Disassembling The Crankcase; Checking The Crankcase; Checking The Timing Chain; Assembling The Crankcase - Yamaha TMAX XP500F 2015 Service Manual

EAS30389

DISASSEMBLING THE CRANKCASE

1. Remove:
• Crankcase bolts
TIP
Loosen each bolt 1/4 of a turn at a time, in stag-
es and in a crisscross pattern. After all of the
bolts are fully loosened, remove them.
• M6 × 35 mm (1.38 in) bolts "1"
• M6 × 50 mm (1.97 in) bolts "2"
• M8 × 110 mm (4.33 in) bolts "3"
2. Remove:
• Crankcase (left)
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.
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.
EAS31445

CHECKING THE TIMING CHAIN

1. Check:
• Timing chain
Damage/stiffness → Replace the timing
chain, camshafts and crankshaft assembly
as a set.
EAS30397

ASSEMBLING THE CRANKCASE

1. Install:
• Cylinder stud bolts "1"
TIP
For the cylinder stud bolt, embedded height "a"
is the standard value and the tightening torque is
the reference value.
Cylinder stud bolt
13 Nm (1.3 m·kgf, 9.4 ft·lbf)
a. 150.2–152.2 mm (5.91–5.99 in)
2. Thoroughly clean all the gasket mating sur-
faces and crankcase mating surfaces.
3. Apply:
• Sealant
(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.
4. Install:
• Dowel pins
• Crankcase (left)
5-74
CRANKCASE