Yamaha YF200 R1 Owner's Manual - Final Assembly
Page 24
YAMAHA YF200 R1
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Final Assembly
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Cylinder Head:
Install the
locating dowels and the head
gasket over the studs. Put the
cylinder head in place and
torque in a crisscross manner
to 220 in/lbs in 25 in/lbs
increments starting at 100 in/
lbs. Bring the piston to TDC on
the compression stroke and
drop in the pushrods. Install the rocker arms and set the lash at .004”. Be
careful not to over tighten the adjuster locknut (75 in/lbs) or back the stud off
during adjustment. Place the valve cover assembly on the head, add the
spacers to the studs and tighten to 50 in/lbs. Install the intake manifold,
carburetor and exhaust header and tighten to 85 in/lbs.
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Note:
With the supplied .040 thick head gasket the installed combustion
chamber volume should be approximately 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.
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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
the air gap any closer
DOES NOT
improve per-
formance and increases the risk of the flywheel
magnets striking the coil.) Install the NKG BPR6ES spark plug and torque it to
160 in/lbs. (Note – If the conditions dictate you may want to use the colder
NGK BPR7ES spark plug.)
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Oil and Start:
Add 14-16 oz of the supplied oil and start the engine running
it between 1800 and 2200 rpm for about 10 to 15 minutes. Break-in under a
load is not necessary. (It may be necessary to lean the carburetor down
during this process.) Immediately drain the oil and let the engine cool down.