Yamaha_Fazer_FZS600 3 in 1 User Manual Pakage (Service Repair + supplementary & Speccification)
Total 432 Pages
Yamaha Fazer FZS600_1998_ Service Repair Manual (364 Pages)
CONTENTS
CHAPTER 1

GENERAL INFORMATION
MOTORCYCLE IDENTIFICATION
VEHICLE IDENTIFICATION NUMBER,MODEL CODE
IMPORTANT INFORMATION
PREPARATION FOR REMOVAL AND DISASSEMBLY,REPLACEMENT PARTS,GASKETS,OIL SEALS AND O-RINGS,LOCK WASHERS/PLATES AND COTTER PINS ,BEARINGS AND OIL SEALS CIRCLIPS
CHECKING THE CONNECTIONS
SPECIAL TOOLS

CHAPTER 2

SPECIFICATIONS
GENERAL SPECIFICATIONS
MAINTENANCE SPECIFICATIONS
ENGINE,CHASSIS,ELECTRICAL,
GENERAL TIGHTENING TORQUE SPECIFICATIONS
LUBRICATIONS AND LUBRICANT TYPES
ENGINE ,CHASSIS ,
COOLING SYSTEM DIAGRAMS
LUBRICATION DIAGRAMS
CABLE ROUTING

CHAPTER 3

INTRODUCTION
PERIODIC MAINTENANCE/LUBRICATION INTERVALS
FRONT COWLING/SEAT/SIDE COVER/FUEL TANK
ENGINE
ADJUSTING THE VALVE CLEARANCE,SYNCHRONIZING THE CARBURETORS,ADJUSTING THE ENGINE IDLING SPEED,ADJUSTING THE THROTTLE CABLE FREE PLAY,CHECKING THE SPARK PLUGS,CHECKING THE IGNITION TIMING,MEASURING THE COMPRESSION PRESSURE,CHECKING THE ENGINE OIL LEVEL,CHANGING THE ENGINE OIL ,EASURING THE ENGINE OIL PRESSURE,ADJUSTING THE CLUTCH CABLE FREE PLAY ,CLEANING THE AIR FILTER ELEMENT ,CHECKING THE CARBURETOR JOINTS AND INTAKE MANIFOLDS , CHECKING THE FUEL HOSES AND FUEL FILTER,CHECKING THE CRANKCASE BREATHER HOSE ,CHECKING THE EXHAUST SYSTEM ,CHECKING THE COOLANT LEVEL ,CHECKING THE COOLING SYSTEM ,CHANGING THE COOLANT.
CHASSIS
ADJUSTING THE FRONT BRAKE ADJUSTING THE REAR BRAKE ,CHECKING THE BRAKE FLUID LEVEL ,ADJUSTING THE REAR BRAKE LIGHT SWITCH ,
CHECKING THE BRAKE HOSESBLEEDING THE HYDRAULIC BRAKE SYSTEM ,ADJUSTING THE SHIFT PEDAL 3-34ADJUSTING THE DRIVE CHAIN SLACK ,LUBRICATING THE DRIVE CHAIN ,CHECKING AND ADJUSTING THE STEERING HEAD ,CHECKING THE FRONT FORK ,ADJUSTING THE REAR SHOCK ABSORBER ASSEMBLY ,CHECKING THE TIRES ,CHECKING THE WHEELS ,CHECKING AND LUBRICATING THE CABLES ,LUBRICATING THE LEVERS AND PEDALS ,LUBRICATING THE SIDESTAND LUBRICATING THE CENTER STAND and LUBRICATING THE REAR SUSPENSION ELECTRICAL SYSTEMS
CHECKING AND CHARGING THE BATTERYCHECKING THE FUSES,REPLACING THE HEADLIGHT BULBS .

CHAPTER 4

OVERHAULING THE ENGINE
REMOVING THE ENGINE
DRIVE SPROCKET AND EXHAUST PIPE ,LEADS AND HOSES ,ENGINE BRACKET AND ENGINE ,INSTALLING THE ENGINE.
CAMSHAFT
CYLINDER HEAD COVERS ,CAMSHAFTS,REMOVING THE CAMSHAFTS ,CHECKING THE CAMSHAFTS ,CHECKING THE TIMING CHAIN,CAMSHAFT SPROCKETS,AND TIMING CHAIN GUIDES ,CHECKING THE TIMING CHAIN TENSIONER ,INSTALLING THE CAMSHAFTS .
CYLINDER HEAD
REMOVING THE CYLINDER HEADS ,CHECKING THE CYLINDER HEADS ,INSTALLING THE CYLINDER HEAD.
VALVES AND VALVE SPRINGS
REMOVING THE VALVES ,CHECKING THE VALVES AND VALVE GUIDES ,CHECKING THE VALVE SEATS ,CHECKING THE VALVE SPRINGS ,CHECKING THE VALVE LIFTERS ,CHECKING THE CAMSHAFT CAP ,INSTALLING THE VALVES .
CYLINDERS AND PISTONS
REMOVING THE CYLINDERS AND PISTONS ,CHECKING THE CYLINDERS AND PISTONS ,CHECKING THE PISTON RINGS ,CHECKING THE PISTON PINS ,INSTALLING THE PISTON AND CYLINDER.
CLUTCH
CLUTCH COVER ,CLUTCH ,REMOVING THE CLUTCH ,CHECKING THE FRICTION PLATES ,CHECKING THE CLUTCH PLATES ,CHECKING THE CLUTCH SPRINGS CHECKING THE CLUTCH SPRING PLATE ,CHECKING THE CLUTCH HOUSING ,CHECKING THE CLUTCH BOSS ,CHECKING THE PRESSURE PLATE ,CHECKING THE CLUTCH PUSH RODS ,INSTALLING THE CLUTCH.
SHIFT SHAFT
CHECKING THE SHIFT SHAFT ,INSTALLING THE SHIFT SHAFT .
AC MAGNETO AND STARTER CLUTCH
STATOR COIL ,STARTER CLUTCH ,AC MAGNETO ROTOR ,REMOVING THE STARTER CLUTCH ,REMOVING THE AC MAGNETO ,CHECKING THE STARTER CLUTCH ,INSTALLING THE AC MAGNETO ,INSTALLING THE STARTER CLUTCH ,
OIL PAN AND OIL STRAINER
OIL STRAINER OIL PUMP ,REMOVING THE OIL PAN ,CHECKING THE OIL PUMP ,CHECKING THE RELIEF VALVE ,CHECKING THE OIL STRAINER ,,CHECKING THE OIL NOZZLE ,ASSEMBLING THE OIL PUMP ,INSTALLING THE OIL PUMP INSTALLING THE OIL STRAINE,RINSTALLING THE OIL PAN ,
CRANKCASE
DISASSEMBLING THE CRANKCASE CHECKING THE CRANKCASE ,ASSEMBLING THE CRANKCASE
CRANKSHAFT
CONNECTING ROD ,REMOVING THE CRANKSHAFT ASSEMBLY ,REMOVING THE CONNECTING RODS ,CHECKING THE CRANKSHAFT AND CONNECTING RODS ,INSTALLING THE CONNECTING RODS,INSTALLING THE CRANKSHAFT
TRANSMISSION
CHECKING THE TRANSMISSION ,INSTALLING THE TRANSMISSION .
SHIFT DRUM AND SHIFT FORKS
CHECKING THE SHIFT FORKS CHECKING THE SHIFT DRUM ASSEMBLY ,INSTALLING THE SHIFT FORKS AND SHIFT DRUM ASSEMBLY ,

CHAPTER 5
COOLING SYSTEM
RADIATOR
CHECKING THE RADIATOR,INSTALLING THE RADIATOR
THERMOSTAT
CHECKING THE THERMOSTAT ,ASSEMBLING THE THERMOSTAT ,INSTALLING THE THERMOSTAT .
WATER PUMP
REMOVING THE WATER PUMP ,CHECKING THE WATER PUMP ,INSTALLING THE WATER PUMP ,

CHAPTER 6
CARBURETORS
CARBURETORS
AIR FILTER CASE ,CARBURETORS ,CHECKING THE CARBURETORS ,ASSEMBLING THE CARBURETORS ,INSTALLING THE CARBURETORS ,MEASURING AND ADJUSTING THE FUEL LEVEL ,CHECKING AND ADJUSTING THE THROTTLE POSITIONSENSOR,

CHAPTER 7
CHASSIS
FRONT WHEEL AND BRAKE DISCS
FRONT WHEEL ,REMOVING THE FRONT WHEEL ,CHECKING THE FRONT WHEEL ,CHECKING THE BRAKE DISCS ,INSTALLING THE FRONT WHEEL ,ADJUSTING THE FRONT WHEEL STATIC BALANCE.
REAR WHEEL,BRAKE DISC AND REAR WHEEL SPROCKET
REAR WHEEL . BRAKE DISC AND REAR WHEEL SPROCKET DISASSEMBLY THE REAR WHEEL ,REMOVING THE REAR WHEEL ,CHECKING THE REAR WHEEL ,CHECKING AND REPLACING THE REAR WHEEL SPROCKET ,
INSTALLING THE REAR WHEEL ,ADJUSTING THE REAR WHEEL STATIC .
FRONT AND REAR BREAKS
FRONT BRAKE PADS ,REAR BRAKE PADS ,REPLACING THE FRONT BRAKE PADS ,REPLACING THE REAR BRAKE PADS ,FRONT BRAKE MASTER CYLINDE,,REAR BRAKE MASTER CYLINDER ,REMOVING THE FRONT BRAKE MASTER CYLINDER ,REMOVING THE REAR BREAKE MASTER CYLINDER ,CHECKING THE FRONT AND REAR BRAKE MASTER CYLINDERS,ASSEMBLING AND INSTALLING THE FRONT BRAKEMASTER CYLINDER ,ASSEMBLING AND INSTALLING THE REAR BRAKE MASTER CYLINDER ,FRONT BRAKE CALIPERS ,REAR BRAKE CALIPER ,DISASSEMBLING THE FRONT BRAKE CALIPER ,DISASSEMBLING THE REAR BRAKE CALIPER ,CHECKING THE FRONT AND REAR BRAKE CALIPERS ,ASSEMBLING AND INSTALLING THE FRONT BRAKECALIPERS ,ASSEMBLING AND INSTALLING THE REAR BRAKECALIPER ,
FRONT FORK
REMOVING THE FRONT FORK LEGS ,DISASSEMBLING THE FRONT FORK LEGS ,CHECKING THE FRONT FORK LEGS,ASSEMBLING THE FRONT FORK LEGS ,INSTALLING THE FRONT FORK LEGS
HANDLEBAR
CHECKING THE HANDLEBAR ,INSTALLING THE HANDLEBAR

STEERING HEAD
LOWER BRACKET ,REMOVING THE LOWER BRACKET ,CHECKING THE STEERING HEAD ,INSTALLING THE STEERING HEAD
REAR SHOCK ABSORBER AND RELAY ARM
HANDLING THE REAR SHOCK ABSORBER ,DISPOSING OF A REAR SHOCK ABSORBER ,REMOVING THE REAR SHOCK ABSORBER ASSEMBLY ,CHECKING THE REAR SHOCK ABSORBER ASSEMBLY ,INSTALLING THE REAR SHOCK ABSORBER ASSEMBLY .
SWINGARM AND DRIVE CHAIN
REMOVING THE SWINGARM . CHECKING THE SWINGARM . CHECKING THE DRIVE CHAIN ,INSTALLING THE SWINGARM ,INSTALLING THE DRIVE CHAIN .

CHAPTER 8
ELECTRICAL
ELECTRICAL COMPONENTS
CIRCUIT DIAGRAM
CHECKING SWITCHES
CHECKING STEPS SWITCH CONNECTION AS SHOWN IN THIS MANUAL .SWITCH POSITION AND TERMINAL CONNECTION .
IGNITION SYSTEM
CIRCUIT DIAGRAM ,TROUBLESHOOTING .
ELECTRIC STARTING SYSTEM
CIRCUIT DIAGRAM ,STARTING CIRCUIT OPERATION ,TROUBLESHOOTING ,STARTER MOTOR CHECKING THE STARTER MOTOR
CHARGING SYSTEM
CIRCUIT DIAGRAM ,TROUBLESHOOTING
LIGHTING SYSTEM
CIRCUIT DIAGRAM,TROUBLESHOOTING ,LIGHTING SYSTEM CHECK .
SIGNAL SYSTEM
CIRCUIT DIAGRAM ,TROUBLESHOOTING,SIGNAL SYSTEM CHECK .
COOLING SYSTEM
CIRCUIT DIAGRAM ,TROUBLESHOOTING .
FUEL PUMP SYSTEM
CIRCUIT DIAGRAM ,FUEL PUMP CIRCUIT OPERATION ,TROUBLESHOOTING ,FUEL PUMP TEST
SELF-DIAGNOSIS
TROUBLESHOOTING

CHAPTER 9.
TROUBLESHOOTING
STARTING FAILURE/HARD STARTING
FUEL SYSTEM ,ELECTRICAL SYSTEM ,COMPRESSION SYSTEM.
POOR ENGINE IDLE SPEED PERFORMANCE
POOR ENGINE IDLE SPEED PERFORMANCE
POOR MEDIUM-AND HIGH-SPEED PERFORMANCE
POOR MEDIUM-AND HIGH-SPEED PERFORMANCE
FAULTY GEAR SHIFTING
HARD SHIFTING ,SHIFT PEDAL DOES NOT MOVE ,JUMPS-OUT-OF GEAR
FAULTY CLUTCH PERFORMANCE
CLUTCH SLIPPING,CLUTCH DRAGGING .
OVERHEATING
OVERHEATING
OVERCOOLING
OVERCOOLING
POOR BRAKING
POOR BRAKING EFFECT
FAULTY FRONT FORK LEGS
MALFUNCTION ,OIL LEAKAGE .
UNSTABLE HANDLING
UNSTABLE HANDLING.
FAULTY LIGHTING AND SIGNAL SYSTEMS
HEADLIGHT DOES NOT LIGHT BULB BURNT OUT .FLASHER DOES NOT LIGHT ,FLASHER BLINKS SLOWLY ,FLASHER REMAINS LIT ,FLASHER BLINKS QUICKLY ,HORN DOES NOT SOUND

FZS600‘98 WIRING DIAGRAM

Yamaha Fazer FZS600_2000_Suplementary_Service _ Manual (41 Pages)
GENERAL INFORMATION
FEATURES
SPEEDOMETER
SPECIFICATIONS
GENERAL SPECIFICATIONS
MAINTENANCE SPECIFICATIONS
ENGINE ,CHASSIS
CABLE ROUTING
PERIODIC INSPECTIONS AND ADJUSTMENTS
PERIODIC MAINTENANCE/LUBRICATION INTERVALS
CHASSIS
ADJUSTING THE FRONT FORK LEGS
CHASSIS
FRONT FORK
CHECKING THE FRONT FORK LEGS,ASSEMBLING THE FRONT FORK LEGS
ELECTRICAL
SIGNAL SYSTEM
CIRCUIT DIAGRAM ,SIGNAL SYSTEM CHECK .
CLOCK
FZS600 2000 WIRING DIAGRAM
Yamaha_Fazer_FZS600(P)_2002_Service Information Manual ( 27 pages)
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