Segment:
Mid-size sport-touring motorcycle
Competitors:
Suzuki GSF600 Bandit, Kawasaki ZX-6R Ninja (older models), Honda CB600 Hornet
Versatility:
Combines comfortable ergonomics for touring with sporty handling for spirited riding
Engine Platform:
Utilizes Yamaha's proven 600cc inline-four cylinder engine, derived from the FZR600 and R6 platforms
Primary Coverage:
Full Service, Repair, Maintenance, Rebuild, Refurbish, Restoration
Type:
Factory Service Manual / Workshop Manual
Format:
Digital (PDF likely)
Engine:
Complete engine disassembly, assembly, tuning, diagnostics, lubrication system, cooling system, fuel system, ignition system, exhaust system
Transmission:
Clutch system, gearbox disassembly and assembly, shift mechanism, transmission lubrication
Chassis And Suspension:
Front fork assembly, rear shock absorber, swingarm, steering system, wheel bearing maintenance
Brakes:
Front and rear brake caliper service, master cylinder overhaul, brake line replacement, bleeding procedures, hydraulic system troubleshooting
Electrical:
Wiring diagrams, battery system, starter motor, alternator, lighting system, ignition coils, CDI unit, instrument cluster troubleshooting, fault diagnosis
Fuel System:
Carburetor disassembly, cleaning, adjustment, jetting, fuel pump, fuel filter replacement
Body And Frame:
Fairing removal and installation, seat, fuel tank, body panel repairs, frame inspection
Maintenance:
Regular scheduled maintenance, oil changes, filter replacements, chain adjustment, spark plug replacement, brake pad inspection
Troubleshooting:
Systematic diagnostic guides for common and uncommon issues, fault codes, symptom analysis
Repair:
Step-by-step instructions for component replacement and repair, including engine, transmission, suspension, and electrical components
Rebuild:
Comprehensive instructions for overhauling engine, gearbox, and other major assemblies
Depth:
Comprehensive from basic maintenance to full engine and transmission rebuilds, including detailed technical specifications and torque values
Digital Format:
PDF (Portable Document Format) - assumed for digital products
Print Readability:
High resolution for clear text and diagrams, suitable for printing
Physical Binding:
N/A (for digital product); if physical, typically spiral-bound or perfect-bound
Physical Paper:
N/A (for digital product); if physical, typically heavy-duty, glossy or matte paper
Engine Type:
Liquid-cooled, 4-stroke, DOHC, inline-four cylinder
Bore X Stroke:
60.0 mm x 53.4 mm
Compression Ratio:
12.0:1
Horsepower:
Approx. 95-98 HP @ 11,500 RPM (claimed)
Torque:
Approx. 6.4 kgf-m (63 Nm) @ 10,000 RPM (claimed)
Carburetor Type:
Mikuni BSR33 (CV type, 4 x 33mm)
Fuel Capacity:
20 Liters (5.3 US gal)
Oil Type:
Yamalube 4 (or equivalent) SAE 10W-40, API SG or higher
Oil Capacity W Filter:
3.4 Liters (3.6 US qt)
Coolant Type:
Yamaha Genuine Coolant (or 50/50 mix of ethylene glycol and deionized water)
Ignition Type:
Digital CDI
Spark Plug Type:
NGK CR9E or DENSO U27ESR-N
Spark Plug Gap:
0.7-0.8 mm (0.028-0.031 in)
Gearbox Type:
Constant mesh, 6-speed sequential
Clutch Type:
Wet, multiple-disc, cable-actuated
Final Drive:
O-ring sealed chain
Transmission Oil Type:
Yamalube 4 (or equivalent) SAE 10W-30, API SE, SF, SG, SH, SJ or SL
Transmission Oil Capacity:
1.7 Liters (1.8 US qt)
Instrument Cluster:
Analog tachometer, digital speedometer, fuel gauge, coolant temperature gauge, trip meters, clock, indicator lights.
ABS Availability:
Not available on this model year.
Charging Port:
Not standard; aftermarket installation is common.
Oil Change Interval:
Every 6,000 km (3,700 miles) or 6 months
Oil Filter Change Interval:
Every 12,000 km (7,500 miles) or 12 months (recommended with oil change)
Air Filter Cleaning:
Every 6,000 km (3,700 miles)
Spark Plug Replacement:
Every 12,000 km (7,500 miles)
Valve Clearance Check:
Every 18,000 km (11,000 miles) or 18 months
Brake Fluid Change:
Every 24,000 km (15,000 miles) or 24 months
Coolant Capacity:
1.90 Liters (2.0 US qt)
Front Fork Oil Type:
Yamaha Sus. Oil 10W or SAE 10W fork oil
Front Fork Oil Capacity:
488 ml (16.5 US oz) per leg
Stalling At Idle:
Can be caused by dirty carburetors, vacuum leaks, or an incorrectly adjusted idle speed.
Cam Chain Noise:
Potential for cam chain tensioner wear, leading to rattling noise on start-up or acceleration.
Electrical Connector Corrosion:
Common issue on older bikes, especially around the main wiring harness connectors, leading to intermittent electrical faults.
Clutch Fade:
Heavy use or worn clutch plates can lead to slipping or fade.
Brand Focus:
Yamaha is renowned for its high-performance motorcycles, musical instruments, and marine products, with a strong emphasis on engineering and innovation.
Predecessors:
The FZS600 Fazer built upon the success of the naked FZR600 and the popular Bandit 600 platform from Suzuki, offering a faired alternative.
Successors:
The FZS600 was eventually succeeded by the FZ6 Fazer, which featured fuel injection and a revised engine based on the YZF-R6.
Production Years:
1998-2003
Manufacturing Location:
Japan
