Service Manual - The Old Wool Shop
Contents
1. 4 19 1 Remove D D e Circlip 1 Shift lever 2 Torsion spring 3 Washer 4 2 Remove Stopper lever 1 Collar 2 Return spring 3 3 Remove D D Circlip 1 Oil pump gear 2 4 Remove Oil pump assembly 1 5 Remove Gasket 1 O ring 2 4 20 6 Remove e Circlip 1 e Collar 2 e Circlip 3 CRANKCASE RIGHT 1 Remove e Bolts crankcase A Crankcase right E Crankcase lett NOTE en e Loosen the bolts 1 4 turn each and remove them after all are loosened e Loosen the bolts starting with the highest numbered one The embossed numbers in the crankcase desi gnate the tightening sequence NOTE Turn the shift cam to the position shown in the figure so that it does not contact the crankcase when separating the crankcase 2 Attach Crankcase separating tool 1 Crankcase separating tool PIN YU 01135 A 90890 01135 3 Remove e Crankcase right 2 ENGINE DISASSEMBLY ENG Ze LE 8 NOTE e Fully tighten the tool holding bolts but make sure the tool body is parallel with the case necessary one screw may be backed out slightly to level too body e As pressure is applied alternately tap on the front engine mounting boss transmission shafts and shift cam CAUTION Use soft hammer to tap on the case half Tap only on reinforced portions of case Do not tap on gasket mating surface Work slow2. CRANKSHAFT 1 Measure e Crank width A Out of specification gt Replace crankshaft Crank width 74 95 75 00 mm e Runout C Out of specification gt Replace crankshaft and or width bearing Runout limit 0 03 mm e Small end free play D Out of specification 3 Replace big end bearing crank pin and or connecting rod Xx Small end free pla 0 8mm Big end radial clearance E Out of specification gt Replace connecting tod big end bearing and or crank pin end radial clearance 0 025 mm DR e Side clearance F Out of specification Replace connecting rod Big end side clearance 0 35 0 65 mm Crankshaft reassembling point The crankshaft 1 and the crank pin 2 oil passages must be properly interconnected with a tolerance of less than 1 0 mm 4 42 INSPECTION AND REPAIR ENG Ze BALANCER DRIVE GEAR AND BALANCER GEAR 1 Inspect e Balancer drive gear teeth 1 e Balancer gear teeth 2 Wear Damage gt Replace both gears 2 Check e Match marks 1 Ifthey are notaligned Align match marks as shown ELECTRIC STARTER DRIVE 1 Inspect e Starter idle gear 1 teeth 1 Starter idle gear 2 teeth 2 e Starter wheel gear teeth 3 Burrs Chips Roughness Wear gt Replace 2 Inspect e Starter wheel gear contacting surfaces Pitting Wear Damage gt Replace 3 Check e Starter clutch operation Checking steps Install t
3. ENGINE REMOVAL CHAPTER 4 ENGINE OVERHAUL D 14 D 14 D 14 D 14 D 14 D 14 D 15 D 15 D 15 D 15 COWLING SEAT AND FUEL TANK ENGINE OIL COOLING SYSTEM BATTERY CABLES RADIATOR EXHAUST PIPE AIR CLEANER CASE AND CARBURETOR CLUTCH CABLE DRIVE CHAIN ENGINE DETACHMENT D 16 ENGINE DISASSEMBLY Et STARTER MOTOR AND HOSES Ei CYLINDER HEAD CYLINDER AND PISTON Ei ROTOR AND STARTER DRIVERS E 3 OIL FILTER AND WATER PUMP EA CLUTCH AND BALANCER GEAR E 5 SHIFT LEVER AND OIL PUMP 6 CRANKCASE RIGHT E7 OIL STRAINER E 8 BALANCER TRANSMIS E 8 CRANKSHAFT E 9 ROCKER ARM E 9 VALVES INSPECTION AND REPAIR e w Ett CYLINDER HEAD onnssssnsanaaee VALVES AND VALVE GUIDES VALVE HOUSING VALVE SPRING CAMSHAFT ROCKER ARMS AND ROCKER ARM SHAFT CAMSHAFT CHAIN SPROCKET AND CHAIN GUIDE CAMSHAFT CHAIN GUIDE CYLINDER AND PISTON PISTON RINGS PISTON PIN CRANKSHAFT BALANCER DRIVE GEAR AND BALANCER GEAR ELECTRIC STARTER DRIVE PRIMARY DRIVE ENGINE REASSEMBLY Fg F 5 CLUTCH TRANSMISSION AND GEARBOX OIL PUMP WATER PUMP AND STRAINER F 6 OIL DELIVERY PIPES F 6 CRANKCASE F 6 BEARINGS AND OIL SEALS CIRCLIP AND WASHER F 6 ENGINE ASSEMBLY AND SETTING F 7 VALVES AND ROCKER ARMS F 7 VALVES F 7 ROCKER ARMS F 8 CRANKSHAFT F 9 F 10 F 10 F 11 F 12 F 12 CRAN
4. Job name Part name Removal of radiator Clamp Clamp Screw Screw Screw Radiator disconnect etectrical connector Qty Remarks Remove the parts in the order Reverse the removal procedure for installa tion 4 2 ENGINE REMovaL ENG Ze ENGINE REMOVAL EXHAUST PIPE AIR FILTER CASE AND CARBURETOR 1 Loosen e Carburetor manifold clamps 1 2 Remove e Air filter case 2 Air panel 3 3 Disconnect Engine idle speed contro knob bracket 4 Starter control knob bracket 5 4 Loosen Carburetor joint clamps 6 5 Remove e Carburetors 7 NOTE Cover the carburetor with a rag to prevent dirt or foreign bodies entering CLUTCH CABLE 1 Loosen Nut 1 2 Disconnect Clutch cable 2 from lever and bracket DRIVE CHAIN 1 Loosen Rear wheel axle nut 1 Lock nut 2 of the chain stretchers Chain stretcher screws 3 JOB INSTRUCTION CHART 2 Remove Sprocket cover 3 Straighten Lock washer tab Order Job name Part name Q ty Remarks 4 Remove Nut 1 Removal of exhaust pipe Remove the parts in the order e Lock washer 2 1 Nut j Sprocket 3 2 Screw 1 NOTE 3 Screw 1 Loosen the sprocket nut 1 while applying the rear 4 Exhaust pipe assembly 1 brake Reverse the removal procedure for in stallation 43 44 ENGINE REMOVAL ENG M i EN
5. lt 100 1 mm 3 941 in gt e Crankcase cover 1 left TIGHTENING SEQUENCE Tal Bolt crankcase cover PISTON TO CYLINDER CLEARANCE 10 Nm 1 0 mkg 0 005 0 070 mm 0 0020 0 0028 in lt LIMIT gt NOTE lt 0 15 mm 0 0059 in gt Tighten the bolts crankcase cover in a crisscross pattern 8 Connect e Neutral switch 2 9 Install e Shaft 1 starter idle gear Needle bearing 2 Starter idle gear 3 Gasket 4 Dowel pin 5 seere 10 Install e Cover 1 Bolt cover al SA 10 Nm 1 0 mko 4 77 4 78 ENGINE ASSEMBLY AND SETTING ENG Ze 6 5 ENGINE ASSEMBLY AND SETTING ENG Ze CAMSHAFT AND CAMSHAFT CHAIN CYLINDER HEAD 1 Cylinder head cover 7 Cylinder head 1 Camshaft 9 Guide stopper plates 2 Tappet cover 8 Valve guide 2 Spring 10 Guide stopper intake m ee oo 3 Decompression lever pin intake 3 Om alve guide 4 Decompression lever 11 Timing chain o cover exhaust exhaust valve 5 Cam chain sprocket 12 Guide stopper 5 O ring 10 Spark plug 6 Decompression cam exhaust 6 Cap 11 Dowel pin 7 Spring 13 Gasket 8 Tensioner shaft 14 Cam chain tensioner SPARK PLUG TYPE I DPRBEA 9 DPR9EA 9 NGK SPARK PLUG GAP 0 8 0 9 mm 0 031 0 035 in CYLINDER HEAD WARPAGE C LIMIT 0 03 mm 0 0012 in 10 Nm 1 0 mekg 7 2 ftelb SHAFT TO CAP CLEARANCE 0 020 0 054 mm
6. 4 54 ROCKER ARMS 1 2 Lubricate e Rocker shaft with engine oil install e Rocker arm e Rocker shaft E Screws 1 rocker shaft 10 Nm 1 0 mkg NOTE Each rocker arm is numbered 1 2 3 4 1 2 3 4 Install Cap 1 ENGINE ASSEMBLY AND SETTING ENG CRANKSHAFT 1 Connecting rod pin 2 Crank left 3 Connecting rod 4 Bearing 5 Bearing CRANK WIDTH RUNOUT LIMIT 0 03 mm 0 0012 in 74 95 75 00 mm 2 950 2 953 in SMALL END FREE PLAY 0 8 mm 0 031 in BIG END RADIAL CLEARANCE 0 01 0 025 mm 0 0004 0 0010 in BIG END SIDE CLEARANCE 0 35 0 65 mm 0 013 0 026 in B6307SH2 C4 150 Nm 15 0 mekg 110 ft ib 4 55 ENGINE ASSEMBLY AND SETTING ENG Ya 1 Attach e Crankshaft installing tool Crankshaft installer set P N YU 90050 Crank pot spacer 1 P N YM 91044 P N 90890 04081 Adapter 10 2 P N YM 90069 P N 90890 04059 Crankshaft installer pot 3 PIN 90890 01274 Crankshaft installer bolt 4 P N 90890 01275 Spacer 5 P N 90890 01288 NOTES Se Hold the connecting rod at top dead center with one hand while turning the nut of the installing tool with the other Operate the installing tool until half of the crankshaft bearing 6 is inserted into the crankcase as shown Then add the spacer 5 as shown and operate the
7. A 14 Nm 1 4 mekg 10 ftelb 14 Nm 1 4 mekg 10 ftelb i 9 o STEM RUNOUT LIMIT l 0 01 mm 0 0004 in a Di p VALVE SEAT WIDTH 0 9 1 1 mm 0 035 0 043 in gt 4 51 s S z ENGINE ASSEMBLY AND SETTING A WARNING For engine reassembly replace the following parts whit new one O ring e Gasket e Oil seal e Key e Lock washer e Circlip VALVES 1 Burrs e Valve stem head Polish the valve stem head with an oil stone 2 Apply e Molybdenum disulfide grease to the valve stem and oi seal 3 Install e Lower valve cap 1 Oil seal 2 Valve 3 Valve spring 4 Upper valve cap 5 into cylinder head 4 52 ENGINE ASSEMBLY AND SETTING ENG Ze 4 53 NOTE e Make sure that the each valve is installed in its original place by reference to it embossed identification mark as follows Intake 3YF e Exhaust 3YF Install the valve spring with larger pitch 6 facing upward 7 Smaller pitch 4 Install e Valve cotters 1 NOTE e Install the valve cotters while compressing the valve spring with the valve spring compressor Valve spring compressor P N YM 04019 90890 04019 5 Secure the valve cotters on to the valve stem by tapping it lightly with a piece of wood CAUTION Do not hit so much as to damage the valve ENGINE ASSEMBLY AND SETTING ENG Ze
8. INSPECTION AND REPAIR ENG Ze E 11 INSPECTION AND REPAIR ENG Ze INSPECTION AND REPAIR VALVES AND VALVE GUIDES 1 Measure CYLINDER HEAD Clearance between stem and guide 1 Eliminate Carbon deposits from combustion chamber Use a rounded scraper Clearance between stem and guide Internal diameter of valve guide a Diameter of valve stem b NOTE 8 Out of specification gt Replace valve Do not use a pointed tool to avoid damaging or vide scratching guide spark plug thread e valve seats combustion chamber Clearance between stem and guide 0 010 0 037 lt Limit gt 0 08 mm 0 025 0 052 lt Limit gt 0 10 mm Intake 2 inspect Cylinder head Scratches Damage gt Replace e Water jacket Exhaust 1 Bore gauge 2 Replace e Valve guide 3 Measure Deformation Out of specification gt Rework the surface Replacement NOTES ee Heat the cylinder head in an oven at 100 C to facilitate the removal and installation of the guides and to maintain correct locking interference Cylinder head deformati Less than 0 03 mm e Remove the valve guide using the speciat punch 1 Install the new guide using the special installa tion tool 2 e After installing the valve guide bore with special toot 3 to obtain valve guide free play 4 Surface e Cylinder head Levelling Level the cyli
9. STARTER GEARS AND ROTOR NOTE 3 ae Fasten a safety wire 3 to the timing chain to prevent it fram falling into crankcase 1 Starter gear e Chain guide 2 2 Starter neutral gear 1 3 Starter neutral gear 2 Bolt chaln guide 4 Starter gear 10 Nm 1 0 mkg 5 Starter clutch 6 Rotor A C generator 2 Apply e Lithium soap base grease onto bearing on starter drives 3 Install Washer 1 e Needle bearing 2 e Wheel gear 3 4 Install e Woodrutf key 1 e Rotor 2 NOTE m When installing the magneto rotor make sure thet the woodruff key is properly seated in the keyway of the crankshaft 5 Install Nut 1 rotor Nut rotor 150 Nm 15 0 mkg NOTE WE Tighten the nut rotor while holding the rotor with the rotor holder 2 Zi Rotor holder P N YS 01880 90890 01701 CAUTION Do not allow the rotor holder to touch the projections 3 on the rotor 150 Nm 15 0 mekg 110 E d 6 d j D Ri e 30 Nm 3 0 mekg 22 ft lb 4 75 4 76 ENGINE ASSEMBLY AND SETTING ENG Ze ENGINE ASSEMBLY AND SETTING 6 Install CYLINDER e Starter idle gear 2 1 Needle bearing 2 1 Cylinder head gasket D e Shaft 3 2 Cylinder e Gasket 4 crankcase cover 3 O ring e Dowel pins 5 4 Cylinder gasket e O rings 6 IS Dowel pin 7 Install F BORE SIZE 100 005 100 045 mm 3 9372 3 9388 In lt LIMIT gt
10. e Rotor 1 e Woodruff key 2 Use the rotor puller 3 and adapter 4 Z Rotor puller P N YU 33270 90890 01362 Adapter P N YM 04063 A 90890 04063 NOTE Tighten the tool holding bolts but make sure that the tool body is parallel with the rotor If necessary one screw may be backed out slightly to tevel tool body 8 Remove Wheel gear 1 e Needle bearing 2 e Washer 3 9 Remove e Chain guide 1 e Timing chain 2 OIL FILTER AND WATER PUMP NOTE The water pump can be maintained with the engine mounted 1 Remove e Oil filter cover 1 ENGINE DISASSEMBLY ENG Ze ENGINE Disassematy ENG Ze 2 Remove Oil filter 1 O rings 2 3 Remove e Water pump cover 1 4 Remove O ring 1 5 Remove e Water pump housing 1 6 Remove Circlip 1 Water pump gear 2 Pin 3 Circlip 4 Water pump housing 5 Impeller shaft 6 4 16 CLUTCH AND BALANCER GEAR NOTE With the engine mounted the clutch can be main tained by removing the following parts e Side pane R e Clutch cable e Water pump housing 1 Remove e Circlip 1 Washer 2 Puli lever 3 Return spring 4 Washer 5 2 Remove e Crankcase cover 1 right NOTE Working in a crisscross pattern loosen the bolts 1 4 turn each Remove them after all are loosened 3 Remove e Gasket 1 crankcase cover e Dowel pins 2 4 Remo
11. D 2 74 2 86 mm 6 pcs 0 108 0 113 in 2 6 mm 0 102 in 2 6 8 Nm 0 8 mekg 5 8 Mib LUTCH PLATE C WARPAGE LIMIT 0 2 mm 0 008 in 6 5 Nm 0 65 mekg 4 7 ftelb ENGINE ASSEMBLY AND SETTING ENG Ze CLUTCH AND BALANCER GEAR 1 install Key 1 Balancer gear 2 Plate 3 Lock washer 4 Nut 5 balancer gear Plate washer 6 Key 7 Piat 8 Balancer drive gear 9 Piate 10 Primary drive gear 11 Lock washer 12 Nut 13 primary drive gear Nut balancer gear 60 Nm 6 0 mkg Nut primary drive gear 120 Nm 12 0 mkg NOTE Wheninstailing the drive gear align the punched mark 14 on the drive gear with the punched mark 15 on the balancer gear Place a folded rag or aluminum plate between the teeth of the balancer drive gear and balancer gear Take care not to damage the gear teeth 2 Bend the lock washer tab along the nut flat 16 4 69 ENGINE ASSEMBLY AND SETTING ENG Ya 4 70 3 Apply Engine oil onto bearing and gear teeth 4 Install e Clutch housing 1 Thrust plate 2 Clutch boss assembly 3 Lock washer 4 Nut 5 clutch boss NOTE Fit the tabs of the lock washer to the groove of the clutch boss 5 Tighten e Nut 1 clutch boss NOTE Tighten the nut clutch boss while holding the clutch boss with the universal clutch holder 2 Universal clutch h
12. Out of specification gt Measure bearing diameter camshaft Q Camshaft to cap clearance 0 020 0 054 mm YA DR Measurement steps e Install the camshaft onto the cylinder head e Positione a strip of Plastigauge onto the camshaft e Install the dowel pins and cylinder head cover Ry Bolt cylinder head cover 10 Nm 1 0 kgm 4 34 INSPECTION AND REPAIR 4 35 NOTE e Tighten the bolts cylinder head cover in a criss cross pattern from innermost to outer e Do not turn the camshaft when measuring clearance with the Plastigauge e Remove the cylinder head cover and measure width of the Plastigauge 5 Measure e Bearing diameter a camshaft Out of specification gt Replace camshaft Within specification gt Replace cylinder head Bearing diameter camshaft DECOMPRESSION 1 Inspect e Spring 1 Damage gt Replace e Decompression pin 2 e Decompression lever 3 e Decompression cams 4 Damage Bends Wear gt Replace 2 Check e Decompression play Play exists gt Replace ENG E 15 INSPECTION AND REPAIR ENG Ze ROCKER ARM AND ROCKER ARM SHAFT 1 Inspect e Rocker arm shaft Blue colour Grooves gt Reptace shaft and check lubrication system 2 Inspect e Rocker arm shaft slot 1 e Surface in contact with cam eccentric 2 e Adjuster surface 3 Pitting Wear Scratches Blue colour 3 Re place a
13. Screw carburetor manifold clamp right 5 Nm 0 5 mkg 13 Install Exhaust pipe 1 Muffier 2 Nuts 3 exhaust pipe 10 Nm 1 0 mkg Muffler mounting bolts 4 40 Nm 4 0 mkg Bolt 5 23 Nm 2 3 mkg Bolt 6 clamp 10 Nm 1 0 mkg 14 Instalt Radiator Bolt radiator 10 Nm 1 0 mkg 15 Connect e Battery cables CAUTION Connect first the positive cable then the negative cable 16 Fill e Radiator e Coolant reservoir tank See the section COOLANT CHANGE in CHAPTER 3 17 Install e Fuel tank e Seat e Cowling See the sections SEAT FUEL TANK AND REAR COWLING and COWLING in CHAPTER 3
14. Wear Damage gt Repiace 4 Inspect e Oil strainer 1 Damage gt Replace 4 49 INSPECTION AND REPAIR ENG Ze OIL DELIVERY PIPES 1 Inspect e Oil delivery pipes Cracks Damages gt Replace Clog gt Blow out with compressed air CRANKCASE 1 Thoroughly wash the case halves in mild solvent 2 Cleanailthe gasket mating surface and crank case mating surface thoroughly 3 Inspect e Crankcase Cracks Damage gt Replace e il delivery passages Clog gt Blow out whit compressed air BEARING AND OIL SEAL 1 Inspect e Bearing Clean and lubricate then rotate inner race with finger Roughness gt Replace 2 Inspect e Oil seal Damage Wear gt Replace CIRCLIP AND WASHER 1 Inspect e Circlip e Washer Damage Free play Warp gt Replace 4 50 ENGINE ASSEMBLY AND SETTING ENG Ze ENGINE ASSEMBLY AND SETTING VALVES AND ROCKER ARMS 1 Rocker arm n 2 6 Upper valve spring retainer 11 Rocker shaft exhaust 2 Wave washer 7 Oil seal 12 Rocker arm n 4 3 Rocker shaft intake 8 Valve spring 13 Rocker arm n 3 4 Rocker arm n 1 9 Valve intake 14 Rocker shaft exhaust 5 Valve cotters 10 Lower valve spring retainer 15 Valve exhaust VALVE SPRING TILT LIMIT Inner spring B 2 5 or 1 4 mm 0 055 in Outer spring 2 5 or 1 6 mm 0 063 in VALVE CLEARANCE COLD Intake 0 10 0 15 mm 0 004 0 006 in Exhaust 0 15 0 20 mm 0 006 0 008 in
15. attempt to straighten a deformed shaft 4 47 INSPECTION AND REPAIR ENG Ze 6 Inspect e Gear teeth Brown colouring Pitting Wear gt Replace e Mating clutches Rounded edges Cracks Missing frag ments gt Replace 7 Check e Proper mating of each gear with corre sponding part e Gear movement Roughness gt Replace Transmission gear assembly stages Fit the 2nd pinion gear 1 to the propeller shaft 2 as shown in the figure 8 Inspect e Spring 1 Damage 3 Replace e Shift lever 2 Damage Bends Wear gt Replace 9 Inspect e Shift shaft BenvWear Damage gt Replace 10 Inspect e Stop lever 1 The rolter rotates jerkily gt Replace Bent Damage gt Replace e Return spring 2 Damage Cracks gt Replace 4 48 INSPECTION AND REPAIR ENG Ze OIL PUMP WATER PUMP AND STRAINER 1 Measure e Clearance between rotors ai Between the internal rotor 1 and the external rotor 2 e Lateral clearance b Between the external rotor 2 and the pump stator 3 Out of specification gt Replace oil pump AY Oil pump clearances Clearance between rotors a 0 12 mm Lateral clearance b 0 03 0 08 mm 2 Inspect e Oi pump drive gear 1 e Ou pump driven gear 2 Wear Cracks Damage gt Replace 3 Inspect e O ring 1 e Water pump housing 2 e Water pump gear 3 Cracks
16. e Dowel pins 2 16 Remove groove is deburred and piston pin is still difficult e Pipe 1 to remove use the piston pin puller Z Piston pin puller PIN YU 01304 90890 01304 CAUTION 17 Remove Do not use a hammer to drive the piston pin out Bolts 1 e Bolts 2 NOTE Working in a crisscross pattern loosen the bolts 1 4 turn each Remove them after all are loosened 18 Remove e Cylinder 1 ROTOR AND STARTER DRIVERS NOTE The AC magneto and starter drivers can be main tained with the engine mounted 1 Remove e Cover 1 19 Remove e Gasket 1 cylinder e Dowel pins 2 4 11 4 12 E NGINE DISASSEMBLY ENG Ze 4 13 2 Remove e Starter idle gear 1 1 e Needle bearing 2 Shaft 3 e Gasket 4 e Dowel pin 5 3 Disconnect e Neutral switch lead 1 4 Remove e Crankcase cover 2 left NOTE Working in a crisscross pattern loosen the bolts 1 4 turn each Remove them after all are loosened 5 Remove Starter idle gear 2 1 Needle bearing 2 Shalt 3 Gasket 4 crankcase cover Dowel pins 5 O rings 6 6 Remove e Nu 1 rotor NOTE Loosen the nut rotor while holding the rotor with the rotor holder 2 s Rotor holder P N YS 01880 90890 01701 CAUTION Do not allow the rotor holder to touch the projection 3 on the rotor ENGINE DisassemBLy ENG Ze 7 Remove
17. the crankcase or the engine may be damaged Oil quantity Camshaft oiL Oil filter chamber 0 06 L 3 Install e Tappet cover intake e Air bleed screw oil filter cover Bolt tapped cover 10 Nm 1 0 mkg Air bleed screw 5 Nm 0 5 mkg 4 Install e Drive sprocket 1 e Loch washer 2 e Nut 3 Nut drive sprocket 110 Nm 11 0 mkg 5 Bend e Lock washer tab along nut flat 6 Adjust e Drive chain slack Refer to the DRIVE CHAIN SLACK ADJUSTMENT section in CHAPTER 3 Drive chain slack 25 40 mm 4 89 4 90 ENGINE ASSEMBLY AND SETTING 7 Install e Sprocket cover Screw sprocket cover 10 Nm 1 0 mkg 8 Install e Shift pedal Bolt shift pedal 10 Nm 1 0 mkg 9 Connect e Ground lead 1 Refer to the CABLE ROUTING section in CHAPTER 2 Nut ground lead 10 Nm 1 mkg 10 Adjust e Clutch cable free play Refer to the CLUTCH ADJUSTMENT section in CHAPTER 3 Free play 10 15mm at clutch lever end 11 Install e Carburetor to intake manifolds IN Screw carburetor joint clamp left 2 Nm 0 2 mkg Screw carburetor joint clamp right 5 Nm 0 5 mkg 12 Connect e Air cleaner joints to carburetors chte ET ENGINE ASS EMBLY AND SETTING ENG Ze 4 92 Screw carburetor manifold Ki clamp left 2 Nm 0 2 mkg
18. width Intake 0 9 1 1 mm Exhaust 0 9 1 4 mm Measurement stages e Apply Prussian blue Dykem to the valve seat 1 e Install the valve in the cylinder head e Press the valve onto the seat through the guide to leave a clear outline e Measure the width of the valve seat Where there is contatc between valve and seat the Prussian blue is wiped away e Ifthe valve seat is too narrow wide or off centre the valve seat must be renewed eee eee ee ee 4 Renew e Valve seat Use the special toot to renew the valve seat 1 with 30 45 and 60 mills Valve seat milling unit P N YM 91043 CAUTION Turning the milling tool maintain uniform pres sure about 4 5 kg to avoid leaving marks on the valve seat INSPECTION AND REPAIR Mill the valve seat as follows Section Mill A 30 B 45 c 60 Valve seat faults recorded by analysing the valve seal surface Al If the valve surface resembies that shown in the figure this means that the valve seat is centred on the surface but is too wide Intervention on the Desired effect valve seat Mill Reduce valve seat type width to 1 0 mm B Ifthe valve surface is like this it means that the valve seat is centred on the vaive surface but is too narrow Intervention on the Desired effect valve seat Increase valve seat width to 1 0 m
19. 0 0008 0 0021 in i 10 Nm 1 0 mekg 7 2 ftelb 20 Nm 2 0 mekg 14 ftelb Ka 8 Nm 0 8 mekg 5 8 ftelb SEALANT QUICK GASKET YAMAHA BOND NO 1215 kel ENGINE ASSEMBLY AND SETTING ENGINE ASSEMBLY AND SETTING ENG CYLINDER HEAD CYLINDER AND PISTON 5 Position A e Top ring 1 Apply i e 2ndring e Engine oil f Offset the piston ring end gaps as shown onto piston rings and piston pin 1 Top ring end 2 Oil ring end lower 3 Ou ring end upper 4 2nd ring end 6 Install e Cylinder 1 2 Install e Piston rings NOTE Be sure to install ring so that manufacture marks or gt numbers are located on the top side of the rings 3 Install NOTE gd e Piston 1 Install the cylinder while compressing the piston e Piston pin 2 rings by the hand e Circlips 3 NOTE e The allow 4 on the piston must point to the front of the engine e Before installing the circlip cover the crankcase with aclean towei or rag so you will not accidentaily drop the pin clip and material into the crankcase 7 Install e Bolts 1 e Bolts 2 Bolts 1 42 Nm 4 2 mkg Bolts 2 10 Nm 1 0 mkg NOTE Tighten the bolts 1 in a crisscross pattern 4 Install e Gasket 1 cylinder i e Dowel pins 2 8 Ne Bolt pipe 10 Nm 1 0 mkg 4 81 4 82 ENGINE ASSE
20. Camshaft 2 NOTE e Fasten a safety wire 3 to the timing chain to prevent if from falling into the crankcase e Do not fall the stopper guide plate 4 into the crankcase when removing the bolts cam sprocket ENGINE DISASSEMBLY ENG Ze 4 Remove e Timing plug 1 e Plug center 2 5 Turn e Crankshaft until TDC mark 3 is aligned with station ary pointer 4 12 Remove 6 Remove e Chain guide 1 exhaust e Tappet cover intake 1 e Tappet cover exhaust 2 7 Remove 13 Remove e Cylinder head cover 1 Pipe 1 e O Ring NOTE Bolts 2 Working in a crisscross pattern loosen the bolts Bolts 3 1 4 turn each Remove them after all are loosened Bolts 4 NOTE Working in a crisscross pattern loosen the bolts 1 4 turn each Remove them after all are loosened 8 Loosen e Bolts 1 cam sprocket 9 Loosen 14 Remove Cap bolt 1 chain tensioner e Cylinder head 1 10 Remove e Chain tensioner 2 4 9 4 10 ENGINE DISASSEMBLY ENG Ze LE 3 ENGINE DISASSEMBLY ENG Ze 20 Remove e Piston pin circlips 1 e Piston pin 2 e Piston 3 NOTE e Before removing the piston pin circlip cover the crankcase with a clean rag to prevent the circlip from falling into the crankcase cavity e Before removing the piston pin deburr the clip grooved and pin hole area If the piston pin 15 Remove e Gasket 1 cylinder head
21. GINE DETACHMENT JOB INSTRUCTION CHART EE EEN 45 Job name Part name ENGINE REMOVAL Remarks Detachment of engine from frame Screw Bracket Crankcase ventilation hose Screw oil recovery hose Screw oil delivery hose Oil tank Spark plug cable Wire harness connector Starter plus leadwire Shift pedal Bolt engine mounting Screw engine mounting Screw engine upper mounting Axle engine front mounting Engine Bolt engine upper mounting stay Engine upper mounting stay Bolt engine front mounting stay Engine front mounting stay 4 6 Remove the parts in the order Reverse the removal procedure forinstalla tion ENGINE DISASSEMBLY ENG Ze LE 1 ENGINE DISASSEMBLY ENG Ze ENGINE DISASSEMBLY STARTER MOTOR AND HOSES 1 Remove e Oil pipe 1 2 Remove e Oil pipe 1 3 Remove Starter motor 1 4 Remove e Oil hose 1 e Breather hose 3 crankcase 5 Remove e Coolant hose 1 4 7 CYLINDER HEAD CYLINDER AND PISTON NOTE With the engine mounted the cylinder head cover camshaft and cylinder head can be maintained by removing the following parts e Seat Fuel tank Cowling Radiator Exhaust pipe Ignition coil Air filter case Air panel Carburetor zs eeeeeee 1 Remove Spark plug 1 2 Remove e Intake manifolds 1 3 Remove e Cap 1 48 ENGINE DISASSEMBLY ENG Ze 11 Remove e Cam sprocket 1 e
22. KSHAFT AND BALANCER SI TRANSMISSION BALANCER TRANSMISSION AND SHIFTER OIL STRAINER EXPLODED VIEW CRANKCASE EXPLODED VIEW SHIFT LEVER AND OIL PUMP F 13 CRANKCASE ASSEMBLING F 13 OIL STRAINER ASSEMBLING F 13 SHIFT LEVER AND OIL PUMP F 14 BALANCER SHAFT GEAR F 15 FS CLUTCH AND BALANCER GEAR F 16 Olt FILTER AND WATER PUMP STARTER GEARS CYLINDER CYLINDER HEAD CAMSHAFT AND CAMSHAFT CHAIN CYLINDER HEAD CYLINDER AND PISTON PIPES AND HOSES G9 ENGINE REMOVAL ENG Vi ENGINE OVERHAUL ENGINE REMOVAL NOTE It is not necessary to detach the engine from the chassis to remove the foliowing parts e Cylinder head e Cylinder e Piston Piston rings e Clutch e Water pump e Oil pump Alternator Support the motorcycle securely to prevent it falling over COWLING SEAT AND FUEL TANK 1 Remove e Side panels L and R e Seat e Fuel tank See the section COWLING and SEAT FUEL TANK AND REAR COWLING in chapter 3 ENGINE OIL 1 Drain e Engine oi See the section ENGINE OIL REPLACE MENT in chapter 3 COOLING CIRCUIT 1 Drain e Cooling circuit See the section CHANGING THE COOLANT in chapter 3 BATTERY CABLES 1 Disconnect e Battery cables CAUTION Disconnect first the negative cable then the positive cable 2 Remove e Battery 44 RADIATOR ENGINE REMOVAL JOB INSTRUCTION CHART
23. MBLY AND SETTING ENG Ze ENGINE ASSEMBLY AND SETTING ENG Ze 9 Instali 13 Install e Gasket 1 cylinder head e Cam sprocket 1 e Dowel pins 2 e Camshaft 2 Installing steps e Turn the crankshaft counterclockwise until the TOC mark 3 is aligned whit the stationary pointer 4 e Align the match mark on the camshaft with the punched mark on the decompression lever Fit the timing chain onto cam sprocket and install the cam sprocket on the camshaft 10 Install e Cylinder head 1 NOTE i e Wheninstalling the cam sprocket keep the timing chain as tense as possible on the exhaust side Align the pins 7 on the decompression lever with the slots 8 in the decompression cam 11 Install e Bolts 1 e Setthe respective match marks 9 to be parallel e Bolt 2 with the case surface on the corresponding sides e Bolts 3 oo the respective match marks 10 to be e O ring pipe 4 vertical e Pipe 4 CAUTION Bolts 1 3 38 Nm 3 8 mkg Bolt 2 10 Nm 1 0 mkg Do not turn crankshaft during the camshaft installation Damage or improper valve timing will result NOTE e Apply the engine oil onto the O ring e While holding the camshaft temporary tighten e Tighten the bolts 1 in a crisscross pattern the bolts 12 Install 14 Install e Chain guide 1 exhaust e Chain tensioner 1 4 83 4 84 ENGINE ASSEMBLY AND SETTING ENG Ins
24. NG ae F 11 ENGINE ASSEMBLY AND SETTING 6 Install Shift fork 1 L 1 Shift fork 3 R 2 Shift fork 2 C 3 Gear cam 4 Guide bar long 5 Guide bar short 6 NOTE En Install the shift forks with the embossed mark on each shift fork facing right side of the engine 7 Instatl e Shift shaft 2 1 e Shift shaft 1 2 8 Check amp Transmission operation Unsmooth operation gt Repair 4 60 ENGINE ASSEMBLY AND SETTING ENG F 12 OIL STRAINER 1 Oil strainer 2 Oil duct oi 3 Gasket ENGINE ASSEMBLY AND SETTING ENG Ze CRANKCASE IW 2 3 4 5 6 Bearing cover piate 7 Dowet pin Lock plate 8 Dowe pin Crankcase ventilation hose 9 O ring Clamp Crankcase Collar 7 Nm 0 7 mekg 5 1 ftelb A TIGHTENING SEQUENCE 4 62 ENGINE ASSEMBLY AND SETTING ENG p F 13 ENGINE ASSEMBLY AND SETTING SHIFT LEVER AND OIL PUMP Stopper lever Collar Torsion spring Collar Shift lever 6 Torsion spring 7 Gasket 8 O ring 9 Oil pump 10 Oil pump gear 10 Nm 1 0 mekg 7 2 ftelb 4 63 ENGINE OIL PUMP SUCTION 1 Install Gasket 1 e Oil pump suction 2 e Oil passage cover 3 Screw pump suction 7 Nm 0 7 mkg Screw oil passage cover 7 Nm 0 7 mkg CRANKCASE 1 Apply e Bonding agent on the semicrank mating surfaces Bon
25. SEMBLY AND SETTING ENG Ze 24 Install e Spark plug 1 Spark plug 18 Nm 1 8 mkg 5 Install e Starter motor 1 Bolt starter motor 10 Nm 1 0 mkg PIPES AND HOSES 1 Apply e Lithium soap base grease onto O rings on oil pipes 6 Install e Oil pipe 1 Union bolt oil pipe 20 Nm 2 0 mkg Bolt 10 Nm 1 0 mkg 7 Install e Oil pipe 1 Union bolt oil pipe 20 Nm 2 0 mkg 2 Install e Coolant hose 1 3 Install e Breather hose 1 crankcase e Oil hose 3 IN Bolts oil hose 10 Nm 1 0 mkg 4 Apply e Lithium soap base grease onto O ring on starter motor 4 87 4 88 ENGINE ASSEMBLY AND SETTING ENG Ze ENGINE ASSEMBLY AND SETTING ENG Ze ENGINE REASSEMBLY When reassembling the engine reverse the removal procedure Note the following points 1 Remove Install the bolts and nuts first and then tighten the bolts and nuts to specifications e Tappet cover 1 intake Air bleed screw 2 oil filter cover 2 Apply e 4 stroke engine oil 65 Nm 6 5 mkg 65 Nm 6 5 mkg 55 Nm 6 5 mkg 65 Nm 6 5 mkg to the camshaft upper side and into the oil filter chamber 10 Nm 1 0 mkg 35 Nm 3 5 mkg 10 Nm 1 0 mkg Apply a liberal amount of 4 stroke engine oil to the oil passage in
26. ate Type A Type B vent 2pes re Bolt crankcase cover inside 10 Nm 1 0 mk diameter D 116 mm 113 mm 9 NOTE Tighten the bolts crankcase cover in a crisscross pattern 4 71 4 72 ENGINE ASSEMBLY AND SETTING ENG Ze 6 2 ENGINE ASSEMBLY AND sernne ENG Yam 13 Install 3 Install e Washer 1 e O ring 1 e Return spring 2 e Pul iever 3 e Washer 4 e Circlip 5 NOTE 4 Instail e Water pump housing 1 Make sure that the mark 6 on the pull lever is e Water pump cover 2 aligned whit the embossed mark 7 on the crankcase while pushing the pull lever If not change the pull lever position e Install the pull lever whit the UP mark 8 facing upward Bolt water pump al 10 Nm 1 0 mkg OIL FILTER AND WATER PUMP 5 Install 7 Install Ou filter 1 e Impeller shaft 1 O rings 2 e Water pump housing 2 e Circlip 3 e Pin 4 Water pump gear 5 e Circlip 6 NOTE CAUTION install the water pump with embossed side 7 facing to inside install the oil filter as shown INSIDE d 6 Install 2 Apply e Oil filter cover 1 e Molybdenum disulfide grease onto impeller shaft end 10 Nm 1 0 mkg 4 73 4 74 ENGINE ASSEMBLY AND SETTING ENG 6 3 ENGINE ASSEMBLY AND SETTING ENG 1 instal Timing chain 1
27. ding agent Quick Gasket amp PIN ACC 11001 01 Yamaha bond N 12150 P N 90890 85505 NOTE Do not allow any sealant to come in contact whit the oil gallery 2 Install e O ring 1 e Dowel pin 2 e Dowel pins 3 3 Assemble the left semicrank to the right semicrank Beat gently with a soft hammer NOTE Turn the gear cam as shown in the figure so that it does not interfere with the crankcase during assembly CAUTION Before installing and tightening the fastening screws be sure that the transmission is work ing properly by hand turning the gear cam in both directions ENGINE ASSEMBLY AND SETTING ENG Ze ENGINE ASSEMBLY AND SETTING ENG Ze 4 Tighten 4 Install e Screws crankcase 1 14 e Gasket 1 NOTE e O rings 2 D Tighten the screws beginning with the one with on pump 8 e Oil pump gear 4 the lowest number e Circlip 5 Install the cable clamp on the bolt No 4 K Screw crankcase 4 Ki Screw oil pump 10 Nm 1 0 mkg 10 Nm 1 0 mkg 5 Apply 5 Install e 4 stroke engine oil e Spring 1 to the connecting rod pin the bearing and e Collar 2 the oil passage e Stop lever 3 6 Check Ki Stop lever screw 4 e Gearbox and transmission functioning 10 Nm 1 0 mkg Jerky functioning gt Repair SHIF LEVER AND OIL PUMP NOTE 1 Install Place the stop lever and the sp
28. emoving the following parts e Cowling e Seat e Fuel tank e Radiator e Exhaust pipes e Cylinder head cover 1 Remove e Plug 1 2 Remove e Bolts 1 rocker arm shaft ENGINE DISASSEMBLY ENG Ze 3 Remove e Rocker arm shaft e Rocker arm NOTE Remove the rocker arm shaft by the slide hammer bolt 1 and weight 2 Slide hammer set PIN YU 01083 A Slide hammer bolt P N 90890 01083 Weight P N 90890 01084 VALVES NOTES EET Before removing the internal parts valve valve spring valve seat etc of the cylinder head the valve sealing should be checked 1 Check e Valve sealing Leakage at valve seat gt inspect the valve face valve seat and valve seat width Refer to the INSPECTION AND REPAIR VALVE SEAT section Checking steps e Pour a clean solvent 1 into the intake and exhaust ports Check the valve sealing There should be no leakage at the valve seat 2 4 25 ENGINE DISASSEMBLY ENG Ze 2 Remove e Valve cotters 1 NOTE Remove the valve cotters while compressing the valve spring with the valve spring compressor H Valve spring compressor P N YM 04019 90890 04019 3 Remove e Valve retainer 1 Valve spring 2 Valve 3 Oil seal 4 Spring seat 5 NOTE 2 Identify each part position very carefully so that it can be reinstalled in its original place 4 26
29. ge Clutch plate warp limit Less than 0 2 mm e Circumferentiat play Free play exists gt Replace 5 Inspect e Clutch springs 10 fn t Damage gt Replace springs as a set epee Gear teeth 1 pull lever axle e Gear teeth 2 pull rod Wear Damage gt Replace as a set 6 Measure e Clutch spring free length a Out of specification gt Replace springs as a set 11 Inspect e Bearing 1 pull rod Wear Damage gt Replace Free length clutch spring 42 8 mm lt Limit 40 8 mm gt 7 Inspect e Dogs on the clutch housing Scoring Wear Damage on edges Moderate Deburr Accentuated gt Replace clutch housing NOTE Scoring on the clutch housing dogs will cause erratic operation 4 45 4 46 INSPECTION AND REPAIR ENG n LF 5 TRANSMISSION AND GEARBOX 1 Inspect Gear fork cam pin 1 Gear fork pawl 2 Lines Creases Wear gt Replace 2 Inspect e Drum groove e Gear cam pins Wear Damage gt Replace 3 Check e Gear fork movement Rough functioning gt Replace gear forks and or guide bars 4 Inspect e Guide bar Turn on a flat surface Curvature gt Replace Do not attempt to straighten a deformed guide bar 5 Measure e Transmission shaft eccentricity Use the centring tool and micrometer Out of specification Replace shaft Eccentricity limit 0 08 mm A WARNING Do not
30. he starter wheel gear to the starter clutch and hold the starter clutch INSPECTION AND REPAIR ENG vA 4 44 e When turning the starter wheel gear clockwise A the starter clutch and the wheel gear should be engaged If not the starter clutch is faulty Replace it e When turning the starter wheel gear counter clockwise D the starter clutch gear should turn freely H not the starter clutch is faulty Reptace it PRIMARY ORIVE 1 Inspect e Primary drive gear teeth 1 e Primary driven gear teeth 2 Wear Damage gt Replace both gears Excessive noises during operation gt Replace both gears CLUTCH 1 Inspect e Friction plates Damage gt Replace friction plate as a set 2 Measure e Friction plate thickness Out of specification gt Replace friction plate as a set Measure at alt four points Thick Wear ickness timit Type 2 94 3 06 mm 2 8mm 2 pes Type B Hees 2 74 2 86 mm 2 6 mm INSPECTION AND REPAIR ENG Ze F 4 INSPECTION AND REPAIR ENG Ze 3 Inspect 8 Inspect e Clutch plates e Clutch boss splines Damage gt Replace clutch plates as a set Scoring Moderate gt Deburr Accentuated gt Replace clutch boss NOTE 2 ee Scoring on the clutch boss splines will cause erratic operation 4 Measure e Clutch plate warpage 9 Check Out of specification gt Repiace clutch plate asa set Use a surface plate and feeler gau
31. installing tool unti the crankshaft bottoms against the bearing CAUTION To protect the crankshaft against scratches or to facilitate the operation of the installation apply the grease to the oil seal lips and apply the engine oil to each bearing 4 56 ENGINE ASSEMBLY AND SETTING ENG ts BALANCER SHAFT AND TRANSMISSION 0 2 3 4 5 6 7 Sprocket 8 Fourth wheel gear 15 Fourth sprocket Oil seal 9 First wheet gear gear Bearing 10 Bearing 16 Main shaft Second wheel gear 11 Bearing 17 Bearing Secondary shaft 12 Second sprocket gear 18 Bearing Fifth wheel gear 13 Fifth sprocket gear 19 Bearing Third wheel gear 14 Third sprocket gear 20 Bearing 0 08 mm 0 003 MAIN AXLE RUNOUT LIMIT in Pa Co i Ko 19 ENGINE ASSEMBLY AND SETTING ENG Ze SHIFTER 1 2 3 4 5 6 Guide bar long Selector fork 3 R Selector fork 1 L Gear cam Guide bar short Selector fork 2 C i 7 Gear shalt 2 8 Gear shaft 1 9 Oil seal T Ba 10 Nm 1 0 mekg 7 2 ftelb pod ENGINE ASSEMBLY AND SETTING 2 Ge 4 5 4 59 3 BALANCER TRANSMISSION AND SHIFTER 3 Install e Neutral switch 1 Instali e Balancer shaft 1 Install e Collar 1 e Drive axle assembly 2 Install e Main axle assembly 1 Apply Engine oil onto guide bars E
32. iston ring lateral clearance Upper ring 0 04 0 08 mm Lower ring 0 03 0 07 mm 2 Position e Ring into cylinder NOTE EE Ha Fit each ring into the cylinder and push it to about 20 mm from the top edge of the cylinder Push the ring into the cylinder with the piston so that it is perfectly perpendicular to the cylinder axis a 20mm 3 Measure e Ring tip port Out of specification gt Replace NOTE itis impossible to measure the oil scraper tip port H the oil scraper port appears too large replace all three rings as a set Piston ring tip port fitted into cylinder Upper ring 0 30 0 45 mm Lower ring 0 30 0 45 mm Oil scraper tracks 0 20 0 70 mm INSPECTION AND REPAIR ENG Ze F 2 PISTON PIN 1 Check e Piston pin Blue colour Grooves gt Replace and check lubrication system q 2 Measure e External diameter a of pin Out of specification gt Replace External diameter pin 21 991 22 000 mm 3 Measure e Clearance between piston pin and piston pin seat Out of specification gt Repiace e Calculate the piston pin piston clearance according to the following formula Clearance between piston pin and piston Diameter on piston b Diameter of pin a Clearance between piston pinand piston 0 004 0 024 mm Maximum clearance 0 07 mm 4 41 INSPECTION AND REPAIR
33. l the lapping compound from the valve surface after every lapping operation INSPECTION AND REPAIR ENG Ze e Apply Prussian blue Dykem to the valve seal surface Install the valve in the cylinder head Press the valve onto the seat through the guide to leave a clear outline e Measure the valve seat width once more If the width of the valve is out of specification alter and relap VALVE SPRING 1 Measure e Free width of valve spring ai Out of specification gt Replace Free width a of valve spring Intake Exhaust 32 63 mm 36 46 mm 2 Measure e Spring load Out of specification gt Replace b Length of loaded spring Valve spring toad Intake c 10 2 11 8 kg b 27 50 mm Exhaust c 12 3 14 1 kg b 31 00 mm 3 Measure e inclination of spring a Out of specification gt Replace Inclination of spring intake Exhaust gt l Lower than 1 4mm Lower than 1 6 mm INSPECTION AND REPAIR 4 33 CAMSHAFT 1 inspect Cam eccentrics Pitting Scratches Blue colour gt Replace camshaft 2 Measure e Cam eccentrics Out of specification gt Replace camshatt intake Exhaust 36 50 36 60 mm 30 11 30 21 mm 3 Measure e Runout camshaft Out of specification gt Replace FAR Runout camshaft FA Less than 0 03 mm 4 Measure e Camshaft to cap clearance
34. ll micrometer Wear Scratches Damage gt Replace 1 2 5 mm from the lower edge of the piston AY Piston skirt P size 3 Eliminate e Score marks and lacquer deposits from the side of the piston Use a 600 800 grit wet sandpaper Standard 99 945 99 985 mm NOTE e H the measurements are out of tolerance re Sand in a crisscross pattern Do not sand exces place the piston and circlips all together sively 4 Inspect e Cylinder water jacket Crust of minerats Rust gt Remove e Cylinder wall Wear Scratches gt Rebore or replace 5 Measure e Piston to cylinder clearance 4 37 4 38 INSPECTION AND REPAIR ENG Ze F 1 Third stage e Caiculate the piston cylinder clearance according to the following formula Piston cylinder clearance Cylinder boring C Piston skirt diameter P Piston cylinder clearance 0 050 0 070 mm Maximum limit 0 15 mm e Ifthe measurements are out of tolerance rebore or replace the cylinder and replace the piston and piston ring as a set 4 39 INSPECTION AND REPAIR ENG Ze 4 40 PISTON RINGS 1 Measure e Lateral clearance of rings Use a thickness gauge Out of specification gt Replace piston and piston ring as a set NOTE Before measuring lateral clearance remove car bon deposits from the piston ring seats and from the tings themselves VAR pistenr 2 P
35. ly and carefully Make sure the case halves separate evenly If one end hans up take pressure off the push screw realign and start over If the cases do not separate check for a remaining case screw or fitting Do not force 4 Remove e Dowel pins 1 e Dowel pin 2 e O ring 3 ENGINE pisassemBLy ENG Ze OIL STRAINER 1 Remove e Oil strainer 1 e Oil passage cover 2 2 Remove e Gasket 1 oil strainer BALANCER TRANSMISSION AND SHIFTER 1 Remove e Shift shaft 1 e Shift shaft 2 2 2 Remove Guide bar 1 short Guide bar 2 long Shift cam 3 Shift fork 2 C 4 Shift fork 3 R 5 Shift fork 1 L 6 3 Remove e Main axle assembly 1 4 22 ENGINE DISASSEMBLY ENG oD 4 Remove e Drive axle assembly 1 e Collar 2 5 Remove e Balancer shaft 1 6 Remove e Neutral switch 1 CRANKSHAFT 1 Remove e Crankshaft assembly 1 Use the crankcase separating tool 2 and adapter 3 XQ Crankease separating tool P N YU 01135 A 90890 01135 Adapter P N YM 04063 A 90890 04063 NOTE Tighten the tool holding bolts but make sure that the tool body is vertical with the crankshaft If necessary one screw may be backed out slightly to level tool body E NGINE DISASSEMBLY ENG Ze 4 24 ROCKER ARM NOTES With the engine mounted the rocker arm can be maintained by r
36. m C Ifthe valve surface is like this it means thatthe valve seat is too narrow and close to the edge of the valve Intervention on the Desired effect valve seat Mill Centring of seat and attainment of 1 0 type mm width D Ifthe valve surface is like this it means that the valve seat is too narrow and situated low down near the lower edge of the valve surface Intervention on the Desired effect valve seat Mill 60 before Centring of seat e and attainment of 1 0 type Ap mm width 4 31 INSPECTION AND REPAIR ENG Dr 4 32 5 Emery e Principal vaive surtace e Valve seat NOTE __ _ If the valve seat is renewed or the valve and guide replaced the valve seat and seal surface must be lapped Lapping e Apply rough lapping compound to the valve seal surface CAUTION Make sure the lapping compound does not run into the space between the guide and valve stem e Apply oil to the molybdenum disulfide on the vaive stem Install the valve in the cylinder head e Turn the valve until face and surface are not evenly polished Then clean away all the lapping compound NOTE For best results during lapping repeatedly apply light pressure to the valve seat turning the valve backwards and forwards by hand Apply a fine lapping compound on the valve seal surface and repeat the procedures described above NOTE Be sure to remove al
37. nd check lubrication system 3 Measure e Rocker arm shaft clearance Rocker arm shaft clearance Internal diameter a of rocker arm External diameter b of shaft Out of specification gt Replace assembly Rocker arm shaft clearanc 0 009 0 042 mm CAMSHAFT CHAIN SPROCKET AND CHAIN GUIDE 1 Inspect e Chain Stifiness Cracks Replace timing chain and sprocket 4 36 INSPECTION AND REPAIR ENG ts INSPECTION AND REPAIR ENG Ze 2 Inspect tenes e Sprocket Measurement stages Wear Damage gt Replace timing chain First stage and sprocket Ss e Measure cylinder bore C with a cylinder gauge 1 1 4 tooth maximum gt er i 2 New sprocket tooth profile lt gt 1 50 mm from top of cylinder 3 Rolter NOTE 4 Sprocket Measure bore parallel and at right angles to the driving shaft Then calculate average measure ment AR AN Standard Cylinder bore C 100 005 100 045 mm 100 1 mm CAMSHAFT CHAIN GUIDE 1 Inspect e Lateral chain guide exhaust 1 e Lateral chain guide intake 2 Wear Damage gt Replace CYLINDER AND PISTON e H the measurements are out of tolerance re 1 Eliminate place the cylinder liner piston and circlips alt Carbon deposits together from the piston crow and ring grooves Second stage 2 Inspect e Measure diameter P of the piston skirt with a e Piston wa
38. nder head with wet 400 600 emery paper in a figure 8 direction 6 mm guide valve puller P N YM 04064 A P N 90890 04064 NOTE To avoid removing too much material on one side only turn the cylinder head a number of times 6 mm valve guide installer P N YM 04065 P N 90890 04065 6 mm valve guide borer P N YM 04066 P N 90890 04066 Crust of minerals Rust Eliminate 4 27 4 28 INSPECTION AND REPAIR Ol NOTE Reface the valve seat after replacing the valve guide 3 Clean the valve surfaces of the carbon depos its 4 Inspect e Valve seal surface Pitting Wear gt Grind the valve seal surface 5 Measure e Edge thickness a Out of specification gt Reface Edge thickness limit 0 8 mm 6 Check e Valve stem tip Deformed mushroom shaped or with a higher diameter than the rest of the stem gt Replace valve e Misalignment valve stem Out of specification gt Replace valve VA Stem offsettig lim VA 0 01 mm NOTE e Changing the valve replace also the valve guide e Pulling the valve out replace the oi seal VALVE HOUSING 1 Clean the valve surface and seat of carbon deposits 2 Inspect e Valve seat Pitting Wear gt Renew vaive seat ENG We E12 INSPECTION AND REPaIR ENG Som 4 30 3 Measure e Valve seat width a Out of specification gt Renew valve seat Valve seat
39. older P N YM 91042 90890 04086 Nut clutch boss 90 Nm 9 0 mkg 6 Bend e Lock washer tab along nut flat 7 Apply e Molybdenum disulfide grease onto gear teeth of pull rod e Engine oil onto bearing pult rod ENGINE ASSEMBLY AND SETTING ENGINE ASSEMBLY AND SETTING ENG Ze NOTE Align the punched mark 12 on the clutch boss with 8 Install e Friction plates 1 e Clutch plates 2 the arrow mark on the clutch pressure plate 13 e Cushion spring 3 e Pull rod 4 e Bearing 5 pull rod e Washer 6 Screw pressure plate plate e Pressure plate 7 Ta 8 Ak mkg j e Clutch springs 8 Bolts 9 9 Apply e Lithium soap base grease onto seal lips in crankcase cover Engine oit onto bearings in crankcase cover NOTE 10 Install Install the clutch plates and friction piates alternately on the clutch boss starting with a friction plate and e Pult lever axie 1 e Washer 2 ending with a friction plate e Bolt 3 CAUTIONS gt Bolt pull tever axle e The friction plates type A 10 with the larger 6 5 Nm 0 65 mkg of the inside diameter must be installed in the second and last places e The cushion spring 11 must be placed on the inside of the second friction plate 11 Install e Gasket 1 crankcase cover e Dowel pins 2 12 Install e Crankcase cover 1 right Friction pl
40. ring in the correct e Circlip 1 to drive axle Position e Collar 2 e Circlip 3 2 Apply 6 Install e 4 stroke engine oit e Flat washer 1 to the oil pipes in crankcase e Spring 2 Q gt e Shift lever 3 CAUTION a e Circlip 4 To avoid damage to the engine lubricate the oi Gg F SH 3 a pump pipes in the crankcase liberally with 4 2 stroke engine oil i 3 Apply NOTE e 4 stroke engine oil to the oil pump pipes When installing the shift lever align the mark on the lever with that on the shitf shaft 4 65 4 66 ENGINE ASSEMBLY AND SETTING ENG Ze F 15 BALANCER SHAFT GEAR 1 Key 2 Balancer shaft gear 3 Plate 4 Lock washer 5 Nut 6 Washer 7 Key 8 Plate 9 Balancer shaft transmission gear 10 Plate 11 Primary transmission gear 12 Lock washer 13 Nut 120 Nm 12 0 mekg 85 ftelb 4 67 ENGINE ASSEMBLY AND SETTING ENG Ze CLUTCH WI 2 3 4 5 6 7 8 Spring Pressure plate Push rod Push lever Push lever axle Friction plate type A Clutch boss spring Clutch plate 9 Friction plate type B 10 Clutch boss 11 Thrust plate 12 Gear assy 13 Primary transmission gear A FRICTION PLATE FREE LENGTH 40 8 mm 1 606 in CLUTCH SPRING MINIMUM Wear Limit 2 8 0 110 in Type Thickness A 2 94 3 06 mm 2pcs 0 116 0 120 in
41. talling steps Remove the cap bolt 2 washer 3 and spring 4 Release the ratchet 5 and push the tension rod 6 e Install the chain tensioner with the ratchet end facing downward Tighten the bolts e Install the spring 4 washer 3 and cap bolt 2 Bolt chain tensioner 10 Nm 1 0 mkg Cap bolt timing chain tensioner 20 Nm 2 0 mkg 15 Tighten e Bolts 1 cam sprocket Bolts cam sprocket 20 Nm 2 0 mkg 16 Check e Valve timing Out of alignment gt Adjust Refer to above steps 13 15 17 Check e Valve clearance Out of specification gt Adjust Refer to VALVE CLEARANCE ADJUSTMENT section in CHAPTER 3 Intake valve cold 0 10 0 15 mm Exhaust valve cold 0 15 0 20 mm ENGINE ASSEMBLY AND SETTING ENG Ze 18 Apply e Sealant 1 onte the cylinder head mating surfaces im Seatant quick gasket P N ACC 11001 01 Yamaha Bond N 1215 P N 90890 85505 19 Install e Dowel pins 2 20 Install e Cylinder head cover 1 NOTE Tighten the bolts in stage using a crisscross pattern Bolt cylinder head cover 10 Nm 1 0 mkg 21 Install e Timing plug 1 Plug 2 22 Install e Cap i Bolt cylinder head cap 10 Nm 1 0 mkg 23 Install e Intake manifolds 1 Bolt intake manifold 10 Nm 1 0 mkg ENGINE ASSEMBLY AND SETTING ENG Ze ENGINE AS
42. ve e Bolt 1 e Washer 2 e Pull lever axle 3 from crankcase cover ENGINE DISASSEMBLY ENG Ze 5 Remove Bolts 1 Clutch springs 2 Pressure plate 3 Washer 4 Bearing 5 Pull rod 6 Friction plate 7 Clutch plate 8 Cushion spring 9 NOTE Working in a crisscross pattern loosen the bolts 1 4 turn each Remove them after all are loosened 6 Straighten e Lock washer tab 7 Loosen Nut 1 clutch boss NOTE Loosen the nut clutch boss while hoiding the clutch boss with universal clutch holder 2 2 Universal clutch holder P N YM 91042 90890 04086 8 Remove e Nut 1 clutch boss Lock washer 2 Clutch boss assembly 3 Thrust plate 4 Clutch housing 5 4 17 ENGINE DISASSEMBLY ENG Ze 9 Straighten e Lock washer tabs 1 10 Loosen e Nut 2 crankshaft e Nut 3 balancer shaft NOTE Place a folded rag or aluminum plate between the teeth of the balancer drive gear and balancer gear Take care not to damage the gear teeth 11 Remove Primary drive gear 1 Plate 2 Balancer drive gear 3 Plate 4 Key 5 Plater washer 6 Plate 7 Balancer gear 8 Key 9 SHIFT LEVER AND OIL PUMP NOTE e With the engine mounted the oil pump can be maintained by removing the following parts e Clutch cable e Water pump housing ENGINE DISASSEMBLY ENG Ze E NGINE DISASSEMBLY ENG D
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