Disassembling The Crankcase; Checking The Crankcase; Checking The Bearings And Oil Seals; Assembling The Crankcase - Yamaha 2009 Diversion XJ6S Service Manual

EAS25550

DISASSEMBLING THE CRANKCASE

1. Place the engine upside down.
2. Remove:
Crankcase bolts
G
TIP
Loosen each bolt 1/4 of a turn at a time, in stag-
G
es and in a crisscross pattern. After all of the
bolts are fully loosened, remove them.
Loosen the bolts in decreasing numerical order
G
(refer to the numbers in the illustration).
The numbers embossed on the crankcase in-
G
dicate the crankcase tightening sequence.
M8 × 85 mm (3.3 in) bolts: "1"–"7", "10"
M8 × 115 mm (4.5 in) bolts: "8", "9"
M8 × 65 mm (2.6 in) bolts: "11", "12"
M6 × 65 mm (2.6 in) bolts: "13", "14"
M6 × 55 mm (2.2 in) bolts: "15", "22"–"26"
M6 × 45 mm (1.8 in) bolts: "16", "19", "20"
M6 × 65 mm (2.6 in) bolts: "17", "27"
M6 × 75 mm (3.0 in) bolt: "18"
M6 × 100 mm (3.9 in) bolt: "21" (in upper side)
13
26 24
7 5
10 4
16
17
19
21
3. Remove:
Lower crankcase
G
ECA13900
NOTICE
Tap on one side of the crankcase with a
soft-face hammer. Tap only on reinforced
portions of the crankcase, not on the crank-
case mating surfaces. Work slowly and care-
fully and make sure the crankcase halves
separate evenly.
23 25
22
27
1 3 9
2 6 8
14
15 18
12
11
20
4. Remove:
Dowel pins
G
5. Remove:
Crankshaft journal lower bearing
G
(from the lower crankcase)
TIP
Identify the position of each crankshaft journal
lower bearing so that it can be reinstalled in its
original place.
EAS25580

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
G
Cracks/damage → Replace.
Oil delivery passages
G
Obstruction → Blow out with compressed air.
EAS4S81034

CHECKING THE BEARINGS AND OIL SEALS

1. Check:
Bearings
G
Clean and lubricate the bearings, then rotate
the inner race with your finger.
Rough movement → Replace.
2. Check:
Oil seals
G
Damage/wear → Replace.
EAS25660

ASSEMBLING THE CRANKCASE

1. Lubricate:
Crankshaft journal bearings
G
(with the recommended lubricant)
Recommended lubricant
Engine oil
2. Apply:
Sealant
G
(onto the crankcase mating surfaces)
Yamaha bond No. 1215
90890-85505
(Three Bond No.1215®)
TIP
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 of
the crankshaft journal bearings.
5-61
CRANKCASE