4. During the machine disassembly,
clean all parts and place them in
trays in the order of disassembly.
This will speed up assembly time
and help assure that all parts are
5. Keep away from fire.
ALL REPLACEMENT PARTS
1. We recommend to use Yamaha
genuine parts for all replace-
ments. Use oil and/or grease rec-
ommended by Yamaha for
assembly and adjustment.
GASKETS, OIL SEALS AND O-
1. All gaskets, oil seals, and O-rings
should be replaced when an en-
gine is overhauled. All gasket sur-
faces, oil seal lips, and O-rings
must be cleaned.
2. Properly oil all mating parts and
bearings during reassembly. Ap-
ply grease to the oil seal lips.
LOCK WASHERS/PLATES AND
1. All lock washers/plates "1" and
cotter pins must be replaced
when they are removed. Lock
tab(s) should be bent along the
bolt or nut flat(s) after the bolt or
nut has been properly tightened.
BEARINGS AND OIL SEALS
1. Install the bearing(s) "1" and oil
seal(s) "2" with their manufactur-
er's marks or numbers facing out-
ward. (In other words, the
stamped letters must be on the
side exposed to view.) When in-
stalling oil seal(s), apply a light
coating of lightweight lithium base
grease to the seal lip(s). Oil the
bearings liberally when installing.
HANDLING THE ELECTRONIC PARTS
Do not use compressed air to spin
the bearings dry. This causes dam-
age to the bearing surfaces.
1. All circlips should be inspected
carefully before reassembly. Al-
ways replace piston pin clips after
one use. Replace distorted cir-
clips. When installing a circlip "1",
make sure that the sharp-edged
corner "2" is positioned opposite
to the thrust "3" it receives. See
the sectional view.
Electronic parts are very sensitive.
Handle with care and do not give
• Mankind has static electricity.
It`s voltage is very high and elec-
tronic parts are very sensitive.
• It is possible that inner small
components of electronic parts
are destroyed by static electrici-
• Do not touch and do not make
Check the leads, couplers, and con-
nectors for stains, rust, moisture, etc.
Moisture → Dry with an air blow-
Rust/stains → Connect and dis-
connect several times.
• All connections
Loose connection → Connect
If the pin "1" on the terminal is flat-
tened, bend it up.