Yamaha FZS 1000 2005 Repair Service Manual

EAS00000 FZS1000 (N) SERVICE 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.

NOTE: CAUTION: EAS00003 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 manual. 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. Repair and maintenance work attempted by anyone without this knowledge is likely to render the vehicle unsafe and unfit for use. This model has been designed and manufactured to perform within certain specifications in regard to performance and emissions. Proper service with the correct tools in necessary to ensure that the vehicle will operate as designed. If there is any question about a service procedure, it is imperative that you contact a Yamaha dealer for any service information changes that apply to this model. This policy is intended to provide the customer with the most satisfaction from his vehicle and to conform with fed- eral environmental quality objectives. Yamaha Motor Company, Ltd. is continually striving 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. S This Service Manual contains information regarding periodic maintenance to the emission control system. Please read this material carefully. S Designs and specifications are subject to change without notice. EAS00004 IMPORTANT INFORMATION Particularly important information is distinguished in this manual by the following. The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR SAFETY IS INVOLVED! Failure to follow WARNING instructions could result in severe injury or death to the motorcycle operator, a bystander or a person checking or repairing the motorcycle. 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.

1 2 6 4 5 7 3 8 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. An abbreviation and symbol in the upper right corner of each page indicate the current chapter. Refer to “SYMBOLS” on the following page. 2 Each chapter is divided into sections. The current section title is shown at the top of each page, except in Chapter 3 (“Periodic Checks 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 are given in the order of the jobs in the exploded diagram. A circled number indicates a disassembly step. 6 Symbols indicate parts to be lubricated or replaced (see “SYMBOLS”). 7 A job instruction chart accompanies the exploded diagram, providing the order of jobs, names of parts, notes in jobs, etc. 8 Jobs requiring more information (such as special tools and technical data) are described sequen- tially.

22 1 3 5 7 9 2 4 8 6 24 25 23 21 19 20 18 16 17 15 14 13 11 12 10 GEN INFO SPEC ENG CARB ELEC COOL CHK ADJ TRBL SHTG CHAS EAS00008 SYMBOLS The following symbols are not relevant to every vehicle. Symbols 1 to 9 indicate the subject of each chapter. 1 General information 2 Specifications 3 Periodic checks and adjustments 4 Chassis 5 Engine 6 Cooling system 7 Carburetor(-s) 8 Electrical 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 indicate the types of lubricants and lubrication points. 18 Engine oil 19 Gear oil 20 Molybdenum disulfide oil 21 Wheel bearing grease 22 Lithium soap base grease 23 Molybdenum disulfide grease Symbols 24 to 25 in the exploded diagrams indicate the following: 24 Apply locking agent (LOCTITE R ) 25 Replace the part

GENERAL INFORMATION SPECIFICATIONS PERIODIC CHECKS AND ADJUSTMENTS CHASSIS ENGINE COOLING SYSTEM CARBURETORS ELECTRICAL SYSTEM TROUBLESHOOTING GEN INFO 1 SPEC 2 3 CHAS 4 ENG 5 COOL 6 CARB 7 ELEC 8 TRBL SHTG 9 CHK ADJ EAS00012 TABLE OF CONTENTS

GEN INFO CHAPTER 1 GENERAL INFORMATION MOTORCYCLE IDENTIFICATION 1-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . VEHICLE IDENTIFICATION NUMBER 1-1 . . . . . . . . . . . . . . . . . . . . . . . . . MODEL CODE 1-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . IMPORTANT INFORMATION 1-2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PREPARATION FOR REMOVAL AND DISASSEMBLY 1-2 . . . . . . . . . . REPLACEMENT PARTS 1-2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . GASKETS, OIL SEALS AND O-RINGS 1-2 . . . . . . . . . . . . . . . . . . . . . . . . LOCK WASHERS/PLATES AND COTTER PINS 1-2 . . . . . . . . . . . . . . . . BEARINGS AND OIL SEALS 1-3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CIRCLIPS 1-3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE CONNECTIONS 1-4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPECIAL TOOLS 1-5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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Yamaha FZS 1000 2005 Repair Service Manual

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