Yamaha Waverunner 3 Manual

							3-4
E
INSP
ADJ
CONTROL SYSTEM
2. Adjust:
Throttle lever free play
Adjustment steps:
NOTE:
When not replacing the throttle cable or
removing the cable from the throttle body,
adjust the throttle cable free play by fol-
lowing steps (f) through (j).
When replacing the throttle cable or
removing the cable from the throttle body,
adjust the throttle cable free play by fol-
lowing steps (a) through (k).
a. Remove the air filter case cover 1
 and
flame arrester.
b. Pull back the cover 2
.
c. Loosen the locknut 3
.
d. Turn the adjusting nut 4
 to adjust the
length a
.
Throttle cable installation length:
18.4 
± 1.0 mm (0.72 
± 0.04 in)
NOTE:
Apply locking agent (LOCTITE®) to the
threads of the adjusting nut 4
.
e. Push in the cover 2
.
f. Remove the handlebar cover.
g. Loosen the locknut 5
.
h. Turn the adjuster 6
 in or out until the
specified free play is obtained.
Turn in  Free play is increased.
Turn out  Free play is decreased.
i. Tighten the locknut.
NOTE:
When adjusting the throttle cable at the
throttle body, fully open the throttle lever
and check that the butterfly valve is fully
open.
If the throttle cable free play cannot be
adjusted properly, replace the throttle
cable. 
						

							3-5
E
INSP
ADJ
CONTROL SYSTEM
 WARNING
After adjusting the free play, turn the han-
dlebar to the right and left and make sure
that the trolling speed does not increase.j. Install the handlebar cover.
T R..
Handlebar cover screw:
1.1 N  m (0.11 kgf  m, 0.8 ft  lb)
LOCTITE
® 242
k. Install the flame arrester and air filter
case cover.
T R..
Flame arrester bolt:
1st:
3.3 N  m 
(0.33 kgf  m, 2.4 ft  lb)
2nd:
6.5 N  m 
(0.65 kgf  m, 4.7 ft  lb)
LOCTITE
® 242
Air filter case cover screw:
2.5 N  m (0.25 kgf  m, 1.8 ft  lb)
LOCTITE
® 572
QSTS cable inspection and adjustment
1. Measure:
Jet thrust nozzle set length a
, b
 
Difference → Adjust.
Measurement steps:
Set the control grip in the neutral position.
Set the jet thrust nozzle in the center
position.
Measure the jet thrust nozzle set length
a
 and b
.
If a
 and b
 length are not even, adjust
the cable joint. 
						

							3-6
E
INSP
ADJ
CONTROL SYSTEM
2. Adjust:
QSTS cable 
NOTE:
If the QSTS cable cannot be properly adjusted
by the cable joint at the QSTS converter end,
adjust the cable joint at the jet pump end so
that the same lengths are obtained. Refer to
“REMOTE CONTROL CABLES AND SPEED
SENSOR LEAD” in Chapter 8. Adjustment steps:
Set the control grip in the neutral position.
Loosen the locknut 1
.
Remove the nut 2
 and pivot pin 3
.
Set the jet thrust nozzle in the center
position.
Turn the cable joint 4
 for adjusting.
Turn in Length 
a is increased.
Turn out Length 
b is increased.
 WARNING
The cable joint must be screwed in more
than 8 mm (0.31 in).
Connect the cable joint 4
 and pivot pin
3
 and tighten the nut 2
.
T R..
Nut:
3.8 N  m (0.38 kgf  m, 2.7 ft  lb)
Tighten the locknut 1
.
T R..
Locknut:
3 N  m (0.3 kgf  m, 2.2 ft  lb) 
						

							3-7
E
INSP
ADJ
CONTROL SYSTEM
Shift cable inspection and adjustment
1. Check:
Reverse gate stopper lever position
Incorrect →
 Adjust.
Checking steps:
Set the shift lever to the reverse position.
Check that the reverse gate 1
 contacts
the stopper 2
 on the bracket and the
lever 3
 contacts the reverse gate.

Set the shift lever to the forward position.

Check that the lever 4
 has been shifted
over the bracket 5
.
4
5
2. Adjust:
Shift cable joint
Adjustment steps:
Loosen the locknut 1
.
Disconnect the cable joint 2
 from the ball
joint 3
.
Situate the reverse gate to the stopper on
the bracket and the lever to the reverse
gate.
Turn the cable joint to align it with the ball
joint.
Turn in Shortens.
Turn out Lengthens.

Turn out the cable joint nine times a to
extend cable 7 mm (0.28 in) from the
aligned position.
 WARNING
The cable joint must be screwed in more
than 8 mm (0.31 in).
Connect the cable joint and tighten the
locknut.
T R..
Locknut:
2.9 N  m (0.29 kgf  m, 2.1 ft  lb) 
						

							3-8
E
INSP
ADJ
CONTROL SYSTEM
Trolling speed check and adjustment
1. Measure:
Trolling speed
Out of specification →
 Adjust.  
Trolling speed:
1,600–1,800 r/min
Checking steps: (Watercraft on water)
Start the engine and allow it to warm up
for a 15 minutes.
Check the engine trolling speed using the
tachometer of the multifunction meter or
using the Yamaha Diagnostic System.
2. Adjust:
Trolling speed 
Adjustment steps:
Remove the air filter case cover 1
.
Start the engine.
Turn the throttle stop screw 2
 in or out
until the specified speed is obtained.
Turn in 
a Increase trolling speed.
Turn out 
b  Decrease trolling speed.
Install the air filter case cover.
T R..
Air filter case cover screw:
2.5 N  m (0.25 kgf  m, 1.8 ft  lb)
LOCTITE
® 572 
						

							3-9
E
INSP
ADJ
FUEL SYSTEM
FUEL SYSTEM
 WARNING
When removing fuel system parts, wrap
them in a cloth and take care that no fuel
spills into the engine compartment.
Fuel line inspection
1. Inspect:
Fuel strainer 1
 
Clog/contaminants →
 Clean.
Fuel pump filter
Clog/contaminants →
 Clean.
Refer to “FUEL TANK AND FUEL
PUMP MODULE” in Chapter 4.
Fuel hose
Damage/cracks →
 Replace.
O-rings (quick connector)
Damage/cracks →
 Replace the quick
connector.
Fuel pipe
Damage/cracks →
 Replace the fuel
pump.
Refer to “FUEL INJECTION SYSTEM”
in Chapter 4.
Fuel filler hose
Fuel tank
Fuel filler cap
Cracks/damage →
 Replace.
1
2. Inspect:
Water separator 1
 
Water accumulation →
 Drain.
NOTE:
If need the water draining, remove the drain
plug 2.
1
2 
						

							3-10
E
INSP
ADJ
POWER UNIT
POWER UNIT
Valve clearance adjustment
The following procedure applies to all of the
valves.
NOTE:
Valve clearance adjustment should be made
on a cold engine, at room temperature. 
When the valve clearance is to be measured
or adjusted, the piston must be at top dead
center (TDC) on the compression stroke. 
1. Remove: 
Air filter case
Refer to “FUEL INJECTION SYSTEM”
in Chapter 4.
2. Remove:
Spark plugs 
Cylinder head cover
Cylinder head cover gasket 
Refer to “CAMSHAFTS” in Chapter 5.
3. Install:
Dial gauge needle
Dial gauge stand 1
 
(into spark plug hole #1)
Dial gauge 2
 
Dial gauge stand:
90890-06583
Dial gauge needle:
90890-06584
Dial gauge stand set:
YW-06585/90890-06585
Dial gauge:
YU-03097/90890-01252
2
1 
						

							3-11
E
INSP
ADJ
POWER UNIT
4. Measure:
Valve clearance
Out of specification →
 Adjust.
Valve clearance (cold):
Intake valve:
0.11–0.20 mm 
(0.0043–0.0079 in)
Exhaust valve:
0.25–0.34 mm 
(0.0098–0.0134 in)
Measurement steps:
Turn the drive coupling counterclockwise,
and then check if cylinder #1 is at TDC of
the compression stroke with a dial gauge.
NOTE:
TDC on the compression stroke can be
found when the camshaft lobes are turned
away from each other.
Measure the valve clearance with a thick-
ness gauge 1
.
NOTE:
If the valve clearance is incorrect, record
the measured reading. 
Measure the valve clearance in the follow-
ing sequence. 
Valve clearance measuring sequence 
Cylinder #1 
→ #2 
→ #4 
→ #3
ÈBow side
To measure the valve clearances of the
other cylinders, starting with cylinder #1
at TDC, turn the drive coupling counter-
clockwise as specified in the following
table.
ÉDegrees that the crankshaft is turned clock-
wise
ÊCylinder
ËCombustion cycle
Cylinder #2 180°
Cylinder #4  360°
Cylinder #3 540°
INEX
1
7205403601800
#4 #3
#2
#1
É
Ê
Ë
Ë
Ë
Ë 
						

							3-12
E
INSP
ADJ
POWER UNIT
5. Remove:
Timing chain tensioner cap bolt 1
 
Gasket
1
6. Turn the timing chain tensioner rod fully
clockwise with a thin screwdriver 1
.
NOTE:
Make sure that the tensioner rod has been fully
set clockwise.
1
7. Remove:
Intake camshaft caps
Exhaust camshaft caps
Timing chain
(from the camshaft sprockets)
Intake camshaft
Exhaust camshaft
NOTE:
Refer to “CAMSHAFTS” in Chapter 5. 
When removing the timing chain and cam-
shafts, fasten the timing chain with a wire to
prevent it from falling into the crankcase.  
						

							3-13
E
INSP
ADJ
POWER UNIT
8. Adjust:
Valve clearance
Adjustment steps:
Remove the valve lifter 1
 and the valve
pad 2
.
NOTE:
Cover the timing chain opening with a rag
to prevent the valve pad from falling into
the crankcase. 
Make a note of the position of each valve
lifter 3
 and valve pad 4
 so that they can
be installed in the correct place. 
Select the proper valve pad from the fol-
lowing table.
Valve pad thickness 
rangeAvailable valve 
pads
Nos. 
120–2401.20–
2.40 mm25 thicknesses in 
0.05 mm increments
NOTE:
The thickness a
 of each valve pad is
marked in hundredths of millimeters on
the side that touches the valve lifter. 
Since valve pads of various sizes are orig-
inally installed, the valve pad number
must be rounded in order to reach the
closest equivalent to the original. 
Round off the original valve pad number
according to the following table.
Last digit Rounded value
0 or 2 0
55
810
EXAMPLE:
Original valve pad number = 148 (thickness
= 1.48 mm) 
Rounded value = 150
Locate the rounded number of the origi-
nal valve pad and the measured valve
clearance in the valve pad selection
table. The point where the column and
row intersect is the new valve pad num-
ber.
1
2
148
a