Checking The Friction Plates

The following procedure applies to all of the friction plates. 1. Check friction plate Damage wear Replace the friction plates as a set. 2. Measure friction plate thickness Out of specification Replace the friction plates as a set. Measure the friction plate at four places. Friction plate thickness Friction plate 3.42 - 3.58 mm < Limit> 3.32 mm Friction plate 2.92 - 3.08 mm < Limit> 2.82 mm 3. Measure assembly width (a) Out of specification a. Assembly width adjusted by clutch plate and...

Checking The Carburetors

Blow Clean Compressed Air

The following procedure applies to all of the carburetors. 1. Check 2. Check fuel passages Obstruction Clean. a. Wash the carburetor in a petroleum-based solvent. Do not use any caustic-carburetor-cleaning solution. b. Blow out all of the passages and jets with compressed air. float chamber body Dirt Clean. float chamber rubber gasket (2) Cracks damage wear Replace. 5. Check float Damage Replace. needle valve seat (2) Damage obstruction wear Replace the needle valve, needle valve seat and...

General Tightening Torques

This chart specifies tightening torques for standard fasteners with a standard ISO thread pitch. Tightening torque specifications for special components or assemblies are provided for each chapter of this manual. To avoid warpage, tighten multi-fastener assemblies in a crisscross pattern and progressive stages until the specified tightening torque is reached. Unless otherwise specified, tightening torque specifications require clean, dry threads. Components should be at room temperature. A...

Yamaha Vacuum Gauge 90890-03094

Yamaha Fazer Vacuum

For installation, reverse the removal procedure. Note the following points. SYNCHRONIZING THE CARBURETORS NOTE - Prior to synchronizing the carburetors, the valve clearance and the engine idling speed should be properly adjusted and the ignition timing should be checked. 1. Stand the motorcycle on a level surface. NOTE Place the motorcycle on a suitable stand. 3. Install vacuum gauge engine tachometer (2) (to the spark plug lead of cyl. 1) Vacuum gauge 90890-03094 Engine tachometer 90890-03113...

Carb

Yamaha Breeze Carburetor Hoses

AIR FILTER CASE CHECKING THE ASSEMBLING THE CARBURETORS 7-8 INSTALLING THE MEASURING AND ADJUSTING THE FUEL LEVEL 7-10 CHECKING AND ADJUSTING THE THROTTLE POSITION SENSOR CHECKING THE FUEL AIR INDUCTION SYSTEM AIR INJECTION AIR CUTOFF VALVE AIR INDUCTION SYSTEM CHECKING THE AIR INDUCTION SYSTEM 7-16 Remove the parts in the order listed. Refer to FRONT COWLING SEAT SIDE COVER FUEL TANK section in chapter 3. Refer to CHANGING THE COOLANT section. For installation, reverse the removal procedure....

Positive tester probe Negative tester probe

Does the headlight rrelay (dimmer) have continuity Replace the headlight relay (dimmer). Check entire lighting system's wiring. Refer to CIRCUIT DIAGRAM. Is the lighting system's wiring properly connected and without defects Is the lighting system's wiring properly connected and without defects Check the condition of each of the lighting system's circuits. Refer to CHECKING THE LIGHTING SYSTEM. Properly connect or repair the lighting system's wiring. 1. The headlight and the high beam...

Checking The Transmission

Vane Drain Inlet For Bikes

Measure main axle runout with a centering device and dial gauge Out of specification Replace the main axle. 2. Measure drive axle runout with a centering device and dial gauge Out of specification Replace the drive axle. Blue discoloration pitting wear Replace the defective gear -s . transmission gear dogs Cracks damage rounded edges Replace the defective gear -s . transmission gear engagement each pinion gear to its respective wheel gear Incorrect Reassemble the transmission axle...

Caution

Yamaha Fazer 1000 Forks

Allow the damper rod to slide slowly down the inner tube 2 until it protrudes from the bottom of the inner tube. Be careful not to damage the inner tube. Install the oil flow stopper with a flat surface part downward. 2. Lubricate inner tube's outer surface Recommended lubricant Fork oil 5W or equivalent While holding the damper rod with the damper rod holder 2, tighten the damper rod bolt. 4. Install oil seal d with the fork seal driver weight 2 and fork seal driver attachemt 3 Fork seal...

Note

Set the torque wrench at a right angle to the ring nut wrench. Lower ring nut initial tightening torque c. Loosen the lower ring nut completely, then tighten it to specification. Do not overtighten the lower ring nut. Lower ring nut final tightening torque d. Check the steering head for looseness or binding by turning the front fork all the way in both directions. If any binding is felt, remove the lower bracket and inspect the upper and lower bearings. Refer to STEERING HEAD AND HANDLEBAR in...

Fazer1000 Rear Shock

Adjusting Rear Suspension Fazer

When setting the time e.g., after reconnecting the battery , first set the clock to 1 00 AM, then set it to the correct time. FRONT WHEEL AND BRAKE DISCS 4-1 FRONT WHEEL REMOVING THE FRONT WHEEL 4-3 DISASSEMBLING THE FRONT WHEEL 4-3 CHECKING THE FRONT CHECKING THE BRAKE ASSEMBLING THE FRONT WHEEL 4-6 INSTALLING THE FRONT ADJUSTING THE FRONT WHEEL STATIC BALANCE 4-7 REAR WHEEL AND BRAKE REAR REMOVING THE REAR CHECKING THE REAR CHECKING THE REAR WHEEL DRIVE HUB 4-13 CHECKING AND REPLACING THE...

Checking The Connections

Pocket Tester 90890 03112

Check the leads, couplers, and connectors for stains, rust, moisture, etc. Moisture Dry with an air blower. Rust stains Connect and disconnect several times. Loose connection Connect properly. If the pin d on the terminal is flattened, bend it up. Make sure that all connections are tight. 5. Check continuity with a pocket tester If there is no continuity, clean the terminals. When checking the wire harness, perform steps 1 to 3. As a quick remedy, use a contact revitalizer available at most...

How To Use This Manual

Yamaha Fazer Engine Exploded

This manual is intended as a handy, easy-to-read reference book for the mechanic. Comprehensive explanations of all installation, removal, disassembly, assembly, repair and check procedures are laid out with the individual steps in sequential order. d The manual is divided into chapters. An abbreviation and symbol in the upper right corner of each page indicate the current chapter. Refer to SYMBOLS on the following page. 2 Each chapter is divided into sections. The current section title is...

Spark plug

Stand the motorcycle on a level surface. Place the motorcycle on a suitable stand. Make sure that the motorcycle is upright. 2. Let the engine idle for a few minutes. The engine oil level should be between the minimum level marks and maximum level marks Below the minimum level mark Add the recommended engine oil to the proper level. Refer to the chart for the engine oil grade which is best suited for certain atmospheric temperatures. API standard SE or higher grade ACEA standard G4 or G5

Adjusting The Rear Brake Checking The Brake Fluid Level

Adjust rear brake light switch Refer to ADJUSTING THE REAR BRAKE LIGHT SWITCH. 1. Stand the motorcycle on a level surface. Place the motorcycle on a suitable stand. Make sure that the motorcycle is upright. 2. Check brake fluid level Below the minimum level mark Add the recommended brake fluid to the proper level.

Seat

CHECKING THE FUEL HOSES AND FUEL FILTER CHECKING THE CRANKCASE BREATHER HOSE CHECKING THE EXHAUST SYSTEM Drain and flush the fuel tank if abrasive damage to any components of the fuel line is evident. The arrow mark on the fuel filter should face to the side of the fuel pump . CHECKING THE CRANKCASE BREATHER HOSE crankcase breather hose Cracks damage Replace. Loose connection Connect properly.

Bleeding The Hydraulic Brake System Adjusting The Shift Pedal

Rear Master Cylinder Suzuki Bandit

Add the recommended brake fluid to the proper level. b. Install the diaphragm brake master cylinder reservoir or brake fluid reservoir . c. Connect a clear plastic hose tightly to the bleed screw . d. Place the other end of the hose into a container. e. Slowly apply the brake several times. f. Fully squeeze the brake lever or fully depress the brake pedal and hold it in position. This will release the tension and cause the brake lever to contact the throttle...

Cable Routing

Rectifier Xt600

A Fasten the handlebar switch lead right and handlebar with a plastic band. IB Route the handlebar switch lead right backward the throttle cable and right side the brake hose guide. C Fasten the handlebar switch lead left and handlebar with a plastic band. D Fasten the handlebar switch lead left , main switch lead, clutch cable and starter cable with a plastic band. Clamp beneath the horn lead branching position. Do not fasten the horn lead. E Route the main switch lead front and left side the...

Adjusting The Exup Cables Checking The Coolant Level

Insert a 4 mm long pin through the notch in the EXUP valve pulley and into the hole in the EXUP valve cover. c. Turn both adjusting bolts 2 counterclockwise until there is no EXUP cable free play. d. Turn both adjusting bolts 1 2 of a turn clockwise. e. Tighten both locknuts and then remove the pin. 6. Install EXUP valve pulley cover

Adjusting The Engine Idling Speed Adjusting The Throttle Cable Free Play

Free Vintage Kart Plans

Turn the throttle stop screw 2 in direction a or until the specified engine idling speed is obtained. 5. Adjust throttle cable free play Refer to ADJUSTING THE THROTTLE CABLE FREE PLAY. 5. Adjust throttle cable free play Refer to ADJUSTING THE THROTTLE CABLE FREE PLAY. Throttle cable free play at the flange of the throttle grip 3 5 mm Throttle cable free play at the flange of the throttle grip 3 5 mm

Adjusting The Engine Idling Speed Note

Prior to adjusting the engine idling speed, the carburetor synchronization should be adjusted properly, the air filter should be clean, and the engine should have adequate compression. 1. Start the engine and let it warm up for several minutes. engine tachometer to the spark plug lead of cyl. 1 3. Measure engine idling speed Out of specification Adjust. Engine idling speed 1,050 - 1,150 r min a. Turn the pilot screw in or out until it is lightly seated. b. Turn the pilot screw out the specified...

Changing The Engine

Oil Filter Wrench 90890 01426

Start the engine, warm it up for several minutes, and then turn it off. 2. Place a container under the engine oil drain bolt. engine oil drain bolt 2 along with the gasket 5. If the oil filter cartridge is also to be replaced, perform the following procedure. a. Remove the oil filter cartridge with an oil filter wrench 2. b. Apply a thin coat of engine oil onto the O-ring d of the new oil filter cartridge.

Electrical Specifications

Transistorized coil ignition 5 BTDC at 1,100 r min 55 BTDC at 5,000 r min Throttle position sensor and electrical 248 372 W Gy-B TNDF66 DENSO Model manufacturer Minimum ignition spark gap Primary coil resistance Secondary coil resistance Throttle position sensor standard resistance AC magneto F4T361 MITSUBISHI 14 V 365 W at 5,000 r min 0.27 0.33 W at 20 C W-W Regulator type Model manufacture No-load regulated voltage Rectifier capacity Withstand voltage Semiconductor short circuit SH650C-11...

Special Tools

The following special tools are necessary for complete and accurate tune-up and assembly. Use only the appropriate special tools as this will help prevent damage caused by the use of inappropriate tools or improvised techniques. Special tools, part numbers or both may differ depending on the country. When placing an order, refer to the list provided below to avoid any mistakes. This tool is used to remove the generator rotor. This tool is used to hold the generator rotor when removing or...