OWNER’S MANUAL FZS1000 FZS1000S YAMAHA MOTOR CO., LTD. PRINTED ON RECYCLED PAPER PRINTED IN JAPAN 2004.08-0.
U1C2E1E0.
U1C2E1E0.book Page 1 Wednesday, August 4, 2004 11:57 AM INTRODUCTION EAU10100 Welcome to the Yamaha world of motorcycling! As the owner of the FZS1000/FZS1000S, you are benefiting from Yamaha’s vast experience and newest technology regarding the design and manufacture of high-quality products, which have earned Yamaha a reputation for dependability. Please take the time to read this manual thoroughly, so as to enjoy all advantages of your FZS1000/FZS1000S.
U1C2E1E0.book Page 1 Wednesday, August 4, 2004 11:57 AM IMPORTANT MANUAL INFORMATION EAU10150 Particularly important information is distinguished in this manual by the following notations: The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR SAFETY IS INVOLVED! WARNING Failure to follow WARNING instructions could result in severe injury or death to the motorcycle operator, a bystander, or a person inspecting or repairing the motorcycle.
U1C2E1E0.book Page 2 Wednesday, August 4, 2004 11:57 AM IMPORTANT MANUAL INFORMATION EAU10200 FZS1000/FZS1000S OWNER’S MANUAL ©2004 by Yamaha Motor Co., Ltd. 1st edition, July 2004 All rights reserved. Any reprinting or unauthorized use without the written permission of Yamaha Motor Co., Ltd. is expressly prohibited. Printed in Japan.
U1C2E1E0.book Page 1 Wednesday, August 4, 2004 11:57 AM TABLE OF CONTENTS SAFETY INFORMATION ..................1-1 DESCRIPTION ..................................2-1 Left view ..........................................2-1 Right view ........................................2-2 Controls and instruments.................2-3 INSTRUMENT AND CONTROL FUNCTIONS .......................................3-1 Main switch/steering lock ................3-1 Indicator and warning lights ............3-2 Speedometer unit ......
U1C2E1E0.book Page 2 Wednesday, August 4, 2004 11:57 AM TABLE OF CONTENTS Checking the front fork .................6-28 Checking the steering ...................6-28 Checking the wheel bearings .......6-29 Battery ..........................................6-29 Replacing the fuses ......................6-31 Replacing a headlight bulb ...........6-32 Replacing a tail/brake light bulb ...6-33 Replacing a turn signal light bulb ...........................................6-34 Replacing an auxiliary light bulb .
U1C2E1E0.book Page 1 Wednesday, August 4, 2004 11:57 AM SAFETY INFORMATION EAU10271 1 MOTORCYCLES ARE SINGLE TRACK VEHICLES. THEIR SAFE USE AND OPERATION ARE DEPENDENT UPON THE USE OF PROPER RIDING TECHNIQUES AS WELL AS THE EXPERTISE OF THE OPERATOR. EVERY OPERATOR SHOULD KNOW THE FOLLOWING REQUIREMENTS BEFORE RIDING THIS MOTORCYCLE. HE OR SHE SHOULD: ● OBTAIN THOROUGH INSTRUCTIONS FROM A COMPETENT SOURCE ON ALL ASPECTS OF MOTORCYCLE OPERATION.
U1C2E1E0.book Page 2 Wednesday, August 4, 2004 11:57 AM SAFETY INFORMATION ● ● due to EXCESSIVE SPEED or undercornering (insufficient lean angle for the speed). • Always obey the speed limit and never travel faster than warranted by road and traffic conditions. • Always signal before turning or changing lanes. Make sure that other motorists can see you. The posture of the operator and passenger is important for proper control.
U1C2E1E0.book Page 3 Wednesday, August 4, 2004 11:57 AM SAFETY INFORMATION 1 Loading The total weight of the operator, passenger, accessories and cargo must not exceed the maximum load limit. Maximum load: 189 kg (417 lb) When loading within this weight limit, keep the following in mind: ● Cargo and accessory weight should be kept as low and close to the motorcycle as possible. Make sure to distribute the weight as evenly as possible on both sides of the motorcycle to minimize imbalance or instability.
U1C2E1E0.book Page 4 Wednesday, August 4, 2004 11:57 AM SAFETY INFORMATION ● tor and may limit control ability, therefore, such accessories are not recommended. Use caution when adding electrical accessories. If electrical accessories exceed the capacity of the motorcycle’s electrical system an electric failure could result, which could cause a dangerous loss of lights or engine power. Gasoline and exhaust gas ● GASOLINE IS HIGHLY FLAMMABLE: • Always turn the engine off when refueling.
U1C2E1E0.book Page 1 Wednesday, August 4, 2004 11:57 AM DESCRIPTION EAU10410 Left view 2 11.Shock absorber assembly spring preload adjusting ring (page 3-15) 12.Shock absorber assembly rebound damping force adjusting knob (page 3-15) 13.Shift pedal (page 3-8) 1. Front fork compression damping force adjusting screw (page 3-13) 2. Front fork rebound damping force adjusting screw (page 3-13) 3. Front fork spring preload adjusting bolt (page 3-13) 4. Air filter element (page 6-14) 5.
U1C2E1E0.book Page 2 Wednesday, August 4, 2004 11:57 AM DESCRIPTION EAU10420 Right view 2 1. 2. 3. 4. 5. 6. 7. 8. 9.
U1C2E1E0.book Page 3 Wednesday, August 4, 2004 11:57 AM DESCRIPTION EAU10430 Controls and instruments 2 1. Clutch lever (page 3-7) 2. Left handlebar switches (page 3-6) 3. Starter (choke) lever (page 3-11) 4. Speedometer unit (page 3-3) 5. Main switch/steering lock (page 3-1) 6. Tachometer unit (page 3-4) 7. Fuel gauge (page 3-5) 8. Right handlebar switches (page 3-6) 9. Brake lever (page 3-8) 10.
U1C2E1E0.book Page 1 Wednesday, August 4, 2004 11:57 AM INSTRUMENT AND CONTROL FUNCTIONS EAU10460 Main switch/steering lock EAU10660 OFF All electrical systems are off. The key can be removed. To unlock the steering EAU10680 LOCK The steering is locked, and all electrical systems are off. The key can be removed. To lock the steering The main switch/steering lock controls the ignition and lighting systems, and is used to lock the steering. The various positions are described below. 3 1. Push. 2.
U1C2E1E0.book Page 2 Wednesday, August 4, 2004 11:57 AM INSTRUMENT AND CONTROL FUNCTIONS EAU10910 3 (Parking) The steering is locked, the taillights and auxiliary lights are on, and the hazard light can be turned on, but all other electrical systems are off. The key can be removed. The steering must be locked before the key can be turned to “ ”.
U1C2E1E0.book Page 3 Wednesday, August 4, 2004 11:57 AM INSTRUMENT AND CONTROL FUNCTIONS EAU11350 Fuel level warning light “ ” This warning light comes on when the fuel level drops below approximately 4.1 L (1.08 US gal) (0.90 Imp.gal). When this occurs, refuel as soon as possible. The electrical circuit of the warning light can be checked by turning the key to “ON”. If the warning light does not come on for a few seconds, then go off, have a Yamaha dealer check the electrical circuit.
U1C2E1E0.book Page 4 Wednesday, August 4, 2004 11:57 AM INSTRUMENT AND CONTROL FUNCTIONS be traveled on a full tank of fuel. This information will enable you to plan future fuel stops. 3 EAU11891 To set the clock 1. Push both the “SELECT” and “RESET” buttons for at least two seconds. 2. When the hour digits start flashing, push the “RESET” button to set the hours. 3. Push the “SELECT” button to change the minutes. 4. When the minute digits start flashing, push the “RESET” button to set the minutes. 5.
U1C2E1E0.book Page 5 Wednesday, August 4, 2004 11:57 AM INSTRUMENT AND CONTROL FUNCTIONS EAU12100 Self-diagnosis devices This model is equipped with a self-diagnosis device for the following electrical circuits: ● throttle position sensor ● speed sensor ● EXUP system ● overturn switch If any of those circuits are defective, the tachometer will repeatedly display the following error code: 0 r/min for 3 seconds Circuit-specific number of r/min for 2.5 seconds (See the table below.
U1C2E1E0.book Page 6 Wednesday, August 4, 2004 11:57 AM INSTRUMENT AND CONTROL FUNCTIONS EAU12330 Anti-theft alarm (optional) This model can be equipped with an optional anti-theft alarm by a Yamaha dealer. Contact a Yamaha dealer for more information. EAU12343 Handlebar switches Right Left 3 1. Engine stop switch “ 2. Start switch “ ” 1. 2. 3. 4. 5.
U1C2E1E0.book Page 7 Wednesday, August 4, 2004 11:57 AM INSTRUMENT AND CONTROL FUNCTIONS position. To cancel the turn signal lights, push the switch in after it has returned to the center position. EAU12500 Horn switch “ ” Press this switch to sound the horn. EAU12660 Engine stop switch “ / ” Set this switch to “ ” before starting the engine. Set this switch to “ ” to stop the engine in case of an emergency, such as when the vehicle overturns or when the throttle cable is stuck.
U1C2E1E0.book Page 8 Wednesday, August 4, 2004 11:57 AM INSTRUMENT AND CONTROL FUNCTIONS EAU12870 Shift pedal EAU12930 Brake lever EAU12941 Brake pedal The brake lever is located at the right handlebar grip. To apply the front brake, pull the lever toward the handlebar grip. 3 1. Shift pedal 1.
U1C2E1E0.book Page 9 Wednesday, August 4, 2004 11:57 AM INSTRUMENT AND CONTROL FUNCTIONS EAU13070 Fuel tank cap EAU13210 NOTE: The fuel tank cap cannot be closed unless the key is in the lock. In addition, the key cannot be removed if the cap is not properly closed and locked. Fuel EWA11090 WARNING 3 Make sure that the fuel tank cap is properly closed before riding. 1. Fuel tank cap lock cover 2. Unlock. 1. Fuel tank filler tube 2. Fuel level Make sure that there is sufficient fuel in the tank.
U1C2E1E0.book Page 10 Wednesday, August 4, 2004 11:57 AM INSTRUMENT AND CONTROL FUNCTIONS ECA10070 CAUTION: Immediately wipe off spilled fuel with a clean, dry, soft cloth, since fuel may deteriorate painted surfaces or plastic parts. or premium unleaded fuel. Use of unleaded fuel will extend spark plug life and reduce maintenance costs. EAU13410 Fuel tank breather hose EAU13320 3 Recommended fuel: REGULAR UNLEADED GASOLINE ONLY Fuel tank capacity: 21.0 L (5.55 US gal) (4.62 Imp.
U1C2E1E0.book Page 11 Wednesday, August 4, 2004 11:57 AM INSTRUMENT AND CONTROL FUNCTIONS EAU13440 Catalytic converter EAU13590 Starter (choke) lever “ ” This vehicle is equipped with a catalytic converter in the muffler. EAU13940 Seat To remove the seat 1. Insert the key into the seat lock, and then turn it clockwise. EWA10860 WARNING The exhaust system is hot after operation. Make sure that the exhaust system has cooled down before doing any maintenance work.
U1C2E1E0.book Page 12 Wednesday, August 4, 2004 11:57 AM INSTRUMENT AND CONTROL FUNCTIONS EAU14350 EAU14411 Helmet holder Storage compartment 1. Helmet holder 2. Unlock. 1. Storage compartment 3 1. Projection 2. Seat holder 2. Push the rear of the seat down to lock it in place. 3. Remove the key. NOTE: Make sure that the seat is properly secured before riding. To open the helmet holder, insert the key into the seat lock, and then turn the key as shown.
U1C2E1E0.book Page 13 Wednesday, August 4, 2004 11:57 AM INSTRUMENT AND CONTROL FUNCTIONS EAU14751 Adjusting the front fork This front fork is equipped with spring preload adjusting bolts, rebound damping force adjusting screws and compression damping force adjusting screws. EWA10180 load and thereby soften the suspension, turn the adjusting bolt on each fork leg in direction (b). NOTE: Align the appropriate groove on the adjusting mechanism with the top of the front fork cap bolt. WARNING 1.
U1C2E1E0.book Page 14 Wednesday, August 4, 2004 11:57 AM INSTRUMENT AND CONTROL FUNCTIONS Rebound damping force Compression damping force ECA10100 CAUTION: Never attempt to turn an adjusting mechanism beyond the maximum or minimum settings. 3 1. Rebound damping force adjusting screw 1. Compression damping force adjusting screw To increase the rebound damping force and thereby harden the rebound damping, turn the adjusting screw on each fork leg in direction (a).
U1C2E1E0.book Page 15 Wednesday, August 4, 2004 11:57 AM INSTRUMENT AND CONTROL FUNCTIONS EAU15041 Adjusting the shock absorber assembly This shock absorber assembly is equipped with a spring preload adjusting ring, a rebound damping force adjusting knob and a compression damping force adjusting screw. ECA10100 CAUTION: Never attempt to turn an adjusting mechanism beyond the maximum or minimum settings.
U1C2E1E0.book Page 16 Wednesday, August 4, 2004 11:57 AM INSTRUMENT AND CONTROL FUNCTIONS Compression damping force 3 1. Compression damping force adjusting screw To increase the compression damping force and thereby harden the compression damping, turn the adjusting screw in direction (a). To decrease the compression damping force and thereby soften the compression damping, turn the adjusting screw in direction (b).
U1C2E1E0.book Page 17 Wednesday, August 4, 2004 11:57 AM INSTRUMENT AND CONTROL FUNCTIONS EAU15280 EAU15300 EXUP system Sidestand This model is equipped with Yamaha’s EXUP (EXhaust Ultimate Power valve) system. This system boosts engine power by means of a valve that regulates the diameter of the exhaust pipe. The EXUP system valve is constantly adjusted in accordance with the engine speed by a computer-controlled servomotor. The sidestand is located on the left side of the frame.
U1C2E1E0.book Page 18 Wednesday, August 4, 2004 11:57 AM INSTRUMENT AND CONTROL FUNCTIONS EAU15321 Ignition circuit cut-off system 3 The ignition circuit cut-off system (comprising the sidestand switch, clutch switch and neutral switch) has the following functions. ● It prevents starting when the transmission is in gear and the sidestand is up, but the clutch lever is not pulled. ● It prevents starting when the transmission is in gear and the clutch lever is pulled, but the sidestand is still down.
U1C2E1E0.book Page 19 Wednesday, August 4, 2004 11:57 AM INSTRUMENT AND CONTROL FUNCTIONS With the engine turned off: 1. Move the sidestand down. 2. Make sure that the engine stop switch is turned on. 3. Turn the key on. 4. Shift the transmission into the neutral position. 5. Push the start switch. Does the engine start? YES NOTE: This check is most reliable if performed with a warmed-up engine. NO The neutral switch may be defective.
U1C2E1E0.book Page 1 Wednesday, August 4, 2004 11:57 AM PRE-OPERATION CHECKS EAU15591 The condition of a vehicle is the owner’s responsibility. Vital components can start to deteriorate quickly and unexpectedly, even if the vehicle remains unused (for example, as a result of exposure to the elements). Any damage, fluid leakage or loss of tire air pressure could have serious consequences.
U1C2E1E0.book Page 2 Wednesday, August 4, 2004 11:57 AM PRE-OPERATION CHECKS EAU15603 Pre-operation check list ITEM CHECKS PAGE Fuel • Check fuel level in fuel tank. • Refuel if necessary. • Check fuel line for leakage. 3-9 Engine oil • Check oil level in engine. • If necessary, add recommended oil to specified level. • Check vehicle for oil leakage. 6-8 Coolant • Check coolant level in reservoir. • If necessary, add recommended coolant to specified level. • Check cooling system for leakage.
U1C2E1E0.book Page 3 Wednesday, August 4, 2004 11:57 AM PRE-OPERATION CHECKS ITEM CHECKS PAGE Throttle grip • Make sure that operation is smooth. • Check cable free play. • If necessary, have Yamaha dealer adjust cable free play and lubricate cable and grip housing. 6-17, 6-26 Control cables • Make sure that operation is smooth. • Lubricate if necessary. Drive chain • • • • Check chain slack. Adjust if necessary. Check chain condition. Lubricate if necessary.
U1C2E1E0.book Page 1 Wednesday, August 4, 2004 11:57 AM OPERATION AND IMPORTANT RIDING POINTS EAU15950 EAU16220 Starting a cold engine EWA10270 WARNING ● ● ● Become thoroughly familiar with all operating controls and their functions before riding. Consult a Yamaha dealer regarding any control or function that you do not thoroughly understand. Never start the engine or operate it in a closed area for any length of time.
U1C2E1E0.book Page 2 Wednesday, August 4, 2004 11:57 AM OPERATION AND IMPORTANT RIDING POINTS ECA11490 CAUTION: ● 5 ● If the oil level warning light flickers or remains on after starting, immediately stop the engine, and then check the engine oil level and the vehicle for oil leakage. If necessary, add engine oil, and then check the warning light again.
U1C2E1E0.book Page 3 Wednesday, August 4, 2004 11:57 AM OPERATION AND IMPORTANT RIDING POINTS EAU16640 Starting a warm engine EAU16671 Shifting ECA10260 CAUTION: Follow the same procedure as for starting a cold engine with the exception that the starter (choke) is not required when the engine is warm. ● 1. Shift pedal 2. Neutral position ● Shifting gears lets you control the amount of engine power available for starting off, accelerating, climbing hills, etc.
U1C2E1E0.book Page 4 Wednesday, August 4, 2004 11:57 AM OPERATION AND IMPORTANT RIDING POINTS EAU16800 Tips for reducing fuel consumption 5 Fuel consumption depends largely on your riding style. Consider the following tips to reduce fuel consumption: ● Turn the starter (choke) off as soon as possible. ● Shift up swiftly, and avoid high engine speeds during acceleration. ● Do not rev the engine while shifting down, and avoid high engine speeds with no load on the engine.
U1C2E1E0.book Page 5 Wednesday, August 4, 2004 11:57 AM OPERATION AND IMPORTANT RIDING POINTS EAU17212 Parking When parking, stop the engine, and then remove the key from the main switch. EWA10310 WARNING ● ● Since the engine and exhaust system can become very hot, park in a place where pedestrians or children are not likely to touch them. Do not park on a slope or on soft ground, otherwise the vehicle may overturn.
U1C2E1E0.book Page 1 Wednesday, August 4, 2004 11:57 AM PERIODIC MAINTENANCE AND MINOR REPAIR EAU17240 EAU17520 Owner’s tool kit 6 Safety is an obligation of the owner. Periodic inspection, adjustment and lubrication will keep your vehicle in the safest and most efficient condition possible. The most important points of inspection, adjustment, and lubrication are explained on the following pages.
U1C2E1E0.book Page 2 Wednesday, August 4, 2004 11:57 AM PERIODIC MAINTENANCE AND MINOR REPAIR EAU17705 Periodic maintenance and lubrication chart NOTE: ● The annual checks must be performed every year, except if a kilometer-based maintenance is performed instead. ● From 50000 km, repeat the maintenance intervals starting from 10000 km. ● Items marked with an asterisk should be performed by a Yamaha dealer as they require special tools, data and technical skills. ODOMETER READING (× 1000 km) NO.
U1C2E1E0.book Page 3 Wednesday, August 4, 2004 11:57 AM PERIODIC MAINTENANCE AND MINOR REPAIR ODOMETER READING (× 1000 km) NO. ITEM 1 9 * Brake hoses 20 30 40 ANNUAL CHECK √ √ √ √ CHECK OR MAINTENANCE JOB 10 √ • Check for cracks or damage. • Replace. Every 4 years 10 * Wheels • Check runout and for damage. √ √ √ √ 11 * Tires • • • • √ √ √ √ 12 * Wheel bearings • Check bearing for looseness or damage. √ √ √ √ • Check operation and for excessive play.
U1C2E1E0.book Page 4 Wednesday, August 4, 2004 11:57 AM PERIODIC MAINTENANCE AND MINOR REPAIR ODOMETER READING (× 1000 km) NO. ITEM 1 10 20 30 40 ANNUAL CHECK CHECK OR MAINTENANCE JOB 22 * Carburetors • Check starter (choke) operation. • Adjust engine idling speed and synchronization. √ √ √ √ √ √ 23 Engine oil • Change. • Check oil level and vehicle for oil leakage. √ √ √ √ √ √ 24 Engine oil filter cartridge • Replace.
U1C2E1E0.book Page 5 Wednesday, August 4, 2004 11:57 AM PERIODIC MAINTENANCE AND MINOR REPAIR ● Hydraulic brake service • Regularly check and, if necessary, correct the brake fluid level. • Every two years replace the internal components of the brake master cylinders and calipers, and change the brake fluid. • Replace the brake hoses every four years and if cracked or damaged.
U1C2E1E0.book Page 6 Wednesday, August 4, 2004 11:57 AM PERIODIC MAINTENANCE AND MINOR REPAIR EAU18771 Removing and installing panels The panels shown need to be removed to perform some of the maintenance jobs described in this chapter. Refer to this section each time a panel needs to be removed and installed. 1. Panel C 2. Panel D 1. Panel C 2. Screw EAU19292 Panels A and C 1. Panel A 2. Panel B To remove one of the panels Remove the screw, and then pull the panel off as shown. 1. Panel A 2.
U1C2E1E0.book Page 7 Wednesday, August 4, 2004 11:57 AM PERIODIC MAINTENANCE AND MINOR REPAIR EAU36570 Panels B and D To remove a panel Remove the screws and the bolt, and then take the panel off. EAU19543 Checking the spark plugs The spark plugs are important engine components, which are easy to check. Since heat and deposits will cause any spark plug to slowly erode, the spark plugs should be removed and checked in accordance with the periodic maintenance and lubrication chart.
U1C2E1E0.book Page 8 Wednesday, August 4, 2004 11:57 AM PERIODIC MAINTENANCE AND MINOR REPAIR 3. Check each spark plug for electrode erosion and excessive carbon or other deposits, and replace it if necessary. Specified spark plug: NGK/CR9E DENSO/U27ESR-N To install a spark plug 1. Measure the spark plug gap with a wire thickness gauge and, if necessary, adjust the gap to specification. 2.
U1C2E1E0.book Page 9 Wednesday, August 4, 2004 11:57 AM PERIODIC MAINTENANCE AND MINOR REPAIR NOTE: The engine oil should be between the minimum and maximum level marks. 2. Place an oil pan under the engine to collect the used oil. 3. Remove the engine oil filler cap and drain bolt to drain the oil from the crankcase. 1. Oil filter wrench 2. Oil filter cartridge 6 1. 2. 3. 4. Engine oil filler cap Engine oil level check window Maximum level mark Minimum level mark 4.
U1C2E1E0.book Page 10 Wednesday, August 4, 2004 11:57 AM PERIODIC MAINTENANCE AND MINOR REPAIR Recommended engine oil: See page 8-1. Oil quantity: Without oil filter cartridge replacement: 2.80 L (2.96 US qt) (2.46 Imp.qt) With oil filter cartridge replacement: 3.00 L (3.17 US qt) (2.64 Imp.qt) ECA11620 1. O-ring NOTE: Make sure that the O-ring is properly seated. 6. Install the new oil filter cartridge with an oil filter wrench, and then tighten it to the specified torque with a torque wrench.
U1C2E1E0.book Page 11 Wednesday, August 4, 2004 11:57 AM PERIODIC MAINTENANCE AND MINOR REPAIR EAU20070 NOTE: After the engine is started, the engine oil level warning light should go off if the oil level is sufficient. CAUTION: The coolant level should be checked before each ride. In addition, the coolant must be changed at the intervals specified in the periodic maintenance and lubrication chart.
U1C2E1E0.book Page 12 Wednesday, August 4, 2004 11:57 AM PERIODIC MAINTENANCE AND MINOR REPAIR ECA10470 CAUTION: ● ● ● If coolant is not available, use distilled water or soft tap water instead. Do not use hard water or salt water since it is harmful to the engine. If water has been used instead of coolant, replace it with coolant as soon as possible, otherwise the engine may not be sufficiently cooled and the cooling system will not be protected against frost and corrosion.
U1C2E1E0.book Page 13 Wednesday, August 4, 2004 11:57 AM PERIODIC MAINTENANCE AND MINOR REPAIR 7. Install the coolant drain bolt, and then tighten it to the specified torque. ECA10470 CAUTION: ● NOTE: Check the washer for damage and replace it if necessary. ● Tightening torque: Coolant drain bolt: 7 Nm (0.7 m·kgf, 5 ft·lbf) 8. Pour the recommended coolant into the radiator until it is full.
U1C2E1E0.book Page 14 Wednesday, August 4, 2004 11:57 AM PERIODIC MAINTENANCE AND MINOR REPAIR EAU20681 Cleaning the air filter element The air filter element should be cleaned at the intervals specified in the periodic maintenance and lubrication chart. Clean the air filter element more frequently if you are riding in unusually wet or dusty areas. 1. Remove the seat. (See page 3-11.) 2. Remove the fuel tank bolts.
U1C2E1E0.book Page 15 Wednesday, August 4, 2004 11:57 AM PERIODIC MAINTENANCE AND MINOR REPAIR out with compressed air as shown. If the air filter element is damaged, replace it. 13. Install the fuel tank by installing the bolts. EWA11290 WARNING ● ● 1. Air filter element 6 9. Insert the air filter element into the air filter case. ECA11330 CAUTION: ● Before installing the fuel tank, make sure that the fuel hoses are not damaged.
U1C2E1E0.book Page 16 Wednesday, August 4, 2004 11:57 AM PERIODIC MAINTENANCE AND MINOR REPAIR EAU21290 Adjusting the carburetors The carburetors are important parts of the engine and require very sophisticated adjustment. Therefore, most carburetor adjustments should be left to a Yamaha dealer, who has the necessary professional knowledge and experience. The adjustment described in the following section, however, may be serviced by the owner as part of routine maintenance.
U1C2E1E0.book Page 17 Wednesday, August 4, 2004 11:57 AM PERIODIC MAINTENANCE AND MINOR REPAIR EAU21381 Checking the throttle cable free play EAU21401 EAU21771 Valve clearance Tires The valve clearance changes with use, resulting in improper air-fuel mixture and/or engine noise. To prevent this from occurring, the valve clearance must be adjusted by a Yamaha dealer at the intervals specified in the periodic maintenance and lubrication chart.
U1C2E1E0.book Page 18 Wednesday, August 4, 2004 11:57 AM PERIODIC MAINTENANCE AND MINOR REPAIR Tire air pressure (measured on cold tires): 0–90 kg (0–198 lb): Front: 250 kPa (36 psi) (2.50 kgf/cm²) Rear: 270 kPa (39 psi) (2.70 kgf/cm²) 90–189 kg (198–417 lb): Front: 250 kPa (36 psi) (2.50 kgf/cm²) Rear: 290 kPa (42 psi) (2.90 kgf/cm²) High-speed riding: Front: 250 kPa (36 psi) (2.50 kgf/cm²) Rear: 290 kPa (42 psi) (2.
U1C2E1E0.book Page 19 Wednesday, August 4, 2004 11:57 AM PERIODIC MAINTENANCE AND MINOR REPAIR EWA10470 WARNING ● ● 6 Have a Yamaha dealer replace excessively worn tires. Besides being illegal, operating the vehicle with excessively worn tires decreases riding stability and can lead to loss of control. The replacement of all wheel and brake related parts, including the tires, should be left to a Yamaha dealer, who has the necessary professional knowledge and experience.
U1C2E1E0.book Page 20 Wednesday, August 4, 2004 11:57 AM PERIODIC MAINTENANCE AND MINOR REPAIR ● ● speed riding to ride conservatively for approximately 100 km (60 mi) after installing a new tire. The tires must be warmed up before a high-speed run. Always adjust the tire air pressure according to the operating conditions. EAU21960 Cast wheels To maximize the performance, durability, and safe operation of your vehicle, note the following points regarding the specified wheels.
U1C2E1E0.book Page 21 Wednesday, August 4, 2004 11:57 AM PERIODIC MAINTENANCE AND MINOR REPAIR EAU22270 NOTE: If the specified free play cannot be obtained as described above or if the clutch does not operate correctly, have a Yamaha dealer check the internal clutch mechanism. Adjusting the rear brake light switch Front brake 1. Rear brake light switch 2.
U1C2E1E0.book Page 22 Wednesday, August 4, 2004 11:57 AM PERIODIC MAINTENANCE AND MINOR REPAIR The front and rear brake pads must be checked for wear at the intervals specified in the periodic maintenance and lubrication chart. Each brake pad is provided with a wear indicator groove, which allows you to check the brake pad wear without having to disassemble the brake. To check the brake pad wear, check the wear indicator grooves.
U1C2E1E0.book Page 23 Wednesday, August 4, 2004 11:57 AM PERIODIC MAINTENANCE AND MINOR REPAIR ● ● ● 6 Be careful that water does not enter the brake fluid reservoir when refilling. Water will significantly lower the boiling point of the fluid and may result in vapor lock. Brake fluid may deteriorate painted surfaces or plastic parts. Always clean up spilled fluid immediately. As the brake pads wear, it is normal for the brake fluid level to gradually go down.
U1C2E1E0.book Page 24 Wednesday, August 4, 2004 11:57 AM PERIODIC MAINTENANCE AND MINOR REPAIR Drive chain slack: 40.0–50.0 mm (1.57–1.97 in) Tightening torque: Axle nut: 150 Nm (15.0 m·kgf, 108 ft·lbf) 5. If the drive chain slack is incorrect, adjust it as follows. EAU22940 To adjust the drive chain slack 1. Loosen the axle nut and the locknut on each side of the swingarm. 2. To tighten the drive chain, turn the adjusting bolt on each side of the swingarm in direction (a).
U1C2E1E0.book Page 25 Wednesday, August 4, 2004 11:57 AM PERIODIC MAINTENANCE AND MINOR REPAIR EAU23021 ECA11110 Lubricating the drive chain CAUTION: The drive chain must be cleaned and lubricated at the intervals specified in the periodic maintenance and lubrication chart, otherwise it will quickly wear out, especially when riding in dusty or wet areas. Service the drive chain as follows.
U1C2E1E0.book Page 26 Wednesday, August 4, 2004 11:57 AM PERIODIC MAINTENANCE AND MINOR REPAIR EAU23110 Checking and lubricating the throttle grip and cable EAU23131 EAU23140 Checking and lubricating the brake and shift pedals Checking and lubricating the brake and clutch levers The operation of the brake and shift pedals should be checked before each ride, and the pedal pivots should be lubricated if necessary.
U1C2E1E0.book Page 27 Wednesday, August 4, 2004 11:57 AM PERIODIC MAINTENANCE AND MINOR REPAIR EAU23210 Checking and lubricating the centerstand and sidestand EAUM1650 Lubricating the rear suspension The swingarm pivots must be lubricated at the intervals specified in the periodic maintenance and lubrication chart. The pivoting points of the rear suspension must be lubricated at the intervals specified in the periodic maintenance and lubrication chart.
U1C2E1E0.book Page 28 Wednesday, August 4, 2004 11:57 AM PERIODIC MAINTENANCE AND MINOR REPAIR EAU23271 EAU23280 Checking the front fork Checking the steering The condition and operation of the front fork must be checked as follows at the intervals specified in the periodic maintenance and lubrication chart. Worn or loose steering bearings may cause danger. Therefore, the operation of the steering must be checked as follows at the intervals specified in the periodic maintenance and lubrication chart.
U1C2E1E0.book Page 29 Wednesday, August 4, 2004 11:57 AM PERIODIC MAINTENANCE AND MINOR REPAIR EAU23290 Checking the wheel bearings EAU33650 Battery The front and rear wheel bearings must be checked at the intervals specified in the periodic maintenance and lubrication chart. If there is play in the wheel hub or if the wheel does not turn smoothly, have a Yamaha dealer check the wheel bearings. 1. Negative battery terminal 2.
U1C2E1E0.book Page 30 Wednesday, August 4, 2004 11:57 AM PERIODIC MAINTENANCE AND MINOR REPAIR ● ● working near batteries. In case of contact, administer the following FIRST AID. • EXTERNAL: Flush with plenty of water. • INTERNAL: Drink large quantities of water or milk and immediately call a physician. • EYES: Flush with water for 15 minutes and seek prompt medical attention. Batteries produce explosive hydrogen gas. Therefore, keep sparks, flames, cigarettes, etc.
U1C2E1E0.book Page 31 Wednesday, August 4, 2004 11:57 AM PERIODIC MAINTENANCE AND MINOR REPAIR EAU23622 Replacing the fuses 6 1. 2. 3. 4. 5. 6. 7. 8. 9. Main fuse Headlight fuse Radiator fan fuse Ignition fuse Signaling system fuse Backup fuse (for odometer and clock) Turn signal light and hazard fuse Spare fuse Spare main fuse The main fuse and the fuse box, which contains the fuses for the individual circuits, are located under the seat. (See page 3-11.) If a fuse is blown, replace it as follows. 1.
U1C2E1E0.book Page 32 Wednesday, August 4, 2004 11:57 AM PERIODIC MAINTENANCE AND MINOR REPAIR ● EAU23900 Replacing a headlight bulb This model is equipped with quartz bulb headlights. If a headlight bulb burns out, replace it as follows. 1. Remove panel D (if replacing the left headlight bulb) or panel B (if replacing the right headlight bulb). (See page 6-6.) 2. Disconnect the headlight coupler, and then remove the headlight bulb cover. 1.
U1C2E1E0.book Page 33 Wednesday, August 4, 2004 11:57 AM PERIODIC MAINTENANCE AND MINOR REPAIR 5. Install the headlight bulb cover, and then connect the coupler. 6. Install the panel. 7. Have a Yamaha dealer adjust the headlight beam if necessary. EAU24160 Replacing a tail/brake light bulb 1. Remove the seat. (See page 3-11.) 2. Remove the tail/brake light bulb cover. 1. Tail/brake light bulb socket 6 1. Tail/brake light bulb cover 3.
U1C2E1E0.book Page 34 Wednesday, August 4, 2004 11:57 AM PERIODIC MAINTENANCE AND MINOR REPAIR EAU24201 Replacing a turn signal light bulb 1. Remove the turn signal light lens by removing the screw. EAU27010 Replacing an auxiliary light bulb This model is equipped with two auxiliary lights. If an auxiliary light bulb burns out, replace it as follows. 1. Remove panel D (if replacing the left auxiliary light bulb) or panel B (if replacing the right auxiliary light bulb). (See page 6-6.) 2.
U1C2E1E0.book Page 35 Wednesday, August 4, 2004 11:57 AM PERIODIC MAINTENANCE AND MINOR REPAIR EAU24360 Front wheel EAU24470 To remove the front wheel 3. Remove the brake hose holder on each side by removing the bolts. 4. Remove the brake caliper on each side by removing the bolts. EWA10820 WARNING ● ● 6 It is advisable to have a Yamaha dealer service the wheel. Securely support the motorcycle so that there is no danger of it falling over. 1. Place the motorcycle on the centerstand. 2.
U1C2E1E0.book Page 36 Wednesday, August 4, 2004 11:57 AM PERIODIC MAINTENANCE AND MINOR REPAIR 7. Push down hard on the handlebar several times to check for proper fork operation. EAU25080 Rear wheel EAU25201 3. Disconnect the brake torque rod from the brake caliper by removing the nut and the bolt. To remove the rear wheel EWA10820 WARNING ● ● It is advisable to have a Yamaha dealer service the wheel. Securely support the motorcycle so that there is no danger of it falling over. 1.
U1C2E1E0.book Page 37 Wednesday, August 4, 2004 11:57 AM PERIODIC MAINTENANCE AND MINOR REPAIR 6. Turn the drive chain slack adjusting bolts fully in direction (a). 7. Push the wheel forward, and then remove the drive chain from the rear sprocket. 6 EAU25841 To install the rear wheel 1. Place the wheel and the brake caliper bracket in the original position. 2. Insert the wheel axle through the brake caliper bracket and wheel from the right-hand side, and then install the axle nut. 3.
U1C2E1E0.book Page 38 Wednesday, August 4, 2004 11:57 AM PERIODIC MAINTENANCE AND MINOR REPAIR EAU25870 Troubleshooting Although Yamaha motorcycles receive a thorough inspection before shipment from the factory, trouble may occur during operation. Any problem in the fuel, compression, or ignition systems, for example, can cause poor starting and loss of power. The following troubleshooting charts represent quick and easy procedures for checking these vital systems yourself.
U1C2E1E0.book Page 39 Wednesday, August 4, 2004 11:57 AM PERIODIC MAINTENANCE AND MINOR REPAIR EAU25911 Troubleshooting charts Starting problems or poor engine performance EWA10840 WARNING Keep away open flames and do not smoke while checking or working on the fuel system. 1. Fuel There is enough fuel. Check the compression. There is no fuel. Supply fuel. There is compression. Check the ignition. There is no compression. Have a Yamaha dealer check the vehicle.
U1C2E1E0.book Page 40 Wednesday, August 4, 2004 11:57 AM PERIODIC MAINTENANCE AND MINOR REPAIR Engine overheating EWA10400 WARNING ● ● Do not remove the radiator cap when the engine and radiator are hot. Scalding hot fluid and steam may be blown out under pressure, which could cause serious injury. Be sure to wait until the engine has cooled.
U1C2E1E0.book Page 1 Wednesday, August 4, 2004 11:57 AM MOTORCYCLE CARE AND STORAGE ucts onto seals, gaskets, sprockets, the drive chain and wheel axles. Always rinse the dirt and degreaser off with water. EAU26010 Care While the open design of a motorcycle reveals the attractiveness of the technology, it also makes it more vulnerable. Rust and corrosion can develop even if high-quality components are used.
U1C2E1E0.book Page 2 Wednesday, August 4, 2004 11:57 AM MOTORCYCLE CARE AND STORAGE After normal use Remove dirt with warm water, a mild detergent, and a soft, clean sponge, and then rinse thoroughly with clean water. Use a toothbrush or bottlebrush for hard-to-reach areas. Stubborn dirt and insects will come off more easily if the area is covered with a wet cloth for a few minutes before cleaning.
U1C2E1E0.book Page 3 Wednesday, August 4, 2004 11:57 AM MOTORCYCLE CARE AND STORAGE ● ● Never apply oil or wax to any rubber and plastic parts, but treat them with a suitable care product. Avoid using abrasive polishing compounds as they will wear away the paint. NOTE: Consult a Yamaha dealer for advice on what products to use. EAU26160 Storage Short-term Always store your motorcycle in a cool, dry place and, if necessary, protect it against dust with a porous cover.
U1C2E1E0.book Page 4 Wednesday, August 4, 2004 11:57 AM MOTORCYCLE CARE AND STORAGE EWA10950 WARNING To prevent damage or injury from sparking, make sure to ground the spark plug electrodes while turning the engine over. °C (90 °F)]. For more information on storing the battery, see page 6-29. NOTE: Make any necessary repairs before storing the motorcycle. 6. Lubricate all control cables and the pivoting points of all levers and pedals as well as of the sidestand/centerstand. 7.
U1C2E1E0.book Page 1 Wednesday, August 4, 2004 11:57 AM SPECIFICATIONS Dimensions: Overall length: 2125 mm (83.7 in) Overall width: 765 mm (30.1 in) Overall height: 1190 mm (46.9 in) Seat height: 820 mm (32.3 in) Wheelbase: 1450 mm (57.1 in) Ground clearance: 140 mm (5.51 in) Minimum turning radius: 2900 mm (114.2 in) Weight: With oil and fuel: 231.0 kg (509 lb) Engine: 8 Engine type: Liquid cooled 4-stroke, DOHC Cylinder arrangement: Forward-inclined parallel 4-cylinder Displacement: 998.0 cm³ (60.
U1C2E1E0.book Page 2 Wednesday, August 4, 2004 11:57 AM SPECIFICATIONS Operation: Left foot operation Gear ratio: 1st: 35/14 (2.500) 2nd: 35/19 (1.842) 3rd: 30/20 (1.500) 4th: 28/21 (1.333) 5th: 30/25 (1.200) 6th: 29/26 (1.115) Chassis: Frame type: Double cradle Caster angle: 26.00 ° Trail: 104.0 mm (4.
U1C2E1E0.book Page 3 Wednesday, August 4, 2004 11:57 AM SPECIFICATIONS Charging system: AC magneto Battery: Model: GT14B-4 Voltage, capacity: 12 V, 12.0 Ah Headlight: Bulb type: Halogen bulb Bulb voltage, wattage x quantity: 8 Headlight: 12 V, 60 W/55.0 W × 2 Tail/brake light: 12 V, 5.0 W/21.0 W × 2 Front turn signal light: 12 V, 21.0 W × 2 Rear turn signal light: 12 V, 21.0 W × 2 Auxiliary light: 12 V, 5.0 W × 2 Meter lighting: 12 V, 2.0 W × 3 Neutral indicator light: 14 V, 1.
U1C2E1E0.book Page 1 Wednesday, August 4, 2004 11:57 AM CONSUMER INFORMATION EAU26351 Identification numbers EAU26381 EAU26400 Key identification number Vehicle identification number 1. Key identification number 1. Vehicle identification number The key identification number is stamped into the key tag. Record this number in the space provided and use it for reference when ordering a new key. The vehicle identification number is stamped into the steering head pipe.
U1C2E1E0.book Page 2 Wednesday, August 4, 2004 11:57 AM CONSUMER INFORMATION EAU26480 Model label 1. Model label The model label is affixed to the frame under the seat. (See page 3-11.) Record the information on this label in the space provided. This information will be needed when ordering spare parts from a Yamaha dealer.
U1C2E1E0.book Page 1 Wednesday, August 4, 2004 11:57 AM INDEX A Air filter element, cleaning .................... 6-14 Anti-theft alarm (optional) ....................... 3-6 Auxiliary light bulb, replacing ................ 6-34 Engine stop switch ..................................3-7 EXUP system ........................................3-17 Front and rear brake pads, checking ....6-21 Front fork, adjusting ..............................3-13 Front fork, checking...............................6-28 Fuel ....
U1C2E1E0.book Page 2 Wednesday, August 4, 2004 11:57 AM INDEX Throttle grip and cable, checking and lubricating ........................................... 6-26 Tires ...................................................... 6-17 Tool kit .................................................... 6-1 Troubleshooting .................................... 6-38 Troubleshooting charts ......................... 6-39 Turn signal indicator lights ...................... 3-2 Turn signal light bulb, replacing ............
U1C2E1E0.
OWNER’S MANUAL FZS1000 FZS1000S YAMAHA MOTOR CO., LTD. PRINTED ON RECYCLED PAPER PRINTED IN JAPAN 2004.08-0.
