User manual YAMAHA L6/L16

[. . . ] principally for the use of Yamaha/MBK agents and qualified mechanics. As it is not possible to give full mechanical instructions in a manual, it is presumed that the persons using the book to carry out the maintenance and repair of Yamaha/MBK motorcycles have a basic knowledge of the concepts and procedures inherent in the technology of motorcycle repair. Without such knowledge any attempt to repair or service this model may cause problems in its use and/or safety. Yamaha Motor España, S. A. , is continually trying to improve all models which it manufactures. [. . . ] Apply: · SE type 10W30 engine oil (on bearing of main axle and drive axle bearing) 6. Install: · Drive axle · Main axle · Conical spring washer · Flat washer 7. Install: · Gasket · Conical pins · Transmission box cover Screw (box cover) 0. 9 m · kg 4-26 ASSEMBLY AND ADJUSTMENT OF ENGINE STARTER SYSTEM MOT Bushing Bearing Starter wheel gear Starter clutch Plate Axle Flat washer Intermediate gear O-ring k Starter engine 10 4-27 ASSEMBLY AND ADJUSTMENT OF ENGINE STARTER SYSTEM 1. Install: · Bushing · Bearing · Starter wheel gear · Starter clutch NOTE: MOT · Apply grease with a lithium soap base on the bearing . · Apply molybdenum disulphide oil on the pin (starter clutch) . 2. Install: · Flat washer · Intermediate gear · Flat washer · Plate (intermediate gear) Screw (intermediate gear plate) 0, 8 m · kg NOTE: Apply engine oil on the intermediate gear 3. Install: · Starter motor Starter motor bolts 1, 3 m · kg NOTE: Apply grease with a lithium soap base on the o-ring of the starter motor. . 4-28 ASSEMBLY AND ADJUSTMENT OF ENGINE SECONDARY AND PRIMARY PULLEY WHEEL MOT Nut Clutch drum Clutch plate Shoe spring Clutch spring Spring seat Oil seal O-ring Secondary sliding pulley wheel k Trapezoidal belt 10 k Guide pin 11 k Secondary fixed pulley wheel 12 k Conical washer 13 k One-way clutch 14 k Washer 15 k Fixed primary pulley wheel 16 k Shim 17 k Hub 18 k Sliding primary pulley wheel 19 k Rollers 20 k Runner 21 k Cam 22 k Washer 23 *: Apply assembly lube FREE LENGTH LIMIT OF VARIATOR: 83 mm WASTE LIMIT OF CLUTCH HOUSING: 107. 4 mm WASTE LIMIT OF CLUTCH SHOES: 1. 0 mm TRAPEZOIDAL BELT WASTE LIMIT: 15. 7 mm VARIATOR ROLLER LIMIT: 14. 5 mm 4-29 ASSEMBLY AND ADJUSTMENT OF ENGINE KICKSTART PEDAL MOT Pedal axle Return spring Bushing Flat washer Elastic retainer Starter pedal Spring Pedal pinion gear 10 Nm (1. 0 m · kg) 150 ~ 250 g 4-30 ASSEMBLY AND ADJUSTMENT OF ENGINE MOT SECONDARY PULLEY WHEEL When assembling the secondary pulley wheel, reverse the disassembly procedure. Apply: · Assembly grease (in the sliding/fixed pulley wheel) 2. Install: · Sliding pulley wheel NOTE: Take care that the lips of the oil seals do not turn when the pulley wheel is installed. 3. Apply: · Assembly grease (on the torsion cam grooves and o-rings) 4. Install: · Small end bearing · Piston · Piston pin · Piston circlips NOTE: · The arrow of the piston should point to the exhaust side. · Before installing the piston circlip, cover the crankcase with a towel or clean cloth so that the circlip and other materials do not accidentally fall into the crankcase. · Always use new piston circlips. CYLINDER AND CYLINDER HEAD 1. Install: · Cylinder gasket (Use a new gasket) 2. Check: · Piston rings NOTE: · Ensure that the ends of the rings are correctly coupled around the centring devices on the piston grooves. · Check that the manufacturers symbols or numbers printed on the rings are on the upper side of same. 4-36 ASSEMBLY AND ADJUSTMENT OF ENGINE 3. Install: · Cylinder MOT NOTE: Install the cylinder with one hand while compressing the piston rings with the other. 4. Install: · Cylinder head gasket (new gasket) 5. Install: · Cylinder head · Spark plug · Air protector NOTE: · The arrow "EX" from the cylinder head should point to the exhaust side. · Tighten the cylinder head positioning nuts in several steps, using a cris-cross pattern Cylinder head positioning screws 1. 4 m · kg spark plug 2. 0 m · kg 6. Install: · Central stand · Spring · Axle · Clasp · Rubber washer · Strap loop 7. [. . . ] · Check if there is a voltage (12 V) on the "Chocolate" or "Dark Green" cable of the bulb holder connector. SATISFIES THE SPECIFIED VALUE (12 V) The circuit is in good condition. The oil indicator light "OIL" does not light. Bulb and bulb holder · Check the bulb and bulb holder for continuity. [. . . ]