User manual YAMAHA MCS-1330

[. . . ] primarily for use by Yamaha dealers and their qualified mechanics. it is not possible to include all the knowledge of a mechanic in one manual. Therefore, anyone who uses this book to perform maintenance and repairs on Yamaha vehicles should have a basic understanding of mechanics and the techniques to repair these types of vehicles. Repair and maintenance work attempted by anyone without this knowledge is likely to render the vehicle unsafe and unfit for use. [. . . ] Measure the compressed Plastigauge® width c each crankshaft journal. If the clearance is out of specification, select replacement crankshaft journal bearings. 2. Select: S crankshaft journal bearings (J1 J5) NOTE: S The numbers stamped into the crankshaft web and the numbers stamped into the lower crankcase are used to determine the replacement crankshaft journal bearing sizes. S "J1" "J5" refer to the bearings shown in the crankshaft illustration. S If "J1" "J5" are the same, use the same size for all of the bearings. For example, if the crankcase "J1" and crankshaft web "J1" numbers are "6" and "2" respectively, then the bearing size for "J1" is: Bearing size for J1: "J1" (crankcase) ­ "J1" (crankshaft web) ­ 1= 6­2­1=3 J1 J2 J3 J4 J5 CRANKSHAFT JOURNAL BEARING COLOR CODE 0 1 2 3 4 White Blue Black Brown Green NOTE: If the size is the same for all "J1 to J5", one digit for that size is indicated. (crankcase side only) 4-81 CRANKSHAFT EAS00407 ENG INSTALLING THE CRANKSHAFT 1. Install: S crankshaft journal upper bearings (into the upper / lower crankcase) NOTE: S Align the projections a on the crankshaft journal upper bearings with the notches b in the upper crankcase. S Be sure to install each crankshaft journal upper bearing in its original place. 4-82 TRANSMISSION EAS00419 ENG TRANSMISSION 12 Nm (1. 2 mSkg) 10 Nm (1. 0 mSkg) Order Job/Part Removing the transmission Crankcase lower Shift shaft and stopper lever Drive axle assembly Circlip Oil seal Bearing Shift bar stopper Shift fork guide bar Q'ty Remarks Remove the parts in the order listed. Refer to "SHIFT SHAFT". 1 2 3 4 5 6 1 1 1 1 1 2 4-83 TRANSMISSION ENG 12 Nm (1. 2 mSkg) 10 Nm (1. 0 mSkg) Order 7 8 9 10 11 12 Job/Part Spring Shift fork "L" Shift fork "R" Shift drum assembly Shift fork "C" Main axle assembly Q'ty 4 1 1 1 1 1 Remarks Refer to "INSTALLING THE TRANSMISSION". Refer to "REMOVING THE TRANSMISSION". For installation, reverse the removal procedure. 4-84 TRANSMISSION ENG Order Job/Part Disassembling the main axle assembly Bearing 2nd pinion gear Toothed lock washer Toothed lock washer retainer 6th pinion gear Collar Washer Circlip 3rd pinion gear Circlip Q'ty Remarks Remove the parts in the order listed. 1 2 3 4 5 6 7 8 9 10 1 1 1 1 1 1 1 1 1 1 4-85 TRANSMISSION ENG Order 11 12 13 14 15 16 Job/Part Washer 5th pinion gear Collar Main axle Bearing housing Bearing Q'ty 1 1 1 1 1 1 Remarks For installation, reverse the removal procedure. 4-86 TRANSMISSION ENG Order Job/Part Disassembling the drive axle assembly Washer 1st wheel gear Collar 5th wheel gear Circlip Washer 3rd wheel gear Collar Toothed lock washer Toothed lock washer retainer 4th wheel gear Q'ty Remarks Remove the parts in the order listed. 1 2 3 4 5 6 7 8 9 10 11 1 1 1 1 1 1 1 1 1 1 1 4-87 TRANSMISSION ENG Order 12 13 14 15 16 17 18 19 20 21 22 23 24 Job/Part Collar Washer Circrip 6th wheel gear Circrip washer 2nd wheel gear Collar Collar Oil seal Bearing Circrip Drive axle Q'ty 1 1 1 1 1 1 1 1 1 1 1 1 1 Remarks For installation, reverse the removal procedure. 4-88 TRANSMISSION EAS00420 ENG REMOVING THE TRANSMISSION 1. S Install shift fork "C" into the groove in the 3rd and 4th pinion gear on the main axle. S Install shift fork "L" into the groove in the 6th wheel gear and shift fork "R" into the groove in the 5th wheel gear on the drive axle. S Make sure that the drive axle bearing circlip is inserted into the grooves in the upper crankcase. NOTE: Oil each gear, shaft, and bearing thoroughly. 4-91 COOL CHAPTER 5. 5-13 5-15 5-15 5-16 RADIATOR COOL COOLING SYSTEM RADIATOR 9 Nm (0. 9 mSkg) 7 Nm (0. 7 mSkg) 28 Nm (2. 8 mSkg) Order Job/Part Removeing the radiator Rider seat and fuel tank Air filter case and heat protector plate Bottom cowling and side cowlings Coolant Coolant reserver hose Breather hose Radiator outlet hose Q'ty Remarks Remove the parts in the order listed. Refer to "SEATS" and "FUEL TANK" in chapter 3. Refer to "AIRFILTER CASE AND IGNITION COILS" in chapter 3. Refer to "COWLINGS" in chapter 3. Drain. 1 2 3 1 2 1 Disconnect. 5-1 RADIATOR COOL 9 Nm (0. 9 mSkg) 7 Nm (0. 7 mSkg) 28 Nm (2. 8 mSkg) Order 4 5 6 7 8 9 Job/Part Radiator inlet hose Oil cooler outlet hose Thermo switch coupler Radiator fan motor coupler Radiator Radiator fan Q'ty 1 1 1 1 1 1 Disconnect. Disconnect. Remarks For installation reverse the removal procedure. 5-2 RADIATOR EAS00455 COOL CHECKING THE RADIATOR 1. Apply compressed air to the rear of the radiator. [. . . ] S Is the fuel level indicator light LED OK?YES NO Repair the fuel level indicator light LED. EB812404 2. Fuel sender S Disconnect the fuel sender coupler from the wire harness. S Connect the pocket tester (W 1) to the fuel sender coupler as shown. [. . . ]