Yamaha Waverunner 3 Manual
Here you can view all the pages of manual Yamaha Waverunner 3 Manual. The Yamaha manuals for WaveRunner VXS Owners Manual are available online for free. You can easily download all the documents as PDF.
Page 171
5-62 EPOWRVALVES AND VALVE SPRINGS VALVES AND VALVE SPRINGS EXPLODED DIAGRAM REMOVAL AND INSTALLATION CHART Step Procedure/Part name Q’ty Service points VALVES AND VALVE SPRINGS REMOVALFollow the left “Step” for removal. Cylinder head Refer to “CYLINDER HEAD”. 1 Intake valve lifter 12 2 Intake valve pad 12 3 Intake valve cotter 24 4 Intake valve upper spring seat 12 5 Intake valve spring 12 6 Intake valve oil seal 12 7 Intake valve lower spring seat 12 8 Intake valve 12 9 Intake valve guide 12 E E E...
Page 172
5-63 EPOWRVALVES AND VALVE SPRINGS EXPLODED DIAGRAM Step Procedure/Part name Q’ty Service points 10 Exhaust valve lifter 8 11 Exhaust valve pad 8 12 Exhaust valve cotter 16 13 Exhaust valve upper spring seat 8 14 Exhaust valve spring 8 15 Exhaust valve oil seal 8 16 Exhaust valve lower spring seat 8 17 Exhaust valve 8 18 Exhaust valve guide 8 Reverse the removal steps for installation. E E E 89 17 18 16 15 14 13 10 11 121 2 3 4 5 6 7 3 12
Page 173
5-64 EPOWRVALVES AND VALVE SPRINGS SERVICE POINTS Valve removal 1. Remove: Valve lifter 1 Valve pad 2 NOTE: Make a note of the position of each valve lifter and valve pad so that they can be reinstalled in their original place. 2. Remove: Valve cotters 1 NOTE: Remove the valve cotters by compressing the valve spring with the valve spring compressor 2 and attachment 3. Valve spring compressor: YM-04019/90890-04019 Valve spring compressor attachment: (for the intake valve) YM-4114/90890-04114 (for...
Page 174
5-65 EPOWRVALVES AND VALVE SPRINGS Valve spring inspection 1. Measure: Valve spring free length a Out of specification → Replace the valve spring. 2. Measure: Valve spring tilt a Out of specification → Replace the valve spring. Valve spring free length: Intake valve spring: 38.90 mm (1.53 in) Exhaust valve spring: 40.67 mm (1.60 in) Valve spring tilt: Intake valve spring: 1.7 mm (0.067 in) Exhaust valve spring: 1.8 mm (0.071 in) Valve inspection 1. Eliminate: Carbon deposits (from the valve face and...
Page 175
5-66 EPOWRVALVES AND VALVE SPRINGS 4. Measure: Valve stem diameter a Out of specification → Replace the valve. Valve stem diameter a: Intake valve: 3.975–3.990 mm (0.1565–0.1571 in) Exhaust valve: 4.460–4.475 mm (0.1756–0.1762 in) 5. Measure: Valve stem runout Out of specification → Replace the valve. NOTE: When installing a new valve, always replace the valve guide. If the valve is removed or replaced, always replace the oil seal. Valve stem runout: 0.01 mm (0.0004 in) Valve guide inspection...
Page 176
5-67 EPOWRVALVES AND VALVE SPRINGS 1. Measure: Valve guide inside diameter a 2. Calculate the valve stem-to-valve guide clearance as follows. Replace the valve guide if out of specification. Valve guide inside diameter: Intake: 4.000–4.012 mm (0.1575–0.1580 in) Exhaust: 4.500–4.512 mm (0.1772–0.1776 in) Valve stem-to-valve guide clearance = valve guide inside diameter – valve stem diameter: Intake: 0.010–0.037 mm (0.0004–0.0015 in) Exhaust: 0.025–0.052 mm (0.0010–0.0020 in) a Valve guide...
Page 177
5-68 EPOWRVALVES AND VALVE SPRINGS 2. Install the new valve guide 2 by striking the special service tool from the camshaft side until the valve guide clip 3 contacts the cylinder head. NOTE: Apply engine oil to the surface of the new valve guide. Valve guide remover: Intake (4.0 mm): YM-04111/90890-04111 Exhaust (4.5 mm): YM-04116/90890-04116 Valve guide installer: Intake (4.0 mm): YM-04112/90890-04112 Exhaust (4.5 mm): YM-04117/90890-04117 3 E 2 3. Insert the special service tool into the valve guide 2,...
Page 178
5-69 EPOWRVALVES AND VALVE SPRINGS Valve seat inspection 1. Eliminate carbon deposits from the valve with a scraper. 2. Apply a thin, even layer of Mechanic’s blueing dye (Dykem) onto the valve seat. 3. Lap the valve slowly on the valve seat with a valve lapper (commercially obtainable) as shown. 4. Measure the valve seat contact width a where the blueing dye is adhered to the valve face. Reface the valve seat if the valve is not seated properly or if the valve seat contact width is out of...
Page 179
5-70 EPOWRVALVES AND VALVE SPRINGS Valve seat reface 1. Reface the valve seat with the valve seat cutter. 2. Cut the surface of the valve seat with a 45° cutter by turning the cutter clockwise until the valve seat face has become smooth. aSlag or rough surface CAUTION: Do not over cut the valve seat. Be sure to turn the cutter evenly downward at a pres- sure of 40–50 N (4–5 kgf, 8.8–11 lbf) to pre- vent chatter marks. Valve seat cutter holder: Intake (4.0 mm): 90890-06811 Exhaust (4.5 mm): 90890-06812...
Page 180
5-71 EPOWRVALVES AND VALVE SPRINGS 4. Use a 60° cutter to adjust the contact width of the bottom edge of the valve seat. bPrevious contact width 60˚ b 5. Use a 45° cutter to adjust the contact width of the valve seat to specification. bPrevious contact width cSpecified contact width 45˚ b c 6. If the valve seat contact area is too wide and situated in the center of the valve face, use a 30° cutter to cut the top edge of the valve seat, a 60° cutter to cut the bottom edge to center the area and set its...
All Yamaha manuals