2002 YAMAHA BT 1100 SERVICE MANUAL

0

Filed Under (Yamaha) by admin on 29-11-2010

download
1. Remove all dirt, mud, dust and foreign material before removal and disassembly. 2. Use proper tools and cleaning equipment. Refer to the “SPECIALTOOLS” section. 3. When disassembling the machine, always keep mated parts together. This includes gears, cylinders, pistons and other parts that have been “mated” through normal wear. Mated parts must always be reused or replaced as an assembly. 4. During machine disassembly, clean all parts and place them in trays in the order of disassembly. This will speed up assembly and allow for the correct installation of all parts. 5. Keep all parts away from any source of fire. EB101010 REPLACEMENT PARTS 1. Use only genuine Yamaha parts for all replacements. Use oil and grease recommended by Yamaha for all lubrication jobs. Other brands may be similar in function and appearance, but inferior in quality. EB101020 GASKETS, OIL SEALS AND O-RINGS 1. Replace all gaskets, seals and O-rings when overhauling the engine. All gasket surfaces, oil seal lips and O-rings must be cleaned. 2. Properly oil all mating parts and bearings during reassembly. Apply grease to the oil seal lips.
GEN INFO IMPORTANT INFORMATION 1-3 EB101030 LOCK WASHERS/PLATES AND COTTER PINS 1. Replace all lock washers/plates 1and cotter pins after removal. Bend lock tabs along the bolt or nut flats after the bolt or nut has been tightened to specification. EB101040 BEARINGS AND OIL SEALS 1. Install bearings and oil seals so that the manufacturer’s marks or numbers are visible. When installing oil seals, apply a light coating of lightweight lithium base grease to the seal lips. Oil bearings liberally when installing, if appropriate. 1Oil seal Do not use compressed air to spin the bearings dry. This will damage the bearing sur- faces. 1Bearing CAUTION: EB101050 CIRCLIPS 1. Check all circlips carefully before reassembly. Always replace piston pin clips after one use. Replace distorted circlips. When installing a circlip 1, make sure that the sharp-edged corner 2is positioned opposite the thrust 3 it receives. See sectional view

AJS DISMANTLING AND REBUILDING FULL-WIDTH FRONT WHEEL HUBS INSTALLATION

0

Filed Under (AJS) by admin on 31-10-2010

download
Removal of the Brake-side Bearing Cup The bearing cup (5) is located endwise by a circlip (1), and between the cup and circlip arc an oil-seal retaining washer (4), oil seal (3), and oil-seal cup washer (2) Before these parts can be removed from the hub the bearing cup must be moved inwards for a very short distance (3/16-inch) so that the circlip can be withdrawn. (n) Gently heat the hub shell. (i) Place a soft metal rod (e.g. brass) against the oil-seal cup washer (2) and apply pressure with a hand press or hammer blows. It is only necessary to move the bearing cup (5) inwards about 1/16-inch. (j) Extract the circlip by inserting a narrow pen-knife blade under one end of the circlip; lift it upwards and outwards and prise the clip out of its groove. (k) Remove the oil-seal cup washer (2), oil seal (3) and oil-seal retaining washer (4). They can be hooked out with the shank of a small and narrow screw­ driver, (l) The bearing cup can now be ejected by placing a suitable rod of soft metal (e.g. brass) in the hub tunnel from the right-hand side and pressing it — with a press or hammer blows — against the bearing cup until the cup is forced out of the bearing. This must be done with care so that the cup remains square with the housing. Reassembly To facilitate replacement of the bearing cups gently heat the hub shell. Just too hot to hold is about the right temperature. (a) Place the brake-side bearing cup squarely in the hub shell — the open end faces inwards — and press it into the hub tunnel A short length of brass rod, slightly less than the outside dia­ meter of the cup, should be interposed between the cup and ram of the press, or hammer head. Press the cup in until the outer face is approximately half-an-inch below the mouth of the hub tunnel. This will allow sufficient room to allow [he circlip to be inserted into its groove. (b) Refit in the following order: oil-seal retaining washer (4), oil seal (3), oil-seal cup washer (2). (c) The circlip can now be replaced. In the interest of reliability use a new circlip, for it is possible that the existing circlip was strained when it was re­ moved. (d) Insert into the hub tunnel from the right-hand side a brass rod of suitable length, and press the bearing cup firmly against the circlip. (e) Before inserting the spindle complete with the roller races, pack them with clean and fresh grease of a suitable grade (Mobilgrease No. 4. Castrolease heavy, Energrease C3, Esso Pressure Gun Grease. Shelf Retinax Grease CD or A). (0 Insert the spindle into the hub. (g) Place the right-hand side bearing cup in the hub tunnel; the open end faces inwards, It may be necessary to re-heat the hub to allow the cup to go into position without difficulty. (h) Press the cup into position, but do not force it fully home, leave some end play on the spindle. (i) Refit in the following order: oil-seal retaining washer (6), oil-seal (7) and oil-seal cup washer (8). (j) Screw into the hub the adjusting sleeve (9) until it comes into contact with the bearing cup (5)

Incoming search terms: