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 the connecting rod and big end
bearings. 
Refer to “Connecting rod and piston
removal”.
Measure the compressed Plastigauge
®
width e on the crankshaft pin. 
If the crankshaft-pin-to-big-end-bearing
clearance is out of specification, select
replacement big end bearings. 
cd
e
2. Select: 
Big end bearings (P
1–P4)
NOTE:
The numbers stamped into the crankshaft
web and the numbers on the connecting rods
are used to determine the replacement big
end bearing sizes. 
“P
1”–”P4” refer to the bearings shown in the
crankshaft illustration. 
P4
P3P2
P1 
						

							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 install the piston rings so that the
manufacturer’s marks or numbers face up. 
2. Install: 
Piston 1 
Connecting rod 2 
Piston pin 3 
Piston pin clip 4 
NOTE:
Apply engine oil onto the piston pin. 
Make sure that the “Y” mark a on the con-
necting rod left when the arrow mark b on
the piston is pointing up. Refer to the illustra-
tion.
Reinstall each piston into its original cylinder
(numbering order starting from the front: #1
to #4).  
						

							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 lubricant)
Recommended lubricant: 
Engine oil 
						

							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 the other
hand.
Make sure the “Y” marks a on the connect-
ing rods face towards the front side of the
crankshaft. 
Make sure the characters b on both the con-
necting rod and connecting rod cap are
aligned. 
8. Align: 
Bolt heads 
(with the connecting rod)
Piston ring compressor: 
YM-08037/90890-05158 
						

							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
reach the specified angle 120°.
T R..
Connecting rod nut:
Final:
Specified angle 120 ± 5°
 WARNING
When the nuts are tightened more than
the specified angle, do not loosen the
nut and then retighten it.
Replace the nut with a new one and per-
form the procedure again.
CAUTION:
Do not use a torque wrench to tighten
the nut to the specified angle.
Tighten the nut until it is at the speci-
fied angle.
NOTE:
When using a hexagonal nut, note that the
angle from one corner to another is 60°. 
						

							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 surfaces 
Crankshaft pin surfaces 
Bearing surfaces 
Scratches/wear → Replace the crank-
shaft.
3. Measure:
crankshaft-journal-to-crankshaft-journal-
bearing clearance 
Out of specification → Replace the
crankshaft journal bearings.
Crankshaft-journal-to-crankshaft-
journal-bearing clearance:
0.020–0.057 mm 
(0.0008–0.0022 in)  
						

							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 crankshaft into the upper
crankcase.
NOTE:
Align the projections a of the crankshaft
journal upper bearings with the notches b
in the upper crankcase. 
Put a piece of Plastigauge
® 2 on each
crankshaft journal.
NOTE:
Do not put the Plastigauge® over the oil
hole in the crankshaft journal. 
Install the crankshaft journal lower bear-
ings into the lower crankcase and assem-
ble the crankcase halves.
NOTE:
Align the projections a of the crankshaft
journal lower bearings with the notches b
in the lower crankcase. 
Do not move the crankshaft until the
clearance measurement has been com-
pleted. 
1
a
b
2 
						

							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 numbers stamped into the crankshaft
web and the numbers stamped into the lower
crankcase are used to determine the
replacement crankshaft journal bearing
sizes. 
“J
1–J5” refer to the bearings shown in the
crankshaft illustration. 
If “J
1–J5” are the same, use the same size
for all of the bearings. 
For example, if the crankcase “J
1” and crank-
shaft web “J
1” numbers are “5” and “2” respec-
tively, then the bearing size for “J
1” is:
Bearing size of J
1:
“J
1” (crankcase) – “J1” (crankshaft web)
5 – 2 = 3 (blue)
BEARING COLOR CODE 
1brown
2 black
3blue
4 green
5 yellow
J5J4J3J2J1
J1J2J3J4J5
J5J4J3J2J1 
						

							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 oil