Model Code Designation:
Thundercat
Model Years Covered:
1997, 1998, 1999, 2000, 2001, 2002, 2003, 2004, 2005, 2006, 2007
Engine Code Range:
4WD Series (1997-2007)
Class:
Supersport / Sportbike segment
Target Audience:
Performance motorcycle enthusiasts, DIY mechanics, service technicians
Key Competitors Era:
Suzuki GSX-R600, Kawasaki Ninja ZX-6R, Honda CBR600F series
Manual Value Proposition:
Empowers owners and technicians with in-depth knowledge for efficient maintenance and repair, ensuring optimal performance and longevity of the YZF600.
Engine:
Engine overhaul, cylinder head, valve train, piston, crankshaft, lubrication system, cooling system
Fuel System:
Carburetor assembly and tuning, fuel pump, fuel filter, fuel tank
Ignition System:
CDI unit, ignition coils, spark plugs, timing
Transmission:
Clutch operation and adjustment, gearbox disassembly and reassembly, shift mechanism
Chassis:
Frame inspection and repair, suspension (front forks, rear shock absorber), steering system
Brakes:
Brake system inspection, hydraulic system maintenance, caliper overhaul, disc replacement, bleeding procedure
Electrical System:
Wiring diagrams, battery, charging system, lighting system, starter system, instrumentation, troubleshooting
Exhaust System:
Exhaust manifold, mufflers, emissions control components
Bodywork:
Fairings, seat, fuel tank, body panel removal and installation
Routine Maintenance:
Oil changes, filter replacement, chain adjustment, brake pad inspection, fluid checks
Troubleshooting:
Diagnostic procedures for common problems, fault finding charts
Repair Procedures:
Step-by-step instructions for component disassembly, repair, and reassembly
Technical Specifications:
Torque values, clearances, measurements, tolerances
Wiring Diagrams:
Detailed electrical schematics for all systems
Depth:
Comprehensive rebuilds, advanced diagnostics, component-level repair
Type:
Inline 4-cylinder, DOHC, 16-valve
Displacement:
599 cc (36.6 cu in)
Bore X Stroke:
62.0 mm x 49.6 mm
Compression Ratio:
12.0:1 (Typical)
Cooling System:
Liquid-cooled
Horsepower:
Approx. 105-109 hp @ 12,500 rpm (at crankshaft)
Torque:
Approx. 46-48 lb-ft @ 10,500 rpm (at crankshaft)
Carburetion:
Four 36mm Mikuni constant velocity carburetors (CV) (e.g., BSL36)
Fuel Type:
Unleaded premium gasoline
Fuel Capacity:
19.0 L (5.0 US gal)
Type:
6-speed constant mesh
Clutch:
Wet, multi-plate, diaphragm spring
Final Drive:
O-ring sealed chain
Gear Ratios:
Specific ratios detailed in manual for each gear
Transmission Oil Type:
Yamalube 4 (or equivalent API SG or higher, SAE 10W-40 motorcycle oil)
Transmission Oil Capacity:
Approx. 3.0 L (3.2 US qt) for transmission and engine
Length:
Approx. 2,085 mm (82.1 in)
Width:
Approx. 720 mm (28.3 in)
Height:
Approx. 1,170 mm (46.1 in)
Wheelbase:
Approx. 1,435 mm (56.5 in)
Ground Clearance:
Approx. 130 mm (5.1 in)
Seat Height:
Approx. 820 mm (32.3 in)
Dry Weight:
Approx. 187 kg (412 lbs)
Wet Weight:
Approx. 207 kg (456 lbs)
Load Capacity:
Recommended rider and passenger weight limits provided in manual
Safety Certifications:
Meets applicable safety standards for motorcycles of its era.
Braking System:
Dual 298mm disc front brakes with 4-piston calipers, Single 245mm disc rear brake with 2-piston caliper.
Suspension Tuning:
Adjustable front fork preload and damping, adjustable rear shock preload and damping for optimized handling and stability.
Lighting:
Halogen headlight, LED tail light, turn signals.
Frame Construction:
Deltabox frame design for rigidity and handling.
Instrument Cluster:
Analog tachometer, speedometer, odometer, trip meter, coolant temperature gauge, warning lights.
ABS:
Anti-lock Braking System (ABS) was an optional feature on some later models or specific markets. Manual will detail if applicable.
Diagnostic Ports:
Specific diagnostic connectors for EFI models or basic electrical system checks.
Oil Change Interval:
Every 3,000 - 5,000 km (1,800 - 3,000 miles) or 6 months, whichever comes first.
Oil Filter Replacement:
At every oil change.
Air Filter Cleaning Replacement:
Every 6,000 - 10,000 km (3,700 - 6,000 miles).
Spark Plug Replacement:
Every 12,000 - 16,000 km (7,500 - 10,000 miles).
Chain Lubrication Adjustment:
Every 1,000 km (600 miles) or after riding in the rain.
Valve Clearance Check:
Every 24,000 km (15,000 miles).
Engine Oil Grade:
SAE 10W-40 (API SG or higher)
Coolant Type:
Permanent type anti-freeze (50/50 mixture with distilled water)
Brake Fluid Type:
DOT 4 hydraulic brake fluid
Fork Oil Type:
Yamaha Fork Oil 10W or equivalent
Carburetor Sync:
Carburetors can go out of sync, leading to rough idling and poor throttle response. Regular syncing is recommended.
Cam Chain Tensioner:
Some models may experience wear in the automatic cam chain tensioner, leading to a rattling noise from the engine. Manual replacement or upgraded units are available.
Fuel Filter:
Clogged fuel filters can impede fuel flow. Periodic inspection and replacement are advised.
Charging System:
While generally reliable, the charging system (stator and regulator/rectifier) can be a point of failure on higher mileage examples. Testing procedures are in the manual.
Yamaha Legacy:
Yamaha Motor Company has a long history of producing high-performance motorcycles, known for innovation and motorsport success.
Yzf600 Genesis:
The YZF600R 'Thundercat' was introduced as a sport-touring oriented supersport, bridging the gap between pure track bikes and more upright sportbikes. It evolved from earlier Yamaha FZR models.
Production Period:
The YZF600R model was produced from approximately 1994 to 2007, with the specific range covered by this manual being 1997-2007.
Manufacturing Location:
Primarily manufactured in Japan.
