User manual YAMAHA MCS-1330

[. . . ] Therefore, anyone who uses this book to perform maintenance and repairs on Yamaha vehicles should have a basic understanding of mechanics and the techniques to repair these types of vehicles. Repair and maintenance work attempted by anyone without this knowledge is likely to render the vehicle unsafe and unfit for use. Modifications and significant changes in specifications or procedures will be forwarded to all authorized Yamaha dealers and will appear in future editions of this manual where applicable. NOTE: Designs and specifications are subject to change without notice. EB002000 IMPORTANT MANUAL INFORMATION Particularly important information is distinguished in this manual by the following. The Safety Alert Symbol means ATTENTION! [. . . ] If out of specification, replace the piston and piston rings as a set. 4-69 CONNECTING RODS AND PISTONS ENG e. Calculate the piston-to-cylinder clearance with the following formula. Piston-to-cylinder clearance = Cylinder bore "C" ­ Piston skirt diameter "P" Piston-to-cylinder clearance 0. 025 0. 045 mm <Limit>: 0. 07 mm f. If out of specification, replace the crankcases, and the pistons and piston rings as a set. EAS00263 CHECKING THE PISTON RINGS 1. NOTE: Before measuring the piston ring side clearance, eliminate any carbon deposits from the piston ring grooves and piston rings. Piston ring side clearance Top ring 0. 030 0. 065 mm <Limit>: 0. 115 mm 2nd ring 0. 020 0. 055 mm <Limit>: 0. 115 mm 2. Install: S piston ring (into the cylinder) NOTE: Level the piston ring in the cylinder with the piston crown. a 5 mm 4-70 CONNECTING RODS AND PISTONS ENG 3. If the oil ring rail's gap is excessive, replace all three piston rings. Piston ring end gap Top ring 0. 15 0. 25 mm <Limit>: 0. 50 mm 2nd ring 0. 40 0. 50 mm <Limit>: 0. 85 mm Oil ring 0. 10 0. 35 mm ABS00266 CHECKING THE PISTON PINS The following procedure applies to all of the piston pins. Measure: S piston pin bore diameter (in the piston) Out of specification !Piston pin bore diameter (in the piston) 16. 002 16. 013 mm 4-71 CONNECTING RODS AND PISTONS ENG 4. Offset: S piston ring end gaps a Top ring b Lower oil ring rail c Upper oil ring rail d 2nd ring A Intake side 4. Lubricate: S piston S piston rings S cylinder (with the recommended lubricant) Recommended lubricant Engine oil 5. Lubricate: S bolt threads S nut seats (with the recommended lubricant) Recommended lubricant Molybdenum disulfide grease 4-75 CONNECTING RODS AND PISTONS ENG 6. Lubricate: S crankshaft pins S big end bearings S connecting rod big end inner surface (with the recommended lubricant) Recommended lubricant Engine oil 7. Install: S big end bearings S connecting rod assembly (into the cylinder and onto the crankshaft pin). S connecting rod cap (onto the connecting rod) NOTE: S Align the projections on the big end bearings with the notches in the connecting rods and connecting rod caps. S While compressing the piston rings with one hand, install the connecting rod assembly into the cylinder with the other hand. S Make sure that the "Y" marks a on the connecting rods face towards the left side of the crankshaft. S Make sure that the characters b on both the connecting rod and connecting rod cap are aligned. Replace the connecting rod bolts and nuts with new ones. CAUTION: Tighten the connecting rod bolts using the plastic-region tightening angle method. Always install new bolts and nuts. 4-76 CONNECTING RODS AND PISTONS ENG b. [. . . ] S If you do accidentally spill gasoline, wipe it up immediately with dry rags. Therefore, make sure that the engine is completely cool before performing the following test. 1. If fuel does not flow, replace the fuel pump. 8-53 SELF-DIAGNOSIS EB812000 ELEC SELF-DIAGNOSIS The MCS-1330 features a self-diagnosing system for the following circuit(-s): S throttle position sensor S fuel level indicator light If any of these circuits are defective, their respective condition codes will be displayed on the tachometer when the main switch is set to "ON" (irrespective of whether the engine is running or not) Circuit Throttle position sensor Defect(-s) S Disconnected S Short-circuit S Locked System response S The ignitor unit stays set to the wide-open throttle ignition timing. Condition code 3, 000 r/min Fuel level indicator light S Improper connection 8, 000 r/min Tachometer display sequence Revolution ( 103 r / min) 1 0 r / min . . . [. . . ]