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PERIODIC MAINTENANCE AND MINOR REPAIR

6-2

NOTE:

If you do not have the tools or experi-
ence required for a particular job, have
a Yamaha dealer perform it for you.

EW000063

WARNING

Modifications not approved by
Yamaha may cause loss of perfor-
mance and render the vehicle unsafe
for use. Consult a Yamaha dealer be-
fore attempting any changes.

U5LV10.book Page 2 Wednesday, October 23, 2002 2:45 PM

Содержание FZ1 FZS1000N

Страница 1: ...PRINTED IN JAPAN 2001 1 2 3 3 CR E PRINTED ON RECYCLED PAPER YAMAHA MOTOR CO LTD 5LV 28199 10 LIT 11626 14 48 FZS1000N FZS1000NC OWNER S MANUAL ...

Страница 2: ...EAU03438 ...

Страница 3: ...ycle If you have any questions concerning the operation or maintenance of your motorcycle please consult a Yamaha dealer The design and manufacture of this Yamaha motorcycle fully comply with the emis sions standards for clean air applicable at the date of manufacture Yamaha has met these standards without reducing the performance or economy of operation of the motorcycle To maintain these high st...

Страница 4: ... taken to avoid damage to the motorcycle NOTE A NOTE provides key information to make procedures easier or clearer NOTE _ This manual should be considered a permanent part of this motorcycle and should remain with it even if the motorcycle is subsequently sold Yamaha continually seeks advancements in product design and quality Therefore while this manual contains the most current product informati...

Страница 5: ... TO OPERATE THIS MOTORCYCLE UNTIL YOU HAVE AT TAINED ADEQUATE KNOWLEDGE OF ITS CONTROLS AND OPERATING FEATURES AND UNTIL YOU HAVE BEEN TRAINED IN SAFE AND PROPER RIDING TECHNIQUES REGULAR INSPECTIONS AND CAREFUL MAINTENANCE ALONG WITH GOOD RIDING SKILLS WILL ENSURE THAT YOU SAFELY ENJOY THE CAPABILITIES AND THE RELI ABILITY OF THIS MOTORCYCLE _ U5LV10 book Page 2 Wednesday October 23 2002 2 45 PM ...

Страница 6: ...2001 by Yamaha Motor Corporation U S A 1st Edition January 2001 All rights reserved Any reprinting or unauthorized use without the written permission of Yamaha Motor Corporation U S A is expressly prohibited Printed in Japan P N LIT 11626 14 48 U5LV10 book Page 3 Wednesday October 23 2002 2 45 PM ...

Страница 7: ...D CONTROL FUNCTIONS 3 4 PRE OPERATION CHECKS 4 5 OPERATION AND IMPORTANT RIDING POINTS 5 6 PERIODIC MAINTENANCE AND MINOR REPAIR 6 7 MOTORCYCLE CARE AND STORAGE 7 8 SPECIFICATIONS 8 9 CONSUMER INFORMATION 9 INDEX EAU00009 U5LV10 book Page 1 Wednesday October 23 2002 2 45 PM ...

Страница 8: ...FORMATION 1 Safe riding 1 1 Protective apparel 1 3 Modifications 1 3 Loading and accessories 1 3 Gasoline and exhaust gas 1 5 Location of important labels 1 7 U5LV10 book Page 1 Wednesday October 23 2002 2 45 PM ...

Страница 9: ...Y MECHANICAL CONDITIONS Safe riding 1 Always make pre operation checks Careful checks may help prevent an accident 2 This motorcycle is designed to carry the operator and a passenger 3 The failure of motorists to detect and recognize motorcycles in traffic is the predominating cause of automobile motorcycle accidents Many accidents have been caused by an automobile driver who did not see the motor...

Страница 10: ...ndercornering insufficient lean angle for the speed a Always obey the speed limit and never travel faster than warranted by road and traffic conditions b Always signal before turning or changing lanes Make sure that other motorists can see you 6 The posture of the operator and passenger is important for proper control a The operator should keep both hands on the handlebar and both feet on the oper...

Страница 11: ...er operation They become very hot and can cause burns Always wear protective clothing that covers your legs ankles and feet 6 A passenger should also observe the above precautions Modifications Modifications made to this motorcycle not approved by Yamaha or the removal of original equipment may render the motorcycle unsafe for use and may cause severe personal injury Modifications may also make yo...

Страница 12: ...ender These items in cluding such items as sleeping bags duffel bags or tents can create unstable handling or a slow steering response Accessories Genuine Yamaha accessories have been specifically designed for use on this motorcycle Since Yamaha cannot test all other accessories that may be available you must personally be responsible for the proper selection installation and use of non Yamaha acc...

Страница 13: ... ability therefore such accessories are not recommended 2 Use caution when adding electrical accessories If electrical accessories exceed the capacity of the motorcycle s electrical system an electric failure could result which could cause a dangerous loss of lights or engine power Gasoline and exhaust gas 1 GASOLINE IS HIGHLY FLAMMABLE a Always turn the engine off when refueling b Take care not t...

Страница 14: ...ater or near an open flame otherwise it could catch fire 4 When transporting the motorcycle in another vehicle make sure that it is kept upright If the motor cycle should lean over gasoline may leak out of the carburetor or fuel tank 5 If you should swallow any gasoline inhale a lot of gasoline vapor or allow gasoline to get into your eyes see your doctor immediately If any gasoline spills on your...

Страница 15: ...NFORMATION 1 2 3 4 5 6 7 8 9 1 7 EAU02977 Location of important labels Please read the following important labels carefully before operating this motorcycle U5LV10 book Page 7 Wednesday October 23 2002 2 45 PM ...

Страница 16: ...SAFETY INFORMATION 1 2 3 4 5 6 7 8 9 1 8 1 2 3 4 5 6 7 California only U5LV10 book Page 8 Wednesday October 23 2002 2 45 PM ...

Страница 17: ...DESCRIPTION 2 Left view 2 1 Right view 2 2 Controls and instruments 2 3 U5LV10 book Page 1 Wednesday October 23 2002 2 45 PM ...

Страница 18: ...Air filter element page 6 19 5 Fuses page 6 38 6 Storage compartment page 3 11 7 Grab bar 8 Seat lock helmet holder page 3 10 9 Shock absorber assembly compression damping force adjusting screw page 3 14 10 Shock absorber assembly spring preload adjusting ring page 3 14 11 Shock absorber assembly rebound damping force adjusting knob page 3 14 12 Shift pedal page 3 6 U5LV10 book Page 1 Wednesday Oc...

Страница 19: ...page 6 30 15 Battery page 6 37 16 Front brake fluid reservoir page 6 29 17 Radiator cap page 6 17 18 Engine oil filter cartridge page 6 12 19 Engine oil level check window page 6 12 20 Brake pedal page 3 7 21 Coolant reservoir page 6 15 U5LV10 book Page 2 Wednesday October 23 2002 2 45 PM ...

Страница 20: ... page 3 5 3 Starter choke lever page 3 9 4 Speedometer unit page 3 3 5 Main switch steering lock page 3 1 6 Tachometer unit page 3 3 7 Fuel gauge page 3 5 8 Right handlebar switches page 3 6 9 Brake lever page 3 7 10 Throttle grip page 6 22 U5LV10 book Page 3 Wednesday October 23 2002 2 45 PM ...

Страница 21: ...ndlebar switches 3 5 Clutch lever 3 6 Shift pedal 3 6 Brake lever 3 7 Brake pedal 3 7 Fuel tank cap 3 7 Fuel 3 8 Starter choke lever 3 9 Seat 3 10 Helmet holder 3 10 Storage compartment 3 11 Adjusting the front fork 3 11 Adjusting the shock absorber assembly 3 13 EXUP system 3 15 Sidestand 3 16 Ignition circuit cut off system 3 17 U5LV10 book Page 1 Wednesday October 23 2002 2 45 PM ...

Страница 22: ...AU00040 LOCK The steering is locked and all electrical systems are off The key can be removed To lock the steering 1 Turn the handlebars all the way to the left 2 Push the key in from the OFF po sition and then turn it to LOCK while still pushing it 3 Remove the key To unlock the steering Push the key in and then turn it to OFF while still pushing it EW000016 WARNING _ Never turn the key to OFF or...

Страница 23: ...ght may flicker when riding on a slope or during sudden acceleration or deceleration but this is not a mal function _ EAU01716 Coolant temperature warning light This warning light comes on when the engine overheats When this occurs stop the engine immediately and allow the engine to cool EC000002 CAUTION _ Do not operate the engine if it is overheated _ EAU03965 Fuel level warning light This warni...

Страница 24: ...meter mode ODO and the tripmeter modes TRIP 1 and TRIP 2 in the following order ODO TRIP 1 TRIP 2 ODO To reset a meter To reset either tripmeter 1 or 2 to 0 0 select either by pushing the SELECT button and then push the RESET button for at least one second EAU03954 Tachometer unit The electric tachometer allows the rider to monitor the engine speed and keep it within the ideal power range EC000003...

Страница 25: ...ensor speed sensor EXUP system overturn switch If any of those circuits are defective the tachometer will repeatedly display the following error code CB 23E Use the chart below to identify the faulty electrical circuit CB 29E If the tachometer displays such an er ror code note the circuit specific num ber of r min and then have a Yamaha dealer check the motorcycle EC000004 CAUTION _ When the tacho...

Страница 26: ...ompletely _ EAU00118 Handlebar switches EAU03888 Dimmer switch Set this switch to for the high beam and to for the low beam EAU03889 Turn signal switch To signal a right hand turn push this switch to To signal a left hand turn push this switch to When released the switch returns to the cen ter position To cancel the turn signal lights push the switch in after it has re turned to the center positio...

Страница 27: ...isengage the clutch pull the lever toward the handle bar grip To engage the clutch release the lever The lever should be pulled rapidly and released slowly for smooth clutch operation The clutch lever is equipped with a clutch switch which is part of the ignition circuit cut off system See page 3 17 for an explanation of the ignition circuit cut off system EAU00157 Shift pedal The shift pedal is l...

Страница 28: ...mark on the brake lever EAU00162 Brake pedal The brake pedal is on the right side of the motorcycle To apply the rear brake press down on the brake pedal EAU02935 Fuel tank cap To open the fuel tank cap Open the fuel tank cap lock cover in sert the key into the lock and then turn it 1 4 turn clockwise The lock will be re leased and the fuel tank cap can be opened To close the fuel tank cap 1 Push ...

Страница 29: ...is properly closed before riding _ EAU03753 Fuel Make sure that there is sufficient fuel in the tank Fill the fuel tank to the bottom of the filler tube as shown EW000130 WARNING _ Do not overfill the fuel tank oth erwise it may overflow when the fuel warms up and expands Avoid spilling fuel on the hot engine _ EAU00185 CAUTION _ Immediately wipe off spilled fuel with a clean dry soft cloth since ...

Страница 30: ...aining ethanol and that contain ing methanol Gasohol containing ethanol can be used if the ethanol con tent does not exceed 10 Gasohol containing methanol is not recom mended by Yamaha because it can cause damage to the fuel system or ve hicle performance problems EAU03839 Starter choke lever Starting a cold engine requires a richer air fuel mixture which is supplied by the starter choke Move the ...

Страница 31: ...t in place 3 Remove the key NOTE _ Make sure that the seat is properly se cured before riding _ EAU00261 Helmet holder To open the helmet holder insert the key into the lock and then turn the key as shown To lock the helmet holder turn the key to the original position and then re move it EW000030 WARNING _ Never ride with a helmet attached to the helmet holder since the helmet may hit objects caus...

Страница 32: ...r documents in the storage com partment be sure to wrap them in a plastic bag so that they will not get wet When washing the motorcycle be careful not to let any water enter the storage compartment EAU04002 Adjusting the front fork This front fork is equipped with spring preload adjusting bolts rebound damp ing force adjusting screws and com pression damping force adjusting screws EW000035 WARNING...

Страница 33: ...und damping force and thereby harden the rebound damping turn the adjusting screw on each fork leg in direction a To de crease the rebound damping force and thereby soften the rebound damping turn the adjusting screw on each fork leg in direction b CI 02E 1 Spring preload adjusting bolt 1 Current setting 2 Front fork cap bolt Setting Minimum soft 5 Standard 2 Maximum hard 1 fully turned out positi...

Страница 34: ...tion the actual number of clicks always represents the entire adjusting range To obtain a precise adjustment it would be advisable to check the num ber of clicks of each damping force ad justing mechanism and to modify the specifications as necessary _ EAU01699 Adjusting the shock absorber assembly This shock absorber assembly is equipped with a spring preload adjust ing ring a rebound damping for...

Страница 35: ... damping force and thereby harden the compres sion damping turn the adjusting screw in direction a To decrease the com pression damping force and thereby soften the compression damping turn the adjusting screw in direction b CI 02E 1 Spring preload adjusting ring 2 Special wrench Setting Minimum soft 1 Standard 6 Maximum hard 11 1 Rebound damping force adjusting knob Minimum soft 20 clicks in dire...

Страница 36: ...r attempt to open the gas cylinder Do not subject the shock ab sorber to an open flame or other high heat sources otherwise it may explode due to excessive gas pressure Do not deform or damage the gas cylinder in any way as this will result in poor damping per formance Always have a Yamaha dealer service the shock absorber _ EAU01571 EXUP system This motorcycle is equipped with Yamaha s EXUP EXhau...

Страница 37: ... EW000044 WARNING _ The motorcycle must not be ridden with the sidestand down or if the sidestand cannot be properly moved up or does not stay up oth erwise the sidestand could contact the ground and distract the opera tor resulting in a possible loss of control Yamaha s ignition circuit cut off system has been designed to assist the operator in fulfilling the responsibility of raising the side st...

Страница 38: ...ents starting when the trans mission is in gear and the clutch lever is pulled but the sidestand is still down It cuts the running engine when the transmission is in gear and the sidestand is moved down Periodically check the operation of the ignition circuit cut off system according to the following procedure EW000046 WARNING _ The vehicle must be placed on the centerstand during this in spection...

Страница 39: ... clutch lever pulled 8 Shift the transmission into gear 9 Move the sidestand down Does the engine stall After the engine has stalled 10 Move the sidestand up 11 Keep the clutch lever pulled 12 Push the start switch Does the engine start The sidestand switch may be defective The motorcycle should not be ridden until checked by a Yamaha dealer The clutch switch may be defective The motorcycle should...

Страница 40: ...PRE OPERATION CHECKS 4 Pre operation check list 4 1 U5LV10 book Page 1 Wednesday October 23 2002 2 45 PM ...

Страница 41: ...in engine If necessary add recommended oil to specified level Check vehicle for oil leakage 6 12 Coolant Check coolant level in reservoir If necessary add recommended coolant to specified level Check cooling system for leakage 6 15 6 16 Front brake Check operation If soft or spongy have Yamaha dealer bleed hydraulic system Check fluid level in reservoir If necessary add recommended brake fluid to ...

Страница 42: ...3 6 26 Brake and shift pedals Make sure that operation is smooth Lubricate pedal pivoting points if necessary 6 33 Brake and clutch levers Make sure that operation is smooth Lubricate lever pivoting points if necessary 6 33 Centerstand sidestand Make sure that operation is smooth Lubricate pivots if necessary 6 34 Chassis fasteners Make sure that all nuts bolts and screws are properly tightened Ti...

Страница 43: ...ion can be accomplished in a very short time and the added safety it assures is more than worth the time involved _ EWA00033 WARNING _ If any item in the Pre operation check list is not working properly have it inspected and repaired before operating the motorcycle _ U5LV10 book Page 3 Wednesday October 23 2002 2 45 PM ...

Страница 44: ...ERATION AND IMPORTANT RIDING POINTS 5 Starting and warming up a cold engine 5 1 Starting a warm engine 5 3 Shifting 5 3 Engine break in 5 5 Parking 5 6 U5LV10 book Page 1 Wednesday October 23 2002 2 45 PM ...

Страница 45: ...tor resulting in a possible loss of control _ EAU00376 CAUTION _ Make sure not to store personal items near the air cleaner in take otherwise air intake will be blocked and performance will suffer Make sure not to put anything near the battery and its termi nals otherwise electrical failure and acid corrosion may result _ EAU01164 Starting and warming up a cold engine In order for the ignition cir...

Страница 46: ...and fuel level warning light should come on for a few sec onds then go off If a warning light does not go off have a Yamaha dealer check the elec trical circuit If the oil level warning light flick ers or remains on after starting immediately stop the engine and then check the engine oil level and the vehicle for oil leak age If necessary add engine oil and then check the warning light again If wh...

Страница 47: ...rter choke use and temperatures below 10 C 50 F re quire about 3 5 seconds with the starter choke turned on then about 2 5 min utes with the starter choke in the half way position _ EAU01258 Starting a warm engine Follow the same procedure as for start ing a cold engine with the exception that the starter choke is not required when the engine is warm EAU00423 Shifting Shifting gears lets you contr...

Страница 48: ...ch lever slowly 4 At the recommended shift points shown in the table on page 5 5 close the throttle and at the same time quickly pull the clutch lever in 5 Shift the transmission into second gear Make sure not to shift the transmission into the neutral posi tion 6 Open the throttle part way and gradually release the clutch lever 7 Follow the same procedure when shifting to the next higher gear NOT...

Страница 49: ... any condition that might result in engine overheating must be avoided EAU03749 0 1 000 km 0 600 mi Avoid prolonged operation above 5 000 r min 1 000 1 600 km 600 1 000 mi Avoid prolonged operation above 6 000 r min EC000052 CAUTION _ After 1 000 km 600 mi of operation the engine oil must be changed and the oil filter cartridge replaced _ 1 600 km 1 000 mi and beyond The vehicle can now be operate...

Страница 50: ... key from the main switch EW000058 WARNING _ Since the engine and exhaust system can become very hot park in a place where pedestri ans or children are not likely to touch them Do not park on a slope or on soft ground otherwise the motorcycle may overturn _ U5LV10 book Page 6 Wednesday October 23 2002 2 45 PM ...

Страница 51: ... 6 27 Adjusting the rear brake light switch 6 28 Checking the front and rear brake pads 6 29 Checking the brake fluid level 6 29 Changing the brake fluid 6 30 Drive chain slack 6 31 Lubricating the drive chain 6 32 Checking and lubricating the cables 6 33 Checking and lubricating the brake and shift pedals 6 33 Checking and lubricating the brake and clutch levers 6 33 Checking and lubricating the ...

Страница 52: ...LLY IMPORTANT ARE THE MAINTENANCE SERVICES RELAT ED TO EMISSIONS CONTROL THESE CONTROLS NOT ONLY FUNCTION TO ENSURE CLEANER AIR BUT ARE ALSO VITAL TO PROPER ENGINE OPERATION AND MAXIMUM PERFORMANCE IN THE FOLLOWING PERIODIC MAINTE NANCE CHARTS THE SERVICES RELATED TO EMISSIONS CON TROL ARE GROUPED SEPARATE LY THESE SERVICES REQUIRE SPECIALIZED DATA KNOWLEDGE AND EQUIPMENT YAMAHA DEAL ERS ARE TRAIN...

Страница 53: ...red for a particular job have a Yamaha dealer perform it for you _ EW000063 WARNING _ Modifications not approved by Yamaha may cause loss of perfor mance and render the vehicle unsafe for use Consult a Yamaha dealer be fore attempting any changes _ U5LV10 book Page 2 Wednesday October 23 2002 2 45 PM ...

Страница 54: ...m 2 Spark plugs Check condition Adjust gap and clean Replace every 8 000 mi 13 000 km or 12 months Replace Replace 3 Crankcase ventilation system Check ventilation hose for cracks or damage Replace if necessary 4 Fuel line Check fuel hoses and vacuum hose for cracks or damage Replace if necessary 5 Fuel filter Replace every 20 000 mi 31 000 km or 30 months Replace 6 Exhaust system Check for leakag...

Страница 55: ...amage Replace if necessary 10 Air induction system Check the air cut valve and reed valve for damage Replace the entire air induction system if necessary No ITEM ROUTINE INITIAL ODOMETER READINGS 600 mi 1 000 km or 1 month 4 000 mi 7 000 km or 6 months 8 000 mi 13 000 km or 12 months 12 000 mi 19 000 km or 18 months 16 000 mi 25 000 km or 24 months 20 000 mi 31 000 km or 30 months U5LV10 book Page...

Страница 56: ...00 mi 13 000 km or 12 months 3 Air filter element Clean with compressed air Replace if necessary 4 Cooling system Check hose for cracks or damage Replace if necessary Replace coolant every 24 months 3 Replace 5 Brake system Check operation pad wear and fluid leakage See NOTE on page 6 7 Correct if necessary 6 Clutch Check operation Adjust or replace cable 7 Control cable Apply chain lube thoroughl...

Страница 57: ... Drive chain Check chain slack alignment condition Adjust and lubricate chain thoroughly 1 Every 600 mi 1 000 km or after washing the motorcycle or riding in the rain 16 Wheel bearings Check bearings for smooth operation 17 Sidestand and centerstand pivots Check operation Lubricate 2 18 Sidestand switch Check and clean or replace if necessary No ITEM ROUTINE INITIAL ODOMETER READINGS 600 mi 1 000 ...

Страница 58: ...the brake fluid level Every two years replace the internal components of the brake master cylinder and caliper and change the brake fluid Replace the brake hoses every four years and if cracked or damaged Engine oil type Yamalube 4 20W 40 or engine oil SAE 20W 40 API SE for temperatures of 5 C 40 F or above Yamalube 4 10W 30 or engine oil SAE 10W 30 API SE for temperatures of 15 C 60 F or below _ ...

Страница 59: ...ng panels The panels shown above need to be removed to perform some of the main tenance jobs described in this chapter Refer to this section each time a panel needs to be removed and installed 1 Panel A 2 Panel B 1 Panel C U5LV10 book Page 8 Wednesday October 23 2002 2 45 PM ...

Страница 60: ...l the panel Place the panel in the original position and then install the screw EAU01315 Panel B To remove the panel Remove the screws and then take the panel off To install the panel Place the panel in the original position and then install the screws 1 Panel A 2 Screw 1 Panel C 2 Screw 1 Panel B 2 Screw 3 U5LV10 book Page 9 Wednesday October 23 2002 2 45 PM ...

Страница 61: ...d in the owner s tool kit To check the spark plugs 1 Check that the porcelain insulator around the center electrode on each spark plug is a medium to light tan the ideal color when the motorcycle is ridden normally 2 Check that all spark plugs installed in the engine have the same color NOTE _ If any spark plug shows a distinctly dif ferent color the engine could be defec tive Do not attempt to di...

Страница 62: ...rk plug a good estimate of the correct torque is 1 4 1 2 turn past finger tight However the spark plug should be tightened to the speci fied torque as soon as possible _ 4 Install the spark plug cap EAU01796 Canister for California only This model is equipped with a canister to prevent the discharging of fuel vapor into the atmosphere Check each hose connection Check each hose and canister for cra...

Страница 63: ... for several minutes and then turn it off 3 Wait a few minutes until the oil set tles and then check the oil level through the check window located at the bottom right side of the crankcase NOTE _ The engine oil should be between the minimum and maximum level marks _ 4 If the engine oil is below the mini mum level mark add sufficient oil of the recommended type to raise it to the correct level To ...

Страница 64: ...r similar device to keep the oil away from the exhaust pipe _ 4 Remove the oil filter cartridge with an oil filter wrench NOTE _ An oil filter wrench is available at a Yamaha dealer _ 5 Apply a thin coat of engine oil to the O ring of the new oil filter car tridge NOTE _ Make sure that the O ring is properly seated _ 1 Engine oil drain bolt 1 Oil filter wrench 2 Oil filter cartridge 1 O ring U5LV1...

Страница 65: ...RVING II or higher Make sure that no foreign mate rial enters the crankcase _ 9 Start the engine and then let it idle for several minutes while checking it for oil leakage If oil is leaking immediately turn the engine off and check for the cause NOTE _ After the engine is started the engine oil level warning light should go off if the oil level is sufficient _ 1 Torque wrench Tightening torque Oil...

Страница 66: ...e and hold it in an upright position NOTE _ The coolant level must be checked on a cold engine since the level varies with engine temperature Make sure that the motorcycle is positioned straight up when checking the coolant level A slight tilt to the side can result in a false reading _ 2 Check the coolant level in the coolant reservoir NOTE _ The coolant should be between the minimum and maximum ...

Страница 67: ...ng system will not be protected against frost and corrosion If water has been added to the coolant have a Yamaha dealer check the antifreeze content of the coolant as soon as possible otherwise the effectiveness of the coolant will be reduced _ EW000067 WARNING _ Never attempt to remove the radia tor cap when the engine is hot _ NOTE _ The radiator fan is automatically switched on or off according...

Страница 68: ...7 WARNING _ Never attempt to remove the radia tor cap when the engine is hot _ 5 Remove the coolant drain bolt to drain the cooling system 6 After the coolant is completely drained thoroughly flush the cool ing system with clean tap water 7 Install the coolant drain bolt and then tighten it to the specified torque NOTE _ Check the washer for damage and re place it if necessary _ 1 Coolant drain bo...

Страница 69: ...iator cap start the engine let it idle for several min utes and then turn it off 10 Remove the radiator cap to check the coolant level in the radiator If necessary add sufficient coolant until it reaches the top of the radia tor and then install the radiator cap 11 Check the coolant level in the res ervoir If necessary remove the coolant reservoir cap add coolant to the maximum level mark and then...

Страница 70: ...stallation procedures 2 Remove the fuel tank bolts 3 Lift the fuel tank to position it away from the air filter case Do not dis connect the fuel hoses EW000071 WARNING _ Make sure that the fuel tank is well supported Do not tilt or pull the fuel tank too much otherwise the fuel hoses may come loose which could cause fuel leakage _ 4 Remove panels A and C See page 6 9 for panel removal and in stall...

Страница 71: ... air filter element to remove most of the dust and dirt and then blow the remaining dirt out with compressed air as shown If the air filter element is damaged replace it 9 Insert the air filter element into the air filter case 1 Air filter case cover 2 Screw 4 1 Air filter element 1 Air filter element U5LV10 book Page 20 Wednesday October 23 2002 2 45 PM ...

Страница 72: ...d If any fuel hose is damaged do not start the engine but have a Yamaha dealer replace the hose other wise fuel may leak Make sure that the fuel hoses are properly connected and routed and not pinched Be sure to place the fuel tank breather hose in the original po sition _ 14 Install the seat EAU00628 Adjusting the carburetors The carburetors are important parts of the engine and emission control ...

Страница 73: ...nd if neces sary have a Yamaha dealer adjust it EAU00637 Adjusting the valve clearance The valve clearance changes with use resulting in improper air fuel mixture and or engine noise To prevent this from occurring the valve clearance must be adjusted by a Yamaha dealer at the intervals specified in the periodic maintenance and lubrication chart a Throttle cable free play U5LV10 book Page 22 Wednes...

Страница 74: ...oosely packed items that can shift Securely pack your heaviest items close to the center of the motorcycle and dis tribute the weight evenly from side to side Properly adjust the suspen sion for your load and check the condition and pressure of your tires NEVER OVERLOAD YOUR MOTOR CYCLE Make sure that the total weight of the cargo rider passen ger and accessories cowling sad dlebags etc if approve...

Страница 75: ... a tire tread begins to show crosswise lines have a Yamaha dealer replace the tire immediately The replacement of all wheel and brake related parts includ ing the tires should be left to a Yamaha dealer who has the necessary professional knowl edge and experience _ Tire information This motorcycle is equipped with cast wheels and tubeless tires with valves 1 Tire sidewall 2 Tire wear indicator a T...

Страница 76: ...Note the following points in order to make the most ef ficient use of these tires Use only the specified replace ment tires Other tires may run the danger of bursting at super high speeds Brand new tires can have a rela tively poor grip on certain road surfaces until they have been broken in Therefore it is ad visable before doing any high speed riding to ride conserva tively for approximately 100...

Страница 77: ...evelop its optimal characteristics EAU00691 Accessories and replacement parts EW000098 WARNING _ This motorcycle is not designed to pull a trailer or to be attached to a sidecar The accessories or replace ment parts you choose for your motorcycle should be designed spe cifically for this model and they must be securely mounted to main tain the inherent stability of the orig inal design Genuine Yam...

Страница 78: ...ction b NOTE _ If the specified free play cannot be ob tained as described above or if the clutch does not operate correctly have a Yamaha dealer check the internal clutch mechanism _ EAU00712 Adjusting the brake pedal position The top of the brake pedal should be po sitioned approximately 43 mm 1 7 in below the top of the footrest as shown Periodically check the brake pedal posi tion and if neces...

Страница 79: ...AU00713 Adjusting the rear brake light switch The rear brake light switch which is ac tivated by the brake pedal is properly adjusted when the brake light comes on just before braking takes effect If necessary adjust the brake light switch as follows Turn the adjusting nut while holding the rear brake light switch in place To make the brake light come on earlier turn the adjusting nut in direction...

Страница 80: ...cator groove has almost disap peared have a Yamaha dealer replace the brake pads as a set EAU03776 Checking the brake fluid level Insufficient brake fluid may allow air to enter the brake system possibly caus ing it to become ineffective Before riding check that the brake fluid is above the minimum level mark and replenish if necessary A low brake flu id level may indicate worn brake pads and or b...

Страница 81: ... fluid may deteriorate paint ed surfaces or plastic parts Al ways clean up spilled fluid immediately As the brake pads wear it is nor mal for the brake fluid level to gradually go down However if the brake fluid level goes down sud denly have a Yamaha dealer check the cause EAU03976 Changing the brake fluid Have a Yamaha dealer change the brake fluid at the intervals specified in the NOTE after th...

Страница 82: ...ck as shown 5 If the drive chain slack is incorrect adjust it as follows EAU03608 To adjust the drive chain slack 1 Loosen the axle nut and the lock nut on each side of the swingarm 2 To tighten the drive chain turn the adjusting bolt on each side of the swingarm in direction a To loos en the drive chain turn the adjust ing bolt on each side of the swingarm in direction b and then push the rear wh...

Страница 83: ...e periodic maintenance and lubrica tion chart otherwise it will quickly wear out especially when riding in dusty or wet areas Service the drive chain as follows EC000097 CAUTION _ The drive chain must be lubricated after washing the motorcycle or riding in the rain _ 1 Clean the drive chain with kero sene and a small soft brush ECA00053 CAUTION _ To prevent damaging the O rings do not clean the dr...

Страница 84: ...oon as possible to prevent unsafe conditions _ EAU03370 Checking and lubricating the brake and shift pedals The operation of the brake and shift pedals should be checked before each ride and the pedal pivots should be lu bricated if necessary EAU03164 Checking and lubricating the brake and clutch levers The operation of the brake and clutch levers should be checked before each ride and the lever p...

Страница 85: ...WARNING _ If the centerstand or sidestand does not move up and down smoothly have a Yamaha dealer check or re pair it _ EAU03166 Lubricating the rear suspension The pivoting points of the rear suspen sion must be lubricated at the intervals specified in the periodic maintenance and lubrication chart Recommended lubricant Lithium soap based grease all purpose grease Recommended lubricant Lithium so...

Страница 86: ...2 While applying the front brake push down hard on the handle bars several times to check if the front fork compresses and re bounds smoothly EC000098 CAUTION _ If any damage is found or the front fork does not operate smoothly have a Yamaha dealer check or re pair it _ EAU00794 Checking the steering Worn or loose steering bearings may cause danger Therefore the operation of the steering must be c...

Страница 87: ...a dealer check or repair the steering EAU01144 Checking the wheel bearings The front and rear wheel bearings must be checked at the intervals specified in the periodic maintenance and lubrica tion chart If there is play in the wheel hub or if the wheel does not turn smoothly have a Yamaha dealer check the wheel bearings U5LV10 book Page 36 Wednesday October 23 2002 2 45 PM ...

Страница 88: ...pt medical attention Batteries produce explosive hy drogen gas Therefore keep sparks flames cigarettes etc away from the battery and pro vide sufficient ventilation when charging it in an enclosed space KEEP THIS AND ALL BATTER IES OUT OF THE REACH OF CHILDREN _ To charge the battery Have a Yamaha dealer charge the bat tery as soon as possible if it seems to have discharged Keep in mind that the b...

Страница 89: ...s follows 1 Turn the key to OFF and turn off the electrical circuit in question 2 Remove the blown fuse and then install a new fuse of the specified amperage EC000103 CAUTION _ Do not use a fuse of a higher amper age rating than recommended to avoid causing extensive damage to the electrical system and possibly a fire _ 3 Turn the key to ON and turn on the electrical circuit in question to check i...

Страница 90: ...pler and then remove the headlight bulb cover 3 Unhook the headlight bulb holder and then remove the defective bulb EW000119 WARNING _ Headlight bulbs get very hot There fore keep flammable products away from a lit headlight bulb and do not touch the bulb until it has cooled down _ 4 Place a new bulb into position and then secure it with the bulb holder 1 Headlight bulb cover 2 Headlight coupler 1...

Страница 91: ...ill be adversely affected Thor oughly clean off any dirt and fin gerprints on the headlight bulb using a cloth moistened with al cohol or thinner Headlight lens Do not affix any type of tinted film or stickers to the head light lens Do not use a headlight bulb of a wattage higher than speci fied _ 5 Install the bulb cover and then connect the coupler 6 Install the panel 7 Have a Yamaha dealer adju...

Страница 92: ...e socket push it in and then turn it clock wise until it stops 6 Install the socket together with the bulb by turning it clockwise 7 Install the bulb cover 8 Install the seat EAU03497 Replacing a turn signal light bulb 1 Remove the turn signal light lens by removing the screw 2 Remove the defective bulb by pushing it in and turning it counter clockwise 3 Insert a new bulb into the socket push it i...

Страница 93: ...he cen terstand 2 Loosen the front wheel axle pinch bolt then the wheel axle and the brake caliper bolts 3 Remove the brake hose holder on each side by removing the bolts 4 Remove the brake caliper on each side by removing the bolts ECA00046 CAUTION _ Do not apply the brake after the brake calipers have been removed otherwise the brake pads will be forced shut _ 5 Pull the wheel axle out and then ...

Страница 94: ...d the brake cali per bolts to the specified torques 7 Push down hard on the handlebar several times to check for proper fork operation EAU03964 Rear wheel To remove the rear wheel EW000122 WARNING _ It is advisable to have a Yamaha dealer service the wheel Securely support the motor cycle so that there is no danger of it falling over _ 1 Loosen the axle nut and the brake caliper bolts 2 Place the ...

Страница 95: ...e forced shut _ 5 Loosen the locknut on each side of the swingarm 6 Turn the drive chain slack adjust ing bolts fully in direction a 7 Push the wheel forward and then remove the drive chain from the rear sprocket NOTE _ The drive chain does not need to be disassembled in order to remove and install the rear wheel _ 8 While supporting the wheel pull the wheel axle out 9 Remove the wheel 1 Bolt 2 2 ...

Страница 96: ... caliper bolts and brake torque rod nut to the specified torques EAU03087 Troubleshooting Although Yamaha motorcycles receive a thorough inspection before shipment from the factory trouble may occur dur ing operation Any problem in the fuel compression or ignition systems for example can cause poor starting and loss of power The following troubleshooting charts represent quick and easy procedures ...

Страница 97: ...ompression Check the ignition Have a Yamaha dealer check the vehicle Remove the spark plugs and check the electrodes 3 Ignition Wipe off with a dry cloth and correct the spark plug gaps or replace the spark plugs Have a Yamaha dealer check the vehicle The engine does not start Have a Yamaha dealer check the vehicle Operate the electric starter 4 Battery The engine turns over quickly The engine tur...

Страница 98: ...s ing sound has stopped press down on the cap while turning it counterclockwise and then remove the cap _ NOTE _ If coolant is not available tap water can be temporarily used instead provided that it is changed to the recommended coolant as soon as possible _ Wait until the engine has cooled Check the coolant level in the reservoir and radiator The coolant level is OK The coolant level is low Chec...

Страница 99: ...MOTORCYCLE CARE AND STORAGE 7 Care 7 1 Storage 7 4 U5LV10 book Page 1 Wednesday October 23 2002 2 45 PM ...

Страница 100: ...rical couplers and connectors including the spark plug caps are tightly in stalled 3 Remove extremely stubborn dirt like oil burnt onto the crankcase with a degreasing agent and a brush but never apply such prod ucts onto seals gaskets sprock ets the drive chain and wheel axles Always rinse the dirt and degreaser off with water Cleaning ECA00010 CAUTION _ Avoid using strong acidic wheel cleaners e...

Страница 101: ...est the product on a small hidden part of the wind shield to make sure that it does not leave any marks If the wind shield is scratched use a quali ty plastic polishing compound after washing _ After normal use Remove dirt with warm water a mild detergent and a soft clean sponge and then rinse thoroughly with clean water Use a toothbrush or bottlebrush for hard to reach areas Stubborn dirt and ins...

Страница 102: ...ystems can be re moved through polishing 4 To prevent corrosion it is recom mended to apply a corrosion pro tection spray on all metal including chrome and nickel plat ed surfaces 5 Use spray oil as a universal clean er to remove any remaining dirt 6 Touch up minor paint damage caused by stones etc 7 Wax all painted surfaces 8 Let the motorcycle dry completely before storing or covering it EWA0000...

Страница 103: ...ent corrosion avoid damp cellars stables because of the presence of ammonia and areas where strong chemi cals are stored _ Long term Before storing your motorcycle for several months 1 Follow all the instructions in the Care section of this chapter 2 For motorcycles equipped with a fuel cock that has an OFF posi tion Turn the fuel cock lever to OFF 3 Drain the carburetor float chamber by loosening...

Страница 104: ...nd the pivoting points of all levers and pedals as well as of the sidestand centerstand 7 Check and if necessary correct the tire air pressure and then lift the motorcycle so that both of its wheels are off the ground Alterna tively turn the wheels a little every month in order to prevent the tires from becoming degraded in one spot 8 Cover the muffler outlet with a plastic bag to prevent moisture...

Страница 105: ...SPECIFICATIONS 8 Specifications 8 1 U5LV10 book Page 1 Wednesday October 23 2002 2 45 PM ...

Страница 106: ...1 Starting system Electric starter Lubrication system Wet sump Engine oil Type Recommended engine oil classification API Service SE SF SG or higher Quantity Without oil filter cartridge replacement 2 8 L 2 46 Imp qt 2 96 US qt With oil filter cartridge replacement 3 L 2 64 Imp qt 3 17 US qt Total amount dry engine 3 7 L 3 26 Imp qt 3 91 US qt 20 10 0 10 20 30 40 50 C SAE 10W 30 SAE 15W 40 SAE 20W ...

Страница 107: ...Clutch type Wet multiple disc Transmission Primary reduction system Spur gear Primary reduction ratio 1 581 Secondary reduction system Chain drive Secondary reduction ratio 2 750 Number of drive chain sprocket teeth front rear 16 44 Transmission type Constant mesh 6 speed Operation Left foot Gear ratio 1st 2 500 2nd 1 842 3rd 1 500 4th 1 333 5th 1 200 6th 1 115 Chassis Frame type Double cradle Cas...

Страница 108: ... riding Front 250 kPa 2 50 kgf cm2 36 psi Rear 290 kPa 2 90 kgf cm2 42 psi Total weight of rider passenger cargo and accessories Wheels Front Type Cast wheel Size 17 MT 3 50 Rear Type Cast wheel Size 17 MT 5 50 Brakes Front Type Dual disc brake Operation Right hand Fluid DOT 4 Rear Type Single disc brake Operation Right foot Fluid DOT 4 Suspension Front Telescopic fork Rear Swingarm link suspensio...

Страница 109: ... signal position light 12 V 27 8 W 2 Rear turn signal light 12 V 27 W 2 Meter lighting 12 V 2 W 3 Neutral indicator light 14 V 1 4 W 1 High beam indicator light 14 V 1 4 W 1 Oil level warning light 14 V 1 4 W 1 Turn signal indicator light 14 V 1 4 W 2 Fuel level warning light 12 V 2 W 1 Coolant temperature warning light LED Fuses Main fuse 30 A Headlight fuse 20 A Radiator fan fuse 10 A Ignition f...

Страница 110: ...entification number 9 1 Model label 9 2 Reporting safety defects 9 3 Motorcycle noise regulation 9 4 Maintenance record 9 5 YAMAHA MOTOR CORPORATION U S A STREET AND ENDURO MOTORCYCLE LIMITED WARRANTY 9 7 YAMAHA EXTENDED SERVICE Y E S 9 9 U5LV10 book Page 1 Wednesday October 23 2002 2 45 PM ...

Страница 111: ...EAU01041 Key identification number The key identification number is stamped into the key tag Record this number in the space provided and use it for reference when ordering a new key EAU01043 Vehicle identification number The vehicle identification number is stamped into the steering head pipe Record this number in the space pro vided NOTE _ The vehicle identification number is used to identify yo...

Страница 112: ...frame under the seat See page 3 10 for seat removal and installation procedures Record the information on this label in the space provided This information will be needed when ordering spare parts from a Yamaha dealer 1 Model label U5LV10 book Page 2 Wednesday October 23 2002 2 45 PM ...

Страница 113: ...tigation and if it finds that a safety defect exists in a group of vehicles it may order a recall and remedy campaign However NHTSA cannot become involved in individual problems between you your dealer or Yamaha Motor Corporation U S A To contact NHTSA you may either call the Auto Safety Hotline toll free at 1 800 424 9393 or 366 0123 in Washington D C area or write to NHTSA U S Department of Tran...

Страница 114: ...for the purpose of noise control prior to its sale or delivery to the ultimate purchaser or while it is in use or 2 the use of the vehicle after such device or element of design has been removed or rendered inoperative by any person AMONG THOSE ACTS PRESUMED TO CONSTITUTE TAMPERING ARE THE ACTS LISTED BELOW These acts include tampering with the following systems i e modification removal etc CL 01E...

Страница 115: ...rinted only as a reminder that maintenance work is required It is not acceptable proof of maintenance work CL 04E Maintenance interval Date of service Mileage Servicing dealer name and address Remarks 600 mi 1 000 km or 1 month 4 000 mi 7 000 km or 6 months 8 000 mi 13 000 km or 12 months 12 000 mi 19 000 km or 18 months 16 000 mi 25 000 km or 24 months 20 000 mi 31 000 km or 30 months 24 000 mi 3...

Страница 116: ...r 42 months 32 000 mi 49 000 km or 48 months 36 000 mi 55 000 km or 54 months 40 000 mi 61 000 km or 60 months Maintenance interval Date of service Mileage Servicing dealer name and address Remarks U5LV10 book Page 6 Wednesday October 23 2002 2 45 PM ...

Страница 117: ...CONSUMER INFORMATION 9 7 9 EAU02918 YAMAHA MOTOR CORPORATION U S A STREET AND ENDURO MOTORCYCLE LIMITED WARRANTY U5LV10 book Page 7 Wednesday October 23 2002 2 45 PM ...

Страница 118: ...CONSUMER INFORMATION 9 8 9 U5LV10 book Page 8 Wednesday October 23 2002 2 45 PM ...

Страница 119: ...CONSUMER INFORMATION 9 9 9 EAU01063 YAMAHA EXTENDED SERVICE Y E S U5LV10 book Page 9 Wednesday October 23 2002 2 45 PM ...

Страница 120: ...CONSUMER INFORMATION 9 10 9 U5LV10 book Page 10 Wednesday October 23 2002 2 45 PM ...

Страница 121: ... 3 6 EXUP system 3 15 F Front fork adjusting 3 11 Front fork checking 6 35 Fuel 3 8 Fuel gauge 3 5 Fuel level warning light 3 2 Fuel tank cap 3 7 Fuses replacing 6 38 H Handlebar switches 3 5 Headlight bulb replacing 6 39 Helmet holder 3 10 High beam indicator light 3 2 Horn switch 3 5 I Identification numbers 9 1 Ignition circuit cut off system 3 17 Indicator and warning lights 3 2 K Key identifi...

Страница 122: ...ht bulb replacing 6 41 Throttle cable free play adjusting 6 22 Tires 6 23 Tool kit 6 1 Troubleshooting 6 45 Troubleshooting charts 6 46 Turn signal indicator lights 3 2 Turn signal light bulb replacing 6 41 Turn signal switch 3 5 V Valve clearance adjusting 6 22 Vehicle identification number 9 1 W Warranty extended 9 9 Warranty limited 9 7 Wheel bearings checking 6 36 Wheel front 6 42 Installing 6...

Страница 123: ...PRINTED IN JAPAN 2001 1 2 3 3 CR E PRINTED ON RECYCLED PAPER YAMAHA MOTOR CO LTD 5LV 28199 10 LIT 11626 14 48 FZS1000N FZS1000NC OWNER S MANUAL ...

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