Segment:
Middleweight sport-touring motorcycle.
Target Audience:
Riders seeking a versatile, reliable, and sporty motorcycle for commuting, touring, and general riding.
Competitors:
Honda CB500/CBF500, Kawasaki ER-5, Suzuki Bandit 600.
Engine Type:
Inline-four cylinder, liquid-cooled.
Design Philosophy:
Balancing performance, comfort, and practicality for everyday use and longer journeys.
Fairing:
Integral fairing providing wind protection and a sporty aesthetic.
Covered Model Years:
1998, 1999, 2000, 2001, 2002, 2003
Estimated Pages:
Approx. 300-400 (typical for this era/type of manual)
Type:
Workshop Service Repair Manual
Format:
Digital (likely PDF)
Engine:
Complete overhaul, tuning, diagnostics, fuel system, ignition system, lubrication, cooling system, emission controls.
Transmission:
Clutch operation, gearbox disassembly and reassembly, maintenance, troubleshooting.
Chassis:
Frame inspection and repair, suspension (front forks, rear shock absorber), steering system, wheel bearings.
Brakes:
Front and rear brake system inspection, maintenance, caliper overhaul, master cylinder, brake lines, bleeding procedures.
Electrical:
Wiring diagrams, component testing, charging system, starting system, lighting, instrumentation, ignition coils, CDI unit, sensors.
Fuel System:
Carburetor inspection, cleaning, adjustment, fuel pump, fuel filter, fuel tank.
Cooling System:
Radiator, coolant hoses, water pump, thermostat, fan operation.
Exhaust System:
Exhaust pipe inspection, muffler replacement.
Bodywork And Fittings:
Fairing removal and installation, seat, handlebars, fuel tank, side panels, tail section.
Routine Maintenance:
Oil and filter changes, chain adjustment and lubrication, air filter cleaning/replacement, spark plug replacement, coolant checks.
Troubleshooting:
Diagnostic flowcharts for common problems, electrical fault finding, engine performance issues.
Repair Procedures:
Step-by-step instructions for component disassembly, repair, and reassembly.
Special Tools:
Identification and usage of specialized tools required for specific tasks.
Torque Specifications:
Precise torque values for all critical fasteners.
Depth:
Comprehensive, covering routine maintenance to full engine rebuilds and electrical system diagnostics.
Engine Type:
DOHC, 4-stroke, liquid-cooled inline four-cylinder
Bore X Stroke:
62.0 mm x 49.6 mm
Compression Ratio:
12.2:1
Horsepower:
Approx. 95-100 PS (70-74 kW) @ 12,000 rpm (varies slightly by market and exact tune)
Torque:
Approx. 60-63 Nm (44-46 lb-ft) @ 10,000 rpm
Fuel Delivery:
Carburetor (likely 4 x Mikuni CV type, e.g., BST36)
Fuel Type:
Unleaded gasoline
Fuel Tank Capacity:
19 Liters (5.0 US gal)
Crash Test Data:
Motorcycle safety is typically assessed through rider skill and adherence to road rules, not formal crash test ratings like cars.
Braking System:
Hydraulic disc brakes front and rear. Optional ABS was available on some later models or specific trims.
Suspension:
Telescopic front forks, Monocross rear suspension contributing to stability.
Lighting:
Halogen headlight for good visibility.
Ergonomics:
Upright riding position for rider comfort and control.
Oil Change:
Every 5,000-6,000 km (3,000-4,000 miles) or 6 months.
Oil Filter Change:
Every oil change.
Chain Maintenance:
Clean and lubricate every 1,000 km (600 miles) and adjust as needed.
Air Filter Check:
Inspect every 5,000 km (3,000 miles), clean or replace as needed.
Spark Plug Replacement:
Typically every 10,000-12,000 km (6,000-7,500 miles).
Engine Oil Type:
SAE 10W-40 or 20W-40 API SG or higher (JASO MA specification recommended for wet clutch compatibility)
Engine Oil Capacity:
Approx. 3.1 Liters (3.3 US qt) without filter, 3.4 Liters (3.6 US qt) with filter change.
Coolant Type:
Ethylene glycol based coolant, 50% mixture with distilled water.
Fork Oil Type:
SAE 10W (refer to manual for exact specification and quantity)
Carburetor Sync:
Carburetors may require periodic synchronization to ensure smooth engine operation and proper fuel mixture.
Stator Failure:
Some models can experience stator failures affecting the charging system; this manual will cover testing and replacement.
Cam Chain Tensioner:
While generally reliable, the cam chain tensioner should be inspected for proper function as part of scheduled maintenance.
Fairing Vibration:
Occasional reports of minor fairing vibration at certain RPMs, often manageable through careful assembly or subtle dampening.
Legacy:
Yamaha has a long and successful history in motorcycle manufacturing, known for performance and innovation.
Development:
The FZS600 Fazer was introduced as a more versatile and comfortable option compared to pure sports bikes, building on the success of Yamaha's inline-four engines.
Updates:
Subtle updates across its production run, often focusing on minor styling tweaks and carburetion adjustments for emissions or performance.
Manufacturing Location:
Japan
Market Reception:
Well-received by critics and riders for its blend of performance, versatility, and value for money.
Performance Reviews:
Praised for its smooth, rev-happy engine and comfortable riding posture for a sport-oriented machine.
Manual Quality:
Official Yamaha workshop manuals are known for their accuracy, detail, and comprehensive coverage.
