Yamaha Waverunner 3 Manual
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8-4 E HULL HOODHANDLEBAR EXPLODED DIAGRAM REMOVAL AND INSTALLATION CHART Step Procedure/Part name Q’ty Service points HANDLEBAR DISASSEMBLY Follow the left “Step” for disassembly. 1Bolt 2 2 Grip end 2 3 Spacer 1 4 Screw/spring washer/washer 1/1/1 5 QSTS grip assembly 1 6 Special nut 1 7Screw 2 NOTE: Tighten the screw from the engine stop switch side.
8-5 E HULL HOODHANDLEBAR EXPLODED DIAGRAM Step Procedure/Part name Q’ty Service points 8 Handlebar switch assembly 1 9Screw 2 10 Throttle lever assembly 1 11 Handlebar grip 1 NOTE: Apply adhesive to the handlebar and the inner surface of the handlebar grip. 12 Handlebar 1 Reverse the disassembly steps for assembly.
8-6 E HULL HOODHANDLEBAR SERVICE POINTS Handlebar inspection 1. Inspect: Handlebar Bends/cracks/damage → Replace. Handlebar switch inspection Refer to “STARTING SYSTEM” in Chapter 7. Handlebar assembly installation 1. Install: Bands 1 NOTE: After inserting the QSTS cables, buzzer lead, handlebar switch lead and throttle cable into the grommets, tie the end of grommets with the bands. 2. Install: Upper handlebar holder 1 NOTE: Align the punch marks a on the handlebar with the top surface of the handlebar holder. The upper handlebar holder should be installed with the punch mark b facing for- ward. CAUTION: Clearance c should be narrower than clearance d. Reference clearance: c: 1.5 mm (0.06 in) d: 3.5 mm (0.14 in)
8-7 E HULL HOODHANDLEBAR 3. Install: Throttle cable NOTE: Fit the seal into the groove in the bracket. 4. Adjust: QSTS cable length a NOTE: Before adjusting the QSTS cables, set the trim grip to the neutral position. Adjust the QSTS cable lengths a to the specified length and be sure to take up any slack. QSTS cable length: 72 ± 0.5 mm (2.83 ± 0.02 in) 5. Install: Handlebar cover 1 NOTE: When the handlebar cover is in contact with the steering boss cover, adjust the handlebar mount angle so that the clearance a and b are equal. 6. Adjust: Throttle cable free play Refer to “CONTROL SYSTEM” in Chap- ter 3. 7. Adjust: QSTS cable Refer to “CONTROL SYSTEM” in Chap- ter 3.
8-8 E HULL HOODQSTS GRIP QSTS GRIP EXPLODED DIAGRAM REMOVAL AND INSTALLATION CHART Step Procedure/Part name Q’ty Service points QSTS GRIP DISASSEMBLY Follow the left “Step” for disassembly. QSTS grip assembly Refer to “HANDLEBAR”. 1 Screw/washer 1/1 2 Cover 1 3Ball 2 4Spring 2 5 QSTS cable 1 1 6 QSTS cable 2 1 with white tape a
8-9 E HULL HOODQSTS GRIP EXPLODED DIAGRAM Step Procedure/Part name Q’ty Service points 7 Screw/washer 2/2 8 Spacer 1 9 QSTS shift lock lever 1 10 Spring 1 11 Spacer 1 12 Cable housing 1 13 QSTS grip 1 Reverse the disassembly steps for assembly.
8-10 E HULL HOODQSTS GRIP SERVICE POINTS QSTS cable inspection 1. Inspect: QSTS cables Frays/kinks/rough movement → Replace. QSTS grip inspection 1. Inspect: QSTS grip Damage/wear → Replace.
8-11 E HULL HOODSTEERING MASTER STEERING MASTER EXPLODED DIAGRAM REMOVAL AND INSTALLATION CHART Step Procedure/Part name Q’ty Service points STEERING MASTER REMOVAL Follow the left “Step” for removal. Steering console cover Refer to “STEERING CONSOLE COVER”. Steering cable end Refer to “REMOTE CONTROL CABLES AND SPEED SENSOR LEAD”. 1 Bolt/washer 1/1 2 Steering arm 1 3 Nut/washer 4/4 4 Steering master assembly 1 5Bolt 4 Reverse the removal steps for installation.
8-12 E HULL HOODSTEERING MASTER EXPLODED DIAGRAM REMOVAL AND INSTALLATION CHART Step Procedure/Part name Q’ty Service points STEERING MASTER DISASSEMBLYFollow the left “Step” for disassembly. 1 Bolt/washer 2/2 2Stay 1 3Spring 1 4 Bolt/washer 6/6 5 Lower housing 1 6Spring 1 7 Bushing 1 8 Bushing 1 9 Upper housing 1 10 Tilt lever 1
8-13 E HULL HOODSTEERING MASTER EXPLODED DIAGRAM Step Procedure/Part name Q’ty Service points 11 Tilt stopper 1 12 Bolt/nut/holder 4/4/4 13 Retainer 2 14 Steering shaft assembly 1 15 Steering tube 1 16 Bolt/washer/spring washer 2/2/2 17 Cap 1 18 Shaft 1 1 19 Cross piece 1 Reverse the disassembly steps for assembly.