Yamaha 2003 TZR50, Service Manual

Page: 79 / 251

CHAPTER 4
ENGINE
REMOVING THE ENGINE ………………………………………………………4-1
PREPARING FOR REMOVAL…………………………………………………4-1
PETROL TANK …………………………………………………………………4-2
AIR FILTER ……………………………………………………………………4-3
EXHAUST PIPE
………………………………………………………………4-4
COOLANT PIPES ………………………………………………………………4-4
SPARK PLUG AND THERMOCONTACT CABLE …………………………4-5
NEUTRAL SWITCH CABLE …………………………………………………4-5
OIL PUMP ………………………………………………………………………4-5
CARBURETTOR ………………………………………………………………4-6
SHIFT LEVER, DRIVE CHAIN AND CLUTCH CABLE ……………………4-6
ENGINE REMOVAL ……………………………………………………………4-7
DISMANTLING THE ENGINE …………………………………………………4-7
OIL PUMP ………………………………………………………………………4-7
WATER PUMP COVER ………………………………………………………4-7
RIGHT CRANKCASE COVER, OIL PUMP SHAFT AND
WATER PUMP SHAFT ……………………………………………………4-7
PRIMARY TRACTION GEARING AND CLUTCH …………………………4-8
CDI MAGNETO ………………………………………………………………4-10
STARTER MOTOR ……………………………………………………………4-10
CYLINDER HEAD AND CYLINDER
………………………………………4-11
PISTON PIN AND PISTON …………………………………………………4-12
CRANKCASE …………………………………………………………………4-12
SELECTOR AND SHIFT ……………………………………………………4-13
CRANKSHAFT ………………………………………………………………4-13
BEARINGS AND OIL SEALS ………………………………………………4-14
INSPECTION AND REPAIR ……………………………………………………4-14
CYLINDER HEAD ……………………………………………………………4-14
PISTON ………………………………………………………………………4-15
CYLINDER ……………………………………………………………………4-16
PISTON RINGS ………………………………………………………………4-17
PISTON PIN AND BEARING ………………………………………………4-17
AUTOLUBE PUMP
…………………………………………………………4-18
CLUTCH ………………………………………………………………………4-18
SELECTOR ……………………………………………………………………4-20
SHIFT …………………………………………………………………………4-20
CRANKSHAFT ………………………………………………………………4-21
REVOLUTION COUNTER SENDER ………………………………………4-21
BEARINGS AND OIL SEALS ………………………………………………4-22
CRANKCASE …………………………………………………………………4-22
ASSEMBLING AND ADJUSTING THE ENGINE ……………………………4-23
CRANKSHAFT ………………………………………………………………4-23
SHIFT AND SELECTOR ……………………………………………………4-25
CRANKCASE …………………………………………………………………4-27
STARTER MOTOR ……………………………………………………………4-29
CDI MAGNETO ………………………………………………………………4-30
CLUTCH AND PRIMARY TRACTION GEARING …………………………4-31
WATER PUMP SHAFT, OIL PUMP SHAFT AND
RIGHT-HAND CRANKCASE COVER ……………………………………4-35
WATER PUMP COVER ………………………………………………………4-36
OIL PUMP ……………………………………………………………………4-36
PISTON PIN AND PISTON …………………………………………………4-37
CYLINDER HEAD AND CYLINDER
………………………………………4-38
INSTALLING THE ENGINE …………………………………………………4-40
ENG