Next phase, fitting the crank and closing the cases
First push the drive shaft through the case and fix the first e clip, then the worm gear
Then lock the worm gear on the shaft with the second e clip
Then fix the locking plate on the outside of the case, again i use stainless allen key heads, rather than the soft cross heads used by Yamaha
Then the outer drive gear can be fitted with its e clip
and the tacho drive gear is fitted
Now i return to the lower case to fit the crank, here are the bits
First, locate the bearing guide circlip into he case
Then you can drop the crank in place with its new seals, check that the bearing is located in its guide and that the seals are located by their grooves
Now make sure you can see the "pips" on the bearing cases
Rotate the bearing cases towards the front of the engine until the "pip" are inside the notches in the case.
Next fit the drive sprocket seal and clutch push rod seal
Now we are ready to fit the upper case, apply a THIN bead of gasket fluid (Yamabond/Hylomar etc) to the mating faces, and gently drop the upper case into position.
Make sure everything (Bearings, seals etc) line up.
I fit the 8 10mm bolts into the top of the case first and tighten them gently, and check the two faces come together easily.
Then i turn the engine on its "arse" to fit the lower bolts
Again i tighten these bolts gently and again check all the faces have closed up evenly.
Only when everything is mated nicely and the seals and bearings are correctly located to i ....
First torque up the bottom nuts (2kg) and then the top case bolts (1kg)
Remember i said "apply a THIN bead of gasket fuid", well now turn the crank through about 90 degrees, you will probably see this
Its a thin film of gasket that has been forced out into the crank well, remove this with a cloth, rotate the crank through 180 degrees and you will probably see this again
Next the external gear selction assembly, kickstart and clutch