Yamaha FZS600 FAZER Shop Manual 1998-2000

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Art.-Nr: 150287

Stichworte: 1998 1999 2000 Fazer FZS600 FAZER Motorcycle Motorcycles Yamaha

Produktvarianten

Beschreibung

This manual covers the FZS600 Fazer models produced between 1998 and 2000. The FZS600 Fazer is a versatile mid-size sport-touring motorcycle, known for its performance-oriented, liquid-cooled, 599 cc inline-four engine, delivering approximately 95 horsepower. Its design emphasizes a balance of sportbike capability with rider comfort, making it suitable for both everyday use and touring. The reputation for engineering quality and reliability underpins this model, which evolved from earlier XJ600 and FZR600 platforms to offer a compelling package in its market segment, competing with models like the Suzuki Bandit 600 and Honda CB600F Hornet. This comprehensive factory service manual provides detailed information for the maintenance, repair, and troubleshooting of your FZS600 Fazer. It covers all essential mechanical and electrical systems, including engine disassembly and reassembly, fuel system servicing, ignition system diagnostics, cooling system maintenance, transmission and clutch procedures, chassis and suspension overhauls, and brake system servicing. With over 400 pages of English-language content, this manual is an indispensable resource for owners and technicians, offering step-by-step instructions, technical specifications, and diagnostic guidance to ensure the longevity and optimal performance of the motorcycle.

🏷️ Basic Information

Identification

Make:

Yamaha

Model:

FZS600 Fazer

Product Name:

Yamaha FZS600 Fazer Shop Manual 1998-2000

Covered Years:

1998, 1999, 2000

Codes

Engine Code Prefix:

👋 Introduction

Market Position

Category:

Mid-size sport-touring motorcycle

Target Audience:

Enthusiast owners, independent repair shops

Competitive Analysis

Competitors 1998:

Suzuki Bandit 600, Honda CB600F Hornet, Kawasaki ZR-7

Key Features

Vehicle Philosophy:

Versatile, reliable, performance-oriented for everyday use and touring.

Manual Value Proposition:

Empowers owners to perform essential maintenance and repairs, saving significant costs over dealership services.

📋 Manual Details

Coverage Areas

Primary Coverage:

Mechanical, Electrical, Troubleshooting, Maintenance, Repair

Bodywork Coverage:

Fairing, fuel tank, seat, frame components

Page Count

Estimated Page Count:

Manual Type

Type:

Factory Service Manual / Workshop Manual

Language

Language:

English

Format

Format:

Digital Download (PDF Compatible)

📖 Manual Coverage

Systems Covered

Engine Mechanical:

Disassembly, inspection, reassembly, timing, valve clearance, compression testing

Fuel System:

Carburetor servicing (VM27, jetting, float levels), fuel pump, fuel lines, fuel tank

Ignition System:

CDI unit, ignition timing, spark plugs, wiring diagrams

Cooling System:

Radiator, fan, coolant, thermostat, water pump

Exhaust System:

Muffler, exhaust pipes, mounting

Transmission Gearbox:

Gearbox disassembly, inspection, lubrication, shift drum and forks

Clutch System:

Clutch operation, plates, springs, hydraulic system (if applicable, although FZS600 is cable)

Chassis Frame:

Frame inspection, steering head bearings

Suspension Front:

Front fork disassembly, oil replacement, seal replacement, spring preload

Suspension Rear:

Rear shock absorber, linkage lubrication, adjustment

Brakes Front:

Caliper service, pad replacement, disc inspection, master cylinder

Brakes Rear:

Caliper service, pad replacement, disc inspection, master cylinder

Wheels Tires:

Wheel bearings, tire pressure, tire replacement, balancing

Electrical System:

Battery, charging system (stator, regulator/rectifier), starter motor, lighting, instrumentation

Wiring Diagrams:

Comprehensive wiring schematics for all electrical components

Troubleshooting:

Diagnostic charts, common problems and solutions

Procedures Included

Basic Maintenance:

Oil change, filter replacement, chain adjustment, lubrication points

Engine Rebuild:

Complete engine overhaul procedures

Suspension Overhaul:

Fork seal replacement, shock absorber servicing

Brake Bleeding:

Procedure for bleeding brake lines

Carburetor Synchronization:

Steps for aligning carburetor throttle slides

Electrical Diagnosis:

Fault finding for charging, ignition, and lighting circuits

Technical Depth

Depth:

Comprehensive, from basic checks to full engine rebuilds and electrical system diagnostics.

Diagnostic Codes:

While not explicitly OBD-II, the manual provides detailed diagnostic procedures based on symptoms.

📊 Manual Specifications

File Format

File Type:

Searchable Text:

Yes (typical for professionally scanned manuals)

Print Quality

Quality:

High Resolution (suitable for printing)

Binding Type

Binding:

N/A (Digital Download)

Paper Type

Paper Type:

N/A (Digital Download)

⚙️ Engine Specifications

Primary Engine

Engine Type:

4-stroke, DOHC, inline-four cylinder

Displacement:

599 cc

Bore X Stroke:

62.0 mm x 49.6 mm

Compression Ratio:

12.2:1

Cooling System:

Liquid-cooled

Valve Train:

DOHC, 4 valves per cylinder

Power Output Hp:

Approx. 95 hp @ 11,500 rpm (at crankshaft)

Torque Lb-Ft:

Approx. 47.9 lb-ft @ 9,000 rpm (at crankshaft)

Fuel System

Fuel Delivery:

4 x Mikuni VM27 carburetors

Fuel Type:

Unleaded gasoline (95 RON minimum recommended)

Fuel Tank Capacity:

19 Liters (5.0 US gallons)

Fuel Pump:

Diaphragm type

Performance

Top Speed:

Approx. 220 km/h (137 mph)

0-60 Mph:

Approx. 3.6 seconds

🔧 Transmission

Standard

Transmission Type:

6-speed constant mesh

Features

Clutch Type:

Wet, multiple-disc, cable operated

Final Drive:

O-ring sealed chain

Fluid Specifications

Transmission Oil Type:

Yamalube 4 (or equivalent SAE 20W-40 API SE, SF, SG type)

Fluid Capacities

Transmission Oil Capacity:

2.9 Liters (when disassembled)

📐 Dimensions

Exterior

Length:

2090 mm (82.3 in)

Width:

745 mm (29.3 in)

Height:

1200 mm (47.2 in)

Wheelbase:

1420 mm (55.9 in)

Weights

Dry Weight:

177 kg (389.3 lbs)

Wet Weight:

Approx. 202 kg (445.3 lbs) (fully fueled)

Front Tire Size:

120/60 ZR17 M/C (55W)

Rear Tire Size:

160/60 ZR17 M/C (69W)

Wheel Bolt Pattern:

N/A (Magnesium alloy wheels, bolted hub)

🛡️ Safety Features

Ratings

Safety Certification:

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

Active Features

Braking System:

Dual front disc brakes (298mm), single rear disc brake (245mm). Optional ABS not widely available or common.

Lighting:

Halogen headlight, LED taillight, front and rear turn signals.

Passive Features

Frame Construction:

Steel diamond frame for rigidity and rider feedback.

💡 Technology Features

Infotainment

Infotainment System:

N/A (No integrated infotainment system on this model)

Driver Assistance

Driver Assistance Features:

N/A (No electronic rider aids such as traction control or ABS as standard)

Connectivity

Connectivity Features:

Instrumentation

Dashboard Features:

Analog speedometer, tachometer, fuel gauge, coolant temperature gauge, indicator lights.

🔧 Maintenance

Service Intervals

Oil Change Interval:

Every 6,000 km (3,700 miles) or 6 months

Oil Filter Change Interval:

Every 6,000 km (3,700 miles) or 6 months (concurrent with oil change)

Valve Clearance Check:

Every 18,000 km (11,000 miles)

Spark Plug Replacement:

Every 12,000 km (7,500 miles) or as needed based on inspection

Chain Lubrication Adjustment:

Every 1,000 km (600 miles) or after washing/rain

Fluid Specifications

Engine Oil Capacity:

3.4 Liters (with filter change)

Engine Oil Viscosity:

20W-40 (API SE, SF, SG)

Coolant Type:

Permanent type antifreeze coolant (50% mixture with distilled water)

Brake Fluid Type:

DOT 4

Known Issues

Common Wear Items:

Stator failure (common on many Yamahas of this era), regulator/rectifier failure, carburetors needing synchronization and cleaning.

Suspension Wear:

Front fork seals and bushings can wear over time, leading to leaks.

Electrical Connectors:

Corrosion in electrical connectors can cause intermittent issues.

📚 Vehicle History

Brand Heritage

Manufacturer Focus:

Yamaha has a long-standing reputation for performance, reliability, and innovation in motorcycles.

Model Evolution

Predecessors:

Direct descendant of the Yamaha XJ600 and FZR600, adapting a sportbike engine for broader usability.

Key Innovations:

The FZS600 was one of the earlier 'naked' sportbikes to offer a comfortable, faired riding experience with a sporty, accessible engine.

Production

Production Years:

1998-2003 (with the manual covering the initial generation)

Manufacturing Location:

Japan

🏆 Awards & Recognition

Recognitions

Awards Received:

While specific awards are not readily cataloged, the FZS600 Fazer was widely praised in motorcycle press for its excellent balance of performance, comfort, and value.