Timing YAMAHA YZ426F 2002 User Guide

4 - 22
ENGCAMSHAFTS
REMOVAL POINTS
Camshaft
1. Remove:
Timing plug 1
Straight plug 2
2. Align:
“I” mark
With stationary pointer.
Checking steps:
Turn the crankshaft counterclockwise with
a wrench.
Align the “I” mark a on the rotor with the
stationary pointer b on the crankcase
cover. When the “I” mark is aligned with
the stationary pointer, the piston is at the
Top Dead Center (T.D.C.).
NOTE:
In order to be sure that the piston is at Top
Dead Center, the punch mark c on the
exhaust camshaft and the punch mark d
on the intake camshaft must align with the
cylinder head surface, as shown in the
illustration.
If there is no clearance, rotate the crank-
shaft counterclockwise one turn.
3. Loosen:
Tensioner cap bolt 1
4. Remove:
Timing chain tensioner 2
5. Remove:
Bolt (camshaft cap) 1
Camshaft caps 2
NOTE:
Remove the bolts (camshaft cap) in a criss-
cross pattern, working from the outside in.
CAUTION:
The bolts (camshaft cap) must be removed
evenly to prevent damage to the cylinder
head, camshafts or camshaft caps.

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ENGCAMSHAFTS
6. Remove:
Clips
Exhaust camshaft 1
Intake camshaft 2
NOTE:
Attach a wire 3 to the timing chain to prevent
it from falling into the crankcase.
INSPECTION
Camshaft
1. Inspect:
Cam lobes
Pitting/scratches/blue discoloration →
Replace.
2. Measure:
Cam lobes length a and b
Out of specification → Replace.
Cam lobes length:
Intake:
a31.7 ~ 31.8 mm
(1.2480 ~ 1.2520 in)
<Limit>: 31.6 mm (1.244 in)
b22.95 ~ 23.05 mm
(0.9035 ~ 0.9075 in)
<Limit>: 22.85 mm (0.900 in)
Exhaust:
a31.2 ~ 31.3 mm
(1.2283 ~ 1.2323 in)
<Limit>: 31.1 mm (1.224 in)
b22.95 ~ 23.05 mm
(0.9035 ~ 0.9075 in)
<Limit>: 22.85 mm (0.900 in)
3. Measure:
Runout (camshaft)
Out of specification → Replace.
Runout (camshaft):
Less than 0.03 mm (0.0012 in)

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ENGCAMSHAFTS
4. Measure:
Camshaft-to-cap clearance
Out of specification → Measure bearing
diameter (camshaft)
Camshaft-to-cap clearance:
0.020 ~ 0.054 mm
(0.0008 ~ 0.0021 in)
<Limit>: 0.08 mm (0.003 in)
Measurement steps:
Install the camshaft onto the cylinder
head.
Position a strip of Plastigauge® 1 onto the
camshaft.
Install the circlip, dowel pins and camshaft
caps.
T R..
Bolt (camshaft cap):
10 Nm (1.0 m • kg, 7.2 ft • lb)
NOTE:
Tighten the bolts (camshaft cap) in a criss-
cross pattern from innermost to outer
caps.
Do not turn the camshaft when measuring
clearance with the Plastigauge®.
Remove the camshaft caps and measure
the width of the Plastigauge
® 1.
5. Measure:
Bearing diameter (camshaft) a
Out of specification → Replace the
camshaft.
Within specification → Replace cam-
shaft case and camshaft caps as a set.
Camshaft sprocket
1. Inspect:
Camshaft sprocket 1
Wear/damage → Replace the camshaft
assembly and timing chain as a set.
Bearing diameter (camshaft):
21.967 ~ 21.980 mm
(0.8648 ~ 0.8654 in)
1

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ENGCAMSHAFTS
Timing chain tensioner
1. Check:
While pressing the tensioner rod lightly
with fingers, use a thin screwdriver 1
and wind the tensioner rod up fully
clockwise.
When releasing the screwdriver by
pressing lightly with fingers, make sure
that the tensioner rod will come out
smoothly.
If not, replace the tensioner assembly.
ASSEMBLY AND INSTALLATION
1. Install:
Exhaust camshaft 1
Intake camshaft 2
Installation steps:
Turn the crankshaft counterclockwise until
the “I” mark a on the rotor is aligned with
the stationary pointer b on the crankcase
cover.
Fit the timing chain 3 onto both camshaft
sprockets and install the camshafts on the
cylinder head.
NOTE:
The camshafts should be installed onto the
cylinder head so that the exhaust cam
sprocket punch mark c and the intake cam
sprocket punch mark d align with the sur-
face of the cylinder head.
CAUTION:
Do not turn the crankshaft during the
camshaft installation. Damage or
improper valve timing will result.

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ENGCAMSHAFTS
2. Install:
Timing chain tensioner
3. Turn:
Crankshaft
Counterclockwise several turns
4. Check:
Rotor “I” mark
Align with the crankcase stationary
pointer.
Camshaft match marks
Align with the cylinder head surface.
Out of alignment → Adjust.
Install the clips and camshaft caps 4.
T R..
Bolt (camshaft cap):
10 Nm (1.0 m • kg, 7.2 ft • lb)
NOTE:
.Tighten the bolts (camshaft cap) 5 in a
crisscross pattern.
CAUTION:
The bolts (camshaft cap) must be tight-
ened evenly, or damage to the cylinder
head, camshaft caps, and camshaft will
result.
Installation steps:
While pressing the tensioner rod lightly
with fingers, use a thin screwdriver and
wind the tensioner rod up fully clockwise.
With the rod fully wound and the chain
tensioner UP mark a facing upward,
install the gasket 1 and the chain ten-
sioner 2, and tighten the bolt 3 to the
specified torque.
T R..
Bolt (timing chain tensioner):
10 Nm (1.0 m • kg, 7.2 ft • lb)
Release the screwdriver, check the ten-
sioner rod to come out and tighten the
gasket 4 and the cap bolt 5 to the speci-
fied torque.
T R..
Tensioner cap bolt:
7 Nm (0.7 m • kg, 5.1 ft • lb)

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ENGCYLINDER HEAD
Extent of removal Order Part name Q’ty Remarks
11 Gasket 1
12 Dowel pin 2
13 Timing chain guide (front) 1

4 - 45
ENGCYLINDER AND PISTON
2. Position:
Top ring
2nd ring
Oil ring
Offset the piston ring end gaps as
shown.
aTop ring end
b2nd ring end
cOil ring end (upper)
dOil ring
eOil ring end (lower)
3. Install:
Piston 1
Piston pin 2
Piston pin clips 3
NOTE:
Apply engine oil onto the piston pin and pis-
ton.
Be sure that the arrow mark a on the piston
points to the exhaust side of the engine.
Before installing the piston pin clip, cover the
crankcase with a clean rag to prevent the
piston pin clip from falling into the crankcase.
Install the piston pin clips with their ends fac-
ing downward.
4. Lubricate:
Piston
Piston rings
Cylinder
NOTE:
Apply a liberal coating of engine oil.
Cylinder
1. Install:
Dowel pins
O-ring
Gasket 1
Cylinder 2
NOTE:
Install the cylinder with one hand while com-
pressing the piston rings with the other hand.
CAUTION:
Pass the timing chain 3 through the tim-
ing chain cavity.
Be careful not to damage the timing chain
guide 4 during installation.
45°
135°135°
a
b ced
3New
New
New

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ENGCRANKCASE AND CRANKSHAFT
CRANKCASE AND CRANKSHAFT
CRANKCASE AND CRANKSHAFT
Extent of removal:1 Crankcase separation2 Crankshaft removal
Extent of removal Order Part name Q’ty Remarks
CRANKCASE SEPARATION
Preparation for removal Engine Refer to “ENGINE REMOVAL” section.
Piston Refer to “CYLINDER AND PISTON” sec-
tion.
Balancer Refer to “BALANCER” section.
Kick axle assembly
Refer to “KICK AXLE AND SHIFT
SHAFT” section.
Segment
Stator Refer to “CDI MAGNETO” section.
1 Timing chain guide (rear) 1
2 Timing chain 1
3 Bolt (40 mm) 3
Refer to “REMOVAL POINTS”. 4 Bolt (50 mm) 4
5 Bolt (60 mm) 2
6 Bolt (75 mm) 3
7 Hose guide 1
8 Clutch cable holder 1
9 Crankcase (right) 1
10 Crankcase (left) 1
21

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ENGCRANKCASE AND CRANKSHAFT
Crankshaft
1. Remove:
Crankshaft 1
Use the crankcase separating tool 2.
CAUTION:
Do not use a hammer to drive out the
crankshaft.
Crankshaft bearing
1. Remove:
Bearing 1
NOTE:
Remove the bearing from the crankcase by
pressing its inner race.
Do not use the removed bearing.
Crankcase separating tool:
YU-1135-A/90890-01135
INSPECTION
Timing chain and timing chain guide
1. Inspect:
Timing chain
Cracks/stiff → Replace the timing chain
and camshaft sprocket as a set.
2. Inspect:
Timing chain guide
Wear/damage → Replace.
EC4N4101
Crankcase
1. Inspect:
Contacting surface a
Scratches → Replace.
Engine mounting boss b, crankcase
Cracks/damage → Replace.
2. Inspect:
Bearing
Rotate inner race with a finger.
Rough spot/seizure → Replace.
3. Inspect:
Oil seal
Wear/damage → Replace.

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ENGCRANKCASE AND CRANKSHAFT
5. Install:
Dowel pin 1
O-ring 2
Crankcase (right)
To crankcase (left).
NOTE:
Fit the crankcase (right) onto the crankcase
(left). Tap lightly on the case with soft ham-
mer.
When installing the crankcase, the connect-
ing rod should be positioned at TDC (top
dead center).
6. Tighten:
Hose guide 1
Clutch cable holder 2
Bolt (crankcase)
NOTE:
Tighten the crankcase tightening bolts in
stage, using a crisscross pattern.
7. Install:
Oil delivery pipe
O-ring
Bolt (oil delivery pipe)
8. Install:
Timing chain
Timing chain guide (rear)
Bolt (timing chain guide)
9. Remove:
Sealant
Forced out on the cylinder mating sur-
face.
10. Apply:
Engine oil
To the crank pin, bearing and oil deliv-
ery hole.
11. Check:
Crankshaft and transmission operation.
Unsmooth operation → Repair.
New
T R..12 Nm (1.2 m · kg, 8.7 ft · lb)
New
T R..10 Nm (1.0 m · kg, 7.2 ft · lb)
T R..10 Nm (1.0 m · kg, 7.2 ft · lb)