YAMAHA YZF1000 2000 Workshop Manual

PERIODIC MAINTENANCE AND MINOR REPAIR
6-3
6
11
*Wheel bearings• Check bearing for looseness or damage.
• Replace if necessary. ÖÖ
12*Swingarm• Check swingarm pivoting point for play.
• Correct if necessary.
• Lubricate with molybdenum disulfide grease every 24,000 km or
24 months (whichever comes first).ÖÖ
13 Drive chain• Check chain slack.
• Adjust if necessary. Make sure that the rear wheel is properly
aligned.
• Clean and lubricate. Every 1,000 km and after washing the
motorcycle or riding in the rain
14*Steering bearings• Check bearing play and steering for roughness.
• Correct accordingly.
• Lubricate with lithium soap base grease every 24,000 km
or 24 months (whichever comes first).ÖÖ
15*Chassis fasteners• Make sure that all nuts, bolts and screws are properly tightened.
• Tighten if necessary.ÖÖ
16 Sidestand• Check operation.
• Lubricate and repair if necessary.ÖÖ
17*Sidestand switch• Check operation.
• Replace if necessary.ÖÖÖ
18*Front fork• Check operation and for oil leakage.
• Correct accordingly.ÖÖ
19*Rear shock absorber
assembly• Check operation and shock absorber for oil leakage.
• Replace shock absorber assembly if necessary. ÖÖ
20*Rear suspension relay
arm and connecting arm
pivoting points• Check operation.
• Lubricate with molybdenum disulfide grease every 24,000 km or
24 months (whichever comes first).ÖÖ
21*Carburetors• Check engine idling speed, synchronization and starter operation.
• Adjust if necessary.ÖÖÖ NO. ITEM CHECKS AND MAINTENANCE JOBSINITIAL
(1,000 km)EVERY
6,000 km
or
6 months
(whichever
comes first)12,000 km
or
12 months
(whichever
comes first)
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PERIODIC MAINTENANCE AND MINOR REPAIR
6-4
6
* Since these items require special tools, data and technical skills, they should be serviced by a Yamaha dealer.
EAU02971*
NOTE:@ l
The air filter needs more frequent service if you are riding in unusually wet or dusty areas.
l
Hydraulic brake and clutch systems
• After disassembling the master cylinder, caliper cylinder or clutch release cylinder, always replace the brake fluid.
Check the brake fluid level of the master cylinder and clutch release cylinder regularly and fill as required.
• Replace the oil seals on the inner parts of the master cylinder, caliper cylinder and clutch release cylinder every two
years.
• Replace the brake and clutch hoses every four years or if cracked or damaged.
@22 Engine oil• Check oil level and vehicle for oil leakage.
• Correct if necessary.
• Change. (Warm engine before draining.)ÖÖÖ
23 Engine oil filter cartridge
• Replace.ÖÖ
24
*Cooling system• Check coolant level and vehicle for coolant leakage.
• Correct if necessary.
• Change coolant every 24,000 km or 24 months
(whichever comes first).ÖÖ NO. ITEM CHECKS AND MAINTENANCE JOBSINITIAL
(1,000 km)EVERY
6,000 km
or
6 months
(whichever
comes first)12,000 km
or
12 months
(whichever
comes first)
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PERIODIC MAINTENANCE AND MINOR REPAIR
6-5
6
EAU01065
Cowling removal and
installationThe cowlings indicated in the illustra-
tion need to be removed to perform
some of the maintenance described in
this chapter. Refer to this section each
time a cowling has to be removed or re-
installed.
EAU00484*
Cowling ATo remove
Remove the screws and pull outward
as shown.
To install
Place in the original position and install
the screws.
EAU00482
Cowling BTo remove
Remove the screws.
1. Screw (´ 13)
1. Screw (´ 3)
2. Pull
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PERIODIC MAINTENANCE AND MINOR REPAIR
6-6
6 To install
Place in the original position and install
the screws.
EAU00483
Cowling CTo remove
Remove the bolts shown and discon-
nect the turn signal leads.To install
Place in the original position, install the
bolts and connect the turn signal leads.1. Cowling C
2. Bolt (´ 14)
1. Turn signal lead (´ 2)
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PERIODIC MAINTENANCE AND MINOR REPAIR
6-7
6
EAU01668*
Spark plugsRemoval
1. Remove cowlings A and C. (See
pages 6-5 and 6-6 for removal and
installation procedures.)
2. Remove the spark plug caps.3. Use the spark plug wrench in the
tool kit to remove the spark plugs
as shown.
Inspection
The spark plug is an important engine
component and is easy to inspect. The
condition of the spark plug can indicate
the condition of the engine.
Normally, all spark plugs from the
same engine should have the same
color on the white insulator around the
center electrode. The ideal color at this
point is a medium-to-light tan color for a
motorcycle that is being ridden normal-
ly. If one spark plug shows a distinctlydifferent color, there could be some-
thing wrong with the engine.
Do not attempt to diagnose such prob-
lems yourself. Instead, take the motor-
cycle to a Yamaha dealer. You should
periodically remove and inspect the
spark plugs because heat and deposits
will cause any spark plug to slowly
break down and erode. If electrode ero-
sion becomes excessive, or if carbon
and other deposits are excessive, you
should replace the spark plug with the
specified plug.1. Spark plug cap (´ 4)
1. Spark plug wrench
Specified spark plug:
DR8EA (NGK)
X24ESR-U (DENSO)
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PERIODIC MAINTENANCE AND MINOR REPAIR
6-8
6 Installation
1. Measure the electrode gap with a
wire thickness gauge and, if nec-
essary, adjust the gap to specifica-
tion.
2. Clean the gasket surface. Wipe off
any grime from the threads.
3. Install the spark plugs and tighten
them to the specified torque.
NOTE:@ If a torque wrench is not available when
you are installing a spark plug, a good
estimate of the correct torque is 1/4 to
1/2 turn past finger tight. Have the
spark plug tightened to the specified
torque as soon as possible. @4. Install the spark plug caps.
5. Install the cowlings.
a. Spark plug gapSpark plug gap:
0.6 ~ 0.7 mm
Tightening torque:
Spark plug:
18 Nm (1.8 m·kg)
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PERIODIC MAINTENANCE AND MINOR REPAIR
6-9
6
EAU01765*
Engine oilOil level inspection
1. Place the motorcycle on a level
place and hold it in an upright posi-
tion. Warm up the engine for seve-
ral minutes.NOTE:@ Be sure the motorcycle is positioned
straight up when checking the oil level.
A slight tilt toward the side can result in
false readings. @
2. With the engine stopped, check
the oil level through the level win-
dow located at the lower part of
the right side crankcase cover.NOTE:@ Wait a few minutes until the oil level
settles before checking. @3. The oil level should be between
maximum and minimum marks. If
the level is low, fill the engine with
sufficient oil to reach the specified
level.Engine oil and oil filter cartridge re-
placement
1. Remove cowling A. (See page 6-5
for removal and installation proce-
dures.)
2. Warm up the engine for several
minutes.
3. Stop the engine. Place an oil pan
under the engine and remove the
oil filler cap.
4. Remove the drain bolt and drain
the oil.
1. Oil level window
2. Maximum level mark
3. Minimum level mark
1. Engine oil filler cap
1. Engine oil drain boltLeft side view
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PERIODIC MAINTENANCE AND MINOR REPAIR
6-10
6 5. Remove the oil filter by using an oil
filter wrench.
NOTE:@ An oil filter wrench is available at a
nearby Yamaha dealer. @6. Reinstall the drain bolt and tighten
it to the specified torque.7. Apply a light coat of engine oil to
the O-ring of the new oil filter.
NOTE:@ Make sure the O-ring is seated proper-
ly. @
8. Install the oil filter and tighten it to
the specified torque with an oil fil-
ter wrench.NOTE:When installing the oil filter, tighten it to
the proper torque by using a torque
wrench.9. Fill the engine with sufficient oil to
reach the specified level. Install
the oil filler cap and tighten it.
1. Oil filter
2. Oil filter wrenchTightening torque:
Drain bolt:
43 Nm (4.3 m·kg)
1. O-ring
1. Torque wrenchTightening torque:
Oil filter:
17 Nm (1.7 m·kg)
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PERIODIC MAINTENANCE AND MINOR REPAIR
6-11
6
EC000066
CAUTION:@ l
Do not put in any chemical addi-
tives. Engine oil also lubricates
the clutch and additives could
cause clutch slippage.
l
Be sure no foreign material en-
ters the crankcase.
@
10. Start the engine and warm it up for
several minutes. While warming
up, check for oil leakage. If oil
leakage is found, stop the engine
immediately and check for the
cause.NOTE:@ After the engine is started, the oil level
indicator light should go off if the oil is at
the specified level. @
EC000067
CAUTION:@ If the indicator light flickers or re-
mains on, immediately stop the en-
gine and consult with a Yamaha
dealer. @11. Install the cowling stay and cowl-
ing.
EAU01594
CoolantCheck the coolant level in the reservoir
tank when the engine is cold. The cool-
ant level will vary with engine tempera-
ture. The coolant level is satisfactory if
it is between the minimum and maxi-
mum marks on the tank. If the coolant
level is at or below the minimum mark,
fill with tap water (soft water) to bring
the level up to the maximum mark.
Have a Yamaha dealer change the
coolant every two years. Recommended oil:
See page 8-1.
Oil quantity:
Total amount:
3.5 L
Periodic oil change:
3.0 L
With oil filter replacement:
3.2 L1. Maximum level mark
2. Minimum level mark
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PERIODIC MAINTENANCE AND MINOR REPAIR
6-12
6
EW000067
WARNING
@ Do not remove the radiator cap
when the engine is hot. @
EC000080
CAUTION:@ Hard water or salt water is harmful
to the engine. You may use distilled
water if you can’t get soft water. @NOTE:@ The radiator fan operation is complete-
ly automatic. It is switched on or off ac-
cording to the coolant temperature in
the radiator. @
EAU01332
Air filterThe air filter should be cleaned at the
specified intervals. It should be cleaned
more frequently if you are riding in un-
usually wet or dusty areas.
1. Remove the seats.
2. Remove cowling B from each side.
(See page 6-5.)
3. Remove the bolts holding the fuel
tank.
4. Lift the fuel tank upward and posi-
tion it away from the air filter case.
(Do not remove the fuel hoses.)
EW000071
WA R N I N G
@ l
Support the fuel tank carefully
during this procedure.
l
Do not tilt the fuel tank too
much or pull it too hard because
the fuel hose connections may
become loose causing fuel
leakage.
@
Reservoir tank capacity:
0.23 L
1. Bolt (´ 2)
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