Yamaha YZ 2018 Series Manuals

Manuals and User Guides for Yamaha YZ 2018 Series. We have 2 Yamaha YZ 2018 Series manuals available for free PDF download: Owner's Service Manual

Yamaha YZ 2018 Series Owner's Service Manual (402 pages)

Brand: Yamaha | Category: Motorcycle | Size: 18 MB

Table of Contens

9
- Table of Contents
  9
- General Information
  11
- Location of Important Labels
  13
- Description
  14
- Identification
  15
- Vehicle Identification Number
  15
- Engine Serial Number
  15
- Fuel Hose Joint Cover
  16
- Coupler for Connecting Optional Part
  16
- Spark Plug Wrench
  16
- Handlebar Protector
  16
- Nipple Wrench
  16
- Included Parts
  16
- Important Information
  17
- Preparation for Removal and Disassembly
  17
- Replacement Parts
  17
- Circlips
  18
- Bearings and Oil Seals
  18
- Lock Washers/Plates and Cotter Pins
  18
- Gaskets, Oil Seals and O-Rings
  18
- Basic Service Information
  19
- Electrical System
  19
- Special Tools
  23
- Start Switch
  29
- Clutch Lever
  29
- Engine Stop Switch
  29
- Warning Lights
  29
- Control Functions
  29
- Shift Pedal
  30
- Throttle Grip
  30
- Front Brake Lever
  30
- Rear Brake Pedal
  30
- Sidestand
  30
- Starter Knob/Idle Adjusting Screw
  30
- Fuel Tank Cap
  31
- Starting a Cold Engine
  32
- Air Filter Maintenance
  32
- Handling Note
  32
- Fuel
  32
- Starting and Break-In
  32
- Starting a Warm Engine
  33
- Break-In Procedures
  33
- Maintenance after Break-In
  34
- Major Maintenance
  34
- Torque-Check Points
  35
- Motorcycle Care and Storage
  37
- Care
  37
- Storage
  38
Specifications

41
- General Specifications
  42
- Engine Specifications
  43
- Chassis Specifications
  47
- Electrical Specifications
  50
- General Tightening Torque Specifications
  52
- Tightening Torques
  52
- Engine Tightening Torques
  53
- Chassis Tightening Torques
  56
- Engine
  59
- Lubrication Points and Lubricant Types
  59
- Chassis
  60
- Lubrication Diagrams
  62
- Lubrication System Chart and Diagrams
  62
- Cable Routing Diagram
  70
Periodic Checks and Adjustments

85
- Maintenance Intervals
  87
- General Inspection and Maintenance
  93
- Pre-Operation Inspection and Maintenance
  93
- Changing the Coolant
  94
- Checking the Coolant Level
  94
- Checking the Cooling System
  94
- Engine
  94
- Checking the Radiator Cap
  95
- Checking the Radiator Cap Valve Opening Pressure
  95
- Adjusting the Clutch Lever Free Play
  96
- Checking the Coolant Circulatory System for Leaks
  96
- Adjusting the Throttle Grip Free Play
  97
- Lubricating the Throttle Cable
  97
- Cleaning the Air Filter Element
  98
- Checking the Breather Hoses
  99
- Checking the Exhaust System
  99
- Checking the Throttle Body Joint
  99
- Checking the Engine Oil Level
  100
- Checking the Fuel Line
  100
- Changing the Engine Oil
  101
- Adjusting the Engine Idling Speed
  102
- Adjusting the Valve Clearance
  103
- Valve Clearance Shim Chart
  106
- Bleeding the Brake System
  108
- Chassis
  108
- Adjusting the Front Brake
  109
- Checking the Brake Hose
  109
- Adjusting the Rear Brake
  110
- Checking the Front Brake Pads
  110
- Checking the Rear Brake Pads
  112
- Checking the Brake Fluid Level
  113
- Checking the Rear Brake Pad Insulator
  113
- Adjusting the Drive Chain Slack
  114
- Air Bleeding from Front Fork
  115
- Checking the Front Fork Legs
  115
- Checking the Front Fork Protector Guide
  115
- Cleaning the Front Fork Oil Seal and Dust Seal
  115
- Adjusting the Front Fork Legs
  116
- Adjusting the Rear Shock Absorber Assembly
  117
- Checking the Rear Suspension
  117
- Checking the Swingarm Operation
  117
- Checking and Tightening the Spokes
  119
- Checking the Tires
  119
- Checking and Adjusting the Steering Head
  120
- Checking the Wheel Bearings
  120
- Checking the Wheels
  120
- Checking and Lubricating the Cables
  121
- Lubricating the Drive Chain
  121
- Lubricating the Levers
  121
- Lubricating the Pedal
  121
- Checking the Chassis Fasteners
  122
- Lubricating the Sidestand
  122
- Checking the Ignition Timing
  123
- Checking the Spark Plug
  123
- Electrical System
  123
- Checking and Charging the Battery
  124
Chassis

125
- General Chassis
  128
- Removing the Left Side Cover
  128
- Removing the Number Plate
  128
- Removing the Seat
  128
- Checking the Front Wheel
  130
- Front Wheel
  130
- Removing the Front Wheel
  130
- Assembling the Front Wheel
  131
- Disassembling the Front Wheel
  131
- Installing the Front Wheel
  132
- Checking and Replacing the Rear Wheel Sprocket
  134
- Checking the Rear Wheel
  134
- Disassembling the Rear Wheel
  134
- Rear Wheel
  134
- Removing the Rear Wheel
  134
- Assembling the Rear Wheel
  135
- Installing the Rear Wheel
  135
- Front Brake
  137
- Checking the Front Brake Disc
  141
- Disassembling the Front Brake Caliper
  141
- Introduction
  141
- Removing the Front Brake Caliper
  141
- Assembling the Front Brake Caliper
  142
- Checking the Front Brake Caliper
  142
- Installing the Brake Caliper Piston
  142
- Installing the Front Brake Caliper
  143
- Assembling the Front Brake Master Cylinder
  144
- Checking the Front Brake Master Cylinder
  144
- Removing the Front Brake Master Cylinder
  144
- Installing the Front Brake Master Cylinder
  145
- Rear Brake
  147
- Checking the Rear Brake Disc
  151
- Introduction
  151
- Assembling the Rear Brake Caliper
  152
- Checking the Rear Brake Caliper
  152
- Disassembling the Rear Brake Caliper
  152
- Removing the Rear Brake Caliper
  152
- Installing the Brake Caliper Piston
  153
- Installing the Rear Brake Caliper
  153
- Checking the Rear Brake Master Cylinder
  154
- Removing the Rear Brake Master Cylinder
  154
- Assembling the Rear Brake Master Cylinder
  155
- Installing the Rear Brake Master Cylinder
  155
- Handlebar
  157
- Checking the Handlebar
  159
- Installing the Handlebar
  159
- Removing the Handlebar
  159
- Front Fork
  164
- Disassembling the Front Fork Legs
  166
- Removing the Front Fork Legs
  166
- Checking the Front Fork Legs
  167
- Assembling the Front Fork Legs
  168
- Installing the Front Fork Legs
  175
- Steering Head
  177
- Checking the Steering Head
  178
- Installing the Steering Head
  178
- Removing the Lower Bracket
  178
- Rear Shock Absorber Assembly
  182
- Disposing of a Rear Shock Absorber
  184
- Handling the Rear Shock Absorber
  184
- Removing the Bearing
  184
- Removing the Rear Shock Absorber Assembly
  184
- Checking the Connecting Arm and Relay Arm
  185
- Checking the Rear Shock Absorber Assembly
  185
- Installing the Relay Arm
  185
- Installing the Rear Shock Absorber Assembly
  186
- Swingarm
  188
- Checking the Swingarm
  189
- Removing the Bearing
  189
- Removing the Swingarm
  189
- Installing the Swingarm
  190
- Chain Drive
  191
- Checking the Drive Chain
  192
- Removing the Drive Chain
  192
- Checking the Drive Sprocket
  193
- Checking the Rear Wheel Sprocket
  193
- Installing the Drive Chain
  193
- Engine
  195
- Cooling System
  277
Fuel System

285
- Fuel Tank
  286
- Checking the Fuel Pump Body
  287
- Installing the Fuel Pump
  287
- Removing the Fuel Pump
  287
- Removing the Fuel Tank
  287
- Checking the Fuel Sender
  288
- Installing the Fuel Sender
  288
- Installing the Fuel Tank
  288
- Removing the Fuel Sender
  288
- Checking and Replacing the Protector
  289
- Checking the Damper
  289
- Checking the Fuel Pressure
  289
- Throttle Body
  292
- Checking the Injector
  294
- Checking the Throttle Body
  294
- Checking the Throttle Body Joint
  294
- Adjusting the Throttle Position Sensor
  295
Electrical System

297
- Circuit Diagram
  300
- Ignition System
  300
- Troubleshooting
  302
- Circuit Diagram
  304
- Electric Starting System
  304
- Starting Circuit Cut-Off System Operation
  306
- Troubleshooting
  308
- Charging System
  310
- Circuit Diagram
  310
- Troubleshooting
  312
- Circuit Diagram
  314
- Signaling System
  314
- Troubleshooting
  316
- Circuit Diagram
  318
- COOLING SYSTEM (for JPN)
  318
- Troubleshooting
  320
- Circuit Diagram
  322
- Fuel Injection System
  322
- Ecu Self-Diagnostic Function
  324
- Troubleshooting Method
  325
- Connecting the Yamaha Diagnostic Tool
  326
- Features of the Yamaha Diagnostic Tool
  326
- Functions of the Yamaha Diagnostic Tool
  326
- Yamaha Diagnostic Tool
  326
- Troubleshooting Details
  328
- Circuit Diagram
  348
- Fuel Pump System
  348
- Troubleshooting
  350
- Electrical Components
  352
- Checking the Switches
  356
- Checking the Bulbs and Bulb Sockets
  359
- Checking the Fuses
  359
- Checking and Charging the Battery
  360
- Checking the Relays
  363
- Checking the Diode
  364
- Checking the Ignition Coil
  365
- Checking the Ignition Spark Gap
  365
- Checking the Spark Plug Cap
  365
- Checking the Crankshaft Position Sensor
  366
- Checking the Lean Angle Sensor
  366
- Checking the Starter Motor Operation
  367
- Checking the Stator Coil
  367
- Checking the Fuel Sender
  368
- Checking the Rectifier/Regulator
  368
- Checking the Coolant Temperature Sensor
  369
- CHECKING the RADIATOR FAN MOTOR (for JPN)
  369
- Checking the Resister
  369
- Checking the Intake Air Pressure Sensor
  370
- Checking the Throttle Position Sensor Input Voltage
  370
- Checking the Fuel Injector
  371
- Checking the Intake Air Temperature Sensor
  371
Troubleshooting

373
- General Information
  374
- Incorrect Engine Idling Speed
  374
- Starting Failures
  374
- Troubleshooting
  374
- Clutch Drags
  375
- Clutch Slips
  375
- Jumps out of Gear
  375
- Overheating
  375
- Poor Medium-And-High-Speed Performance
  375
- Shift Pedal Does Not Move
  375
- Shifting Is Difficult
  375
- Faulty Front Fork Legs
  376
- Front Fork Oil Leaking
  376
- Overcooling
  376
- Poor Braking Performance
  376
- Unstable Handling
  376
- Communication Error with Yamaha Diagnostic Tool
  378
- List of Diagnostic Codes
  378
- List of Self-Diagnostic and Fail-Safe Actions
  378
- Sensor Operation Table
  379
- Actuator Operation Table
  380
Tuning

381
- Chassis
  382
- Drive and Rear Wheel Sprockets Setting Parts
  382
- Selection of the Secondary Reduction Ratio (Sprocket)
  382
- Tire Pressure
  382
- Change in Amount and Characteristics of Fork Oil
  383
- Front Fork Setting
  383
- Setting of Spring after Replacement
  383
- Choosing Set Length
  384
- Front Fork Setting Parts
  384
- Rear Suspension Setting
  384
- Suspension Setting (Front Fork)
  387
- Suspension Setting (Rear Shock Absorber)
  388
- Kick Starter Kit (Optional Parts)
  390
- Parts Location
  390
- Setup Procedures
  392
- Starting the Engine
  395
- Maintenance
  396

Yamaha YZ 2018 Series Owner's Service Manual (252 pages)

Brand: Yamaha | Category: Motorcycle | Size: 10 MB

Important Manual Information
4
Safety Information
5
How to Use this Manual
7
Manual Format
7
Illustrated Symbols
9
Table of Contents
11
General Information
12
Specifications
12
Regular Inspection and Adjustments
12
Engine
13
Chassis
13
Electrical
13
Tuning
14
Consumer Information
17
Vehicle Identification Number
17
Engine Serial Number
17
Included Parts
18
Nipple Wrench
18
Preparation for Removal and Disassembly
19
All Replacement Parts
19
Gaskets, Oil Seals and O-Rings
19
Lock Washers/Plates and Cotter Pins
20
Bearings and Oil Seals
20
Checking of Connection
21
Special Tools
22
Control Functions
25
Rear Brake Pedal
26
Starter Knob (Choke)
26
Starting and Break-In
27
Break-In Procedures
28
Torque-Check Points
29
Maintenance after Break-In
30
Major Maintenance
30
Cleaning and Storage
31
Specifications General Specifications
32
Maintenance Specifications
35
Tightening Torques
41
General Torque Specifications
46
Definition of Units
47
Cable Routing Diagram
48
Maintenance Intervals
59
Pre-Operation Inspection and Maintenance
62
General Inspection and Maintenance
62
Checking the Coolant Level
63
Changing the Coolant
63
Checking the Radiator Cap Opening Pressure
64
Checking the Cooling System
65
Adjusting the Clutch Lever Position
65
Adjusting the Clutch Lever Free Play
65
Adjusting the Throttle Grip Free Play
66
Cleaning the Air Filter Element
67
Checking the Transmission Oil Level
68
Changing the Transmission Oil
69
Adjusting the Engine Idling Speed
70
Checking the Exhaust Pipe
70
Bleeding the Hydraulic Brake System
71
Adjusting the Front Brake
71
Adjusting the Rear Brake
72
Checking the Rear Brake Pad Insulator
75
Checking the Brake Fluid Level
76
Adjusting the Drive Chain Slack
79
Checking the Front Fork
79
Checking the Front Fork Protector Guide
80
Cleaning the Front Fork Oil Seal and Dust Seal
80
Checking the Tire Pressure
84
Checking and Tightening the Spokes
85
Checking the Wheels
85
Checking and Adjusting the Steering Head
85
Checking the Spark Plug
90
Checking the Ignition Timing
90
Seat, Fuel Tank and Side Covers
92
Removing the Side Cover
94
Removing the Number Plate
94
Exhaust Pipe and Silencer
95
Changing the Silencer Fiber
96
Removing the Radiator
97
Checking the Radiator
98
Installing the Radiator
98
Carburetor and Reed Valve
100
Disassembling the Carburetor
101
Handling Note
102
Checking the Carburetor
102
Checking the Jet Needle
103
Checking the Reed Valve
104
Assembling the Carburetor
105
Installing the Carburetor
107
Cylinder Head, Cylinder and Piston
109
Removing the Cylinder Head and Cylinder
109
Checking the Cylinder Head
113
Checking the Cylinder
114
Checking the Piston
115
Checking the Piston Ring
116
Checking the Piston Clearance
116
Removing the Clutch
123
Kick Shaft and Shift Shaft
129
Removing the Primary Drive Gear
129
Installing the Segment
133
Installing the Shift Guide and Shift Lever Assembly
133
Installing the Stopper Lever
133
Installing the Kick Shaft Assembly
134
Installing the Shift Shaft
134
Installing the Kick Idle Gear
135
Installing the Primary Drive Gear
135
Ypvs Governor
137
Checking the Bearing
138
Disassembling the Water Pump
140
Installing the Oil Seal
142
CDI Magneto
144
Removing the Rotor
145
Checking the Woodruff Key
145
Engine Removal
147
Removing the Engine
147
Handling Note
149
Removing the Drive Sprocket
149
Installing the Engine
149
Installing the Brake Pedal
150
Installing the Drive Sprocket
150
Crankcase and Crankshaft
151
Removing the Crankshaft
151
Removing the Segment
153
Disassembling the Crankcase
153
Removing the Crankcase Bearing
153
Checking the Crankcase
154
Checking the Crankshaft
154
Installing the Crankshaft
155
Transmission, Shift Cam and Shift Fork
158
Removing the Transmission
159
Installing the Transmission
160
Front Wheel and Rear Wheel
163
Removing the Front Wheel
163
Removing the Rear Wheel
165
Checking the Brake Disc
167
Installing the Front Wheel
167
Installing the Rear Wheel
168
Front Brake and Rear Brake
171
Installing the Brake Caliper Piston
177
Checking the Brake Hose
177
Installing the Front Brake Caliper
178
Installing the Rear Brake Caliper
178
Installing the Front Brake Master Cylinder
180
Installing the Rear Brake Master Cylinder
181
Removing the Front Fork
185
Installing the Front Fork
196
Removing the Handlebar
198
Checking the Handlebar
200
Installing the Handlebar
201
Checking the Steering Stem
207
Removing the Swingarm
210
Disassembling the Swingarm
211
Installing the Swingarm
214
Removing the Rear Shock Absorber
217
Notes on Disposal (Yamaha Dealers Only)
219
Removing the Bearing
219
Checking the Rear Shock Absorber
220
Installing the Bearing
220
Installing the Rear Shock Absorber
221
Electrical Components and Wiring Diagram
223
Wiring Diagram
224
Color Code
224
Ignition System
225
Inspection Steps
225
Spark Gap Test
226
Checking the Ignition Coil
226
Checking the Spark Plug Cap
227
Checking the Neutral Switch
228
Checking the CDI Unit
228
Solenoid Valve System
229
Throttle Position Sensor System
231
Checking the Throttle Position Sensor Input Voltage
234
Carburetor Setting Parts
239
Selection of the Secondary Reduction Ratio (Sprocket)
243
Drive and Rear Wheel Sprockets Setting Parts
243
Tire Pressure
243
Front Fork Setting
244
Change in Amount and Characteristics of Fork Oil
244
Setting of Spring after Replacement
244
Suspension Setting (Front Fork)
248
Suspension Setting (Rear Shock Absorber)
249

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Yamaha YZ 2018 Series Manuals

Yamaha YZ 2018 Series Owner's Service Manual (402 pages)

Table of Contents

Table of Contens

Specifications

Periodic Checks and Adjustments

Chassis

Fuel System

Electrical System

Troubleshooting

Tuning

Yamaha YZ 2018 Series Owner's Service Manual (252 pages)

Table of Contents

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