Yamaha FZR400 1988-1989 Manuals

Manuals and User Guides for Yamaha FZR400 1988-1989. We have 1 Yamaha FZR400 1988-1989 manual available for free PDF download: Service Manual

Yamaha FZR400 1988-1989 Service Manual

Yamaha FZR400 1988-1989 Service Manual (477 pages)

Brand: Yamaha | Category: Motorcycle | Size: 28.33 MB

Table of Contents

Table of Contents

3
- Chapter 3
  
  4
  - Periodic Inspection and Adjustment
    4
  - Cooling System
    7
Table of Contents

10
- Chapter 1
  
  11
  - Motorcycle Identification
    11
  - Vehicle Identification Number
    11
  - Engine Serial Number
    12
  - General Information
    12
  - Specifications
    13
    
    General Specifications
    13
    
    Chassis
    14
    
    Maintenance Specifications
    14
    
    Tightening Torque
    15
    
    Definition of Units
    16
    
    General Torque Specifications
    16
  - Periodic Inspections and Adjustments
    17
    
    Drive Chain Slack Adjustment
    17
  - Chassis
    19
    
    Rearwheel
    20
    
    Removal
    20
    
    Inspection
    21
    
    Installation
    21
    
    Static Wheel Balance Adjustment
    22
    
    Front and Rear Brake
    23
    
    Brake Pad Replacement
    25
    
    Caliper Disassembly
    30
    
    Master Cylinder Disassembly
    32
    
    Inspection and Repair
    34
    
    Assembly
    37
Table of Contents

44
- Motorcycle Identification
  52
  - Engine Serial Number
    52
  - Vehicle Identification Number
    52
- Important Information
  53
  - All Replacement Parts
    53
  - Gaskets, Oil Seals, and O-Rings
    53
  - Preparation for Removal
    53
  - Bearings and Oil Seals
    54
  - Circlips
    54
  - Lock Washers/Plates and Cotter Pins
    54
- Special Tools
  55
  - For Tune up
    55
  - For Engine Service
    56
  - For Chassis Service
    59
  - For Electrical Components
    60
- Chapter 2. Specifications
  
  61
  - Specifications
    61
    
    Engine
    61
    
    General Specifications
    61
    
    General Torque Specifications
    62
    
    Maintenance Specifications
    70
    
    Chassis
    71
    
    Electrical
    74
    
    Definition of Units
    76
    
    General Torque Specifications
    76
    
    Lubrication Point and Grade of Lubricant
    77
  - Lubrication Diagram
    79
  - Coolant Diagram
    80
  - Cable Routing
    88
    
    Maintenance Intervals Chart
    89
    
    Cowling Removal and Installation
    92
    
    Engine
    95
    
    Valve Clearance Adjustment
    96
    
    Valve Clearance Adjustment
    98
    
    Carburetor Synchronization
    103
    
    Idle Speed Adjustment
    105
    
    Throttle Cable Free Play Adjustment
    106
    
    Spark Plug Inspection
    107
    
    Ignition Timing Check
    108
    
    Compression Pressure Measurement
    109
    
    Engine Oil Level Inspection
    111
    
    Engine Oil Replacement
    111
    
    Engine Oil Filter Replacement
    112
    
    Clutch Adjustment
    114
    
    Air Filter Cleaning
    115
    
    Crankcase Ventilation Hose Inspection
    116
    
    Coolant Level Inspection
    117
    
    Coolant Replacement
    118
    
    Chassis
    120
    
    Brake Fluid Inspection
    121
    
    Brake Hose Inspection
    122
    
    Drive Chain Slack Adjustment
    123
    
    Drive Chain Lubrication
    125
    
    Steering Head Inspection
    127
    
    Front Fork Inspection
    128
    
    Rear Shock Absorber Adjustment
    128
    
    Tire Inspection
    129
    
    Wheel Inspection
    130
    
    Cable Inspection
    131
    
    Electrical
    132
    
    Battery Inspection
    133
    
    Fuse Inspection
    134
    
    Headlight Bulb Replacement
    135
    
    Tail/Brake Bulb Replacement
    136
    
    Air Filter Case and Carburetor
    137
    
    Coolant
    137
    
    Engine Oil
    137
    
    Engine Removal
    137
    
    Fuel Tank
    137
    
    Lower Cowling, Center Cowling, Upper Cowling and Top Cover
    137
- Chapter 4
  
  137
  - Engine Overhaul
    137
    
    Muffler Assembly
    138
    
    Radiator
    138
    
    Engine Disassembly
    139
    
    Clutch Cable and Drive Chain
    140
    
    Engine Removal
    140
    
    Leads
    140
    
    Engine Removal
    141
  - Engine Disassembly
    143
    
    Cylinder Head
    143
    
    Cylinder and Piston
    146
    
    Starter Clutch
    148
    
    Clutch
    149
    
    A.C. Magneto
    150
    
    Water Pump
    151
    
    Oil Pump and Shift Shaft
    152
    
    Oil Pan and Oil Strainer
    153
    
    Starter Motor
    154
    
    Transmission, Shifter and Shift Cam
    155
    
    Crankshaft
    156
    
    Valve Pad and Valve
    157
    
    Connecting Rod
    159
    
    Inner Rotor (Oil Pump)
    159
  - Inspection and Repair
    160
    
    Cylinder Head
    160
    
    Valve
    161
    
    Valve Guide
    162
    
    Valve Seat
    163
    
    Valve Spring
    166
    
    Camshaft, Cam Chain and Cam Sprocket
    167
    
    Valve Lifter
    167
    
    Cylinder and Piston
    169
  - Piston Ring and Piston Pin
    171
  - Crankshaft and Connecting Rod
    173
  - Starter Clutch
    179
  - Clutch
    180
  - Transmission
    182
  - Bearing and Oil Seal
    183
  - Crankcase
    183
  - Relief Valve and Pipe
    183
  - Connecting Rod
    185
  - Engine Assembly and Adjustment
    185
  - Inner Rotor (Oil Pump)
    185
  - Crankshaft
    186
  - Valve Pad and Valve
    187
  - Crankcase
    190
  - Transmission
    191
  - Transmission, Shifter and Shift Cam
    192
  - Crankcase Assembly
    193
  - Oil Pan and Oilstrainer
    195
  - Starter Motor
    195
  - Oil Pump and Shift Shaft
    196
  - A.C. Magneto
    197
  - Clutch
    199
  - Starter Clutch
    201
  - Piston and Cylinder
    203
  - Cylinder Head and Camshaft
    206
  - Cam Chain Tensioner
    211
  - Remounting Engine
    212
  - YAMAHA EXHAUST VARIABLE VALVE (for California Only)
    214
    
    Front Wheel
    238
    
    Front Fork
    265
    
    Steering Head
    281
    
    Rear Shock Absorber and Swingarm
    285
    
    Circuit Diagram
    297
    
    Electrical Components
    298
    
    Ignition System
    306
    
    Electric Starting System
    316
    
    Charging System
    327
    
    Lighting System
    333
    
    Signal System
    346
    
    Fuel System
    373
  - Meter Assembly
    382
  - Troubleshooting
    385
- Chapter 9
  
  387
  - Poor Idle Speed Performance
    387
  - Faulty Gear Shifting
    388
  - Poor Medium and High Speed Performance
    388
  - Clutch Slipping/Dragging
    389
  - Faulty Brake
    391
  - Front Fork Oil Leakage/Malfunction
    391
  - Instable Handling
    392
Introduction

398
- FOX RACING SHOX History
  399
- General Information
  399
- Warranty
  399
- Methods of Shipping
  400
- Optional Springs
  400
- Replacement Parts
  400
- Return Policy
  400
- Service
  400
  - Methods of Payment
    400
- Valving Warranty
  400
- Disclaimer
  401
- Installation and Basic Set-Up Instructions
  401
- International Orders
  401
- Tuning Instructions
  403
  - Spring Preload
    403
  - Ride Height / Shock Length Adjustment (if Equipped)
    403
  - When to Adjust Ride Height Vs. Spring Preload
    404
  - Damping
    405
- Maintenance Checklist
  407
  - Other Maintenance Considerations
    407
    
    Cylinder Head
    413
    
    Water Pump
    419
    
    Oil Pump
    422
    
    Oil Filter
    423
    
    Air Filter
    424

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