Yamaha Waverunner 3 Manual

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 SAFETY WHILE WORKING
 SAFETY WHILE WORKING
The procedures given in this manual are those
recommended by Yamaha to be followed by
Yamaha dealers and their mechanics.
FIRE PREVENTION
Gasoline (petrol) is highly flammable.
Gasoline vapor is explosive if ignited. 
Do not smoke while handling gasoline (petrol)
and keep it away from heat, sparks, and open
flames.
VENTILATION
Gasoline vapor is heavier than air and is
deadly if inhaled in large quantities. Engine
exhaust gases are harmful to breathe. When
test-running an engine indoors, maintain good
ventilation.
SELF-PROTECTION
Protect your eyes with suitable safety specta-
cles or safety goggles when grinding or doing
any operation which may cause particles to fly
off.
Protect hands and feet by wearing safety
gloves or protective shoes if appropriate to the
work you are doing.
OILS, GREASES AND SEALING 
FLUIDS
Use only genuine Yamaha oils, greases, and
sealing fluids or those recommended by
Yamaha. 
						

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 SAFETY WHILE WORKING
Under normal conditions of use there should
be no hazards from the use of the lubricants
mentioned in this manual, but safety is all-
important, and by adopting good safety prac-
tises any risk is minimized. A summary of the
most important precautions is as follows:
1. While working, maintain good standards of
personal and industrial hygiene.
2. Clothing which has become contaminated
with lubricants should be changed as soon
as practicable and laundered before fur-
ther use.
3. Avoid skin contact with lubricants (e.g., do
not place a soiled rag in your pocket).
4. Hands and any other part of the body
which have been in contact with lubricants
or lubricant-contaminated clothing should
be thoroughly washed with hot water and
soap as soon as practicable.
5. To protect the skin, the application of a
suitable barrier cream to the hands before
working is recommended.
6. A supply of clean lint-free cloths should be
available for wiping purposes.
GOOD WORKING PRACTICES
1.The right tools
Use the recommended special tools to
protect parts from damage. Use the right
tool in the right manner – do not improvise.
2.Tightening torque
Follow the tightening torque instructions.
When tightening bolts, nuts and screws,
tighten the larger sizes first and tighten
inner-positioned fixings before outer-posi-
tioned ones. 
						

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 SAFETY WHILE WORKING
3.Non-reusable items
Always use new gaskets, packings, O-
rings, oil seals, split-pins, circlips, etc., on
reassembly.
DISASSEMBLY AND ASSEMBLY
1. Clean parts with compressed air when dis-
assembling.
2. Oil the contact surfaces of moving parts
during assembly.
3. After assembly, check that moving parts
operate normally.
4. Install bearings with the manufacturer’s
markings on the side exposed to view and
liberally oil the bearings.
CAUTION:
Do not spin bearings with compressed air
because this will damage their surfaces.
5. When installing oil seals, apply a light coat
of water-resistant grease to the outside
diameter. 
						

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SPECIAL TOOLS
SPECIAL TOOLS
Using the correct special tools recommended
by Yamaha, will aid the work and enable accu-
rate assembly and tune-up. Improvisations
and using improper tools can damage the
equipment.
NOTE:
For U.S.A. and Canada, use part numbers
starting with “J-”, “YB-”, “YM-”, “YS-”, “YU-” or
“YW-”.
For other countries, use part numbers start-
ing with “90890-”.
MEASURING
1
Dial gauge
P/N. YU-03097
90890-01252
2
Dial gauge stand
P/N. 90890-06583
3
Dial gauge needle
P/N. 90890-06584
4
Dial gauge stand set
P/N. YW-06585
90890-06585
5
Pocket tester
P/N. YU-03112
90890-03112
6
Digital circuit tester
P/N. YU-34899-A
90890-03174
7
Carburetor synchronizer
P/N. YU-08030
8
Vacuum gauge
P/N. 90890-03094
Vacuum attachment
P/N. 90890-03060
9
Test connector
P/N. YW-06862
90890-06862
0
Fuel pressure gauge adapter
P/N. YW-06842
90890-06842
1
23
4
56
78YU-03097 90890-01252
90890-06583 90890-06584
YW-06585
90890-06585
YU-03112
90890-03112YU-34899-A
90890-03174
YU-08030 90890-03094 90890-03060
90YW-06862
90890-06862YW-06842
90890-06842 
						

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SPECIAL TOOLS
A
Fuel pressure gauge
P/N. YB-06766
90890-06786
B
Compression gauge extension
P/N. 90890-06582
C
Cylinder gauge set
P/N. YU-03017
90890-06759
D
Compression gauge
P/N. YU-33223-1
90890-03160
E
Peak voltage adapter
P/N. YU-39991
90890-03172
F
Spark gap tester
P/N. YM-34487
90890-06754
G
Test harness (2 pins)
P/N. YB-06792
90890-06792
H
Test harness (3 pins)
P/N. YB-06791
90890-06791
I
Test harness (3 pins)
P/N. YB-06770
90890-06770
J
Test harness (6 pins)
P/N. YB-06790
90890-06790
K
Test harness (3 pins)
P/N. YB-06793
90890-06793
L
Test harness (3 pins)
P/N. YB-06777
90890-06777
A
BC
D
E
F
GH
IJYB-06766 90890-06786
90890-06582 YU-03017
90890-06759
YU-33223-1 90890-03160
YU-39991 90890-03172
YM-34487 90890-06754
YB-06792
90890-06792YB-06791
90890-06791
YB-06770
90890-06770YB-06790
90890-06790
YB-06793
90890-06793YB-06777
90890-06777KL 
						

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SPECIAL TOOLS
M
Test harness (3 pins)
P/N. YB-06769
90890-06769
N
Vacuum/pressure pump gauge set
P/N. YB-35956-A
90890-06756
O
Yamaha diagnostic system for Watercraft
P/N. 60E-85300-01
P
Yamaha diagnostic system for Watercraft
(CD-ROM only)
P/N. 60E-WS853-00
M
PNYB-06769
90890-06769YB-35956-A
90890-06756
60E-WS853-00
O60E-85300-01
YAMAHA DIAGNOSTIC SYSTEM
for Watercraft
INSTALLATION MANUAL
60E-2819K-10 
						

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SPECIAL TOOLS
REMOVAL AND INSTALLATION
1
Oil filter wrench
P/N. YU-38411 
90890-01426
2
Coupler wrench
P/N. YW-06551 
90890-06551
3
Sheave holder
P/N. YS-01880-A
90890-01701
4
Rotor puller
P/N. YM-01082
90890-01080
5
Rotor holder
P/N. YU-01235
90890-01235
6
Valve spring compressor
P/N. YM-04019
90890-04019
7
Valve spring compressor attachment
P/N. YM-4114 (ø19 mm)
90890-04114 (ø19 mm)
YM-4108 (ø22 mm)
90890-04108 (ø22 mm)
8
Valve guide remover
P/N. YM-04111 (ø4.0 mm)
90890-04111 (ø4.0 mm)
YM-04116 (ø4.5 mm)
90890-04116 (ø4.5 mm)
9
Valve guide installer
P/N. YM-04112 (ø4.0 mm)
90890-04112 (ø4.0 mm)
YM-04117 (ø4.5 mm)
90890-04117 (ø4.5 mm)
0
Valve guide reamer
P/N. YM-04113 (ø4.0 mm)
90890-04113 (ø4.0 mm)
YM-04118 (ø4.5 mm)
90890-04118 (ø4.5 mm)12
34
56
78
90YU-38411 
90890-01426YW-06551 
90890-06551
YS-01880-A
90890-01701YM-01082
90890-01080
YU-01235
90890-01235YM-04019
90890-04019
YM-4114 (ø19 mm)
90890-04114 (ø19 mm)
YM-4108 (ø22 mm)
90890-04108 (ø22 mm)YM-04111 (ø4.0 mm)
90890-04111 (ø4.0 mm)
YM-04116 (ø4.5 mm)
90890-04116 (ø4.5 mm)
YM-04112 (ø4.0 mm)
90890-04112 (ø4.0 mm)
YM-04117 (ø4.5 mm)
90890-04117 (ø4.5 mm)YM-04113 (ø4.0 mm)
90890-04113 (ø4.0 mm)
YM-04118 (ø4.5 mm)
90890-04118 (ø4.5 mm) 
						

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SPECIAL TOOLS
A
Valve seat cutter
Intake
P/N. 90890-06813 (60°)
90890-06814 (45°)
90890-06815 (30°)
Exhaust
P/N. 90890-06315 (60°)
90890-06312 (45°)
90890-06328 (30°)
B
Valve seat cutter holder
P/N. 90890-06811 (ø4.0 mm)
90890-06812 (ø4.5 mm)
C
Valve seat cutter set
P/N. YM-91043-C
D
Piston ring compressor
P/N. YM-08037
90890-05158
E
Drive shaft holder (impeller)
P/N. YB-06151 
90890-06519
F
Slide hammer set (jet pump bearing)
P/N. YB-06096
G
Stopper guide plate (jet pump bearing)
P/N. 90890-06501
H
Bearing puller (jet pump bearing)
P/N. 90890-06535
I
Bearing puller claw 1 (jet pump bearing)
P/N. 90890-06536
J
Stopper guide stand (jet pump bearing)
P/N. 90890-06538
K
Drive rod L3 (jet pump bearing)
P/N. 90890-06652
L
Needle bearing attachment 
(jet pump bearing and oil seal)
P/N. YB-06112, YB-06196
90890-06614, 90890-06653
90890-06315 (60°)
90890-06312 (45°)
90890-06328 (30°)
YM-08037 90890-05158
YB-06096
90890-06501 90890-06535
90890-06536 90890-06538
90890-06652 YB-06112 90890-06614
B
D
EF
GH
IJ
KL90890-06811 (ø4.0 mm)
90890-06812 (ø4.5 mm)
YB-06196 90890-06653 YB-06151 
90890-06519
A90890-06813 (60°)
90890-06814 (45°)
90890-06815 (30°)
YM-91043-C
C 
						

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SPECIAL TOOLS
M
Ball bearing attachment 
(jet pump oil seal)
P/N. YB-06085 
90890-06634
N
Driver rod 
(intermediate shaft and jet pump)
P/N. YB-06071
90890-06606 
O
Bearing inner/outer race attachment 
(jet pump bearing)
P/N. YB-34474
P
Shaft holder (intermediate shaft)
P/N. YB-06552
90890-06552
Q
Bearing outer race attachment 
(intermediate shaft)
P/N. YB-06156
90890-06626
YB-06071 90890-06606 YB-34474NO
YB-06552
90890-06552YB-06156 90890-06626PQ
YB-06085 90890-06634M