Yamaha YZF-R1K Manuals

Manuals and User Guides for Yamaha YZF-R1K. We have 1 Yamaha YZF-R1K manual available for free PDF download: Service Manual

Yamaha YZF-R1K Service Manual

Yamaha YZF-R1K Service Manual (398 pages)

Brand: Yamaha | Category: Motorcycle | Size: 19.83 MB

Table of Contents

Important Manual Information
3
How to Use this Manual
4
Table of Contents
7
Motorcycle Identification

18
- Vehicle Identification Number
  18
- Model Code
  18
Chapter 1. General Information

18
Important Information

19
- Preparation for Removal and Disassembly
  19
- Replacement Parts
  19
- Gaskets, Oil Seals and O-Rings
  19
- Using a Dynamometer
  20
- Lock Washers/Plates and Cotter Pins
  20
- Bearings and Oil Seals
  20
- Circlips
  20
Checking the Connections

21
Special Tools

22
General Specifications

26
Chapter 2. Specifications

26
Engine Specifications

27
Chassis Specifications

36
Electrical Specifications

40
Tightening Torques

43
Lubrication Points and Lubricant Types

48
- Engine Lubrication Points and Lubricant Types
  48
- Chassis Lubrication Points and Lubricant Types
  49
Oil Flow Diagrams

50
Coolant Flow Diagrams

54
Cable Routing

58
Introduction

69
Periodic Maintenance Chart for Emission Control System

69
Chapter 3. Periodic Checks and Adjustments

69
Adj

69
General Maintenance and Lubrication Chart

70
Seats

72
Fuel Tank

73
Cowlings

74
- Removal
  75
- Installation
  75
Air Filter Case and Ignition Coil Plate

76
- Removal
  77
- Installation
  77
Engine

78
- Adjusting the Valve Clearance
  78
- Valve Pad Selection Table
  82
- Synchronizing the Carburetors
  83
- Adjusting the Engine Idling Speed
  85
- Adjusting the Throttle Cable Free Play
  87
- Checking the Spark Plugs
  89
- Checking the Ignition Timing
  90
- Measuring the Compression Pressure
  91
- Checking the Engine Oil Level
  93
- Changing the Engine Oil
  94
- Adjusting the Clutch Cable Free Play
  97
- Cleaning the Air Filter Element
  98
- Checking the Carburetor Joints
  98
- Checking the Fuel Hoses and Fuel Filter
  99
- Checking the Crankcase Breather Hose
  100
- Checking the Exhaust System
  100
- Adjusting the Exup Cables
  101
- Checking the Coolant Level
  102
- Checking the Cooling System
  103
- Changing the Coolant
  104
Chassis

107
- Adjusting the Front Brake
  107
- Adjusting the Rear Brake
  107
- Checking the Brake Fluid Level
  109
- Checking the Brake Pads
  110
- Adjusting the Rear Brake Light Switch
  110
- Checking the Brake Hoses
  111
- Bleeding the Hydraulic Brake System
  111
- Adjusting the Shift Pedal
  113
- Adjusting the Drive Chain Slack
  113
- Lubricating the Drive Chain
  115
- Checking and Adjusting the Steering Head
  115
- Checking the Front Fork
  118
- Adjusting the Front Fork Legs
  119
- Adjusting the Rear Shock Absorber Assembly
  121
- Checking the Tires
  123
- Checking the Wheels
  125
- Checking and Lubricating the Cables
  126
- Lubricating the Levers and Pedals
  126
- Lubricating the Sidestand
  126
- Lubricating the Rear Suspension
  126
Electrical System

127
- Checking and Charging the Battery
  127
- Checking the Fuses
  132
- Replacing the Headlight Bulbs
  134
- Adjusting the Headlight Beams
  135
Engine

136
- Installing the Engine
  142
Chapter 4. Overhauling the Engine

136
Camshafts

143
- Removing the Camshafts
  146
- Checking the Camshafts
  147
- And Timing Chain Guides
  148
- Checking the Timing Chain Tensioner
  149
- Installing the Camshafts
  150
Cylinder Head

153
- Removing the Cylinder Head
  154
- Checking the Cylinder Head
  154
- Installing the Cylinder Head
  155
Valves and Valve Springs

156
- Removing the Valves
  158
- Checking the Valves and Valve Guides
  159
- Checking the Valve Seats
  161
- Checking the Valve Springs
  163
- Checking the Valve Lifters
  164
- Installing the Valves
  164
Generator

167
- Removing the Generator
  168
- Installing the Generator
  168
Pickup Coil

170
- Removing the Pickup Coil Rotor
  172
- Installing the Pickup Coil Rotor
  172
Clutch

174
- Removing the Clutch
  178
- Checking the Friction Plates
  178
- Checking the Clutch Plates
  179
- Checking the Clutch Spring Plate
  179
- Checking the Clutch Housing
  179
- Checking the Clutch Boss
  180
- Checking the Pressure Plate
  180
- Checking the Pull Lever Shaft and Pull Rod
  180
- Checking the Starter Clutch
  180
- Installing the Clutch
  181
Shift Shaft

184
- Checking the Shift Shaft
  185
- Checking the Stopper Lever
  185
- Installing the Shift Shaft
  185
Oil Pan and Oil Pump

186
- Removing the Oil Pan
  189
- Checking the Oil Pump
  189
- Checking the Relief Valve
  190
- Checking the Oil Delivery Pipe and Oil Pipe
  190
- Checking the Oil Strainer
  190
- Assembling the Oil Pump
  190
- Installing the Oil Pump
  191
- Installing the Oil Strainer
  191
- Installing the Oil Pan
  191
Crankcase

192
- Disassembling the Crankcase
  195
- Checking the Crankcase
  196
- Checking the Bearings and Oil Seals
  196
- Checking the Sprockets and Chains
  196
- Assembling the Crankcase
  197
Connecting Rods and Pistons

199
Crankshaft

209
- Removing the Crankshaft
  210
- Checking the Crankshaft
  210
- Checking the Crankshaft Journal Bearings
  210
- Installing the Crankshaft
  213
Transmission

214
- Removing the Transmission
  220
- Checking the Shift Forks
  220
- Checking the Shift Drum Assembly
  221
- Checking the Transmission
  221
- Installing the Transmission
  222
Radiator

223
- Checking the Radiator
  225
- Installing the Radiator
  226
Chapter 5. Cooling System

223
Oil Cooler

227
- Checking the Oil Cooler
  228
- Installing the Oil Cooler
  228
Thermostat Assembly

230
Water Pump

235
Cool

235
- Disassembling the Water Pump
  237
- Checking the Water Pump
  237
- Assembling the Water Pump
  238
Carburetors

240
- Checking the Carburetors
  245
- Assembling the Carburetors
  247
- Installing the Carburetors
  249
- Measuring and Adjusting the Fuel Level
  250
- Checking and Adjusting the Throttle Position Sensor
  251
- Checking the Fuel Pump
  254
Chapter 6. Carburetors

240
Carb

240
Front Wheel and Brake Discs

255
- Removing the Front Wheel
  257
- Disassembling the Front Wheel
  257
- Checking the Front Wheel
  258
- Checking the Brake Discs
  259
- Assembling the Front Wheel
  260
- Installing the Front Wheel
  261
- Adjusting the Front Wheel Static Balance
  261
Chapter 7. Chassis

255
Rear Wheel, Brake Disc, and Rear Wheel Sprocket

264
- Removing the Rear Wheel
  267
- Checking the Rear Wheel
  267
- Checking the Rear Wheel Drive Hub
  268
- Checking and Replacing the Rear Wheel Sprocket
  268
- Installing the Rear Wheel
  269
- Adjusting the Rear Wheel Static Balance
  269
Front and Rear Brakes

270
Front Fork

298
- Removing the Front Fork Legs
  301
- Disassembling the Front Fork Legs
  301
- Checking the Front Fork Legs
  303
- Assembling the Front Fork Legs
  304
- Installing the Front Fork Legs
  309
Handlebars

310
- Removing the Handlebars
  312
- Checking the Handlebars
  312
- Installing the Handlebars
  313
Steering Head

315
- Removing the Lower Bracket
  317
- Checking the Steering Head
  317
- Installing the Steering Head
  318
Rear Shock Absorber Assembly

320
Swingarm and Drive Chain

324
- Removing the Swingarm
  326
- Removing the Drive Chain
  327
- Checking the Swingarm
  327
- Checking the Drive Chain
  328
- Installing the Swingarm
  330
Chapter 8

331
Electrical Components

331
Instrument Functions

332
- Indicator Lights
  332
- Oil Level/Coolant Temperature Warning Light
  332
- Combination Meter
  333
Switches

335
- Checking Switch Continuity
  335
Checking the Switches

336
Checking the Bulbs and Bulb Sockets

338
- Types of Bulbs
  338
- Checking the Condition of the Bulbs
  338
- Checking the Condition of the Bulb Sockets
  340
- CHECKING the Leds
  340
Ignition System

341
- Circuit Diagram
  341
- Troubleshooting
  342
Electric Starting System

346
- Circuit Diagram
  346
- Starting Circuit Cutoff System Operation
  347
- Troubleshooting
  348
Starter Motor

352
- Checking the Starter Motor
  354
- Assembling the Starter Motor
  355
Charging System

356
- Circuit Diagram
  356
- Troubleshooting
  357
Lighting System

359
- Circuit Diagram
  359
- Troubleshooting
  360
- Checking the Lighting System
  361
Signaling System

365
- Circuit Diagram
  365
- Troubleshooting
  367
- Checking the Signaling System
  368
Cooling System

374
- Circuit Diagram
  374
- Troubleshooting
  375
Fuel Pump System

378
- Circuit Diagram
  378
- Fuel Pump Circuit Operation
  379
- Troubleshooting
  380
- Checking the Fuel Pump
  382
Exup System

383
- Circuit Diagram
  383
- Troubleshooting
  384
Self-Diagnosis

387
- Troubleshooting
  392
Chapter 9

392
- Engine
  392
- Fuel System
  392
- Electrical Systems
  392
Starting Problems

392
Incorrect Engine Idling Speed

393
- Engine
  393
- Fuel System
  393
- Electrical Systems
  393
Poor Medium-And-High-Speed Performance

393
Faulty Gear Shifting

393
- Shifting Is Difficult
  393
- Shift Pedal Does Not Move
  393
- Jumps out of Gear
  393
Overcooling

394
Faulty Clutch

394
- Clutch Slips
  394
- Clutch Drags
  394
Overheating

394
- Engine
  394
- Cooling System
  394
- Fuel System
  394
- Chassis
  394
- Electrical Systems
  394
Poor Braking Performance

395
Faulty Front Fork Legs

395
- Leaking Oil
  395
- Malfunction
  395
Unstable Handling

395
Faulty Lighting and Signaling Systems

396
- Headlight Does Not Light
  396
- Headlight Bulb Burnt out
  396
- Tail/Brake Light Does Not Light
  396
- Tail/Brake Light Bulb Burnt out
  396
- Turn Signal Does Not Light
  396
- Turn Signal Blinks Slowly
  396
- Turn Signal Remains Lit
  396
- Turn Signal Blinks Quickly
  396
- Horn Does Not Sound
  396

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