Using it to save you a lot and keep your motorcycle working in the long run. This Service Manual has easy-to-read text sections with top quality diagrams and instructions. Trust Yamaha YZ service manual repair YZ will give you everything you need to do the job.
Messen: 1. Monter: in ] 1 1. Install: 9Friction plate 1 1 9Clutch plate 2 9Friction plate 2 3 NOTE: 9Install the clutch plates and friction plates alter- nately on the clutch boss, starting with a friction plate and ending with a friction plate. Install: 9 Clutch cover 1 9 Bolt clutch cover 2 10 Nm 1. Monter: 9. Einbauen: 9. Install: 9Plain washer 1 9 Circlip 2 Monter: 4. Einbauen: 4. Installare: 9 Rondelle ordinaire 1 9 Rossetta 1 9 Beilegescheibe 1 9 Circlip 2 9 Sprengring 2 9 Anello elastico di arresto 2 Loosen: 9Bolt primary drive gear 1 NOTE: Place an aluminum plate a between the teeth of the primary drive gear 2 and driven gear 3.
EC4B Kick axle assembly 1. Measure: 9Kick clip friction force Out of specification Replace. Use a spring gauge 1. Kick clip friction force: 0. Install: 9Bolt shift guide 1 10 Nm 1. EC4C Kick idle gear 1. Crocher: 4. Haken: 4. Agganciare: 9 Ressort de torsion 1 9 Molla di torsione 1 9 Torsionsfeder 1 N.
Install: 9Bolt [crankcase cover right ] 1 10 Nm 1. EC4K Bearing 1. Install: 9Ball 1 9Retainer 2 To governor shaft 3. NOTE: Apply the transmission oil on the retainer and ball. EC4H Bearing 1. Inspect: 9Bearing 1 Rotate inner race with a finger.
EC Oil seal 1. Install: 9Impeller shaft 1 NOTE: 9Take care so that the oil seal lip is not dam- aged or the spring does not slip off its position. Einbauen: 1. Remove: 9Nut rotor 1 9Plain washer 2 Use the rotor holding tool 3. Remove: 9Rotor 1 Use the flywheel puller 2.
Install: 9Gasket [crankcase cover left ] 9Crankcase cover left 1 9Screw [crankcase cover left ] 2 5 Nm 0. Connecter: 7. Install: 9Engine 1 Install the engine from right side. Install: 9Lock washer 1 9Nut drive sprocket 2 60 Nm 6. Bend the lock washer tab to lock the nut. Install: 9Chain cover 1 9Screw chain cover 2 5 Nm 0. EC4N Crankcase 1. Remove: 9Crankcase right 1 Use the crankcase separating tool 2 and crankcase separating bolt 3. Remove: 9Crankshaft 1 Use the crankcase separating tool 2 and crankcase separating bolt 3.
EC4N Crankshaft bearing 1. Inspect: 9Bearings 1 Rotate inner race with a finger. Inspect: 9Oil seal 1 Damage Replace. EC4N Crankshaft 1. Measure: 9Runout limit a 9Small end free play limit b 9Connecting rod big end side clearance c 9Crank width d Out of specification Replace. Page Unsmooth operation Repair. Install: 9Dowel pin 1 9O-ring 2 9Crankcase right 3 To crankcase left 4.
Install: 9Holder 1 9Bolt holder 2 10 Nm 1. Install: 9Segment 1 9Bolt segment 2 30 Nm 3. Monter: 6. Einbauen: 6. Note the position of each part.
Pay particular attention to the lo- cation and direction of shift forks. Ausbauen: 9 Axe principal 1 9 Asse principale 1 9 Hauptwelle Check: 9Shift fork movement On its guide bar. Install: 92nd wheel gear 28T 1 96th wheel gear 24T 2 94th wheel gear 27T 3 93rd wheel gear 26T 4 95th wheel gear 26T 5 91st wheel gear 30T 6 To drive axle 7. NOTE: 9Apply the molybdenum disulfide oil on the 1st, 2nd, 3rd and 4th wheel gears inner circumfer EC Wheel bearing if necessary 1.
Togliere: 9 Roue 1 9 Rad 1 9 Ruota 1 N. Measure: 9Wheel axle bends Out of specification Replace. Use the dial gauge 1. Wheel axle bending limit: 0. Install: 9Nut wheel axle 1 Nm Tighten: 9Bolt axle holder 1 23 Nm 2. Installare: 9 Axe de roue 1 9 Asse della ruota 1 9 Radachse 1 N.
Install: 9Bearing right 1 9Circlip 2 9Spacer Installare: 9 Couvercle de tuyau 1 9 Copertura del tubo flessibile 1 9 Schlauchdeckel 1 9 Rondelle ordinaire 2 9 Beilegescheibe 2 9 Rosetta 2 9 Boulon 9 Schraube Install: 9Driven sprocket 1 9Bolt driven sprocket 2 9Plain washer driven sprocket 3 9Nut driven sprocket 4 42 Nm 4. Monter: 8. Einbauen: 8.
A Front B Rear 2. Connect the transparent hose 1 to the bleed screw 2 and place a suitable contain- er under its end. Never attempt to pry out piston seals and dust seals. Togliere: 9 Parapolvere 1 9 Joint de piston 2 9 Kolbendichtung Replace the piston seals and dust seals 2 2 whenever a caliper is disassembled. Install: 9Piston seal 1 9Dust seal 2 Always use new piston seals and dust seals.
NOTE: Fit the piston seals and dust seals onto the slot on caliper correctly. A Front B Rear 3. Install: 9Copper washer 1 9Union bolt 2 30 Nm 3. Install the brake hose so that its pipe por- tion a a directs as show and lightly touches the projection b b on the caliper. Install: 9Disc cover 1 9Bolt disc cover 2 7 Nm 0. Install: 9Copper washer 1 9Brake hose 2 9Union bolt 3 30 Nm 3. Install the brake hose to the caliper with the paint a a on the pipe facing the caliper and with the pipe contacting the caliper Clean: 9Master cylinder 9Master cylinder kit Clean them with brake fluid.
Install: 9Master cylinder cup primary 1 9Master cylinder cup secondary 2 To master cylinder piston 3. NOTE: Apply the brake fluid on the master cylinder cup. Nettoyer: 1. Reinigen: 1. Install: 9Brake lever 1 9Bolt brake lever 2 6 Nm 0. Installare: 9 Levier de frein 1 9 Leva di comando del freno 1 9 Bremshebel 1 9 Boulon levier de frein 2 9 Schraube Bremshebel 2 9 Bullone leva di comando del freno EC5A Front brake hose 1.
Install: 9Brake hose 1 10 Nm 1. Install the brake hose so that its pipe por- tion a a directs as show and lightly touches the projection b b on the master cylinder. Install: 9Brake hose holder 1 9Screw brake hose holder 2 4 Nm 0.
If it does, correct its twist. Installare: 9 Support de tuyau de frein 1 9 Supporto del tubo flessibile del 9 Bremsschlauchhalter 1 9 Vis support de tuyau de frein 2 9 Schraube Bremsschlauchhal- freno 1 ter Inspect: 9Brake fluid level Fluid at lower level Fill up. So it is recommended that the front fork be maintained at the dealers. To prevent an accidental explosion of air, the following instructions should be ob- served: 9 The front fork with a built-in piston rod has a very sophisticated internal con- struction and is particularly sensitive to Daher wird N.
Remove: 9Dust seal 1 9Stopper ring 2 Using slotted-head screwdriver. Take care not to scratch the inner tube. Remove: 9Inner tube 1 Oil seal removal steps: a the inner tube just be- 9 Push in slowly fore it bottoms out and then pull it back quickly b. EC Fork spring 1. Measure: 9Fork spring free length a Out of specification Replace. Wash the all parts in a clean solvent. Install: 9Damper rod 1 To inner tube 2. Install: 9Spring guide 1 9Locknut 2 To damper rod 3.
NOTE: 9Install the spring guide with its cut a facing up- ward. Sulla barra dello smorzatore 3. Install: 9Slide metal 1 9 Plain washer 2 To outer tube slot. The oil must be changed every kilometres approx. How do I remove rust from my Yamaha Motorcycle? Soak the rusty part in vinegar until completely soaked through. Let the vinegar work on the rust for 24 hours. Remove the rust with a wire brush or aluminium foil.
Is the manual of the Yamaha YZ available in English? Unfortunately, we do not have the manual for the Yamaha YZ available in English. How do I convert miles into kilometres? What is the difference between E10 and E5 petrol? E10 petrol consists of up to ten per cent ethanol while E5 petrol will contain less than five per cent ethanol. As a result, the percentage of E10 petrol is lower than that of E5 petrol, making it less bad for the environment. How often should I replace the oil filter on my Yamaha engine?
An oil filter must be replaced every kilometres approx. How often should I change the oil of my Yamaha engine?
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