Yamaha YF200 R1 User manual

Title Page
Block & Side Cover 4-5
Crank, Piston & Rod 6- 7
Cylinder Head 8-9
Cam & Valve train 10-11
Carburetor / Manifold 12-13
Flywheel & Ignition 14-15
Assembly & 6 Packs 16
Torque Values
17
Special Tools 18-19
Pre-Assembly
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 Range) products

YAMAHA YF200 R1

BLOCK & SIDE COVER
YAMAHA YF200 R1
Ref # Burris P/N Description Qty
1 F21-101-00 Block / Crankcase with Sleeve 1
2 F21-102-00 Main Bearing 2
3 F21-103-00 Seal -Flywheel Side 1
4 F21-104-00 Oil Drain Plug - 10X16mm 1
5 F21-105-00 Oil Drain Plug Gasket 1
6 F21-106-00 Side Cover Dowel Pin -8mm (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 - 8mm 10.9 6
16 F21-116-00 Cylinder Sleeve 1
17 F21-117-00 Rubber Side Cover Plug 1

CRANK, PISTON & ROD
Page 7
YAMAHA YF200 R1
Ref # Burris P/N Description Qty
1 F21-200-00 Crankshaft 1
2 F21-201-01 Billet Rod Assy - Billet w/insert 1
F21-201-02 Bearing Insert For Billet Rod 1
F21-201-03 Rod Bolt & Washer Set 2
3 F21-202-00 Piston 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 (0.2mm) 1
F21-206-02 Crank Shim - .012 (0.3mm) 1

CYLINDER HEAD
Page 9
YAMAHA YF200 R1
Ref # Burris P/N Description Qt
y
0 F21-300-18 R1 Complete Gasket Kit w/.018" HG 1
F21-300-27 R1 Complete Gasket Kit w/.027" HG 1
F21-300-30 R1 Complete Gasket Kit w/.030" HG 1
F21-300-36 R1 Complete Gasket Kit w/.036" HG 1
F21-300-40 R1 Complete Gasket Kit w/.040" HG 1
1 F21-301-00 Cylinder Head - Bare 1
2F21-302-10 Exhaust Header Stud - 6X27mm 2
3 F21-303-00 Intake Manifold Stud - 6X18mm 2
4 F21-304-18 Head Gasket - .018" Thick 1
F21-304-27 Head Gasket - .027" Thick 1
F21-304-30 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 Manifold Hex Nut 6mm 2
12 F21-312-00 Cylinder Head Flange Nut - 8mm 4
13 F21-313-00 Valve Cover Baffle Gasket 1
14 F21-314-00 Valve Cover Gasket 1
15 F21-315-00 Valve Cover Baffle Assy. 1
16 F21-316-00 Valve Cover 1
19 F21-319-00 Valve Cover Stud & Nut Kit 1
(4) 6X15mmStud, (4) 6mmFlange Nut, (4) Spacers

CAM & VALVE TRAIN
Page 11
YAMAHA YF200 R1
Ref # Burris P/N Description Qty
1 F21-401-00 Camshaft - Unground Lobes 1
F21-401-51 Camshaft - #51 Grind 1
2 F21-402-00 Intake Valve - 26mm 1
F21-402-20 XR Intake Valve - 26mm Stainless 1
3 F21-403-00 Exhaust Valve - 24mm 1
F21-403-20 XR Exhaust Valve - 24mm Stainless 1
4 F21-404-00 Valve Lifter 2
5-E F21-405-00 Valve Spring - Red (OEM Exhaust) 1
5-I F21-405-01 Valve Spring - Blue (OEM Intake) 1
5-E F21-405-10 XR Valve Spring - Orange (Exhaust) 1
5-I F21-405-11 XR Valve Spring - White (Intake) 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 Push Rod (For OEM Valve Length) 2
F21-413-20 XR Tubular Push Rod (Extended Length For XR Valves) 2
14 F21-414-00 Intake Valve Stem Seal 1
15 F21-415-10 XR Intake & Exhaust Valve Kit 1
Valves,Locks,Retainers,Shims, Springs & Push Rods
16 F21-416-30 XR .030 Valve Spring Shim 2
17 F21-417-00 XR Stainless Valve Wear Caps 2