Yamaha Waverunner 3 Manual

							8-4
E
HULL
HOODHANDLEBAR
EXPLODED DIAGRAM
REMOVAL AND INSTALLATION CHART
Step Procedure/Part name Q’ty Service points
HANDLEBAR DISASSEMBLY
Follow the left “Step” for disassembly.
1Bolt 2
2 Grip end 2
3 Spacer 1
4 Screw/spring washer/washer 1/1/1
5 QSTS grip assembly 1
6 Special nut 1
7Screw 2
NOTE:
Tighten the screw from the engine stop
switch side. 
						

							8-5
E
HULL
HOODHANDLEBAR
EXPLODED DIAGRAM
Step Procedure/Part name Q’ty Service points
8 Handlebar switch assembly 1
9Screw 2
10 Throttle lever assembly 1
11 Handlebar grip 1
NOTE:
Apply adhesive to the handlebar and the
inner surface of the handlebar grip.
12 Handlebar 1
Reverse the disassembly steps for 
assembly. 
						

							8-6
E
HULL
HOODHANDLEBAR
SERVICE POINTS
Handlebar inspection
1. Inspect:
Handlebar
Bends/cracks/damage →
 Replace.
Handlebar switch inspection
Refer to “STARTING SYSTEM” in
Chapter 7.
Handlebar assembly installation
1. Install:
Bands 1
 
NOTE:
After inserting the QSTS cables, buzzer lead,
handlebar switch lead and throttle cable into
the grommets, tie the end of grommets with
the bands.
2. Install:
Upper handlebar holder 1
 
NOTE:
Align the punch marks a
 on the handlebar
with the top surface of the handlebar holder.
The upper handlebar holder should be
installed with the punch mark b
 facing for-
ward.
CAUTION:
Clearance 
c should be narrower than
clearance 
d.
Reference clearance:
c: 1.5 mm (0.06 in)
d: 3.5 mm (0.14 in) 
						

							8-7
E
HULL
HOODHANDLEBAR
3. Install:
Throttle cable
NOTE:
Fit the seal into the groove in the bracket.
4. Adjust:
QSTS cable length a
 
NOTE:
Before adjusting the QSTS cables, set the
trim grip to the neutral position.
Adjust the QSTS cable lengths a
 to the
specified length and be sure to take up any
slack.
QSTS cable length:
72 
± 0.5 mm (2.83 
± 0.02 in)
5. Install:
Handlebar cover 1
 
NOTE:
When the handlebar cover is in contact with
the steering boss cover, adjust the handlebar
mount angle so that the clearance a
 and b
are equal.
6. Adjust:
Throttle cable free play
Refer to “CONTROL SYSTEM” in Chap-
ter 3.
7. Adjust:
QSTS cable
Refer to “CONTROL SYSTEM” in Chap-
ter 3. 
						

							8-8
E
HULL
HOODQSTS GRIP
QSTS GRIP
EXPLODED DIAGRAM
REMOVAL AND INSTALLATION CHART
Step Procedure/Part name Q’ty Service points
QSTS GRIP DISASSEMBLY
Follow the left “Step” for disassembly.
QSTS grip assembly Refer to “HANDLEBAR”.
1 Screw/washer 1/1
2 Cover 1
3Ball 2
4Spring 2
5 QSTS cable 1 1
6 QSTS cable 2  1 with white tape a
  
						

							8-9
E
HULL
HOODQSTS GRIP
EXPLODED DIAGRAM
Step Procedure/Part name Q’ty Service points
7 Screw/washer 2/2
8 Spacer 1
9 QSTS shift lock lever 1
10 Spring 1
11 Spacer 1
12 Cable housing 1
13 QSTS grip 1
Reverse the disassembly steps for 
assembly. 
						

							8-10
E
HULL
HOODQSTS GRIP
SERVICE POINTS
QSTS cable inspection
1. Inspect:
QSTS cables
Frays/kinks/rough movement →
 
Replace.
QSTS grip inspection
1. Inspect:
QSTS grip
Damage/wear →
 Replace. 
						

							8-11
E
HULL
HOODSTEERING MASTER
STEERING MASTER
EXPLODED DIAGRAM
REMOVAL AND INSTALLATION CHART
Step Procedure/Part name Q’ty Service points
STEERING MASTER REMOVAL
Follow the left “Step” for removal.
Steering console cover Refer to “STEERING CONSOLE COVER”.
Steering cable end Refer to “REMOTE CONTROL CABLES 
AND SPEED SENSOR LEAD”.
1 Bolt/washer 1/1
2 Steering arm 1
3 Nut/washer 4/4
4 Steering master assembly 1
5Bolt 4
Reverse the removal steps for installation. 
						

							8-12
E
HULL
HOODSTEERING MASTER
EXPLODED DIAGRAM
REMOVAL AND INSTALLATION CHART
Step Procedure/Part name Q’ty Service points
STEERING MASTER 
DISASSEMBLYFollow the left “Step” for disassembly.
1 Bolt/washer 2/2
2Stay 1
3Spring 1
4 Bolt/washer 6/6
5 Lower housing 1
6Spring 1
7 Bushing 1
8 Bushing 1
9 Upper housing 1
10 Tilt lever 1 
						

							8-13
E
HULL
HOODSTEERING MASTER
EXPLODED DIAGRAM
Step Procedure/Part name Q’ty Service points
11 Tilt stopper 1
12 Bolt/nut/holder 4/4/4
13 Retainer 2
14 Steering shaft assembly 1
15 Steering tube 1
16 Bolt/washer/spring washer 2/2/2
17 Cap 1
18 Shaft 1 1
19 Cross piece 1
Reverse the disassembly steps for 
assembly.