Yamaha FZS1000TC manual

PRINTED IN JAPAN 2004.10-1.1 × 1 CR (E) PRINTED ON RECYCLED PAPER Y AMAHA MO T OR CO . , L TD . 1C2-28199-10 LIT-11626-18-52 FZS1000T FZS1000TC OWNER’S MANUAL[...]

EAU10041 U1C210E0.book Page 1 T uesday, September 21, 2004 1:28 PM[...]

INTRODUCTION EAU10080 Cong ratul atio ns on y our pu rchas e of t he Yam aha FZS 1000 /FZS 1000C. This model is the resu lt of Ya maha ’s va st expe rienc e in the p roduc tion of f ine spo rting , touri ng, an d paces etting racin g machi nes. It repre sents the high degree of craf tsmans hip and re liabilit y that have made Ya maha a leader in [...]

IMPORTANT MANUAL INFORMATION EAU1013 0 Parti cular ly impo rtant in for mation is disti nguis hed in th is manua l by the followi ng nota tions: NOTE: ● This ma nual sho uld be co nsid ered a pe rmanent part of this motorc ycle and should remain w ith it e ven if th e motorc ycle is subs equently so ld. ● Yamaha continually s e eks adva ncement[...]

IMPORTANT MANU AL INFORMATION AND UNTIL YOU HAVE BEEN TRAIN ED IN S AFE AND P ROPER RIDIN G TECHNIQUE S. REGULAR I NSPECTIONS AND CAREFUL MAINTENAN CE, ALONG WITH GOOD RIDING SKILLS, WILL ENSURE THAT YOU SAFELY ENJOY THE CAPAB ILITIES A ND THE RE LIABILITY OF THIS MOT ORCYCLE. U1C210E0.book Page 2 T uesday, September 21, 2004 1:28 PM[...]

IMPORTANT MANUAL INFORMATION EAU10192 FZS100 0T/FZS1 000TC OW N E R ’ S MANU AL ©2004 by Y amaha Motor Corporation, U .S.A. 1st edition, September 2004 All rights reserved. Any reprinting or unauthorized use without th e written permission of Y amaha Motor Corporation, U.S.A. is expressl y prohibite d. Printed in Japan. P/N LIT -1162 6-18-5 2 AF[...]

TABLE OF CONTENTS SAFETY INFORMATION ............. ..... 1-1 Location of important lab els ........... 1-5 DESCRIPTION ............ ...................... 2-1 Left view ............... ...................... ..... 2-1 Right view .................. ................. ..... 2-2 Controls a nd instrumen ts ................2-3 INSTRUMENT AND CONTROL FUNC[...]

TABLE OF CONTENTS Checking the whee l bearings .......6-32 Battery ....... ...................... .............6-33 Replacing the fuses .................... ..6-34 Replaci ng a head light bul b ......... ..6-35 Replaci ng a tail /brake lig ht bulb ....6-36 Replaci ng a turn s ignal li ght bulb ........ ...................... .............6-37 Front[...]

1-1 1 SAFETY INFORMATION EAU10272 MOT ORCYC LES A RE SI NGLE TRAC K V EHIC LE S. TH EIR SAFE USE AND OPERATION AR E DEPEN- DENT UPON THE USE OF PROPER RID ING T ECH NIQU ES A S WEL L AS THE EXPERTISE OF THE OPERA- TOR. EVERY OPERATOR SHOULD KNOW THE FOLLOWING REQUIRE- MENTS B EFORE RIDI NG THIS MOTOR CYCLE. HE OR SHE SHOULD: ● OBTAIN THOROUGH INS[...]

SAFETY INFORMATION 1-2 1 turn du e to EXCESSI VE SPEED or und ercorn ering (ins ufficien t lea n angle for th e sp eed). • Alway s obey the s peed lim it and never trav el f aster than warr ant- ed by ro ad an d traffi c con dition s. • Alway s signa l befor e turnin g or chan ging lane s. M ake su re tha t othe r motorists can see you. ● The[...]

SAFETY INFORMATION 1-3 1 Loadin g The to tal weig ht of th e operat or, pas- senger, acce ssories and ca rgo must not exce ed the ma ximum loa d limit. When lo ading with in this weight limi t, keep the f ollowing in mind: ● Cargo and a cces sory we igh t shoul d be kept as low and cl ose to the mo torcycl e as possible. Make sure t o dist ribu t[...]

SAFETY INFORMATION 1-4 1 tor an d may limi t contro l ability, therefo re, such acce ssories are not re comm ende d. ● Use ca utio n whe n addi ng el ectr i- cal accesso ries. If elect rical acces- sories e xceed t he cap acity o f the motor cycle ’ s elect rical system , an elec tric fa ilure coul d result, wh ich could cause a dang erous loss[...]

SAFETY INFORMATION 1-5 1 EAU10381 Location of important labels Plea se re ad the f oll owing i mport ant l abels carefu lly befor e oper atin g this vehi cle. U1C210E0.book Page 5 T uesday, September 21, 2004 1:28 PM[...]

SAFETY INFORMATION 1-6 1 1 3 4 2 5 California onl y 6 7 CA UTION Cleaning with alkaline or acid cleaner , gasoline or solvent will damage windshield. Use neutral detergent. 5JW-00 Improper loading can cause loss of control. 3JJ-28446-A1 U1C210E0.book Page 6 T uesday, September 21, 2004 1:28 PM[...]

DESCRIPTI O N 2-1 2 EAU10410 Left view 1. F ront f o rk compression damping force adjusting screw (page 3-11) 2. F ront f o rk rebound damping force adjusting screw (page 3-11) 3. F ront f o rk spring preload adjus ting bolt (page 3-11) 4. Air filter element (page 6-17) 5. Main fuse (p age 6-34) 6. Fuse box (page 6-34) 7. Storage compar tment (page[...]

DESC RIPTION 2-2 2 EAU1042 0 Right view 1. Owner ’ s tool kit (page 6-1) 2. Rear brake fluid reser voir (page 6-25) 3. Batter y (page 6-33) 4. Front brak e fluid reser voir (page 6-25) 5. Radiator cap (page 6-14) 6. Engine oil filter car tridge (pag e 6-12) 7. Engine oil level chec k window (page 6-12) 8. Brake pedal (page 3-7) 9. Coolant r eserv[...]

DESCRIPTI O N 2-3 2 EAU10430 Controls and instruments 1. Clutch lev er (page 3-6) 2. Left handlebar switches (page 3-5) 3. Star ter (c hoke) le ver (page 3-9) 4. Speedometer un it (page 3-3) 5. Main s witch/steering lock (page 3-1) 6. T achom eter unit (page 3-4) 7. Fuel gauge (page 3-5) 8. Right handlebar s wit ches (page 3-5) 9. Brake lev er (pag[...]

INSTRUMENT A ND CONTROL FUNCTIONS 3-1 3 EAU10460 Main s wit ch/s teeri ng lo ck The mai n switch/s teering l o ck contr ols the ig nition and lighting systems, and is used to lo ck the s teerin g. The v ariou s positi ons are describ ed belo w. EAU10510 ON All elec trical system s are su pplied wi th power, and the h eadl ight, m eter l ight- ing, [...]

INSTRUMENT AND CONTROL FUNCTIONS 3-2 3 EAU11002 Indicator and warning lights EAU11030 Turn signal indicator lights “” and “” The c orresp onding i ndicato r lig ht fl ash- es when the tur n sign al sw itch is pushe d to th e le ft or ri ght. EAU11060 Neutral indicator light “” This i ndica tor li ght co mes on when the trans miss ion is[...]

INSTRUMENT A ND CONTROL FUNCTIONS 3-3 3 CAUTION: ECA10020 Do not operate the e ngine if it is overheated. EAU11810 Speedometer unit The spee dome ter uni t is eq uipped with the fo llowin g: ● an odom eter ● two t ripme ters When s et to “ ODO ” , the veh icle ’ s tota l milea ge is in dicate d. When s et to “ TRIP 1 ” or “ TRIP 2 ?[...]

INSTRUMENT AND CONTROL FUNCTIONS 3-4 3 EAU11891 Tachometer unit The el ectr ic tach omet er allo ws the ride r to mon itor the en gine speed and k eep i t with in the id eal pow er rang e. CAUTION: ECA10031 Do not operate the engine in the ta- chometer red zone. Red zone: 11500 r/min and above This tach ometer unit is equip ped wi th a clock. To se[...]

INSTRUMENT A ND CONTROL FUNCTIONS 3-5 3 If the tachomet er disp lays su ch an erro r code, note t he cir cuit- speci fic numb er of r/ min, an d then h ave a Yamaha deal- er check th e vehicle. CAUTION: ECA10040 When t he tach omet er disp lays a n er- ror code, the v ehicle should be checked as soon as possible in or- der to avoid engine damage. E[...]

INSTRUMENT AND CONTROL FUNCTIONS 3-6 3 EAU12400 Dimmer switch “ / ” Set this s witch to “” for the high beam a nd to “” for the l ow beam. EAU12460 Turn signal s witch “ / ” To sign al a righ t-hand turn, pu sh this switch to “” . To s ignal a l eft-ha nd turn , push this switc h to “” . Wh en re- leas ed, the s witch retur [...]

INSTRUMENT A ND CONTROL FUNCTIONS 3-7 3 EAU12870 Shift pedal The s hift pe dal i s locate d on the lef t side o f the engi ne and i s use d in com- binati on with th e clutc h le ver whe n shift ing the gears of th e 6-spee d con- stant- mesh t ransm ission equi pped on this mo torcycl e. EAU12930 Brake l ever The br ake lev er is lo cate d at the [...]

INSTRUMENT AND CONTROL FUNCTIONS 3-8 3 EAU13070 Fuel tank cap To open the fuel tank cap Open the f uel tank cap l ock co ver, in- sert t he key into th e lock, and th en turn it 1/4 tur n cloc kwis e. The lo ck wil l be re- leas ed and the fuel tank cap ca n be opened . To clo se the fuel t ank cap 1. Pu sh th e fue l tank cap i nto p ositi on with[...]

INSTRUMENT A ND CONTROL FUNCTIONS 3-9 3 CAUTION: ECA10070 Immediately wi pe off spilled fuel with a cle an, dry, soft cl oth, sinc e fuel ma y det eriorat e pai nted surfac- es or plastic pa rts. EAU13300 CAUTION: ECA11400 Use only unleaded gas oline. The use of lead ed ga solin e will cause se vere damage to internal engine parts, such a s th e va[...]

INSTRUMENT AND CONTROL FUNCTIONS 3-10 3 EAU13940 Seat To re move t he se at 1. Insert t he key int o the seat lock, and the n tur n it c lockw ise. 2. While ho lding the key in that po si- tion, li ft the rear of th e sea t, and then pull th e seat of f. To ins tall the se at 1. Ins ert th e proj ectio n on th e fron t of the se at int o the seat h[...]

INSTRUMENT A ND CONTROL FUNCTIONS 3-11 3 EAU14451 Storage compartm ent The st orage c ompa rtmen t is lo cated under the seat. ( See page 3 -10 .) W ARNING EWA10961 ● Do not ex ceed the lo ad limi t of 3 kg (7 lb) for the storage com- partment. ● Do not exce ed the maximu m load o f 18 8 kg (4 14 lb) (CAL) 189 kg (417 lb) (U49) for the ve- hicl[...]

INSTRUMENT AND CONTROL FUNCTIONS 3-12 3 load an d there by soften t he susp ens ion, tur n th e adjus ting bolt on eac h fork le g in dir ect ion ( b). NOTE: Alig n the ap propri ate groo ve on the ad- justin g mec hanis m with the to p of the fron t fork ca p bolt. Rebound damping force To in crea se th e rebo und d ampi ng fo rce and th ereby ha [...]

INSTRUMENT A ND CONTROL FUNCTIONS 3-13 3 CAUTION: ECA10100 Never a ttempt to tur n an ad justing mechanism beyond the maximum or minimum settings. NOTE: Altho ugh the tota l number of cl icks of a dampin g for ce ad jus ting m echa nism may no t exac tly m atch t he ab ove spec- ific ations due to sm all dif ference s in produ ction, the actu al nu[...]

INSTRUMENT AND CONTROL FUNCTIONS 3-14 3 Rebound damping force To in crea se th e rebo und d ampi ng fo rce and ther eby hard en t he re boun d da mp- ing, t urn the adjusti ng knob in direct ion (a). To de crease the re bound da mping forc e and ther eby s often t he r ebound dam ping , turn the adju stin g knob in di - rection (b). Compression dam[...]

INSTRUMENT A ND CONTROL FUNCTIONS 3-15 3 ● Do not sub ject t he shock ab - sorber to an open flame or other high heat sources , otherwise it may exp lode du e to exces sive gas pr essur e. ● Do not deform or damage the gas c ylinder in an y way, as this will result in poor dampin g per- formance. ● Always have a Yamaha dealer servic e th e sh[...]

INSTRUMENT AND CONTROL FUNCTIONS 3-16 3 below and h ave a Yamaha dealer re- pair it if it does not function proper- ly. EAU15321 Ignition circuit cut-off system The igni tion circ uit cut -off s ystem (com- prising th e sidestand switch, clutch switch and neutr a l switc h) has the fol- lowi ng fu nctions . ● It preven ts sta rting when the tra n[...]

INSTRUMENT A ND CONTROL FUNCTIONS 3-17 3 With the engine turned off: 1. Mov e the sidestand down. 2. Make sure that the engine stop s witch is tur ned on. 3. T ur n the key on. 4. Shift the transmission into the neutral position. 5. Push the star t switch. Does the engine start? With the engine still running: 6. Mov e the sidestand up. 7. K eep the[...]

PRE-OPERATION CHE CKS 4-1 4 EAU15591 The c onditi on of a v ehicle is the ow ner ’ s res ponsi bility . Vital comp onen ts can star t to de teriora te qui ckly an d unex pected ly, even i f the veh icl e rema ins unu sed (for exa mple , as a re sult of e xposu re to the elem ents ). Any damage , flui d leak age or l oss of tir e air press ure c o[...]

PRE-OPERATION CH ECKS 4-2 4 EAU15603 Pre-opera tion check list ITEM CHECKS P A GE Fuel • Check fuel l evel in fuel tank. • Refuel if necessary . • Check fuel l ine for leakage. 3-8 Engin e oil • Check oil lev el in engine. • If necessar y , add recommended oil t o specified lev el. • Check v ehicle for oil leak age. 6-12 Coolant • Che[...]

PRE-OPERATION CHE CKS 4-3 4 Thr ottle grip • Make sure that operation is smooth. • Check cab le free pla y . • If necessar y , hav e Y amaha dealer adjust cable f ree pla y and lubricate cable and grip housing. 6-19, 6-29 Cont rol c ables • Make sure that operation is smooth. • Lubricate if necessar y . 6-29 Drive chain • Check chain sl[...]

OPERATION AND IM PORTANT RIDING POINTS 5-1 5 EAU15950 W ARNING EWA10270 ● Become thoroughly familiar with all operating c ontrols and their functions before riding. Consult a Yamaha dealer re- garding any control or function that you do not thoroughly un- derstand. ● Never start the engine or oper- ate it in a clo sed ar ea for any length of ti[...]

OPERATION AND IMPORTANT RIDING P OINTS 5-2 5 CAUTION: ECA11490 ● If the oil le vel wa rning ligh t flick- ers or remains on after sta rting, immediately stop the engine, and then check the engine oil level an d th e veh icle fo r oi l leak - age. If n ece ssary, add e ngine oil , and th en check t he warn ing light again. If, when the key is turn[...]

OPERATION AND IM PORTANT RIDING POINTS 5-3 5 EAU16640 Starting a warm engine Follow t he sa me proc edur e as for start- ing a co ld engine with t he excep t ion that t he st arter (cho ke) is not requ ired when th e eng ine is warm . EAU16671 Shifting Shifti ng ge ars let s you con trol th e amount of engin e power ava ila ble for starti ng off, a[...]

OPERATION AND IMPORTANT RIDING P OINTS 5-4 5 4. At the r ecom mend ed sh ift po ints sho wn in the fo llow ing tabl e, clos e the thr ottle, and at th e sam e ti me, quickl y pull th e clutch lever in. 5. Sh ift t he trans missi on i nto s eco nd gear. (M ake su re not t o shi ft the transm ission int o the neut ral posi- tion.) 6. Open the th rott[...]

OPERATION AND IM PORTANT RIDING POINTS 5-5 5 CAUTION: ECA10301 After 1000 km (600 mi) of operation, the engine oil must be changed and the o il fil ter c artri dge or el ement re- plac ed. 1600 km (10 00 mi) and bey ond The vehi cle c an no w be oper ated no r- mally . CAUTION: ECA10310 ● Keep the engine speed out of the tachometer red zone. ● [...]

PERIODI C MAINTENAN CE AND MINOR REPAIR 6-1 6 EAU17231 Safety is an obliga tion of the o wner . Pe- riod ic ins pecti on, ad just ment and lubr i- cation will keep your vehi cle in th e safest and most eff icient co ndition po s- sible. The most im portan t points of motor cycle inspectio n, adjus tment, an d lubri cation a re explai ned on t he fo[...]

PERIODI C MAINTENA NCE AND MINOR REP AIR 6-2 6 W ARNING EWA10340 Modifications not approved by Yamaha may cause loss of perfor- mance, exce ssive e missi ons, and render the ve hicle u nsaf e for us e. Consult a Yamaha dealer before at- tem pting an y cha nges. U1C210E0.book Page 2 T uesday, September 21, 2004 1:28 PM[...]

PERIODI C MAINTENAN CE AND MINOR REPAIR 6-3 6 EAU17600 Periodi c mainte nance c hart fo r the em ission c ontrol sy stem No. ITEM ROUTINE INITIAL ODOMETER READINGS 600 mi (1000 km) or 1 month 4000 mi (7000 km) or 6 month s 8000 mi (13000 km) or 12 mo nths 12000 mi (19000 km) or 18 months 16000 mi (25000 km) or 24 months 20000 mi (31000 km) or 30 mo[...]

PERIODI C MAINTENA NCE AND MINOR REP AIR 6-4 6 * Since th ese items re quire special tools, da ta and techn ical skills, ha ve a Yamaha de aler pe rform the ser vice. 10 * Air induction sys- tem • Check the air cut-off valve , reed valv e, and hose for damage. • Replace any damaged par ts. √√√√√ No. ITEM ROUTINE INITIAL ODOMETER READI[...]

PERIODI C MAINTENAN CE AND MINOR REPAIR 6-5 6 EAU32183 General maintenance and lubrication chart No. ITEM ROUTINE INITIAL ODOMETER READINGS 600 mi (1000 km) or 1 month 4000 mi (7000 km) or 6 month s 8000 mi (13000 km) or 12 mo nths 12000 mi (19000 km) or 18 months 16000 mi (25000 km) or 24 months 20000 mi (31000 km) or 30 months 1 * Air filter elem[...]

PERIODI C MAINTENA NCE AND MINOR REP AIR 6-6 6 9 * Swingarm piv ot bearings • Check bearing as semblies for looseness. • Moderately repack with lit hium- soap-based grease. √ Repack. 10 Drive chain • Check chain slack, alignment and condition. • Adjust and lubricate chain with a special O-ring chain lubricant thoroughly . Every 600 mi (10[...]

PERIODI C MAINTENAN CE AND MINOR REPAIR 6-7 6 17 * Fr ont f ork • Check operation and for oil leak- age. • Replace if necessary . √√√√√ 18 * Shock absorber as- sembly • Check operation and for oil leak- age. • Replace if necessary . √√√√√ 19 * Rear suspension link piv ots • Apply lithium-soap-based grease lightly . √[...]

PERIODI C MAINTENA NCE AND MINOR REP AIR 6-8 6 * Since th ese items re quire special tools, da ta and techn ical skills, ha ve a Yamaha de aler pe rform the ser vice. NOTE: From 24000 mi ( 37000 km) or 36 months, repe at th e maint enance interval s starting from 8000 mi (13 000 km) or 12 mon ths. EAU17630 NOTE: ● The air f ilte r needs mor e fre[...]

PERIODI C MAINTENAN CE AND MINOR REPAIR 6-9 6 EAU18771 Removing and installing panels The p anels sh own ne ed to be remov ed to pe rform some of th e mai nten ance jobs descri b ed in this chapter. Refer to this s ectio n each tim e a pane l need s to be r emoved a nd installe d. EAU19292 Panels A and C To rem ove one of the panels Remov e the scr[...]

PERIODI C MAINTENA NCE AND MINOR REP AIR 6-10 6 EAU36570 Panels B a nd D To re move a pa nel Remov e the scre ws and the bolt , and then ta ke t he pa nel off. To ins tall the pa nel Place the p anel in the or igin al po sitio n, and then in stall th e screws and t he bolt. EAU19543 Checki ng the spark pl ugs The spa rk plugs are importan t engine [...]

PERIODI C MAINTENAN CE AND MINOR REPAIR 6-11 6 3. Che ck ea ch spark plug for elec- trode e rosion and e xces sive car- bon or other de posits, and replac e it if ne cessary. To i nstal l a s park pl ug 1. Me asure the sp ark pl ug gap wi th a wire t hick ness gauge a nd, if n ec- essary, adjust th e gap to spe cifica- tion. 2. Cle an th e surf ace[...]

PERIODI C MAINTENA NCE AND MINOR REP AIR 6-12 6 EAU19890 Engine oil and oil filter cartridge The en gine oil le vel s houl d be che cke d befor e each ride . In addi tion, the oil must be change d and th e oil fil ter car - tridge replaced a t the i nterv als speci- fie d in the perio dic mainte nanc e and lubri catio n ch art. To check the e ngine[...]

PERIODI C MAINTENAN CE AND MINOR REPAIR 6-13 6 NOTE: An oi l f ilter wrenc h i s av ailabl e at a Yama ha de aler. 5. Ap ply a thin coa t of engine oil to the O- ring of th e new oil filter car- tridge . N O TE: Make s ure th at the O-r ing is properl y seated . 6. Inst all th e new oil filter cartridge with an o il f ilter wrenc h, and th en tigh [...]

PERIODI C MAINTENA NCE AND MINOR REP AIR 6-14 6 CAUTION: ECA11620 ● In order to pre vent clutch slip- page (since the engine oi l also lubricates the clutch), do not mix a ny ch emica l addi tive s. Do not use oil s with a diesel speci- fication of “ CD ” or oils of a high- er quality than spec ified. In addition, do not use oils labeled “ [...]

PERIODI C MAINTENAN CE AND MINOR REPAIR 6-15 6 3. If th e coolan t is at or be low the minimu m le vel m ark, remov e pan - el A (S ee p age 6-9.), r emo ve the rese rvoir ca p, add co olan t to the maxim um le vel mark, and th en in - stall the rese rvoi r cap and the pan - el. CAUTION: ECA10470 ● If coolant is not available , use distilled wate[...]

PERIODI C MAINTENA NCE AND MINOR REP AIR 6-16 6 5. Re mov e the c oolant d rain bolt to drain th e cooling system. 6. A fter the co olant i s co mplete ly drai ned, tho rou ghly fl ush th e coo l- ing syste m with clean tap w ater. 7. In stall the cool ant drai n bolt, an d then ti ghte n it to the s pecif ied torqu e. NOTE: Check the wa sher for d[...]

PERIODI C MAINTENAN CE AND MINOR REPAIR 6-17 6 until it reaches th e top of the r adia- tor , and then install th e radia tor cap. 11. Check the cool ant leve l in the re s- ervoir . If necess ary, remo ve the coolan t re serv oir ca p, ad d coo lan t to the max imum level ma rk, and then in stall the cap. 12. Sta rt th e engin e, and then check th[...]

PERIODI C MAINTENA NCE AND MINOR REP AIR 6-18 6 7. P ull th e ai r filter elem ent o ut. 8. Ligh tly tap the air fi lter elemen t to remov e most of t h e dust and dirt, and th en blow t he rema ining dir t out with compre ssed air as show n. If the air filt er elem ent is da mage d, repl ace it . 9. Inser t the air filt er elemen t into the air fi[...]

PERIODI C MAINTENAN CE AND MINOR REPAIR 6-19 6 14. Ins tall t he sea t. EAU21271 Carburetors The ca rbur etors are impo rtant par ts of the engin e and emissio n control sys- tem , which r equ ire very soph istic ated adjust ment. Ther efor e, all c a rbure tor adjust ments sho uld be lef t to a Yamah a deal er, who ha s the necessary profes - sion[...]

PERIODI C MAINTENA NCE AND MINOR REP AIR 6-20 6 EAU21401 Valve c learance The v alve c learance changes wit h use, resul ting in improp er ai r-fu el mixt ure and/or engine nois e. To p reven t thi s from oc cur ring, t he va lve c leara nce must be adjust ed by a Y amaha d ealer at the inte rval s spec ifie d in the per iodi c mainte nanc e and lu[...]

PERIODI C MAINTENAN CE AND MINOR REPAIR 6-21 6 est it ems close to the ce nter of th e vehicle, and distribute the we ight evenly from side to side. Properly adjust the suspensio n for your loa d , and check the condition and pres- sure of your tires. NE VER OVER - LOAD YOUR VEHIC LE. Make sure that the total weight of the cargo, rid- er, passenger[...]

PERIODI C MAINTENA NCE AND MINOR REP AIR 6-22 6 This motor cycle is equipped with cast wheels an d tubeless tires with valves. W ARNING EWA10480 ● The front and rear tires should be of the same ma ke and de- sign, otherwise the handling char acter istics of the moto r- cycle cannot be gua ranteed. ● After extensive tests, only the tires listed [...]

PERIODI C MAINTENAN CE AND MINOR REPAIR 6-23 6 EAU21960 Cast w heels To ma ximize the p erfor mance, durab il- ity, a nd safe operat ion of your ve hicle, note t he fo llowing poi nts regard ing th e spec ifie d whe els. ● The wh eel rims sh ould be check ed for cr acks, ben d s or warp age be- for e each ride . If any damage is foun d, have a Ya[...]

PERIODI C MAINTENA NCE AND MINOR REP AIR 6-24 6 EAU22080 Adjusting the clutch le ver free play The cl utch l eve r free play s hould m ea- sure 10.0 – 15.0 m m (0.3 9 – 0.59 in) as shown. Pe riodicall y check the clu tch le- ver fr ee play an d, if necessar y, adju st it as follo ws. To increase the clut ch lever f ree play, turn t he ad jus ti[...]

PERIODI C MAINTENAN CE AND MINOR REPAIR 6-25 6 EAU22321 Checking the front and rear brake pads Front brake Rear b rake The fro nt and rear brake pads mu st be checked for wear at the in tervals spec- ified in the period ic maintenanc e and lubri cation ch art. Each brake pa d is prov ided w ith a wear indica tor groov e, which al lows you to check [...]

PERIODI C MAINTENA NCE AND MINOR REP AIR 6-26 6 Befor e ridi ng, che ck that the bra ke flui d is a bove th e minimum l evel mark a nd reple nish if ne cess ary. A low bra ke flui d level ma y indicat e worn b rake pa ds and/ or brak e sy stem leak age . If th e brak e fluid lev el is low, be sure to ch eck the bra ke pads for wea r and th e brak e[...]

PERIODI C MAINTENAN CE AND MINOR REPAIR 6-27 6 EAU22760 Drive c hain sla ck The dri ve ch ain sla ck sho uld be checked before each ride and adj usted if nece ssa ry. EAU22791 To c heck the d rive chain s lack 1. Pla ce the mot orcyc le on the ce n- terstand . 2. Sh ift t he tr ansmi ssio n int o the neu- tral p osition . 3. Sp in th e rea r whe el[...]

PERIODI C MAINTENA NCE AND MINOR REP AIR 6-28 6 EAU23021 Lubricating the drive chain The dri ve ch ain m ust be clean ed an d lubri cated at the int ervals speci fied i n the pe riodi c mainte nance and lubr ica- tion c hart, otherw ise i t will quickl y wear out, esp ecial ly when riding in dus ty or wet ar eas. Servi ce the dr ive ch ain as follo[...]

PERIODI C MAINTENAN CE AND MINOR REPAIR 6-29 6 EAU23090 Checking and lubricating the cables The o perati on of all co ntr ol cabl es and the c ondi tion of t he ca bles sho uld be chec ked be fore each r ide, an d the ca- bles and ca ble en ds shou ld be lubric at- ed if necessa ry. If a cabl e is dam aged or do es not mov e smoot hly, h ave a Yama[...]

PERIODI C MAINTENA NCE AND MINOR REP AIR 6-30 6 EAU23140 Checking and lubricating the brake and clutch levers The o peratio n of th e brake and clut ch levers sh ould be c hecked before each ride, and the lev er pivots shou ld b e lu - bricate d if nec essar y. EAU23210 Checki ng and lubricat ing the centerstand and sidestand The op eratio n of the[...]

PERIODI C MAINTENAN CE AND MINOR REPAIR 6-31 6 EAU23250 Lubricating the rear susp ension The pivoti ng poi nts o f the re ar sus pen- sion must b e lubri cated at the int erval s speci fied in the perio dic main tenance and lubri catio n c hart. EAU23271 Checking the front fork The c ondit ion a nd op era tion of the f ront fork must be ch ecked as[...]

PERIODI C MAINTENA NCE AND MINOR REP AIR 6-32 6 EAU23280 Checking the steering Worn or lo ose st eerin g bearin gs ma y caus e danger . Ther efore, the ope rati on of the stee ring m ust be c hecke d as fo l- lows at the in ter vals s peci fied i n the pe- riod ic maint enance and lubri cation char t. 1. Place a stand un der th e engine to rais e t[...]

PERIODI C MAINTENAN CE AND MINOR REPAIR 6-33 6 EAU33650 Battery This mod el is eq uipped with a seal ed- type (MF ) battery , which do es not re- quire any maint enance . There is n o need to check the ele ctrol yte or t o add distill ed water. W ARNING EWA10760 ● Electrolyte is p oisonous and dangerous since i t contains s ul- fur ic ac id, wh i[...]

PERIODI C MAINTENA NCE AND MINOR REP AIR 6-34 6 If you do not have access to a sealed-type (MF) battery charg- er, have a Yamaha de aler charge your battery. EAU23622 Repl acing the f uses The ma in fus e and th e fuse bo x, which contai ns the fu ses fo r the in dividua l cir- cuits , are lo cate d unde r the se at. ( See page 3- 10. ) If a fuse i[...]

PERIODI C MAINTENAN CE AND MINOR REPAIR 6-35 6 EAU23900 Replacing a headlight bulb This mode l is equi pped w ith quar tz bu lb headli ghts. If a headlight b ulb bur ns out , repl ace it as follow s. 1. Rem ove panel D (if rep lacin g the left headlight bulb) or pa nel B (if r e- placi ng the rig ht headli ght bul b). (See page 6-9.) 2. Di sco nnec[...]

PERIODI C MAINTENA NCE AND MINOR REP AIR 6-36 6 5. Instal l the head light bu lb cover, and the n connec t the coupler. 6. In sta ll the pane l. 7. Have a Ya maha deal er adju st the headli ght beam if nec essary. EAU24160 Replacing a ta il/brake light bulb 1. Remove the seat . (See page 3-10 .) 2. Remove th e tail/brak e light bu lb cover. 3. Remo[...]

PERIODI C MAINTENAN CE AND MINOR REPAIR 6-37 6 EAU24201 Replacing a turn signal light bulb 1. Rem ove the tu rn si gnal l ight l ens by rem oving the screw . 2. Rem ove the de fect ive bu lb by pushi ng it in and t u rnin g it counte r- clock wis e. 3. Insert a n ew bulb in t o the socke t , push i t in, and th en tur n it cl ock- wise un til it st[...]

PERIODI C MAINTENA NCE AND MINOR REP AIR 6-38 6 EAU33691 To install the front wheel 1. Lift the whe el up between t he fork legs. 2. Inser t the wh eel axle. 3. In sta ll t he bra ke ca lipe rs by inst all - ing th e bo lts. NOTE: Make s ure that ther e is enou gh sp ace betwee n the br ake pa ds before in stall- ing the brak e calip ers ont o the [...]

PERIODI C MAINTENAN CE AND MINOR REPAIR 6-39 6 3. Di sconn ect th e brake torque r od fro m the b rake c alipe r by re moving the nut and t he bo lt. 4. Rem ove the ax le nu t, then the brake calipe r by r emov ing the bolt s. CAUTION: ECA11300 Do not apply the brake after the brake ca liper h as been remo ved, otherwise the brake pa ds will be for[...]

PERIODI C MAINTENA NCE AND MINOR REP AIR 6-40 6 NOTE: Make s ure that ther e is enou gh sp ace betwee n the br ake pa ds before in stall- ing the br ake cal iper on to the brak e disc. 6. Ta ke the motorcyc le off the cen ter- stand so th at the rear wheel is on the gro und. 7. T ighte n the axle nut , br ake c aliper bolts an d brake torque r od n[...]

PERIODI C MAINTENAN CE AND MINOR REPAIR 6-41 6 EAU25911 Troubleshooting charts Starting problems or poor engine performanc e W ARNING EWA10840 Keep away open flames and do not smoke while checking or wor king on the fuel system. Check the fuel level in the fuel tank. 1. Fuel There is enough fuel. There is no fuel. Check the compression. Supply fuel[...]

PERIODI C MAINTENA NCE AND MINOR REP AIR 6-42 6 Engine overheating W ARNING EWA10400 ● Do not remove the radiator cap when the engine a nd radiator are h ot. Scalding hot fluid and steam ma y be blown out under press ure, which coul d cause serious in jury. Be sure to wait until the engine has cooled. ● After removing the radiator cap retaining[...]

MOTORCYCLE CAR E AND STORAGE 7-1 7 EAU26010 Care While t he open design of a mo torcycl e reve als th e at tracti venes s o f the tech- nology, it als o makes it mo re vuln era- ble. Ru st an d corr osion can dev elop even if h igh-q uali ty co mpon ents ar e used. A rus ty exha ust p ipe may go un - noti ced on a car, howeve r, it detract s from t[...]

MOTORCYCLE CARE A ND ST ORAGE 7-2 7 After normal use Remove dirt with warm water, a mild deterg ent, and a sof t, clea n spong e, and then rins e tho roughl y with clea n wate r. Use a to othbrush or bo ttlebrush for hard -to-r each a reas . Stub born d irt and in sects will co me off more eas ily if the ar ea is covered with a w et clot h for a fe[...]

MOTORCYCLE CAR E AND STORAGE 7-3 7 ● Never ap ply oi l or w ax to an y rubber and plastic parts, but treat t hem wit h a sui table ca re product. ● Avoid using abr asive polishing compounds as t hey will we ar away the pai nt. NOTE: Cons ult a Ya maha deal er for a dvice on what produ cts t o use. EAU26160 Storage Short-term Always s tore yo ur[...]

MOTORCYCLE CARE A ND ST ORAGE 7-4 7 W ARNING EWA10950 To prevent damage or injury from sparking, make sure to ground the spark plug electrodes while turning the engine over. 6. L ubri cate a ll c ontro l ca ble s and th e pivo ting poin ts of a ll leve rs an d pedals a s well as of th e side- stand/ center stand. 7. Check and, if necessary, correct[...]

SPECIFICATIONS 8-1 8 Dimensions: Overall le ngth: 2125 mm (83.7 in) Overall w idth: 765 mm ( 30.1 in) Overall h eight: 1190 mm (46.9 in) Seat heig ht: 820 mm ( 32.3 in) Wheelb ase: 1450 mm (57.1 in) Groun d clearan ce: 140 mm (5.51 in) Minimu m turni ng radi us: 2900 mm (114.2 in ) Weight: With oil an d fuel: 231.0 kg (509 lb ) (U49 ) 232.0 kg (511[...]

SPECI FI CAT IONS 8-2 8 Gear ratio: 1st: 35/14 (2. 500) 2nd: 35/19 (1. 842) 3rd : 30/20 (1. 500) 4th: 28/21 (1. 333) 5th: 30/25 (1. 200) 6th: 29/26 (1. 115) Chassis: Frame type : Double c radle Caster angle: 26.0 0 ° Tra il: 104.0 mm (4. 09 in) Front tire: Type : Tubele ss Size: 120/7 0 ZR17M /C (58W ) Manuf acturer /mode l: BRIDGESTONE/BT020F U R[...]

SPECIFICATIONS 8-3 8 Chargin g syst em: AC magn eto Battery: Model : GT14B-4 Voltag e, capacit y: 12 V, 12.0 Ah Headlight: Bulb type: Halogen bu lb Bulb voltage, wattage x quantity: Headligh t: 12 V, 60 W /55.0 W × 2 Tail/bra ke light: 12 V, 5.0 W/ 21.0 W × 2 Front turn signal/position light: 12 V, 27 W /8.0 W × 2 Rear t urn s ignal light: 12 V,[...]

CONSUMER INFORMA T ION 9-1 9 EAU26351 Identification numbers Record th e key id enti ficatio n numb er, vehicl e ide ntifica tion numb er and mod- el labe l info rmati on in the spa ces pro - vided be low for assista nce when order ing sp are pa rts from a Yam aha dealer or for refer ence in cas e the veh i- cle is sto len. KEY IDENTIFICATION NUM B[...]

CONSUMER INFORMATI ON 9-2 9 EAU26480 Model label The mode l labe l is affix ed to the frame under the seat . (Se e page 3- 10.) Rec ord the in form at ion on this labe l in the space provide d. This informat ion will b e needed when or deri ng spa re parts from a Yamaha de aler. 1. Model label U1C210E0.book Page 2 T uesday, September 21, 2004 1:28 [...]

CONSUMER INFORMA T ION 9-3 9 EAU26550 Reporting safety defects If you be lieve th at your vehicle has a defect whic h could cause a cra sh or coul d cause i njury or de ath, you sho uld immediat ely infor m the Na tion al Hig hway Tr affic Safety Admi nistra tion (NHTSA) in ad dition to n otifying Yamaha Moto r Cor poration , U.S.A. If NHTSA rec ei[...]

CONSUMER INFORMATI ON 9-4 9 EAU26560 Motorcycle noise regulation TAMPERING WITH NOISE CONTROL SYS TEM PROHIBIT ED: Fede ral law proh ibit s the foll owin g act s or the c ausing ther eof: (1) The re mova l or rend erin g ino perati ve by an y per son othe r tha n for pur poses of ma intena nce, repair , or r eplace ment of any devic e or el emen t [...]

CONSUMER INFORMA T ION 9-5 9 EAU26632 Maintenance record Copie s of wor k orde rs and/o r receipts fo r parts purc hased an d instal led on your ve hicle wi ll be r equir ed to do cument that mainte nanc e has be en co mple ted in accorda nce with th e emiss ion s warra nty. T he ch art bel ow is pr inted o nly a s a remi nder that main tena nce wo[...]

CONSUMER INFORMATI ON 9-6 9 36000 mi (55000 km) or 54 months 40000 mi (61000 km) or 60 months Maintena nce inter val Date of service Mileage Ser vicing dealer name and address Remarks U1C210E0.book Page 6 T uesday, September 21, 2004 1:28 PM[...]

CONSUMER INFORMA T ION 9-7 9 EAU26661 YAMAHA MOTOR CORPORATION, U.S.A. STREET AND ENDURO MOTORCYCLE LIMITED WARRANTY U1C210E0.book Page 7 T uesday, September 21, 2004 1:28 PM[...]

CONSUMER INFORMATI ON 9-8 9 U1C210E0.book Page 8 T uesday, September 21, 2004 1:28 PM[...]

CONSUMER INFORMA T ION 9-9 9 EAU26750 YAMAHA EXTEND ED SERVICE (Y.E.S.) K eep your Y amaha protected even after y our warranty expires with gen uine Y amaha Extended Ser vice (Y .E.S.). Y .E.S. is designed and administered by Y amaha Motor Corporation to provide maximum owner satisf action. Y ou get uninterrupted factory-backed co ver age for e xtr[...]

CONSUMER INFORMATI ON 9-10 9 We urge y ou to act now . Y ou ’ ll get the excellent benefits of TRIP cov erage right aw ay , and you ’ ll rest easy knowing you ’ ll hav e strong factory-back ed protection even after y our Y amaha Limited W arranty expires. A special note: If visiting your dealer isn ’ t con venient, contact Y amaha with your[...]

INDEX A Accessories and replacement par ts . ..... 6-23 Air filter element, cleaning ..................... 6-17 B Batte ry....... ...... ...... ......... ...... .......... ....... 6-33 Brake and clut ch levers, c hecking and lubricatin g ........... .......... ........... .... 6-30 Brake and shif t pedals, ch ecking and lubricatin g ........... ...[...]

INDEX Throttle grip a nd cable, checking and lubricating ........................ ............ 6-29 Tires......... ...... ........ ....... .......... ......... ..... 6-20 Tool kit ......... ...... .... ....... .... ...... ...... ......... . 6-1 Troubleshooting .................... ................ 6-40 Troubleshooting charts ....... ...............[...]

PRINTED IN JAPAN 2004.10-1.1 × 1 CR (E) PRINTED ON RECYCLED PAPER Y AMAHA MO T OR CO . , L TD . 1C2-28199-10 LIT-11626-18-52 FZS1000T FZS1000TC OWNER’S MANUAL[...]