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Disassembling the Top End and Cylinders

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Written by Randy Fox   
Saturday, 03 November 2007

Introduction

Big Bore, Yamaha Road Star

This article is one of a series that describes how to disassemble, work on, and reassemble the Road Star engine. This particular article describes how to begin tearing the engine down, including removing the engine's rocker, head, piston, and cylinder assemblies. See the Complete Engine Tear Down, Orientation article in this series for details.

Be sure you refer to the service manual through all phases of this project.

 

 

 

 

 

Disassembling the External Oil Hookups

Disconnect both breather hoses from the top, right side of the rear cylinder’s rocker cover. See photo below.

 

PCV nipples, Yamaha Road Star

 

Set aside and label two storage areas--one for each cylinder. See photo below.

 

Engine parts, Yamaha Road Star

 

Remove, label, and store the chrome, 'Y' shaped, oil delivery pipe from the left-side of the engine. To do this, remove the two union bolts from the cylinders while holding onto the delivery pipe near each bolt as it is removed.

Hold the pipe so as to reduce the possibly of damaging the pipe. It is delicate and easily bent. Then remove the larger union bolt where the oil delivery pipe connects to the engine case.

Tip: There are two copper washers for each union bolt. Ideally, they should be replaced during reassembly. Although, if they are in excellent condition, you could reuse these. Even if they leaked, they could be easily replaced.

Carefully wrap and label the oil delivery pipe. Then place the union bolts and copper washers in a labeled sandwich bag, and store the oil delivery pipe and sandwich bag together. Just remember, this pipe is easily bent or broken, so store it somewhere safe.



 
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