EAU03338 Welcome to the Yamaha world of motorcycling! As the owner of an FZS600, you are benefiting from Yamaha’s vast experience and newest technology regarding the design and manufacture of high-quality products, which have earned Yamaha a reputation for dependability.
This manual should be considered a permanent part of this motorcycle and should remain with it even if the motorcycle is subsequently sold. Yamaha continually seeks advancements in product design and quality. Therefore, while this manual contains the most current product information available at the time of printing, there may be minor discrepancies between your motorcycle and this manual.
EAU00009 TABLE OF CONTENTS 1 GIVE SAFETY THE RIGHT OF WAY 2 DESCRIPTION 3 INSTRUMENT AND CONTROL FUNCTIONS 4 PRE-OPERATION CHECKS 5 OPERATION AND IMPORTANT RIDING POINTS 6 PERIODIC MAINTENANCE AND MINOR REPAIR 7 MOTORCYCLE CARE AND STORAGE 8 SPECIFICATIONS 9 CONSUMER INFORMATION INDEX...
GIVE SAFETY THE RIGHT OF WAY GIVE SAFETY THE RIGHT OF WAY ..........1-1...
G IVE SAFETY THE RIGHT OF WAY EAU00021 Motorcycles are fascinating vehicles, which can give you an unsurpassed feeling of power and freedom. However, they also impose certain limits, which you must accept; even the best motorcycle does not ignore the laws of physics. Regular care and maintenance are essential for preserving value and operating condition of your motorcycle.
D ESCRIPTION EAU00026 Left view 1. Front fork spring preload adjusting bolt (page 3-13) 8. Seat lock (page 3-12) 2. Starter (choke) lever (page 3-12) 9. Rear shock absorber spring preload 3. Air filter element (page 6-17) adjusting ring (page 3-14) 4.
INSTRUMENT AND CONTROL FUNCTIONS Main switch/steering lock ........3-1 Fuel tank cap ............ 3-10 Indicator and warning lights ........3-3 Fuel ..............3-11 Speedometer unit ..........3-4 Starter (choke) lever .......... 3-12 Tachometer unit ...........3-5 Seat ..............3-12 Self-diagnosis devices .........3-6 Storage compartment ........3-13 Anti-theft alarm (optional) ........3-6 Adjusting the front fork ........
I NSTRUMENT AND CONTROL FUNCTIONS EAU00027 1. Push. 2. Turn. EAU00029 EAU00040 Main switch/steering lock LOCK EW000016 The steering is locked, and all electrical WARNING The main switch/steering lock controls systems are off. The key can be re- the ignition and lighting systems, and is Never turn the key to “OFF”...
INSTRUMENT AND CONTROL FUNCTIONS EAU01574 (Parking) The steering is locked, and the taillights and auxiliary lights are on, but all other electrical systems are off. The key can be removed. The steering must be locked before the key can be turned to “ ”.
5. Right turn signal indicator light “ ” 1. Turn the key to “ON”. 6. Coolant temperature warning light “ ” have a Yamaha dealer check the 2. If the warning light does not come 7. Fuel level warning light “ ” electrical circuit.
2. If the warning light does not come 3. “SELECT” button on for a few seconds, then go off, 4. “RESET” button To reset a meter have a Yamaha dealer check the To reset either tripmeter 1 or 2 to 0.0, EAU04289 electrical circuit. Speedometer unit select either by pushing the “SELECT”...
INSTRUMENT AND CONTROL FUNCTIONS This tachometer unit is equipped with a clock. To set the clock: 1. Push both the “SELECT” and “RESET” buttons for at least two seconds. 2. When the hour digits start flashing, push the “RESET” button to set the hours.
INSTRUMENT AND CONTROL FUNCTIONS EAU03889 Turn signal switch “ ” To signal a right-hand turn, push this switch to “ ”. To signal a left-hand turn, push this switch to “ ”. When released, the switch returns to the cen- ter position.
INSTRUMENT AND CONTROL FUNCTIONS EC000006 EAU00143 Start switch “ ” CAUTION: Push this switch to crank the engine Do not use the hazard light for an ex- with the starter. tended length of time, otherwise the EC000005 battery may discharge. CAUTION: See page 5-1 for starting instruc- tions prior to starting the engine.
INSTRUMENT AND CONTROL FUNCTIONS 1. Clutch lever 1. Shift pedal 1. Brake lever 2. Brake lever position adjusting dial EAU00152 EAU00157 3. Arrow mark Clutch lever Shift pedal a. Distance between brake lever and handlebar The clutch lever is located at the left The shift pedal is located on the left grip handlebar grip.
INSTRUMENT AND CONTROL FUNCTIONS 2. Turn the key counterclockwise to the original position, remove it, and then close the lock cover. NOTE: The fuel tank cap cannot be closed un- less the key is in the lock. In addition, the key cannot be removed if the cap is not properly closed and locked.
INSTRUMENT AND CONTROL FUNCTIONS EAU00185 Your Yamaha engine has been de- CAUTION: signed to use regular unleaded gaso- Immediately wipe off spilled fuel line with a research octane number of with a clean, dry, soft cloth, since 91 or higher. If knocking (or pinging)
INSTRUMENT AND CONTROL FUNCTIONS 1. Starter (choke) lever “ ” 1. Seat lock 1. Projection 2. Unlock. 2. Seat holder EAU03839 Starter (choke) lever “ ” To install the seat EAU01319 Seat Starting a cold engine requires a richer 1. Insert the projection on the rear of air-fuel mixture, which is supplied by the seat into the seat holder as To remove the seat...
This storage compartment is designed This front fork is equipped with spring other documents in the storage com- to hold an optional genuine Yamaha preload adjusting bolts. partment, be sure to wrap them in a U-LOCK. (Other locks may not fit.) EW000035 plastic bag so that they will not get wet.
INSTRUMENT AND CONTROL FUNCTIONS Adjust the spring preload as follows. To increase the spring preload and thereby harden the suspension, turn the adjusting ring in direction a. To de- crease the spring preload and thereby soften the suspension, turn the adjust- ing ring in direction b.
It cuts the running engine when check this system regularly as de- the transmission is in gear and the scribed below and have a Yamaha sidestand is moved down. dealer repair it if it does not function Periodically check the operation of the properly.
5. Push the start switch. Does the engine start? The neutral switch may be defective. The motorcycle should not be ridden until checked by a Yamaha dealer. With the engine still running: 6. Move the sidestand up. 7. Keep the clutch lever pulled.
• If necessary, add recommended coolant to specified level. 6-12–6-13 • Check cooling system for leakage. • Check operation. • If soft or spongy, have Yamaha dealer bleed hydraulic system. Front brake • Check fluid level in reservoir. 6-26–6-28 • If necessary, add recommended brake fluid to specified level.
PAGE • Make sure that operation is smooth. Throttle grip • Check free play. 6-20, 6-30 • If necessary, have Yamaha dealer make adjustment or lubricate. • Make sure that operation is smooth. Control cables 6-30 • Lubricate if necessary.
PRE-OPERATION CHECKS NOTE: Pre-operation checks should be made each time the motorcycle is used. Such an inspection can be accomplished in a very short time; and the added safety it assures is more than worth the time involved. EWA00033 WARNING If any item in the Pre-operation check list is not working properly, have it inspected and repaired before operating the motorcycle.
Before starting out, make sure should be on, otherwise have a Yamaha dealer check the electrical cir- that the sidestand is up. If the sidestand is not raised com- cuit. pletely, it could contact the 3.
NOTE: If the engine fails to start, release the ing light flickers or remains on fuel, have a Yamaha dealer start switch, wait a few seconds, and after starting, immediately stop check the electrical circuit.
OPERATION AND IMPORTANT RIDING POINTS EAU01258 EC000048 Starting a warm engine CAUTION: Follow the same procedure as for start- Even with the transmission in ing a cold engine with the exception the neutral position, do not that the starter (choke) is not required coast for long periods of time when the engine is warm.
OPERATION AND IMPORTANT RIDING POINTS EAU02937 EAU00424 EAU01128 Recommended shift points Tips for reducing fuel Engine break-in (for Switzerland only) consumption There is never a more important period in the life of your engine than the period The recommended shift points during Fuel consumption depends largely on between 0 and 1,600 km.
The vehicle can now be operated nor- mally. EC000053 CAUTION: Keep the engine speed out of the tachometer red zone. If any engine trouble should oc- cur during the engine break-in period, immediately have a Yamaha dealer check the vehi- cle.
PERIODIC MAINTENANCE AND MINOR REPAIR Owner’s tool kit ............6-1 Checking and lubricating the throttle grip and cable ..........6-30 Periodic maintenance and lubrication chart ..6-2 Checking and lubricating the brake and Removing and installing panels ......6-5 shift pedals ............6-31 Checking the spark plugs ........6-7 Checking and lubricating the brake and Engine oil and oil filter cartridge ......6-9...
Periodic inspection, adjustment and lu- ence required for a particular job, have brication will keep your vehicle in the a Yamaha dealer perform it for you. safest and most efficient condition pos- EW000063 sible. The most important points of in-...
The annual checks must be performed every year, except if a kilometer-based maintenance is performed instead. From 50,000 km, repeat the maintenance intervals starting from 10,000 km. Items marked with an asterisk should be performed by a Yamaha dealer as they require special tools, data and techni- cal skills.
PERIODIC MAINTENANCE AND MINOR REPAIR ODOMETER READING (× 1,000 km) ANNUAL ITEM CHECK OR MAINTENANCE JOB CHECK √ √ √ √ √ • Check for cracks or damage. Brake hoses • Replace. (See NOTE on page 6-4.) Every 4 years √...
PERIODIC MAINTENANCE AND MINOR REPAIR ODOMETER READING (× 1,000 km) ANNUAL ITEM CHECK OR MAINTENANCE JOB CHECK • Change. √ √ √ √ √ √ Engine oil • Check oil level and vehicle for oil leakage. √ √ √ Engine oil filter cartridge • Replace. √...
PERIODIC MAINTENANCE AND MINOR REPAIR 1. Panel A 1. Panel C 1. Panel A 2. Panel B 2. Bolt EAU01122 EAU00491 Removing and installing Panel A, C To remove the panel panels Remove the bolt, and then pull the pan- The panels shown above need to be el off as shown.
PERIODIC MAINTENANCE AND MINOR REPAIR 1. Panel C 1. Panel B 2. Bolt 2. Screw (× 3) EAU01315 Panel B To remove the panel Remove the screws, and then take the panel off. To install the panel Place the panel in the original position, and then install the screws.
Do not attempt to diagnose such problems yourself. Instead, have a Yamaha dealer check the motorcycle. 3. Check each spark plug for elec- trode erosion and excessive car- bon or other deposits, and replace 1.
PERIODIC MAINTENANCE AND MINOR REPAIR 3. Install the spark plug with the spark plug wrench, and then tight- en it to the specified torque. Tightening torque: Spark plug: 12.5 Nm (1.25 m·kgf) NOTE: a. Spark plug gap If a torque wrench is not available when installing a spark plug, a good estimate To install a spark plug of the correct torque is 1/4–1/2 turn...
PERIODIC MAINTENANCE AND MINOR REPAIR To check the engine oil level Right Right 1. Place the motorcycle on the cen- terstand. NOTE: Make sure that the motorcycle is posi- tioned straight up when checking the oil level. A slight tilt to the side can result in a false reading.
O-ring of the new oil filter car- the crankcase. tridge. NOTE: NOTE: An oil filter wrench is available at a NOTE: Skip steps 4–6 if the oil filter cartridge is Yamaha dealer. Make sure that the O-ring is properly not being replaced. seated. 6-10...
PERIODIC MAINTENANCE AND MINOR REPAIR 8. Add the specified amount of the ECA00105 CAUTION: recommended engine oil, and In order to prevent clutch slip- then install and tighten the oil filler page (since the engine oil also cap. lubricates the clutch), do not mix any chemical additives with Recommended engine oil: the oil or use oils of grade “CD”...
If the oil level warning light flickers on a cold engine since the level varies with engine temperature. or remains on, immediately turn the Make sure that the motorcycle is engine off and have a Yamaha deal- positioned straight when er check the vehicle.
If water has been added to the 2. Remove the seat. (See page 3-12 coolant, have a Yamaha dealer for seat removal and installation check the antifreeze content of procedures.) the coolant as soon as possible, 3.
PERIODIC MAINTENANCE AND MINOR REPAIR 1. Hose 1. Water pump drain bolt 1. Radiator cap 2. Fuel cock 2. Sidestand switch lead 2. Radiator overflow hose 3. Fuel level sensor coupler 3. Lead holder EW000067 4. Funnel 4. Lift the fuel tank, and then turn the WARNING 7.
PERIODIC MAINTENANCE AND MINOR REPAIR NOTE: Check the washer for damage and re- place it if necessary. Tightening torque: Coolant drain bolt: 10 Nm (1,0 m·kgf) 17. Connect the radiator overflow 1. Hose holder hose and make sure that it is prop- 13.
Yamaha 23. Install the fuel tank bolts. dealer replace the hose, other- If water has been used instead 24.
PERIODIC MAINTENANCE AND MINOR REPAIR EAU03559* Air filter The air filter element should be cleaned at the specified intervals. It should be cleaned more frequently if you are riding in unusually wet or dusty areas. 1. Remove the seat. (See page 3-12 for seat removal and installation procedures.) 1.
PERIODIC MAINTENANCE AND MINOR REPAIR 1. Air filter case cover 1. Air filter element 1. Air filter element 2. Screw (× 4) 6. Pull out the air filter element. 7. Tap the air filter element lightly to 5. Remove the screws holding the air remove most of the dust and dirt.
The valve clearance changes with use, resulting in improper air-fuel mixture and/or engine noise. To prevent this from occurring, the valve clearance must be adjusted by a Yamaha dealer at the intervals specified in the periodic maintenance and lubrication chart. 1. Throttle stop screw a.
PERIODIC MAINTENANCE AND MINOR REPAIR EAU00658 CE-01E EWA00012 Tire air pressure Tires WARNING (measured on cold tires) To maximize the performance, durabil- Load* Front Rear Because loading has an enormous ity, and safe operation of your motor- 225 kPa 250 kPa impact on the handling, braking, Up to 90 kg 2.25 kgf/cm...
160/60 ZR17 M/C (69W) proved this model 2. Tire air valve core 160/60 ZR17 (69W) Yamaha Motor Co., Ltd. Dunlop D207J 3. Tire air valve cap with seal 160/60 ZR17 M/C (69W) Always make sure that the valve Tire information...
If any damage is the danger of bursting at super 1. Clutch lever free play locknut found, have a Yamaha dealer re- high speeds. 2. Clutch lever free play adjusting bolt place the wheel. Do not attempt Brand-new tires can have a rela- c.
A soft or spongy feeling in the brake clutch does not operate correctly, have pedal can indicate the presence of a Yamaha dealer check the internal air in the hydraulic system. If there clutch mechanism. is air in the hydraulic system, have a Yamaha dealer bleed the system be- fore operating the motorcycle.
EAU03985 Changing the brake fluid Drive chain slack: 30–45 mm Have a Yamaha dealer change the brake fluid at the intervals specified in 5. If the drive chain slack is incorrect, the NOTE after the periodic mainte- adjust it as follows.
PERIODIC MAINTENANCE AND MINOR REPAIR EAU03006 NOTE: Lubricating the drive chain Using the alignment marks on each The drive chain must be cleaned and side of the swingarm, make sure that lubricated at the intervals specified in both adjusting nuts are in the same po- the periodic maintenance and lubrica- sition for proper wheel alignment.
If a cable is damaged the periodic maintenance chart. lubricants for the drive chain, as or does not move smoothly, have a they may contain substances that Yamaha dealer check or replace it. could damage the O-rings. Recommended lubricant: Engine oil EW000112...
Recommended lubricant: Recommended lubricant: EW000114 WARNING Lithium-soap-based grease Lithium-soap-based grease If the centerstand or sidestand does (all-purpose grease) (all-purpose grease) not move up and down smoothly, have a Yamaha dealer check or re- pair it. 6-31...
PERIODIC MAINTENANCE AND MINOR REPAIR EAU04282 Recommended lubricant: Lubricating the rear Lithium-soap-based grease suspension (all-purpose grease) The pivoting points of the rear suspen- sion must be lubricated at the intervals specified in the periodic maintenance and lubrication chart. Recommended lubricant: Lithium-soap-based grease 6-32...
To charge the battery Batteries produce explosive hy- charge it if necessary. Have a Yamaha dealer charge the bat- drogen gas. Therefore, keep 3. Fully charge the battery before in- tery as soon as possible if it seems to sparks, flames, cigarettes, etc.,...
PERIODIC MAINTENANCE AND MINOR REPAIR 2. Remove the blown fuse, and then 4. If the fuse immediately blows install a new fuse of the specified again, have a Yamaha dealer amperage. check the electrical system. Specified fuses: Main fuse: 30 A...
PERIODIC MAINTENANCE AND MINOR REPAIR 1. Headlight bulb cover 1. Headlight bulb holder 1. Do not touch this area. 2. Headlight coupler 2. Unhook the headlight bulb holder, EW000119 EAU00826 WARNING and then remove the defective Replacing the headlight bulb Headlight bulbs get very hot.
4. Install the bulb cover, and then 5. Insert a new bulb into the socket, connect the coupler. push it in, and then turn it clock- 5. Have a Yamaha dealer adjust the wise until it stops. headlight beam if necessary. 6-38...
2. Remove the defective bulb by 4. Remove the brake calipers by re- WARNING pushing it in and turning it counter- moving the bolts. It is advisable to have a Yamaha clockwise. ECA00047 dealer service the wheel. 3. Insert a new bulb into the socket,...
PERIODIC MAINTENANCE AND MINOR REPAIR 5. Remove the plastic fastener hold- ing the speed sensor lead and the brake hose together. 6. While supporting the speed sen- sor, pull the wheel axle out, and then remove the wheel. 1. Speed sensor 1.
EW000122 3. Place the motorcycle on the cen- WARNING terstand. It is advisable to have a Yamaha 4. Remove the axle nut and the dealer service the wheel. brake caliper by removing the Securely support the motorcy- bolts.
PERIODIC MAINTENANCE AND MINOR REPAIR 5. Loosen the locknut and drive NOTE: Make sure that there is enough space chain slack adjusting nut on each between the brake pads before install- side of the swingarm. ing the brake caliper onto the brake 6.
The following troubleshooting charts represent quick and easy procedures for checking these vital systems your- self. However, should your motorcycle require any repair, take it to a Yamaha dealer, whose skilled technicians have the necessary tools, experience, and know-how to service the motorcycle properly.
Remove spark plugs and check electrodes. Engine doesn’t start, go to battery Dry. Ask a Yamaha dealer to inspect. check. 4. Battery Engine turns over Battery good. quickly. Engine doesn’t start, ask a Yamaha Use the electric starter.
Restart the engine. If the engine overheats again, ask a Level is OK. Yamaha dealer to inspect and repair the cooling system. NOTE: If coolant is not available, tap water can be temporarily used instead, provided that it is changed to the recommended coolant as soon as possible.
MOTORCYCLE CARE AND STORAGE Care ....................7-1 Storage ....................7-4...
M OTORCYCLE CARE AND STORAGE EAU03426 Care Before cleaning Cleaning 1. Cover the muffler outlet with a ECA00010 While the open design of a motorcycle CAUTION: plastic bag after the engine has reveals the attractiveness of the tech- Avoid using strong acidic wheel cooled down.
MOTORCYCLE CARE AND STORAGE Do not use any harsh chemical For motorcycles equipped with After riding in the rain, near the sea or products on plastic parts. Be a windshield: Do not use strong on salt-sprayed roads sure to avoid using cloths or cleaners or hard sponges as Since sea salt or salt sprayed on roads sponges which have been in...
MOTORCYCLE CARE AND STORAGE ECA00012 After cleaning EWA00001 CAUTION: WARNING 1. Dry the motorcycle with a chamois Do not use warm water since it in- Make sure that there is no oil or or an absorbing cloth. wax on the brakes or tires. If creases the corrosive action of the 2.
NOTE: fuel tank. To prevent corrosion, avoid Consult a Yamaha dealer for advice on 4. Fill up the fuel tank and add fuel damp cellars, stables (because what products to use. stabilizer (if available) to prevent...
MOTORCYCLE CARE AND STORAGE c. Install the spark plug caps onto the 7. Check and, if necessary, correct spark plugs, and then place the the tire air pressure, and then lift spark plugs on the cylinder head the motorcycle so that both of its so that the electrodes are ground- wheels are off the ground.
S PECIFICATIONS EAU01038 Specifications CS-01E Model FZS600 Engine oil Dimensions Type -20 -10 10 20 30 40 50 ˚C Overall length 2,080 mm (except for N, SF) SAE 10W-30 2,175 mm (for N, SF) SAE 10W-40 Overall width 710 mm...
SPECIFICATIONS Cooling system capacity (total Number of drive chain amount) 1.95 L sprocket teeth (rear/front) 48/15 Air filter Dry element Transmission type Constant-mesh 6-speed Fuel Operation Left foot Type REGULAR UNLEADED Gear ratio GASOLINE ONLY 2.846 Fuel tank capacity 22 L 1.947 Fuel reserve amount 3.6 L...
SPECIFICATIONS Rear Rear Type Tubeless Type Cast wheel 17 × MT 5.00 Size 160 / 60 ZR17 (69W) Size 17 M/C × MT 5.00 160 / 60 ZR17 M/C (69W) Manufacturer/ Brakes model Bridgestone / BT-57R Front Dunlop / D207J Type Dual disc brake Maximum load*...
SPECIFICATIONS Electrical system Fuses Ignition system Transistorized coil ignition Main fuse 30 A (digital) Headlight fuse 20 A Charging system Signaling system fuse 10 A Model A.C. magneto Radiator fan fuse 10 A Standard output 14 V, 21 A @ 5,000 r/min Ignition fuse 20 A Battery...
SPECIFICATIONS EAU03941 Conversion table CS-03E Conversion table All specification data in this manual are listed in SI and METRIC SYSTEM TO IMPERIAL SYSTEM METRIC UNITS. Metric unit Conversion factor Imperial unit × m·kgf 7.233 ft·lb × m·kgf 86.794 in·lb Use this table to convert METRIC unit values to IMPERIAL Torque ×...
Record the key identification number, vehicle identification number and mod- el label information in the spaces pro- vided below for assistance when ordering spare parts from a Yamaha dealer or for reference in case the vehi- cle is stolen. 1. Key identification number 1.
The model label is affixed to the frame under the passenger seat. (See page 3-12 for seat removal and instal- lation procedures.) Record the informa- tion on this label in the space provided. This information will be needed when ordering spare parts from a Yamaha dealer.
I NDEX 1 0 - Drive chain, lubricating ......6-29 Drive chain slack ........6-28 Air filter ............6-17 Light switch ..........3-8 Adjusting..........6-29 Anti-theft alarm ........3-6 Luggage strap holders ......3-15 Checking.......... 6-28 Battery ...........6-35 Main switch/steering lock ......3-1 Engine break-in ........5-4 Brake and clutch levers, Model label ..........9-2 Engine oil and oil filter cartridge ....
INDEX Starter (choke) lever ......3-12 Removing ........6-41 Starting a cold engine ......5-1 Wheels..........6-24 Starting a warm engine......5-3 Start switch..........3-8 Steering, checking ......... 6-33 Storage............ 7-4 Storage compartment ......3-13 Suspension (rear), lubricating ....6-32 Tachometer unit ........
YAMAHA MOTOR CO., LTD. PRINTED ON RECYCLED PAPER PRINTED IN JAPAN 8 - 0.3 × 1 CR 2001...