Yta Practice Manual - 2010

YAMAHA MOTOR CO., LTD.
Table of Contents
I. BASIC WORKSHOP PRACTICE [4] Torque Control ............................. 2-5

1. Tighten to Specified Torque ................ 2-5
[1] Cautions When Performing
2. Torque Control is Important in 4-Stroke
Maintenance .................................. 1-1
and Water-Cooled Engines ................. 2-5
1. For Efficient, Safe and Proper
Maintenance ......................................... 1-1 [5] Tools Required for Basic Repair
Operations ...................................... 2-6
[2] Preparation for Basic
1. Wrenches.............................................. 2-6
Operations ...................................... 1-3
2. Offset wrench (box wrench) .................. 2-6
1. Proper Maintenance Begins with
3. Sockets ................................................. 2-7
Good Preparation ................................ 1-3
4. Socket handles ..................................... 2-7
2. Proper Clean Up
(Orderly, Organized, Clean) .................. 1-5 5. T-shaped wrench................................... 2-8
6. T-shaped flex wrench ............................ 2-8
7. Adjustable wrench................................. 2-9
II. BASIC REPAIR OPERATIONS 8. Allen wrench.......................................... 2-9
9. Screwdriver ........................................... 2-9
[1] Disassembly ................................... 2-1
10. Impact screwdriver ............................. 2-10
1. Disassembly Procedure ........................ 2-1
11. Hammer ............................................. 2-11
2. Sequential Bolt Pattern Procedure........ 2-1
12. Pliers .................................................. 2-11
3. Confirm How Each Part Is Installed During
Disassembly ......................................... 2-1 [6] Types and Usage of Machining
4. Organize the Disassembled Parts ........ 2-1 Tools ............................................... 2-13
5. Always Keep Work Table Clean and 1. Chisel .................................................. 2-13
Organized ............................................. 2-1 2. File ...................................................... 2-13
[2] Assembly ......................................... 2-2 3. Saw ..................................................... 2-13

4. Tap ...................................................... 2-14
1. Clean and Inspect Each Part ................ 2-2
5. Die ...................................................... 2-14
2. Always Apply Oil or Grease to Required
Areas for Initial Lubrication ................... 2-2 6. Heli-sert .............................................. 2-15
3. Fundamentals of Tightening Threaded 7. Reamer ............................................... 2-15
Parts ..................................................... 2-2 8. Screw Extractor .................................. 2-15
4. Assembly Procedure ............................. 2-3 9. Vise ..................................................... 2-16
5. Confirm Operation After Assembling 10. Scraper .............................................. 2-16
Each Part .............................................. 2-3
11. Electric terminals and the crimpers .... 2-17
[3] Inspection and Cleaning of 12. Helisert (helical coil wire screw
Fasteners ........................................ 2-4 thread insert) ...................................... 2-20
1. Cleaning and Inspecting Threaded

Sections ................................................ 2-4
2. Inspect the Threaded Holes in All
Aluminum Parts .................................... 2-4
3. Apply Oil to Threaded Section and
Bearing Surface .................................... 2-4
III. HANDLING OF BASIC PARTS [8] Liquid Gasket ............................... 3-12

1. Preparation for Application.......................... 3-12
[1] Circlip ................................................. 3-1
2. Application Pre-cautions ...................... 3-12
1. Type ....................................................... 3-1
3. Storage Pre-cautions ........................... 3-12
2. Function and Installation Direction......... 3-1
4. Three Bond No.1215............................ 3-12
3. Procedure for Installation and Removal... 3-1
4. Assembly Pre-cautions .......................... 3-1 [9] Super Check .................................. 3-13
5. E-type Clip Pre-cautions ........................ 3-1 1. Type ..................................................... 3-13
2. Procedure ............................................ 3-13
[2] Piston Pin Clip ................................ 3-2
1. Type ....................................................... 3-2
2. Function ................................................. 3-2
IV. MEASURING INSTRUMENTS
3. Procedure for Removing ........................ 3-2
4. Procedure and Assembly Pre-cautions.. 3-2 [1] Vernier Caliper ................................ 4-1
1. Measuring .............................................. 4-1
[3] Washer ............................................... 3-3
1. Type ....................................................... 3-3 [2] Micrometer ....................................... 4-2
2. Function and Installation Direction......... 3-3 1. Inspecting and Adjusting the Zero
Setting ................................................... 4-2
[4] Pin ....................................................... 3-4
2. Measuring .............................................. 4-3
1. Dowel Pin............................................... 3-4
2. Cotter Pin............................................... 3-4
[3] Dial Gauges ..................................... 4-4
3. Spring Pin and Spiral Pin....................... 3-4 1. Measuring .............................................. 4-4
[5] Ball Bearing ..................................... 3-5 [4] Cylinder Gauge .............................. 4-5
1. Type ....................................................... 3-5 1. Measuring .............................................. 4-5
2. Function and Installation Direction......... 3-5 [5] Thickness Gauge ........................... 4-7
3. Fundamentals of Assembly ................... 3-5 1. Measuring .............................................. 4-7
4. Handling Pre-cautions ........................... 3-5
[6] Torque Wrench ................................ 4-8
5. Press ..................................................... 3-7
1. Measuring .............................................. 4-8
[6] Oil Seal .............................................. 3-9
[7] Pocket Tester ................................... 4-9
1. Type ....................................................... 3-9
1. Type of Multimeter ................................. 4-9
2. Function and Installation Direction ........ 3-9
2. Yamaha Pocket Tester.......................... 4-10
3. Oil Seal Removal Pre-cautions .............. 3-9
4. Handling Pre-cautions ......................... 3-10 [8] Engine Tachometer ..................... 4-15
1. Engine Tachometer .............................. 4-15
[7] Gasket (Packing), O-ring .......... 3-11
1. Type ..................................................... 3-11
2. Function ............................................... 3-11
V. APPENDIX
3. Gasket Installation ............................... 3-11
4. Confirm a Matching Surface during [1] International System of
Assembly ............................................. 3-11 Units (SI) ........................................... 5-1
5. Handling of O-Rings ............................ 3-11
[2] Table for Converting Torque into
SI Units ............................................. 5-2
I. BASIC WORKSHOP PRACTICE

[1] Cautions when Performing Maintenance

1. For Efficient, Safe and Proper Main-
tenance
(1) Wash the vehicle
Wash the entire motorcycle to prevent dirt from
getting into the area being worked on.
(2) Keep Open Flames Away

Make absolutely sure to keep open flames
away from the maintenance area.
Do not
Smoke
(3) Use the Proper Tools

Use the proper special tools as required to
prevent damage to parts.
Use the proper tools and measuring equip-
ment as required when performing mainte-
nance procedures.
Avoid the use of open end wrenches. Use
sockets and box wrenches whenever possible.
(4) Use Genuine Yamaha Parts

Always use genuine Yamaha parts and lubri-
cants or parts and lubricants recommended
by Yamaha.
(5) Replace Consumable Parts (with

mark)
Always replace consumable parts, such as
gaskets, O-rings, cotter pins, circlips and lock
washers with new parts.
1-1
(6) Think Safety First

Take care in preventing personal injury while
performing maintenance. Such as being
burned by the engine, exhaust pipe, or muf-
fler.
Use each tool properly. Make sure the tool is
positioned properly and that you are in a stable
position before applying force.
(7) Disassemble Carefully and In the Proper

Order
Loosen screws or bolts in the proper se-
quence. Moving in a diagonal sequence
across the part, loosen the screws or bolts on
the outer edge and work toward the center.
Repeat process 2 to 3 times.
During disassembly, always record any inspec-
tions, measurements or other information nec-
essary for reassembly.
Organize the disassembled parts by section
to prevent then from being mixed up or lost.
After disassembly, wash all engine and trans-
mission parts and blow dry with compressed
air.
(8) Assemble by Section and Confirm Opera-

tion
Moving in a diagonal sequence across the
part, tighten the screws or bolts from the cen-
ter toward the outer edge. Repeat process 2
to 3 times.
Proceed with assembly while verifying repair
results as well as data prior to disassembly.
Take care to keep dust or foreign objects from
entering the section being assembled.
Assemble each section, verifying the opera-
tion of each section as you proceed.
Apply engine oil to all rotating and moving
parts.
Tighten the bolts to the specified torque.
Make sure to maintain close communication
whenever an operation is being performed by
two people.
(9) Keep the service manual and parts cata-

logue nearby for easy reference.
This will assist in performing efficient, safe and
proper maintenance.
1-2
[2] Preparation for Basic Operations

1. Proper Maintenance Begins with
Good Preparation
(1) General Tools
Arrange and organize the tool box so that the
necessary tools can be easily located.
Make sure the tools are not damaged.
(Tools must be maintained as well.)
(2) Air Tools

Air tools utilize compressed air to rapidly install
or remove nuts and bolts, speeding up the over-
all work process.
Always use these tools with the appropriate
air pressure setting.
Be careful not to get tangled up in the air hose.
Do not touch rotating parts.
Do not overtighten.
Use air tool oil for periodic lubrication and rust- Air tool oil
proofing.
<Loosening nuts or bolts>

Nuts may fly off if the air tool is used to com-
pletely remove them from the screw.
<Tightening nuts or bolts>

Before using air tools, screw the nut or bolt on
partially by hand. Failure to do this may dam-
age the threads.
Verify that the nut or bolt has been tightened
using a torque wrench.
1-3
(3) Special Tools

Make sure that all necessary special tools are
available and arranged so that the necessary
tools can be easily located.
(4) Measuring Equipment

Make sure that all necessary measuring equip-
ment is available and arranged in a specified
place so that the necessary equipment can
be easily located.
(5) Other Equipment

Medium-size items
Parts stand, engine maintenance table, oil and
coolant measuring devices, oil pan, rags, etc.
Small-size items
Oil can, oil, grease, liquid gasket, etc.
(6) Replacement Parts and Consumable Parts

Prepare the parts to be used for repair or main-
tenance.
Always replace consumable parts. Never re-
use any of the following parts after disassem-
bly: gaskets, circlips, lock washers, O-rings,
cotter pins, etc.
Always use Genuine Yamaha Parts!
1-4
(7) Reference Materials

Always have the service manual, service data
and parts catalogue nearby for quick refer-
ence.
Keep a notebook and pen or pencil nearby.
2. Proper Clean Up (Orderly, Organized, Clean)

(1) Tools (General and Special)
Wipe off all oil and return tools to their proper location.
Confirm that no tools have been lost.
(2) Measuring Equipment

Wipe off all oil and return tools to their proper location.
Make sure that all testers have been turned off.
Set all QL-type torque wrenches to below zero (0) and in the free movement zone.
(3) Small-size Equipment

Return oil can, grease can, and liquid packages to their proper location.
Replace all stoppers and lids, screwing them on tightly.
(4) Medium-size Equipment

Wipe way remaining oil or fluids off the work table, engine stand, part stand, oil and coolant measur-
ing devices, and return these items to their proper location.
(5) Keep Service Area Clean and Neat

Properly dispose of all removed parts and other trash.
Properly dispose of all oil drained from the engine.
Clean the floor.
1-5
II. BASIC REPAIR OPERATIONS

[1] Disassembly
1. Disassembly Procedure
Always review the service manual if this is your
first time performing this procedure.
Pay particular attention to areas marked NO-
TICE and TIP. NOTICE
2. Sequential Bolt Pattern Procedure TIP:
If a loosening sequence is specified, follow that
sequence.
The following procedure should be followed if
( 1 2 6 mm screw 3 ~ 6 8 mm screw)
no loosening sequence is specified:
• Moving in a diagonal sequence across the part,
loosen the screws or bolts on the outer edge and
work toward the center. Repeat process 2 to 3
times.
• If there are both small and large screws or bolts
in the same section, loosen the small ones first.
Summary
• 1st time - loosen with 1/2 to 1 rotation (di-
agonal sequence) Example: Loosening Different - sized screws
• 2nd time - loosen with 3 to 4 rotations (di-

agonal sequence)
• 3rd time - remove by loosening completely
Make the last screw you remove on the top,
and remove the part while supporting it with
your hand to prevent dropping it.
3. Confirm How Each Part Is Installed
During Disassembly
Confirm the installation position and direction
of the part being disassembled as well as its
relationship with other parts.
Example
Always record this information (position, direc-
Disassembly of Cylinder Head,
tion and relationship with other parts) for use Valve, Camshaft, etc.
during reassembly.
Cylinders are numbered 1, 2, 3, 4; counted Crankshaft, Transmission,
Shift Fork, Crankcase
left to right while sitting on the motorcycle.
4. Organize the Disassembled Parts Case Cover, Clutch, Kick Arm,
Oil Pump, etc.
Organize the parts on the parts table in the
correct order and direction. Cylinder Head, Cylinder, Pis-
Organize the disassembled parts by section ton
to prevent loss or mix up.
Keep bolts, nuts, screws, pins, etc., together
with the removed parts.
5. Always Keep Work Table Clean and
Organized
Never place anything on the work table other
than necessary tools and disassembled parts.
(Prevents damage or loss of tools and parts.)
Clean up spilled gasoline, oil or coolant im-
mediately to prevent injury.
2-1
[2] Assembly
1. Clean and Inspect Each Part
Clean each part and blow dry with com-
pressed air.
Confirm that the part is not worn or damaged.
(Refer to data in the Service Manual.)
Replace all consumable parts with new ones.
(Shown with mark in Service Manual.)
2. Always Apply Oil or Grease to Re- Example

quired Areas for Initial Lubrication
Apply oil or grease to all revolving and/or mov-
ing parts and bearings.
Apply grease to the lip of oil seals. Autolube Oil
Refer to the Service Manual for the areas re- Gear Oil
quiring lubrication. 4-Cycle Oil
Wheel Bearing
Grease
3. Fundamentals of Tightening
Threaded Parts
If a tightening sequence is specified, follow
that sequence:
If there is no specified tightening sequence:

• Moving in a diagonal sequence across the
part, tighten the screws or bolts from the
center and work toward the outside edge.
Slowly repeat process 2 to 3 times.
• If there are both small and large screws or
bolts in the same section, tighten the large
ones first.
Procedure
Example: Tightening sequence (used when no specified se-
• If there are screws or bolts of different lengths, quence exists)
(Loosening is the reverse of this sequence.)
start all of them into the holes and confirm
that the length of the screw or bolt matches
the depth of the hole. Adjust as necessary. ( 1 ~ 10 8 mm bolts 11 ~ 26 6 mm bolts)
• First Time ......... Tighten 1/2 to 1 turn from
the point when the screw,
nut or bolt stops turning
easily. (Temporary tighten-
ing)
• Second Time .... Tighten to 1/2 the specified
torque.
• Third Time ........ Tighten to the specified
torque.
*Check the operation of the part (rotation and
movement) with each tightening step. Example: When there is a specified tightening sequence
(sequence shown)
(Loosening is the reverse of this sequence.)
2-2
4. Assembly Procedure Example

Assemble Properly by Following the Reverse
Alignment Mark
Sequence of Disassembly. Always Confirm
Assembly Position and Direction Alignment Mark
Confirm mounting position alignment marks.
Parts requiring adjustment should be adjusted NOTICE
according to data acquired before disassem-
TIP:
bly or as specified.
Always read sections in the Service Manual
displaying either the CA
NOTICE or
TIP: mark.
5. Confirm Operation After Assembling Example

Each Part
Confirm the rotation and/or motion of parts
before going to the next assembly process.
Confirm the small parts to be assembled
(washers, knock pins, circlips, etc.) while they
are still in the parts stand in order to avoid
forgetting parts.
2-3
[3] Inspection and Cleaning of Fasteners

1. Cleaning and Inspecting Threaded
Sections
Clean and inspect both the male and female Matching Surface Bearing
threaded surfaces for abnormalities. Surface
Matching Surface
Male Matching Surface
Clean and inspect the bearing surface of the
Female Matching
nut, bolt or screw and its matching surface on Surface
the part for damage or scratches.
Remove liquid gasket from the female sections

with an air gun.
Matching Surface
2. Inspect the Threaded Holes in All
Aluminum Parts (cylinder head,
head cover, crankcase and case
cover) Oil Stone
Clean, inspect and repair all matching sur-

faces.
• Carefully check for deformities from
overtorque if the part is frequently disas-
sembled.
If the matching surfaces are warped or have

burrs, use an oil stone to repair them.
Clean the inside of each threaded hole so Oil Remover (Thinner or Gasoline)
there in no liquid gasket, gasket pieces, or
other foreign material in them. Remove oil
around the matching surfaces.
3. Apply Oil to Threaded Section and

Bearing Surface
Bearing Surface
Apply a small amount of oil (one drop) to the
Apply oil
threaded section of each nut, bolt and screw
and to the bearing surface. Threaded Section
Apply oil
2-4
[4] Torque Control

1. Tighten to Specified Torque
Over-torque can result in warpage, deformi-
ties, improper movement and/or damage. Al-
ways follow the torque specifications given in
the Service Manual.
F-Type Torque Wrench
(Plate Type)
Adjust air pressure for impact screwdrivers and
wrenches so that they will not cause over-tight-
ening. Use a torque wrench to finish tighten-
ing.
QL Type Torque Wrench

(Preset Type)
2. Torque Control is Important in 4-

Stroke and Water-Cooled Engines
Pressure builds in the crankcase as oil is pres-
surized and circulated. If torque application is
not uniformly performed with a torque wrench,
oil leakage will occur.
Sections in the D.O.H.C. engines that require

oil clearance control, such as the camshaft,
crankshaft journal section, and connecting rod
journal must be torqued with a torque wrench
or insufficient lubrication will result in seizure.
Pressure builds in the water jacket or water

passage in a liquid cooled engine as the cool-
ant temperature rises. If torquing is not uni- (Example: End of Connecting Rod)
formly performed with a torque wrench, cool-

ant leakage will occur.
2-5
[5] Tools Required for Basic Repair Operations

1. Wrenches
Wrenches are used to tighten or loosen bolts and nuts. Types of wrenches include single open-end,
double open-end, open-end and box type, and other types. The size of the wrenches is equal to the
width of the jaw. This figure represents the size of the bolt head for which the wrenches fit.
Single open-end Double open-end Open-end and box-type
Distance
across flats
Bolthead
Wrench size number
(indicates the fitting bolt/nut size)
Use wrenches that fit the bolthead of nut Do not extend the length of the wrench handle.
snugly.
Correct: 12-mm wrench used

for 12-mm bolthead
Incorrect
Incorrect: 13-mm wrench used
for 12-mm bolthead
Do not use a hammer to strike the wrench nor
Pull on the wrench rather than push, whether step on it when tightening or loosening.
tightening or loosening.
2. Offset wrench (box wrench)

The box portion of these wrenches is offset and tilted at an angle of 45°,15° etc. from the plane of the
wrench handle. Open-end wrenches may slip around the nut or bolthead, damaging the bolt if a large
amount of torque is applied to the wrench. The box wrench is safer in this respect than the open-end
wrench.
The same precautions must be given to use the offset wrench as to the open-end.
Size number
Offset wrench
Diameter
2-6
3. Sockets
Sockets are used when working in awkward positions, to tighten or loosen a nut or a nut made of soft
metal. They are often combined with a hinged or ratchet handle and usually reduces the amount of time
required to remove or install a fasteners.
Slotted
Diameter 12-angle
Standard socket
Diameter Hexagonal Socket sizes

6.35 mm (1/4) in
Long 9.5 mm (3/8) in
12.7 mm (1/2) in
19.0 mm (3/4) in
25.4 mm (1/1) in
Deep socket
4. Socket handles
(1) Ratchet handle
The handle drives the socket only in one direction and slips when returning. The direction of drive is
switchable with the selector knob provided.
Handle Drive direction

selector knob
Slip
Drive
Ratchet handle
Socket end
2-7
(2) Hinged handle (3) Sliding offset handle

A hinge is built in the handle near the socket The handle bar fits and slides in a hole of the
end. socket end. You can adjust the offset of the
handle appropriately.
For
fast
turning
Socket
For more torque
(4) Speed handle (5) Universal joint

The crank-shaped handle is convenient to When inserted between the socket end and
quickly loosen or tighten nuts. handle, the universal joint allows the handle to
be operated at any convenient angle.
Universal joint
(6) Extension bar (7) Socket adaptor

Insert an extension between the socket and This is a piece that goes between the handle
handle to access hard-to-reach nuts or bolts. and socket to adapt the handle to different-sized
socket drives.
Extension bar
Socket adaptor
5. T-shaped wrench
This combines the socket with a T-shaped
handle, improving working speed.
6. T-shaped flex wrench

This wrench combines a T-shaped wrench with
a universal joint attached to the neck. If allows
for bolts to be handled quickly even at awkward
angles.
2-8
7. Adjustable wrench
In addition to a stationary jaw the adjustable Stationary jaw
wrench has an adjustable jaw which can be
moved with an adjusting screw to vary the jaw
width. The size of the adjustable wrench indi-
Adjustable jaw
cates its overall length. The stationary jaw of the Correct
adjustable wrench can support greater force than
the adjustable jaw does. When using an adjust-
able wrench, first be sure that the jaws fit tight
with the nut or bolthead, and then apply force to
the handle in the right direction (see illustration). Incorrect
8. Allen wrench
The allen wrench drives an allen screw which
contains a hexagonal socket on its head.
Nominal size
Allen screw
For more torque Used when object is
hard to reach
9. Screwdriver
The screwdriver is used to install and remove screws. The length in which the shank penetrates the
handle varies. The stub type is short but provides for a large torque thanks to its thick handle. It is also
convenient when minimal working space is available.
Flat(–)tip Fluted(+)tip
Penetrating shank type Short
Stub type
Incorrect example
2-9
10. Impact screwdriver

Used to loosen extremely tight or corroded
screws.
Counterclockwise (loosening)
Striking the head of the handle with a hammer
causes the blade to rotate rapidly and with
great force.
Rotate the handle to switch the direction in
Clockwise (tightening)
which the blade rotates.
Replace the screwdriver blade to match the
shape and size of the screw head.
Apply lubricant to help loosen the screw. Lubricant
NOTICE
Line up directly
Place the screwdriver to line up directly with
the screw and strike it with a fair amount of
force. If the striking force is insufficient, the
force of rotation will exceed the thrust, which
Loosen
could result in damage to the screw slot.
Verify the direction of rotation, as screws which

were already tight to begin with may be dam- Tighten 'em up!
aged by further tightening.
Do not use the impact screwdriver in cases

where parts may become damaged or de-
formed.
2-10
11. Hammer
Hammers come in varying types: ball-peen, copper head, plastic tip, wooden mallet, rubber head, test
hammer, etc.
Ball-peen Copper head Test hammer
Plastic tip Rubber head Wooden mallet
Make sure that the hammerhead is tight in the

handle. If you hold the handle near the head,
the striking force will be reduced and it will be
hard to strike the right place.
Grip on the end of the handle and strike the
object flatly.
12. Pliers
Pliers are used to bend wires and grip small parts.
(1) Combination pliers

This type is most commonly used. The joint of Built-in wire
cutter
the jaws are adjustable to accomodate differ-
ent sizes.
For a small object For a large object
Cloth
Parts or wires which are easily damaged can
be gripped with a cloth in between.
(2) Long-nose pliers

Use this type to grip a small object or cut a
thin wire.
Do not allow excessive force to be applied to

the plier tip, which could bend open and ren-
der the tip unusable for detailed work.
2-11
(3) Electrician’s pliers

Use this to cut wire and remove wire insula-
tion.
Do not use these pliers to cut thick or hard

wires, as the sharp blades may become dam-
aged.
(4) Nippers
Use this to cut wire, grip or bend things.
The wide jaws allow for wide hose clips to be

gripped easily.
Blade
When cutting thick items, work the blade edge
around the item instead of trying to cut it in
one snap.
Blade edge
(5) Snap ring pliers

Use this to install and remove snap rings.
(6) Locking pliers

Only a small amount of force is needed to
squeeze the handle.
To grip, squeeze the handle toward the body.
To release, you only have to pull the release
lever.
The width of the jaws is adjustable with the

adjusting screw provided at the end of the
body.
2-12
[6] Types and Usage of Machining Tools

1. Chisel
(1) Flat chisel
This is used to chip over a flat face and to cut
thin sheets.
(2) Cape chisel

This is used to chip over a flat face coarsely and
Tip angle
to cut a groove or hole.
(3) Grooving chisel

Flat chisel Cape chisel Grooving chisel
This is used mainly to make a narrow groove.
The tip should be dressed at an appropriate
angle according to the material.
2. File Flat
Files are used mainly to cut and finish metal parts
by hand.
Half-round
Files include metal working files and assorted
files.
Round
They are normally made of carbon tool steel
and the faces are treated with heat. Square
The metal working files are classified into flat,
half-round, round, square and triangular by Triangular
shape; single- and double- cut by the manner

of cutting teeth; and coarse, bastard, smooth-
cut and dead-smooth by the coarseness of
cut. Handle
An assorted set of files includes varying types Tip

Heel
Idle edge Face Tang
of small-sized files. A set normally includes
five or ten files. They are also classified into Cutting edge
coarse, bastard and smooth-cut.
3. Saw
Used for cutting round metal, panels, pipes and
other pieces. Although the fixed-frame-type saw
can only be used with blades of fixed length, an Butterfly Fixed-type
adjustable type is available in which the frame wing nut
is split into two pieces (one piece attachable at

various lengths by snapping it into the other and
Adjustable type
fixing it in place with a screw). The blade faces
25.4mm blade length
the direction of the wing nut screw. Be sure to
use the blade with the correct number of teeth
Mild steel, copper, soft cast iron 14 teeth
to match the materials and shape of the Hard cast iron, bronze alloy, gas pipe 18 teeth
Solid steel, angles, shaped steel 24 teeth
workpiece. Thin iron panel, thin steel piping 32 teeth
2-13
4. Tap
The first roughing tap, second roughing tap and
bottoming tap are used in combination.
First roughing tap
(1) First roughing tap
This is tapered over some seven leading threads.
Second roughing tap
The leading end should be slightly smaller than
the drilled hole so that the tap can bite the work
easily. Bottoming tap
(2) Second roughing tap

Tapered over three to four leading threads, this
is used to finish the threads cut with the first
roughing tap. Tap wrench
(3) Bottoming tap

This is tapered at only one thread and used to
finish the threads. A tap wrench is used to hold
a tap when cutting threads.
5. Die
Dies are used to cut outside threads on round
bars and pipes, the round split die has a slit for
some adjustability of thread diameter. Two to Round split die
three leading teeth are cut obliquely so that the
die can bite the work easily.
The square die permits adjustability to the di-
ameter of the threads and is used for cutting Diestock
threads on pipes. The solid die does not per-

mit adjustment of thread diameter and is used
for threads of under 6 mm in diameter. Caliper gauge
Determine the diameter and pitch of fasten-

ers to be repaired.
Bolt diameter: measured using caliper gauge
Pitch: measured using pitch gauge. Line the Bolt diameter
bolt up with a tap to check. Match with tap
Pitch gauge
[Reference] symbol M10 ¥ 1.25

≠ ≠
BOLT DIAMETER PITCH Pitch
Lubricate the threads of the fastener to be re-

paired to allow smooth thread cutting.
Tap
Apply equal force to the fastener at right angles
with both hands and turn the fastener. Die
2-14
6. Heli-sert
This tool is used to repair female threads which
have been damaged, or to increase the grip
strength of male threads.
Heli-sert
7. Reamer
The reamer is used for finishing clearance to
holes such as piston pin holes.
8. Screw Extractor
This tool allows for broken bolts to be removed.
This is accomplished by drilling a hole in the bolt,
driving the extractor into the hole and turn it in
the direction in which the fasterner is loosened.
<Wedge-shaped screw extractor>
This variation includes a four-cornered cutaway
surface with cutting blades. It cuts more sharply
than the drill-type and can cut into the bolt eas-
ily.
<Drill-type>
The blade of this type is drill-shaped. Center punch
Shave flat
Repair
1) Shave the top face of the broken bolt flat.
2) Punch a mark into the center of the bolt.
Diameter equal to 50~60 % of

3) Drill a hole in the center of the bolt equivalent bolt diameter
Turn to loosen
to 50~60 % of the bolt diameter (diameter ad-
Drill
justed to fit the extractor).
4) Drive the extractor into the hole and turn it in
the direction in which the fasterner is loos-
Prepared hole
ened.
Continue turning
5) Turn the extractor until the broken bolt is re-
moved.
6) Having removed the broken bolt, grip it using Turn in tightening direction
a vise and turn the extractor in the direction
(to the right) in which the fastener is tightened
in order to remove it from the bolt.
2-15
9. Vise
Vises are usually made of cast iron and their
size is represented by the width of the jaws that
grip the work.
The bench vise is installed on a table and used
Jaw metal
widely for handwork like filing. A metal sur-
face is screwed to the face of the jaw and
grooves are cut over the face of the jaw metal.
Pads
So, place pads of copper or lead between the
jaws and the work for protection.
To grip work with the vise, place the work near
the horizontal center of the jaws. If it is neces-
Work Wooden block
sary to grip the work at either side of the jaws,
place something like a block of wood having
the same thickness as the work at the other
end of the jaws so that the jaws always re-
main parallel.
Vise
10. Scraper
Used to remove gaskets, liquid sealant, stick-
ers, etc. from various surfaces.
<Cut strength depends on blade tip surface> Gasket

The scraper will work effectively when the
blade tip cuts into the gasket. However, this Blade tip surface
cutting
may scratch the surface.
The blade tip shown at right is unable to cut Blade tip surface
cutting
into the gasket, and is thus unable to scrape.
However, scratching is less likely to occur.
When using the scraper for easily damaged

surfaces, wrap vinyl tape around the scraper Wrap tape around
(but not the blade). the scraper head
NOTICE
Keep your hands away from the blade tip, in
order to avoid getting cut.
2-16
11. Electric terminals and the crimpers.

Electric terminals have 3 variations on its socket design.
The crimper and the dies size have to be matched with the wire. Discontinuity, noise on the signal,
cable slip off will be happened as the result.
Socket type Type Crimper dies Dies shape Finishing
Open barrel
Conventional
Insulated
• Insulated
Wire connector • Conventional
• Open barrel
Yamaha have been used burette connector with open barrel socket.
Crimping procedure is a little bit complicated and therefore the procedure is instructed as follows.
YAMAHA MARINE TERMINAL KIT: 90890-05354
TIP:
Electric terminal and electric wire could not be crimped perfectly by regular pliers. Insufficient crimping
generates connection trouble.
(1) Crimper, type FRH-07 for open barrel

and coupler terminals
(1) Crimping die [1.25-2.0mm2 wire]
(2) Crimping die [0.5-0.85mm2 wire]
(3) Crimping die [0.3mm2 wire]
(4) insulator crimping
(5) Wire stripper
(4) (3) (2) (1) (5)
2-17
1) Remove the insulation approximately 1mm

longer than the crimping barrel length.
Select the wire size indication on the wire
stripper part and remove the insulation.
2) Insert the cover on to the wire first.

TIP:
The insulator cover could not be installed
after cramp the wire.
3) Set the open barrel terminal on to the

crimper, insert the wire and then cramp the
wire.
TIP:
Terminal open end facing “M” shape in the
die of crimper. [Photo]
4) Shift the terminal to large die and cramp the

insulator.
5) Lightly pull the wire to confirm the cramping

condition.
Then slide the insulation cover on to the
terminal.
2-18
(2) Coupler repairing

Coupler repairing requires special extracting
tool (1) and special crimper (2). (1)
Regular crimper could not be applied on.
(2)
1) Extract damaged terminal in the coupler by

the special tool.
1 Pull the retainer out (a) Release
2 Release the stopper Release
3 Pull the wire backward to remove the

terminal out
(a)
2) Put new rubber seal onto the removed lead.
3) Crimp the terminal and regulate the end.
4) Shift the wire to insurator crimping die and

crimp the cable insulation, seal with the
terminal.
5) Re-install the terminal into the coupler.

1 Check the crimping condition.
Loose crimping should be re-crimped.
2 Align terminal stopper recess and the
stopper projection in the coupler shell.
3 Insert the terminal from back side of the
shell.
2-19
12. Helisert (helical coil wire screw thread insert)

Helisert kit (90890-05155)
(1) Purpose:
Rethreading damaged thread hole with special
coil to be applicable original screw size.
(2) Components:
1. Finishing tap (#2)
2. Bottoming tap (3)
3. Insert coil
4. Coil installation mandrel
5. Tang break tool
6. Extracting tool
(3) Thread rehabilitation procedure:

1) Check the diameter and the pitch of the original screw (bolt).
Finding... Instruments Photograph
Diameter Vernier calipers
Pitch Pitch gauge
TIP:
2 types measuring instruments are available. There are “METRIC” and “SAE standard”. Yamaha have
been used metric tool only.
2-20
2) Find the optimum drill size from the table

and drill the pilot hole.
TIP:
• No need to drill the hole if the damaged
thread is not plugged.
• If larger hole drilled, the tap and the bolt
should be shifted larger.
• Drilling bit should be positioned right angle
for perfect rethreading.
3) Find the matched tap by #2 & #3: (1)
Regular tap (M10 x 1.25)…(1)

Helisert tap (M10 x 1.25)…(2) (2)
Bolt diameter M4 M5 M6 M8 M9 M10 M12

Drilling bit diameter 4.2mm 5.2mm 6.3mm 8.4mm 9.3mm 10.5mm 12.5mm
Tap indication M4x0.7 M5x0.8 M6x1.0 M8x1.25 M9x1.25 M10x1.5 M12x1.75
TIP:
Do not use regular tap for helisert rethreading. The helicoil diameter has been included in the indica-
tion and therefore the tap diameter is larger than regular tap.
4) Rethreading by #2 & #3 taps.

1 Set the tap#2 into the tap handle.
2 Lube the tap and the thread with lubri-
cant.
3 Follow the original thread, turn the handle
1/2 turns clockwise.
4 Reverse the tap 1/4 counterclockwise
and blow off the flakes.
5 Continue rethreading up to the tap touch-
ing to the bottom.
6 Remove the tap by turning counterclock-
wise.
7 Change the tap to #3 and rethread as
same manner.
8 Clean the thread and the hole by air
blowing.
5) Set the insert coil onto the installation man-

drel.
TIP:
The lead tang have to be engaged with the
recess of the insert tool.
Loose fitting may damaging the lead tang and
stuck the coil in the thread.
2-21
6) Insert the coil by rotating the mandrel clock-

wise.
1 Lube the helicoil and the thread with
lubricant.
2 Turn the mandrel handle clockwise with
depressing the mandrel lightly.
3 After the threads engaged, turn the man-
drel handle slowly without pressing.
4 Continue turning until the coil end
touches to the bottom or coil top posi-
tioned one thread deep.
TIP:
Do not stop or reverse the rotation or the coil
will stuck immediately.
If the coil stuck, remove the coil by using
extracting tool.
Removed coil has been deformed and there-
fore not for reusing.
7) The coil inserted in position, break the lead

tang by the tang break tool.
The coil end should not be projected from

the hole. Projected coil end disturbs
contacts and loosen bolt.
Emergency measures:
If the coil stuck incorrect position. The coil have to
be removed by “coil extractor”.
TIP:
Do not pull out the coil by long nose pliers, the
threads may damage during pull out.
2-22
2-23
III. HANDLING OF BASIC PARTS

[1] Circlip (Snap Ring)

1. Type
There are different types of circlips to meet differ-
ent needs. S Type R Type C Type
Types (Shapes): S Type, R Type, C Type, E
Type, etc.
Surface Shape: Flat, Round.
E Type O Type Half-Ring
For shafts and holes.
2. Function and Installation Direction

Circlips are used to hold the part in place and
prevent it from coming off when a force (axial
and horizontal) is applied. Force Clip
If the cross-section configuration is a level type
clip (S, C, R, E Type), position the clip so that
Angle Angle
(Case)
it has a large right-angle surface area with the
clip groove in relation to the direction of the
force being applied. Rounded (Axle) Force
In other words “position the rounded edge to-

wards the applied force and the angled edge
on the opposite side of the applied force.”
3. Procedure for Installation and Removal

Use snap ring pliers that match the size of the For axle
circlip used. (Clip size and closed and open
hole size.)
Do not open or close anymore than neces-
For holes
sary.
If the location of the circlip to be installed is on
Snap ring pliers
a long shaft, move it with one hand so that it
does not become twisted.
Circlip
4. Assembly Pre-cautions
Always use new circlips. Never re-use circlips.
Confirm the direction of force and position the
circlip accordingly. Axle
(Correct)
Make sure the circlip is seated securely in the
groove.
If the circlip is used on a splined shaft, make
(Incorrect)
sure it covers all the protrusions.
5. E-type Clip Pre-cautions

Whenever removing the clip with a straight
blade screw driver or a pair of pliers, always
cover the clip with your hand to prevent it from
flying off.
3-1
[2] Piston Pin Clip

1. Type
1) Common to all models.
2) Used for scooters and small-displacement en-
gines.
2. Function
These clips are used to fix the position of the
piston pin that connects the piston to the con- Clip
necting rod and prevent it from coming out.

(Piston pin is completely full floating, the clips
are attached on the left and right.)
3. Procedure for Removing

1) Wrap the crank hole with a rag to prevent the
clip from falling into the crankcase.
2) Use long nose pliers, or a flat-bladed screw-
driver (narrow type).
3) Turn the end of the clip to the cut out in the
piston pin hole.
4) Remove the clip end while twisting and press-
ing down on it.
5) To prevent the clip end springing out, keep
your other hand under it.
4. Procedure and Assembly Pre-cau-

tions
1) Always replace with a new clip. Never reuse
the old one.
2) Grasp the end of the clip with long nose pli-
ers (or use a flat-bladed screwdriver). Posi-
tion the other end into the cut out in the pin
hole and push the clip towards the groove. Clip end
3) Use your finger to keep the clip from coming
out. Gently twist and push the clip into place.
4) Move the end of the clip to opposite side of
the cut out in the pin hole.
5) Confirm that the clip is securely in the clip
Cut out
groove.
3-2
[3] Washer
1. Type
The type of washer used varies according to the
Plate Spring Conical Lock
location and type of material and other factors.

The washer is used to provide even torque when Rounded
corner
tightening nuts and bolts, and to prevent them
from coming loose.
If a plate washer has a flat surface and a
Flat
rounded surface, the flat surface is mounted surface
toward the part. (Plain washer direction)
The recessed side of conical washers faces Protruding side outward (to nut)
inward.
Always replace a lock washer that has been
removed with a new one. Make sure that the Recessed side inward (to part)
plates are properly bent after tightening the (Direction of conical washer)
nut. (Use water pump pliers.)
NOTICE
Check the washers for damage or other ab-
normalities. Replace the washers with new
ones if necessary. (Lock washer)
3-3
[4] Pin
1. Dowel Pin
Used during assembly of high precision parts to
fix positions and prevent movement.
If the dowel pin cannot be easily removed, use
long nose pliers. (Do not grasp the middle of
Long nose
the dowel pin with the pliers.) pliers
Take care not to damage or deform the dowel
pins during removal. (If you cannot remove it
Do not damage or de-
due to rust, crush it and replace it with a new form the area with the
pliers.
one.)
Clean both sides of the pin hole before as-
sembling and insert into the side to which the
part is mounted.
2. Cotter Pin
Used on clevis pins, grooved nuts and other parts
to prevent the nut from turning or the part from
coming off.
Always replace removed cotter pins with new
ones.
Clevis pin Grooved
Make sure the cotter pin is bent properly. nut
Pin hole in bolt
3. Spring Pin and Spiral Pin

These are assembled to integrate with the part.
Always replace these parts with new ones
when removed.
Spring pin Spiral pin
3-4
[5] Ball Bearing

1. Type
There are different types and sizes to meet a
variety of applications.
In general, ball bearings and needle bearings Radial ball Radial roller
are mainly used. bearings bearings
Roller bearings and taper roller bearings are

also used.
Thrust ball Thrust roller
bearings bearings
(Self-aligning)
2. Function and Installation Direction Inner side of case
Receives and maintains load on rotating parts,
reducing wear and making rotation smoother.
If there is a mark on the outer race of the bear-
ing, assemble so that it can be seen.
Take care not to incorrectly install single-side
sealed bearings or those that have a clip
Outer side of case
groove. (Mounting direction)
3. Fundamentals of Assembly
Assembly is done using a striking plate, a
press or a steel hammer.
Use the proper size striking plate and posi- Installing into a case
tion it properly in order to prevent twisting of

the inner race and outer race.
Apply pressure with a press or striking with a
hammer vertically in a steady and even man-
ner.
4. Handling Pre-cautions
Perform this operation in a clean location us- Mounting onto an axle
ing clean tools.
• Prevent bearings from coming in contact with
dirt or dust.
• Do not unpack a new bearings until just prior
to installation.
Take care not to mistake type, size and/or di-
rection.
• There are bearings with slightly bigger clear-
ances (for crankshaft) that appear to be the Install both sides
same size and shape.
• Make sure sealed bearings and those with a
clip groove are mounted in the proper direc-
tion.
• If there is no particular instruction, mount the
size inscription side facing the striking plate.
3-5
Use the Proper Size Striking Plate (Installing

and Removing)
• Never directly strike the bearings with a ham-
mer.
• Use a striking plate and hammer that will not
break or splinter.
• Use a striking plate that is the proper size for
the bearings size.
Procedure for Positioning Striking Plate and

Installing or Removing Bearings
• On Case Side ---- Striking Plate on Outer Race
• On Shaft Side ---- Striking Plate on Inner Race
• On Both Sides ---- Striking Plate on Both Correct Incorrect
• Apply pressure with a press or striking with
a hammer vertically to the center in a steady
and even manner.
Follow the Instruction Manual for Using the

Bearing Puller Correct Incorrect
• The procedure for removing bearings with a
bearing puller is fundamentally different from
using a striking plate. Since the inner and
outer areas are usually twisted during this
process, never reuse bearings that have
been pulled out.
Check Case Surface for Burrs or surface peel-

ing
• If there is any defect and repair it with an oil
stone or sand paper.
Check for Abnormality and Clean Bearings

Before Reusing
• Place in kerosene and slowly turn the bear-
ings to clean the internal areas.
• After the bearings has been cleaned, hold it
by the inner race and turn the outer race.
Make sure there are no abnormal noises.
• Never use compressed air to turn a bearing
at high speed.
Apply Oil After Installing
• Slowly turn the bearings while applying the
oil to confirm smooth operation.
• New bearings are coated with grease to pre-
vent rust. They may be used as they are or
oil may be applied also.
3-6
5. Press
Pressure gauge
Operating the pressure handle causes strong Pressure handle
hydraulic pressure to push the ram down.
The height of the table can be adjusted to Release handle
match the part size.
The amount of pressure applied is displayed Ram
on the pressure gauge.
Hoisting wire
Pin
Hoisting handle
Table
(1) Setting up the table

Ram
Use the hoisting handle to raise the height of Table
the table to match the height of the part. Lower

Pin
Hoisting
Raise handle
NOTICE Unfasten the lock,

releasing the hoist-
Once the table height has been set, loosen ing handle and al-
lowing the cable to
the hoisting cable. sag
Lock
Table should be held by the locating pins, not
the hoisting cable. Hoisting cable
Hoisting handle
(2) Setting up the part (workpiece)

1) Use an SST appropriate for the shape of the part, setting it up so that the force will be distributed
evenly over a wide area.
Applied over Shaft slips
a flat surface through
Push on the
inner race
Push on the Small
outer race
Large
Large Small
Insert flat Insert
completely
Small surface load Large surface load
3-7
2) Twist and extend the ram by hand until it

touches the center of the SST.
Twist the ram by hand
SST (Striking plate)
NOTICE
Do not overextend the ram.
The ram may become misaligned when pres-
sure is applied.
(3) <Pressure>
1) Apply pressure while verifying that the
workpiece (part) is set up properly.
2) Check the pressure gauge.
a: Move the handle up and down to achieve
the desired pressure.
b: While you move the handle up and down,
Ram
the needle on the gauge should move, indi-
cating that the workpiece is moving.
c: After the desired pressure is reached, you
will notice that the pressure suddenly rises.
NOTICE
While pressure is rising (a to b), be sure that
the alignment is correct if the pressure gauge
reads at a high level.
When you have finished adding pressure (c),

do not apply more pressure than is required.
Do not apply more pressure than the press

will safely allow.
Cushion
When the workpiece is removed, the other
parts in the assembly may suddenly fall off.
Place a supporter below the assembly.
Release handle
If you loosen the release handle while the pres-
sure handle is in the upward position, the sud-
den decrease in pressure will cause the pres-
sure handle to swing down very quickly.
3-8
[6] Oil Seal Housing Housing
1. Type Spring
Reinforcement
cam Spring
There are many types and sizes available. Dust lip
Main lip
Common oil seals are: S, SD, SW, SDD etc.
Shaft Shaft
(Change shaft/kick shaft) (Magnet side of crank shaft)

S Type SW Type
Housing Housing
Reinforcement
cam Spring
Main lip
Main lip Dust lip
Shaft Shaft
(Clutch side of crank shaft) (Wheel shaft)

SD Type SDD Type

Used on the rotating sections of shafts and mov- Main lip Dust lip
ing parts to keep them sealed.(Keeps oil and/or Spring
coolant from going out and dust and dirt from Oil Air
Water (Dust,Dir)
coming in) (Coolant) Reinforcement
drawing
The main lip faces the relevant part.
3. Oil Seal Removal Pre-cautions

Tap out the seal using the proper size striking
plate or use oil seal puller.
If the seal is located shallow inside and is rela- Special tool for removing oil seals
tively loose, a straight blade screwdriver can

be used. However, as shown in the illustra-
tion, use a rag to prevent damage to the case.
Rag
3-9
4. Handling Pre-cautions
Use the proper tool for removing and install-
ing.
• Use a striking plate. Striking plate
• Use an oil seal puller.

• Take steps to prevent damage to the case.
Do not mistake type, size or direction of seals.

• Do not reuse seals that have been removed.
• The main lip faces the part to be sealed.
Inspect the inner of the lip and lubricate it with

grease.
• Clean the inside of the lip and check for dam-
age or wear.
• Apply grease to the inside of the lip.
Inside
Use the proper size striking plate when as- (Part to be sealed) Outside
sembling.
• Use a striking plate that matches the outside Dust lip
Main lip Grease
diameter of the seal. Strike it in a smooth
level and even stroke.
• Make sure the spring remains in place.
If the seal must pass over a shaft, take care

not to damage the lip.
• Check that there are no burrs on the end of
the shaft, or anything that could damage the
lip.
• If the seal must pass over a long shaft, splined
shaft or grooved shaft, wrap the shaft in plas-
tic or oiled paper to prevent damage to the
lip. Cover
3-10
[7] Gasket (Packing) , O-RING

Replace all parts with a mark. Always use
Genuine Yamaha Parts.
Parts marked in the Service Manual
are consumerable parts. Replace them with
new ones each time when disassembly and
removal is performed.
1. Type
Seals include gaskets (metal types and paper
types), O-Rings (rubber) and oil seals.
Gasket O-Ring
2. Function
Seals and maintains pressure between parts and
between a part and the outside.
Upward
3. Gasket Installation Cylinder head
Position as indicated on the gasket (such as
“up”, “case”, and “head”) if such a mark is
present. Protruding
surface
If one side has sealant applied to it, it should
be faced toward the inside.
Items such as head gaskets that have re-
Surface with sealant to the inside
cessed and protruding grooves on both sur-
faces should put the protruding grooves to-
ward the head.
4. Confirm a Matching Surface During

Assembly Gasket
If a dowel pin is used, insert the pin first.
Clean matching surface and remove oil.
Use an oil stone to remove burrs or scratches Dowel pin
Dowel pin
from the matching surfaces.
5. Handling of O-Rings Apply grease
If the relevant part has a groove for the O-

ring, Make sure that the O-ring seats firmly in
it.
Apply a thin coating of grease.
When assembling onto a pipe joint in the cool-
ing system, place it on the pipe to be inserted,
coat it with grease and then insert into the
matching pipe.
3-11
[8] Liquid Gasket (Three-Bond 1102, 1105B, 1215)

In general, liquid gasket materials are used to
assist the seal being used. It is not an adhesive.
1. Preparation for Application
Clean the surface to which the liquid gasket is
to be applied with a solvent or thinner. Use a
clean rag to remove all dirt, dust, oil and wa-
ter.
Check the matching surfaces for burrs or
scratches. Remove them with an oil stone if
they are present.
2. Application Pre-cautions
Use only approved liquid gasket.
It is best to only apply to one surface. Apply to
the side that is the easiest.
Apply a thin, even coat.
Keep the time short between when you start
applying the liquid gasket and when you fin-
ish applying it.
Do not apply to screw holes, oil grooves or
clip grooves .
After applying, allow to set for a few minutes
until it feels somewhat dry to the touch and
then join the pieces.
3. Storage Pre-cautions
Air will cause the liquid gasket to harden. Always
squeeze air out of the tube before putting on the
cap tightly.
4. Three Bond No.1215

This is a gray, solventless, semi-dry, viscoelastic liquid gasket with silicon as its main component.
It has excellent build-up characteristics, and provides powerful sealing of joining surfaces. Contact with
air causes formation of a rubber-like flexible form, so it provides good vibration and shock absorption,
and provides excellent heat and cold resistance. It retains rubber-like flexibility over a wide temperature
range from –60 °C to 250 °C.
3-12
[9] Super Check (Red Check Penetrate Dye)

Super Check is a red dye that has been dissolved into a penetrating liquid. It is applied to the part to be
inspected and allowed to seep into it. The penetrating liquid is then washed off the surface of the part
with a cleaning liquid. A developer is applied that draws out any of the penetrating liquid that has
seeped into the part, revealing defective areas.
1. Type
Solution Name (Can Color)
1 • 3 Cleaning Liquid (Yellow) : Used as a pretreatment to remove dirt, used to remove
excessive red penetrating liquid and to clean off devel-
oper after the inspection.
2 Penetrating Liquid (Red) : A powerful oil-based red-colored penetrating liquid that
quickly seeps into extremely small defective areas.
4 Developer (Blue) : A special white-colored powder that is dissolved into a
liquid. It draws the penetrating liquid that has seeped
into defective areas to the surface, enlarging the ap-
pearance of extremely small defects.
2. Procedure
1) Pretreatment (Cleaning Liquid - Yellow Can)
Apply the liquid to the defective area of the part
(Cleaning Liquid - Yellow Can)
to be inspected to remove dirt.
2) Penetrating (Penetrating Liquid - Red Can)

Apply the liquid to the defective area of the part
and allow to set for 5 to 10 minutes. If the ap-
plied liquid appears to have dried, another coat- (Penetrating Liquid - Red Can)
ing may be applied and allowed to seep into the
defective area of the part to be inspected.
3) Washing (Cleaning Liquid - Yellow Can)

Soak a piece of cloth in the liquid and remove
the excessive penetrating liquid. (Cleaning Liquid - Yellow Can)
4) Developing (Developer - Blue Can)
Hold the developer about 30 to 40 cm from the
surface of the inspected item and apply an even
coating. As the developer dries, it will draw out
the penetrating liquid that has seeped into the (Developer - Blue Can)
defective areas and clearly show the defective
area in a red color.
3-13
IV. MEASURING INSTRUMENTS

[1] Vernier Caliper

Beak of main body
Vernier calipers are used to make the following Beak of slider
measurements: a. outside diameter, b. inside
diameter and c. depth. Most calipers read dimen-
sions to 0.05 mm.
On calipers that read dimensions to 0.05 mm,
the graduation on the main body is shown every Dips bar
1 mm while that on the vernier is 19/20 of it. The
Gradation of main body
Vernier
difference between the main body and the ver-
nier is 0.05 mm. Jaw of slider
Jaw of main
body Vernier caliper
1. Measuring
To take a measurement, start by making sure
that the graduations for the main body and
verniers are aligned at zero (0) and that the
surface for inside measurements and the sur-
face for outside measurements form a per-
fectly straight line.
Outside diameter measurements are taken by
placing the space between the main body and Checking the zero setting
the jaw of the slider over the item to be mea-
sured and reading the value. Place the cali-
pers as deep as possible and take care not to
push too hard.
To read the caliper, first look for the value above 37 mm
1 mm shown on the main body, which is the

value above the zero (0). Next, for the value
below 1 mm, look for the number where the
graduations for the vernier and main body meet.
The example in the illustration shows 37.60 mm. 0.60 mm
The “37” is read from the main body and the Reading of vernier caliper
“6” or 0.60 mm, is read at where the gradua-

tions of the main body and verniers meet. To-
gether these read 37.60.
Bad example
Use the thin tip of the jaw for measuring nar-
row or recessed surfaces, such as grooves.
For inside diameters, use the jaws on the top
of the slider and main body. This is done by
properly placing the flat sides of the jaws
against the inside walls of the object to be
Good example
measured.
4-1
[2] Micrometer
There are micrometers for measuring exterior sur-
Outside micrometer
faces and interior surfaces. Most micrometers mea-
sure to 1/100 mm and are limited in measuring range
to 25 mm. Ranges of over 25 mm would require a Standard gauge
Special adjustment
large screw and be inconvenient to use. Thus, com- wrench
monly used micrometers come in ranges of 0 to 25
mm, 25 to 50 mm, 50 to 75 mm and 75 to 100 mm.
Outside micrometers of over 25 mm have a standard
gauge for checking the zero (0) setting and a special
wrench for adjusting it.
The illustration shows the design of a micrometer.
The part to be measured is placed between the anvil
Case
and spindle. A ratchet stop is built into the microme-
ter to provide an even measuring force. When the set
force is exceeded, the ratchet will spin idly.
Spindle Sleeve Inner sleeve
The outside thimble has graduations to 50
Spring Taper nut
while graduations above the base line on the
Anvil
sleeve are in increments of 1 mm. The gradu- Thimble
ations below the base line on the sleeve are
also in increments of 1 mm and are positioned
between those above the base line. In other
words, the graduations below the base line
indicate the 0.5 mm position for the gradua- Ratchet stop
tions above the base line. Clamp lever
The threads for the spindle are at a 0.5 mm Frame
pitch so the spindle will move 0.5 mm for each
turn of the thimble. Thus, each graduation on
the thimble means the spindle moves, 50 mm standard gauge Ratchet stop
0.5/50 = 1/100 = 0.01 mm.
1. Inspecting and Adjusting the Zero
Setting
Check that the zero (0) setting is always prop-
erly aligned when using the micrometer.
On a micrometer with a 50 to 75 mm range,

properly position the 50 mm standard gauge Checking the zero setting
and turn the ratchet stop 2 or 3 times. Then Sleeve
confirm that the base line on the sleeve and Spindle Thimble
the zero (0) on the thimble align.
Clamp Special adjustment wrench
If this inspection shows that there is less than
a 2/100 mm error, adjustment can be made
by fixing the spindle with the clamp and in-
serting the special adjustment wrench into the
hole at the end of the sleeve and then moving
the sleeve.
Adjusting the zero setting
If the error is greater than 2/100 mm, fix the
spindle with the clamp as explained above and
Sleeve
as shown in the illustration, loosen the ratchet Thimble
stop by turning the special adjustment tool in
the direction of the arrow and align the zero Special adjustment wrench
(0) mark on the graduation on the thimble with Spindle
the base line on the sleeve. Retighten the
Clamp
ratchet stop with the special adjustment tool,
fixing the thimble to the spindle.
Adjusting the zero setting
4-2
2. Measuring
First properly position the anvil on the object
to be measured. Then turn the thimble until
the spindle nears the object. Turn the ratchet
stop until the spindle contacts the object. Frame
Hold the frame in the center. Do not touch the

spindle or anvil.
Spindle Anvil
Never lift or move the measured object with
Ratchet stop
micrometer.
Moving the spindle rapidly will result in mis-
alignment of the spindle and thimble.
Never use the micrometer as a feeler gauge.
The illustration shows the measurement on a

micrometer for measuring 25 to 50 mm exte-
1 mm unit
rior surfaces.
First, read the “33” above the base line and
then read the “38” where the base line and 0.5 mm unit
the graduations on the thimble align. Thus, the

reading is 33.38 mm.
The lock clamp is for fixing the spindle in the Sleeve
measured position. Thimble
4-3
[3] Dial Gauges

Right side
The dial gauge is used to measure bend and de-
viation of shafts, parallel, backlash of gears, etc. Long
needle
Short
The dial scale is graduated in units of needle
Reverse side
1/100 mm ordinarily. The movement of the Pinion
spindle tip appears directly on the dial. When Gear

Rack
the needle moves 5 increments it means that Spindle
Tip
the spindle tip has moved 5/100 mm.
Spring
In the dial gauge, rack and pinion gears are
used to convert a very small movement of the
spindle tip into a magnified deflection of the
needle.
Bend = Deflection of needle (reading)
2
If the spindle tip is pressed, the needle moves Deflection of

needle (reading)
like a clock. The needle returns by spring ac- Bend
tion as soon as the tip is released. The out-

V-block
side frame can be turned freely.
Reading
1. Measuring
Attach the dial gauge to the magnet stand to Fixed screw Fixed screw
use.
Arm
When measuring, adjust the position of the

magnet stand and set up the gauge at the cen-
ter of it’s range.
Center position
<How to read the measurement value>
Rotate the part, reading the values corre- Magnet stand
sponding to the needle's run out range.
Face towards center
Run out range

(example: 0.07 mm)
<Shaft run out, warpage>
4-4
[4] Cylinder Gauge

The cylinder gauge is a variation of the dial Cylinder
gauge
gauge. Graduations are made normally in units
of 0.01 mm.
In the common colmartype cylinder gauge,
expansion or contraction of the measuring tip
is transmitted to the indicator through a link
mechanism. It can even measure stepped
wear accurately with the guiding plate. You can
choose the interchangeable rod suitable for
Interchangeable rod
the cylinder inner diameter to perform the Interchangeable rod mounting screw
measurement.
Interchangeable rod
Gauge
The cylinder gauge is supported at two points: head
the guiding plate and the tip of the rod. Move
the grip right and left until the reading becomes
minimum. Interchangeable rod
To measure wear inside the cylinder, read the Interchangeable rod
mounting screw
minimum and maximum diameters by moving
the cylinder gauge over the inside surface of
the cylinder.
Adjustment washers
1. Measuring
Interchangeable rod
(1) Cylinder gauge set
Measure the inner diameter of the cylinder
using a caliper gauge, and determine the stan-
dard measurements. Micrometer
Set up the interchangeable rod and adjustable Spindle
washer so that the gauge is 0.5 to 1.0 mm
longer than the inner diameter of the cylinder. Fixed screw Clamp
Caliper
gauge
Stand
Standard measurement 1
(example: 87.00 mm) Standard measurement
(example: 87.00 mm)
Cylinder
Push the dial gauge spindle into the bore
gauge about 1mm to attach. If the spindle is
pressed in too hard, the gauge head will be
forced upwards. Standard measurement
Support (example: 87.00 mm)
point
(2) Cylinder Gauge Zero Adjustment
Stator shrinks
1 Set the micrometer to the standard measure-
Turn the dial to set the
ment value found by using the caliper gauge, zero point to the
Stator standard measurement
and stabilize the spindle with the clamp. lengthens
2 Move the gauge back and forth, using the in-
2
terchangeable rod as a support.
3 As you move the cylinder gauge back and
forth, the needle on the dial gauge will find
the largest point in the micrometer and then
change direction. Set the “O” mark on the dial
on the needle, at the point that the needle 3
changes direction.
4-5
(3) Measuring the cylinder bore

1 Gently push the guide plate in and carefully
insert the gauge into the cylinder bore.
1
Guide plate
2 Move the gauge to find the shortest measured
distance. Gauge head 2
Distance is shortest
Shrinking
Lengthening side
side
3 Read the measurement at this position.
Example: Gauge reading “0.05”

(4) How to read measurement values
Measurement value = standard measurement + gauge reading (when read from lengthening side)
Or, measurement value _ gauge reading (when read from shrinking side)
Example: Standard measurement Gauge reading Measurement value
87.00 mm _ 0.05 mm = 86.95 mm
Lengthening side Shrinking side
NOTICE
Refer to the repair manual for the measure- Thrust direction
Upper
ment position.
Center
Crank axis Lower

direction
The elliptical angle, taper angle, and amount

of abrasion can be determined from the inner
diameter of the cylinder.
Abrasion amount = max. value _ min. value
Elliptical angle = A _ B (A>B) Taper angle = a _ b (a>b)
4-6
[5] Thickness Gauge

A set of assorted steel thickness gauges may
come in ranges such as 0.03 mm to 0.30 mm.
They are used to measure small clearances like
valve clearance, point gaps, piston ring gaps,
etc.
Thickness gauge
Special thickness gauge
1. Measuring
Insert the gauge in the gap, and make a thick-
ness measurement at a place where the gauge
can still be inserted or removed without too much
resistance. If the gauge can be inserted or re-
moved with no resistance, you may need to use
a combination of two or three gauges that add
up to the appropriate thickness.
NOTICE
Do not bend the gauge or crack the tip. (Be
especially careful of this with thinner gauges.)
After using the gauge, clean the surface, and

apply oil to avoid rusting.
Apply a thin coating of oil
4-7
[6] Torque Wrench

Grip
The grip’s side force causes the arm (manu- Needle
factured from a leaf spring) to deflect. The
amount of deflection is indicated by the needle
Arm Deflection
on the dial. Dial amount
The maximum measurable torque is deter-

mined by the torque wrench size.
1. Measuring Handle Grip
Only use a torque wrench for final tightening

of fasterners, Use a ratcher or air tools for in-
stallation and partial tightening to keep work
productivity high.
Apply force without letting the handle touch

Pin
the grip, force from any other source besides
the pin will result in incorrect torque measure-
ments.
NOTICE
Use the torque wrench up to 50~70 % of the
torque wrenches capability to insure an accu-
rate reading. If this cannot be achieved, use a
torque wrench with a higher rating.
When making several turns to tighten, apply

equal force two to three times.
Types of Torque Wrenches

<Preset Type> ”
k
“Clic
The torque wrench will make a “click” sound
Ratchet mechanism
when the preset torque specification is rea- Dial
ched.
Sleeve
<Small torque type>

A maximum value of approx. 10 kgf-cm is used
for preload measurements.
(Refer to V. APPENDIX [2] Table for Converting Torque into SI Units on page 5-2.)
4-8
[7] Pocket Tester

1 2
1. Type of Multimeter
Various types of multimeters are commercially available to meet various purposes and uses. The two
main categories are “analog type” and “digital type”.
The advantages and disadvantages of the analog and digital multimeters are listed below.
Advantage Disadvantage
1) The pointer swings so that you can visually observe a slight 1) It is easier to make a mistake when reading many gradu-
change or condition. ated marks.
2) Reading changes are slower compared to a digital multim- 2) Zero-ohm adjustment is necessary each time the ohms
eter. mode is selected.
Analog
3) When the indicated value is not important, you can use the 3) Unless you are careful with the polarity of the test leads, the
movement of the pointer as a guide. pointer can swing the wrong direction and damage the meter.
4) It is often to read the indication when the pointer is between
two graduations. This makes it easy to read the meter in-
correctly.
1) With a digital readout, the indicated value is easy for any- 1) The indicated value fluctuates.
one to read. 2) Caution must be taken when reading the indicated value.You
2) Zero-ohm adjustment is not necessary when using the ohms must be sure that you read the decimal placement correctly
mode. and if it is megaohms, kilovolts etc.
Digital
3) You have more confidence that your readings are correct. 3) The “1” sign, which means the meter is out of range or infin-
4) Incorrect polarity will not damage the meter. The display will ity, can cause confusion for unfamiliar operators of the meter.
read the same value with a “-” sign next to it if the polarity is 4) You can see a change of the indicated value, but cannot
incorrect. see the movement of a pointer.
5) It takes for the indication to stabilize.
The procedures for using an analog and digital multimeter are very similar. The following examples will
use the analog meter for demonstration.
1 Analog type: Yamaha Pocket Tester 2 Digital type: Multi-Tester
(Type 3002Y) (Type CD-720CK)
4-9
:2)
2. Yamaha Pocket Tester

Type:3002Y
(1) Part description (2) Amounts to be measured
1 Meter scale plate The following four kinds of amounts can be mea-
2 Pointer sured with the Yamaha Pocket Tester:
3 Zero adjust screw “AC V” ................. AC voltage
4 “Negative” test lead jack “DC 20V” ............. DC voltage (20 V or less)
5 “Positive” test lead jack “DC A” ................. DC current
6 Meter cover “Ω” ....................... Resistance
7 Panel
8 Case Some commercially available multimeters can
9 Ohmmeter zero adjust knob test for continuity, diodes, hFE (amplification fac-
10 Selector knob tor of transistor), temperature, and engine speed.
11 +DC A jack
4-10
(3) Measuring voltage

When measuring voltage, you should remember that 1) Measuring AC voltage
there are the following two kinds of voltage: “AC” (Al- Select the measuring range of AC V (AC volt-
ternating Current voltage) and “DC” (Direct Current
age). The ranges include 300 V, 120 V, and 20 V.
voltage). Home electric appliances which are plugged
into sockets usually use AC as a power supply while These values also represent the maximum volt-
those with batteries use DC as a power supply. age values that can be measured with the re-
spective ranges. When you do not know an ap-
The electricity generated by generators is alternat-
ing current (AC). It can also be drawn off of the con- proximate voltage value beforehand, start with
trol box as direct current through a diode (mainly for the highest range. While observing the move-
charging the battery). A generator with an electric ment of the pointer, switch to the proper range.
starter is provided with a battery and delivers DC
current to the motor.
2) Measuring DC voltage
It is important to determine if the voltage to be mea- Select the measuring range of DC 20V (DC volt-
sured is AC or DC. If the voltage is measured incor-
age).
rectly, inaccurate data will be obtained and the multi-
This “20 V” represents the maximum voltage
meter may be damaged.
value that can be measured with the range. The
For accurate measurement, you should under-
DC outputs of generators are all 12 V for charg-
stand the following three items.
ing the batteries. So you can measure the DC
“The range to be used” voltage with this range.
“How to connect the test leads”
“Which scale on the multimeter should be
read”
4-11
(4) Measuring resistance (6) Measuring DC current

To measure resistance, select one of the follow- Measure DC current by selecting either of the
ing ranges ( ¥1 k, ¥100, ¥10, ¥1) in ohms. “Be- DC A ranges, 5 A and 10 A. If an approximate
fore measuring, be sure to “zero” the meter for value of the current is not known beforehand,
accurate measurement.” After changing the select the higher maximum measurement range
range, also be sure to “zero” the meter before of 10 A. For measurement, connect the Tester
measuring. in series with the circuit.
(5) How to use the test leads

There are two test leads, red and black. Con-
nect the red test lead to the positive jack, and
the black test lead to the negative jack. The
Yamaha Pocket Tester has two positive test lead
jacks. One of them is for measuring large DC
current (+DC A) only.
When measuring, always apply the red lead to

the point of higher voltage, and the black lead to
the point of lower voltage.
* To measure the voltage of a battery, apply the

red test lead to the positive terminal of the bat-
tery, and the black lead to the negative termi-
nal of the battery.
4-12
(7) Measuring procedures 1 DC V

1 DC voltage (DC V)
2 AC voltage (AC V) 2 AC V
3 Resistance (Ω) 3 Ω
4 DC A
4 DC current (DC A)
* For measuring 1 to 3 , connect the Tester in

parallel with the circuit. For measuring DC cur-
rent 4 , connect the Tester in series with the
circuit.
4-13
(8) How to read the meter

The scales of the meter from top to bottom are: the ohms scale (0 to ∞), DC V scale (0 to 20), AC V
scales (0 to 20, 0 to 120, 0 to 300), and DC A scales (0 to 5, 0 to 10).
For practice, try reading the pointers, marked with 1 , 2 , and 3 in the figure at left, in each range.
Answers:
Range Pointer 1 Pointer 2 Pointer 3
DC20V 9V 14.5V 0.7V
AC300V 135V 220V * 12V
AC120V 54V 88V 5V
AC20V 9.2V 14.5V 1V
×1kΩ 12kΩ 4kΩ
×100Ω 1,200Ω(1.2kΩ) 400Ω Because of the absence of a
graduation, you must change
×10Ω 120Ω 40Ω the range
×1Ω 12Ω 4Ω
DC 5A 2.2A 3.6A 0.25A
DC10A 4.4A 7.2A 0.5A
* To measure AC voltage (AC 300 V, 120 V) with pointer 3 , select the AC 20 V range for more accurate
and easier reading.
4-14
[8] Engine Tachometer
With generators, the engine speed is an important factor for generating the proper amount of electricity.
Before inspecting the engine, you must accurately adjust the engine speed by using a tachometer.
1. Engine Tachometer
Type: PET-1000
(1) Part description (2) Measurement items

1 Antenna lead jack Engine Measurement
Position
2 High sensitivity sensor (built-in) Stroke No. of Cylinders Range RPM
3 , 5 , D Strap lugs 2 1
P21:42 100~19,000
4 2
4 Liquid crystal display
2 2
6 Position key P22:44 100~9,500
4 4
7 Reset key
4-15
(3) Measuring engine speed

1 Non-contact measurement
Bring the tachometer near the spark plug
lead. Press the Position key to obtain the
proper position. Locate a position where the
engine speed is stable, within a distance of 1
to 50 cm between the cord and the tachom-
eter. Then measure the engine speed.
2 Contact measurement
Connect the antenna lead to the tachometer
and the spark plug lead. Then measure the
engine speed.
* The TCI ignition system used on the four-stroke engines of Yamaha generators, produces a spark on
both compression and exhaust strokes.
Set the tachometer at a position where the number of cylinders is doubled. In other words, select the
four-stroke 2-cylinder position P21:42 . You cannot measure speed of rotation of diesel engines with
this tachometer because they do not use high-tension ignition systems.
Ignition at the compression top dead center Ignition at the exhaust top dead center
4-16
4-17
V. APPENDIX
[1] International System of Units (SI)

1. What is the International System of Units (SI)?
The system of units that is now in general use is called the gravitational system of units. Both the
gravitational system of units and SI units are unit systems within the metric system, so basically length
is expressed in meters, time in seconds and mass in kilograms.
The basic difference between the gravitational system of units and SI units is that the unit of mass and
the unit of force are clearly distinguished between.
Furthermore, as the unit of force changes, the related unit of quantity (energy, etc.) also changes.
SI is an abbreviation of the French term, “Le System International d’Unites”.
2. SI Examples in the Service Manual

This Service Manual uses both SI units and traditional units.
E.g. Tightening torque 10 Nm (1.0 kg-m)
Main unit examples

Item SI (traditional units)
Capacity or displacement 1 L (1,000 cm3)
Pressure 1 kPa (0.01 kg/cm2)
Output 1 kW (1.360 PS)
Torque 1 Nm (0.1 kg-m)
5-1
[2] Table for Converting Torque into SI Units

kgf·cm kgf·cm
N·m kgf·m 1 N·m = 10.1972 kgf·cm
1 N·m = 0.101972 kgf·m kgf·m N·m 1 kgf·cm = 0.098066 N·m
1 kgf·m = 9.8066 N·m
kgf·cm N·m
N·m 0 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 kgf·cm 0 1 2 3 4 5 6 7 8 9
1 10.2 11.2 12.2 13.3 14.3 15.3 16.3 17.3 18.4 19.4 10 0.981 1.08 1.18 1.27 1.37 1.47 1.57 1.67 1.77 1.86
2 20.4 21.4 22.4 23.5 24.5 25.5 26.5 27.5 28.6 29.6 20 1.96 2.06 2.16 2.26 2.35 2.45 2.55 2.65 2.75 2.84
3 30.6 31.6 32.6 33.7 34.7 35.7 36.7 37.7 38.7 39.8 30 2.94 3.04 3.14 3.24 3.33 3.43 3.53 3.63 3.73 3.82
4 40.8 41.8 42.8 43.8 44.9 45.9 46.9 47.9 48.9 50.0 40 3.92 4.02 4.12 4.22 4.31 4.41 4.51 4.61 4.71 4.81
5 51.0 52.0 53.0 54.0 55.1 56.1 57.1 58.1 59.1 60.2 50 4.90 5.00 5.10 5.20 5.30 5.39 5.49 5.59 5.69 5.79
6 61.2 62.2 63.2 64.2 65.3 66.3 67.3 68.3 69.3 70.4 60 5.88 5.98 6.08 6.18 6.28 6.37 6.47 6.57 6.67 6.77
* 7 71.4 72.4 73.4 74.4 75.5 76.5 77.5 78.5 *79.5 80.6 70 6.86 6.96 7.06 7.16 7.26 7.35 7.45 7.55 7.65 7.75
8 81.6 82.6 83.6 84.6 85.7 86.7 87.7 88.7 89.7 90.8 80 7.85 7.94 8.04 8.14 8.24 8.34 8.43 8.53 8.63 8.73
9 91.8 92.8 93.8 94.8 95.9 96.9 97.9 98.9 99.9 101 90 8.83 8.92 9.02 9.12 9.22 9.32 9.41 9.51 9.61 9.71
10 102 103 104 105 106 107 108 109 110 111 100 9.81 9.90 10.0 10.1 10.2 10.3 10.4 10.5 10.6 10.7
kgf·m N·m
N·m 0 1 2 3 4 5 6 7 8 9 kgf·cm 0 10 20 30 40 50 60 70 80 90
10 1.02 1.12 1.22 1.33 1.43 1.53 1.63 1.73 1.84 1.94 100 9.81 10.8 11.8 12.7 13.7 14.7 15.7 16.7 17.7 18.6
20 2.04 2.14 2.24 2.35 2.45 2.55 2.65 2.75 2.86 2.96 200 19.6 20.6 21.6 22.6 23.5 24.5 25.5 26.5 27.5 28.4
30 3.06 3.16 3.26 3.37 3.47 3.57 3.67 3.77 3.87 3.98 300 29.4 30.4 31.4 32.4 33.3 34.3 35.3 36.3 37.3 38.2
40 4.08 4.18 4.28 4.38 4.49 4.59 4.69 4.79 4.89 5.00 400 39.2 40.2 41.2 42.2 43.1 44.1 45.1 46.1 47.1 48.1
50 5.10 5.20 5.30 5.40 5.51 5.61 5.71 5.81 5.91 6.02 500 49.0 50.0 51.0 52.0 53.0 53.9 54.9 55.9 56.9 57.9
60 6.12 6.22 6.32 6.42 6.53 6.63 6.73 6.83 6.93 7.04 600 58.8 59.8 60.8 61.8 62.8 63.7 64.7 65.7 66.7 67.7
70 7.14 7.24 7.34 7.44 7.55 7.65 7.75 7.85 7.95 8.06 700 68.6 69.6 70.6 71.6 72.6 73.5 74.5 75.5 76.5 77.5
80 8.16 8.26 8.36 8.46 8.57 8.67 8.77 8.87 8.97 9.08 800 78.5 79.4 80.4 81.4 82.4 83.4 84.3 85.3 86.3 87.3
90 9.18 9.28 9.38 9.48 9.59 9.69 9.79 9.89 9.99 10.1 900 88.3 89.2 90.2 91.2 92.2 93.2 94.1 95.1 96.1 97.1
100 10.2 10.3 10.4 10.5 10.6 10.7 10.8 10.9 11.0 11.1 1000 98.1 99.0 100 101 102 103 104 105 106 107
kgf·m N·m
N·m 0 10 20 30 40 50 60 70 80 90 kgf·m 0 1 2 3 4 5 6 7 8 9
100 10.2 11.2 12.2 13.3 14.3 15.3 16.3 17.3 18.4 19.4 10 98.1 108 118 127 137 147 157 167 177 186
200 20.4 21.4 22.4 23.5 24.5 25.5 26.5 27.5 28.6 29.6 20 196 206 216 226 235 245 255 265 275 284
300 30.6 31.6 32.6 33.7 34.7 35.7 36.7 37.7 38.7 39.8 30 294 304 314 324 333 343 353 363 373 382
400 40.8 41.8 42.8 43.8 44.9 45.9 46.9 47.9 48.9 50.0 40 392 402 412 422 431 441 451 461 471 481
500 51.0 52.0 53.0 54.0 55.1 56.1 57.1 58.1 59.1 60.2 50 490 500 510 520 530 539 549 559 569 579
600 61.2 62.2 63.2 64.2 65.3 66.3 67.3 68.3 69.3 70.4 60 588 598 608 618 628 637 647 657 667 677
700 71.4 72.4 73.4 74.4 75.5 76.5 77.5 78.5 79.5 80.6 **70 686 696 706 716 726 735 745 755 765 775
800 81.6 82.6 83.6 84.6 85.7 86.7 87.7 88.7 89.7 90.8 80 785 794 804 814 824 834 843 853 863 873
900 91.8 92.8 93.8 94.8 95.9 96.9 97.9 98.9 99.9 101 90 883 892 902 912 922 932 941 951 961 971
1000 102 103 104 105 106 107 108 109 110 111 100 981 990 1000 1010 1020 1030 1040 1050 1060 1070
Example: When converting 7.8 N·m into kgf·cm, Example: When converting 78 kgf·m into N·m, move
move to the 0.8 column along the to the 8 column along the
*7 row to obtain 79.5 kgf·cm. *70 row to obtain 765 N·m.
5-2
5-3
OMDO SERVICE
ENGINEERING GENERAL
c 2009 by Yamaha Motor Co.,Ltd.
1st Edition, December 2009
All rights reserved. Any reprinting or
unauthorized use without the written
permission of Yamaha Motor Co,. Ltd.
is expressly prohibited.
Printed in Japan
09.12– 0.5 1E

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YAMAHA MOTOR CO., LTD.

I. BASIC WORKSHOP PRACTICE [4] Torque Control ............................. 2-5

[2] Assembly ......................................... 2-2 3. Saw ..................................................... 2-13

1. Cleaning and Inspecting Threaded

III. HANDLING OF BASIC PARTS [8] Liquid Gasket ............................... 3-12

I. BASIC WORKSHOP PRACTICE

[1] Cautions when Performing Maintenance

(2) Keep Open Flames Away

(3) Use the Proper Tools

(4) Use Genuine Yamaha Parts

(5) Replace Consumable Parts (with

(6) Think Safety First

(7) Disassemble Carefully and In the Proper

(8) Assemble by Section and Confirm Opera-

(9) Keep the service manual and parts cata-

[2] Preparation for Basic Operations

(2) Air Tools

Be careful not to get tangled up in the air hose.

Do not touch rotating parts.

<Loosening nuts or bolts>

<Tightening nuts or bolts>

(3) Special Tools

(4) Measuring Equipment

(5) Other Equipment

(6) Replacement Parts and Consumable Parts

(7) Reference Materials

2. Proper Clean Up (Orderly, Organized, Clean)

(2) Measuring Equipment

(3) Small-size Equipment

(4) Medium-size Equipment

(5) Keep Service Area Clean and Neat

II. BASIC REPAIR OPERATIONS

• 2nd time - loosen with 3 to 4 rotations (di-

2. Always Apply Oil or Grease to Re- Example

If there is no specified tightening sequence:

4. Assembly Procedure Example

5. Confirm Operation After Assembling Example

[3] Inspection and Cleaning of Fasteners

Remove liquid gasket from the female sections

Clean, inspect and repair all matching sur-

If the matching surfaces are warped or have

3. Apply Oil to Threaded Section and

[4] Torque Control

QL Type Torque Wrench

2. Torque Control is Important in 4-

Sections in the D.O.H.C. engines that require

Pressure builds in the water jacket or water

formly performed with a torque wrench, cool-

[5] Tools Required for Basic Repair Operations

Single open-end Double open-end Open-end and box-type

Correct: 12-mm wrench used

2. Offset wrench (box wrench)

Diameter Hexagonal Socket sizes

Handle Drive direction

(2) Hinged handle (3) Sliding offset handle

For more torque

(4) Speed handle (5) Universal joint

(6) Extension bar (7) Socket adaptor

6. T-shaped flex wrench

Penetrating shank type Short

10. Impact screwdriver

Apply lubricant to help loosen the screw. Lubricant

Verify the direction of rotation, as screws which