Segment:
Middleweight sport-touring motorcycle, known for its blend of performance, comfort, and versatility.
Reputation:
Highly regarded for its reliability, smooth engine, and user-friendly nature, making it popular for commuting, touring, and spirited riding.
Competitors:
Honda CB500/CBF500, Suzuki Bandit GSF600, Kawasaki ZR-7.
Engine Type:
Inline-four cylinder, DOHC, 16-valve.
Chassis Design:
Steel diamond frame, fully faired bodywork providing wind protection.
Suspension Setup:
Conventional telescopic front forks, adjustable rear monoshock.
Coverage:
All models, all repairs A-Z for 1998-2000 FZS600 FAZER
Specificity:
Vehicle/Model Specific, not generic information
Estimated Pages:
400-600 (typical for comprehensive service manuals of this era)
Type:
Service Repair Workshop Manual
Intended User:
Dealership Technicians, Professional Mechanics, Advanced DIY Enthusiasts
Format:
Digital (likely PDF or similar electronic format for distribution)
Engine Mechanical:
Engine disassembly, assembly, inspection, troubleshooting, valve clearance, timing, piston/cylinder, crankshaft, lubrication system, cooling system.
Fuel System:
Carburetor (CV type) removal, disassembly, cleaning, adjustment, synchronization, fuel pump, fuel filter, fuel tank inspection.
Ignition System:
CDI system, ignition coil testing, spark plug specifications, timing adjustment.
Electrical System:
Wiring diagrams, starter motor, alternator, battery, lighting system (headlight, taillight, signals), horn, fuses, relays, battery charging system.
Transmission Drivetrain:
Clutch operation, gear selection mechanism, transmission disassembly/assembly, lubrication, final drive (chain and sprockets).
Suspension Steering:
Front fork (telescopic) overhaul, oil levels, spring rates, rear shock absorber adjustment and overhaul, steering head bearing service, wheel bearings.
Braking System:
Front and rear brake calipers, master cylinders, brake lines, brake fluid replacement, bleeding procedures, disc and pad inspection/replacement.
Chassis Bodywork:
Frame inspection, body panel removal/installation, seat, fairing, handlebars, footpegs, exhaust system.
Diagnostics Troubleshooting:
Common problems, symptom-based troubleshooting guides, diagnostic charts, error codes (if applicable).
Routine Maintenance:
Oil changes, filter replacements, chain adjustment, lubrication points, spark plug checks, tire pressure.
Major Repairs:
Engine rebuilds, carburetor overhaul, fork seal replacement, brake system overhauls, electrical component repair.
Adjustments:
Carburetor synchronization, valve clearance adjustment, clutch lever adjustment, throttle cable adjustment, chain slack adjustment.
Inspection:
Pre-ride checks, component wear inspection, fluid level checks, fastener torque checks.
Depth:
Comprehensive, covering everything from basic maintenance to complete engine and chassis overhauls. Includes detailed diagrams and specifications.
Diagnostic Capability:
Advanced troubleshooting guides enabling diagnosis of complex issues beyond simple component replacement.
Engine Type:
4-stroke, liquid-cooled, DOHC, inline-four cylinder
Bore X Stroke:
60.0 mm x 53.4 mm
Compression Ratio:
12.2:1
Valve Train:
DOHC, 4 valves per cylinder
Horsepower Claimed:
Approx. 95-97 hp @ 11,000 rpm (varies slightly by market and specific model year)
Torque Claimed:
Approx. 6.5 kgf-m (63.7 Nm; 47.0 lb-ft) @ 9,000 rpm
Carburetion:
4 x Mikuni CV (Constant Velocity) carburetors, BDSR32
Fuel Tank Capacity:
20 Liters (approx. 5.3 US gallons)
Oil Type Specification:
Yamalube 4 (or equivalent SAE 10W-40, API SG or higher, JASO MA)
Coolant Type:
High-quality ethylene glycol-based antifreeze coolant (50/50 mix with distilled water)
Safety Features Design:
Designed with a balance of stability and maneuverability. Full fairing offers rider protection from elements.
Braking System Specs:
Dual 298mm discs with 2-piston calipers (front), Single 245mm disc with 2-piston caliper (rear).
Lighting:
Halogen headlight, LED taillight, amber turn signals.
Frame Construction:
Steel diamond frame for structural integrity.
Tires:
Tubeless radial tires. Front: 120/70ZR17, Rear: 160/60ZR17 (typical sizes, confirm with manual).
Oil Change Interval:
Every 6,000 km (3,700 miles) or 6 months.
Oil Filter Change Interval:
Every 12,000 km (7,500 miles) or 12 months (concurrent with oil change).
Valve Clearance Check:
Every 24,000 km (15,000 miles) or 24 months.
Spark Plug Replacement:
Every 12,000 km (7,500 miles) or 12 months.
Brake Fluid Change:
Every 24 months, regardless of mileage.
Engine Oil Capacity W Filter:
3.4 Liters (3.6 US qt)
Engine Oil Capacity Wo Filter:
3.1 Liters (3.3 US qt)
Coolant Capacity:
2.2 Liters (2.3 US qt)
Fork Oil Type And Level:
Yamaha Fork Oil 10W or equivalent, Level: 140 mm (Refer to manual for precise measurement).
Common Wear Items:
Clutch plates, brake pads, fork seals, rear shock absorber (age-related degradation).
Carburetor Issues:
Pilot jet blockages due to infrequent use or poor fuel quality, leading to poor idling and low-speed running.
Electrical Quirks:
Corrosion in connectors, particularly for rectifier/regulator and starter solenoid, can cause charging issues or starting problems.
Storage Recommendations:
Fuel stabilizer, battery tender, and proper cover for long-term storage.
Yamaha Legacy:
Yamaha Motor Company is renowned for its innovation in motorcycle engineering, consistently producing high-quality and performance-oriented vehicles.
Fzs600 Introduction:
The FZS600 Fazer was introduced in 1998 as a sport-touring derivative of the FZS600 (original naked Fazer), offering enhanced comfort and wind protection through its fairing.
Predecessor:
Evolved from Yamaha's XJ600 Diversion platform, adapting the inline-four engine into a more performance-oriented package.
Manufacturing Location:
Primarily manufactured in Japan.
Production Run:
The FZS600 FAZER was produced from 1998 until around 2004, with updates and revisions during its lifespan. This manual covers the initial production years.
