Power Unit

PERSONAL WATER CRAFT

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 INTRODUCTION

More than 20 years have elapsed since our personal watercraft (hereinafter the “PWC”)
first appeared on the market, and now the PWC has become a product that occupies a
major place in the world of marine pleasure just like outboards and motorboats.
The increasing opportunities for the use of the PWC by people are accompanied by the
increasing needs for more of the product knowledge of the PWC and its servicing
techniques and skills. And we, who handle our own PWC, should commit ourselves to
enhancing the product reliability through improved servicing skills and user
enlightenment of safety.
This book has been produced as a textbook for those PWC servicemen who receive
Marine YTA training. The text contains important basics that are required to better
understand the engines, propellers, hulls, and so on that are involved in the PWC.
Therefore, you are requested to carefully read and understand the contents of this
textbook so you will be knowledgeable enough to win customer reliance. Also if,
together with this book, you use the CAI (Computer Aided Instructions) containing
animation, we assure you that you will be able to get further and more effective learning
and knowledge.

Marine Business Operations

Yamaha Motor Co., Ltd.

YTA PWC Text

Issued in December 2008

All rights reserved
memo Compiled and issued by:
Marine Business Operations
Yamaha Motor Co., Ltd.
 WHAT WE LEARN IN VOLUME
INTRODUCTION
In this volume we will learn about the power unit of
the PWC. We will learn in detail not only about the
basics of the internal combustion engine but also
about the differences between the 4- and 2-stroke
engines including the mechanisms specific to the
PWC engine.

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 CHAPTER 1 CHAPTER 3
BASICS OF INTERNAL 2-STROKE ENGINE
COMBUSTION ENGINE
INTRODUCTION……….………………....…3-1
INTRODUCTION……….………………....…1-1 WHAT WE LEARN IN CHAPTER 3…....3-1
WHAT WE LEARN IN CHAPTER 1…....1-1 BASICS OF TWO STROKE
WHAT IS AN INTERNAL COMBUSTION ENGINES………………………………….3-2
ENGINE?……………………………………..1-2 ENGINE CONSTRUCTION……...…3-2
OPERATIONS OF ENGINE…….…..3-4
INTERNAL ENGINE AND
EXTERNAL ENGINE……………….1-2
RECIPROCATING ENGINE…………….....1-3
OVERVIEW OF RECIPROCATING
ENGINE………………………………….1-3
CHAPTER 4
FOUR PROCESSES OF FEATURES OF PWC ENGINE
ENGINE………………………………......1-3
COMBUSTION AND ENGINE INTRODUCTION ………………………...…4-1
SPEED………………………………….…1-6 WHAT WE LEARN IN CHAPTER 4.…...4-1
THREE ELEMENTS OF COMPARISON WITH MC ENGINE…….....4-2
THE ENGINE……………………………1-6 LOCATION AND DIRECTION OF
EVOLUTION OF RECIPROCATING INSTALLATION…………….……......4-2
ENGINE……………………………..……..1-10 CONSTRUCTION………..…………..…..4-2
EFFICIENCY OF ENGINE……………1-10
COMBUSTION EFFICIENCY..………1-11
CONTROL AIR-FUEL MIXING
RATIO…………………………………..1-11

CHAPTER 2
4-STROKE ENGINE
INTRODUCTION ………………………...…2-1
WHAT WE LEARN IN CHAPTER 2.…...2-1
BASICS OF FOUR STROKE
ENGINES ……………...…………..………...2-2
ENGINE CONSTRUCTION……...……..2-2
OPERATIONS OF ENGINE.……..……..2-2

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 INTRODUCTION
CHAPTER 1. BASICS OF
INTERNAL COMBUSTION
ENGINE
INTRODUCTION
WHAT WE LEARN IN CHAPTER 1
In this chapter we will learn about the basics of the
internal combustion engine. We will learn briefly
about the subjects ranging from the three engine
elements to the evolution of engines.

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 WHAT IS AN INTERNAL COMBUSTION ENGINE?
WHAT IS AN INTERNAL
COMBUSTION ENGINE?
INTERNAL ENGINE AND EXTERNAL
ENGINE
An engine outside which fuel is consumed is called
an external combustion engine and an engine
inside which fuel is consumed is called an internal
combustion engine. Engines used for MC,
outboards, and PWC are the internal combustion
ones. In an internal combustion engine, fuel and air
are mixed at an appropriate ratio and are burned in
the cylinder, thus producing kinetic energy.

1. Kinds of engines
An external combustion engine as represented by a
steam engine used to equipped with large auxiliary
equipment like a boiler or the like that was attached
to the engine unit, and there was also a limit to the
efficiency of energy that was made available.
Between the 18th and 19th century, one internal
combustion engine after another was developed.
Thereafter, internal combustion engines continued
to evolve until at present they come in the kinds of
engines as shown. Both 2-stroke and 4-stroke
engines are now mounted on PWC.

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 RECIPROCATING ENGINE
RECIPROCATING ENGINE
OVERVIEW OF RECIPROCATING
ENGINE
The reciprocating engine converts the up-and-down
motion of the engine into the rotation of the
crankshaft.

FOUR PROCESSES OF ENGINE

The four engine processes consist of intake,
compression, explosion, and exhaust. The 2-stroke
engine completes these four processes one rotation
of the crankshaft while the 4-stroke engine
completes the same processes two rotation of the
crankshaft.

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 RECIPROCATING ENGINE
1．Outline of fore stroke engine
In the 4-stroke engine, as the piston goes down in
the cylinder and the intake valve opens, vacuum is
created causing air and fuel to mix at once and the
mixture thus produce is drawn into the cylinder.
When enough mixture is drawn into the cylinder,
the intake valve closes and the piston begins to
compress this mixture. Just before the piston goes
up to the uppermost top (Top dead center), the
sparkplug produces sparks, which ignite the
compressed air-fuel mixture. The ignited mixture
quickly spreads while burning and pushes down the
piston with great force. As the piston goes up, the
exhaust valve opens and expels the exhaust
gasses.

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 RECIPROCATING ENGINE
2．Outline of two stroke engine
The 2-stroke engine completes these four
processes every one crankshaft rotations. And the
engine is largely divided into the combustion
chamber and the crankcase. The process of
compressing the crankcase is called primary
compression and that of compressing the
combustion chamber is called secondary
compression.

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 RECIPROCATING ENGINE
COMBUSTION AND ENGINE SPEED
As throttle is opened, more fuel is supplied to the
engine. More fuel thus supplied produces more
combustion energy in the combustion process. This
energy causes the piston to go down faster. The
downward stroke is changed to an upward stroke
while rotating the crankshaft more swiftly. In this
way, the more fuel is fed to the cylinder, the faster
the engine speed becomes.

1. Throttle opening vs. engine speed

THREE ELEMENTS OF THE ENGINE

The three elements of the engine consist of
・Good Mixture,
・Good Compression
・Good Ignition.
When an air-fuel mixture, which is sufficiently
compressed to meet the operating requirement, is
ignited with good timing, it produces a large amount
of combustion energy.
1. What is good air-fuel mixture?
Fuel will not burn in a liquid state but it will easily
burn when it is tuned into a gas. An air-fuel mixture
is a sort of gas into which a liquid fuel is atomized
so that it can be easily vaporized. Good mixture
refers to a mixing state of air and fuel that meets
the operating condition of the engine. The engine
requires a different mixture ratio of air and fuel
depending on its operating requirements (cold start,
idle run, acceleration, full-throttle run). This ratio is
called an 'air-fuel ratio,' which is usually
represented in a weight ratio. There is also a
‘stoichiometric air-fuel ratio,' which means the air-
fuel ratio at which the mixture is to burn completely
from a theoretical point of view.

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 RECIPROCATING ENGINE

1) Appropriate air-fuel mixture

2) Stoichiometric air-fuel ratio

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 RECIPROCATING ENGINE

2. Compression of air-fuel mixture

When an air-fuel mixture is compressed, its
temperature goes up, making it easier for the
mixture to burn.The temperature goes up to about
400 to 500 C. If the mixture is further compressed,
it will self-ignite, causing an irregular combustion
and resulting in poor engine performance.

3. Ignition with good timing

Normally, ignition takes place just before top dead
center. After ignition, the flame spreads to the
mixture in the combustion chamber, producing the
greatest explosion force immediately after top dead
center.

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 RECIPROCATING ENGINE

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 EVOLUTION OF RECIPROCATING ENGINE
EVOLUTION OF RECIPROCATING
ENGINE
EFFICIENCY OF ENGINE
Gasoline engines cannot use all of the combustion
energy. In actuality, only about 30% of the
combustion energy can be used with the rest being
lost due to mechanical friction, unburned gases,
and so forth. Thus, reciprocating engines have
gone through various stages of evolution to achieve
as much energy efficiency as possible.

1. Increasing number of valves

Let us introduce one of the contrivances for
enhancing energy efficiency. If a cylinder of the
same volume can take in more fuel, then it will be
possible to produce the more energy. So, engineers
thought of increasing the number of valves for a
greater intake of fuel.

2. Exhaust-pulse scavenging
Smooth discharge of exhaust gases allows for a
smooth intake of an air-fuel mixture. Especially in
multi cylinders, a higher intake efficiency can be
achieved by adjusting the exhaust pipe or exhaust
timing.

3. Supercharging mechanism
Higher engine power can be achieved by burning
more fuel in the cylinder. Burning more fuel
requires more oxygen, and a natural intake would
require a larger amount of exhaust gases.
Increasing oxygen with the same exhaust amount
can be achieved by taking in compressed air.
Compressing the air and taking it in is called a
supercharging method. As a means of
supercharging, a supercharger is mounted on the
latest PWC.

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 EVOLUTION OF RECIPROCATING ENGINE
COMBUSTION EFFICIENCY
A larger cylinder volume can produce more energy,
but then the mere increase in the cylinder volume
may produce more unburned gasses with the
resultant drop in efficiency. Thus, increasing the
total exhaust amount with an increasing number of
cylinders makes it possible to acquire more energy
without reducing the combustion efficiency of each
cylinder. This provides another advantage of getting
less vibratory engine revolutions by distributing the
combustion timing.

1. Cylinder capacity more

CONTROL AIR-FUEL MIXING RATIO

The engine requires an optimum air-fuel mixture
ratio depending on its operating requirements. The
latest engines are equipped with sensors that
detect the engine speed, atmospheric temperatures,
etc. for control in supplying the engine with an
optimum air-fuel mixture.

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 EVOLUTION OF RECIPROCATING ENGINE

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 INTRODUCTION
CHAPTER 2. 4-STROKE
ENGINE
INTRODUCTION
WHAT WE LEARN IN CHAPTER 2
In this chapter we will learn about the 4-stroke
engine construction including Yamaha's own
features. 4-stroke engines are more excellent than
2-stroke counterparts in less noise and fuel
economy and covers most of the gasoline engines.

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 BASICS OF FOUR STROKE ENGINES
BASICS OF FOUR STROKE
ENGINES
ENGINE CONSTRUCTION
The construction of the 4-stroke engine is shown
here. The cylinder head has a lot of parts mounted
on it because of the valves for intake and exhaust.

1. Cam shaft
Cam shaft is a shaft provided with a cam that
controls the intake and exhaust valves. This shaft
moves in tandem with the crankshaft rotations, and
in the 4-stroke engine the cam shaft rotates once
for every two crankshaft rotations. Cam is an
important part because it controls the valve
movement with its shape, thereby determining the
flow of the intake and exhaust gases.

2. Valve
Valve is shaped like an umbrella and acts as a
control for the flow of intake and exhaust gases by
opening and closing the port. Valve reciprocates in
tandem with the rotation of the cam that is attached
to the cam shaft, and it is also rotated slowly in
order to prevent its eccentric wear. Valves are
installed respectively for the intake and exhaust
ports independently. Since different performance is
required of these respective valves, they consist of
a different material and shape.

3. Piston
Piston reciprocates within the cylinder and converts
the energy of gas in it into kinetic energy. During
compression and expansion the piston is exposed
to gases of high temperature and pressure, so
specific care is taken of its shape and material. To
assist in airtightness of the combustion chamber,
the piston is provided with a groove to which a
piston ring is fitted. Piston is greatly different in
configuration for the 4-stroke and 2-stroke engines
because of its respective different roles.

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 BASICS OF FOUR STROKE ENGINES
4. Piston ring
In the 4-stroke engine, the piston is equipped on its
circumference with a compression ring for
airtightness of the combustion chamber and with an
oil ring for enhanced lubrication. For maintenance
of function and durability, these rings are carefully
manufactured in their configuration, material, and
surface treatment. All piston rings have meeting
ends and these ends must not align when the rings
are installed.

5. Cylinder
Cylinder body is fitted with a cylinder liner to help
the piston reciprocate smoothly and also with a
water jacket for cooling and oil passage for
lubrication. Cylinder liner is made of a material of
high resistance to wear because it is rubbed
against the piston and piston rings, and its inner
wall is provided with thin, delicate grooves to hold
the lubricant. Cylinder body is made of a strong
material for enough resistance to strain or stress
due to explosion or heat.

6. Connecting rod
Part that connects the piston and crankshaft. This is
made of a light and strong material because it
transmits the explosion force the piston receives to
the crankshaft. The piston, crankshaft, and
connecting rod, all combined, convert the piston
reciprocating motion into the rotary motion of the
crankshaft. Upper and lower bearings are provided
with lubricant passages because they are subjected
to high load while rotating.

7. Crank shaft
Main shaft of the engine, which converts
reciprocating motion into rotary motion by means of
the crank configuration. The portion connected with
the crankcase is called the main journal, and the
portion connected with the connecting rod is called
the crank pin, maintaining smooth motion with the
plain bearing and oil film. Oil passages are
provided to feed oil to the respective bearings.

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 BASICS OF FOUR STROKE ENGINES
8. Crankcase
Provided with high stiffness to support large load
and the rapidly revolving crankshaft. This is often
integrated into the cylinder and is made rugged as
a whole of the cylinder and crankcase. Oil passage
is provided for the crankshaft bearing. Combination
with the plain bearing helps support high load and
high speeds. The interior is open to the atmosphere
because of resistance offered by pressure variance
caused by piston reciprocating motion, but it is
designed not to let the air directly out into the
atmosphere because it contains exhaust gases,
unburned gases, oil splashes and so on.
9. Oil filter
Filter that removes foreign matter from the engine
oil that circulates within the engine. This filter is
located within the oil passage so that the operating
oil must pass through it. Oil should be replaced in
periodical intervals according to the assigned
schedule because otherwise an accumulation of
foreign matter deteriorates the filtering function after
an extended operation time. A filter is also available
that has a bypass function in an emergency where
a clogging occurs during operation and no oil can
be replenished.
10. Oil pan
Pan in which engine oil is kept. Oil should be
replaced periodically, so this pan is provided with a
drain plug in the bottom.

11. Oil pump

Pump that pressure-feeds engine oil to the
respective parts of the engine. A gear pump or
scavenge pump of precision manufacture is used
as a pressure-feed pump. Also, a relief valve is
normally used to keep the feeding pressure
constant.

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 BASICS OF FOUR STROKE ENGINES
OPERATIONS OF ENGINE
We will introduce the operation of an individual
component of the 4-stroke engine for each of the
four processes.

1. Intake stroke
The piston functions as an intake pump. As
illustrated to the right, as the piston travels from top
dead center to bottom dead center, the open intake
valve guides an air-fuel mixture into the combustion
chamber.

2. Compression
As the piston moves upward, the intake and
exhaust valves open. As the piston moves further
upward, the cylinder interior space becomes
smaller compressing the air-fuel mixture in it. As
the air-fuel mixture is further compressed with the
piston approaching top dead center, the mixture
increases its temperature.

3. Expansion
As the piston reaches a specific position in
accompaniment with the engine speed timing, the
sparkplug ignites the air-fuel mixture. The mixture
attains a complete combustion (After top dead
center), and its explosion pushes the piston
downward.

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 BASICS OF FOUR STROKE ENGINES
4. Exhaust stroke
As the piston reached bottom dead center, it begins
to go up again. At that point, the exhaust valve
opens, causing the piston to force out the exhaust
gases produced by the combustion. And when the
piston is approximately at top dead center, the
exhaust valve opens. Also just before that, the
intake valve begins to open. In the 4-stroke engine,
the intake valve begins to open before the exhaust
valve closes. This state of both valves being open
is called an overlapping state.

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 INTRODUCTION
CHAPTER 3. 2-STROKE
ENGINE
INTRODUCTION
WHAT WE LEARN IN CHAPTER 3
In this chapter we will learn about the 2-stroke
engine construction including Yamaha's own
features. Unlike the 4-stroke engine, the 2-stroke
engine is simpler in construction and less
expensive in manufacturing cost and great power
can be attained in spite of its small size. These
features of the 2-stroke engine have found wide
application in small displacement compact engines
used for MC, OM, multipurpose engines, etc. Most
of the PWC used to be equipped with 2-stroke
engines, but now from an environmental viewpoint,
these engines are sold for a limited range of models.

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 BASICS OF TWO STROKE ENGINES
BASICS OF TWO STROKE
ENGINES
ENGINE CONSTRUCTION
The construction of the 2-stroke engine is shown
here. It consists respectively of a combustion
chamber above the piston and a crankcase below
the piston, and they are both airtight. Also the
cylinder has ports provided in it for intake, exhaust,
and scavenging, which are equivalent to the valves
in the 4-stroke engine. On the other hand, the
absence of the valve stems makes the 2-stroke
engine's cylinder head very compact.
1. Piston
Cylinder has a longer skirt than in the 4-stroke
engine and also has the functions of intake and
exhaust in combination with the cylinder ports. A
knock pin is provided for the piston ring groove to
keep the piston ring from turning along the
circumference. Piston ring should be installed
correctly.

2. Piston ring
For the 2-stroke engine, in which lubricant and air-
fuel mixture are fed together, the piston is fitted with
a compression ring but not with an oil ring. To
maintain the function and durability, the piston is
provided with reinforcement in terms of shape,
material, and surface treatment. If the meeting ends
of the 2-stroke piston ring are moved, they will get
caught in the cylinder port edge with the resultant
damage, so to keep the ring from moving, it is fixed
with a knock pin in the piston ring groove.
3. Cylinder
As with the 4-stroke cylinder, the cylinder liner and
cooling water passage are provided but not the oil
passage. Cylinder wall is provided with passages or
openings called ports, through which intake air or
exhaust gases are allowed to pass. Thus, the
cylinder is less stiff than in the 4-stroke engine.

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 BASICS OF TWO STROKE ENGINES
4. Connecting rod
Parts connecting the piston and crankshaft. The
function is the same as in the 4-stroke engine, but
as roller bearings are used for the upper and lower
bearing keeps, no oil passages are provided.

5. Crank shaft
Basic construction and functions are the same as in
the 4-stroke engine, but roller bearing keeps are
used due to a big difference in the lubrication
system. Assembled crank, which consists of an
assembly of respective parts, is used in many
compact engines.

6. Crankcase
Essential difference from the 4-stroke crankcase is
that the crankcase interior is sealed airtight for each
cylinder. (In the 2-stroke engine, the crankcase
performs all the processes of the intake,
compression, and exhaust of the air-fuel mixture in
it.) For cylinder airtightness, a unique method of
keeping the crankshaft bearings airtight is
employed with the use of a labyrinth seal or piston
ring seal.

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 BASICS OF TWO STROKE ENGINES
OPERATIONS OF ENGINE
We will explain the operation of each component of
the 2-stroke engine in relation to the combustion
chamber and crankcase respectively.

1. Combustion chamber
The rising piston closes the scavenging and
exhaust ports, thereby compressing the air-fuel
mixture trapped in the combustion chamber. Then
the compressed mixture is ignited and explodes,
forcing the piston downward rapidly. As the piston
moves down away from the top edge of the exhaust
port, high-pressure exhaust gasses begin to be
expelled through the exhaust port. As the piston
further goes down causing the scavenging port to
open, a fresh air-fuel mixture comes in while at the
same time pushing the remaining exhaust gases
out of the cylinder.

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 BASICS OF TWO STROKE ENGINES

2. Crankcase
As the piston moves up, the crankcase space
expands with the consequent creation of vacuum
inside. Since this vacuum opens the reed valve, a
fresh air-fuel mixture is drawn into the crankcase.
As the piston passes Top dead center and begins
to go down, the reed valve closes, making the
crankcase airtight. After that, the crankcase space
becomes smaller as the piston moves down,
causing the pressure to go further up. As the piston
goes down from the top edge of the scavenging
port, the high-pressure air-fuel mixture begins to
flow into the combustion chamber through the
scavenging port.

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 BASICS OF TWO STROKE ENGINES

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 INTRODUCTION
CHAPTER 4. FEATURES OF
PWC ENGINE
INTRODUCTION
WHAT WE LEARN IN CHAPTER 4
In this chapter we will learn about the features of
the PWC engines. PWC engines were originally
developed on the bases of MC engines, so many of
their parts are common. However, there are many
others of their own construction to meet the
installation and operating requirements that are
different from those MC.

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 COMPARISON WITH MC ENGINE
COMPARISON WITH MC ENGINE
LOCATION AND DIRECTION OF
INSTALLATION
In the PWC engine, the cylinders are provided
lengthwise in the direction the PWC runs. PWC
uses its crankshaft output to directly rotate the
impeller.

CONSTRUCTION
PWC and MC engines are equipped with almost
the same internal parts. Only, the cylinder block or
oil pan is different in shape to facilitate control of
the systems for lubrication and intake/ exhaust.

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