Yamaha 2002 CS50, Service Manual, Page: 63 / 204

CHAPTER 4
ENGINE
ENGINE REMOVAL ………………………………………………………………4-1
COVER REMOVAL ……………………………………………………………4-1
COOLING SYSTEM (CS50Z only)……………………………………………4-1
CABLES, LEADS AND HOSES ………………………………………………4-1
ENGINE REMOVAL ……………………………………………………………4-2
ENGINE DISASSEMBLY …………………………………………………………4-3
REMOVING THE REAR WHEEL ……………………………………………4-3
REMOVING THE CYLINDER HEAD AND CYLINDER ……………………4-3
REMOVING THE PISTON PIN AND PISTON ………………………………4-3
REMOVING THE KICKSTARTER SYSTEM …………………………………4-4
REMOVING THE PRIMARY SHEAVE ………………………………………4-5
DISASSEMBLING THE SECONDARY SHEAVE ……………………………4-6
REMOVING THE STARTER SYSTEM ………………………………………4-7
TRANSMISSION ………………………………………………………………4-7
DC-CDI MAGNETO ……………………………………………………………4-8
AUTOLUBE OIL PUMP ………………………………………………………4-9
REMOVING THE CENTERSTAND……………………………………………4-9
DISASSEMBLING THE CRANKCASE AND CRANKSHAFT ………………4-9
INSPECTION AND REPAIR ……………………………………………………4-11
CHECKING THE CYLINDER HEAD ………………………………………4-11
CHECKING THE CYLINDER AND PISTON ………………………………4-12
CHECKING THE PISTON RINGS …………………………………………4-14
CHECKING THE PISTON PIN AND PISTON PIN BEARING ……………4-15
CHECKING THE KICKSTARTER ……………………………………………4-16
TRANSMISSION………………………………………………………………4-16
AUTOLUBE OIL PUMP ………………………………………………………4-17
CHECKING THE CRANKSHAFT ……………………………………………4-17
CHECKING THE BEARINGS ………………………………………………4-18
CHECKING THE PRIMARY SHEAVE ………………………………………4-18
CHECKING THE SECONDARY SHEAVE …………………………………4-19
CHECKING THE V-BELT ……………………………………………………4-20
STARTER CLUTCH AND GEARS …………………………………………4-21
ENGINE ASSEMBLY AND ADJUSTMENT …………………………………4-22
CRANKSHAFT AND CRANKCASE…………………………………………4-22
INSTALLING THE CRANKSHAF ……………………………………………4-23
AUTOLUBE OIL PUMP AND DC-CDI MAGNETO ………………………4-24
INSTALLING THE AUTOLUBE OIL PUMP
………………………………4-25
INSTALLING THE DC-CDI MAGNETO ……………………………………4-25
TRANSMISSION………………………………………………………………4-27
INSTALLING THE TRANSMISSION ………………………………………4-28
STARTER SYSTEM …………………………………………………………4-29
INSTALLING THE STARTER SYSTEM ……………………………………4-30
PRIMARY AND SECONDARY SHEAVE ……………………………………4-31
KICKSTARTER ………………………………………………………………4-32
ASSEMBLING THE SECONDARY SHEAVE ………………………………4-33
ASSEMBLING THE PRIMARY SHEAVE……………………………………4-34
INSTALLING THE KICKSTARTER …………………………………………4-36
PISTON, CYLINDER AND CYLINDER HEAD (CS50) ……………………4-37
PISTON, CYLINDER AND CYLINDER HEAD (CS50Z) …………………4-38
PISTON AND PISTON PIN …………………………………………………4-39
CYLINDER AND CYLINDER HEAD
………………………………………4-39
ENGINE REMOUNTING ……………………………………………………4-41
ENG