Crankcase Assembly

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 gallerly "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.

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

1. 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.

e. Install the right-front crankcase cover. 4. Oil pump and strainer cover a. Install the relief valve, strainer housing and strainer screen.

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

b. Install the strainer cover and torque the bolts to the specification.

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

1. Wire clamps

c. Install the shift lever assembly with the positioning spring is properly located on the stopper pin.

d. Install the oil pump assembly and oil pump securing screws.

e. Install the oil pump driven sprocket.