Target Audience:
Mechanical technicians familiar with BRP products and general automobile practices, as well as knowledgeable Yamaha FZ600 owners.
Value Proposition:
Enables owners to be better informed and perform repairs like a professional technician, saving money on labor costs.
Accuracy Statement:
Endeavored to ensure accuracy of information, stating it is a complete Service Manual.
Manual Aim:
To help users get the best value from their Yamaha FZ600 and build a reputation for quality service.
Engine:
Complete engine disassembly, assembly, overhaul, and tune-ups.
Fuel System:
Repair and maintenance of the fuel system components.
Ignition System:
Diagnostic and repair procedures for the ignition system.
Lubrication System:
Maintenance and repair of the lubrication system.
Exhaust System:
Procedures for the exhaust system.
Electrical System:
Comprehensive coverage of the motorcycle's electrical system.
Bodywork:
Repair and maintenance of the body panels and components.
Transmission:
Detailed procedures for transmission disassembly, assembly, and repair.
Routine Maintenance:
Instructions for routine maintenance and servicing.
Troubleshooting:
Diagnostic procedures for identifying and resolving issues.
Repair:
Step-by-step repair procedures for various components.
Removal Installation:
Procedures for removing and installing components.
Assembly Disassembly:
Detailed instructions for assembly and disassembly of major components.
Depth Level:
Comprehensive, suitable for professional technicians and knowledgeable DIY enthusiasts.
Diagnostic Capabilities:
Advanced diagnostic information and repair strategies.
Rebuild Procedures:
Detailed procedures for engine and transmission rebuilds.
Proprietary Components:
Includes instructions for proprietary components manufactured for the FZ600.
Warnings Cautions Notes:
Emphasizes specific information using WARNING, CAUTION, and NOTE symbols.
Tool Identification:
Refers to special tools by Yamaha FZ600 special tool number and provides illustrations.
Engine Type:
Inline-four cylinder, DOHC, 4-stroke
Displacement:
598 cc (36.5 cubic inches)
Bore X Stroke:
62.0 mm x 49.6 mm (2.44 in x 1.95 in)
Compression Ratio:
10.0:1
Cooling System:
Liquid-cooled
Horsepower:
Approx. 65-70 HP (Specific figures vary by source and tuning)
Torque:
Approx. 40-45 lb-ft (Specific figures vary by source and tuning)
Carburetion:
Four Mikuni constant velocity carburetors (e.g., VM22SS or similar)
Fuel Type:
Unleaded gasoline
Dashboard:
Analog speedometer and tachometer, fuel gauge, coolant temperature gauge, indicator lights.
Engine Technology:
Yamaha's DOHC, 4-valve per cylinder technology for efficient combustion and power delivery.
Handling Features:
Advanced suspension geometry and frame design for its era, contributing to sporty handling.
Oil Change:
Typically every 3,000-5,000 km (1,800-3,000 miles) or annually, refer to manual for specifics.
Spark Plug Check:
Recommended at scheduled intervals (e.g., 6,000-10,000 km / 4,000-6,000 miles).
Engine Oil Type:
API SG, SAE 10W-40 or 20W-40 (Specific Yamaha recommendations should be followed, consult manual for exact specs).
Engine Oil Capacity:
Approx. 2.4 - 2.8 liters (2.5 - 3.0 US qt) with filter change.
Coolant Type:
Ethylene glycol-based antifreeze with water (50/50 mix typically).
Brake Fluid Type:
DOT 3 or DOT 4 brake fluid (Check manual for exact specification).
Fork Oil Type:
Yamaha Genuine Fork Oil (e.g., 10W) or equivalent (Consult manual for viscosity and quantity).
Carburetor Cleaning:
Carburetors can become gummed up over time, requiring cleaning and synchronization.
Fuel Line Degradation:
Older fuel lines can degrade and leak.
Electrical Connections:
Corrosion or loose connections in the electrical system can cause intermittent issues.
Suspension Wear:
Fork seals and rear shock absorbers may wear over time, affecting handling.
Yamaha Motorcycle Division:
Yamaha Motor Company, established in 1955, known for innovation and performance in motorcycles.
Fz600 Positioning:
The FZ600 was part of Yamaha's FZ series, known for its sporty performance and inline-four engines. It was a popular sportbike in the mid-1980s.
Manufacturing Period:
Produced from approximately 1984 to 1988, with the 1986-1988 models being the focus of this manual.
