Yamaha Waverunner 3 Manual

							5-42
EPOWRGENERATOR AND STARTER MOTOR
2. Check:
Starter clutch 1 
Starter gear 2 
Burrs/chips/roughness/wear → Replace
the defective part(s).
3. Check:
Starter clutch gear’s contacting surfaces 
a 
Damage/pitting/wear → Replace the
starter clutch gear.
12
a
4. Check:
Starter clutch operation
Checking steps:
Install the starter gear 1 onto the starter
clutch 2 and hold the starter clutch.
When turning the starter gear clockwise
È, it should turn freely, otherwise the
starter clutch is faulty and must be
replaced.
When turning the starter gear counter-
clockwise É, the starter clutch and the
starter gear should engage, otherwise
the starter clutch is faulty and must be
replaced. 
						

							5-43
EPOWRGENERATOR AND STARTER MOTOR
Flywheel magneto installation
1. Install:
Woodruff key
Flywheel magneto
Washer
Flywheel magneto bolt
NOTE:
Clean the tapered portion of the crankshaft
and the flywheel magneto hub.
When installing the flywheel magneto, make
sure the woodruff key is properly seated in
the keyway of the crankshaft.
Lubricate the flywheel magneto bolt and
washer with engine oil.
2. Tighten:
Flywheel magneto bolt 1 
NOTE:
While holding the flywheel magneto 2 with the
sheave holder 3, tighten the flywheel mag-
neto bolt.
CAUTION:
Do not reuse the flywheel magnet bolt and
washer, always replace them with new
ones.
T R..
Flywheel magneto bolt:
75 N  m (7.5 kgf  m, 54 ft  lb)
Sheave holder:
YS-01880-A/90890-01701 
						

							5-44
EPOWRCAMSHAFTS
CAMSHAFTS
EXPLODED DIAGRAM
REMOVAL AND INSTALLATION CHART
Step Procedure/Part name Q’ty Service points
CYLINDER HEAD COVER 
REMOVALFollow the left “Step” for removal.
Air filter case Refer to “FUEL INJECTION SYSTEM” in 
Chapter 4.
1 Spark plug 4
2 Clamp/breather hose 1/1È To oil tank
White mark a 
3Bolt 1
4 Camshaft position sensor 1
5 Clamp/cooling water hose 1/1É To thermostat
6 Rubber seal 1
E
2
4 3 5
6
8
9
10
117
LT
572
LT
LT
572
LT
12
14
13
1
13 N 
 m (1.3 kgf  m, 9.4 ft  Ib)
10 N 
 m (1.0 kgf  m, 7.2 ft  Ib)
6 × 16 mm
6 × 16 mm
2nd   7.6 N  m (0.76 kgf 
 m, 5.5 ft 
 Ib) 1st    3.7 N  m (0.37 kgf 
 m, 2.7 ft 
 Ib)
12 N 
 m (1.2 kgf  m, 8.7 ft  Ib)
6 × 22 mm
aÈ
É 
						

							5-45
EPOWRCAMSHAFTS
EXPLODED DIAGRAM
Step Procedure/Part name Q’ty Service points
7Bolt 1
8 Cooling water pipe 1
9 O-ring 1
10 Bolt 6
11 Rubber mount 6
12 Cylinder head cover 1
13 Cylinder head cover gasket 1
14 Timing chain guide (top side) 1
Reverse the removal steps for installation.
E
2
4 3 5
6
8
9
10
117
LT
572
LT
LT
572
LT
12
14
13
1
13 N 
 m (1.3 kgf  m, 9.4 ft  Ib)
10 N 
 m (1.0 kgf  m, 7.2 ft  Ib)
6 × 16 mm
6 × 16 mm
2nd   7.6 N  m (0.76 kgf 
 m, 5.5 ft 
 Ib) 1st    3.7 N  m (0.37 kgf 
 m, 2.7 ft 
 Ib)
12 N 
 m (1.2 kgf  m, 8.7 ft  Ib)
6 × 22 mm
aÈ
É
Not reusable
Not reusable 
						

							5-46
EPOWRCAMSHAFTS
EXPLODED DIAGRAM
REMOVAL AND INSTALLATION CHART
Step Procedure/Part name Q’ty Service points
CAMSHAFT REMOVALFollow the left “Step” for removal.
Cylinder head cover
Reduction drive gear case Refer to “REDUCTION DRIVE GEAR”.
NOTE:
When removing camshafts it is not neces-
sary to remove the reduction drive gear
case.
1 Cap bolt 1
2Gasket 1
3Bolt 2
4 Timing chain tensioner 1
E
EE
E
E
E
M
M
10
11
10
11
10
11
121617
8
18
8
8
13
9
14
7
15
620
19
1 2
3 4 5
10 N 
 m (1.0 kgf  m, 7.2 ft  Ib)
6 × 35 mm
10 N 
 m (1.0 kgf  m, 7.2 ft  Ib)
6 × 35 mm
10 N 
 m (1.0 kgf  m, 7.2 ft  Ib)
6 × 25 mm
10 N 
 m (1.0 kgf  m, 7.2 ft  Ib)
6 × 8 mm
24 N 
 m (2.4 kgf  m, 17 ft  Ib)
7 × 11 mm
24 N 
 m (2.4 kgf  m, 17 ft  Ib)
7 × 11 mm
Not reusable 
						

							5-47
EPOWRCAMSHAFTS
EXPLODED DIAGRAM
Step Procedure/Part name Q’ty Service points
5 Timing chain tensioner gasket 1
6 Timing chain guide (exhaust side) 1
7Bolt 18
8 Intake camshaft cap 3
9 Dowel pin 6
NOTE:
During removal, the dowel pins may still be
connected to the camshaft caps. 10 Bolt 10
11 Exhaust camshaft cap 3
12 Dowel pin 6
13 Intake camshaft 1
14 Bolt 2
15 Intake camshaft sprocket 1
E
EE
E
E
E
M
M
10
11
10
11
10
11
121617
8
18
8
8
13
9
14
7
15
620
19
1 2
3 4 5
10 N 
 m (1.0 kgf  m, 7.2 ft  Ib)
6 × 35 mm
10 N 
 m (1.0 kgf  m, 7.2 ft  Ib)
6 × 35 mm
10 N 
 m (1.0 kgf  m, 7.2 ft  Ib)
6 × 25 mm
10 N 
 m (1.0 kgf  m, 7.2 ft  Ib)
6 × 8 mm
24 N 
 m (2.4 kgf  m, 17 ft  Ib)
7 × 11 mm
24 N 
 m (2.4 kgf  m, 17 ft  Ib)
7 × 11 mm
Not reusable 
						

							5-48
EPOWRCAMSHAFTS
EXPLODED DIAGRAM
Step Procedure/Part name Q’ty Service points
16 Exhaust camshaft 1
17 Bolt 2
18 Exhaust camshaft sprocket 1
19 Pin 1
20 Timing chain guide (intake side) 1
Reverse the removal steps for installation.
E
EE
E
E
E
M
M
10
11
10
11
10
11
121617
8
18
8
8
13
9
14
7
15
620
19
1 2
3 4 5
10 N 
 m (1.0 kgf  m, 7.2 ft  Ib)
6 × 35 mm
10 N 
 m (1.0 kgf  m, 7.2 ft  Ib)
6 × 35 mm
10 N 
 m (1.0 kgf  m, 7.2 ft  Ib)
6 × 25 mm
10 N 
 m (1.0 kgf  m, 7.2 ft  Ib)
6 × 8 mm
24 N 
 m (2.4 kgf  m, 17 ft  Ib)
7 × 11 mm
24 N 
 m (2.4 kgf  m, 17 ft  Ib)
7 × 11 mm 
						

							5-49
EPOWRCAMSHAFTS
SERVICE POINTS
Camshaft removal
1. Install:
Dial gauge needle
Dial gauge stand 1 
(into spark plug hole #1)
Dial gauge 2 
Dial gauge stand:
90890-06583
Dial gauge needle:
90890-06584
Dial gauge stand set:
YW-06585/90890-06585
Dial gauge:
YU-03097/90890-01252
2
1
2. Turn the drive coupling counterclockwise,
and then check if cylinder #1 is at TDC of
the compression stroke with a dial gauge.
NOTE:
TDC on the compression stroke can be found
when the camshaft lobes are turned away from
each other.
INEX
3. Make an alignment mark a on the timing
chain and camshaft sprockets.
a 
						

							5-50
EPOWRCAMSHAFTS
4. Remove:
Timing chain tensioner 1 
Gasket
1
5. Remove:
Camshaft caps
Dowel pins
NOTE:
Loosen the intake and exhaust camshaft cap
bolts in the sequence shown.
1 10 7 6 3
2
14 18 15 11 4 10 7 52 8 9
4 5
1 12 16 17 13
6 8 9 3
6. Remove:
Intake camshaft 1 
Exhaust camshaft 2 
NOTE:
To prevent the timing chain from falling into the
crankcase, fasten it with a wire 3.
Camshaft inspection
1. Check:
Camshaft lobes
Blue discoloration/pitting/scratches →
Replace the camshaft.
2. Measure:
Camshaft lobe dimensions a and b 
Out of specification → Replace the cam-
shaft.
Minimum cam lobe dimensions:
Intake camshaft:
a 32.25 mm (1.270 in)
b 25.00 mm (0.984 in)
Exhaust camshaft:
a 32.65 mm (1.285 in)
b 25.00 mm (0.984 in) 
						

							5-51
EPOWRCAMSHAFTS
3. Measure:
Camshaft runout
Out of specification → Replace.
Maximum camshaft runout:
0.03 mm (0.0012 in)
4. Measure:
Camshaft-journal-to-camshaft-cap 
clearance
Out of specification → Measure the
camshaft journal diameter.
Camshaft-journal-to-camshaft-
cap clearance:
0.05–0.08 mm (0.0020–0.0031 in)
Measurement steps:
Install the camshaft into the cylinder head
(without the dowel pins and camshaft
caps).
Position a strip of Plastigauge
® 1 onto
the camshaft journal as shown.
Install the dowel pins and camshaft caps.
NOTE:
Tighten the intake and exhaust camshaft
cap bolts in the sequence shown.
Do not turn the camshaft when measuring
the camshaft journal-to-camshaft cap
clearance with the Plastigauge®.
T R..
Camshaft cap bolt:
10 N  m (1.0 kgf  m, 7.2 ft  lb)
Remove the camshaft caps and then
measure the width of the Plastigauge
®
1.
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