900RK

Pistons, Cylinder and Head

Submitted by xjcdadmin on Sat, 06/22/2013 - 11:17

11. Pistons and cylinder

a. Install the pistons on the rods. The arrow on the piston must point to the front of the engine.

NOTE: Before installing the piston pin clips, cover the crankcase with a clean rag so you will not accidentally drop the circlip into the crank-case. Always install new piston pin circlips.

Transmission, Clutch and Middle gear

Submitted by xjcdadmin on Sat, 06/22/2013 - 10:51

TRANSMISSION

3. Crankcase assembly a. Apply Yamaha bond #4 sealant or equivalent to the crankcase mating surface. Be very careful not to allow any sealant to come in contact with the oil gallery "O-ring" and crankshaft bearings. It is extremely important, however, that sealant be applied around the case stud holes. Apply sealant to within 2 — 3 mm (0.08 0.12 in) of the bearings.

Middle gear

Submitted by xjcdadmin on Sat, 06/22/2013 - 10:33

Middle gear

1. Damper disassembly

NOTE: Disassembly of the middle gear damper requires the damper compressor (special tool) and a hydraulic press.

a. Place the middle drive shaft in a press with the damper compressor (special tool) in place as shown.

Piston, Rings and Crankshaft

Submitted by xjcdadmin on Fri, 06/21/2013 - 16:33

Piston and piston rings

1. Piston

a. Measure the outside diameter of the piston at the piston skirt. Measurement should be made at a point 7.8 mm (0.307 in) above the bottom edge of the piston. Place the micrometer at right angles to the piston pin.

 

Size

Cylinder, Head and Valves

Submitted by xjcdadmin on Fri, 06/21/2013 - 16:21

Cylinder head cover

Place head cover on a surface plate. There should be no warpage. Correct by re-surfacing as follows:

Place # 400 or # 600 grit wet sandpaper on surface plate and re-surface head cover using a figure-eight sanding pattern. Rotate head cover several times to avoid removing too much material from one side.

Cylinder head