Vehicle Segment:
Middleweight naked sportbike/sport touring motorcycle.
Target Audience:
Riders seeking a versatile, reliable, and relatively affordable motorcycle for commuting, sport riding, and light touring.
Key Competitors:
Suzuki Bandit 600, Kawasaki ZR-7, Honda CB600F Hornet (depending on market).
Engine Type:
Liquid-cooled, DOHC, inline-four-cylinder.
Frame Type:
Steel diamond frame.
Styling:
Naked bike styling with an optional half-fairing for improved aerodynamics.
Completeness:
Offers complete coverage for maintenance, repair, and parts identification.
Bonus Content:
Includes an update and parts catalogue, enhancing its utility.
Engine:
Complete engine disassembly, assembly, tuning, and troubleshooting.
Fuel System:
Carburetor service, fuel pump, fuel lines, fuel tank maintenance.
Ignition System:
CDI unit, ignition coils, spark plugs, timing checks.
Transmission:
Clutch operation, gearbox inspection, maintenance, and repair.
Suspension:
Front fork (telescopic) and rear shock absorber (monoshock) service, adjustments, and rebuilds.
Brakes:
Front and rear brake system service (hydraulic disc brakes), including caliper, master cylinder, and fluid replacement.
Electrical System:
Wiring diagrams, charging system (alternator, regulator/rectifier), lighting, battery, starting system, and accessories.
Cooling System:
Radiator, coolant, water pump, fan operation.
Exhaust System:
Exhaust pipe and muffler inspection and maintenance.
Frame And Bodywork:
Chassis inspection, fairing removal/installation, seat, fuel tank, and body panel maintenance.
Wheels And Tires:
Wheel bearing service, tire inspection and replacement, spoke tensioning (if applicable).
Steering:
Steering head bearing service and adjustment.
Maintenance:
Scheduled maintenance, oil changes, filter replacements, chain adjustment, brake checks, and fluid top-offs.
Troubleshooting:
Diagnostic procedures for common issues, fault finding, and solutions.
Repair:
Step-by-step instructions for component repair and replacement.
Disassembly Reassembly:
Detailed procedures for complete disassembly and reassembly of all major components and systems.
Adjustments:
Carburetor synchronization, valve clearance adjustment, chain slack, and brake lever adjustments.
Wiring Diagrams:
Comprehensive wiring schematics for all electrical systems.
Depth Of Coverage:
Factory-level detail, suitable for both amateur mechanics and professional technicians.
Diagnostic Capabilities:
Includes troubleshooting guides and diagnostic trees for identifying and resolving performance issues.
Rebuild Procedures:
Covers complete engine rebuilds and major component overhauls.
Engine Type:
4-stroke, liquid-cooled, DOHC, 4-valve per cylinder, inline-four.
Bore X Stroke:
64.0 mm x 46.0 mm
Compression Ratio:
12.2:1
Horsepower:
Approx. 95 HP (70 kW) @ 12,000 rpm (claimed)
Torque:
Approx. 61 Nm (45 lb-ft) @ 9,500 rpm (claimed)
Fuel Delivery:
Four Mikuni CVKD36 carburetors.
Fuel Type:
Unleaded gasoline, minimum 91 octane.
Ignition System:
Digital CDI with electronic advance.
Oil Type Capacity:
Yamalube 4 (or equivalent SAE 20W-40) oil, 3.4 L (3.6 US qt) without filter change, 3.6 L (3.8 US qt) with filter change.
Cooling System:
Forced wet-sump lubrication with oil cooler.
Transmission Type:
Constant mesh 6-speed sequential.
Clutch Type:
Wet, multiple disc.
Final Drive:
O-ring sealed chain.
Gear Ratios:
Specific ratios detailed in the manual (e.g., 1st: 2.750, 2nd: 2.063, 3rd: 1.647, 4th: 1.381, 5th: 1.227, 6th: 1.045).
Transmission Oil:
Yamalube Gear Oil (or equivalent SAE 80W hypoid gear oil).
Safety Certifications:
Not typically rated by formal crash test agencies like NHTSA/IIHS for motorcycles, but designed to meet relevant regulatory standards.
Braking System:
Dual 298mm hydraulic disc brakes (front), Single 245mm hydraulic disc brake (rear).
Lighting:
Halogen headlight, LED taillight.
Frame Construction:
Rigid steel diamond frame for stable handling.
Ergonomics:
Upright riding position for rider comfort and control.
Display Type:
Analog speedometer and tachometer, with a simple LCD for odometer, trip meter, and clock.
ABS:
ABS was not a standard or widely available option for the FZS600 Fazer within these model years; it was primarily a non-ABS model.
Connectivity Features:
No modern connectivity features like Bluetooth or smartphone integration are present on this model.
Headlight Type:
Halogen bulb.
Fuel Injection:
Carbureted, not fuel-injected.
Oil Filter Change:
Every 6,000 km (3,700 miles) or 6 months.
Air Filter Cleaning:
Every 6,000 km (3,700 miles).
Spark Plug Replacement:
Every 12,000 km (7,500 miles).
Valve Clearance Check:
Every 12,000 km (7,500 miles).
Brake Fluid Replacement:
Every 2 years or 24,000 km (15,000 miles).
Coolant Replacement:
Every 2 years or 24,000 km (15,000 miles).
Chain Lubrication Adjustment:
Every 1,000 km (600 miles) or after washing/rain.
Engine Oil:
SAE 20W-40 Yamalube 4 or equivalent API SE, SF, SG, SH or SJ classification.
Coolant:
High-quality ethylene glycol-based coolant with distilled water, typically a 50/50 mix.
Transmission Oil:
SAE 80W hypoid gear oil (for final drive if applicable, though this is chain drive, so primary transmission oil is engine oil).
Charging System Wear:
Some early models could experience regulator/rectifier failures or stator issues, leading to charging problems. Regular testing is advised.
Carburetor Synchronization:
Carburetors may require periodic synchronization to maintain smooth running and optimal performance, especially at higher mileage.
Front Fork Seals:
Like many motorcycles of this era, fork seals can eventually develop leaks and require replacement.
Clutch Wear:
Clutch plates can wear over time, especially with aggressive riding, leading to slipping. The manual covers clutch inspection and replacement.
Exhaust Corrosion:
The stock exhaust system can be prone to corrosion over time, particularly in damp climates.
Manufacturer:
Yamaha Motor Company, Ltd. is a Japanese manufacturer of motorcycles, marine products, and other motorized products.
Introduction Year:
The FZS600 Fazer was introduced in 1998 as a more civilized and practical version of the FZ600, featuring a half-fairing and more relaxed ergonomics.
Development Basis:
Built around the reliable 599cc engine derived from Yamaha's sports bike lineage (similar to the YZF600R Thundercat engine but detuned for broader torque).
Production Period:
1998-2003 (FZS600), with the 1998-2001 models specifically covered by this manual. Later models (e.g., FZ6) saw significant updates.
Manufacturing Location:
Primarily manufactured in Japan.
