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YZF-R1 98
Yamaha YZF-R1 98 Manuals
Manuals and User Guides for Yamaha YZF-R1 98. We have
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Yamaha YZF-R1 98 manual available for free PDF download: Service Manual
Yamaha YZF-R1 98 Service Manual (419 pages)
Brand:
Yamaha
| Category:
Motorcycle
| Size: 9.47 MB
Table of Contents
Chapter 2
3
Manual Information
3
Specifications
3
How to Use this Manual
4
Symbols
5
Chapter Titles
6
Troubleshooting Trbl
6
Table of Contents
8
General Information
8
Chapter 1
10
General Information
10
Motorcycle Identification
10
Vehicle Identification Number
10
Model Code
10
Important Information
11
Preparation for Removal and Disassembly
11
Replacement Parts
11
Gaskets, Oil Seals and O-Rings
11
Using a Dynamometer
12
Lock Washers/Plates and Cotter Pins
12
Bearings and Coiil Seals
12
Circlips
12
Checking the Connections
13
Special Tools
14
Specifications
19
General Specifications
21
Engine Specifications
22
Chassis Specifications
31
Electrical Specifications
35
Conversion Table
38
General Tightening Torques
38
Engine Tightening Torques
39
Crankcase Tightening Sequence
41
Chassis Tightening Torques
42
Engine Lubrication Points and Lubricant Types
43
Chassis Lubrication Points and Lubricant Types
44
Oil Flow Diagrams
45
Coolant Flow Diagrams
49
Cable Routing
53
Periodic Checks and Adjustments
66
Introduction
68
Periodic Maintenance and Lubrication Intervals
68
Chapter 3
68
Periodic Checks and Adjustments
68
Seats
70
Fuel Tank
71
Cowlings
72
Removal
73
Installation
73
Air Filter Case and Ignition Coil Plate
74
Removal
75
Installation
75
Engine
76
Adjusting the Valve Clearance
76
Valve Pad Selection Table
80
Exhaust
80
Intake
80
Synchronizing the Carburetors
81
Adjusting the Engine Idling Speed
83
Adjusting the Throttle Cable Free Play
85
Handlebar Side
86
Checking the Spark Plugs
87
Checking the Ignition Timing
88
Measuring the Compression Pressure
89
Checking the Engine Oil Level
91
Changing the Engine Oil
92
Adjusting the Clutch Cable Free Play
95
Engine Side
95
Checking the Carburetor Joints
96
Cleaning the Air Filter Element
96
Checking the Crankcase Breather Hose
97
Checking the Fuel Hoses and Fuel Filter
97
Checking the Crankcase Breather Hose
98
Checking the Exhaust System
98
Adjusting the Exup Cables
99
Checking the Coolant Level
100
Checking the Cooling System
101
Changing the Coolant
102
Adjusing the Front Brake
105
Adjusting the Rear Brake
105
Chassis
105
Checking the Brake Fluid Level
107
Adjusting the Rear Brake Light Switch
108
Checking the Brake Pads
108
Bleeding the Hydraulic Brake System
109
Checking the Brake Hoses
109
Adjusting the Drive Chain Slack
111
Adjusting the Shift Pedal
111
Checking and Adjusting the Steering Head
113
Lubricating the Drive Chain
113
Checking the Front Fork
116
Adjusting the Front Fork Legs
117
Spring Preload
117
Compression Damping
118
Rebound Damping
118
Adjusting the Rear Shock Absorber Assembly
119
Checking the Tires
121
Checking the Wheels
123
Checking and Lubricating the Cables
124
Lubricating the Levers and Pedals
124
Lubricating the Rear Suspension
124
Lubricating the Sidestand
124
Checking and Charging the Battery
125
Electrical System
125
First Aid in Case of Bodily Contact
125
Charging Method Using a Variable-Voltage Charger
128
Charging Method Using a Constant-Voltage Charger
129
Checking the Fuses
130
Replacing the Headlight Bulbs
132
Adjusting the Headlight Beams
133
Overhauling the Engine
135
Chapter 4
137
Overhauling the Engine
137
Engine
137
Installing the Engine
143
Cam Shaft
144
Removing the Camshafts
145
Removing the Camshafts
147
Checking the Camshafts
148
Checking the Timing Chain, Cam Shaft Sprockets and Timing Chain Guides
149
Checking the Timing Chain Tensioner
150
Installing the Cam Shafts
151
Cylinder Head
154
Removing the Cylinder Head
154
Checking the Cylinder Head
155
Removing the Cylinder Head
155
Installing the Cylinder Head
156
Valves and Valve Springs
157
Removing the Valves
159
Checking the Valves and Valve Guides
160
Checking the Valve Seats
162
Checking the Valve Springs
164
Checking the Valve Lifters
165
Installing the Valves
165
Generator
168
Installing the Generator
169
Removing the Generator
169
Pickup Coil
171
Installing the Pickup Coil Rotor
173
Removing the Pickup Coil Rotor
173
Clutch
175
Removing the Clutch
177
Checking the Friction Plates
179
Removing the Clutch
179
Chcking the Clutch Plates
180
Checking the Clutch Housing
180
Checking the Clutch Spring Plate
180
Checking the Clutch Boss
181
Checking the Pressure Plate
181
Checking the Pull Lever Shaft and Pull Rod
181
Checking the Starter Clutch
181
Installing the Clutch
182
Shift Shaft
185
Checking the Shift Shaft
186
Checking the Stopper Lever
186
Installing the Shift Shaft
186
Oil Pan and Oil Pump
187
Removing the Oil Pan
187
Checking the Oil Pump
190
Removing the Oil Pan
190
Assembling the Oil Pump
191
Checking the Oil Delivery Pipe and Oil Pipe
191
Checking the Oil Strainer
191
Checking the Relief Valve
191
Installing the Oil Pan
192
Installing the Oil Pump
192
Installing the Oil Strainer
192
Crankcase
193
Disassembling the Crankcase
196
Checking the Bearings and Oil Seals
197
Checking the Sprockets and Chains
197
Cheking the Crankcase
197
Assembling the Crankcase
198
Connecting Rods and Pistons
200
Removing the Connecting Rods and Pistons
200
Removing the Connecting Rods and Pistons
201
Checking the Cylinders and Pistons
202
Checking the Piston Rings
203
Checking the Piston Pins
204
Checking the Big End Bearings
205
Installing the Pistons and Connecting Rods
207
Removing the Crankshaft
210
Checking the Crankshaft Journal Bearings
211
Removing the Crankshaft
211
Crankshaft Journal Bearing Color Code
213
Installing the Crankshaft
214
Removing the Transmission
215
Checking the Shift Forks
221
Removing the Transmission
221
Checking the Shift Drum Assembly
222
Checking the Transmission
222
Installing the Transmission
223
Cooling System
226
Radiator
228
Checking the Radiator
230
Installing the Radiator
231
Oil Cooler
232
Checking the Oil Cooler
233
Installing the Oil Cooler
233
Thermostat Assembly
235
Assembling the Thermostat Assembly
238
Checking the Thermostat
238
Installing the Thermostat Assembly
239
Water Pump
240
Checking the Water Pump
242
Disassembling the Water Pump
242
Assembling the Water Pump
243
Carburetors
247
Checking the Carburetors
254
Assembling the Carburetors
256
Installing the Carburetors
258
Measuring and Adjusting the Fuel Level
259
Checking and Adjusting the Throttle Position Sensor
260
Checking the Fuel Pump
263
Chapter 7. Chassis
268
Front Wheel and Brake Discs
268
Disassembling the Front Wheel
269
Disassembling the Front Wheel
270
Removing the Front Wheel
270
Checking the Front Wheel
271
Checking the Brake Discs
272
Assembling the Front Wheel
273
Adjusting the Front Wheel Static Balance
274
Installing the Front Wheel
274
Rear Wheel, Brake Disc, and Rear Wheel Sprocket
277
Removing the Rear Wheel
277
Checking the Rear Wheel
280
Removing the Rear Wheel
280
Checking and Replacing the Rear Wheel Sprocket
281
Checking the Rear Wheel Drive Hub
281
Adjusting the Rear Wheel Static Balance
282
Installing the Rear Wheel
282
Front and Rear Brakes
283
Replacing the Front Brake Pads
285
Replacing the Rear Brake Pads
287
Disassembling the Front Brake Master Cylinder
292
Disassembling the Rear Brake Master Cylinder
294
Checking the Front and Rear Brake Master Cylinder
295
Disassembling the Front Brake Master Cylinder
295
Disassembling the Rear Brake Master Cylinder
295
Master Cylinders
295
Assembling and Installing the Front Brake Master Cylinder
296
Assembling the Rear Brake Master Cylinder
298
Disassembling the Front Brake Calipers
301
Disassembling the Rear Brake Caliper
303
Disassembling the Fornt Brake Calipers
304
Disassembling the Rear Brake Caliper
305
Checking the Front and Rear Brake Calipers
306
Assembling and Installing the Front Brake Calipers
307
Assembling and Installing the Rear Brake Caliper
309
Front Fork
311
Removing the Front Fork Legs
311
Disassembling the Front Fork Legs
314
Removing the Front Fork Legs
314
Checking the Front Fork Legs
316
Assembling the Front Fork Legs
317
Installing the Front Fork Legs
322
Removing the Handlebars
323
Checking the Handlebars
325
Removing the Handlebars
325
Installing the Handlebars
326
Removing the Lower Bracket
328
Steering Head
328
Checking the Steering Head
330
Removing the Lower Bracket
330
Installiing the Steering Head
331
Rear Shock Absorber Assembly
333
Disposing of a Rear Shock Absorber and Gas Cylinder
334
Handling the Rear Shock Absorberband Gas Cylinder
334
Checking the Rear Shock Absorber Assembly and Gas Cylinder
335
Removing the Rear Shock Absorber Assembly
335
Checking the Relay Arm and Connecting Arm
336
Installing the Rear Shock Absorber Assembly
336
Swingarm and Drive Chain
337
Removing the Swingarm
339
Checking the Swingarm
340
Removing the Drive Chain
340
Checking the Drive Chain
341
Installing the Swingarm
343
Electrical
345
Chapter 8
347
Electrical Components
347
Instrument Functions
348
Indicator Lights
348
Oil Level/Coolant Temperature Warning Light
348
Combination Meter
349
Odometer and Trip Meters
349
Clock
350
Checking Switch Continuity
351
Switches
351
Checking the Switches
352
Checking the Bulbs and Bulb Sockets
354
Checking the Condition of the Bulbs
354
Types of Bulbs
354
Checking the Condition of the Bulb Sockets
356
Checking the Leds
356
Circuit Diagram
357
Ignition System
357
Troubleshooting
358
Circuit Diagram
362
Electric Starting System
362
Starting Circuit Cutoff System Operation
363
Troubleshooting
364
Starter Motor
368
Checking the Starter Motor
370
Assembling the Starter Motor
371
Charging System
372
Circuit Diagram
372
Circuit Diagram
375
Lighting System
375
Circuit Diagram
381
Signaling System
381
Checking the Signaling System
384
Circuit Diagram
390
Cooling System
390
Circuit Diagram
394
Fuel Pump System
394
Fuel Pump Circuit Operation
395
Circuit Diagram
399
Exup System
399
Self-Diagnosis
403
Self-Diagnosis
404
Throttle Position Sensor
404
Exup
405
Fuel Level Indicator Light
406
Fuel Sender
406
Electrical Systems
412
Fuel System
412
Troubleshooting
412
Electrical Systems
413
Faulty Gear Shifting
413
Fuel System
413
Incorrect Engine Idling Speed
413
Jumps out of Gear
413
Poor Medium-And-High-Speed Performance
413
Shift Pedal Does Not Move
413
Shifting Is Difficult
413
Starting Problems
413
Chassis
414
Clutch Drags
414
Clutch Slips
414
Cooling System
414
Electrical Systems
414
Engine
414
Faulty Clutch
414
Fuel System
414
Overcooling
414
Overheating
414
Starting Problems
412
Faulty Front Fork Legs
415
Poor Braking Performance
415
Unstable Handling
415
Faulty Lighting and Signaling Systems
416
Wiring Diagram
418
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