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Yamaha Fzs600 Fazer 2000 WSM Service Manual Repair

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🏷️ Basic Information Identification Make: Yamaha Model: FZS600 Fazer Year: 2000 Chassis Code: RJ02 👋 Introduction Market Position Segment: Middleweight sport-touring motorcycle. Target Audience: Riders seeking a versatile, practical, and...
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UGS: 165177
Yamaha Fzs600 Fazer 2000 WSM Service Manual RepairYamaha Fzs600 Fazer 2000 WSM Service Manual RepairYamaha Fzs600 Fazer 2000 WSM Service Manual Repair
🏷️ Basic Information
Identification
Make:
Yamaha
Model:
FZS600 Fazer
Year:
2000
Chassis Code:
RJ02
👋 Introduction
Market Position
Segment:
Middleweight sport-touring motorcycle.
Target Audience:
Riders seeking a versatile, practical, and sporty motorcycle for commuting, touring, and spirited riding.
Competitive Analysis
Competitors:
Suzuki SV650, Kawasaki ER-5, Honda CB500/CB600F Hornet.
Key Features
Versatility:
Combines sporty performance with comfort for longer rides, often seen as a more affordable alternative to larger sport-tourers.
Engine Character:
Smooth and tractable inline-four engine offering a good balance of power and usability.
📋 Manual Details
Coverage Areas
Scope:
Comprehensive service and repair procedures for the Yamaha FZS600 Fazer 2000 model.
Page Count
Estimated Pages:
Over 300 (typical for WSMs of this era and scope)
Manual Type
Type:
Workshop Service Manual (WSM)
Language
Language:
English (presumed based on common market availability)
Format
Format:
Digital Download (PDF)
📖 Manual Coverage
Systems Covered
Powertrain:
Engine disassembly, assembly, troubleshooting, tuning, performance specifications.
Fuel System:
Carburetor tuning, cleaning, overhaul, fuel pump, fuel tank.
Ignition System:
Ignition timing, spark plugs, CDI unit, troubleshooting.
Cooling System:
Radiator, coolant, water pump, thermostat, fan operation.
Transmission:
Clutch operation, gear selection mechanism, gearbox overhaul, lubrication.
Suspension:
Front forks (spring rates, damping, oil levels), rear shock absorber, linkage maintenance.
Brakes:
Front and rear brake caliper overhaul, master cylinder, brake lines, bleeding procedures, pad replacement.
Electrical System:
Wiring diagrams, battery, charging system, starter motor, lighting, instrument cluster, fuse box.
Frame And Bodywork:
Frame inspection, fairing removal and installation, seat, fuel tank, body panel repair and replacement.
Wheels And Tires:
Wheel bearing replacement, tire mounting and balancing, spoke tension.
Exhaust System:
Exhaust pipe and muffler inspection, gasket replacement.
Procedures Included
Routine Maintenance:
Oil changes, filter replacements, chain adjustment, spark plug replacement, air filter cleaning/replacement.
Troubleshooting:
Diagnostic charts for common problems, symptom-based fault finding.
Major Repairs:
Engine rebuilds, transmission overhauls, suspension component replacement, electrical system diagnostics.
Component Overhaul:
Detailed steps for dismantling, cleaning, inspecting, and reassembling key components.
Adjustments:
Carburetor synchronization, valve clearance adjustment, throttle cable adjustment.
Technical Depth
Depth:
In-depth, professional-level repair and maintenance information suitable for experienced mechanics and serious DIY enthusiasts.
Detail Level:
Includes torque specifications, clearance measurements, disassembly/assembly sequences, and diagnostic procedures.
📊 Manual Specifications
File Format
Format:
PDF
Searchability:
Likely text-searchable if a high-quality scan or original digital file.
Printability:
Designed for printing individual sections or the entire manual.
Print Quality
Image Resolution:
High-resolution images and diagrams for clarity.
Binding Type
Binding:
N/A (Digital Download)
Paper Type
Paper Type:
N/A (Digital Download)
⚙️ Engine Specifications
Primary Engine
Engine Type:
Liquid-cooled, four-stroke, DOHC, inline-four.
Displacement:
599 cc
Bore X Stroke:
62.0 mm x 49.6 mm
Compression Ratio:
12.2:1
Performance
Horsepower Approx:
95-100 hp @ 12,000 rpm (claimed)
Torque Approx:
60-63 Nm @ 10,000 rpm (claimed)
Fuel System
Carburetion:
Four 34mm Mikuni CV carburetors.
Fuel Tank Capacity:
19 Liters
Lubrication
Oil Type:
Yamaha recommends Yamalube 4 (API SG, SF or SE) or equivalent SAE 10W-40 or 20W-50.
Oil Capacity With Filter:
Approx. 3.4 Liters
🔧 Transmission
Standard
Type:
Constant-mesh 6-speed sequential.
Features
Clutch:
Wet, multiple-disc, cable-actuated.
Final Drive:
O-ring sealed chain drive.
📐 Dimensions
Exterior
Length:
2,110 mm (83.1 in)
Width:
740 mm (29.1 in)
Height:
1,205 mm (47.4 in)
Wheelbase:
1,415 mm (55.7 in)
Weights
Dry Weight:
194 kg (427.7 lbs)
Wet Weight Approx:
216 kg (476.2 lbs)
🛡️ Safety Features
Active Features
Braking System:
Dual 298mm discs with dual-piston calipers (front), Single 245mm disc with dual-piston caliper (rear).
Suspension Type:
Telescopic front forks, Monoshock rear suspension.
Passive Features
Lighting:
Dual Halogen headlights for improved visibility.
💡 Technology Features
Infotainment
Instrumentation:
Analog tachometer, digital speedometer, fuel gauge, odometer, trip meter, clock, and indicator lights.
Driver Assistance
ABS:
ABS was an optional feature on some markets but not standard on all 2000 models.
Connectivity
Charging Port:
No integrated USB or power outlet as standard; aftermarket installation may be present.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Every 6,000 km (3,750 miles) or 6 months.
Valve Clearance Interval:
Every 24,000 km (15,000 miles).
Spark Plug Replacement Interval:
Every 12,000 km (7,500 miles).
Air Filter Cleaning Interval:
Every 6,000 km (3,750 miles).
Fluid Specifications
Coolant:
Permanent type antifreeze coolant (ethylene glycol base) with demineralized water at a 1:1 ratio.
Brake Fluid:
DOT 4 (SAE J1703 or FMVSS No. 116).
Fork Oil:
Yamaha Suspension Fluid 10W or equivalent (10W fork oil).
Fork Oil Quantity Per Leg:
474 ml (16.0 US fl oz) (with forks compressed, no spring installed).
Known Issues
Carburetor Cleaning:
Carburetors may require periodic cleaning and synchronization due to their CV design, especially if not used regularly or with stale fuel.
Stator Reliability:
Some owners report stator failures over time, impacting charging system performance.
Rear Shock ABSorber:
The stock rear shock can become less effective with age and mileage, potentially requiring replacement or servicing for optimal performance.
📚 Vehicle History
Brand Heritage
Manufacturer:
Yamaha Motor Company, a globally recognized manufacturer of motorcycles, marine products, and other motorized products.
Model Evolution
Generation:
The FZS600 Fazer was introduced in 1998 as a faired version of the FZR600R, designed to offer better comfort and wind protection for sport-touring applications.
Updates For 2000:
The 2000 model received minor updates, primarily aesthetic and possibly minor carburetion or suspension tweaks, building on the established platform.
Production
Production Years:
1998-2003 (in its initial form, later evolved into the FZ6 Fazer).
🏆 Awards & Recognition
Recognitions
Market Reputation:
Praised for its blend of performance, comfort, reliability, and value for money, making it a popular choice for its segment.
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