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Yamaha Fzs600 Fazer 2000 Factory Service Manual Repair
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Basic Information Identification Make: Yamaha Model: FZS600 Fazer Year: 2000 Generation Generation Code: RJ02 Codes Vin Code Prefix: JYARJ02 Introduction Market Position Category: Sport Touring Motorcycle Target Segment: Mid-weight sport-touring,...
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| Basic Information | |
| Identification | |
| Make: | Yamaha |
| Model: | FZS600 Fazer |
| Year: | 2000 |
| Generation | |
| Generation Code: | RJ02 |
| Codes | |
| Vin Code Prefix: | JYARJ02 |
| Introduction | |
| Market Position | |
| Category: | Sport Touring Motorcycle |
| Target Segment: | Mid-weight sport-touring, commuting, and general sporty riding. |
| Competitive Analysis | |
| Key Competitors: | Honda CBR600F, Kawasaki ZZ-R600, Suzuki Bandit 600/1200, Triumph TT600. |
| Key Features | |
| Engine Layout: | Inline-four cylinder, liquid-cooled, DOHC, 16-valve. |
| Styling: | Full fairing with twin headlights, providing wind protection for touring. |
| Ergonomics: | Comfortable, upright riding position suitable for longer distances. |
| Performance: | Balanced blend of sporty performance and everyday usability. |
| Manual Details | |
| Coverage Areas | |
| Market Availability: | Global (primarily Europe/UK) |
| Target Audience: | Professional Technicians, Experienced DIY Enthusiasts |
| Page Count | |
| Estimated Pages: | 350-400 |
| Manual Type | |
| Type: | Factory Service Manual / Repair Manual |
| Language | |
| Language: | English |
| Format | |
| Format: | PDF Download |
| Manual Coverage | |
| Systems Covered | |
| Engine Mechanical: | Comprehensive coverage of the 4-stroke, DOHC, inline-four cylinder engine. |
| Fuel System: | Carburetor system (CV carbs), fuel delivery, tank, lines, and filters. |
| Ignition System: | CDI ignition system, spark plugs, coils, and timing. |
| Cooling System: | Radiator, fan, coolant flow, thermostat, and hoses. |
| Transmission: | 6-speed constant mesh gearbox, clutch assembly, and operation. |
| Chassis Frame: | Steel diamond frame, subframe, and mounting points. |
| Suspension Front: | Telescopic front forks, damping, spring preload, and seals. |
| Suspension Rear: | Monoshock rear suspension, linkage, adjustability, and bearings. |
| Braking System: | Front and rear disc brakes, hydraulic system, calipers, master cylinders, pads, and lines. |
| Wheels Tires: | Wheel bearing maintenance, tire pressures, and sizes. |
| Electrical System: | Wiring diagrams, battery, charging system (stator, regulator/rectifier), lighting, and instrumentation. |
| Fuel Gauge: | Operation and troubleshooting of the fuel level sender and gauge. |
| Instruments Controls: | Speedometer, tachometer, indicators, and switchgear. |
| Bodywork: | Fairing, seat, tank, and trim component removal and installation. |
| Emission Controls: | Basic information on emission-related components relevant to the model year. |
| Procedures Included | |
| Routine Maintenance: | Oil changes, filter replacements, chain adjustment, spark plug service, air filter cleaning/replacement. |
| Engine Disassembly Reassembly: | Top-end rebuild (cylinder head, valves, pistons), bottom-end service (crankshaft, con-rods). |
| Carburetor Overhaul: | Complete disassembly, cleaning, rebuilding, and synchronization. |
| Clutch Service: | Clutch lever adjustment, cable inspection, clutch plate replacement. |
| Transmission Service: | Gearbox inspection, shift drum and fork service. |
| Fork Rebuild: | Fork oil change, seal replacement, damper rod service. |
| Rear Shock Overhaul: | Linkage bearing inspection and lubrication. |
| Brake System Maintenance: | Bleeding, pad replacement, caliper servicing, master cylinder rebuild. |
| Electrical Troubleshooting: | Diagnostic procedures for common electrical faults using wiring diagrams. |
| Wiring Harness Repair: | Inspection and repair of damaged wiring. |
| Troubleshooting Guides: | Detailed symptom-based diagnostic tables for various systems. |
| Torque Specifications: | Precise torque values for all critical fasteners. |
| Special Tool Requirements: | Identification of proprietary Yamaha tools needed for specific tasks. |
| Technical Depth | |
| Depth: | Comprehensive factory-level repair and diagnostic information. |
| Diagnostic Level: | Advanced, including electrical diagnostics and component testing. |
| Rebuild Level: | Full engine and component rebuild procedures. |
| Customization Info: | Limited; focuses on factory specifications and repair. |
| Manual Specifications | |
| File Format | |
| File Type: | Searchable PDF |
| Image Quality: | High-resolution scans, clear diagrams and photographs. |
| Searchability: | Text-based search functionality for quick information retrieval. |
| Print Quality | |
| Printable: | Yes, can be printed for offline use. |
| Binding Type | |
| Binding: | N/A (Digital PDF) |
| Paper Type | |
| Paper Type: | N/A (Digital PDF) |
| Engine Specifications | |
| Primary Engine | |
| Engine Type: | 4-stroke, liquid-cooled, DOHC, inline-four cylinder |
| Displacement: | 599 cc |
| Bore X Stroke: | 64.0 mm x 46.0 mm |
| Compression Ratio: | 12.0:1 |
| Valve Actuation: | DOHC, 4 valves per cylinder |
| Performance | |
| Horsepower: | Approx. 95-98 hp @ 11,500 rpm (claimed) |
| Torque: | Approx. 62-65 Nm @ 9,500 rpm (claimed) |
| Fuel System | |
| Carburetors: | 4 x Mikuni BDSR32 CV (Constant Velocity) carburetors |
| Fuel Tank Capacity: | 20 Liters (approx. 5.3 US gallons) |
| Ignition System | |
| Ignition Type: | Digital CDI (Capacitor Discharge Ignition) |
| Cooling System | |
| Cooling Method: | Liquid-cooled, with electric fan |
| Transmission | |
| Standard | |
| Transmission Type: | Constant mesh, 6-speed return type |
| Clutch Type: | Wet, multiple disc |
| Features | |
| Gear Ratios: | Refer to manual for specific ratios (e.g., 1st: 2.714, 2nd: 1.944, 3rd: 1.555, 4th: 1.333, 5th: 1.160, 6th: 1.045) |
| Final Drive: | Sealed O-ring chain |
| Fluid Specifications | |
| Transmission Oil: | Yamalube SAE 20W-40 API SE, SF or SG, or equivalent motorcycle-specific transmission oil. |
| Dimensions | |
| Exterior | |
| Overall Length: | Approx. 2,115 mm (83.3 in) |
| Overall Width: | Approx. 775 mm (30.5 in) |
| Overall Height: | Approx. 1,235 mm (48.6 in) |
| Seat Height: | Approx. 815 mm (32.1 in) |
| Wheelbase: | Approx. 1,430 mm (56.3 in) |
| Weights | |
| Dry Weight: | Approx. 194 kg (428 lbs) |
| Wet Weight: | Approx. 216 kg (476 lbs) (fully fueled) |
| Safety Features | |
| Ratings | |
| Safety Features: | Dual front disc brakes with opposed piston calipers, single rear disc brake. Standard lighting and indicators. |
| Active Features | |
| Braking Performance: | Responsive and strong braking, aided by larger front discs for its class. |
| Passive Features | |
| Frame Construction: | Rigid steel frame for stable handling. |
| Technology Features | |
| Infotainment | |
| Infotainment System: | N/A (no integrated infotainment system typical for this era). |
| Driver Assistance | |
| ABS Availability: | ABS was typically an optional extra on some European models, not standard. |
| Connectivity | |
| Connectivity Features: | N/A (no Bluetooth or smartphone integration). |
| Maintenance | |
| Service Intervals | |
| Oil Change Interval: | Every 6,000 km (3,700 miles) or annually, whichever comes first. |
| Major Service Interval: | Check valve clearances every 24,000 km (15,000 miles) or as per manual recommendations. |
| Fluid Specifications | |
| Engine Oil Type: | Yamalube 4 (4-stroke motorcycle oil) SAE 10W-40 API SG or higher. |
| Coolant Type: | High-quality ethylene glycol-based antifreeze coolant with distilled water (50:50 mix). |
| Brake Fluid Type: | DOT 4 hydraulic fluid. |
| Fork Oil Type: | Yamaha Fork Oil G10 or equivalent (e.g., Showa SS-09, Golden Spectro 10W). |
| Known Issues | |
| Common Wear Items: | Clutch wear, fork seal leaks, exhaust system corrosion, cam chain tensioner (can become noisy). |
| Electrical Quirks: | Stator failures (leading to charging issues) can occur, and corrosion in connectors is possible in damp climates. |
| Carburetor Maintenance: | Carburetors may require periodic cleaning and synchronization, especially if the bike has been sitting or run on stale fuel. |
| Vehicle History | |
| Brand Heritage | |
| Yamaha Legacy: | Yamaha Motor Corporation has a long history of innovation and performance in motorcycles, known for its advanced engineering and sporty heritage. |
| Model Evolution | |
| Fazer Lineage: | The FZS600 Fazer was introduced in 1998 as a versatile middleweight sport-tourer, evolving from the naked FZ600. The 2000 model is part of the first generation (RJ02). |
| Production | |
| Production Years: | First Generation (RJ02): 1998-2003. Second Generation (FZS600 Fazer S2): 2004-2007. |
| Awards & Recognition | |
| Recognitions | |
| Motorcycle Press Reviews: | Consistently praised by motorcycle journalists for its excellent balance of performance, comfort, and value for money. |
| Ratings | |
| Reliability: | Generally regarded as a reliable motorcycle with proper maintenance. |