Yamaha FAZER 600 FZS600 Workshop Repair Manual All 1998-2003 ModelS COVERED

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Taper: Motorcycle

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UGS: 126523

Mots clés: 1998 1999 2000 2001 2002 2003 Fazer FAZER 600 FZS600 Motorcycle Motorcycles Yamaha

Variantes de produits

Description

The Yamaha Fazer 600 (FZS600) is a versatile mid-weight sport-touring motorcycle produced from 1998 to 2003. Renowned for its smooth 599 cc inline-four engine, practical fairing offering wind protection, and comfortable ergonomics, the Fazer 600 strikes an excellent balance between commuting ease and enjoyable touring capabilities. It represents Yamaha's commitment to delivering reliable and engaging motorcycles that cater to a broad spectrum of riders, offering a blend of performance and everyday usability that set it apart from more track-focused sportbikes of its era. This comprehensive workshop service repair manual provides essential information for the maintenance, repair, and understanding of all FZS600 Fazer 600 models from 1998 through 2003. It covers a wide array of systems, including detailed procedures for engine overhaul, transmission, chassis components, brakes, and the electrical system. Owners and technicians will find step-by-step instructions for scheduled maintenance, troubleshooting common issues, component disassembly and reassembly, and necessary adjustments, ensuring the longevity and optimal performance of their Yamaha Fazer 600.

🏷️ Basic Information

Identification

Make:

Yamaha

Model:

Fazer 600

Model Code:

FZS600

Generation

Model Years Covered:

1998, 1999, 2000, 2001, 2002, 2003

👋 Introduction

Market Position

Segment:

Mid-weight sport-touring motorcycle

Competitive Analysis

Competitors:

Suzuki Bandit GSF600, Honda CB600F Hornet (though FZS600 is more faired)

Key Features

Features:

Versatile, comfortable for commuting and touring, smooth inline-four engine, practical fairing for wind protection

Manual Value Proposition

Value:

Empowers owners to perform a wide range of maintenance and repairs, saving on dealership costs and ensuring longevity.

Manual Utility

Usefulness:

Indispensable for DIY mechanics, aspiring technicians, and owners who want a deep understanding of their FZS600.

📋 Manual Details

Coverage Areas

Covered Models:

All FZS600 Fazer 600 models from 1998-2003

Page Count

Estimated Pages:

Extensive (typical workshop manuals are 300-600+ pages)

Manual Type

Type:

Workshop Service Repair Manual

Language

Language:

English

Format

Format:

📖 Manual Coverage

Systems Covered

Engine:

Engine overhaul, top-end, bottom-end, lubrication, cooling, fuel delivery, ignition

Transmission:

Clutch, gearbox, internal components, lubrication, adjustments

Chassis:

Frame, suspension (front forks, rear shock), steering, wheels, tires

Brakes:

Front and rear brake systems, hydraulic lines, calipers, master cylinders, bleeding procedures

Electrical:

Wiring diagrams, lighting, ignition system, charging system, starter motor, battery, fuses, relays, instrument cluster

Fuel System:

Carburetor service and adjustment, fuel pump, fuel lines, fuel tank

Exhaust System:

Exhaust components, gasket replacement

Bodywork:

Fairing removal and installation, seat, body panel fasteners

Procedures Included

Maintenance:

Scheduled maintenance, oil changes, filter replacements, chain adjustment, brake pad replacement, fluid checks and changes

Troubleshooting:

Diagnostic procedures for common issues, fault finding guides

Repair:

Step-by-step instructions for component repair and replacement

Disassembly Reassembly:

Detailed guidance for dismantling and rebuilding major components and systems

Adjustments:

Carburetor synchronization, valve clearance adjustment, clutch lever adjustment

Technical Depth

Depth:

Comprehensive, covering basic maintenance to complete engine and transmission rebuilds

📊 Manual Specifications

File Format

Compatibility:

PC & Mac Compatible (Windows 95, 98, 2000, NT, XP, Vista, 7, 8, etc.)

Print Quality

Quality:

High quality, suitable for printing

Binding Type

Binding:

Not Applicable (Digital Download)

Paper Type

Paper:

Not Applicable (Digital Download)

⚙️ Engine Specifications

Primary Engine

Type:

4-stroke, liquid-cooled, DOHC, inline-four cylinder

Displacement:

599 cc

Bore X Stroke:

62.0 mm x 49.6 mm

Compression Ratio:

12.0:1

Performance

Horsepower Approx:

95 hp @ 12,000 rpm (approximate, varies slightly by year)

Torque Approx:

63.7 Nm @ 9,500 rpm (approximate, varies slightly by year)

Fuel System

Carburetion:

Mikuni CVKD36 x 4

Fuel Capacity:

20 Liters

Ignition

Ignition System:

TCBI (Transistor Controlled Ignition)

Lubrication

Oil Type:

API SE, SF, SG, SH, SJ, or higher, SAE 10W-40 recommended

Cooling

Cooling Method:

Liquid-cooled

🔧 Transmission

Standard

Type:

Constant mesh 6-speed

Clutch Type:

Wet, multiple disc

Features

Final Drive:

O-ring sealed chain

Gear Ratios:

(Specific ratios available in manual)

📐 Dimensions

Exterior

Length:

2085 mm

Width:

770 mm

Height:

1220 mm

Wheelbase:

1435 mm

Weights

Dry Weight:

184 kg

Wet Weight:

208 kg (approximate, fully fueled)

Seat Height:

810 mm

🛡️ Safety Features

Ratings

Crash Test Data:

N/A (Motorcycle)

Active Features

Brakes:

Front: Dual 298 mm discs; Rear: Single 245 mm disc (ABS optional on some later models outside this range, but likely not on early FZS600)

Passive Features

Lighting:

Halogen headlight, LED tail light

💡 Technology Features

Infotainment

Display:

Analog tachometer, digital speedometer, fuel gauge, odometer, trip meters

Driver Assistance

Optional on certain markets/years, but generally not standard on the early FZS600 models.

Connectivity

Connectivity Features:

N/A (Basic analog/digital instrumentation)

🔧 Maintenance

Service Intervals

Oil Change:

Every 6,000 km or 6 months

Oil Filter Change:

Every 6,000 km or 6 months (with oil change)

Air Filter Check:

Every 6,000 km

Spark Plug Replacement:

Every 10,000-12,000 km

Valve Clearance Check:

Every 12,000 km

Fluid Specifications

Coolant:

Yamaha Yamalube Coolant or equivalent ethylene glycol-based anti-freeze with demineralized water (50/50 mix)

Brake Fluid:

DOT 4

Fork Oil:

SAE 10W (Approx. 480ml per fork leg)

Chain Lube:

High-quality motorcycle chain lubricant

Known Issues

Common Wear Items:

Cam chain tensioner (can become noisy), stator output (can fail), rear shock absorber damping

Carburetor Issues:

Carburetors can require syncing and cleaning over time due to wear and deposits.

Filter Part Numbers

Oil Filter:

Yamaha 5DM-13440-00-00 (or equivalent aftermarket like KN-145)

📚 Vehicle History

Brand Heritage

Brand Identity:

Yamaha Motor Company, known for innovation and performance in motorcycles and other motorized products.

Model Evolution

Predecessor:

Indirectly evolved from Yamaha's inline-four sportbike lineage (e.g., FZR600).

Positioning:

Introduced as a more practical and comfortable alternative to pure sportbikes, bridging the gap to sport-touring.

Production

Manufacturing Origin:

Japan

🏆 Awards & Recognition

Recognitions

Industry Acclaim:

Praised for its balance of performance, comfort, and value, making it a popular choice for riders of all levels.