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 mkg)

: 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 mkg)
 Front fender and outer tube 10 Nm (1.0 mkg)
 Front wheel axle 59 Nm (5.9 mkg)
 Front wheel axle pinch bolt 20 Nm (2.0 mkg)
 Master cylinder and bracket 10 Nm (1.0 mkg)

 Side cover 4 Nm (0.4 mkg)

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 mkg)

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 mkg)

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 mkg)

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 mkg)

A: Tighten the nuts to specified

torque.

Tightening torque:

6 Nm (0.6 mkg)

B: Tighten the screw to specified

torque.

Tightening torque:

6 Nm (0.6 mkg)

–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 mkg)

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–

11. Windscreen

12. Inner panel

1 Windscreen 1 C
2 Special nut 6 V d = 5
3 Screw 6 V d = 5,  = 23

CAUTION:

The windscreen is made of an
acrylate resin. Take care so that
it is not scratched.

A: Tighten the screw to specified

torque.

Tightening torque:

0.4 Nm (0.04 mkg)

1 Inner panel (left and right) 2 C
2 Button head screw 4 V d = 5,  = 13
3 Button head screw 2 V d = 6,  = 16
4 Plastic washer 2 V d = 6

13. Side cover (left)

A: Tighten the screw to specified

torque.

Tightening torque

1.5 Nm (0.2 mkg)

B: Tighten the screw to specified

torque.

Tightening torque

4.5 Nm (0.5 mkg)

1 Side cover (left) 1 C
2 Button head screw 1 V d = 6,  = 16

A: Tighten the screw to specified

torque.

Tightening torque:

3.8 Nm (0.4 mkg)

–6–

14. Battery

1 Battery 1
2 Bolt 2 d = 6,  = 10
3 Band 1
4 Seat 1

A: Installing the battery.

NOTE:

Refer to “ADJUSTMENTS AND
PREDELIVERY SERVICE”.

B: First, connect the positive lead

(Red color lead) to the positive
terminal.

C: Connect the negative lead

(Black color lead) to the nega­tive terminal.

NOTE:

Refer to “CABLE ROUTING”.

–7–

CABLE ROUTING

WARNING

Proper cable and lead routing is essential to insure
safe motorcycle operation.

1

Handlebar switch lead (right)

2

Throttle cable 1

3

Throttle cable 2

4

Clutch cable

5

Starter cable

6

Handlebar switch lead (left)

7

Main switch lead

8

Battery negative lead

9

Battery positive lead

10

Battery

A

Fasten the handlebar switch lead (right) and handle­bar with a plastic band.

B

Route the handlebar switch lead (right) backward
the throttle cable and right side the brake hose guide.

C

Fasten the handlebar switch lead (left) and handle­bar with a plastic band.

D

Route the throttle cable 1 and 2 backward the brake
hose, and left side the brake hose guide.

E

Fasten the battery negative lead with a battery band.

F

Insert the ground lead coupler in the battery band.

–8–

ADJUSTMENTS AND PREDELIVERY SERVICE

–9–

A. CHECKING AND CHARGING THE BAT-

TERY

NOTE:

The battery used in this motorcycls is a new ver­sion maintenance free “Valve Regulated Lead
Acid Battery”, it has been pre-filled with electrolyte
at the factory so there is no need for you to add any
fluid at any time.

1. Check:
Using a digital volt meter, the state of a dis­charged MF battery can be chacked by mea­suring open-circuit voltage (the voltage mea­sured with the positive and negative terminals
being disconnected).

Open-circuit
voltage

12.8 V or
higher

Charging time

Charging is not necessary

WARNING

 Do not attempt boost charging under any

circumstances.

 Battery electrolyte is poisonous and danger-

ous, causing severe burns, etc. Contains
sulfric acid. Avoid contact with skin, eyes or
clothing.
Antidote: External – Flush with water. Inter­nal – Drink large quantities of water or milk.
Follow with milk of magnesia, beaten egg, or
vegetable oil. Call physician immediately .
Eyes: Flush with water for 15 minutes and
get prompt medical attention. Batteries pro­duce explosive gases. Keep sparks, flame,
cigarettes, etc., away . V entilate when charg­ing or using in enclosed space. Always
shield eyes when working near batteries.
KEEP OUT OT REACH OF CHILDREN.

CAUTION:

 If the voltage is lower than 12.8 V the battery

must be charged. If this is not done, the life
of the battery will be shortened drastically.
Since the procedure for charging the battery
is not explained in the assembly manual, re­fer to the service manual for more datails.

 Never remove the strip of caps, nor add any

water or electrolyte.

B. DRAIN THE FUEL

1. Put a rag under the carburetor drain hose so
fuel does not contact the crankcase.

2. Loosen the four drain screws
standing fuel.

and drain the

1

WARNING

FUEL IS HIGHLY FLAMMBLE:

 Always turn off the engine when draining.
 Take care not to spill any fuel on the engine

or exhaust pipe(s)/muffler(s) when drain­ing.

 Never drain fuel while smoking or in the vi-

cinity of an open flame.

3. Retighten the four drain screws securely.

–10–

EAA00128

C. CHECKING THE TIRE PRESSURE

1. Measure:

 tire pressure

Out of specification  Adjust.

WARNING

 Tire inflation pressure should be checked

and adjusted when the temperature of the
tire equals the ambient air temperature. Tire
inflation pressure must be adjusted accord­ing to total weight of cargo, rider, and acces­sories (fairing, saddlebags, etc. if approved
for this model), and vehicle speed.

 Proper loading of your motorcycle is impor-

tant for the handling, braking, and other per­formance and safety characteristics of your
motorcycle. Do not carry loosely packed
items that can shift.
Securely pack your heaviest items close to
the center of the motorcycle, 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 MOTORCYCLE.
Make sure the total weight of the cargo, rider,
and accessories (fairing, saddlebags, etc. if
approved for this model) does not exceed the
maximum load of the motorcycle. Operation of
an overload motorcycle could cause tire dam­age, an accident, or even injury.

Basic weight
with oil and a

231 kg

full fuel tank
Maximum

load*
Cold tire

pressure
Up to 90 kg

load*
90 kg 

maximum load*
High

speed riding

(2.5 kgf/cm2)

(2.5 kgf/cm2)

(2.5 kgf/cm2)

189 kg

Front Rear

250 kPa

270 kPa

2.7 kgf/cm2)

250 kPa

290 kPa

(2.9 kgf/cm2)

250 kPa

290 kPa

(2.9 kgf/cm2)

*: total of cargo, rider, passenger and accessories

EAA00129

D. CHECKING THE ENGINE OIL LEVEL

1. Stand the motorcycle on a level surface.

NOTE:

 Place the motorcycle on a suitable stand.
 Make sure that the motorcycle is upright.

2. Let the engine idle for a few minutes.

3. Check:
 engine oil level

The engine oil level should be between the

a

minimum level marks
marks

.

b

and maximum level

Below the minimum level mark  Add the rec­ommended engine oil to the proper level.

Recommended engine oil

Refer to the chart for the engine oil grade
which is best suited for certain atmospheric
temperatures.
API standard

SE or higher grade

ACEA standard

G4 or G5

Quantity

With oil filter element replacement

3.0 L

CAUTION:

 Engine oil also lubricates the clutch and the

wrong oil types or additives could cause
clutch slippage. Therefore, do not add any
chemical additives or use engine oils with a
grade of CD
labeled “ENERGY CONSERVING II”

a

or higher and do not use oils

or

b

higher.

 Do not allow foreign materials to enter the

crankcase.

4. Start the engine, warm it up for several min­utes, and then turn it off.

5. Check the engine oil level again.

NOTE:

Before checking the engine oil level, wait a few
minutes until the oil has settled.

–11–

EAA00136

E. CHECKING THE COOLANT LEVEL

1. Stand the motorcycle on a level surface.

NOTE:

 Place the motorcycle on a suitable stand.
 Make sure that the motorcycle is upright.

2. Check:
 coolant level

The coolant level should be between the maxi­mum level mark

.

b

a

and minimum level marks

Below the minimum level mark  Add the rec­ommended coolant to the proper level.

CAUTION:

 Adding water instead of coolant lowers the

antifreeze content of the coolant. If water is
used instead of coolant, check and correct
the antifreeze concentration of the coolant.

 Use only distilled water. Soft water may be

used if distilled water is not available.

3. Start the engine, warm it up for several min­utes, and then turn it off.

4. Check:

 coolant level

NOTE:

Before checking the coolant level, wait a few min­utes until it settles.

EAA00140

F. ADJUSTING THE ENGINE IDLING SPEED
NOTE:

Prior to adjusting the engine idling speed, the car­buretor synchronization should be adjusted prop­erly, the air filter should be clean, and the engine
should have adequate compression.

1. Start the engine and let it warm up for several
minutes.

2. Attach:

 engine tachometer

(to the spark plug lead of cylinder #1)

Engine tachometer

90890-031 13

3. Measure:

 engine idling speed

Out of specification  Adjust.

Engine idling speed

1,050  1,150 r/min

EAA00141

G. ADJUSTING THE THROTTLE CABLE FREE

PLA Y

NOTE:

Prior to adjusting the throttle cable free play, the
engine idling speed should be adjusted.

1. Measure:

 throttle cable free play

a

Out of specification  Adjust.

Throttle cable free play (at the
flange of the throttle grip)

3  5 mm

4. Adjust:
 engine idling speed

a. Turn the pilot screw

in or out until it is lightly

1

seated.

b. Turn the pilot screw out the specified number of

turns.

Pilot screw

2 turns out

c. Turn the throttle stop screw

or

until the specified engine idling speed is

b

in direction

2

obtained.

Engine idling speed is

Direction

Direction

a

increased.
Engine idling speed is

b

decreased.

2. Adjust:

a. Loosen the locknut
b. Turn the adjusting nut 2 in direction

.

1

a

or
until the specified throttle cable free play is ob­tained.

Throttle cable free play is

Direction

Direction

a

increased.
Throttle cable free play is

b

decreased.

c. Tighten the locknut.

WARNING

After adjusting the throttle cable free play, turn
the handlebar to the right and to the left to en­sure that this does not cause the engine idling
speed to change.

a

b

–12–

EAA00142

H. ADJUSTING THE FRONT BRAKE

1. Adjust:
D brake lever position

(distance
lever)

a. While pushing the brake lever forward, turn the

adjusting dial
desired position.

NOTE:

Be sure to align the setting on the adjusting dial
with the arrow mark

Position #1 Distance is the largest.
Position #4 Distance is the smallest.

a

from the throttle grip to the brake

until the brake lever is in the

1

on the brake lever holder.

2

a
a

WARNING

After adjusting the brake lever position, make
sure that the pin on the brake lever holder is
firmly inserted in the hole in the adjusting dial.

CAUTION:

After adjusting the brake lever position, make
sure that there is no brake drag.

WARNING

A soft or spongy feeling in the brake lever can
indicate the presence of air in the brake sys­tem. Before the vehicle is operated, the air
must be removed by bleeding the brake sys­tem. Air in the brake system will considerably
reduce braking performance and could result
in loss of control and possibly an accident.
Therefore, check and, if necessary, bleed the
brake system.

EAA00146

I. ADJUSTING THE REAR BRAKE

1. Measure:
D brake pedal position

(distance
the top of the brake pedal)
Out of specification  Adjust.

Brake pedal position (below the top of the
rider footrest)

40 mm

2. Adjust:
D brake pedal position

a. Loosen the locknut
b. Turn the adjusting bolt 2 in direction

until the specified brake pedal position is ob­tained.

Direction Brake pedal is raised.
Direction Brake pedal is lowered.

a

from the top of the rider footrest to

.

1

a
b

a

or

WARNING

After adjusting the brake pedal position, check
that the end of the adjusting bolt
through the hole

c

.

is visible

2

c. Tighten the locknut

Locknut

18 Nm (1.8 mSkg)

to specification.

1

WARNING

A soft or spongy feeling in the brake pedal can
indicate the presence of air in the brake sys­tem. Before the vehicle is operated, the air
must be removed by bleeding the brake sys­tem. Air in the brake system will considerably
reduce braking performance and could result
in loss of control and possibly an accident.
Therefore, check and, if necessary, bleed the
brake system.

b

CAUTION:

After adjusting the brake pedal position, make
sure that there is no brake drag.

–13–

A

B

EAA00151

J. CHECKING THE BRAKE FLUID LEVEL

1. Stand the motorcycle on a level surface.

NOTE:

D Place the motorcycle on a suitable stand.
D Make sure that the motorcycle is upright.

2. Check:
D brake fluid level

Below the minimum level mark

a

 Add the

recommended brake fluid to the proper level.

Recommended brake fluid

DOT 4

WARNING

D Use only the designated brake fluid. Other

brake fluids may cause the rubber seals to
deteriorate, causing leakage and poor brake
performance.

D Refill with the same type of brake fluid that is

already in the system. Mixing brake fluids
may result in a harmful chemical reaction,
leading to poor brake performance.

D When refilling, be careful that water does not

enter the reservoir. Water will significantly
lower the boiling point of the brake fluid and
could cause vapor lock.

Front brake

A

Rear brake

B

EAA00154

K. BLEEDING THE HYDRAULIC BRAKE SYS-

TEM

WARNING

Bleed the hydraulic brake system whenever:

D the system was disassembled,
D a brake hose was loosened or removed,
D the brake fluid level is very low,
D brake operation is faulty.

1. Remove:

D reservoir cap
D diaphragm

1

2

NOTE:

D Be careful not to spill any brake fluid or allow the

brake fluid reservoir to overflow.

D When bleeding the hydraulic brake system,

make sure that there is always enough brake
fluid before applying the brake. Ignoring this pre­caution could allow air to enter the hydraulic
brake system, considerably lengthening the
bleeding procedure.

D If bleeding is difficult, it may be necessary to let

the brake fluid settle for a few hours. Repeat the
bleeding procedure when the tiny bubbles in the
hose have disappeared.

2. Bleed:
D hydraulic brake system

CAUTION:

Brake fluid may damage painted surfaces and
plastic parts. Therefore, always clean up any
spilt brake fluid immediately.

NOTE:

In order to ensure a correct reading of the brake
fluid level, make sure that the top of the reservoir is
horizontal.

c. Connect a clear plastic hose

tightly to the

1
bleed screw 2.
Front

A

Rear

B

d. Place the other end of the hose into a contain-

er.

e. Slowly apply the brake several times.
f. Fully squeeze the brake lever or fully depress

the brake pedal and hold it in position.

g. Loosen the bleed screw.

This will release the tension and cause the
brake lever to contact the throttle grip or the
brake pedal to fully extend.

h. Tighten the bleed screw and then release the

brake lever or brake pedal.

i. Repeat steps (e) to (h) until all of the air

bubbles have disappeared from the brake fluid
in the plastic hose.

j. Tighten the bleed screw to specification.

Bleed screw

6 Nm (0.6 mSkg)

k. Fill the reservoir to the proper level.

Refer to “CHECKING THE BRAKE FLUID
LEVEL”.

WARNING

After bleeding the hydraulic brake system,
check the brake operation.

a. Add the recommended brake fluid to the prop-

er level.

b. Install the brake fluid resorvoir diaphragm.

–14–

L. ADJUSTING THE CLUTCH CABLE FREE

PLAY

1. Check:
 clutch cable free play

Out of specification  Adjust.

Clutch cable free play (at the end of the clutch
lever)

10  15 mm

2. Adjust:
 clutch cable free play

a

Clutch cable free play is

Direction

Direction

c. Tighten the locknut.

NOTE:

If the specified clutch cable free play cannot be ob­tained on the handlebar side of the cable, use the
adjusting nut on the engine side.

a

increased.
Clutch cable free play is

b

decreased

a. Loosen the locknut
b. Turn the adjusting bolt 2 in direction

until the specified clutch cable free play is ob­tained.

.

1

a

or

b

–15–

EAA00159

M. ADJUSTING THE FRONT FORK LEGS

The following procedure applies to both of the front
fork legs.

WARNING

 Always adjust both front fork legs evenly.

Uneven adjustment can result in poor han­dling and loss of stability.

 Securely support the motorcycle so that

there is no danger of it falling over.

Rebound damping

CAUTION:

Never go beyond the maximum or minimum
adjustment positions.

1. Adjust:
 rebound damping

a. Turn the adjusting screw

.

b

in direction

2

a

or

Spring preload

CAUTION:

 Grooves are provided to indicate the adjust-

ment position.

 Never go beyond the maximum or minimum

adjustment positions.

1. Adjust:
 spring preload

a. Turn the adjusting bolt

Spring preload is

Direction

Direction

Adjusting positions

Standard: 4
Minimum: 8
Maximum: 1

increased (suspension is

a

harder).
Spring preload is

decreased (suspension is

b

softer).

in direction

1

a

or

b

Rebound damping is

Direction

Direction

Adjusting positions

Standard: 7 clicks out*

.

Minimum: 17 clicks out*
Maximum: 1 clicks out*

*: from the fully turned-in position

Compression damping

increased (suspension is

a

harder).
Rebound damping is

decreased (suspension is

b

softer).

CAUTION:

Never go beyond the maximum or minimum
adjustment positions.

1. Adjust:
 compression damping

a. Turn the adjusting screw

.

b

Compression damping is

Direction

Direction

increased (suspension is

a

harder).
Compression damping is

decreased (suspension is

b

softer).

in direction

3

a

or

–16–

Adjusting positions

Standard: 6 clicks out*
Minimum: 21 clicks out*
Maximum: 1 clicks out*

*: from the fully turned-in position

EAA00169

N. ADJUSTING THE REAR SHOCK ABSORB-

ER ASSEMBL Y

WARNING

Securely support the motorcycle so that there
is no danger of it falling over.

Spring preload

CAUTION:

Never go beyond the maximum or minimum
adjustment positions.

1. Adjust:
 spring preload

NOTE:

Adjust the spring preload with the special wrench
and extension bar included in the owner’s tool kit.

a. Turn the adjusting ring
b. Align the desired position on the adjusting ring

with the stopper

Direction

Direction

a

b

in direction

1

.

2

Spring preload is
increased (suspension
is harder).

Spring preload is
decreased (suspension
is softer).

a

or

b

Rebound damping

CAUTION:

Never go beyond the maximum or minimum
adjustment positions.

1. Adjust:
 rebound damping

a. Turn the adjusting knob

.

b

Direction

Direction

Adjusting positions

.

Standard: 20 clicks out*
Minimum: 10 clicks out*
Maximum: 3 clicks out*

*: from the fully turned-in position

Compression damping

a

b

Rebound damping is
increased (suspension
is harder).

Rebound damping is
decreased (suspension
is softer).

in direction

2

CAUTION:

Never go beyond the maximum or minimum
adjustment positions.

a

or

Adjusting positions

Standard: 6
Minimum: 1
Maximum: 11

1. Adjust:
 compression damping

a. Turn the adjusting screw

.

b

Compression damping is

a

Direction

Direction

Adjusting positions

Standard: 7 clicks in*
Minimum: 1 clicks in*
Maximum: 12 clicks in*

*: from the fully turned-out position

increased (suspension
is harder).

Compression damping is
decreased (suspension

b

is softer).

in direction

3

a

or

–17–

EAA00178

O. ADJUSTING THE DRIVE CHAIN SLACK
NOTE:

The drive chain slack must be checked at the tight­est point on the chain.

CAUTION:

A drive chain that is too tight will overload the
engine and other vital parts, and one that is too
loose can skip and damage the swingarm or
cause an accident. Therefore, keep the drive
chain slack within the specified limits.

1. Stand the motorcycle on a level surface.

WARNING

Securely support the motorcycle so that there
is no danger of it falling over.

4. Loosen:
D wheel axle nut

1

5. Adjust:
D drive chain slack

a. Loosen both locknuts 2.
b. Turn both adjusting bolts 3 in direction

until the specified drive chain slack is ob-

b

a

or

tained.

Direction Drive chain is tightened.
Direction Drive chain is loosened.

a
b

NOTE:

D To maintain the proper wheel alignment, adjust

both sides evenly.

D Push the rear wheel forward to make sure that

there is no clearance between the wheel axle
plates and the end of the adjusting bolts.

NOTE:

Both wheels should be on the ground without a rid­er on the motorcycle.

2. Rotate the rear wheel several times and check
the drive chain to locate its tightest point.

3. Measure:

D drive chain slack

a

Out of specification  Adjust.

Drive chain slack

40  50 mm

EAA00181

P. ADJUSTING THE REAR BRAKE LIGHT

SWITCH

NOTE:

The rear brake light switch is operated by move­ment of the brake pedal.
The rear brake light switch is properly adjusted
when the brake light comes on just before the brak­ing effect starts.

1. Check:

D rear brake light operation timing

Incorrect  Adjust.

c. Tighten the wheel axle nut to specification.

Wheel axle nut

150 Nm (15 mSkg)

d. Tighten the locknuts to specification.

Locknut

16 Nm (1.6 mSkg)

2. Adjust:
D rear brake light operation timing

a. Hold the main body

of the rear brake light

1

switch so that it does not rotate and turn the ad-

a

justing nut

in direction

2

or

b

until the rear

brake light comes on at the proper time.

Direction

Direction

a

b

Brake light comes on
sooner.

Brake light comes on
later.

EAA00184

Q. ADJUSTING THE HEADLIGHT BEAMS

The following procedure applies to both of the
headlights.

1. Adjust:

D headlight beam (vertically)

a. Turn the adjusting screw

.

b

Direction Headlight beam is raised.
Direction Headlight beam is lowered.

a
b

in direction

1

a

or

–18–

2. Adjust:
D headlight beam (horizontally)

a. Turn the adjusting knob

.

b

2

Left headlight

Direction

Direction

a

b

Headlight beam moves to
the right.

Headlight beam moves to
the left.

Right headlight

Direction

Direction

a

b

Headlight beam moves to
the left.

Headlight beam moves to
the right.

in direction

a

or

EAA00185

R. ADJUSTING THE DIGITAL CLOCK
NOTE:

This digital clock constantly displays the time.

1. Adjust:

 digital clock

a. Hold down the “RESET” button 2 and “SE-

LECT” button

b. Push the “RESET” button 2 to set the hour.

And push the “SELECT” button.

c. Push the “RESET” button 2 to set the min-

utes. And push the “SELECT” button.

NOTE:

When setting the time (e.g., after reconnecting the
battery), first set the clock to 1:00 AM, then set it to
the correct time.

1

.

3

–19–

APPENDICES

SERVICE DAT A

FZS1000 (N) 2001
Engine idling speed: 1,050  1,150 r/min
Spark plug:

Type
Gap

Fuel:

Recommended fuel
Fuel tank capacity Total:

Valve clearance (cold): IN

EX

Maximum load * 201 kg

Up to 90 kg load *

Tire pressure

90 kg  Maximum load *

High speed riding

CR9E (NGK), U27ESR-N (DENSO)

0.7  0.8 mm

Regular unleaded gasoline
21 L

0.11  0.20 mm

0.21  0.25 mm

Front Rear

250 kPa

(2.5 kgf/cm

2

, 2.5 bar)

250 kPa

(2.5 kgf/cm2, 2.5 bar)

250 kPa

(2.5 kgf/cm2, 2.5 bar)

270 kPa

(2.7 kgf/cm

2

, 2.7 bar)

290 kPa

(2.9 kgf/cm2, 2.9 bar)

290 kPa

(2.9 kgf/cm2, 2.9 bar)

* Load is the total weight of cargo, rider, passenger, and accessories.

ST ANDARD EQUIPMENT

No.

Part name Q’ty
1 Owner’s manual 1
2 Owner’s tool kit 1

OWNER’S TOOL KIT

No. Part name Q’ty

1 Owner’s tool bag 1
2 Pliers 1
3 Wrench (10 – 12) 1
4 Wrench (12 – 14) 1
5 Wrench (14 – 17) 1
6 Wrench (32) 1
7 Special wrench 1
8 Extension bar 1
9 Spark plug wrench 1

10 Screwdriver grip 1

11 Screwdriver bit (phillips-slotted) 1
12 Screwdriver bit (phillips) 1
13 Hexagon wrench (3) 1
14 Hexagon wrench (4) 1
15 Hexagon wrench (5) 1

–20–

TIGHTENING TORQUE

Part to be tightened

Thread size

Engine:

Spark plug
Engine oil drain bolt

Chassis

Upper bracket pinch bolt
Upper bracket cap nut
Upper bracket and handlebar holder
Handlebar holder
Lower bracket pinch bolt
Lower bracket ring nut
Front brake master cylinder
Front brake hose union bolt
Engine mounting

Engine mounting bolt/nut
Engine mounting bolt/nut

Frame and down tube
Clutch cable lock nut
Ignition coil and stay
Pivot shaft
Rear shock absorber (upper)
Rear shock absorber and relay arm
Relay arm and frame
Relay arm and connecting arm
Connecting arm and swing arm
Drive chain guard
Drive chain case
Fuel cock
Fuel sender
Side cover
Coolant reservoir tank
Front wheel axle
Front wheel axle pinch bolt
Front brake caliper
Front brake disk
Front brake bleed screw
Rear brake torque rod
Rear wheel sprocket
Drive chain adjusting nut
Rear brake caliper
Rear wheel axle
Rear brake hose union bolt
Rear brake bleed screw
Rear brake disk
Rider footrest bracket and frame
Rear brake reservoir tank
Rear brake master cylinder
Rider footrest and bracket
Passenger footrest bracket and frame
Passenger footrest bracket and muffler

M10
M14

M8
M22
M10

M8

–

M25

M6
M10

M10

M8
M10

M8

M6
M18
M10
M10
M10
M12
M12

M6

M6

M6

M5

M6

M6
M16

M8
M10

M6

M8

M8
M10

M8
M10
M24
M10

M8

M8

M8

M6

M8
M10

M8
M10

Tightening torque

Nm mkg

13
43

30

110

32
23
23

See note
10
30

55
33
89

7
7

125

40
40
40
48
48

7
7
7
4
4

4
72
23
40
18

6
23
69
16
40

150

30

6
23
30

4
23
55
28
48

1.3

4.3

3.0
11

3.2

2.3

2.3
10

3.0

5.5

3.3

8.9

0.7

0.7

12.5

4.0

4.0

4.0

4.8

4.8

0.7

0.7

0.7

0.4

0.4

0.4

7.2

2.3

4.0

1.8

0.6

2.3

6.9

1.6

4.0
15

3.0

0.6

2.3

3.0

0.4

2.3

5.5

2.8

4.8

NOTE:

1. First, tighten the ring nut approximately 52 Nm (5.2 mkg) by using the torque wrench, then loosen the ring nut

2. Retighten the ring nut 18 Nm (1.8 mkg).

completely .

–21–

HOW TO USE THE CONVERSION TABLE

Torque

Weight

Distance

Mi

neous

All specification date in this manual is listed
in SI and METRIC UNITS.
Use this table to convert METRIC unit data
to IMP unit data.

Ex.

METRIC MULTIPLIER IMP

**mm 0.03937 = **in

2 mm 0.03937 = 0.08in

Volume/
Capacity

scella-

CONVERSION TABLE

METRIC TO IMP

Known Multiplier Result
mSkg 7.233 ftSlb
mSkg 86.794 inSlb
cmSkg 0.0723 ftSlb
cmSkg 0.8679 inSlb
kg 2.205 lb
g 0.03527 oz
km/hr 0.6214 mph
km 0.6214 mi
m 3.281 ft
m 1.094 yd
cm 0.3937 in
mm 0.03937 in
cc (cm3) 0.03527 oz (IMP liq.)
cc (cm3) 0.06102 cu. in
lit (liter) 0.8799 qt (IMP liq.)
lit (liter) 0.2199 gal (IMP liq.)
kg/mm 55.997 lb/in

2

kg/cm
Centigrade 9/5 (_C) +32 Fahrenheit (_F)

14.2234 psi (lb/in2)

–22–

PRINTED ON RECYCLED PAPER

PRINTED IN BELGIUM
2000  12 - 1.4  1

I