Category:
Mid-size sport-touring motorcycle
Target Audience:
Enthusiast owners, independent repair shops
Competitors 1998:
Suzuki Bandit 600, Honda CB600F Hornet, Kawasaki ZR-7
Vehicle Philosophy:
Versatile, reliable, performance-oriented for everyday use and touring.
Manual Value Proposition:
Empowers owners to perform essential maintenance and repairs, saving significant costs over dealership services.
Primary Coverage:
Mechanical, Electrical, Troubleshooting, Maintenance, Repair
Bodywork Coverage:
Fairing, fuel tank, seat, frame components
Estimated Page Count:
400+
Type:
Factory Service Manual / Workshop Manual
Format:
Digital Download (PDF Compatible)
Engine Mechanical:
Disassembly, inspection, reassembly, timing, valve clearance, compression testing
Fuel System:
Carburetor servicing (VM27, jetting, float levels), fuel pump, fuel lines, fuel tank
Ignition System:
CDI unit, ignition timing, spark plugs, wiring diagrams
Cooling System:
Radiator, fan, coolant, thermostat, water pump
Exhaust System:
Muffler, exhaust pipes, mounting
Transmission Gearbox:
Gearbox disassembly, inspection, lubrication, shift drum and forks
Clutch System:
Clutch operation, plates, springs, hydraulic system (if applicable, although FZS600 is cable)
Chassis Frame:
Frame inspection, steering head bearings
Suspension Front:
Front fork disassembly, oil replacement, seal replacement, spring preload
Suspension Rear:
Rear shock absorber, linkage lubrication, adjustment
Brakes Front:
Caliper service, pad replacement, disc inspection, master cylinder
Brakes Rear:
Caliper service, pad replacement, disc inspection, master cylinder
Wheels Tires:
Wheel bearings, tire pressure, tire replacement, balancing
Electrical System:
Battery, charging system (stator, regulator/rectifier), starter motor, lighting, instrumentation
Wiring Diagrams:
Comprehensive wiring schematics for all electrical components
Troubleshooting:
Diagnostic charts, common problems and solutions
Basic Maintenance:
Oil change, filter replacement, chain adjustment, lubrication points
Engine Rebuild:
Complete engine overhaul procedures
Suspension Overhaul:
Fork seal replacement, shock absorber servicing
Brake Bleeding:
Procedure for bleeding brake lines
Carburetor Synchronization:
Steps for aligning carburetor throttle slides
Electrical Diagnosis:
Fault finding for charging, ignition, and lighting circuits
Depth:
Comprehensive, from basic checks to full engine rebuilds and electrical system diagnostics.
Diagnostic Codes:
While not explicitly OBD-II, the manual provides detailed diagnostic procedures based on symptoms.
Engine Type:
4-stroke, DOHC, inline-four cylinder
Bore X Stroke:
62.0 mm x 49.6 mm
Compression Ratio:
12.2:1
Cooling System:
Liquid-cooled
Valve Train:
DOHC, 4 valves per cylinder
Power Output Hp:
Approx. 95 hp @ 11,500 rpm (at crankshaft)
Torque Lb-Ft:
Approx. 47.9 lb-ft @ 9,000 rpm (at crankshaft)
Fuel Delivery:
4 x Mikuni VM27 carburetors
Fuel Type:
Unleaded gasoline (95 RON minimum recommended)
Fuel Tank Capacity:
19 Liters (5.0 US gallons)
Fuel Pump:
Diaphragm type
Top Speed:
Approx. 220 km/h (137 mph)
0-60 Mph:
Approx. 3.6 seconds
Oil Change Interval:
Every 6,000 km (3,700 miles) or 6 months
Oil Filter Change Interval:
Every 6,000 km (3,700 miles) or 6 months (concurrent with oil change)
Valve Clearance Check:
Every 18,000 km (11,000 miles)
Spark Plug Replacement:
Every 12,000 km (7,500 miles) or as needed based on inspection
Chain Lubrication Adjustment:
Every 1,000 km (600 miles) or after washing/rain
Engine Oil Capacity:
3.4 Liters (with filter change)
Engine Oil Viscosity:
20W-40 (API SE, SF, SG)
Coolant Type:
Permanent type antifreeze coolant (50% mixture with distilled water)
Common Wear Items:
Stator failure (common on many Yamahas of this era), regulator/rectifier failure, carburetors needing synchronization and cleaning.
Suspension Wear:
Front fork seals and bushings can wear over time, leading to leaks.
Electrical Connectors:
Corrosion in electrical connectors can cause intermittent issues.
Manufacturer Focus:
Yamaha has a long-standing reputation for performance, reliability, and innovation in motorcycles.
Predecessors:
Direct descendant of the Yamaha XJ600 and FZR600, adapting a sportbike engine for broader usability.
Key Innovations:
The FZS600 was one of the earlier 'naked' sportbikes to offer a comfortable, faired riding experience with a sporty, accessible engine.
Production Years:
1998-2003 (with the manual covering the initial generation)
Manufacturing Location:
Japan
