2000 YAMAHA YZ426F maintenance

EC020000
INTRODUCTION
Congratulations on your purchase of a
Yamaha YZ series. This model is the culmina-
tion of Yamaha’s vast experience in the pro-
duction of pacesetting racing machines. It
represents the highest grade of craftsmanship
and reliability that have made Yamaha a
leader.
This manual explains operation, inspection,
basic maintenance and tuning of your
machine. If you have any questions about this
manual or your machine, please contact your
Yamaha dealer.
NOTE:

As improvements are made on this model,
some data in this manual may become out-
dated. If you have any questions, please con-
sult your Yamaha dealer.
WARNING

PLEASE READ THIS MANUAL CAREFULLY
AND COMPLETELY BEFORE OPERATING
THIS MACHINE. DO NOT ATTEMPT TO
OPERATE THIS MACHINE UNTIL YOU
HAVE ATTAINED A SATISFACTORY
KNOWLEDGE OF ITS CONTROLS AND
OPERATING FEATURES AND UNTIL YOU
HAVE BEEN TRAINED IN SAFE AND
PROPER RIDING TECHNIQUES. REGULAR
INSPECTIONS AND CAREFUL MAINTE-
NANCE, ALONG WITH GOOD RIDING
SKILLS, WILL ENSURE THAT YOU SAFETY
ENJOY THE CAPABILITIES AND THE RELI-
ABILITY OF THIS MACHINE.

EC050000
TO THE NEW OWNER
This manual will provide you with a good basic
understanding of features, operation, and
basic maintenance and inspection items of this
machine. Please read this manual carefully
and completely before operating your new
machine. If you have any questions regarding
the operation or maintenance of your machine,
please consult your Yamaha dealer.
NOTE:

This manual should be considered a perma-
nent part of this machine and should remain
with it even if the machine is subsequently
sold.
EC060000
NOTICE
Some data in this manual may become out-
dated due to improvements made to this
model in the future. If there is any question
you have regarding this manual or your
machine, please consult your Yamaha
dealer.
EC070001
F.I.M. MACHINE WEIGHTS:
Weights of machines without fuel
The minimum weights for motocross
machines are:
for the class 125 cc....................... minimum
88 kg (194 lb)
for the class 250 cc....................... minimum
98 kg (216 lb)
for the class 500 cc....................... minimum
102 kg (225 lb)
In modifying your machine (e.g., for weight
reduction), take note of the above limits of
weight.

EC0A0000
CONTENTS
CHAPTER 1
GENERAL INFORMATION
DESCRIPTION
.......................................... 1-1
MACHINE IDENTIFICATION
.................... 1-2
IMPORTANT INFORMATION
................... 1-3
CHECKING OF CONNECTION
................ 1-5
SPECIAL TOOLS
...................................... 1-6
CONTROL FUNCTIONS
........................... 1-9
FUEL
....................................................... 1-12
STARTING AND BREAK-IN
................... 1-13
TORQUE-CHECK POINTS
..................... 1-17
CLEANING AND STORAGE
.................. 1-18
CHAPTER 2
SPECIFICATIONS
GENERAL SPECIFICATIONS
.................. 2-1
MAINTENANCE SPECIFICATIONS
......... 2-4
GENERAL TORQUE
SPECIFICATIONS
.................................. 2-18
DEFINITION OF UNITS
.......................... 2-18
LUBRICATION DIAGRAMS
................... 2-19
CABLE ROUTING DIAGRAM
................ 2-21
CHAPTER 3
REGULAR INSPECTION AND
ADJUSTMENTS
MAINTENANCE INTERVALS
................... 3-1
PRE-OPERATION INSPECTION AND
MAINTENANCE
........................................ 3-4
ENGINE
..................................................... 3-5
CHASSIS
................................................. 3-24
ELECTRICAL
.......................................... 3-45

1 - 17
GEN
INFO
TORQUE-CHECK POINTS
EC1A0012
TORQUE-CHECK POINTS
Frame construction
Combined seat and tank
Engine mounting
Steering Steering shaft to
handlebar
Suspension Front Steering shaft to front
fork
Rear For link type
Rear Installation of shock
absorber
Rear Installation of swing-
arm
Wheel Installation of wheel Front
Rear
Brake Front
Rear
Fuel systemFrame to rear frame
Fuel tank to frame
Frame to engine
Steering shaft to frame
Steering shaft to handle crown
Handle crown to handlebar
Front fork to handle crown
Front fork to under bracket
Assembly of links
Link to frame
Link to shock absorber
Link to swingarm
Shock absorber to frame
Tightening of pivot shaft
Tightening of front axle
Tightening of axle holder
Tightening of rear axle
Wheel to sprocket
Caliper to front fork
Brake disc to wheel
Tightening of union bolt
Master cylinder to handlebar
Tightening of air bleeder
Brake disc to wheel
Tightening of union bolt
Master cylinder to frame
Tightening of air bleeder
Fuel tank to fuel cock
NOTE:
Concerning the tightening torque, refer to
“MAINTENANCE SPECIFICATIONS” section
in the CHAPTER 2.

SPEC

2 - 4
MAINTENANCE SPECIFICATIONS
MAINTENANCE SPECIFICATIONS
ENGINE
Item Standard Limit
Cylinder head:
Warp limit ---- 0.05 mm
(0.002 in)
Cylinder:
Bore size95.00 ~ 95.01 mm
(3.7402 ~ 3.7406 in)----
Out of round limit ---- 0.05 mm
(0.002 in)
Camshaft:
Drive method Chain drive (Left) ----
Cam cap inside diameter 22.000 ~ 22.021 mm
(0.8661 ~ 0.8670 in)----
Camshaft outside diameter 21.967 ~ 21.980 mm
(0.8648 ~ 0.8654 in)----
Shaft-to-cap clearance 0.020 ~ 0.054 mm
(0.0008 ~ 0.0021 in)----
Cam dimensions
Intake “A” 31.7 ~ 31.8 mm
(1.248 ~ 1.252 in)31.6 mm
(1.244 in)
“B” 22.95 ~ 23.05 mm
(0.9035 ~ 0.9075 in)22.85 mm
(0.900 in)
“C” 8.65 ~ 8.85 mm
(0.3406 ~ 0.3484 in)----
Exhaust “A” 31.2 ~ 31.3 mm
(1.2283 ~ 1.2323 in)31.1 mm
(1.224 in)
“B” 22.95 ~ 23.05 mm
(0.9035 ~ 0.9075 in)22.85 mm
(0.900 in)
“C” 8.15 ~ 8.35 mm
(0.3209 ~ 0.3287 in)----
C
A
B

SPEC

2 - 5
MAINTENANCE SPECIFICATIONS
Camshaft runout limit ---- 0.03 mm
(0.0012 in)
Cam chain:
Cam chain type/No. of links 92RH2010-120MPX/120 ----
Cam chain adjustment method Automatic ----
Valve, valve seat, valve guide:
Valve clearance (cold) IN 0.15 ~ 0.20 mm
(0.0059 ~ 0.0079 in)----
EX 0.25 ~ 0.30 mm
(0.0098 ~ 0.0118 in)----
Valve dimensions:
“A” head diameter IN 26.9 ~ 27.1 mm
(1.0591 ~ 1.0669 in)----
EX 27.9 ~ 28.1 mm
(1.0984 ~ 1.1063 in)----
“B” face width IN 2.26 mm (0.089 in) ----
EX 2.26 mm (0.089 in) ----
“C” seat width IN0.9 ~ 1.1 mm
(0.0354 ~ 0.0433 in)1.5 mm
(0.0591 in)
EX 0.9 ~ 1.1 mm
(0.0354 ~ 0.0433 in)1.5 mm
(0.0591 in)
“D” margin thickness IN 1 mm (0.0394 in) 0.85 mm
(0.033 in)
EX 1 mm (0.0394 in) 0.85 mm
(0.033 in)
Stem outside diameter IN4.475 ~ 4.490 mm
(0.1762 ~ 0.1768 in)----
EX 4.960 ~ 4.975 mm
(0.1953 ~ 0.1959 in)----
Guide inside diameter IN 4.500 ~ 4.512 mm
(0.1772 ~ 0.1776 in)----
EX 5.000 ~ 5.012 mm
(0.1969 ~ 0.1973 in)----
Stem-to-guide clearance IN0.010 ~ 0.037 mm
(0.0004 ~ 0.0015 in)0.08 mm
(0.003 in)
EX 0.025 ~ 0.052 mm
(0.0010 ~ 0.0020 in)0.10 mm
(0.004 in) Item Standard Limit
Head Diameter
B
Face WidthC
Seat Width
D
Margin ThicknessA

SPEC

2 - 6
MAINTENANCE SPECIFICATIONS
Stem runout limit ---- 0.01 mm
(0.0004 in)
Valve seat width IN0.9 ~ 1.1 mm (0.0354 ~ 0.0433 in)----
EX 0.9 ~ 1.1 mm (0.0354 ~ 0.0433 in)----
Valve spring:
Free length IN 39.42 mm (1.55 in) 37.5 mm
(1.48 in)
EX 41.80 mm (1.65 in) 39.8 mm
(1.57 in)
Set length (valve closed) IN 32.87 mm (1.29 in) ----
EX 35.35 mm (1.39 in) ----
Compressed pressure
(installed) IN 124 ~ 136 N
(12.6 ~ 13.8 kg, 27.78 ~ 30.42 lb)----
EX 123 ~ 143 N
(12.6 ~ 14.6 kg, 27.78 ~ 32.19 lb)----
Tilt limit IN ----2.5˚/ 1.7 mm
(2.5˚/0.067 in)
EX ----2.5˚/1.8 mm
(2.5˚/0.071 in)
Direction of winding
(top view) IN Clockwise ----
EX Clockwise ----
Piston:
Piston to cylinder clearance 0.040 ~ 0.065 mm
(0.0016 ~ 0.0026 in)0.1 mm
(0.004 in)
Piston size “D” 94.945 ~ 94.960 mm
(3.738 ~ 3.739 in)----
Measuring point “H” 9 mm (0.354 in) ----
Piston off-set 1 mm (0.0394 in) ----Item Standard Limit
*
H
D

SPEC

2 - 7
MAINTENANCE SPECIFICATIONS
Piston pin bore inside diameter19.004 ~ 19.015 mm
(0.7482 ~ 0.7486 in)19.045 mm
(0.7498 in)
Piston pin outside diameter18.991 ~ 19.000 mm
(0.7477 ~ 0.7480 in)18.971 mm
(0.7469 in)
Piston rings:
Top ring:
Type Barrel ----
Dimensions (B

´

T) 1.2
´
3.5 mm (0.05
´
0.14 in) ----
End gap (installed) 0.20 ~ 0.30 mm
(0.008 ~ 0.012 in)0.55 mm
(0.022 in)
Side clearance (installed) 0.030 ~ 0.065 mm
(0.0012 ~ 0.0026 in)0.13 mm
(0.005 in)
2nd ring:
Type Taper ----
Dimensions (B

´

T) 1.00
´
3.35 mm (0.04
´
0.13 in) ----
End gap (installed) 0.35 ~ 0.50 mm
(0.014 ~ 0.020 in)0.85 mm
(0.033 in)
Side clearance 0.020 ~ 0.055 mm
(0.0008 ~ 0.0022 in)0.13 mm
(0.005 in)
Oil ring:
Dimensions (B

´

T) 2.0
´
2.9 mm (0.08
´
0.11 in) ----
End gap (installed) 0.2 ~ 0.5 mm (0.01 ~ 0.02 in) ----
Crankshaft:
Crank width “A” 61.95 ~ 62.00 mm
(2.439 ~ 2.441 in)----
Runout limit “C” 0.03 mm (0.0012 in) 0.05 mm
(0.002 in)
Big end side clearance “D” 0.15 ~ 0.45 mm
(0.0059 ~ 0.0177 in)0.50 mm
(0.02 in)
Small end free play “F” 0.4 ~ 1.0 mm (0.02 ~ 0.04 in) 2.0 mm
(0.08 in)
Balancer:
Balancer drive method Gear ----
Decompression device:
Type Manual ----
Cable free play 5 ~ 9 mm (0.20 ~ 0.35 in)
Air filter oil grade: Engine oil ----Item Standard Limit
T
B
B
T
B
T