Yamaha Waverunner 3 Manual

							3-14
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POWER UNIT
NOTE:
The new valve pad number is only an
approximation. The valve clearance must
be measured again and the above steps
should be repeated if the measurement is
still incorrect. 
Install the new valve pad 5
 and the valve
lifter 6
.
NOTE:
Lubricate the valve pad with molybdenum
disulfide grease. 
Lubricate the valve lifter with molybdenum
disulfide oil. 
The valve lifter must turn smoothly when
rotated by hand. 
Install the valve lifter and the valve pad in
the correct place. 
Install the exhaust and intake camshafts,
timing chain and camshaft caps.
T R..
Camshaft cap bolt:
10 N  m (1.0 kgf  m, 7.2 ft  lb)
NOTE:
Refer to “Camshaft installation — CAM-
SHAFTS” in Chapter 5.
Lubricate the camshafts, camshaft lobes
and camshaft journals. 
First, install the exhaust camshaft. 
Align the camshaft marks with the cam-
shaft cap marks. 
Turn the crankshaft clockwise several full
turns to seat the parts. 
Measure the valve clearance again.
If the valve clearance is still out of specifi-
cation, repeat all of the valve clearance
adjustment steps until the specified clear-
ance is obtained.
6
5 
						

							3-15
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Intake
Exhaust
MEASURED 
CLEARANCEORIGINAL VALVE PAD NUMBER
120 125 130 135 140 145
150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240
0.00–0.02 120 125 130
135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225
0.03–0.07 120 125 130 135
140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230
0.08–0.10 120 125 130 135 140
145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235
0.11–0.20 STANDARD CLEARANCE
0.21–0.22 125 130 135 140 145 150
155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240
0.23–0.27130135140145150155160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240
0.28–0.32 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240
0.33–0.37 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240
0.38–0.42 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240
0.43–0.47 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240
0.48–0.52 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240
0.53–0.57 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240
0.58–0.62 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240
0.63–0.67 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240
0.68–0.72 175 180 185 190 195 200 205 210 215 220 225 230 235 240
0.73–0.77 180 185 190 195 200 205 210 215 220 225 230 235 240
0.78–0.82 185 190 195 200 205 210 215 220 225 230 235 240
0.83–0.87 190 195 200 205 210 215 220 225 230 235 240
0.88–0.92 195 200 205 210 215 220 225 230 235 240
Example:
Intake valve clearance (cold)
0.11–0.20 mm (0.0043–0.0079 in)
Rounded value 150
Measured valve clearance is 0.24 mm (0.0094 in)
Replace pad 150 with pad 160
Pad No. 150 = 1.50 mm (0.0591 in)
Pad No. 160 = 1.60 mm (0.0630 in)0.93–0.97 200 205 210 215 220 225 230 235 240
0.98–1.02 205 210 215 220 225 230 235 240
1.03–1.07 210 215 220 225 230 235 240
1.08–1.12 215 220 225 230 235 240
1.13–1.17 220 225 230 235 240
1.18–1.22 225 230 235 240
1.23–1.27 230 235 240
1.28–1.32 235 240
1.33–1.37 240
MEASURED 
CLEARANCEORIGINAL VALVE PAD NUMBER
120 125 130 135 140 145 150 155 160 165
170 175 180 185 190 195 200 205 210 215 220 225 230 235 240
0.00–0.01 120 125 130 135
140 145 150 155 160 165 170 175 180 185 190 195 200 205 210
0.02–0.06 120 125 130 135 140
145 150 155 160 165 170 175 180 185 190 195 200 205 210 215
0.07–0.11 120 125 130 135 140 145
150 155 160 165 170 175 180 185 190 195 200 205 210 215 220
0.12–0.16 120 125 130 135 140 145 150
155 160 165 170 175 180 185 190 195 200 205 210 215 220 225
0.17–0.21 120 125 130 135 140 145 150 155
160 165 170 175 180 185 190 195 200 205 210 215 220 225 230
0.22–0.24 120 125 130 135 140 145 150 155 160
165 170 175 180 185 190 195 200 205 210 215 220 225 230 235
0.25–0.34 STANDARD CLEARANCE
0.35–0.37 125 130 135 140 145 150 155 160 165 170
175 180 185 190 195 200 205 210 215 220 225 230 235 240
0.38–0.42 130 135 140 145 150 155 160 165 170 175
180 185 190 195 200 205 210 215 220 225 230 235 240
0.43–0.47135140145150155160165170175180185 190 195 200 205 210 215 220 225 230 235 240
0.48–0.52 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240
0.53–0.57 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240
0.58–0.62 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240
0.63–0.67 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240
0.68–0.72 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240
0.73–0.77 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240
0.78–0.82 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240
0.83–0.87 175 180 185 190 195 200 205 210 215 220 225 230 235 240
0.88–0.92 180 185 190 195 200 205 210 215 220 225 230 235 240
0.93–0.97 185 190 195 200 205 210 215 220 225 230 235 240
0.98–1.02 190 195 200 205 210 215 220 225 230 235 240
1.03–1.07 195 200 205 210 215 220 225 230 235 240
Example:
Exhaust valve clearance (cold)
0.25–0.34 mm (0.0098–0.0134 in)
Rounded value 170
Measured valve clearance is 0.44 mm (0.0173 in)
Replace pad 170 with pad 185
Pad No. 170 = 1.70 mm (0.0669 in)
Pad No. 185 = 1.85 mm (0.0728 in)1.08–1.12 200 205 210 215 220 225 230 235 240
1.13–1.17 205 210 215 220 225 230 235 240
1.18–1.22 210 215 220 225 230 235 240
1.23–1.27 215 220 225 230 235 240
1.28–1.32 220 225 230 235 240
1.33–1.37 225 230 235 240
1.38–1.42 230 235 240
1.43–1.47 235 240
1.48–1.52 240 
						

							3-16
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9. Remove:
Dial gauge
Dial gauge stand
Dial gauge needle
10. Install:
All removed parts
NOTE:
For installation, reverse the removal proce-
dure.
Engine oil level check
1. Place the watercraft in a horizontal posi-
tion.
2. Check:
Engine oil level
Checking steps:
CAUTION:
When checking the oil level in water,
stay clear of other boats. The water-
craft could be drifted away by the cur-
rent or wind.
Do not run the engine for more than 15
seconds without supplying water,
when checking the oil level on land.
The engine could overheat.
Do not run the engine with too much or
not enough oil in the oil tank. Oil could
spray out or the engine could be dam-
aged. 
						

							3-17
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Remove the oil filler cap 1
 and check for
oil on the dipstick 2
.
If there is no oil on the dipstick, pour
enough oil so that the tip of the dipstick
comes into contact with the oil, and then
install the filler cap.
In water
a. Place the watercraft in water, and then
start the engine.
b. Run the engine at 7,000 r/min or more
for more than 5 minutes.
c. Run the engine at trolling speed for 2–
3 minutes.
d. Stop the engine.
On land
a. Connect the flushing hose connector to
the watercraft.
b. Start the engine, and then turn on the
water supply.
c. Run the engine at trolling speed for 6–
8 minutes.
d. Turn the water supply off, and then
stop the engine.
CAUTION:
When checking the oil level on land, be
sure to connect a garden hose to the
watercraft for proper water supply. 
NOTE:
If the ambient temperature is less than
15°C (59°F), run the engine for an addi-
tional 5 minutes.
Remove the oil filler cap 1
, wipe the dip-
stick 2
 clean, insert it back into the filler
hole, and then remove it again to check
the oil level.
NOTE:
The engine oil should be between the mini-
mum level mark a
 and maximum level
mark b
. 
						

							3-18
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POWER UNIT
If the engine oil is below the minimum
level mark a
, add sufficient oil of the rec-
ommended type to raise it to the correct
level. 
If the engine oil is above the maximum
level mark b
, extract sufficient oil using
an oil changer to lower it to the correct
level.
NOTE:
If the oil temperature is low, the reading on
the dipstick will be low, and if the tempera-
ture is high, the reading on the dipstick will
be high.
Engine oil change — using oil changer
 WARNING
Avoid changing the engine oil immediately
after turning the engine off. The oil is hot
and should be handled with care to avoid
burns.
CAUTION:
Do not run the engine with too much or
not enough oil in the oil tank. Oil could
spray out or the engine could be dam-
aged.
Do not run the engine for more than 15
seconds without supplying water, when
checking the oil level on land.
The engine could overheat.
Be sure to change the engine oil after the
first 10 hours of operation, and every 100
hours thereafter or at the start of a new
season, otherwise the engine will wear
quickly.
1. Warm the engine up, and then put the
watercraft in a horizontal position. 
						

							3-19
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ADJ
POWER UNIT
2. Remove:
Oil filler cap 1
 
1
3. Insert the tube of an oil changer into the oil
filler hole.
4. Operate the oil changer to extract the oil.
5. If the oil filter is also to be replaced, per-
form the following procedure.
Replacing steps:
Place a rag under the oil filter.
Remove the oil filter 1
 with an oil filter
wrench 2.
Oil filter wrench:
YU-38411/90890-01426
Lubricate the O-ring 3 of the new oil filter
with a thin coat of engine oil.
CAUTION:
Make sure the O-ring 3 is positioned
correctly in the groove of the oil filter.
Tighten the new oil filter to specification
with an oil filter wrench.
T R..
Oil filter:
17 N  m (1.7 kgf  m, 12 ft  lb)
1
2 
						

							3-20
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INSP
ADJ
POWER UNIT
6. Pour the specified amount of the recom-
mended engine oil into the oil filler hole.
7. Fill:
Oil tank 
(with the specified amount of the recom-
mended engine oil)
CAUTION:
When starting the engine make sure the
dipstick is securely fitted into the oil tank.
8. Install:
Oil filler cap
Recommended oil:
SAE 10W-30
API SE, SF, SG, SH, SJ
Oil quantity:
Total amount:
4.3 L (4.5 US qt, 3.8 Imp qt)
With oil filter replacement:
2.2 L (2.3 US qt, 1.9 Imp qt)
Without oil filter replacement:
2.0 L (2.1 US qt, 1.8 Imp qt)
Air filter element clean
1. Remove:
Air filter case cover 1
  
						

							3-21
E
INSP
ADJ
POWER UNIT
2. Remove the air filter element and check it
for dirt and oil. Replace the air filter ele-
ment if there is any oil buildup.
CAUTION:
Make sure that the air filter element is
installed in the filter case properly.
Do not start the engine with the air filter
element removed, otherwise the engine
could be damaged.
If cleaning the air filter element, use cold
or lukewarm water and let it air dry com-
pletely. Do not use detergent or an sol-
vent to clean the air filter element, or dry
it with heat or compressed air, otherwise
it could be damaged.
3. Install:
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
Spark plug inspection
1. Remove:
Air filter case cover 1
 
2. Remove:
Air filter element
CAUTION:
Be careful not to get any foreign sub-
stances or water in the air intake port and
spark plug hole. 
						

							3-22
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POWER UNIT
3. Inspect:
Electrodes 1
 
Damage/wear →
 Replace.
Insulator color 2
 
Distinctly different color →
 Check the
engine condition. 
4. Clean:
Spark plug
(with a spark plug cleaner or wire brush)
5. Measure:
Spark plug gap a
 
Out of specification →
 Regap.
Color guide:
Medium to light tan color:
Normal
Whitish color:
Lean fuel mixture
Air leak
Incorrect settings
Blackish color:
Overly rich mixture
Electrical malfunction
Defective spark plug
Spark plug gap:
0.7–0.8 mm (0.028–0.031 in)
6. Tighten:
Spark plug
NOTE:
Before installing the spark plug, clean the
gasket surface and spark plug surface. Also,
it is suggested to apply a thin film of anti-
seize compound to the spark plug threads to
prevent thread seizure.
If a torque wrench is not available, a good
estimate of the correct tightening torque for a
new spark plug is to finger tighten a
 the
spark plug and then tighten it another 1/4 to
1/2 of a turnb
.
T R..
Spark plug:
13 N  m (1.3 kgf  m, 9.4 ft  lb) 
						

							3-23
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ADJ
POWER UNIT/ELECTRICAL
7. Install:
Air filter element
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
ELECTRICAL
Battery inspection
 WARNING
Battery electrolyte is poisonous and dan-
gerous, causing severe burns, etc. Electro-
lyte contains sulfuric acid. Avoid contact
with skin, eyes or clothing. 
Antidotes
External: Flush with water. 
Internal: Drink large quantities of water or
milk. Follow with milk of magnesia, beaten
egg or vegetable oil. Call physician immedi-
ately. 
Eyes: Flush with water for 15 minutes and
get prompt medical attention. 
Batteries produce explosive gases. Keep
sparks, flame, cigarettes, etc., well away. If
using or charging the battery in an
enclosed space, make sure that it is well
ventilated. Always shield your eyes when
working near batteries. 
KEEP OUT OF THE REACH OF CHILDREN.
CAUTION:
Be careful not to place the battery on its
side. 
Make sure to remove the battery from the
battery compartment when adding battery
electrolyte or charging the battery. 
When checking the battery, make sure the
breather hose is connected to the battery
and not obstructed.