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 
Valve 3 
Valve spring 4 
Upper spring seat 5 
(into the cylinder head)
NOTE:
Make sure that each valve is installed in its
original place. Refer to the following
embossed marks.
Right and left intake valve(-s): “4XV:”
Middle intake valve(-s): “4XV.”
Exhaust valve(-s): “5LV”
Install the valve spring with the larger pitch
a facing up.
bSmaller pitch 
						

							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 installation. 
						

							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 “OIL TANK”.
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, 11 ft 
• Ib) 1st    7.8 N • m (0.78 kgf 
• m, 5.6 ft 
• Ib)
9 × 105 mm
3rd   49 ± 5˚
8.4 N •
 m (0.84 kgf • m, 6.1 ft • Ib)
12 N •
 m (1.2 kgf • m, 8.7 ft • Ib)
6 × 55 mm
12 N •
 m (1.2 kgf • m, 8.7 ft • Ib)
6 × 55 mm
7.6 N •
 m (0.76 kgf • m, 5.5 ft • Ib)
6 × 16 mm
15 N •
 m (1.5 kgf • m, 11 ft • Ib)
12 N •
 m (1.2 kgf • m, 8.7 ft • Ib)
6 × 25 mm
12 N •
 m (1.2 kgf • m, 8.7 ft • Ib)
6 × 20 mm
20 
						

							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 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, 11 ft 
• Ib) 1st    7.8 N • m (0.78 kgf 
• m, 5.6 ft 
• Ib)
9 × 105 mm
3rd   49 ± 5˚
8.4 N •
 m (0.84 kgf • m, 6.1 ft • Ib)
12 N •
 m (1.2 kgf • m, 8.7 ft • Ib)
6 × 55 mm
12 N •
 m (1.2 kgf • m, 8.7 ft • Ib)
6 × 55 mm
7.6 N •
 m (0.76 kgf • m, 5.5 ft • Ib)
6 × 16 mm
15 N •
 m (1.5 kgf • m, 11 ft • Ib)
12 N •
 m (1.2 kgf • m, 8.7 ft • Ib)
6 × 25 mm
12 N •
 m (1.2 kgf • m, 8.7 ft • Ib)
6 × 20 mm
20 
						

							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, 11 ft 
• Ib) 1st    7.8 N • m (0.78 kgf 
• m, 5.6 ft 
• Ib)
9 × 105 mm
3rd   49 ± 5˚
8.4 N •
 m (0.84 kgf • m, 6.1 ft • Ib)
12 N •
 m (1.2 kgf • m, 8.7 ft • Ib)
6 × 55 mm
12 N •
 m (1.2 kgf • m, 8.7 ft • Ib)
6 × 55 mm
7.6 N •
 m (0.76 kgf • m, 5.5 ft • Ib)
6 × 16 mm
15 N •
 m (1.5 kgf • m, 11 ft • Ib)
12 N •
 m (1.2 kgf • m, 8.7 ft • Ib)
6 × 25 mm
12 N •
 m (1.2 kgf • m, 8.7 ft • Ib)
6 × 20 mm
20
Not reusable 
						

							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 kgf 
• m, 11 ft 
• Ib) 1st    7.8 N • m (0.78 kgf 
• m, 5.6 ft 
• Ib)
9 × 105 mm
3rd   49 ± 5˚
8.4 N •
 m (0.84 kgf • m, 6.1 ft • Ib)
12 N •
 m (1.2 kgf • m, 8.7 ft • Ib)
6 × 55 mm
12 N •
 m (1.2 kgf • m, 8.7 ft • Ib)
6 × 55 mm
7.6 N •
 m (0.76 kgf • m, 5.5 ft • Ib)
6 × 16 mm
15 N •
 m (1.5 kgf • m, 11 ft • Ib)
12 N •
 m (1.2 kgf • m, 8.7 ft • Ib)
6 × 25 mm
12 N •
 m (1.2 kgf • m, 8.7 ft • Ib)
6 × 20 mm
20
Not reusable 
						

							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 kgf 
• m, 25 ft 
• Ib)
Not reusable
Not reusable 
						

							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
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 crankcase
indicate the crankcase tightening sequence.
3. Remove:
Lower crankcase
CAUTION:
Tap on one side of the crankcase with a
soft-face hammer. Tap only on reinforced
portions of the crankcase, not on he crank-
case mating surfaces. Work slowly and
carefully and make sure the crankcase
halves separate evenly.
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
CAEG H
FB
DJ 
						

							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 the recommended lubricant)
Recommended lubricant:
Engine oil 
						

							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
CAEG H
FB
DJ
5. Tighten:
Crankcase bolts 1–0 
NOTE:
Do not reuse crankcase bolts 1–0.
The tightening procedure of crankcase bolts
1–0 is angle controlled, therefore tighten
the bolts using the following procedure.
86240
93157
I
CAEG H
FB
DJ