Positioning:
The Yamaha FZS600 Fazer was positioned as a versatile middleweight sport-tourer, offering a blend of performance, comfort, and practicality for daily commuting and longer journeys.
Competitors:
Competed against models like the Suzuki GSF600 Bandit, Kawasaki ZZ-R600, and Honda CB600F Hornet.
Engine:
Liquid-cooled, DOHC, inline four-cylinder engine derived from the Yamaha YZF600R Thundercat.
Handling:
Sportbike-derived chassis and suspension for agile handling, coupled with a comfortable riding position.
Versatility:
Effective as both a commuter and a touring machine, with optional luggage and comfort accessories available.
Primary Coverage:
Complete mechanical and electrical repair, maintenance, troubleshooting, and servicing of the Yamaha FZS600 Fazer.
Secondary Coverage:
Specifications, diagrams, special tools, wiring schematics, torque values, and diagnostic procedures.
Estimated Pages:
Approximately 300-400 pages (typical for comprehensive workshop manuals of this era and model).
Type:
Workshop Service Repair Manual
Engine System:
Engine disassembly, inspection, assembly, lubrication, cooling system, carburetor tuning/rebuilding, valve clearance adjustment, ignition system, engine mounting.
Transmission System:
Clutch operation and adjustment, gearbox disassembly, inspection, and assembly, shift mechanism.
Chassis System:
Frame, front fork (suspension, seals, oil), rear shock absorber, swingarm, wheel bearings, steering system.
Braking System:
Front and rear brake caliper service, brake pad replacement, brake fluid bleeding, master cylinder overhaul, brake hose replacement.
Electrical System:
Wiring diagrams, battery maintenance, charging system (stator, rectifier/regulator), lighting system, ignition system troubleshooting, starter motor, horn, instrumentation.
Fuel System:
Fuel tank, fuel pump operation, fuel filter replacement, carburetor synchronization, fuel line routing.
Exhaust System:
Exhaust pipe and muffler inspection and replacement.
Bodywork And Fittings:
Fairing removal and installation, seat, fuel tank, handlebars, controls, lighting assemblies.
Routine Maintenance:
Oil and filter changes, air filter service, spark plug replacement, chain adjustment and lubrication, brake fluid level checks, coolant checks.
Troubleshooting:
Diagnostic charts and procedures for common issues, electrical system faults, engine performance problems.
Repair Procedures:
Step-by-step guides for component removal, repair, and reinstallation (e.g., fork rebuild, carburetor overhaul, clutch replacement).
Diagnostic Techniques:
Methods for identifying and resolving mechanical and electrical faults.
Special Tool Identification:
Listing and description of Yamaha-specific tools required for certain tasks.
Depth:
Comprehensive, suitable for both home mechanics and professional technicians. Covers everything from basic fluid changes to full engine and transmission rebuilds.
Configuration:
Liquid-cooled, four-stroke, DOHC, inline-four cylinder
Bore X Stroke:
62.0 mm x 49.6 mm
Compression Ratio:
12.0:1
Horsepower Ps:
Approx. 95 PS (70 kW) @ 12,000 rpm (claimed)
Torque Nm:
Approx. 61 Nm (45 lb-ft) @ 10,000 rpm (claimed)
Carburetion:
Four Mikuni CV carburetors, 31 mm (BST31)
Fuel Tank Capacity:
20 Liters (5.3 US gal)
Ignition Type:
Digital TCI (Transistor Controlled Ignition)
Oil Type:
Yamalube 4 (or equivalent motorcycle-specific SAE 10W-40 API SG or higher, JASO MA)
Coolant Type:
Ethylene glycol-based antifreeze coolant, 50% mixture with distilled water
Length:
Approx. 2,105 mm (82.9 in)
Width:
Approx. 745 mm (29.3 in)
Height:
Approx. 1,225 mm (48.2 in)
Wheelbase:
Approx. 1,430 mm (56.3 in)
Dry Weight:
Approx. 188 kg (414.5 lbs)
Wet Weight:
Approx. 212 kg (467.4 lbs) (fully fueled and ready to ride)
Frame Type:
Steel diamond
Braking System:
Dual 298mm front discs with dual-piston calipers; 245mm rear disc with dual-piston caliper. Optional ABS system available on some models/markets.
Suspension Front:
Telescopic fork, 43mm stanchions, adjustable preload (on some models), 130mm travel
Suspension Rear:
Monoshock, adjustable preload and rebound damping, 130mm travel
Lighting:
Dual Halogen headlights, LED taillight
Infotainment System:
N/A (basic motorcycle instrumentation of the era)
ABS:
Optional Anti-lock Braking System (ABS) available on certain variants and markets.
Connectivity Features:
N/A
Dashboard Layout:
Analog speedometer and tachometer, with digital odometer, trip meter, fuel gauge, and warning lights.
Oil Change:
Every 6,000 km (3,700 miles) or 6 months, whichever comes first.
Air Filter Check:
Every 6,000 km (3,700 miles).
Spark Plug Replacement:
Every 12,000 km (7,500 miles) or 12 months.
Valve Clearance Check:
Every 24,000 km (15,000 miles).
Brake Fluid Flush:
Every 2 years or as needed based on condition.
Coolant Flush:
Every 2 years or 24,000 km (15,000 miles).
Engine Oil Capacity:
3.4 Liters (3.6 US qt) without filter change; 3.7 Liters (3.9 US qt) with filter change.
Fork Oil Type:
Yamaha Fork Oil 10W or equivalent (10W ISO VG 32)
Fork Oil Quantity:
456 ml (15.4 US oz) per fork leg.
Coolant Capacity:
2.0 Liters (2.1 US qt)
Common Wear Items:
Cam chain tensioner (can become noisy and require replacement), rear shock absorber (potential for leaks or damping loss over time), regulator/rectifier (prone to overheating and failure, especially on earlier models).
Carburetor Issues:
Carburetors can become slightly out of sync over time, leading to rough idling or uneven throttle response, requiring synchronization and potential cleaning.
Manufacturer:
Yamaha Motor Company is a renowned Japanese manufacturer known for its extensive range of motorcycles, musical instruments, and marine products.
Generation Start:
The FZS600 Fazer was introduced in 1998 and was produced until 2004, before being succeeded by the FZ6 Fazer.
Key Updates 2001:
The 2001 model received minor updates including color scheme changes and potentially minor refinements. The fundamental mechanicals remained largely consistent with the original model.
Manufacturing Location:
Japan (primary manufacturing)
