Powr - Yamaha E60HWD Service Manual

POWR

Special service tools ................................................................................... 5-1
Power unit ..................................................................................................... 5-5
Checking the compression pressure ....................................................... 5-5
Disassembling the manual starter ......................................................... 5-17
Checking the spiral spring ..................................................................... 5-17
Checking the drive pawl ........................................................................ 5-17
Measuring the starter rope .................................................................... 5-17
Assembling the manual starter .............................................................. 5-17
Removing the power unit ....................................................................... 5-18
Removing the flywheel magnet ............................................................. 5-20
Removing the electrical components .................................................... 5-20
Removing the control levers .................................................................. 5-20
Assembling the control lever ................................................................. 5-21
Reed valves ................................................................................................ 5-22
Removing the reed valve assembly ....................................................... 5-23
Checking the reed valves ...................................................................... 5-23
Cylinder head ............................................................................................. 5-24
Removing the cylinder head .................................................................. 5-26
Checking the cylinder head ................................................................... 5-26
Removing the exhaust cover ................................................................. 5-26
Checking the exhaust cover .................................................................. 5-26
Installing the stud bolt ............................................................................ 5-26
Installing the thermoswitch .................................................................... 5-27
Crankcase ................................................................................................... 5-28
Removing the oil seal housing .............................................................. 5-32
Removing the crankcase ....................................................................... 5-32
Removing the crankshaft assembly ....................................................... 5-32
Checking the cylinder bore .....................................................................5-32
Disassembling the oil seal housing ....................................................... 5-33
Checking the oil seal housing ................................................................ 5-33
Assembling the oil seal housing ............................................................ 5-33
Disassembling the upper bearing .......................................................... 5-33
Assembling the upper bearing ............................................................... 5-33
Checking the piston diameter ................................................................ 5-34
Checking the piston clearance .............................................................. 5-34
Checking the piston rings ...................................................................... 5-34
Checking the piston ring side clearance ............................................... 5-35
Checking the piston pin boss bore ........................................................ 5-35
Checking the piston pin ......................................................................... 5-35
Checking the internal anodes ................................................................ 5-35
Disassembling the crankshaft ................................................................ 5-36
Assembling the crankshaft .................................................................... 5-37
Checking the crankshaft ........................................................................ 5-39
Assembling the piston ........................................................................... 5-40
Assembling the power unit .................................................................... 5-40
Installing the power unit ......................................................................... 5-43
69D5G11
Power unit
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