User manual YAMAHA CS30L

[. . . ] This model is the culmination of Yamaha's vast experience in the production of pacesetting racing machines. It represents the highest grade of craftsmanship and reliability that have made Yamaha a leader. This manual explains operation, inspection, basic maintenance and tuning of your machine. If you have any questions about this manual or your machine, please contact your Yamaha dealer. [. . . ] G Before removing each piston pin, deburr the clip groove and pin hole area. If the piston pin groove is deburred and the piston pin is still difficult to remove, use the piston pin puller 4. Piston pin puller: YU-1304/90890-01304 CAUTION: Do not use a hammer to drive the piston pin out. Remove: G Piston rings NOTE: Spread the end gaps apart while at the same time lifting the piston ring over the top of the piston crown, as shown in the illustration. INSPECTION Cylinder and piston 1. Inspect: G Cylinder and piston walls Vertical scratches Replace cylinder and piston. Measure: G Piston-to-cylinder clearance Measurement steps: 1st step: G Measure the cylinder bore "C" with a cylinder bore gauge. NOTE: Measure the cylinder bore "C" in parallel to and at right angles to the crankshaft. Then, find the average of the measurements. 4 - 43 CYLINDER AND PISTON ENG 95. 00 ~ 95. 01 mm (3. 7402 ~ 3. 7406 in) 0. 05 mm (0. 002 in) 0. 05 mm (0. 002 in) Cylinder bore "C" Taper limit "T" Out of round "R" "C" = Maximum D "T" = (Maximum D1 or D2) ­ (Maximum D5 or D6) "R" = (Maximum D1, D3 or D5) ­ (Minimum D2, D4 or D6) G If out of specification, replace the cylinder, and replace the piston and piston rings as set. 2nd step: G Measure the piston skirt diameter "P" with a micrometer. a 8 mm (0. 315 in) from the piston bottom edge Piston size "P" Standard G 94. 945 ~ 94. 960 mm (3. 738 ~ 3. 739 in) If out of specification, replace the piston and piston rings as a set. 3rd step: G Calculate the piston-to-cylinder clearance with following formula: Piston-to-cylinder clearance = Cylinder bore "C" ­ Piston skirt diameter "P" Piston-to-cylinder clearance: 0. 040 ~ 0. 065 mm (0. 0016 ~ 0. 0026 in) <Limit>: 0. 1 mm (0. 004 in) G If out of specification, replace the cylinder, and replace the piston and piston rings as set. 4 - 44 CYLINDER AND PISTON ENG Piston ring 1. Measure: G Ring side clearance Use a feeler gauge 1. Out of specification Replace the piston and rings as a set. Lubricate: G Piston G Piston rings G Cylinder NOTE: Apply a liberal coating of engine oil. Install: G Dowel pins G O-ring New G Gasket 1 G Cylinder 2 NOTE: Install the cylinder with one hand while compressing the piston rings with the other hand. 3 New CAUTION: G G Pass the timing chain 3 through the timing chain cavity. Be careful not to damage the timing chain guide 4 during installation. Install: G Bolt (cylinder) 10 Nm (1. 0 m · kg, 7. 2 ft · lb) R. T. 4 - 47 CLUTCH CLUTCH CLUTCH ENG Extent of removal: 1 Push rod and push lever removal 2 Push pod 1 disassembly 3 Friction plate and clutch plate removal 4 Clutch housing removal Order Part name CLUTCH REMOVAL Drain the engine oil. Brake pedal Clutch cable Clutch cover Gasket Dowel pin Clutch spring Pressure plate Push rod 1 Circlip Plain washer Bearing Ball Push rod 2 4 - 48 Q'ty Remarks Refer to "ENGINE OIL REPLACEMENT" section in the CHAPTER 3. Refer to "ENGINE REMOVAL" section. 1 1 2 6 1 1 1 1 1 1 1 Extent of removal Preparation for removal 1 2 3 4 1 1 2 3 4 5 6 7 8 9 10 11 CLUTCH ENG Extent of removal Order 12 13 14 15 16 17 18 19 Part name Clutch plate Friction plate Nut Look washer Clutch boss Thrust washer Clutch housing Push lever Q'ty 8 9 1 1 1 1 1 1 Remarks 3 4 Use special tool. Refer to "REMOVAL POINTS". 1 4 - 49 CLUTCH EC493000 ENG REMOVAL POINTS EC483211 Clutch boss 1. Remove: G Nut 1 G Lock washer 2 G Clutch boss 3 NOTE: Straighten the lock washer tab and use the clutch holding tool 4 to hold the clutch boss. Å i Clutch holding tool: YM-91042/90890-04086 Å For USA and CDN i Except for USA and CDN EC494000 INSPECTION EC484100 Clutch housing and boss 1. [. . . ] Turn adjuster clockwise (about 2 clicks) to increase damping. Increase oil level by about 5 ~ 10 mm (0. 2 ~ 0. 4 in). Decrease oil level by about 5 mm (0. 2 in). Increase oil level by about 5 mm (0. 2 in). [. . . ]