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ECA13900
NOTICE
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.
EAS31378
CHECKING THE BALANCER DRIVE GEAR
1. Check:
• Balancer drive gear
Damage/wear → Replace the balancer drive
gear and balancer shaft assembly as a set.
Excessive noise during operation → Replace
the balancer drive gear and balancer shaft
assembly as a set.
EAS30880
CHECKING THE TIMING CHAIN AND TIMING
CHAIN GUIDE (INTAKE SIDE)
1. Check:
• Timing chain
Damage/stiffness → Replace the timing
chain, camshaft sprockets, and crankshaft as
a set.
• Timing chain guide (intake side)
Damage/wear → Replace.
EAS30390
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.
EAS30744
CHECKING THE OIL NOZZLES
1. Check:
• Oil nozzle
Damage/wear → Replace.
• Oil passage
Obstruction → Blow out with compressed air.
EAS30397
ASSEMBLING THE CRANKCASE
1. Lubricate:
• Crankshaft journal bearing inner surface
(with the recommended lubricant)
Recommended lubricant
Engine oil
2. Apply:
• Sealant
(onto the crankcase mating surfaces)
Yamaha bond No. 1215
90890-85505
(Three bond No.1215®)
ECA20880
NOTICE
Do not allow any sealant to come into con-
tact with the oil gallery, crankshaft journal
bearings, or balancer shaft journal bearings.
3. Install:
• Dowel pins
4. Set the shift drum assembly and transmission
gears in the neutral position.
5. Install:
• Upper crankcase "1"
(onto the lower crankcase "2")
ECA13980
NOTICE
Before tightening the crankcase bolts, make
sure the transmission gears shift correctly
when the shift drum assembly is turned by
hand.
5-72
CRANKCASE
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Troubleshooting
