OWNER’S MANUAL FZS1000S FZS1000SC YAMAHA MOTOR CO., LTD. PRINTED ON RECYCLED PAPER PRINTED IN JAPAN 2003.06-0.
5LV13.
5LV13.book Page 1 Monday, June 9, 2003 5:08 PM INTRODUCTION EAU10080 Congratulations on your purchase of the Yamaha FZS1000/FZS1000C. This model is the result of Yamaha’s vast experience in the production of fine sporting, touring, and pacesetting racing machines. It represents the high degree of craftsmanship and reliability that have made Yamaha a leader in these fields. This manual will give you an understanding of the operation, inspection, and basic maintenance of this motorcycle.
5LV13.book Page 1 Monday, June 9, 2003 5:08 PM IMPORTANT MANUAL INFORMATION EAU10130 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.
LV13.book Page 2 Monday, June 9, 2003 5:08 PM IMPORTANT MANUAL INFORMATION EAU10192 AFFIX DEALER LABEL HERE FZS1000S/FZS1000SC OWNER’S MANUAL ©2003 by Yamaha Motor Corporation, U.S.A. 1st edition, June 2003 All rights reserved. Any reprinting or unauthorized use without the written permission of Yamaha Motor Corporation, U.S.A. is expressly prohibited. Printed in Japan.
5LV13.book Page 1 Monday, June 9, 2003 5:08 PM TABLE OF CONTENTS SAFETY INFORMATION ..................1-1 Location of important labels ............1-5 Sidestand ..................................... 3-15 Ignition circuit cut-off system ........ 3-16 DESCRIPTION ..................................2-1 Left view ..........................................2-1 Right view ........................................2-2 Controls and instruments.................2-3 PRE-OPERATION CHECKS .............
5LV13.book Page 2 Monday, June 9, 2003 5:08 PM TABLE OF CONTENTS Checking the steering ...................6-32 Checking the wheel bearings .......6-33 Battery ..........................................6-33 Replacing the fuses ......................6-34 Replacing a headlight bulb ...........6-35 Replacing a tail/brake light bulb ...6-36 Replacing a turn signal light bulb ...........................................6-37 Front wheel ...................................6-37 Rear wheel ...........................
5LV13.book Page 1 Monday, June 9, 2003 5:08 PM SAFETY INFORMATION EAU10270 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.
5LV13.book Page 2 Monday, June 9, 2003 5:08 PM 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.
5LV13.book Page 3 Monday, June 9, 2003 5:08 PM SAFETY INFORMATION 1 Loading The total weight of the operator, passenger, accessories and cargo must not exceed the maximum load limit of 188 kg (415 lb) (CAL) 189 kg (417 lb) (U49). 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.
5LV13.book Page 4 Monday, June 9, 2003 5:08 PM SAFETY INFORMATION Gasoline and exhaust gas ● GASOLINE IS HIGHLY FLAMMABLE: • Always turn the engine off when refueling. • Take care not to spill any gasoline on the engine or exhaust system when refueling. • Never refuel while smoking or in the vicinity of an open flame. ● Never start the engine or let it run for any length of time in a closed area. The exhaust fumes are poisonous and may cause loss of consciousness and death within a short time.
5LV13.book Page 5 Monday, June 9, 2003 5:08 PM SAFETY INFORMATION EAU10381 Location of important labels Please read the following important labels carefully before operating this vehicle.
5LV13.book Page 6 Monday, June 9, 2003 5:08 PM SAFETY INFORMATION 1 5 California only CAUTION 1 Cleaning with alkaline or acid cleaner, gasoline or solvent will damage windshield. Use neutral detergent.
5LV13.book Page 1 Monday, June 9, 2003 5:08 PM DESCRIPTION EAU10410 Left view 2 1. 2. 3. 4. 5. 6. 7. 8. 9. Shock absorber assembly compression damping force adjusting screw (page 3-13) 10.Shock absorber assembly spring preload adjusting ring (page 3-13) 11.Shock absorber assembly rebound damping force adjusting knob (page 3-13) 12.
5LV13.book Page 2 Monday, June 9, 2003 5:08 PM DESCRIPTION EAU10420 Right view 2 1. 2. 3. 4. 5. 6. 7. 8. 9.
5LV13.book Page 3 Monday, June 9, 2003 5:08 PM DESCRIPTION EAU10430 Controls and instruments 2 1. 2. 3. 4. 5. 6. 7. 8. 9. Brake lever (page 3-7) 10.
5LV13.book Page 1 Monday, June 9, 2003 5:08 PM INSTRUMENT AND CONTROL FUNCTIONS EAU10460 Main switch/steering lock EAU10680 LOCK The steering is locked, and all electrical systems are off. The key can be removed. To unlock the steering To lock the steering 3 1. Push. 2. Turn. The main switch/steering lock controls the ignition and lighting systems, and is used to lock the steering. The various positions are described below.
5LV13.book Page 2 Monday, June 9, 2003 5:08 PM INSTRUMENT AND CONTROL FUNCTIONS EAU11001 Indicator and warning lights EAU11080 EAU11350 High beam indicator light “ ” This indicator light comes on when the high beam of the headlight is switched on. Fuel level warning light “ ” This warning light comes on when the fuel level drops below approximately 4.0 L (1.06 US gal) (0.88 Imp.gal). When this occurs, refuel as soon as possible.
5LV13.book Page 3 Monday, June 9, 2003 5:08 PM INSTRUMENT AND CONTROL FUNCTIONS ECA10020 CAUTION: EAU11810 Speedometer unit Do not operate the engine if it is overheated. be traveled on a full tank of fuel. This information will enable you to plan future fuel stops. To set a mode Push the “SELECT” button to change between the odometer mode “ODO”, and the tripmeter modes “TRIP 1” and “TRIP 2” in the following order: ODO → TRIP 1 → TRIP 2 → ODO 1. 2. 3. 4.
5LV13.book Page 4 Monday, June 9, 2003 5:08 PM INSTRUMENT AND CONTROL FUNCTIONS EAU11890 Tachometer unit 3 1. Tachometer 2. Tachometer red zone 3. Clock The electric tachometer allows the rider to monitor the engine speed and keep it within the ideal power range. ECA10030 CAUTION: 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.
5LV13.book Page 5 Monday, June 9, 2003 5:08 PM INSTRUMENT AND CONTROL FUNCTIONS If the tachometer displays such an error code, note the circuit-specific number of r/min, and then have a Yamaha dealer check the vehicle. EAU12110 Fuel gauge EAU12341 Handlebar switches Left ECA10040 CAUTION: When the tachometer displays an error code, the vehicle should be checked as soon as possible in order to avoid engine damage. 3 1. Fuel gauge The fuel gauge indicates the amount of fuel in the fuel tank.
5LV13.book Page 6 Monday, June 9, 2003 5:08 PM INSTRUMENT AND CONTROL FUNCTIONS EAU12400 Dimmer switch “ / ” Set this switch to “ ” for the high beam and to “ ” for the low beam. ECA10050 EAU12820 Clutch lever CAUTION: See page 5-1 for starting instructions prior to starting the engine. EAU12460 3 Turn signal switch “ / ” To signal a right-hand turn, push this switch to “ ”. To signal a left-hand turn, push this switch to “ ”. When released, the switch returns to the center position.
5LV13.book Page 7 Monday, June 9, 2003 5:08 PM 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. Brake pedal The shift pedal is located on the left side of the engine and is used in combination with the clutch lever when shifting the gears of the 6-speed constant-mesh transmission equipped on this motorcycle.
5LV13.book Page 8 Monday, June 9, 2003 5:08 PM 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.
5LV13.book Page 9 Monday, June 9, 2003 5:08 PM 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. EAU13300 Recommended fuel: UNLEADED GASOLINE ONLY Fuel tank capacity: 21.0 L (5.55 US gal) (4.62 Imp.gal) Fuel reserve amount: 4.0 L (1.06 US gal) (0.88 Imp.gal) knocking (or pinging) occurs, use a gasoline of a different brand or premium unleaded fuel.
5LV13.book Page 10 Monday, June 9, 2003 5:08 PM INSTRUMENT AND CONTROL FUNCTIONS EAU13940 EAU14290 Seat Helmet holder To remove the seat 1. Insert the key into the seat lock, and then turn it clockwise. 3 1. Projection 2. Seat holder 2. Push the rear of the seat down to lock it in place. 3. Remove the key. 1. Seat lock 2. Unlock. 2. While holding the key in that position, lift the rear of the seat, and then pull the seat off. NOTE: Make sure that the seat is properly secured before riding. 1.
5LV13.book Page 11 Monday, June 9, 2003 5:08 PM INSTRUMENT AND CONTROL FUNCTIONS EAU14450 Storage compartment When washing the vehicle, be careful not to let any water enter the storage compartment. EAU14750 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 WARNING Always adjust both fork legs equally, otherwise poor handling and loss of stability may result. 1.
5LV13.book Page 12 Monday, June 9, 2003 5:08 PM INSTRUMENT AND CONTROL FUNCTIONS load and thereby soften the suspension, turn the adjusting bolt on each fork leg in direction (b). Rebound damping force Compression damping force 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).
5LV13.book Page 13 Monday, June 9, 2003 5:08 PM INSTRUMENT AND CONTROL FUNCTIONS ECA10100 CAUTION: Never attempt to turn an adjusting mechanism beyond the maximum or minimum settings. NOTE: Although the total number of clicks of a damping force adjusting mechanism may not exactly match the above specifications due to small differences in production, the actual number of clicks always represents the entire adjusting range.
5LV13.book Page 14 Monday, June 9, 2003 5:08 PM INSTRUMENT AND CONTROL FUNCTIONS Rebound damping force Compression damping force 1. Rebound damping force adjusting knob 1. Compression damping force adjusting screw To increase the rebound damping force and thereby harden the rebound damping, turn the adjusting knob in direction (a). To decrease the rebound damping force and thereby soften the rebound damping, turn the adjusting knob in direction (b).
5LV13.book Page 15 Monday, June 9, 2003 5:08 PM INSTRUMENT AND CONTROL FUNCTIONS ● ● ● Do not subject the shock absorber to an open flame or other high heat sources, otherwise it may explode due to excessive gas pressure. Do not deform or damage the gas cylinder in any way, as this will result in poor damping performance. Always have a Yamaha dealer service the shock absorber. EAU15280 EAU15300 EXUP system Sidestand This model is equipped with Yamaha’s EXUP (EXhaust Ultimate Power valve) system.
5LV13.book Page 16 Monday, June 9, 2003 5:08 PM INSTRUMENT AND CONTROL FUNCTIONS below and have a Yamaha dealer repair it if it does not function properly. 3 EAU15321 Ignition circuit cut-off system 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.
5LV13.book Page 17 Monday, June 9, 2003 5:08 PM 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. The motorcycle should not be ridden until checked by a Yamaha dealer.
5LV13.book Page 1 Monday, June 9, 2003 5:08 PM 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. Therefore, it is very important, in addition to a thorough visual inspection, to check the following points before each ride.
5LV13.book Page 2 Monday, June 9, 2003 5:08 PM PRE-OPERATION CHECKS EAU15601 Pre-operation check list ITEM CHECKS PAGE Fuel • Check fuel level in fuel tank. • Refuel if necessary. • Check fuel line for leakage. 3-8 Engine oil • Check oil level in engine. • If necessary, add recommended oil to specified level. • Check vehicle for oil leakage. 6-12 Coolant • Check coolant level in reservoir. • If necessary, add recommended coolant to specified level. • Check cooling system for leakage.
5LV13.book Page 3 Monday, June 9, 2003 5:08 PM 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. 6-19, 6-30 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.
5LV13.book Page 1 Monday, June 9, 2003 5:08 PM OPERATION AND IMPORTANT RIDING POINTS EAU15950 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. Exhaust fumes are poisonous, and inhaling them can cause loss of consciousness and death within a short time.
5LV13.book Page 2 Monday, June 9, 2003 5:08 PM 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.
5LV13.book Page 3 Monday, June 9, 2003 5:08 PM 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.
5LV13.book Page 4 Monday, June 9, 2003 5:08 PM OPERATION AND IMPORTANT RIDING POINTS 4. At the recommended shift points shown in the following table, close the throttle, and at the same time, quickly pull the clutch lever in. 5. Shift the transmission into second gear. (Make sure not to shift the transmission into the neutral position.) 6. Open the throttle part way and gradually release the clutch lever. 7. Follow the same procedure when shifting to the next higher gear.
5LV13.book Page 5 Monday, June 9, 2003 5:08 PM OPERATION AND IMPORTANT RIDING POINTS ECA10301 EAU17200 CAUTION: Parking After 1000 km (600 mi) of operation, the engine oil must be changed and the oil filter cartridge or element replaced. When parking, stop the engine, and then remove the key from the main switch. 1600 km (1000 mi) and beyond The vehicle can now be operated normally. EWA10310 WARNING ● ECA10310 CAUTION: ● ● Keep the engine speed out of the tachometer red zone.
5LV13.book Page 1 Monday, June 9, 2003 5:08 PM PERIODIC MAINTENANCE AND MINOR REPAIR EAU17231 EAU17300 PERIODIC MAINTENANCE 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 motorcycle inspection, adjustment, and lubrication are explained on the following pages.
5LV13.book Page 2 Monday, June 9, 2003 5:08 PM PERIODIC MAINTENANCE AND MINOR REPAIR EWA10340 WARNING Modifications not approved by Yamaha may cause loss of performance, excessive emissions, and render the vehicle unsafe for use. Consult a Yamaha dealer before attempting any changes.
5LV13.book Page 3 Monday, June 9, 2003 5:08 PM PERIODIC MAINTENANCE AND MINOR REPAIR EAU17600 Periodic maintenance chart for the emission control system INITIAL No. 6 ITEM ROUTINE 1 * Fuel line • Check fuel and vacuum hoses for cracks or damage. • Replace if necessary. 2 * Fuel filter • Replace. 3 Spark plugs • Check condition. • Adjust gap and clean. • Replace every 8000 mi (13000 km) or 12 months. 4 * Valve clearance • Check and adjust valve clearance when engine is cold.
5LV13.book Page 4 Monday, June 9, 2003 5:08 PM PERIODIC MAINTENANCE AND MINOR REPAIR INITIAL No. 10 * ITEM Air induction system ROUTINE 600 mi (1000 km) or 1 month • Check the air cut-off valve, reed valve, and hose for damage. • Replace any damaged parts.
5LV13.book Page 5 Monday, June 9, 2003 5:08 PM PERIODIC MAINTENANCE AND MINOR REPAIR EAU32181 General maintenance and lubrication chart INITIAL No. ITEM ROUTINE 600 mi (1000 km) or 1 month ODOMETER READINGS 4000 mi (7000 km) or 6 months 8000 mi 12000 mi 16000 mi 20000 mi (13000 km) (19000 km) (25000 km) (31000 km) or or or or 12 months 18 months 24 months 30 months 1 * Air filter element • Clean with compressed air. • Replace if necessary. 2 * Clutch • Check operation.
5LV13.book Page 6 Monday, June 9, 2003 5:08 PM PERIODIC MAINTENANCE AND MINOR REPAIR INITIAL No. ITEM ROUTINE Swingarm pivot bearings • Check bearing assemblies for looseness. • Moderately repack with lithiumsoap-based grease. Drive chain • Check chain slack/alignment and condition. • Adjust and lubricate chain with a special O-ring chain lubricant thoroughly. 11 * Steering bearings • Check bearing assembly for looseness.
5LV13.book Page 7 Monday, June 9, 2003 5:08 PM PERIODIC MAINTENANCE AND MINOR REPAIR INITIAL No. 6 ITEM ROUTINE 600 mi (1000 km) or 1 month ODOMETER READINGS 4000 mi (7000 km) or 6 months 8000 mi 12000 mi 16000 mi 20000 mi (13000 km) (19000 km) (25000 km) (31000 km) or or or or 12 months 18 months 24 months 30 months 17 * Front fork • Check operation and for oil leakage. • Replace if necessary. √ √ √ √ √ 18 * Shock absorber assembly • Check operation and for oil leakage.
5LV13.book Page 8 Monday, June 9, 2003 5:08 PM PERIODIC MAINTENANCE AND MINOR REPAIR NOTE: From 24000 mi (37000 km) or 36 months, repeat the maintenance intervals starting from 8000 mi (13000 km) or 12 months. EAU17630 NOTE: ● The air filter needs more frequent service if you are riding in unusually wet or dusty areas. ● Hydraulic brake service • After disassembling the brake master cylinders and calipers, always change the fluid. Regularly check the brake fluid levels and fill the reservoirs as required.
5LV13.book Page 9 Monday, June 9, 2003 5:08 PM PERIODIC MAINTENANCE AND MINOR REPAIR EAU18770 Removing and installing panels The panels shown above 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. EAU19292 Panels A and C To remove one of the panels Remove the screw, and then pull the panel off as shown. 1. Panel C 2.
5LV13.book Page 10 Monday, June 9, 2003 5:08 PM PERIODIC MAINTENANCE AND MINOR REPAIR EAU19210 Panel B To remove the panel Remove the screws, 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.
5LV13.book Page 11 Monday, June 9, 2003 5:08 PM 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. 6 2.
5LV13.book Page 12 Monday, June 9, 2003 5:08 PM PERIODIC MAINTENANCE AND MINOR REPAIR EAU19890 Engine oil and oil filter cartridge The engine oil level should be checked before each ride. In addition, the oil must be changed and the oil filter cartridge replaced at the intervals specified in the periodic maintenance and lubrication chart. 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.
5LV13.book Page 13 Monday, June 9, 2003 5:08 PM PERIODIC MAINTENANCE AND MINOR REPAIR 1. Oil filter wrench 2. Oil filter cartridge 6 NOTE: An oil filter wrench is available at a Yamaha dealer. 5. Apply a thin coat of engine oil to the O-ring of the new oil filter cartridge. 1. O-ring 1. Torque wrench 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.
5LV13.book Page 14 Monday, June 9, 2003 5:08 PM PERIODIC MAINTENANCE AND MINOR REPAIR EAU20070 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 CAUTION: ● ● In order to prevent clutch slippage (since the engine oil also lubricates the clutch), do not mix any chemical additives.
5LV13.book Page 15 Monday, June 9, 2003 5:08 PM PERIODIC MAINTENANCE AND MINOR REPAIR ECA10470 CAUTION: ● ● 1. Coolant reservoir 2. Maximum level mark 3. Minimum level mark 6 3. If the coolant is at or below the minimum level mark, remove panel A (See page 6-9.), remove the reservoir cap, add coolant to the maximum level mark, and then install the reservoir cap and the panel. Coolant reservoir capacity (up to the maximum level mark): 0.30 L (0.32 US qt) (0.26 Imp.
5LV13.book Page 16 Monday, June 9, 2003 5:08 PM 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. ● 1. Radiator cap 5. Remove the coolant drain bolt to drain the cooling system. 1. Coolant drain bolt 6. After the coolant is completely drained, thoroughly flush the cooling system with clean tap water. Tightening torque: Coolant drain bolt: 7 Nm (0.
5LV13.book Page 17 Monday, June 9, 2003 5:08 PM PERIODIC MAINTENANCE AND MINOR REPAIR until it reaches the top of the radiator, and then install the radiator cap. 11. Check the coolant level in the reservoir. If necessary, remove the coolant reservoir cap, add coolant to the maximum level mark, and then install the cap. 12. Start the engine, and then check the vehicle for coolant leakage. If coolant is leaking, have a Yamaha dealer check the cooling system. 13. Install the panels.
5LV13.book Page 18 Monday, June 9, 2003 5:08 PM 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 case cover 2. Screw 7. Pull the air filter element out. ● 1. Air filter element 9. Insert the air filter element into the air filter case. ECA11330 CAUTION: 1. Air filter element 8.
5LV13.book Page 19 Monday, June 9, 2003 5:08 PM PERIODIC MAINTENANCE AND MINOR REPAIR 14. Install the seat. EAU21270 Adjusting the carburetors The carburetors are important parts of the engine and emission control system, which require very sophisticated adjustment. Therefore, all carburetor adjustments should be left to a Yamaha dealer, who has the necessary professional knowledge and experience. EAU21380 Adjusting the throttle cable free play 1.
5LV13.book Page 20 Monday, June 9, 2003 5:08 PM PERIODIC MAINTENANCE AND MINOR REPAIR EAU21400 EAU21750 Adjusting the 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.
5LV13.book Page 21 Monday, June 9, 2003 5:08 PM PERIODIC MAINTENANCE AND MINOR REPAIR 6 est items close to the center of the vehicle, and distribute the weight evenly from side to side. Properly adjust the suspension for your load, and check the condition and pressure of your tires. NEVER OVERLOAD YOUR VEHICLE. Make sure that the total weight of the cargo, rider, passenger, and accessories (cowling, saddlebags, etc. if approved for this model) does not exceed the maximum load of the vehicle.
5LV13.book Page 22 Monday, June 9, 2003 5:08 PM PERIODIC MAINTENANCE AND MINOR REPAIR This motorcycle is equipped with cast wheels and tubeless tires with valves. EWA10480 WARNING ● ● ● ● The front and rear tires should be of the same make and design, otherwise the handling characteristics of the motorcycle cannot be guaranteed. After extensive tests, only the tires listed below have been approved for this model by Yamaha Motor Co., Ltd.
5LV13.book Page 23 Monday, June 9, 2003 5:08 PM PERIODIC MAINTENANCE AND MINOR REPAIR EAU21960 Cast wheels 6 To maximize the performance, durability, and safe operation of your vehicle, note the following points regarding the specified wheels. ● The wheel rims should be checked for cracks, bends or warpage before each ride. If any damage is found, have a Yamaha dealer replace the wheel. Do not attempt even the smallest repair to the wheel. A deformed or cracked wheel must be replaced.
5LV13.book Page 24 Monday, June 9, 2003 5:08 PM PERIODIC MAINTENANCE AND MINOR REPAIR EAU22080 Adjusting the clutch lever free play EAU22240 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. 1. Clutch lever free play adjusting bolt 2. Clutch lever free play Adjusting the brake pedal position 1.
5LV13.book Page 25 Monday, June 9, 2003 5:08 PM PERIODIC MAINTENANCE AND MINOR REPAIR the braking performance, which may result in loss of control and an accident. EAU22270 Adjusting the rear brake light switch EAU22321 Checking the front and rear brake pads Front brake 1. Rear brake light switch 2. Rear brake light switch adjusting nut 6 The rear brake light switch, which is activated by the brake pedal, is properly adjusted when the brake light comes on just before braking takes effect.
5LV13.book Page 26 Monday, June 9, 2003 5:08 PM 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.
5LV13.book Page 27 Monday, June 9, 2003 5:08 PM 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.
5LV13.book Page 28 Monday, June 9, 2003 5:08 PM PERIODIC MAINTENANCE AND MINOR REPAIR NOTE: Using the alignment marks on each side of the swingarm, make sure that both chain pullers are in the same position for proper wheel alignment. 3. Tighten the locknuts, and then tighten the axle nut to the specified torque. Tightening torque: Axle nut: 150 Nm (15.0 m·kgf, 108 ft·lbf) 1. Drive chain slack 5. If the drive chain slack is incorrect, adjust it as follows. EAU22940 To adjust the drive chain slack 1.
5LV13.book Page 29 Monday, June 9, 2003 5:08 PM PERIODIC MAINTENANCE AND MINOR REPAIR EAU23020 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.
5LV13.book Page 30 Monday, June 9, 2003 5:08 PM 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.
5LV13.book Page 31 Monday, June 9, 2003 5:08 PM PERIODIC MAINTENANCE AND MINOR REPAIR EAU23210 Checking and lubricating the centerstand and sidestand EAU23250 Lubricating the rear suspension The pivoting points of the rear suspension must be lubricated at the intervals specified in the periodic maintenance and lubrication chart.
5LV13.book Page 32 Monday, June 9, 2003 5:08 PM PERIODIC MAINTENANCE AND MINOR REPAIR EAU23280 Checking the steering ECA10590 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. 1. Place a stand under the engine to raise the front wheel off the ground.
5LV13.book Page 33 Monday, June 9, 2003 5:08 PM PERIODIC MAINTENANCE AND MINOR REPAIR EAU23290 EAU23370 Checking the wheel bearings 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. This model is equipped with a sealedtype (MF) battery, which does not require any maintenance.
5LV13.book Page 34 Monday, June 9, 2003 5:08 PM PERIODIC MAINTENANCE AND MINOR REPAIR 2. If the battery will be stored for more than two months, check it at least once a month and fully charge it if necessary. 3. Fully charge the battery before installation. 4. After installation, make sure that the battery leads are properly connected to the battery terminals. EAU23622 Replacing the fuses ECA10630 CAUTION: ● ● Always keep the battery charged.
5LV13.book Page 35 Monday, June 9, 2003 5:08 PM PERIODIC MAINTENANCE AND MINOR REPAIR ● EAU23730 Replacing a headlight bulb This model is equipped with two quartz bulb headlights. If a headlight bulb burns out, replace it as follows. 1. Remove panel B. (See page 6-9.) 2. Disconnect the headlight coupler, and then remove the bulb cover. 1. Headlight bulb holder EWA10790 WARNING 6 1. Headlight bulb cover 2. Headlight coupler 3. Unhook the headlight bulb holder, and then remove the defective bulb.
5LV13.book Page 36 Monday, June 9, 2003 5:08 PM 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 3-10.) 2. Remove the tail/brake light bulb cover. 1. Tail/brake light bulb socket 1. Tail/brake light bulb cover 3. Remove the socket (together with the bulb) by turning it counterclockwise.
5LV13.book Page 37 Monday, June 9, 2003 5:08 PM PERIODIC MAINTENANCE AND MINOR REPAIR EAU24201 Replacing a turn signal light bulb 1. Remove the turn signal light lens by removing the screw. 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 1. Screw 2. Remove the defective bulb by pushing it in and turning it counterclockwise. 3.
5LV13.book Page 38 Monday, June 9, 2003 5:08 PM PERIODIC MAINTENANCE AND MINOR REPAIR EAU25020 To install the front wheel 1. Lift the wheel up between the fork legs. 2. Insert the wheel axle. 3. Lower the front wheel so that it is on the ground. 4. Install the brake calipers by installing the bolts. 7. Push down hard on the handlebar several times to check for proper fork operation.
5LV13.book Page 39 Monday, June 9, 2003 5:08 PM PERIODIC MAINTENANCE AND MINOR REPAIR 3. Disconnect the brake torque rod from the brake caliper by removing the nut and the bolt. 6 1. 2. 3. 4. 5. Bolt Brake torque rod Brake torque rod bolt Brake torque rod nut Brake caliper bracket 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. EAU25841 To install the rear wheel 1.
5LV13.book Page 40 Monday, June 9, 2003 5:08 PM PERIODIC MAINTENANCE AND MINOR REPAIR EAU25870 NOTE: Make sure that there is enough space between the brake pads before installing the brake caliper onto the brake disc. 6. Take the motorcycle off the centerstand so that the rear wheel is on the ground. 7. Tighten the axle nut, brake caliper bolts and brake torque rod nut to the specified torques. Tightening torques: Axle nut: 150 Nm (15.0 m·kgf, 108 ft·lbf) Brake caliper bolt: 40 Nm (4.
5LV13.book Page 41 Monday, June 9, 2003 5:08 PM 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. Check the fuel level in the fuel tank.
5LV13.book Page 42 Monday, June 9, 2003 5:08 PM 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.
5LV13.book Page 1 Monday, June 9, 2003 5:08 PM 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.
5LV13.book Page 2 Monday, June 9, 2003 5:08 PM 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.
5LV13.book Page 3 Monday, June 9, 2003 5:08 PM 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.
5LV13.book Page 4 Monday, June 9, 2003 5:08 PM 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 6-33. 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.
5LV13.book Page 1 Monday, June 9, 2003 5:08 PM 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) (U49) 232.
5LV13.book Page 2 Monday, June 9, 2003 5:08 PM SPECIFICATIONS 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: 26.0 ° Trail: 104.0 mm (4.
5LV13.book Page 3 Monday, June 9, 2003 5:08 PM SPECIFICATIONS 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 W/21.0 W × 2 Front turn signal/position light: 12 V, 27 W/8.0 W × 2 Rear turn signal light: 12 V, 27.0 W × 2 Meter lighting: 12 V, 2.0 W × 3 Neutral indicator light: 14 V, 1.4 W × 1 High beam indicator light: 14 V, 1.4 W × 1 Oil level warning light: 14 V, 1.
5LV13.book Page 1 Monday, June 9, 2003 5:08 PM CONSUMER INFORMATION EAU26351 Identification numbers EAU26380 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. Record this number in the space provided.
5LV13.book Page 2 Monday, June 9, 2003 5:08 PM CONSUMER INFORMATION EAU26480 Model label 1. Model label The model label is affixed to the frame under the seat. (See page 3-10.) Record the information on this label in the space provided. This information will be needed when ordering spare parts from a Yamaha dealer.
5LV13.book Page 3 Monday, June 9, 2003 5:08 PM CONSUMER INFORMATION EAU26550 Reporting safety defects If you believe that your vehicle has a defect which could cause a crash or could cause injury or death, you should immediately inform the National Highway Traffic Safety Administration (NHTSA) in addition to notifying Yamaha Motor Corporation, U.S.A.
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5LV13.book Page 5 Monday, June 9, 2003 5:08 PM CONSUMER INFORMATION EAU26631 Maintenance record Copies of work orders and/or receipts for parts purchased and installed on your motorcycle will be required to document that maintenance has been completed in accordance with the emissions warranty. The chart below is printed only as a reminder that maintenance work is required. It is not acceptable proof of maintenance work.
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5LV13.book Page 7 Monday, June 9, 2003 5:08 PM CONSUMER INFORMATION EAU26661 YAMAHA MOTOR CORPORATION, U.S.A.
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5LV13.book Page 9 Monday, June 9, 2003 5:08 PM CONSUMER INFORMATION EAU26750 YAMAHA EXTENDED SERVICE (Y.E.S.) Keep your Yamaha protected even after your warranty expires with genuine Yamaha Extended Service (Y.E.S.). In addition, Travel and Recreation Interruption Protection (TRIP) is included at no extra cost.
5LV13.book Page 10 Monday, June 9, 2003 5:08 PM CONSUMER INFORMATION We urge you to act now. You’ll get the excellent benefits of TRIP coverage right away, and you’ll rest easy knowing you’ll have strong factory-backed protection even after your Yamaha Limited Warranty expires. A special note: If visiting your dealer isn’t convenient, contact Yamaha with your Primary ID number (your frame number). We’ll be happy to help you get the Y.E.S. coverage you need. Yamaha Service Marketing P.O.
5LV13.book Page 1 Monday, June 9, 2003 5:08 PM INDEX A Accessories and replacement parts ..... 6-23 Air filter element, cleaning .................... 6-17 EXUP system ........................................3-15 F Front and rear brake pads, checking..............................................6-25 Front fork, adjusting ..............................3-11 Front fork, checking...............................6-31 Fuel .........................................................3-8 Fuel gauge ...................
5LV13.book Page 2 Monday, June 9, 2003 5:08 PM INDEX T Tachometer unit ...................................... 3-4 Tail/brake light bulb, replacing .............. 6-36 Throttle cable free play, adjusting ......... 6-19 Throttle grip and cable, checking and lubricating .................................... 6-30 Tires ...................................................... 6-20 Tool kit .................................................... 6-1 Troubleshooting ....................................
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OWNER’S MANUAL FZS1000S FZS1000SC YAMAHA MOTOR CO., LTD. PRINTED ON RECYCLED PAPER PRINTED IN JAPAN 2003.06-0.
