Yamaha FZS1000 2003 Supplementary Service Manual Download Page 34

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TROUBLESHOOTING

TRBL

SHTG

TURN SIGNAL DOES NOT LIGHT

Faulty turn signal switch

Faulty turn signal relay

Burnt-out turn signal bulb

Incorrect connection

Damaged or faulty wire harness

Improperly grounded circuit

Faulty battery

Blown, damaged or incorrect fuse

TURN SIGNAL BLINKS SLOWLY

Faulty turn signal relay

Faulty main switch

Faulty turn signal switch

Incorrect turn signal bulb

TURN SIGNAL REMAINS LIT

Faulty turn signal relay

Burnt-out turn signal bulb

TURN SIGNAL BLINKS QUICKLY

Incorrect turn signal bulb

Faulty turn signal relay

Burnt-out turn signal bulb

HORN DOES NOT SOUND

Improperly adjusted horn

Damaged or faulty horn

Faulty main switch

Faulty horn switch

Faulty battery

Blown, damaged or incorrect fuse

Faulty wire harness

EAS00866

FAULTY LIGHTING OR SIGNALING SYSTEM

HEADLIGHT DOES NOT LIGHT

Wrong headlight bulb

Too many electrical accessories

Hard charging

Incorrect connection

Improperly grounded circuit

Poor contacts (main switch)

Burnt-out headlight bulb

HEADLIGHT BULB BURNT OUT

Wrong headlight bulb

Faulty battery

Faulty rectifier / regulator

Improperly grounded circuit

Faulty main switch

Headlight bulb life expired

TAIL / BRAKE LIGHT DOES NOT LIGHT

Wrong tail / brake light bulb

Too many electrical accessories

Incorrect connection

Burnt-out tail / brake light bulb

TAIL / BRAKE LIGHT BULB BURNT OUT

Wrong tail / brake light bulb

Faulty battery

Incorrectly adjusted rear brake light switch

Tail / brake light bulb life expired

Summary of Contents for FZS1000 2003

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Page 3: ...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 ...

Page 4: ... 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 S...

Page 5: ...hecks 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 3 Sub section titles appear in smaller print than the section title 4 To help identify parts and clarify procedure steps there are exploded diagrams at the start of each removal and disassembly section 5 Numbers ...

Page 6: ...al system 9 Troubleshooting 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 g...

Page 7: ...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 2...

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Page 9: ...F 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 X 0 035 mm 73 955 X 73 970 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 ...

Page 10: ...e 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 X 64 mm 64 X 140 mm No Suspension oil 01 or equivalent 435 cm3 140 mm SSS SSS SSS SSS SSS SSS SSS SSS SSS SSS SSS ...

Page 11: ...e 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 bra...

Page 12: ...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 neutralswitch lead and speed sensor lead with a plastic clamp un der the fuel...

Page 13: ... 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 ho...

Page 14: ...oir 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 l...

Page 15: ...ble 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 cabl...

Page 16: ...ute 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 s...

Page 17: ...d 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 coola...

Page 18: ...ank 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 circui...

Page 19: ...ect 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 ...

Page 20: ...r 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 batte...

Page 21: ... HH Place the white mark on the coolant reservoir tank hose within the range of 20 mm to the clamp position along the axial direction of hose II Position the fitting part of clamp lower than the centerline of frame JJ Push in the ignition coil lead between the cross pipe and ignition coil under this line KK Route the wire harness beneath the rectifier reg ulator a ...

Page 22: ... direction a or b until the specified clutch cable free play is ob tained Direction Clutch cable free play is increased Direction Clutch cable free play is decreased 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 Engine side a Loosen the locknuts 1 b Turn the adjusting nut 2 in direction a or b until the specif...

Page 23: ...n Crankshaft sprocket Pin Oil water pump assembly drive chain guide 1 1 1 1 Remove the parts in the order listed Refer to ENGINE Manual No 5LV1 AE1 Refer to CYLINDER HEAD Manual No 5LV1 AE1 Refer to PICKUP COIL Manual No 5LV1 AE1 Refer to GENERATOR Manual No 5LV1 AE1 Refer to CLUTCH Manual No 5LV1 AE1 Refer to OIL PAN AND OIL PUMP Manual No 5LV1 AE1 10 Nm 1 0 mSkg 10 Nm 1 0 mSkg EAS00381 OVERHAULI...

Page 24: ...7 8 9 10 11 Oil water pump assembly drive chain Washer Oil water pump assembly drive sprocket Washer Plate Lower crankcase Dowel pin 1 1 1 1 1 1 3 For installation reverse the removal procedure 10 Nm 1 0 mSkg 10 Nm 1 0 mSkg CRANKCASE ENG ...

Page 25: ... 2 c Measure the maximum throttle position sen sor resistance Out of specification Replace the throttle position sensor Maximum throttle position sensor resistance 4 0 X 6 0 kΩ at 20_C blue black d Connect the pocket tester Ω 1k to the throttle position sensor Tester positive probe yellow terminal 3 Tester negative probe black terminal 2 e While slowly opening the throttle check that the throttle ...

Page 26: ...terminal 1 Tester negative probe black terminal 2 c Measure the throttle position sensor input voltage Throttle position sensor input voltage 4 95 X 5 05 V Out of specification SCheck the throttle sensor coupler connection SCheck the entire throttle sensor system s wir ing 3 Adjust Sthrottle position sensor angle a Loosen the throttle position sensor screws 4 b Connect the pocket tester DC20 V to ...

Page 27: ...hrottle position sensor output voltage 0 65 X 0 75 V d After adjusting the throttle position sensor angle tighten the throttle position sensor screws 4 To tighten the screws 4 when the adjustment of throttle position sensor is complete make sure to tighten it while monitoring the measurement value without detaching the tester probe ...

Page 28: ...e 13 Side stand switch 14 Neutral switch 15 Oil level switch CHECKING THE SWITCHES ELEC EAS00731 ELECTRICAL CHECKING THE SWITCHES Check each switch for damage or wear proper connections and also for continuity between the termi nals Refer to CHECKING SWITCH CONTINUITY Manual No 5LV1 AE1 Damage wear Repair or replace the switch Improperly connected Properly connect Incorrect continuity reading Repl...

Page 29: ...t 57 Fuse ignition 60 Fuse headlight 65 Headlight relay on off 66 Headlight relay dimmer 1 Main switch 5 Battery 7 Fuse main 15 Igniter 31 Hi beam indicator light 34 Meter light 44 Pass switch LIGHTING SYSTEM ELEC EAS00780 LIGHTING SYSTEM CIRCUIT DIAGRAM ...

Page 30: ...tinuity Refer to CHECKING THE FUSES in CHAPTER 3 Manual No 5LV1 AE1 EAS00738 YES NO EAS00739 1 Main headlight and ignition fuses SAre the main headlight and ignition fuses OK Replace the fuse s 2 Battery SCheck the condition of the battery Refer to CHECKING THE BATTERY in CHAPTER 3 Manual No 5LV1 AE1 Minimum open circuit voltage 12 8 V or more at 20_C SIs the battery OK EAS00781 TROUBLESHOOTING An...

Page 31: ...t relay dimmer SDisconnect the headlight relay dimmer from the coupler SConnect the pocket tester Ω 1 and bat tery 12 V to the headlight relay dimmer coupler as shown YES NO EAS00787 8 Wiring SCheck entire lighting system s wiring Refer to CIRCUIT DIAGRAM Check the condition of each of the lighting system s circuits Refer to CHECK ING THE LIGHTING SYSTEM Manual No 5LV1 AE1 Properly connect or repa...

Page 32: ...nnect the pocket tester DC 20 V to the headlight and high beam indicator light cou plers as shown A B When the dimmer switch is set to When the dimmer switch is seto to SSet the main switch to ON SStart the engine SSet the dimmer switch to or SMeasure the voltage 12 V wire harness side YES NO This circuit is OK Headlight coupler wire harness side Meter light coupler wire harness side SAre the head...

Page 33: ...ket or both YES NO SSet the main switch to ON SStart the engine SMeasure the voltage 12 V of blue red on the tail brake light coupler tail brake light side 1 This circuit is OK SSet the main switch to ON SStart the engine SMeasure the voltage 12 V of blue on the meter light coupler wire harness side YES NO This circuit is OK 1 1 Tail brake light bulb and socket SIs the voltage within specification...

Page 34: ... faulty horn SFaulty main switch SFaulty horn switch SFaulty battery SBlown damaged or incorrect fuse SFaulty wire harness EAS00866 FAULTY LIGHTING OR SIGNALING SYSTEM HEADLIGHT DOES NOT LIGHT SWrong headlight bulb SToo many electrical accessories SHard charging SIncorrect connection SImproperly grounded circuit SPoor contacts main switch SBurnt out headlight bulb HEADLIGHT BULB BURNT OUT SWrong h...

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Page 37: ...itch 45 Dimmer switch 46 Horn switch 47 Clutch switch 48 Hazard switch 49 Turn signal switch 50 Front turn signal light left 51 Front turn signal light right 52 Rear turn signal light left 53 Rear turn signal light right 54 Headlight 55 Tail brake light 56 Fuse turn signal 57 Fuse ignition 58 Alarm 59 Fuse alarm 60 Fuse headlight 61 Fuse fan 62 Fan motor relay 63 Fan motor 64 Rear brake light swit...

Page 38: ... Handlebar switch left 44 Pass switch 45 Dimmer switch 46 Horn switch 47 Clutch switch 48 Turn signal switch 49 Front turn signal light left 50 Front turn signal light right 51 Rear turn signal light left 52 Rear turn signal light right 53 Headlight 54 Tail brake light 55 Fuse ignition 56 Fuse turn signal 57 Fuse headlight 58 Fuse fan 59 Fan motor relay 60 Fan motor 61 Rear brake light switch 62 H...

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