Yamaha Fazer FZS600 2001 Service Repair Manual

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Type: Motorcycle

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Sku: 145974

Tags: 2001 Fazer FZS600 Motorcycle Motorcycles Yamaha

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Description

The Yamaha FZS600 Fazer, produced in 2001, is a versatile middleweight sport-touring motorcycle designed for riders seeking a blend of performance and practicality. Featuring a liquid-cooled, 599 cc inline-four-cylinder engine with a steel diamond frame, it offers robust handling and stability. Its engineering quality is evident in its smooth power delivery, and effective stopping power from dual front disc brakes and a rear disc brake. The FZS600 Fazer is celebrated for its balanced capabilities, making it suitable for commuting, touring, and spirited riding, positioning it as a compelling option against competitors of its era. This comprehensive Service and Repair Manual in English provides in-depth guidance for maintaining and repairing the Yamaha FZS600 Fazer. It covers all essential systems, including the engine, transmission, chassis, and electrical components, detailing everything from routine maintenance procedures like oil changes and spark plug replacement to complete engine overhauls and carburetor synchronization. With abundant illustrations and searchable content, this manual serves as an indispensable resource for owners, mechanics, and technicians, enabling them to ensure the optimal performance, reliability, and longevity of their vehicle.

🏷️ Basic Information

Identification

Make:

Yamaha

Model:

FZS600 Fazer

Model Variant:

FZS600

Year:

Codes

Chassis Code:

Engine Code:

👋 Introduction

Market Position

Motorcycle Segment:

Middleweight Sport-Touring Motorcycle

Target Audience:

Riders seeking a versatile, reliable, and economical motorcycle for commuting, touring, and spirited riding.

Competitive Analysis

Key Competitors Era:

Suzuki Bandit GSF600, Honda CB600 Hornet, Kawasaki ER-5

Key Features

Model Philosophy:

Combines the performance of a 600cc inline-four with the comfort and practicality of a sport-touring package.

Engine Type:

Liquid-cooled, DOHC, inline-four-cylinder

Chassis Design:

Steel diamond frame for robust handling and stability.

Braking System:

Dual front disc brakes and a rear disc brake for effective stopping power.

Fuel Delivery:

Four Mikuni CV carburetors for smooth power delivery.

📋 Manual Details

Coverage Areas

Manual Type:

Service and Repair Manual

Language:

English

Format:

PDF (Digital)

Page Count Estimated:

Hundreds (Specific count not provided but described as extensive)

Delivery Method:

Instant Download

📖 Manual Coverage

Systems Covered

Engine:

Complete Engine Overhaul, Carburetion, Ignition System, Lubrication System, Cooling System

Transmission:

Gearbox Operation, Clutch Assembly, Transmission Repair

Chassis:

Frame, Suspension (Front and Rear), Steering System, Wheels, Tires, Braking System (Front and Rear)

Electrical:

Wiring Diagrams, Lighting System, Ignition Switch, Starter Motor, Alternator, Battery, Fuses, Relays

Bodywork:

Fairings, Seat, Fuel Tank, Handlebars, Footrests, Body Panel Removal and Installation

Procedures Included

Maintenance:

Routine Service, Oil Changes, Filter Replacements, Chain Maintenance, Spark Plug Replacement, Valve Clearance Adjustment

Diagnostics:

Troubleshooting Common Problems, Fault Finding Procedures, Symptom Analysis

Repair:

Component Disassembly, Reassembly, Component Replacement, Major Component Repairs (e.g., transmission swap, engine rebuild)

Adjustment:

Carburetor Synchronization, Clutch Lever Free Play, Brake Lever Free Play, Suspension Settings

Technical Depth

Depth:

Comprehensive (from basic maintenance to full engine and transmission overhauls)

Illustrations:

Abundant illustrations to aid in procedures

Searchability:

Searchable PDF for quick information retrieval

Printability:

All pages are printable

📊 Manual Specifications

File Format

Format:

File Quality:

Excellent Quality (as per product description)

Text Readability:

Easy to read text

Search Capability:

Enabled

Print Quality

Print Feature:

Printable pages

Binding Type

Binding:

N/A (Digital PDF)

Paper Type

Paper Type:

N/A (Digital PDF)

⚙️ Engine Specifications

Primary Engine

Engine Type:

Inline 4-cylinder, 4-stroke, DOHC, 16-valve

Displacement:

599 cc

Bore X Stroke:

62.0 mm x 49.6 mm

Compression Ratio:

11.5:1

Performance

Horsepower Claimed:

Approx. 95 HP @ 11,500 RPM (at crankshaft)

Torque Claimed:

Approx. 63 Nm (46.5 lb-ft) @ 10,000 RPM (at crankshaft)

Fuel System

Carburetor Type:

Mikuni BSR36 (CV type) x 4

Fuel Tank Capacity:

20 Liters (5.3 US gal)

Ignition System

Ignition Type:

Digital TCI (Transistor Controlled Ignition)

Cooling System

Cooling Method:

Liquid-cooled

🔧 Transmission

Standard

Transmission Type:

Constant mesh, 6-speed sequential

Clutch Type:

Wet, multiple-disc, cable-actuated

Final Drive:

O-ring sealed chain

Features

Gear Ratios:

Specific gear ratios available in the manual

📐 Dimensions

Exterior

Overall Length:

2,065 mm (81.3 in)

Overall Width:

760 mm (29.9 in)

Overall Height:

1,160 mm (45.7 in)

Wheelbase:

1,415 mm (55.7 in)

Weights

Dry Weight Claimed:

188 kg (414.5 lbs)

Wet Weight Estimated:

Approx. 207 kg (456 lbs) with all fluids

Seat Height:

810 mm (31.9 in)

Wheels

Front Wheel Size:

MT3.50x17

Rear Wheel Size:

MT5.00x17

Tires

Front Tire Size:

120/70 ZR17 M/C (58W)

Rear Tire Size:

170/60 ZR17 M/C (72W)

🛡️ Safety Features

Ratings

Safety Ratings Motorcycle:

Not Applicable (Motorcycle safety ratings are not standardized like cars)

Active Features

Braking System Front:

Dual 298 mm discs with dual-piston calipers

Braking System Rear:

Single 245 mm disc with dual-piston caliper

Suspension Front:

Telescopic forks with adjustable pre-load

Suspension Rear:

Monoshock with adjustable pre-load and rebound damping

Passive Features

Lighting:

Halogen headlight, taillight, brake lights, turn signals

Instrumentation:

Analog speedometer, tachometer, fuel gauge, coolant temperature gauge, warning lights

💡 Technology Features

Infotainment

Infotainment System:

N/A (Focus is on mechanical and electrical systems)

Driver Assistance

Driver Assistance Features:

N/A (Motorcycle, focus on rider control)

Connectivity

Connectivity Features:

🔧 Maintenance

Service Intervals

Oil Change Interval:

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

Oil Filter Replacement Interval:

Every 12,000 km (7,500 miles) or 12 months

Air Filter Cleaning Interval:

Every 6,000 km (3,700 miles)

Spark Plug Replacement Interval:

Every 12,000 km (7,500 miles)

Valve Clearance Check:

Every 24,000 km (15,000 miles)

Fluid Specifications

Engine Oil Type:

Yamalube 4 (or equivalent) SAE 10W-40 API SE, SF, SG or SH, JASO MA

Engine Oil Capacity:

3.4 Liters (3.6 US qt) without filter, 3.6 Liters (3.8 US qt) with filter change

Coolant Type:

Ethylene glycol based antifreeze and water (50:50 mix)

Brake Fluid Type:

DOT 4

Fork Oil Type:

Yamaha Fork Oil 10W (or equivalent)

Fork Oil Capacity:

453 ml (0.478 US qt) per fork leg

Known Issues

Common Wear Items:

Chain and sprockets, brake pads, tires, fork seals, regulator/rectifier (potential failure point on some older Yamahas).

Carburetor Issues:

Carburetors can sometimes become gummed up if the bike sits for long periods without fuel stabilizer, leading to rough running or starting issues.

📚 Vehicle History

Brand Heritage

Yamaha Motorcycles:

Yamaha Motor Company is a Japanese manufacturer of motorcycles, marine products, and other motorized products. Renowned for innovation and performance since its founding in 1955.

Model Evolution

Fzs600 Lineage:

The FZS600 Fazer was introduced in 1998 as a more comfortable and practical variant of the FZ600 naked bike, featuring a half-fairing for improved aerodynamics and rider comfort. The 2001 model represents a refinement of this successful formula.

Production

Production Period:

1998-2003 (for the FZS600 generation before the FZ6)

Manufacturing Location:

Japan

🏆 Awards & Recognition

Recognitions

Motorcycle Reviews:

The FZS600 Fazer was generally well-received by the motorcycling press for its versatility, performance, and value for money.

Award Type:

Not Specific Awards (but consistently rated highly for its class)