Instruction manual

COPY
-4-
Dec./08/’06
◇Install a spark plug.
Specified torque : 13 N・m (1.3kgf・m)
※Be sure to replace the spark plug with the one
with high thermal value of CR8E (NGK) or the
higher one.
◇ Install and tighten the spark plug cap securely.
●Cam Chain Tensioner Installation
◇ Turn up a one-way pawl on the cam chain
tensioner, and press a tensioner rod into it.
◇Install a provided gasket and cam-chain tensioner
to the cylinder with two bolts.
Ｏ Install a ring, spring and cap bolt.
Specified torque:
Tensioner mounting bolt
: 9 N・m (0.9kgf・m)
Cap bolt : 8 N・m (0.8kgf・m)
◇ Rotate the crank shaft clockwise, and check that
“I” mark on the cam sprocket is aligned with the
alingment mark on the cylinder head when the ”T”
mark on the flywheel is aligned again with the
“｢” alignment mark on the crankcase cover.
◇ Attach a cover on the cam chain tensioner.
●Spark Plug Installation
◇ Loosely tighten two nuts on the cylinder head
side.
◇Temporarily fix the exhaust pipe onto the rear arm
with a bolt & washer.
●Air Shroud Installation
◇ Put together the left and right side cylinder air
shrouds, and fix them with tapping screws.
Be careful not to jam a heat protector.
◇ Install a fan air shroud with a tapping screw and
pan screw.
● Exhaust Pipe Installation
◇ With reference to YAMAHA genuine parts
service manual, reinstall or connect all the
removed parts.
●Carburetor Installation
◇ Insert the carburetor into the manifold, and
tighten a carburetor clamp to fix the carburetor.
● Parts Reinstallation
◇ We have designed the clearance between
piston and cylinder narrow. So, refrain from
sudden acceleration, and, in addition, never fail
to carry out shakedown for about 100 km at
reduced engine revolutions.
●Engine Starting
1. About fuel
◇ High-octane gasoline should always be used.
◇ When regular gasoline is remaining in the fuel
tank, always replace it with high-octane
gasoline.
2. Final Checking
◇ Check every section for slacks in screws, nuts
or the like.
◇Make sure that engine oil is remaining in a
specified amount or more.
◇Drive the engine in a well-ventilated safe place
with great care. Keep the engine idling for about
5 minutes so the engine oil gets circulated all
around the engine.
◇Check that there is no abnormal noise from the
engine or oil leak in every gasket.
◇Shut off the engine and wait for it to be cool.
Then double check each section for slack in
screws and nuts.
●About Shakedown
3-5-16 Nishikiorihigashi Tondabayashi
Osaka Japan
TEL : [phone]
FAX : [phone]
URL : http://www.takegawa.co.jp
◇Degrease the mating surface of the cylinder
head with thinner or the like. Pass the cam chain
through the cylinder head and install the
cylinder head.
Loosely tighten four washers / nuts and two
bolts to the stud bolts. Tighten nuts to the
specified torque in several speps in order of
the numbers in the figure below.
Specified torque
Cylinder head nut : 22 N・m (2.2kgf・m)
Cylinder head bolt : 10 N・m (1.0kgf・m)
●Cylinder Head Installation
１
２
３
４
５
６
◇Install the cam sprocket to the cam chain,
aligning the “I” mark on the cam sprocket with
the “ △ ” mark on the cylinder head.
※ Fix the cam chain so the lower part of it (at the
exhaust side) is stretched tight.
◇Aligning the notch on the cam shaft with the
cam sprocket pawl, fix a breather plate and
bolts. While holding the flywheel, tighten cam
sprocket bolts.
Specified torque : 30 N・m (3.0kgf・m)
◇Check that the “I” mark on the flywheel is still
aligned with the“△”mark on the crank case.
●Cam Sprocket Installation
Flywheel
Crank case
“I” mark
Alignment
mark
Slack
Tense
◇ Tighten all loosely-tightend nuts, bolts and
washers to the specified torque.
Specified torque
Cylinder head nut : 13 N・m (1.3kgf・m)
Rear arm bolt : 31 N・m (3.1kgf・m)
Rear arm bolt / washer
: 53 N・m (5.3kgf・m)
Bolt
Bolt
Bolt / washer
◇ Insert a thickness gauge between the adjusting
screw and valve stem to adjust the valve
clearance. Holding the adjusting screw, tighten
up the lock nut.
Valve clearance: 0.04 ∼ 0.07 mm both for intake
and exhaust.
Specified torque : 7 N・m (0.7kgf・m)
◇Install the cam sprocket cover and O-ring with
two bolts.
Specified torque : 7 N・m (0.7kgf・m)
◇Install a tappet cover and O-ring for both intake
and exhaust with three bolts each.
Specified torque : 7 N・m (0.7kgf・m)
●Adjustment of valve clearance:
(In the case of a cam being provided.)