900RL

Cylinder, Head and Valves

Submitted by xjcdadmin on Thu, 06/27/2013 - 10:26

Cylinder head cover

Place head cover on a surface plate. There should be no warpage. Correct by re-surfacing as follows:

Place # 400 or # 600 grit wet sandpaper on surface plate and re-surface head cover using a figure-eight sanding pattern. Rotate head cover several times to avoid removing too much material from one side.

Cylinder head

Middle Gear

Submitted by xjcdadmin on Thu, 06/27/2013 - 10:26

MIDDLE GEAR/DAMPER

a. Middle gear lash 0 2 mm (0.008 in)

d. Measure the gap between the driven gear bearing housing flange and the crankcase with a feeler gauge. This is the shim size required.

Clutch and Handlebars adjustment

Submitted by xjcdadmin on Thu, 06/27/2013 - 10:26

Clutch adjustment

This model has two clutch cable length adjusters. The cable length adjusters are used to take up slack from cable stretch and to provide sufficient free play for proper clutch operation. Normally, once the clutch cable length adjuster (crankcase) is properly set; the only adjustment required is maintenance of free play at the clutch cable length adjuster (handlebar lever).

Transmission, Clutch and Middle gear

Submitted by xjcdadmin on Thu, 06/27/2013 - 10:26

TRANSMISSION

3. Crankcase assembly a. Apply Yamaha bond #4 sealant or equivalent to the crankcase mating surface. Be very careful not to allow any sealant to come in contact with the oil gallery "O-ring" and crankshaft bearings. It is extremely important, however, that sealant be applied around the case stud holes. Apply sealant to within 2 — 3 mm (0.08 0.12 in) of the bearings.