Yamaha FZS1000(N) 2001 User manual

EAS00000
FZS1000 (N)
SERVICE MANUAL
2000 by Yamaha Motor Co.Ltd.
First edition, December 2000
All rights reserved. Any reproduction or
unauthorized use without the written
permission of Yamaha Motor Co., Ltd. is
expressly prohibited.

NOTE:
CAUTION:
EAS00003 NOTICE
This manual was produced by the Yamaha Motor Company, Ltd. primarily for use by Yamaha dealers
andtheirqualifiedmechanics.Itisnotpossibletoincludealltheknowledgeofamechanicinonemanu-
al. Therefore, anyone who uses this book to perform maintenance and repairs on Yamaha vehicles
shouldhaveabasicunderstandingofmechanicsandthetechniquestorepairthesetypesofvehicles.
Repair and maintenance work attempted by anyone without this knowledge is likely to render the ve-
hicle unsafe and unfit for use.
This model has been designed and manufactured to perform within certain specifications in regard to
performance and emissions. Proper service with the correct tools in necessary to ensure that the ve-
hicle will operate as designed. If there is any question about a service procedure, it is imperative that
you contact a Yamaha dealer for any service information changes that apply to this model. This policy
isintendedto providethecustomerwiththe mostsatisfactionfromhis vehicleandtoconformwith fed-
eral environmental quality objectives.
YamahaMotorCompany,Ltd.iscontinuallystrivingtoimproveallitsmodels.Modificationsandsignifi-
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.
This Service Manual contains information regarding periodic maintenance to the emission control
system. Please read this material carefully.
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!
FailuretofollowWARNINGinstructions couldresultinsevereinjury ordeathto
themotorcycleoperator,abystanderorapersonchecking or repairing the mo-
torcycle.
ACAUTIONindicatesspecialprecautionsthatmustbetaken to avoid damage
to the motorcycle.
NOTE: A NOTE provides key information to make procedures easier or clearer.

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2
6
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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 ofeach
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.

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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 intheexplodeddiagramsindi-
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 intheexplodeddiagramsindi-
cate the following:
24 Apply locking agent (LOCTITER)
25 Replace the part

GENERAL INFORMATION
SPECIFICATIONS
PERIODIC CHECKS AND
ADJUSTMENTS
CHASSIS
ENGINE
COOLING SYSTEM
CARBURETORS
ELECTRICAL SYSTEM
TROUBLESHOOTING
GEN
INFO 1
SPEC 2
3
CHAS 4
ENG 5
COOL 6
CARB 7
ELEC 8
TRBL
SHTG 9
CHK
ADJ
EAS00012 TABLE OF CONTENTS

GEN
INFO
CHAPTER 1
GENERAL INFORMATION
MOTORCYCLE IDENTIFICATION 1-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
VEHICLE IDENTIFICATION NUMBER 1-1. . . . . . . . . . . . . . . . . . . . . . . . .
MODEL CODE 1-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
IMPORTANT INFORMATION 1-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PREPARATION FOR REMOVAL AND DISASSEMBLY 1-2. . . . . . . . . .
REPLACEMENT PARTS 1-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
GASKETS, OIL SEALS AND O-RINGS 1-2. . . . . . . . . . . . . . . . . . . . . . . .
LOCK WASHERS/PLATES AND COTTER PINS 1-2. . . . . . . . . . . . . . . .
BEARINGS AND OIL SEALS 1-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CIRCLIPS 1-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE CONNECTIONS 1-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SPECIAL TOOLS 1-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

GEN
INFO

1-1
MOTORCYCLE IDENTIFICATION GEN
INFO
EAS00014
GENERAL INFORMATION
MOTORCYCLE IDENTIFICATION
EAS00017
VEHICLE IDENTIFICATION NUMBER
Thevehicleidentificationnumber 1isstamped
into the right side of the steering head.
EAS00018
MODEL CODE
The model code label 1is affixed to the frame.
This information will be needed to order spare
parts.

1-2
IMPORTANT INFORMATION GEN
INFO
spring
lip
oil grease
lip
EAS00020
IMPORTANT INFORMATION
PREPARATION FOR REMOVAL AND DIS-
ASSEMBLY
1. Before removal and disassembly, remove all
dirt, mud, dust and foreign material.
2. Use only the proper tools and cleaning
equipment.
Refer to the “SPECIAL TOOLS” section.
3. When disassembling, always keep mated
parts together. This includes gears, cylin-
ders, pistons and other parts that have been
”mated” through normal wear. Mated parts
mustalwaysbereusedorreplaced as an as-
sembly.
4. During disassembly, clean all of the parts
and place them in trays in the order of disas-
sembly. This will speed up assembly and al-
low for the correct installation of all parts.
5. Keep all parts away from any source of fire.
EAS00021
REPLACEMENT PARTS
1. Use only genuine Yamaha parts for all re-
placements. Use oil and grease recom-
mended by Yamaha for all lubrication jobs.
Other brands may be similar in function and
appearance, but inferior in quality.
EAS00022
GASKETS, OIL SEALS AND O-RINGS
1. When overhauling the engine, replace all
gaskets, seals and O-rings. All gasket sur-
faces, oil seal lips and O-rings must be
cleaned.
2. During reassembly, properly oil all mating
parts and bearings and apply grease onto
the oil seal lips with greace.
EAS00023
LOCK WASHERS/PLATES AND COTTER
PINS
1. After removal, replace all lock wash-
ers/plates
1andcotterpins.Afterthebolt or
nuthasbeentightenedtospecification,bend
the lock tabs along a flat of the bolt or nut.

1-3
IMPORTANT INFORMATION GEN
INFO
CAUTION:
EAS00024
BEARINGS AND OIL SEALS
1. Install bearings and oil seals so that the
manufacturer’s marks or numbers are vis-
ible. When installing oil seals, apply a light
coat of lithium soap base grease onto the oil
seal lips. Oil bearings liberally when instal-
ling, if appropriate.
1Oil seal
Donotspin the bearing withcompressedair
because this will damage the bearing sur-
faces.
1Bearing
EAS00025
CIRCLIPS
1. Beforereassembly, check all circlips careful-
ly and replace damaged or distorted circlips.
Alwaysreplacepistonpinclipsafteroneuse.
When installing a circlip 1, make sure that
the sharp-edged corner 2is positioned op-
posite the thrust 3that the circlip receives.
4Shaft

1-4
CHECKING THE CONNECTIONS GEN
INFO
NOTE:
NOTE:
NOTE:
EAS00026
CHECKING THE CONNECTIONS
Check the leads, couplers, and connectors for
stains, rust, moisture, etc.
1. Disconnect:
lead 1
coupler 2
connector 3
2. Check:
lead
coupler
connector
Moisture Dry with an air blower.
Rust/stains Connect and disconnect sev-
eral times.
3. Check:
all connections
Loose connection Connect properly.
If the pin 1on the terminal is flattened, bend it
up.
4. Connect:
lead
coupler
connector
Make sure that all connections are tight.
5. Check:
continuity
(with a pocket tester)
Pocket tester
90890-03112
If there is no continuity, clean the terminals.
When checking the wire harness, perform
steps 1 to 3.
As a quick remedy, use a contact revitalizer
available at most part stores.

1-5
SPECIAL TOOLS GEN
INFO
EAS00027
SPECIAL TOOLS
The following special tools are necessary for complete and accurate tune-up and assembly. Use only
theappropriatespecialtoolsasthiswillhelpprevent damage caused by the use of inappropriate tools
or improvised techniques. Special tools, part numbers or both may differ depending on the country.
When placing an order, refer to the list provided below to avoid any mistakes.
Tool No. Tool name/Function Illustration
90890-01080
Rotor puller
This tool is used to remove the generator
rotor.
90890-01235
Rotor holding tool
This tool is used to hold the generator rotor
when removing or installing the generator
rotor bolt or pickup coil rotor bolt.
90890-01304
Piston pin puller set
This tool is used to remove the piston pins.
90890-01312
Fuel level gauge
This tool is used to measure the fuel level in
the float chamber.
Radiator cap
tester
90890-01325
Adapter
90890-01352
Radiator cap tester
Adapter
These tools are used to check the cooling
system.
90890-01403
Steering nut wrench
This tool is used to loosen or tighten the
steering stem ring nuts.
90890-01447
Damper rod holder
This tool is used to hold the damper rod as-
sembly when loosening or tightening the
damper rod assembly bolt.

1-6
SPECIAL TOOLS GEN
INFO
Tool No. Tool name/Function Illustration
90890-01426
Oil filter wrench
This tool is needed to loosen or tighten the
oil filter cartridge.
90890-01434
Rod holder
This tool is used to support the damper ad-
justing rod.
Rod puller
90890-01437
Rod puller
attachment
90890-01436
Rod puller
Rod puller attachment
These tools are used to pull up the front
fork damper rod.
Fork seal driver
weight
90890-01367
Fork seal driver
attachment (ø43)
90890-01374
Fork seal driver weight
Fork seal driver attachment (ø43)
This tool is used to install the front fork’s oil
seal and dust seal.
90890-03008
Micrometer (50 75 mm)
This tool is used to measure the piston skirt
diameter.
Vacuum gauge
90890-03094
Vacuum gauge
This guide is used to synchronize the car-
buretors.
Compression
gauge
90890-03081
Compression
gauge adapter
90890-04136
Compression gauge
Compression gauge adapter
These tools are used to measure engine
compression.
90890-03112
Pocket tester
This tool is used to check the electrical sys-
tem.
90890-03113
Engine tachometer
This tool is used to check engine speed.

1-7
SPECIAL TOOLS GEN
INFO
Tool No. Tool name/Function Illustration
90890-03141
Timing light
This tool is used to check the ignition tim-
ing.
90890-03173
Carburetor angle driver 2
This tool is used to turn the pilot screw
when adjusting the engine idling speed.
Valve spring com-
pressor
90890-04019
Attachmenht
90890-04108
90890-04114
Valve spring compressor
Valve spring compressor attachment
These tools are used to remove or install
the valve assemblies.
Middle driven shaft
bearing driver
90890-04058
Mechanical seal
installer
90890-04078
Middle driven shaft bearing driver
Mechanical seal installer
These tools are used to install the water
pump seal.
90890-04086
Universal clutch holder
This tool is used to hold the clutch boss
when removing or installing the clutch boss
nut.
90890-04111
90890-04116
Valve guide remover (ø4)
Valve guide remover (ø4.5)
This tool is used to remove or install the
valve guides.
90890-04112
90890-04117
Valve guide installer (ø4)
Valve guide installer (ø4.5)
This tool is used to install the valve guides.
90890-04113
90890-04118
Valve guide reamer (ø4)
Valve guide reamer (ø4.5)
This tool is used to rebore the new valve
guides.
90890-06754
Ignition checker
This tool is used to check the ignition sys-
tem components.

1-8
SPECIAL TOOLS GEN
INFO
Tool No. Tool name/Function Illustration
90890-85505
Yamaha bond No. 1215
This bond is used to seal two mating sur-
faces (e.g., crankcase mating surfaces).