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Yamaha FZS600 2002 SUPPLEMENTARY Service Repair Manual

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$16.99
This manual covers the FZS600 Fazer, a versatile middleweight naked sportbike produced for the 2002 model year. Known for its reliable inline 4-cylinder, 599cc engine, the FZS600 Fazer offers a...
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Type: Motorcycle
Vendor:
Yamaha
Sku: 132488
Tags: 2002 FZS600 Marine Motorcycle Sterndrive Yamaha
Yamaha FZS600 2002 SUPPLEMENTARY Service Repair Manual
This manual covers the FZS600 Fazer, a versatile middleweight naked sportbike produced for the 2002 model year. Known for its reliable inline 4-cylinder, 599cc engine, the FZS600 Fazer offers a balanced blend of performance, comfort, and everyday usability, making it a popular choice for commuting and sport touring. Its engineering quality and market reputation highlight its robust design and all-around capability, providing an engaging riding experience for a variety of purposes. This supplementary service repair manual provides comprehensive guidance for the FZS600 Fazer. It details general information, specifications, periodic checks and adjustments, chassis, engine, cooling system, fuel system, and electrical system components. The manual includes procedures for maintenance, troubleshooting, adjustments, component servicing, system diagnostics, and wiring checks, offering detailed repair and diagnostic information suitable for both DIY enthusiasts and professional technicians.
🏷️ Basic Information
Identification
Make:
Yamaha
Model:
FZS600
Year:
2002
Type:
Motorcycle
Sub Model:
FZS600 Fazer
👋 Introduction
Market Position
Market Segment:
Middleweight Naked Sportbike
Competitive Analysis
Competitors:
Suzuki Bandit 600, Honda CB600F Hornet, Kawasaki ZZR600 (depending on market specifics)
Key Features
Model Purpose:
Versatile sport-standard motorcycle offering a balance of performance, comfort, and everyday usability.
Manual Value Proposition:
Empowers owners to perform essential maintenance and repairs, saving money and enhancing understanding of their Yamaha FZS600.
Ease Of Use:
Designed for easy following with step-by-step instructions, catering to all skill levels.
📋 Manual Details
Coverage
Models Covered:
Yamaha FZS600 (2002 Model Year)
Supplementary Nature:
Supplementary Service Repair Manual
Format
File Format:
PDF
Downloadable:
Yes
Compatibility:
All Versions of Windows & Mac
Requirements:
Adobe PDF Reader
Language
Language:
English
Printability
Printable:
Yes (All Pages)
📖 Manual Coverage
Systems
Systems Covered:
General Information, Specifications, Periodic Checks & Adjustments, Chassis, Engine, Cooling System, Fuel System, Electrical System, Troubleshooting, Wiring Diagram
Procedures
Procedures Included:
Maintenance, Troubleshooting, Adjustments, Component Servicing, System Diagnostics, Wiring Checks
Depth
Technical Depth:
Detailed repair and diagnostic information, suitable for DIY enthusiasts and professional technicians.
📊 Manual Specifications
File Attributes
File Format Type:
Digital (PDF)
Searchable:
Likely searchable text within PDF (standard for most professional PDFs)
Production Quality
Print Quality:
High-resolution, suitable for clear printing.
Binding Type
Binding Type:
N/A (Digital Download)
Paper Type
Paper Type:
N/A (Digital Download)
⚙️ Engine Specifications
Primary Engine
Engine Type:
Inline 4-cylinder, 4-stroke, DOHC, 4 valves per cylinder
Displacement:
599 cc
Bore X Stroke:
64.0 mm x 44.1 mm
Cooling System:
Liquid-cooled
Performance
Horsepower:
Approx. 95 hp @ 11,000 rpm (varies by region/spec)
Torque:
Approx. 62 Nm (46 ft-lb) @ 9,500 rpm (varies by region/spec)
Fuel System
Carburetion:
Four Mikuni CV carbs (likely BDSR36)
Fuel Type:
Unleaded gasoline
Ignition
Ignition System:
Digital CDI
Lubrication
Oil Type:
API SG, SF Type SAE 20W-40 or 10W-30 (Consult Manual for precise spec)
Oil Capacity
Oil Capacity With Filter:
Approx. 3.4 L / 3.6 US qt (Consult Manual for precise spec)
Valve Clearance
Valve Clearance Intake:
0.11-0.20 mm (0.0043-0.0079 in) (Cold) (Consult Manual for precise spec)
Valve Clearance Exhaust:
0.21-0.30 mm (0.0083-0.0118 in) (Cold) (Consult Manual for precise spec)
🔧 Transmission
Gearbox
Transmission Type:
6-speed, constant mesh
Clutch Type:
Wet, multiple-disc
Final Drive:
O-ring sealed chain
Transmission Oil:
Yamalube Gear Oil or equivalent SAE 80W API GL-4 (Consult Manual for precise spec)
📐 Dimensions
Exterior
Length:
Approx. 2,085 mm (82.1 in)
Width:
Approx. 750 mm (29.5 in)
Height:
Approx. 1,190 mm (46.9 in)
Seat Height:
Approx. 810 mm (31.9 in)
Weights
Dry Weight:
Approx. 183 kg (403 lbs)
Wet Weight:
Approx. 204 kg (450 lbs) (Fully fueled)
Fuel Capacity:
20 L (5.3 US gal)
Chassis
Frame Type:
Diamond, High-tensile steel
Front Suspension:
Telescopic fork, 43mm stanchion diameter, adjustable preload (typically)
Front Suspension Travel:
Approx. 130 mm (5.1 in)
Rear Suspension:
Monoshock, linkage-type spring preload and rebound damping adjustable
Rear Suspension Travel:
Approx. 130 mm (5.1 in)
Front Brake:
Dual 298mm hydraulic discs with 4-piston calipers
Rear Brake:
Single 245mm hydraulic disc with 2-piston caliper
Front Tire:
120/60ZR17 M/C (55W)
Rear Tire:
160/70ZR17 M/C (73W)
Wheelbase:
Approx. 1,420 mm (55.9 in)
Ground Clearance:
Approx. 150 mm (5.9 in)
🛡️ Safety Features
Features
Active Features:
Powerful dual disc front brakes, responsive rear disc brake, good chassis dynamics.
Passive Features:
Sturdy frame, reliable engine, integrated lighting.
💡 Technology Features
Instrumentation
Dashboard:
Analog tachometer, speedometer, fuel gauge, coolant temperature gauge, odometer, trip meter, warning lights.
Lighting
Headlight Type:
Halogen bulb (typically H4)
🔧 Maintenance
Service Intervals
Oil Change Interval:
Every 6,000 km (3,700 miles) or 6 months (Consult Manual for precise spec and conditions)
Air Filter Cleaning Interval:
Every 6,000 km (3,700 miles) or 6 months (Consult Manual for precise spec)
Spark Plug Replacement Interval:
Every 12,000 km (7,500 miles) (Consult Manual for precise spec and plug type)
Valve Clearance Check Interval:
Every 12,000 km (7,500 miles) or 12 months (Consult Manual for precise spec)
Fluid Specifications
Coolant Type:
Ethylene glycol based coolant, 50% mixture with distilled water (Consult Manual for precise spec)
Brake Fluid Type:
DOT 4 hydraulic fluid (Consult Manual for precise spec)
Known Issues
Common Wear Items:
Chain and sprockets, brake pads, fork seals, wheel bearings, clutch plates due to high mileage use.
Electrical Notes:
Corrosion on connectors or grounds can be a concern in older bikes; the wiring diagram is crucial for diagnosis.
Carburetor Issues:
Carburetors may require periodic cleaning and synchronization, especially if the bike has been sitting or running poorly.
📚 Vehicle History
Brand Heritage
Manufacturer:
Yamaha Motor Company, a renowned Japanese manufacturer of motorcycles, marine products, and musical instruments.
Model Evolution
Fzs Series Origin:
The FZS600 Fazer was introduced in the late 1990s as a versatile, sport-touring oriented version of the popular FZR600 sports bike, later evolving into a more naked 'Fazer' designation.
Production
Production Period:
The FZS600 Fazer was produced from 1998 to 2003, before being succeeded by the fuel-injected FZS600 (later FZ6) model.
🏆 Awards & Recognition
Recognitions
Market Reputation:
Praised for its reliable engine, comfortable riding position, and all-around usability, making it a popular choice for commuting and sport touring.
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