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XS400 (1976-1982)
Инструкция по эксплуатации Страница: 14

Yamaha XS400 (1976-1982) [14/34] Yamaha xs360 400

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Yamaha XS360 400 Bore the cylinders so that the piston clear ance will be 0 030 0 050 mm 0 00120 0020 in 6 If only the pistons are being replaced and no boring is being done to the cylinders note that pistons and cylinders are graded A or B The piston is marked on the crown and the cylinders at the cylinder base Fit A pistons with A cylinders and B pistons with B cylinders 7 Check the condition of the wrist pins If the pins are blued or show indications of step wear they should be replaced Usually step wear can be detected by running a fingernail along the length of the wrist pin A more conclusive method is to measure the di ameter of the pin at three places along its length and compare the readings Check that any o rings and the important dowel pins fitted to the cylinders are in their proper locations before installation PISTON RINGS Two checks to be made on the piston rings are side clearance and end gap These checks should be made on both new and used rings 1 Piston ring side clearance for compres sion rings is checked with the rings installed on the piston Insert a feeler gauge blade be tween the ring and the ring groove and check that the clearance is within the specification given for your machine in the Engine Speci fications chart at the end of this section If the clearance is too large the rings or grooves are worn If too small metal may have been pushed into the grooves due to a piston seizure Check that the grooves are not just carboned up If new rings do not bring the clearance to the proper value the pistons must be replaced 2 To remove the rings from the piston use a ring spreader as illustrated They are available at most auto stores Decarbonize the ring grooves 3 To check the ring end gap ensure first Piston grading mark locations 8 Insert each wrist pin into its piston and check for play of the pin in the piston hole There must be none The pin must be a fairly tight fit If the pin is easily inserted and can be turned or moved vertically with no ef fort the pistons should be replaced 9 Lightly oil each wrist pin and insert it into its connecting rod Check for vertical play There should be none If play exists or if the rod small end is discolored the rod and or pin should be replaced 10 Check the connecting rods for a bent condition This can be accomplished with two small rectangular blocks of metal of equal thickness Insert the wrist pins into the rods and position the pieces of metal beneath them on either side of the rods and resting on the crankcase Rotate the engine so that the wrist pin rests on the blocks Both sides of the wrist pin must contact the metal blocks or the rod is bent and must be replaced 11 Before installation decarbonize the piston crowns Remove any carbon from the ring grooves with a piece of broken ring or a very thin screwdriver Be careful not to scratch the grooves Carefully check the cylinder cleaning the bore thoroughly If considerable mileage has been covered honing the cylinders and fit ting new rings is recommended If the cylin ders are honed make a strenuous effort to clean them thoroughly afterwards preferably with very hot soapy water and a stiff brush This is to remove any abrasive particles de posited by the hone in the course of the operation Remove any traces of gasket material from the cylinder base and the head mating sur face 12 Be sure that all oil passages in the cyl inder are clear Check the condition of the cam chain tensioner guides and replace them if damaged 13 Replace the cylinder base o rings 1276 Removing piston rings with an expander makes breakage unlikely stamped 25 50 75 or 100 and must be fitted to the correct oversized piston Oversized oil rings have painted expan ders Red is standard and the four oversizes are brown blue black and yellow in ascending order Stagger the ring end gaps around the piston as shown 2 To install the three piece oil ring in stall one rail on the piston below the oil ring groove fit the expander then move the rail into place Install the top rail 3 Use a ring expander to install the rings to reduce the chance of breaking them 4 Ring end gaps must be staggered around the piston so that they do not overlap Position the end gaps as shown in the illus tration Note that none of the end gaps are positioned at the very front or sides of the piston 5 Install the pistons on their connecting rods so that the arrow marks on the crown face the front exhaust side of the engine NOTE Be sure to use new wrist pin cir clips 6 Slip the wrist pins into place heating the piston crown as on removal if necessary Install the wrist pin circlips with a needle nosed pliers Be sure each circlips is firmly seated in its groove and arranged so that the circlip end gap and the cut out in the piston do not align 7 Lubricate the rings and piston skirts with clean motor oil 8 Install the o ring on the oil delivery passage which is around the right rear stud 9 Install the cylinder base gasket Check that the cam chain is properly engaged with the crankshaft sprocket 10 Install the cylinder routing the cam chain up through its passage as the cylinders are lowered Compress the piston rings with your fingers as the pistons enter the bores Be sure the cylinders are firmly seated that the cylinder bore is not excessively worn Place each ring in tum into the bot tom of its cylinder and push it in an inch or more using the piston skirt to align the ring in the bore Measure the end gap with a feeler gauge If the end gap is larger than the service limit the rings must be replaced If the measured end gap of new rings is too large the cylinder is worn and should be bored to the next oversize If new rings are fitted and the end gap is too small the ring ends must be filed Hold the ring steady as illustrated closing the ends over a thin fine file Do not squeeze the ring as this is the easiest way to break it A few strokes of the file will increase the endCylinder Head gapCAUTION Do not make more than a few Installation strokes before checking the end gap again 1 Be sure that the oil delivery passage It is easy to remove too much metal o ring is fitted to the right rear stud Check Do not allow the file to slip out of the ring that the dowel pins are fitted to the right and as this risks breaking it left front studs Install the cylinder head gas 4 Roll each ring around its own groove ket and ensure that this can be done easily If a 2 Fit the cylinder head over the studs ring sticks or binds in the groove the pistons and gradually lower it into position while must be replaced pulling the cam chain through the cut out 3 Install and tighten the cylinder head bolts and nuts Bolts should be torqued to 7 ft Cylinder and Piston lbs nuts to 24 ft lbs Tightening should be Installation done gradually and in a cross pattern begin 1 When installing piston rings note that ning with the centermost nuts Refer to the all rings are installed with the manufacturer s illustration showing tightening sequence mark the small letter near the end gap fac Lubricate the cam bearings on the head ing up 4 Pull up the cam chain and slip the cam NOTE Oversize compression rings are through Fit the cam sprocket so that the

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