Yamaha YF200 R1 Owner'S Manual Download | Manualshive

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Summary of Contents for YF200 R1

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Page 2: ...ly 20 21 Cylinder Head Prep Assembly 22 Final Assembly 23 25 Table of Contents For more information about the F200 Concept and Rules or to find Resources for your YF200 R1 please visit www Speedway Karting com 1 1 2007 Go to www burrisracing com and click on Tech Shop for the latest Updates FAQ s or download the most recent version of the YF200R1 Manual Items in Blue are upgrades or XR Extended Ra...

Page 3: ...YAMAHA YF200 R1 ...

Page 4: ...m Solid 2 7 F21 107 10 Side Cover Complete 1 Includes 2 7 8 10 11 12 13 17 8 F21 108 00 Seal PTO Side Cover Side 1 9 F21 317 10 Side Cover Gasket 1 10 F21 110 00 Front Oil Filler Plug Dip Stick 1 11 F21 111 00 Front Oil Filler Plug Gasket 1 12 F21 112 00 Rear Oil Filler Plug 1 13 F21 113 00 Rear Oil Filler Plug O Ring 1 14 F21 114 20 Side Cover Stud 8X44mm A 1 6 15 F21 115 10 Side Cover Flange Nut...

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Page 6: ...Assy Std 71 00mm 1 F21 202 05 Piston Assy 002 71 05mm 1 F21 202 10 Piston Assy 004 71 10mm 1 F21 202 15 Piston Assy 006 71 15mm 1 F21 202 20 Piston Assy 008 71 20mm 1 F21 202 25 Piston Assy 010 71 25mm 1 4 F21 203 00 Ring Set Std thru 004 71 00mm 71 10mm 1 F21 203 25 Ring Set 006 thru 010 71 15mm 71 25mm 1 5 F21 204 00 Piston Wrist Pin 1 6 F21 205 00 Circlip set of 2 1 7 F21 206 01 Crank Shim 008 ...

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Page 8: ...21 304 30 Head Gasket 030 Thick 1 F21 304 36 Head Gasket 036 Thick 1 F21 304 40 Head Gasket 040 Thick 1 5 F21 305 00 Cylinder Head Stud 8X55mm 2 6 F21 306 00 Cylinder Head Stud 8X40mm 2 7 F21 307 00 Cylinder Head Dowel Pin 10mm 2 8 F21 308 00 Spark Plug NGK BPR6ES 1 9 F21 309 00 Exhaust Gasket 1 10 F21 310 10 Intake Gasket 1 11 F21 311 10 Exhaust Flange Nut 6mm Grade 10 9 2 F21 311 20 Itntake Mani...

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Page 10: ...ake 1 6 F21 406 00 Valve Spring Retainer OEM 2 F21 406 20 XR Aluminum Valve Spring Retainer 2 7 F21 407 00 Valve Spring Ratainer Lock 2 F21 407 20 XR Valve Spring Ratainer Lock Set 2 8 F21 408 00 Rocker Arm 2 9 F21 409 00 Rocker Arm Pivot 2 10 F21 410 00 Rocker Arm Stud 2 11 F21 411 00 Rocker Arm Lock Nut 2 12 F21 412 00 Push Rod Guide Plate 1 13 F21 413 00 Push Rod OEM 2 F21 413 10 XR Tubular Pus...

Page 11: ...YAMAHA YF200 R1 Page 12 ...

Page 12: ...nd gently crack the throttle to keep the engine running 2 Adjust throttle linkage so it stops at the pedal not the carburetor throttle shaft YAMAHA YF200 R1 Ref Burris P N Description Qty 1 F21 501 30 YF200 R1Carburetor 790 Venturi 1 2 F21 502 20 Filter Cup Mounting Screws 790 Carb 1 3 F21 503 00 Intake Manifold Complete 1 4 F21 504 00 Air Filter 1 5 F21 505 00 Pre Filter Wrap 1 6 F21 506 10 Yamah...

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Page 14: ...603 00 T C I Mounting Flange Bolt 6X20mm 2 4 F21 604 00 Spark Plug Cap 1 5 F21 605 00 T C I Unit 1 6 F21 606 00 Flywheel offse key 6 Advance 1 F21 606 10 Flywheel straight key Billet Flywheel 1 7 F21 607 00 Flywheel OEM 1 F21 607 10 Flywheel Billet Adjsutable Timing Hub 1 8 F21 608 00 Flywheel Nut Starter 3 4 Hex 1 9 F21 609 00 Flywheel Screen 1 NOTES ...

Page 15: ...1 4 6X12mmFlange Bolt 7 F21 707 00 T C I Mounting Flange Bolt kit 1 2 6X20mmFlange Bolt Ref Burris P N Description Qty 8 F21 708 00 Cylinder Head Side Cover Flange Nut 6 8mmFlange Nut six pack 9 F21 709 00 Intake Exhaust Flange Nut 6 6mmFlange nut six pack 10 F21 710 00 Cylinder Head Stud 6 8X40mmStud six pack 11 F21 711 00 Cylinder Head Stud 6 8X55mmStud six pack 12 F21 712 10 Side Cover Stud 6 8...

Page 16: ...m Stud 85 7 1 9 8 1 0 Rocker Arm Lock Nut 75 6 2 8 6 0 9 Valve Cover Nuts 50 4 2 5 8 0 6 T C I Flange Bolts 85 7 1 9 8 1 0 Flywheel Shroud 85 7 1 9 8 1 0 Oil Drain Plug 150 12 5 17 3 1 7 Intake Manifold Nuts 85 7 1 9 8 1 0 Exhaust Manifold Nuts 85 7 1 9 8 1 0 Spark Plug 160 13 3 18 4 1 8 YAMAHA YF200 R1 Note Torque values listed above take into account using 30 wt oil or equivalent lube on threads...

Page 17: ...YAMAHA YF200 R1 Page 18 SPECIAL TOOLS ...

Page 18: ...ption Qty 1 F21 800 00 Complete Tool Kit 1 Includes items 2 3 4 5 6 8 9 2 F21 801 00 Torque Plate 1 3 F21 802 00 Dowel Remover 8mm 10mm 1 4 F21 803 00 Seal Installer Side Cover 1 5 F21 804 00 Seal Installer Block 1 6 F21 805 00 Piston Installer 71 0mm 71 05mm 1 7 F21 805 10 Piston Installer 71 1mm 71 20mm 1 8 F21 806 00 6mm Stud Installer 1 Intake Exhaust Valve Cover 9 F21 807 00 8mm Stud Installe...

Page 19: ...lso keep from binding the crank when the engine is attached to the motor mount Fitting the Piston Remove all sharp edges from piston with a deburring wheel or fine sand paper Hone the block using a 280 400 grit stone to achieve 0035 0055 piston to cylinder clearance measure the piston 90 from the wrist pin and from the bottom Finish the bore with a plateau hone using about 15 20 strokes After the ...

Page 20: ...stud and install using a stud driver as shown see Special Tools Note there are two different ends to the studs dimpled and rounded install the dimpled end in the block Run the stud down until it lightly bottoms and tighten it turn more An alternative method to the stud driver is to use a nut and jam nut Dowel Installation When installing the dowels be sure the holes are clean and they slide in eas...

Page 21: ...ey can be lightly lapped with a fine lapping compound Either way is acceptable Cylinder Head Assembly Thoroughly clean the head to remove grinding dust and lapping compound if used Be fore installing the rocker arm studs run them down onto their threaded holes to make sure they seat correctly against the hex If they do not seat on the hex it will be necessary to run a 6X1 0 mm tap into the hole to...

Page 22: ...n the cap is attached Note Due to the fragile nature of the rings collapsible type piston installers are not recommended Attach the cap with the dipper pointing down and torque the rod bolts to 150 in lbs Go in 25 in lbs increments starting at 75 in lbs Install Lifters Cam Place the lifters in the block and install the cam with the timing marks lined up as shown Note The hole in the cam closest to...

Page 23: ... 24 3 to 24 6 cc Thinner head gas kets are available to adjust this if necessary 036 less 5cc and 030 less 1 0cc Check the cylinder head section of this book for part numbers Coil Shroud and Spark Plug Install the T C I with a minimum of 022 air gap use 3 different feeler gauges for example 006 007 009 022 torque coil mounting bolts to 85in lbs Install the shroud and tighten to 85 in lbs Setting t...

Page 24: ...and carburetor to be leaned out to tune properly which in turn makes the engine run hotter and does not show an increase in power over the pump gas Mounting 1 We recommend the use of a 15 angle mount This increases the flow of air to the cylinder head and also creates a sump for the oil to collect in 2 Fuel filter should be mounted low on the frame rail and near the gas tank Page 25 YAMAHA YF200 R...

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