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Assembling the Crankcases

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Written by Randy Fox   
Saturday, 03 November 2007

Beginning Reassembly

Reassemble and pre-lube the crank/connecting-rod assembly, if you took it apart. Refer to the service manual for details.

If any cylinder studs are easily loosened, remove them, clean the threads, apply thread-lock liquid, and then tighten them moderately with some pliers.

Next, lay down a bed of clean rags for the right-side case, and then lay the case down, internal side up.

Tip: Actually, I rested mine on bubble wrap, on a padded furniture-moving dolly. This allowed the case to rest totally on its side. It also provided space for the crank and transmission shafts, as I installed them. See photo below.

 

Crankcase, right, open, empty, Yamaha Road Star

 

Install the oil splash using blue thread-lock on the four bolts. Torque the bolts to 7.2 ft-lbs, which is 86.4 in-lbs.

Take picts of the bearings in the cases.

Tip: Moderately lube all bearing surfaces with engine assembly lube as assembly proceeds.

Lubricate all the bearings in both crankcases using assembly lube. Oil the bearing surfaces of the generator shaft using assembly lube. Install the generator shaft into the right-side case.

 
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