Crankcase Assembly - Yamaha V star 1100 Owner's Manual

158
(B) from the left crankcase half. Store each individ-
ual shaft assembly in a sealed and labeled plastic
bag.
20. Use the crankcase separating tool to drive the
crankshaft from the left crankcase half. Keep the
tool centered over the crankshaft and follow the in-
structions from the tool's manufacturer. The left
main bearing should come out with the crankshaft.

Crankcase Assembly

This procedure describes the installation of the
crankshaft, transmission shaft assemblies, and in-
ternal shift mechanism as well as the assembly of
the crankcase halves.
NOTE
Coat all parts with engine oil prior to
assembly.
1. Install the oil pressure relief valve (Figure 78),
with a new O-ring, into the right crankcase half. Lu-
bricate the O-ring with lithium soap grease.
2. Place the left crankcase half on wooden blocks.
3. If removed, install the neutral switch and its
washer (Figure 86) into the crankcase. Apply a me-
dium-strength threadlocking compound to the
threads of the switch and torque the neutral switch
to 20 N•m (15 ft.-lb.).
CAUTION
Do not attempt to install the crank
shaft without the special tools. If these
tools are not available, have a
Yamaha dealership or other qualified
service shop install the crankshaft.
4. Following the tool manufacturer's instructions,
assemble the crankshaft installer pot (A, Figure
87), crankshaft installer bolt (B), adapter (C) and
spacer (D) onto the crankshaft, and pull the crank-
shaft into the left crankcase half. Make sure the con-
necting rods align within their respective cylinder
openings. Continually monitor this alignment until
the crankshaft is completely seated in the left
crankcase half.
5. Mesh the mainshaft (A, Figure 85) and
countershaft (B) assemblies together and simulta-
neously lower both assemblies into place in the left
crankcase half. Make sure each shaft slides into its
respective bearing.
86
87
NOTE
Each shift fork is identified by a letter
embossed on its face. See Figure 81.
Install each shift fork with the letter
facing up toward the right side of the
engine.
6. Install the left shift fork into the countershaft
fifth gear (Figure 88) so its identification mark
faces up. Rotate the countershaft so the fifth gear
dogs can slide up and engage second gear.
7. Install the right shift fork (A, Figure 84) into the
countershaft fourth gear. The identification mark
must face up.
8. Rotate the shift forks outward as necessary so
the shift drum can be lowered into place.
9. Install the shift drum (C, Figure 83). Use a pick
to lift the left shift fork (B, Figure 83) so the drum
can fall into place in the case.
10. Rotate each shift fork (A and B, Figure 83) so
its guide pin engages the respective groove in the
shift drum. Turn the shift drum into the neutral posi-
CHAPTER FIVE