Instruction manual

COPY
-2-
Dec./08/’06
∼ Kit Contents ∼
∼ Installation Procedures ∼
◎ Please be informed that, mainly because of improvement in performance, design changes, and cost increase, product specifications and prices are
subject to change without prior notice.
◎ A defective product which we acknowledge is caused by product materials or defect in manufacturing will be repaired or replaced with a new one
by us at our expense, if and when a claim is filed with us within one (1) month of your purchase. However, replacing of parts shall be made at users’
expenses. And we shall be held free from responsibility for any defect caused by improper installation or use.
◎ You are requested to keep this instruction manual until you discard this product.
◇ With reference to YAMAHA genuine parts
service manual, disconnect the following parts.
・Negative pressure hose on the manifold
・Spark plug cap
・Blow-by gas hose on the cam sprocket cover
・Secondary air supply pipe on the cylinder head
◇ Before doing work, place the motorcycle on
level ground to stablize the position of your
motorcycle. As to the following procedures,
work only when the engine and the muffler are
cool. (Otherwise, you will burn yourself.)
●Parts Removal
1. Body Cover
◇ With reference to YAMAHA genuine parts
service manual, remove following parts.
・Front cover
・Fuel-pump-mounting bolts
・Seat / trunk
・Seat lock
・Standing handle
・Left / Right side covers
・Tail light unit
・Left / Right side mauls
・Under cowl
・Foot rest board
2. Junctions
●Carburetor Removal
◇Loosen the carburetor clamp on the manifold, and
disconnect the carburetor.
●Exhaust Pipe Removal
◇ Remove two nuts on the cylinder head.
◇Remove bolts on a rear arm, and remove an
exhaust pipe.
●Air Shroud Removal
◇ Remove pan screws and tapping screws, and
remove a fan air shroud.
◇ Remove tapping screws, divide right and left
side cylinder air shrouds, and remove them.
●Spark Plug Removal
◇Remove a spark plug.
Manifold
Hose
Hose
Spark plug cap
Pipe
Cylinder head
Cam sprocket cover
Hose
※ A camshaft is not included in Item No. of 01-05-
4460.
１
２
３
４
５
６
７
８
９
◇ Remove a cam sprocket cover and O-ring.
◇ Rotate a flywheel clockwise, and align an “I”
mark on the cam sprocket with an “ △ ”mark
on the cylinder head. This position is at what is
called TDC (Top Dead Center) on the
compression stroke.
●Cam Sprocket Removal
“I” mark
Alignment
mark
◇Holding the flywheel, loosen a cam sprocket
bolt. Remove a cap bolt of the cam chain
tensioner and take out a spring.
◇ Unfasten the cam sprocket bolts and remove
breather plate and cam sprocket.
◇Remove bolts and the cam chain tensioner frm
the cylinder.
No. Parts Name Qty
１ Piston １
２ Piston ring set １
３ Wrist pin １
４ Wrist pin circlips ２
５ Cylinder １
６ Cylinder head gasket １
７ Cylinder gasket １
８ Tenstioner lifter gasket １
※９ Camshaft １