FUEL
SYSTEMS
EXHAUST DRIVE LINE
HANDLING
ELECTRICAL WATERLINE/
BILGE
STEERING
&
CONTROLS
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/
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CHEMICAL
BODY
ACCESSORIES
ENGINE/
GASKETS
37
Model
YAMAHA
Cyl. I.D.
★
L.A.
SLEEVE
STD
0.50
1.00
1.50
STD
0.50
1.00
1.50
2.00
496
503
509
517
633
641
649
658
667
Piston
Style
WaveJammer, WaveRunner
(496
cc) 1987-92
WaveBlaster, WaveBLaster II
WaveRaider, WaveRunner GP760
WaveVenture, XL760 1996-00
(754
cc) Twin
Super Jet 1990-93, WaveRunner III
1996,
WaveRunner VXR 1992-95
(
from
817001)
(633
cc) Twin
Piston
Kit
Wrist
Pin
586
M07200
586
M07250
586
M07300
586
M07350
602
M07700
602
M07750
602
M07800
602
M07850
602
M07900
2835
CD
2854
CD
2874
CD
2894
CD
3032
TD
3051
TD
3071
TD
3091
TD
3110
TD
50-4184 01325
72
mm RS
77
mm RS
Bore
Size
mm
CC
72.00
72.50
73.00
73.50
77.00
77.50
78.00
78.50
79.00
CW20 S478
50-3302 01325
CW20 S423
Over
Size
mm
YA-5025
STD 784
WaveRunner GP800 1998-00
WaveRunner XL800 2000
(784
cc) Twin
758
M08000
3150
KD
01343
80
mm AC
80.00
CW22 S639
YA-5356
STD
0.50
1.00
1.50
2.00
1051
1064
1077
1090
1104
WaveRaider 1100 1995-97
WaveVenture 1100
(1051
cc) Triple
791
M08100
791
M08150
791
M08200
791
M08250
791
M08300
3189
KD
3207
KD
3228
KD
3248
KD
3268
KD
50-3483 01325
81
mm RS
81.00
81.50
82.00
82.50
83.00
CW20 S512
YA-5282
STD
0.50
1.00
1.50
2.00
1131
1142
1156
1169
1184
WaveRunner GP1200 1997-99
SUV1200 1999-00
(1131
cc) Triple
757
M08400
757
M08450
757
M08500
757
M08550
757
M08600
3307
KD
3327
KD
3347
KD
3366
KD
3386
KD
50-3483 01325
84
mm RS
84.00
84.50
85.00
85.50
86.00
CW20 S631
YA-5349
YA-5139
Ring Set Circlip
Wrist
Pin
Bearing
Big
End
Bearings
WaveRunner 91-92, WaveRunner LX 93
WaveRunner III 1990-95
WaveRunner VXR
(
from816999)
91-92
(633
cc) Twin
77
mm RS
YA-5176
STD
0.50
1.00
1.50
2.00
3.00
701
710
718
726
735
753
Super Jet, WaveRunner IIIGP
WaveBlaster, WaveRunner II
WaveRunner Pro VXR, FX700
WaveRaider
(701
cc) Twin
790
M08100
790
M08150
790
M08200
790
M08250
790
M08300
790
M08400
3189
KD
3209
KD
3228
KD
3248
KD
3268
KD
3307
KD
81
mm RS
81.00
81.50
82.00
82.50
83.00
84.00
50-3483 01325
CW20 S512
YA-5187
STD
0.50
1.00
1.50
2.00
754
763
771
780
789
757
M08400
757
M08450
757
M08500
757
M08550
757
M08600
3307
KD
3327
KD
3347
KD
3368
KD
3386
KD
84.00
84.50
85.00
85.50
86.00
50-3483 01325
CW20 S512
STD 1176
XL 1200 LTD 1998-00
GP1200R 2000
(1176
cc) Triple
758
M08000
3150
KD
01343
80
mm AC
80.00
CW22 S639
YA-5356
WaveRaider
WaveRaider DX, WaveVenture
WaveVenture XL700
(701
cc)Twin
81
mm RS
YA-5284
YA-5304
84
mm
84
mm RS
YA-5187B
}
93-
00
1996-97
}
1994-95
95-00
Super Jet, WaveRunner IIIGP
WaveBlaster, WaveRunner II
WaveRunner Pro VXR, FX700
WaveRaider
Big Bore to 789ccTwin
}
93-
00
1996-97
Model
TIGERSHARK
Cyl. I.D.
★
L.A.
SLEEVE
0.31
0.81
1.31
639
652
661
Piston
Style
Tigershark 640 1993-99
Daytona, Monte Carlo 770, 1996-99
TS770, TS770L, TS770R
Piston
Kit
Wrist
Pin
632
M07600
632
M07650
632
M07700
2992
TD
3012
TD
3032
TD
B1024
75.7
mm
CI
83
mm
Bore
Size
mm
CC
76.00
76.50
77.00
CW20 S461
Over
Size
mm
FL-5237
FL-5298
Ring Set Circlip
Wrist
Pin
Bearing
Big
End
Bearings
Tigershark 900 1995-96
TS 900L 1999
76.5
mm
FL-5281
Daytona, Monte Carlo 1000 1997-98
TS-1000R, TS-1000L 1999
81
mm
FL-5343
TS1100R, TS1100Li 1999
85
mm
FL-5418
General Rules for Sleeve Installation:
These tips are intended to be a guide for installing sleeves into cylinders. There are always exceptions to the rule and care must be taken on special applications.
ALWAYS WAIT UNTIL THE SLEEVE ARRIVES BEFORE BEGINNING ANY MACHINEWORK. NEVER ASSUMETHATTHE STATED MODEL
ANDYEAR OFTHE CYLINDER IS CORRECT. ALWAYS CHECKTO SEE IFTHE SLEEVE PORTS MATCHTHE CYLINDER PORTS.
1.
Interference fit for cylinder sleeve to aluminum bore is .004.
2.
Interference fit for cylinder sleeve to a cast iron bore is .002 to .003.
3.
Installation of flanged type sleeves follow the same rules, but the top of the cylinder must have a countersink to the correct depth to accept
the flanged sleeve. .000 to .001 interference fit on the flange diameter is recommended.
4.
Heating the cylinder for 45 minutes to one hour at 350 degrees to 450 degrees is preferable.
5.
The sleeve should slide in very easily when the cylinder is properly heated. Freeze shrinking the sleeve is not necessary. (Some machinists
believe this assists installation of the sleeve.)
6.
REMEMBER:
Rap or press the sleeve down while the cylinder is cooling down. Use a hydraulic press for this procedure.
7.
Milling the top deck of the cylinder always adds a quality touch. A caution here, some cylinders may not be able to have the top surface
decked.
8.
For two-stroke cylinders, blending or matching the aluminum cylinder to the sleeve ports is recommended for proper fuel flow.
*
Cylinder Sleeving Required for
85.5
mm and 86mm bore.
Ceramic Composite Bore
Ceramic Composite Bore
STD
4.00
896
998
2349
M07650
2349
M08050
9012
TDW
3169
TD
B1024
76.50
80.50
CW20 S512
STD
4.00
1000
1100
2349
M08100
718
M08500
3189
KD
3347
KD
B1024
81.00
85.00
CW22 S539
*
Nikasil Bore – Cylinder sleeving required for 85mm bore.