Yamaha 2003 YFZ450S, Service Manual

Page: 141 / 375

ENG
CLUTCH ........................................................................................................ 4-48
REMOVING THE CLUTCH ..................................................................... 4-50
CHECKING THE FRICTION PLATES..................................................... 4-50
CHECKING THE CLUTCH PLATES ....................................................... 4-51
CHECKING THE CLUTCH SPRINGS..................................................... 4-51
CHECKING THE CLUTCH HOUSING .................................................... 4-51
CHECKING THE CLUTCH BOSS........................................................... 4-52
CHECKING THE PRESSURE PLATE .................................................... 4-52
CHECKING THE PUSH RODS ............................................................... 4-52
CHECKING THE PUSH LEVER.............................................................. 4-52
CHECKING THE PRIMARY DRIVEN GEAR .......................................... 4-52
INSTALLING THE CLUTCH.................................................................... 4-53
BALANCER ................................................................................................... 4-55
REMOVING THE BALANCER DRIVE GEAR
AND BALANCER DRIVEN GEAR .......................................................... 4-56
CHECKING THE PRIMARY DRIVE GEAR, BALANCER DRIVE GEAR
AND BALANCER DRIVEN GEAR .......................................................... 4-56
CHECKING THE BALANCER ................................................................. 4-56
INSTALLING THE BALANCER DRIVE GEAR
AND BALANCER DRIVEN GEAR .......................................................... 4-57
OIL PUMP ...................................................................................................... 4-58
CHECKING THE OIL PUMP ................................................................... 4-60
SHIFT SHAFT ................................................................................................ 4-61
CHECKING THE SHIFT SHAFT ............................................................. 4-63
CHECKING THE STOPPER LEVER ...................................................... 4-63
CHECKING THE SHIFT GUIDE AND SHIFT LEVER............................. 4-63
CHECKING THE SHIFT DRUM SEGMENT ........................................... 4-63
INSTALLING THE SHIFT LEVER ........................................................... 4-63
INSTALLING THE SHIFT SHAFT ........................................................... 4-64
CRANKCASE ................................................................................................ 4-65
OIL SEAL AND BEARING....................................................................... 4-67
SEPARATING THE CRANKCASE.......................................................... 4-68
CHECKING THE OIL STRAINER AND OIL DELIVERY PIPE 2 ............. 4-68
CHECKING THE TIMING CHAIN AND GUIDE....................................... 4-69
CHECKING THE BEARINGS AND OIL SEALS...................................... 4-69
CHECKING THE CRANKCASE .............................................................. 4-69
ASSEMBLING THE CRANKCASE.......................................................... 4-70
CRANKSHAFT .............................................................................................. 4-72
REMOVING THE CRANKSHAFT ........................................................... 4-73
CHECKING THE CRANKSHAFT ............................................................ 4-73
INSTALLING THE CRANKSHAFT .......................................................... 4-74