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Resourcing Tools and Parts
This article is one of a series that describes how to disassemble, work on, and reassemble the Road Star engine. This particular article identifies skills required, lists parts selection, gaskets (and other consumables) needed, and tools recommended. It also offers comparative ways to estimate project time. Lastly, this document deciphers Yamaha bolt part numbers and lists a few important errors found in the Yamaha service manual. See the Complete Engine Tear Down, Orientation article in this series for details of other aspects of engine details.
Be sure you refer to the service manual through all phases of this project.
In my opinion, cleanliness, orderliness, and attention to detail are required.
Do not attempt this level of work unless you have a fairly complete tool set--and you know how to use it all. See the Tools section of this article for details. You should also have some experience in taking engine covers off--how much force to use, and where to apply it.
If you are not planning to remove the entire engine from the frame, and split the crankcases, the patience and skills needed are primarily in the following areas:
- You must be able to follow service manual instructions to rotate the crankshaft into proper position to place cams, rockers and pistons in proper syncrony.
- You'll need to be able to install piston rings on to the pistons, and then install pistons into the cylinders.
- You should have experience in properly torquing bolts.
- You'll need to install and adjust the valve train.
Even if you've never done this before, but you are patient, mechanical, and methodical--and you're not shy to ask for help--your chances of building a strong, long-lived engine are good.
If you are contemplating splitting-the-cases for your project, you will also be required to do the following:
- Properly form a very large, liquid-paste gasket.
- Keep track of many more parts (large and tiny) for a much longer time.
- Remove and install a complete (though simple) transmission.
- Know how to thoroughly clean and dry (or replace) pressed-in ball bearings.
If you hate asking for help, and you avoid looking things up in manuals, then working on the innards of your engine may not be for you.