Yamaha FZS1000N User manual

EAS00001
FZS1000N (C)
SERVICE MANUAL
2001 by Yamaha Motor
Corporation, U.S.A.
First edition, January 2001
All rights reserved. Any reproduction
or unauthorized use without the written
permission of Yamaha Motor Corporation,
U.S.A. is expressly prohibited.
Printed in U.S.A.
P/N LIT-11616-14-48

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 mostsatisfactionfromhisvehicleandtoconformwith 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.
SThis Service Manual contains information regarding periodic maintenance to the emission control
system. Please read this material carefully.
SDesigns 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.

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
ELECCHAS
COOL
CHK
ADJ
TRBL
SHTG
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
4Engine
5Cooling system
6Carburetor(-s)
7Chassis
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
ENGINE
COOLING SYSTEM
CARBURETORS
CHASSIS
ELECTRICAL SYSTEM
TROUBLESHOOTING
GEN
INFO 1
SPEC 2
3
ENG 4
COOL 5
CARB 6
CHAS 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.Aftertheboltor
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
Donotspinthe bearing withcompressedair
because this will damage the bearing sur-
faces.
1Bearing
EAS00025
CIRCLIPS
1. Beforereassembly, check allcirclipscareful-
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:
Slead 1
Scoupler 2
Sconnector 3
2. Check:
Slead
Scoupler
Sconnector
Moisture !Dry with an air blower.
Rust/stains !Connect and disconnect sev-
eral times.
3. Check:
Sall connections
Loose connection !Connect properly.
If the pin 1on the terminal is flattened, bend it
up.
4. Connect:
Slead
Scoupler
Sconnector
Make sure that all connections are tight.
5. Check:
Scontinuity
(with a pocket tester)
Pocket tester measurement
YU-03112-C
SIf there is no continuity, clean the terminals.
SWhen checking the wire harness, perform
steps 1 to 3.
SAs 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
YM-01080-A
Alternator Rotor Puller
This tool is used to remove the generator
rotor.
YU-01235
Universal Magneto & Rotor Holder
This tool is used to hold the generator rotor
when removing or installing the generator
rotor bolt or pickup coil rotor bolt.
YU-01304
Piston Pin Puller
This tool is used to remove the piston pins.
YU-01312-A
Fuel Level Gauge
This tool is used to measure the fuel level in
the float chamber.
Radiator
Pressure Tester
YU-24460-01
Radiator
Pressure
Tester Adapter
YU-33984
Radiator Pressure Tester
Radiator Pressure Tester Adapter
These tools are used to check the cooling
system.
YU-33975
Spanner Wrench
This tool is used to loosen or tighten the
steering stem ring nuts.
YU-1268
Steering Nut Wrench
This tool is used to loosen the steering stem
ring nuts.
YM-01447
Damper Rod Holder
This tool is used to hold the damper rod
assembly when loosening or tightening the
damper rod assembly bolt.

1-6
SPECIAL TOOLS GEN
INFO
Tool No. Tool name/Function Illustration
YU-38411
Oil Filter Wrench
This tool is needed to loosen or tighten the
oil filter cartridge.
YM-01434
Rod Holder
This tool is used to support the damper
adjusting rod.
Rod puller
YM-01437
Rod Puller
This tool is used to pull up the front fork
damper rod.
Driver
YM-33963
43 mm
Adapters
YM-8020-A
Driver
43 mm Adapters
This tool is used to install the front fork’s oil
seal and dust seal.
YU-03008
Micrometers (50 X75 mm)
This tool is used to measure the piston skirt
diameter.
YU-8030
Carburetor Synchronizer
This guide is used to synchronize the
carburetors.
Compression
Gauge Set
YU-33223
Compression Gauge Set
Compression Gauge Adapter
These tools are used to measure engine
compression.
YU-03112-C
Pocket Tester Measurement
This tool is used to check the electrical
system.
YU-8036-B
Inductive Self-Powered Tachometer
This tool is used to check engine speed.

1-7
SPECIAL TOOLS GEN
INFO
Tool No. Tool name/Function Illustration
YM-33277-A
Battery Powered Timing Light
This tool is used to check the ignition
timing.
Valve Spring
Compressor
YM-04019
Adapter
YM-4108
YM-4114
Valve Spring Compressor Set, Quick
Release
Adapter
These tools are used to remove or install
the valve assemblies.
40 and 50 mm
Bearing Driver
YM-4058
Water Pump
Seat Installer
YM-33221
40 and 50 mm Bearing Driver
Water Pump Seal Installer
These tools are used to install the water
pump seal.
YM-91042
Universal Clutch Holder (Grabbit)
This tool is used to hold the clutch boss
when removing or installing the clutch boss
nut.
YM-04111
YM-4116
Valve Guide Remover (ø4)
Valve Guide Remover (ø4.5)
This tool is used to remove or install the
valve guides.
YM-04112
YM-4117
Valve Guide Installer (ø4)
Valve Guide Installer (ø4.5)
This tool is used to install the valve guides.
YM-04113
YM-4118
Valve Guide Reamer (ø4)
Valve Guide Reamer (ø4.5)
This tool is used to rebore the new valve
guides.
YM-34487
Dynamic Spark Tester
This tool is used to check the ignition
system components.
ACC-11001-
05-01
Yamaha bond No. 1215
This bond is used to seal two mating
surfaces (e.g., crankcase mating surfaces).

SPEC
CHAPTER 2.
SPECIFICATIONS
GENERAL SPECIFICATIONS 2-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ENGINE SPECIFICATIONS 2-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHASSIS SPECIFICATIONS 2-11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ELECTRICAL SPECIFICATIONS 2-15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TIGHTENING TORQUES 2-18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
GENERAL TIGHTENING TORQUES 2-18. . . . . . . . . . . . . . . . . . . . . . . . . .
ENGINE TIGHTENING TORQUES 2-19. . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHASSIS TIGHTENING TORQUES 2-22. . . . . . . . . . . . . . . . . . . . . . . . . . .
LUBRICATION POINTS AND LUBRICANT TYPES 2-23. . . . . . . . . . . . . . . .
ENGINE 2-23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHASSIS 2-24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
COOLING SYSTEM DIAGRAMS 2-25. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ENGINE OIL LUBRICATION CHART 2-29. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
LUBRICATION DIAGRAMS 2-30. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CABLE ROUTING 2-35. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SPEC

2-1
GENERAL SPECIFICATIONS SPEC
SPECIFICATIONS
GENERAL SPECIFICATIONS
Item Standard Limit
Model code 5LV5 (USA except for California)
5LV6 (CDN)
5LV7 (California)
Dimensions
Overall length
Overall width
Overall height
Seat height
Wheelbase
Minimum ground clearance
Minimum turning radius
2,125 mm (83.7 in)
765 mm (30.1 in)
1,190 mm (46.9 in)
820 mm (32.3 in)
1,450 mm (57.1 in)
140 mm (5.5 in)
2,900 mm (114.2 in)
Weight
Wet (with oil and a full fuel tank)
Dry (without oil and fuel)
Maximum load (total of cargo, rider,
passenger, and accessories)
231 kg (509 lb)
232 kg (512 lb) (for california)
208 kg (459 lb)
209 kg (461 lb) (for california)
189 kg (417 lb)
188 kg (415 lb) (for california)