Basic HTML Version
47
FUEL
SYSTEMS
ENGINE/
GASKETS
EXHAUST DRIVE LINE
HANDLING
ELECTRICAL WATERLINE
/BILGE
STEERING
& CONTROLS
BODY
ACCESSORIES SERVICE TOOLS
/HARDWARE
CHEMICAL FREESTYLE
& 800SXR
FOUR
STROKE
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
(496cc) 1987-92
WaveBlaster, WaveBLaster II
WaveRaider, WaveRunner GP760
WaveVenture, XL760 1996-00
(754cc) Twin
Super Jet 1990-93, WaveRunner III
1996, WaveRunner VXR 1992-95
(from
817001)
(633cc) Twin
Piston
Kit
Wrist
Pin
586M07200
586M07250
586M07300
586M07350
602M07700
602M07750
602M07800
602M07850
602M07900
2835CD
2854CD
2874CD
2894CD
3032TD
3051TD
3071TD
3091TD
3110TD
50-4184 01325
72mm RS
77mm 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
(784cc) Twin
758M08000
3150KD
01343
80mm AC
80.00
CW22 S640
YA-5356
STD
0.50
1.00
1.50
2.00
1051
1064
1077
1090
1104
WaveRaider 1100 1995-97
WaveVenture 1100
(1051cc) Triple
791M08100
791M08150
791M08200
791M08250
791M08300
3189KD
3209KD
3228KD
3248KD
3268KD
50-3483 01325
81mm 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
XL1200
1998
(1131cc) Triple
757M08400
757M08450
757M08500
757M08550
757M08600
3307KD
3327KD
3347KD
3366KD
3386KD
50-3483 01325
84mm 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
(from 816999)
91-92
(633cc) Twin
77mm RS
YA-5176
STD
0.50
1.00
1.50
2.00
3.00
701
710
718
726
735
753
Super Jet, WaveRunner III GP
WaveBlaster, WaveRunner II
WaveRunner Pro VXR, FX700
WaveRaider
(701cc) Twin
790M08100
790M08150
790M08200
790M08250
790M08300
790M08400
3189KD
3209KD
3228KD
3248KD
3268KD
3307KD
81mm 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
757M08400
757M08450
757M08500
757M08550
757M08600
3307KD
3327KD
3347KD
3368KD
3386KD
84.00
84.50
85.00
85.50
86.00
50-3483 01325
CW20 S512
STD 1176
XL 1200 LTD 1998-00
GP1200R 2000
(1176cc) Triple
758M08000
3150KD
01343
80mm AC
80.00
CW22 S640
YA-5469
WaveRaider
WaveRaider DX, WaveVenture
WaveVenture XL700
(701cc)Twin
81mm RS
YA-5284
YA-5304
84mm
84mm RS
YA-5187B
}
93-
00
1996-97
}
1994-95
95-00
Super Jet, WaveRunner III GP
WaveBlaster, WaveRunner II
WaveRunner Pro VXR, FX700
WaveRaider
Big Bore to 789cc Twin
}
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
632M07600
632M07650
632M07700
2992TD
3012TD
3032TD
B1024
75.7mm
CI
83mm
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
76.5mm
FL-5281
Daytona, Monte Carlo 1000 1997-98
TS-1000R, TS-1000L 1999
81mm
FL-5343
TS1100R, TS1100Li 1999
85mm
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
85.5mm and 86mm bore.
Ceramic Composite Bore
STD
4.00
896
998
2349M07650
2349M08050
3012TDW
3169TD
B1024
76.50
80.50
CW20 S512
STD
4.00
1000
1100
2394M08100
718M08500
3189KD
3347KD
B1024
81.00
85.00
CW22 S539
* Nikasil Bore – Cylinder sleeving required for 85mm bore.