Yamaha Waverunner 3 Manual

							3-24
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ELECTRICAL
1. Remove:
Bands
Battery negative lead 1
 
Battery positive lead 2
 
Battery
Battery breather hose 3
 
 WARNING
When removing the battery, disconnect
the negative lead first.
Remove the battery to prevent acid loss
during turning the machine on its side for
the impeller service.
2
3 1
2. Inspect:
Electrolyte level
Low →
 Add distilled water.
The electrolyte level should be between
the upper a and lower b level marks.
CAUTION:
Use only distilled water. Other types of
water contain minerals which are harmful
to batteries.Filling steps:
Remove each filler cap.
Add distilled water.
When the electrolyte level reaches the
upper level mark, allow the cell to stand
for 20 minutes. If the electrolyte level
drops, add more distilled water so the
level reaches the upper level mark. 
						

							3-25
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ELECTRICAL
3. Inspect:
Specific gravity
Out of specification →
 Charge.
4. Install:
Filler caps
CAUTION:
Before installation, rinse off any fluid from
the battery box and battery and make sure
that the battery is dry before installing it.
Specific gravity at 20 °C (68 °F):
1.28
Charging current:
1.9 amps 
× 10 hrs
5. Install:
Battery breather hose 1
 
Battery 
Battery positive lead 2
 
Battery negative lead 3
 
Bands
CAUTION:
Connect the positive lead to the battery
terminal first.
Make sure the battery leads are con-
nected properly. Reversing the leads can
seriously damage the electrical system.
Make sure that the battery breather hose is
properly connected and is not obstructed.
Coat the terminals with a water resistant
grease to minimize terminal corrosion.
2
1 3 
						

							3-26
E
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JET PUMP UNIT
JET PUMP UNIT
Impeller inspection
1. Check:
Impeller 1
 
Damage/wear →
 Replace.
Nicks/scratches →
 File or grind.
2. Measure:
Impeller-to-housing clearancea
 
Out of specification →
 Replace.
Max. impeller-to-housing 
clearance:
0.6 mm (0.0236 in)
Measurement steps:
Remove the battery leads.
Remove the intake grate and intake duct.
Refer to “INTAKE GRATE, RIDE PLATE,
AND INTAKE DUCT” in Chapter 6.
Measure the clearance at each impeller
blade as shown (a total of three measure-
ments).
Install the intake duct and intake grate.
Refer to “INTAKE GRATE, RIDE PLATE,
AND INTAKE DUCT” in Chapter 6.
Install the battery leads. 
						

							3-27
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JET PUMP UNIT/BILGE PUMP
Water inlet strainer inspection
1. Inspect:
Water inlet strainer
Contaminants →
 Clean.
Cracks/damage →
 Replace.
Inspection steps:
Remove the ride plate.
Refer to “INTAKE GRATE, RIDE PLATE,
AND INTAKE DUCT” in Chapter 6.
Remove the rubber plate.
Refer to “JET PUMP UNIT” in Chapter 6.
Remove the water inlet cover 1
.
Inspect the water inlet strainer mesh a
.
Install the water inlet cover.
Install the rubber plate.
Refer to “JET PUMP UNIT” in Chapter 6.
Install the ride plate.
Refer to “INTAKE GRATE, RIDE PLATE,
AND INTAKE DUCT” in Chapter 6.
BILGE PUMP
Bilge strainer inspection
1. Inspect:
Bilge strainer
Contaminants →
 Clean.
Cracks/damage →
 Replace.
Inspection steps:
Remove the deck beam.
Refer to “SEATS AND HAND GRIP” in
Chapter 8.
Remove the coupling cover.
Disconnect the bilge strainer 1
 from the
bilge strainer holder.
Inspect the bilge strainer.
Install the coupling cover.
Install the deck beam.
Refer to “SEATS AND HAND GRIP” in
Chapter 8.
1 
						

							3-28
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BILGE PUMP/GENERAL
Electric bilge pump strainer inspection
1. Inspect:
Cap
Strainer
Contaminants →
 Clean.
Inspection steps:
Remove the band 1
.
Remove the cap 2
 and strainer 3
.
Inspect the cap and strainer.
Install the strainer and cap.
Install the band.
1
3
2
GENERAL
Drain plug inspection
1. Inspect:
Drain plugs
Cracks/damage →
 Replace.
O-rings
Cracks/wear →
 Replace.
Screw threads
Contaminants →
 Clean. 
						

							3-29
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GENERAL
Lubrication points
1. Lubricate:
Throttle cable (handlebar end)
NOTE:
Before lubricating the throttle cable, squeeze
the throttle lever and remove the rubber seal
1
.
2. Lubricate:
Throttle cable (throttle body end)
Recommended lubricant:
Rust inhibitor
Recommended lubricant:
Yamaha marine grease, 
Yamaha grease A 
(Water resistant grease)
3. Lubricate:
QSTS control cables (handlebar end)
NOTE:
Before lubricating the QSTS control cables,
remove the QSTS cable housing cover. Spray
the rust inhibitor into the outer cables, and
apply grease to the inner cables.
Recommended lubricant:
Yamaha marine grease, 
Yamaha grease A 
(Water resistant grease)
4. Lubricate:
QSTS cables (pulley end)
Recommended grease:
Yamaha marine grease, 
Yamaha grease A 
(Water resistant grease) 
						

							3-30
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GENERAL
5. Lubricate:
Nozzle pivot shaft 
Steering cable (nozzle end)
QSTS cable (nozzle end)
Recommended grease:
Yamaha marine grease, 
Yamaha grease A 
(Water resistant grease)
6. Lubricate:
Steering cable 
Steering cable joint
Shift cable
Shift cable joint 
NOTE:
Disconnect the joints and apply a small
amount of grease.
Recommended grease:
Yamaha marine grease, 
Yamaha grease A 
(Water resistant grease) 
						

							3-31
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GENERAL
7. Fill:
Intermediate housing
NOTE:
Fill the intermediate housing with the recom-
mended grease through the grease nipple 1
.
Recommended grease:
Yamaha marine grease, 
Yamaha grease A 
(Water resistant grease)
Grease quantity:
Initial 10 hours:
33.0–35.0 cm
3 (1.11–1.18 oz)
Every 100 hours or 12 months:
6.0–8.0 cm
3 (0.20–0.27 oz)
1 
						

							EFUEL
1
2
3
4
5
6
7
8
9
CHAPTER 4
FUEL SYSTEM
FUEL TANK AND FUEL PUMP MODULE...................................................... 4-1
EXPLODED DIAGRAM ............................................................................. 4-1
REMOVAL AND INSTALLATION CHART ................................................ 4-1
SERVICE POINTS .................................................................................... 4-4
Fuel hose disconnection ..................................................................... 4-4
Fuel pump module removal................................................................. 4-4
Fuel sender disassembly .................................................................... 4-4
Check valve inspection ....................................................................... 4-5
Rollover valve inspection .................................................................... 4-5
Fuel level sender inspection................................................................ 4-5
Fuel tank inspection ............................................................................ 4-5
Fuel hose inspection ........................................................................... 4-5
Fuel pump filter inspection .................................................................. 4-6
Fuel strainer inspection ....................................................................... 4-6
Fuel pump module installation ............................................................ 4-6
Fuel hose connect ............................................................................... 4-6
FUEL INJECTION SYSTEM ............................................................................ 4-7
EXPLODED DIAGRAM ............................................................................. 4-7
REMOVAL AND INSTALLATION CHART ................................................ 4-7
SERVICE POINTS .................................................................................. 4-16
Hose clamps removal........................................................................ 4-16
Hose clamps installation ................................................................... 4-16
Fuel hose disconnection ................................................................... 4-16
Fuel line inspection ........................................................................... 4-17
Fuel hose installation (replacing with new fuel hose) ........................ 4-18
Fuel hose connection ........................................................................ 4-18
Throttle body removal ....................................................................... 4-18
Fuel injector inspection ..................................................................... 4-19
Throttle body inspection .................................................................... 4-19
Throttle body installation ................................................................... 4-20
Throttle bodies synchronization ........................................................ 4-21
Fuel pressure measurement ............................................................. 4-26 
						

							4-1
EFUELFUEL TANK AND FUEL PUMP MODULE
FUEL TANK AND FUEL PUMP MODULE
EXPLODED DIAGRAM
REMOVAL AND INSTALLATION CHART
Step Procedure/Part name Q’ty Service points
FUEL TANK REMOVAL
Follow the left “Step” for removal.
Service lid 1 Refer to “FRONT HOOD” in Chapter 8.
Service lid 2
Ventilation hose From ventilation fitting
Engine unit Refer to “ENGINE UNIT” in Chapter 5.
NOTE:
When removing the pump module only, it is
not necessary to remove the engine unit.
1 Rollover valve 1
2 Fuel tank breather hose 2
3 Check valve 1
1.3 N •
 m (0.13 kgf • m, 0.9 ft • Ib)
8 × 18 mm 16 N •
 m (1.6 kgf • m, 11 ft • Ib)
5.9 N • m (0.59 kgf 
• m, 4.3 ft 
• Ib)
4.2 N • m (0.42 kgf 
• m, 3.0 ft 
• Ib)
17
18
163
2
2 17
10 9 4
5
118
19
20 22
23 2114 12 14
LT
572
LT
572
LT
572
LT
572
2nd   6.4 N •
 m (0.64 kgf • m, 4.6 ft • Ib) 1st    3.2 N •
 m (0.32 kgf • m, 2.3 ft • Ib)
15
136