Help! Warrior Valve Adjustment - Yamaha ATV Forum
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post #1 of 5 Old 08-07-2004, 11:11 AM Thread Starter
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Help! Warrior Valve Adjustment

I've tried to find sites to tell me how to adjust the valves in my '91 Warrior. I checked out the manual download on the YFZ site but everytime Adobe comes up the manual freezes and I can't look at any page BUT the first page. If anyone could sent me a website or anything to help me it would be highly appreciated. I would like to print out the few pages from the manual so that I could have them on file, but my computer freezes up if I try to print it or save it. If anyone could e-mail those few pages that would be even better!!! Thanx!

1991 Warrior
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post #2 of 5 Old 08-07-2004, 11:10 PM
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This How-To is for helping you guys adjust you valves i know alot of people ask me how to do this so here goes.You will need to remove the gas tank and cover,hood,and front fenders.

Tools Needed:
10mm socket
Allen head socket (cant remember which size)
15mm wrench
flathead screwdriver
feeler gauges
small crescent wrench/ignition wrenchs/or needle nose pliars


First off remove the plastic cover are on the drivers side part of the motor.Also remove the black flathead plug on top of the stator cover. Use the 15mm wrench to turn the motor over until you line up a small T in the hole there is also an F dont get that confused with it.Taking the spark plug out will aid in turning the motor over


Secondly you take the valve cover off the intake side I like to do the intake side first then exhaust.Now that the cover is off back off the 10mm jam nut.A set of ignition wrenches or small needle nose or crescentwrench will help with this.After the jam nut is backed off (do not remove it) insert the feeler gauge in between the rocker arm an top of the valve spring.

Tighten the small square stud down until you can pull the feeler gauge out with a bit of a drag.(For the correct clearances look below)

Follow the same steps as 2 for adjusting the exhaust valve.

Intake:0.06~0.10mm or 0.00236~0.00394in
Exhaust:0.16~0.20mm or 0.00630~ 0.00787in

Well that wraps that up if you guys need any additional help PM me or get ahold of me on AIM.Its a little tricky at first but after that it becomes second nature.

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post #3 of 5 Old 08-08-2004, 07:14 AM
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One thing that I do to make my life easier when adjusting the valves is to leave the front fenders and hood on, and take the gas tank off by sliding it rearward. It is kind of a tight fit, but it can be done, and it saves you the trouble of pulling all that other stuff off.

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post #4 of 5 Old 08-08-2004, 10:31 AM
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This page I made might help. Look on the last pages for adjustment info.

04 YFZ450 - WR crank, oil mod, CP 13:1 piston, Full Yosh TRS Ti pipe, hotcams intake, cam mod, YZ clutch mod, GYTR basket, FCI, 1" lowering peg nerfs, LSR axle, Pro tapers and Housier +1" stem, PRM desert grab bar, AC bumper, XCR tires and more 175M NCVQ #5 50p | 2010 YFZ450X - HMF Tuner, PRM bolt-ons, Aluminum airbox + K&N Filter
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post #5 of 5 Old 02-10-2010, 04:46 PM
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are u positive about those clearance specs i went to another site and they said intake 0.05 and exhaust 0.07
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