The Yamaha Fazer FZS600, produced from 1998 to 2003, represents the first generation of this versatile middleweight sport-touring motorcycle. Engineered as a blend of sporty performance and everyday practicality, it offers a comfortable riding position, effective wind protection, and a reliable, torquey inline-four engine. Building on Yamaha's reputation for quality and innovation, the FZS600 was designed for riders seeking a capable machine for commuting, touring, and spirited rides, competing with other popular models of its era through its balanced engineering and user-friendly characteristics.
This comprehensive Service Repair Manual, totaling 432 pages, provides in-depth guidance for the Yamaha Fazer FZS600, including supplementary information for 2000 and 2002 models. It covers essential areas such as detailed maintenance procedures, engine overhaul, fuel system servicing, transmission and clutch repair, brake system maintenance, suspension adjustments, and electrical system diagnostics. The manual is designed to assist owners, mechanics, and technicians in effectively maintaining, troubleshooting, and repairing the FZS600, ensuring its continued optimal performance and longevity.
Yamaha_Fazer_FZS600 3 in 1 User Manual Pakage (Service Repair + supplementary & Speccification)
Yamaha Fazer FZS600_1998_ Service Repair Manual (364 Pages)
MOTORCYCLE IDENTIFICATION
VEHICLE IDENTIFICATION NUMBER,MODEL CODE
IMPORTANT INFORMATION
PREPARATION FOR REMOVAL AND DISASSEMBLY,REPLACEMENT PARTS,GASKETS,OIL SEALS AND O-RINGS,LOCK WASHERS/PLATES AND COTTER PINS ,BEARINGS AND OIL SEALS CIRCLIPS
CHECKING THE CONNECTIONS
GENERAL SPECIFICATIONS
MAINTENANCE SPECIFICATIONS
ENGINE,CHASSIS,ELECTRICAL,
GENERAL TIGHTENING TORQUE SPECIFICATIONS
LUBRICATIONS AND LUBRICANT TYPES
COOLING SYSTEM DIAGRAMS
PERIODIC MAINTENANCE/LUBRICATION INTERVALS
FRONT COWLING/SEAT/SIDE COVER/FUEL TANK
ADJUSTING THE VALVE CLEARANCE,SYNCHRONIZING THE CARBURETORS,ADJUSTING THE ENGINE IDLING SPEED,ADJUSTING THE THROTTLE CABLE FREE PLAY,CHECKING THE SPARK PLUGS,CHECKING THE IGNITION TIMING,MEASURING THE COMPRESSION PRESSURE,CHECKING THE ENGINE OIL LEVEL,CHANGING THE ENGINE OIL ,EASURING THE ENGINE OIL PRESSURE,ADJUSTING THE CLUTCH CABLE FREE PLAY ,CLEANING THE AIR FILTER ELEMENT ,CHECKING THE CARBURETOR JOINTS AND INTAKE MANIFOLDS , CHECKING THE FUEL HOSES AND FUEL FILTER,CHECKING THE CRANKCASE BREATHER HOSE ,CHECKING THE EXHAUST SYSTEM ,CHECKING THE COOLANT LEVEL ,CHECKING THE COOLING SYSTEM ,CHANGING THE COOLANT.
ADJUSTING THE FRONT BRAKE ADJUSTING THE REAR BRAKE ,CHECKING THE BRAKE FLUID LEVEL ,ADJUSTING THE REAR BRAKE LIGHT SWITCH ,
CHECKING THE BRAKE HOSESBLEEDING THE HYDRAULIC BRAKE SYSTEM ,ADJUSTING THE SHIFT PEDAL 3-34ADJUSTING THE DRIVE CHAIN SLACK ,LUBRICATING THE DRIVE CHAIN ,CHECKING AND ADJUSTING THE STEERING HEAD ,CHECKING THE FRONT FORK ,ADJUSTING THE REAR SHOCK ABSORBER ASSEMBLY ,CHECKING THE TIRES ,CHECKING THE WHEELS ,CHECKING AND LUBRICATING THE CABLES ,LUBRICATING THE LEVERS AND PEDALS ,LUBRICATING THE SIDESTAND LUBRICATING THE CENTER STAND and LUBRICATING THE REAR SUSPENSION ELECTRICAL SYSTEMS
CHECKING AND CHARGING THE BATTERYCHECKING THE FUSES,REPLACING THE HEADLIGHT BULBS .
OVERHAULING THE ENGINE
DRIVE SPROCKET AND EXHAUST PIPE ,LEADS AND HOSES ,ENGINE BRACKET AND ENGINE ,INSTALLING THE ENGINE.
CYLINDER HEAD COVERS ,CAMSHAFTS,REMOVING THE CAMSHAFTS ,CHECKING THE CAMSHAFTS ,CHECKING THE TIMING CHAIN,CAMSHAFT SPROCKETS,AND TIMING CHAIN GUIDES ,CHECKING THE TIMING CHAIN TENSIONER ,INSTALLING THE CAMSHAFTS .
REMOVING THE CYLINDER HEADS ,CHECKING THE CYLINDER HEADS ,INSTALLING THE CYLINDER HEAD.
VALVES AND VALVE SPRINGS
REMOVING THE VALVES ,CHECKING THE VALVES AND VALVE GUIDES ,CHECKING THE VALVE SEATS ,CHECKING THE VALVE SPRINGS ,CHECKING THE VALVE LIFTERS ,CHECKING THE CAMSHAFT CAP ,INSTALLING THE VALVES .
CYLINDERS AND PISTONS
REMOVING THE CYLINDERS AND PISTONS ,CHECKING THE CYLINDERS AND PISTONS ,CHECKING THE PISTON RINGS ,CHECKING THE PISTON PINS ,INSTALLING THE PISTON AND CYLINDER.
CLUTCH COVER ,CLUTCH ,REMOVING THE CLUTCH ,CHECKING THE FRICTION PLATES ,CHECKING THE CLUTCH PLATES ,CHECKING THE CLUTCH SPRINGS CHECKING THE CLUTCH SPRING PLATE ,CHECKING THE CLUTCH HOUSING ,CHECKING THE CLUTCH BOSS ,CHECKING THE PRESSURE PLATE ,CHECKING THE CLUTCH PUSH RODS ,INSTALLING THE CLUTCH.
CHECKING THE SHIFT SHAFT ,INSTALLING THE SHIFT SHAFT .
AC MAGNETO AND STARTER CLUTCH
STATOR COIL ,STARTER CLUTCH ,AC MAGNETO ROTOR ,REMOVING THE STARTER CLUTCH ,REMOVING THE AC MAGNETO ,CHECKING THE STARTER CLUTCH ,INSTALLING THE AC MAGNETO ,INSTALLING THE STARTER CLUTCH ,
OIL PAN AND OIL STRAINER
OIL STRAINER OIL PUMP ,REMOVING THE OIL PAN ,CHECKING THE OIL PUMP ,CHECKING THE RELIEF VALVE ,CHECKING THE OIL STRAINER ,,CHECKING THE OIL NOZZLE ,ASSEMBLING THE OIL PUMP ,INSTALLING THE OIL PUMP INSTALLING THE OIL STRAINE,RINSTALLING THE OIL PAN ,
DISASSEMBLING THE CRANKCASE CHECKING THE CRANKCASE ,ASSEMBLING THE CRANKCASE
CONNECTING ROD ,REMOVING THE CRANKSHAFT ASSEMBLY ,REMOVING THE CONNECTING RODS ,CHECKING THE CRANKSHAFT AND CONNECTING RODS ,INSTALLING THE CONNECTING RODS,INSTALLING THE CRANKSHAFT
CHECKING THE TRANSMISSION ,INSTALLING THE TRANSMISSION .
SHIFT DRUM AND SHIFT FORKS
CHECKING THE SHIFT FORKS CHECKING THE SHIFT DRUM ASSEMBLY ,INSTALLING THE SHIFT FORKS AND SHIFT DRUM ASSEMBLY ,
CHECKING THE RADIATOR,INSTALLING THE RADIATOR
CHECKING THE THERMOSTAT ,ASSEMBLING THE THERMOSTAT ,INSTALLING THE THERMOSTAT .
REMOVING THE WATER PUMP ,CHECKING THE WATER PUMP ,INSTALLING THE WATER PUMP ,
AIR FILTER CASE ,CARBURETORS ,CHECKING THE CARBURETORS ,ASSEMBLING THE CARBURETORS ,INSTALLING THE CARBURETORS ,MEASURING AND ADJUSTING THE FUEL LEVEL ,CHECKING AND ADJUSTING THE THROTTLE POSITIONSENSOR,
FRONT WHEEL AND BRAKE DISCS
FRONT WHEEL ,REMOVING THE FRONT WHEEL ,CHECKING THE FRONT WHEEL ,CHECKING THE BRAKE DISCS ,INSTALLING THE FRONT WHEEL ,ADJUSTING THE FRONT WHEEL STATIC BALANCE.
REAR WHEEL,BRAKE DISC AND REAR WHEEL SPROCKET
REAR WHEEL . BRAKE DISC AND REAR WHEEL SPROCKET DISASSEMBLY THE REAR WHEEL ,REMOVING THE REAR WHEEL ,CHECKING THE REAR WHEEL ,CHECKING AND REPLACING THE REAR WHEEL SPROCKET ,
INSTALLING THE REAR WHEEL ,ADJUSTING THE REAR WHEEL STATIC .
FRONT AND REAR BREAKS
Yamaha_Fazer_FZS600 3 in 1 User Manual Pakage (Service Repair + supplementary & Speccification)
Yamaha Fazer FZS600_1998_ Service Repair Manual (364 Pages)
MOTORCYCLE IDENTIFICATION
VEHICLE IDENTIFICATION NUMBER,MODEL CODE
IMPORTANT INFORMATION
PREPARATION FOR REMOVAL AND DISASSEMBLY,REPLACEMENT PARTS,GASKETS,OIL SEALS AND O-RINGS,LOCK WASHERS/PLATES AND COTTER PINS ,BEARINGS AND OIL SEALS CIRCLIPS
CHECKING THE CONNECTIONS
GENERAL SPECIFICATIONS
MAINTENANCE SPECIFICATIONS
ENGINE,CHASSIS,ELECTRICAL,
GENERAL TIGHTENING TORQUE SPECIFICATIONS
LUBRICATIONS AND LUBRICANT TYPES
COOLING SYSTEM DIAGRAMS
PERIODIC MAINTENANCE/LUBRICATION INTERVALS
FRONT COWLING/SEAT/SIDE COVER/FUEL TANK
ADJUSTING THE VALVE CLEARANCE,SYNCHRONIZING THE CARBURETORS,ADJUSTING THE ENGINE IDLING SPEED,ADJUSTING THE THROTTLE CABLE FREE PLAY,CHECKING THE SPARK PLUGS,CHECKING THE IGNITION TIMING,MEASURING THE COMPRESSION PRESSURE,CHECKING THE ENGINE OIL LEVEL,CHANGING THE ENGINE OIL ,EASURING THE ENGINE OIL PRESSURE,ADJUSTING THE CLUTCH CABLE FREE PLAY ,CLEANING THE AIR FILTER ELEMENT ,CHECKING THE CARBURETOR JOINTS AND INTAKE MANIFOLDS , CHECKING THE FUEL HOSES AND FUEL FILTER,CHECKING THE CRANKCASE BREATHER HOSE ,CHECKING THE EXHAUST SYSTEM ,CHECKING THE COOLANT LEVEL ,CHECKING THE COOLING SYSTEM ,CHANGING THE COOLANT.
ADJUSTING THE FRONT BRAKE ADJUSTING THE REAR BRAKE ,CHECKING THE BRAKE FLUID LEVEL ,ADJUSTING THE REAR BRAKE LIGHT SWITCH ,
CHECKING THE BRAKE HOSESBLEEDING THE HYDRAULIC BRAKE SYSTEM ,ADJUSTING THE SHIFT PEDAL 3-34ADJUSTING THE DRIVE CHAIN SLACK ,LUBRICATING THE DRIVE CHAIN ,CHECKING AND ADJUSTING THE STEERING HEAD ,CHECKING THE FRONT FORK ,ADJUSTING THE REAR SHOCK ABSORBER ASSEMBLY ,CHECKING THE TIRES ,CHECKING THE WHEELS ,CHECKING AND LUBRICATING THE CABLES ,LUBRICATING THE LEVERS AND PEDALS ,LUBRICATING THE SIDESTAND LUBRICATING THE CENTER STAND and LUBRICATING THE REAR SUSPENSION ELECTRICAL SYSTEMS
CHECKING AND CHARGING THE BATTERYCHECKING THE FUSES,REPLACING THE HEADLIGHT BULBS .
OVERHAULING THE ENGINE
DRIVE SPROCKET AND EXHAUST PIPE ,LEADS AND HOSES ,ENGINE BRACKET AND ENGINE ,INSTALLING THE ENGINE.
CYLINDER HEAD COVERS ,CAMSHAFTS,REMOVING THE CAMSHAFTS ,CHECKING THE CAMSHAFTS ,CHECKING THE TIMING CHAIN,CAMSHAFT SPROCKETS,AND TIMING CHAIN GUIDES ,CHECKING THE TIMING CHAIN TENSIONER ,INSTALLING THE CAMSHAFTS .
REMOVING THE CYLINDER HEADS ,CHECKING THE CYLINDER HEADS ,INSTALLING THE CYLINDER HEAD.
VALVES AND VALVE SPRINGS
REMOVING THE VALVES ,CHECKING THE VALVES AND VALVE GUIDES ,CHECKING THE VALVE SEATS ,CHECKING THE VALVE SPRINGS ,CHECKING THE VALVE LIFTERS ,CHECKING THE CAMSHAFT CAP ,INSTALLING THE VALVES .
CYLINDERS AND PISTONS
REMOVING THE CYLINDERS AND PISTONS ,CHECKING THE CYLINDERS AND PISTONS ,CHECKING THE PISTON RINGS ,CHECKING THE PISTON PINS ,INSTALLING THE PISTON AND CYLINDER.
CLUTCH COVER ,CLUTCH ,REMOVING THE CLUTCH ,CHECKING THE FRICTION PLATES ,CHECKING THE CLUTCH PLATES ,CHECKING THE CLUTCH SPRINGS CHECKING THE CLUTCH SPRING PLATE ,CHECKING THE CLUTCH HOUSING ,CHECKING THE CLUTCH BOSS ,CHECKING THE PRESSURE PLATE ,CHECKING THE CLUTCH PUSH RODS ,INSTALLING THE CLUTCH.
CHECKING THE SHIFT SHAFT ,INSTALLING THE SHIFT SHAFT .
AC MAGNETO AND STARTER CLUTCH
STATOR COIL ,STARTER CLUTCH ,AC MAGNETO ROTOR ,REMOVING THE STARTER CLUTCH ,REMOVING THE AC MAGNETO ,CHECKING THE STARTER CLUTCH ,INSTALLING THE AC MAGNETO ,INSTALLING THE STARTER CLUTCH ,
OIL PAN AND OIL STRAINER
OIL STRAINER OIL PUMP ,REMOVING THE OIL PAN ,CHECKING THE OIL PUMP ,CHECKING THE RELIEF VALVE ,CHECKING THE OIL STRAINER ,,CHECKING THE OIL NOZZLE ,ASSEMBLING THE OIL PUMP ,INSTALLING THE OIL PUMP INSTALLING THE OIL STRAINE,RINSTALLING THE OIL PAN ,
DISASSEMBLING THE CRANKCASE CHECKING THE CRANKCASE ,ASSEMBLING THE CRANKCASE
CONNECTING ROD ,REMOVING THE CRANKSHAFT ASSEMBLY ,REMOVING THE CONNECTING RODS ,CHECKING THE CRANKSHAFT AND CONNECTING RODS ,INSTALLING THE CONNECTING RODS,INSTALLING THE CRANKSHAFT
CHECKING THE TRANSMISSION ,INSTALLING THE TRANSMISSION .
SHIFT DRUM AND SHIFT FORKS
CHECKING THE SHIFT FORKS CHECKING THE SHIFT DRUM ASSEMBLY ,INSTALLING THE SHIFT FORKS AND SHIFT DRUM ASSEMBLY ,
CHECKING THE RADIATOR,INSTALLING THE RADIATOR
CHECKING THE THERMOSTAT ,ASSEMBLING THE THERMOSTAT ,INSTALLING THE THERMOSTAT .
REMOVING THE WATER PUMP ,CHECKING THE WATER PUMP ,INSTALLING THE WATER PUMP ,
AIR FILTER CASE ,CARBURETORS ,CHECKING THE CARBURETORS ,ASSEMBLING THE CARBURETORS ,INSTALLING THE CARBURETORS ,MEASURING AND ADJUSTING THE FUEL LEVEL ,CHECKING AND ADJUSTING THE THROTTLE POSITIONSENSOR,
FRONT WHEEL AND BRAKE DISCS
FRONT WHEEL ,REMOVING THE FRONT WHEEL ,CHECKING THE FRONT WHEEL ,CHECKING THE BRAKE DISCS ,INSTALLING THE FRONT WHEEL ,ADJUSTING THE FRONT WHEEL STATIC BALANCE.
REAR WHEEL,BRAKE DISC AND REAR WHEEL SPROCKET
REAR WHEEL . BRAKE DISC AND REAR WHEEL SPROCKET DISASSEMBLY THE REAR WHEEL ,REMOVING THE REAR WHEEL ,CHECKING THE REAR WHEEL ,CHECKING AND REPLACING THE REAR WHEEL SPROCKET ,
INSTALLING THE REAR WHEEL ,ADJUSTING THE REAR WHEEL STATIC .
FRONT AND REAR BREAKS
