Yamaha Waverunner 3 Manual
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2-10 ESPECTIGHTENING TORQUES Engine Engine unit – engine mount Bolt M8 4 17 1.7 12 271LT Oil filter——117 1.7 12 Coupling cover Bolt M6 1 7.8 0.78 5.6 572LT Thermoswitch (exhaust) – exhaust pipe 3Bolt M6 2 7.6 0.76 5.5572LT Outer exhaust joint clamp – exhaust pipe 3/exhaust pipe 21st ——24.4 0.44 3.2 2nd 4.4 0.44 3.2 Inner exhaust joint clamp – exhaust pipe 3/exhaust pipe 21st ——24.4 0.44 3.2 2nd 4.4 0.44 3.2 Exhaust pipe 3 – crankcase1st Bolt M10 12.0 0.2 1.4 242LT5th 15 1.5 11 9th 39 3.9 28 2nd Bolt M10 12.0 0.2 1.4 242LT6th 15 1.5 11 10th 39 3.9 28 3rd Bolt M10 12.0 0.2 1.4 242LT7th 15 1.5 11 11th 39 3.9 28 4th Bolt M10 12.0 0.2 1.4 242LT8th 15 1.5 11 12th 39 3.9 28 Exhaust pipe end – exhaust pipe 31st Bolt M6 33.7 0.37 2.7 572LT2nd 7.6 0.76 5.5 Exhaust pipe stay – crankcase1st Bolt M8 215 1.5 11 242LT2nd 42 4.2 30 Exhaust pipe 1 – exhaust pipe stay1st Bolt M10 115 1.5 11 242LT2nd 42 4.2 30 Exhaust pipe 2 – exhaust pipe 11st Nut—139 3.9 28 E 6th 39 3.9 28 2nd Nut—139 3.9 28 7th 39 3.9 28 3rd Nut—139 3.9 28 8th 39 3.9 28 4th Nut—139 3.9 28 9th 39 3.9 28 5th Nut—139 3.9 28 10th 39 3.9 28 Exhaust pipe 1 – exhaust manifold 1/ exhaust manifold 21st Bolt M8 1022 2.2 16 242LT2nd 22 2.2 16 3rd 35 3.5 25 Part to tightened Part nameThread sizeQ’tyTightening torque Remarks Nmkgfmftlb
2-11 ESPECTIGHTENING TORQUES Exhaust manifold 1 – cylinder head1st Bolt M8 622 2.2 16242LT2nd 22 2.2 16 3rd 35 3.5 25 Exhaust manifold 2 – cylinder head1st Bolt M8 522 2.2 16 242LT2nd 22 2.2 16 3rd 35 3.5 25 Water jacket – oil tank1st Bolt M6 43.7 0.37 2.7 572LT2nd 7.6 0.76 5.5 Oil tank stay/reduction drive gear case – oil separator1st Bolt M6 33.7 0.37 2.7 572LT 2nd 7.6 0.76 5.5 Cover (ground lead) – oil tank Bolt M6 3 7.6 0.76 5.5 572LT Ground lead – oil tank Bolt M6 2 7.6 0.76 5.5E Oil tank – reduction drive gear case1st Bolt M8 415 1.5 11572LT2nd 28 2.8 20 Oil tank – oil tank stay1st Nut—22.0 0.2 1.4 572LT2nd 15 1.5 11 3rd 39 3.9 28 Oil tank stay – cylinder head1st Bolt M10 22.0 0.2 1.4 572LT2nd 15 1.5 11 3rd 39 3.9 28 Bracket (coupling cover) – oil tank1st Bolt M6 23.7 0.37 2.7 572LT2nd 7.6 0.76 5.5 Hanger – oil tank cover1st Bolt M6 43.7 0.37 2.7 572LT2nd 7.6 0.76 5.5 Oil tank cover – oil tank1st Bolt M6 83.7 0.37 2.7 572LT2nd 7.6 0.76 5.5 Oil breather plate 1/ oil breather plate 2 – oil tank cover1st Bolt M5 101.9 0.19 1.4 E 2nd 4.4 0.44 3.2 Baffle plate – oil tank1st Bolt M5 31.9 0.19 1.4 E2nd 4.4 0.44 3.2 Oil strainer – oil tank1st Bolt M6 23.7 0.37 2.7 E2nd 7.6 0.76 5.5 Oil cooler cover – oil tank 1st Bolt M6 243.7 0.37 2.7 572LT2nd 7.6 0.76 5.5 Anode – oil tank Screw M4 1 3.7 0.37 2.7 E Oil pump assembly – reduction drive gear case1st Bolt M6 121.4 0.14 1.0572LT2nd 10 1.0 7.2 Drain plug (engine oil) Bolt M8 1 18 1.8 13 Oil pump housing cover 1/oil pump housing – oil pump housing cover 2Bolt M6 2 7.9 0.79 5.7 Drive coupling – drive shaft——128 2.8 20 572LT Part to tightened Part nameThread sizeQ’tyTightening torque Remarks Nmkgfmftlb
2-12 ESPECTIGHTENING TORQUES Reduction drive gear case – crankcase1st Bolt M6 23.7 0.37 2.7572LT2nd 7.6 0.76 5.5 1st Bolt M8 715 1.5 11 572LT2nd 28 2.8 20 Holder (relief valve) – reduction drive gear caseBolt M6 1 10 1.0 7.2 E Bearing housing – reduction drive gear case1st Bolt M8 415 1.5 11E2nd 28 2.8 20 Battery negative lead – starter motorNut—118 1.8 13 A Starter motor lead – starter motor Bolt M8 1 4.9 0.49 3.5A Starter motor – crankcase Bolt M8 1 18 1.8 13 Generator cover – crankcase1st Bolt M10 815 1.5 11 572LT2nd 50 5.0 36 Rotor – crankshaft Bolt M10 1 75 7.5 54 E Rotor – starter clutch Bolt M8 6 24 2.4 17 Washer/pulser coil lead and lighting coil lead – generatorBolt M5 3 4.9 0.49 3.5 242LT Pulser coil – generator cover Bolt M5 4 4.9 0.49 3.5242LT Holder (wire harness) – generator coverBolt M6 2 14 1.4 10242LT Lighting coil – generator cover Bolt M6 3 14 1.4 10242LT Spark plug——413 1.39.4 Camshaft position sensor Bolt M6 1 10 1.0 7.2 572LT Cooling water pipe – cylinder1st Bolt M6 13.7 0.37 2.7572LT2nd 7.6 0.76 5.5 Cylinder head cover – cylinder head Bolt M6 6 12 1.2 8.7 E Timing chain tensioner cap bolt Bolt M6 1 10 1.0 7.2 Timing chain tensioner – cylinder headBolt M6 2 10 1.0 7.2 Exhaust camshaft cap – cylinder headBolt M6 10 10 1.0 7.2 E Intake camshaft cap – cylinder headBolt M6 18 10 1.0 7.2E Exhaust camshaft sprocket – exhaust camshaftBolt M7 2 24 2.4 17E Intake camshaft sprocket – intake camshaftBolt M7 2 24 2.4 17E Hanger – cylinder head Bolt M8 2 40 4.0 29271LT Cylinder head – crankcaseBolt M6 3 10 1.0 7.2E 1st Nut—220 2.0 14 2nd 64 6.4 46 1st Nut—820 2.0 14 2nd 49 4.9 35 Part to tightened Part nameThread sizeQ’tyTightening torque Remarks Nmkgfmftlb
2-13 ESPECTIGHTENING TORQUES Plug (vacuum pressure) Bolt M6 4 10 1.0 7.2 Engine temperature sensor – crankcase——115 1.5 11 Thermoswitch (engine) – crankcaseBolt M6 2 7.6 0.76 5.5 572LT Oil pressure switch——1 8.4 0.84 6.1572LT Anode cover – anode Bolt M6 1 12 1.2 8.7271LT Anode cover – cylinder head Bolt M8 1 20 2.0 14 Oil pan – lower crankcase Bolt M6 13 12 1.2 8.7 572LT Lower crankcase – upper crankcaseBolt M6 10 12 1.2 8.7 572LT 1st Bolt M9 107.8 0.78 5.6 E2nd 15 1.5 11 3rd 49 ± 5° Oil pipe – lower crankcase Bolt M6 1 12 1.2 8.7 E Cover – lower crankcase Screw M6 2 12 1.2 8.7572LT Oil filter bolt – lower crankcase——135 3.5 25E Connecting rod cap1st Nut—820 2.0 14 2nd 120 ± 5° Thermostat housing cover – Thermostat housing 1st Bolt M6 23.7 0.37 2.7 572LT2nd 7.6 0.76 5.5 Pressure control valve – upper crankcase1st Bolt M6 33.7 0.37 2.7 572LT2nd 7.6 0.76 5.5 Collar/pressure control valve housing cover – pressure control housing1st Bolt M6 23.7 0.37 2.7 572LT 2nd 7.6 0.76 5.5 Jet pump unit Steering cable joint – jet thrust nozzleNut—1 6.8 0.68 4.9 242LT Ride plate – hull Bolt M8 4 17 1.7 12572LT Intake duct – hull Bolt M8 4 20 2.0 14242LT Intake grate – hull Bolt M6 4 7.8 0.78 5.6242LT Speed sensor – ride plate Screw M5 4 3.7 0.37 2.7242LT Jet pump unit assembly/impeller housing 2 – transomBolt M10 4 40 4.0 29572LTBolt M6 1 7.8 0.78 5.6 Rubber plate – bracket Bolt M6 4 6.8 0.68 4.9 Roller – reverse gate stayBolt M8 1 8.3 0.83 6.0 271LTNut—126 2.6 19 Reverse gate stay – jet pump Bolt M6 6 7.8 0.78 5.6 242LT Reverse gate – reverse gate stay Bolt M8 2 20 2.0 14242LT Lever 1 – Reverse gate stay Bolt M6 1 7.8 0.78 5.6242LT Lever 2– Reverse gate stay Nut—1 7.8 0.78 5.6242LT Nozzle ring – nozzle Bolt M8 2 15 1.5 11271LT Jet thrust nozzle – nozzle ring Bolt M8 2 15 1.5 11271LT Nozzle/impeller duct assembly – impeller housing 1Bolt M10 4 40 4.0 29572LT Part to tightened Part nameThread sizeQ’tyTightening torque Remarks Nmkgfmftlb
2-14 ESPECTIGHTENING TORQUES Water inlet cover/water inlet strainer – impeller ductBolt M6 4 6.6 0.66 4.8572LT Drive shaft nut – drive shaft Nut—169 6.9 50 Impeller (left-hand threads) – drive shaftImpeller M22 1 27 2.7 19 572LT Transom plate – hull Nut—426 2.6 19 Bilge strainer holder – bulkhead Screw M5 1 3.7 0.37 2.8 Intermediate housing – bulkhead Bolt M8 3 17 1.7 12 572LT Driven coupling – shaftDriven couplingM24 1 36 3.6 25572LT Grease nipple – intermediate housingNipple—1 5.4 0.54 3.9572LT Hull and hood Handlebar holder – steering master Bolt M8 4 20 2.0 14 242LT Handlebar cover stay – steering masterBolt M6 2 1.1 0.11 0.8271LT Handlebar cover – handlebar cover stayScrew M6 4 1.1 0.11 0.8242LT Handle boss cover – steering masterScrew M6 4 0.9 0.09 0.7242LT QSTS converter – hull Nut—2 5.4 0.54 3.9 Throttle lever assembly – handlebarScrew M5 2 3 0.3 2.2 Handlebar switch assembly – handlebarScrew M5 2 3.4 0.34 2.5 QSTS grip assembly – handlebar Screw M6 1 3.4 0.34 2.5 Grip end – handlebar Bolt M5 2 1.2 0.12 0.9 242LT Cable housing – QSTS grip assemblyScrew M4 1 1 0.1 0.7 Steering master – deck Nut—420 2.0 14 Steering cable ball joint – steering armNut—1 6.8 0.68 4.9 QSTS cable locknut (QSTS converter side)Nut—13 0.32.2 QSTS cable locknut (nozzle ring side)Nut—1 3.8 0.38 2.7 QSTS cable grommet – hull Nut—1 5.9 0.59 4.3 QSTS cable end pin – QSTS converterNut—1 3.8 0.38 2.7 Shift cable locknut (reverse gate side)Nut—1 2.9 0.29 2.1 Shift cable grommet – hull Nut—1 5.9 0.59 4.3 Shift cable holder – shift lever base Nut—2 5.4 0.54 3.9 Steering cable locknut (steering arm side)Nut—1 6.4 0.64 4.6 Part to tightened Part nameThread sizeQ’tyTightening torque Remarks Nmkgfmftlb
2-15 ESPECTIGHTENING TORQUES Steering cable locknut (jet thrust nozzle side)Nut—1 6.5 0.65 4.7 Steering cable grommet – hull Nut—1 5.9 0.59 4.3 Steering cable bracket – steering cable holderNut—2 5.4 0.54 3.9 Steering cable bracket – deck Nut—2 5.4 0.54 3.9 Speed sensor lead grommet – hull Nut—1 5.9 0.59 4.3 Front hood assembly – deck Nut—4 5.4 0.54 3.9 Service lid 1 – deck Bolt M6 4 5.4 0.54 3.9 271LT Service lid 2– deck Screw M4 4 1.5 0.15 1.1 Panel – steering console cover Bolt M5 4 3.9 0.39 2.8 242LT Multifunction meter – steering console coverBolt M5 4 3.9 0.39 2.8242LT Mirror – steering console cover Nut—4 6.9 0.69 5.0 Side cover – deck Bolt M6 8 5.4 0.54 3.9 271LT Bracket (side cover) – deck Bolt M6 4 5.4 0.54 3.9 Steering console cover – glove boxBolt M6 2 5.4 0.54 3.9 242LT Hood lock assembly Bolt M6 2 5.4 0.54 3.9 Steering console cover – deck Nut—2 5.4 0.54 3.9 Glove compartment – deck Nut—220 2.0 14 Shift lever handle – shift lever Bolt M6 2 5.4 0.54 3.9 271LT Latch – glove compartment Screw M6 2 5.4 0.54 3.9271LT Pilot water outlet – hull Nut—2 4.2 0.42 3.0 Shift lever plate – deck Screw M6 3 5.4 0.54 3.9 Shift lever plate – deck/shift lever base assemblyScrew M6 3 5.4 0.54 3.9 242LT Shift lever – base assembly Bolt M6 1 5.4 0.54 3.9271LT Hand grip – deck Nut—4 5.2 0.52 3.8 Front seat stay – deck Nut—215 1.5 11 Seat lock projection – deck beam Nut—126 2.6 19 Seat lock projection – deck Nut—126 2.6 19 Rear seat stay – deck Nut—4 5.2 0.52 3.8 Seat lock assembly – seat Bolt M6 4 6.4 0.64 4.6 271LT Deck beam – deck Nut—418 1.8 13 Plate/rubber hose/exhaust valve – hullNut—6 5.4 0.54 3.9 Exhaust joint protector 1 – Exhaust joint protector 21st Bolt M6 63.7 0.37 2.7 572LT2nd 12 1.2 8.8 Sponson – hull Bolt M8 10 16 1.6 12 Cleat – deck Nut—215 1.5 11 Cleat – hull Nut—415 1.5 11 Spout – hull Nut—1 5.4 0.54 3.9 Protector (bow) – hullBolt M6 4 5.4 0.54 3.9 271LT Nut—3 5.4 0.54 3.9 Part to tightened Part nameThread sizeQ’tyTightening torque Remarks Nmkgfmftlb
2-16 ESPECTIGHTENING TORQUES Bow eye – hull Bolt M6 2 13 1.3 9.4 Drain plug/packing – hull Bolt M5 4 2.0 0.2 1.4 Engine mount – hull Bolt M8 8 17 1.7 12 572LT Engine damper – hull Bolt M6 4 6.4 0.64 4.6271LT Electrical Battery box – hull Bolt M6 2 5.4 0.54 3.9 572LT Battery box/spacer – hull Bolt M6 2 5.4 0.54 3.9271LT Electrical box – bulk head Bolt M8 4 17 1.7 12572LT Terminal cover – electrical box Screw M5 4 4.9 0.49 3.5 Cover – electrical boxTapping screwø5 18 4.9 0.49 3.5 Starter motor lead– electrical box Screw M6 1 7.6 0.76 5.5 A Battery positive lead – electrical boxScrew M6 1 7.6 0.76 5.5A Fuse holder stay – electrical boxTapping screwø613.90.392.8 ECM – electrical boxTapping screwø643.90.392.8 Bracket (coupler) – electrical boxTapping screwø613.90.392.8 Slant detection switch – electrical boxTapping screwø623.90.392.8 Main and fuel pump relay Tapping screwø613.90.392.8 Rectifier/regulatorTapping screwø623.90.392.8 Ignition coil – oil tank Bolt M6 3 7.6 0.76 5.5 Ignition coil cover – ignition coil caseTapping screwø6 10 4.9 0.49 3.5 Ignition coil – ignition coil caseTapping screwø644.90.493.5 Part to tightened Part nameThread sizeQ’tyTightening torque Remarks Nmkgfmftlb
2-17 ESPECTIGHTENING TORQUES GENERAL TORQUE This chart specifies tightening torques for stan- dard fasteners with a standard ISO thread pitch. Tightening torque specifications for spe- cial components or assemblies are provided in applicable sections of this manual. To avoid warpage, tighten multi-fastener assemblies in a crisscross fashion and progressive stages until the specified tightening torque is reached. Unless otherwise specified, tightening torque specifications require clean, dry threads. Components should be at room temperature.Nut A Bolt B General torque specifications Nmkgfmftlb 8 mm M5 5.0 0.5 3.6 10 mm M6 8.0 0.8 5.8 12 mm M8 18 1.8 13 14 mm M10 36 3.6 25 17 mm M12 43 4.3 31
2-18 ESPECCABLE AND HOSE ROUTING CABLE AND HOSE ROUTING DOWN BOW20˚ DOWN UP + G F-F E-E G F FC D A EE D C B B A A-A B-B D-DC-C 2 11 1 4 3 6 5 7 6 5 1 8 9 0 A B 6 5C DEF 43 2 G 1Fuel tank breather hose 2QSTS cable 3Steering cable 4Shift cable 5Electrical box lead 6Speed sensor lead 7Cooling water pilot outlet 8Cooling water pilot outlet hose 9Cooling water pilot outlet 0Battery negative leadABattery positive lead BBattery CThrottle cable DFuel hose ECooling water pilot outlet hose FHandlebar switch lead GElectrical bilge pump lead
2-19 ESPECCABLE AND HOSE ROUTING 3A 3A3A 3A3A 3AS P A R E20A 3A 3AMAIN A B C D BC F D 8 6 1 23 4 55 E E A A B 0 1CDE F A 3 B G 9 8 7 0 5 0 5 B A 5 E-EF 1Throttle cable 2Handlebar switch lead 3QSTS cable 4Buzzer lead 5Fuel tank breather hose 6Ignition coil lead 7Battery positive lead 8Starter motor lead 9Wire harness 0Fuel hoseAShift cable BSteering cable CElectrical box lead DCooling water pilot outlet hose EBattery negative lead FBattery breather hose GSpeed sensor lead