YamahaYDS3EngineRebuild-YDSParts.pptVIP

Yamaha YDS3Engine Rebuild Strip and rebuild of a 1965 YDS3 engine. Within this presentation, you will find details on how to correctly strip down a YDS3 engine. This is also valid for all of the vertically split crankcase Yamaha models such as the YDS2, YDS3, YM1 and YDS5. Stripdown of the engine First job is to remove the sump pan by turning the engine over on itself. This is held on by 8 6mm No 3 Phillips headed screws. The shifter cam assembly is then taken off by removing the 4 screws in the corners of the assembly. This can then be gently levered out after the linkage is removed. This is done by removing the 2 circlips and then the special washers and springs. Note the way these come off. These were not present on this engine as can be seen. A nut had been forced on one side and the wrong circlip forced on the other. Be careful as after the cam assembly has been removed, the end of the shifter shaft sits proud of the base of the engine. Support the rear of the engine with a bit of 2 by 2 wood. The bottom of the oil pan was found to contain bits of clutch plate and 4 broken gear teeth as well as a fair bit of sludge. This does not look good for this engine! The rotor is removed by installing an extractor bolt into the threaded portion of the rotor. This was not required on this engine due to it already being a loose fit on its shaft. This will require replacement due to damage to it from being loose. Remove the tacho drive gearbox by taking out the 4 Phillips screws and then gently prizing it from the casing. Also remove the breather bolt from the back of the crankcase if fitted. Next remove all 8 clutch casing screws, noting the 2 longer screws that go though the location dowels. Gently tap the cover to break the seal. Be careful when pulling the 2 plastic oil lines through the hole in the crankcase, these can be very fragile. It was noted on this engine that the crankseal was sitting proud of the case. I have seen this a couple of times on en