Yamaha Waverunner 3 Manual
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Page 161
5-52 EPOWRCAMSHAFTS 5. Measure: Camshaft journal diameter a Out of specification → Replace the cam- shaft. Within specification → Replace the cyl- inder head and the camshaft caps as a set. Camshaft journal diameter: 24.44–24.45 mm (0.9622–0.9626 in) Camshaft sprockets inspection 1. Check: Camshaft sprocket Wear/damage → Replace the camshaft sprockets and timing chain as a set. a1/4 of a tooth bCorrect 1Timing chain 2Camshaft sprocket Timing chain tensioner inspection 1. Check: Timing chain...
Page 162
5-53 EPOWRCAMSHAFTS Camshaft installation 1. Install: Exhaust camshaft sprocket 1 Intake camshaft sprocket 2 (with the special tool 3) NOTE: Install the camshaft sprocket with the punch mark a facing outside. Rotor holder: YU-01235/90890-01235 T R.. Camshaft sprocket bolt: 24 N m (2.4 kgf m, 17 ft lb) 2. Install: Exhaust camshaft Intake camshaft Exhaust camshaft caps Intake camshaft caps Installation steps: Turn the drive coupling counterclockwise, and then check if cylinder #1 is at TDC...
Page 163
5-54 EPOWRCAMSHAFTS Install the exhaust and intake camshaft caps. NOTE: Gradually tighten the intake and exhaust camshaft cap bolts in 2–3 steps in the sequence shown. T R.. Camshaft cap bolt: 10 N m (1.0 kgf m, 7.2 ft lb) NOTE: Make sure that the punch marks c on the camshafts are aligned with the arrow marks d on the camshaft caps. Out of alignment → Reinstall. Remove the wire from the timing chain. 10 1 4 5 8 17 5 1 4 8 15 9 12 149 3 2 7 6 18 7 3 2 6 13 11 10 16 3. Install: Timing chain...
Page 164
5-55 EPOWRCAMSHAFTS Tighten the timing chain tensioner bolts 3 to the specified torque. NOTE: The “UP” mark on the timing chain ten- sioner should face up. T R.. Timing chain tensioner bolt: 10 N m (1.0 kgf m, 7.2 ft lb) Remove the screwdriver, make sure the timing chain tensioner rod releases, and then tighten the cap bolt to the specified torque. T R.. Cap bolt: 10 N m (1.0 kgf m, 7.2 ft lb) 4. Turn: Drive coupling (several turns counterclockwise) 5. Check: Turn the drive coupling...
Page 165
5-56 EPOWRCAMSHAFTS 7. Install: Cylinder head cover gasket Cylinder head cover NOTE: Apply Gasket Maker® onto the mating sur- faces of the cylinder head cover gasket and cylinder head. Tighten the cylinder head cover bolts stages and in a crisscross pattern. T R.. Cylinder head cover bolt: 12 N m (1.2 kgf m, 8.7 ft lb)
Page 166
5-57 EPOWRCYLINDER HEAD CYLINDER HEAD EXPLODED DIAGRAM REMOVAL AND INSTALLATION CHART Step Procedure/Part name Q’ty Service points CYLINDER HEAD REMOVALFollow the left “Step” for removal. Engine unit Refer to “ENGINE UNIT”. Air filter case Refer to “FUEL INJECTION SYSTEM” in Chapter 4. Exhaust pipe 3 Refer to “EXHAUST PIPE 3”. Exhaust pipes 1 and 2 Refer to “EXHAUST PIPES 1 AND 2”. Oil tank Refer to “OIL TANK”. Intake and exhaust camshaft Refer to “CAMSHAFTS”. 1Bolt 2 2 Hunger 1 3Bolt 3 E EE E E E 24...
Page 167
5-58 EPOWRCYLINDER HEAD EXPLODED DIAGRAM Step Procedure/Part name Q’ty Service points 4 Nut/washer 2/2 5 Nut/washer 8/8 6 Cylinder head 1 7 Cylinder head gasket 1 8 Dowel pin 2 Reverse the removal steps for installation. E EE E E E 24 1 75 5 6 8 3 5 5 5 LT 271 2nd 49 N m (4.9 kgf m, 35 ft Ib) 1st 20 N m (2.0 kgf m, 14 ft Ib) 2nd 64 N m (6.4 kgf m, 46 ft Ib) 1st 20 N m (2.0 kgf m, 14 ft Ib) 10 N m (1.0 kgf m, 7.2 ft Ib) 6 × 12 mm 10 N m (1.0 kgf m, 7.2...
Page 168
5-59 EPOWRCYLINDER HEAD SERVICE POINTS Cylinder head removal 1. Remove: Cylinder head bolts 1 2. Remove: Cylinder head nuts NOTE: Loosen the cylinder head nuts in the sequence shown. Cylinder head inspection 1. Eliminate: Combustion chamber carbon deposits (with a rounded scraper) NOTE: Do not use a sharp instrument to avoid damag- ing or scratching: spark plug bore threads valve seats 2. Check: Cylinder head Damage/scratches → Replace. Cylinder head water jacket Mineral deposits/rust → Eliminate.
Page 169
5-60 EPOWRCYLINDER HEAD 3. Measure: Cylinder head warpage Out of specification → Replace the cyl- inder head. Cylinder head warpage limit: 0.1 mm (0.004 in) Measurement steps: Place a straightedge 1 and a thickness gauge 2 across the cylinder head. Measure the warpage. If the limit is exceeded, replace the cylin- der head. Cylinder head installation 1. Install: Cylinder head NOTE: Pass the timing chain through the timing chain cavity. Lubricate the cylinder head nuts with engine oil. Tighten the...
Page 170
5-61 EPOWRCYLINDER HEAD 2. Tighten: Cylinder head bolts 1 NOTE: Lubricate the cylinder head bolts with engine oil. T R.. Cylinder head bolt: 10 N m (1.0 kgf m, 7.2 ft lb)
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