Yamaha Waverunner 3 Manual

							8-44
E
HULL
HOODEXHAUST SYSTEM
EXPLODED DIAGRAM
REMOVAL AND INSTALLATION CHART
Step Procedure/Part name Q’ty Service points
EXHAUST JOINT DISASSEMBLY
Follow the left “Step” for disassembly.
1Bolt 6
2 Exhaust joint protector 1 1
3 Exhaust joint protector 2 1
4 Exhaust joint pipe 1
Reverse the disassembly steps for 
assembly.
3 421
6 × 25 mm
2nd   12 N • m (1.2 kgf 
• m, 8.8 ft 
• Ib) 1st     3.7 N • m (0.37 kgf 
• m, 2.7 ft 
• Ib)
LT
572
LT
572 
						

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HULL
HOODEXHAUST SYSTEM
SERVICE POINTS
Exhaust system inspection
1. Inspect:
Water lock band
Cracks/damage →
 Replace.
2. Inspect:
Rubber hoses
Burns/cracks/damage →
 Replace.
3. Inspect:
Water lock
Cracks/leaks →
 Replace.
4. Inspect:
Water tank
Cracks/damage/leaks →
 Replace.
Exhaust component parts sub-assembly
1. Install:
Rubber hose
Plate
NOTE:
Be sure to fit the projections on the rubber
hose with the grooves in the plate.
2. Install:
Rubber hoses
Water tank
NOTE:
Be sure to insert the rubber hose to the line
a
 on the water tank.
Make sure that there is a surface distance of
47 mm (1.9 in) b
 between the parting lines
of the water tank and rubber hose.
Align the parting line c
 of the rubber hose
with the parting line d
 of the water tank.
b
a
a c
d 
						

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HULL
HOODEXHAUST SYSTEM
Exhaust system installation
1. Install:
Exhaust joint
NOTE:
Be sure to fit the slit a
 on the exhaust joint
with the projection b
 on the exhaust pipe.b
a
2. Install:
Water lock
NOTE:
Be sure to insert the rubber hose to the line a
on the water lock.a 
						

							8-47
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HULL
HOODDECK AND HULL
DECK AND HULL
EXPLODED DIAGRAM
REMOVAL AND INSTALLATION CHART
Step Procedure/Part name Q’ty Service points
DECK AND HULL DISASSEMBLY
Follow the left “Step” for disassembly.
1Nut 1
2 Spout 1
3Nut 2
4 Cleat 1
5Plate 2
6Bolt 10
7 Sponson 2
8 Nut/washer 4/4
9 Screw/washer 4/4
10 Drain plug 2
1617
18453
7
6
15
1314 12
13
1
9 10 11 82
5.4 N •
 m (0.54 kgf • m, 3.9 ft • Ib)
15 N •
 m (1.5 kgf • m, 11 ft • Ib)
8 × 35 mm 
16 N • m (1.6 kgf 
• m, 12 ft 
• Ib) 6 × 22 mm 
5.4 N •
 m (0.54 kgf • m, 3.9 ft • Ib)
5 × 25 mm
2.0 N •
 m (0.2 kgf • m, 1.4 ft • Ib)
LT
271
5
5.4 N •
 m (0.54 kgf • m, 3.9 ft • Ib)
15 N •
 m (1.5 kgf • m, 11 ft • Ib)
13 N •
 m (1.3 kgf • m, 9.4 ft • Ib) 
						

							8-48
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HULL
HOODDECK AND HULL
EXPLODED DIAGRAM
Step Procedure/Part name Q’ty Service points
11 Packing 2
12 Nut 4
NOTE:
To remove the cleat, remove the exhaust
system first.
13 Plate 4
14 Cleat 2
15 Packing 2
16 Nut/washer 3/3
17 Bolt 4
18 Protector 1
Reverse the disassembly steps for 
assembly.
1617
18453
7
6
15
1314 12
13
1
9 10 11 82
5.4 N •
 m (0.54 kgf • m, 3.9 ft • Ib)
15 N •
 m (1.5 kgf • m, 11 ft • Ib)
8 × 35 mm 
16 N • m (1.6 kgf 
• m, 12 ft 
• Ib) 6 × 22 mm 
5.4 N •
 m (0.54 kgf • m, 3.9 ft • Ib)
5 × 25 mm
2.0 N •
 m (0.2 kgf • m, 1.4 ft • Ib)
LT
271
5
5.4 N •
 m (0.54 kgf • m, 3.9 ft • Ib)
15 N •
 m (1.5 kgf • m, 11 ft • Ib)
13 N •
 m (1.3 kgf • m, 9.4 ft • Ib) 
						

							8-49
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HULL
HOODENGINE MOUNT
ENGINE MOUNT
EXPLODED DIAGRAM
REMOVAL AND INSTALLATION CHART
Step Procedure/Part name Q’ty Service points
ENGINE MOUNT REMOVAL
Follow the left “Step” for removal.
Engine unit Refer to “ENGINE UNIT” in Chapter 5.
1Bolt 4
2 Damper 1 1
3 Damper 2 1
4Bolt 8
5 Engine mount 4
6 Liner 2 Stern side
Reverse the removal steps for installation. 
						

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HULL
HOODENGINE MOUNT
HULL REPAIR
Shallow scratches
1. Sand the scratches with 400 grit sandpa-
per (either wet or dry) until the scratches
are smooth. Then, sand the scratches
once again with 600 grit sandpaper (either
wet or dry).
Deep scratches
1. Remove any sharp or rough edges from
the hull surface.
2. Sand the scratches and a 1-inch circum-
ference around them with 80 grit sandpa-
per (either wet or dry).
3. Clean the entire area with acetone and let
it completely dry.
4. Mix gel-coat and gel-coat thickener to form
a putty, and then add the catalyst to the
putty.
5. Apply the putty, spread it with a squeegee,
and then cover the putty with wax paper.
6. When the putty has set, sand it. Smooth
the area with 80–400 grit sandpaper
(either wet or dry) and a sanding block.
7. Clean the area with a dry cloth and then
polish it.
 WARNING
Resins, catalysts, and solvents are flamma-
ble and toxic; only use them in a well-venti-
lated area and keep them away from open
flames and sparks. Always follow the man-
ufacturer’s instructions and warnings. 
						

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HULL
HOODENGINE MOUNT
Cracks and punctures
NOTE:
Before attempting to repair any cracks or
punctures, refer to “WATERCRAFT FRP
REPAIR MANUAL”.
1. Remove any damaged fiberglass.
2. Cut the damaged area and separate it
approximately 0.25 inch.
3. On the outside of the hull, grind the sepa-
rated edge of the area to less than 5° as
shown.
4. Working from inside the hull, grind the
damaged area approximately 4 inches
beyond the damage.
5. Clean the area with acetone, apply BP-1
or an equivalent primer onto both sides of
the damaged area, and then allow it to
cure for approximately 30 minutes.
6. Cover a piece of cardboard with wax paper
1
 and then cover the damaged area with
it.
7. Combine the polyester resin and the cata-
lyst, and then apply the mixture onto the
hull.
8. Install a glass mat 2
 (2 inches smaller
than the ground area).
9. Apply the resin.
10. Install a 20 oz. fiberglass cloth 3
 (1 inch
smaller than the glass mat).
11. Apply the resin.
12. Install another glass mat 4
 (1 inch smaller
than the ground area).
13. When the resin has hardened remove the
piece of cardboard.
14. Finish the outer surface.
Refer to steps (3)–(7) in the “Deep
scratches” section. 
						

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HULL
HOODENGINE MOUNT
Insert nut
NOTE:
Use the insert nut when:
A pop nut which was attached to the hull
slipped off or,
When a bolt which was fastened to an insert
nut or pop nut broke.
Nut 1
 
Thread direction 2
 
Slot to be threaded 3
 
NOTE:
Drilling size
Part No.Part 
nameRemarks
EW2-62733-09 NutStainless 
steel, M6
Material Pilot hole diameter
FRP or SMC 9.1–9.2 mm (0.36 in)
Brass 9.4 mm (0.37 in)
Example 1:
NOTE:
Before attempting to install the insert nut, refer
to “WATERCRAFT FRP REPAIR MANUAL”.
The insert nut is used to repair the pop nut
designed for the ride plate. 
(By repairing the FRP portion, the insert nut
can be used for all models.)
1. Remove:
Pop nut
2. Clean the surface to be scarfed and the
inside of the hull with acetone.
3. Scarf the shaded portion of the hull. 
						

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HULL
HOODENGINE MOUNT
4. First, apply tape 1
 to the inner surface of
the hull and then laminate fiberglass mats
over the tape with resin.
NOTE:
When it is possible to work inside the hull, lam-
inate the mats from the inside.
5. Sand the outer surface of the hull until it is
smooth.
6. Install the ride plate. 
7. Drill a 20 mm (0.79 in) deep hole in the
center of the laminated fiberglass layers
with a 9.2 mm (0.36 in) diameter drill bit.
8. Pass the bolt 2
 through the insert nut and
lock the bolt with the nut 3
 as shown. 
9. Screw in the insert nut so that the top is
flush with the FRP surface. 
10. Loosen the locknut and remove the bolt.
CAUTION:

Only use a steel bolt with a tensile
strength of 8T or more.

If the bolt is inferior in strength or is made
of stainless steel it may break.
Bolt 2
 
Locknut 3
 
Example 2:
The brass insert nut, which is designed for the
Super Jet ride plate or the intake screen, is
used as follows.
NOTE:
If the bolt is broken, drill it out.
1. Drill a hole in the hull.
NOTE:
First, use a small-diameter drill bit followed
by drill bits of gradually increasing diameter.
Use a 9.4 mm (0.37 in) drill bit for the final
drilling.