Engine removal Removing the drive sprocket Order Job/Parts to remove Quantity Remarks 1 Locknut 2 2 Shift rod 1 3 Shift arm 1 4 Drive sprocket cover 1 5 Drive sprocket nut 1 6 Lock washer 1 7 Drive sprocket 1 8 Plate 1 For installation, reverse the removal...
Installing the engine 1. Install: Right front engine mounting bolt 2 «1». Refer to « Cylinder head ». 2. Tighten: Right front engine mounting bolt 2 Right front engine mounting bolt 2: 50 Nm (5.0 m·kg, 36 ft·lb). 3. Install: Engine mounting adjust bolts (temporarily...
Removing the camshafts Removing the cylinder head cover Order Job/Parts to remove Quantity Remarks Fuel tank Refer to « Fuel tank ». Throttle body assembly Refer to « Throttle bodies ». Radiator assembly Refer to « Radiator ». Air cut-off valve Refer to « Air induction...
Checking the camshafts 1. Check: Camshaft lobes Blue discoloration/pitting/scratches → Replace the camshaft. 2. Measure: Camshaft lobe dimensions «a» and «b». Out of specification → Replace the camshaft. Camshaft lobe dimension limit: Intake camshaft «a»: 32.50–32.60 mm...
Checking the timing chain and camshaft sprocket 1. Check: Timing chain «1» Damage/stiffness → Replace the timing chain and camshaft and camshaft sprocket as a set. 2. Check: Camshaft sprocket More than 1/4 tooth wear «a» → Replace the camshaft sprockets and the timing chain as a set. a. 1/4...
Cheking the timing chain guides The following procedure applies to all of the camshaft sprockets and timing chain guides. 1. Check: Timing chain guide (exhaust side) «1» Timing chain guide (intake side) «2» Timing chain guide (top side) «3» Damage/wear → Replace the defective...
Cheking the timing chain tensioner 1. Remove: Timing chain tensioner housing «1» Timing chain tensioner rod «2» Timing chain tensioner spring «3» Note: Squeeze the timing chain tensioner clip, and then remove the timing chain tensioner spring and timing chain tensioner rod. 2. Check:...
Installing the camshafts 1. Align: «T» mark «a» on the pickup rotor (with the crankcase mating surface «b») a. Turn the crankshaft clockwise. b. When position #1 is at TDC, align the «T» mark «a» with the crankcase mating surface «b». 2. Install: Intake camshaft sprocket...
Removing the cylinder head Order Job/Parts to remove Quantity Remarks Engine Refer to « Engine removal ». Intake camshaft Refer to « Camshafts ». Exhaust camshaft Refer to « Camshafts ». 1 Cylinder head 1 2 Cylinder head gasket 1 3 Dowel pin 2 4 Coolant pipe 1 5 O-ring 1 6...
Checking the cylinder head 1. Eliminate: Combustion chamber carbon deposits (with a rounded scraper) Note: Do not use a sharp instrument to avoid damaging or scratching: Spark plug bore threads Valve seats 2. Check: Cylinder head. Damage/scratches → Replace. Cylinder head...
Installing the cylinder head 1. Check: Cylinder head bolts «1» Cylinder head bolt: 8 Nm (0.8 m·kg, 5.8 ft·lb) Note: Retighten the cylinder head bolts to specification, before installing the cylinder head. 2. Install: Gasket «1» Dowel pins 3. Install: Cylinder head 4. Tighten:...
Removing the valves and valve springs Order Job/Parts to remove Quantity Remarks Cylinder head Refer to « Cylinder head ». 1 Intake valve lifter 12 2 Intake valve pad 12 3 Intake valve cotter 24 4 Intake valve upper spring seat 12 5 Intake valve spring 12 6 Intake valve stem seal 12 7...
Checking the valves and valve guides The following procedure applies to all of the valves and valve guides. 1. Measure: Valve-stem-to-valve-guide clearance. Out of specification → Replace the valve guide. Valve-stem-to-valve-guide clearance = Valve guide inside diameter «a» - Valve...
Checking the valve seats The following procedure applies to all of the valves and valve seats. 1. Eliminate: Carbon deposits (from the valve face and valve seat) 2. Check: Valve seat Pitting/wear → Replace the cylinder head. 3. Measure: Valve seat width «a» Out of...
Checking the valve springs The following procedure applies to all of the valve springs. 1. Measure: Valve spring free length «a» Out of specification → Replace the valve spring. Valve spring free length: Intake valve spring: 40.5 mm (1.60 in) Limit: 38.5 mm (1.47 in) Exhaust...
Checking the valve lifters The following procedure applies to all of the valve lifters. 1. Check: Valve lifter Damage/scratches → Replace the valve lifters and cylinder head.
Installing the valves The following procedure applies to all of the valves and related components. 1. Deburr: Valve stem end (with an oil stone) 2. Lubricate: Valve stem «1» Valve stem seal «2» (with the recommended lubricant) Recommended lubricant: Molybdenum disulfide...
Removing the crankshaft position sensor Order Job/Parts to remove Quantity Remarks Rider and passenger seat Refer to « General chassis ». Fuel tank Refer to « Fuel tank ». Engine oil Drain. Refer to « Changing the engine oil ». 1 Crankshaft position sensor lead coupler 1 Disconnect. 2...
Installing the crankshaft position 1. Install: Gasket Pickup rotor cover «1» Pickup rotor cover: 12 Nm (1.2 m·kg, 8.7 ft·lb). O-ring Crankshaft position sensor Crankshaft position sensor bolt: 10 Nm (1.0 m·kg, 7.2 ft·lb). 2. Connect: Crankshaft position sensor lead coupler
Separating the crankcase Order Job/Parts to remove Quantity Remarks Air filter case Refer to « General chassis ». Throttle body assembly Refer to « Throttle bodies ». Engine Refer to « Engine removal ». Cylinder head Refer to « Cylinder head ». Generator Refer to «...
Disassembling the crankcase 1. Place the engine upside down. 2. Remove: Crankcase bolts Notes: Loosen each bolt 1/4 of a turn at a time, in stages and in a crisscross pattern. After all of the bolts are fully loosened, remove them. Loosen the bolts in decreasing numerical...
Checking the crankcase 1. Thoroughly wash the crankcase halves in a mild solvent. 2. Thoroughly clean all the gasket surfaces and crankcase mating surfaces. 3. Check: Crankcase. Cracks/damage → Replace. Oil delivery passages. Obstruction → Blow out with compressed air.
Checking the bearing and oil seals 1. Check: Bearings. Clean and lubricate the bearings, then rotate the inner race with your finger. Rough movement → Replace. 2. Check: Oil seals. Damage/wear → Replace.
Assembling the crankcase 1. Lubricate: Crankshaft journal bearings (with the recommended lubricant) Recommended lubricant: Engine oil. 2. Apply: Sealant Yamaha bond No. 1215 (Three Bond No.1215®): 90890-85505. Note: Do not allow any sealant to come into contact with the oil...
Removing the connecting rods and pistons Order Job/Parts to remove Quantity Remarks Lower crankcase Refer to « Crankcase ». 1 Connecting rod cap 4 2 Big end lower bearing 4 3 Big end upper bearing 4 4 Piston pin clip 8 5 Piston pin 4 6 Piston 4 7 Connecting rod 4 8 Top ring 4 9 2nd ring 4...
Removing the crankshaft assembly Order Job/Parts to remove Quantity Remarks Crankcase Separate. Refer to « Crankcase ». Connecting rod and connecting rod caps Refer to « Removing the connecting rods and pistons ». 1 Crankshaft 1 2 Crankshaft journal lower bearing 5 3 Crankshaft...
Checking the cylinder and piston 1. Check: Piston wall Cylinder wall Vertical scratches → Replace the cylinder, and the piston and piston rings as a set. 2. Measure: Piston-to-cylinder clearance a. Measure cylinder bore «C» with the cylinder bore gauge. Note: Measure cylinder bore...
Checking the piston rings 1. Measure: Piston ring side clearance Out of specification → Replace the piston and piston rings as a set. Note: Before measuring the piston ring side clearance, eliminate any carbon deposits from the piston ring grooves and piston rings. Piston...
Checking the piston pins The following procedure applies to all of the piston pins. 1. Check: Piston pin Blue discoloration/grooves → Replace the piston pin and then check the lubrication system. 2. Measure: Piston pin outside diameter «a». Out of specification → Replace...
Checking crankshaft big end bearings 1. Measure: Crankshaft-pin-to-big-end-bearing clearance Out of specification → Replace the big end bearings. Crankshaft-pin-to-big-end-bearing clearance: 0.034-0.058 mm (0.0013-0.0023 in) Limit: 0.09 mm (0.0035 in) The following procedure applies to...
Installing the connecting rod and piston The following procedure applies to all of the connecting rods and pistons. 1. Install: Top ring «1» 2nd ring «2» Upper oil ring rail «3» Oil ring expander «4» Lower oil ring rail «5» Note: Be sure to install the piston rings so that the...
Checking the crankshaft 1. Measure: Crankshaft runout Out of specification → Replace the crankshaft. Crankshaft runout: Less than 0.03 mm (0.0012 in). 2. Check: Crankshaft journal surfaces Crankshaft pin surfaces Bearing surfaces Scratches/wear → Replace the crankshaft.