Yamaha FZS600 1998 Service Manual
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Yamaha FZS600 1998 Service Manual

Yamaha FZS600 1998 Service Manual

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  • Page 2: How To Use This Manual

    YP002000 HOW TO USE THIS MANUAL This manual is intended as a handy, easy-to-read reference book for the mechanic. Comprehensive explanations of all installation, removal,disassembly, assembly, repair and inspection procedures are laid out with the individual steps in sequential order. 1 The manual is divided into chapters.
  • Page 3 EB003000 SYMBOLS The following symbols are not relevant to every vehicle. Symbols 1 to 9 indicate the subject of each chapter. General information Specifications Periodic inspection and adjustment Engine Cooling system Carburetor(-s) Chassis Electrical system Troubleshooting Symbols indicate the following. Serviceable with engine mounted Filling fluid Lubricant...

  • Page 4: Troubleshooting

    INDEX GENERAL INFORMATION INFO SPECIFICATIONS SPEC PERIODIC INSPECTIONS AND ADJUSTMENTS ENGINE COOLING SYSTEM COOL CARBURETORS CARB CHASSIS CHAS ELECTRICAL SYSTEM ELEC TROUBLESHOOTING TRBL SHTG...
  • Page 5 INFO...

  • Page 6: General Information

    INFO CHAPTER 1 GENERAL INFORMATION MOTORCYCLE IDENTIFICATION ......... . VEHICLE IDENTIFICATION NUMBER .

  • Page 7: Motorcycle Identification

    MOTORCYCLE IDENTIFICATION INFO EB100000 GENERAL INFORMATION MOTORCYCLE IDENTIFICATION EB100010 VEHICLE IDENTIFICATION NUMBER The vehicle identification number 1 is stamped into the right side of the steering head. EB100020 MODEL CODE The model code label 1 is affixed to the frame. This information will be needed to order spare parts.

  • Page 8: Preparation For Removal And Disassembly

    5. Keep all parts away from any source of fire. EB102010 REPLACEMENT PARTS 1. Use only genuine Yamaha parts for all re- placements. Use oil and grease recom- mended by Yamaha for all lubrication jobs. Other brands may be similar in-function and appearance, but inferior in quality.

  • Page 9: Lock Washers/Plates And Cotter Pins

    IMPORTANT INFORMATION INFO EB102030 LOCK WASHERS/PLATES AND COTTER PINS 1. After removal, replace all lock washers/ plates 1 and cotter pins. After the bolt or nut has been tightened to specification, bend the lock tabs along a flat of the bolt or nut. EB102040 BEARINGS AND OIL SEALS 1.

  • Page 10: Checking The Connections

    CHECKING THE CONNECTIONS INFO EB103000 CHECKING THE CONNECTIONS Check the leads, couplers, and connectors for stains, rust, moisture, etc. 1. Disconnect: S lead S coupler S connector 2. Check: S lead S coupler S connector Moisture !Dry with an air blower. Rust/stains ! Connect and disconnect several times.
  • Page 11 SPECIAL TOOLS INFO EB104000 SPECIAL TOOLS The following special tools are necessary for complete and accurate tune-up and assembly. Use only the appropriate special tools as this will help prevent damage caused by the use of inappropriate tools or improvised techniques. When placing an order, refer to the list provided below to avoid any mistakes.
  • Page 12 SPECIAL TOOLS INFO Tool No. Tool name/Usage Illustration 90890-01399 Special thickness gauge This tool is used to measure the valve clearance. 90890-01401 Spark plug wrench This tool is used for removing or installing the spark plug. 90890-01403 Ring nut wrench This tool is used to tighten the steering ring nut.
  • Page 13 SPECIAL TOOLS INFO Tool No. Tool name/Usage Illustration 90890-03141 Timing light This tool is necessary for checking ignition timing. 90890-04044 Piston ring compressor This tool is used to compress piston rings when installing the cylinder. 90890-03158 Carburetor angle driver This tool is used to adjust the pilot screw. 90890-04086 Clutch holding tool This tool is used for holding the clutch boss.

  • Page 14: Special Tools

    SPECIAL TOOLS INFO Tool No. Tool name/Usage Illustration 90890-85505 Yamaha bond No.1215 This sealant (bond) is used for crankcase mating surface, etc.
  • Page 15 SPEC...

  • Page 16: Chapter 2 Specifications

    SPEC CHAPTER 2 SPECIFICATIONS GENERAL SPECIFICATIONS ..........MAINTENANCE SPECIFICATIONS .

  • Page 17: General Specifications

    SPEC GENERAL SPECIFICATIONS SPECIFICATIONS GENERAL SPECIFICATIONS Model FZS600 Model code: 5DM1 Dimensions: Overall length 2,080 mm Overall width 710 mm Overall height 1,170 mm Seat height 790 mm Wheelbase 1,415 mm Minimum ground clearance 130 mm Minimum turning radius 2,900 mm Basic weight: With oil and full fuel tank 210 kg...
  • Page 18 SPEC GENERAL SPECIFICATIONS Model FZS600 Carburetor: Type/quantity BSR 33/4 Manufacturer MIKUNI Spark plug: Type CR9E, CR8E/U27ESR-NU24ESR-N Manufacturer NGK/DENSO 0.7 X 0.8 mm Spark plug gap Clutch type: Wet, multiple-disc Transmission: Primary reduction system Spur gear Primary reduction ratio 82/48 (1.708) Secondary reduction system Chain drive Secondary reduction ratio...
  • Page 19 SPEC GENERAL SPECIFICATIONS Model FZS600 Brake: Front brake type Dual disc brake operation Right hand operation Rear brake type Single disc brake operation Right foot operation Suspension: Front suspension Telescopic fork Rear suspension Swingarm (link suspension) Shock absorber: Front shock absorber Coil spring/Oil damper Rear shock absorber Coil spring/Gas-oil damper...
  • Page 20 SPEC MAINTENANCE SPECIFICATIONS MAINTENANCE SPECIFICATIONS ENGINE Item Standard Limit Cylinder head: Warp limit 0.05 mm Cylinder: 62.00 X 62.01 mm Bore size 62.1 mm Taper limit 0.09 mm Out of round limit 0.07 mm Camshaft: Drive method Chain drive (center) 23.000 X 23.021 mm Cam cap inside dia.

  • Page 21: Maintenance Specifications

    SPEC MAINTENANCE SPECIFICATIONS Item Standard Limit Stem-to-guide clearance 0.010 0.037 mm 0.08 mm 0.025 0.052 mm 0.1 mm Stem runout limit 0.04 mm Valve seat width 1.1 mm 1.6 mm 1.1 mm 1.6 mm Valve spring: Free length IN/EX 40.09 mm 37.5 mm Set length (valve closed) IN/EX...
  • Page 22 SPEC MAINTENANCE SPECIFICATIONS Item Standard Limit Clutch: 2.94 X 3.06 mm Friction plate thickness Quantity 8 pcs Wear limit 2.8 mm 2.94 X 3.06 mm Friction plate thickness Quantity 1 pcs 1.9 X 2.1 mm Clutch plate thickness Quantity 8 pcs Warp limit 0.1 mm Clutch spring free length...
  • Page 23 SPEC MAINTENANCE SPECIFICATIONS Item Standard Limit Lubrication system: Oil filter type Paper type Oil pump type Trochoid type Tip clearance “A” or “B” 0.03 0.09 mm 0.15 mm Side clearance 0.03 0.08 mm 0.15 mm Bypass valve setting pressure 120 kPa (0.8 1.2 kg/cm Relief valve operating pressure 550 kPa (4.5...

  • Page 24: Tightening Torques Engine

    SPEC MAINTENANCE SPECIFICATIONS TIGHTENING TORQUES ENGINE Tightening Thread torque Part to be tightened Part name Q’ty Remarks size size mSkg Camshaft cap Bolt Cylinder head Spark plug – Cylinder head cover Bolt Cylinder head side cover Bolt Connecting rod cap See NOTE Camshaft sprocket Bolt...
  • Page 25 SPEC MAINTENANCE SPECIFICATIONS Tightening Thread torque Part to be tightened Part name Q’ty Remarks size size mSkg Starter cover Bolt Oil gallery – Clutch cover Bolt Clamp (A.C magneto cover) Screw Starter clutch assembly Bolt Starter clutch outer Bolt Pressure plate Screw Clutch boss Bolt...
  • Page 26 SPEC MAINTENANCE SPECIFICATIONS CHASSIS Item Standard Limit Steering system: Angular bearing Steering bearing type Front suspension: Front fork travel 120 mm Fork spring free length 323 mm 319 mm Fitting length 315.9 mm Collar length 200 mm Spring Rate (K1) 7.5 N/mm (0.75 kg/mm) (K2) 14 N/mm (1.4 kg/mm)
  • Page 27 SPEC MAINTENANCE SPECIFICATIONS Item Standard Limit Front disc brake: Type Dual Disc outside dia. thickness 4 mm Disc deflection limit 0.2 mm Pad thickness Inner 5.5 mm 0.5 mm Pad thickness Outer 5.5 mm 0.5 mm Master cylinder inside dia. 14 mm Caliper cylinder inside dia.

  • Page 28: Tightening Torques Chassis

    SPEC MAINTENANCE SPECIFICATIONS TIGHTENING TORQUES CHASSIS Tightening Remarks torque Part to be tightened Thread size mSkg Upper bracket and inner tube 1.25 Upper bracket and steering stem 11.0 Handlebar under holder 1.25 Handlebar upper holder 1.25 Under bracket and inner tube 1.25 Ring nut (steering stem) –...
  • Page 29 SPEC MAINTENANCE SPECIFICATIONS Tightening torque Part to be tightened Thread size Remarks mSkg Side cover and frame Garb bar 1.25 Front wheel axle Front wheel axle pinch bolt Front brake caliper 1.25 Front brake disc 1.25 Front brake caliper bleed screw Compression bar 1.25 Rear wheel sprocket...
  • Page 30 SPEC MAINTENANCE SPECIFICATIONS ELECTRICAL Item Standard Limit Voltage 12 V Ignition system: Ignition timing (B.T.D.C.) 10_/1,250 r/min Advanced timing (B.T.D.C.) 50_/4,500 r/min Advance type TPS and electrical type T.C.I.: 189 X 231 Ω Y-L Pickup coil resistance T.C.I. unit model/manufacturer J4T085/MITSUBISHI Ignition coil: Model/manufacturer...
  • Page 31 SPEC MAINTENANCE SPECIFICATIONS Item Standard Limit Starter motor: Model/manufacturer SM-13/MITSUBA I.D. number SM-13 Output 0.7 kW 0.0025 Ω at 20_C Armature coil resistance 0.0015 Brush overall length 10 mm 4 mm Brush spring pressure 10.2 N (780 1.020 gf) Commutator dia. 28 mm 27 mm Mica undercut (depth)
  • Page 32 SPEC MAINTENANCE SPECIFICATIONS Item Standard limit Amperage for individual circuit: Main 30 A Headlight 20 A Signal 20 A Ignition 20 A 10 A Back up Reserve 30 A 20 A 10 A 2-16...

  • Page 33: General Tightening Torque Specifications

    SPEC GENERAL TIGHTENING TORQUE SPECIFICATIONS EB201000 GENERAL TIGHTENING TORQUE SPECIFICATIONS This chart specifies tightening torques for standard fasteners with a standard ISO thread pitch. Tight- ening torque specifications for special components or assemblies are provided for each chapter of this manual.
  • Page 34 Starter idrer gear shaft 1 Neutral switch O-ring Push rod Push rod 1 O-ring Shift pedal Shift shaft Water pump O-ring Cylinder head cover gasket Yamaha bond No. 1215 Shift cam plug Breather plate Crankcase Yamaha bond No. 1215 Taper plug Bearing plate 2-18...

  • Page 35: Lubrication Point And Lubrication Types

    SPEC LUBRICATION POINT AND LUBRICATION TYPES CHASSIS Lubrication Point Symbol Steering bearing and bearing race (upper and lower) Pivot shaft Rear arm bearing Rear arm oil seal Rear arm cover oil seal lips Relay arm bearing Relay arm oil seal Rear shock absorber (upper/lower) Front wheel oil seal Speed sensor oil seal...
  • Page 36 SPEC COOLING SYSTEM DIAGRAMS EB203000 COOLING SYSTEM DIAGRAMS 1 Engine outlet hose 8 Radiator outlet hose 2 Engine outlet hose 9 Radiator 3 Carburetor inlet hose 10 Radiator inlet hose 4 Carburetor outlet hose 5 Water pump 6 Coolant drain bolt 7 Water pump outlet hose 2-20...

  • Page 37: Cooling System Diagrams

    SPEC COOLING SYSTEM DIAGRAMS 1 Radiator 2 Water pump outlet hose 3 Oil cooler inlet hose 4 Oil cooler outlet hose 5 Carburetor outlet hose 2-21...

  • Page 38: Lubrication Diagrams

    SPEC LUBRICATION DIAGRAMS EB204000 LUBRICATION DIAGRAMS 1 Oil nozzle (main nozzle) 2 Oil nozzle (drive axle) 3 Projection 4 Oil filter 5 Relief valve 6 Oil strainer 7 Oil pump 2-22...
  • Page 39 SPEC LUBRICATION DIAGRAMS 1 Main axle 2 Drive axle 3 Camshaft 4 Oil delivery pipe 2-23...
  • Page 40 SPEC LUBRICATION DIAGRAMS 1 Camshaft 2 Crankshaft 2-24...

  • Page 41: Cable Routing

    SPEC CABLE ROUTING EB205000 CABLE ROUTING 1 Throttle cable 9 Handlebar switch (left) 2 Clutch cable A Use a plastic clamp to fasten 3 Handlebar switch (right) together the handlebar switch 4 Starter cable lead (left), clutch cable and 5 Main switch starter cable.
  • Page 42 SPEC CABLE ROUTING 1 Main switch lead 11 Battery 21 Speed sensor lead 2 Starter cable 12 Starting circuit cut-off relay 22 Horn 3 Handlebar switch lead (left) 13 Battery positive (+) lead 23 Starter relay 14 Seat lock cable 24 Fuse box 4 Clutch cable 5 Rectifier/ regulator...
  • Page 43 SPEC CABLE ROUTING A Use a plastic clamp to fasten Position the band end to out side of D Use a steel holder to fasten the handlebar switch lead (left), chassis. together the AC magneto lead, main switch lead, clutch cable C Use a plastic locking tie to sidestand lead and oil and starter cable to the frame.
  • Page 44 SPEC CABLE ROUTING 1 Battery negative (–) lead 10 Throttle cable A Use a plastic clamp to fasten 2 Rear brake switch lead 11 Brake hose together the throttle cables, 3 Battery 12 Headlight lead headlight lead handlebar switch 13 Speed sensor lead 4 Reservoir tank hose (right) and speed sensor lead.
  • Page 45 SPEC CABLE ROUTING C Pass the main switch lead under E Pass the battery negative (–) the throttle cables, headlight lead inside of the reservoir lead, handlebar switch lead hose. (right) and speed sensor lead, then insert it right side of the box. D Pass the reservoir tank over flow hose, fuel tank breather hose and fuel tank drain hose...
  • Page 46 SPEC CABLE ROUTING 1 Throttle cable 11 Battery negative (–) lead 21 Starter relay 2 Handlebar switch lead (right) 12 Battery 22 Starting circuit cut-off relay 3 Headlight lead 13 Rear brake reservoir tank 23 Flasher relay 14 Rear brake switch lead 24 Fuel pump lead coupler 4 Speed sensor lead 5 Carburetor heater hose...
  • Page 47 SPEC CABLE ROUTING 31 Starter cable B Pass the rectifier / regulator turn signal light lead and clamp 32 Clutch cable lead, fan motor lead, handlebar 33 Handlebar switch lead (left) switch lead (left), main switch D Pass the reservoir hose left side 34 Main switch lead lead, headlight lead, handlebar of thermo stat housing.

  • Page 49: Chapter 3 Periodic Inspections And Adjustments

    CHAPTER 3 PERIODIC INSPECTIONS AND ADJUSTMENTS INTRODUCTION ............PERIODIC MAINTENANCE/LUBRICATION INTERVALS .

  • Page 50: Periodic Maintenance/Lubrication Intervals

    INTRODUCTION / PERIODIC MAINTENANCE/LUBRICATION INTERVALS EB300000 PERIODIC INSPECTIONS AND ADJUSTMENTS INTRODUCTION This chapter includes all information necessary to perform recommended inspections and adjust- ments. If followed, these preventive maintenance procedures will ensure more reliable vehicle opera- tion, a longer service life and reduce the need for costly overhaul work. This information applies to ve- hicles already in service as well as to new vehicles that are being prepared for sale.
  • Page 51 S Change coolant every 24,000 km or 24 months (whichever comes first). *Since these items require special tools, data and technical skills, they should be serviced by a Yamaha dealer. NOTE: S The air filter needs more frequent service if you are riding in unusually wet or dusty areas.
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