Yamaha TZR50 '03 Service Manual page 79

REMOVING THE ENGINE ...............................................................4-1
PREPARING FOR REMOVAL.........................................................4-1
PETROL TANK ...........................................................................4-2
AIR FILTER ..............................................................................4-3
EXHAUST PIPE ........................................................................4-4
COOLANT PIPES ........................................................................4-4
SPARK PLUG AND THERMOCONTACT CABLE ..............................4-5
NEUTRAL SWITCH CABLE .........................................................4-5
OIL PUMP .................................................................................4-5
CARBURETTOR ........................................................................4-6
SHIFT LEVER, DRIVE CHAIN AND CLUTCH CABLE ........................4-6
ENGINE REMOVAL .....................................................................4-7
DISMANTLING THE ENGINE .........................................................4-7
OIL PUMP .................................................................................4-7
WATER PUMP COVER ...............................................................4-7
RIGHT CRANKCASE COVER, OIL PUMP SHAFT AND
WATER PUMP SHAFT ............................................................4-7
PRIMARY TRACTION GEARING AND CLUTCH ..............................4-8
CDI MAGNETO ........................................................................4-10
STARTER MOTOR .....................................................................4-10
CYLINDER HEAD AND CYLINDER .............................................4-11
PISTON PIN AND PISTON .........................................................4-12
CRANKCASE ...........................................................................4-12
SELECTOR AND SHIFT ............................................................4-13
CRANKSHAFT ........................................................................4-13
BEARINGS AND OIL SEALS ......................................................4-14
INSPECTION AND REPAIR ............................................................4-14
CYLINDER HEAD .....................................................................4-14
PISTON .................................................................................4-15
CYLINDER ..............................................................................4-16
PISTON RINGS ........................................................................4-17
PISTON PIN AND BEARING ......................................................4-17
AUTOLUBE PUMP ..................................................................4-18
CLUTCH .................................................................................4-18
SELECTOR ..............................................................................4-20
SHIFT ....................................................................................4-20
CRANKSHAFT ........................................................................4-21
REVOLUTION COUNTER SENDER .............................................4-21
BEARINGS AND OIL SEALS ......................................................4-22
CRANKCASE ...........................................................................4-22
ASSEMBLING AND ADJUSTING THE ENGINE .................................4-23
CRANKSHAFT ........................................................................4-23
SHIFT AND SELECTOR ............................................................4-25
CRANKCASE ...........................................................................4-27
STARTER MOTOR .....................................................................4-29
CDI MAGNETO ........................................................................4-30
CLUTCH AND PRIMARY TRACTION GEARING ..............................4-31
WATER PUMP SHAFT, OIL PUMP SHAFT AND
RIGHT-HAND CRANKCASE COVER ..........................................4-35
WATER PUMP COVER ...............................................................4-36
OIL PUMP ..............................................................................4-36
PISTON PIN AND PISTON .........................................................4-37
CYLINDER HEAD AND CYLINDER .............................................4-38
INSTALLING THE ENGINE .........................................................4-40
CHAPTER 4
ENGINE
ENG