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Document Organization
The detailed information for tearing down and reassembling the Road Star engine is far too involved to put into one or two articles, so here’s how the information has been organized:
- Going Full Bore describes big-bore options and a bit of engine performance/upgrade theory.
- Parts and Tools identifies skills required. It lists parts selection, gaskets (and other consumables) needed, and tools recommended. It also offers comparative ways to estimate project time. Lastly, this document deciphers Yamaha's bolt part numbers, and lists a few important errors found in the Yamaha service manual.
- Starting the Project covers preparation of your workspace, parts storage, parts labeling, bolt organization, and instructions for disassembling basic items prior to beginning the detailed engine tear-down.
- Disassembling the Top End and Cylinders describes how to begin tearing the engine down, including removing the engine's rocker, head, piston, and cylinder assemblies.
- Disassembling The Engine’s Left Side describes how to tear down the engine's clutch, shift-shaft, primary drive gear, pickup coil, and oil-pump driven gear assemblies.
- Disassembling The Transfer Case shows how to remove and tear down the transfer case assembly.
- Disassembling The Cam Area covers the tear-down of the cams Assembly.
- Disassembling The Generator Area tells how to remove the generator assembly.
- Removing and Disassembling the Crankcase shows you how to remove the engine from the frame, and how to split the crankcases. It also describes how to remove the crank, transmission, and oil pump assemblies.
- Working on the Disassembled Engine covers important details in preparing your parts for machining, powdercoating, and painting. In addition, issues involved in oil-pump repair, transmission fixes, and case-welding are discussed. Finally, tips are offered in preparing parts for reassembly.
- Assembling the Crankcases shows how to reassemble the engine’s crank, transmission, and oil pump assemblies into the crankcase. It also shows how to put the crankcases back together, and install the assembly back into the frame.
- Assembling the Engine’s Left Side describes how to install the engine's clutch, shift-shaft, primary drive gear, pickup coil, and oil-pump driven gear assemblies.
- Assembling the Generator Area explains how to install the generator assembly. It also offers tips on fixing a potential Yamaha design flaw, and upgrading the generator’s power.
- Assembling the Cam Area tells how to reassemble cams and lifters, including several time saving and verification tips.
- Assembling and Installing the Transfer Case tells how to reassemble and install the transfer case.
- Assembling the Pistons and Cylinders shows how to install pistons and cylinders.
- Assembling the Top End shows how to install the heads. It also shows how to reassemble rocker-arms, adjust valve sync, and install and adjust adjustable-pushrods.
- Finishing Up highlights how to finish putting the rest of the bike back together.
Each of these articles includes many tips, notes, and warnings to help you along the way. Although the articles are written around my big-bore project, I tried to make them appropriate to anyone tearing down the engine for any reason. Furthermore, they have been written to synchronize well with related articles, such as:
Other articles may pertain to a complete engine tear down, as well. We recommend you review the entire Road Star Clinic, Technical Tip library.
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