Yamaha Waverunner 3 Manual
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![Page 250
6-29
E
JET
PUMPBEARING HOUSING
3. Install:
Oil seal 1
[8 mm (0.31 in)]
Oil seal 2
[11 mm (0.43 in)]
Distance
a:
10.3–10.7 mm (0.41–0.42 in)
Distance
b:
0.6–1.0 mm (0.02–0.04 in)
b
a
2
1
Intermediate housing installation
1. Install:
Intermediate housing
Shim
NOTE:
Install the shim(s) to the original position if the
intermediate housing is not replaced.Installation steps:
Install the intermediate housing.
Measure the clearance a
at each bolt
hole.
Install the suitable shim from the table...](http://img.usermanuals.tech/thumb/83/105002/w64_waverunner-3-manual-1526652781_d-249.png "Page 250
6-29
E
JET
PUMPBEARING HOUSING
3. Install:
Oil seal 1
[8 mm (0.31 in)]
Oil seal 2
[11 mm (0.43 in)]
Distance
a:
10.3–10.7 mm (0.41–0.42 in)
Distance
b:
0.6–1.0 mm (0.02–0.04 in)
b
a
2
1
Intermediate housing installation
1. Install:
Intermediate housing
Shim
NOTE:
Install the shim(s) to the original position if the
intermediate housing is not replaced.Installation steps:
Install the intermediate housing.
Measure the clearance a
at each bolt
hole.
Install the suitable shim from the table...")
E –+ELEC 1 2 3 4 5 6 7 8 9 CHAPTER 7 ELECTRICAL SYSTEM ELECTRICAL COMPONENTS........................................................................ 7-1 ELECTRICAL BOX AND IGNITION COIL BOX ............................................. 7-2 EXPLODED DIAGRAM ............................................................................. 7-2 REMOVAL AND INSTALLATION CHART ................................................ 7-2 ELECTRICAL ANALYSIS ............................................................................. 7-11 INSPECTION........................................................................................... 7-11 Digital tester ...................................................................................... 7-11 Low resistance measurement ........................................................... 7-12 Peak voltage measurement .............................................................. 7-12 Peak voltage adaptor ........................................................................ 7-13 Test harness .................................................................................... 7-13 IGNITION SYSTEM ....................................................................................... 7-14 WIRING DIAGRAM ................................................................................. 7-14 IGNITION SPARK GAP ........................................................................... 7-16 IGNITION SYSTEM PEAK VOLTAGE .................................................... 7-17 BATTERY ................................................................................................ 7-19 FUSE ....................................................................................................... 7-19 SPARK PLUGS ....................................................................................... 7-19 SPARK PLUG LEAD ASSEMBLY ........................................................... 7-19 IGNITION COIL ....................................................................................... 7-20 ENGINE STOP SWITCH ......................................................................... 7-20 ENGINE TEMPERATURE SENSOR ...................................................... 7-21 INTAKE AIR TEMPERATURE SENSOR ................................................ 7-21 THERMOSWITCH (ENGINE).................................................................. 7-22 THERMOSWITCH (EXHAUST) .............................................................. 7-22 MAIN AND FUEL PUMP RELAY............................................................. 7-23 THROTTLE POSITION SENSOR ........................................................... 7-24 CAM POSITION SENSOR ...................................................................... 7-25 INTAKE AIR PRESSURE SENSOR........................................................ 7-26 SLANT DETECTION SWITCH ................................................................ 7-27
E –+ELEC FUEL CONTROL SYSTEM ........................................................................... 7-28 WIRING DIAGRAM ................................................................................. 7-28 FUEL PUMP ............................................................................................ 7-30 FUEL SENDER ....................................................................................... 7-30 FUEL INJECTOR .................................................................................... 7-31 MAIN AND FUEL PUMP RELAY............................................................. 7-31 OIL PRESSURE SWITCH ....................................................................... 7-31 THERMOSWITCH (ENGINE).................................................................. 7-31 THERMOSWITCH (EXHAUST) .............................................................. 7-31 SLANT DETECTION SWITCH ................................................................ 7-31 STARTING SYSTEM ..................................................................................... 7-32 WIRING DIAGRAM ................................................................................. 7-32 BATTERY ................................................................................................ 7-33 WIRING CONNECTIONS........................................................................ 7-33 FUSE ....................................................................................................... 7-33 START SWITCH...................................................................................... 7-33 STARTER RELAY ................................................................................... 7-34 STARTER MOTOR ........................................................................................ 7-35 EXPLODED DIAGRAM ........................................................................... 7-35 REMOVAL AND INSTALLATION CHART ............................................. 7-35 SERVICE POINTS .................................................................................. 7-38 Armature inspection .......................................................................... 7-38 Brush holder inspection..................................................................... 7-39 Starter motor front cover inspection .................................................. 7-39 CHARGING SYSTEM .................................................................................... 7-40 WIRING DIAGRAM ................................................................................. 7-40 FUSE ....................................................................................................... 7-41 BATTERY ................................................................................................ 7-41 LIGHTING COIL ...................................................................................... 7-41 RECTIFIER/REGULATOR ...................................................................... 7-41 ELECTRIC BILGE PUMP .............................................................................. 7-42 WIRING DIAGRAM ................................................................................. 7-42 ELECTRIC BILGE PUMP ........................................................................ 7-43
E –+ELEC INDICATION SYSTEM .................................................................................. 7-44 WIRING DIAGRAM ................................................................................. 7-44 FUSE ....................................................................................................... 7-45 BATTERY ................................................................................................ 7-45 LIGHTING COIL ...................................................................................... 7-45 RECTIFIER/REGULATOR ...................................................................... 7-45 ECM......................................................................................................... 7-45 ENGINE TEMPERATURE SENSOR ...................................................... 7-45 THERMOSWITCH (ENGINE).................................................................. 7-45 THERMOSWITCH (EXHAUST) .............................................................. 7-45 BUZZER .................................................................................................. 7-45 OIL PRESSURE SWITCH ....................................................................... 7-46 MULTIFUNCTION METER...................................................................... 7-46 Multifunction meter ............................................................................ 7-46 MULTIFUNCTION METER REMOVAL ................................................... 7-46 Display function ................................................................................. 7-47 Speedometer display ........................................................................ 7-48 Tachometer display ........................................................................... 7-49 Hour meter display ............................................................................ 7-49 Voltage meter display........................................................................ 7-49 Low oil pressure warning indicator .................................................... 7-49 Fuel level meter display and fuel warning indicator .......................... 7-49 Overheat warning indicator ............................................................... 7-50 Engine trouble warning indicator ....................................................... 7-50 Diagnostic display ............................................................................. 7-51
7-1 E –+ELECELECTRICAL COMPONENTS ELECTRICAL COMPONENTS L K J I H G F E D C B A 0 9 87 6 5 4 3 2 1 1Thermoswitch (engine) 2Starter motor 3Engine temperature sensor 4Spark plugs 5Ignition coils 6Electrical box 7Battery 8Speed sensor 9Electric bilge pump0Cam position sensor AFuel injectors BThermoswitch (exhaust) COil pressure switch DIntake air pressure sensor EIntake air temperature sensor FThrottle position sensor GLighting coil and pulser coil HEngine stop switch, engine shut-off switch and start switchIBuzzer JFuel pump KFuel sender LMultifunction meter
7-2 E –+ELECELECTRICAL BOX AND IGNITION COIL BOX ELECTRICAL BOX AND IGNITION COIL BOX EXPLODED DIAGRAM REMOVAL AND INSTALLATION CHART Step Procedure/Part name Q’ty Service points ELECTRICAL BOX REMOVAL Follow the left “Step” for removal. 1 Battery negative lead 1 2 Battery positive lead 1 3 Clip/breather hose 1/1 4 Band 2 5 Battery 1 6 Damper 1 7Bolt 2 8Bolt 2 AA AA 22 2311 14 13 121516 21 20 19 23 23 23 23 2317 1823 101 9 7 86 5 2 3 4 (VENT) LT 572 LT LT 271 LT LT 572 LT AA LT 572 LT E 7.6 N • m (0.76 kgf • m, 5.5 ft • Ib) 6 × 12 mm 7.6 N • m (0.76 kgf • m, 5.5 ft • Ib) 6 × 16 mm 7.6 N • m (0.76 kgf • m, 5.5 ft • Ib) 6 × 10 mm 5.4 N • m (0.54 kgf • m, 3.9 ft • Ib) 6 × 30 mm 5.4 N • m (0.54 kgf • m, 3.9 ft • Ib) 6 × 16 mm 8 × 28 mm 17 N • m (1.7 kgf • m, 12 ft • Ib) 4.9 N • m (0.49 kgf • m, 3.5 ft • Ib) 5 × 20 mm
7-3 E –+ELECELECTRICAL BOX AND IGNITION COIL BOX EXPLODED DIAGRAM Step Procedure/Part name Q’ty Service points 9 Battery box 1 10 Spacer 2 11 Bolt 4 12 Screw 4 13 Terminal cover 1 14 Gasket 1 15 Screw 1 16 Starter motor lead 1 17 Bolt 3 18 Cover 1 AA AA 22 2311 14 13 121516 21 20 19 23 23 23 23 2317 1823 101 9 7 86 5 2 3 4 (VENT) LT 572 LT LT 271 LT LT 572 LT AA LT 572 LT E 7.6 N • m (0.76 kgf • m, 5.5 ft • Ib) 6 × 12 mm 7.6 N • m (0.76 kgf • m, 5.5 ft • Ib) 6 × 16 mm 7.6 N • m (0.76 kgf • m, 5.5 ft • Ib) 6 × 10 mm 5.4 N • m (0.54 kgf • m, 3.9 ft • Ib) 6 × 30 mm 5.4 N • m (0.54 kgf • m, 3.9 ft • Ib) 6 × 16 mm 8 × 28 mm 17 N • m (1.7 kgf • m, 12 ft • Ib) 4.9 N • m (0.49 kgf • m, 3.5 ft • Ib) 5 × 20 mm Not reusable
7-4 E –+ELECELECTRICAL BOX AND IGNITION COIL BOX EXPLODED DIAGRAM Step Procedure/Part name Q’ty Service points 19 Gasket 1 20 Bolt 2 21 Ground lead 2 22 Holder 1 23 Coupler 15 NOTE: Disconnect all couplers. Reverse the removal steps for installation. AA AA 22 2311 14 13 121516 21 20 19 23 23 23 23 2317 1823 101 9 7 86 5 2 3 4 (VENT) LT 572 LT LT 271 LT LT 572 LT AA LT 572 LT E 7.6 N • m (0.76 kgf • m, 5.5 ft • Ib) 6 × 12 mm 7.6 N • m (0.76 kgf • m, 5.5 ft • Ib) 6 × 16 mm 7.6 N • m (0.76 kgf • m, 5.5 ft • Ib) 6 × 10 mm 5.4 N • m (0.54 kgf • m, 3.9 ft • Ib) 6 × 30 mm 5.4 N • m (0.54 kgf • m, 3.9 ft • Ib) 6 × 16 mm 8 × 28 mm 17 N • m (1.7 kgf • m, 12 ft • Ib) 4.9 N • m (0.49 kgf • m, 3.5 ft • Ib) 5 × 20 mm Not reusable
7-5 E –+ELECELECTRICAL BOX AND IGNITION COIL BOX EXPLODED DIAGRAM REMOVAL AND INSTALLATION CHART Step Procedure/Part name Q’ty Service points ELECTRICAL BOX DISASSEMBLYFollow the left “Step” for disassembly. 1 Tapping screw 18 2 Cover 1 3Gasket 1 4Clamp 3 5Screw 4 6 Terminal cover 1 7Gasket 1 8Screw 2 2 31 24 25 232221 19 16 20 18 1712 13 14 15 9 11 4 7 6 5810 27 26 6 × 20 mm 3.9 N • m (0.39 kgf • m, 2.8 ft • Ib) 6 × 30 mm 3.9 N • m (0.39 kgf • m, 2.8 ft • Ib) 4.9 N • m (0.49 kgf • m, 3.5 ft • Ib) 5 × 20 mm 7.6 N • m (0.76 kgf • m, 5.5 ft • Ib) 6 × 10 mm 7.6 N • m (0.76 kgf • m, 5.5 ft • Ib) 6 × 12 mm 6 × 16 mm 3.9 N • m (0.39 kgf • m, 2.8 ft • Ib) 3.9 N • m (0.39 kgf • m, 2.8 ft • Ib) 6 × 30 mm 3.9 N • m (0.39 kgf • m, 2.8 ft • Ib) 6 × 16 mm 4.9 N • m (0.49 kgf • m, 3.5 ft • Ib) 5 × 30 mm 4 4 4
7-6 E –+ELECELECTRICAL BOX AND IGNITION COIL BOX EXPLODED DIAGRAM Step Procedure/Part name Q’ty Service points 9 Battery positive lead 1 10 Starter motor lead 1 11 Wire harness 1 12 Tapping screw 1 13 Fuse holder stay 1 14 Screw 1 15 Starter relay 1 16 Clamp 2 17 Tapping screw/washer 4/4 18 ECM 1 2 31 24 25 232221 19 16 20 18 1712 13 14 15 9 11 4 7 6 5810 27 26 6 × 20 mm 3.9 N • m (0.39 kgf • m, 2.8 ft • Ib) 6 × 30 mm 3.9 N • m (0.39 kgf • m, 2.8 ft • Ib) 4.9 N • m (0.49 kgf • m, 3.5 ft • Ib) 5 × 20 mm 7.6 N • m (0.76 kgf • m, 5.5 ft • Ib) 6 × 10 mm 7.6 N • m (0.76 kgf • m, 5.5 ft • Ib) 6 × 12 mm 6 × 16 mm 3.9 N • m (0.39 kgf • m, 2.8 ft • Ib) 3.9 N • m (0.39 kgf • m, 2.8 ft • Ib) 6 × 30 mm 3.9 N • m (0.39 kgf • m, 2.8 ft • Ib) 6 × 16 mm 4.9 N • m (0.49 kgf • m, 3.5 ft • Ib) 5 × 30 mm 4 4 4
7-7 E –+ELECELECTRICAL BOX AND IGNITION COIL BOX EXPLODED DIAGRAM Step Procedure/Part name Q’ty Service points 19 Tapping screw 1 20 Bracket 1 21 Joint connector 2 22 Tapping screw 2 23 Slant detection switch 1 24 Tapping screw 1 25 Main and fuel pump relay 1 26 Tapping screw 2 27 Rectifier/regulator 1 Reverse the disassembly steps for assembly. 2 31 24 25 232221 19 16 20 18 1712 13 14 15 9 11 4 7 6 5810 27 26 6 × 20 mm 3.9 N • m (0.39 kgf • m, 2.8 ft • Ib) 6 × 30 mm 3.9 N • m (0.39 kgf • m, 2.8 ft • Ib) 4.9 N • m (0.49 kgf • m, 3.5 ft • Ib) 5 × 20 mm 7.6 N • m (0.76 kgf • m, 5.5 ft • Ib) 6 × 10 mm 7.6 N • m (0.76 kgf • m, 5.5 ft • Ib) 6 × 12 mm 6 × 16 mm 3.9 N • m (0.39 kgf • m, 2.8 ft • Ib) 3.9 N • m (0.39 kgf • m, 2.8 ft • Ib) 6 × 30 mm 3.9 N • m (0.39 kgf • m, 2.8 ft • Ib) 6 × 16 mm 4.9 N • m (0.49 kgf • m, 3.5 ft • Ib) 5 × 30 mm 4 4 4