![Yamaha FAZER FZS1000(N) (2001) [291/403] Transmission](/img/pdf.png)
Yamaha FAZER FZS1000(N) (2001) [291/403] Transmission
![Yamaha FAZER FZS1000(N) (2001) [291/403] Transmission](/views2/1121443/page291/bg123.png)
5-84
TRANSMISSION
ENG
EAS00422
CHECKING THE SHIFT DRUM ASSEMBLY
1. Check:
shift drum grooves
Damage/scratches/wear Replace the
shift drum.
shift drum segment
1
Damage/wear Replace.
shift drum bearing
2
Damage/pitting Replace.
EAS00425
CHECKING THE TRANSMISSION
1. Measure:
main axle runout
(with a centering device and dial gauge
1
)
Out of specification Replace the main
axle.
Main axle runout limit
0.08 mm
2. Measure:
drive axle runout
(with a centering device and dial gauge
1
)
Out of specification Replace the drive
axle.
Drive axle runout limit
0.08 mm
3. Check:
transmission gears
Blue discoloration/pitting/wear Replace
the defective gear(-s).
transmission gear dogs
Cracks/damage/rounded edges Replace
the defective gear(-s).
4. Check:
transmission gear engagement
(each pinion gear to its respective wheel
gear)
Incorrect Reassemble the transmission
axle assemblies.
5. Check:
transmission gear movement
Rough movement Replace the defective
part(-s).
6. Check:
circlips
Damage/bends/looseness Replace.
Содержание
- Caution 4
- Important information 4
- Notice 4
- How to use this manual 5
- Carb elec 6
- Chk adj 6
- Gen info spec 6
- In the exploded diagrams indi cate the following 6
- In the exploded diagrams indi cate the types of lubricants and lubrication points 6
- Indicate the following 6
- Indicate the subject of each chapter 6
- Symbols 6
- The following symbols are not relevant to every vehicle symbols 6
- Trbl shtg 6
- Carburetors 7
- Chassis 7
- Cooling system 7
- Electrical system 7
- Engine 7
- General information 7
- Periodic checks and adjustments 7
- Specifications 7
- Table of contents 7
- Troubleshooting 7
- Chapter 1 general information 10
- Gen info 10
- General information 10
- Gen info 12
- General information 12
- Motorcycle identification 12
- Gen info 13
- Important information 13
- Caution 14
- Gen info 14
- Important information 14
- Checking the connections 15
- Gen info 15
- Gen info 16
- Special tools 16
- Gen info 17
- Special tools 17
- Gen info 18
- Special tools 18
- Gen info 19
- Special tools 19
- Chapter 2 specifications 21
- Specifications 21
- General specifications 23
- Specifications 23
- Engine specifications 24
- Engine specifications 25
- Engine specifications 26
- Engine specifications 27
- Engine specifications 28
- Engine specifications 29
- Engine specifications 30
- Engine specifications 31
- Engine specifications 32
- Chassis specifications 33
- Chassis specifications 34
- Chassis specifications 35
- Chassis specifications 36
- Electrical specifications 37
- Electrical specifications 38
- Electrical specifications 39
- Tightening torque 40
- Tightening torques 40
- Tightening torques 41
- Tightening torques 42
- Tightening torques 44
- Lubrication points and lubricant types 45
- Lubrication points and lubricant types 46
- Cooling system diagrams 47
- Cooling system diagrams 48
- Cooling system diagrams 49
- Engine oil lubrication chart 51
- Lubrication diagrams 52
- Lubrication diagrams 53
- Lubrication diagrams 54
- Lubrication diagrams 55
- Lubrication diagrams 56
- Cable routing 57
- Cable routing 58
- Cable routing 59
- Cable routing 60
- Cable routing 61
- Alarm coupler free 62
- Battery 62
- Battery negative lead 62
- Battery positive lead 62
- Cable routing 62
- Clutch cable 62
- Coolant reservoir hose 62
- Emergency engine stop switch 62
- Exup servo motor lead 62
- Fan motor lead 62
- Flasher light lead 62
- Flasher relay 62
- Fuel hose 62
- Fuse box 62
- Handlebar switch lead 62
- Handlebar switch lead right 62
- Igniter unit 62
- Ignition coil 62
- Ignition coil lead 62
- Main harness 62
- Main switch lead 62
- Rectifier regulator lead 62
- Starter cable 62
- Starter relay 62
- Starting circuit cutoff relay 62
- Taillight lead 62
- Thermo unit lead 62
- Throttle cable 1 62
- Throttle cable 2 62
- White paint mark 62
- Cable routing 63
- Cable routing 64
- Chapter 3 periodic checks and adjustments 66
- Chk adj 66
- Periodic checks and adjustments 66
- Chk adj 67
- Chk adj 68
- Introduction 68
- Introduction periodic maintenance lubrication intervals 68
- Periodic checks and adjustments 68
- Periodic maintenance lubrication intervals 68
- The annual checks must be performed every year except if a kilometer based maintenance is performed instead from 50 000 km repeat the maintenance intervals starting from 10 000 km items marked with an asterisk should be performed by a yamaha dealer as they require special tools data and technical skills 68
- This chapter includes all information necessary to perform recommended checks and adjustments if followed these preventive maintenance procedures will ensure more reliable vehicle operation a longer service life and reduce the need for costly overhaul work this information applies to vehicles already in service as well as to new vehicles that are being prepared for sale all service technicians should be familiar with this entire chapter 68
- Chk adj 69
- It is recommended that these items be serviced by a yamaha dealer 69
- Periodic maintenance lubrication intervals 69
- The air filter needs more frequent service if you are riding in unusually wet or dusty areas hydraulic brake service regularly check and if necessary correct the brake fluid level every two years replace the internal components of the brake master cylinders and calipers and change the brake fluid replace the brake hoses every four years and if cracked or damaged 69
- Chk adj 70
- Front cowling 70
- Front cowling seat side cover fuel tank 70
- Chk adj 71
- Seat side cover and fuel tank 71
- Adjusting the valve clearance 72
- Chk adj 72
- Engine 72
- Adjusting the valve clearance 73
- Chk adj 73
- Adjusting the valve clearance 74
- Chk adj 74
- Adjusting the valve clearance 75
- Chk adj 75
- Exhaust 75
- Installed pad number 75
- Valve pad selection table intake 75
- Adjusting the valve clearance 76
- Chk adj 76
- Chk adj 77
- Synchronizing the carburetors 77
- Chk adj 78
- Synchronizing the carburetors 78
- Adjusting the engine idling speed 79
- Chk adj 79
- Adjusting the engine idling speed adjusting the throttle cable free play 80
- Chk adj 80
- Adjusting the throttle cable free play 81
- Chk adj 81
- Warning 81
- Adjusting the throttle cable free play checking the spark plugs 82
- Caution 82
- Chk adj 82
- Checking the spark plugs checking the ignition timing 83
- Chk adj 83
- Caution 84
- Checking the ignition timing measuring the compression pressure 84
- Chk adj 84
- Chk adj 85
- Measuring the compression pressure 85
- Warning 85
- Caution 86
- Checking the engine oil level 86
- Chk adj 86
- Caution 87
- Changing the engine oil 87
- Chk adj 87
- Changing the engine oil 88
- Chk adj 88
- Changing the engine oil adjusting the clutch cable free play 89
- Chk adj 89
- Caution 90
- Chk adj 90
- Cleaning the air filter element 90
- Chk adj 91
- Caution 92
- Chk adj 92
- Adjusting the exup cables 93
- Caution 93
- Chk adj 93
- Adjusting the exup cables checking the coolant level 94
- Chk adj 94
- Caution 95
- Checking the coolant level 95
- Chk adj 95
- Checking the cooling system 96
- Chk adj 96
- Changing the coolant 97
- Chk adj 97
- Warning 97
- Changing the coolant 98
- Chk adj 98
- Warning 98
- Caution 99
- Changing the coolant 99
- Chk adj 99
- Adjusting the front brake 100
- Caution 100
- Chassis 100
- Chk adj 100
- Warning 100
- Adjusting the rear brake 101
- Caution 101
- Chk adj 101
- Warning 101
- Adjusting the rear brake checking the brake fluid level 102
- Caution 102
- Chk adj 102
- Warning 102
- Checking the brake pads adjusting the rear brake light switch 103
- Chk adj 103
- Checking the brake hoses bleeding the hydraulic brake system 104
- Chk adj 104
- Warning 104
- Bleeding the hydraulic brake system adjusting the shift pedal 105
- Chk adj 105
- Warning 105
- Adjusting the shift pedal adjusting the drive chain slack 106
- Caution 106
- Chk adj 106
- Warning 106
- Adjusting the drive chain slack 107
- Chk adj 107
- Chk adj 108
- Lubricating the drive chain checking and adjusting the steering head 108
- Warning 108
- Checking and adjusting the steering head 109
- Chk adj 109
- Warning 109
- Caution 110
- Chk adj 110
- Warning 110
- Adjusting the front fork legs 111
- Caution 111
- Chk adj 111
- Adjusting the front fork legs adjusting the rear shock absorber assembly 112
- Caution 112
- Chk adj 112
- Warning 112
- Adjusting the rear shock absorber assembly 113
- Caution 113
- Chk adj 113
- Adjusting the rear shock absorber assembly checking the tires 114
- Caution 114
- Chk adj 114
- Warning 114
- Checking the tires 115
- Chk adj 115
- Warning 115
- Checking the tires 116
- Chk adj 116
- Warning 116
- Chk adj 117
- Warning 117
- Caution 118
- Checking and charging the battery 118
- Chk adj 118
- Electrical system 118
- Warning 118
- Caution 119
- Checking and charging the battery 119
- Chk adj 119
- Caution 120
- Checking and charging the battery 120
- Chk adj 120
- Warning 120
- Checking and charging the battery 121
- Chk adj 121
- Checking and charging the battery 122
- Chk adj 122
- Caution 123
- Checking and charging the battery checking the fuses 123
- Chk adj 123
- Checking the fuses 124
- Chk adj 124
- Warning 124
- Caution 125
- Chk adj 125
- Replacing the headlight bulbs 125
- Warning 125
- Adjusting the headlight beams adjusting the digital clock 126
- Chk adj 126
- Chapter 4 chassis 129
- Chassis 129
- Chassis 131
- Front wheel and brake discs 131
- Front wheel and brake discs 132
- Front wheel and brake discs 133
- Warning 133
- Front wheel and brake discs 134
- Warning 134
- Caution 135
- Front wheel and brake discs 135
- Caution 136
- Front wheel and brake discs 136
- Caution 137
- Front wheel and brake discs 137
- Warning 137
- Front wheel and brake discs 138
- Rear wheel and brake disc 139
- Rear wheel and brake disc 140
- Rear wheel and brake disc 141
- Rear wheel and brake disc 142
- Warning 142
- Rear wheel and brake disc 143
- Rear wheel and brake disc 144
- Rear wheel and brake disc 145
- Front and rear brakes 146
- Front and rear brakes 147
- Caution 148
- Front and rear brakes 148
- Front and rear brakes 149
- Front and rear brakes 150
- Front and rear brakes 151
- Front and rear brakes 152
- Front and rear brakes 153
- Front and rear brakes 154
- Front and rear brakes 155
- Front and rear brakes 156
- Front and rear brakes 157
- Front and rear brakes 158
- Caution 159
- Front and rear brakes 159
- Warning 159
- Caution 160
- Front and rear brakes 160
- Warning 160
- Caution 161
- Front and rear brakes 161
- Warning 161
- Front and rear brakes 162
- Front and rear brakes 163
- Front and rear brakes 164
- Front and rear brakes 165
- Front and rear brakes 166
- Front and rear brakes 167
- Warning 167
- Front and rear brakes 168
- Warning 168
- Front and rear brakes 169
- Warning 169
- Caution 170
- Front and rear brakes 170
- Warning 170
- Caution 171
- Front and rear brakes 171
- Warning 171
- Caution 172
- Front and rear brakes 172
- Warning 172
- Caution 173
- Front and rear brakes 173
- Warning 173
- Front fork 174
- Front fork 175
- Front fork 176
- Warning 176
- Caution 177
- Front fork 177
- Caution 178
- Front fork 178
- Warning 178
- Caution 179
- Front fork 179
- Warning 179
- Caution 180
- Front fork 180
- Front fork 181
- Caution 182
- Front fork 182
- Front fork 183
- Warning 183
- Handlebar 184
- Handlebar 185
- Warning 185
- Caution 186
- Handlebar 186
- Warning 186
- Handlebar 187
- Steering head 188
- Steering head 189
- Warning 189
- Caution 190
- Steering head 190
- Rear shock absorber assembly 191
- Rear shock absorber assembly 192
- Warning 192
- Rear shock absorber assembly 193
- Warning 193
- Rear shock absorber assembly 194
- Swingarm and drive chain 195
- Swingarm and drive chain 196
- Swingarm and drive chain 197
- Warning 197
- Swingarm and drive chain 198
- Warning 198
- Swingarm and drive chain 199
- Caution 200
- Swingarm and drive chain 200
- Swingarm and drive chain 201
- Caution 202
- Swingarm and drive chain 202
- Chapter 5 overhauling the engine 204
- Overhauling the engine 204
- Engine 208
- Overhauling the engine 208
- Engine 209
- Engine 210
- Engine 211
- Camshaft 212
- Camshaft 213
- Camshaft 214
- Camshaft 215
- Camshaft 216
- Caution 216
- Camshaft 217
- Camshaft 218
- Camshaft 219
- Camshaft 220
- Caution 220
- Camshaft 221
- Warning 221
- Camshaft 222
- Cylinder head 223
- Cylinder head 224
- Cylinder head 225
- Valves and valve springs 226
- Valves and valve springs 227
- Valves and valve springs 228
- Valves and valve springs 229
- Valves and valve springs 230
- Valves and valve springs 231
- Caution 232
- Valves and valve springs 232
- Valves and valve springs 233
- Valves and valve springs 234
- Caution 235
- Valves and valve springs 235
- Generator 236
- Caution 237
- Generator 237
- Warning 237
- Generator 238
- Pickup coil 239
- Pickup coil 240
- Pickup coil 241
- Pickup coil 242
- Clutch 243
- Clutch 244
- Clutch 245
- Clutch 246
- Clutch 247
- Clutch 248
- Clutch 249
- Clutch 250
- Clutch 251
- Clutch 252
- Clutch 253
- Clutch 254
- Shift shaft 255
- Shift shaft 256
- Oil pan and oil pump 257
- Oil pan and oil pump 258
- Oil pan and oil pump 259
- Oil pan and oil pump 260
- Oil pan and oil pump 261
- Oil pan and oil pump 262
- Oil pan and oil pump 263
- Warning 263
- Crankcase 264
- Crankcase 265
- Crankcase 266
- Crankcase 267
- Caution 268
- Crankcase 268
- Caution 269
- Crankcase 269
- Crankcase 270
- Crankcase 271
- Crankcase 272
- Crankcase 273
- Crankcase 274
- Caution 275
- Crankcase 275
- Crankcase 276
- Caution 277
- Crankcase 277
- Caution 278
- Crankcase 278
- Crankcase 279
- Crankcase 280
- Crankcase 281
- Caution 282
- Crankcase 282
- Crankcase 283
- Caution 284
- Crankcase 284
- Transmission 285
- Transmission 286
- Transmission 287
- Transmission 288
- Transmission 289
- Transmission 290
- Warning 290
- Transmission 291
- Transmission 292
- Chapter 6 cooling system 295
- Cooling system 295
- Cooling system 297
- Radiator 297
- Radiator 298
- Radiator 299
- Thermostat 300
- Thermostat 301
- Thermostat 302
- Caution 303
- Thermostat 303
- Water pump 304
- Water pump 305
- Water pump 306
- Caution 307
- Water pump 307
- Caution 308
- Water pump 308
- Carburetors 310
- Chapter 7 carburetors 310
- Carburetors 312
- Carburetors 313
- Carburetors 314
- Carburetors 315
- Carburetors 316
- Carburetors 317
- Carburetors 318
- Carburetors 319
- Caution 319
- Carburetors 320
- Carburetors 321
- Carburetors 322
- Carburetors 323
- Carburetors 324
- Air induction system 325
- Air induction system 326
- Air induction system diagrams 326
- Air induction system 327
- Chapter 8 electrical 329
- Electrical 329
- Battery 331
- Electrical 331
- Electrical components 331
- Emargency stop switch 331
- Fan motor relay 331
- Flasher relay 331
- Fuel sender 331
- Ignition coil 331
- Ignitor unit 331
- Main switch 331
- Neutral switch 331
- Oil level gauge 331
- Rear brake switch 331
- Rectifier regulator 331
- Sidestand switch 331
- Speed sensor 331
- Starter relay 331
- Starting circuit cutoff relay 331
- Thermo unit 331
- Arrangement of the electrical components and couplers 332
- Pickup coil 332
- Pickup rotor 332
- Starter motor 332
- Thermo unit 332
- Arrangement of the electrical components and couplers 333
- Battery 333
- Brake light switch coupler 333
- Fuel pump 333
- Fuel pump coupler 333
- Fuse box 333
- Ignitor unit 333
- Newtral switch coupler 333
- Pickup coil coupler 333
- Speed sensor coupler 333
- Arrangement of the electrical components and couplers 334
- Ignition coil 1 334
- Ignition coil 2 334
- Rectifier regulator 334
- Stator coil 334
- Arrangement of the electrical components and couplers 335
- Emargency stop switch 335
- Fan motor relay 335
- Flasher relay 335
- Fuel sender coupler 335
- Oil level switch coupler 335
- Sidestand switch coupler 335
- Starter relay 335
- Starting circuit cutoff relay 335
- Stator coil coupler 335
- Caution 336
- Instrument functions 336
- Instrument functions 337
- Caution 338
- Checking switch continuity 338
- Check each switch for damage or wear proper connections and also for continuity between the termi nals refer to checking switch continuity damage wear repair or replace the switch improperly connected properly connect incorrect continuity reading replace the switch 339
- Checking the switches 339
- Checking the bulbs and bulb sockets 340
- Caution 341
- Checking the bulbs and bulb sockets 341
- Warning 341
- Checking the bulbs and bulb sockets 342
- Warning 342
- Circuit diagram 343
- Ignition system 343
- Ignition system 344
- Ignition system 345
- Ignition system 346
- Circuit diagram 347
- Electric starting system 347
- Electric starting system 348
- Electric starting system 349
- Warning 349
- Electric starting system 350
- Electric starting system 351
- Electric starting system 352
- Electric starting system 353
- Electric starting system 354
- Electric starting system 355
- Electric starting system 356
- Charging system 357
- Circuit diagram 357
- Charging system 358
- Charging system 359
- Circuit diagram 360
- Lighting system 360
- Lighting system 361
- Lighting system 362
- Lighting system 363
- Lighting system 364
- Signal system 366
- Signal system 367
- Signal system 368
- Signal system 369
- Signal system 370
- Signal system 371
- Signal system 372
- Circuit diagram 373
- Cooling system 373
- Cooling system 374
- Cooling system 375
- Warning 375
- Circuit diagram 376
- Fuel pump system 376
- Fuel pump circuit operation the ignitor unit includes the control unit for the fuel pump 377
- Fuel pump system 377
- Fuel pump system 378
- Fuel pump system 379
- Fuel pump system 380
- Warning 380
- Circuit diagram 381
- Exup system 381
- Exup system 382
- Caution 383
- Exup system 383
- Exup system 384
- Self diagnosis 385
- Is 0 r min 386
- Self diagnosis 386
- Tachometer display sequence 386
- When more than one item is being monitored the tachometer needle displays the condition codes in ascending order cycling through the sequence repeatedly if the engine is stopped the engine speed 386
- Self diagnosis 387
- Self diagnosis 388
- Self diagnosis 389
- Self diagnosis 390
- Chapter 9 troubleshooting 392
- Trbl shtg 392
- Troubleshooting 392
- Trbl shtg 393
- Starting problems 394
- Trbl shtg 394
- Troubleshooting 394
- Incorrect engine idling speed 395
- Trbl shtg 395
- Troubleshooting 395
- Faulty gear shifting 396
- Poor medium and high speed performance 396
- Trbl shtg 396
- Troubleshooting 396
- Faulty clutch 397
- Overheating 397
- Trbl shtg 397
- Troubleshooting 397
- Faulty front fork legs 398
- Overcooling 398
- Poor braking performance 398
- Trbl shtg 398
- Troubleshooting 398
- Trbl shtg 399
- Troubleshooting 399
- Unstable handling 399
- Faulty lighting or signaling system 400
- Trbl shtg 400
- Troubleshooting 400
- Fzs1000 2001 wiring diagram eur 402
- Wiring diagram eur 402
- Fzs1000 n 2001 wiring diagram oce 403
- Wiring diagram oce 403
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