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YZF1000D 2020
Service manual
Yamaha YZF1000D 2020 Service Manual
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Contents
Table of Contents
Bookmarks
Table of Contents
Table of Contents
General Information
Identification
Vehicle Identification Number
Model Label
Glossary
Display
Menu Screen
Basic Service Information
Electrical System
Special Tools
Specifications
General Specifications
Engine Specifications
Chassis Specifications
Electrical Specifications
Tightening Torques
Engine Tightening Torques
Chassis Tightening Torques
Cable Routing
Periodic Checks and Adjustments
General Maintenance and Lubrication Chart
Introduction
Periodic Maintenance
Periodic Maintenance Chart for the Emission Control System
CHECKING the FUEL LINE (Primary Injector)
CHECKING the FUEL LINE (Secondary Injector)
Checking the Vehicle Using the Yamaha Diagnostic Tool
Checking the Spark Plugs
Adjusting the Valve Clearance
Checking the Engine Idling Speed
Synchronizing the Throttle Bodies
Checking the Canister
Checking the Crankcase Breather Hose
Checking the Exhaust System
Checking the Throttle Body Joints
Adjusting the Exhaust Gas Volume
Checking the Air Induction System
Replacing the Air Filter Element
Adjusting the Clutch Lever Free Play
Checking the Brake Fluid Level
Checking the Brake Operation
Adjusting the Front Disc Brake
Checking the Front Brake Pads
Adjusting the Rear Disc Brake
Checking the Front Brake Hoses
Checking the Rear Brake Pads
Bleeding the Hydraulic Brake System (Abs)
Checking the Rear Brake Hose
Checking the Tires
Checking the Wheels
Checking the Swingarm Operation
Checking the Wheel Bearings
Drive Chain Slack
Lubricating the Swingarm Pivot
Checking and Adjusting the Steering Head
Lubricating the Drive Chain
Checking the Chassis Fasteners
Checking the Front Fork
Checking the Sidestand
Checking the Sidestand Switch
Checking the Steering Damper
Lubricating the Brake Lever
Lubricating the Clutch Lever
Lubricating the Pedal
Lubricating the Sidestand
Lubricating the Steering Head
ADJUSTING the FRONT FORK LEGS (for YZF-R1)
ADJUSTING the PRELOAD of the FRONT FORK LEGS (for YZF-R1M)
ADJUSTING the DAMPING FORCE of the FRONT FORK LEGS and REAR SHOCK ABSORBER ASSEMBLY (for YZF-R1M)
ADJUSTING the REAR SHOCK ABSORBER ASSEMBLY (for YZF-R1)
Checking the Rear Shock Absorber Assembly
ADJUSTING the PRELOAD of the REAR SHOCK ABSORBER ASSEMBLY (for YZF-R1M)
Changing the Engine Oil
Checking the Connecting Arm and Relay Arm
Checking the Engine Oil Level
Measuring the Engine Oil Pressure
Changing the Coolant
Checking the Coolant Level
Checking the Cooling System
Adjusting the Exup Cables
Adjusting the Rear Brake Light Switch
Checking the Front Brake Light Switch
Adjusting the Headlight Beams
Checking and Charging the Battery
Checking and Lubricating the Cables
Checking the Fuses
Checking the Throttle Grip
Chassis
General Chassis (1)
Installing the Imu
Removing the Rear Side Cover
Removing the Tail Cover
General Chassis (2)
Removing the Tail Cover
INSTALLING the CCU (for YZF-R1M)
CONNECTING to the CCU (for YZF-R1M)
Installing the Tail Cover
Installing the Rear Side Cover
Installing the Tail Cover
General Chassis (3)
Removing the Front Panel (Left)
Removing the Front Panel Cover (Left)
Removing the Front Panel (Right)
Removing the Front Panel Cover (Right)
Installing the Front Panel Cover (Left)
Installing the Front Panel (Left)
Installing the Front Panel Cover (Right)
Installing the Front Panel (Right)
General Chassis (4)
Removing the Front Upper Cowling
Installing the Front Upper Cowling
General Chassis (5)
Removing the Front Muffler Protector (Left)
Removing the Front Muffler Protector (Right)
REMOVING the FRONT SIDE COWLING (LEFT) (for YZF-R1)
REMOVING the FRONT SIDE COWLING (RIGHT) (for YZF-R1)
REMOVING the FRONT SIDE COWLING (LEFT) (for YZF-R1M)
REMOVING the FRONT SIDE COWLING (RIGHT) (for YZF-R1M)
INSTALLING the FRONT SIDE COWLING (RIGHT) (for YZF-R1)
INSTALLING the FRONT SIDE COWLING (LEFT) (for YZF-R1)
INSTALLING the FRONT SIDE COWLING (RIGHT) (for YZF-R1M)
INSTALLING the FRONT SIDE COWLING (LEFT) (for YZF-R1M)
Installing the Front Muffler Protector (Left)
Installing the Front Muffler Protector (Right)
General Chassis (6)
Removing the Side Cover (Left)
Removing the Side Cover (Right)
Installing the Side Cover (Left)
Installing the Side Cover (Right)
General Chassis (7)
Checking the Air Intake Duct Valve
Checking the Vacuum Line
Assembling the Air Intake Duct Assembly
Installing the Air Intake Duct Valve
General Chassis (8)
REMOVING the ECU (Engine Control Unit)
INSTALLING the ECU (Engine Control Unit)
General Chassis (9)
Front Wheel
Removing the Front Wheel
Disassembling the Front Wheel
Checking the Front Wheel
Assembling the Front Wheel
Maintenance of the Front Wheel Sensor and Sensor Rotor
Adjusting the Front Wheel Static Balance
Installing the Front Wheel (Disc Brake)
Rear Wheel
Removing the Rear Wheel
Disassembling the Rear Wheel
Checking the Rear Wheel
Checking the Rear Wheel Drive Hub
Checking and Replacing the Rear Wheel Sprocket
Checking the Rear Wheel Sprocket Bracket
Assembling the Rear Wheel
Maintenance of the Rear Wheel Sensor and Sensor Rotor
Adjusting the Rear Wheel Static Balance
Installing the Rear Wheel (Disc Brake)
Front Brake
Introduction
Checking the Front Brake Discs
Replacing the Front Brake Pads
Removing the Front Brake Calipers
Disassembling the Front Brake Calipers
Checking the Front Brake Calipers
Assembling the Front Brake Calipers
Installing the Front Brake Calipers
Removing the Front Brake Master Cylinder
Checking the Front Brake Master Cylinder
Assembling the Front Brake Master Cylinder
Installing the Front Brake Master Cylinder
Rear Brake
Introduction
Checking the Rear Brake Disc
Replacing the Rear Brake Pads
Removing the Rear Brake Caliper
Disassembling the Rear Brake Caliper
Checking the Rear Brake Caliper
Assembling the Rear Brake Caliper
Installing the Rear Brake Caliper
Removing the Rear Brake Master Cylinder
Checking the Rear Brake Master Cylinder
The Rear Brake Master Cylinder
Installing the Rear Brake Master Cylinder
ABS (Anti-Lock Brake System)
Abs Components Chart
Removing the Hydraulic Unit Assembly
Checking the Hydraulic Unit Assembly
Checking the Brake Pipes
Installing the Hydraulic Unit Assembly
Hydraulic Unit Operation Test
Checking the Abs Warning Light
Handlebars
Removing the Handlebars
Checking the Handlebars
Installing the Handlebars
FRONT FORK (for YZF-R1)
REMOVING the FRONT FORK LEGS (for YZF-R1)
DISASSEMBLING the FRONT FORK LEGS (for YZF-R1)
CHECKING the FRONT FORK LEGS (for YZF-R1)
ASSEMBLING the FRONT FORK LEGS (for YZF-R1)
INSTALLING the FRONT FORK LEGS (for YZF-R1)
FRONT FORK (for YZF-R1M)
HANDLING the FRONT FORK (for YZF-R1M)
DISPOSING of FRONT FORK LEG (for YZF-R1M)
REMOVING the FRONT FORK LEGS (for YZF-R1M)
DISASSEMBLING the FRONT FORK LEGS (for YZF-R1M)
CHECKING the FRONT FORK LEGS (for YZF-R1M)
ASSEMBLING the FRONT FORK LEGS (for YZF-R1M)
Installing the Front Fork Legs
Steering Head
Removing the Lower Bracket
Checking the Steering Head
Installing the Steering Head
Checking the Steering Damper
Rear Shock Absorber Assembly
Handling the Rear Shock Absorber
Disposing of a Rear Shock Absorber
Removing the Rear Shock Absorber Assembly
Disassembling the Rear Shock Absorber Assembly
Checking the Rear Shock Absorber Assembly
Checking the Connecting Arm and Relay Arm
Assembling the Rear Shock Absorber Assembly
Installing the Relay Arm
Installing the Rear Shock Absorber Assembly
Swingarm
Removing the Swingarm
Checking the Swingarm
Installing the Swingarm
Chain Drive
Removing the Drive Chain
Checking the Drive Chain
Checking the Drive Sprocket
Checking the Rear Wheel Sprocket
Checking the Rear Wheel Drive Hub
Installing the Drive Chain
Adjusting the Shift Pedal
Engine
Lubrication System Chart and Diagrams
Engine Oil Lubrication Chart
Lubrication Diagrams
Engine Inspection
Measure the Compression Pressure
Engine Removal
Removing the Engine
Installing the Engine
Installing the Exhaust Pipe and Muffler
Camshafts
Engine
Removing the Camshafts
Removing the Rocker Arms and Rocker Arm Shafts
Checking the Camshafts
Checking the Rocker Arms and Rocker Arm Shafts
Checking the Timing Chain and Camshaft Sprocket
Checking the Timing Chain Guides
Checking the Timing Chain Tensioner
Assembling the Timing Chain Cover
Installing the Rocker Arms and Rocker Arm Shafts
Installing the Timing Chain Cover
Installing the Camshafts
Cylinder Head
Removing the Cylinder Head
Checking the Cylinder Head
Installing the Cylinder Head
Valves and Valve Springs
Removing the Valves
Checking the Valves and Valve Guides
Checking the Valve Seats
Checking the Valve Springs
Checking the Valve Spring Seat
Installing the Valves
Generator
Removing the Generator
Installing the Generator
Starter Clutch
Removing the Starter Clutch
Checking the Starter Clutch
Installing the Starter Clutch
Electric Starter
Checking the Starter Motor
Assembling the Starter Motor
Oil Pump
Removing the Oil Pan
Checking the Sprocket and Chain
Checking the Oil Pump
Checking the Relief Valve
Checking the Oil Delivery Pipes
Checking the Oil Strainer
Assembling the Oil Pump
Installing the Oil Pump
Installing the Oil Pan
Clutch
Removing the Clutch
Checking the Friction Plates
Checking the Clutch Plates
Checking the Clutch Springs
Checking the Clutch Housing
Checking the Clutch Boss
Checking the Pressure Plate
Checking the Primary Drive Gear
Checking the Primary Driven Gear
Checking the Pull Lever Shaft and Pull Rod
Installing the Clutch
Shift Shaft
Checking the Shift Shaft
Checking the Stopper Lever
Installing the Shift Shaft
Crankcase
Disassembling the Crankcase
Checking the Crankcase
Assembling the Crankcase
Installing the Crankcase Breather Cover
Installing the Oil Pressure Switch
Installing the Gear Position Sensor
Connecting Rods and Pistons
Removing the Connecting Rods and Pistons
Checking the Cylinder and Piston
Checking the Piston Rings
Checking the Piston Pin
Checking the Connecting Rods
Installing the Connecting Rod and Piston
Crankshaft and Balancer Shaft
Removing the Crankshaft and Balancer Shaft
Checking the Oil Nozzles
Checking the Crankshaft
Checking the Balancer Shaft
Installing the Crankshaft
Installing the Thrust Bearing
Installing the Balancer Assembly
Transmission
Removing the Transmission
Checking the Shift Forks
Checking the Shift Drum Assembly
Checking the Transmission
Assembling the Main Axle and Drive Axle
Installing the Transmission
Cooling System
Fuel System
Electrical System
Self Diagnostic
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2020
SERVICE MANUAL
YZF-R1
YZF-R1M
YZF1000L
YZF1000
YZF1000DL
YZF1000D
B3L-28197-20
Table of
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Chapters
Table of Contents
7
Specifications
39
Periodic Checks and Adjustments
105
Chassis
145
Engine
281
Table of Contents
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