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05 Yamaha Zuma discussion forum:RE: Crankshaft install on a Zuma? |
| RE: Crankshaft install on a Zuma? |
| Cig said 2007-07-29 22:11 |
| A crankshaft replacement is major surgery. Its not impossible but if you´ve never done one before I´d suggest that you get some help. The following is from the Yahoo Zuma Users Group: How do I drop my crank case out to replace the crank? DISCLAIMER: I make no promises on these instructions, first off, as I am doing this from memory and I´m not sure if you have a pre-bugeye or bugeye (I have a pre-bug). Also, I goofed a few things last-minute...no harm, but caused more trouble than it should have been. But, these should be more helpful than the service manual...which was NO help. It´s not that hard, just takes patience. INSTRUCTIONS: The centerstand is part of the crankcase, so you will need to prop-up the scooter somehow. I removed the belly pan (which involved removing the floorboards and nose and front fairing) and blocked-up the scooter using the frame and a floor jack and a bunch of crap wood. Even so, I needed someone´s help to balance it. I suggest having a buddy over to help or suspending it from the celing somehow. Removing the floorboards and belly pan make it easier to see what you´re doing anyway. You´ll need to remove the rear footpegs and their brackets (they get in the way at the final step. Disconnect everything from the crankcase: --Remove the exhaust. --Remove rear wheel. --There are two grey wiring harness that disconnect up under the bodywork near the back. Remove all the wire ties between the connectors and the engine so they are free of the bike. I had two metal clamps (welded to the frame) that needed bending to release the wiring as well. --The oil tank connects to the flywheel. Clamp the hose, squeeze the tiny clamp down inside the flywheel and remove. You´ll need to remove the flywheel cover and the plastic engine shroud to do this. Have lots of rags handy...in case you don´t get it completely clamped-off (I didn´t). You can use a screw to plug the hole, then bring the open end of the hose above the level of the tank and secure it. --Disconnect the airbox (remember the squeeze clamp holding it to the carb) --Disconnect the oil feed from the carb. On the 17.5mm Delorto, and I think the stock 14mm this is a small hose leading to an outlet next to a cluster of other brass-colored nozzles on the side of the carb facing the front of the scooter. --Disconnect the carb from the engine. Simply remove it at the intake (4 allen bolts) and swing it up out of the way (no need to disconnect the cables) --Disconnect spark plug wire --Disconnect the rear brake (I missed this since it was \ |
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