Yamaha Waverunner 3 Manual

5-92
EPOWRCONNECTING RODS AND PISTONS
NOTE:
Do not move the connecting rod or crank-
shaft until the clearance measurement
has been completed. 
Lubricate the bolts threads and nut seats
with molybdenum disulfide grease. 
Make sure the “Y” mark c on the con-
necting rod faces towards the front side of
the crankshaft. 
Make sure the characters d on both the
connecting rod and connecting rod cap
are aligned. 
Tighten the connecting rod nuts. 
Refer to “Connecting rod and piston
installation”.
Remove...

5-93
EPOWRCONNECTING RODS AND PISTONS
For example, if the connecting rod “P1” and the
crankshaft web “P
1” numbers are “5” and “1”
respectively, then the bearing size for “P
1” is:
Bearing size of P
1:
“P
1” (connecting rod) – 
“P
1” (crankshaft web)
5 – 1 = 4 (green)
BEARING COLOR CODE 
1brown
2 black
3blue
4 green5 G
P4P3P2P1
Connecting rod and piston installation
The following procedure applies to all of the
pistons and connecting rods.
1. Install: 
Top ring 
2nd ring 
Oil ring 
NOTE:
Be sure to...

5-94
EPOWRCONNECTING RODS AND PISTONS
3. Offset: 
Piston ring end gaps 
aTop ring 
bLower oil ring rail 
cUpper oil ring rail 
d2nd ring
ÈIntake side
4. Lubricate: 
Piston 
Piston rings 
Cylinder 
(with the recommended lubricant)
Recommended lubricant: 
Engine oil
5. Lubricate: 
Bolt threads 
Nut seats 
(with the recommended lubricant)
Recommended lubricant: 
Molybdenum disulfide grease
6. Lubricate: 
Crankshaft pins 
Big end bearings 
Connecting rod inner surface 
(with the recommended...

5-95
EPOWRCONNECTING RODS AND PISTONS
7. Install: 
Big end bearings 
Connecting rod assembly 1 
(into the cylinder and onto the 
crankshaft pin)
Connecting rod cap 
(onto the crankshaft pin)
NOTE:
Align the projections on the big end bearings
with the notches in the connecting rods and
connecting rod caps. 
Be sure to reinstall each big end bearing in
its original place. 
While compressing the piston rings with pis-
ton ring compressor 2, install the connecting
rod assembly into the cylinder with...

5-96
EPOWRCONNECTING RODS AND PISTONS
9. Tighten: 
Connecting rod nuts
 WARNING
Replace the connecting rod bolts and
nuts with new ones. 
Clean the connecting rod bolts and nuts. 
NOTE:
The tightening procedure of the connecting rod
nuts is angle controlled, therefore tighten the
nuts using the following procedure. 
Tightening steps:
Tighten the connecting rod nuts to the
specified torque.
T R..
Connecting rod nut:
1st:
20 N  m (2.0 kgf  m, 14 ft  lb)
Tighten the connecting rod nuts further to...

5-97
EPOWRCRANKSHAFT
CRANKSHAFT
EXPLODED DIAGRAM
REMOVAL AND INSTALLATION CHART
Step Procedure/Part name Q’ty Service points
CRANKSHAFT REMOVALFollow the left “Step” for removal.
Crankcase Separate
Refer to “CRANKCASE”.
Connecting rod caps Refer to “CONNECTING RODS AND 
PISTONS”.
1 Crankshaft 1
2 Crankshaft journal lower bearing 5
3 Crankshaft journal upper bearing 5
Reverse the removal steps for installation.
2
2 133 

5-98
EPOWRCRANKSHAFT
SERVICE POINTS
Crankshaft removal
1. Remove: 
Crankshaft 1 
Crankshaft journal lower bearings 
(from the lower crankcase)
Crankshaft journal upper bearings 
(from the upper crankcase)
NOTE:
Identify the position of each crankshaft journal
bearing so that it can be reinstalled in its origi-
nal place. 
1
Crankshaft inspection
1. Measure: 
Crankshaft runout 
Out of specification → Replace the
crankshaft.
Maximum crankshaft runout: 
0.03 mm (0.0012 in)
2. Check: 
Crankshaft journal...

5-99
EPOWRCRANKSHAFT
CAUTION:
Do not interchange the crankshaft journal
bearings. To obtain the correct crankshaft-
journal-to-crankshaft-journal-bearing clear-
ance and prevent engine damage, the
crankshaft journal bearings must be
installed in their original positions. 
Measurement steps:
Clean the crankshaft journal bearings,
crankshaft journals, and bearing portions
of the crankcase. 
Place the upper crankcase upside down
on a bench. 
Install the crankshaft journal upper bear-
ings 1 and the...

5-100
EPOWRCRANKSHAFT
Tighten the bolts to specification in the
tightening sequence cast on the crank-
case.
Refer to “Crankcase assembly”—
“CRANKCASE”.
Remove the lower crankcase and the
crankshaft journal lower bearings. 
Measure the compressed Plastigauge
®
width c on each crankshaft journal. 
If the crankshaft-journal-to-crankshaft-
journal-bearing clearance is out of speci-
fication, select replacement crankshaft
journal bearings. 
c
4. Select: 
Crankshaft journal bearings (J
1–J5)
NOTE:
The...

5-101
EPOWRCRANKSHAFT
Crankshaft installation
1. Install: 
Crankshaft journal upper bearings 
(into the upper crankcase)
Crankshaft journal lower bearings 
(into the lower crankcase)
NOTE:
Align the projections a on the crankshaft
journal upper bearings with the notches b in
the upper crankcase. 
Be sure to install each crankshaft journal
bearing in its original place. 
a
b
2. Lubricate: 
Crankshaft pins 
Connecting rod inner surface 
(with the recommended lubricant)
Recommended lubricant: 
Engine...