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Yamaha FZS600'98 User Manual

Yamaha FZS600'98
364 pages
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Table of Contents

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Yamaha FZS600'98 Specifications

General IconGeneral
Displacement599 cc
Bore x stroke62.0 mm x 49.6 mm
Compression ratio12.0:1
Starting systemElectric
ClutchWet, multi-plate
Final driveChain
Rear tyre160/60 ZR17
Engine TypeLiquid-cooled, 4-stroke, DOHC, inline-4
Fuel systemCarburetor
IgnitionDigital TCI
Max. power95 hp @ 11, 500 rpm
Max. torque61 Nm @ 9, 500 rpm
Transmission6-speed
Frame typeDeltabox
Front suspensionTelescopic fork
Rear suspensionSwingarm, mono-shock
Front brakesDual hydraulic disc, 298 mm
Rear brakesSingle hydraulic disc, 245 mm
Front tyre120/60 ZR17
Seat height790 mm
Fuel capacity18 L (4.8 US gal)
Dry weight189 kg
Ground Clearance135 mm

Summary

How to Use This Manual

Chapter 2: Specifications

General Specifications

Lists dimensions, engine type, displacement, bore, stroke, and other general specifications.

Maintenance Specifications - Engine

Provides standard and limit values for engine components like cylinder head warp and camshaft dimensions.

Tightening Torques - Engine

Specifies torque values for engine components during assembly and disassembly.

Electrical Specifications

Lists specifications for ignition, charging, lighting, and starting systems.

General Tightening Torque Specifications

Specifies general tightening torques for standard fasteners based on ISO thread pitch.

Chapter 3: Periodic Inspections and Adjustments

Periodic Maintenance/Lubrication Intervals

Outlines recommended service intervals for various maintenance and lubrication jobs.

Engine Inspections and Adjustments

Covers engine-related inspections and adjustments, including valve clearance and carburetor synchronization.

Adjusting Valve Clearance

Provides a detailed procedure for measuring and adjusting valve clearances on a cold engine.

Synchronizing Carburetors

Explains how to synchronize the carburetors using vacuum gauges and an engine tachometer.

Measuring Compression Pressure

Describes how to measure engine compression pressure to diagnose performance issues.

Changing Engine Oil

Provides step-by-step instructions for draining and replacing engine oil and filter.

Measuring Engine Oil Pressure

Explains how to measure engine oil pressure to diagnose lubrication system faults.

Adjusting Clutch Cable Free Play

Guides on adjusting the clutch cable free play for optimal clutch operation.

Bleeding Hydraulic Brake System

Provides a procedure for removing air from the hydraulic brake system.

Chapter 4: Overhauling the Engine

Cylinders and Pistons Procedures

Covers removal, checking, and installation of cylinders, pistons, and piston rings.

Crankcase Procedures

Covers disassembly, checking, and assembly of the crankcase halves.

Crankshaft Procedures

Details removal, checking, and installation of the crankshaft and connecting rods.

Chapter 5: Cooling System

Chapter 6: Carburetors

Carburetor Procedures

Covers removal, disassembly, assembly, installation, and adjustment of the carburetors.

Measuring and Adjusting Fuel Level

Guides on measuring and adjusting the fuel level within the carburetor float chambers.

Chapter 7: Chassis

Front and Rear Brakes Procedures

Covers inspection and replacement of brake pads, master cylinders, and calipers.

Chapter 8: Electrical

Circuit Diagrams

Provides detailed wiring diagrams for the motorcycle's electrical systems.

Ignition System Troubleshooting

Covers the ignition system's circuit diagram, troubleshooting steps, and component checks.

Electric Starting System Troubleshooting

Details the starting system's circuit diagram, operation, and troubleshooting procedures.

Charging System Troubleshooting

Covers the charging system's circuit diagram, troubleshooting, and component checks.

Lighting System Troubleshooting

Details the lighting system's circuit diagram, troubleshooting for various lights, and checks.

Signal System Troubleshooting

Covers the signal system's circuit diagram and troubleshooting for lights, horn, and switches.

Self-Diagnosis Feature

Explains the motorcycle's self-diagnosis feature and how to interpret condition codes.

Chapter 9: Troubleshooting

Starting Failure/Hard Starting Causes

Lists potential causes for starting difficulties related to fuel, electrical, compression, and carburetor systems.

Overheating Causes

Lists potential causes for engine overheating, including ignition, fuel, cooling, and engine oil issues.

Poor Braking Causes

Identifies causes for poor braking effect, related to brake discs, fluid, calipers, and hoses.

Unstable Handling Causes

Covers potential causes for unstable handling related to tires, wheels, suspension, frame, and steering.

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