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[Archive] (Part 1) Re-assembling your Triple Engine - How to With Pics!


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    Today class, we’re rebuilding my Triple engine. Dont know how long its going to take me but some pretty pics with words surely will help others rebuild theirs later on…

    I know this has been done in the past by other forum members, but I’m going to show my engine getting rebuilt from scratch!

    1st of all we start with the crank case top half…
    I had my top half sandblasted and repainted with Hi-temp black paint

    0_1511093458957_01.JPG

    Turn it over and let the fun begin.
    Install the kickstarter gear. Manouver the shaft in, and line up the clip into the case and install the holder and the allen bolts. Then put the gear on with the washer and circlip

    0_1511093482742_02.JPG

    Next we’re going to install the bearings.
    Now in my case, the crank was linshed and the rods were resized and completely cleaned up by a machining shop.
    They even had to remove the balls on the sides of the crank to clean out the crap that had accumulated behind and into the crank.
    The machine shop said for me to use the biggest size bearings - these are the ones Yamaha marked blue. I was advised to put the new bearings in and torque the cases up and make sure everything spins freely. You probably wont need to do this, but its always good to dummy assemble like this…

    Anyways here I learnt that Ebay is your friend… Bearing shell kits, a LOT cheaper than paying the arm or leg that Yamahaha charges!

    0_1511093500673_03.JPG

    0_1511093522334_04.JPG

    Install the bearing shells into the crankcase, dont forget about the sidethrust bearing

    0_1511093541250_05.JPG

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    Apply oil to the bearing surfaces:

    0_1511093575699_07.JPG

    And carefully place the crank into the case

    0_1511093598202_08.JPG

    Next get your nice clean rods, install the bearing shells and apply oil to the bearing surfaces.

    0_1511093616147_09.JPG

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    0_1511093656210_11.JPG

    Assemble them onto the crank and carefully tighten the rod bolts to the required 27 ft lb

    0_1511093680206_12.JPG

    Rods are on!

    0_1511093704203_13.JPG

    Now gently lift the crank and insert the rods through the holes into their correct position

    0_1511093733578_14.JPG

    Thats the top half done! (well for now)

    Next Insert the bearings into the crank case bottom half, and apply oil to the bearing surfaces!

    0_1511093760414_15.JPG

    Insert the case locating dowels, disregard the one in the middle there… its just there for looks and isnt actually needed at all

    0_1511093795240_16.JPG

    Put the cases together!

    0_1511093816003_17.JPG

    Install bolts numbered 1-10. Then tighten in 2 steps with your torque wrench to the specifications in the book
    1st stage i think is 16 ft lb for bolts 1-8 and 7 ft lb for bolts 9-10
    2nd stage is 27 ft lb for bolts 1-8 and 14 for bolts 9-10 (will check book later to confirm these numbers)

    0_1511093854306_18.JPG

    Now turn the crank, make sure everything spins freely with your new bearings etc etc

    0_1511093884364_19.JPG

    All Fantastic!

    Now pull it apart again!!
    Losen bolts 1/2 turn in reverse order to how you installed them, and then remove them in that order.

    0_1511093903190_20.JPG

    And now we’ve got the 2 crankcase halves separated - Top half with the crank still sitting there, and bottom half ready for the transmission to be installed.

    0_1511093922177_21.JPG

    Put the top half with crank aside, as its not needed for a little while, and be ready for the next part - Installing the transmission!!

    Ok… I cheated a little bit, as you may have seen in a few of the above pics, some of the transmission was already installed when I started!

    I’ll tell how to do it anyways…
    Install the shift cam

    0_1511094453582_22.JPG

    Install the detent bolt and neutral switch

    0_1511094474372_23.JPG

    And the locating bolt

    0_1511094493039_24.JPG

    Manouver the gear shaft into place

    0_1511094510364_25.JPG

    Place the clip into the grove on the bearing, and install the cap so the clip sits in the grove and holds the bearing in the correct position

    0_1511094529294_26.JPG

    Insert the shift forks onto the 4th and 5th gears and line the pins up into the shift cam
    Insert the fork shaft through the RHS of the engine so it passes through the gearshaft cap, add the washer, and push the shaft through the shift forks.

    0_1511094550441_27.JPG

    Install the E-clip, making sure it holds the washer against the gearshaft cap.

    0_1511094571969_28.JPG

    The SF model has a lock-bracket to stop the nuts from working loose. Place the lock bracket over over the studs, and apply loctite to the threads.

    0_1511094589358_30.JPG

    Install the nuts and torque to correct specification of 14 ft lb
    Carefully bend the lock tabs up very gently by hitting a screwdriver against them with a hammer so they’re locked in place. The tabs break easily, notice one has already broken off!

    0_1511094605042_31.JPG

    Apply loctite to the layshaft bolt

    0_1511094626595_32.JPG

    And install it with the spring washer and plate washer into the countershaft

    0_1511094647676_33.JPG

    Hold the gearshaft with a big screwdriver, and torque the countershaft bolt to 18 ft lb

    0_1511094737489_34.JPG

    Next, Install the main gearshaft

    0_1511094763190_35.JPG

    Add the shift fork, insert the bar and install the E clips as shown here

    0_1511094795706_36.JPG

    And here

    0_1511094810978_37.JPG

    Next, install the Clutch pushrod seal. Apply some grease to the lip. I’ve run some gasket sealant around the outside of the seal

    0_1511094845487_38.JPG

    Next add the middle gear assembly. Take note in the book of how the circlip halves sit. Again with the seal, Ive applied gasket sealant around it.

    0_1511094876015_39.JPG

    Again apply oil to your bearing shells

    0_1511094896201_40.JPG

    And place the crank into the case

    0_1511094917844_41.JPG

    Dont forget to add this O-ring!

    0_1511094936117_42.JPG

    Apply gasket sealant to the mating surfaces of both crank halves

    0_1511094952535_43.JPG

    Carefully join both halves together, check the locating dowels have inserted properly.

    0_1511094968758_44.JPG

    Next, carefully turn it all over and start installing bolts 1-14 in the correct numbered pattern, and then torque them in the two stages again.
    Torque stages for the bolts are:
    1st stage, bolts 1-8 are 13 ft lb. Bolts 9-24 are 7 ft lb
    2nd stage, bolts 1-8 are 27 ft lb. Bolts 9-24 are 14 ft lb

    0_1511094992376_45.JPG

    Turn it over and do the same with bolts 15-24, and again torque these in two stages.

    0_1511095009772_46.JPG

    Then install the last bolt which goes in the RHS above the layshaft bolt

    0_1511095023587_47.JPG

    Now there you are, assembled engine crankcase, waiting for more!

    0_1511095034552_48.JPG

    Next up will be the installation of the clutch components, the electric starter gears and the pistons/cylinders/head etc
    Like I said, this may take me some time (well the rest definitely will) so keep checking for updates, and feel free to comment!!

    Credit: yamaha-triples.org


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