Yamaha FZS1000(N) Fazer Service Manual, 2001 (P/N 5LV1-AE1)

This is Yamaha’s 2001 FZS1000(N) Fazer service manual, P/N 5LV1-AE1, first edition December 2000. It covers the base model and the market variants listed above, rather than later FZS1000 revisions as a group.

PDF Search, Bookmarks and Page Breakdown

Search and wiring detail: The main chapters have searchable text, with embedded bookmarks for the chapters and both wiring diagrams. Legacy return bookmarks point to separate files. Small wire-color codes and connector labels in the EUR/OCE diagrams require zooming.

One printable 403-page PDF contains 361 numbered manual pages and two wiring-diagram pages. The total also includes the cover, five introductory pages, 15 chapter-index pages, nine chapter dividers, and ten blank or header-only separator pages.

Engine Overhaul, Carburetor Service and Circuit Diagnosis

The following selected contents highlight major workshop procedures rather than reproduce the full contents list. Other topics include sealed-battery charging checks and headlight-beam adjustment.

• Engine overhaul: Engine removal and installation, camshaft and timing-chain work, cylinder-head and valve service, crankcase separation, piston inspection, and crankshaft checks.

• Clutch and transmission: Clutch and starter-clutch repair, shift-shaft and shift-drum inspection, shift-fork checks, transmission disassembly, and reassembly procedures.

• Carburetion and EXUP: Mikuni BSR37 rack service, synchronization, fuel-level adjustment, throttle-position-sensor setting, fuel-pump checks, and EXUP cable and servomotor diagnosis.

• Cooling system: Radiator removal and pressure testing, thermostat inspection, water-pump disassembly, mechanical-seal installation, leak checks, and coolant service.

• Brakes and chassis: Wheel repair, master-cylinder and caliper overhaul, hydraulic bleeding, fork-seal replacement, steering-head service, rear-shock inspection, swingarm service, and drive-chain work.

• Electrical diagnosis: Circuit diagrams and fault isolation for ignition, starting, charging, lighting, signals, cooling fan, fuel pump, EXUP, and self-diagnosis, plus EUR/OCE wiring diagrams.

Written primarily for Yamaha dealers and their qualified mechanics, this manual assumes a basic understanding of mechanics and vehicle repair techniques.

Engine Inspection and Assembly

Removal and disassembly sections open with exploded views and job charts showing part names, quantities, work order, replacement symbols, lubrication points, and cross-references. These references connect parts identification with the factory checks and assembly requirements for the job being planned.

Cylinder head and crankshaft: Step-by-step procedures extend to valve guides and seats, valve springs and lifters, connecting rods, pistons, and crankshaft bearings. Bearing-selection information uses the crankcase, crankshaft, and connecting-rod markings, with color-code tables and clearance checks.

Timing and lubrication: Camshaft-cap and crankcase tightening sequences accompany timing-chain and tensioner service. Generator and pickup-coil removal, oil-pan work, oil-pump clearance checks, relief-valve inspection, and oil-strainer service are also covered.

Clutch and Gearbox Repair

Clutch inspection distinguishes the friction plates, steel plates, springs, housing, boss, pressure plate, pull lever, and pull rod. Assembly-width checks and selectable clutch plates address stack fit, while the starter-clutch material covers its rollers, gears, and engagement checks.

Transmission inspection reaches the gear dogs, shaft runout, shift-fork movement, and shift-drum grooves. Reassembly information includes fork placement and gear-engagement checks.

Carburetor Adjustment and Fuel-System Checks

Fuel-system coverage follows the BSR37 carburetor rack rather than EFI mapping. Rack separation and reassembly include internal inspection, diaphragm and piston-valve checks, and fuel-level measurement.

Throttle-position-sensor testing is paired with tachometer-based angle adjustment. Periodic maintenance also covers valve-pad selection, compression testing, and ignition-timing checks; the ignition timing itself is not adjustable. Air-induction coverage explains the reed valve and air-cutoff valve and provides their inspection criteria.

Cooling, Brakes and Suspension

The water pump and oil pump share an assembly. Water-pump coverage distinguishes the mechanical seal, oil seal, bearing, and impeller components, alongside thermostat testing and cooling-system leak checks.

Wheels and suspension: Additional procedures cover wheel bearings, brake-disc inspection, wheel static balance, damper-rod service, fork oil-level checks, steering-head bearings, and swingarm linkage inspection.

Rear-shock coverage includes removal, inspection, installation, adjustment, handling, and disposal. The pressurized nitrogen unit must not be opened for an internal overhaul.

Electrical Fault Isolation and Visual References

The starting-circuit cutoff section explains the neutral, clutch, and sidestand interlocks. System-specific test paths help distinguish wiring and switch faults from component faults before replacement is considered.

Self-diagnosis uses tachometer condition codes for the throttle position sensor, EXUP, speed sensor, and emergency-stop-switch circuit.

Routing and lubrication: The engine oil lubrication chart and lubrication-passage views show the cylinder-head and transmission oil paths. Cooling-system diagrams, air-induction system diagrams, cable-routing layouts, and electrical component and coupler-location views support work on connected systems.

Tools and specifications: Tool callouts include vacuum gauge 90890-03094 for synchronization, universal clutch holder 90890-04086, and ignition checker 90890-06754.

Cooling and fork work identify radiator-cap tester and adapter 90890-01325 / 90890-01352 and fork-seal driver components 90890-01367 / 90890-01374. Torque tables, wear limits, clearance specifications, lubricant and sealant information, electrical test values, and symptom-based troubleshooting accompany the procedures.

Repair Cautions

Valve-clearance notes address pads falling into the crankcase and keeping lifters and pads in their original positions; wheel-bearing installation cautions address damage from loading the inner race or balls. The EXUP test warns that prolonged battery power can damage the servomotor.

Motorcycle repair at this level can expose hot coolant, brake fluid, stored spring or gas pressure, and live electrical circuits. Support the motorcycle securely before wheel, fork, engine, or suspension work, disconnect the negative battery lead before electrical teardown, and never open the cooling system while it is hot.

Examples of Valve, Clutch and Sensor Specifications

For valve-clearance checks on a cold engine at room temperature, the specified intake clearance is 0.11–0.20 mm and exhaust clearance is 0.21–0.25 mm. The adjustment section pairs these measurements with valve-pad selection tables.

Clutch inspection includes an assembly-width specification of 43.1–43.9 mm and selectable plate thicknesses. The throttle-position-sensor test specifies a maximum resistance of 4–6 kΩ at 20°C.