Yamaha YXZ1000R Engine Teardown

Welcome to the beginning of our 2016 Yamaha YXZ1000R engine rebuild, in which we tear down the engine piece by piece for a future turbo upgrade. 

There’s nothing particularly wrong with our Yamaha side-by-side engine, but its 11.3 to 1 compression ratio and the connector rods it has aren’t going to work for this upcoming turbo build. For this part of the rebuild, we're pulling it apart, checking everything out, and later on for the rebuild we'll upgrade the connector rods, drop the compression ratio with new pistons, and then it'll be ready for a turbo application. 

For the low compression setup, Wiseco forged pistons will be installed. 

Yamaha UTV engine rebuild Wiseco forged pistons

As for changing out the connecting rods, the ones in the 2016 model aren’t up to the task because they're a little bit too thin, so they’ll be updated to rods for a newer model. 

Yamaha YXZ1000R engine rebuild connecting rods

Other upgrades for the upcoming rebuild include installing a top-end gasket set and a new gasket for the oil pan. 

Yamaha YXZ1000R top end gasket set

For this turbo build, an ARP stud kit will also be installed, since a full turbo application is probably not going to survive having the stock studs in place.

Yamaha YXZ1000 rebuild ARP stud kit

Other parts needed will be determined as the engine is broken down, but the connector rod bearings and the main bearings for the crankshaft will likely be replaced. Those will be determined by markings on the crankshaft and the and the block. 

Watch the video above or read on below to learn how to tear down a Yamaha YXZ1000R engine to prepare it for a turbo upgrade.

Tools Needed - Yamaha YXZ1000R Engine Teardown

  • Standard tools (wrenches, Allens, screwdrivers, ratchet and sockets, etc.)
  • Pry bar
  • Dead blow hammer

Buy Yamaha flyhweel puller kit

Buy blind bearing puller set

PRO TIP: Have a marker and ziplock bags ready when you're pulling apart an engine so you can organize and label all of the parts for when it’s time to put the engine back together.

Yamaha YXZ1000R Engine Teardown - Remove Wiring and Throttle Bodies

Step 1. Remove all the different venting and the intake, and any of the wiring still attached to the engine.

Yamaha YXZ1000R engine rebuild teardown

Yamaha YXZ1000R UTV engine rebuild teardown

Step 2. Remove the throttle bodies. The best way to do that is to take them off by leaving the adapters in place and pulling them out of the adapters. 

Yamaha YXZ1000R side by side engine rebuild teardown

NOTE: Expect a fair amount of resistance here because there's a lip more or less locking them in, so be careful not to damage anything when pulling it apart.

Step 3. Remove the cooling lines and the oil cooler as an assembly. 

Yamaha YXZ1000R SxS engine rebuild teardown

Yamaha YXZ1000R SxS engine teardown

Step 4. Remove any electrical components that are in the way, including the coils up top.

Yamaha YXZ1000R side-by-side engine teardown

Watch the clip below to see the wiring and throttle bodies removal segment of our Yamaha YXZ1000R engine teardown video.

Yamaha YXZ1000R Engine Teardown - Remove Valve Cover

Step 5. Remove the inspection covers and the valve cover from the engine.

Yamaha YXZ1000R UTV engine teardown

Yamaha YXZ1000 UTV engine disassembly

Yamaha YXZ1000 side-by-side engine disassembly

Watch the clip below to see the valve cover removal segment of our Yamaha YXZ1000R engine teardown video.

Yamaha YXZ1000R Engine Teardown - Find Top Dead Center

Step 6. Bring the engine to top dead center by looking for the TDC mark through the inspection hole and lining up the TDC marks on top.

Yamaha YXZ1000 engine disassembly

Yamaha YXZ1000 engine dismantling top dead center

Step 7. Remove the chain tensioner from the engine. 

Yamaha YXZ1000 engine dismantling

Yamaha YXZ1000 engine dismantling chain tensioner

Watch the clip below to see the finding top dead center segment of our Yamaha YXZ1000R engine teardown video.

Yamaha YXZ1000R Engine Teardown - Remove Camshafts

Step 8. Remove the camshaft caps from the engine, followed by the cams themselves.

Yamaha YXZ1000 UTV engine dismantling

Yamaha YXZ1000 SxS engine dismantling

NOTE: The difference between the intake and exhaust cams is the intake cam has a larger middle section than what’s on the exhaust cam.

Yamaha YXZ1000 side-by-side engine dismantling

Watch the clip below to see the camshaft removal segment of our Yamaha YXZ1000R engine teardown video.

Yamaha YXZ1000R Engine Teardown - Remove the Head

Step 9. Remove the center support bolt, followed by the head bolts in sequence. 

Yamaha YXZ1000 side-by-side engine head removal

NOTE: The head bolts in the picture above are labeled 3 thru 10 since the first two bolts on the side had already been removed. For disassembling the head, each bolt was loosened in sequence order at about a half a turn per bolt to release pressure on the head evenly. Doing it this way reduces the chances of warping the head. 

Yamaha YXZ1000 side-by-side engine head bolts removal

Step 10. Pry the head off the engine and lift it out carefully because if you tip it over, the shims are going to fall out. Next, remove the cylinder head gasket. 

Yamaha YXZ1000 engine head removal

Yamaha YXZ1000 engine head gasket removal

Watch the clip below to see the head removal segment of our Yamaha YXZ1000R engine teardown video.

Yamaha YXZ1000R Engine Teardown - Remove the Rotor, Flywheel and Output Shaft

Step 11. Remove the bolts from the crankcase cover, which has the stator under it, followed by the crankcase cover itself. 

Yamaha YXZ1000 engine crankcase cover removal

NOTE: The cover bolts are all the same except for the one that was holding the pipe in. The top two bolts have washers on them, and the cover has arrows indicating which bolts have washers. Be careful when removing the cover, as there’s a magnet from the rotor trying to keep it in there, so don't let it pinch your fingers.

Yamaha YXZ1000 crankcase cover removal

Step 12. Remove the starter reduction gear, followed by the rotor. 

Yamaha UTV engine teardown

PRO TIP: Use a basic flywheel puller if you don’t have the one made by Yamaha, which is pricey. Make sure that whatever puller you use doesn’t damage the end of the crankshaft. 

Yamaha SxS engine teardown

Yamaha side-by-side engine teardown

Step 13. Spin the engine around and remove the output shaft retaining bolts, followed by the output shaft itself. 

Yamaha side-by-side engine rebuild teardown

Step 14. Remove the flywheel bolts, followed by the flywheel itself. 

Yamaha SxS engine rebuild teardown

Yamaha UTV engine rebuild teardown

Step 15. Remove the timing chain guides, then turn the engine upside down and remove the starter motor. 

Yamaha YXZ1000R engine teardown timing chain guides

Yamaha YXZ1000R engine teardown starter motor removal

Watch the clip below to see the rotor, flywheel and output shaft removal segments of our Yamaha YXZ1000R engine teardown video.

Yamaha YXZ1000R Engine Teardown - Remove the Oil Pump

Step 16. Remove the 5mm Allens from the oil pump cover, then carefully pry the cover off.

Yamaha YXZ1000R engine teardown oil pump cover

Yamaha YXZ1000R engine teardown oil pump cover removed

Step 17. Remove the oil pump assembly.

Yamaha YXZ1000R engine teardown oil pump assembly removal

Yamaha YXZ1000R oil pump assembly removal

Yamaha YXZ1000R motor teardown

Yamaha YXZ1000R UTV motor teardown

Watch the clip below to see the oil pump removal segment of our Yamaha YXZ1000R engine teardown video.

Yamaha YXZ1000R Engine Teardown - Split the Crankcase

Step 18. Loosen the crankcase bolts out one half turn at a time, going from number 24 down to number 1 (as pictured below). Start with number 24 first, then work your way down in sequence. 

Yamaha YXZ1000R engine teardown crankcase bolts

Step 19. Remove the timing chain out of the way, then split the crankcase open carefully. Use a pry bar first (don’t pry on it too hard), then a dead blow hammer to tap it loose, and pull the crankcase apart. 

Yamaha YXZ1000R engine teardown crankcase splitting

Yamaha YXZ1000R engine crankcase splitting

Watch the clip below to see the crankcase splitting segment of our Yamaha YXZ1000R engine teardown video.

Yamaha YXZ1000R Engine Teardown - Remove the Pistons and Crankshaft

Step 20. Remove the connecting rod bolts and bearings, then pull the pistons out from the bottom of the crankcase one by one. 

Yamaha YXZ1000R engine connecting rod bearings

Yamaha YXZ1000R engine connecting rod removal

Yamaha YXZ1000R engine piston removal

Step 21. Lift out and remove the crankshaft. 

Yamaha YXZ1000R engine crankshaft removal

Step 22. Remove the counterbalance, which is held in by a bolt on either side that has a tab you need to bend to remove it. You’ll also need to remove the water pump assembly on the other side to get the counterbalance out.

Yamaha YXZ1000R engine counterbalance

Yamaha YXZ1000R engine counterbalance removal

PRO TIP: Use a small piece of wood to keep the counterbalance from rotating while you’re disassembling its components.

Yamaha YXZ1000R engine water pump removal

Yamaha YXZ1000R engine teardown water pump removal

Yamaha YXZ1000R UTV engine teardown counterbalance removal

Yamaha YXZ1000R side by side engine teardown counterbalance removal

Step 23. Remove all the bearings, O-rings, cooling line, dowels and any other components left on the crankcase.  

Yamaha YXZ1000R side by side engine teardown bearings removal

PRO TIP: Use a blind bearing puller kit to remove the remaining bearings from the crankcase. 

Yamaha YXZ1000R side by side engine teardown O-ring removal

Yamaha YXZ1000R side by side engine teardown crankcase parts removal

Yamaha YXZ1000R side by side engine teardown dowels removal

PRO TIP: Use a dowel pin puller tool to remove the dowels from the crankcase.

Watch the clip below to see the pistons and crankshaft removal segment of our Yamaha YXZ1000R engine teardown video.