Page 285 of 457
5-63
Order Job / Part Q’ty Remarks
1
2
3
4
5
6
7
8Removing the oil pan and oil pump
Side cowlings
Bottom cowlings
Engine oil
Exhaust pipe and exhaust valve pipe
Clutch assembly
Water pump inlet pipe
Water pump outlet pipe
Oil level switch lead coupler
Oil level switch
Oil level switch lead holder
Oil pan
Oil pan gasket
Dowel pin
Drain pipe
Oil strainer1
1
1
1
1
2
1
1Remove the parts in the order listed.
Drain.
Refer to “CHANGING THE ENGINE OIL”
in chapter 3.
Refer to “EXHAUST PIPE”.
Refer to “CLUTCH”.
Refer to “OIL COOLER” in chapter 6.
Disconnect.
Refer to “COWLINGS” in chapter 3.
10 Nm (1.0 mkg, 7.2 ftlb)
10 Nm (1.0 mkg, 7.2 ftlb)
10 Nm (1.0 mkg, 7.2 ftlb)10 Nm (1.0 mkg, 7.2 ftlb)
12 Nm (1.2 mkg, 8.7 ftlb)43 Nm (4.3 mkg, 31 ftlb)
12 Nm (1.2 mkg, 8.7 ftlb)
OIL PAN AND OIL PUMPENG
EAS00356
OIL PAN AND OIL PUMP
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5-68
OIL PAN AND OIL PUMPENG
EAS00367
CHECKING THE OIL DELIVERY PIPE AND
OIL PIPE
1. Check:
oil delivery pipe
1
oil pipe 2
Damage Replace.
Obstruction Wash and blow out with com-
pressed air.
EAS00368
CHECKING THE OIL STRAINER
1. Check:
oil strainer
1
Damage Replace.
Contaminants Clean with solvent.
EAS00373
CHECKING THE OIL NOZZLES
The following procedure applies to all of the oil
nozzles.
1. Check:
oil nozzle
1
Damage / wear Replace the oil nozzle.
O-ring
2
Damage / wear Replace.
oil nozzle passage
Obstruction Blow out with compressed air.
EAS00374
ASSEMBLING THE OIL PUMP
1. Lubricate:
inner rotor
outer rotor
oil pump shaft
(with the recommended lubricant)
Recommended lubricant
Engine oil
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5-71
OIL PAN AND OIL PUMPENG
12 Nm (1.2 mkg, 8.7 ftlb)
10 Nm (1.0 mkg, 7.2 ftlb)
43Nm (4.3 mkg, 31 ftlb)
WARNING
NOTE:
EAS00380
INSTALLING THE OIL PAN
1. Install:
dowel pins
gasket
New
oil pan
1
oil level switch 2
engine oil drain bolt 3
Always use new copper washers.
Tighten the oil pan bolts in stages and in a
crisscross pattern.
Lubricate the oil level switch O-ring with en-
gine oil.
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Page 294 of 457
5-72
Order Job / Part Q’ty Remarks
Removing the crankcase
Air filter case
Throttle body assembly
Engine
Cylinder head
Starter clutch and generator
Shift shaft
Crankshaft position sensor
Clutch
Oil pan and oil pump
Starter motorRemove the parts in the order listed.
Refer to “AIR FILTER CASE” in chapter 3.
Refer to “THROTTLE BODIES” in
chapter 7.
Refer to “ENGINE”.
Refer to “CYLINDER HEAD”.
Refer to “STARTER CLUTCH AND
GENERATOR”.
Refer to “SHIFT SHAFT”.
Refer to “CRANKSHAFT POSITION
SENSOR”.
Refer to “CLUTCH”.
Refer to “OIL PAN AND OIL PUMP”.
Refer to “STARTING SYSTEM” in
chapter 8.
12 Nm (1.2 mkg, 8.7 ftlb)12 Nm (1.2 mkg, 8.7 ftlb)
24 Nm (2.4 mkg, 17 ftlb)
10 Nm (1.0 mkg, 7.2 ftlb)
24 Nm (2.4 mkg, 17 ftlb)
12 Nm (1.2 mkg, 8.7 ftlb)
20 Nm (2.0 mkg, 14 ftlb) +60
CRANKCASEENG
CRANKCASE
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Page 296 of 457
5-74
CRANKCASEENG
NOTE:
CAUTION:
NOTE:
EAS00384
DISASSEMBLING THE CRANKCASE
1. Place the engine upside down.
2. Remove:
crankcase bolts
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 or-
der (refer to the numbers in the illustration).
The numbers embossed on the crankcase in-
dicate the crankcase tightening sequence.
M9 105 mm (4.1 in) bolts:
1 10
M8 60 mm (2.4 in) bolt: 11 LOCTITE
M8 60 mm (2.4 in) bolts: 12, 16
M6 70 mm (2.8 in) bolts: 19, 21, 23
M6 65 mm (2.5 in) bolts: 17, 18
M6 60 mm (2.4 in) bolts: 22, 24, 25
M6 50 mm (2.0 in) bolts: 20, 26
M8 50 mm (2.0 in) bolts: 13 15
3. Remove:
lower crankcase
Tap on one side of the crankcase with a soft-
face hammer. Tap only on reinforced por-
tions of the crankcase, not on the crankcase
mating surfaces. Work slowly and carefully
and make sure the crankcase halves sepa-
rate evenly.
4. Remove:
dowel pins
5. Remove:
crankshaft journal lower bearing
(from the lower crankcase)
Identify the position of each crankshaft journal
lower bearing so that it can be reinstalled in its
original place.
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CRANKCASEENG
NOTE:
EAS00399
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.
EAS00401
CHECKING THE BEARINGS 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
90890-85505, ACC-1109-05-01
Do not allow any sealant to come into contact
with the oil gallery or crankshaft journal bear-
ings. Do not apply sealant to within 2 3 mm
(0.08 0.12 in) of the crankshaft journal bear-
ings.
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CRANKCASEENG
CAUTION:
NOTE:
3. Install:
dowel pin
4. Set the shift drum assembly and transmis-
sion gears in the neutral position.
5. Install:
lower crankcase
1
(onto the upper crankcase 2)
Before tightening the crankcase bolts, make
sure that the transmission gears shift cor-
rectly when the shift drum assembly is
turned by hand.
6. Install:
crankcase bolts
Lubricate the bolt threads with engine oil.
Install a washer on bolts
1 10 and 22.
Seal bolt
18
Tighten the bolts in the tightening sequence
cast on the crankcase.
M9 105 mm (4.1 in) bolts:
1 10
M8 60 mm (2.4 in) bolt: 11 LOCTITE
M8 60 mm (2.4 in) bolts: 12, 16
M6 70 mm (2.8 in) bolts: 19, 21, 23
M6 65 mm (2.5 in) bolts: 17, 18
M6 60 mm (2.4 in) bolts: 22, 24, 25
M6 50 mm (2.0 in) bolts: 20, 26
M8 50 mm (2.0 in) bolts: 13 15
Crankcase bolt
Bolt
1 10
1st: 20 Nm (2.0 mkg, 14 ftlb)
2nd*: 20 Nm (2.0 mkg, 14 ftlb)
3rd: +60
Bolt
11 16
24 Nm (2.4 mkg, 17 ftlb)
Bolt
17 26
12 Nm (1.2 mkg, 8.7 ftlb)
* Following the tightening order, loosen the bolt
one by one and then retighten it to the specific
torque.
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5-83
CAUTION:
CONNECTING RODS AND PISTONSENG
NOTE:
NOTE:
Do not interchange the big end bearings and
connecting rods. To obtain the correct
crankshaft-pin-to-big-end-bearing clear-
ance and prevent engine damage, the big
end bearings must be installed in their origi-
nal positions.
a. Clean the big end bearings, crankshaft pins,
and the inside of the connecting rods halves.
b. Install the big end upper bearing into the con-
necting rod and the big end lower bearing
into the connecting rod cap.
Align the projections
a on the big end bearings
with the notches
b in the connecting rod and
connecting rod cap.
c. Put a piece of Plastigauge
1 on the crank-
shaft pin.
d. Assemble the connecting rod halves.
Do not move the connecting rod or crankshaft
until the clearance measurement has been
completed.
Lubricate the bolt threads with molybdenum
disulfide grease.
Make sure that the “Y” mark
c on the connect-
ing rod faces towards the left side of the crank-
shaft.
Make sure that the characters
d on both the
connecting rod and connecting rod cap are
aligned.
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