Written from hands-on experience gained from the complete strip-down and rebuild of a Yamaha YZF, Haynes can help you understand, care for and repair your Yamaha YZF. We do it ourselves to help you do-it-yourself, and whatever your mechanical ability, the practical step-by-step explanations, linked to over photos, will help you get the job done right. Regular servicing and maintenance of your Yamaha YZF can help maintain its resale value, save you money, and make it safer to ride. Access this manual immediately on your internet browser on your mobile, desktop or tablet. With a Haynes Online Manual in an online format you get all the trusted content of a printed manual, with additional features to help you get the job done. Take your entire manual with you on every journey.
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Quick Links. Table of Contents. Any reprinting or unauthorized use without the written permission of Yamaha Motor Co. Printed in Japan Take care to a Yamaha YZ series. This model is not spill any gasoline on the the culmination of Yamaha's vast ex- engine or exhaust system.
Page 7: General Information and item. Page 8 der of the jobs in the exploded di- 4. A number that is enclosed panies the exploded diagram, To help identify parts and clarify pro- by a circle indicates a disassem- providing the order of jobs, names cedure steps, there are exploded dia- bly step.
Fuel cock Hot starter lever Cold starter knob Front brake lever Drive chain Throttle grip Air filter Radiator cap Oil level check window Fuel tank cap Shift pedal Engine stop switch Remove all dirt, mud, dust, and 1. When ordering parts, you can foreign material before removal give the number to your Yamaha and disassembly.
During the machine disassembly, clean all parts and place them in trays in the order of disassembly. This will speed up assembly time and help assure that all parts are correctly reinstalled.
Using the correct special tool will help prevent damage caused by the use of improper tools or improvised techniques. The shape and part number used for the special tool differ by country, so two types are provided. Radiator cap tester adapter YU, Steering nut wrench This tool is used when tighten the YU, steering ring nut to specification. Valve spring compressor This tool is needed to remove and YM, install the valve assemblies.
Clutch holding tool This tool is used to hold the clutch YM, when removing or installing the Continue push- ing the engine stop switch till the en- gine comes to a stop. Before starting the engine, fill the fuel tank with the fuel. Perform the pre-operation checks on the machine. Start and warm up the engine. Check the idle speed, and check the operation of the controls and the engine stop switch. Tank capacity 7.
First, tighten the steering ring nut approximately 38 Nm 3. Retighten the steering ring nut 7 Nm 0. Torque specifications 6 mm for special components or assem- blies are included in the applicable sections of this book. Hot starter cable Aligh the paint mark on the cylin- Radiator hose 1 Fuel hose der head breather hose with the Connector cover Carburetor overflow hose front end of the hose guide. Cylinder head breather hose Insert the end of the fuel tank Pass the cylinder head breather Pass the fuel hose between the hot starter cable and throttle po- sition sensor lead.
Pass the carburetor breater hos- es so that they are not pinched between the upper engine bracket and carburetor. Radiator breather hose Fasten the throttle position sen- Radiator hose 2 Engine stop switch lead sor lead behind the hump of the Clamp Sub-wire harness frame. Ignition coil lead CDI unit bracket Fasten the neutral switch lead Throttle position sensor lead Pass the radiator breather hose in front of the radiator, on the left of the chassis, and then be- tween the frame and radiator hose 4.
Ignition coil Fasten the throttle cables with Cylinder head breather hose the clamp so that the cables are Clamp not bent, and pass them under Rear arm bracket Install the brake hose so that its Install the brake hose so that its pipe portion directs as shown pipe portion directs as shown and lightly touches the projec- and lightly touches the projec Clutch cable Pass the brake hose in front of Engine stop switch lead the number plate.
Cable guide Pass the throttle cables through Brake hose the cable guide. Bear in mind that such factors as weather, terrain, geographical location, and individual usage will alter the required maintenance and lubrication intervals. If you are a doubt as to what intervals to follow in maintaining and lubricating your machine, consult your Yamaha dealer. Before using this machine, check the following points. Thoroughly wash your eye with Do not remove the radiator cap water and see your doctor.
Apply the specified pressure. Check: 1. Proper air filter maintenance is the biggest key to preventing premature engine wear and damage. Install the new pads "3" and the valve lifters "4". Connect the transparent hose "5" Install the pad pin plug "10". PADS" section. Loosen the pad pin "3". Remove the rear wheel "4" and Install the brake caliper "12" and brake caliper "5". Measure: 3.
Adjust: 1 Nm 0. Turn the handlebar lock to lock. Check the steering stem by turn- ing it lock to lock. Clutch cable end All control cable Disconnect the fuel hose. Seat Air scoop left and right Bolt fuel tank Fuel tank Left side cover Bolt silencer clamp Only loosening. Bolt [silencer front ] Bolt [silencer rear ] Collar Silencer Silencer clamp Radiator guard Radiator hose clamp Only loosening. Scalding hot fluid and steam may be blown out under pressure, which could cause serious injury.
When the engine has cooled, open 3. Float pin Float Needle valve Throttle shaft assembly Push rod link lever assembly Pilot air jet Cold starter plunger Blow out all passages and changing the throttle position sen- jets with compressed air. Recheck the float height. Spark plug Cylinder head breather hose Bolt cylinder head cover Cylinder head cover Cylinder head cover gasket Timing chain guide top side Crankshaft end accessing screw Refer to removal section.
Timing chain tensioner cap bolt Refer to removal section. Timing chain tensioner Refer to removal section.
Camshaft cap Refer to removal section. Remove: Camshaft-to-cap clear- ance: 0. Fit the timing chain "3" onto both 5. While pressing the tensioner rod "2" Radiator hose 1 Disconnect at cylinder head side. Valve lifter Refer to removal section. Adjusting pad Refer to removal section. Valve cotter Refer to removal section. Install the new valve guide using a be reinstalled in their original place. Margin thickness: Intake: 0. Install the valve into the cylinder head.
Measurement steps: d. Turn the valve until the valve face a. Onto the valve stem and valve stem seal. Bolt cylinder Cylinder Piston pin clip Refer to removal section.
Piston pin Refer to removal section. Piston Refer to removal section.
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