Yamaha YZF1000RJ Motorcycle Cover Manuals

Manuals and User Guides for Yamaha YZF1000RJ Motorcycle Cover. We have 2 Yamaha YZF1000RJ Motorcycle Cover manuals available for free PDF download: Service Manual

Yamaha YZF1000RJ Service Manual (407 pages)

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

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

Yamaha YZF1000RJ Service Manual (407 pages)

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

Notice
3
Important Information
3
Page Features
4
Exploded Diagrams
4
Illustrated Symbols
5
Chapter Titles
6
Contents
7
Motorcycle Identification
16
General Information
16
Vehicle Identification Number
16
Engine Serial Number
16
Preparation for Removal
17
Replacement Parts
17
Gaskets, Oil Seals and O-Rings
17
Lock Washers/Plates and Cotter Pins
18
Bearings and Oil Seals
18
Circlips
18
Special Tools
19
For Tune-Up
19
For Engine Service
20
For Chassis Service
22
For Electrical Components
22
Specifications
23
General Specifications
23
Maintenance Specifications
26
Lubrication Chart
32
Crankcase Tightening Sequence
32
Crankcase
32
Tightening Torques
33
How to Use the Conversion Table
41
General Torque Specifications
41
Conversion Table
41
Lubrication Points and Lubricant Types
42
Cooling System Diagrams
44
Lubrication Diagrams
47
Cable Routing
51
Emission Hose Routing
58
Periodic Inspections and Adjustments
60
General Maintenance/Lubrication
61
Cowlings
63
Valve Clearance Adjustment
70
Intake
76
Exhaust
76
Carburetor Synchronization
78
Idling Speed Adjustment
81
Throttle Cable Adjustment
81
Spark Plug Inspection
83
Ignition Timing Check
84
Compression Pressure Measurement
86
Engine Oil Replacement
89
Engine Oil Pressure Inspection
91
Clutch Adjustment
92
Clutch Fluid Level Inspection
93
Air Bleeding
94
Hydraulic Clutch System
94
Air Filter Cleaning
95
Carburetor Joint Inspection
96
Fuel Line Inspection
97
Crankcase Breather Hose Inspection
97
Exup Cable Adjustment
98
Exhaust System Inspection
100
Coolant Level Inspection
101
Coolant Replacement
101
Cooling System Inspection
105
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
Shift Pedal Adjustment
111
Drive Chain Slack Adjustment
112
Steering Head Inspection
114
Front Fork Inspection
117
Front Fork Adjustment
117
Spring Preload
118
Rebound Damping
118
Compression Damping
119
Rear Shock Absorber Adjustment
119
Tire Inspection
121
Front Tire
123
Rear Tire
123
Wheel Inspection
124
Cable Inspection and Lubrication
124
Lever and Pedal Lubrication
125
Sidestand Lubrication
125
Rear Suspension Lubrication
125
Battery Inspection
126
Electrical
126
Battery Connection Checking Steps
127
Charging Method Using a Variable-Current Type Charger
129
Charging Method Using a Constant-Voltage Type Charger
130
Fuse Inspection
131
Replacement Steps
132
Headlight Beam Adjustment
133
Headlight Bulb Replacement
134
Engine Removal
135
Fuel Tank and Cowlings
135
Engine Oil and Coolant
135
Battery Leads
136
Air Filter Case
136
Carburetors
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 Disassembly
143
Oil Filter and Oil Cooler
143
Cylinder Head Cover, Cylinder Head and Camshafts
144
Oil Pump and Shift Shaft
153
Crankcase Disassembly
154
Shift Forks and Shift Cam
155
Transmission
156
Starter Clutch and Crankshaft
156
Valves and Camshaft Case
157
Connecting Rods
159
Oil Pump
159
Inspection and Repair
160
Cylinder Head
160
Valves and Valve Guides
161
Valve Seats
162
Valve Springs
164
Camshaft Case
165
Valve Lifters
165
Camshafts
165
Timing Chain
167
Hy-Vo Chain
167
Camshaft Sprockets and Chain Guides
167
Piston Rings
169
Piston Pins
170
Crankshaft and Connecting Rods
170
Starter Drives
176
Tip Clearance
176
Side Clearance
176
AC Generator Shaft
177
Clutch Operation Checking
177
Clutch
177
Warp Limit
178
Free Length
178
Oil Cooler
183
Circlips and Washers
183
Engine Assembly and Adjustment
184
Connecting Rod and Crankshaft
185
Camshaft Case and Valves
187
Starter Clutch
190
Crankshaft and Starter Clutch
191
Radiator/Oil Cooler
224
Radiator
225
Thermostatic Valve
231
Water Pump
231
Thermostatic Valve Remoavl
232
Water Pump Removal
236
Water Pump Installation
240
Carburetion
242
Front Wheel
256
Rear Wheel
262
Front and Rear Brakes
265
Front Fork
296
Steering Head and Handlebars
308
Drive Chain and Sprockets
326
Ignition System Circuit Diagram
334
Ignition System Troubleshooting
335
Electric Starting System
350
Charging System
355
If the Battery Is Not Charged
356
Fuel Pump Circuit Operation
385
If the Fuel Pump Fails to Operate
386

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Yamaha YZF1000RJ Motorcycle Cover Manuals

Yamaha YZF1000RJ Service Manual (407 pages)

Table of Contents

Chapter 2. Specifications

Chapter 3. Periodic Inspections and Adjustments

Chapter 4. Engine

Chapter 5. Cooling

Chapter 6 . Carburetion

Chapter 8. Electrical

Yamaha YZF1000RJ Service Manual (407 pages)

Table of Contents

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