Positioning:
The Yamaha FZS600 Fazer, often referred to as the 'Fazer 600', was positioned as a versatile middleweight sport-touring motorcycle. It offered a blend of performance, comfort, and practicality, making it a popular choice for commuting, touring, and spirited riding.
Competitors:
Key competitors in its segment during the late 1990s included the Honda CB500, Suzuki Bandit 600, and Kawasaki ZR-7. The Fazer distinguished itself with its semi-faired design, offering better wind protection than naked alternatives.
Features:
The FZS600 Fazer's key features included its reliable 599cc liquid-cooled inline-four engine, comfortable ergonomics, capable chassis, and the practical semi-fairing. This manual provides in-depth knowledge for maintaining and repairing these features.
Engine:
Complete engine overhaul, diagnosis, tuning, lubrication system, cooling system, fuel system (carburetors), ignition system, exhaust system.
Transmission:
Clutch operation and maintenance, gearbox inspection and repair, shift mechanism.
Chassis:
Frame inspection and repair, suspension (forks, rear shock absorber), steering system, swingarm maintenance.
Brakes:
Front and rear brake systems, hydraulic fluid, caliper servicing, disc inspection, bleeding procedures.
Electrical:
Wiring diagrams, battery, charging system (alternator, regulator/rectifier), starting system, lighting, ignition coils, instrument panel.
Fuel System:
Carburetor identification, cleaning, synchronization, jetting, fuel pump (if applicable), fuel lines, fuel tank.
Bodywork:
Fairing removal and installation, seat, fuel tank, fenders, instruments.
Exhaust:
Exhaust system inspection, repair, and emissions-related components.
Maintenance:
Regular servicing, oil changes, filter replacements, chain adjustment, spark plug replacement, valve clearance checks.
Repair:
Component-level repair for engine, transmission, brakes, suspension, electrical systems.
Troubleshooting:
Diagnostic charts for common problems, fault finding procedures.
Disassembly Assembly:
Step-by-step instructions for major component removal and reinstallation.
Suspension Adjustment:
Information on adjusting front fork pre-load and rear shock absorber spring preload and damping (if applicable).
Wheel And Tire Service:
Wheel bearing replacement, tire mounting and balancing, spoke tension checks (if applicable).
Charging System Diagnosis:
Testing the stator output, regulator/rectifier function, and battery health.
Carburetor Synchronization:
Detailed steps for balancing the four carburetors for optimal engine performance and fuel economy.
Depth:
Comprehensive, suitable for professional technicians and experienced DIY mechanics. Covers detailed specifications, tolerances, and diagnostic procedures.
Diagnostic Tools:
Details on using standard mechanic's tools, multimeter for electrical testing, and potentially synchronization tools for carburetors.
Torque Specifications:
Precise torque values for all critical fasteners during engine, chassis, and component assembly/disassembly.
Clearances And Tolerances:
Specific measurements for valve clearances, bearing play, and other critical component clearances.
Engine Type:
599cc, liquid-cooled, DOHC, 4-stroke, inline four-cylinder
Bore X Stroke:
64.0 mm x 46.0 mm
Compression Ratio:
12.0:1
Horsepower Hp:
Approximately 95 hp @ 11,000 rpm (manufacturer's claim, may vary)
Torque Ft Lb:
Approximately 49 ft-lb @ 9,500 rpm (manufacturer's claim, may vary)
Fuel Delivery:
Four Mikuni BST40 constant velocity (CV) carburetors
Fuel Type:
Unleaded gasoline, 91 octane or higher recommended
Ignition System:
TCBI (Transistor Controlled By Ignition) with electronic advance
Thermostatic Control:
Engine-driven water pump with thermostat for temperature regulation.
Oil Pump Type:
Wet sump, trochoid pump.
Oil Change Interval:
Every 6,000 km (3,700 miles) or 6 months, whichever comes first.
Valve Clearance Check:
Every 12,000 km (7,500 miles) or 12 months.
Spark Plug Replacement:
Every 12,000 km (7,500 miles).
Engine Oil Type:
SAE 10W-40 API SG or higher, JASO MA certified.
Engine Oil Capacity W Filter:
3.40 liters (3.59 US qt)
Coolant Type:
Ethylene glycol-based permanent anti-freeze mixed with distilled water (50:50 ratio).
Brake Fluid Type:
DOT 4 hydraulic brake fluid.
Transmission Oil Type:
Yamalube SAE 80W API GL-4 hypoid gear oil (or equivalent).
Common Wear Items:
Carburetor diaphragm wear, exhaust valve clearance tightening, regulator/rectifier failure (common on many Japanese bikes of this era), fork seal leaks.
General Maintenance:
Regular chain lubrication and adjustment, checking tire pressures, and inspecting brake pads are crucial for longevity and performance.
Yamaha Legacy:
Yamaha Motor Corporation has a rich history in motorcycle manufacturing, known for innovation, performance, and reliability across various segments, from sportbikes to cruisers and off-road models.
Fazer Lineage:
The FZS600 Fazer was introduced in 1998 as a successor to the FZR600R and aimed to capture the sport-touring market with a more accessible and versatile package. It was a precursor to later Fazer models and the highly successful FZ6.
Fzs600 Development:
The FZS600 was developed to offer a more practical and user-friendly alternative to more aggressively styled sportbikes, focusing on all-around usability for a broader range of riders.
Manufacturing Location:
Primarily manufactured in Japan.
