2 28 c;lses tor adequate pisron clearance.

Ald10Ugh rilt: Y780 is a good bike

FLAWS: weak low-end power, hard on O~her additjons to rhe 100-cc COIl\'er­ for expert mini riders due to an abun­
clutches sion include a 11m ~lide Kt:ihin 28-mm dance at high-rpm power and good
FIXES: mdchine cylinder bdse Jnd head, carb and an R&D pipe and silencer. suspension, ir ha.~ LOO Ii trlt: low e[ld and
use srt:el c1urch plares and srronger midrange For mo~r riders. The problem
Hinson basker CHASSIS AND SUSPENSION

rr
is a combination of tadical POrt timing
When Yamaha bumped the Yal1lahd'.~accessory divi~ion, YZR, offers and hig.h gearing. Like mo~t or the

Go
(li~plact:mt:nr For tht: clas~ limit, the an exrended swingarm and wheel kits minis, the Y7 doe~[l'r have rhe quick
exhausr parr was raised roo. Some thar include tims and spokes. In order respome to keep lip wirh the KMs out

ric
1 iders complain rhar rhis bike doesn'r tor Lhe YZ to be legal for racing in the ot turns.

-E
dccelerare Ollt of the turns like rhe KX ~lIpt:rrnini cbs~, ir needs a longer wheel­
or RM. Those models use power valves, base and bigger wheels. Normally, when BEST VALUE MODS

n
so rhe YZ is ar a disadvalHage. By you switch to a longer ~wing~lrm, you'll ENGINE: cylindet aod head mods
turning down the cylinder base (0.030
io
nt:t:d to switch to stiffer springs frotH SUSPENSION: base valve kit
ot
in. or 0.75 mm) and rhe head corre­ and tear.
M

spondingly, you can raise rhe CYLINDER MODS

compression and tetard rhe parr timing 1993-2001 VA ~ YZ80 To get more midrange trom rhe YZ80,
d

for berter midrange hie FLAWS: poor low-end power, non­ turn down the baSt: of the cylinder
ar

adjustable forks 0.028 in. or 0.7 mm and remove the

rw

BEST VALUE MODS AXES: cylinder and he'l(i mods, adjustable same amount from [he squish band of
Fo

Hinson c1uLch widl sLeei plaLe.~ base valve the cylinder head. This reta.rds tht: port
of

993-2004
Y AH YZ100 CO ER 10
rty

lr is pmsible w convert a YZ80 inro a

e

big-wheel 100 with a combinarion of

op

afrermarket engi ne and OEM parts.

Pr

ENGINE MODS
·1\..... 0 big bore pisron kits on [he marker
have displacemelll Slles suited to
difterem racing ;lssociatjons. The biggesr
displacemenr kit is made by U\ Sleeve.
lr srans ar 103.) cc w 108 cc on the
maximum over~ize. The orher kir i~
made by \'I(:'iseco and uses scock gaskets.
The W'iseco kir requires the cylinder to
be bored, porred. ,mt! e1ecrroplared. Th.e
head musr be enlarged ro accepr rhe
52.')-mm pisron. The crankcases musr
also be modified because rhe piswn skin
contacr~ rhe exhau~t ~ide of rhe cases. Jr's
acceptable ro mask off the crankshaft The world's first Yamaha yz was raced by 1973 AMA National Champion Pierre Karsmakers. Karsmakers has a
and grind away the minor dreas or the motocross museum in the mezzanine of hiS motorcycle dealership In Eindoven, Netherlands.

206
 1997-2004 YAMAHA YZ125

riming and reduces rhe pOrT duration, areas ro pay atrenrion to are rhe top eDd,
plus increases rhe compression rario. coDnecring rod. and frame. The 1999
cylinder has dle besr performance bur is
INTAKE [he mosr prone co failure. The 2000
Ins rail a see of Boyesen dual-srage reeds. model cylinder is rhe besf overall design
and includes a new exhausr valve design.
GEARING The frames are prone [0 cracking when
The srock gearing is roo high and the bikes ;lre jumped roo hard and key
should be changed [Q 12/')2 for quicker bolts are lefr loose like fhe engine
accelerarion. Expen riders prefer mounrs and swingarm piVOL Refer co
changing [() a larger carb (28-mm thr Chaprer 4 for rips on inspecting and
slide Keihin) for more over-rev. srrengfhening frames.

GEARBOX BEST VALUE MODS

Earli.n models had problems with wear ENGINE: \XTiseco Pro-Lire piston kif, Check the tranny gears of the Yl80s. Stiffer after­
on the teerh of second gear. Yamaha has weld cylinder emaLlsr bridge market clutch springs can make the gears wear faster.

rr
since improved dle gear and pulled all SUSPENSION: Magnum a.nri-bo[(oming

Go
rhe old pans trom srock. If you ever have fork accessory, weld fmlne cracks
to splir rhe cases for engine rebuilding, so closely around rhe pin hole rhar rhey

ric
check the gear reerh for wear. The wear CYLINDER shroud rhe hig end beari ng (rom getti ng

-E
parrern looks like corrosion. The cylinder's exhausr pon is very wide. eTlough lubricarion. The crank gees hor
The exhausr pon bridge has a weak around rhe big end and the plasrie srans

n
CLUTCH spar. aboll[ 10 mm down from rhe cop ro swell up, dlUS compounding rhe
Yamah;l reCOlTlmends swiLching LO
io
of rhe porr. The problem is Lhal Lhe problem. Fvenrllally, tile plasric melrs
ot
sriffer c1urch sp6ngo. The parr number exhaust valve pockers are machined too and flows inro rhe big end bearing,
M

is 90501-21 GAG. deep and inrersecr rhe bridge, reducing causing the bearing to fail. Disassemble
its [hickness ar a crirical point. The rile crank rn replace the rod :l.ssemhly.
d

FORKS bridge is prone LO cracking at this POillf Remove fhe mdred plas[ic wirh a die
ar

The forks can be improved by insralling if the pisro.n seizes. Ir's besr ro replace grinder and a large Aured rool bit. l3evel
rw

an adjusrable base valve kit co make d1e rhe pis ron rings every five hours of dle plasric slug ar a 45-degree angle all
Fo

Forks plusher. There are rwo oprions for engine rime. If rhe exhausr bridge around the pin hole. so ,IS fO allow more
base valves: 19')2 YZ125 OEM base n:lcks, have ir rep:lired by a company area for rhe pre-mix to lubricare dle big
of

valVE: or a tuned valve from Pro Racing rhat specializes in elecrroplaring. The end bearing. Removing pla.sric from rhe
or Race-Tech. The srock fork and shock bridge needs ro be welded and made slug does lower rhe crankcase compres­
rty

springs are roo sofr fO( mosr riders. The wider (3 mm). This modiflcarion will sion. rario and char C<1uses a sligla loss of
way ro check the sprin~ rare is [Q SCt rhe
e

require you ro fir rhc exhallsr valves. low-end power, bur reliahiliry is wonh
op

race sag (Q 75 mm in rile re;u and check You'll have [Q chamfer rhe corner of rhe rhe sacrifice in perlormJllce.
(he unladen sag (bike's weighr withour valves that hun rbe exhaust port bridge.
Pr

rider). If (he unladen sag is UDder 10 If you don'r grind (he valves properly, CARBURETOR
mm, you need ro ins rail a sriffer shock rhey won'r dose all (he way_ The carb jerring on rhe 1999 model has
spring. The from fork sag should be LOO rich ofa slide. Swirch fO a 7.0 slide if
berween. 20 and 30 mm. If rhe fork, sag CRANKSHAFT your bike bogs when Aucruaeing rhe
more thaD 30 mm, you need fO insrall Anorher signiflcanr design error lies in rhrorr/e ovcr whoops and rhrough rurns.
stiffer springs. rhe crankshafL A rv{O-srroke cranlc.,hafL
has less m:1SS on top netr the pin hole fO FORKS
'1991 20 A.HA YZ125 compensare (he balance facror of rhe The YL 125 has rhe hesr performing
FlAWS: requll'es frequenr fOp-end reciproca(ing mass of d1e connec(ing rod fork for a 125. However, SOI\1(: rioers
service, forks botrom and pisLOn .l.ssen,hly. Manuf':LCrurers use compl:lin abour rhe me[aLlic clunking
FIXES: replace rhe pisron kir every 15 dilterenr designs fO fiJl in rhe void around noise when rhe forks borrom our.
hours of running, sriffer fork springs. the pin hole. Honda firs sheerme(al Yamaha swirched ro an elaswmer foam
and hydraulic ami-borroming device covers around d1e crank. Kawasalc.i and bumper for the al1ri-borwming device.
This bike is widely considered [<) have SIJI.uki lise lighrweight aluminum slugs. Hydraulic produces work much berrcc.
rhe besr engine in its class, bur ir sacri­ Yamaha uses plasric slugs. The problem Devol Racing has a producr called rhe
fices some reliahiliry: A couple of key seems ro be dur rhe plasric slugs are firred Magnum. IL is an anti-horruming device

207
TUNING TIPS FOR YAMAHA DIRT BIKES

The lale-model YZ125s use plaslic Inserts to stuff

the crankshaft and maximize throttle response.
When the rod wears and produces more friction, the

rr
Ileal melts the edges ollhe Insert. Here. a porting

Go
tool IS used to grind away the burnt material pnor to
InstallatIOn of a new connecting rod kit II the plastic

ric
is melted. II'S cheaper to buy a new Hal Rod crank­ lhis is a cylinder and crankcase set for 1994 to 98 YZ250s, modified for a rear boost port.lhis offers a

-E
shaft rather than repair the stock crank. midrange to top-end powerband

n
(har rlrs illside (he canridge. Ir requires
io
ot
specialized knowledge of cartridge forb
M

ro install me device so if's besr (0 rely on

a suspension teehrtieian who has rhe
d

proper rools. Take care ro use (he curreCl

ar

spring rare ror your geared weighr and

rw

riding style. lf rhe front fork race sag is

Fo

less rhan 30 min, switch ro a sofrer

spring rate. 1r rhe race sag i~ more than
of

)) mm, swiTCh ro a stiffer spring rare.

rty

SHOCK
e

The srock shock valving is very good

op

and ir's nor likely (har you'll need to

have it revalved.
Pr

FRAME
The frame is especially prone [Q cracking
,Il the f()0l peg mounts. The best preven­

rive maintenance is ro reinforce (he foor ThiS is a cylinder and crankcase set before the modifications, showing the new ports marked in blue ink.
pegs wirh gusser plares welded under (he
four pegs and along rhe frallle Lubes.
Anmher rrouble spm is rhe lower engine FIXES: gusser frame, install head align­ 1')04 model ha~ sOllle teething problenJs.
mounts. They are only spar-welded On ment p1J1S Yam;lha redesigned the connecting rod
one side of rhe plate. Find a skilled fabri­ This hike is d good design. The and bearing ro reduce premarure failure.
CHor in your local :lre:l to reinrorce rhe exhaUST valve ~ystem is similar (Q rhe RM The problem of second gear seiwres W:lS
foor peg and engine mounts. in rhar ir reduces the volume of d1e remedied in Lhe 1995 model. The ftarne
exhausr pon and hoosts the porL velocity 011 the 1995 model was gussered in several
1994-1' 96 YA HA Z1.25 dt low rpm. The sysrem was rehned each places because the 1994 model develops
FlAWS; frame rabs crack, dlrunic coolan! model year ro improve performance and cracks ar (he radiator mounts. fOp ~hock
leaks reduce the need for mainrenance. The mount, anu h:,lor pegs. Thar problem can

208
 1.994-1.996 YAMAHA YZ1.25

rr
Go
ric
-E
n
io
ot
M
d
ar

BBR makes these trick aluminum frame kits for YZFs and other brands of dirt bikes.
rw
Fo

be easily corrected ",ith frame gussering. SHIFTER MODS CYLINDER AND HEAD
of

The yz cylinder and head need aJign­ Over the years, Yamahas have been crir­ The cylinder and head designs of Lhe
mem pins because the forces from me icized as being hard to shift. Polishing 1994 to 1996 models are similar. The
rty

head-scay can cause chronic coolant leaks. the shifting mechanism and drilling oil cylinder rr:ansfer porrs have the right
e

This problem manifests into erosion at holes in the clutch hub will help, bur profile. but the exhaust port needs LO he
op

rhe top edge of rhe eyl inder, damagi ng the the besr product on rhe marker is Race­ raised and widened for a 12,500-rpm
Nikasil plaring. Tech's external shifter mechanism. It's peale The exhaust porr must be raised co
Pr

The powerband is simuar to that of the fairly expensive, bLlI many riders swear 28 mm from the tOp of the cylinder and
mher 125s--good midrange but falls flat by it. Th is produ cr enhances rhe leverage enlarged 1 mm on each side. The head
ar 10,600 rpm. making 29 horsepower ar rario of rhe shift lever. should be Illachined for a higber
me rcar whed. Don't believe rhe exagger­ compres.'>ion rario. If YOllI YZ 125 suffers
ared hotsepower claims of some Japanese FORKS from chronic coolant loss, machine the
manubcrurers. They all make this same The Kayaba forks have grear damping, squish band's recess in the head to 0.75
pe<1k power at nearly me same rpm. The but rhe spring rate is set for a fairly tight ro 1.0 mm. This belps keep the engine
yz has great low to midrange power, rider (l60 pounds). Tf' you have any from developing coolant leaks because it
making it an ideal trail hike. Tf yOLl W:lJ1t to problems wirh head shaking or from­ reduces rhe pressure on rhe O-ring in the
make your YZ competirive in morocross, end diving when braking for rums, cylinder. Also, yOll should elongare rhe
you have ro modif)r me cylinder and head, consider stiffer fork spring.~. head-scay bolr hole to allow for a bir of
plus add a pipe and silencer. movement in dut area of dle Illotor
HIGH-RPM POWERBAND mount. Older bikes especially need more
BEST VALUE MODS The serup for prodLlcing cop-end power clearance at rhe head-stay because rhe
ENGINE: FMF pipe and silencer from the YZ is simi lar La the other 125s frames rend ro ger deformed from tOO
SUSPENSION: Eibach fork springs bur much less expensive rhan rhe Honda. many hard landings.

209
TUNING TIPS FOR YAMAHA DIRT BIKES

Check the small end of the connecting rod on

YlF250s. If scouring occurs. replace the crankshaft.

rr
Go
PISTON
Inscall a Wiseco piston because the

ric
piswn ring ahgnmem pins ccnd co ftll

-E
our of rhe OEM piscons afcer sustained
over-revving of (he engine.

n
In order to check the valve clearance on aYlF, you'll need this special Yamaha tool-a til in-blade feeler gauge set.
io HEAD MOD
ot
The squish band of rhe cyli nder head
M

PISTON INTERCHANGE CRANKCASE PORTING needs co be narrowed to 6 mm, meas­

The 1998 model piswn has a boosr porr This final mod is optional, but it makes ured From one side of rhe chamber. The
d

in the intake side chat improves top-end a significam difference. The cr;lnkcases work can be performed on a metal
ar

over-rev and helps rhe piston run are slightly mismarched w rhe cylinder, lathe. If you raise rhe exh3Llst porr,
rw

cooler. The 1998-anJ-newer pisrons use and rhe rransicion bern'een rhe incake you'll h;lve to reduce rhe volume of the
Fo

a smaller pin and a bearing wirh chicker POrt and the crankcase pons call be cylinder he.ad ro a wcal of9 cc.
needle bearings. The pin is lighcer, and improved wi th fili ng and polishing.
of

the bearing will take a higher load rhan CYLINDER MODS

rhe old-seyle bearing. These pans can 1992 H 5 Recommendcd cylinder mods include
rty

only be lIsed as a seL The \X!iseco order FLAWS: flar power, ring pins vibrate our rurning down the cylinder base 0.5 mm
e

numbers are a 726P8 pisron kir and a FIXES: march power valves, Wiseco and raising the exh;lllst porr to 26 mm
op

B 1038 needle bearing. Pro-Lice from che top of rhe cylinder. Apply
The 1992 Jnd ]')93 model cylinders epoxy to rhe hook angles of che rear
Pr

EXHAUST SYSTEM are si milar ro rhe 1990 model. rransfer ports. These mods reduce the
The srock silencer is roo resrricrive tor a rime-are3 of rhe transfer porcs and
high-revving engine. In 1994, World BEST VALUE MODS increase rhe exhausc pore. This will help
Champ Bob Moore and Motocross des ENGINE: power valve luarching, carb che bike accelerate harder in the
Natioll.~ C:halllpion Paul Malin used jercing midrange wirh more rap-end over-rev.
FMF pipes and silencers. SUSPENSION: basic servicing
CARB JETTING
INTAKE SYSTEM POWER VALVE MODS Recommended haseline jetring fur rhe
The inrake sysrem is rhe nexr componenr Marching rhe power valve ro the exhausc 3cJ-111 IT1 Miku ni carb: 20 pilor jec, 4.5
ro be modified. You'll need ro upgrade co porc can provide big gains in perfonnance slide, 56 needle, and a .) 10 main jee.
a :"IS-mm carb (Mikuni Jeccing: 20 pilm, when the v:Jlve is hilly open. The power
4 slide, 63 needle, 360 m:lin jer). valve governor cameol is located under REED VALVE
lnsra)] carbon-fiber reeds (0.5 mm the righr-side engine cover. lns(alling a The Royesen Ri\D valve works well for
rhick) or a R.AD valve because rhe srock ramp cup and spring (90501-30742-00 overall power gains, and Carbolllech
reeds scare ro IlUlLef and restrict the ramp cup; 3X]-119I2-00 spring) From carbon-fiber reeds work well for high­
in rake flow ar 11,200 rpm. carlier YLs can help the midrange power. rpm powerbands.

210
 1.985-1.989 YAMAHA YZ1.25

1~;;n_.99 H YZ125 1990 power valve parr.). ll-roo[h coun­ BEST VALUE MODS
FLAWS: weak low-t:nd power (1991 [ershah sprocke[ ENGINE: T-vents fOI carbuteror
L1lodel) SUSPENSION: basic servicing SUSPENSION: regular service
FIXES: change gearing, reeds, and 1990
power v:dve pans CYLINDER INTERCHANGE CLUTCH
The 1990 rap-end parr, :Ire regarded If you have a 1991 model and need ro The clu(ch is easy to fLx. S[iffer durch
as (he besr-runed componenr, Yamaha repl.lCe the cylinder, consider swirching springs and bec(er-quali(y plares such as
ever designed tor [he YL125, and [he {Q the 1990 model parts. You'll need to those found in Ramen clutch ki(s will
1991 model i, norarious as [he wom. change the cylinder and power valve as fix [he slipping problem. Polishing the
Where [he 1990 engine is greaI tOI a set. clutch ac[uating rod helps, tOO. Yamaha
motocross, [he 1991 has a narren.", hard­ recnl1llllend~ drilling cwo oil holes
[Q-Llse powerband. The weak low end GEARING (l/.lG-in. diameter) in each of the
made 1991 YZ1.25s slow our of turns. Use a front sprocket (hat is one tOOth female splines of rhe innet c1mch hub,
Cha.nging [0 a lower fmal-drive rario and smaller ro gel more low-end to midrange This helps the oil flow, keeping the
insr;llling Boyesen reeds helps a lac. On power from either of these models. clutch plates cooler.

rr
[he 1991 model, iI'S besr to switch m [he Second gear dril'e :lOd driven gears

Go
ramp cup and spring from rhe 1990 REEDS ate prone [Q breakage. ·1 he besr precau­
power valve governor. The 1991 model Boye-sen Dual-Stage reeds will d ralll:lti­ lion IS lO use (he c1u(ch when
down.>h ifti ng and change rhe rrallsrni.~­

ric
uses a rn'o-angle ralllp cup [hac ac[ualty cally improve rhe YZ's low-end power.
works well on the 1992 and 199.3 models. sion oil often. The gear ratios ;:Ire very

-E
198 ·989 AH YZ125 wide beTWeen hIS[ and second gear and
BESTVAlUE MODS FLAWS: weak c1urch, engine bogs the engines don'r have much low-end

n
ENGINE: 1991 modd: Floyesen reeds, FIXES: BaIl1t:tr clutch, carb jels
io power. If yOll are having problems
The 125s from [he late 1980s suffer bogging [he engine out of [urns, switch
ot
from driveuain problem,. The clutches to d 12-LOolh counlershafi: sprocket.
M

don'r get enough oil flow, rhe durch

springs are tOO soft, and second gear is CARBURETOR
d
ar

prone ro breakage. [n addj[ion, [he The carb on the 1986 to L988 models is
Mikuni carb bas bogging problems prone ro boggi ng and sldrvalion. I\.-fake
rw

when landing from jumps, sure rhe floa[ level is set parallel ro rhe
Fo
of
e rty
op
Pr

Moose Off· Road makes these crankcase vent lillers

to prevent dirt from entering the crankcase. Mike Brown's YlF250.

211
TUNING TIPS FOR YAMAHA DIRT BIKES

100 hours before it's prone [Q cracking.

Yamaha recommends I5-hour sen'ice
intervals. %en me mp end is being
rebuilr, always get a neVi cam chain and
check the rear chain guide For we;,r.

VALVETRAIN
The ritanium valves are for racing only.
If you ride a lor and wan.t a more reli­
able alrernarive, consider stainless-steel
valves. They're more durable and rhe
service ilJ[ervals are longer.

CRANKSHAFTS
Always replace the crankshart when rhe

rr
rod wears our. The price is under $200.

Go
On Four-srroke engines, rhe journal
ends and the cam chain sprocket ger

ric
worn beyond repair.

-E
FUEL MIXTURE NEEDLE
The srock fuel mixture screw tend~ to

n
Zip-Ty makes this trick fuel adjuster for the YlFs.
io vibrate and bll our. The mixrure screw
i.~ [ocared under rhe Front and center of
ot
rhe carburecor. It can be adjusred wirh a
M

were traced ro undersized crankshaft short, narrow, srraighr-blade screw­

journals and roo much clearance. AI; driver. There i~ a berrer ahermarket
d
ar

described in Chapter 9, four-srroke producr made by Ty Davis. The acces­

crankshafLs should be replaced for the sory mixture screw is much longer so
rw

mai.n re;,son of cam chain sprocket wear_ you can adjusr ir withom a special cool,
Fo

The lighrweight ritanium valves have a and ir i~ red-and-whire anodized so you

This 41-mm Keihin FeR carburetor gives big bore limited parr life, and if allowed ro rigbren can easily see rhe setring.
of

YlFs more top end. in clearance, could fail by cracking the

heads off. StainleSS-Steel valves suit [he BIG BORE KITS
rty

maimenance habits of even ;J bck­ Wiseco makes a 2-mm oversize high­

e

float bowl base, and use these jets as a adaisical owner, and are far less expensive compression kit rhat boosrs rhe
op

sraning poinr: 45 pilar, 4 slide, Q-O than srock replacement parrs. displacemenr ro 262 cc. Arhena and
needle jet, 290 main jer, and a 3.5 inler In 2003, Yamalla included an auto­ RPM make 290-cc replacement cylinder
Pr

needle and seaL Insrall the modern T- matic decompressor in the exhausr cam. and piston kits for about $900 complete.
vent setup. The 2003 OEM or ahermarker Hot
Cams fir in me older models ofYZF250. 1999-200 A H Y2250
REED VALVES );LAWS: wheeJspin, Hat tOp end
The FMF RM1 valve works well on BEST VALUE MODS FIXES: flywheel weight, raise exhausr
YZ125s. Use rhe shan rev plates for Hot Cam, Wiseco high-compression porr to 39 mm
more low-end power. pismn, K..ibblewhite stainless valves and Yamaha inrroduced a new 250-cc
spring kir engine in 1999. The bore and srroke were
001-0 YAMA YZF250 changed to the same as all orher 250s.
FlAWS: no auro-decompressor on older EASY POWER 11le old engine was a square bore and
models, crank and valvemun prone ro wear The rwo besr products thar give rhe stroke and rhe new engine is over-square,
FIXES: 2004 Hor Cam for exhausr biggest difference in power and reliability meaning rhat tbe stroke is longer. The
auro-decompressor, replace crankshaFr, are rhe high-compression WlSeco Pro-Lite new exhaust valve sy~rem is similar to rhe
sr;, in less-sreel v;,lves pisron kir and HQ[ Cams wirh [he auro­ CR and RM designs, wirh rhe exception
The 2001 YZF250 srarted out widl decompressor on rhe exhausr c;,m. The mar the sub-exhaust ports open ar a
some chronic crankshaft problems, which stock pisron kir williasr for a maximwn of higher rpm than the eenrer valve.

212
 1997-1998 YAMAHA YZ250

market. The new reed valve is excellent

and you won't have to worry abour ir
prorruding imo lhe rear boose port like
previous models. However, Yamaha chose
very conservacive rransfer POrt riming.

BEST VALUE MODS

ENGINE: Come ric rhick base gasket
0.039. flywheel weig.hr
SUSPENSION: set sag and clicker>, sriffer
fork springs for riders over 180 pOLinds

CYLINDER
Raise rhe rransfer ports 1 mm or lise rhe
oprional rhick base plare markered hy

rr
Yamaha. The plare requires you to tum

Go
down lhe head 1 1111ll. The .,ub-exhausL
porrs have been raised, bur rhe power
Wrapping "header tape" around the pipe as It snakes past the carburetor could prevent fuel boiling and vapor lock. valve's sub-exhausr channels have been

ric
alrered [0 retard rhe pon's opening

-E
riming. You can use a rOLind file to
adjusr rhe sub-ex.hausr channels on dle

n
io power valve for more rop-end power.
ModifY rhe channeh ro open sooner by
ot
filing rhe leading edge of rhe power
M

valve 4 mm at a 45-degree angle. Don't

be tempred ro raise rhe Illain exhausr
d

parr a~ Yamaha recommends in irs

ar

published Wrmch Reports. Thar modiFi­

rw

carion will only make the plaring peel

Fo

from rhe pon, causing cylinder failure.

of

HEAD MODS
If you :lre using jllsr rhe srock Yamaha
rty

base gasker, rhe rnosr yOll can rllm

e

down rhe head is 0.'5 rnm. No adjusr­

op

menrs ro rhe squish band depth or angle

are neceSS'HY. Ifyoll wam w insrall rhe
Pr

'W'iseco flat-wp pisron (#70GPS), rllrn

The old YZf400 has asmaller small end pin diameter than current Ylfs. When the connecting rods are pushed down the head 2 111m, set the squish
past their normal service II mit, they tend to snap like this one. hand deprh to 1 111111, and ser rhe squish
hand angle ro 4 degrees.

BEST VALUE MODS ,ive in rhe midrange. A flywheel weighr FORKS

ENGINE: flywheel weighr will make the power more rraCtable. The fork valving is good in stock fonn.
SUSPENSION: springs for your weighr Heavier riders will need ro change to a
- 998 A A Z2 0 sriffer spring rate like a 0.41 kilogram.
CYLINDER AND HEAD MODS FLAWS: sorr rop end, wheelspin The fork oil level works hesl dL 90 111m.
The sub-exhausr porrs can be raised to FIXES: port cylinder, raise compression, Ser the compression dicker from four ro
38 111111 from dle top of dlC cylinder for flywheel weighr eighr clicks alit.
more lOp end, and rhe head can be Yamaha redesigned rhis engwe,
[limed down ar rbe gasker Sllrface 0.5 parricularly the cylinder and head. The SHOCK
mm. The serup requires race gas ro run new cylinder has rransfer ports similar ro Ser rhe race ~-ag ro 9') mm for besr resllirs.
properly. The engine rends ro be explo­ a Honda. me mosr copied design on rhe The rebound adjuster is very sensitive ro

213
TUNING TIPS FOR YAMAHA DIRT BIKES

plswn at TOC, a greater prt:~s\l[e rise

could occur inside rhe combustion
chamher before rhe pisron starrs on Its
down-stroke.

WHAT CHANGES WHAT?

Using a lOflger connecring rod mal(es it
necessary to insraJI a spacer plare under
rhe cylinder with a rhickne~s equal ro the
di FFerence bem'een rhe srock and longer
coflnecring rods. The common lniseun­
cepcion is thar a longer rod gives rhe
engine more displacemenr. Ir doesn'r
increase rhe displacemenr because the
srroke lengrh can only be changed ar the

rr
crankshafr Ayvveighrs. That is called

Go
srroking a crankshafc because rhe
diseance from rhe cemer uf rhe crank ru
rhe big-end pin is reloeared hlrther away

ric
from the cemer. The biggesr change in

-E
Kibblewhite makes high·performance stainless-steel valves that last much longer than the OEM titanium valves. rhe engine comes from the increase in
crankcase volume and rhe resulranr

n
io decrease ill the primary compression
changes, The rebound adjuster wurks midrange performers. rario. This may cause a loss of throttle
ot
besr in rhe r.ll1ge of fum ro eighr clicks Building a facror)" replica YZ Ii ke response and low-end power. Some
M

uur. Ser rhe compression adjusrer w 12 rhis isn'r cheap, The average price is runers use epm:y to line rhe walls of rhe
clicks and experimen r from there, abour $1,600. Tr requires rmal engine rransfer pons in an efrorr [Q decrease rhe
d
ar

disassembly and a new exhausr sysrem. crankcase volume and raise rhe primary
Here is a shorr explanarion of rhe key compression rauo.
rw

OD' -liT components ru this expensive conver­

Fo

Theres bccn a lor of hoopla in rhe maga­ sion and huw ro ger rhe mosr from rhe CYLINDER INTERCHANGE
zines abour rhings like "Iuflg rod" kirs and in\'esrmenr in parrs. Alrhough rhe cylinders are the same
of

rhe 1994 YZ250 cylinder. In 1997, heighr, rhe power valve, porrs, and
Yamaha riders Kevin Wyndam and Ezra ROD RATIOS exhausr spigur are all diffcreflf. In order to
rty

Lusk u.sed long-rod kil$ and 1994 cyliu­ Cunnecring rods are all abou r ri me insraJl a 1994 YZ250 cylinder on a larer
e

ders un rheir bcrory bikes. The mag<lZines and leverage. On a rwo-srruke engine, model, you have to swap the exhausr pipe
op

never explained whar rhe individual parts changing rhe conneering rod length flange or huy a pipe from Pro-Cjrcuir.
do and how rhey aJ1ecr performance. The aft(:crs a uumber of orher componenrs. Check on availabiliry of rhe pipe first.
Pr

1994 YZ250 cylinder doesn'r urilize a The rod rario is the connecring rod The rransfer ports ar rhe crankcase side
resonarur like rhe newer models, The lengrh (cenrer [() cenrer) versus rhe length arc much difFerenr, requiring borh the
resonawr impwves the low end of rhe of rhe srroke. Generally speaking, u1e 1994 cylinder and rhe larer model cases
powerband before rhe power valve opens higher rbe rod racio (longer connecting ro be marched as a ser. The power valve
(6.000 to 8.000 rpm). The 1994 YZ has a rod), rhe berrer suired rhe engine will be and head from a 1994 cylinder musr also
puwerband with a hard midrange hir. It for more high-rpm puwer. be installed. Regardiflg reed valves, rhe
also has a lack of low-end power-grear When rhe pisrofl reaches borrom dead Royesen or rhe V-Force is a berrer choice
for pro riders bur bad for mil riders. 11K cenrer of the srroke (BOC), the lunger over srock valves.
1994 YZ c)'linder has larger rransfer pores eonnecring rod will cause rhe pisron ro
and an addirional boosr porr linking the acceler:tre (,srer on rhe upsrroke. The 2-1996 Y MA A YZ250
crankcase ro u1e inrake side of rhe rapid changes in crankcase volume cause FLAWS: shock linkage, reeds, delollarion,
cylinder. When comhined wirb the 1989 rhe reeds w open to rheir maximum flow lean jerring (Mikuni carbs)
YZ250 cuooecring rod and crankcase area. When rhe pisron rises ro rop dead FIXES: DeVol linkage, Boyesen reeds, 59
mods co feed rhe boosr porr, rhe 1994 center (TOC), rhe long rod will dwell needle and 400 main jer for Mikuni only.
cylinder conversion can make rhe rhe pisron ar TOC for a longer period of This engine and cha.ssis have grear
1997 .lntl 1998 YZ250s in ro powerful rime unn a shoner rod. R~' dwelling rhe porencial for improvemenr. The srock

214
 1992-1996 YAMAHA YZ250

exhausr ga~ vel06ry and improve flow a[

high rpm. Regarding rhe porring, [he bes(
mod for gaining cop end is to raise (he
sub-exhau~r pons ro 38 mm, measured
from the rap of the cylinder. The squish
velociry ra(ing of the srock head is very
high-too high for premium-unleaded
fuel. The srock engine deronates in Lhe
midrange due (0 rhe high compressiol1
ra(io and squish velociry. The solution
is ro narrow the cylinder head's squish
band 9 mm, measllfeu from one side
of (he chamber.

IGNITION TIMING

rr
Set rhe ignition timing ro G.B mm

Go
BTDC. This will diminare any chance
of pinging bur unforruIl3tely reduces
the midrange hi[ in rhe powerband.

ric
-E
When aYlF overheats. It may suffer from chronic head gasket leakage due to warpmg of the head. CYLINDER AND HEAD MODS 1996
The 1996 cylil1der and head have less

n
io transfer time area rhan the previous
engine has a hard midrange hit but falls the rear suspension by eliminating rhe models. You can adjust the POrtS [.() the
ot
flat ar high rpm. The stOck cha.~sis has a mid-speed damping spike caused when same specs as rhe earlier models by
M

shock linkage system wirh a high rising going in and out of turns. DeVol raising rhe rransfer pons 1 mm. The
rate ratio. This makes the rear end changed the linkage rario curve to be cylinder head can be turned down
d
ar

handle harshly when accelerating out of more linear. This reduces rhe shock shaft 0.020 in. or 0.5 mm on (he face.
turns. The carb jerring on the models speed to a range where rhe stock shock
rw

with Mikuni earbs (1994 and earlier) can be adjusted to handle the braking POWER VALVE MOD FOR WR250
Fo

were jetred too leall. The Keihin carbu­ and acceleration bumps rhar lurk in [he Many riders complain thar the power­
rewr was inrroduced in 1995, and rhe bends of a racecourse. band on the WR i~ diff'Lcult ro manage
of

srandard JcrtIng is very dose to on slippery off-cambers because the

oprimum. The 1995 model feawrcs an INTAKE AND CARBURETOR power hits roo hard because [he power
rty

updared exhausr valve system. The new The best products for berTer engine valve ~naps open in a narrow rplll band.
e

sysrem uses a surge chamber f<>r low performance are the Boyesen Superbowl The power valve riming can be changed
op

rpm. This helps soften rhe midrange hit and RAD valve. The original reed valve using a file. '10 mellow the WR's
bur rhe power valve is srill susceprible to peaks and starts to flurrer at only about powerband, file open the sub-exhausr
Pr

wearing, as were the e:ulier models. The 7,000 rpm. The RAD valve has a wider pons on the power valve. This will
1996 model features a ne\v chassis with a flow range so i[ ex[ends the top end. The enable [hose porrs to open sooner and
shock linkage sysrem similar to rhe new float bowl design prevellts the fuel slowly bleed off some of the combus­
DeVol design. The top end wa.~ changed from foaming and starving rhe engine. tjon pre~sllre before the big exhauH
tOo. Yamaha changed rhe cylinder head parr opens. Th is is (he same principle
design to one with greater piston-to-head CYLINDER AND HEAD MODS that rhe 1995 YZ YPVS is based on.
clearance. This modificHion reduces rhe The POrt timing of me original c'ylinder
need for race gas. makes [he powerband come on abruptly CARBJffilNG
and fall flat early. Careful use of epoxy The carb jet[ing for rhe Mikuni is roo
BEST VALUE MODS and a grinding rool can tran~form the leall. The needle and main je( can be
ENGINE: Boyesen reeds, head mod cylinder into a wide, mong pulling richened ro a 59 needle a.nd :l4QO main
SUSPENSION: DeVol linkage engine wirh more [Op-end potenrial than jet.. This makes the engine rev higher
any of rhe orher bikes. An easy 'I'.'ay ro with more power. The Keihin carb used
SHOCK LINKAGE extract more top end from the YZ250 i~ on rhe I 995-and-later models is jened
DeVol Engineering has developed a rear to grind round the lower side of (he oval very close and only needs changes ro
suspension linkage kif. The kit improves exnau.<;t port ourlel. This will reduce the suit local conditions.

215
TUNING TIPS FOR YAMAHA DIRT BIKES

REEDS accelerate quicker from BDC, causing is a common prohlem. The oil bypasses
The nexr time you remove me cylinder the reeds to open Farther. The rod spends rhe rebound pisron and flows past the
from yom YZ or WI{, wm it upside more time ar TOC, which enables the hushing. rhereby eliminating mosr of the
down and look up rhe rear crankcase Hame froll( co sptead across rhe chamber damping effect. The bushings musr be
boosr parr. You'll notice rhat the reed srop before cl1e piston moves on [he down­ replaced as a set, and they are available
plates block rhe upper and lower ports. stroke. The spacer plare raises me cylinder from afrermarket companies such as Pro­
Insrall a ser of Boyescn reeds because they to lowet the primary compression racio Action, Race-Tech, and Pro-Circuit.
doo't require the use of the reed stop (increase in the volume of the crankcase)
plates and that will enable me boost POrtS and positions the cylinder tUI rhe pro pet REAR SUSPENSION
to flow as mey wete intended to. POrt timing. This kit is in tended for DeVol makes a linkage kit for this bike
expert-level moTOCross and OTX racing. rhar will make clle older YZs handle
CLUTCH MODS This mod works well with ()[het compo­ almost as well as the 1996 YZ. The tear
You em make the durch easier (Q pull llelllS such as aggtessive potting, a shock should be revalved in conjunCtion
by rouoding the edge on the actuating 39.5-mm c.,rb, and a high-tevving pipe. wirh rhe DeVol linkage kit. Check the
lever. Oil circulation holes can be chrome finish on the shock shaft bec.,use
drilled in each female spline on the 99 9~ V ,N Z250

rr
it is prone co peeling. Check the bo([o01
clurch hub. I recommend using Cratex FLAWS: forks rebound fast, tear end

Go
or rhe shock linkage because the links
rubberized abrasives ;JI1d an eleCtrie drill kicks, engine pings and deronates hang so Iowan rhe YZ and are pcooe to
(Q polish the splines on the c1urch hub. FIXES: replace fork bushings, insrall cracking when the bike bottoms OUt.

ric
This will make the clurch plates teact DeVol linkage, richen jetting and

-E
quicker without genetating excess fric­ modify cylinder head CYLINDER HEAD MOD
tion. The 1994 Yamaha W,-rnch Rrport These models don't handle a.<; well as The squish band of the cylinder head is

n
recommends teplacing the thtust washer clle next generarion ofYZ, bur they have roo wide and cames rhe engine ro ping
thar fitS between the crankcase and the
io
good engines with strong low-end power. in rhe midrange. Using a lathe, n;lrrow
ot
clutch basket with part number 2K7­ The bikes arc excellent second-hand bikes rhe squish band to a width of 9 mm,
M

16154-00-00. This rhrusr washer is 1 and can be bought for bargain prices. measured from nne side of the chamber.
mm chinner and will improve che The WR150 used engine designs This mod also helps rop-end power and
d

leverage ac rhe handlebar. rbat were a generation behind the YZs

ar

makes it possible for the engine to burn

(until 1994). Many of the mods and supet-unleaded premium fuel.
rw

POWER VALVE GOVERNOR accessory parts recommended for cl1e

Fo

In 1994, Y;'lmaha swicched to a five-ball YZ250 will wotk well on the WR250. POWER VALVE PROBLEMS
tamp from a four-ball ramp in the power The power valve has a Stop rab on the
of

\,alve governoc mechanism. The mecha­ BEST VALUE MODS lefr side thar con trob rhe full-open and
nism is locared under rhe riglu-side ENGINE: Boyesen RAD valve closed positions of che power valve. The
rty

engine cover. Yamaha recommends SUSPENSION: stiffer fork springs power vaJve is made of aluminum, and
e

S\virching back w the four-ball ramp the srop plate is made of sreeL The
op

because che extra baJl makes me power EXHAUST SYSTEM aluminum rab wears, allowing the
vaJve open roo soon. This effect is benefi­ The scock exhausr syscem doesn't work powet valve ro fOCate open and closed
Pr

cial ro enduro riders, but l11orocross ridet'S very well. Pro-Circuir makes an exceJ­ roo far. When the valve closes roo far, it
will nOtice that rhe engine is sluggish lem pipe and silencer tur rhis bike thar contaCts the piSTOn aod could cause the
when shifring from chitd ro fOLUrh gear improves rbe power all rhroughout the piston rings to break. inspeCt rhe tab of
on uphills. The balls are the same dimen­ rev range. the power valve. If it has worn more
sion for 1990 [Q 1994, so all you need ro than 1 1111ll, replace ir.
change is rhe ramp and discard one of che INTAKE SYSTEM
ball bearings. The Yamalla pan numher is Replace rhe srock teeds with Boyesen SLEEVE NUT
5X5-11911-01-00 (rerainer). d ual-s rage reeds and discard rhe srock The alulninulll sleeve nut [har retains
reed srops. The reed SlOpS block the rear the LOp tapered bearing on the steering
VZR LONG·ROD KIT boost porrs. Stem ren.ds ro seize to eirher the stem or
Yamaha markel5 a kit that includes a the rop clamp. Remove the sleeve nm
longer conneCting rod, a spacer plate for FORKS and apply allLi-seize or moly pasre ro
che cylinder, and longer power vaJve Change [() a set of 0 AI-kilogram Eibach the inside and ourside of rhe nul. If rhe
linkage. The long rod yields benefits for forks springs. If the forks rebound roo nur seizes on your bike, apply heat wirh
engines designed for high rpm. Wirh a quickly and malce a clanking noise, tbe a propane rorch and spray penetrating
longer connecring rod, rhe piston will pisron rod hushings are worn our. That oil on the nut. Calnion: Never spray the

216
 :1.985-:1.990 YAMAHA YZ250

penetrating oil at the (Orch because it is yOll c.ln'r inrerchange rhe rods. Jusr huller block. Swi tch to the block from
a flammable liquid. moniror the rod', side clearance and rhe 1989 modd, which is made trom a
replace it when ir becomes worn. softer marerial.
98
FLAWS: rod breakage, shifr cenrenng BOYESEN PORTS CLUTCHES
geT; loose On the 1985 to 1990 models, rhere is The 1988 YZ has an inferior clurch pres­
FIXES: moniror rod dearam;e, epoxy pin only one pon linking rhe imake ro rhe sure plare design. Swi rch [Q the 1989
Yamaha has always had a great 250. rransfer pons. On Lhese models, drill an parr. It ha.~ srronger ribs on rhe back side.
Every year, the development ream addirional hole (l/2-in. diameter) on rhe The 1989 parr make;, ir easier to adjust
focuses irs arrenrion 011 making rhe opposire side of [he exisring hole and rhe clurch co prevenr dra~~ing and slip­
bike perform bener and laSt longer. insrall Boyesen reeds. The midrange ping. Sritrer clurch springs will also help.
Overall, the YZs are durable bikes. The power will be grearJy improved.
following is a lisr of some areas to pay FORKS
careful :irtenrion roo SHIFT CENTERING PIN The best mod tor che damper rod forks
BEST VALUE MODS On rhe righr side of the crankcase (before 1989) is a Race-Tech Emulator
ENGINE: Boyesen boosr ports, Boycscn

rr
behind rhe shift lever, there is a sreel pin valve.

Go
reeds rhar is used as a pivor for rhe shift-shaft
SUSPENSION: Emulator valve, chain spring. The fit of rhe pin in rhe cases is REAR SHOCK
bufFer loose, and ir can fall our, causing the Tn rhe mid-1980s, YZ250s used d

ric
shift lever co flop around. Smear a dab componenr mUed a BASS system. The

-E
CRANKSHAFT CONNECTING RODS of epoxy on rhe pin co hoJd ir inco the device was activared by clle toor brake
Before 1990, the YZ250 had a l.10-mm­ case. Be sure to clean rhe surhces (j rs, through a cable. The cable operated the

n
long connecring rod rhar was prone co or the epoxy won'r adhere.
io compression valve of rhe rear shock. It
breaking to mm below rhe sm;11I end. was designed co adjust rhe shock
ot
This happens when rhe connecting rod's NOISY CHAIN BUFFERS damping when ricLng rhrough whooped­
M

side clearance is allowed co wear past rhe The chain bufJt:r blocks on rhe 1988 our srraights while t1ragging the rear
manUhlCtlirer'S service limir. In 1990, YZs arc made of a hard, clurable mare­ brake. The B.A.S.S. s)'srem requires
d
ar

Yamaha shortened rhe rod ro 125 Inm, rial. Cntonullalely, clle chain makes a consran t adjusting, cleani ng, and serv­
which fixed the problem. Unfortunately, horrible slapping noise ,,,hen iL hilS the icing, and che cable adjuqer is prone to
rw

corrosion hilme. ,[\·10sr suspension rech­

Fo

nicians disable rhe BASS. sysrem when

servicing rhe shocb.
of

Anorher charaererisric problem wirh

rhe YZ shocks is shock shaft corrosion.
rty

This problem is aggravared by lack of

e

oil changing. The shah- srarrs co rum

op

blue and rhe chrome peels off rhe shafr,

eventually causing seal failure. Change
Pr

your shock oil ofren.

TRANSMISSION PROBLEMS
Pur your YZ up on a stand. Wirh clle
engine 01T and rhe tr3nsmi.ssion in
nellcral, rry ro rorare rhe rear wheel. If jr
is very diffjculr and rhere is a lor ot d ra~,
rhe hearing lilar supports the lerl side of
rhe c1mch shah- could be worki ng irs W~I}'
our of rhe crankcases and rubbing LIp
against clle second-gear drive. Eventually,
rhe bron/,e hush ing in.side rhe gear will
seize to rhe ;hafT. Whenever you have rhe
engine aparr for new bearings, replace
rhe lefr-side c1urch-shafr bearing and use
The head can be lapped flat using sandpaper and asurface plate. a sharp drift rod to srake ir ro rhe elses.

217
TUNING TIPS FOR YAMAHA DIRT BIKES

Installing ~n oversize header pipe or a CARB JETTING

heavier flywheel weight will came the hit The stock jetting on the 1998 js a bit
in the 450 and make it more like the old lean, especially for loamy terrain and
426_ There have been some connecting cold climates. Good baseline settings
rod f;lilures and Falicon tesponded by ate a 50 pilot jet, a 1R5 mdin jet, :lnd
making a knife-shaped connecting tod adj liSt the air and fuel screw to rune it
dUt reduces windage and is much in. The acceleratOr pump needs peri­
stronger than srock connecting tods. odic cleaning; dirt and water seep past.
the rubber hoot and slow down the
BEST VALUE MODS action of rhe pump. For more informa­
Oversized header pipe tion abour this high-main tenance carb,
look [Q Chapt.er 5.
2 00-2002' A AH Z 426
FLAWS: hard to start HOT START BUTTON
FIXES: allco-decompressor cam The Hot SIaLT Bunon from Terry
Pruducr.~ is a h;lndlebar control for rhe

rr
The YZr426 is one of the beSt-built

Go
dirt bikes of all time. There are some carb's air bypass system. The Hot Seatt
characteristic Y;lmaha items ro pay Button makes it easier to restart the bike
atrenrioTl to: monitoring the valve in a hurry and can be used ro lean the

ric
clearance, taking care to torque the cam jetting. The blltron has a wide range of

-E
cap bolts to only 60 in.lpounds, incrementa! movemem. If you're riding at
replacing the C<1.m chain and head bolts a steadily increasing alriTllde, you can

n
at every rop-end job. and changing the
io adjust the carb jetting for the less dense
oil frequently. Some other problems are air by cracking the button open.
ot
Falicon makes this knife-shaped connecting rod for C0lJ11nOn to Y7Fs raced on hard-pack
M

the YlF4 50. It's astronger design than stock, and terrain such as clay, pavement, or ice­ FLYWHEEL WEIGHT
the shape reduces oil windage. fifrh gear tends to disengage in a In rocky or slippery terrain, rhe yz may
d
ar

high-load situation. The problem is the be prone ro stalling or quick wheelspin.

engagement dogs wear rounded and You can buy flyv...heel weights rhat bolt
rw

This will prevent l[ fwm sliding our won\ hold engagement with the on t.o tbe perimeter uf rhe srock flywheel.
Fo

roward rhe gear. opposing gear. In most ca.~es, if t.he 426

suffers from a slipping {lanny, rhere <Lre CLUTCH BREAKAGE
of

ELECTRICAL PROBLEMS several gears in matching pairs rhat Riders with tendencies ro fan the clurch
The biggest cause of hard starting is a need to be changed all at once. frequendy should change the aluminum
rty

poor ground at the secondary coil (cop clutch places for steel ones. If the places
e

coil under the fuel t;mk). Remove the BEST VALUE MODS sharrer, the debris tends to flow to the
op

coil and file the frame rabs where rhe HOt Cams oil slimp screen, causing it to dog and
coil mounts. Another common problem teduce lubrication.
Pr

is high resistance in the generating coils 99 - '9 .0 .

(rhe coils behind the flywheel). The FLAWS: Too-lean jetting CRANKCASE BREATHER
coils can be repaired for half rhe price of FIXES: Carb jetting The cr.ankcase vem hose exitS from the
a new statot plate assembly_ rop of rhe engine. That huse needs a
BEST VALUE MOD filrer at the end to reduce rhe dust thar
2003- 00 ZF 50 ENGINE: Hot Starr Button, jetting eolleces in the hose. K&N makes a
FLAWS: weak tOO hard SUSPENSION: springs srainless-sreel filrer, marketed mainly for
hitting The besr-selling MX bike has had spon riders. Look ro a TOad bike shop
FIXES: insrall Falicon connecring rod rhousands of magazine pages wrirten for ehe crankcase vent filters.
kir, oversize header pipe about every aspect of irs maintenance
Yamaha built the YZF450 to compete and performance. With rhe huge range BIG BORE KITS
with Honda's big bore entry. Redesigning of accessories available, you can get The 1998 and 1999 YZ400 cylinders
the 426 engines, making the casrings and carried away buying things for this can be overboted 2 mm ro 94 mm for a
steel pares thinner and lighter, may lead to bike. So rather than focus on particular tOra! displacement of 420 cc. The 2000
lUrure reliability issues. Riders complain aeeessorjes, lee's look at the basics YZ426 cylinder casting is mudl thicker
thar the power hilS hard like a rwo-Stroke. affecring reliability. than t.he earlier models_ \'V'iseco makes a

218
 1998-1999 YZF400

97-mm pi,ton kit for the YZ426 dla[ pump. The unit features total control of
boom the displacement to 450 cc. It is the ignition and fuel system via a
possible w inmll the 2000 cylinder on handlebar switch.
the previous models of YZ400, but in A laptOp or PDA can diagnose
order ro use the Wiseco 97-mm piSLOll system errors and make programming
you have to insrall a rod kit from a changes. You cao even download igni­
YZ426 because the small-end pin size is tion and fuel maps from Oprimum's
larger. The parr nllmber for the 97-mm website, ,,,,,vw.optimum-power.com
Wiseco kit is 469SPS. Comeri<.: makes a Thar way, you can cusLOmi:Le the
correspondlng gasket kit. fuel and ignition systems ro suit a
variety of aftennarket compo nents or
PISTONS displacement sizes.
Wiseco makes I;be overslze pismn kits in
the smck a.nd high-compression models. GEARING
The si7..e5 range from 94 to 97. The Most riders increase the size of the rcar

rr
compression ratios ate l2.5 to 1 (parr sprocker as much as 54 teeth, depending

Go
4(49) and 13.5 ro 1 (parI; 4(50). on rhe local ri.di.ng conditio,ru;.
High-compression pisrons are good for
high-altitude <.:orrection and give more SUSPENSION

ric
low-end to midrange rorque. The 13.5 Overall, the shock spring and valving

-E
10 ] pistons perform best using VP C­ arc stiff and the forks are soh:. This bike
IS fuel. That fuel is blended for need.s balanced springs front to back. A

n
pro-stock drag racing and improves rhe simple rule of rhumb is riders with
io
I;hrmde response. geared weigh t under 165 pounds need
ot
sofrer fork springs and riders with
M

AFTERMARKET ENGINE geared weight over 175 pounds need

MANAGEMENT KITS stiffet fork springs and revalving.
d
ar

Optimum Power Technologies offers an For beavicr ridcrs, (hc bike may
engine maoagemem solution for the seem ro ride pirched forward. If the
rw

YZ400/426. The system includes a Front race sag is 2 in. or greater, rhe
Fo

generaror, DC power sysrem, complere springs arc either sacked au [ or too soft
igni rion sysl;em, throtde body, and fuel for your weight.
of
e rty
op
Pr

219
TECHNOGEEK'S LIBRARY

If you are looking For rhe highesr level Motorcycle Comtructors Handbook, Prt'cision Auto Research S~ftUJare, $400
of technical inFormation about racing volumes 1 and 2, $100 each By David Redzus, Ph.D.
D1morcycle engine and c11a.~sis design, By John Bradley wwv.'.precisiollautoresearch.com
these' six book~ and related software W\'IW.eurospares.com
programs are rhe besc ro get you starred. This sofrware set Features over 200
NioSt of these books are written For In my opinion, John Bradley is the Excel macro progr:lms related to rhe
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mecllanicaJ engineering programs. With cycle engineer alive today. His motorcycle engineering wpics. These
the exceprion of Kevin Cameron's tv.'o-volume set or books thoroughly programs are though t provoking and

rr
sporrbilee boole, all of rhese books may covers the theory of how motOrcycle have proven in practice to help solve

Go
seem shockingly expensive and yOll systems work, the design of compo­ inherenr maladies wirh componenr
can'r JUSt run down ro rhe local book­ nentS, seleceion of materials, and ;1 wide designs. The web sire features many
swre w find them. Once you ohrain array of praCtical maoubcruring and

ric
demos of the individual programs.
some of these books and sofrware, 1 fabricarion methods. John's books are

-E
encollrage you ro seek our orher related wrirren to teach you how to design and
works by these talented aurhots. In my huild a motorcycle from the ground up. Two-Stroke Racing Software. $60-$300

n
own library, I have copies of SAE io ByTom Turner
papers, parenrs, and nores from semi­ www.rsrsofrware.com
ot
nars led by some of rhese men. Motorcycle Handling and Chassis Design,
M

$50 'lom Turner had a grear career as a

Design and Tuning ofFour-Stroke By Tony Foale tuner and drag racer, building engines
d
ar

FngineJ, $90 www.ronyfoale.com for legendary racers in the sporrs of din

crack, drag racing, and motocross. Tom
rw

DeJign and Tuning ofTwo-Stroke Tony srarred his career as a nuclear channeled his eFforrs inro writing over
Fo

Engine!, $90 scienrisr, but his love of racing mowrey­ 100 software programs ro hel p amaceur
By Cordon P Blair des directed him to dedicate his life ro funers wirh che math and la~'out of
of

www.sae.org discovering and explaining the rheory of chings like cylinder pom, heads, and
www.professorblair.com haw these wonderful machines work. His expansion chambers. Most of the twO­
rty

books, COs, and software focus on srroke porring and cylinder head
e

Professor Gordon l~ 13Iair was the Pro Illlproving mororcycJe handling. specifications listed in th is book were
op

Vice Chancellor of the Queen's Alrhough the mare rial is geared [Q"'-'ard developed using PORT 2000 sofc\'{are.
Universiry or Belfast. He is a mororcycle road racing bikes, it's all relative and
Pr

racing emhusiasr and was the driving exeelJenc reading, especially for mechan­
force in combining the power of dle ical engineers. Tony also cuns a series of
digital computer with the disciplines of technical seminars based on his book.
unsrt:ady gas dynamics and iliermody­
namics ro produce a line of programs and
booles. The Prof's hoob are d1readed SportlJl'ke Perftrmance Handbook, $25
with math equations, and his lively By Kevin Cameron
wriring style gives the reader a sense of www.motorhooks.com
hisrory and the insight gained from simu­
lations that dehunk many of the Kevin is the cechnical editor for C'ycu
performance myrhs that plague rhe WorU magazine and the most prolific
motorcycle indusrry. Professor Blair sells a wricer in the history of the sporr. Kevin's
line of high-end software with his partner book covers all the major systems of a
Hans Herman and they work as comulr­ sponbike, scarring with design cheory,
ams to many of the NexteJ Cup reams. history of developmenr, and pracrical
modificacion Lechniques.

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