Segment:
Middleweight naked sportbike/standard motorcycle
Target Audience:
Riders seeking a versatile, sporty, and reliable motorcycle for commuting, touring, and spirited riding.
Key Competitors:
Suzuki Bandit 600, Honda CB600F Hornet, Kawasaki ZR-7
Engine Type:
Inline-four cylinder, liquid-cooled, DOHC
Styling:
Half-faired design offering some wind protection without the full fairing of a supersport.
Versatility:
Balances sporty performance with comfort suitable for everyday use and longer journeys.
Applicable Years:
1998, 1999, 2000, 2001, 2002, 2003
Estimated Pages:
Hundreds (specific count not provided, but implies comprehensive content)
Type:
Factory Service Repair Manual
Language:
English (presumed, based on typical factory service manual distribution for international markets)
Engine:
Complete overhaul, tuning, diagnostics, internal components (pistons, crankshaft, valves, camshafts, timing chain, etc.)
Fuel System:
Carburetor system (cleaning, adjustment, synchronization), fuel pump, fuel lines, fuel tank inspection
Cooling System:
Radiator, cooling fan, thermostat, water pump, coolant specifications and replacement
Ignition System:
Spark plugs, ignition coils, ECU (Engine Control Unit) testing and troubleshooting, timing
Transmission:
Gearbox overhaul, clutch assembly inspection and replacement, shift mechanism
Chassis And Frame:
Frame inspection, front fork overhaul and adjustment, rear shock absorber inspection and replacement, swingarm service
Brakes:
Front and rear brake systems, caliper service, master cylinder overhaul, brake fluid specifications and bleeding procedures, pad and disc inspection
Electrical System:
Wiring diagrams, battery, starter motor, alternator, lighting systems, fuses, relays, switches, instrument panel
Bodywork And Trim:
Fairing removal and installation, seat, tank cover, fenders, decals
Maintenance:
Scheduled maintenance, oil changes, filter replacements, chain adjustment, tire pressure checks, brake fluid changes, coolant flushes
Troubleshooting:
Systematic diagnostic procedures for common and uncommon faults, fault code interpretation (if applicable)
Repair:
Detailed step-by-step repair instructions for all major and minor components, including engine rebuilds, suspension work, and electrical repairs
Overhaul:
Complete overhaul procedures for engine, gearbox, suspension, and braking components
Adjustments:
Carburetor synchronization, valve clearance adjustment, chain tension adjustment, suspension settings
Depth:
Comprehensive: Covers basic maintenance to full engine and component rebuilds, including detailed diagrams and specifications.
Displacement:
599 cc (36.6 cu in)
Bore X Stroke:
73.0 mm x 71.5 mm (2.87 in x 2.81 in)
Compression Ratio:
10.4:1
Valve Train:
DOHC, 16 valves (4 valves per cylinder)
Cooling Method:
Liquid-cooled
Horsepower Approx:
96 hp (71.6 kW) @ 11,000 rpm
Torque Approx:
62 Nm (45.7 lb-ft) @ 9,000 rpm
Carburetors:
Four Mikuni BST36 (slide-valve type) with dual throttle valves
Fuel Capacity:
20 Liters (5.3 US gal)
Engine Oil Type:
Yamalube 4-stroke Motorcycle Oil (API SG, JASO MA)
Engine Oil Capacity:
3.1 L (3.3 US qt) without filter change; 3.4 L (3.6 US qt) with filter change
Oil Filter Part Number:
Yamaha 5JX-13440-00 (or equivalent aftermarket)
Spark Plug Type:
NGK CR9E or Denso U27ESR-N
Valve Clearance Intake:
0.06 – 0.11 mm (0.0024 – 0.0043 in)
Valve Clearance Exhaust:
0.07 – 0.12 mm (0.0028 – 0.0047 in)
Instrument Cluster:
Analog tachometer, digital speedometer, odometer, trip meter, fuel gauge, coolant temperature gauge, warning lights.
ABS:
Optional anti-lock braking system available on some models.
Connectivity Features:
N/A (No modern connectivity features like Bluetooth or smartphone integration as this is a pre-2004 model.)
Initial Service:
1000 km (600 miles) or 1 month
Subsequent Major Service:
Every 6000 km (3750 miles) or 6 months, whichever comes first.
Valve Clearance Check Interval:
Every 12,000 km (7,500 miles)
Chain Lubrication And Adjustment Interval:
Every 1000 km (600 miles) or after washing/rain riding
Coolant Type:
Permanent antifreeze, ethylene glycol based, with high-purity water (50:50 mixture). Refer to manual for specific Yamaha coolant recommendation.
Common Wear Items:
Clutch plates, brake pads and discs, chain and sprockets, fork seals, rear shock absorber (over time).
Potential Electrical Issues:
Regulator/rectifier failure (though less common than on some other Yamahas of the era), stator coil issues. Wiring loom degradation over time.
Engine Performance:
Carburetor synchronization drift can lead to rough idling or uneven throttle response. Valve clearances can drift out of spec, affecting performance.
Suspension:
Front fork oil can degrade, requiring replacement for optimal damping. Rear shock absorber may lose damping over high mileage.
Heritage:
Yamaha Motor Company, established in 1955, is renowned for its high-performance motorcycles, musical instruments, and marine products. Its motorcycle division has a long history of innovation and success in racing and road-going vehicles.
Predecessors:
The FZS600 Fazer built upon the success of Yamaha's inline-four sportbikes, offering a more practical and comfortable package than the R-series models.
Successors:
The FZS600 was later replaced by the FZS600 Fazer (updated model) and subsequently the FZ6 Fazer, which featured fuel injection and a revised engine derived from the R6.
Production Years Covered:
1998-2003
Manufacturing Location:
Japan (typically)
