Yamaha FJ (1984-1992) [6/200] Maintenance techniques tools and working facilities
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Yamaha FJ (1984-1992) [6/200] Maintenance techniques tools and working facilities

Yamaha FZ (1984-1992) [6/200] Maintenance techniques tools and working facilities

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0 8 Maintenance techniques tools and working facilities Basic maintenance techniques There are a number of techniques involved in maintenance and repair that will be referred to throughout this manual Application of these techniques will enable the amateur mechanic to be more efficient better organized and capable of performing the various tasks properly which will ensure that the repair job is thorough and complete Fastening systems Fasteners basically are nuts bolts and screws used to hold two or more parts together There are a tew things to keep in mind when working with fasteners Almost all of them use a locking device ot some type either a lock washer locknut locking tab or thread adhesive All threaded fasteners should be clean straight have undamaged threads and undamaged corners on the hex head where the wrench fits Develop the habit of replacing all damaged nuts and bolts with new ones Rusted nuts and bolts should be treated with a penetrating oil to ease removal and prevent breakage Some mechanics use turpentine in a spout type oil can which works quite well After applying the rust penetrant let it wcrk for a few minutes before trying to loosen the nut or bolt Badly rusted fasteners may have to be chiseled off or removed with a special nut breaker available at tool stores If a bolt or stud breaks off in an assembly it can be drilled out and removed with a special tool called an E Z out or screw extractor Most dealer service departments and motorcycle repair shops can perform this task as well as others such as the repair of threaded holes that have been stripped out Flat washers and lock washers when removed from an assembly should always be replaced exactly as removed Replace any damaged washers with new ones Always use a flat washer between a lock washer and any soft metal surface such as aluminum thin sheet metal or plastic Special locknuts can only be used once or twice before they lose their locking ability and must be replaced Tightening sequences and procedures When threaded fasteners are tightened they are often tightened to a specific torque value torque is basically a twisting force Overtightening the fastener can weaken it and cause it to break while under tightening can cause it to eventually come loose Each bolt depending on the material it s made of the diameter of its shank and the material it is threaded into has a specific torque value which is noted in the Specifications Be sure to follow the torque recommen dations closely Fasteners laid out in a pattern i e cylinder head bolts engine case bolts etc must be loosened or tightened in a sequence to avoid warping the component Initially the bolts nuts should go on finger tight only Next they should be tightened one full turn each in a criss cross or diagonal oattern After each one has been tightened one full turn return to the first one tightened and tighten them all one half turn following the same pattern Finally tighten each of them one quarter turn at a time until each fastener has been tightened to the proper torque To loosen and remove the fasteners the procedure would be reversed Disassembly sequence Component disassembly should be done with care and purpose to help ensure that the parts go back together properly during reassembly Always keep track of the sequence in which parts are removed Take note of special characteristics or marks on parts that can be installed more than one way such as a grooved thrust washer on a shaft It s a good idea to lay the disassembled parts out on a clean surface in the order that they were removed It may also be helpful to make sketches or take instant photos of components before removal When removing fasteners from a component keep track of thei locations Sometimes threading a bolt back in a part or putting the washers and nut back on a stud can prevent mixups later If nuts and bolts can t be returned to their original locations they should be kept in a compartmented box or a series of small boxes A cupcake or muffin tin is ideal for this purpose since each cavity can hold the bolts and nuts from a particular area i e engine case bolts valve cover bolts engine mount bolts etc A pan of this type is especially helpful when working on assemblies with very small parts such as the carburetors and the valve train The cavities can be marked with paint or tape to identify the contents Whenever wiring looms harnesses or connectors are separated it s a good idea to identify the two halves with numbered pieces o masking tape so they can be easily reconnected Gasket sealing surfaces Throughout any motorcycle gaskets are used to seal the mating surfaces between components and keep lubricants fluids vacuum o pressure contained in an assembly Many times these gaskets are coated with a liquid or paste type gasket sealing compound before assembly Age heat and pressure can sometimes cause the two parts to stick together so tightly tha they are very difficult to separate In most cases the part can be loosened by striking it with a soft faced hammer near the mating surfaces A regular hammer can be used if a block of wood is placed between the hammer and the part Do not hammer on cast parts or parts that could be easily damaged With any particularly stubborn part always recheck to make sure that every fastener has been removed Avoid using a screwdriver or bar to pry apart components as they can easily mar the gasket sealing surfaces of the parts which mus remain smooth It prying is absolutely necessary use a piece of wood but keep in mind that extra clean up will be necessary if the wood splinters After the parts are separated the old gasket must be carefully scraped off and the gasket surfaces cleaned Stubborn gasket materia can be soaked with a gasket remover available in aerosol cans to soften it so it can be easily scraped off A scraper can be fashioned from a piece of copper tubing by flattening and sharpening one end Copper is recommended because it is usually softer than the surfaces to be scraped which reduces the chance of gouging the part Some gaskets can be removed with a wire brush but regardless of the method used the mating surfaces must be left clean and smooth If for some reason the gasket surface is gouged then a gasket sealer thick enough to fill scratches will have to be used during reassembly of the components For most applications a non drying or semi drying gasket sealer is best Hose removal tips Hose removal precautions closely parallel gasket remova precautions Avoid scratching or gouging the surface that the hose mates against or the connection may leak Because of various chemical reactions the rubber in hoses can bond itself to the meta spigot that the hose fits over To remove a hose first loosen the hose clamps that secure it to the spigot Then with slip joint pliers grab the hose at the clamp and rotate it around the spigot Work it back and forth until it is completely free then pull it off silicone or other lubricants will ease removal if they can be applied between the hose and the outside ot the spigot Apply the same lubricant to the inside o the hose and the outside of the spigot to simplify installation

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