Yamaha FZS1000 2003 Supplementary Service Manual
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Yamaha FZS1000 2003 Supplementary Service Manual

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  • Page 3 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.

  • Page 4: Important Information

    EAS00002 NOTICE This manual was produced by the Yamaha Motor Company, Ltd. primarily for use by Yamaha dealers and their qualified mechanics. It is not possible to include all the knowledge of a mechanic in one manu- al. Therefore, anyone who uses this book to perform maintenance and repairs on Yamaha vehicles should have a basic understanding of mechanics and the techniques to repair these types of vehicles.

  • Page 5: How To Use This Manual

    EAS00007 HOW TO USE THIS MANUAL This manual is intended as a handy, easy-to-read reference book for the mechanic. Comprehensive explanations of all installation, removal, disassembly, assembly, repair and check procedures are laid out with the individual steps in sequential order. 1 The manual is divided into chapters.
  • Page 6 EAS00008 SYMBOLS The following symbols are not relevant to every SPEC vehicle. INFO Symbols 1 to 9 indicate the subject of each chapter. 1 General information 2 Specifications CHAS 3 Periodic checks and adjustments 4 Chassis 5 Engine 6 Cooling system 7 Carburetor(-s) COOL 8 Electrical system...

  • Page 7: Table Of Contents

    ....... FZS1000 2003 WIRING DIAGRAM (EUR) FZS1000R 2003 WIRING DIAGRAM (OCE)

  • Page 9: Specifications

    SPEC GENERAL SPECIFICATIONS/ENGINE SPECIFICATIONS SPECIFICATIONS GENERAL SPECIFICATIONS Item Standard Limit Model code 5LVF (A) (B) (D) (DK) (E) (GB) (GR) (I) (N) (NL) (S) (SF) (CH) (P) 5LVG (D) 5LVH (F) 5LVJ (AUS) ENGINE SPECIFICATIONS Item Standard Limit Piston 0.010 X 0.035 mm Piston-to-cylinder clearance 0.12 mm 73.955 X 73.970 mm...

  • Page 10: Chassis Specifications

    SPEC CHASSIS SPECIFICATIONS CHASSIS SPECIFICATIONS Item Standard Limit Front suspension Spring Free length 344.0 mm Spacer length 78.5 mm Installed length 320.0 mm Spring rate (K1) 7.8 N/mm (0.8 kg/mm) Spring rate (K2) 11.8 N/mm (1.2 kg/mm) 0 X 64 mm Spring stroke (K1) 64 X 140 mm Spring stroke (K2)

  • Page 11: Cable Routing

    SPEC CABLE ROUTING CABLE ROUTING Brake hose F Pass the horn leads from the outside of vehicle to Front fork the inner side and clamp it to the under-bracket. Point the tip of clamp to the front of vehicle. There A Fasten the right handlebar switch lead to the han- should be no slack with the lead between horn and dlebar with a plastic band.
  • Page 12 SPEC CABLE ROUTING Fuel pump lead Handlebar upper bracket Fuel pump Brake hose guide EXUP cable Front brake hose Carburetor heater hose Right handlebar switch lead A Fasten the fuel pump lead, pickup coil lead, neutral Throttle cable 2 switch lead, speed sensor lead, rear brake light Throttle cable 1 switch lead and fuel pump with a plastic clamp.
  • Page 13 SPEC CABLE ROUTING E Route the throttle position sensor lead inward the M Fasten the radiator hose with a plastic band. EXUP cable. N Fasten the pickup coil lead with a steel clamp. F Clamp the Al system hose and carburetor heater O Route the coolant reservoir tank over flow hose, fuel hose with a plastic clamp.
  • Page 14 SPEC CABLE ROUTING T Route the right handlebar switch lead between han- dle upper bracket and wire guide. U Route the neutral switch lead and speed sensor lead left side the coolant reservoir hose. V Route the coolant reservoir hose left side the en- gine mounting bracket.
  • Page 15 SPEC CABLE ROUTING Starter cable Spark plug leads Clutch cable EXUP cable Left handlebar switch lead Min switch lead A Fasten the main switch lead and left handlebar EXUP motor switch lead to the frame with a plastic band. Starting circuit cut-off relay B Fasten the coolant hose and carburetor heater Starter motor lead hose with a plastic band.
  • Page 16 SPEC CABLE ROUTING F Fasten the clutch cable with a steel clamp. O Fasten the sidestand switch lead, oil level switch G Route the all leads on the shift shaft. lead, A.C. magneto lead, starter motor lead, battery H Route the fuel sender lead inside of the seat rail. negative lead and air filter case drain hose with a I Route the battery negative lead forward of the plastic clamp.
  • Page 17 SPEC CABLE ROUTING U Route the sidestand switch lead oil level switch lead CC Route the spark plug leads #2, 3 between EXUP outside the hose. cable and spark plug lead #4. V To the cylinder #4. DD Route the throttle cables 1 and 2 between right W Route the carburetor heater hose through outside coolant hose and left coolant hose, and upward of of the coolant pipe.
  • Page 18 SPEC CABLE ROUTING Clutch cable Red/ Black lead Battery negative lead Left handlebar switch lead Orange lead Starting circuit cut-off relay Main switch lead Rectifier/ regulator lead White mark Starter cable Battery Wire harness EXUP motor lead Emergency engine stop switch Ignition coil lead Radiator fan motor lead Turn signal relay...
  • Page 19 SPEC CABLE ROUTING A Route the throttle cables through right side of the ra- J Route the coolant reservoir tank hose through un- diator fan motor lead and thermo switch lead. der the air vent hose and AI system hose. and EXUP motor lead K Route the coolant reservoir tank hose through un- B Clamp the right turn signal lead (front).
  • Page 20 SPEC CABLE ROUTING S Route the rectifier / regulator lead through under the Y Clamp the stay, wire harness and rectifier / regulator wire harness. leads. Cut the surplus part of clamp. Leave the re- T Place the coupler of each lead in the coupler cover. mained part to be within 3 mm after cutting.
  • Page 21 SPEC CABLE ROUTING GG Clamp the throttle position sensor lead with the coolant reservoir tank hose in front of the coupler. Point the tip of clamp to the downward. 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.

  • Page 22: Periodic Checks And Adjustments Engine

    ADJUSTING THE CLUTCH CABLE FREE PLAY PERIODIC CHECKS AND ADJUSTMENTS ENGINE EAS00078 ADJUSTING THE CLUTCH CABLE FREE PLAY 1. Check: S clutch cable free play a Out of specification ! Adjust. Clutch cable free play (at the end of the clutch lever) 10 X 15 mm 2.

  • Page 23: Overhauling The Engine

    CRANKCASE EAS00381 OVERHAULING THE ENGINE CRANKCASE CRANKCASE 10 Nm (1.0 mSkg) 10 Nm (1.0 mSkg) Order Job/Part Q’ty Remarks Removing the crankcase Remove the parts in the order listed. Engine Refer to “ENGINE”. (Manual No.: 5LV1-AE1) Cylinder head Refer to “CYLINDER HEAD”. (Manual No.: 5LV1-AE1) Pickup coil and pickup coil rotor Refer to “PICKUP COIL”.
  • Page 24 CRANKCASE 10 Nm (1.0 mSkg) 10 Nm (1.0 mSkg) Order Job/Part Q’ty Remarks Oil/water pump assembly drive chain Washer Oil/water pump assembly drive sprocket Washer Plate Lower crankcase Dowel pin For installation, reverse the removal procedure. –16–...

  • Page 25: Carburetors

    CARB CARBURETORS EAS00502 CARBURETORS CARBURETORS CHECKING AND ADJUSTING THE THROTTLE POSITION SENSOR NOTE: Before adjusting the throttle position sensor, the engine idling speed should be properly ad- justed. 1. Check: S throttle position sensor (installed on the throttle body) a. Disconnect the throttle position sensor cou- pler from the throttle position sensor.
  • Page 26 CARB CARBURETORS Throttle position sensor resistance 0.4 X 5.4 kΩ at 20_C (yellow – black) 2. Check: S throttle position sensor angle a. Connect the throttle position sensor coupler to the throttle position sensor. b. Connect the pocket tester (DC 20 V) to the throttle position sensor coupler.
  • Page 27 CARB CARBURETORS c. Adjust the throttle position sensor angle so the measured output voltage is within the specified range. Throttle 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 .

  • Page 28: Electrical

    ELEC CHECKING THE SWITCHES 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.

  • Page 29: Lighting System

    ELEC LIGHTING SYSTEM EAS00780 LIGHTING SYSTEM CIRCUIT DIAGRAM Dimmer switch Main switch Headlight Battery Fuse (main) Tail / brake light Igniter Fuse (ignition) Fuse (headlight) Hi-beam indicator light Headlight relay (on / off) Meter light Pass switch Headlight relay (dimmer) –21–...

  • Page 30: Troubleshooting

    ELEC LIGHTING SYSTEM EAS00781 TROUBLESHOOTING Any of the following fail to light: headlight, S Clean the battery high beam indicator light, taillight, auxilia- terminals. ry light or meter light. S Recharge Check: place the battery. 1. Main, headlight and ignition fuses 2.
  • Page 31 ELEC LIGHTING SYSTEM Hi-beam 6. Headlight relay (on/off) (for EUR) Positive battery lead ! yellow S Disconnect the headlight relay (on/off) from Negative battery lead ! black the coupler. S Connect the pocket tester (Ω Positive tester probe ! black/blue 1) and bat- Negative tester probe ! black/yellow tery (12 V) to the headlight relay (on/off)

  • Page 32: Checking The Lighting System

    ELEC LIGHTING SYSTEM EAS00788 S Set the main switch to “ON”. CHECKING THE LIGHTING SYSTEM S Start the engine. 1. The headlight and the high beam indicator S Set the dimmer switch to “ light fail to come on. ” or “ ”.
  • Page 33 ELEC LIGHTING SYSTEM Positive tester probe ! blue 2. Voltage Negative tester probe ! black S Connect the pocket tester (DC 20 V) to the tail/brake light coupler (wire harness side) as shown. Positive tester probe ! blue/red Negative tester probe ! black S Set the main switch to “ON”.

  • Page 34: Troubleshooting

    TRBL TROUBLESHOOTING SHTG EAS00866 FAULTY LIGHTING OR SIGNALING SYSTEM HEADLIGHT DOES NOT LIGHT TURN SIGNAL DOES NOT LIGHT S Wrong headlight bulb S Faulty turn signal switch S Too many electrical accessories S Faulty turn signal relay S Hard charging S Burnt-out turn signal bulb S Incorrect connection S Incorrect connection...
  • Page 37 FZS1000 2003 WIRING DIAGRAM (EUR) Main switch Meter light Rectifier/ regulator Oil level gauge Fuel sender AC magneto Fuse (back up) Turn signal relay Battery Handlebar switch (right) Front brake light switch Starter relay Fuse (main) Engine stop switch Starter motor...

  • Page 38: Fzs1000R 2003 Wiring Diagram (Oce)

    FZS1000R 2003 WIRING DIAGRAM (OCE) Main switch Turn signal indicator light (left) Rectifier/ regulator Turn signal indicator light (right) AC magneto Meter light Fuse (back up) Oil level gauge Battery Fuel sender Starter relay Turn signal relay Handlebar switch (right) Fuse (main) Starter motor Front brake light switch...

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