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Yamaha FZ600 1986-1988 Workshop Service Repair Manual

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This workshop service repair manual provides comprehensive information for the FZ600, also known as the Fazer 600, produced between 1986 and 1988 (model codes 46X, 1FN). This sportbike is celebrated...
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Type: Motorcycle
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Sku: 50999
Yamaha FZ600 1986-1988 Workshop Service Repair ManualYamaha FZ600 1986-1988 Workshop Service Repair ManualYamaha FZ600 1986-1988 Workshop Service Repair ManualYamaha FZ600 1986-1988 Workshop Service Repair Manual
This workshop service repair manual provides comprehensive information for the FZ600, also known as the Fazer 600, produced between 1986 and 1988 (model codes 46X, 1FN). This sportbike is celebrated for its balanced blend of performance and agility, making it a notable contender in the middleweight sportbike segment of its era. The FZ600 features a 598 cc inline-four engine, liquid cooling, and a 6-speed transmission, delivering approximately 72 horsepower. Its design includes telescopic front forks, a monoshock rear suspension, and dual front disc brakes with a rear disc brake, all contributing to its dynamic riding experience. This manual is meticulously designed to assist both do-it-yourself enthusiasts and professional mechanics in maintaining and repairing the FZ600. It covers a vast array of systems, including detailed procedures for engine overhaul, fuel system service, transmission and clutch operation, electrical system diagnostics and wiring diagrams, suspension adjustments, brake system maintenance, cooling, and exhaust systems. Furthermore, it offers in-depth guidance on chassis and frame inspection, bodywork, routine maintenance tasks, troubleshooting common and uncommon issues, disassembly and reassembly of all major components, and essential technical data tables with specifications and torque values.
🏷️ Basic Information
Identification
Make:
Yamaha
Model:
FZ600
Model Nickname:
Fazer 600
Body Style:
Sportbike
Codes
Model Code Range:
46X, 1FN
👋 Introduction
Market Position
Segment:
Middleweight sportbike, popular for its blend of performance and agility
Competitive Analysis
Key Competitors:
Suzuki GS550/GSX-R600, Honda CBR600F, Kawasaki Ninja 600
Key Features
Manual Value Proposition:
Complete factory service information, detailed illustrations, troubleshooting guides, and specifications to maintain and repair the Yamaha FZ600
Manual Description
Target Audience:
Do-it-yourself enthusiasts and experienced motorcycle mechanics
📋 Manual Details
Coverage Areas
Applicable Years:
1986, 1987, 1988
Page Count
Estimated Page Count:
Hundreds of pages
Manual Type
Manual Type:
Workshop Service Repair Manual
Language
Language:
English
Format
File Format:
PDF
📖 Manual Coverage
Systems Covered
Engine:
Complete engine overhaul, disassembly, reassembly, tuning
Fuel System:
Carburetor service and tuning, fuel pump, fuel lines
Transmission:
Gearbox, clutch operation, shift mechanism
Electrical System:
Ignition system, charging system, lighting, starter, wiring diagrams, troubleshooting
Suspension:
Front forks (telescopic), rear monoshock, adjustments, servicing
Brakes:
Front and rear disc brakes, caliper service, hydraulic system, bleeding
Cooling System:
Liquid-cooled engine, radiator, coolant flow, fan operation
Exhaust System:
Exhaust pipes, muffler maintenance
Chassis And Frame:
Frame inspection, steering head bearings
Bodywork And Trim:
Fairings, seat, fuel tank removal and installation
Procedures Included
Maintenance:
Regular servicing, oil changes, filter replacements, chain adjustment
Troubleshooting:
Diagnostic procedures for common and uncommon issues, fault finding
Repair:
Step-by-step repair instructions for all major components
Disassembly Reassembly:
Complete disassembly and reassembly guidance for all sections
Technical Data Tables:
Specifications, torque values, clearances, electrical data
Lubrication Points:
Identification and specification of lubrication points and types
Technical Depth
Depth Of Coverage:
Comprehensive factory-level detail suitable for both novice and professional mechanics
📊 Manual Specifications
File Format
File Format:
PDF
Print Quality
Printability:
Printable without restriction, allowing users to print specific pages or the entire manual
Binding Type
Binding Type:
Digital download (PDF)
Paper Type
Paper Type:
N/A (Digital)
Software Requirements
Reader Requirement:
Adobe PDF Reader
Delivery Method
Delivery:
Instant download link provided on checkout page
⚙️ Engine Specifications
Primary Engine
Engine Type:
4-stroke, DOHC, 4 valves per cylinder, Inline-four
Engine Displacement:
598 cc (36.5 cu in)
Bore X Stroke:
62.0 mm x 49.6 mm (2.44 in x 1.95 in)
Compression Ratio:
9.7:1
Performance
Horsepower Rating:
Approx. 72 hp @ 9,000 rpm (claimed)
Torque Rating:
Approx. 41 lb-ft @ 7,500 rpm (claimed)
Fuel System
Carburetor Type:
Mikuni BS30 (4 x 30mm constant velocity carburetors)
Fuel Tank Capacity:
16 L (4.2 US gal)
Recommended Fuel:
Unleaded gasoline, 91 octane (95 RON) or higher
Cooling System
Cooling Method:
Liquid-cooled
Ignition
Ignition System:
CDI (Capacitor Discharge Ignition)
Lubrication
Lubrication System:
Wet sump
Engine Oil Capacity:
2.7 L (2.9 US qt) without filter change; 3.0 L (3.2 US qt) with filter change
Recommended Engine Oil:
Yamalube 4 (or equivalent) SAE 20W-40 API SE, SF or SG
🔧 Transmission
Standard
Transmission Type:
Constant mesh, 6-speed
Clutch Type:
Wet, multi-plate
Features
Final Drive:
Chain drive
Transmission Oil Type:
Yamalube Gear Oil Plus (or equivalent) API GL-4 SAE 80W
Transmission Oil Capacity:
1.0 L (1.1 US qt)
📐 Dimensions
Exterior
Overall Length:
2155 mm (84.8 in)
Overall Width:
750 mm (29.5 in)
Overall Height:
1220 mm (48.0 in)
Weights
Dry Weight:
184 kg (405.7 lbs)
Wet Weight:
204 kg (450 lbs) (approx.)
Wheelbase
Wheelbase:
1430 mm (56.3 in)
Ground Clearance
Ground Clearance:
145 mm (5.7 in)
Seat Height
Seat Height:
780 mm (30.7 in)
🛡️ Safety Features
Ratings
Braking System Front:
Dual 282 mm (11.1 in) discs, hydraulic
Braking System Rear:
Single 245 mm (9.6 in) disc, hydraulic
Active Features
Suspension Front:
Telescopic forks, 140 mm (5.5 in) travel
Suspension Rear:
Monoshock, adjustable preload and rebound damping, 110 mm (4.3 in) wheel travel
Passive Features
Tires Front:
110/90-16
Tires Rear:
130/80-18
Wheels:
Cast aluminum alloy
💡 Technology Features
Infotainment
Instrumentation:
Analog tachometer, speedometer, odometer, trip meter, coolant temperature gauge, fuel level warning light
Driver Assistance
Braking Technology:
Hydraulic disc brakes front and rear (no ABS)
Connectivity
Connectivity Features:
None (analog era)
🔧 Maintenance
Service Intervals
Engine Oil Change Interval:
Every 6,000 km (3,700 miles) or 6 months
Oil Filter Replacement Interval:
Every 6,000 km (3,700 miles) or 6 months (concurrent with oil change)
Spark Plug Replacement Interval:
Every 12,000 km (7,500 miles) or 12 months
Air Filter Cleaning Interval:
Every 6,000 km (3,700 miles) or 6 months
Valve Clearance Check Interval:
Every 12,000 km (7,500 miles) or 12 months
Brake Fluid Change Interval:
Every 24,000 km (15,000 miles) or 24 months
Coolant Change Interval:
Every 24,000 km (15,000 miles) or 24 months
Fluid Specifications
Engine Oil Grade:
SAE 20W-40 (API SE, SF, or SG)
Transmission Oil Grade:
SAE 80W API GL-4
Coolant Type:
Ethylene glycol-based coolant with a 50/50 mix of antifreeze and distilled water
Brake Fluid Type:
DOT 3 or DOT 4 hydraulic brake fluid
Known Issues
Common Wear Items:
Clutch plates, brake pads, fork seals, chain and sprockets
Potential Electrical Issues:
Aging wiring harnesses, rectifier/regulator failures, ignition coil issues
Carburetor Related:
Carburetors can become gummed up if the bike sits for extended periods, requiring cleaning and synchronization
Suspension Wear:
Front fork seals can leak over time, and rear shock absorbers may lose damping effectiveness.
📚 Vehicle History
Brand Heritage
Manufacturer:
Yamaha Motor Corporation
Model Evolution
Fz600 Development:
Evolved from the Yamaha XJ600 Seca II, introducing a more modern design and improved performance for its era.
Production
Production Years:
1986-1990 (for FZ600 variant)
Manufacturing Location:
Japan
🏆 Awards & Recognition
Recognitions
Awards Received:
N/A (Specific awards for this model are not widely documented, but it was generally well-regarded in its class).
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