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[Archive] (Part 3) Re-assembling your Triple Engine - How to With Pics!


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    We’re Onto the LHS today…

    1st is the transmission countershaft bearing housing. Apply silastic around the O ring and around the edge

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    Install into the motor with the 4 allen bolts

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    Install the oil delivery pipe and torque the bolts to 14ft lb

    0_1511096769150_80.JPG

    Next are the cam chain guides. Make sure you’ve got the dowel through the middle, and the washers either side

    0_1511096784197_81.JPG

    Next install the starter clutch. Make sure you’ve got the large shim washer behind and the smaller one infront

    0_1511096803009_82.JPG

    Next is cam chain, Ive got a new one from Steve Lloyd…

    0_1511096818241_83.JPG

    Install the chain and secure the ends with wire so it doesnt fall back in

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    Install the oil pump drive gear, make sure its slotted into the gear on the crank correctly, install the washer and torque the bolt to 73 ft lb

    0_1511096869587_85.JPG

    And lastly the starter motor Idle gear and shaft

    0_1511096894524_86.JPG

    Next, carefully install the Clutch pushrod from the LHS of the engine, rotate it as you gently push it past the seal

    0_1511096912854_87.JPG

    Apply some grease to the rear of the Clutch Push Lever Assembly that the clutch cable attaches to

    0_1511096933125_88.JPG

    Next apply some silastic to the mating face of the LHS Engine cover

    0_1511096954169_89.JPG

    And also silastic to the crank case

    0_1511096978280_90.JPG

    Put new gasket on and check that the dowels are in place

    0_1511097007631_91.JPG

    Bolt on the LH Side cover, make sure you put washers under the 2 bolts with Red arrows

    0_1511097062644_92.JPG

    LHS Completed - Back to the clutch now…

    Install the ball bearing into the shaft

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    Push it in with a thin screw driver until its against the end of the pushrod

    0_1511097108949_94.JPG

    Install the rectangular bar

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    And slide the washer over so its against the rectangular bar

    0_1511097145262_96.JPG

    Next is to install the clutch pressure plate. Make sure the arrows on the front of the pressure plate line up with the arrows on the clutch boss assembly

    0_1511097166220_97.JPG

    Get your clutch springs ready. If the length is 41.5mm or less they need to be replaced. I’ve got a set of Barnett Heavy Duty springs for mine

    0_1511097180192_98.JPG

    Install 2 springs with bolts and tighten them with a screw driver, but not all the way, because as you can see in the picture, the tabs on the clutch plates need to be aligned properly

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    To align the tabs on the clutch plates, slide on the clutch outer housing, and the ‘fingers’ on the housing will help align the tabs, you might need to turn/adjust some by hand to get it right.

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    Remove the clutch outer housing and tighten the 2 bolts. Install the remaining 4 bolts and then torque them all up to 6 ft lb

    0_1511097243604_101.JPG

    Install new circlip

    0_1511097257732_102.JPG

    And then slide washer on

    0_1511097273335_103.JPG

    Slide on the clutch outer housing and make sure you dont forget the large shim - indicated with the red arrow

    0_1511097296487_104.JPG

    Next, primary chain and the Primary driven gear. I’ve got a new primary chain, so I wont be using a tensioner for now.

    0_1511097321860_105.JPG

    Insert the clutch damper assembly into the Primary driven Gear

    0_1511097337526_106.JPG

    Next is the Large Circlip which can be a little bit tricky to get on

    0_1511097354872_107.JPG

    And then Shim followed by washer and then small circlip

    0_1511097373151_108.JPG

    Bearing housing bracket is next. Make sure the dowels are in place and tighten the 4 bolts that hold it on

    0_1511097390627_109.JPG

    Apply Silastic to the RHS Cover

    0_1511097400531_110.JPG

    And to the Crank case mating surface. Make sure the dowels are in place.

    0_1511097413888_111.JPG

    Put new gasket on, and gently tap the side cover on with a soft mallet

    0_1511097429809_112.JPG

    Bolt it all up, and install the Alternator Rotor torque the bolt up to specification in the book

    0_1511097438730_113.JPG

    RHS COMPLETED!

    Credit: yamaha-triples.org


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