Segment:
Middleweight Sport-Touring Motorcycle
Target Audience:
Motorcycle enthusiasts, owners seeking to perform maintenance and repairs, independent repair shops.
Competitors:
Honda CB500, Kawasaki ER-5, Suzuki SV650 (early models).
Vehicle Strengths:
Versatile performance, comfortable riding position for a sportbike, reliable Yamaha engineering, affordable maintenance.
Manual Value Proposition:
Provides comprehensive, A-Z coverage for all mechanical and electrical aspects, enabling owners to maintain and repair their FZS600 effectively, saving time and money.
Covered Years:
1998, 1999, 2000, 2001
Covered Models:
All FZS600 Fazer models
Repair Scope:
Mechanical and Electrical Repairs, A-Z
Estimated Page Count:
Varies by specific edition, but comprehensive for the model years. Typically over 300 pages for full workshop manuals.
Manual Type:
Workshop Service Repair Manual
Language:
English (Assumed based on common manual availability for this model and market)
Format:
Printable (Digital format implied, with printable pages)
Engine Mechanical:
Engine disassembly, assembly, inspection, tuning, lubrication system, cooling system, cylinder head, valves, pistons, crankshaft, connecting rods, transmission (internal gears, clutch).
Fuel System:
Carburetor (Mikuni BDSR 34) disassembly, cleaning, adjustment, troubleshooting, fuel tank, fuel lines, fuel pump (if applicable).
Electrical System:
Ignition system (CDI, spark plugs), starting system (starter motor, solenoid), charging system (alternator, regulator/rectifier), lighting system (headlight, taillight, turn signals), battery, wiring diagrams, fuses, relays, sensors.
Chassis And Suspension:
Front fork (oil change, seal replacement, adjustment), rear shock absorber, swingarm, bearings, steering system, wheel and tire maintenance.
Braking System:
Front and rear brake systems (discs, calipers, master cylinders, brake lines, fluid change), ABS (if equipped), parking brake.
Bodywork And Fittings:
Fairing removal and installation, seat, fuel tank, fenders, instrumentation, controls, exhaust system.
Routine Maintenance:
Oil changes, filter replacements, spark plug checks, chain adjustment, brake pad checks, tire pressure checks, lubrication points.
Troubleshooting:
Diagnostic procedures for common issues, fault finding charts, electrical troubleshooting using wiring diagrams.
Repair Procedures:
Step-by-step instructions for component removal, installation, and repair for all major systems.
Rebuilding Procedures:
Detailed instructions for engine and transmission component rebuilding.
Specifications And Torques:
Torque values for all fasteners, engine specifications, valve clearances, ignition timing, fluid capacities, performance data.
Depth:
Comprehensive (Covers everything from basic maintenance to complete engine and transmission rebuilds, including electrical diagnostics and troubleshooting).
Diagrams And Illustrations
Visual Aids:
Tons of detailed pictures and diagrams included.
Engine Type:
Inline 4-cylinder, DOHC, 16-valve
Bore X Stroke:
61.0 mm x 49.5 mm (Typical for this engine)
Compression Ratio:
12.5:1 (Typical for this engine)
Horsepower:
Approx. 95 PS (70 kW) at 12,000 rpm (Stock, varies slightly by market)
Torque:
Approx. 6.2 kgf·m (61 Nm) at 9,500 rpm (Stock, varies slightly by market)
Carburetor Type:
4 x Mikuni BDSR34 CV Carburetors
Fuel Type:
Unleaded gasoline
Cooling Method:
Liquid-cooled
Oil Type:
Yamalube or equivalent SAE 10W-40 API SE, SF, SG, SH or SJ classification.
Safety Certification:
ECE standards (for European models), DOT standards (for North American models - applies to tires and rider gear, not the motorcycle itself).
Braking System:
Dual front disc brakes, single rear disc brake. Optional ABS available on some later models or specific markets.
Lighting:
Halogen headlight, LED taillight (typical for the era), turn signals.
Frame:
Steel diamond frame
Tires:
Tubeless radial tires. Common sizes: Front 120/70 ZR17, Rear 160/60 ZR17.
Instrumentation:
Analog tachometer, speedometer, fuel gauge, coolant temperature gauge, odometer, trip meter, warning lights.
Lighting Technology:
Halogen headlight for primary illumination.
ABS:
Optional Anti-lock Braking System (ABS) available on some versions.
Connectivity Features:
N/A (No modern connectivity features like Bluetooth or GPS integration on these models).
Oil Change Interval:
Every 6,000 km or 6 months, whichever comes first.
Oil Filter Replacement:
Every 6,000 km or 6 months (Recommended with oil change).
Spark Plug Check:
Every 6,000 km.
Valve Clearance Check:
Every 24,000 km.
Chain Lubrication Adjustment:
Every 1,000 km or after washing/riding in rain.
Engine Oil Capacity:
3.4 L (Without filter change), 3.7 L (With filter change).
Coolant Type:
Permanent type antifreeze (ethylene glycol based), mixed with water in a 50:50 ratio.
Brake Fluid Type:
SAE J1703 or DOT 3/DOT 4.
Common Wear Items:
Regulator/rectifier failures (especially on early models), clutch wear, fork seal leaks, carburetor synchronization issues, cam chain noise.
Preventative Measures:
Regular maintenance, ensuring proper cooling system function, using quality electrical components, keeping carburetors clean and synchronized.
Brand History:
Yamaha Motor Company is a Japanese manufacturer of motorcycles, marine products, and other motorized products. Founded in 1955, Yamaha has a long history of innovation and performance in motorcycling.
Fazer Lineage:
The FZS600 Fazer was introduced as a more comfortable and practical alternative to pure sportbikes, offering a balance of performance and everyday usability. It was part of Yamaha's strategy to broaden its sportbike offerings.
Predecessors Successors:
Evolved from Yamaha's FZR series of sportbikes. The FZS600 was eventually succeeded by the FZ6 Fazer, which featured fuel injection and a different engine based on the YZF-R6.
Manufacturing Location:
Japan
Production Years:
1998-2003
