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Yamaha_YZF1000RJ(RJC)_Service_Repair_Manual
Pages 407
CONTENTS
CHAPTER 1
GENERAL INFORMATION-MOTORCYCLE IDENTIFICATION -VEHICLE IDENTIFICATION NUMBER ENGINE SERIAL NUMBER -MODEL LABEL -IMPORTANT INFORMATION PREPARATION FOR REMOVAL PROCEDURES -REPLACEMENT PARTS -GASKETS OIL SEALS AND ORINGS
LOCK WASHERS/PLATES AND COMER PINS -BEARINGS AND OIL SEALS CIRCLIPS SPECIAL TOOLS FOR TUNE??UP FOR ENGINE SERVICE FOR CHASSIS SERVICE FOR ELECTRICAL COMPONENTS
CHAPTER 2
SPECIFICATIONS
GENERAL SPECIFICATIONS -MAINTENANCE SPECIFICATIONS-ENGINE
CHASSIS -ELECTRICAL -HOW TO USE THE CONVERSION TABLE -GENERAL TORQUE SPECIFICATIONS -LUBRICATION POINTS AND LUBRICANT TYPES -ENGINE
CHASSIS -COLING SYSTEM DIAGRAMS -LUBRICATION DIAGRAMS
CHAPTER 3
PERIODIC INSPECTIONS AND ADJUSTMENTS-INTRODUCTION PERIODIC MAINTENANCE/ EMISSION CONTROL SYSTEM - GENERAL MAINTENANCE/LUBRICATION-COWLINGS REMOVAL
INSTALLATION -SEATS REMOVAL
INSTALLATION
FUEL TANK
REMOVAL
INSTALLATION
ENGINE
VALVE CLEARANCE ADJUSTMENT
CARBURETOR SYNCHRONIZATION
SPEED ADJUSTMENT THROTTLE CABLE ADJUSTMENT SPARK PLUG INSPECTION
IGNITION TIMING CHECK COMPRESSION PRESSURE MEASUREMENT
ENGINE OIL LEVEL INSPECTION ENGINE OIL REPLACEMENT
ENGINE OIL PRESSURE INSPECTION
CLUTCH ADJUSTMENT CLUTCH FLUID LEVEL INSPECTION
AIR BLEEDING (HYDRAULIC CLUTCH SYSTEM) AIR FILTER CLEANING
CARBURETOR JOINT INSPECTION
FUEL LINE INSPECTION
CRANKCASE BREATHER HOSE INSPECTION
EXUP CABLE ADJUSTMENT
EXHAUST SYSTEM INSPECTION
COOLANT LEVEL INSPECTION
COOLANT REPLACEMENT
COOLING SYSTEM INSPECTION
CHASSIS
FRONT BRAKE ADJUSTMENT
REAR BRAKE ADJUSTMENT
BRAKE FLUID LEVEL INSPECTION BRAKE PAD INSPECTION
BRAKE LIGHT SWITCH ADJUSTMENT
BRAKE HOSE INSPECTION
AIR BLEEDING (HYDRAULIC BRAKE SYSTEM)
SHIFT PEDAL ADJUSTMENT
DRIVE CHAIN SLACK ADJUSTMENT
DRIVE CHAIN LUBRICATION
STEERING HEAD INSPECTION
FRONT FORK INSPECTION
FRONT FORK ADJUSTMENT
REAR SHOCK ABSORBER ADJUSTMENT
TIRE INSPECTION
WHEEL INSPECTION
CABLE INSPECTION AND LUBRICATION
LEVER AND PEDAL LUBRICATION
SIDESTAND LUBRICATION
REAR SUSPENSION LUBRICATION ELECTRICAL
BATIERY INSPECTION
FUSE INSPECTION
HEADLIGHT BEAM ADJUSTMENT
HEADLIGHT BULB REPLACEMENT
CHAPTER 4
ENGINE
ENGINE REMOVAL FUEL TANK AND COWUNGS
ENGINE OIL AND COOLANT
BATIERY LEADS
AIR FILTER CASE
CARBURETORS
RADIATOR
HOSES AND LEADS
DRIVE SPROCKET
WATER JACKET JOINTS AND WATER PUMP
AC GENERATOR AND STARTER MOTOR
MUFFLER ASSEMBLY ENGINE REMOVAL
ENGINE DISASSEMBLY
OIL FILTER AND OIL COOLER
CYLINDER HEAD COVER CYLINDER HEAD AND CAMSHAFTS
CYLINDERS AND PISTONS
CLUTCH
OIL PAN AND OIL STRAINER
OIL PUMP AND SHIFT SHAFT
CRANKCASE DISASSEMBLY SHIFT FORKS AND SHIFT CAM
TRANSMISSION
STARTER CLUTCH AND CRANKSHAFT o
VALVES AND CAMSHAFT CASE
CONNECTING RODS
OIL PUMP
INSPECTION AND REPAIR
CYLINDER HEAD
VALVES AND VALVE GUIDES
VALVE SEATS
VALVE SPRINGS
CAM S HAFT CASE
VALVE LIFTERS
CAMSHAFTS
TIMING CHAIN HYVO CHAIN CAMSHAFT SPROCKETS
AND CHAIN GUIDES
TIMING CHAIN TENSIONER
CYLINDERS AND PISTONS
PISTON RINGS
PISTON PINS
CRANKSHAFT AND CONNECTING RODS
OIL PUMP
PRI MARY DRIVE
STARTER DRIVES
AC GENERATOR SHAFT
CLUTCH
TRANSMISSION AND SHIFTER
SHIFT SHAFT AND STOPPER LEVER OILJET NOZZLE
RELIEF VALVE OIL PIPE AND STRAINER
OIL COOLER
CRANKCASE
BEARINGS AND OIL SEALS
CIRCLIPS AND WASHERS
ENGINE ASSEMBLY AND ADJUSTMENT
OIL PUMP
CONNECTING RODS
CAMSHAFT CASE AN D VALVES
CRANKSHAFT AND STARTER CLUTCH
TRANSMISSION
SHIFT CAM AND SHIFT FORKS
CRANKCASE ASSEMBLY
SHIFT SHAFT AND OIL PUMP
OIL PAN AND OIL STRAINER
CLUTCH
PISTONS AND CYLINDERS
CYLINDER HEAD AND CAMSHAFTS
TIMING CHAIN TENSIONER
OIL COOLER AND OIL FILTER
ENGINE REMOUNTING
CHAPTER 5
COOLING
RADIATOR/OIL COOLER
RADIATOR
REMOVAL
INSPECTION
INSTALLATION
OIL COOLER
REMOVAL
I NSPECTION
INSTALLATION
THERMOSTATIC VALVE/WATER PUMP THERMOSTATIC VALVE
REMOVAL
INSPECTION
INSTALLATION
WATER PUMP ·
REMOVAL
INSPECTION
INSTALLATION
CHAPTER 6
CARBURETION
CARBURETORS
REMOVAL
DISASSEMBLY
INSPECTION
ASSEMBLY
INSTALLATION
FUEL LEVEL ADJUSTMENT
THROTTLE POSITION SENSOR (TPS) ADJUSTMENT
AND INSPECTION
CHAPTER 7
CHASSIS
FRONT WHEEL
REMOVAL
INSPECTION
INSTALLATION
FRONT WHEEL STATIC BALANCE ADJUSTMENT
REAR WHEEL
REMOVAL
INSPECTION
INSTALLATION
REAR WHEEL STATIC BALANCE ADJUSTMENT
FRONT AND REAR BRAKES
FRONT BRAKE
REAR BRAKE
BRAKE PAD REPLACEMENT
BRAKE CALIPER DISASSEMBLY
MASTER CYLINDER DISASSEMBLY
INSPECTION AND REPAIR
BRAKE CALIPER ASSEMBLY
MASTER CYLINDER ASSEMBLY HYDRAULIC CLUTCH
DISASSEMBLY
INSPECTION AND REPAIR
ASSEMBLY
FRONT FORK
REMOVAL
DISASSEMBLY
INSPECTION
ASSEMBLY
INSTALLATION
STEERING HEAD AND HANDLEBARS
REMOVAL
INSPECTION
IN ST ALLA TION
REAR SHOCK ABSORBER AND SWINGARM
HANDLING NOTES <
NOTES ON DISPOSAL
REMOVAL
INSPECTION
I NST ALLATIO N
DRIVE CHAIN AND SPROCKETS
REMOVAL
INSPECTION
INSTALLATION
CHAPTER 8
ELECTRICAL
ELECTRICAL COMPONENTS
CHECKING OF CONNECTIONS
IGNITION SYSTEM
CIRCUIT DIAGRAM
TROUB LESHOOTIN G
ELECTRIC STARTING SYSTEM
CIRCUIT DIAGRAM
STARTING CIRCUIT OPERATION
TROU BLESHOOTING
STARTER MOTOR
CHARGING SYSTEM
CIRCUIT DIAGRAM
TROU BLESHOOTI N G
LIGHTING SYSTEM
CIRCUIT DIAGRAM
TROUBLESHOOTING
LIGHTING SYSTEM CHECK
SIGNAL SYSTEM
CIRCUIT DIAGRAM
TROUBLESHOOTING
SIGNAL SYSTEM CHECK
COOLING SYSTEM
CIRCUIT DIAGRAM
TROUBLESHOOTING
FUEL PUMP SYSTEM
CIRCUIT DIAGRAM
FUEL PUMP CIRCUIT OPERATION
TROUBLESHOOTING
FUEL PUMP TEST
EXUP SYSTEM
CIRCUIT DIAGRAM
TROUBLESHOOTING
SELFDIAGNOSIS
TROUBLESHOOTING
CHAPTER
TROUBLESHOOTING
STARTING FAILURE/HARD STARTING
FUEL SYSTEM
ELECTRICAL SYSTEM
COMPRESSION SYSTEM
POOR IDLE SPEED PERFORMANCE POOR IDLE SPEED PERFORMANCE
POOR MEDIUMAND HIGHSPEED PERFORMANCE
POOR MEDIUMAND HIGHSPEED PERFORMANCE
FAULTY GEAR SHIFTING
HARD SHIFTING
SHIFT PEDAL DOES NOT MOVE
JUMPSOUTOF GEAR
CLUTCH SLIPPING/DRAGGING
CLUTCH SLIPPING
CLUTCH DRAGGING
OVERHEATING
OVERHEATING FAUL TV BRAKE
POOR BRAKING EFFECT
FRONT FORK OIL LEAKAGE: AND FRONT FORK MALFUNCTION
MALFUNCTION
OIL LEAKAGE UNSTABLE HANDLING
UNSTABLE HANDLING
FAUL TV LIGHTING AND SIGNAL SVSTEMS
HEADLIGHT DOES NOT LIGHT
BULB BURNT OUT
FLASHER DOES NOT LIGHT
FLASHER BLINKS SLOWLY
FLASHER REMAINS LIT
FLASHER BLINKS QUICKL Y
HORN DOES NOT SOLJND
VZFR WIRNING DIAGRAM
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