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Removing the A. C. Magneto rotor
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• Remove:
A.C. magneto rotor cover
NOTE:
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.
• Remove:
A.C. magneto rotor nut 1
spacer 2
NOTE:
Й While holding the A.C. magneto rotor 3 with the sheave holder 4, loosen the A.C. mag-neto rotor nut.
Й Do not allow the sheave holder to touch the projection on the A.C. magneto rotor.
Sheave holder 90890-01701, YS-01880-A
К Remove:
A.C. magneto rotor 1
(with the flywheel puller set 2)
woodruff key
NOTE:
Л Remove the A.C. magneto rotor 1 using the flywheel puller.
Л Center the flywheel puller over the A.C. mag-neto rotor. Make sure after installing the holding bolts that the clearance between the flywheel puller and the A.C. magneto rotor is the same everywhere. If necessary, one holding bolt maybe turned out slightly to adjust the flywheel puller’s position.
CAUTION:
Cover the crankshaft end with the box wrench for protection.
Flywheel puller 90890-01362, YU-33270-B
5 - 39
STARTER CLUTCH AND A.C. MAGNETO ROTOR ENG
CHECKING THE STARTER CLUTCH
П Check:
starter clutch Damage/wear → Replace.
П Check:
starter clutch idle gear
starter clutch idle gear shaft
starter clutch gear Pitting/burrs/chips/roughness/wear → Replace the defective parts.
П Check:
starter clutch operation
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Т Install the starter clutch drive gear 1 onto the starter clutch 2 and hold the starter clutch.
Т When turning the starter clutch drive gear counterclockwise Й, the starter clutch and the starter clutch drive gear should engage. If the starter clutch drive gear and starter clutch do not engage, the starter clutch is faulty and must be replaced.
Т When turning the starter clutch drive gear clockwise И, it should turn freely.
If the starter clutch drive gear does not turn freely, the starter clutch is faulty and must
be replaced.
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INSTALLING THE A.C. MAGNETO ROTOR
У Install:
woodruff key
A.C. magneto rotor 1
spacer 2
A.C. magneto rotor nut 3
NOTE:
Ф Clean the tapered portion of the crankshaft and the A.C. magneto rotor hub.
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Ф When installing the A.C. magneto rotor, make sure the woodruff key is properly seated in the key way of the crankshaft.
5 - 40
STARTER CLUTCH AND A.C. MAGNETO ROTOR ENG
2. Tighten:
• A.C. magneto rotor nut 1
T.
R.
60 Nm (6.0 m · kg, 43 ft · lb) + 120°
NOTE:
Х While holding the A.C. magneto rotor 2 with the sheave holder 3, tighten the A.C. mag-neto rotor nut.
Х Do not allow the sheave holder to touch the projection on the A.C. magneto rotor.
Sheave holder 90890-01701, YS-01880-A
CAUTION:
Ч When tightening the A.C. magneto rotor nut, be sure to use an F-type torque wrench.
Ч After tightening the A.C. magneto rotor nut, to the specified torque, turn the A.C. magneto rotor nut another + 120°.
Ш Apply:
sealant
(onto the stator coil assembly lead grom-met)
Yamaha bond No. 1215 90890-85505
Sealant (Quick Gasket®) ACC-11001-05-01
CC Install:
A.C. magneto rotor cover
T.
R.
10 Nm (1.0 m · kg, 7.2 ft · lb)
NOTE:
Tighten the A.C. magneto rotor cover bolts in stages and in a crisscross pattern.
5 - 41
OIL PUMP ENG
OIL PUMP
| Order | Job/Part | Q’ty | Remarks |
| Removing the oil pump | Removing the parts in the order listed. | ||
| Left side panel/lower side cover mould- | Refer to “COVER AND PANEL” in chap- | ||
| ing/footrest board | ter 3. | ||
| Coolant | Drain. | ||
| Refer to “CHANGING THE COOLANT” in | |||
| chapter 3. | |||
| Engine oil | Drain. | ||
| Refer to “CHANGING THE ENGINE OIL” | |||
| in chapter 3. | |||
| A.C. magneto cover/Starter clutch gear | Refer to “STARTER CLUTCH AND A.C. | ||
| MAGNETO ROTOR”. | |||
| Oil pump assembly | |||
| Oil pump drive chain | |||
| O-ring | |||
| Oil delivery pipe | |||
5 - 42
OIL PUMP ENG
| Order | Job/Part | Q’ty | Remarks |
| Oil delivery pipe | |||
| Relief valve assembly | |||
| For installation, reverse the removal pro- | |||
| cedure. | |||
5 - 43
OIL PUMP ENG
| Order | Job/Part | Q’ty | Remarks | ||
| Disassembling the oil pump | Remove the parts in the order listed. | ||||
| Oil pump housing | |||||
| Oil pump outer rotor | |||||
| Oil pump inner rotor | Refer to “ASSEMBLING THE OIL | ||||
| Pin | PUMP”. | ||||
| Dowel pin | |||||
| Oil pump housing center | |||||
| Washer | |||||
| Oil pump cover | |||||
| Oil pump driven gear | |||||
| For assembly, reverse the disassembly | |||||
| procedure. | |||||
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5 - 44
OIL PUMP ENG
CHECKING THE OIL PUMP
Й Check:
oil pump driven gear 1
oil pump housing 2
oil pump cover 3
Cracks/damage/wear → Replace the defec-tive part(s).
Й Measure:
The following procedure applies to all of the inner rotor and outer rotor.
К inner-rotor-to-outer-rotor-tip clearance a
К outer-rotor-to-oil-pump-housing clearance b
К oil-pump-housing-to-inner-and-outer-rotor
clearanace c
Out of specification → Replace the oil
pump.
1 Inner rotor
2 Outer rotor
3 Oil pump housing
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