Yamaha FJ Manuals

Manuals and User Guides for Yamaha FJ. We have 1 Yamaha FJ manual available for free PDF download: Owners Workshop Manual

Yamaha FJ Owners Workshop Manual (201 pages)

Air-Cooled Fours 598cc

Brand: Yamaha | Category: Motorcycle | Size: 93.96 MB

Contents
2
Identification Numbers
4
Identifying Model Years
4
Buying Parts
5
General Specifications
5
Maintenance Techniques, Tools and Working Facilities
6
Fastening Systems
6
Tightening Sequences and Procedures
6
Gasket Sealing Surfaces
6
Maintenance and Minor Repair Tool Kit
10
Repair and Overhaul Tool Set
10
Special Tools
10
Care and Maintenance of Tools
10
Working Facilities
11
Safety First
12
Essential Dos and Don'ts
12
Asbestos
12
Fire
12
Motorcycle Chemicals and Lubricants
13
Troubleshooting
14
Engine Doesn't Start or Is Difficult to Start
15
Starter Motor Does Not Rotate
15
Starter Motor Rotates but Engine Does Not Turn over
15
No Fuel Flow
15
Poor Running at Low Speed
16
Stalls after Starting
16
Rough Idle
16
Spark Weak
16
Poor Running or no Power at High Speed
17
Overheating
17
Firing Incorrect
17
Fuel/Air Mixture Incorrect
17
Clutch Problems
18
Compression too High
18
Engine Load Excessive
18
Clutch Slipping
18
Gear Shifting Problems
19
Abnormal Engine Noise
19
Abnormal Driveline Noise
19
Valve Noise
19
Abnormal Frame and Suspension Noise
20
Oil Level Indicator Light Comes on
20
Excessive Exhaust Smoke
20
Brake Noise
20
Poor Handling or Stability
21
Braking Problems
21
Electrical Problems
21
Handlebar Hard to Turn
21
Battery Overcharged
22
Tune-Up and Routine Maintenance
23
Specifications
24
Recommended Lubricants and Fluids
25
Yamaha FJ, FZ, XJ, YX Radian 600 Routine Maintenance Intervals
26
Daily or before Riding
26
After the Initial 500 Miles
26
Every 500 Miles
26
Introduction to Tune-Up and Routine Maintenance
27
Fluid Levels - Check
27
Engine Oil
27
Battery Electrolyte Level/Specific Gravity - Check
28
Brake Fluid
28
Brake Pads - Check
30
Brake Shoes - Check
30
Brake System - General Check
30
Brake Lever Play and Pedal Position - Check and Adjustment
31
Front Brake
31
Rear Brake
31
Drum Brake Models
31
Tires/Wheels - General Check
32
Throttle Operation/Grip Freeplay - Check and Adjustment
32
Throttle Check
32
Throttle Cable Adjustment
32
Clutch - Check
33
Drive Chain and Sprockets - Check, Adjustment and Lubrication
33
Engine Oil/Filter - Change
35
Lubrication
35
Air Filter Element - Servicing
36
Cylinder Compression - Check
37
Spark Plugs - Replacement
37
Lubrication - General
38
Valve Clearances - Check and Adjustment
40
Early Models
41
Later Models
41
All Models
42
With Yamaha Valve Adjusting Tool
42
With Universal Valve Adjusting Tool
43
Idle Speed - Check and Adjustment
44
Carburetor Synchronization - Check and Adjustment
44
Intake Valve Shim Selection Chart
44
Exhaust Valve Shim Selection Chart
45
Evaporative Emission Control System - Check
46
Exhaust System - Check
46
Steering Head Bearings - Check, Adjustment and Lubrication
46
Fasteners - Check
48
Fuel System - Check and Filter Cleaning
48
Suspension - Check
48
Fork Oil - Replacement
49
Cam Chain Adjustment
50
Engine, Clutch and Transmission
51
General Information
55
Operations Possible with the Engine in the Frame
55
Operations Requiring Engine Removal
55
Engine - Removal and Installation
55
Engine Disassembly and Reassembly - General Information
57
Valve Cover - Removal and Installation
58
Camshaft Chain Tensioner - Removal and Installation
58
Camshafts, Valves and Chain Tensioner - Exploded View
60
Camshafts Removal
61
Camshafts Inspection
62
Camshafts Installation
64
Valve Lifters Removal
65
Valve Listers Inspection
65
Valve Listers Installation
65
Cylinder Head Removal
65
Cylinder Head - Exploded View
66
Cylinder Head Installation
68
Valves/Valve Seats/Valve Guides - Servicing
68
Cylinder Head and Valves Disassembly
68
Cylinder Head and Valves Inspection
69
Cylinder Head and Valves Reassembly
71
Cylinder Block Removal
72
Cylinder Block Inspection
73
Cylinder Block Installation
73
Cylinder Block Details
74
Pistons Removal
75
Pistons Inspection
76
Pistons Installation
77
Piston Rings - Installation
77
Oil Pan and Relief Valves - Removal
78
Relief Valve Inspection
78
Relief Valve Installation
80
Oil Pump Pressure Check
80
Oil Pump Removal
81
Oil Pump Exploded View
81
Oil Pump Inspection
82
Oil Pump Installation
82
Oil Cooler and Hoses - Removal and Installation
82
Clutch Removal
83
Oil Cooler Details
83
Clutch Inspection
84
Clutch - Exploded View
84
Clutch Installation
85
Clutch Cable - Removal
87
External Shift Mechanism
88
Shift Linkage and Pedal
88
Shift Mechanism Removal
88
External Shift Linkage - Exploded View
88
Shift Mechanism Inspection
89
Shift Mechanism Installation
89
Crankcase Disassembly
90
Lower Crankcase - Exploded View
90
Crankcase Reassembly
91
Upper Crankcase - Exploded View
91
Crankcase Components - Inspection and Servicing
92
Main and Connecting Rod Bearings - General Note
92
Crankshaft and Connecting Rod Details
93
Crankshaft Removal
94
Crankshaft Inspection
94
Crankshaft Main Bearing Selection
94
Crankshaft Installation
95
Connecting Rods and Bearings - Removal
96
Connecting Rods and Bearings Inspection
97
Connecting Rod Bearing Selection
97
Connecting Rods and Bearings Installation
98
Starter Chain and Camshaft Chain Removal
98
Chain Guides
98
Starter Chain and Camshaft Chain Inspection
99
Chain Guides Installation
99
Transmission Shafts Removal
99
Transmission Shafts Installation
99
Mainshaft Disassembly
100
Transmission Gears and Shafts - Exploded View
100
Mainshaft Inspection
101
Mainshaft Reassembly
102
Driveshaft Disassembly
102
Driveshaft Inspection
103
Driveshaft Reassembly
103
Shift Cam and Forks Removal
103
Shift Cam and Forks Inspection
103
Shift Cam and Forks Installation
104
Starter Clutch and Drive Chain Tensioner Removal
104
Starter Clutch and Drive Chain Tensioner Disassembly, Inspection and Reassembly
105
Starter Clutch and Drive Chain Tensioner Installation
105
Initial Start-Up after Overhaul
105
Recommended Break-In Procedure
106
Fuel and Exhaust Systems
107
Fuel Tank - Removal and Installation
109
Fuel Tank - Cleaning and Repair
109
Idle Fuel/Air Mixture Adjustment - General Information
109
Carburetor Overhaul - General Information
110
Carburetors - Removal and Installation
110
Carburetors - Disassembly, Cleaning and Inspection
111
Carburetors Exploded View
112
Carburetors - Separation and Joining
118
Carburetors Float Height Adjustment
119
Carburetors Fuel Level Adjustment
119
Throttle Cable and Grip Removal
119
Throttle Cable and Grip Installation
120
Throttle Cable and Grip Adjustment
120
Choke Cable Removal
120
Choke Cable Installation
120
Exhaust System Exploded Views
121
Ignition System
123
Ignition System General Information
124
Ignition System Check
124
Engine will Not Start
124
Engine Starts but Misfires
124
Ignition Coils Check
125
Ignition Coils Removal and Installation
125
Pickup Coils Check
125
Pickup Coils Removal
126
Pickup Coils Installation
126
Igniter Check
126
Igniter Removal and Installation
126
Frame, Suspension and Final Drive
127
Frame, Suspension and Final Drive General Information
128
Frame - Inspection and Repair
128
Side and Centerstand - Maintenance
128
Handlebars - Removal and Installation
129
Front Forks - Removal
130
Front Forks - Installation
130
Forks Disassembly
130
Front Forks Exploded Views
131
Forks Inspection
134
Forks Reassembly
135
Steering Head Bearings - Replacement
135
Steering Head Bearings Removal
135
Steering Head Bearings Inspection
139
Steering Head Bearings Installation
139
Rear Shock Absorber Removal
139
Rear Shock Absorber Inspection
140
Rear Shock Absorber Installation
142
Rear Suspension Linkage - Removal, Inspection and Installation
143
Rear Suspension Linkage and Swingarm Details
143
Swingarm Bearings - Check
144
Swingarm Details
144
Swingarm - Removal and Installation
145
Swingarm Bearings - Inspection and Replacement
145
Drive Chain Removal
146
Drive Chain Cleaning
146
Drive Chain Installation
146
Sprockets - Check and Replacement
146
Rear Wheel Coupling/Rubber Damper - Check and Replacement
147
Suspension Adjustments
147
Brakes, Wheels and Tires
149
Rear Caliper Exploded View
150
Rear Calipers
150
Brake Caliper Removal
151
Rear Brake Caliper Exploded View
151
Brake Caliper Overhaul
152
Brake Caliper Installation
153
Brake Discs Removal
153
Brake Discs Inspection
153
Brake Discs Installation
153
Front Brake Master Cylinder Removal
154
Front Brake Master Cylinder Overhaul
154
Front Brake Master Cylinder - Exploded View
154
Front Brake Master Cylinder Installation
155
Rear Brake Master Cylinder Removal
156
Rear Brake Master Cylinder Overhaul
156
Rear Brake Master Cylinder Exploded View
156
Front Brake Hose Details
157
Rear Brake Master Cylinder Installation
157
Brake Hoses Inspection
157
Brake Hoses Replacement
158
Brake System Bleeding
158
Rear Drum Brakes Removal
159
Rear Drum Brakes Inspection
159
Rear Drum Brakes Installation
159
Wheels Inspection and Repair
160
Wheels Alignment Check
160
Front Wheel Removal
161
Front Wheel Installation
161
Front Wheel Details
161
Rear Wheel Details
162
Rear Wheel Removal
163
Rear Wheel Installation
164
Wheel Bearings - Inspection and Maintenance
165
Front Wheel Bearings
165
Tubeless Tires - General Information
166
Rear Coupling Bearing
166
Rear Wheel Bearings
166
Tire Changing Sequence - Tubeless Tires
167
Fairings and Bodywork
168
Seat Removal and Installation
168
Side Covers Removal and Installation
169
Lower Fairing Removal and Installation
169
Upper Fairing Removal and Installation
170
Lower and Center Fairings Removal and Installation
170
Electrical System
171
Electrical System General Information
173
Electrical Troubleshooting
173
Battery Inspection and Maintenance
173
Battery Charging
173
Fuses - Check and Replacement
174
Lighting System Check
174
Headlight
174
Taillight/License Plate Light
174
Headlight Bulb - Replacement
175
Brake Light
175
Neutral Indicator Light
175
Oil Level Warning Light
175
Headlight Aim - Check and Adjustment
176
Turn Signal and Taillight Bulbs Replacement
177
Turn Signal Circuit - Check
178
Brake Light Switches - Check and Replacement
178
Circuit Check
178
Switch Replacement
178
Electrical Component Locations
179
Instruments and Speedometer Cable Removal and Installation
180
Rear Brake Pedal Switch
180
Meters and Gauges Check
181
Instrument and Warning Light Bulbs Replacement
181
Tachometer and Speedometer
181
Oil Level Sender Removal
182
Oil Level Sender Check
182
Oil Level Sender Installation
182
Ignition Main (Key) Switch Check and Replacement
182
Handlebar Switches Check
183
Handlebar Switches Removal and Installation
183
Neutral Switch Check and Replacement
184
Sidestand Switch Check and Replacement
184
Clutch Switch Check and Replacement
184
Horn Check
185
Horn Replacement
185
Starter Relay Check
185
Starter Relay Replacement
185
Starter Motor Installation
186
Starter Motor Disassembly
186
Starter Exploded View
187
Starter Motor Inspection
188
Starter Motor Reassembly
189
Charging System Testing - General Information and Precautions
190
Charging System - Output Test
190
Charging System - Component Tests
190
Alternator - Removal and Installation
191
Regulator/Rectifier Removal and Installation
192
Wiring Diagrams
193
Color Code
195
Conversion Factors
196
Index
197

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