1987 Yamaha FZR 1000 Service Manual

The 1987 Yamaha FZR 1000 is a high-performance sport motorcycle featuring a 1002cc liquid-cooled, DOHC, 20-valve inline-four engine with Genesis technology, 5-speed transmission, aluminum Deltabox frame, anti-dive front suspension, and monoshock rear suspension. This service manual covers maintenance procedures, specifications, troubleshooting, and repair guidelines for proper upkeep and optimal performance.

1. General Information 2. Specifications 3. Periodic Maintenance 4. Engine 5. Cooling System 6. Fuel System 7. Electrical System 8. Chassis 9. Troubleshooting 10. Wiring Diagrams

General Information

This manual provides technical information for the 1987 Yamaha FZR 1000. Includes identification numbers, safety precautions, and general maintenance guidelines.

Component	Location/Description
Frame Number	Stamped on steering head
Engine Number	Stamped on left side of crankcase
Model Code	FZR1000
Manufacture Date	1987

Specifications

Engine Type: Liquid-cooled, 4-stroke, DOHC, 20-valve inline-four
Displacement: 1002cc
Bore x Stroke: 75.5mm x 56.0mm
Compression Ratio: 11.2:1
Fuel System: 4x Mikuni BDST38 carburetors
Ignition System: CDI
Transmission: 5-speed constant mesh
Final Drive: Chain
Frame: Aluminum Deltabox
Suspension Front: 41mm telescopic fork with anti-dive
Suspension Rear: Monoshock
Brakes Front: Dual disc
Brakes Rear: Single disc
Fuel Capacity: 18 liters
Dry Weight: 215 kg

Periodic Maintenance

Regular maintenance schedule for optimal performance and longevity.

Item	Every 1000km	Every 6000km	Every 12000km
Engine Oil	Check	Replace	-
Oil Filter	-	Replace	-
Spark Plugs	Check	Replace	-
Air Filter	Clean	-	Replace
Valve Clearance	-	Check/Adjust	-
Chain	Lubricate/Adjust	-	-
Brake Fluid	Check	Replace	-
Coolant	Check	-	Replace

Engine

Service procedures for engine components and systems.

Cylinder Head Removal: Drain coolant, remove camshafts, disconnect cables, unbolt head
Valve Adjustment: Set piston at TDC compression, measure clearance (IN: 0.10-0.15mm, EX: 0.15-0.20mm)
Piston/Cylinder: Inspect for wear, measure clearance (0.030-0.045mm)
Crankshaft: Check runout (max 0.03mm), bearing clearance
Clutch: Adjust free play (10-15mm at lever end), inspect plates

WARNING! Always use proper torque values and follow sequence for engine assembly.

Cooling System

Liquid cooling system maintenance and repair.

Radiator: Inspect for leaks, clean fins, check cap pressure (0.9-1.1 kg/cm²)
Thermostat: Check opening temperature (80-84°C)
Water Pump: Inspect seal, impeller, bearing
Coolant Replacement: Use ethylene glycol antifreeze, capacity 2.4 liters

CAUTION! Never open radiator cap when engine is hot.

Fuel System

Carburetor and fuel delivery system service.

Component	Specification
Carburetor Type	Mikuni BDST38 x 4
Main Jet	#115
Pilot Jet	#35
Float Level	14.5mm
Idle Speed	1100-1300 rpm

Carburetor Synchronization: Use vacuum gauges, adjust balance screws
Float Level Adjustment: Measure from carburetor body to float bottom
Fuel Filter: Replace if clogged

Electrical System

Electrical components testing and service.

Battery: 12V 10Ah, specific gravity 1.280
Alternator: Output 14V 25A at 5000 rpm
Spark Plug: NGK CR9E, gap 0.7-0.8mm
Ignition Timing: 10° BTDC at 1200 rpm, 35° BTDC at 5000 rpm

Testing Procedures: Use multimeter to check resistance and voltage values per specifications.

Chassis

Frame, suspension, and brake system maintenance.

Front Fork: Oil capacity 486ml per leg, oil type SAE 10W
Rear Shock: Check preload adjustment, inspect for oil leaks
Steering Head Bearings: Adjust play, lubricate with grease
Brake Pads: Replace if thickness below 1.0mm
Brake Discs: Minimum thickness 4.0mm front, 5.0mm rear
Wheel Bearings: Check for play, replace if rough rotation
Tire Pressure: Front 2.25 kg/cm², Rear 2.50 kg/cm²

Troubleshooting

Symptom	Possible Cause	Corrective Action
Engine won't start	No spark, fuel issue, compression	Check spark plugs, fuel flow, compression test
Poor idle	Carb sync, vacuum leak, valves	Synchronize carbs, check hoses, adjust valves
Overheating	Coolant low, thermostat, radiator	Check coolant level, test thermostat, clean radiator
Brake drag	Stuck caliper, contaminated fluid	Clean calipers, replace brake fluid
Electrical failure	Battery, alternator, connections	Test battery/alternator output, check grounds

Wiring Diagrams

Complete electrical schematics for the 1987 Yamaha FZR 1000. Includes color codes, connector locations, and circuit descriptions for proper electrical system diagnosis and repair.

Note: Refer to separate fold-out diagram pages for full-scale wiring schematics.