CRANKSHAFT AND CONNECTING ROD
Crankshaft Runout
1. Place both ends of crankshaft on V-blocks.
2. Rotate Crankshaft
3. Measure the crankshaft runout at main journal bearings. Use a Dial Gauge (90890-03097).
IGNITION TIMING CHECK
Flywheel is marked as follows:
(1) Pickup coil mark
(2) TDC for No. 1 cylinder
(3) Firing range for the No. 1 cylinder
1. Check:
• Ignition timing
OIL PUMP AND OIL PAN
1 Chain cover
2 Oil pump sprocket
3 Oil pump drive sprocket
4 Oil pump cover
5 Inner rotor
6 Spring
7 Relief valve
8 Shaft
9 Dowel pin
10 Outer rotor
11 Dowel pin
12 O-ring
CAMSHAFT, CAM CHAIN, AND CAM SPROCKET
Camshaft
1. Measure:
• Large cam lobe length 1
• Small cam lobe length 2
ENGINE OIL
At 5°C(40°F) or Higher: Yamalube 4-Cycle Oil or SAE 20W40 Type SE Motor Oil
At15°C(60°F) or Lower: SAE 10W30 Type SE Motor Oil
TRANSMISSION
1. Inspect:
• Shift fork cam follower 1
• Shift fork pawl 2
• Guide bar 3
Scoring/Bends/Wear-> Replace.
RADIATOR PIPES, CARBURETOR JOINT, AND OIL DELIVERY PIPE
1. Install:
• Union bolt with copper washer 1
• Cylinder head side cover 2
Oil Delivery Pipe: 21 Nm (2.1 m-kg, 15 ft-lb)
LOWER CRANKCASE
1. Remove
• Lifters 1
• Valve pads 2
NOTE:
Identify each lifter and pad position very carefully so that it can be reinstalled in its original place.
CLUTCH ADJUSTMENT
1. Loosen the adjuster locknut (1)
2. Adjust the clutch lever free play (a) by turning adjuster (2) in or out.
Free Play (a): 2 - 3mm (0.08-0.12 in)
