1987-1988 Yamaha FZR 750 FZR 1000 Service & Repair Manual

LIT-11616-FZ-1 0

FZR750RT/RU FZR 1 OOOT /TC SERVICE MANUAL © 1987 by Yamaha Motor Corporation, U.S.A. 1st Edition, March 1987 All rights reserved. Any reprinting or unauthorized use without the written permission of Yamaha Motor Corporation, U.S.A. is expressly prohibited. Printed in U.S.A. P/N: LIT-11616-FZ-10

NOTICE This manual was written by the Yamaha Motor Company primarily for use by Yamaha dealers and their qualifi~d mechanics. It is not possible to put an entire mechanic's education into one manual, so it is assumed that persons using this book to perform maintenance and repairs on Yamaha motorcycles have a basic understanding of the mechanical concepts and procedures inherent in motorcycle repair technology. Without such knowledge, attempted repairs or service to this model may render it unfit to use and/or unsafe. Yamaha Motor Company, Ltd. is continually striving to improve all models manufactured by Yamaha. Modifications and significant changes in specifications or procedures will be forwarded to all Autho- rized Yamaha dealers and will, where applicable, appear in future editions of this manual. TECHNICAL PUBLICATIONS SERVICE DIVISION MOTORCYCLE OPERATIONS YAMAHA MOTOR CO., L TO. HOW TO USE THIS MANUAL PARTICULARLY IMPORTANT INFORMATION This material is distinguished by the following notation. NOTE: WARNING: A NOTE provides key information to make procedures easier or clearer. A CAUTION indicates special procedures that must be followed to avoid damage to the motorcycle. A WARNING indicates special procedures that must be followed to avoid injury to a motorcycle operator or person inspecting or repairing the motorcycle. MANUAL FORMAT All of the procedures in this manual are organized in a sequential, step-by-step format. The information has been compiled to provide the mechanic with an easy to read, handy reference that contains comprehensive explanations of all disassembly, repair, assembly, and inspection operations. In this revised format, the condition of a faulty component will precede an arrow symbol and the course of action required will follow the symbol, e.g., • Bearings Pitting/Damage ~ Replace. EXPLODED DIAGRAM Each chapter provides exploded diagrams before each disassembly section for ease in identifying correct disassembly and assembly procedures.

CD ® I~N'bl~l Is PEel ~fl @ @ ~~~II~E~I I ENG l'-1 ® ® lcooLI ~~ lcARslfl (J) @ lcHAsl~l I ELECI iiiiil ® ® ~ ~~~¥~ ? I @ ~ @ ~ @ ~ @ ~ @ [0] ® [ml @ i @ i @) i m - - m G ® ® @ ~ ~~ @ & a ILLUSTRATED SYMBOLS (Refer to the illustration) Illustrated symbols CD to ® are designed as thumb tabs to indicate the chapter's number and content. CD General information ®Specifications @Periodic inspection and adjustment @Engine @Cooling system @ Carburetion (J) Chassis @ Electrical ®Troubleshooting Illustrated symbols ® to ® are used to iden- tify the specifications appearing. ® Filling fluid @Lubricant @Special tool @Tightening @Wear limit, clearance @Engine speed @n,V,A Illustrated symbols @ to @ in the exploded diagram indicate grade of lubricant and location of lubrication point. @Apply engine oil @Apply gear oil @)Apply molybdenum disulfide oil ®Apply wheel bearing grease ®Apply lightweight lithium-soap base grease @Apply molybdenum disulfide grease @Apply locking agent (LOCTITE®)

CONTENTS CHAPTER 1. GENERAL INFORMATION MOTORCYCLE IDENTIFICATION ................................ 1-1 VEHICLE IDENTIFICATION NUMBER ......................... 1-1 ENGINE SERIAL NUMBER ................................... 1-1 IMPORTANT INFORMATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2 PREPARATION FOR REMOVAL .............................. 1-2 ALL REPLACEMENT PARTS ........ . . . . . . . . . . . . . . . . . . . . . . . . . 1-2 GASKET, 01 L SEALS, AND 0-R INGS . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2 LOCK WASHER/PLATES AND COTTER PINS... . . . . . . . . . . . . . . . . . 1-3 BEARINGS AND OIL SEALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3 CIRCLIPS ................................................. 1-3 SPECIAL TOOLS .............................................. 1-4 FOR TUNE UP ........ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4 FOR ENGINE SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5 FOR CHASSIS SERVICE ..................................... 1-8 FOR ELECTRICAL COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9 CHAPTER 2. SPECIFICATIONS SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 GENERAL SPECIFICATIONS ................................. 2-1 MAINTENANCE SPECIFICATIONS ............................ 2-4 ENGINE .................................................. 2-4 CHASSIS .................................................. 2-11 ELECTRICAL .............................................. 2-14 GENERAL TORQUE SPECIFICATIONS ......................... 2-16 LUBRICATION POINT AND GRADE OF LUBRICANT ............. 2-17 DEFINITION OF UNITS ..................................... 2-19 CONVERSION TABLES ...................................... 2-19 LUBRICATION DIAGRAM ...................................... 2-20 COOLANT DIAGRAM .......................................... 2-23 CABLE ROUTING ............................................. 2-24

CONTENTS SPECIFICATIONS SPECIFICATIONS ............................................. 2-1 GENERAL SPECIFICATIONS ................................. 2-1 MAINTENANCE SPECIFICATIONS ............................ 2-4 ENGINE .................................................. 2-4 CHASSIS .................................................. 2-11 ELECTRICAL .............................................. 2-14 GENERAL TORQUE SPECIFICATIONS ......................... 2-16 LUBRICATION POINT AND GRADE OF LUBRICANT ............. 2-17 DEFINITION OF UNITS ..................................... 2-19 CONVERSION TABLES ...................................... 2-19 LUBRICATION DIAGRAM ...................................... 2-20 COOLANT DIAGRAM .......................................... 2-23 CABLE ROUTING ............................................. 2-24 PERIODIC INSPECTION AND ADJUSTMENT INTRODUCTION ............................................... 3-1 MAINTENANCE INTERVALS CHART .............................. 3-1 PERIODIC MAINTENANCE EMISSION CONTROL SYSTEM ......... 3-1 GENERAL MAINTENANCE/LUBRICATION ...................... 3-2 COWLINGS REMOVAL AND INSTALLATION ...................... 3-4 ENGINE ..................................................... 3-7 VALVE CLEARANCE ADJUSTMENT .......................... 3-7 CARBURETOR SYNCHRONIZATION .......................... 3-14 IDLE SPEED ADJUSTMENT .................................. 3-15 THROTTLE CABLE FREE PLAY ADJUSTMENT ................. 3-16 SPARK PLUG INSPECTION .................................. 3-17 IGNITION TIMING CHECK ................................... 3-19 COMPRESSION PRESSURE MEASUREMENT .................... 3-19 ENGINE OIL LEVEL INSPECTION ............................. 3-21 ENGINE OIL REPLACEMENT ................................ 3-21 ENGINE OIL FILTER REPLACEMENT ......................... 3-22 AIR FILTER CLEANING ..................................... 3-24 CARBURETOR JOINT INSPECTION ........................... 3-24 FUEL LINE INSPECTION ..................................... 3-24 CRANKCASE VENTILATION HOSE INSPECTION ................ 3-25 EXHAUST SYSTEM INSPECTION ............................. 3-25 COOLANT LEVEL INSPECTION .............................. 3-26 COOLANT REPLACEMENT .................................. 3-26

CHAPTER 3. PERIODIC INSPECTION AND ADJUSTMENT INTRODUCTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 MAINTENANCE INTERVALS CHART ............................. 3-1 PERIODIC MAINTENANCE EMISSION CONTROL SYSTEM ........ 3-1 GENERAL MAINTENANCE/LUBRICATION ..................... 3-2 COWLINGS REMOVAL AND INSTALLATION ...................... 3-4 ENGINE ..................................................... 3-7 VALVE CLEARANCE ADJUSTMENT .......................... 3-7 CARBURETOR SYNCHRONIZATION .......................... 3-14 IDLE SPEED ADJUSTMENT .................................. 3-15 THROTTLE CABLE FREE PLAY ADJUSTMENT ................. 3-16 SPARK PLUG INSPECTION .................................. 3-17 IGNITION TIMING CHECK ................................... 3-19 COMPRESSION PRESSURE MEASUREMENT .................... 3-19 ENGINE OIL LEVEL INSPECTION ............................. 3-21 ENGINE OIL REPLACEMENT ................................ 3-21 ENGINE OIL FILTER REPLACEMENT ......................... 3-22 AIR FILTER CLEANING ..................................... 3-24 CARBURETOR JOINT INSPECTION ........................... 3-24 FUEL LINE INSPECTION .................................... 3-24 CRANKCASE VENTILATION HOSE INSPECTION ................ 3-25 EXHAUST SYSTEM INSPECTION ............................. 3-25 COOLANT LEVEL INSPECTION .............................. 3-26 COOLANT REPLACEMENT .................................. 3-26 CHASSIS ..................................................... 3-28 FRONT BRAKE ADJUSTMENT ............................... 3-28 REAR BRAKE ADJUSTMENT ................................ 3-28 BRAKE FLUID INSPECTION ................................. 3-29 BRAKE PAD INSPECTION ................................... 3-29 BRAKE LIGHT SWITCH INSPECTION .......................... 3-29 BRAKE HOSE INSPECTION .................................. 3-30 DRIVE CHAIN SLACK CHECK ................................ 3-30 DRIVE CHAIN SLACK ADJUSTMENT .......................... 3-30 DRIVE CHAIN LUBRICATION ................................ 3-31 STEERING HEAD INSPECTION ............................... 3-32 FRONT FORK INSPECTION .................................. 3-34 FRONT FORK ADJUSTMENT ................................ 3-36 RECOMMENDED COMBINATIONS OF FRONT FORK AND REAR SHOCK ABSORBER .................................. 3-37 TIRE INSPECTION ......................................... 3-38 WHEEL INSPECTION ....................................... 3-39 CABLE INSPECTION ........................................ 3-40 LUBRICATION ............................................ 3-40 ~ GEN INFO SPEC INSP ADJ ENG CHAS ELEC ? • TRBL SHTG

ELECTRICAL ................................................. 3-41 BATTERY INSPECTION ..................................... 3-41 FUSE INSPECTION ......................................... 3-43 HEADLIGHT BEAM ADJUSTMENT ............................ 3-43 HEADLIGHT BULB REPLACEMENT ........................... 3-44 TAIL/BRAKE BULB REPLACEMENT .......................... 3-45 AIR INDUCTION SYSTEM INSPECTION (FOR FZR1000TC ONLY) .................................... 3-46 CHAPTER 4. ENGINE OVERHAUL ENGINE REMOVAL ............................................ 4-1 SIDE COWLING, SEAT, AND SIDE COVERS AND FUEL TANK ...... 4-1 AIR CLEANER .............................................. 4-1 CARBURATOR ............................................. 4-2 RADIATOR ................................................ 4-2 MUFFLER ASSEMBLY ....................................... 4-3 CLUTCH RELEASE CYLINDER AND DRIVE SPROCKET ........... 4-4 LEADS .................................................... 4-4 ENGINE REMOVAL ......................................... 4-5 ENGINE DISASSEMBLY ......................................... 4-6 CAMSHAFT AND CYLINDER HEAD ............................ 4-6 CYLINDER AND PISTON ..................................... 4-9 CLUTCH .................................................. 4-10 01 L PAN AND 01 L STRAINER ................................ 4-11 OIL PUMP AND SHIFT SHAFT ................................ 4-12 WATER PUMP ............................................. 4-13 STARTER MOTOR AND AC GENERATOR ...................... 4-13 CRANKCASE DISASSEMBLY ................................. 4-13 TRANSMISSION ........................................... 4-15 STARTER CLUTCH AND CRANKSHAFT ....................... 4-15 SHIFT FORK AND SHIFT CAM ............................... 4-16 CYLINDER HEAD AND CAMSHAFT CASE ...................... 4-17 VALVE ................................................... 4-17 INSPECTION AND REPAIR ..................................... 4-20 CYLINDER HEAD .......................................... 4-20 VALVE ................................................... 4-20 VALVE GUIDE ............................................ 4-21 VALVE SEAT .............................................. 4-22 VALVE SPRING ............................................ 4-25 VALVE INSTALLATION ..................................... 4-26 VALVE LIFTER AND CAMSHAFT CASE ....................... 4-27 CAMSHAFT, CAM CHAIN AND CAM SPROCKET ................. 4-29

CYLINDER AND PISTON .................................... 4-31 PISTON RING AND PISTON PIN .............................. 4-32 CRANKSHAFT AND CONNECTING ROD ....................... 4-34 OIL PUMP ................................................. 4-39 PRIMARY DRIVES ......................................... 4-40 STARTER DRIVES ......................................... 4-40 CLUTCH .................................................. 4-41 TRANSMISSION ........................................... 4-43 OIL JET NOZZLE .......................................... 4-44 RELIEF VALVE AND PIPE ................................... 4-44 CRANKCASE .............................................. 4-45 BEARING AND OIL SEAL ................................... 4-45 CIRCLIP AND WASHER ..................................... 4-45 ENGINE ASSEMBLY AND ADJUSTMENT .......................... 4-46 CRANKSHAFT ............................................. 4-46 LOWER CRANKCASE ....................................... 4-48 UPPER CRANKCASE ........................................ 4-50 TRANSMISSION ........................................... 4-52 CRANKCASE ASSEMBLY .................................... 4-53 SHIFT SHAFT AND OIL PUMP ................................ 4-54 OIL STRAINER AND OIL PAN ................................ 4-56 WATER PUMP ............................................. 4-57 AC GENERATOR AND STARTER MOTOR ...................... 4-58 CLUTCH .................................................. 4-59 PISTON AND CYLINDER .................................... 4-62 CYLINDER HEAD .......................................... 4-65 CAMSHAFT ............................................... 4-66 CAM CHAIN TENSIONER .................................... 4-70 CYLINDER HEAD COVER AND OIL DELIVERY PIPE ............. 4-71 REMOUNTING ENGINE ..................................... 4-72 MUFFLER ASSEMBLY ...................................... 4-73 CARBURATOR AND THROTTLE CABLE ....................... 4-74 ~ GEN INFO SPEC INSP ADJ ENG CHAS Iii ELEC ? • TRBL SHTG

CHAPTER 5. COOLING SYSTEM RADIATOR .................................................. 5-1 REMOVAL ................................................ 5-1 INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1 ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2 WATER PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4 DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4 INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4 BEARING AND SEAL REPLACEMENT ......................... 5-4 ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6 THERMOSTATIC VALVE ....................................... 5-6 REMOVAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6 INSPECTION .............................................. 5-6 ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7 CHAPTER 6. CARBURETOR CARBURETOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1 SECTION VIEW............................................ 6-2 REMOVAL ................................................ 6-3 DISASSEMBLY ...................................... • ..... 6-4 INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5 ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7 INSTALLATION ........................................... 6-8 ADJUSTMENT ............................................. 6-8 CHAPTER 7. CHASSIS FRONT WHEEL • ............................................... 7-1 REMOVAL ................................................. 7-2 INSPECTION ............................................... 7-2 INSTALLATION ............................................ 7-5 REAR WHEEL ................................................. 7-6 REMOVAL ................................................. 7-7 INSPECTION ............................................... 7-7 INSTALLATION ............................................ 7-8

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1987-1988 Yamaha FZR 750 FZR 1000 Service & Repair Manual

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