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Yamaha FZS600 2002 - Service Manual

Yamaha FZS600 2002
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Summary

FOREWORD

NOTICE

IMPORTANT INFORMATION

Notations for warnings and essential information.

HOW TO USE THIS MANUAL

SYMBOLS

GENERAL SPECIFICATIONS

MAINTENANCE SPECIFICATIONS

ENGINE

Engine maintenance specs, incl. carburetor and torques.

CHASSIS

Chassis maintenance specs, incl. drive chain and torques.

ELECTRICAL

Electrical system specs, incl. charging and amperage.

LUBRICATION POINT AND LUBRICATION TYPES

ENGINE

Specifies lubrication points and types for engine components.

COOLING SYSTEM DIAGRAMS

CABLE ROUTING

PERIODIC CHECKS AND ADJUSTMENTS

INTRODUCTION

Overview of checks and adjustments for reliable operation.

PERIODIC MAINTENANCE;LUBRICATION INTERVALS

Schedule for maintenance tasks based on mileage and time.

FRONT COWLING;SEAT;SIDE COVER;FUEL TANK

FRONT COWLING

Procedure for removing and installing the front cowling.

SEAT, SIDE COVER AND FUEL TANK

ADJUSTING THE FRONT BRAKE; REPLACING THE HEADLIGHT BULBS

CHASSIS

Adjusting the front brake lever position.

ELECTRICAL SYSTEM

Procedure for replacing headlight bulbs.

ENGINE

CYLINDER HEAD

Procedure for removing and installing the cylinder head.

CLUTCH

INSTALLING THE CLUTCH

Step-by-step guide for installing the clutch assembly.

AC MAGNETO AND STARTER CLUTCH

STARTER CLUTCH

Procedure for removing and installing the starter clutch.

COOLING SYSTEM

RADIATOR

Procedure for removing and installing the radiator.

THERMOSTAT

ASSEMBLING THE THERMOSTAT

Step-by-step guide for assembling the thermostat.

WATER PUMP

DISASSEMBLING THE WATER PUMP

Step-by-step procedure for disassembling the water pump.

CHECKING THE WATER PUMP

Checks to perform on water pump components.

ASSEMBLING THE WATER PUMP

Step-by-step guide for assembling the water pump.

CHASSIS

FRONT FORK

Procedure for removing and installing the front fork assembly.

FRONT FORK

REMOVING THE FRONT FORK LEGS

Detailed steps for removing the front fork legs.

INSTALLING THE FRONT FORK LEGS

Detailed steps for installing the front fork legs.

HANDLEBAR

STEERING HEAD

LOWER BRACKET

Procedure for removing and installing the lower bracket.

SWINGARM AND DRIVE CHAIN

ELECTRICAL SYSTEM

INSTRUMENT FUNCTION

How to set the digital clock on the instrument panel.

CIRCUIT DIAGRAM

CHECKING SWITCHES

SWITCH POSITION AND TERMINAL CONNECTION

Details on checking switch positions and terminal connections.

LIGHTING SYSTEM

CIRCUIT DIAGRAM

Wiring diagram specific to the lighting system.

LIGHTING SYSTEM CHECK

SIGNAL SYSTEM

CIRCUIT DIAGRAM

Wiring diagram for the signal system.

SIGNAL SYSTEM CHECK

COOLING SYSTEM

CIRCUIT DIAGRAM

Wiring diagram for the cooling system.

TROUBLESHOOTING

Troubleshooting fan motor and coolant temperature meter.

FZS600 (P) 2002 WIRING DIAGRAM (EUR)

FZS600 N (P) 2002 WIRING DIAGRAM (OCE)

Summary

FOREWORD

NOTICE

IMPORTANT INFORMATION

Notations for warnings and essential information.

HOW TO USE THIS MANUAL

SYMBOLS

GENERAL SPECIFICATIONS

MAINTENANCE SPECIFICATIONS

ENGINE

Engine maintenance specs, incl. carburetor and torques.

CHASSIS

Chassis maintenance specs, incl. drive chain and torques.

ELECTRICAL

Electrical system specs, incl. charging and amperage.

LUBRICATION POINT AND LUBRICATION TYPES

ENGINE

Specifies lubrication points and types for engine components.

COOLING SYSTEM DIAGRAMS

CABLE ROUTING

PERIODIC CHECKS AND ADJUSTMENTS

INTRODUCTION

Overview of checks and adjustments for reliable operation.

PERIODIC MAINTENANCE;LUBRICATION INTERVALS

Schedule for maintenance tasks based on mileage and time.

FRONT COWLING;SEAT;SIDE COVER;FUEL TANK

FRONT COWLING

Procedure for removing and installing the front cowling.

SEAT, SIDE COVER AND FUEL TANK

ADJUSTING THE FRONT BRAKE; REPLACING THE HEADLIGHT BULBS

CHASSIS

Adjusting the front brake lever position.

ELECTRICAL SYSTEM

Procedure for replacing headlight bulbs.

ENGINE

CYLINDER HEAD

Procedure for removing and installing the cylinder head.

CLUTCH

INSTALLING THE CLUTCH

Step-by-step guide for installing the clutch assembly.

AC MAGNETO AND STARTER CLUTCH

STARTER CLUTCH

Procedure for removing and installing the starter clutch.

COOLING SYSTEM

RADIATOR

Procedure for removing and installing the radiator.

THERMOSTAT

ASSEMBLING THE THERMOSTAT

Step-by-step guide for assembling the thermostat.

WATER PUMP

DISASSEMBLING THE WATER PUMP

Step-by-step procedure for disassembling the water pump.

CHECKING THE WATER PUMP

Checks to perform on water pump components.

ASSEMBLING THE WATER PUMP

Step-by-step guide for assembling the water pump.

CHASSIS

FRONT FORK

Procedure for removing and installing the front fork assembly.

FRONT FORK

REMOVING THE FRONT FORK LEGS

Detailed steps for removing the front fork legs.

INSTALLING THE FRONT FORK LEGS

Detailed steps for installing the front fork legs.

HANDLEBAR

STEERING HEAD

LOWER BRACKET

Procedure for removing and installing the lower bracket.

SWINGARM AND DRIVE CHAIN

ELECTRICAL SYSTEM

INSTRUMENT FUNCTION

How to set the digital clock on the instrument panel.

CIRCUIT DIAGRAM

CHECKING SWITCHES

SWITCH POSITION AND TERMINAL CONNECTION

Details on checking switch positions and terminal connections.

LIGHTING SYSTEM

CIRCUIT DIAGRAM

Wiring diagram specific to the lighting system.

LIGHTING SYSTEM CHECK

SIGNAL SYSTEM

CIRCUIT DIAGRAM

Wiring diagram for the signal system.

SIGNAL SYSTEM CHECK

COOLING SYSTEM

CIRCUIT DIAGRAM

Wiring diagram for the cooling system.

TROUBLESHOOTING

Troubleshooting fan motor and coolant temperature meter.

FZS600 (P) 2002 WIRING DIAGRAM (EUR)

FZS600 N (P) 2002 WIRING DIAGRAM (OCE)

Yamaha FZS600 2002 Specifications

General IconGeneral
Year2002
ManufacturerYamaha
ModelFZS600
CategoryMotorcycle
Engine TypeLiquid-cooled, 4-stroke, DOHC, 4-cylinder
Compression Ratio12.0:1
Fuel SystemCarburetor
Transmission6-speed
Final DriveChain
Front SuspensionTelescopic fork
Front BrakesDual disc
Rear BrakesSingle disc
Front Tire120/70-ZR17
Rear Tire160/60-ZR17
Width725 mm
Seat Height790 mm
Rear SuspensionSwingarm
Length2, 080 mm
Wheelbase1, 440 mm
Dry Weight189 kg
IgnitionDigital TCI

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