Yamaha FZS600 FAZER 1998-2001 Service Repair Manual

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Art.-Nr: 120678

Stichworte: 1998 1999 2000 2001 Fazer FZS600 FAZER Motorcycle Motorcycles Yamaha

Produktvarianten

Beschreibung

This manual covers the FZS600 Fazer, produced from 1998 to 2001. Known for its inline-four cylinder, liquid-cooled engine and full faired design, the Fazer is a versatile middleweight sport touring motorcycle. It offers a comfortable yet capable riding experience, suitable for both commuting and longer journeys, and is recognized for its balance of performance, reliability, and value. Key features include a robust braking system with dual front discs, a comfort-oriented suspension setup, and a focus on rider accessibility, making it a popular choice for riders seeking an all-around capable machine. This comprehensive Service Repair Manual provides detailed information essential for the maintenance and repair of your FZS600 Fazer. It encompasses a wide range of topics, including complete engine mechanical procedures, fuel system servicing, ignition system diagnostics, cooling system maintenance, transmission and clutch overhauls, chassis and suspension adjustments, brake system servicing, and electrical system troubleshooting. The manual also includes preventative maintenance schedules, detailed repair procedures, disassembly and assembly guides, and clear wiring diagrams. With over 400 pages of technical information, this English-language resource is designed to assist owners, mechanics, and technicians in keeping their motorcycle in optimal condition.

🏷️ Basic Information

Identification

Make:

Yamaha

Model:

FZS600 Fazer

Model Nickname:

Fazer

Model Year Start:

Model Year End:

Codes

Chassis Code:

Engine Code Prefix:

👋 Introduction

Market Position

Segment:

Middleweight Sport Touring Motorcycle

Target Audience:

Riders seeking a versatile, reliable, and affordable motorcycle for commuting and touring.

Competitive Analysis

Key Competitors:

Suzuki Bandit 600, Honda CB600F Hornet, Kawasaki ZZ-R600.

Key Features

Engine Type:

Inline-four cylinder, liquid-cooled, DOHC.

Styling:

Full faired design for improved aerodynamics and rider comfort.

Suspension Setup:

Comfort-oriented yet capable suspension for varied road conditions.

Braking System:

Dual front discs and single rear disc, known for strong performance.

📋 Manual Details

Coverage Areas

Country Of Origin:

Japan

Market Regions:

Global (Europe, North America, Asia, etc.)

Page Count

Estimated Page Count:

Manual Type

Type:

Service Repair Manual

Language

Language:

English

Format

Format:

Digital Download (PDF)

📖 Manual Coverage

Systems Covered

Engine Mechanical:

Complete engine disassembly, assembly, tuning, and troubleshooting.

Fuel System:

Carburetor identification, cleaning, adjustment, and synchronization; fuel pump and lines.

Ignition System:

CDI unit, ignition coils, spark plugs, wiring diagrams, timing adjustments.

Cooling System:

Radiator, coolant flow, thermostat operation, fan assembly.

Exhaust System:

Exhaust pipe inspection, muffler maintenance, gasket replacement.

Transmission:

Gearbox disassembly, inspection, clutch operation, gear shift mechanism.

Clutch:

Wet multi-plate clutch inspection, adjustment, replacement of friction plates and springs.

Chassis Frame:

Frame inspection for damage, steering head bearing maintenance.

Suspension Front:

Telescopic fork service, oil replacement, seal replacement, spring preload adjustment.

Suspension Rear:

Monoshock absorber inspection, linkage maintenance, preload adjustment.

Brakes Front:

Disc brake service, caliper disassembly, piston inspection, pad replacement, fluid flush.

Brakes Rear:

Disc brake service, caliper disassembly, piston inspection, pad replacement, fluid flush.

Wheels And Tires:

Wheel bearing inspection, tire pressure, tire replacement, rim inspection.

Electrical System:

Battery maintenance, starter motor, alternator, lighting circuits, fuses, wiring diagrams.

Instrumentation:

Speedometer, tachometer, indicator lights, gauges, diagnostic checks.

Bodywork And Trim:

Fairing removal and installation, seat maintenance, panel alignment.

Procedures Included

Preventative Maintenance:

Regular service checks, lubrication points, fluid changes, filter replacements.

Troubleshooting:

Diagnostic flowcharts and common problem identification for various systems.

Repair Procedures:

Step-by-step instructions for component removal, repair, and reinstallation.

Disassembly Assembly:

Detailed procedures for dismantling and reassembling major motorcycle components.

Wiring Diagrams:

Comprehensive electrical schematics for all circuits and components.

Technical Depth

Depth:

Comprehensive, covering from basic owner maintenance to full engine rebuilds and electrical diagnostics.

📊 Manual Specifications

File Format

Format:

Searchability:

Searchable text content

Print Quality

Resolution:

High-resolution scans for clarity of diagrams and text

Binding Type

Binding:

N/A (Digital Download)

Paper Type

Paper:

N/A (Digital Download)

⚙️ Engine Specifications

Primary Engine

Engine Type:

Inline Four-Cylinder

Displacement:

599 cc

Bore X Stroke:

62.0 mm x 49.6 mm

Compression Ratio:

11.5:1

Valve Train:

DOHC, 16 Valves (4 per cylinder)

Performance

Horsepower Peak:

96 hp (approx. at 11,000 rpm)

Torque Peak:

62.2 Nm (approx. at 9,500 rpm)

Fuel System

Carburetors:

Four Mikuni CV carburetors (e.g., BST34)

Fuel Capacity:

20 Liters (5.3 US gallons)

Fluid Specifications

Engine Oil Type:

API SG, SF or above, JASO MA

Engine Oil Viscosity:

10W-40

Coolant Type:

Antifreeze coolant (Ethylene Glycol base, 50% dilution)

🔧 Transmission

Standard

Type:

6-speed constant mesh

Features

Clutch Type:

Wet, multi-plate

Fluid Specifications

Transmission Oil Type:

Yamalube SAE 80 API GL-4 hypoid gear oil

Transmission Oil Capacity:

1.9 Liters (2.0 US qt) (with filter change)

📐 Dimensions

Exterior

Length:

2,110 mm (83.1 in)

Width:

780 mm (30.7 in)

Height:

1,215 mm (47.8 in)

Wheelbase:

1,420 mm (55.9 in)

Weights

Dry Weight:

194 kg (427.7 lbs)

Wet Weight:

213 kg (470 lbs) (approx.)

Max Load:

200 kg (441 lbs) (including rider and luggage)

Wheels And Tires

Front Tire Size:

120/60 ZR17 M/C (55W)

Rear Tire Size:

160/60 ZR17 M/C (64W)

Wheel Type:

Cast Aluminum Alloy

Wheelbase Front:

Wheelbase Rear:

🛡️ Safety Features

Ratings

Crash Safety Standard:

Not Applicable (Motorcycle)

Active Features

Front Brakes:

Dual Hydraulic Disc, 298 mm diameter

Rear Brakes:

Hydraulic Disc, 245 mm diameter

Passive Features

Lighting:

Halogen headlight, LED taillight, turn signals.

Instrumentation Warnings:

Oil pressure warning light, neutral indicator, high beam indicator, turn signal indicators.

💡 Technology Features

Infotainment

Features:

Basic instrumentation: Speedometer, Tachometer, Odometer, Trip Meter, Fuel Gauge, Indicator Lights.

Driver Assistance

Features:

ABS was an optional feature on some models/markets, but not standard across the range.

Connectivity

Features:

N/A (Analog systems, no modern connectivity features).

🔧 Maintenance

Service Intervals

Oil Change Interval:

Every 5,000 km (3,000 miles) or 6 months

Oil Filter Change Interval:

Every 10,000 km (6,000 miles) or 12 months

Spark Plug Inspection:

Every 10,000 km (6,000 miles)

Valve Clearance Check:

Every 20,000 km (12,000 miles)

Fork Oil Change:

Every 20,000 km (12,000 miles) or as needed

Brake Fluid Flush:

Every 2 years

Coolant Change:

Every 2 years

Known Issues

Common Problems:

Fork seal leaks, occasional clutch judder if not maintained.

Fluid Specifications

Brake Fluid Type:

DOT 4

Coolant Capacity:

1.8 Liters (1.9 US qt)

Fork Oil Type:

Kayaba #0W (or equivalent, e.g., 10W)

Fork Oil Quantity:

452 ml (15.3 US fl oz) per leg

📚 Vehicle History

Brand Heritage

Manufacturer:

Yamaha Motor Corporation

Heritage Focus:

Known for performance motorcycles, sportbikes, and innovation in engine technology.

Model Evolution

Predecessor:

Yamaha XJ600 Diversion (introduced earlier, less faired).

Segment Introduction:

Introduced as a more comfortable and versatile option than pure sportbikes, targeting the sport-touring market.

Production

Production Period:

1998-2003 (First Generation)

Manufacturing Location:

Japan

🏆 Awards & Recognition

Recognitions

Reputation:

Consistently praised for its balance of performance, comfort, reliability, and value for money in its class.

Ratings

Motorcycle Journalist Reviews:

Highly rated for its user-friendly nature, accessible power delivery, and suitability for everyday riding and touring.