Yamaha Fazer FZS600 Service Repair Manual

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This manual covers the Fazer FZS600, a middleweight sport touring motorcycle produced from 1998 to 2003. Renowned for its blend of sporty performance and touring comfort, the FZS600 Fazer features...

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Type: Motorcycle

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Sku: 129922

Tags: Fazer FZS600 Motorcycle Motorcycles Yamaha

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Description

This manual covers the Fazer FZS600, a middleweight sport touring motorcycle produced from 1998 to 2003. Renowned for its blend of sporty performance and touring comfort, the FZS600 Fazer features a liquid-cooled, 4-stroke, DOHC, 4-valve inline-four engine with a displacement of 599 cc. Its engineering quality and reliability are hallmarks of commitment to rider experience, making it a popular choice for commuting and spirited riding. This model is characterized by its comfortable riding position, effective fairing for wind protection, and a torquey engine that provides strong performance across a range of riding conditions. This comprehensive Service and Repair Manual provides detailed information for owners and technicians working on the Fazer FZS600 for the applicable years 1998, 2000, and 2002. The manual covers all essential systems, including the engine, fuel system, transmission, electrical system, chassis, brakes, cooling system, exhaust system, and bodywork. It offers step-by-step procedures for maintenance tasks such as oil changes, filter replacements, and valve clearance adjustments, as well as in-depth guidance for repairs, troubleshooting common issues, and understanding technical specifications. With a total of 421 pages, including numerous pictures and diagrams, this English-language manual is designed to empower users to maintain and repair their vehicle effectively, ensuring optimal performance and longevity.

🏷️ Basic Information

Identification

Make:

Yamaha

Model:

Fazer FZS600

Model Code:

FZS600

Platform:

FZS600 Fazer

Codes

Vin Prefix:

JY...

Engine Code Prefix:

👋 Introduction

Market Position

Segment:

Middleweight Sport Touring Motorcycle

Target Audience:

Owners of the Yamaha FZS600 Fazer seeking to perform maintenance, repairs, or understand their motorcycle's technical aspects.

Competitive Analysis

Competitors:

Suzuki Bandit 600S, Kawasaki ZR-7S, Honda CB600F Hornet (non-faired).

Key Features

Unique Selling Proposition:

Comprehensive coverage for multiple model years, detailed diagrams, and essential technical data crucial for accurate maintenance and repair.

Manual Value

Benefit To Owner:

Empowers owners to perform routine maintenance, diagnose issues, and undertake repairs, saving costs and increasing self-sufficiency.

📋 Manual Details

Coverage Areas

Applicable Years:

1998, 2000, 2002

Page Count

Total Pages:

1998 Service Manual Pages:

2000 Supplementary Manual Pages:

2002 Service Information Pages:

Manual Type

Type:

Service and Repair Manual

Language

Language:

English

Format

File Format:

📖 Manual Coverage

Systems Covered

Engine:

Complete overhaul, diagnosis, tuning, timing, valve clearance, lubrication system, cooling system

Fuel System:

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

Transmission:

Clutch operation, gearbox disassembly and reassembly, shift mechanism

Electrical System:

Ignition system, lighting, charging system, starting system, instrumentation, wiring diagrams

Chassis:

Frame inspection, steering system, front fork disassembly and assembly, rear suspension, swingarm

Brakes:

Front and rear brake caliper overhaul, master cylinder, brake lines, bleeding procedures

Cooling System:

Radiator, fan, coolant flow, thermostat

Exhaust System:

Exhaust pipe and muffler inspection, gasket replacement

Bodywork And Trim:

Fairing removal and installation, seat, tank, panels

Procedures Included

Maintenance:

Oil changes, filter replacement, chain adjustment, spark plug replacement, air filter cleaning/replacement, brake fluid replacement, coolant flush, battery maintenance

Troubleshooting:

Diagnostic charts for common starting, running, and electrical issues

Repair:

Complete disassembly and reassembly of major components

Technical Specifications:

Torque specifications for all critical fasteners, valve clearances, engine timing, fluid capacities, electrical component specifications

Technical Depth

Depth:

Comprehensive, covering complete tear-down and rebuild

📊 Manual Specifications

File Format

Compatibility:

Windows and Mac

Print Quality

Printable:

Yes, all pages are printable

Image Quality:

Includes numerous pictures and diagrams

Binding Type

Binding:

Digital PDF (no physical binding)

Paper Type

Paper:

Not Applicable (Digital)

Download Type

Delivery:

Instant Download

⚙️ Engine Specifications

Primary Engine

Engine Type:

Liquid-cooled, 4-stroke, DOHC, 4-valve inline-four

Displacement:

599 cc

Bore X Stroke:

62.0 mm x 49.6 mm

Compression Ratio:

11.5:1

Performance

Horsepower Approx:

95 HP @ 11,000 rpm (claimed)

Torque Approx:

63 Nm @ 9,500 rpm (claimed)

Fuel System

Carburetor Type:

Four Mikuni CVKD37 carburetors

Fuel Capacity:

19 Liters (5.0 US gal)

Lubrication

Oil Type Recommendation:

Yamalube 4 (or equivalent) SAE 20W-40 API SG or higher

Cooling System

Coolant Type:

High-quality ethylene glycol-based coolant with antifreeze protection

🔧 Transmission

Standard

Type:

6-speed constant mesh

Clutch Type:

Wet, multiple-disc

Features

Final Drive:

O-ring sealed chain

Fluid Specifications

Transmission Oil Type:

Yamaha Genuine Gear Oil or equivalent SAE 80 API GL-4

📐 Dimensions

Exterior

Length:

2145 mm (84.4 in)

Width:

775 mm (30.5 in)

Height:

1210 mm (47.6 in)

Wheelbase:

1440 mm (56.7 in)

Ground Clearance:

150 mm (5.9 in)

Weights

Dry Weight Approx:

191 kg (421 lbs)

Wet Weight Approx:

213 kg (470 lbs)

🛡️ Safety Features

Ratings

Safety Features General:

Stable chassis, effective braking, aerodynamic fairing for rider comfort and wind protection.

Active Features

Front Brakes:

Dual 298 mm discs, hydraulic

Rear Brakes:

Single 245 mm disc, hydraulic

Suspension Front:

Telescopic forks, non-adjustable (some models may have preload adjustment)

Suspension Rear:

Monoshock, adjustable preload

Passive Features

Lighting:

Halogen headlight, LED taillight

💡 Technology Features

Infotainment

Dashboard Features:

Analog tachometer, speedometer, fuel gauge, coolant temperature gauge, indicator lights (neutral, turn signals, high beam, oil pressure).

Driver Assistance

Rider Aids:

None (This era of motorcycle typically did not feature electronic rider aids like ABS or traction control).

Connectivity

Connectivity Features:

None (No modern connectivity features like Bluetooth or GPS integration).

🔧 Maintenance

Service Intervals

Oil Change Interval:

Every 6,000 km (3,700 miles) or 6 months

Filter Change Interval:

At every oil change

Air Filter Check:

Every 6,000 km (3,700 miles)

Valve Clearance Check:

Every 24,000 km (15,000 miles)

Coolant Replacement:

Every 2 years or as needed

Fluid Specifications

Engine Oil Capacity W Filter:

3.4 L (3.6 US qt)

Engine Oil Capacity Wo Filter:

3.0 L (3.2 US qt)

Coolant Capacity:

2.0 L (2.1 US qt)

Brake Fluid Type:

DOT 4

Known Issues

Common Wear Items:

Cam chain tensioner (potential for rattling), voltage regulator/rectifier (can fail, leading to charging issues), clutch wear

Carburetor Cleaning:

Carburetors may require periodic cleaning and synchronization due to their complexity and susceptibility to fuel varnish.

Part Numbers Example

Oil Filter Part Number:

Yamaha 5JX-13440-00-00 (or aftermarket equivalents like HiFlofiltro HF145)

Air Filter Part Number:

Yamaha 4BH-14451-00-00 (or aftermarket equivalents)

📚 Vehicle History

Brand Heritage

Manufacturer Focus:

Yamaha is renowned for its diverse range of motorcycles, from high-performance sportbikes to reliable touring and commuter models, with a strong emphasis on engineering and rider experience.

Model Evolution

Generation Overview:

The FZS600 Fazer was introduced as a versatile middleweight motorcycle combining sportbike performance with touring comfort, featuring a sporty engine in a comfortable, faired chassis.

Production

Production Period:

The FZS600 Fazer was produced from 1998 to 2003, before being replaced by the FZ6 Fazer.

Manufacturing Origin:

Japan

🏆 Awards & Recognition

Recognitions

Industry Perception:

The FZS600 Fazer was generally well-regarded for its blend of performance, comfort, and value, making it a popular choice for commuting and sport touring.

Ratings

Motorcycle Reviews:

Praised for its torquey engine, comfortable riding position, and effective fairing for highway use. Criticisms sometimes pointed to slightly soft suspension on aggressive riding.