fuel tank removal YAMAHA YZ426F 2002 Owners Manual

CHAPTER 4
ENGINE
SEAT, FUEL TANK
AND SIDE COVERS
................................. 4-1
EXHAUST PIPE AND SILENCER
............ 4-2
RADIATOR
................................................ 4-4
CARBURETOR
......................................... 4-7
CAMSHAFTS
.......................................... 4-20
CYLINDER HEAD
................................... 4-27
VALVES AND VALVE SPRINGS
........... 4-31
CYLINDER AND PISTON
....................... 4-40
CLUTCH
.................................................. 4-46
OIL FILTER, WATER PUMP
AND CRANKCASE COVER (RIGHT)
.... 4-53
BALANCER
............................................ 4-60
OIL PUMP
............................................... 4-63
KICK AXLE AND SHIFT SHAFT
............ 4-67
CDI MAGNETO
....................................... 4-74
ENGINE REMOVAL
................................ 4-78
CRANKCASE AND CRANKSHAFT
....... 4-83
TRANSMISSION, SHIFT CAM
AND SHIFT FORK
.................................. 4-92
CHAPTER 5
CHASSIS
FRONT WHEEL AND REAR WHEEL
...... 5-1
FRONT BRAKE AND REAR BRAKE
..... 5-10
FRONT FORK
......................................... 5-27
HANDLEBAR
.......................................... 5-40
STEERING
.............................................. 5-46
SWINGARM
............................................ 5-51
REAR SHOCK ABSORBER
................... 5-58

4 - 1
ENG

EC400000
ENGINE
EC4R0000
SEAT, FUEL TANK AND SIDE COVERS
Extent of removal:
1
Seat removal
2
Fuel tank removal
3
Side covers removal
4
Number plate removal
Extent of removal Order Part name Q’ty Remarks
Preparation for removal
SEAT, FUEL TANK AND SIDE
COVERS REMOVAL
Turn the fuel cock to “OFF”.
Disconnect the fuel hose.
1 Seat 1
2 Air scoop (left and right) 2
3 Fitting band 1 Remove on fuel tank side.
4 Bolt (fuel tank) 2
5 Fuel tank 1
6 Side cover (left) 1
7 Side cover (right) 1
8 Number plate 1
13
4
2
3

SEAT, FUEL TANK AND SIDE COVERS
4

4 - 2
ENG

EXHAUST PIPE AND SILENCER
EC4S0000
EXHAUST PIPE AND SILENCER
Å
Except for USA
Extent of removal:
1
Silencer removal
2
Exhaust pipe removal
Extent of removal Order Part name Q’ty Remarks
EXHAUST PIPE AND
SILENCER REMOVAL
Preparation for removal Side cover (right) Refer to “SEAT, FUEL TANK AND SIDE
COVERS” section.
1 Bolt (clamp) 1 Only loosening.
2 Bolt [silencer (front)] 1
3 Bolt [silencer (rear)] 1
4 Collar 1
5 Silencer 1
6 Clamp 1
7 Nut (exhaust pipe) 1
8 Bolt (exhaust pipe) 1
9 Exhaust pipe 1
10 Gasket 2
2
1
2

4 - 4
ENG

RADIATOR
EC450001
RADIATOR
Extent of removal:
1
Radiator removal
Extent of removal Order Part name Q’ty Remarks
RADIATOR REMOVAL
Preparation for removal Drain the coolant. Refer to “COOLANT REPLACEMENT”
section in the CHAPTER 3.
Seat and fuel tank Refer to “SEAT, FUEL TANK AND SIDE
COVERS” section.
Exhaust pipe Refer to “EXHAUST PIPE AND
SILENCER” section.
1 Engine guard 1
2 Panel 2
3 Clamp 8
4 Radiator (right) 1
5 Hose 2 1
6 Hose 3 1
7 Hose 4 1
8 Pipe 2/O-ring 1/1
9 Radiator breather hose 1
10 Radiator (left) 1
11 Hose 1 1
12 Pipe 1/O-ring 1/1
1

4 - 7
ENGCARBURETOR
CARBURETOR
Extent of removal:1 Carburetor removal
Extent of removal Order Part name Q’ty Remarks
CARBURETOR REMOVAL
Preparation for removal Fuel tank Refer to “SEAT, FUEL TANK AND SIDE
COVERS” section.
1 Band 1
2 TPS coupler 1
3 Throttle cable cover 1
4 Throttle cable 2
5 Throttle cable cap 1
6 Clamp (air cleaner joint) 1 Loosen the screw (air cleaner joint).
7 Clamp (carburetor joint) 2 Loosen the screws (carburetor joint).
8 Carburetor 1
9 Carburetor joint 1
1

4 - 20
ENGCAMSHAFTS
CAMSHAFTS
CYLINDER HEAD COVER
Extent of removal:1 Cylinder head cover removal
Extent of removal Order Part name Q’ty Remarks
CYLINDER HEAD COVER
REMOVAL
Preparation for removal Seat and fuel tank Refer to “SEAT, FUEL TANK AND SIDE
COVERS” section.
Carburetor Refer to “CARBURETOR” section.
1 Spark plug 1
2 Engine upper bracket (right) 1
3 Engine upper bracket (left) 1
4 Cylinder head breather hose 1
5 Oil tank breather hose 1
6 Bolt (cylinder head cover) 2
7 Cylinder head cover 1
8 Gasket 1
9 Timing chain guide (upper) 1
1

4 - 27
ENGCYLINDER HEAD
CYLINDER HEAD
CYLINDER HEAD
Extent of removal:1 Cylinder head removal
Extent of removal Order Part name Q’ty Remarks
CYLINDER HEAD REMOVAL
Preparation for removal Seat and fuel tank Refer to “SEAT, FUEL TANK AND SIDE
COVERS” section.
Exhaust pipe and silencer Refer to “EXHAUST PIPE AND
SILENCER” section.
Radiator Refer to “RADIATOR” section.
Carburetor Refer to “CARBURETOR” section.
Camshaft Refer to “CAMSHAFTS” section.
1 Decompression cable 1
2 Cable guide 1
3 Bolt 1
4 Decompression shaft 1
5 Oil delivery pipe 1
6 Nut (M6) 2
7 Nut (M8) 2
8 Bolt (L = 150 mm) 2
9 Bolt (L = 160 mm) 2
10 Cylinder head 1
1

4 - 74
ENGCDI MAGNETO
EC4L0000
CDI MAGNETO
Extent of removal:1 CDI magneto removal
Extent of removal Order Part name Q’ty Remarks
CDI MAGNETO REMOVAL
Preparation for removal Seat and fuel tank Refer to “SAET, FUEL TANK AND SIDE
COVERS” section.
Bolt [radiator (left)]
Disconnect the CDI magneto lead.Refer to “RADIATOR” section.
1 Shift pedal 1
2 Crankcase cover (left) 1
3 Gasket 1
4 Dowel pin 2
5 Nut (rotor) 1 Use special tool.
Refer to “REMOVAL POINTS”.
6 Rotor 1
7 Stator 1
8 Woodruff key 1
1

4 - 78
ENGENGINE REMOVAL
EC4M0000
ENGINE REMOVAL
Extent of removal Order Part name Q’ty Remarks
ENGINE REMOVAL
Preparation for removal Hold the machine by placing the
suitable stand under the frame.
WARNING
Support the machine securely so there is no
danger of it falling over.
Seat and fuel tank Refer to “SEAT, FUEL TANK AND SIDE
COVERS” section.
Carburetor Refer to “CARBURETOR” section.
Exhaust pipe and silencer Refer to “EXHAUST PIPE AND
SILENCER” section.
Clutch cable Disconnect at engine side.
Decompression cable and guide Disconnect at engine side.
Radiator Refer to “RADIATOR” section.
Shift pedal Refer to “CDI MAGNETO” section.
Cylinder head breather hose and
oil tank breather hoseRefer to “CAMSHAFTS” section.
Drain the engine oil Refer to “ENGINE OIL REPLACEMENT”
section in the CHAPTER 3.
Spark plug cap
Disconnect the CDI magneto lead.

5 - 58
CHASREAR SHOCK ABSORBER
EC580000
REAR SHOCK ABSORBER
Extent of removal:1 Rear shock absorber removal2 Rear shock absorber disassembly
Extent of removal Order Part name Q’ty Remarks
Preparation for removalREAR SHOCK ABSORBER
REMOVAL
Hold the machine by placing the
suitable stand under the engine.
WARNING
Support the machine securely so there is nodanger of it falling over.
Seat and fitting band Refer to “SEAT, FUEL TANK AND SIDE
COVERS” section.
Silencer Refer to “EXHAUST PIPE AND
SILENCER” section in the CHAPTER 4.
1 Bolt (reservoir tank) 1
2 Clamp (air cleaner joint) 1 Only loosening.
3 Rear frame 1
4 Bolt (rear shock absorber-relay
arm)1 Hold the swingarm.
5 Bolt (rear shock absorber-frame) 1
6 Rear shock absorber 1
7 Locknut 1 Only loosening.
8 Adjuster 1 Only loosening.
9 Spring guide (lower) 1
1
2