BATTERY

1.      Disconnect:
•   Negative lead (1)
•  Positive lead (2)
•  Breather hose (3)

2.      Pull:
•  Battery

3. Check:
• Fluid level

Incorrect — Refill.

Fluid level should be between upper (1) and lower (2) level marks.

Refill with distilled water only; tap water contains minerals harmful to a battery.

2.      Connect:
•   Breather hose

Be sure the hose is properly attached and routed.

3.      Inspect:
•   Breather hose Obstruction — Remove. Damage — Replace.

HOW TO ROUTE BATTERY BREATHER PIPE.

CAUTION:
Always charge a new battery before using it to ensure maximum performance.

Charging Current: 1.4 amps/10 hrs

Specific Gravity: 1.280 at 20°C(68°F)

Battery electrolyte is dangerous; it contains sulfuric acid and therefore is poisonous and highly caustic. Always follow these preventive measure:
•  Avoid bodily contact with electrolyte as it can cause severe burns or permanent eye injury.
•  Wear protective eye gear when handling or working near batteries.

Antidote (EXTERNAL):
•   SKIN — Flush with water.
•   EYES — Flush with water for 15 minutes and get immediate medical attention.

Antidote (INTERNAL):
•   Drink large quantities of water or milk follow with milk of magnesia) beaten egg, or vegetable oil. Get immediate medical attention.

Batteries also generate explosive hydrogen gas, therefore, you should always follow these preventive measures:
•   Charge batteries in a well-ventilated area.
•   Keep batteries away from fire, sparks, or open flames (e.g., welding equipment, lighted cigarettes, etc.)
•   DO NOT SMOKE when charging or handling batteries.

KEEP BATTERIES AND ELECTROLYTE OUT OF REACH OF CHILDREN.

HEADLIGHT

Headlight Bulb Replacement

1.      Remove:
•   Securing screws (1) (from light unit assembly/headlight body.)

2.      Disconnect:
•   Lead wire

3.      Remove:
•   Light unit assembly

4.      Rotate:
•   Bulb holder (1) Turn it counterclockwise.

5.      Remove:
•   Defective bulb

6. Install:
• Bulb (New)

Secure with bulb holder.

•   Avoid touching glass part of bulb.
•   Keep the bulb free from oil otherwise, transparency of glass, bulb life, and illumi-nous flux will be adversely affected.
•   If oil gets on bulb, clean it with a cloth moistened thoroughly with alcohol or lacquer thinner.

Do not touch the headlight bulb when it is on, as the bulb generates enormous heat; keep flammable objects away.

7. Install:
• Light unit assembly (to headlight body.)

 

Headlight Beam Adjustment 

Horizontal adjustment:

1. Rotate:
• Horizontal adjusting screw (1)

Horizontal Adjustment of Headlight Beam
Adjusting screw	Beam direction
Turn clockwise	- to Right
Turn counterclockwise	- to Left

Vertical adjustment:

1. Rotate:
• Vertical adjusting screw (2)

Vertical Adjustment of Headlight Beam
Adjusting screw	Beam direction
Turn clockwise	1 to Raise
Turn counterclockwise	1 to Lower

FUSE

The fuse box is under the indicator light panel. The main fuse is under the seat.

(1) Main fuse
(2) Other fuse block
(3) Spare fuses

Blown fuse replacement steps.

•  Turn off ignition and the circuit.
•   Install a new fuse of proper amperage.
•  Turn on switches to verify operation of electrical device.
•   If fuse blows immediately again, check circuit in question.

Do not use fuses of higher amperage rating than recommended. Extensive electrical system damage and fire could result from substitution of a fuse of improper amperage.

Proper periodic maintenance is important. Especially important are the maintenance services related to emissions control. These controls not only function to ensure cleaner air but are also vital to proper engine operation and maximum performance. In the following maintenance tables, the services related to emissions control are grouped separately.

PERIODIC MAINTENANCE EMISSION CONTROL SYSTEM

ITEM	REMARKS	INITIAL ODOMETER READING
		1.000 km (600 mi) or 1 month	*#1 7.000 km (4.400 mi) or 7 months	"2 13,000 km (8,200 mi) or 13 months	19,000 km {12.000 mi) or 19 months	25,000 km [15,800 mi) or 25 months	31,000 km <19.600m or 31 months
Valve clearance	Check and adjust valve clearance when engine is cold.					o
Spark plug	Check condition. Adjust gap and clean. Replace at 13,000 km (or 13 months) and thereafter every 12,000 km (or 12 months).		o	Replace	o	Replace	o
Crankcase ventilation system	Check ventilation hose for cracks or damage. Replace if necessary.		o		o		o
Fuel line	Check fuel hose and vacuum pipe for cracks or damage. Replace if necessary.			o	o	o	o
Exhaust system	Check for leakage. Retighten if necessary. Replace gasket(s) if necessary.		o	o	o	o	o
Idle speed	Check and adjust engine idle speed. Adjust cable free play.		o	o	o	o	o
Carburetor synchronization	Adjust synchronization of carburetors.	o	o	o	o	o	o

•It is recommended that these items be serviced by a Yamaha dealer or other qualified mechanic.

NOTE:

For farther odometer reading, repeat the above maintenance at the period establish; **1: Every 6.000 km (3,800 mi) "2. Every 12,000 km (7,600 mi) intervals.

GENERAL MAINTENANCE/LUBRICATION

No.	ITEM	REMARKS	TYPE	INITIAL ODOMETER READINGS
				1,000 km (600 mi) or 1 month	**1 7,000 km (4,400 mi) or 7 months	**2  13,000 km (8,200 mi) or 13 months	**3 19,000 km (12,000 mi) or 19 months	**4 25,000 km (15.800 mi) or 25 months	31,000 km (19,600 mi or 31 months
1	Engine oil	Warm-up engine before draining.	See page 12	o	o	o	o	o	o
2	Oil filter	Replace.	—	o		o		o
3	Air filter	Clean with compressed air. Replace if necessary.	—		o	o	o	o	o
4	Brake system	Adjust free play. Replace pads if necessary. (Front) Replace shoes if necessary (Rear)		o	o	o	o	o	o
5	Clutch	Adjust free play.	—	o	o	o	o	o	o
6	Final gear oil	Check oil level and leakage. Replace every 24,000 km (15,000 mi) or 24 months.	SAE80 API GL-4 hypoid gear oil	Replace		o		Replace
7	Control and meter cable	Apply chain lube thoroughly.	Yamaha chain and cable lube or SAE 10W30 motor oil.	°	o	o	o	o	o
8	Rear arm pivot shaft	Check bearings assembly for looseness. Moderately repack every 24,000 km (15,200 mi)	Medium weight wheel bearing grease					o
9	Brake/ Clutch ever pivot shaft.	Apply chain lube lightly.	Yamaha chain and cable lube or SAE 10W30 motor oil.		o	o	o	o	o
10	Brake pedal and change pedal shaft	Lubricate Apply chain lube lightly.	Yamaha chain and cable lube or SAE 10W30 motor oil.		o	o	o	o	o
11	Center/Side stant pivots	Check operation and lubricate. Apply chain lube lightly.	Yamaha chain and cable lube or SAE 10W30 motor oil.		o	o	o	o	o
12	Front fork oil	Check operation and leakage.	—		o	o	o	o	o
13	Steering bearings	Check bearings assembly for looseness. Moderately repack every 24,000 km (15,000 mi)	Medium weight wheel bearing grease		O	o	o	o	o
14	Wheel bearings	Check bearings for smooth rotation.	—		o	o	O	o	o
15	Battery	Check specific gravity and breather pipe for proper operation.	—		o	o	o	o	o
16	A.C. Generator	Replace generator brushes.				o		o
17	Sidestand switch	Check and clean or replace if necessary.		O	o	o	o	o	o

■ it is recommended that these items be serviced by a Yamaha Dealer or other qualified mechanic.

NOTE:

For greater odometer readings repeat the above maintenance at the period established, IE: **1: Every 6,000 km (3,800 mi), **2: Every 12,000 km (7,600 mi), **3: Every 18,000 km (11,400 mi), **4: Every, 24,000 km (15,200 mi) intervals.

 

Contents of Engine Maintenance:

 

FINAL GEAR OIL

Oil Level Measurement

1. Place the motorcycle on a level area and place on its centerstand. 

2 Remove:
•  Oil filler cap 

3. Observe:
•  Oil level (2)

Low level— Add oil. (1) Oil

NOTE:
Oil level must be up to the brim of the filler hole.

CAUTION:
Be sure that no foreign material enters the final gear case.

Gear Oil Replacement

1.      Place a receptacle under the final gear case.

2.      Remove:
•  Filler cap
•  Drain plug (1) Drain final gear oil.

3.      Install:
•  Drain plug

23 Nm (2.3 m-kg, 17ftlb)

4. Fill
• Gear case (to specified level.)

Final Gear oil:
SAE80 API "GL-4" Hypoid

gear oil Oil Capacity:
0.20 / (0.18 imp qt, 0.21 qt)

NOTE:
If desired, an SAE 80W90 Hypoid gear oil may be used for all conditions.

5. Install:
• Filler cap

23 Nm (2.3 m-kg, 17 ft-lb)

 

AIR FILTER

1.      Remove:
•  Seat
•  Fuel tank
•   Rubber cover

2.      Remove:
•  Air filter cover (1)

3.      Eliminate:
•   Dust

Use compressed air

4.      Inspect:
•   Element Damage - Replace.

CAUTION:
The engine should never be run without the air/filter element installed; excessive piston and/or cylinder wear may result.

5. Install:
• Element

CAUTION:
Make sure the element cover fits into the corresponding filter case edge.

FRONT BRAKE

 Brake Fluid Inspection

1. Check:
• Brake fluid level

Level low — Replenish.

NOTE:
Use only a designated, quality fluid.

DOT NO. 3

NOTE:

Be sure that:
•  Water does not enter the master cylinder when refilling.
•   Spilled fluid is cleaned up immediately to prevent painted surfaces or plastic parts from eroding.

(1) Lower level

FRONT BRAKE/REAR BRAKE

Front Brake Lever Free Play Adjustment

1.      Loosen:
•  Adjuster lockout (1)

2.      Adjust:
•  Free play (3)

Turn the adjuster (2) until the free play (3) is within the specified limits.

Brake Lever Free Play:

2-5 mm (0.08 ~ 0.2 in)

CAUTION:
Proper level free play is essential to avoid excessive brake drag.

3. Tighten:
• Adjuster locknut

Brake Pad Inspection

1.      Activate the brake lever

2.      Inspect:
• Wear indicator (1) Indicator almost contacts disc (2) — Replace pads. Refer to CHAPTER 5, "CHASSIS."

REAR BRAKE

Rear Brake Pedal Height Adjustment

1.     Loosen:
•  Adjust locknut (1) .

2.      Adjust:
•   Brake pedal height (2).

Turn the adjuster (3) until the brake pedal position is at the specified height.

Brake Pedal Height: 10 mm (0.4 in) Below the Top of the Footrest

Adjust pedal height, then adjust brake pedal free play.

REAR BRAKE

Rear Brake Shoe Inspection

1.      Depress brake pedal

2.      Inspect:
• Wear indicator (2)

Indicator at wear limit line — Replace brake shoes.

(1) Wear limit line

Rear Brake Pedal Free Play Adjustment

1. Rotate:
• Adjuster nut (1)

Turn it clockwise or counterclockwise until proper brake pedal free play is attained.

Brake Pedal Free Play:
20-30 mm (0.8 -1.2 in)

Check to verify correct brake light operation after adjustment.

Brake Light Switch Adjustment

1. Hold the switch body (1) with your hand so that it does not rotate and turn the adjusting nut (2) .

CABLE INSPECTION AND LUBRICATION

Cable inspection and lubrication steps:
•   Remove the two screws that secure throttle housing to handlebar.
•   Hold cable end high and apply several drops of lubricant to cable.
•   Coat metal surface of disassembled throttle twist grip with suitable all-purpose grease to minimize friction.
•  Check for damage to cable insulation. Replace any corroded or obstructed cables.
•  Lubricate any cables that do not operate smoothly.

SAE 10W30 Motor Oil

 

BRAKE AND CHANGE PEDALS/ BRAKE CLUTCH LEVERS

Lubricate pivoting parts of each lever and pedal.

CENTERSTAND AND SIDESTAND

Lubricate centerstand and sidestand at their pivot points.

SAE 10W30 Motor Oil

FRONT FORK OIL CHANGE

Securely support the motorcycle so there is no danger of it falling over.

1.     Place a suitable stand under the engine to raise the front wheel off the ground.

2.     Loosen:
•  Inner tube pinch bolt (1)

3.     Remove:
•  Fork cap (2)
•  Cap bolt (3)

Use the Front Fork Cap Socket (YM-01104) (4)

4. Remove:

• Drain screw (1) Drain the fork oil.

Do not allow any oil to contact the disc brake components. If oil is discovered, be sure to remove it, otherwise diminished braking capacity and damage to the rubber components of the brake assembly will occur.

7.      Inspect:
•  O-ring (1) (Cap-bolt)
•  Gasket (Drain screw) Wear/Damage — Replace.

8.      Install:
•   Drain screw

9.      Fill:
•  Front fork

Each Fork:
383cm³(13.51 impoz, 12.95 USoz)

After filling pump the forks slowly up and down to distribute the oil. 

10. Tighten:
•  Cap-bolt
•   Pinch bolt

Cap Bolt: 23 Nm (2.3 rrvkg, 17ftlb) 
Pinch Bolt: 20 Nm (2.0 mkg, 14ft-lb)

11. Install:
• Fork cap

 

REAR SHOCK ABSORBER ADJUSTMENT

If the spring seat is raised, the spring becomes stiffer, and if lowered, it becomes softer.

Standard Position: B      A. — Softest (1) E. — Stiffest (2)

Always adjust each shock absorber to the same setting. Uneven adjustment can cause poor handling and loss of stability.

 

 

STEERING HEAD ADJUSTMENT

Steering Head Inspection

1.      Place the motorcycle on its centerstand, then elevate the front wheel.

2.      Check:
• Steering assembly bearings

Grasp the bottom of the forks and gently rock the fork assembly back and forth. Looseness — Adjust.

Adjustment

Steering head adjustment steps: 
•   Remove the handlebar securing bolts (1)
•   Remove the handlebars .
•   Remove the steering stem nut (2)
•   Loosen the pinch bolts (3) .
•   Remove the steering crown (4) .
•   Remove the lock washer (5) .
•   Loosen the ring nut (6) ,
•   Tighten the ring nut (7) .

Ring Nut (Lower):
50 Nm (5.0 m-kg, 36 ft-lb)

The tapered side of ring nuts must face downward.

• Loosen the ring nut (7) completely and retighten it to specification.

Ring Nut (Lower):
6Nm(0.6 m-kg,4.3ft-lb)

•   Check the steering stem by turning it lock to lock. If there is any binding, remove the steering stem assembly and inspect the steering bearings 8 .

(See CHAPTER 5, STEERING HEAD for more details.)

•   Hand-tighten the ring nut (6) , then align the slots of both ring nuts. If not aligned, hold the lower ring nut (7) and tighten the other until they are aligned.

•   Install the lock washer (5) .

NOTE:
Make sure the lock washer tab is placed in the slots.

• Install the steering crown (4) and tighten the steering stem nut (2) to specification.

Steering Stem Nut:
110 Nm (11.0 m-kg, 80 ft*]

• Install the handlebar and torque the bolt 0 to specification.

Pinch Bolt: 20Nm(2.0m-kg, 14ft-lb) 
Handlebar Bolt: 20 Nm (2.0 m-kg, 14 ft-lb)

 

 

WHEEL BEARINGS 

 

Front Wheel Bearings

1. Raise the front end of the motorcycle, and spin the wheel by hand. Touch the axle or front fork while spinning the wheel-Excessive vibration — Replace bearings.

Rear Wheel Bearings

1.      Remove: 
•   Rear wheel

2.      Check:
•   Bearing movement Rotate with the fingers. Roughness/Wear — Replace.

 

 

TUBELESS TIRES AND ALUMINUM WHEELS

•   Always inspect aluminum wheels before a ride.
•   Place the motorcycle on its centerstand and check for cracks, bends, or warpage of the wheels.
•   Do not attempt any repairs to the wheel; replace any defective wheel.
•   Do not attempt to use tubeless tires on a wheel designed for use with tube-type tire only. Tire failure and subsequent personal injury may result from sudden deflation.
•   Be sure to install the proper tube when using tube-type tires.
•   New tires have a relatively poor adhesion on the road surface so do not allow them to be subjected to high speed load from maximum speed until after a break-in run of approx. 100 km (60 mi).
•   Always use the correct tire inflation pressure acording to the operating conditions.

Wheel	Tire
Tube type	Tube type only
Tubeless	Tube type or tubeless

A Tire	C Tubeless tire
B Wheel	D Tube type tire

(1)  Air valve
(2)  Aluminum wheel (Tubeless type)
(3)  Tube
(4)  Aluminum wheel (tube type)

Always perform the following steps to ensure safe operation, maximum tire performance, and long service. 1. Measure:

• Tire pressure Out of specification — Adjust.

Basic weight: With oil and full fuel tank	224 kg (494 lb)
Maximum load *	246 kg	542 lb)
Cold tire pressure	Front	Rear
Upto90kg(198lb) load"	177 kPa (1.8 kg/cm2. 26 psi)	196 kPa (2.0 kg/cm2. 28 psi)
90 kg (198 lb) load ~ 246 kg (542 lb) load-	196 kPa (2.0 kg/cm*, 28 psi)	275 kPa (2.8 kg/cm2. 40 psi)
High speed riding	206 kPa (2.1 kg/cm? 30 psi)	225 kPa (2.3 kg/cm2 32 psi)

* Load is the total weight of cargo, rider, passenger, and accessories.

2. Inspect:

• Tire surfaces Wear/Damage — Replace.

Minimum Tire Tread Depth: (Front and Rear) 1.0 mm (0.04 in)

(1) Tread depth

(2)  Side wall

(3) Wear indicator

3. Inspect:
• Aluminum wheels 
Damage/Bends — Replace. Never attempt even small repairs to the wheel.

NOTE:
Always balance the wheel when a tire or wheel has been changed or replace.

Ride conservatively after installing a tire to allow it to seat itself properly on the rim.

ENGINE REMOVAL

NOTE:
It is not necessary to remove the engine in order to remove the following components:

•   Piston
•   Clutch
•  Carburetor
•  Oil pump

PREPARATION FOR REMOVAL

1.      Remove all dirt, mud, dust, and foreign material before removal and disassembly.

2.      Use proper tools and cleaning equipment. Refer to CHAPTER 1, "SPECIAL TOOL"

NOTE: 
When disassembling the engine, keep mated parts together. This includes gear, cylinders, pistons, and other parts that have been "mated" through normal wear. Mated parts must be reused as an assembly or replaced.

3. During the engine disassembly, clean all parts and place them in trays in the order of disassembly. This will speed up assembly time and help assure that all parts are correctly reinstalled in the engine.

SEAT AND FUEL TANK

1.     Remove:
•  Seat (1)
•  Fuel tank (2)
•  Left side cover (3)

2.     Drain:
•  Engine oil

BATTERY

1. Disconnect:
•  Battery leads (1),(2)
•  Breather hose (3)

NOTE:
Disconnect the negative lead first.

EXHAUST PIPE AND MUFFLER

1.     Remove:
•  Nuts

2.     Loosen:
•  Clamp bolts

3.     Remove:
•  Exhaust pipes (1)

4. Remove:
•  Chamber mount bolt (1)
•  Muffler mount bolts (2)
•  Muffler with chamber

CARBURETOR AND CABLES

1.      Loosen:
•  Clamp screws

2.      Remove:
•  Air cleaner case (1) mount bolts (2)

3.      Push the air cleaner case toward the rear to disconnect air outlet hoses from carburetors.

4.      Disconnect:
•  Choke cables (3)

5.      Remove:
•  Carburetors
•  Throttle cable (4)

NOTE: 
After removing the carburetors, cover the carburetors with a clean cloth to keep dust and dirt out.

7. Disconnect:
•  Crankcase ventilation hose (1) (from crankcase)
•  Clutch cable (2)

CONNECTOR

1.      Remove:
•  Plate

2.      Disconnect:
•  Pickup coil lead
•  Generator lead
•  Neutral switch lead
•  Oil level switch lead
•  Starter motor lead (1) (from starter motor)

SHIFT PEDAL BRAKE PEDAL, FOOTREST AND DRIVE SHAFT

1.      Remove:
•  Shift pedal (1)
•  Left footrest (2)

2.      Disconnect:
•  Rubber boot (3)

3.      Remove:
•  Joint bolts (4)

4. Remove:
•  Brake pedal (1)
•  Right footrest (2)

ENGINE REMOVAL

1.     Place a suitable stand under the engine.

2.     Remove:
•  Mounting bolts
•  Downtube frame (1)

3. Remove:
• Engine assembly (from chassis right side)

ENGINE OVERHAUL

A. Cylinder Head and Cylinder

1.    Remove the cylinder head cover.

2.    Remove the left crankcase cover (pickup coil cover).

3.    Remove the cam chain tensioner.

4. Use a 19 mm wrench on the timing plate flats to rotate the crankshaft counterclockwise until the engine is at T.D.C.

CAUTION:

Never use an alien wrench to rotate the crankshaft. Always use the 19 mm flats provided on the timing plate to rotate this engine.

5. Remove the four cam sprocket bolts.

6. Slip each sprocket off its mounting boss on the cam.

CAUTION:

From this point on, do not rotate the cam shaft or valve damage may occur. On this, it is not necessary to break the cam chain. However, it can be broken if so desired. It is easier to disassemble the engine without separating the chain.

7. Remove the cam chain guide.

1. Cam chain guide

8. Remove the cam caps. Note the location of the cam caps. The caps for the intake cam shaft are identified 1-1 through I-3. The exhaust cam caps are identified E-1 through E-3. Directional arrows are cast on each cap and point toward the clutch side.

9. Fasten safety wire to the cam chain to prevent its falling into the crankcase cavity.

Slide the cams and sprockets from under the chain and remove the cams and sprockets.

10. Remove the front cam chain guide.

1. Front cam chain guide

11.    Remove the spark plugs.

 

12.    Remove the cylinder head bolts and nuts in the numerical order as shown. Start by loosening each nut 1/2 turn until all of the nuts are loose. Remove the cylinder head.

 

 

13. Remove the front cylinder holding nut and remove the cylinder assembly. It may be necessary to tap the cylinder lightly to loosen it from the base gasket.

14. Remove the rear cam chain guide by loosening the holding bolt.

1. Holding bolt 2. Rear cam chain guide

B. Cylinder Head Disassembly

1. Remove the valve lifters and pads. Be careful not to scratch the lifter bodies or lifter bores in the cylinder head. Be very careful to identify each lifters position so that it may be returned to its original place.

1. Valve filter 2. Adjusting pad

2. Mount the valve spring compressor on the head and depress each valve spring. Take out the retainer and valve spring with tweezers.

1. Valve spring compressor

3. Remove valves.

NOTE:

Deburr any deformed valve stem end. Use an oil stone to smooth the stem end. This will help prevent damage to the valve guide during valve removal.

4. Use a small box to hold the parts and identify the original position of each lifter and valve. Be very careful not to mix the location of these components.

 

C. Piston

1. Mark each piston to aid in reassembly.

2.   Place a clean towel or rag into the crank-case to keep circlips and material from falling into the engine.

3.    Remove piston pin clips, piston pins, and pistons.

D. Pick-up Coil Assembly

1. Remove the alien bolt that holds the timing plate.

2. Remove the pick-up coil securing screws and remove the pick-up coil assembly.

E. Shifter

1.    Remove the change pedal.

2.    Remove the left crankcase cover.

3. Remove the shift lever assembly and shift shaft assembly.

1. Shift lever assembly 2. Shift shaft assembly

4. Remove the middle gear case oil level maintaining plug.

F. Starter Motor and Generator

1. Remove the starter motor securing bolts and remove the motor assembly.

2. Remove the generator cover and stator coil assembly.

 

3. Install the rotor holding tool (special tool) on the rotor as shown and remove the rotor holding bolt.

1. Rotor holding tool

4. Invert the holding tool as shown and insert the rotor puller adapter (special tool) into the rotor shaft and screw in the rotor puller (special tool). Remove the rotor.

1. Rotor puller adapter

G. Clutch

1. Remove right crankcase cover.

2. Release the tension evenly on the 6 mm bolts and remove the clutch pressure plate and clutch springs.

NOTE:
The outermost friction plate has a tab with a V-cut (1) in it. Give some identifying mark to the corresponding dog (2) in the clutch housing. This dog is the narrowest.

 

3.    Remove the friction plates and clutch plates.

(1) Clutch spring bolts
(2) Clutch springs
(3) Pressure plate
(4) Friction plates
(5) Clutch plates

 

 

4.   Straighten the lock washer tab. Use the clutch boss holder (special tool) to hold the clutch boss and remove the lock nut and lock washer.

1. Clutch boss holder

5. Remove the clutch boss and spacer.

6. Screw in a suitable length of 6 mm bolt into the one of the threaded holes on the collar and pull out the collar and needle bearing from the primary driven gear.

1. Collar

7. Remove the primary driven gear assembly and oil pump drive sprocket.

H. Oil Pump Removal and Disassembly

1. Remove the strainer cover. Note the wire harness clip position.

2a. Remove the oil pump securing bolts and remove the sprocket cover and oil pump assembly.

 

2b. Remove the Oil pump drive sprocket (1), Chain (2) Collar (3) and thrust plate. 

 

CAUTION:

Do not attempt to remove the strainer screen as it is permanently fitted onto the pump housing. If the pump housing and/or any parts of the pump are damaged, the pump assembly must be replaced with a new one.

3. Remove the oil pump driven sprocket.

4. Remove the oil pump cover and rotor assembly.

5. Remove the pressure relief valve spring and plunger.

I. Middle Gear

1. Remove the middle driven gear housing holding bolts.

2.    Remove the middle driven gear housing assembly and shims.

NOTE:

If it is difficult to remove housing assembly, loosen the two crankcase bolts located near the middle driven gear housing.

3. Remove "TORX" screws holding the middle drive gear assembly.

4. Remove the bearing retainers.

J. Crankcase Disassembly

1. Remove the upper crankcase bolts, starting the highest numbered bolt. Turn over the engine and remove the lower crankcase bolts,

CRANKCASE TORQUE SEQUENCE

UPPER CASE

LOWERCASE

2. Separate the lower case from the engine. Use a soft rubber hammer to carefully separate the crankcase.

K. Upper Crankcase

1. Remove the middle drive gear and damper assembly.

2. Remove the transmission main shaft assembly.

3. Remove the A.C.G. shaft cover.

4, Remove the oil spray nozzle.

5. Carefully remove the A.C.G. shaft from the gear.

6. Remove the gear from the chain.

7. Straighten the lock washer tube and remove the bolt securing the starter idle gear shaft. Remove the shaft and starter idle gear.

L. Lower Crankcase

1.    Remove the dowel pin and "O-ring".

2.    Remove the shift fork guide bar and shift forks. The shift forks are identified by numbers cast on their sides.

3.    Remove the bolt securing the shift cam locating pin and remove the stopper plate and locating pin.

4.    Remove the neutral switch.

1. Shift cam locating pin   2. Neutral switch

5.   Pull out the shift cam.

6.    Remove the driven shaft bearing cover holding screws and remove the bearing cover.

7. Remove the bearing and 5th wheel gear from the driven shaft and pull out the driven shaft assembly.

1. 5th wheel gear

INSPECTION AND REPAIR

A.   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.

B.   Cylinder Head

1. Using a rounded scraper, remove carbon deposits from combustion chamber. Take care to avoid damaging spark plug threads and valve seats. Do not use a sharp instrument. Avoid scratching the aluminum.

2.    Check the cylinder head warpage with a straight edge as shown.

The warpage should not exceed the specified limit, if necessary resurface. If the warpage exceeds allowable limit, the cylinder head should be replaced with a new one.

Cylinder head warpage: less than 0.03 mm (0.0012 in)

Allowable limit: 0.25 mm (0.010 in)

C. Valve, Valve Guide, and Valve Seat

1a. Check the valve face and the stem end for wear. If the valve face and/or the stem end are pitted or worn, regrind the valve with a valve refacer. Replace the valve if any dimension exceeds the specifications:
(1) 0.7 mm (0.028 in) Minimum Thickness (service limit)
(2) 0.5mm (0.020 in) bevel
(3) 4.0mm (0.157 in) Minimum Length (Service limit)

1b. Measure the contacting mark position on the valve face (1) and verify it is 0.3 mm (0.12 in) from the edge and 1.0mm +/- 0.1mm (0.039 +/- 0.004 in) wide. If it is out of range, the valve seat should be recut as detailed below.

2. Valve stem wear must be measured and then combined with valve guide measurements to guide clearance. This clearance must be within tolerances. If it exceeds the maximum limit, then replace either or both valve and guide, as necessary.

	Valve Stem Clearance	Maximum
Intake	0.010 — 0.037 mm (0.0004-0.0015 in)	0.10 mm (0.004 in)
Exhaust	0.025-0.052 mm (0.0010-0.0020 in)	0.12 mm (0.005 in)

3.    Valve stem end

Inspect the end of the valve stem. If the end appears to be "mushroomed" or has a larger diameter than the rest of the stem, the valve, valve guide, and oil seal should be replaced.

4.   Turn valve on "V" blocks and measure the amount of stem runout with a dial gauge. If it exceeds the maximum limit, replace the valve.

Maximum valve stem runout: 0.03 mm (0.0012 in)

5. Valve guide and valve oil seal replacement If oil leaks into the cylinder through a valve due to a worn valve guide, or if a valve is replaced, the valve guide should also be replaced.

NOTE:

The valve oil seal should be replaced whenever a valve is removed or replaced.

a. Measure valve guide inside diameter with a small bore gauge. If it exceeds the limit, replace with an oversize valve guide.

Guide diameter (I.D.):

Limit: 7.10 mm (0.280 in)

b.  To ease guide removal and reinstallation, and to maintain the correct interference fit, heat the head to 100t (212°F). Use an oven to avoid any possibility of head warpage due to uneven heating.

c.   Use the appropriate shouldered punch (special tool) to drive the old guide out and drive the new guide in.

NOTE:

When a valve guide is replaced, the O-ring should also be replaced.

1. Valve guide remover 2. Valve guide installer

d. After installing the valve guide, use the 7 mm reamer (special tool) to obtain the proper valve guide to valve stem clearance.

e. After installing the valve guide in the cylinder head, the valve seat must be recut. The valve should be lapped to the new seat.

6. Grinding the Valve Seat

a. The valve seat is subject to severe wear. Whenever the valve is replaced or the valve face is re-surfaced (see caution) the valve seat should be re-surfaced at a 45° angle. If a new valve guide has been installed the valve seat must be recut to guarantee complete sealing between the valve face and seat.

CAUTION:

If the valve seat is obviously pitted or worn, it should be cleaned with a valve seat cutter. Use the 45° cutter, and when twisting the cutter, keep an even downward pressure to prevent chatter marks.

If cutting section "A" of the valve seat, use 30° cutter. If cutting section "B", use the 45° cutter. If cutting section "C" use 60° cutter. b. Measure valve seat width. Apply mechanic's bluing dye (such as Dykem) to the valve face and valve seat, apply a very small amount of fine grinding compound around the surface of the valve face insert the valve into position, and spin the valve quickly back and forth. Lift the valve, clean off all grinding compound, and check valve seat width. The valve seat and valve face will have removed bluing wherever they contacted each other. Measure the seat width with vernier calipers. It should measure approximately 1.1 mm (0.0433 in). Also, the seat should be uniform in contact area. If valve seat width varies, or if pits still exist, further cutting will be necessary. Remove just enough material to achieve a satisfactory seat.

	Standard Width	Wear Limit
Seat width	1.0 ±0.1 mm (0.0394 ± 0.0039in)	1.4 mm (0.055 in)

a. Seat width

c. If the valve seat is uniform around the perimeter of the valve face, but is too wide or not centered on the valve face, it must be altered. Use either the 30°, 45° or 60° cutters to correct the improper

seat location in the manner described below:

1) If the valve face shows that the valve seat is centered on the valve face, but too wide, then lightly use both the 30° and the 60° cutters to reduce the seat width to 1.1 mm (0.0433 in).

1. Valve seat cutter

2)   If the seat shows to be in the middle of the valve face, but too narrow, use the 45°cutter until the width equals 1.1 mm(0.0433 in).

3)   If the seat is too narrow and right up near the valve margin, then first use the 30° cutter and then the 45° cutter to get the correct seat width.

4)   If the seat is too narrow and down near the bottom edge of the valve face, then first use the 60° cutter and then the 45° cutter.

7. Lapping the valve/valve seat assembly a. The valve/valve seat assembly should be lapped if neither the seat nor the valve face are severely worn.

b. Apply asmall amount of coarse lapping compound to valve face. Insert the valve into the head. Rotate the valve until the valve and valve seat are evenly polished. Clean off the coarse compound, then follow the same procedure with fine compound.

Continue lapping until the valve face shows a complete and smooth surface all the way around. Clean off the compound material. Apply bluing dye to the valve face and seat and rotate the valve face for full seat contact which is indicated by a grey surface all around the valve face where the bluing has been rubbed away.

c. Valve leakage check

After all work has been performed on the valve and valve seat, and all head parts have been assembled, check for proper valve/valve seat sealing by pouring solvent into each of the intake ports, then the exhaust ports. There should be no leakage past the seat. If fluid leaks, disassemble and continue to lap with fine lapping compound. Clean all parts thoroughly, reassemble and check again with solvent. Repeat this procedure as often as necessary to obtain a satisfactory seal.

 

D. Valve Spring and Lifters

1. Checking the valve springs

a.   This engine uses two springs of different sizes to prevent valve float or surging. The valve spring specifications show the basic value characteristics.

b.   Even though the spring is constructed of durable spring steel, it gradually loses some of it's tension. This is evidenced by a gradual shortening of free length. Use a vernier caliper to measure spring free length. If the free length of any spring has decreased more than 2 mm (0.080 in) from its specification replace it.

c. Another symptom of a fatigued spring is insufficient spring pressure when compressed. This can be checked using a valve spring compression rate gauge. Test each spring individually. Place it in the gauge and compress the spring first to the specified compressed length with the valve closed (all spring specifications can be found in the previous section, Valve Spring), then to the length with the valve open. Note the poundage indicated on the scale at each setting. Use this procedure with the outer springs, then the inner springs.

NOTE:

All valve springs must be installed with larger pitch upward as shown.

Valve Spring Specifications
	OUTER	INNER
Free length	37.0 mm (1.457 in)	33.5 mm (1.319 in)
Installed length (valve closed)	34.0 mm (1.339 in)	31.0 mm (1.220 in)
Installed pressure	17.2 kg -21.0 (37.9 - 46.3 lb)	8.1 - 9.9 kg (17.9 - 21.8 1b)
Allowable tilt from vertical	1.6°

2. Valve lifter

a. Check each valve lifter for scratches or other damage. If the lifter is damaged in any way, the cylinder head surface in which it rides is probably also damaged. If the damage is severe, it may be necessary to replace both the lifter and the cylinder head.

NOTE:

For proper valve lifter-to-head clearance, always install lifters on their original valves.

E. Camshafts, Cam chain and Cam Sprockets

1. Camshaft

a.   The cam lobe metal surface may have a blue discoloration due to excessive friction. The metal surface could also start to flake off or become pitted.

b.   If any of the above wear conditions are readily visible, the camshaft should be replaced.

c.   Even though the cam lobe surface appears to be in satisfactory condition, the lobes should be measured with a micrometer. Cam lobe wear can occur without scarring the surface. If this wear exceeds a pre-determined amount, valve timing and lift are affected. Replace the camshaft if wear exceeds the limits.

	Cam Lobe A	Cam Lobe B
Intake	36.8 mm (1.449 in)	28.1 mm (1.106 in)
Exhaust	36.3 mm (1.429 in)	28.06 mm (1.105 in)

 

 

d.   Install the camshaft on the cylinder head. Place a strip of Plastigage between camshaft and camshaft cap as illustrated (lengthwise along camshaft). Tighten the nuts with specified torque. Remove the camshaft cap and determine the clearance by measuring the width of the flattened Plastigage.

Cap nut tightening torque: 1.0m-kg(7.2ft-lb)

1. Plastigage

NOTE:

Do not turn camshaft when measuring clearance with Plastigage.

Camshaft-to-cap clearance:

Standard:	0.020-0.054 mm
	(0.0008- 0.0021 in)
Maximum:	0.160 mm (0.006 in)

If the camshaft-to-cap clearance exceeds specification, measure camshaft bearing surface diameter.

Bearing surface diameter:

Standard:	24.967-24.980 mm
	(0.9830-0.9835 in)

1) If camshaft diameter is less than specification, causing excessive clearance, replace camshaft.

2)  If camshaft is within specification and camshaft-to-cap clearance is excessive, replace cylinder head.

2.    Cam chain

Except in cases of oil starvation, the cam chain wears very little. If the cam chain has stretched excessively and it is difficult to keep the proper cam chain tension, the chain should be replaced.

3.    Cam sprockets

Check cam sprockets for obvious wear.

4, Cam chain dampers

Inspect the top cam chain damper (stopper guide) and two (2) vertical (slipper-type) dampers for excessive wear. Any that shows excessive wear should be replaced. Worn dampers may indicate an improperly adjusted or worn-out cam chain.

(1) Upper guide
(2) Front guide
(3) Rear guide

5  Automatic Cam Chain Tensioner

Ensure operation is one-way and smooth. Inspect all parts for wear or damage

(1) End plug
(2) Washer
(3) Springs
(4) Tensioner body
(5) One way cam
(6) Tensioner rod

 

 

. Cylinder

1.    Inspect the cylinder walls for scratches. If vertical scratches are evident, the cylinder wall should be rebored or the cylinder should be replaced.

2.   Measure cylinder wall wear as shown. If wear is excessive, compression pressure will decrease. Rebore the cylinder wall and replace the piston and piston rings. Cylinder wear should be measured at three depths with a cylinder bore gauge. (See illustration.)

	Standard	Wear Limit
Cylinder bore	65.00 mm (2.5591 in)	65.005 mm (2.5592 in)
Cylinder taper	—	0.05 mm (0.002 in)
Cylinder out-of-round	—	0.01 mm (0.0004 in)

If the cylinder wall is worn more than the wear limit, it should be rebored.

G. Piston andPiston Rings

1. Piston

a. Measure the outside diameter of the piston at the piston skirt. Measurement should be made at a point 7.5 mm (0.3 in) above the bottom edge of the piston. Place the micrometer at right angles to the piston pin.

Standard	64.955 - 64.970 mm (2.5573 - 2.5579 in)
Oversize 1	65.5 mm (2.58 in)
Oversize 2	66.0 mm (2.60 in)

a. 7.5 mm (0.3 in)

b. Determine piston clearance as follows:

Minimum bore measurement — Maximum piston measurement * Piston clearance

EXAMPLE:

63.0 mm (2.4803 in) - 62.96 mm (2.4787 in)= 0.04 mm (0.0016 in)

Piston clearance

Piston clearance:

Standard: 0.030 - 0.050 mm (0.0012 - 0.0020 in)
Service limit: 0.1 mm (0.0039 in)

c. Piston ring/ring groove fit must have correct clearance. If the piston and ring have already been used, the ring must be removed and the ring groove cleaned of carbon. The ring should then be reinstalled. Use a feeler gauge to measure the gap between the ring and the land.

Side clearance	Top	0.03- 0.07 mm (0.0012- 0.0028 in) Limit: 0.15 mm (0.0059 in)
	2nd	0.02-0.06 mm (0.0008- 0.0024 in) Limit: 0.15 mm (0.0059 in)

1. Feeler gauge

2. Piston ring

a. The oversize top and middle ring sizes are stamped on top of the ring.

Oversize 2	0.50 mm (0.0197 in)
Oversize 4	1.00 mm (0.0394 in)

b. The expander spacer of the bottom ring (oil control ring) is color-coded to identify sizes.

The color mark is painted on the expander spacer.

Size	Color
Oversize 2	Blue
Oversize 4	Yellow

c. Push the ring into the bore and check end gap clearance with a feeler gauge.

NOTE:

The end gap on the expander spacer of the oil control ring is unmeasurable. If the oil control ring rails show excessive gap, all three components should be replaced.

	Standard	Limit
Top/2nd ring	0.15 — 0.30 mm (0.006- 0.012 in)	1.0 mm (0.04 in)
Oil control (Rails)	0.2-0.7 mm (0.008-0.028 in)	---

H. Piston Pin

1.    Apply a light film of oil to pin. Install in connecting rod small end. Check for play. There should be no noticeable vertical play. If play exists, check connecting rod small end for wear. Replace pin and connecting rod as required.

2.    The piston pin should have no noticeable free play in piston. If the piston pin is loose, replace the pin and/or the piston.

I. Crankshaft

1. Crankshaft run-out

Support the crankshaft at both ends on V-blocks. Measure the amount of crankshaft run-out on the main bearing journals with a dial gauge while rotating crankshaft.

Run-out limit: 0.030 mm (0.0012 in)

If run-out exceeds limit, replace crankshaft.

2. Inspection of bearings

Check the bearings. If the inner or outer surface is burned, flaked, rough, scratched or worn, the bearings should be replaced.

3. Measuring main bearing oil clearance

a.   Clean all crankshaft and crankcase journal surfaces.

b.  Place upper crankcase half upside-down on a bench. Install bearing inserts into top crankcase.

c.   Install crankshaft into upper crankcase.

d.  Place Plastigage on crankshaft journal surface to be inspected.

NOTE:

Do not move crankshaft until clearance check has been completed.

e.   Install bearings into bottom crankcase. Carefully, place lower crankcase onto upper crankcase.

The crankshaft main bearing which has no groove on the bearing surface should be installed in the upper crankcase.

f.   Install crankcase holding bolts 1 through 10. Tighten to full torque in torque sequence cast on crankcase.

Crankcase torque (8 mm bolt): 2.4 m-kg (17 ft-lb)

 

g.   Remove bolts in reverse assembly order (10,9,8... etc.)

h. Carefully remove lower crankcase. Measure width of Plastigage on crankshaft journals to determine clearance.

Main bearing oil clearance: 0.020 - 0.044 mm (0.0008-0.0017 in)

1. Plastigage

4. Crankshaft main bearing selection a. Numbers used to indicate crankshaft journal sizes are stamped on the L.H. crank web. The first five (5) are main bearing journal numbers, starting with the left journal. The four (4) rod bearing journal numbers follow in the same sequence.

 

For greater clarity:

The upper crankcase half is numbered 4, 5, or 6 as shown.

1. Main bearing numbers

 

b. The connecting rods are numbered 3 or 4. The numbers for rods are stamped with ink on the rod itself.

1. Connecting rod size number

c. The proper bearing selection is made by subtracting the crankshaft journal number from the crankcase or rod size number. Use the color code to choose the proper bearing.

EXAMPLE:

Rod No. (Minus) Journal No. = Bearing No. 5-2 = 3 No. 3 bearing is Brown. Use Brown bearing inserts.

BEARING COLOR CODE
No. 1	Blue
No. 2	Black
No. 3	Brown
No. 4	Green
*No. 5	Yello

^#For crankshaft main bearing only.

d.  When assembling, apply a liberal coat of motor oil to all bearing surfaces.

NOTE:

When applying final torque to the rod caps, observe the following procedures:

e.  Be sure the letter on both components align to form a perfect character:

f.  Apply molybdenum disulfide grease to connecting rod bolt threads. Apply torque evenly to both ends of the cap. While tightening, if a torque of 2.0 m-kg (14.5 ft-lb) or more is reached, DO NOT STOP tightening until final torque is reached. If tightening is interrupted between 2.0 m-kg and 2.5 m-kg, loosen the nut to less than 2.0 m-kg and start again. Tighten to full torque specification (25 m-kg, 18 ft-lb) without pausing.

 

J. Oil Pump

1. Check the clearance between housing and outer rotor.
Standard clearance B : 0.03 ~ 0.08 mm (0.0012 ~ 0.0031 in)

2. Check the clearance between outer rotor and inner rotor.
Standard clearance: 0.03 - 0.09 mm (0.001 - 0.003 in)

3 Check the rotor to housing clearance using a straight-edge.
Standard clearance: 0.03 - 0.08 mm (0.001 - 0.003 in)

 

4. Check the plunger for scratches and wear.

1. Relief valve plunger

K. Clutch

1. Clutch housing

a. Check the dogs on the clutch housing. Look for cracks and signs of galling on edges. If damage is moderate, deburr. If severe, replace the clutch housing.

NOTE:

Galling on the friction plate dogs of the clutch housing will cause erratic clutch operation. These can be dressed with a flat file using the indentations as a guide for depth.

b. Check the clutch housing bearing for damage. If damaged replace bearing.

2. Clutch boss

a.   The clutch boss contains a built-in damper beneath the first clutch plate (clutch plate 2). It is not normally necessary to remove the circlip and disassemble the built-in damper unless there is serious clutch chattering.

b.   Check splines on clutch boss for galling. If damage is slight to moderate, deburr; if it is severe, replace clutch boss.

NOTE:

Galling on clutch plate splines will cause erratic operation.

3. Friction and clutch plates

Check clutch steel plates and friction plates for heat damage. Measure friction plate thickness at 3 or 4 points. Measure clutch plates for warpage with a dial gauge and stand. Replace clutch plate or friction plates as a set if any is faulty or beyond wear limits.

	Standard	Wear limit
Friction plate thickness	3.0 mm (0.12 in)	2.8 mm (0.11 in)
Clutch plate warp limit	—	0.05 mm (0.0020 in)

1. Feeler gauge

4. Clutch actuating mechanism

1. Plate washer    2. Thrust bearing    3. Pull rod

a.   Check the pull rod rack gear teeth for wear and damage, replace if damaged.

b.  Check the pull rod thrust bearing for damage, replace if damaged.

c.   Check the clutch lever shaft pinion gear teeth for damage, replace if damaged.

5. Clutch springs

Measure the clutch spring free length. Replace the springs as a set if any is less than minimum free length.

Clutch spring minimum length: 50.1 mm (1.969 in)

L. Transmission

1. Inspect each shift fork for signs of galling on gear contact surfaces. Check for bending. Make sure each fork slides freely on its guide bar.

2.    Roll the guide bar across a surface place. If the bar is bent, replace.

3.    Check the shift cam grooves for signs of wear or damage. If any profile has excessive wear and/or damage, replace cam.

4. Check the cam followers on each shift fork for wear. Check the ends that ride in the grooves in the shift cam. If they are worn or damaged, replace the shift forks.

5.    Check shift cam dowel pins and side plate for looseness, damage or wear. Replace as required.

6.    Check the shift cam stopper plate and circlip and stopper for wear. Replace as required.

7.   Check the transmission shafts using a centering device and dial gauge. If any shaft is bent beyond specified limit, replace shaft.

Maximum run-out: 0.08 mm (0.0031 in)

8.    Carefully inspect each gear. Look for signs of obvious heat damage (blue discoloration). Check the gear teeth for signs of pitting, galling or other extreme wear. Replace as required.

9.    Check to see that each gear moves freely on its shaft.

10.    Check to see that all washers and clips are properly installed and undamaged. Replace bent or loose clips and bent washers.

11.    Check to see that each gear properly engages its counterpart on the shaft. Check the mating dogs for rounded edges, cracks, or missing portions. Replace as required.

M. Starter Drivers

1. Electric starter clutch and gears

a.   Check the surface of the idle gear for pitting or other damage. If severe, replace the gear.

b.   Check the spring caps and the springs for deformation or damage. If severe, replace as necessary.

c.   Check the starter clutch bolts (alien screw) for looseness. If loose, remove the bolts and replace with new bolts. Apply a thread locking compound such as "LOCTITE" to threads and tighten to specified torque. Stake over the end of the bolts.

Starter clutch bolt torque: 3.0 m-kg (21.7 ft-lb)

d.  Check the "HY-VO" chain for damage and wear, replace if damaged.

e.   Check the "HY-VO" chainguide for damage, replace if damaged.

N. Crankcases and Strainer Cover

1. Check crankcase for cracks or other damage.

2.    Clean all oil passages and blow out with compressed air.

3.    Strainer cover: Apply a thread locking compound such as "LOCTITE" to strainer cover bolts during reassembly.

O. Bearing and Oil Seals

1. After cleaning and lubricating bearings, rotate inner race with a finger. If rough spots are felt, replace the bearing.

NOTE:

Bearings are most easily removed or installed if the housings are first heated to approximately 95°~12E?C (200°~250°F). Bring the case up to proper temperature slowly. Use an oven to avoid distortion.

2.    Check oil seal lips for damage and wear. Replace as required.

P. 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.

1. Damper compressor

b.   Press the damper spring and remove the spring retainers.

c.   Remove the spring seat, spring, and damper cams from the drive shaft.

2. Inspection

a. Inspect the damper cam surfaces. Check for smooth cam action and excessive wear on the cam surface. If cam surface is severely worn, replace damper assembly.

b.   Inspect the damper spring for fatigue, wear and damage. Replace as necessary.

c.   Check bearing movement for damage to balls, rouge spots, bearing looseness. Inspect gear teeth. If any gear tooth and/or bearing are damaged, the gear set and/or bearing must be replaced.

3. Middle drive/driven shaft bearing removal

CAUTION:

The following procedures should be performed only if the bearing or gear is to be replaced.

a. Middle drive gear

1) Bend down the locking collar of the nut with a suitable center punch.

2) Support the middle drive shaft holder (special tool) in a vise securely and put the drive pinion on it as shown. Remove the bearing holding nut with the 46 mm socket (special socket) and remove the bearing.

1. Middle drive shaft nut wrench (46 mm socket)
2. Middle drive shaft holder

b. Middle driven gear

1) Support the drive flange in a vise securely. Remove the flange holding nut.

CAUTION:

This holding nut has been locked with a thread locking compound, when reinstalling do not forget to apply a thread locking compound such as "LOCTITE" and punch.

2) Remove the drive flange from the driven shaft.

NOTE:

Driven gear shaft bearing should be replaced together with a bearing housing.

4. Middle gear reassembly

a. Middle drive gear bearing and damper

1) Install the bearing onto the drive pinion and secure it with a new lock nut using the middle drive shaft  holder and special socket.

Tightening torque: 11 m-kg (80 ft-lb)

2) Stake the locking collar of the nut to the slot on the drive pinion shaft.

3) Install the driven damper cam onto the drive pinion shaft with the cam lobes positioned 90° from the row of shaft oil holes. Positioning tolerance is ± 1 spline (15°) from the 90° position.

1. Oil hole

4) Install the drive damper cams, spring, spring seat, and retainers using a press and the damper compressor.

b. Middle driven gear

1) Install the new bearing housing assembly onto the driven pinion shaft.

CAUTION:

Do not press the bearing outer race. Always press the inner race with care when installing.

2) Install the drive flange and new "O-ring" onto the driven gear shaft. Apply a thread locking compound such as "LOCTITE" to the shaft threads and tighten the nut to the specified torque.

Tightening torque: 12 m-kg (87 ft-lb)

3) Stake the nut with a center punch to lock as shown.

4) Install the new "O-ring" onto the bearing housing.

ENGINE ASSEMBLY AND ADJUSTMENT

A. Important Information

1.    Gasket and seal

All gaskets and seals should be replaced when an engine is overhauled. All gasket surfaces and oil seal lips must be cleaned.

2.    Properly oil all mating engine and transmission parts and bearings during reassembly.

3.    Circlip

All circlips should be inspected carefully before reassembly. Always replace piston pin clips after one use. Replace distorted circlips.

When installing a circlip, make sure that the sharp edged corner is positioned opposit to the thrust it receives. See the sectional view below.

4. Lock washer/plate and cotter pin

All lock washers/plates and cotter pins must be replaced when they are removed. Lock washer/plate tab(s) should be bent over along the bolt or nut flat(s) after tightening the bolt or nut properly (see illustration).

Cotter pins should be replaced after one use.

B. Engine Assembly

1. Upper crankcase

a. Install the connecting rods onto the crankshaft with the proper connecting rod bearings. Apply oil to bearings and molybedenum disulfide grease to the bolt threads. Apply torque evenly to both ends of the cap.

CAUTION:

While tightening, if a torque of 2.0 m-kg (14.5 ft-lb) or more is reached, DO NOT STOP tightening until final torque is reached.

If tightening is interrupted between 2.0 m-kg and 2.5 m-kg, loosen the nut to less than 2.0 m-kg and start again. Tighten to full torque specification without pausing.

Rod cap torque: 2.5 m-kg (18.1 ft-lb)

b- Install the proper cankshaft main bearings into the crankcase and place the crankshaft. Oil the bearings liberaly.

NOTE:

Do not forget to install the crankshaft oil seal (L.H.), blind plug (R.H.), "HY-VO" chain and cam chain on the crankshaft before installing. Also, install the chain guide into upper crankcase if removed.

c. Install the starter idle gear, shaft, stopper plate, and new lock plate. Tighten the bolt securely and bend the lock tabs along the bolt flats.

1. Lock washer

Tightening torque: 1.0 m-kg (7.2 ft-lb)

d.  Put the starter clutch and sprocket assembly in the "HY-VO" chain and lay it into the crankcase.

e.   Install the A.C.G. Generator shaft into the starter clutch assembly.

f. Install the "HY-VO" chain oil spray nozzle. The locating pin on the nozzle should be placed into the crankcase locating slot. Do not forget to install the new "O-ring" onto the nozzle.

1. O-ring

g. Install the new "O-ring" onto the bearing housing and install it with the panhead screw. Torque to 1.0 m-kg (7.2 ft-lb).

h. Install the transmission main axle assembly on the upper crankcase. Point the bearing locating pin toward the crankshaft and lav it on the case.

1. Bearing locating pin

i. Install the middle driven gear (without the middle drive pinion gear).

j. Install the middle driven gear shaft end bearing.

k. Install the dowel pin with "O-ring" into the crankcase.

1 a.   Install the shift cam and secure it with the guide pin. Install the stopper plate and bolt and tighten securely.

b.   Install the neutral switch. Torque to 2.0 m-kg (14 ft-lb).

c. Install the transmission drive axle assembly into the crankcase.

d. Install the 5th wheel gear and bearing onto the drive axle. Install the bearing cover. Be sure the "O-ring" is on the cover.

1. O-ring

e. Install the shift forks and guide bar. Each shift fork is identified by a number cast on its side. All the numbers should face the left side and numbered 1, 2, and 3 from left.

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. Do not allow sealant to come in contact with the oil galley O-ring or crankshaft bearings.

CAUTION:

Failure to apply sealant here will result in reduced oil pressure and possible crank seizure.

a. 2~3 mm (0.08~0.12 in) Do not apply sealant.

b. The crankcases are assembled by placing the upper case half on the bench and lowering the lower case onto it.

NOTE:

Be sure that shift fork No. 2 engages the groove in the 2nd pinion gear on the main axle.

CAUTION:

Before installing and torquing the crankcase bolts, check to make sure the transmission is functioning properly by shifting it by hand with the shift cam.

c.   Start installation of the crankcase bolts with the center crankshaft area bolts. Place the two bolts without washers in the oil filter area.

d.  The crankcase bolts should be torqued in proper sequence. Refer to the tightening sequence in the illustration.

LOWERCASE

UPPERCASE

1. Engine ground wire 2. Battery ground wire

4. Oil pump and strainer cover

a.   Place the oil pump drive chain on the transmission main axle.

b.   Place the drive chain on the oil pump driven sprocket and install the pump on the crankcase. The "O-ring" should be installed properly.

c. Install the drive chain cover on the oil pump and secure with the 2 shouldered bolts and one normal 6 mm bolt.

Tightening torque: 1.2 m-kg(8.7 ft-lb)

d. Install the strainer cover and torque the bolts to 1.2 m-kg(8.7 ft-lb)

 

e. Install oil pan (with wire clamps) and torque bolts to 1.2 m-kg(8.7 ft-lb)

1. Wire clamps

 Clutch assembly

a. Install the thrust plate onto the transmission main axle.

1. Thrust plate

b. Install the oil pump drive sprocket onto the main axle without the spacer collar and place the oil pump drive chain on its sprocket.

1. Oil pump drive sprocket

c. Insert the spacer collar into the oil pump drive sprocket.

1. Spacer collar

 

(1)Bearing  (2)Collar  (3)Thrust plate (4)Clutch boss  (5)Lock washer  (6)Nut

d. Install the primary driven gear (clutch housing) without the bearing and inner spacer.

CAUTION:
Be sure that the oil pump drive gear tabs engage the clutch housing grooves on it's back or the tabs will be damaged when tightening the clutch boss securing nut.

 

e. Installing the primary driven gear bearing and inner spacer into the clutch housing.

1. Driven gear bearing 2. Inner spacer

f. Install the large thrust plate and clutch boss onto the main axle.

g. Install a new lock washer and nut and tighten the nut to the specified torque. Use the clutch boss holder (special tool).

1. Clutch boss holder

Tightening torque: 7.0 m-kg (50 ft-lb)

h. Bend the lock washer tabs along the nut flats.

1. Lock tab

i. Install the clutch plates without V-cut in tab and friction plates alternately on the clutch boss, starting with a friction plate and ending with clutch plate. Install friction plate wth V-cut (1) last.

NOTE:
Install the friction plate so that the V-cut tab is in the identified dog that was marked during disassembly. If you forgot to identify the position with a mark, measure the width of each dog. The narrow dog is 13.8 mm (0.543 in). All others are 14 mm (0.551 in)

 

 

j. Install the plate washer, thrust bearing, and clutch pull rod into the clutch pressure plate from inside.

1. Pull rod   2. Thrust bearing   3. Plate washer

k. Install the pressure plate assembly onto the clutch boss.

NOTE:
Pressure plate has a dot on it which must line up with the dot on clutch boss.

I. Install the clutch springs and screws. Tighten the screws.

Clutch screw torque: 0.8 m-kg (5.8 ft-lb)

m. Set the gear of the clutch pull rod on the pressure plate facing approximately 45° from horizontal toward the rear; set the clutch lever (if installed) on the right crankcase cover parallel to the gasket surface and install the cover to the crankcase. Do not forget to install two dowel pins.

n. If the clutch lever has been removed, install the lever return spring and lever on the shaft after installing the right crankcase cover. In this case make sure that the punch mark on the lever should align with the mark on the crankcase cover when pushing the lever towards the front by hand and then install the circlip.