Yamaha YZ 2020 Series Manuals

Manuals and User Guides for Yamaha YZ 2020 Series. We have 1 Yamaha YZ 2020 Series manual available for free PDF download: Owner's Service Manual

Yamaha YZ 2020 Series Owner's Service Manual

Yamaha YZ 2020 Series Owner's Service Manual (376 pages)

Brand: Yamaha | Category: Motorcycle | Size: 45.07 MB

Table of Contents

Table of Contents

9
- Safety Information
  13
- For Safety, be Sure to Obey the Following
  13
- Location of Important Labels
  16
- Description
  17
- Identification
  18
- Vehicle Identification Number
  18
- Engine Serial Number
  18
- Power Tuner
  19
- Fuel Hose Joint Cover
  19
- Handlebar Protector
  19
- Nipple Wrench
  19
- Included Parts
  19
- Important Information
  21
- Preparation for Removal and Disassembly
  21
- Replacement Parts
  21
- Gaskets, Oil Seals and O-Rings
  21
- Lock Washers/Plates and Cotter Pins
  22
- Bearings and Oil Seals
  22
- Circlips
  22
- Basic Service Information
  23
- Electrical System
  23
- Special Tools
  27
- Instrument and Control Functions
  34
- Warning Lights
  34
- Engine Stop Switch
  34
- Start Switch
  34
- Mode Switch
  34
- Shift Pedal
  35
- Front Brake Lever
  35
- Sidestand
  35
- Rear Brake Pedal
  35
- Starter Knob
  35
- Fuel Tank Cap
  36
- Starting and Break-In
  37
- Fuel
  37
- Starting a Cold Engine
  37
- Starting a Warm Engine
  38
- Break-In Procedures
  38
- Engine Starting Precaution
  38
- Maintenance after Break-In
  39
- Major Maintenance
  39
- Air Filter Maintenance
  39
- Torque-Check Points
  40
- Motorcycle Care and Storage
  42
- Care
  42
- Storage
  43
Specifications

45
- General Specifications
  46
- Engine Specifications
  47
- Chassis Specifications
  52
- Electrical Specifications
  54
- General Tightening Torque Specifications
  55
- Tightening Torques
  55
- Engine Tightening Torques
  56
- Chassis Tightening Torques
  59
- Cable Routing Diagram
  62
Periodic Checks and Adjustments

75
- Maintenance Intervals
  77
- General Inspection and Maintenance
  81
- Pre-Operation Inspection and Maintenance
  81
- Adjusting the Valve Clearance
  82
- Engine
  82
- Valve Clearance Shim Chart
  85
- Checking the Engine Idling Speed
  87
- Checking the Throttle Grip
  87
- Checking the Spark Plug
  88
- Changing the Engine Oil
  89
- Checking the Engine Oil Level
  89
- Adjusting the Clutch Lever Free Play
  91
- Adjusting the Clutch Lever Position
  91
- Cleaning the Air Filter Element
  92
- Checking the Fuel Line
  93
- Checking the Throttle Body Joint
  93
- Checking the Cylinder Head Breather Hose
  94
- Checking the Exhaust System
  94
- Checking the Coolant Level
  96
- Changing the Coolant
  97
- Checking the Cooling System
  97
- Adjusting the Front Disc Brake
  98
- Adjusting the Rear Disc Brake
  98
- Chassis
  98
- Checking the Brake Fluid Level
  99
- Checking the Front Brake Hose
  99
- Checking the Front Brake Pads
  99
- Checking the Rear Brake Pads
  99
- Bleeding the Hydraulic Brake System
  100
- Checking the Brake Operation
  100
- Checking the Rear Brake Hose
  100
- Drive Chain Slack
  101
- Checking and Adjusting the Steering Head
  102
- Lubricating the Drive Chain
  102
- Checking the Front Fork Legs
  103
- Lubricating the Steering Head
  103
- Adjusting the Front Fork Legs
  104
- Checking the Rear Shock Absorber Assembly
  105
- Adjusting the Rear Shock Absorber Assembly
  106
- Checking and Tightening the Spokes
  108
- Checking the Connecting Arm and Relay Arm
  108
- Checking the Swingarm Operation
  108
- Checking the Tires
  108
- Lubricating the Swingarm Pivot
  108
Chassis

113
- General Chassis
  117
- Installing the Air Scoop
  117
- Removing the Number Plate
  117
- Removing the Seat
  117
- Installing the Side Cover
  118
- Removing the Side Cover
  118
- Front Wheel
  119
- Checking the Front Wheel
  120
- Disassembling the Front Wheel
  120
- Removing the Front Wheel
  120
- Assembling the Front Wheel
  121
- Installing the Front Wheel (Disc Brake)
  122
- Checking and Replacing the Rear Wheel Sprocket
  124
- Checking the Rear Wheel
  124
- Disassembling the Rear Wheel
  124
- Rear Wheel
  124
- Removing the Rear Wheel
  124
- Assembling the Rear Wheel
  125
- Installing the Rear Wheel (Disc Brake)
  125
- Front Brake
  128
- Checking the Front Brake Disc
  131
- Introduction
  131
- Replacing the Front Brake Pads
  132
- Disassembling the Front Brake Caliper
  133
- Removing the Front Brake Caliper
  133
- Assembling the Front Brake Caliper
  134
- Checking the Front Brake Caliper
  134
- Installing the Front Brake Caliper
  134
- Assembling the Front Brake Master Cylinder
  135
- Checking the Front Brake Master Cylinder
  135
- Removing the Front Brake Master Cylinder
  135
- Installing the Front Brake Master Cylinder
  136
- Rear Brake
  138
- Checking the Rear Brake Disc
  142
- Introduction
  142
- Replacing the Rear Brake Pads
  142
- Assembling the Rear Brake Caliper
  144
- Checking the Rear Brake Caliper
  144
- Disassembling the Rear Brake Caliper
  144
- Removing the Rear Brake Caliper
  144
- Installing the Rear Brake Caliper
  145
- Assembling the Rear Brake Master Cylinder
  146
- Checking the Rear Brake Master Cylinder
  146
- Removing the Rear Brake Master Cylinder
  146
- Installing the Rear Brake Master Cylinder
  147
- Handlebar
  149
- Checking the Handlebar
  150
- Installing the Handlebar
  150
- Removing the Handlebar
  150
- Front Fork
  155
- Disassembling the Front Fork Legs
  157
- Removing the Front Fork Legs
  157
- Checking the Front Fork Legs
  158
- Assembling the Front Fork Legs
  159
- Installing the Front Fork Legs
  165
- Steering Head
  168
- Checking the Steering Head
  169
- Installing the Steering Head
  169
- Removing the Lower Bracket
  169
- Rear Shock Absorber Assembly
  172
- Checking the Rear Shock Absorber Assembly
  175
- Disposing of a Rear Shock Absorber
  175
- Handling the Rear Shock Absorber
  175
- Removing the Rear Shock Absorber Assembly
  175
- Checking the Connecting Arm and Relay Arm
  176
- Installing the Rear Shock Absorber Assembly
  176
- Installing the Relay Arm
  176
- Swingarm
  178
- Checking the Swingarm
  179
- Installing the Swingarm
  179
- Removing the Swingarm
  179
- Chain Drive
  181
- Checking the Drive Chain
  182
- Removing the Drive Chain
  182
- Checking the Drive Sprocket
  183
- Checking the Rear Wheel Sprocket
  183
- Installing the Drive Chain
  183
Engine

185
- Engine Oil Lubrication Chart
  188
- Lubrication System Chart and Diagrams
  188
- Lubrication Diagrams
  189
- Engine Removal
  193
- Installing the Engine
  198
- Removing the Engine
  198
- Installing the Exhaust Pipe and Muffler
  199
- Camshaft
  201
- Removing the Camshaft
  203
- Checking the Camshaft
  204
- Checking the Decompression System
  205
- Checking the Timing Chain and Camshaft Sprocket
  205
- Checking the Timing Chain Tensioners
  205
- Installing the Camshafts
  206
- Cylinder Head
  208
- Checking the Cylinder Head
  210
- Checking the Timing Chain Guide (Intake Side)
  210
- Removing the Cylinder Head
  210
- Installing the Cylinder Head
  211
- Removing the Valves
  214
- Valves and Valve Springs
  214
- Checking the Valves and Valve Guides
  215
- Checking the Valve Seats
  216
- Checking the Valve Lifters
  218
- Checking the Valve Springs
  218
- Installing the Valves
  218
- Cylinder and Piston
  220
- Checking the Cylinder and Piston
  221
- Removing the Piston
  221
- Checking the Piston Pin
  222
- Checking the Piston Rings
  222
- Installing the Piston and Cylinder
  223
- Generator
  225
- Checking the Generator
  226
- Checking the Woodruff Key
  226
- Installing the Generator
  226
- Removing the Generator
  226
- Starter Clutch
  228
- Checking the Starter Clutch
  229
- Installing the Starter Clutch
  229
- Removing the Starter Clutch
  229
- Electric Starter
  231
- Assembling the Starter Motor
  233
- Checking the Starter Motor
  233
- Clutch
  235
- Checking the Clutch Plates
  238
- Checking the Friction Plates
  238
- Removing the Clutch
  238
- Checking the Clutch Boss
  239
- Checking the Clutch Housing
  239
- Checking the Clutch Springs
  239
- Checking the Pressure Plate
  239
- Checking the Push Lever Shaft
  239
- Checking the Push Rods
  239
- Checking the Primary Drive Gear
  240
- Checking the Primary Driven Gear
  240
- Installing the Clutch
  240
- Shift Shaft
  243
- Checking the Shift Shaft
  244
- Checking the Stopper Lever
  244
- Installing the Shift Shaft
  244
- Removing the Segment
  244
- Oil Pump
  247
- Checking the Oil Pump
  249
- Removing the Oil Pump
  249
- Assembling the Oil Pump
  250
- Installing the Oil Pump
  250
- Crankcase
  253
- Checking the Crankcase
  255
- Checking the Timing Chain Guide (Exhaust Side)
  255
- Disassembling the Crankcase
  255
- Assembling the Crankcase
  256
- Crankshaft and Balancer Shaft
  257
- Checking the Crankshaft
  258
- Removing the Crankshaft
  258
- Installing the Crankshaft
  259
- Transmission
  260
- Checking the Shift Drum Assembly
  261
- Checking the Shift Forks
  261
- Removing the Transmission
  261
- Checking the Transmission
  262
Cooling System

265
- Cooling System Diagrams
  266
- Radiator
  267
- Checking the Radiator
  269
- Installing the Radiator
  269
- Water Pump
  271
- Assembling the Water Pump
  272
- Checking the Water Pump
  272
- Disassembling the Water Pump
  272
Fuel System

275
- Fuel Tank
  276
- Checking the Fuel Pump Body
  277
- Checking the Fuel Pump Operation
  277
- Installing the Fuel Pump
  277
- Removing the Fuel Pump
  277
- Removing the Fuel Tank
  277
- Installing the Fuel Tank
  278
- Throttle Body
  279
- Checking the Fuel Pressure
  282
- Checking the Injector
  282
- Checking the Throttle Body
  282
- Adjusting the Throttle Position Sensor
  283
Electrical System

285
- Circuit Diagram
  288
- Ignition System
  288
- Troubleshooting
  290
- Circuit Diagram
  292
- Electric Starting System
  292
- Troubleshooting
  294
- Charging System
  296
- Circuit Diagram
  296
- Troubleshooting
  298
- Circuit Diagram
  300
- Signaling System
  300
- Troubleshooting
  302
- Circuit Diagram
  304
- Fuel Injection System
  304
- Ecu Self-Diagnostic Function
  306
- Troubleshooting Method
  307
- Connecting the Yamaha Diagnostic Tool
  308
- Yamaha Diagnostic Tool
  308
- Troubleshooting Details (Fault Code)
  309
- Circuit Diagram
  328
- Fuel Pump System
  328
- Troubleshooting
  330
- Electrical Components
  331
- Checking the Switches
  332
- Checking the Bulbs and Bulb Sockets
  334
- Checking the Fuses
  334
- Checking and Charging the Battery
  335
- Checking the Relay Unit (Diode)
  337
- Checking the Relays
  337
- Checking the Ignition Spark Gap
  338
- Checking the Spark Plug Cap
  338
- Checking the Crankshaft Position Sensor
  339
- Checking the Ignition Coil
  339
- Checking the Lean Angle Sensor
  340
- Checking the Rectifier/Regulator
  340
- Checking the Starter Motor Operation
  340
- Checking the Stator Coil
  340
- Checking the Fuel Sender
  341
- Checking the Resistor
  341
- Checking the Coolant Temperature Sensor
  342
- Checking the Throttle Position Sensor Input Voltage
  342
- Checking the Gear Position Switch
  343
- Checking the Intake Air Temperature Sensor
  343
- Checking the Injector
  344
Troubleshooting

345
Tuning

361
- Chassis
  362
- Drive and Rear Wheel Sprockets Setting Parts
  362
- Selection of the Secondary Reduction Ratio (Sprocket)
  362
- Tire Pressure
  362
- Change in Amount and Characteristics of Fork Oil
  363
- Front Fork Setting
  363
- Setting of Spring after Replacement
  363
- Choosing Set Length
  364
- Front Fork Setting Parts
  364
- Rear Suspension Setting
  364
- Setting of Spring after Replacement
  365
- Rear Shock Absorber Setting Parts
  366
- Suspension Setting (Front Fork)
  367
- Suspension Setting (Rear Shock Absorber)
  368

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