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Installing the crankshaft main




JOURNAL BEARINGS

 

У Attach:

 

crankshaft main journal bearings

 

NOTE:

Attach the crankshaft main journal bearing to the plane bearing installer 1.

 

Plane bearing installer 90890-04139

 

Ф Install:

 

crankshaft main journal bearings 2

 

NOTE:

14 Align the projection a on the bearing with the projection b on the crankcase.

 

15 Place an iron 3 plate beneath the crankcase and press fit until the end of the plain bearing installer touches the iron plate.

 

INSTALLING THE CONNECTING RODS

 

И Install:

 

big end bearings 1

NOTE:

Й Align the projection a of the big end bear-ings with the notches b in the connecting rod cap.

 

Й Install each big end bearing in its original place.

К Install:

 

connecting rods

NOTE:

Л The stamped “Y” mark a on the connecting rods should face towards the left side of the crankcase.

 

Л Install each connecting rod in its original place.


 

 

5 - 80


CRANKCASE AND CRANKSHAFT ENG

 

М Install:

 

connecting rod cap

NOTE:

Be sure that the characters a on the side of the cap and connecting rod are aligned.

П Tighten:

 

nuts (connecting rod cap)


 

T.

R.


 

16 Nm (1.6 m · kg, 11 ft · lb) + 90°


 

NOTE:

Apply molybdenum disulfide grease to the rod cap bolt threads and nut surfaces.

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Р Replace the connecting rod bolts and nuts with new ones.

 

CAUTION:

Tighten the connecting rod bolts using the plastic-region tightening angle method. Always install new bolts and nuts.

С Clean the connecting rod bolts and nuts.

 

С Tighten the connecting rod nuts with speci-fied torque.

 

С Put a mark 1 on the corner of the connect-ing rod nut 2 and the connecting rod 3.

 

С Tighten the nut further to reach the speci-fied angle (90°).

WARNING

When the nut is tightened more than the specified angle, do not loosen the nut and then retighten it.

Replace the bolt with a new one and per-form the procedure again.

CAUTION:

Т Do not use a torque wrench to tighten the nut to the specified angle.

Т Tighten the nut until it is at the specified angles.

NOTE:

When using a hexagonal nut, note that the angle from one corner to another is 60°.

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5 - 81


CRANKCASE AND CRANKSHAFT ENG

 

У Install:

 

balancer connecting rod

 

connecting rod cap


 

T.

R.


60 Nm (6.0 m · kg, 43 ft · lb)


 

CAUTION:

Х When tightening the nuts be sure to use an F-type torque wrench.

Х Without pausing, tighten to full torque specification. Apply continuous torque 57 ~ 63 Nm (5.7 ~ 6.3 m · kg, 41 ~ 45 ft · lb). Once you reach 57 Nm (5.7 m · kg, 41 ft · lb) DO NOT STOP TIGHTENING until final torque is reached. If the tightening is inter-rupted 57 ~ 63 Nm (5.7 ~ 6.3 m · kg, 41 ~ 45 ft · lb) loosen the nut to less than 57 Nm (5.7 m · kg, 41 ft · lb) and start again.

 

 

INSTALLING THE CRANKSHAFT

П Install:

 

crankshaft assembly 1

 

balancer piston cylinder 2


 

T.

R.


58 Nm (5.8 m · kg, 42 ft · lb)


 

CAUTION:

To avoid scratching the crankshaft and to ease the installation procedure, apply grease onto the oil seal lips and apply engine oil onto each bearing.

 

 

EAS00418

ASSEMBLING THE CRANKCASE

 

Р Thoroughly clean all the gasket mating sur-faces and crankcase mating surfaces.


 

5 - 82


CRANKCASE AND CRANKSHAFT ENG

 

2. Apply:

• sealant

 

(onto the crankcase mating surfaces)

Yamaha bond No. 1215 90890-85505

 

Sealant (Quick Gasket®) ACC-11001-05-01

 

NOTE:

Do not allow any sealant to come into contact with the oil gallery.

3. Install:

 

• dowel pins

 

• left crankcase


 

5 - 83


TRANSMISSION ENG

TRANSMISSION

 

Order Job/Part Q’ty Remarks
       
  Removing the transmission   Remove the parts in the order listed.
  Left crankcase   Refer to “CRANKCASE AND CRANK-
      SHAFT”.
  Secondary shaft    
  Main axle    
  Primary driven gear    
  First pinion gear    
  Washer    
  Drive axle    
  First wheel gear    
  Circlip    
  Bearing    
  Oil seal    
      For installation, reverse the removal pro-
      cedure.
       

 

 

5 - 84


TRANSMISSION ENG

REMOVING THE TRANSMISSION

 

С Remove:

 

left crankcase

 

Refer to “CRANKCASE AND CRANK-SHAFT”.

 

С Remove:

 

secondary shaft 1

 

main axle 2

 

drive axle 3

 

primary driven gear 4

 

first wheel gear 5

 

first pinion gear

 

EAS00425

CHECKING THE TRANSMISSION

У Measure:

 

main axle runout

 

(with a centering device and dial gauge) Out of specification → Replace the main axle.

Maximum main axle runout

Mm (0.0031 in)

Ц Measure:

 

drive axle runout

 

(with a centering device and dial gauge) Out of specification → Replace the drive axle.

Maximum drive axle runout

Mm (0.0031 in)

● Measure:

 

• secondary shaft runout

 

(with a centering device and dial gauge) Out of specification → Replace the second-ary shaft.

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