1989-1995 Yamaha FZR1000 Printed Motorcycle Service Manual

Description

This very rare and sought after 1989 1990 1991 1992 1993 1994 1995 Yamaha FZR1000 Service Manual is an original printing. This manual provides detailed service information, step-by-step repair instruction and maintenance specifications for 1989-1995 Yamaha FZR1000(W-G) motorcycles. This is the same service manual used by the service department at your local Yamaha dealer. It has everything in it you need to know in order to repair and service your motorcycle.

Table of Contents

Chapter 1
General Information
Motorcycle Identification
Vehicle Identification Number
Engine Serial Number
Important Information
Preparation for Removal
All Replacement Parts
Gasket, Oil Seals, and O-Rings
Lock Washer/plates and Cotter 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
General Torque Specifications
Definition of Units
Lubrication Point and Grade of Lubricant
Engine
Chassis
Coolant Diagram
Lubrication Diagram
Cable Routing
Emission Hose Routing (FZR10001000 WC Only)

Chapter 3
Periodic Inspection and Adjustment
Introduction
Maintenance Intervals Chart
Periodic Maintenance Emission Control System
General Maintenance/lubrication
Cowlings
Removal
Installation ‘
Fuel Tank
Removal
Installation
Engine
EXUP Cable Adjustment
Valve Clearance Adjustment
Carburetor Synchronization
Idle Speed Adjustment
Throttle Cable Free Play Adjustment
Spark Plug Inspection
Ignition Timing Check
Compression Pressure Measurement
Engine Oil Level Inspection
Engine Oil Replacement
Engine Oil Filter Replacement
Clutch Fluid Level Inspection
Air Bleeding (hydraulic Clutch System)
Air Filter Cleaning
Carburetor Joint Inspection
Fuel Line Inspection
Crankcase Ventilation Hose Inspection
Exhaust System Inspection
Coolant Level Inspection
Coolant Replacement
Canister Inspection (FZR10001000 WC Only)
Chassis
Front Brake Adjustment
Rear Brake Adjustment
Brake Fluid Inspection
Brake Pad Inspection
Brake Light Switch Adjustment
Brake Hose Inspection
Air Bleeding (hydraulic Brake System)
Change 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
Lubrication
Electrical
Battery Inspection
Fuse Inspection
Headlight Beam Adjustment
Headlight Bulb Replacement
Tail/brake Light Bulb Replacement

Chapter 4
Engine Overhaul
Engine Removal
Cowling and Fuel Tank
Engine Oil and Coolant
Battery Leads
Air Filter Case
Air Baffle Plate
Carburetor
Radiator
Oil Cooler
Muffler Assembly
Clutch Release Cylinder and Drive Sprocket
Leads
Engine Removal
Engine Disassembly
Cylinder Head, Camshaft and Cylinder Head
Cylinder and Piston
Clutch
Oil Pan, Oil Filter and Oil Strainer
Oil Pump and Shift Shaft
Water Pump
Starter Motor and AC Generator
Crankcase Disassembly
Transmission
Starter Clutch and Crank Shaft
Shift Fork and Shift Cam
Valve and Camshaft Case
Connecting Rod
Oil Pump
Inspection and Repair
Cylinder Head
Valve and Valve Guide
Valve Seat
Valve Spring
Camshaft Case
Valve Lifter
Camshaft, Timing Chain, Hy-Vo Chain, And
Cam Sprocket
Cylinder and Piston
Piston Ring and Piston Pin
Crankshaft and Connecting Rod
Oil Pump
Primary Drive
Starter Drives
Clutch
Transmission
Shift Shaft and Stopper Lever
Oil-Jet Nozzle
Relief Valve and Oil Pipe
EXUP
Crankcase
Bearing and Oil Seal
Circlip and Washer
Engine Assembly and Adjustment
Oil Pump
Connecting Rod
Valve and Camshaft Case
Shift Fork and Shift Cam
Starter Clutch and Crankshaft
Transmission
Crankcase Assembly
AC Generator and Starter Motor
Water Pump
Shift Shaft and Oil Pump
Oil Strainer, Oil Filter and Oil Pan
Clutch
Piston and Cylinder
Cylinder Head and Camshaft
Timing Chain Tensioner
Cylinder Head Cover and Oil Delivery Pipe
Remounting Engine
EXUP

Chapter 5
Cooling System
Radiator
Removal
Inspection
Installation
Thermostatic Valve
Removal
Inspection
Installation
Water Pump
Removal
Inspection
Installation

Chapter 6
Carburetor
Carburetor
Section View
Removal
Disassembly
Inspection
Assembly
Installation
Fuel Level Adjustment

Chapter 7
Chassis
Front Wheel
Removal
Inspection
Installation
Static Wheel Balance Adjustment
Rear Wheel
Removal
Inspection
Installation
Static Wheel Balance Adjustment
Front and Rear Brake
Brake Pad Replacement
Caliper Disassembly
Master Cylinder Disassembly
Inspection and Repair
Assembly
Hydraulic Clutch
Disassembly
Inspection and Repair
Assembly
Front Fork
Removal
Disassembly
Inspection
Assembly
Installation
Steering Head and Handlebar
Removal
Inspection
Installation
Rear Shock Absorber and Swingarm
Handling Notes
Disposal Notes
Removal
Inspection|
Installation
Drive Chain and Sprocket
Removal
Inspection and Cleaning
Installation

Chapter 8
Electrical
FZR1000 Circuit Diagram
Color Code
Electrical Components
Checking of Switches
Switch Connection as Shown in Manual
Checking Switch for Terminal Connection
Checking of Bulbs/for Headlight, Tail/brake, Light,
Flasher Light, Meter Light, Etc
Kinds of Bulbs
Checking Bulb Condition
Ignition System
Circuit Diagram
Digital Ignition Control System Description
Operation
Troubleshooting
Electrical Starting System
Circuit Diagram
Starting Circuit Operation
Troubleshooting
Starter Motor
Charging System
Circuit Diagram
Troubleshooting
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
Meter Assembly
Removal
Installation

Chapter 9
Troubleshooting
Starting Failure/head Starting
Poor Idle Speed Performance
Poor Medium and High Speed Performance
Faulty Gear Shifting
Clutch Slipping/dragging
Overheating or Over-Cooling
Faulty Brake
Front Fork Oil Leakage/malfunction
Instable Handling
Faulty Signals and Lighting System
Faulty EXUP