Primary/Secondary Sheave Removal And Disassembly; Sheave Holder Used On Primary/Secondary Sheave Views - Yamaha XP500 TMax Technical Manual

PRIMARY SHEAVE REMOVAL AND DISASSEMBLY
After the V-belt has been removed:
n Install the sheave holder on the primary sheave.
n Take off the nut.
n Take off the front sheave.
n Take off the rear sheave from the
crankshaft.
To disassemble the primary sheave:
n Remove the screws.
n Remove the sheave cap.
n Remove the cam.
n Remove and inspect the weights and sliders
for damage.
Clean and check the sheave surfaces for cracks or other damage. Clean the entire sheave assembly of the
old grease and repack it with 80 to 90 grams of the same special sheave grease as used on the YP250 and
re-assemble.
When re-installing the primary sheave on the crankshaft, be sure to grease the crankshaft splines with the
special grease and that the sheave plate splines are properly aligned with the crankshaft splines.
SECONDARY SHEAVE REMOVAL AND DISASSEMBLY
Follow the same procedures for the secondary
sheave removal as the primary sheave using the
opposite side of the sheave holding tool:
n Install the secondary spring compressor tool in
a vise.
n Install the secondary sheave onto the tool.
n Remove the nut and spring from the assembly.
n Then separate the sheaves by removing the collar
and pins from the cam.
Clean and inspect all parts for wear or damage. Lube all sliding parts with assembly lube and reassemble
the sheave.
MAIN BEARING REPLACEMENT
Because the TMax uses full circumference plain
bearings, it is necessary to use the special bearing
installer/remover to remove and install them.
Use extreme caution when installing these
bearings to prevent damage.
For detailed drawings and instructions refer to the
XP500 Service Manual.
XP500 TMax Technical Orientation Guide
Sheave holder used on primary sheave
Sheave holder used on secondary sheave
32