Yamaha Waverunner 3 Manual

							4-22
EFUELFUEL INJECTION SYSTEM
c. Turn synchronizing screw #1 3
 clock-
wise approximately 7 times until it starts
to contact the lever.
NOTE:
Butterfly valve #1 should be fully closed.
Butterfly valves #2 and #3 open if the
screw is turned more than 7 times.
If butterfly valves #1, #2, and #3 are not
fully closed, close the valves by adjusting
synchronizing screw #1 3
.
d. Turn synchronizing screw #3 5
 clock-
wise approximately 7 times until it starts
to contact the lever.
NOTE:
Butterfly valve #4 should be fully closed.
Butterfly valves #1, #2, and #3 open if the
screw is turned more than 7 times.
If all butterfly valves are not fully closed,
close the valves by adjusting synchroniz-
ing screw #3 5
.
e. Check that all butterfly valves are fully
closed and that they open simulta-
neously.
NOTE:
If all butterfly valves are not fully closed,
close the valves by repeating steps a–d.
f. Turn the throttle stop screw 2
 clockwise
approximately 1.5 times until it starts to
contact the throttle lever.
g. Remove the plugs 6
.
h. Install the carburetor synchronizer 7
 or
vacuum gauge 8
.
Carburetor synchronizer:
YU-08030
Vacuum gauge:
90890-03094
6
#1#2#3#4
7
È
8
É 
						

							4-23
EFUELFUEL INJECTION SYSTEM
NOTE:
For best results, use a vacuum gauge
(commercially obtainable), like 9
 or 0
shown in the illustration, that has four
adapters.
ÈFor USA and Canada
ÉFor worldwide
i. Install the throttle bodies.
NOTE:
Adjust the throttle body synchronization
with the air filter case uninstalled.
j. Connect the fuel hose and clamp.
k. Connect the Yamaha Diagnostic Sys-
tem.
l. Remove the sub wire harness from the
air filter case, and then connect it to the
throttle bodies and main wire harness.
m. Connect the test harness (3 pin) to the
throttle position sensor A
.
Test harness (3 pins):
YB-06793/90890-06793
n. To start the ECM normally, start the
Yamaha Diagnostic System.
CAUTION:
If the Yamaha Diagnostic System and
ECU are started, fuel can spurt out. Be
sure to connect the fuel hoses and throt-
tle bodies when adjusting the throttle
position sensor.
NOTE:
Use the test connector B
 to start the ECU
normally only if the Yamaha Diagnostic
System is not available.
Test connector:
YW-06862/90890-06862
o. Measure the throttle position sensor out-
put voltage (DC). Adjust the throttle posi-
tion sensor A
 position if out of
specification.
0
9
A
B/O
P
B 
						

							4-24
EFUELFUEL INJECTION SYSTEM
Throttle position sensor output 
voltage:
Pink (P) – Black/Orange (B/O)
0.8 
± 0.1 V
NOTE:
To decrease the output voltage, turn the
throttle position sensor clockwise.
Slightly tighten the throttle position screw.
p. Start the engine and let it run at trolling
speed for 20 minutes.
NOTE:
Warm the engine up in the water.
While checking the engine temperature
with the Yamaha Diagnostic System,
warm the engine up until the engine tem-
perature is 50 °C (122 °F).
q. Adjust the throttle stop screw 2
 until
trolling speed is within specification.
Trolling speed:
Season TemperatureSpecified 
engine speed
Summer30 °C (86 °F) 
or more1,650 r/min
Winter10 °C (50 °F) 
or less1,720 r/min
Spring/
Fall20 °C (68 °F) 1,680 r/min
r. Adjust each cylinder to the cylinder dif-
ferences shown in the table using syn-
chronizing screws 3
–5
 and using
cylinder #2 as the standard.
0     5     10    15    20    25   30    35    40    45     50 1,740
1,720
1,700
1,680
1,660
1,640
1,620
1,600
˚C
r/min 
						

							4-25
EFUEL
3. Remove:
• Throttle bodies
 Air filter case
4. Remove:
 Carburetor synchronizer or vacuum 
gauge
5. Install:
 Plugs
6. Install:
 Air filter case
 Throttle bodies
Vacuum pressure at trolling 
speed:
CylinderCylinder 
differenceExample
#1–30 ± 10 mmHg
(–4.00 ± 
1.33 kPa, 
–1.2 ± 0.4 inHg)–210 ± 10 mmHg
(–27.99 ± 
1.33 kPa, 
–8.3 ± 0.4 inHg)
#2 Standard*0–180 mmHg
(–23.99 kPa, 
–7.1 inHg)
 #30 ± 10 mmHg
(0 ± 1.33 kPa, 
0 ± 0.4 inHg)–180 ± 10 mmHg
(–23.99 ± 
1.33 kPa, 
–7.1 ± 0.4 inHg)
#4–20 ± 10 mmHg
(–2.67 ± 
1.33 kPa, 
–0.8 ± 0.4 inHg)–200 ± 10 mmHg
(–26.66 ± 
1.33 kPa, 
–7.8 ± 0.4 inHg)
Standard*: When setting the specified 
engine speed, the value is zero.
NOTE:
Always maintain the specified trolling speed
when making this adjustment.
s. Measure the throttle position sensor out-
put voltage. Adjust the throttle position
sensor A
 position if out of specification.
Throttle position sensor output 
voltage:
Pink (P) – Black/Orange (B/O)
0.760 ± 0.016 V
FUEL INJECTION SYSTEM 
						

							4-26
EFUELFUEL INJECTION SYSTEM
Fuel pressure measurement
1. Disconnect:
Fuel hose
Refer to “Fuel hose disconnection”.
2. Install:
Fuel pressure gauge adapter 1
 
Fuel pressure gauge 2
 
NOTE:
To connect the fuel pressure gauge adapter,
follow the procedures for connecting a fuel
hose. (Refer to “Fuel hose connection”.)
3. Start the engine and arrow it to warm up
for several minutes.
4. Measure:
Fuel pressure
Out of specification →
 Replace the fuel
pump module.
5. Remove:
Fuel pressure gauge
Fuel pressure gauge adapter
NOTE:
To disconnect the fuel pressure gauge
adapter, follow the procedures for disconnect-
ing a fuel hose. (Refer to “Fuel hose discon-
nection”.)
6. Connect:
Fuel hose
Refer to “Fuel hose connection”.
Fuel pressure gauge adapter:
YW-06842/90890-06842
Fuel pressure gauge:
YB-06766/90890-06786
Fuel pressure:
310–330 kPa 
(3.1–3.3 kgf/cm
2, 45–47 psi)
1 2 
						

							EPOWR
CHAPTER  5
POWER UNIT
ENGINE UNIT .................................................................................................. 5-1
EXPLODED DIAGRAM ............................................................................. 5-1
REMOVAL AND INSTALLATION CHART ................................................ 5-1
SERVICE POINTS .................................................................................... 5-4
Compression pressure measurement ................................................. 5-4
Oil filter removal and installation ......................................................... 5-6
Engine unit removal ............................................................................ 5-6
Shim removal ...................................................................................... 5-7
Engine mount inspection ..................................................................... 5-7
Coupling clearance inspection ............................................................ 5-7
EXHAUST PIPE 3 ............................................................................................ 5-8
EXPLODED DIAGRAM ............................................................................. 5-8
REMOVAL AND INSTALLATION CHART ................................................ 5-8
EXHAUST PIPES 1 AND 2............................................................................ 5-11
EXPLODED DIAGRAM ........................................................................... 5-11
REMOVAL AND INSTALLATION CHART .............................................. 5-11
EXHAUST MANIFOLD .................................................................................. 5-13
EXPLODED DIAGRAM ........................................................................... 5-13
REMOVAL AND INSTALLATION CHART .............................................. 5-13
OIL TANK ...................................................................................................... 5-15
EXPLODED DIAGRAM ........................................................................... 5-15
REMOVAL AND INSTALLATION CHART .............................................. 5-15
SERVICE POINTS .................................................................................. 5-22
Oil tank removal ................................................................................ 5-22
Oil strainer inspection........................................................................ 5-23
Oil tank installation ............................................................................ 5-23 
						

							EPOWR
1
2
3
4
5
6
7
8
9
OIL PUMP ...................................................................................................... 5-26
EXPLODED DIAGRAM ........................................................................... 5-26
REMOVAL AND INSTALLATION CHART .............................................. 5-26
SERVICE POINTS .................................................................................. 5-27
Oil pump removal .............................................................................. 5-27
Oil pump inspection........................................................................... 5-27
Oil strainer inspection........................................................................ 5-27
Oil pump installation .......................................................................... 5-28
REDUCTION DRIVE GEAR .......................................................................... 5-29
EXPLODED DIAGRAM ........................................................................... 5-29
REMOVAL AND INSTALLATION CHART .............................................. 5-29
SERVICE POINTS .................................................................................. 5-34
Drive coupling removal...................................................................... 5-34
Drive shaft removal ........................................................................... 5-34
Oil pump driven gear inspection........................................................ 5-34
Relief valve inspection ...................................................................... 5-34
Drive shaft installing .......................................................................... 5-35
Drive coupling installation ................................................................. 5-35
GENERATOR AND STARTER MOTOR ....................................................... 5-36
EXPLODED DIAGRAM ........................................................................... 5-36
REMOVAL AND INSTALLATION CHART  ............................................. 5-36
SERVICE POINTS .................................................................................. 5-41
Flywheel magneto removal ............................................................... 5-41
Starter clutch inspection .................................................................... 5-41
Flywheel magneto installation ........................................................... 5-43
CAMSHAFTS................................................................................................. 5-44
EXPLODED DIAGRAM ........................................................................... 5-44
REMOVAL AND INSTALLATION CHART .............................................. 5-44
SERVICE POINTS .................................................................................. 5-49
Camshaft removal ............................................................................. 5-49
Camshaft inspection.......................................................................... 5-50
Camshaft sprockets inspection ......................................................... 5-52
Timing chain tensioner inspection ..................................................... 5-52
Camshaft installation ......................................................................... 5-53 
						

							EPOWR
CYLINDER HEAD.......................................................................................... 5-57
EXPLODED DIAGRAM ........................................................................... 5-57
REMOVAL AND INSTALLATION CHART  ............................................. 5-57
SERVICE POINTS .................................................................................. 5-59
Cylinder head removal ...................................................................... 5-59
Cylinder head inspection ................................................................... 5-59
Cylinder head installation .................................................................. 5-60
VALVES AND VALVE SPRINGS .................................................................. 5-62
EXPLODED DIAGRAM ........................................................................... 5-62
REMOVAL AND INSTALLATION CHART  ............................................. 5-62
SERVICE POINTS .................................................................................. 5-64
Valve removal ................................................................................... 5-64
Valve spring inspection ..................................................................... 5-65
Valve inspection ................................................................................ 5-65
Valve guide inspection ...................................................................... 5-66
Valve guide replacement................................................................... 5-67
Valve seat inspection ........................................................................ 5-69
Valve seat reface .............................................................................. 5-70
Valve installation ............................................................................... 5-72
CRANKCASE ................................................................................................ 5-74
EXPLODED DIAGRAM ........................................................................... 5-74
REMOVAL AND INSTALLATION CHART .............................................. 5-74
SERVICE POINTS .................................................................................. 5-79
Crankcase disassembly .................................................................... 5-79
Crankcase inspection ........................................................................ 5-80
Timing chain inspection..................................................................... 5-80
Crankcase assembly ......................................................................... 5-80
CONNECTING RODS AND PISTONS .......................................................... 5-84
EXPLODED DIAGRAM ........................................................................... 5-84
REMOVAL AND INSTALLATION CHART .............................................. 5-84
SERVICE POINTS .................................................................................. 5-86
Connecting rod and piston removal .................................................. 5-86
Cylinder and piston inspection .......................................................... 5-87
Piston ring inspection ........................................................................ 5-88
Piston pin inspection ......................................................................... 5-89
Connecting rod inspection................................................................. 5-91
Connecting rod and piston installation .............................................. 5-93 
						

							EPOWR
CRANKSHAFT .............................................................................................. 5-97
EXPLODED DIAGRAM ........................................................................... 5-97
REMOVAL AND INSTALLATION CHART .............................................. 5-97
SERVICE POINTS .................................................................................. 5-98
Crankshaft removal ........................................................................... 5-98
Crankshaft inspection........................................................................ 5-98
Crankshaft installation ..................................................................... 5-101
THERMOSTAT ............................................................................................ 5-102
EXPLODED DIAGRAM ......................................................................... 5-102
REMOVAL AND INSTALLATION CHART ............................................ 5-102
SERVICE POINTS ................................................................................ 5-104
Thermostat inspection ..................................................................... 5-104
Thermostat installation .................................................................... 5-104
PRESSURE CONTROL VALVE.................................................................. 5-105
EXPLODED DIAGRAM ......................................................................... 5-105
REMOVAL AND INSTALLATION CHART ............................................ 5-105
SERVICE POINTS ................................................................................ 5-109
Pressure control valve inspection ................................................... 5-109 
						

							5-1
EPOWRENGINE UNIT
ENGINE UNIT
EXPLODED DIAGRAM
REMOVAL AND INSTALLATION CHART
Step Procedure/Part name Q’ty Service points
ENGINE UNIT REMOVAL
Follow the left “Step” for removal.
Engine oil Drain.
Refer to “POWER UNIT” in Chapter 3.
Service lid 1 Refer to “FRONT HOOD” in Chapter 8.
Battery negative and positive lead Refer to “ELECTRICAL BOX AND 
IGNITION COIL BOX” in Chapter 7.
Throttle cable and fuel hose Refer to “FUEL INJECTION SYSTEM” in 
Chapter 4.
Water lock and exhaust joint Refer to “EXHAUST SYSTEM” in Chapter 8.
1 Oil filter 1
2Bolt 4
4
1011
12
6
3
7
2
8
1
9
5
9 14 91315
LT
271
LTLT
572
LT
7.8 N •
 m (0.78 kgf • m, 5.6 ft • Ib)
6 × 25 mm
8 × 28 mm
17 N • m (1.7 kgf 
• m, 12 ft 
• Ib)
17 N • m (1.7 kgf 
• m, 12 ft 
• Ib) 8 × 40 mm
17 N • m (1.7 kgf 
• m, 12 ft 
• Ib)
LT
572
LT