Yamaha Waverunner 3 Manual

5-72
EPOWRVALVES AND VALVE SPRINGS
9. Apply a thin, even layer of lapping com-
pound onto the valve seat, and then lap
the valve using a valve lapper (commer-
cially obtainable).
CAUTION:
Do not get the lapping compound on the
valve stem and valve guide.
10. After every lapping procedure, be sure to
clean off any remaining lapping compound
from the cylinder head and the valve.
11. Check the valve seat contact area of the
valve again.
Valve installation
1. Install:
Lower spring seat 1 
Oil seal 2...

5-73
EPOWRVALVES AND VALVE SPRINGS
2. Compress the valve spring, and then
install the valve cotter 1 using a thin
screwdriver with a small amount of grease
applied to it.
Valve spring compressor:
YM-04019/90890-04019
Valve spring compressor 
attachment:
(for the intake valve)
YM-4114/90890-04114
(for the exhaust valve)
YM-4108/90890-04108
3. Lightly tap the valve spring retainer with a
plastic hammer to set the valve cotter
securely.
NOTE:
Apply engine oil to the valve shims and valve
lifters before...

5-74
EPOWRCRANKCASE
CRANKCASE
EXPLODED DIAGRAM
REMOVAL AND INSTALLATION CHART
Step Procedure/Part name Q’ty Service points
OIL PAN AND CRANKCASE 
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”.
Exhaust manifold Refer to “EXHAUST MANIFOLD”.
Generator cover Refer to “GENERATOR AND STARTER 
MOTOR”.
Oil tank Refer to...

5-75
EPOWRCRANKCASE
EXPLODED DIAGRAM
Step Procedure/Part name Q’ty Service points
Oil pump Refer to “OIL PUMP”.
Reduction drive gear case Refer to “REDUCTION DRIVE GEAR”.
Cylinder head Refer to “CAMSHAFTS”.
1 Timing chain 1
2 Engine temperature sensor 1
3 Washer 1
4Bolt 2
5 Thermoswitch (engine) 1
6 Oil pressure switch 1
7Bolt 1
6
23 22
22 11
10
9
87
23
4
5
17
19161820
14 15
12
1321
1
LT
271
LT
LT
572
LT
LT
572
LT
LT
572
LT
LT
572
LT
LT
572
LT
LT
572
LT
E
E
AA
12 N •
 m (1.2 kgf • m, 8.7 ft • Ib)
6 × 70...

5-76
EPOWRCRANKCASE
EXPLODED DIAGRAM
Step Procedure/Part name Q’ty Service points
8Bolt 1
9 Anode cover 1
10 Grommet 1
11 Anode 1
12 Bolt 4
13 Bolt 9
14 Oil pan 1
15 Gasket 1
16 Bolt 2
17 Bolt 1
18 Bolt 7
6
23 22
22 11
10
9
87
23
4
5
17
19161820
14 15
12
1321
1
LT
271
LT
LT
572
LT
LT
572
LT
LT
572
LT
LT
572
LT
LT
572
LT
LT
572
LT
E
E
AA
12 N •
 m (1.2 kgf • m, 8.7 ft • Ib)
6 × 70 mm
12 N •
 m (1.2 kgf • m, 8.7 ft • Ib)
6 × 20 mm
20 N •
 m (2.0 kgf • m, 14 ft • Ib)
8 × 40 mm
2nd   15 N • m (1.5 kgf 
• m,...

5-77
EPOWRCRANKCASE
EXPLODED DIAGRAM
Step Procedure/Part name Q’ty Service points
19 Cap 4
20 Bolt/washer 10/10
21 Lower crankcase 1
22 Dowel pin 2
23 Dowel pin/O-ring 1/1
Reverse the removal steps for installation.
6
23 22
22 11
10
9
87
23
4
5
17
19161820
14 15
12
1321
1
LT
271
LT
LT
572
LT
LT
572
LT
LT
572
LT
LT
572
LT
LT
572
LT
LT
572
LT
E
E
AA
12 N •
 m (1.2 kgf • m, 8.7 ft • Ib)
6 × 70 mm
12 N •
 m (1.2 kgf • m, 8.7 ft • Ib)
6 × 20 mm
20 N •
 m (2.0 kgf • m, 14 ft • Ib)
8 × 40 mm
2nd   15 N • m (1.5...

5-78
EPOWRCRANKCASE
EXPLODED DIAGRAM
REMOVAL AND INSTALLATION CHART
Step Procedure/Part name Q’ty Service points
OIL PIPE AND OIL FILTER BOLT 
REMOVALFollow the left “Step” for removal.
Crankshaft Refer to “CRANKSHAFT”.
1Bolt 1
2 Oil pipe 1
3 O-ring 2
4Screw 2
5 Cover 1
6 O-ring 1
7 Oil filter bolt 1
8 Lower crankcase 1
Reverse the removal steps for installation.
E
E
81
2
3
7
4 6
5
LT
572
LT
AA
6 × 12 mm
12 N • m (1.2 kgf 
• m, 8.7 ft 
• Ib)6 × 10 mm
12 N • m (1.2 kgf 
• m, 8.7 ft 
• Ib)
35 N • m (3.5...

5-79
EPOWRCRANKCASE
SERVICE POINTS
Crankcase disassembly
1. Remove:
Oil pan bolts
NOTE:
Loosen each bolt 1/4 of a turn at a time, in
stages and in a crisscross pattern. After all of
the bolts are fully loosened, remove them.
Loosen the bolts in decreasing numerical
order (refer to the numbers in the illustra-
tion).
The numbers embossed on the oil pan indi-
cate the oil pan tightening sequence.
6
10
13
9
13
711 12
58 4
2
2. Remove:
Crankcase bolts
NOTE:
Loosen each bolt 1/4 of a turn at a time, in...

5-80
EPOWRCRANKCASE
4. Remove:
Dowel pins
Crankcase inspection
1. Thoroughly wash the crankcase halves in
a mild solvent.
2. Thoroughly clean all the gasket surfaces
and crankcase mating surfaces.
3. Check:
Crankcase
Cracks/damage → Replace.
Oil delivery passages
Obstruction → Blow out with com-
pressed air.
Timing chain inspection
1. Check:
Timing chain 1 
Damage/stiffness → Replace the timing
chain and camshaft sprockets as a set.
Crankcase assembly
1. Lubricate:
Crankshaft journal bearings
(with...

5-81
EPOWRCRANKCASE
2. Apply:
Gasket Maker
® 
(onto the crankcase mating surfaces)
NOTE:
Do not allow any Gasket Maker® to come into
contact with the oil gallery or crankshaft journal
bearings.
3. Install:
Dowel pins 1 
O-ring 2 
GM
1
1
2
1
4. Install:
Crankcase bolts
NOTE:
Lubricate the bolt 1–0 threads and wash-
ers with engine oil.
Finger tighten the crankcase bolts.
M9 × 105 mm bolts: 1–0 
M6 × 55 mm bolts: A–F 
M6 × 55 mm bolts: G, H 
M6 × 70 mm bolts: I 
M6 × 55 mm bolts: J 
86240
93157
I...