Piston: Make sure opening in the ring straddles the ring locating pin on the ring land. After installing on the piston make sure it expand and contract freely. If they do not, swap the two rings. (On single ring pistons this does not apply.) Check for free movement.
Install wrist pin bearing on the rod.
Use a drop of oil on and rotate to spread on inner race of rod.
Immediately before installation of the
cylinder, WASH the cylinder with dishwashing soap and water.
Scrub all the ports and the bore. Dry thoroughly with a lint
free cloth. Make sure cylinder is both dry and clean.
Slip the cylinder over the piston while
compressing the ring(s) with one hand. Make sure ring ends are
straddling the ring locating pin on the piston ring land. Rotate
crankshaft and make sure piston moves up and down freely. Install
head gasket. (if Head gasket has a raised ridge. It goes up.)
Install head. Torque head nuts to 11-ft lbs. using a cross pattern.
(If you are using the oil injector, don't forget to hook up oil
line!) (Do not add
oil to the gas tank!!!!)
It is important that during this break
in time the RPM is varied constantly. Do not run at a sustained
RPM for a long time. If you are cruising at 35mph for a minute,
change to 40mph, etc. Do not put on the stand and let idle for
any part of the break in period. Engine needs to have air going
past it and the RPM constantly varied.
Yamaha circlips are difficult at best. Pay particular attention to seating them properly. Yamaha head gaskets have a ridge on them. The ridge goes up.
Polini requires the use of a "long reach" spark plug such as an NGK B9ES
|Page 1||Exhaust Systems|
|Page 2||Fine Tuning-Belts, Springs|
|Page 3||Cylinder Kits|
|Page 5||Final Drive|
|Page 9||Front Suspension|
|Page 10||Rear Suspension|
|Page 11||Dual Head Light Mod|
|Page 12||Corbin Seats|
|Page 13||Rear Luggage|
|Page 14||2008 Zuma Fix it Kit|
|Page 16||Tech Tips|
|Page 17||Engine Work|