Yamaha YXZ1000R 2020 User manual

2020
SERVICE MANUAL
YXZ1000R
YXZ1000E
YXZ1000ET
YX10ZXPSL
BAS-F8197-E0

EBS20003
IMPORTANT
This manual was produced by the Yamaha Motor Company, Ltd. primarily for use by Yamaha dealers
and their qualified mechanics. It is not possible to include all the knowledge of a mechanic in one man-
ual. Therefore, anyone who uses this book to perform maintenance and repairs on Yamaha vehicles
should have a basic understanding of mechanics and the techniques to repair these types of vehicles.
Please refer to “BASIC INFORMATION” (separate volume, Y0B-28197-E0*) for basic instructions that
must be observed during servicing. Repair and maintenance work attempted by anyone without this
knowledge is likely to render the vehicle unsafe and unfit for use.
This model has been designed and manufactured to perform within certain specifications in regard to
performance and emissions. Proper service with the correct tools is necessary to ensure that the vehi-
cle will operate as designed. If there is any question about a service procedure, it is imperative that you
contact a Yamaha dealer for any service information changes that apply to this model. This policy is
intended to provide the customer with the most satisfaction from their vehicle and to conform to federal
environmental quality objectives.
Yamaha Motor Company, Ltd. is continually striving to improve all of its models. Modifications and sig-
nificant changes in specifications or procedures will be forwarded to all authorized Yamaha dealers and
will appear in future editions of this manual where applicable.
TIP
•*Ifthecontentsofthemanualarerevised,thelast digit of the manual number will be increased by
one.
•ThisServiceManualcontainsinformationregarding periodic maintenance to the emission control sys-
tem. Please read this material carefully.
•Designsandspecificationsaresubject to change without notice.
EBS30001
IMPORTANT MANUAL INFORMATION
Particularly important information is distinguished in this manual by the following notations.
This is the safety alert symbol. It is used to alert you to potential personal inju-
ry hazards. Obey all safety messages that follow this symbol to avoid possible
injury or death.
A WARNING indicates a hazardous situation which, if not avoided, could result
in death or serious injury.
A NOTICE indicates special precautions that must be taken to avoid damage to
the vehicle or other property.
A TIP provides key information to make procedures easier or clearer.
WARNING
NOTICE
TIP
EBS20002
YXZ1000E/YXZ1000ET/YX10ZXPSL
SERVICE MANUAL
©2020 by Yamaha Motor Co., Ltd.
First edition, September 2019
All rights reserved.
Any reproduction or unauthorized use
without the written permission of
Yamaha Motor Co., Ltd.
is expressly prohibited.

EBS20004
HOW TO USE THIS MANUAL
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.
•Themanualisdividedintochaptersandeachchapterisdivided into sections. The current section title
“1” is shown at the top of each page.
•Sub-sectiontitles“2”appearinsmallerprintthanthesectiontitle.
•Tohelpidentifypartsandclarifyproceduresteps,there are exploded diagrams “3” at the start of each
removal and disassembly section.
•Numbers“4”aregivenintheorderofthejobsintheexplodeddiagram.Anumberindicatesadisas-
sembly step.
•Symbols“5”indicatepartstobelubricatedorreplaced.
Refer to “SYMBOLS”.
•Ajobinstructionchart“6”accompaniestheexplodeddiagram,providingtheorderofjobs,namesof
parts, notes in jobs, etc. This step explains removal and disassembly procedure only. For installation
and assembly procedure, reverse the steps.
•Jobs“7”requiringmoreinformation(suchasspecialtoolsandtechnicaldata)aredescribedsequen-
tially.
1
7
3
5
4
6
2
G101419

EBS20005
SYMBOLS
The following symbols are used in this manual for easier understanding.
TIP
The following symbols are not relevant to every vehicle.
SYMBOL DEFINITION SYMBOL DEFINITION
Serviceable with engine mounted Gear oil
Filling fluid Molybdenum disulfide oil
Lubricant Brake fluid
Special tool Wheel bearing grease
Tightening torque Lithium-soap-based grease
Wear limit, clearance Molybdenum disulfide grease
Engine speed Silicone grease
Electrical data Apply locking agent (LOCTITE®).
Engine oil Replace the part with a new one.
G
M
BF
B
T
R
.
.
LS
M
S
LT
E
New

EBS10003 TABLE OF CONTENTS
GENERAL INFORMATION 1
SPECIFICATIONS 2
PERIODIC CHECKS AND
ADJUSTMENTS 3
CHASSIS 4
ENGINE 5
COOLING SYSTEM 6
FUEL SYSTEM 7
DRIVE TRAIN 8
ELECTRICAL SYSTEM 9
TROUBLESHOOTING 10

1
GENERAL INFORMATION
IDENTIFICATION ............................................................................................1-1
VEHICLE IDENTIFICATION NUMBER .....................................................1-1
MODEL LABEL..........................................................................................1-1
FEATURES......................................................................................................1-2
INSTRUMENT FUNCTIONS .....................................................................1-2
SPECIAL TOOLS ............................................................................................1-7

IDENTIFICATION
1-1
EBS20009
IDENTIFICATION
EBS30003
VEHICLE IDENTIFICATION NUMBER
The vehicle identification number “1” is stamped
into the frame.
EBS30004
MODEL LABEL
The model label “1” is affixed to the frame under
the driver seat. This information will be needed
to order spare parts.
1
1

FEATURES
1-2
EBS20010
FEATURES
EBS30008
INSTRUMENT FUNCTIONS
Multi-function meter unit
The multi-function meter unit is equipped with
the following:
•speedometer
•tachometer
•odometer
•twotripmeters
•clock
•hourmeter
•voltagedisplay
•coolanttemperaturedisplay
•fuelgauge
•transmissiongeardisplay
•shiftlightcontrolmode
•faultcodedisplay
Speedometer
The speedometer shows the vehicle’s traveling
speed. The speedometer can be set to “MPH” or
“km/h”. This also changes the odometer and trip-
meter units between miles and kilometers. To
change the display between “MPH” and “km/h”,
turn the key to “ ” (off), then hold the “SELECT”
button pushed and turn the key to “ ” (on).
Tachometer
The tachometer shows the engine speed in
crankshaft revolutions per minute (r/min).
When the vehicle is first powered on, the ta-
chometer needle will sweep once across the r/
min range and then return to zero r/min in order
to test the electrical circuit.
NOTICE
ECB03060
Do not operate the engine in the tachometer
red zone.
1. Tachometer
2. Transmission gear display
3. Shift light
4. Speedometer
5. “SELECT” button
6. “MODE” button
7. “RESET” button
8. Clock/Hour meter/Voltage display/Coolant
temperature display
9. Fuel gauge
10.Odometer/Tripmeter A/Tripmeter B
123456
10 9 87
1. Speedometer
1. Tachometer
2. Tachometer red zone
Red zone
10500 r/min and above
1
1
2

FEATURES
1-3
Odometer and tripmeters
The odometer shows the total distance traveled
by the vehicle. The odometer can be used for
maintenance and service intervals.
The tripmeters show the distance traveled since
they were last reset. The tripmeters can be used
to record the distance traveled on a single trip, or
to estimate the distance that can be traveled
with a full tank of gas, etc.
Push the “SELECT” button to switch between
the odometer “ODO” and the tripmeters “TRIP
A” and “TRIP B” in the following order:
ODO →TRIP A →TRIP B →ODO
To reset a tripmeter, set the display to the trip-
meter you want to reset, then push the “RESET”
button until it is reset.
TIP
•Theodometerwilllockat99999.
•Thetripmeterswillresetandcontinuecounting
after 9999.9 is reached.
Clock, hour meter, voltage display and cool-
ant temperature display
The clock displays time in 12-hour format.
The hour meter shows the total time the engine
has been running.
The voltage display shows the battery voltage.
The coolant temperature display shows the tem-
perature of the coolant.
Push the “MODE” button to switch between the
clock “CLOCK”, the hour meter “HOUR”, the
voltage display “VOLTAGE”, and the coolant
temperature display in the following order:
CLOCK →HOUR →VOLTAGE →coolant tem-
perature →CLOCK
[To set the clock]
1. Set the display to the clock.
2. Push both the “SELECT” button and “RE-
SET” button until the hour digits start flashing.
3. Push the “RESET” button to set the hours.
4. Push the “SELECT” button, and the minute
digits will start flashing.
5. Push the “RESET” button to set the minutes.
6. Push the “SELECT” button, and then release
it to start the clock.
[Voltage display]
This display shows “ ” and the battery voltage.
When the battery voltage is low, “LO” will be dis-
played. When the battery voltage is high, “HI” will
be displayed.
NOTICE
ECB02020
If the voltage display indicates “LO” or “HI”,
there may be trouble with the battery
charging circuit or the battery may be faulty.
If this occurs, check or repair the vehicle.
1. Odometer/Tripmeter A/Tripmeter B
2. “SELECT” button
3. “RESET” button
1. Clock/Hour meter/Voltage display/Coolant
temperature display
2. “SELECT” button
3. “RESET” button
1 2 3
1 2 3 4
4. “MODE” button
1. Voltage display
1

FEATURES
1-4
[Coolant temperature display]
When the coolant temperature is in the normal
operating range, the temperature will be dis-
played. When the coolant temperature is low,
“LO” will be displayed. When the coolant tem-
perature rises, the coolant temperature display
will begin to flash. If the coolant temperature
continues to rise, the message “HI” will flash.
TIP
•Thecoolanttemperaturedisplaycanbesetto
“°C” or “°F”. To switch the temperature units,
turn the key to “ ” (off), then hold the “RE-
SET” button pushed and turn the key to “ ”
(on).
•Theradiatorfanturnsonandoffautomatically
according to the coolant temperature.
Fuel gauge
The fuel gauge indicates the amount of fuel in
the fuel tank. The display segments of the fuel
gauge disappear from “F” (full) towards “E”
(empty) as the fuel level decreases. When the
last segment of the fuel gauge starts flashing, re-
fuel as soon as possible.
TIP
This fuel gauge is equipped with a self-diagnosis
system. If a problem is detected in an electrical
circuit, the fuel gauge will flash repeatedly. If this
occurs, check the electrical circuit.
Refer to “SIGNALING SYSTEM” on page 9-23.
Transmission gear display
This display shows the selected gear. The neu-
tral position is indicated by “N” and by the neutral
indicator light “N”.
Shift light control mode
The shift light has three settings which can be
adjusted.
•Flashingpattern:thisfunctionallowsyouto
choose whether or not the light will come on
and whether it should flash or stay on when ac-
tivated.
•Activationpoint:thisfunctionallowsyoutose-
lect the engine speed at which the light is acti-
vated.
•Deactivationpoint:thisfunctionallowsyouto
select the engine speed at which the light is de-
activated.
1. Coolant temperature display
1. Fuel gauge
1
1
1. Transmission gear display
2. Neutral indicator light “N”
1. Shift light
2. “MODE” button
3. “RESET” button
1 2
1
2
3

FEATURES
1-5
[To enter the shift light control mode]
1. Turn the key to “ ” (off).
2. Push and hold the “MODE” button.
3. Turn the key to “ ” (on), and then release
the “MODE” button after all segments of the
display disappear and the shift light comes
on. The shift light can be adjusted as follows.
[To set the flashing pattern]
1. Push the “RESET” button to select one of the
following flashing pattern settings:
•On:theshiftlightstaysonwhenactivated.
(The shift light will confirm this setting by stay-
ing on.)
•Flash:theshiftlightflasheswhenactivated.
(The shift light will confirm this setting by
flashing four times per second.)
•Off:theshiftlightisdeactivated;inother
words, it does not come on or flash. (The shift
light will confirm this setting by flashing once
every two seconds.)
2. Push the “MODE” button to confirm the se-
lected flashing pattern. The control mode
changes to the activation point setting mode.
The shift light remains on and the tachometer
shows the current setting r/min for the activa-
tion point.
[To set the shift activation point]
TIP
•Theshiftlightactivationpointcanbesetbe-
tween 7000 r/min and 12000 r/min. The activa-
tion point can be set in increments of 500 r/min.
•Thetachometerneedlewillstartoverat7000r/
min after 12000 r/min.
1. Push the “RESET” button to select the de-
sired engine speed for activating the shift
light.
2. Push the “MODE” button to confirm the se-
lected engine speed. The shift light flashes
and the tachometer shows the current setting
r/min for the deactivation point.
[To set the deactivation point]
TIP
•Besuretosetthedeactivationpointtoahigher
engine speed than for the activation point, oth-
erwise the shift light will not come on.
•Theshiftlightdeactivationpointcanbesetbe-
tween 7000 r/min and 12000 r/min. The deac-
tivation point can be set in increments of 500 r/
min.
•Thetachometerneedlewillstartoverat7000r/
min after 12000 r/min.
1. Push the “RESET” button to select the de-
sired engine speed for deactivating the shift
light.
2. Push the “MODE” button to confirm the se-
lected engine speed. The display exits the
shift light control mode and returns to the
standard multi-function display mode.
Fault code display (YXZ1000E)
This model is equipped with a self-diagnosis de-
vice for various electrical circuits.
If a problem is detected in any of those circuits,
the engine trouble warning light will come on or
flash, and the display will indicate a fault code.
If the display indicates a fault code, note the
code number, and then check the fuel injection
system.
Refer to “FUEL INJECTION SYSTEM” on page
9-43.
NOTICE
ECB02030
If the display indicates a fault code, the vehi-
cle should be checked as soon as possible
in order to avoid engine damage.
Fault code display (YXZ1000ET/YX10ZXPSL)
1. Fault code display
2. Engine trouble warning light “ ”
1. Fault code display
2. YCC-S system fault code display
12
1 2 3 4

FEATURES
1-6
This model is equipped with a self-diagnosis de-
vice for various electrical circuits.
If a problem is detected in any of those circuits,
the engine trouble warning light and/or the YCC-
S system warning light will come on or flash, and
the display will indicates a fault code.
TIP
•YCC-Ssystemfaultcodesaredisplayedonly
when the engine is stopped.
•Ifthedisplayindicatesafaultcode,notethe
code number, and then check the fuel injection
system or YCC-S system.
NOTICE
ECB02030
If the display indicates a fault code, the vehi-
cle should be checked as soon as possible
in order to avoid engine damage.
3. Engine trouble warning light “ ”
4. YCC-S system warning light “ ”

SPECIAL TOOLS
1-7
EBS20013
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.
TIP
•ForU.S.A.andCanada,usepartnumberstartingwith “YM-”, “YU-”, “YS-”, “YK-”, or “ACC-”.
•Forothers,usepartnumberstartingwith“90890-”.
Tool name/Tool No. Illustration Reference
pages
Thickness gauge
90890-03268
Feeler gauge set
YU-26900-9
3-6, 5-68
Valve lapper (ø14)
90890-04101
Valve lapping tool (14mm)
YM-A8998
3-6
Ya m a h a d i a g n o s t i c t o ol U S B
90890-03267
3-9, 7-17, 9-49
Ya m a h a d i a g n o s t i c t o ol ( A / I )
90890-03264
3-9, 7-17, 9-49
Vacuum gauge
90890-03094
Vacuummate
YU-44456
3-11
90890-04101
YM-A8998
YU-44456

SPECIAL TOOLS
1-8
Oil filter wrench
90890-01426
Oil filter wrench
YU-38411
3-20
Vacuum/pressure pump gauge set
90890-06756
Mityvac brake bleeding tool
YS-42423
3-27, 7-5, 9-170
Ring nut wrench (R60)
90890-01584
Ring nut wrench (R60)
YM-01584
3-39, 3-41, 3-45,
3-47, 4-83, 4-83
Ring nut wrench (R60 1/2square wrench)
90890-01585
Ring nut wrench (R60 1/2square wrench)
YM-01585
3-40, 3-42, 3-45,
3-47
Steering nut wrench
90890-01443
Spanner wrench
YU-33975
3-42, 3-43, 3-48,
3-48
Boots band installation tool
90890-01526
Boots band installation tool
YM-01526
4-68, 8-11, 8-13,
8-25, 8-28
Ball joint installer
90890-01586
YM-01586
4-71, 4-76
Compression gauge extension 122mm
90890-04136
Compression gauge extension 122mm
YM-04136
5-8
Tool name/Tool No. Illustration Reference
pages
R60
R60

SPECIAL TOOLS
1-9
Compression gauge
90890-03081
Engine compression tester
YU-33223
5-8
Rotor holding tool
90890-01235
Universal magneto and rotor holder
YU-01235
5-20, 5-22, 5-47,
5-48, 5-84, 5-87
Ya m a h a b o n d N o. 1 2 1 5
90890-85505
(Three bond No.1215®)
5-25, 5-39, 5-85,
5-110
Valve spring compressor
90890-04019
Valve spring compressor
YM-04019
5-30, 5-34
Valve spring compressor attachment
90890-04114
Valve spring compressor adapter 19.5 mm
YM-04114
5-30, 5-34
Valve guide remover (ø4.5)
90890-04116
Valve guide remover (4.5 mm)
YM-04116
5-31
Valve guide installer (ø4.5)
90890-04117
Valve guide installer (4.5 mm)
YM-04117
5-31
Tool name/Tool No. Illustration Reference
pages
90890-03081
YU-33223

SPECIAL TOOLS
1-10
Valve guide reamer (ø4.5)
90890-04118
Valve guide reamer (4.5 mm)
YM-04118
5-31
Rotor holding tool
90890-04166
Rotor holding tool
YM-04166
5-37, 5-37, 5-38,
5-38
Flywheel puller
90890-01362
Heavy duty puller
YU-33270-B
5-37
Digital circuit tester (CD732)
90890-03243
Model 88 Multimeter with tachometer
YU-A1927
5-42, 9-163,
9-164, 9-167,
9-167, 9-168,
9-169, 9-169,
9-170, 9-170,
9-171, 9-172,
9-173, 9-173,
9-174, 9-174,
9-174, 9-175,
9-176, 9-176,
9-176, 9-177,
9-177, 9-178
Universal clutch holder
90890-04086
Universal clutch holder
YM-91042
5-67, 5-70, 5-72
Piston pin puller set
90890-01304
Piston pin puller
YU-01304
5-89
Tool name/Tool No. Illustration Reference
pages
YU-01304

SPECIAL TOOLS
1-11
Piston ring compressor
90890-05158
Piston ring compressor
YM-08037
5-94
Universal joint holder
90890-04062
Universal joint holder
YM-04062
5-109, 5-113,
5-130, 5-131,
8-13, 8-16
Coupling gear/middle shaft tool
90890-01229
Gear holder
YM-01229
5-109, 5-112
Damper spring compressor (120 mm)
90890-01588
YM-01588
5-117, 5-118,
5-130, 5-131
Radiator cap tester
90890-01325
Mityvac cooling system tester kit
YU-24460-A
6-9
Tool name/Tool No. Illustration Reference
pages
ø35
ø25
YU-24460-A