Yamaha Waverunner 3 Manual
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ESPEC 1 2 3 4 5 6 7 8 9 CHAPTER 2 SPECIFICATIONS GENERAL SPECIFICATIONS ....................................................................... 2-1 MAINTENANCE SPECIFICATIONS ............................................................... 2-3 ENGINE .................................................................................................... 2-3 JET PUMP UNIT ...................................................................................... 2-6 HULL AND HOOD .................................................................................... 2-6 ELECTRICAL ............................................................................................ 2-6 TIGHTENING TORQUES ................................................................................ 2-9 SPECIFIED TORQUES ............................................................................. 2-9 GENERAL TORQUE ............................................................................... 2-17 CABLE AND HOSE ROUTING ..................................................................... 2-18
2-1 ESPECGENERAL SPECIFICATIONS GENERAL SPECIFICATIONS Item UnitModel FX140 Model code Hull F1B Engine/jet 60E Dimensions Length mm (in) 3,340 (131.5) Width mm (in) 1,230 (48.4) Height mm (in) 1,160 (45.7) Dry weight kg (lb) 362 (798) Maximum capacity Person/kg (lb) 3/240 (530) Performance Maximum output kW (PS) @ r/min 103 (140) @ 10,000 Maximum fuel consumption l/h (US gal/h, lmp gal/h)44 (11.6, 9.7) Cruising range h 1.59 Engine Engine type 4-stroke, L4, DOHC Displacement cm 3 (cu. in) 998 (60.9) Bore × stroke mm (in) 74.0 × 58.0 (2.91 × 2.28) Compression ratio 11.4:1 Exhaust system Wet exhaust Lubrication system Dry sump Cooling system Water cooled Starting system Electric starter Ignition system TCI Ignition timing Degree BTDC 35–ATDC 5 Spark plug model (manufacturer)CR9EB (NGK) Spark plug gap mm (in) 0.7–0.8 (0.028–0.031) Battery capacity V/Ah 12/19 Generator output A @ r/min 14–16 @ 6,000 Drive unit Propulsion system Jet pump Jet pump type Axial flow, single stage Impeller rotation (from rear) Counterclockwise Transmission Direct drive from engine Gear ratio 19/28 (0.68) Jet thrust nozzle horizontal angleDegree 24 + 24 Jet thrust nozzle trim angle Degree–10, –5, 0, 5, 10 Trim system Manual 5 positions Reverse system Reverse gate
2-2 ESPEC PON*: Pump Octane Number = (Motor Octane Number + Research Octane Number)/2 RON*: Research Octane NumberFuel and oil Fuel type Regular unleaded gasoline Minimum fuel rating PON* 86 RON* 90 Fuel tank capacity L (US gal, Imp gal)70 (18.5, 15.4) Engine oil type 4-stroke motor oil Engine oil grade API SE, SF, SG, SH, or SJ SAE 10W-30 Engine oil quantity L (US qt, Imp qt)4.3 (4.5, 3.8) (without oil filter replacement) L (US qt, Imp qt)2.0 (2.1, 1.8) (with oil filter replacement) L (US qt, Imp qt)2.2 (2.3, 1.9) Item UnitModel FX140 GENERAL SPECIFICATIONS
2-3 ESPECMAINTENANCE SPECIFICATIONS MAINTENANCE SPECIFICATIONS ENGINE Item UnitModel FX140 Cylinder head Warpage limit mm (in) 0.1 (0.004) Compression pressure *1 kPa (kgf/cm2, psi)1,350 (13.5, 192) Cylinder Bore size mm (in) 74.060–74.075 (2.9157–2.9163) Taper limit mm (in) 0.08 (0.003) Out-of-round limit mm (in) 0.05 (0.002) Wear limit mm (in) 74.2 (2.9213) Camshaft Drive system Chain drive Intake A mm (in) 32.25 (1.270) Exhaust A mm (in) 32.65 (1.285) Intake and exhaust Bmm (in) 25.00 (0.984) Camshaft cap inside diameter mm (in) 24.5 (0.9646) Camshaft journal diameter mm (in) 24.44–24.45 (0.9622–0.9626) Camshaft-journal-to-camshaft- cap clearancemm (in) 0.05–0.08 (0.0020–0.0031) Max.camshaft runout mm (in) 0.03 (0.0012) Timing chain Model/number of links DID SCR-0412SV/130 Tensioning system Automatic Valves, valve seats, valve guides Valve clearance (cold) Intake mm (in) 0.11–0.20 (0.0043–0.0079) Exhaust mm (in) 0.25–0.34 (0.0098–0.0134) Valve dimensions Valve head diameter A Intake mm (in) 22.9–23.1 (0.9016–0.9094) Exhaust mm (in) 24.4–24.6 (0.9606–0.9685) Valve face width B Intake mm (in) 1.76–2.90 (0.0693–0.1142) Exhaust mm (in) 1.76–2.90 (0.0693–0.1142) *1: At 760 mmHg and 20 °C (68 °F)
2-4 ESPECMAINTENANCE SPECIFICATIONS Valve seat width C Intake mm (in) 0.9–1.1 (0.0354–0.0433) Exhaust mm (in) 0.9–1.1 (0.0354–0.0433) Valve margin thickness D Intake mm (in) 0.5–0.9 (0.0197–0.0354) Exhaust mm (in) 0.5–0.9 (0.0197–0.0354) Valve stem diameter Intake mm (in) 3.975–3.990 (0.1565–0.1571) Exhaust mm (in) 4.460–4.475 (0.1756–0.1762) Valve guide inside diameter Intake mm (in) 4.000–4.012 (0.1575–0.1580) Exhaust mm (in) 4.500–4.512 (0.1772–0.1776) Valve-stem-to-valve-guide clearance Intake mm (in) 0.010–0.037 (0.0004–0.0015) Exhaust mm (in) 0.025–0.052 (0.0010–0.0020) Valve stem runout mm (in) 0.01 (0.0004) Valve spring Free length Intake mm (in) 38.90 (1.53) Exhaust mm (in) 40.67 (1.60) Installed length Intake mm (in) 34.50 (1.36) Exhaust mm (in) 35.00 (1.38) Spring limit Intake Degree/mm (in) 2.5/1.7 (0.067) Exhaust Degree/mm (in) 2.5/1.8 (0.071) Piston Piston-to-cylinder clearance mm (in) 0.10–0.11 (0.0039–0.0043) Piston diameter mm (in) 73.955–73.970 (2.9116–2.9121) Measuring point H* mm (in) 5 (0.2) Wear limit mm (in) 0.17 (0.0067) Piston pin boss inside diameter mm (in) 17.002–17.013 (0.6693–0.6698) Piston pins Outside diameter mm (in) 16.991–17.000 (0.6689–0.6693) Wear limit mm (in) 16.971 (0.6681)Item UnitModel FX140
2-5 ESPECMAINTENANCE SPECIFICATIONS Piston ring Top ring Type Barrel Dimension (B × T) mm (in) 0.90 × 2.75 (0.04 × 0.11) End gap (installed) mm (in) 0.38–0.55 (0.0150–0.0217) Ring groove clearance mm (in) 0.030–0.065 (0.0012–0.0026) 2nd ring Type Taper Dimensions (B × T)mm (in) 0.80 × 2.80 (0.03 × 0.11) End gap (installed) mm (in) 0.49–0.69 (0.0193–0.0272) Ring groove clearance mm (in) 0.020–0.055 (0.0008–0.0022) Oil ring Dimensions (B × T)mm (in) 1.50 × 2.60 (0.06 × 0.10) End gap (installed) mm (in) 0.29–0.59 (0.0114–0.0232) Ring groove clearance mm (in) 0.040–0.160 (0.0016–0.0063) Connecting rod Big end oil clearance mm (in) 0.016–0.040 (0.0006–0.0016) Bearing color code 1. Brown 2. Black 3. Blue 4. Green Small end inside diameter mm (in) 17.005–17.018 (0.6694–0.6699) Crankshaft Crank width A mm (in) 304.8–306.0 (12.00–12.05) Deflection limit B mm (in) 0.03 (0.0012) Crankshaft journal oil clearance mm (in) 0.020–0.057 (0.0008–0.0022) Bearing color code 1. Brown 2. Black 3. Blue 4. Green 5. Yellow Throttle body Type/quantity 40EIS/4 Manufacturer Mikuni ID mark 60E00 Trolling speed r/min 1,600–1,800 Fuel pump Pump type Electrical Output pressure kPa (kgf/cm 2, psi)310–330 (3.1–3.3, 45–47) Item UnitModel FX140 T B B T B T BBB A
2-6 ESPECMAINTENANCE SPECIFICATIONS JET PUMP UNIT HULL AND HOOD ELECTRICAL Oil filter Oil filter type Cartridge type Oil pump Oil pump type Trochoid Rotor tip clearance mm (in) 0.09–0.15 (0.004–0.006) Oil pump housing clearance Rotor (feed pump) mm (in) 0.09–0.17 (0.0035–0.0067) Rotor (scavenge pump) mm (in) 0.09–0.19 (0.0035–0.0075) Item UnitModel FX140 Jet pump Impeller material Stainless steel Number of impeller blades 3 Impeller pitch angle Degree 16.3 Impeller clearance mm (in) 0.35–0.45 (0.01384–0.0177) Impeller clearance limit mm (in) 0.6 (0.0236) Drive shaft runout limit mm (in) 0.3 (0.0118) Nozzle diameter mm (in) 86.5–87.1 (3.41–3.43) Item UnitModel FX140 Free play Throttle lever free play mm (in) 4–7 (0.16–0.28) Item UnitModel FX140 Battery Type Fluid Capacity V/Ah 12/19 Specific gravity 1.28 ECM unit (B/R – Ground for cylinder #1 and #4) (B/W – Ground for cylinder #2 and #3) Output peak voltage lower limit @cranking V 7 @2,000 r/min V 258 @3,500 r/min V 258 Item UnitModel FX140
2-7 ESPECMAINTENANCE SPECIFICATIONS Stator Pulser coil (W – B, R – B) Output peak voltage @cranking 1 V 4 @cranking 2 V 4 @2,000 r/min V 23 @3,500 r/min V 38 Lighting coil (G – G) Output peak voltage @cranking 1 V 9 @cranking 2 V 8 @2,000 r/min V 11 @3,500 r/min V 12 Pulser coil resistanceΩ (color) 459–561 (W – B, R – B) Pulser coil resistance 2Ω (color) 459–561 (W – B, R – B) Lighting coil resistanceΩ (color) 0.54–0.66 (G – G) Minimum charging current A @ r/min 14 @ 6,000 Ignition coil Minimum spark gap mm (in) 7–8 (0.28–0.31) Primary coil resistanceΩ (color) 1.53–2.07 (B/W – R) Secondary coil resistance kΩ 12.5–16.9 Spark plug lead resistance #1 kΩ 6.4–14.9 #2 kΩ 5.9–13.8 #3 kΩ 4.7–11.1 #4 kΩ 4.4–10.5 Rectifier/regulator (R – B) Output peak voltage (loaded) @3,500 r/min V 14.5 Starter motor Type Constant mesh Output kW 0.8 Rating Seconds 30 Brush length mm (in) 12.5 (0.49) Wear limit mm (in) 6.5 (0.26) Commutator undercut mm (in) 0.7 (0.03) Limit mm (in) 0.2 (0.01) Commutator diameter mm (in) 28.0 (1.10) Limit mm (in) 27.0 (1.06) Starter relay Rating Seconds 30 Cranking 1: unloaded Cranking 2: loadedItem UnitModel FX140
2-8 ESPECMAINTENANCE SPECIFICATIONS Thermoswitch ON temperature (Engine)°C (°F) 84–90 (183–194) OFF temperature (Engine)°C (°F) 70–84 (158–183) ON temperature (Exhaust)°C (°F) 94–100 (201–212) OFF temperature (Exhaust)°C (°F) 80–94 (176–201) Engine temperature sensor Engine temperature sensor resistance (B/Y – B/Y) @ 20 °C (68 °F) kΩ 54.2–69.0 @ 100 °C (212 °F) kΩ 3.12–3.48 Intake air temperature sensor Intake air temperature sensor resistance @ 0 °C (32 °F) kΩ 5.4–6.6 @ 80 °C (176 °F) kΩ 0.29–0.39 Intake air pressure sensor output voltage (P/G – B/O)V @ kPa (kgf/cm 2, psi)4.00 @ 101.3 (1.01, 14.4) V @ kPa (kgf/cm 2, psi)1.97 @ 50 (0.5, 7.1) V @ kPa (kgf/cm 2, psi)0.79 @ 20 (0.2, 2.8) Speed sensor Output voltage (on pulse) V 11.6 Output pulse/one full turn 2 Throttle position sensor Output voltage (P – B/O) @ trolling speed V 0.760 ± 0.016 Cam position sensor Output voltage (G/O – B/O) Position A V More than 0.8 Position B V Less than 4.8 Fuel sender Fuel sender resistance Position AΩ 91–93 Position BΩ 6–8 Oil pressure switch Oil pressure switch continuity pressurekPa (kgf/cm 2, psi)128 (12.8, 18.2)–166 (1.66, 23.6) Fuel injector Fuel injector resistanceΩ 14.0–15.0 Fuse Rating Main V/A 12/20 Multifunction meter V/A 12/3 Electrical bilge pump V/A 12/3Item UnitModel FX140
2-9 ESPECTIGHTENING TORQUES TIGHTENING TORQUES SPECIFIED TORQUES Part to tightened Part nameThread sizeQ’tyTightening torque Remarks Nmkgfmftlb Fuel system Retainer/fuel pump module – fuel tank1st Nut—93.2 0.32 2.3 2nd 6.4 0.64 4.6 Fuel filler neck/rubber seal – deck Nut—1 5.9 0.59 4.3 Fuel tank belt/fuel tank – hull Bolt M8 4 16 1.6 11 572LT Air filter case cover – air filter case Screw M5 2 2.5 0.25 1.8572LT Flame arrester – throttle bodies1st Bolt M6 43.3 0.33 2.4242LT2nd 6.5 0.65 4.7 Throttle cable holder – air filter case1st Bolt M6 23.8 0.38 2.7 572LT2nd 7.6 0.76 5.5 Fuel hose holder – fuel hose bracket1st Bolt M4 21.7 0.17 1.2 572LT2nd 3.3 0.33 2.4 Throttle bodies – throttle body joint1st Bolt M8 811 1.1 8.0 E2nd 22 2.2 16 Air filter case – air filter case stay 1/ air filter case stay 21st Bolt M8 38.8 0.88 6.4 242LT 2nd 18 1.8 13 Wire harness bracket 1/ sub wire harness – air filter case1st Bolt M6 23.8 0.38 2.7 572LT 2nd 7.6 0.76 5.5 Fuel hose bracket/wire harness bracket 2 – air filter case1st Bolt M6 23.8 0.38 2.7 242LT 2nd 7.6 0.76 5.5 Wire harness bracket 2 – air filter case Screw M5 1 2.5 0.25 1.8 572LT Air filter case stay 1 – exhaust pipe 31st Bolt M8 215 1.5 11271LT2nd 39 3.9 28 Air filter case stay 2 – cylinder head1st Bolt M8 115 1.5 11 271LT2nd 39 3.9 28 Fuel rail – throttle bodies Screw M6 3 5.0 0.5 3.6 Intake air pressure sensor – bracket 1Screw M5 2 3.5 0.35 2.5 Intake air temperature sensor – bracket 1Nut—115 1.5 11 Bracket 1 – fuel rail Screw M6 1 5.0 0.5 3.6 Fuel pipe – fuel rail Screw M5 2 3.5 0.35 2.5 Bracket 2 – fuel rail Screw M5 2 3.5 0.35 2.5 Throttle stop guide – throttle bodies Screw M6 2 5.0 0.5 3.6 Throttle stop screw bracket – throttle bodiesScrew M6 2 5.0 0.5 3.6 Throttle position sensor – throttle bodiesScrew M4 2 2.0 0.2 1.4