Segment:
Mid-size sport-touring motorcycle
Target Audience:
Riders seeking a versatile, reliable, and performance-oriented motorcycle for commuting, touring, and spirited riding.
Key Competitors:
Honda CB600F Hornet, Suzuki Bandit GSF600, Kawasaki ER-5.
Unique Selling Points:
Smooth power delivery, comfortable ergonomics for extended rides, Yamaha's renowned reliability, accessible performance for a wide range of riders.
Primary Coverage:
Service, Repair, Maintenance, Rebuilding, Refurbishment, Restoration
Specific Systems Detailed:
Engine, Fuel System, Exhaust System, Ignition System, Transmission, Clutch, Drivetrain, Suspension (Front & Rear), Brakes (Front & Rear), Wheels & Tires, Electrical System, Lighting System, Frame, Bodywork, Troubleshooting, Specifications, Torque Values, Wiring Diagrams.
Estimated Pages:
Hundreds
Type:
Service Repair Manual
Engine:
Complete engine overhaul, tuning, carburetor synchronization, valve clearance adjustment, ignition system diagnostics, cooling system maintenance.
Transmission:
Clutch inspection and replacement, gearbox disassembly and reassembly, shift mechanism troubleshooting, maintenance of transmission lubrication.
Brakes:
Hydraulic system bleeding, brake pad and disc inspection/replacement, caliper maintenance, master cylinder servicing.
Electrical:
Wiring diagrams, battery testing and maintenance, starter motor and charging system diagnosis, lighting system troubleshooting, ignition coil and spark plug checks.
Suspension And Steering:
Front fork disassembly and service (including oil changes), rear shock absorber inspection, steering head bearing adjustment and replacement, swingarm maintenance.
Fuel System:
Carburetor overhaul and jetting, fuel pump operation, fuel filter replacement, fuel tank maintenance.
Cooling System:
Radiator inspection, coolant replacement, thermostat operation, fan system checks.
Chassis And Bodywork:
Frame inspection, fairing removal and installation, seat maintenance, luggage system compatibility.
Routine Maintenance:
Oil and filter changes, air filter cleaning/replacement, spark plug replacement, chain adjustment and lubrication, brake fluid checks, tire pressure checks.
Troubleshooting:
Diagnostic charts, common problems and solutions, symptom-based troubleshooting guides.
Rebuild Procedures:
Detailed step-by-step instructions for major component overhauls (engine, transmission, suspension).
Component Replacement:
Instructions for replacing wear items and damaged parts (e.g., clutch plates, brake pads, bearings).
Advanced Diagnostics:
Includes procedures for diagnosing electrical faults, ignition system issues, fuel delivery problems, and mechanical wear.
Depth:
Comprehensive: Covers basic maintenance to full engine rebuilds and advanced troubleshooting, suitable for both amateur mechanics and professional technicians.
Scope:
This is a comprehensive workshop manual, not an owner's manual or parts catalog, offering in-depth repair and maintenance guidance.
PDF Quality:
High-resolution scans, clear text, well-organized layout.
Searchable:
Yes, fully text-searchable PDF for quick information retrieval.
Printable:
Yes, designed for easy printing of individual pages or sections.
Binding:
N/A (Digital PDF format)
Paper Type:
N/A (Digital PDF format)
Engine Type:
Inline 4-cylinder, 4-stroke, DOHC, 16-valve
Displacement:
599 cc (599 cm³)
Bore X Stroke:
62.0 mm x 49.6 mm
Compression Ratio:
12.2:1
Horsepower Max:
Approx. 95-98 hp @ 12,000 rpm (depending on specific market tune)
Torque Max:
Approx. 62-65 Nm @ 10,000 rpm (depending on specific market tune)
Carburetor Type:
Four Mikuni CV (Constant Velocity) carburetors
Fuel Capacity:
20 Liters (5.3 US gal)
Cooling Method:
Liquid-cooled
Length:
Approx. 2,105 mm (82.9 in)
Width:
Approx. 770 mm (30.3 in)
Height:
Approx. 1,210 mm (47.6 in)
Dry Weight:
Approx. 187 kg (412 lbs)
Wet Weight:
Approx. 208 kg (459 lbs) (fully fueled)
Wheelbase:
Approx. 1,440 mm (56.7 in)
Crash Test Data:
N/A for motorcycles (Focus is on rider protection through equipment and bike design)
Braking System:
Dual 298mm discs with 2-piston calipers (front), Single 245mm disc with 2-piston caliper (rear). Optional ABS available on some models/markets.
Lighting:
Halogen headlamp, LED taillight.
Frame Construction:
Steel diamond frame.
Rider Ergonomics:
Upright riding position, comfortable seat and handlebar placement for extended use.
Display Panel:
Analog tachometer and speedometer, LCD odometer and trip meter, indicator lights.
ABS:
Optional Anti-lock Braking System (ABS) available on select models and markets.
Bike Features:
Standard USB charging port often added as an aftermarket accessory, but not standard from factory.
Oil Change Interval:
Every 6,000 km (3,700 miles) or 6 months, whichever comes first.
Valve Clearance Check:
Every 12,000 km (7,500 miles)
Air Filter Check:
Every 6,000 km (3,700 miles), clean or replace as needed.
Spark Plug Replacement:
Every 12,000 km (7,500 miles)
Engine Oil Type:
API SG, SF or earlier; JASO MA certified (e.g., Yamalube 10W-40 or equivalent).
Engine Oil Capacity:
3.4 L (3.6 US qt) with filter change; 3.1 L (3.3 US qt) without filter change.
Coolant Type:
Permanent type antifreeze coolant (50/50 mixture with distilled water recommended).
Fork Oil Type:
Yamaha Fork Oil 10W or equivalent
Fork Oil Quantity:
472 ml (15.9 US fl oz) per leg
Common Wear Items:
Clutch wear, fork seal leaks, swingarm bearing wear, carburetors can become slightly out of sync over time.
Electrical Quirks:
Occasional stator or rectifier failure, particularly on higher mileage units. Wiring harness integrity should be checked.
Engine Performance Issues:
Carburetor jetting can be sensitive to modifications or altitude changes. Ignition timing should be verified if performance is poor.
Yamaha Legacy:
Yamaha Motor Company, a subsidiary of Yamaha Corporation, has a long-standing reputation for producing high-quality, innovative motorcycles across various genres, known for performance and reliability.
Fzs600 Development:
The FZS600 Fazer was introduced as a more comfortable, sport-touring oriented version of the naked FZ600/FZS600 Hornet, featuring a half-fairing for improved wind protection and long-distance comfort.
Production Years:
1998-2003 (This manual covers this specific generation)
Manufacturing Location:
Primarily Japan
