2002 YAMAHA YZ426F oil

4 - 46
ENGCLUTCH
CLUTCH
CLUTCH
Extent of removal:1 Push rod and push lever removal2 Push pod 1 disassembly
3 Friction plate and clutch plate removal4 Clutch housing removal
Extent of removal Order Part name Q’ty Remarks
CLUTCH REMOVAL
Preparation for removal Drain the engine oil. Refer to “ENGINE OIL REPLACEMENT”
section in the CHAPTER 3.
Brake pedal Refer to “ENGINE REMOVAL” section.
Clutch cable Disconnect at engine side.
1 Clutch cover 1
2 Gasket 1
3 Dowel pin 2
4 Clutch spring 6
5 Pressure plate 1
6 Push rod 1 1
7 Circlip 1
8 Plain washer 1
9 Bearing 1
10 Ball 1
11Push rod 2
1
41
2
3
1

4 - 49
ENG
EMBRAYAGE
KUPPLUNG
Reibscheiben
1. Messen:
Reibscheibenstärke
Unvorschriftsmäßig → Die Reibschei-
ben im Satz erneuern.
Die Reibscheiben an vier Stellen mes-
sen.
Kupplungsscheiben
1. Messen:
Verzug der Kupplungsscheiben
Unvorschriftsmäßig → Kupplungsschei-
ben im Satz erneuern.
Eine Richtplatte 1 und eine Fühlerleh-
re 2 verwenden.
Reibscheibenstärke
2,9–3,1 mm
2,7 mm
Verzugsgrenze
0,1 mm
Druckhebel
1. Kontrollieren:
Druckhebel 1
Verschleiß/Beschädigung → Erneuern.
Druckstangen
1. Kontrollieren:
Druckstange 1 1
Lager 2
Beilagscheibe 3
Druckstange 2 4
Kugel 5
Verschleiß/Beschädigung/Verbiegung
→ Erneuern. Disque de friction
1. Mesurer:
Epaisseur de disque de friction
Hors-spécification → Changer tous les dis-
ques de friction.
Mesurer chaque disque en quatre endroits.
Disque d’embrayage
1. Mesurer:
Voile de disque d’embrayage
Hors-spécification → Changer tous les dis-
ques d’embrayage.
Utiliser une plaque à surfacer 1 et une
jauge d’épaisseur 2.
Epaisseur de disque de friction:
2,9 à 3,1 mm (0,114 à 0,122 in)
: 2,7 mm (0,106 in)
Limite de déformation:
0,1 mm (0,004 in)
Levier de poussée
1. Contrôler:
Levier de poussée 1
Usure/endommagement → Changer.
Tige de poussée
1. Contrôler:
Tige de poussée 1 1
Roulement 2
Rondelle ordinaire 3
Tige de poussée 2 4
Bille 5
Usure/endommagement/déformation →
Changer.

4 - 50
ENGCLUTCH
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).
2
1
a
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)
Åı

4 - 51
ENG

CLUTCH
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.
1
2
c
3
a
b

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
2 1
3
E

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 - 52
ENG

CLUTCH
7. IInstall:

Push rod 2
1


Ball
2


Push rod 1
3

NOTE:

Apply the engine oil on the push rod 1, 2 and
ball.
8. Install:

Pressure plate
1

9. Install:

Clutch spring

Bolt (clutch spring)
NOTE:

Tighten the bolts in stage, using a crisscross
pattern.
T R..8 Nm (0.8 m · kg, 5.8 ft · lb)

10. Install:

Gasket (clutch cover)
1


Dowel pin
2

New

11. Install:

Clutch cover
1


Bolt (clutch cover)
NOTE:

Tighten the bolts in stage, using a crisscross
pattern.
T R..10 Nm (1.0 m · kg, 7.2 ft · lb)

4 - 53
ENG

OIL FILTER, WATER PUMP AND CRANKCASE COVER
(RIGHT)
OIL FILTER, WATER PUMP AND CRANKCASE COVER (RIGHT)
OIL FILTER, WATER PUMP AND CRANKCASE COVER (RIGHT)
Extent of removal:
1
Oil filter removal
2
Water pump removal
3
Crankcase cover (right) removal
Extent of removal Order Part name Q’ty Remarks
OIL FILTER, WATER PUMP
AND CRANKCASE COVER
(RIGHT) REMOVAL
Preparation for removal Drain the engine oil. Refer to “ENGINE OIL REPLACEMENT”
section in the CHAPTER 3.
Drain the coolant. Refer to “COOLANT REPLACEMENT”
section in the CHAPTER 3.
Exhaust pipe Refer to “EXHAUST PIPE AND
SILENCER” section.
Brake pedal Refer to “ENGINE REMOVAL” section.
Clutch cover Refer to “CLUTCH” section.
1 Oil filter cover 1
2 Oil filter 1
3 Coolant pipe 2 1
4 Water pump housing 1
5 Pin 2
6 Oil delivery pipe 1
1
2
3

4 - 54
ENG

OIL FILTER, WATER PUMP AND CRANKCASE COVER
(RIGHT)
Extent of removal Order Part name Q’ty Remarks
7 Oil hose 1
8 Kick crank 1
9 Crankcase cover (right) 1
10 Gasket 1
11 Dowel pin/O-ring 4/2
12 Impeller 1
Refer to “REMOVAL POINTS”. 13 Plain washer 1
14 Impeller shaft 1
15 Oil seal 1 1
16 Oil seal 2 1
17 Bearing 1
2
3
2

4 - 55
ENG
OIL FILTER, WATER PUMP AND CRANKCASE COVER
(RIGHT)
REMOVAL POINTS
EC4G3110
Impeller shaft
1. Remove:
Impeller 1
Plain washer 2
Impeller shaft 3
NOTE:
Hold the impeller shaft on its width across the
flats a with spanners, etc. and remove the
impeller.
EC4G3210
Oil seal
NOTE:
It is not necessary to disassemble the water
pump, unless there is an abnormality such as
excessive change in coolant level, discolora-
tion of coolant, or milky transmission oil.
1. Remove:
Bearing 1
Oil seal 2
INSPECTION
EC444200
Impeller shaft
1. Inspect:
Impeller shaft 1
Bend/wear/damage → Replace.
Fur deposits → Clean.