🏷️ Basic Information

Make:

Yamaha

Model:

Fazer FZS600

Model Year Covered:

2000

Sub Model:

FZS600

👋 Introduction

Positioning:

The Yamaha FZS600 Fazer, particularly the 2000 model, occupied a significant position in the middleweight sport-touring segment. It was known for its blend of performance, comfort, and versatility, offering a capable machine for both commuting and longer journeys. Its competitive landscape included bikes like the Suzuki Bandit 600/1200, Honda CB600F Hornet/CBR600F, and Kawasaki ZR-7.

Comparison Points:

The FZS600 stood out with its faired design providing better wind protection than naked rivals, a smooth inline-four engine derived from the acclaimed YZF600R, and a comfortable riding posture. It was often praised for its reliability and ease of maintenance, making it an attractive option for riders seeking a practical yet engaging motorcycle.

Distinctive Attributes:

The 2000 FZS600 is characterized by its well-balanced performance, robust build quality, and user-friendly ergonomics. This supplementary service manual provides crucial information for maintaining and repairing this specific model, ensuring optimal performance and longevity.

📋 Manual Details

Primary Coverage:

Official Supplementary Factory Service / Repair / Workshop Manual

Page Count:

Not specified in product information, but expected to be comprehensive for factory documentation.

Manual Type:

Factory Service Manual / Repair Manual / Workshop Manual

Language:

English (assumed based on product description and common industry practice for international markets)

Format:

Digital PDF Download

📖 Manual Coverage

Engine:

Complete engine overhaul, including cylinder head, camshafts, valve train, pistons, rings, connecting rods, crankshaft, oil pump, crankcase, bearings, seals, gaskets, timing chain, and timing gear.

Fuel System:

Carburetor assembly, fuel pump, fuel filter, fuel lines, fuel tank, and related components.

Ignition System:

Ignition system components, spark plugs, spark plug wires, ignition coils, and related wiring.

Transmission Drivetrain:

Transmission internals, gears, shift linkage, clutch components (pressure plate, clutch shoe, clutch case), and clutch lines.

Brakes:

Front and rear brake systems, including brake pads, brake shoes, rotors, brake calipers, brake lines, clutch lines, and bleeding procedures.

Suspension Steering:

Front forks, rear shock absorber, suspension linkages, steering system components, and related adjustments.

Electrical System:

Wiring harness, electrical diagrams, sensors, regulators, starter motor, alternator, battery, switches, relays, and lighting systems (headlights, taillights, turn signals, interior lighting).

Exhaust System:

Muffler, downpipe, catalytic converter, headers, exhaust gaskets, and heat wrap.

Cooling System:

Radiator, radiator fan, oil radiator, coolant hoses, and cooling system maintenance.

Chassis Body:

Frame, body panels, fairings, dashboard, console, seats, fenders, bumpers, and trim.

Wheel Hub Bearings:

Includes procedures for inspection, repacking, and replacement of wheel hub bearings and seals.

Radiator Fan Operation:

Details on the operation, testing, and replacement of the radiator fan and its associated sensor.

Fuel Pump Testing:

Procedures for testing fuel pump pressure and flow rates.

Alternator Testing:

Methods for testing the output and functionality of the alternator and its charging system.

Air Intake System:

Information on the air filter housing, air intake ducts, and related seals.

Pressure Sensors:

Details on oil pressure sensors and their testing/replacement.

Gasket Seal Replacement:

Specific procedures and specifications for replacing various gaskets and seals throughout the motorcycle.

Engine Mounts:

Information on engine mount inspection and replacement.

Wiring Harness Repair:

Comprehensive wiring diagrams and troubleshooting for the main chassis and engine wiring harnesses, including connectors and sensors.

Maintenance:

Routine maintenance tasks such as oil changes, transmission fluid changes, tire rotation, brake pad replacement, air filter replacement, spark plug replacement, and fluid level checks.

Repair:

Detailed step-by-step repair procedures for all major and minor mechanical and electrical components, including engine rebuilding, transmission overhauls, brake system repairs, suspension adjustments, and electrical diagnostics.

Troubleshooting:

Diagnostic procedures and fault finding guides for common issues, electrical problems, and engine performance anomalies.

Specifications:

Torque specifications, fluid capacities, technical data, part numbers, and recommended service intervals.

Assembly Disassembly:

Detailed instructions for the disassembly and reassembly of all vehicle components.

Suspension Tuning:

Guidance on adjusting suspension settings (if applicable to the model's adjustability) and fork oil replacement.

Carburetor Synchronization:

Detailed steps for synchronizing the four carburetors for optimal engine performance and fuel mixture.

Fastener Torque Specifications:

Crucial torque values for all critical fasteners, ensuring correct assembly and preventing component damage.

Depth:

Comprehensive factory-level detail, suitable for professional technicians and experienced DIY mechanics. Covers everything from basic maintenance to complete engine and transmission rebuilds, including machining and balancing procedures.

Diagnostic Capabilities:

The manual provides detailed diagnostic procedures for identifying and resolving issues across all vehicle systems, including electrical troubleshooting using wiring diagrams and symptom-based fault finding.

Diagrams Illustrations:

Includes detailed diagrams, exploded views, and illustrations to aid in understanding component relationships and repair procedures.

📊 Manual Specifications

File Format:

PDF

Printability:

Yes

Zoom Functionality:

Yes (zoom in/out)

Binding Type:

N/A (Digital PDF)

Paper Type:

N/A (Digital PDF)

Quality:

Factory Original Quality

⚙️ Engine Specifications

Engine Type:

Liquid-cooled, 4-stroke, DOHC, 4-valve per cylinder, Inline 4-cylinder

Displacement:

599 cc

Bore X Stroke:

62.0 mm x 49.6 mm (typical for this generation)

Compression Ratio:

12.0:1 (typical)

Horsepower:

Approximately 95-98 HP at 11,500 RPM (manufacturer-quoted, may vary slightly)

Torque:

Approximately 62 Nm (46 lb-ft) at 10,000 RPM (manufacturer-quoted, may vary slightly)

Carburetion:

Four Mikuni BST36 carburetors (likely) with CV (Constant Velocity) operation.

Oil Capacity:

Approximately 3.4 Liters (with filter change) - needs manual verification.

Ignition Type:

Digital CDI (Capacitor Discharge Ignition)

Cooling Method:

Liquid-cooled

Camshaft Type:

Double Overhead Camshaft (DOHC)

🔧 Transmission

Transmission Type:

6-speed constant mesh

Optional Transmission:

N/A (standard manual transmission)

Clutch Type:

Wet, multiple-disc, cable-actuated

Final Drive:

Chain drive

📐 Dimensions

Length:

Approx. 2085 mm (subject to regional variations)

Width:

Approx. 745 mm (subject to regional variations)

Height:

Approx. 1205 mm (subject to regional variations)

Dry Weight:

Approx. 187 kg (Dry weight - not including fluids)

Wet Weight:

Approx. 209 kg (Wet weight - with all fluids)

Fuel Capacity:

Approx. 18 Liters

Front Tire Size:

120/60ZR17 M/C (55W) (Tubeless)

Rear Tire Size:

160/60ZR17 M/C (69W) (Tubeless)

Front Wheel Type:

Cast aluminum alloy

Rear Wheel Type:

Cast aluminum alloy

🛡️ Safety Features

Safety Features:

While specific safety ratings like NHTSA or Euro NCAP are not applicable to motorcycles in the same way as cars, the FZS600 is equipped with standard safety features of its era, including powerful braking systems and stable handling characteristics.

Braking System:

Dual 298mm hydraulic disc brakes with twin-piston calipers (front); Single 245mm hydraulic disc brake with twin-piston caliper (rear).

Lighting:

Halogen headlight, LED taillight, and amber turn signals.

💡 Technology Features

Infotainment Systems:

As a 2000 model, infotainment systems in the modern sense (GPS, touchscreens, Bluetooth) were not standard. The primary 'infotainment' was the analog instrument cluster displaying speed, RPM, odometer, trip meter, and essential warning lights.

Driver Assistance Features:

No advanced driver assistance systems (ADAS) were present. The focus was on mechanical and electrical integrity for safe operation.

Connectivity Features:

No integrated connectivity features were available.

🔧 Maintenance

Oil Change Interval:

Every 6,000 km or 6 months, whichever comes first (typical recommendation; consult manual for exact specification).

Valve Clearance Check:

Every 24,000 km or 24 months (typical recommendation; consult manual for exact specification).

Spark Plug Replacement:

Every 12,000 km or 12 months (typical recommendation; consult manual for exact specification).

Engine Oil Type:

Yamalube 4 (or equivalent) SAE 10W-40 API SG or higher, JASO MA certified (consult manual for precise specifications and viscosity grades).

Coolant Type:

Permanent type antifreeze coolant, 50% solution in distilled water (consult manual for specific Yamaha coolant recommendations).

Brake Fluid Type:

DOT 4 recommended (consult manual for specific recommendations).

Common Wear Items:

Common wear items for this era of motorcycle include the chain and sprockets, brake pads and rotors, tires, fork seals, and the clutch friction plates due to mileage. Carburetor synchronization and cleaning can also be a periodic maintenance item.

Potential Faults:

While generally reliable, some owners have reported occasional issues with stator failure or regulator/rectifier problems, common to many motorcycles of this period. Proper maintenance, as detailed in this manual, is key to preventing these.

📚 Vehicle History

Yamaha Legacy:

Yamaha Motor Corporation, founded in 1955, has a rich heritage in motorcycle manufacturing, renowned for its innovation, performance, and reliability across various segments, from sportbikes to cruisers and off-road machines.

Fzs600 Lineage:

The FZS600 Fazer was introduced in 1998 as a versatile middleweight sport-touring motorcycle. It evolved from Yamaha's successful 600cc inline-four engine platform, sharing components with models like the YZF600R Thundercat and the FZR600R. The 2000 model represents a refinement of the initial design.

Manufacturing Origin:

Typically manufactured in Japan, although specific assembly locations could vary by market.

🏆 Awards & Recognition

Industry Awards:

While specific awards for the 2000 FZS600 Fazer might not be widely documented, the model was consistently praised in motorcycle reviews for its excellent value proposition, sporty performance, and practicality, contributing to its positive reputation in the sport-touring segment.