Yamaha YZF1000RJ Manuals

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Yamaha YZF1000RJ Service Manual

Yamaha YZF1000RJ Service Manual (407 pages)

Brand: Yamaha | Category: Motorcycle | Size: 15.46 MB

Table of Contents

Table of Contents
7
Engine Serial Number
16
General Information
16
Model Label
16
Motorcycle Identification
16
Vehicle Identification Number
16
Gaskets, Oil Seals and O-Rings
17
Importantinformation
17
Preparation.for Removal Procedures
17
Bearings and Oil Seals
18
Circlips
18
Lock Washers/Plates and Cotter Pins
18
For Tune-Up
19
Special Tools
19
For Engine Service
20
For Chassis Service
22
For Electrical Components
22
Chapter 2. Specifications

23
- General Specifications
  23
- Maintenance Specifications
  26
- Engine
  26
- Chassis
  35
- Electrical
  39
- How to Use the Conversion Table
  41
- General Torque Specifications
  41
- Lubrication Points and Lubricant Types
  42
- Engine
  42
- Chassis
  43
- Cooling System Diagrams
  44
- Lubrication Diagrams
  47
- Cable Routing
  51
- EMISSION HOSE ROUTING (California Only)
  58
Chapter 3. Periodic Inspections and Adjustments

60
- Introduction
  60
- Periodic Maintenance/Emission Control System
  60
- General Maintenance/Lubrication
  62
- Cowling
  63
- Removal
  65
- Installation
  66
- Seats
  67
- Removal
  67
- Installation
  67
- Fuel Tank
  68
- Removal
  68
- Installation
  69
- Engine
  70
- Valve Clearance Adjustment
  77
- Carburetor Synchronization
  79
- Idling,Speed Adjustment
  80
- Throttle Cable Adjustment
  81
- Spark Plug Inspection
  83
- Ignition Timing Check
  84
- Compression Pressure Measurement
  87
- Engine Oil Level Inspection
  88
- Engine Oil Replacement
  89
- Engine Oil Pressure Inspection
  91
- Clutch Adjustment
  92
- Clutch Fluid Level Inspection
  93
- Air Bleeding (Hydraulic Clutch System)
  94
- Air Filter Cleaning
  95
- Carburetor Joint Inspection
  96
- Fuel Line Inspection
  97
- Crankcase Breather Hose Inspection
  98
- Exup Cable Adjustment
  99
- Exhaust System Inspection
  100
- Coolant Level Inspection
  101
- Coolant Replacement
  101
- Cooling System Inspection
  105
- Chassis
  106
- Front Brake Adjustment
  106
- Rear Brake Adjustment
  106
- Brake Fluid Level Inspection
  108
- Brake Pad Inspection
  109
- Brake Light Switch Adjustment
  109
- Brake Hose Inspection
  110
- Air Bleeding (Hydraulic Brake System)
  110
- Shift Pedal Adjustment
  111
- Drive Chain Slack Adjustment
  112
- Drive Chain Lubrication
  114
- Steering Head Inspection
  116
- Front Fork Inspection
  117
- Front Fork Adjustment
  119
- Rear Shock Absorber Adjustment
  119
- Tire Inspection
  122
- Wheel Inspection
  124
- Cable Inspection and Lubrication
  124
- Lever and Pedal Lubrication
  125
- Sidestand Lubrication
  125
- Rear Suspension Lubrication
  125
- Electrical
  126
- Battery Inspection
  128
- Fuse Inspection
  132
- Headlight Beam Adjustment
  133
- Headlight Bulb Replacement
  134
Chapter 4. Engine

135
- Engine Removal
  135
- Fuel Tank and Cowlings
  135
- Engine Oil and Coolant
  135
- Battery Leads
  136
- Air Filter Case
  136
- Carburetors
  136
- Radiator
  136
- Hoses and Leads
  137
- Drive Sprocket
  137
- Water Jacket Joints and Water Pump
  138
- Ac Generator and Starter Motor
  139
- Muffler Assembly
  140
- Engine Removal
  140
- Engine Disassembl V
  143
- Oil Filter and Oil Cooler
  143
- Cylinder Head Cover, Cylinder Head and Camshafts
  144
- Cylinders and Pistons
  148
- Clutch
  149
- Oil Pan and Oil Strainer
  151
- Oil Pump and Shift Shaft
  153
- Crankcase Disassembly
  154
- Shift Forks and Shift Cam
  155
- Transmission
  156
- Valves and Camshaft Case
  157
- Connecting Rods
  159
- Oil Pump
  159
- Inspection and Repair
  160
- Cylinder Head
  160
- Valves and Valve Guides
  161
- Val Ve Sea Ts
  162
- Valve Springs
  164
- Camshaft Case
  165
- Valve Lifters
  165
- Camshafts
  165
- Timing Chain, Hy-Vo Chain, Camshaft Sprockets and Chain Guides
  167
- Timing Chain Tensioner
  167
- Cylinders and Pistons
  167
- Piston Rings
  169
- Piston Pins
  170
- Crankshaft and Connecting Rods
  170
- Oil Pump
  175
- Primary Drive
  176
- Starter Drives
  176
- Ac Generator Shaft
  177
- Clutch
  177
- Transmission and Shifter
  179
- Shift Shaft and Stopper Lever
  181
- Oil-Jet Nozzle
  181
- Relief Valve, Oil Pipe and Strainer
  182
- Oil Cooler
  183
- Crankcase
  183
- Bearings and Oil Seals
  183
- Circlips and Washers
  183
- Engine Assembl V and Adjustment
  184
- Oil Pump
  184
- Connecting Rods
  186
- Camshaft Case and Valves
  187
- Shift Cam and Shift Forks
  194
- Shift Shaft and Oil Pump
  198
- Oil Pan and Oil Strainer
  199
- Clutch
  201
- Pistons and Cylinders
  205
- Cylinder Head and Camshafts
  210
- Timing Chain Tensioner
  211
- Oil Cooler and Oil Filter
  215
- Engine Remounting
  216
Chapter 5. Cooling

224
- Radiator/Oil Cooler
  224
- Radiator
  225
- Removal
  225
- Inspection
  227
- Installation
  228
- Oil Cooler
  229
- Removal
  229
- Inspection
  229
- Installation
  230
- Thermostatic Valve/Water Pump
  231
- Thermostatic Valve
  232
- Removal
  232
- Inspection
  233
- Installation
  234
- Water Pump
  236
- Removal
  236
- Inspection
  237
- Installation
  240
Chapter 6 . Carburetion

242
- Carburetors
  242
- Removal
  244
- Disassembly
  246
- Inspection
  248
- Assembly
  253
- Fuel Level Aojustment
  253
- And Inspection
  254
- Front Wheel
  256
- Removal
  257
- Inspection
  258
- Installation
  259
- Front Wheel Static Balance Adjustment
  260
- Rear Wheel
  263
- Removal
  263
- Inspection
  264
- Installation
  264
- Front and Rear Brakes
  265
- Front Brake
  265
- Rear Brake
  266
- Brake Caliper Disassembly
  271
- Inspection and Repair
  275
- Master Cylinder Assembly
  277
- Hydraulic Clutch
  288
- Inspection and Repair
  291
- Assembly
  292
- Front Fork
  296
- Removal
  297
- Inspection
  300
- Assembly
  306
- Installation
  306
- Steering Head and Handlebars
  308
- Removal
  309
- Inspection
  312
- Installation
  313
- Rear Shock Absorber and Swingarm
  316
- Handling Notes
  317
- Notes on Disposal
  317
- Removal
  317
- Inspection
  322
- Installation
  323
- Drive Chain and Sprockets
  327
- Removal
  327
- Inspection
  328
- Installation
  330
Chapter 8. Electrical

331
- Electrical Components
  331
- Checking of Connections
  333
- Ignition System
  335
- Troubleshooting
  335
- Starting Circuit Operation
  342
- Troubleshooting
  343
- Charging System
  355
- Circuit Diagram
  355
- Troubleshooting
  356
- Lighting System
  361
- Troubleshooting
  386
- Self-Diagnosis
  398
- Troubleshooting
  403
- Starting Failure/Hard Starting
  403
- Fuel System
  403
- Electrical System
  403
- Compression System
  404
- Poor Idle Speed Performance
  404
- Poor Medium-And High-Speed Performance
  404
- Hard Shifting
  405
- Shift Pedal Does Not Move
  405
- Jumps-Out-Of Gear
  405
- Clutch Slipping/Dragging
  405
- Clutch Slipping
  405
- Clutch Dragging
  405
- Overheating
  406
- Poor Braking Effect
  406
- Front Fork Oil Leakage and Front Fork Malfunction
  406
- Malfunction
  406
- Oil Leakage
  406
- Unstable Handling
  407
- Faul Tv Lighting and Signal Systems
  407
- Headlight Does Not Light
  407
- Bulb Burnt out
  407
- Flasher Does Not Light
  407
- Flasher Blinks Slowly
  407
- Flasher Remains Lit
  407

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Yamaha YZF1000RJ Service Manual

Yamaha YZF1000RJ Service Manual (407 pages)

Brand: Yamaha | Category: Motorcycle | Size: 38.29 MB

Table of Contents

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