRAM Step Procedure/Part name Q’ty Service points 9Bolt 1 10 Holder 1 11 Bolt 8 12 Generator cover 1 13 Dowel pin 2 14 Packing 1 15 Idle gear shaft 1 16 Idle gear 1 17 Bolt/washer 1/1 18 Rotor 1 19 Bolt 6 4 3 2 1 5 6 8 7 10 9 111214 13 19 17182021 22 16 15 AA E E E LT 572 LT 572 AA AA 8 × 30 mm 18 N m (1.8 kgf m, 13 ft Ib) 4.9 N m (0.49 kgf m, 3.5 ft Ib) 10 × 47 mm 75 N m (7.5 kgf m, 54 ft Ib) 5 × 10 mm 8 × 20 mm 24 N m (2.4 kgf m, 17 ft Ib) 10 × 60 mm 2nd 50 N m (5.0 kgf m, 36 ft Ib) 1st 15 N m (1.5 kgf m, 11 ft Ib) Not reusable Not reusable
5-38 EPOWRGENERATOR AND STARTER MOTOR EXPLODED DIAGRAM Step Procedure/Part name Q’ty Service points 20 Starter clutch 1 21 Starter gear 1 22 Woodruff key 1 Reverse the removal steps for installation. 4 3 2 1 5 6 8 7 10 9 111214 13 19 17182021 22 16 15 AA E E E LT 572 LT 572 AA AA 8 × 30 mm 18 N m (1.8 kgf m, 13 ft Ib) 4.9 N m (0.49 kgf m, 3.5 ft Ib) 10 × 47 mm 75 N m (7.5 kgf m, 54 ft Ib) 5 × 10 mm 8 × 20 mm 24 N m (2.4 kgf m, 17 ft Ib) 10 × 60 mm 2nd 50 N m (5.0 kgf m, 36 ft Ib) 1st 15 N m (1.5 kgf m, 11 ft Ib)
5-39 EPOWRGENERATOR AND STARTER MOTOR EXPLODED DIAGRAM REMOVAL AND INSTALLATION CHART Step Procedure/Part name Q’ty Service points GENERATOR DISASSEMBLYFollow the left “Step” for disassembly. 1 Bolt/washer 3/3 2Bolt 4 3Pulser coil 2 NOTE: There washers holds the pulser coil lead. Make sure to not pitch the lead between the projection and the washer when installing the bolt. 4Bolt 2 1 7 6 3 2 45 LT 242 LT 242 LT 242LT 242 14 N m (1.4 kgf m, 10 ft Ib) 6 × 14 mm 4.9 N m (0.49 kgf m, 3.5 ft Ib) 5 × 14 mm 14 N m (1.4 kgf m, 10 ft Ib) 6 × 33 mm 4.9 N m (0.49 kgf m, 3.5 ft Ib) 5 × 10 mm 1 1 2 3
5-40 EPOWRGENERATOR AND STARTER MOTOR EXPLODED DIAGRAM Step Procedure/Part name Q’ty Service points 5 Holder 1 6Bolt 3 7 Lighting coil 1 Reverse the disassembly steps for assembly. 1 7 6 3 2 45 LT 242 LT 242 LT 242LT 242 14 N m (1.4 kgf m, 10 ft Ib) 6 × 14 mm 4.9 N m (0.49 kgf m, 3.5 ft Ib) 5 × 14 mm 14 N m (1.4 kgf m, 10 ft Ib) 6 × 33 mm 4.9 N m (0.49 kgf m, 3.5 ft Ib) 5 × 10 mm 1 1 2 3
5-41 EPOWRGENERATOR AND STARTER MOTOR SERVICE POINTS Flywheel magneto removal 1. Remove: Flywheel magneto bolt 1 Washer NOTE: While holding the flywheel magneto 2 with the sheave holder 3, loosen the flywheel magneto bolt. Sheave holder: YS-01880-A/90890-01701 2. Remove: Flywheel magneto 1 Woodruff key NOTE: While holding the flywheel magneto with sheave holder 2, remove the flywheel mag- neto with the rotor puller 3. Rotor puller: YM-01082/90890-01080 Starter clutch inspection 1. Check: Starter clutch rollers 1 Damage/wear → Replace.