Yamaha YZ 2002 Series Manuals

Manuals and User Guides for Yamaha YZ 2002 Series. We have 1 Yamaha YZ 2002 Series manual available for free PDF download: Owner's Service Manual

YAMAHA YZ 2002 Series Owner's Service Manual

YAMAHA YZ 2002 Series Owner's Service Manual (569 pages)

YZ series

Brand: YAMAHA | Category: Motorcycle | Size: 13.46 MB

Table of Contents

Important Notice
6
Safety Information
6
Wichtige Hinweise
7
Machine Weights
10
Description
12
How to Use this Manual
12
Renseignements Generaux
13
- How to Read Descriptions
  14
- Manual Format
  14
- Illustrated Symbols
  16
- Index
  18
- Table of Contents
  20
CHAPTER 1 General Information

26
- Vehicle View and Parts Identification
  26
- Description
  26
  - Informazioni Generali
    27
  - Vehicle Identification
    28
  - Frame Serial Number
    28
  - Engine Serial Number
    28
  - Model Label
    28
- Identification de la Machine
  29
- Preparation for Removal and Assembly
  30
- Important Information
  30
- Informations Importantes
  31
- Wichtige Informationen
  31
- Informazioni Importanti
  31
  - Gaskets, Oil Seals and O-Rings
    32
  - Lock Washers, Plates and Cotter Pins
    32
  - Bearings and Oil Seals
    32
  - Circlips
    34
- Checking of Connection
  36
- Vérification des Connexions
  37
- Controllo Dei Collegamenti
  37
- Special Tools
  38
- Outils Speciaux
  40
- Utensili Speciali
  44
- Control Functions
  46
  - "Engine Stop" Button
    46
  - Clutch Lever
    46
  - Shift Pedal, Kick Starter, Throttle Grip
    46
- Fonctions des Commandes
  47
  - Front Brake Lever
    48
  - Rear Brake Pedal
    48
  - Fuel Cock
    48
  - Starter Knob (Choke)
    48
- Funzioni Dei Comandi
  49
  - Detachable Sidestand
    50
  - Valve Joint
    50
  - Collar (Tool for YPVS)
    50
  - Nipple Wrench
    50
- Fuel and Engine Mixing Oil
  52
- Essence Et Huile de Melange du Moteur
  53
- Starting and Break-In
  54
  - Starting a Cold Engine
    54
  - Starting a Warm Engine
    54
- Mise en Marche Et Rodage
  55
- Break-In Procedures
  56
- Starten und Einfahren
  57
- After the Break-In or before each Race
  58
- Torque-Check Points
  60
- Points de Verification de Couple de Serrage
  61
- Cleaning and Storage
  64
- Nettoyage Et Rangement
  65
- Storage
  66
Chapter 2

68
- General Specifications
  68
- Maintenance Specifications
  70
- Caracteristiques Generales
  80
- Caracteristiques D'entretien
  82
- Specifications Generales de Couple
  91
- Definition des Unites
  91
- Moteur
  91
- Technische Daten
  92
- Allgemeine Technische Daten
  92
- Wartungsdaten
  94
- Allgemeine Anzugsdaten
  103
- Definition der Einheiten
  103
- Motor
  104
- Specifiche
  104
- Specifiche Generali
  104
- Specifiche DI Manutenzione
  106
- Alla Coppia
  115
- Definizione Delle Unità
  115
- Cable Routing Diagram
  116
- Diagramma del Passaggio Dei Cavi
  117
  - Schema de Cheminement des Cables
    117
  - Kabelführungsübersichtplan
    117
Chapter 3

126
- Maintenance Intervals
  126
- Regular Inspection and Adjustments
  126
- Revisione Eregolazioni Regolari
  135
- Intervalli DI Manutenzione
  135
  - Pre-Operation Inspection and Maintenance
    138
  - General Inspection and Maintenance
    138
- Engine
  138
- Chassis
  138
- Ispezione E Manutenzione Prima del Funzionamento
  141
  - Engine
    142
  - Coolant Level Inspection
    142
  - Coolant Replacement Warning
    142
- Motore
  143
  - Coolant Replacement
    144
  - Radiator Cap Inspection
    146
  - Radiator Cap Opening Pressure Inspection
    148
  - Cooling System Inspection
    148
  - Clutch Adjustment
    150
  - Clutch Lever Free Play Adjustment Steps
    150
  - Throttle Cable Adjustment
    152
  - Throttle Grip Free Play Adjustment Steps
    152
  - Throttle Lubrication
    152
  - Air Filter Cleaning
    154
  - Transmission Oil Level Check
    156
  - Transmission Oil Replacement
    158
  - Pilot Air Screw Adjustment
    160
  - Idle Speed Adjustment
    162
  - Muffler Inspection
    162
  - Silencer Fiber Replacement
    162
  - Silencer Fiber Replacement
    164
  - Chassis
    166
  - Brake System Air Bleeding
    166
- Telaio
  167
  - Partie Cycle
    167
  - Front Brake Adjustment
    168
  - Rear Brake Adjustment
    170
  - Pedal Height Adjustment Steps
    170
  - Front Brake Pad Inspection and Replacement
    170
  - Rear Brake Pad Inspection and Replacement
    174
  - Rear Brake Pad Insulator Inspection
    178
  - Brake Fluid Level Inspection
    178
  - Sprockets Inspection
    180
  - Drive Chain Inspection
    180
  - Drive Chain Slack Adjustment
    182
  - Front Fork Inspection
    184
  - Front Fork Oil Seal and Dust Seal Cleaning
    186
  - Front Fork Internal Pressure Relieving
    186
  - Front Fork Rebound Damping Force Adjustment
    186
  - Front Fork Compression Damping Force Adjustment
    188
  - Rear Shock Absorber Inspection
    190
  - Rear Shock Absorber Spring Preload Adjustment
    192
  - Rear Shock Absorber Rebound Damping Force Adjustment
    194
  - Rear Shock Absorber Low Compression Damping Force Adjustment
    196
  - Rear Shock Absorber High Compression Damping Force Adjustment
    198
  - Tire Pressure Check
    200
  - Spokes Inspection and Tightening
    200
  - Wheel Inspection
    200
  - Steering Head Inspection and Adjustment
    202
  - Lubrication
    206
- Electrical
  208
- Spark Plug Inspection
  208
- Parte Elettrica
  209
- Moteur
  209
  - Ignition Timing Check
    210
  - Seat, Fuel Tank and Side Covers Removal
    214
  - Side Cover Removal Points
    216
- Exhaust Pipe and Silencer
  218
- Tubo DI Scarico E Silenziatore
  219
- Radiator
  220
  - Radiator Handling
    222
  - Radiator Inspection
    222
  - Radiator Assembly and Installation
    224
- Carburetor and Reed Valve
  226
- Vergaser und Zungenventil
  227
  - Carburetor Disassembly
    228
  - Carburetor Handling
    230
  - Throttle Valve Removal Points
    230
  - Carburetor Inspection
    230
  - Needle Valve Inspection
    232
  - Throttle Valve Inspection
    232
  - Jet Needle Inspection
    232
  - Filter Inspection
    234
  - Fuel Level Measuring
    234
  - Carburetor Assembly and Installation
    236
  - Float Inspection
    236
  - Reed Valve Inspection
    236
  - Reed Valve Installation
    236
  - Carburetor Installation
    238
- Cylinder Head, Cylinder and Piston
  246
  - Piston and Power Valve Removal
    248
  - Push Rod Removal
    250
  - Piston and Piston Ring Removing Points
    250
  - Cylinder Head Inspection
    252
  - Cylinder Inspection
    252
  - Piston Inspection
    254
  - Piston Pin and Small End Bearing Inspection
    256
  - Piston Ring Inspection
    258
  - Combination of Piston and Cylinder Check
    260
  - Power Valve Inspection
    262
  - Power Valve Hole on Cylinder
    262
  - Piston Ring and Piston Installation
    266
  - Cylinder Head and Cylinder Installation
    268
- Clutch and Primary Driven Gear
  272
  - Clutch Plate and Friction Plate Removal
    272
  - Primary Driven Gear Removal
    274
  - Clutch Boss Removal Points
    276
  - Clutch Housing and Boss Inspection
    276
  - Primary Driven Gear Inspection
    276
  - Clutch Spring Inspection
    276
  - Friction Plate Inspection
    278
  - Clutch Plate Inspection
    278
  - Push Lever and Push Rod Inspection
    278
  - Clutch Cover Inspection
    278
  - Clutch Assembly and Installation
    280
  - Push Lever Installation
    284
- Kick Axle, Shift Shaft and Primary Drive Gear
  288
  - Primary Drive Gear Removal
    288
  - Kick Axle and Shift Shaft Removal
    290
  - Primary Drive Gear Removal Points
    292
  - Kick Axle Assembly Removal
    292
  - Shift Guide and Shift Lever Assembly Removal
    292
  - Kick Axle and Kick Gear Inspection
    292
  - Kick Gear Clip Inspection
    294
  - Shift Shaft Inspection
    294
  - Shift Guide and Shift Lever Assembly Inspection
    294
  - Stopper Lever Inspection
    294
  - Stopper Lever Installation
    296
  - Shift Guide and Shift Lever Assembly Installation
    296
  - Shift Shaft Installation
    298
  - Kick Axle Assembly Installation
    298
  - Kick Idle Gear Installation
    300
  - Primary Drive Gear Installation
    300
  - YPVS Governor Removal
    304
- Regulateur Ypvs
  305
- Ypvs Regler
  305
- Regolatore Ypvs
  305
  - Governor Groove Inspection
    306
  - Bearing Inspection
    306
  - Governor Assembly and Installation
    306
  - Water Pump Disassembly
    310
- Pompe a Eau
  311
  - Impeller Shaft Removal
    312
  - Oil Seal Removal
    312
  - Impeller Shaft Inspection
    312
  - Impeller Shaft Gear Inspection
    314
  - Oil Seal Inspection
    314
  - Water Pump Assembly and Installation
    314
  - Oil Seal Installation
    314
  - Impeller Shaft Installation
    316
  - CDI Magneto Removal
    318
- Magneto CDI
  319
  - Rotor Removal
    320
  - CDI Magneto Inspection
    320
  - Woodruff Key Inspection
    320
  - CDI Magneto Assembly and Installation
    320
- Engine Removal
  326
- Depose du Moteur
  327
- Rimozione del Motore
  329
  - Drive Sprocket Removal
    330
  - Engine Removal Procedure
    330
  - Engine Installation
    332
  - Brake Pedal Installation
    332
  - Drive Sprocket Installation
    332
  - Crankcase and Crankshaft Removal
    336
- Carter Et Vilebrequin
  337
  - Segment Removal
    338
  - Crankcase Removal
    338
  - Crankshaft Removal
    340
  - Crankshaft Bearing Removal
    340
  - Crankcase Inspection
    340
  - Crankshaft Inspection
    342
  - Crankcase and Crankshaft Assembly and Installation
    342
  - Crankshaft Bearing Installation
    342
  - To Install the Oil Seal
    344
  - Crankshaft Installation
    344
  - Transmission, Shift Cam and Shift Fork Removal
    350
  - Transmission Removal
    352
  - Gears Inspection
    352
  - Shift Fork, Shift Cam and Segment Inspection
    354
  - Transmission, Shift Cam and Shift Fork Assembly and Installation
    354
  - Transmission Assembly
    354
  - Shift Cam and Shift Fork Installation
    358
  - Front Wheel Removal
    362
Chapter 5 Chassis

362
- Front Wheel and Rear Wheel
  362
- Partie Cycle
  363
- Motor
  363
- Fahrgestell
  363
  - Rear Wheel Removal
    364
  - Ruota Anteriore E Ruota Posteriore
    365
  - Wheel Bearing Removal
    366
  - Rear Wheel Inspection
    366
  - Wheel Axle Inspection
    368
  - Brake Disc Inspection
    368
  - Front Wheel Installation
    370
  - Rear Wheel Installation
    374
  - Front Brake Removal
    380
- Front Brake and Rear Brake
  380
- Frein Avant Et Frein Arriere
  381
  - Rear Brake Removal
    382
  - Freno Posteriore
    383
  - Caliper Disassembly
    384
  - Master Cylinder Disassembly
    386
  - Brake Fluid Removal
    388
  - Piston Seal Removal
    390
  - Master Cylinder Inspection
    390
  - Caliper Inspection
    392
  - Brake Hose Inspection
    392
  - Front Brake and Rear Brake Assembly and Installation
    392
  - Caliper Piston Installation
    392
  - Front Caliper Installation
    394
  - Rear Caliper Installation
    396
  - Master Cylinder Kit Installation
    398
  - Front Master Cylinder Installation
    400
  - Rear Master Cylinder Installation
    402
  - Front Brake Hose Installation
    404
  - Rear Brake Hose Installation
    406
  - Brake Fluid Filling
    408
  - Front Fork Removal
    412
  - Fourche Avant
    413
  - Front Fork Disassembly
    414
- Forcella Anteriore
  415
  - Front Fork Handling
    416
  - Cap Bolt Removal
    416
  - Inner Tube Removal
    418
  - Oil Seal Removal Steps
    418
  - Damper Rod Removal
    418
  - Damper Rod Inspection
    418
  - Base Valve Inspection
    420
  - Fork Spring Inspection
    420
  - Inner Tube Inspection
    420
  - Outer Tube Inspection
    420
  - Cap Bolt Inspection
    422
  - Front Fork Assembly
    422
  - Front Fork Installation
    434
  - Handlebar Removal
    438
  - Handlebar
    440
  - Throttle Disassembly
    440
  - Master Cylinder Removal
    442
  - Handlebar Inspection
    442
  - Throttle Assembly
    442
  - Handlebar Installation
    444
  - Steering Removal
    452
  - Ring Nut Removal
    454
  - Bearing (Lower) Removal
    454
  - Ball Race Removal
    454
  - Steering Shaft Inspection
    454
  - Bearing and Ball Race
    456
  - Steering Assembly and Installation
    456
  - Under Bracket Installation
    456
  - Swingarm Removal
    462
- Bras Oscillant
  463
- Swingarm Disassembly
  464
- Forcellone Oscillante
  465
  - Bearing Removal
    466
  - Swingarm Inspection
    466
  - Relay Arm Inspection
    466
  - Connecting Rod Inspection
    468
  - Swingarm Assembly and Installation
    468
  - Bearing and Oil Seal Installation
    468
  - Swingarm Installation
    470
  - Rear Shock Absorber Removal
    478
- Et Couvercles Lateraux
  479
  - Rear Shock Absorber Handling
    480
  - Shock Absorber Disposal (Yamaha Dealers Only)
    480
- Ammortizzatore Posteriore
  481
- Spezialwerkzeuge
  494
- Utensili Speciali
  495
  - Spark Gap Test
    496
  - Couplers and Leads Connection Inspection
    496
  - "Engine Stop" Button Inspection
    496
  - Ignition Coil Inspection
    498
  - Spark Plug Cap Inspection
    500
  - CDI Magneto Check
    500
  - Magneto CDI
    501
  - CDI-Magnetzünder
    501
- Magnete CDI
  501
  - Tuning
    504
  - Carburetor Setting
    504
  - Atmospheric Conditions and Carburetor Setting
    504
  - Test Run
    506
  - Effect of Setting Parts in Relation to Throttle Valve Opening
    508
  - Main Jet Adjustment
    508
  - Pilot Air Screw - to Adjust
    510
  - Pilot Jet Adjustment
    510
  - Jet Needle Groove Position Adjustment
    512
  - Jet Needle Adjustment (for USA, CDN, ZA, aus and NZ)
    514
  - Jet Needle Adjustment (for EUROPE)
    518
  - Relationship with Throttle Opening
    522
  - Carburetor Setting Parts
    524
  - Road Condition and Examples of Carburetor Setting
    526
  - Examples of Carburetor Setting Depending on Symptom
    526
  - Change of the Heat Range of Spark Plugs
    534
  - Selecting the Rotor
    536
  - Chassis Setting
    538
  - Selection of the Secondary Reduction Ratio (Sprocket)
    538
  - Drive and Driven Sprockets Setting Parts
    540
  - Tire Pressure
    540
  - Front Fork Setting
    542
  - Change in Level and Characteristics of Fork Oil
    542
- Fourche Avant
  543
- Vorderradgabel
  543
  - Spring Preload Adjustment
    544
  - Setting of Spring after Replacement
    544
  - Front Fork Setting Parts
    548
  - Rear Suspension Setting
    550
  - Choosing Set Length
    550
  - To Set the Spring after Replacement
    552
  - Rear Shock Absorber Setting Parts
    556
  - Suspension Setting
    558

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