Yamaha Waverunner 3 Manual

							5-32
EPOWRREDUCTION DRIVE GEAR
EXPLODED DIAGRAM 
*1: EPNOC grease AP #0 Step Procedure/Part name Q’ty Service points
9 Circlip 2
10 Driven gear 1
11 Washer 2
12 Circlip 1
13 Oil seal 2
14 Bearing 1
NOTE:
Remove parts 12 to 15 as a set.
15 Drive shaft 1
16 Circlip 1
17 Circlip 1
E
EE
E
E
15
13
14
16
18
17
12
9
11
10
11
9
8
7
61
2
34521
20
19
E
E
E
*1
AA
*1
5 × 10 mm
10 N 
 m (1.0 kgf  m, 7.2 ft  Ib)
6 × 16 mm8 × 40 mm
2nd   28 N  m (2.8 kgf 
 m, 20 ft 
 Ib) 1st    15 N  m (1.5 kgf 
 m, 11 ft 
 Ib)
E
Not reusable
Not reusable
Not reusable
Not reusable
Not reusable
Not reusable 
						

							5-33
EPOWRREDUCTION DRIVE GEAR
EXPLODED DIAGRAM 
*1: EPNOC grease AP #0 Step Procedure/Part name Q’ty Service points
18 Bearing 1
19 Circlip 1
20 Bearing 1
21 Reduction drive gear case 1
Reverse the disassembly steps for 
assembly.
E
EE
E
E
15
13
14
16
18
17
12
9
11
10
11
9
8
7
61
2
34521
20
19
E
E
E
*1
AA
*1
5 × 10 mm
10 N 
 m (1.0 kgf  m, 7.2 ft  Ib)
6 × 16 mm8 × 40 mm
2nd   28 N  m (2.8 kgf 
 m, 20 ft 
 Ib) 1st    15 N  m (1.5 kgf 
 m, 11 ft 
 Ib)
E
Not reusable
Not reusable
Not reusable 
						

							5-34
EPOWRREDUCTION DRIVE GEAR
SERVICE POINTS
Drive coupling removal
1. Remove:
Drive coupling 1 
NOTE:
While holding the flywheel magneto 2 with the
sheave holder 3, loosen the drive coupling
with coupler wrench 4.
Coupler wrench:
YW-06551/90890-06551
Sheave holder:
YS-01880-A/90890-01701
1
4
23
Drive shaft removal
1. Remove:
Circlip
Drive shaft
NOTE:
Press in the direction of the arrow.
Oil pump driven gear inspection
1. Check:
Oil pump driven gear 1 
Cracks/damage/wear → Replace.
1
Relief valve inspection
1. Check:
Relief valve 1 
Spring 2 
Damage/wear → Replace the defective
part(s).1
2 
						

							5-35
EPOWRREDUCTION DRIVE GEAR
Drive shaft installing
1. Install:
Drive shaft
NOTE:
Press in the direction of the arrow.
2. Install:
Oil seals 1 
Distance a:
8.9–9.3 mm (0.35–0.37 in)
1 a
Drive coupling installation 
1. Install:
Drive coupling 1 
NOTE:
While holding the flywheel magneto 2 with the
sheave holder 3, tighten the drive coupling
with coupler wrench 4.
Coupler wrench:
YW-06551/90890-06551
Sheave holder:
YS-01880-A/90890-01701
1
4
23 
						

							5-36
EPOWRGENERATOR AND STARTER MOTOR
GENERATOR AND STARTER MOTOR
EXPLODED DIAGRAM
REMOVAL AND INSTALLATION CHART 
Step Procedure/Part name Q’ty Service points
GENERATOR COVER AND 
FLYWHEEL MAGNET REMOVALFollow the left “Step” for removal.
Engine unit Refer to “ENGINE UNIT”.
1 Nut/washer 1/1
2 Starter motor lead 1
3Bolt 2
4 Battery negative lead 1
5 Starter motor 1
6 Band 1
7 Lighting coil coupler 1
8 Pulser coil coupler 1
4 3
2 1
5
6
8
7
10
9
111214 13
19 17182021 22
16 15
AA
E
E
E
LT
572
LT
572
AA
AA
8 × 30 mm
18 N  m (1.8 kgf 
 m, 13 ft 
 Ib)
4.9 N 
 m (0.49 kgf  m, 3.5 ft  Ib)
10 × 47 mm
75 N  m (7.5 kgf 
 m, 54 ft 
 Ib)
5 × 10 mm
8 × 20 mm
24 N  m (2.4 kgf 
 m, 17 ft 
 Ib)
10 × 60 mm
2nd   50 N  m (5.0 kgf 
 m, 36 ft 
 Ib) 1st    15 N  m (1.5 kgf 
 m, 11 ft 
 Ib) 
						

							5-37
EPOWRGENERATOR AND STARTER MOTOR
EXPLODED DIAGRAM
Step Procedure/Part name Q’ty Service points
9Bolt 1
10 Holder 1
11 Bolt 8
12 Generator cover 1
13 Dowel pin 2
14 Packing 1
15 Idle gear shaft 1
16 Idle gear 1
17 Bolt/washer 1/1
18 Rotor 1
19 Bolt 6
4 3
2 1
5
6
8
7
10
9
111214 13
19 17182021 22
16 15
AA
E
E
E
LT
572
LT
572
AA
AA
8 × 30 mm
18 N  m (1.8 kgf 
 m, 13 ft 
 Ib)
4.9 N 
 m (0.49 kgf  m, 3.5 ft  Ib)
10 × 47 mm
75 N  m (7.5 kgf 
 m, 54 ft 
 Ib)
5 × 10 mm
8 × 20 mm
24 N  m (2.4 kgf 
 m, 17 ft 
 Ib)
10 × 60 mm
2nd   50 N  m (5.0 kgf 
 m, 36 ft 
 Ib) 1st    15 N  m (1.5 kgf 
 m, 11 ft 
 Ib)
Not reusable
Not reusable 
						

							5-38
EPOWRGENERATOR AND STARTER MOTOR
EXPLODED DIAGRAM 
Step Procedure/Part name Q’ty Service points
20 Starter clutch 1
21 Starter gear 1
22 Woodruff key 1
Reverse the removal steps for installation.
4 3
2 1
5
6
8
7
10
9
111214 13
19 17182021 22
16 15
AA
E
E
E
LT
572
LT
572
AA
AA
8 × 30 mm
18 N  m (1.8 kgf 
 m, 13 ft 
 Ib)
4.9 N 
 m (0.49 kgf  m, 3.5 ft  Ib)
10 × 47 mm
75 N  m (7.5 kgf 
 m, 54 ft 
 Ib)
5 × 10 mm
8 × 20 mm
24 N  m (2.4 kgf 
 m, 17 ft 
 Ib)
10 × 60 mm
2nd   50 N  m (5.0 kgf 
 m, 36 ft 
 Ib) 1st    15 N  m (1.5 kgf 
 m, 11 ft 
 Ib) 
						

							5-39
EPOWRGENERATOR AND STARTER MOTOR
EXPLODED DIAGRAM 
REMOVAL AND INSTALLATION CHART
Step Procedure/Part name Q’ty Service points
GENERATOR DISASSEMBLYFollow the left “Step” for disassembly.
1 Bolt/washer 3/3
2Bolt 4
3Pulser coil 2
NOTE:
There washers holds the pulser coil lead.
Make sure to not pitch the lead between the
projection and the washer when installing
the bolt.
4Bolt 2
1
7
6
3
2
45
LT
242
LT
242
LT
242LT
242
14 N 
 m (1.4 kgf  m, 10 ft  Ib)
6 × 14 mm
4.9 N 
 m (0.49 kgf  m, 3.5 ft  Ib)
5 × 14 mm
14 N 
 m (1.4 kgf  m, 10 ft  Ib)
6 × 33 mm
4.9 N 
 m (0.49 kgf  m, 3.5 ft  Ib)
5 × 10 mm
1
1
2
3 
						

							5-40
EPOWRGENERATOR AND STARTER MOTOR
EXPLODED DIAGRAM 
Step Procedure/Part name Q’ty Service points
5 Holder 1
6Bolt 3
7 Lighting coil 1
Reverse the disassembly steps for 
assembly.
1
7
6
3
2
45
LT
242
LT
242
LT
242LT
242
14 N 
 m (1.4 kgf  m, 10 ft  Ib)
6 × 14 mm
4.9 N 
 m (0.49 kgf  m, 3.5 ft  Ib)
5 × 14 mm
14 N 
 m (1.4 kgf  m, 10 ft  Ib)
6 × 33 mm
4.9 N 
 m (0.49 kgf  m, 3.5 ft  Ib)
5 × 10 mm
1
1
2
3 
						

							5-41
EPOWRGENERATOR AND STARTER MOTOR
SERVICE POINTS
Flywheel magneto removal
1. Remove:
Flywheel magneto bolt 1 
Washer
NOTE:
While holding the flywheel magneto 2 with the
sheave holder 3, loosen the flywheel magneto
bolt.
Sheave holder:
YS-01880-A/90890-01701
2. Remove:
Flywheel magneto 1 
Woodruff key
NOTE:
While holding the flywheel magneto with
sheave holder 2, remove the flywheel mag-
neto with the rotor puller 3.
Rotor puller:
YM-01082/90890-01080
Starter clutch inspection
1. Check:
Starter clutch rollers 1 
Damage/wear → Replace.