Yamaha YX600 (1984-1992) [105/200] Disassembly inspection and reassembly

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2 56 Chapter 2 Engine clutch and transmission 31 6 Lift tho starter clutch out of the crankcase 31 10b then remove the pins and springs 6 Lift the starter clutch from the drive chain and lift it out see illustration 7 Remove the Allen bolts that hold the chain tensioner pad to the case and remove the tensioner see illustration 22 8a 8 Remove the Allen bolts that hold the starter chain tensioner see illustration 22 8a and unscrew the oil pressure relief valve used to secure the oil supply line see Section 16 Disassembly inspection and reassembly Refer to illustrations 31 10a 31 10b and 31 10c 9 Refer to illustration 22 8b and separate the starter clutch components Check all parts for wear and damage and replace as necessary 10 Press a starter clutch pin away from the roller with a small screwdriver against the spring tension and remove the roller see illustration Remove the pin and spring seo illustration Remove the other rollers springs and pins in the same way Inspect the rollers springs and pins and replace any that show wear or damage Reassemble the starter clutch so the pins retain the rollers in position see illustration 11 Rotate the bearing on the starter clutch shaft and check for roughness looseness or noise If the bearing is bad have it pressed off the shaft and a new one pressed on by a Yamaha dealer or machine shop 12 The oil seal in the bearing housing should be replaced if it s worn 31 10a Push the pins away from the rollers with a small screwdriver and take tho rollers out 31 10c The pins should fit against the rollers like this Since the seal is inexpensive and a good deal of work is required t to it it s a good idea to replace the seal as a matter of course Tap seal out of the housing with a hammer and a bearing driver or so then install a new one with the same tools 13 Pull the piston and spring assembly from the starter drive c tensioner housing see illustration 22 8b 14 Use a pair of pliers to remove the oil pipe from the bottom o tensioner housing Be sure to replace the O ring whenever the oil is removed Installation 15 Installation is the reverse of the removal steps Use n permanent thread locking agent on the threads of the starter c guide bolts starter chain tensioner bolts and the bearing hou screws 32 Initial start up after overhaul 1 Make sure the engine oil level is correct then remove the s plugs from the engine Place the engine kill switch n the Off pos and unplug the primary low tension wires from the coils 2 Turn on the key switch and crank the engine over with the st several times to build up oil pressure Reinstall the spark p connect the wires and turn the switch to On

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