Yamaha FZS1000 2003 Manual

FOREWORD
This Supplementary Service Manual has been prepared to introduce new service and data for the
FZS1000 (R) 2003. For complete service information procedures it is necessary to use this Supple-
mentary Service Manual together with the following manual.
FZS1000 (N) 2001 SERVICE MANUAL: 5LV1-AE1
FZS1000 (R) 2003
SUPPLEMENTARY
SERVICE MANUAL
E2002 by Yamaha Motor Co., Ltd.
First Edition, July 2002
All rights reserved.
Any reproduction or unauthorized use
without the written permission of
Yamaha Motor Co., Ltd.
is expressly prohibited.

NOTE:
WARNING
CAUTION:
EAS00002
NOTICE
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 manu-
al. 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.
Repair and maintenance work attempted by anyone without this knowledge is likely to render the ve-
hicle unsafe and unfit for use.
Yamaha Motor Company, Ltd. is continually striving to improve all its models. Modifications and signifi-
cant changes in specifications or procedures will be forwarded to all authorized Yamaha dealers and
will appear in future editions of this manual where applicable.
Designs and specifications are subject to change without notice.
EAS00004
IMPORTANT INFORMATION
Particularly important information is distinguished in this manual by the following.
The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR
SAFETY IS INVOLVED!
Failure to follow WARNING instructions could result in severe injury or death to
the motorcycle operator, a bystander or a person checking or repairing the mo-
torcycle.
A CAUTION indicates special precautions that must be taken to avoid damage
to the motorcycle.
NOTE: A NOTE provides key information to make procedures easier or clearer.

1
2
6
4
5
7
3
8
EAS00007
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.
1The manual is divided into chapters. An abbreviation and symbol in the upper right corner of each
page indicate the current chapter. Refer to “SYMBOLS” on the following page.
2Each chapter is divided into sections. The current section title is shown at the top of each page,
except in Chapter 3 (“Periodic Checks and Adjustments”), where the sub-section title(-s) appears.
(In Chapter 3, “Periodic Checks and Adjustments”, the sub-section title appears at the top of each
page, instead of the section title.)
3Sub-section titles appear in smaller print than the section title.
4To help identify parts and clarify procedure steps, there are exploded diagrams at the start of each
removal and disassembly section.
5Numbers are given in the order of the jobs in the exploded diagram. A circled number indicates a
disassembly step.
6Symbols indicate parts to be lubricated or replaced (see “SYMBOLS”).
7A job instruction chart accompanies the exploded diagram, providing the order of jobs, names of
parts, notes in jobs, etc.
8Jobs requiring more information (such as special tools and technical data) are described sequen-
tially.

22
1
3
5
7
9
2
4
8
6
24 25
2321
19 2018
16 1715
1413
11 12
10
GEN
INFO SPEC
ENG
CARB ELEC
COOL
CHK
ADJ
TRBL
SHTG
CHAS
EAS00008
SYMBOLS
The following symbols are not relevant to every
vehicle.
Symbols 1to 9indicate the subject of each
chapter.
1General information
2Specifications
3Periodic checks and adjustments
4Chassis
5Engine
6Cooling system
7Carburetor(-s)
8Electrical system
9Troubleshooting
Symbols 10 to 17 indicate the following.
10 Serviceable with engine mounted
11 Filling fluid
12 Lubricant
13 Special tool
14 Tightening torque
15 Wear limit, clearance
16 Engine speed
17 Electrical data
Symbols 18 to 23 in the exploded diagrams indi-
cate the types of lubricants and lubrication
points.
18 Engine oil
19 Gear oil
20 Molybdenum disulfide oil
21 Wheel bearing grease
22 Lithium soap base grease
23 Molybdenum disulfide grease
Symbols 24 to 25 in the exploded diagrams indi-
cate the following:
24 Apply locking agent (LOCTITER)
25 Replace the part

CONTENTS
SPECIFICATIONS
GENERAL SPECIFICATIONS 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ENGINE SPECIFICATIONS 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHASSIS SPECIFICATIONS 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CABLE ROUTING 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PERIODIC CHECKS AND ADJUSTMENTS
ENGINE 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ADJUSTING THE CLUTCH CABLE FREE PLAY 14. . . . . . . . . . . .
OVERHAULING THE ENGINE
CRANKCASE 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CRANKCASE 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CARBURETORS
CARBURETORS 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING AND ADJUSTING THE THROTTLE POSITION
SENSOR 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ELECTRICAL
CHECKING THE SWITCHES 20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
LIGHTING SYSTEM 21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CIRCUIT DIAGRAM 21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TROUBLESHOOTING 22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE LIGHTING SYSTEM 24. . . . . . . . . . . . . . . . . . . . . .
TROUBLESHOOTING
FAULTY LIGHTING OR SIGNALING SYSTEM 26. . . . . . . . . . . . . . . . .
HEADLIGHT DOES NOT LIGHT 26. . . . . . . . . . . . . . . . . . . . . . . . . . .
HEADLIGHT BULB BURNT OUT 26. . . . . . . . . . . . . . . . . . . . . . . . . .
TAIL /BRAKE LIGHT DOES NOT LIGHT 26. . . . . . . . . . . . . . . . . . . .
TAIL /BRAKE LIGHT BULB BURNT OUT 26. . . . . . . . . . . . . . . . . . .
TURN SIGNAL DOES NOT LIGHT 26. . . . . . . . . . . . . . . . . . . . . . . . .
TURN SIGNAL BLINKS SLOWLY 26. . . . . . . . . . . . . . . . . . . . . . . . . .
TURN SIGNAL REMAINS LIT 26. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TURN SIGNAL BLINKS QUICKLY 26. . . . . . . . . . . . . . . . . . . . . . . . .
HORN DOES NOT SOUND 26. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FZS1000 2003 WIRING DIAGRAM (EUR)
FZS1000R 2003 WIRING DIAGRAM (OCE)

–1–
GENERAL SPECIFICATIONS/ENGINE SPECIFICATIONS SPEC
SPECIFICATIONS
GENERAL SPECIFICATIONS
Item Standard Limit
Model code 5LVF (A) (B) (D) (DK) (E) (GB) (GR) (I)
(N) (NL) (S) (SF) (CH) (P)
5LVG (D)
5LVH (F)
5LVJ (AUS)
SSS
SSS
SSS
SSS
ENGINE SPECIFICATIONS
Item Standard Limit
Piston
Piston-to-cylinder clearance
Diameter D
Height H
0.010 X0.035 mm
73.955 X73.970 mm
5 mm
0.12 mm
SSS
SSS
Carburetors
ID mark 5LV1 00 (A) (B) (D) (DK) (E) (GB) (GR)
(I) (N) (NL) (S) (SF) (CH) (P)
(AUS)
5LV3 20 (D)
5LV2 10 (F)
SSS
SSS
SSS

–2–
CHASSIS SPECIFICATIONS SPEC
CHASSIS SPECIFICATIONS
Item Standard Limit
Front suspension
Spring
Free length
Spacer length
Installed length
Spring rate (K1)
Spring rate (K2)
Spring stroke (K1)
Spring stroke (K2)
Optional spring available
Fork oil
Recommended oil
Quantity (each front fork leg)
Level (from the top of the inner
tube, with the inner tube fully
compressed, and without the
fork spring)
344.0 mm
78.5 mm
320.0 mm
7.8 N/mm (0.8 kg/mm)
11.8 N/mm (1.2 kg/mm)
0 X64 mm
64 X140 mm
No
Suspension oil “01” or equivalent
435 cm3
140 mm
SSS
SSS
SSS
SSS
SSS
SSS
SSS
SSS
SSS
SSS
SSS

–3–
CABLE ROUTING SPEC
1Brake hose
2Front fork
A Fasten the right handlebar switch lead to the han-
dlebar with a plastic band. Point the end of clamp to
the downward.
B Route the right handlebar switch lead by the right
side of the wire guide behind the throttle cable.
C Fasten the left handlebar switch lead to the handle-
bar with a plastic band. Point the end of clamp to the
downward.
D Fasten the left handlebar switch lead, main switch
lead, clutch cable and starter cable with a plastic
band. Clamp beneath the horn lead branching posi-
tion. Do not fasten the horn lead. Direct the end of
clamp to the rear inner side of vehicle.
Clamp it at 90 mm below the bottom end of the up-
per bracket.
E Route the main switch lead front and left side the
another leads.
F Pass the horn leads from the outside of vehicle to
the inner side and clamp it to the under-bracket.
Point the tip of clamp to the front of vehicle. There
should be no slack with the lead between horn and
clamp.
Clamp it at the position of 20 mm from the inner side
of the inner tube.
G Clamp the brake hose to the inner tube. Cut the sur-
plus part of clamp tip leaving 2 to 10 mm and point
the tip of clamp to the front of vehicle.
Clamp it at 80 mm from the top end of the under
bracket.
H Route the brake hose through the brake hose
guide.
I Route the throttle cable 1 and 2 behind the brake
hose and pass it by the left side of wire guide.
J Position the remained part of clamp tip within this
range.
K Direct the horn lead coupler to the rear.
CABLE ROUTING

–4–
1Fuel pump lead
2Fuel pump
3EXUP cable
4Carburetor heater hose
5Right handlebar switch lead
6Throttle cable 2
7Throttle cable 1
8Radiator fan motor lead
9Coolant reservoir tank over flow hose
10 Fuel tank drain hose
11 Fuel tank breather hose
12 White paint mark
13 Rear brake light switch lead
14 Neutral switch lead
15 Speed sensor lead
16 Pickup coil lead
17 Handlebar upper bracket
18 Brake hose guide
19 Front brake hose
A Fasten the fuel pump lead, pickup coil lead, neutral
switch lead, speed sensor lead, rear brake light
switch lead and fuel pump with a plastic clamp.
Pass the clamp tip between the frame and rear
fender and point it to the downward.
B Fasten the fuel hose, pickup coil lead, neutral switch
lead and speed sensor lead with a plastic clamp un-
der the fuel hose. Place the fitting part on the up-
ward.
C Put the EXUP cable into the air box cover.
D Clamp the throttle position sensor lead to the carbu-
retor with a steel clamp.
CABLE ROUTING SPEC

–5–
CABLE ROUTING SPEC
E Route the throttle position sensor lead inward the
EXUP cable.
F Clamp the Al system hose and carburetor heater
hose with a plastic clamp.
G Route the carburetor heater hose inside the EXUP
cable.
H Route the carburetor heater hose between frame
and radiator fan motor lead.
I Route the carburetor heater hose over the frame.
J Clamp the right handlebar switch lead to the frame
with a plastic clamp.
K Align the taping section of the right handlebar switch
lead with the weld beads of tank rail and clamp with
the throttle cables 1 and 2. Point the tip of clamp to
the downward outside of the vehicle.
L To the carburetor.
M Fasten the radiator hose with a plastic band.
N Fasten the pickup coil lead with a steel clamp.
O Route the coolant reservoir tank over flow hose, fuel
tank drain hose and fuel tank breather hose through
the frame hose holder from the inside of the vehicle
to the outside. At this time, pull the fuel tank drain
hose and fuel tank breather hose so that the white
paint marks are within a 20 mm range.
P Route the EXUP cable forward the another hoses,
and upward the engine mounting bracket.
Q Fasten the rear brake light switch lead with a plastic
guide.
R Route the rear brake light switch lead inside the
another leads.
S Insert the all couplers into the rubber cover.

–6–
CABLE ROUTING SPEC
T Route the right handlebar switch lead between han-
dle upper bracket and wire guide.
U Route the neutral switch lead and speed sensor
lead left side the coolant reservoir hose.
V Route the coolant reservoir hose left side the en-
gine mounting bracket.
W Route the coolant reservoir over flow hose forward
the neutral switch lead and speed sensor lead.
X Route the coolant reservoir hose backward the
another hoses.
Y Route the EXUP cable forward the another hoses.
Z Route the EXUP cable forward the frame cross
pipe.
AA Route the fuel tank drain hose and fuel tank
breather hose forward the neutral switch lead and
speed sensor lead.

–7–
CABLE ROUTING SPEC
1Starter cable
2Clutch cable
3Left handlebar switch lead
4Min switch lead
5EXUP motor
6Starting circuit cut-off relay
7Starter motor lead
8Radiator fan motor relay
9Sidestand switch lead
10 Air filter case drain hose
11 Oil level switch lead
12 A.C. magneto lead
13 Coolant pipe
14 Carburetor heater hose
15 Throttle cable 1
16 Throttle cable 2
17 Spark plug leads
18 EXUP cable
A Fasten the main switch lead and left handlebar
switch lead to the frame with a plastic band.
B Fasten the coolant hose and carburetor heater
hose with a plastic band.
Clamp it at 50 mm from the top end of the cylinder
head cover.
C Route the spark plug lead #1 outside of the starter
cable and carburetor heater hose, and under the
clutch cable and rectifier/ regulator lead.
D Fasten the clutch cable with a plastic clamp to the
frame.
E Fasten the wire harness with a plastic clamp to the
frame.

–8–
CABLE ROUTING SPEC
F Fasten the clutch cable with a steel clamp.
G Route the all leads on the shift shaft.
H Route the fuel sender lead inside of the seat rail.
I Route the battery negative lead forward of the
frame stay.
J Route the wire harness around inside of the rear
fender rib.
K Fasten the wire harness, sidestand switch lead and
oil level switch lead to the frame with a plastic
clamp. Do not fasten the A.C. magneto lead coupler
(white).
L Route the starter motor lead and battery negative
lead inside of the clamp.
M Route the all leads outside of fuel hose.
N Route the fuel hose the clamp of the frame.
O Fasten the sidestand switch lead, oil level switch
lead, A.C. magneto lead, starter motor lead, battery
negative lead and air filter case drain hose with a
plastic clamp.
P Fasten the sidestand switch lead, oil level switch
lead, A.C. magneto lead and air filter case drain
hose with a plastic clamp.
Q Clamp the sidestand switch lead to the frame.
R Route the air filter case drain hose through inside
the sidestand switch lead, and put end of the hose
backward.
S Fasten the sidestand switch lead to the frame with a
clamp.
T Fasten the sidestand switch lead and oil level switch
lead with a plastic clamp. Do not crush the air filter
case drain hose.

–9–
CABLE ROUTING SPEC
U Route the sidestand switch lead oil level switch lead
outside the hose.
V To the cylinder #4.
W Route the carburetor heater hose through outside
of the coolant pipe.
X Route the starter cable through outside of the cool-
ant hose and upward of the carburetor heater hose.
Y Tail/brake light and right turn signal light lead
should not be stick out from the gap between the
rear fender and tail/ brake light.
Z Route the turn signal light lead through hole on the
rear fender.
AA Push in the coupler of tail/brake light leads be-
tween the rear fender and frame.
BB Push in the wire harness between ribs.
CC Route the spark plug leads #2, 3 between EXUP
cable and spark plug lead #4.
DD Route the throttle cables 1 and 2 between right
coolant hose and left coolant hose, and upward of
the EXUP cable.
EE Route the spark plug lead #4 forward of the cool-
ant hose and downward of the EXUP cable.

–10–
1Clutch cable
2Left handlebar switch lead
3Main switch lead
4Starter cable
5EXUP motor lead
6Radiator fan motor lead
7Thermo switch lead
8Throttle cable 1
9Throttle cable 2
10 Right handlebar switch lead
11 Coolant reservoir tank hose
12 Ignition coil
13 Fuel tank drain hose
14 Fuel tank breather hose
15 Fuel hose
16 Red/ Black lead
17 Orange lead
18 Rectifier/regulator lead
19 Battery
20 Emergency engine stop switch
21 Turn signal relay
22 Fuse box
23 Igniter unit
24 Rear turn signal light lead
25 Tail/brake light lead
26 Seat lock cable
27 Immobilizer coupler (free)
28 Starter relay
29 Battery positive lead
30 Radiator fan motor relay
31 Battery negative lead
32 Starting circuit cut-off relay
33 White mark
34 Wire harness
35 Ignition coil lead
36 White mark
CABLE ROUTING SPEC

–11–
CABLE ROUTING SPEC
A Route the throttle cables through right side of the ra-
diator fan motor lead and thermo switch lead.
and EXUP motor lead
B Clamp the right turn signal lead (front).
C Route the all leads through between frame cross
pipe and bracket.
D Route the coolant reservoir tank hose through un-
der the cross pipe.
E Do not excessively bend the throttle cable.
F Fasten the ignition coil and ignition coil lead with a
plastic band and end of the plastic band downward.
G Route the throttle position sensor lead through un-
der the air vent hose.
H It is allowed to select either color for leads. Point the
lead toward the inner side.
I Clamp the EXUP cable with a plastic clamp and
clamp open end upward.
J Route the coolant reservoir tank hose through un-
der the air vent hose and AI system hose.
K Route the coolant reservoir tank hose through un-
der the frame cross pipe.
L Clamp the fuel hose with a plastic clamp.
M Put the fuel tank breather hose into the forward nip-
ple on the fuel tank.
N Put the fuel tank breather hose into the backward
nipple on the fuel tank.
O Insert the positioning clamp of wire harness to the
T-stud of frame.
P Fasten the fuel hose and AI system hose with a
plastic band and end of band downward.
Q Put air vent hoses (left and right) into air filter case
groove.
R Route the air vent hose through over the wire har-
ness.

–12–
CABLE ROUTING SPEC
S Route the rectifier/ regulator lead through under the
wire harness.
T Place the coupler of each lead in the coupler cover.
U Clamp the wire harness and rectifier/ regulator lead
with a clamp.
V Attach the ignition coil lead and clamp it with the
frame cross pipe at the right side of bracket. Howev-
er, do not clamp a bare lead.
W Route the rectifier/ regulator lead through over the
radiator fan motor lead and EXUP motor lead.
X Clamp the left and right handlebar switch leads,
main switch lead, EXUP motor lead, radiator fan
motor lead and thermo switch lead with a plastic
clamp.
There should be no interference of each lead with
the throttle cable and spark plug leads.
Y Clamp the stay, wire harness and rectifier /regulator
leads. Cut the surplus part of clamp. Leave the re-
mained part to be within 3 mm after cutting.
Z Clamp the left turn signal lead and headlight sub-
wire harness.
AA Clamp the battery negative lead with a battery
band.
BB Insert the coupler of negative lead to the hole of
battery band.
CC To the turn signal light.
DD Fasten the tail/ brake light lead and turn signal
light lead, and put in the groove on the tail/ brake
light bracket.
EE Put the lock cable into the groove on the rear
fender.
FF Fasten the battery positive lead to the frame with
a plastic clamp.