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2002 Yamaha Fazer FZS600 P Supplementary Service Repair Workshop Manual

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This manual covers the FZS600 P Fazer, a middleweight sport touring motorcycle produced around 2002. Engineered for a balance of performance, rider comfort, and practicality, the FZS600 Fazer is designed...
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Tipo: Motorcycle
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SKU: 133182
2002 Yamaha Fazer FZS600 P Supplementary Service Repair Workshop Manual
This manual covers the FZS600 P Fazer, a middleweight sport touring motorcycle produced around 2002. Engineered for a balance of performance, rider comfort, and practicality, the FZS600 Fazer is designed for enthusiasts who seek versatility for both commuting and light touring. Its inline-four engine, known for its smooth power delivery, and comfortable ergonomics make it a capable machine in its class, often compared to models like the Suzuki Bandit 600S and Honda CBF600S. The FZS600 P Fazer represents a commitment to creating reliable and enjoyable motorcycles. This comprehensive Supplementary Service Repair Workshop Manual provides detailed information for the maintenance and repair of your FZS600 P Fazer. It includes in-depth coverage of all major systems, such as the engine, cooling, fuel, chassis, electrical, and braking systems, along with step-by-step instructions for disassembly, assembly, and repair. The manual also contains essential troubleshooting guides, diagnostic procedures, and technical specifications, including torque settings and fluid recommendations. This resource is an invaluable tool for owners, mechanics, and technicians to ensure the optimal performance and longevity of the motorcycle.
🏷️ Basic Information
Identification
Make:
Yamaha
Model:
FZS600 P Fazer
Year:
2002
Codes
Model Code:
FZS600 P
👋 Introduction
Market Position
Category:
Middleweight Sport Touring Motorcycle
Target Audience:
Enthusiasts seeking performance, comfort, and versatility for commuting and touring.
Competitive Analysis
Key Competitors:
Suzuki Bandit 600S, Honda CBF600S, Kawasaki ZZR600.
Key Features
Design Philosophy:
Balanced performance, rider comfort, and practicality for everyday use and light touring.
📋 Manual Details
Coverage Areas
Language:
English
Format:
PDF
Page Count
Page Count Estimate:
Varies based on specific supplemental content, typically hundreds of pages for a complete service manual.
Manual Type
Manual Type:
Supplementary Service Repair Workshop Manual
📖 Manual Coverage
Systems Covered
Engine:
Complete engine overhaul, diagnosis, and repair procedures.
Cooling System:
Radiator, coolant, water pump, thermostat maintenance and repair.
Fuel System:
Carburetor specifications, adjustment, cleaning, and repair.
Chassis:
Frame, suspension (front and rear forks, shock absorber), steering, and wheels.
Electrical System:
Wiring diagrams, ignition system, lighting, charging system, starter, battery, and electronic components.
Brakes:
Brake system components, hydraulic lines, calipers, master cylinders, and brake fluid.
Exhaust System:
Exhaust pipes, mufflers, and related components.
Lubrication System:
Oil pump, oil passages, and oil filter.
Procedures Included
Maintenance:
Periodic inspections, adjustments, lubrication, and fluid changes.
Repair:
Step-by-step repair instructions for all major components and systems.
Troubleshooting:
Diagnostic procedures and solutions for common and uncommon issues.
Disassembly Assembly:
Complete disassembly and reassembly instructions for the entire motorcycle.
Specifications Setting:
Torque specifications, clearances, and adjustment procedures.
Technical Depth
Depth:
Comprehensive, covering detailed engine rebuilds, carburetor tuning, electrical diagnostics, and chassis overhauls.
📊 Manual Specifications
File Format
File Type:
PDF
Compatibility:
All Versions of Windows & Mac
Print Quality
Printability:
All pages are printable.
Binding Type
Binding Type:
Digital (Downloadable PDF)
Paper Type
Paper Type:
N/A (Digital)
Requirements
Software Requirements:
Adobe PDF Reader & WinZip
⚙️ Engine Specifications
Primary Engine
Engine Type:
Liquid-cooled, 4-stroke, DOHC, inline 4-cylinder
Displacement:
599 cc (36.5 cu. in.)
Bore X Stroke:
62.0 mm x 49.6 mm (2.44 in x 1.95 in)
Compression Ratio:
12.5:1
Performance
Horsepower:
Approx. 95 hp @ 11,000 rpm (subject to regional tuning)
Torque:
Approx. 62 Nm (45.7 lb-ft) @ 9,500 rpm (subject to regional tuning)
Fuel System
Fuel Delivery:
4x Mikuni CVKD32 carburetors
Fuel Tank Capacity:
20 Liters (5.3 US gal)
Lubrication System
Oil Type:
Yamalube 4 (or equivalent SAE 10W-40 API SG or higher)
Oil Capacity:
3.4 Liters (3.6 US qt) without filter change; 3.7 Liters (3.9 US qt) with filter change.
🔧 Transmission
Standard
Transmission Type:
Constant mesh 6-speed
Clutch Type:
Wet, multiple-disc
Features
Final Drive:
O-ring sealed chain
📐 Dimensions
Exterior
Overall Length:
2,075 mm (81.7 in)
Overall Width:
745 mm (29.3 in)
Overall Height:
1,215 mm (47.8 in)
Wheelbase:
1,440 mm (56.7 in)
Weights
Dry Weight:
Approx. 189 kg (417 lbs)
Wet Weight:
Approx. 212 kg (467 lbs) (fully fueled and ready to ride)
🛡️ Safety Features
Active Features
Front Brakes:
Dual 298 mm discs, hydraulic dual-action calipers
Rear Brakes:
Single 245 mm disc, hydraulic single-action caliper
Passive Features
Lighting:
Halogen headlight, LED taillight
💡 Technology Features
Infotainment
Instrument Cluster:
Analog tachometer and speedometer, LCD multi-function display (odometer, trip meter, clock).
Driver Assistance
ABS:
Not typically available on this model year unless specified as an option for certain markets.
Connectivity
Connectivity Features:
None (basic motorcycle electronics).
🔧 Maintenance
Service Intervals
Oil Change Interval:
Every 6,000 km (3,700 miles) or 6 months, whichever comes first.
Valve Clearance Interval:
Every 12,000 km (7,500 miles) or 12 months.
Spark Plug Replacement:
Every 12,000 km (7,500 miles).
Fluid Specifications
Brake Fluid:
DOT 4
Coolant:
Permanent type antifreeze coolant (ethylene glycol based, 50% mixture with distilled water)
Known Issues
Common Wear Items:
Clutch plates, brake pads, chain and sprockets, fork seals, carburetor diaphragm wear.
Potential Problems:
Carburetor synchronization drift, occasional stator failures, regulator/rectifier issues (common to many motorcycles of this era).
📚 Vehicle History
Brand Heritage
Manufacturer:
Yamaha Motor Company
Model Evolution
Generation Overview:
The FZS600 Fazer was introduced as a comfortable and versatile middleweight sport tourer, building on Yamaha's expertise in inline-four engines. The 'P' designation typically refers to specific market or minor specification updates for the year.
Production
Production Period:
1998 - 2003 (for the FZS600 Fazer model line, with updates in between)
🏆 Awards & Recognition
Recognitions
Awards:
The FZS600 Fazer was generally well-received for its balance of performance, comfort, and value, often praised in motorcycle publications of its time, though specific 'awards' may not be readily documented for this particular model year.
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