Yamaha FZS1000 User Manual
FOREWORD
This Assembly Manual contains the information required for the correct reassembly of this Y amaha motorcycle prior to delivery to the customer. Since some external parts of the motorcycle have been removed at the
Y amaha factory for the convenience of packing, assembly by the Y amaha dealer is required. It should be noted
that the reassembled motorcycle should be throughly
cleaned, inspected, and adjusted prior to delivery to the
customer.
NOTICE
The service specifications given in this assembly manual are based on the model as manufactured. Modifications and significant changes in specifications and / or
procedures will be forwarded to Authorized Yamaha
Dealers. The procedures below are described in the order that the procedures are carried out correctly and
completely.Failure to do so can result in poor performance and possible harm to the motorcycle and/or rider.
Particularly important information is distinguished in this
manual by the following notations.
SYMBOLS USED IN
ASSEMBLY MANUAL
In order to simplify descriptions in assembly manuals,
the following symbols are used:
: Coat with lithium soap base grease.
: Tighten to 10 Nm.
: (10 Nm = 1.0 mkg)
: Front ward of the motorcycle.
: Provide a clearance.
: Install so that the arrow mark faces
: upward.
: Apply a motor oil.
: Made of rubber or plastics.
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.
CAUTION:
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.
A: Ref No. (indicating the order or operations.)
B: Part name
C: Quantity of parts per motorcycle.
D: Place where parts are held.
V: Stored in vinyl bag.
C: Stored in carton box.
S: Fixed inside the steel frame and/or contained
in the styrofoam tray (upper or lower).
: Temporarily installed or secured.
E: Size or material of parts.
d/D:Diameter of part.
: Length of part.
ex, 5 = 5 mm
FZS1000 (N) 2001
ASSEMBLY 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.
Printed in BELGIUM
FZS1000 (N) 2001
SET-UP AND PREDELIVERY CHECKLIST
NOTE:
Check the following items again when set up and predelivery service are completed.
A: INSTALLATION OF THE PARTS INCLUDED IN THE CRATE
Handlebar
Throttle grip
Front wheel
Front fender
Front brake hose clamp
Front brake master cylinder
Handlebar switch (left)
B: TIGHTENING TORQUE OF EACH PART
Handlebar holder (upper) 28 Nm (2.8 mkg)
Front fender and outer tube 10 Nm (1.0 mkg)
Front wheel axle 59 Nm (5.9 mkg)
Front wheel axle pinch bolt 20 Nm (2.0 mkg)
Master cylinder and bracket 10 Nm (1.0 mkg)
Side cover 4 Nm (0.4 mkg)
C: ROUTING OF WIRE, CABLES, ETC.
Throttle cables
Brake hose
Clutch cable
Left handlebar switch lead
Clutch cable
Band
Rear view mirror
Windscreen
Inner panel
Side cover (left)
Battery
Right handlebar switch lead
Battery positive lead
Battery negative lead
Starter cable
D: ADJUSTMENTS
Checking and charging the battery
Drain the fuel
Checking the tire pressure
Checking the engine oil level
Checking the coolant level
Adjusting the engine idling speed
Adjusting the throttle cable free play
Adjusting the front brake
Adjusting the rear brake
Checking the brake fluid level
Breeding the hydraulic brake system
Adjusting the clutch cable free play
Adjusting the front fork legs
Adjusting the rear shock absorber assembly
Adjusting the drive chian slack
Adjusting the rear brake light switch
Adjusting the headlight beams
Adjusting the digital clock
E: FUNCTION AND PERFORMANCE
Check for the function of headlight, meter light and tail light
Check for the funciton of brake light
Check for the function of flasher light and indicator light
Check for the tone quality of the horn
Check for the function of the indicator on the speedometer
Check for brake feeling
Check for engine noise (Yes/No)
Check for exhaust leak (Yes/No)
F: ACCESSORIES, ETC. FOR DELIVERY
Owner’s manual
Owner’s tool kit
SETUP PROCEDURES
–1–
1. Handlebar
1 Handlebar 1 C
2 Handlebar holder 2 V
3 Hexagon socket bolt 4 V d = 8, = 30
4 Plug 4 V
2. Throttle grip
A: The handlebar holder should be
installed with the arrow mark
forward.
Tightening torque:
23 Nm (2.3 mkg)
CAUTION:
First tighten the bolts on the
front side, and then tighten the
bolts on the rear side.
B: Align the punch mark on the
handlebar with the top of the
lower handlebar holder.
C: Tighten the bolts to specified
torque.
1 Throttle grip 1
2 Screw 1 d = 5, = 30
3 Screw 1 d = 5, = 50
4 Grip end 1 V
A: Align the projection on the han-
dlebar switch with the hole in
the handlebar.
B: Tighten the bolt to specified
torque.
Tightening torque
3.5 Nm (0.4 mkg)
C: Check the throttle grip for
smooth action.
CAUTION:
Proper cable routing is essential
to assure safe motorcycle operation.
Refer to “CABLE ROUTING”.
–2–
3. Front wheel
1 Front wheel 1 S
2 Collar 2 V
3 Front wheel axle 1
4 Axle pinch bolt 1 d = 8, = 45
4. Front fender
A: Clean the brake disc.
B: Clean the front wheel axle.
C: Clean the collar .
D:
WARNING
Take care not to put grease
on the brake disc or inner
surface of the brake pads. If
you do so, clean using a rag
dampened with a solvent.
Foreign material on braking
surface can cause impaired
braking action.
E: Lift the front wheel and install
the front wheel axle.
1 Front fender 1 C
2 Flange bolt 2 V d = 6, = 9
3 Nut 2 V d = 6
4 Screw 2 V d = 6, = 61
F: Tighten the front wheel axle to
specified torque.
Tightening torque:
72 Nm (7.2 mkg)
CAUTION:
Before tightening the pinch bolt,
stroke the front forks several
times to make sure of proper fork
operation. With the pinch bolt
loose, work the left fork leg back
and forth until the proper clearance between the disc and caliper bracket on the front fork are
obtained.
G: Tighten the axle pinch bolt to
specified torque.
Tightening torque:
23 Nm (2.3 mkg)
A: Tighten the nuts to specified
torque.
Tightening torque:
6 Nm (0.6 mkg)
B: Tighten the screw to specified
torque.
Tightening torque:
6 Nm (0.6 mkg)
–3–
5. Front brake hose clamp
6. Front brake master cylinder
1 Brake hose clamp (right) 1 V
2 Brake hose clamp (left) 1 V
3 Flange bolt 2 V d = 6, = 25
A: Install the brake hose clamp on
the right side brake hose.
B: Install the brake hose clamp on
the left side brake hose.
C: Pass the brake hose through
the brake hose holder and secure the holder to the front fork.
CAUTION:
Proper hose routing is essential
to assure safe motorcycle operation.
Refer to “CABLE ROUTING”.
1
Master cylinder 1
2 Bracket 1 V
3 Hexagon socket bolt 2 V d = 6, = 10
4 Brake switch lead 2
7. Handlebar switch (left)
A: Make sure that the “UP” mark
with the bracket is pointed upward.
B: Align the punch mark on the
handlebar with the gap of the
master cylinder bracket.
C: Tighten the bolts in stages and
maintain an equal gap on each
side of the bracket.
Tightening torque:
10 Nm (1.0 mkg)
D: Check the brake lever for
smooth action.
1
Starter cable 1
2 Starter lever 1 V
3 handlebar switch (left) 1
4 Panhead screw 2 C d = 5, = 25
A: Align the projection on the han-
dlebar switch (left) with the hole
in the handlebar.
CAUTION:
Proper cable and hose routing is
essential to assure safe motorcycle operation. Refer to
“CABLE ROUTING”.
CAUTION:
Proper cable routing is essential
to assure safe motorcycle operation.
Refer to “CABLE ROUTING”.
–4–
8. Clutch cable
9. Band
1 Clutch cable 1
2 Clutch switch coupler 1
A: Check the clutch lever for
smooth action.
CAUTION:
Proper cable routing is essential
to assure safe motorcycle operation.
Refer to “CABLE ROUTING”.
1 Band 2 V
A: Clamp the left handlebar switch
lead.
B: Clamp the right handlebar
switch lead.
10. Rear view mirror
NOTE:
Refer to “CABLE ROUTING”.
Rear view mirror
1
(left and right)
2 Cap nut 4 V d = 6
2 C
–5–
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