Yamaha EK40G, Service Manual

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Power unit
Special service tools ................................................................................... 5-1
Power unit ..................................................................................................... 5-4
Checking the compression pressure ....................................................... 5-4
Disassembling the manual starter ......................................................... 5-13
Checking the spiral spring ..................................................................... 5-13
Checking the drive pawl ........................................................................ 5-13
Measuring the starter rope .................................................................... 5-13
Assembling the manual starter .............................................................. 5-14
Removing the power unit ....................................................................... 5-15
Removing the flywheel magnet ............................................................. 5-16
Removing the electrical components .................................................... 5-17
Removing the throttle pulley assembly ................................................. 5-17
Disassembling the base assembly ........................................................ 5-18
Assembling the base assembly ............................................................. 5-18
Reed valves ................................................................................................ 5-19
Removing the reed valve assembly ...................................................... 5-21
Checking the reed valves ...................................................................... 5-21
Cylinder head ............................................................................................. 5-22
Removing the cylinder head .................................................................. 5-24
Checking the cylinder head ................................................................... 5-24
Removing the exhaust cover ................................................................. 5-24
Checking the exhaust cover .................................................................. 5-24
Crankcase ................................................................................................... 5-25
Removing the crankcase ....................................................................... 5-27
Removing the crankshaft assembly and oil seal housing ..................... 5-27
Checking the cylinder bore .................................................................... 5-27
Disassembling the oil seal housing ....................................................... 5-28
Checking the oil seal housing ............................................................... 5-28
Assembling the oil seal housing ............................................................ 5-28
Disassembling the piston ...................................................................... 5-28
Checking the piston diameter ................................................................ 5-29
Checking the piston clearance .............................................................. 5-29
Checking the piston rings ...................................................................... 5-29
Checking the piston ring side clearance ............................................... 5-30
Checking the piston pin boss bore ........................................................ 5-30
Checking the piston pin ......................................................................... 5-30
Checking the internal anodes ................................................................ 5-30
Disassembling the crankshaft ............................................................... 5-30
Checking the crankpin ........................................................................... 5-32
Assembling the crankshaft .................................................................... 5-32
Checking the crankshaft ........................................................................ 5-36
Installing the crankshaft bearings .......................................................... 5-36
Assembling the piston ........................................................................... 5-37
Assembling the power unit .................................................................... 5-37
Installing the power unit ......................................................................... 5-39
POWR
6H95G11_05 04.8.6 11:00 Page 1