Yamaha Waverunner 3 Manual

							5-82
EPOWRCRANKCASE
Tightening steps:
Tighten the bolts in the tightening
sequence cast on the crankcase.
T R..
Crankcase bolt 1–0:
1st:
7.8 N  m 
(0.78 kgf  m, 5.6 ft  lb)
Loosen and retighten the crankcase bolts
in the proper tightening sequence as
shown. 
T R..
Crankcase bolt 1–0:
2nd:
15 N  m (1.5 kgf  m, 11 ft  lb)
Tighten the crankcase bolts further to
reach the specified angle 49° in the
proper tightening sequence as shown.
T R..
Crankcase bolt 1–0:
Final:
Specified angle 49 ± 5°
 WARNING
When the bolts are tightened more than
the specified angle, do not loosen the
bolt and then retighten it.
Replace the bolt with a new one and per-
form the procedure again.
CAUTION:
Do not use a torque wrench to tighten
the bolt to the specified angle.
Tighten the bolt until it is at the speci-
fied angle.
NOTE:
When using a hexagonal bolt, note that the
angle from one corner to another is 60°. 
						

							5-83
EPOWRCRANKCASE
6. Tighten: 
Crankcase bolts A–J 
NOTE:
Tighten the bolts in the tightening sequence
cast on the crankcase. 
T R..
Crankcase bolt A–J:
12 N  m (1.2 kgf  m, 8.7 ft  lb)
86240
93157
I
CAEG H
FB
DJ
7. Tighten: 
Oil pan bolts
NOTE:
Tighten the bolts in the tightening sequence
cast on the oil pan. 
T R..
Oil pan bolt:
12 N  m (1.2 kgf  m, 8.7 ft  lb)
6
10
13
9
13
711 12
58 4
2 
						

							5-84
EPOWRCONNECTING RODS AND PISTONS
CONNECTING RODS AND PISTONS
EXPLODED DIAGRAM
REMOVAL AND INSTALLATION CHART
Step Procedure/Part name Q’ty Service points
CONNECTING RODS AND 
PISTONS REMOVALFollow the left “Step” for removal.
Crankcase Separate
Refer to “CRANKCASE”.
1Nut 8
2 Connecting rod cap 4
3 Big end lower bearing 4
4 Piston pin clip 8
5 Piston pin 4
6Piston 4
7 Connecting rod 4
EE
E
E
1 2 310
11
12
4
5
6
8
7
9
2nd   120 ± 5˚ 1st    20 N • m (2.0 kgf 
• m, 14 ft 
• Ib)
Not reusable
Not reusable 
						

							5-85
EPOWRCONNECTING RODS AND PISTONS
EXPLODED DIAGRAM
Step Procedure/Part name Q’ty Service points
8Bolt 8
9 Big end upper bearing 4
10 Top ring 4
11 2nd ring 4
12 Oil ring 4
Reverse the removal steps for installation.
EE
E
E
1 2 310
11
12
4
5
6
8
7
9
2nd   120 ± 5˚ 1st    20 N • m (2.0 kgf 
• m, 14 ft 
• Ib)
Not reusable 
						

							5-86
EPOWRCONNECTING RODS AND PISTONS
SERVICE POINTS
Connecting rod and piston removal
The following procedure applies to all of the
connecting rods and pistons. 
1. Remove: 
Connecting rod cap 1 
Big end bearings
NOTE:
Identify the position of each big end bearing so
that it can be reinstalled in its original place. 
1
2. Remove:
Piston pin clips 1 
Piston pin 2 
Piston 3 
Connecting rod 4 
CAUTION:
Do not use a hammer to drive the piston
pin out. 
NOTE:
For reference during installation, put identifi-
cation marks on the piston crown.
Before removing the piston pin, deburr the
piston pin clip’s groove and the piston’s pin
bore area. 
						

							5-87
EPOWRCONNECTING RODS AND PISTONS
3. Remove: 
Top ring 
2nd ring 
Oil ring
NOTE:
When removing a piston ring, open the end
gap with your fingers and lift the other side of
the ring over the piston crown. 
Cylinder and piston inspection
The following procedure applies to all of the
cylinders and pistons.
1. Check: 
Piston wall 
Cylinder wall 
Vertical scratches → Replace the cylin-
der, and the piston and piston rings as a
set.
2. Measure: 
Piston-to-cylinder clearance 
Measurement steps:
Measure cylinder bore “C” with the cylin-
der bore gauge.
NOTE:
Measure cylinder bore “C” by taking side-to-
side and front-to-back measurements of the
cylinder. Then, find the average of the mea-
surements. 
Cylinder bore “C”74.060–74.075 mm 
(2.9157–2.9163 in)
Taper limit “T”0.08 mm (0.003 in)
Out of round “R”0.05 mm (0.002 in)
“C” = maximum of D
1–D6 
“T” = maximum of D
1–D5 (direction d) 
and D
2–D6 (direction e)
“R” = maximum of D
2–D1 (measuring 
point a) and D
6–D5 (measuring point c)
D1D2
D3D4
D5D6
d
e a
b
c 
						

							5-88
EPOWRCONNECTING RODS AND PISTONS
If out of specification, replace the piston
and piston rings as a set. 
Measure piston skirt diameter “P” with the
micrometer.
a5 mm (0.2 in) from the bottom edge of the
piston
Piston size “P”
Standard73.955–73.970 mm 
(2.9116–2.9121 in)
If out of specification, replace the piston
and piston rings as a set. 
Calculate the piston-to-cylinder clearance
with the following formula.
Piston-to-cylinder clearance = 
Cylinder bore “C” – 
Piston skirt diameter “P”
Piston-to-cylinder clearance:
0.10–0.11 mm (0.0039–0.0043 in)
: 0.17 mm (0.0067 in)
If out of specification, replace the piston
and piston rings as a set.
Piston ring inspection
1. Measure: 
Piston ring side clearance 
Out of specification → Replace the pis-
ton and piston rings as a set.
NOTE:
Before measuring the piston ring side clear-
ance, eliminate any carbon deposits from the
piston ring grooves and piston rings. 
Piston ring groove: 
Top ring:
0.030–0.065 mm 
(0.0012–0.0026 in)
2nd ring:
0.020–0.055 mm 
(0.0008–0.0022 in) 
						

							5-89
EPOWRCONNECTING RODS AND PISTONS
2. Install:
Piston ring 
(into the cylinder)
NOTE:
Level the piston ring in the cylinder with the
piston crown. 
a5 mm (0.2 in)
3. Measure: 
Piston ring end gap 
Out of specification → Replace the pis-
ton ring.
NOTE:
The oil ring expander spacer’s end gap cannot
be measured. If the oil ring rail’s gap is exces-
sive, replace all three piston rings. 
Piston ring end gap: 
Top ring:
0.38–0.55 mm 
(0.0150–0.0217 in)
2nd ring:
0.49–0.69 mm 
(0.0193–0.0272 in)
Oil ring:
0.29–0.59 mm 
(0.0114–0.0232 in)
Piston pin inspection
The following procedure applies to all of the
piston pins.
1. Check: 
Piston pin 
Blue discoloration/grooves → Replace
the piston pin and then check the lubri-
cation system. 
						

							5-90
EPOWRCONNECTING RODS AND PISTONS
2. Measure: 
Piston pin outside diameter a 
Out of specification → Replace the pis-
ton pin.
Piston pin outside diameter: 
16.991–17.000 mm 
(0.6689–0.6693 in)
: 16.971 mm (0.6681 in)
3. Measure: 
Piston pin bore diameter (in the piston) 
b 
Out of specification → Replace the pis-
ton.
4. Calculate: 
Piston-pin-to-piston clearance 
Out of specification → Replace the pis-
ton pin.
Piston pin bore diameter 
(in the piston): 
17.002–17.013 mm 
(0.6693–0.6698 in)
Piston-pin-to-piston clearance = 
Piston pin bore diameter (in the piston) 
b – Piston pin outside diameter a 
Piston-pin-to-piston clearance: 
0.002–0.042 mm 
(0.0001–0.0017 in) 
						

							5-91
EPOWRCONNECTING RODS AND PISTONS
Connecting rod inspection
1. Measure: 
Crankshaft-pin-to-big-end-bearing 
clearance 
Out of specification → Replace the big
end bearings.
Crankshaft-pin-to-big-end-
bearing clearance: 
0.016–0.040 mm 
(0.0006–0.0016 in)
Measurement steps:
The following procedure applies to all of the
connecting rods.
CAUTION:
Do not interchange the big end bearings
and connecting rods. To obtain the cor-
rect crankshaft-pin-to-big-end-bearing
clearance and prevent engine damage,
the big end bearings must be installed in
their original positions. 
Clean the big end bearings, crankshaft
pins, and the inside of the connecting rod
halves. 
Install the big end upper bearing into the
connecting rod and the big end lower
bearing into the connecting rod cap.
NOTE:
Align the projections a on the big end bear-
ings with the notches b in the connecting
rod and connecting rod cap. 
Put a piece of Plastigauge
® 1 on the
crankshaft pin. 
Assemble the connecting rod halves.
1