Yamaha FZS 600 FAZER Full Service & Repair Manual 1998-2000

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Typ: Motorcycle

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Art.-Nr: 148095

Stichworte: 1998 1999 2000 Fazer FZS 600 FAZER Motorcycle Motorcycles Yamaha

Produktvarianten

Beschreibung

This manual covers the FZS 600 FAZER, a versatile middleweight sportbike known for its balanced performance and rider-friendly characteristics, produced from 1998 to 2000. Engineered with a liquid-cooled, 599 cc inline-four engine, this motorcycle offers an engaging riding experience suitable for commuting, touring, and spirited rides. Its design philosophy emphasizes a blend of sportbike capability with naked styling, making it a practical and enjoyable machine for a wide range of riders. The FZS 600 FAZER is recognized for its reliable engineering and has been a competitive offering in its segment, praised for its value and performance. This comprehensive service and repair workshop manual provides detailed instructions and technical specifications essential for maintaining and repairing your FZS 600 FAZER. It covers all major systems, including the engine, fuel system, transmission, chassis, brakes, and electrical system, offering guidance on everything from routine maintenance and scheduled service intervals to in-depth troubleshooting and complete component overhauls. With step-by-step procedures, diagnostic guides, and clear wiring diagrams, this manual is an indispensable resource for owners, mechanics, and technicians aiming to ensure the optimal performance and longevity of their vehicle.

🏷️ Basic Information

Identification

Make:

Yamaha

Model:

FZS 600 FAZER

Model Code Common:

FZS600

Generation

Generation Designation:

First Generation (RJ02)

Codes

Vin Decoder Start Year:

Vin Decoder End Year:

👋 Introduction

Market Position

Category:

Middleweight Sportbike/Naked Bike Segment

Competitive Analysis

Competitors:

Honda CBR600F, Suzuki GSF600 Bandit, Kawasaki ZR-7

Key Features

Design Philosophy:

Versatile sport-touring capability with naked styling, user-friendly engine characteristics.

Target Audience:

Riders seeking a balance of performance, comfort, and practicality for commuting, touring, and spirited riding.

📋 Manual Details

Coverage Areas

Covered Years:

1998, 1999, 2000

Page Count

Estimated Page Count:

Hundreds (Exact number not specified, but indicated as extensive)

Manual Type

Type:

Full Service & Repair Workshop Manual

Language

Primary Language:

English (Implied by product description and typical availability)

Format

Digital Format:

PDF (Portable Document Format)

📖 Manual Coverage

Systems Covered

Engine:

Full engine overhaul, internal components, top-end, bottom-end, valve train, lubrication, cooling, ignition.

Fuel System:

Carburetor tuning and overhaul, fuel pump, fuel lines, fuel filter replacement, fuel tank maintenance.

Transmission:

Clutch operation, gearshift mechanism, internal transmission components, gearbox oil, maintenance.

Chassis:

Frame inspection and repair, swingarm, bearings, suspension (front forks and rear shock absorber), steering head assembly.

Brakes:

Front and rear brake systems, hydraulic lines, master cylinders, calipers, brake fluid, bleeding procedures, disc and pad replacement.

Electrical System:

Battery, charging system (stator, regulator/rectifier), starter motor, lighting circuits, ignition system, wiring diagrams, troubleshooting.

Cooling System:

Radiator, coolant, fan, hoses, thermostat, water pump.

Exhaust System:

Exhaust pipes, mufflers, gaskets, inspection and replacement.

Wheels And Tires:

Wheel bearing maintenance, tire pressure, tire replacement, wheel balancing.

Procedures Included

Maintenance:

Scheduled maintenance, oil changes, filter replacements, chain adjustment, spark plug service, lubrication points.

Troubleshooting:

Diagnostic procedures for common and uncommon issues, fault finding guides based on symptoms.

Repair:

Step-by-step instructions for all repair tasks, from minor adjustments to major component overhauls.

Disassembly Reassembly:

Detailed procedures for removing and reinstalling all major and minor components.

Wiring Diagrams:

Comprehensive electrical schematics for all circuits.

Technical Depth

Depth:

Comprehensive and detailed, suitable for professional mechanics and advanced DIY enthusiasts. Covers complete rebuilds and in-depth diagnostics.

📊 Manual Specifications

File Format

Digital Format:

Print Quality

Printability:

Printable (single pages or entire manual)

Binding Type

Binding Type:

Digital Download (No physical binding)

Paper Type

Paper Type:

N/A (Digital Format)

Compatibility

Operating Systems:

Windows and macOS compatible

Access

Device Compatibility:

Usable on computers, tablets, and smartphones

Licensing

Usage License:

Unlimited use, no expiry dates, no renewal fees

⚙️ Engine Specifications

Primary Engine

Engine Type:

Inline-four, DOHC, 4-stroke

Displacement:

599 cc (Cubic Centimeters)

Bore X Stroke:

62.0 mm x 49.6 mm

Compression Ratio:

12.2:1

Cooling System:

Liquid-cooled

Valves Per Cylinder:

Performance

Horsepower Est:

93.5 hp @ 11,000 rpm (Approximate)

Torque Est:

62 Nm @ 9,000 rpm (Approximate)

Fuel System

Carburetor Type:

Four Mikuni CVKD36 carburetors

Fuel Capacity:

20 Liters

Fuel Type:

Unleaded gasoline (95 RON recommended)

Ignition System

Ignition Type:

TCI (Transistor Controlled Ignition)

Lubrication

Oil Type Recommendation:

Yamalube 4 (or equivalent) SAE 10W-40 API SG or higher

Oil Capacity W Filter:

3.4 Liters

Oil Capacity Wo Filter:

3.0 Liters

🔧 Transmission

Standard

Transmission Type:

Constant mesh 6-speed

Clutch Type:

Wet, multiple disc, cable-actuated

Features

Drive Type:

Chain drive

Final Drive Ratio:

17/46 (Approximate, refer to manual for exact)

Transmission Oil Type:

Yamaha Gear Oil (or equivalent) SAE 80 API GL-4

Transmission Oil Capacity:

0.8 Liters

📐 Dimensions

Exterior

Overall Length:

2,135 mm

Overall Width:

770 mm

Overall Height:

1,195 mm

Seat Height:

815 mm

Wheelbase:

1,430 mm

Weights

Dry Weight:

192 kg

Wet Weight:

213 kg (Approximate)

Max Load Capacity:

180 kg (Rider + Passenger + Luggage)

🛡️ Safety Features

Ratings

Safety Certification:

Meets relevant national and international motorcycle safety standards for its era.

Active Features

Braking System:

Dual 298mm front discs with 4-piston calipers, 245mm rear disc with 2-piston caliper. (Optional ABS may have been available in some markets, refer to specific model)

Lighting:

Halogen headlight, LED taillight and indicators (standard)

Passive Features

Frame Construction:

Steel diamond frame for rigidity and rider feedback.

💡 Technology Features

Infotainment

Instrumentation:

Analog tachometer, digital speedometer, fuel gauge, clock, trip meter, warning lights.

Driver Assistance

ABS Availability:

Optional in certain markets for this generation.

Connectivity

Connectivity Features:

N/A (Motorcycle of its era, no advanced digital connectivity)

🔧 Maintenance

Service Intervals

Oil Change Interval:

Every 6,000 km or 6 months, whichever comes first.

Oil Filter Change Interval:

Every 12,000 km or 12 months (recommended with oil change).

Spark Plug Replacement Interval:

Every 12,000 km or 12 months.

Valve Clearance Check Interval:

Every 24,000 km or 24 months.

Chain Lubrication Inspection:

Every 1,000 km or after riding in wet conditions.

Fluid Specifications

Brake Fluid Type:

DOT 4

Coolant Type:

Yamaha Super Coolant (or equivalent ethylene glycol-based coolant, 50% mixture with distilled water)

Known Issues

Common Wear Item:

Cam chain wear, leading to rattling noise.

Common Issue Electrical:

Regulator/rectifier failure leading to charging problems. Spark plug cap corrosion.

Common Issue Fuel:

Carburetor float bowl deposits or needle wear leading to poor running.

Common Issue Suspension:

Fork seal leaks, rear shock absorber degradation over time.

📚 Vehicle History

Brand Heritage

Manufacturer Origin:

Japan

Engineering Focus:

Known for reliable inline-four engines and performance-oriented motorcycles.

Model Evolution

Predecessor:

Yamaha XJ600 Diversion (in some markets)

Successor:

Yamaha FZ6 Fazer (2004 onwards)

Production

Introduction Year:

Production Continuation:

Produced until 2003/2004 before being replaced by the FZ6 Fazer.

🏆 Awards & Recognition

Recognitions

Industry Recognition:

Praised for its blend of performance, comfort, and value in the middleweight sport-touring class during its production run.