Disassembling The Crankcase; Checking The Crankcase; Checking The Timing Chain; Assembling The Crankcase - Yamaha 2009 XP500Y TMAX Service Manual

EAS25560

DISASSEMBLING THE CRANKCASE

1. Remove:
• Crankcase bolts
TIP
Loosen each bolt 1/4 of a turn at a time, in stag-
es and in a crisscross pattern. After all of the
bolts are fully loosened, remove them.
• M8 × 110 mm bolts "1"
• M6 × 50 mm bolts "2"
• M6 × 35 mm bolts "3"
1
1
2
2. Remove:
• Left crankcase
ECA13900
NOTICE
Tap on one side of the crankcase with a soft-
face hammer. Tap only on reinforced por-
tions of the crankcase, not on the crankcase
mating surfaces. Work slowly and carefully
and make sure the crankcase halves sepa-
rate evenly.
EAS25580

CHECKING THE CRANKCASE

1. Thoroughly wash the crankcase halves in a
mild solvent.
2. Thoroughly clean all the gasket surfaces and
crankcase mating surfaces.
3. Check:
• Crankcase
Cracks/damage → Replace.
• Oil delivery passages
Obstruction → Blow out with compressed air.
EAS4B51032

CHECKING THE TIMING CHAIN

1. Check:
• Timing chain
Damage/stiffness → Replace the timing
chain and camshafts as a set.
3 2
3 1 2
5-69
EAS25700

ASSEMBLING THE CRANKCASE

1. Thoroughly clean all the gasket mating sur-
faces and crankcase mating surfaces.
2. Apply:
• Sealant
(onto the crankcase mating surfaces)
Yamaha bond No. 1215
90890-85505
(Three Bond No.1215®)
TIP
Do not allow any sealant to come into contact
with the oil gallery.
3. Install:
• Dowel pins
• Left crankcase
4. Install:
• Crankcase bolts (M8)
• Crankcase bolts (M6)
Crankcase bolt (M8)
24 Nm (2.4 m·kg, 17 ft·lb)
Crankcase bolt (M6)
10 Nm (1.0 m·kg, 7.2 ft·lb)
TIP
Tighten each bolt 1/4 of a turn at a time, in stag-
es and in a crisscross pattern.
• M8 × 110 mm bolts "1"
• M6 × 50 mm bolts "2"
CRANKCASE