🏷️ Basic Information

Make:

Yamaha

Model:

FZS600 Fazer

Year:

2002

Vehicle Type:

Sport Touring Motorcycle

👋 Introduction

Category:

Mid-weight Sport Touring Motorcycle

Target Audience:

Riders seeking a versatile motorcycle for commuting, touring, and spirited riding, with an emphasis on practicality and performance.

Key Competitors:

Suzuki GSF600 Bandit, Kawasaki ZRX400/ZRX1100, Honda CB600F Hornet/CBR600F.

Engine Type:

Reliable inline-four cylinder engine known for its smooth power delivery.

Ergonomics:

Comfortable riding position suitable for longer distances compared to pure sportbikes.

Practicality:

Benefited from a practical fairing for wind protection, making it more comfortable for touring.

📋 Manual Details

Primary Coverage:

Workshop Service and Repair

Additional Coverage:

Maintenance, Troubleshooting, Diagnostics

Estimated Pages:

Refer to actual manual content for exact count. Typically 300-500 pages for comprehensive service manuals.

Type:

Workshop Service Manual / Repair Manual

Language:

English

Format:

PDF Download

📖 Manual Coverage

Engine:

Complete overhaul, tuning, cooling system, lubrication system, fuel system (carburetion), exhaust system, ignition system.

Transmission:

Clutch assembly, gearbox operation, gear shifting mechanisms, maintenance and repair of transmission components.

Chassis:

Frame inspection, front suspension (forks, steering head bearings), rear suspension (shock absorber, linkage), swingarm.

Braking System:

Front and rear brake caliper service, master cylinders, brake lines, fluid replacement, bleeding procedures, disc and pad inspection.

Electrical System:

Wiring diagrams, battery, charging system (alternator, regulator/rectifier), starting system, lighting, instrumentation, sensors, ECU diagnosis.

Fuel System:

Carburetor removal, cleaning, adjustment, synchronization, fuel tank, petcock, fuel lines.

Cooling System:

Radiator, fan, thermostat, coolant replacement, leak detection.

Bodywork And Trim:

Fairing removal and installation, seat, fuel tank removal, body panel fasteners.

Routine Maintenance:

Oil change, filter replacement, chain adjustment and lubrication, spark plug replacement, air filter cleaning/replacement.

Troubleshooting:

Diagnosis of common problems, symptom-based troubleshooting guides, electrical fault finding.

Repair Procedures:

Step-by-step instructions for disassembly, repair, and reassembly of all major components.

Overhaul Procedures:

Detailed instructions for complete engine and transmission rebuilds.

Specifications And Tolerances:

Torque values, clearances, measurements for all critical components.

Depth:

Comprehensive, covering everything from basic checks to full engine rebuilds. Suitable for professional technicians and experienced DIY mechanics.

📊 Manual Specifications

File Type:

PDF

Searchable Text:

Likely included, allowing for keyword searches within the document.

Quality:

High resolution, designed for clear viewing and printing of diagrams and text.

Binding:

N/A (Digital PDF Download)

Paper Type:

N/A (Digital PDF Download)

⚙️ Engine Specifications

Engine Type:

Liquid-cooled, 4-stroke, DOHC, 5-valve per cylinder, Inline-four

Displacement:

599 cc

Bore X Stroke:

62.0 mm x 49.6 mm

Compression Ratio:

12.2:1

Ignition System:

Digital TCI (Transistor Controlled Ignition)

Horsepower:

Approximately 98 PS (96.5 bhp; 72 kW) at 12,000 rpm (Manufacturer Claim)

Torque:

Approximately 62.0 Nm (45.7 lb-ft) at 10,000 rpm (Manufacturer Claim)

Carburetion:

Four Mikuni CVKD32 carburetors

Fuel Tank Capacity:

20 Liters (approx. 5.3 US gal)

Oil Type:

Yamalube 4 (or equivalent) SAE 10W-40 API SG or higher.

Oil Capacity:

3.4 Liters (without filter change), 3.6 Liters (with filter change).

🔧 Transmission

Type:

Constant mesh, 6-speed return

Clutch Type:

Wet, multiple-disc, spring-loaded

Final Drive:

O-ring sealed chain

Transmission Oil:

Yamalube Gear Oil (or equivalent) SAE 80 API GL-4

Transmission Oil Capacity:

0.75 Liters

📐 Dimensions

Length:

2,085 mm (82.1 in)

Width:

745 mm (29.3 in)

Height:

1,210 mm (47.6 in)

Wheelbase:

1,425 mm (56.1 in)

Ground Clearance:

150 mm (5.9 in)

Dry Weight:

182 kg (401 lbs)

Wet Weight:

207 kg (456 lbs) (Estimated, with all fluids)

Front Tire:

120/70 ZR17M/C (58W) Tubeless

Rear Tire:

160/60 ZR17M/C (69W) Tubeless

Front Brake:

Dual 298 mm discs, 4-piston calipers

Rear Brake:

Single 245 mm disc, 2-piston caliper

Wheelbase Type:

Aluminum alloy 3-spoke

🛡️ Safety Features

Braking:

Dual front discs and single rear disc provide effective stopping power. ABS was typically optional or not available on this model year in most markets.

Suspension:

Telescopic front forks and rear monoshock linkage system offer stable handling and ride comfort.

Lighting:

Halogen headlight, taillight, and turn signals for visibility.

Ergonomics:

Upright riding position contributes to rider fatigue reduction on longer journeys.

💡 Technology Features

Display Type:

Analog speedometer and tachometer, with LCD for odometer, trip meter, and basic indicators.

ABS:

Anti-lock Braking System (ABS) was typically an optional feature, not standard across all models or markets.

Features:

Minimal modern connectivity. Focus is on mechanical and electrical systems for operation and maintenance.

🔧 Maintenance

Oil And Filter Change:

Every 6,000 km (3,700 miles) or 6 months, whichever comes first.

Air Filter Inspection:

Inspect every 6,000 km (3,700 miles), clean or replace as needed.

Spark Plug Replacement:

Every 12,000 km (7,500 miles).

Chain Lubrication:

Every 1,000 km (600 miles) or after riding in wet conditions.

Valve Clearance Check:

Every 12,000 km (7,500 miles).

Brake Fluid Replacement:

Every 2 years or as needed.

Engine Oil Spec:

Yamalube 4 (or equivalent) SAE 10W-40 API SG or higher.

Coolant Spec:

Permanent type antifreeze coolant (50% mixture) - Yamaha Super Coolant (or equivalent).

Brake Fluid Spec:

DOT 4

Fork Oil Spec:

Refer to manual for specific viscosity (often SAE 10W or equivalent).

Common Wear Items:

Clutch plates, brake pads, chain and sprockets, regulator/rectifier (can be prone to failure, though less common than on some other Yamahas of the era).

Carburetor Synchronization:

Periodic carburetor synchronization is essential for smooth running and optimal performance, as they can drift over time.

Front Fork Seals:

Fork seal leaks can occur with age and mileage, requiring replacement.

📚 Vehicle History

Heritage:

Yamaha has a long and distinguished history in motorcycle manufacturing, known for performance, reliability, and innovation across various motorcycling disciplines.

Fazer Lineage:

The FZS600 Fazer was introduced in 1998, evolving from the naked FZS600 'S' model. It offered a blend of performance, comfort, and practicality, aiming to capture the sport-touring market. The 2002 model represents a refined iteration of this successful formula.

Production Years:

1998-2003

Manufacturing Location:

Japan

🏆 Awards & Recognition

Market Reception:

The FZS600 Fazer was generally well-received for its balance of performance, comfort, reliability, and value for money. It was a popular choice in the mid-size sport-touring segment.