Segment:
Middleweight sport-touring motorcycle
Target Audience:
Riders seeking a versatile motorcycle for commuting, touring, and spirited riding, with a focus on reliability and accessible performance.
Key Competitors:
Honda CBF500/CB500S, Suzuki Bandit 600S, Kawasaki ZZR600 (early models).
Design Philosophy:
Combines the sporty performance of a naked bike with the comfort and practicality of a faired tourer.
Engine Type:
Smooth, reliable inline-four cylinder engine known for its user-friendliness.
Versatility:
Adaptable for various riding conditions from urban commuting to longer journeys.
Engine Mechanical:
Complete disassembly and reassembly of the 4-cylinder, liquid-cooled engine, including cylinder head, pistons, connecting rods, crankshaft, lubrication system, and cooling system.
Fuel System:
Carburetor overhaul (Mikuni BDST series), fuel tank, fuel pump operation, fuel lines, and fuel filter replacement.
Ignition System:
CDI ignition system, spark plugs, ignition coils, wiring diagrams, and troubleshooting for ignition faults.
Transmission And Drivetrain:
Gearbox inspection, shifting mechanism, clutch operation and adjustment, chain and sprockets maintenance, and final drive.
Suspension And Steering:
Front telescopic forks (including oil change and seal replacement), rear monoshock absorber adjustment and overhaul, swingarm, linkage maintenance, and steering head bearing service.
Brakes:
Front and rear disc brake systems, caliper inspection and service, master cylinder overhaul, brake fluid replacement, and bleeding procedures.
Electrical System:
Full wiring diagrams, battery maintenance, charging system (stator and regulator/rectifier), lighting system, starter motor, horn, and dashboard indicators.
Chassis And Bodywork:
Frame inspection, fairing removal and installation, seat, handlebars, footpegs, and other body components.
Routine Maintenance:
Oil and filter changes, air filter cleaning/replacement, chain lubrication and adjustment, brake fluid checks, tire pressure checks, coolant checks.
Troubleshooting:
Diagnostic procedures for common starting issues, poor running conditions, electrical faults, brake problems, and suspension issues.
Major Repairs:
Engine rebuilds, transmission overhauls, suspension component replacement (fork seals, shock absorber), brake caliper rebuilds, carburetor synchronization and tuning.
Electrical Diagnostics:
Tracing electrical faults using wiring diagrams, testing charging system components, diagnosing starter circuit issues.
Torque Specifications:
Detailed torque values for all critical fasteners (engine bolts, suspension fasteners, brake caliper mounting, etc.).
Depth Level:
Comprehensive workshop level, suitable for professional mechanics and experienced DIY enthusiasts. Covers diagnostics, repair, and rebuilding.
Engine Type:
4-stroke, DOHC, inline-four cylinder, 599cc
Bore X Stroke:
62.0 mm x 49.6 mm
Compression Ratio:
12.0:1
Cooling System:
Liquid-cooled
Horsepower:
Approx. 95 hp @ 11,000 rpm (claimed)
Torque:
Approx. 62 Nm (46 lb-ft) @ 9,500 rpm (claimed)
Carburetor Type:
Four Mikuni BDST36 carburetors
Fuel Capacity:
20 Liters (5.3 US gallons)
Oil Type:
Yamaha API SG, JASO MA, SAE 10W-40 or 20W-40
Oil Capacity With Filter:
3.4 Liters (3.6 US qt)
Oil Filter Part Number Example:
Yamaha 5H0-13440-00-00, or aftermarket equivalents like HF145 (HiFloFiltro)
Transmission Type:
Constant-mesh, 6-speed
Clutch Type:
Wet, multiple-disc
Gear Ratios:
1st: 2.750, 2nd: 2.063, 3rd: 1.611, 4th: 1.333, 5th: 1.115, 6th: 0.960
Final Drive:
Chain, DID 525V8 or similar, 106 links
Transmission Oil Type:
Yamalube 10W-40 API SG, JASO MA or equivalent
Transmission Oil Capacity:
0.9 Liters (0.95 US qt)
First Service:
1000 km or 1 month
Subsequent Oil Filter Change:
Every 6000 km or 6 months
Air Filter Inspection:
Every 6000 km or 6 months
Spark Plug Replacement:
Every 12,000 km or 12 months (depending on plug type)
Brake Fluid Replacement:
Every 2 years
Coolant Replacement:
Every 2 years
Coolant Type:
Yamaha Performance Coolant (Blue) or equivalent ethylene glycol-based antifreeze, mixed 50/50 with distilled water.
Common Wear Items:
Clutch plates, fork seals, steering head bearings, rear shock absorber (especially seals), chain and sprockets.
Potential Electrical:
Regulator/rectifier failure is a known issue on many bikes of this era, leading to battery charging problems.
Carburetor Issues:
Can become slightly out of sync or require cleaning/rebuild over time, especially if fuel is left standing for long periods.
Manufacturer:
Yamaha Motor Company, Ltd., a Japanese manufacturer known for its broad range of products including motorcycles, marine products, and musical instruments.
Design Inspiration:
Evolved from the FZR600 and YZF600R Thunder Cat, aiming for a more comfortable and practical all-rounder.
Updates During Production:
Minor cosmetic updates, color changes, and potential refinements to suspension or electrical components throughout its production run. ABS option introduced later.
Manufacturing Location:
Japan
Model Lifecycle End:
2003, replaced by the FZ6 Fazer (5VL chassis).
