lock YAMAHA WR 426F 2002 Notices Demploi (in French)

ENG
4 - 24
ARBRES A CAMES
NOCKENWELLE
ÁRBOLES DE LEVAS
AUSBAU
Nockenwelle
1. Demontieren:
Schwungrad-Abdeckschrau-
be 1
Rotorzapfen-Abdeckschrau-
be 2
2. Ausrichten:
I-Markierung
(auf Gehäusemarkierung)
Arbeitsschritte
Kurbelwelle mit einem Schrau-
benschlüssel gegen den Uhr-
zeigersinn drehen.
I-Markierung a am Rotor mit
der Markierung b am Kurbel-
gehäusedeckel ausrichten.
Wenn die I-Markierung mit der
Markierung des Kurbelgehäu-
sedekkels fluchtet, steht der
Kolben im oberen Totpunkt
(OT).
HINWEIS:
Der Kolben steht im oberen Tot-
punkt, wenn die Markierung c
an der AuslaßNockenwelle und
d an der Einlaß-Nokkenwelle
laut Abbildung mit der Zylinder-
kopfkante fluchtet.
Wenn kein Spiel vorhanden ist,
die Kurbelwelle um eine ganze
Umdrehung gegen den Uhrzei-
gersinn drehen.
3. Lockern:
Steuerkettenspanner-Ab-
deckschraube 1
4. Demontieren:
Steuerkettenspanner 2
5. Demontieren:
Schraube (Nockenwellen-
Lagerdeckel) 1
Nockenwellen-Lagerdeckel
2
HINWEIS:
Die Schrauben der Nockenwellen-
Lagerdekkel kreuzweise von außen
nach innen herausschrauben.
ACHTUNG:
Die Schrauben der Nockenwellen-
Lagerdeckel müssen gleichmäßig
herausgeschraubt werden, um Be-
schädigung an Zylinderkopf, Nok-
kenwellen und Lagerdeckeln zu
vermeiden. POINTS DE DEPOSE
Arbre à cames
1. Déposer:
Bouchon de distribution 1
Bouchon droit 2
2. Aligner:
Repère “I”
Avec l’index fixe.
Etapes de la vérification:
Tourner le vilebrequin à l’aide
d’une clé dans le sens inverse des
aiguilles d’une montre.
Aligner le repère “I” a sur le rotor
sur l’index fixe b sur le couvercle
du carter. Quand le repère “I” est
aligné sur l’index fixe, le piston se
trouve au Point Mort Haut (PMH).
N.B.:
Les pistons sont au PMH lorsque le
repère d’alignement c de l’arbre à
cames d’échappement et le repère
d’alignement d de l’arble à cames
d’admission s’alignent sur la sur-
face de la culasse, comme illustré.
S’il n’y a pas de jeu, tourner le
vilebrequin dans le sens inverse
des aiguilles d’une montre sur un
tour.
3. Desserrer:
Boulon capuchon du tendeur
1
4. Déposer:
Tendeur de la chaîne de distri-
bution 2
5. Déposer:
Boulon (chapeau d’arbre à
cames) 1
Chapeau d’arbre à cames 2
N.B.:
Enlever les boulons chopeaux d’arbre à
cames en suivant un ordre entrecroisé et
en commençant par l’intérieur.
ATTENTION:
Les boulons (chapeaux d’arbre à
cames) doivent être enlevés uniformé-
ment pour éviter d’abîmer la culasse,
l’arbre à cames ou les chapeaux
d’arbre à cames.PUNTOS DE EXTRACCIÓN
Árbol de levas
1. Extraer:
Tapón de distribución 1
Tapón recto 2
2. Alinear:
Marca “I”
Con el indicador fijo.
Pasos de comprobación:
Gire el cigüeñal hacia la izquierda
con una llave.
Alinee la marca “I” a del rotor
con el indicador fijo b de la
cubierta del cárter. Cuando esté ali-
neada la marca “I” con el indicador
fijo, el pistón estará en el Punto
Muerto Superior (PMS).
NOTA:
Para asegurar que el pistón esté en
el Punto Máximo Superior, la
marca de perforación c del árbol
de levas de escape y la marca de
perforación d del árbol de levas
de admisión deben estar alineadas
con la superficie de la culata, tal y
como se muestra en la ilustración.
Si no existe holgura, gire el árbol
de levas hacia la izquierda una vez.
3. Aflojar:
Perno de la tapa del tensor 1
4. Extraer:
Tensor de la cadena de distri-
bución 2
5. Extraer:
Perno (tapa del árbol de levas)
1
Tapas del árbol de levas 2
NOTA:
Extraiga los pernos (tapa del árbol de
levas) mediante un patrón cruzado,
desde dentro hacia fuera.
PRECAUCION:
Los pernos (tapa del árbol de levas)
deben extraerse uniformemente para
evitar daños a la culata, árbol de levas
o tapas del árbol de levas.

4 - 27
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.

4 - 28
ENG

CAMSHAFTS
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)

4 - 51
ENGCLUTCH (WR426F)
EC493000
REMOVAL POINTS
EC483211
Clutch boss
1. Remove:
Nut 1
Lock washer 2
Clutch boss 3
NOTE:
Straighten the lock washer tab and use the
clutch holding tool 4 to hold the clutch boss.
ÅFor USA and CDN
ıExcept for USA and CDN
Clutch holding tool:
YM-91042/90890-04086
Å
ı
EC494000
INSPECTION
EC484100
Clutch housing and boss
1. Inspect:
Clutch housing 1
Cracks/wear/damage → Replace.
Clutch boss 2
Scoring/wear/damage → Replace.
EC484201
Primary driven gear
1. Check:
Circumferential play
Free play exists → Replace.
Gear teeth a
Wear/damage → Replace.
EC484400
Clutch spring
1. Measure:
Clutch spring free length a
Out of specification → Replace springs
as a set.
Clutch spring free length:
Standard
48.4 mm (1.91 in) 47.4 mm (1.87 in)

4 - 53
ENGCLUTCH (WR426F)
EC4A5000
ASSEMBLY AND INSTALLATION
Push lever
1. Install:
Push lever 1
Bolt (push lever)
NOTE:
Apply the lithium soap base grease on the oil
seal lip.
Apply the engine oil on the push lever.
Fit the seat plate 2 in the groove a of the
push lever 1 and tighten the bolt (seat
plate).
T R..10 Nm (1.0 m · kg, 7.2 ft · lb)
Clutch
1. Install:
Primary driven gear 1
Thrust washer 2
Clutch boss 3
NOTE:
Apply the engine oil on the primary driven gear
inner circumference.
2. Install:
Lock washer 1
Nut (clutch boss) 2
NOTE:
Use the clutch holding tool 3 to hold the clutch
boss.
Å
For USA and CDN
ıExcept for USA and CDN
Clutch holding tool:
YM-91042/90890-04086
New
T R..75 Nm (7.5 m · kg, 54 ft · lb)
Å
ı

4 - 54
ENGCLUTCH (WR426F)
3. Bend the lock washer 1 tab.
4. Install:
Seat plate 1
Clutch damper spring 2
NOTE:
Install the seat plate with its chamfered por-
tion a facing the clutch boss 3.
Install the seat plate so that it is not caught
on the step b.
Install the clutch damper spring with the
“OUT SIDE” mark c facing out.
5. Install:
Friction plate 1 [d = ø128 mm (5.04 in)]
1
Clutch plate 2
Friction plate 2 [d = ø119 mm (4.69 in)]
3
NOTE:
Install the clutch plates and friction plates
alternately on the clutch boss, starting with a
friction plate and ending with a friction plate.
Use the friction plate 1 for the first while pay-
ing attention to the difference in inner diame-
ter.
1
2
c
3
a
b
6. Install:
Bearing 1
Plain washer 2
Circlip 3
To push rod 1 4.
NOTE:
Apply the engine oil on the bearing and plain
washer.
New

4 - 58
ENGCLUTCH (WR400F)
EC493000
REMOVAL POINTS
EC483211
Clutch boss
1. Remove:
Nut 1
Lock washer 2
Clutch boss 3
NOTE:
Straighten the lock washer tab and use the
clutch holding tool 4 to hold the clutch boss.
ÅFor USA and CDN
ıExcept for USA and CDN
Clutch holding tool:
YM-91042/90890-04086
Åı
EC494000
INSPECTION
EC484100
Clutch housing and boss
1. Inspect:
Clutch housing 1
Cracks/wear/damage → Replace.
Clutch boss 2
Scoring/wear/damage → Replace.
EC484201
Primary driven gear
1. Check:
Circumferential play
Free play exists → Replace.
Gear teeth a
Wear/damage → Replace.
EC484400
Clutch spring
1. Measure:
Clutch spring free length a
Out of specification → Replace springs
as a set.
Clutch spring free length:
Standard
44 mm (1.73 in) 43 mm (1.69 in)

4 - 60
ENGCLUTCH (WR400F)
EC4A5000
ASSEMBLY AND INSTALLATION
Push lever
1. Install:
Push lever 1
Bolt (push lever)
NOTE:
Apply the lithium soap base grease on the oil
seal lip.
Apply the engine oil on the push lever.
Fit the seat plate 2 in the groove a of the
push lever 1 and tighten the bolt (seat
plate).
T R..10 Nm (1.0 m · kg, 7.2 ft · lb)
Clutch
1. Install:
Primary driven gear 1
Thrust washer 2
Clutch boss 3
NOTE:
Apply the engine oil on the primary driven gear
inner circumference.
2. Install:
Lock washer 1
Nut (clutch boss) 2
NOTE:
Use the clutch holding tool 3 to hold the clutch
boss.
ÅFor USA and CDN
ıExcept for USA and CDN
Clutch holding tool:
YM-91042/90890-04086
New
T R..75 Nm (7.5 m · kg, 54 ft · lb)
Å
ı

4 - 61
ENGCLUTCH (WR400F)
3. Bend the lock washer 1 tab.
4. Install:
Friction plate 1 [d = ø112 mm (4.41 in)]
1
Clutch plate 2
Friction plate 2 [d = ø116 mm (4.57 in)]
3
NOTE:
Install the clutch plates and friction plates
alternately on the clutch boss, starting with a
friction plate 1 and ending with a friction plate
2.
Apply the engine oil on the friction plates and
clutch plates.
5. Install:
Bearing 1
Plain washer 2
Circlip 3
To push rod 1 4.
NOTE:
Apply the engine oil on the bearing and plain
washer.
6. Install:
Push rod 2 1
Push rod 1 2
NOTE:
Apply the engine oil on the push rod 1, 2.
New
7. Install:
Pressure plate 1
NOTE:
Align the much mark a on the pressure plate
with the punched mark b on the clutch boss.

ENG
4 - 70
BALANCER
BALANCER
BALANCER
Extent of removal:1 Balancer drive gear2 Balancer
Extent of removal Order Part name Q’ty Remarks
BALANCER REMOVAL
Preparation for removal Clutch housing Refer to “CLUTCH” section.
Crankcase cover (right)Refer to “OIL FILTER, WATER PUMP AND
CRANKCASE COVER (RIGHT)” section.
Stator Refer to “CDI MAGNETO” section.
1 Nut (primary drive gear) 1
Refer to “REMOVAL POINTS”.
2 Nut (balancer) 1
3 Lock washer 1
4 Primary drive gear 1
5 Balancer drive gear 1
6 Lock washer 1
7 Balancer driven gear 1
8 Balancer 1 Refer to “REMOVAL POINTS”.
2
1
2