Yamaha FZS600 2000 Supplementary Service Manual
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Yamaha FZS600 2000 Supplementary Service Manual

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Summary of Contents for Yamaha FZS600 2000

  • Page 3 FOREWORD This Supplementary Service Manual has been prepared to introduce new service and data for the FZS600 2000. For complete service information procedures it is necessary to use this Supplementary Service Manual together with the following manual. FZS600 SERVICE MANUAL: 5DM1-AE1...

  • Page 4: Important Information

    It is not possible to include all the knowledge of a mechanic in one manual, so it is assumed that anyone who uses this book to perform maintenance and repairs on Yamaha scooter has a basic understanding of the mechanical ideas and the procedures of scooter repair.

  • Page 5: 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 6 EB003000 SYMBOLS The following symbols are not relevant to every SPEC vehicle. INFO Symbols 1 to 9 indicate the subject of each chapter. 1 General information 2 Specifications 3 Periodic inspection and adjustment 4 Engine 5 Cooling system 6 Carburetor(-s) 7 Chassis COOL CARB...

  • Page 7: Table Of Contents

    ............FZS600 2000 WIRING DIAGRAM...

  • Page 9: General Information

    FEATURES INFO GENERAL INFORMATION FEATURES SPEEDOMETER 1 Speedometer 2 Odometer / Tripmeter / Clock 3 “SELECT” button 4 “RESET” button This speedometer is equipped with: S an odometer S two tripmeters S a clock Odometer and tripmeter modes When set to “ODO”, the motorcycle’s total mileage is indicated. When set to “TRIP 1”...

  • Page 10: Specifications

    SPEC GENERAL SPECIFICATIONS SPECIFICATIONS GENERAL SPECIFICATIONS Model FZS600 Model code: 5DM7 5DM8 5DM9 Fuel: Type Regular unleaded gasoline Fuel tank capacity 20 L Fuel reserve amount 3.5 L Tire pressure: Maximum load-except motorcycle 187 kg 0 X 90 kg Loading condition A* front 225 kPa (2.25 kg/cm , 2.25 bar)

  • Page 11: Maintenance Specifications

    SPEC MAINTENANCE SPECIFICATIONS MAINTENANCE SPECIFICATIONS ENGINE Item Standard Limit Valve spring: Free length IN/EX 40.09 mm 37.5 mm Set length (valve closed) IN/EX 34.5 mm 131.4 X 153.0 N (13.4 X 15.6 kg) Compressed pressure IN/EX Tilt limit IN/EX 2.5_/1.8 mm Direction of winding IN/EX Clockwise...

  • Page 12: Chassis

    SPEC MAINTENANCE SPECIFICATIONS CHASSIS Item Standard Limit Front suspension: Front fork travel 120 mm Fork spring free length 316.8 mm 319 mm Fitting length 309.8 mm Collar length 183 mm Spring Rate (K1) 7.35 N/mm (0.75 kg/mm) (K2) 13.72 N/mm (1.4 kg/mm) 0 X 70 mm Stroke (K1)
  • Page 13 SPEC MAINTENANCE SPECIFICATIONS ELECTRICAL Item Standard Limit 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 Digital type T.C.I.: 189 X 231 Ω Y-L Pickup coil resistance T.C.I. unit model/manufacturer J4T095/MITSUBISHI Charging system: Type A.C. magneto Model/manufacturer F4T359 /MITSUBISHI Standard output...
  • Page 14 SPEC MAINTENANCE SPECIFICATIONS Item Standard limit Starting circuit cut-off relay: Model/manufacture G8R-30Y-B/OMRON 202.5 X 247.5 Ω at 20_C Coil winding resistance Fuel pump relay: Model/manufacture G8R-30Y-B/OMRON 202.5 X 247.5 Ω at 20_C Coil winding resistance Amperage for individual circuit: Main 30 A Headlight 20 A...

  • Page 15: Cable Routing

    SPEC CABLE ROUTING EB205000 CABLE ROUTING Throttle cable A Use a plastic band to fasten to- D Pass the brake hose out side of Clutch cable gether the handlebar switch lead the speed sensor lead, then use Handlebar switch (left) (L) and the handlebar.
  • Page 16 SPEC CABLE ROUTING Main switch lead Flasher leray Sidestand switch lead Handlebar switch lead (left) Battery Neutral switch lead Clutch cable Starter relay Oil level switch lead Starter cable Battery positive (+) lead Radiator Rectifier/ regulator Seat lock cable Rectifier/ regulator lead Horn lead Seat lock stay Horn...
  • Page 17 SPEC CABLE ROUTING Wire harness Oil level / neutral switch lead D When installing the plug cap, the Relay high tension code should be fac- Fuse box A Use a plastic clamp to fasten the ing the inside of the body. To front brake switch handlebar switch lead (left), E Pass the wire harness, starter...
  • Page 18 SPEC CABLE ROUTING G Use a plastic clamp to fasten to- the clamp to the frame bracket. L Use a steel holder to fasten to- gether the wire harness and the Position the band end to out side gether the AC magneto lead, frame.
  • Page 19 SPEC CABLE ROUTING O Use a plastic clamp to fasten to- S Use a steel holder to fasten to- times from the bottom end by gether the sidestand switch lead gether the speed sensor lead running along the brake hose. and the frame.
  • Page 20 SPEC CABLE ROUTING Rear brake switch lead Handlebar switch lead (right) A Pass the fuel tank drain hose, Battery Throttle cable fuel tank breather hose and res- Reservoir tank over flow hose Brake hose ervoir tank over flow pipe be- Cross tube Guide wire tween the rear arm and the en-...
  • Page 21 SPEC CABLE ROUTING C Pass the T.P.S lead as shown, F Pass the throttle cable, with the J Pass the throttle cable under the then install cover to the air filter pull side up, through the center box. case. of the clamp. K Pass the reservoir tank over flow D Use a plastic clamp to fasten to- G Pass the throttle cable through...
  • Page 22 SPEC CABLE ROUTING O Pass the battery negative lead and rear brake switch lead inside the air filter bracket of the frame. P Pass the reservoir tank over flow pipe between the air filter case and cross tube, and then outside of engine bracket.
  • Page 23 SPEC CABLE ROUTING Throttle cable Pipe Ignitor Speed sensor lead Fuel hose Rear turn signal light lead (right) Handlebar switch lead (right) T.P.S lead Taillight lead Headlight lead Fuel pipe Rear turn signal light lead (left) Thermostat housing Fuel sender, coupler Taillight bracket Carburetor heater hose Battery negative (–) lead...
  • Page 24 SPEC CABLE ROUTING Clutch cable A Tighten the ground lead and the the coolant reservoir tank, be- Starter cable thermostat housing together tween the reservoir hose and the Ground lead with a bolt. battery, then are connected at B Pass the reservoir hose left side the right side of the battery.
  • Page 25 SPEC CABLE ROUTING K Pass the wire harness inside of P Pass the fuel pump lead be- U Set the clamp, which is fixed to the rear fender rib. tween the ignition coil and fuel fil- the wire harness, in T-stud of the L Pass the wireharness under the ter, then push under.
  • Page 26 SPEC CABLE ROUTING W Pass the rectifier / regulator lead, Y Align the connector position of fan motor lead, handlebar switch rear turn signal light leads (left lead (left), main switch lead, and right), then bend the rear headlight lead, handlebar switch lead (right) and speed sensor lead through front side of the box, then connecte each coupler...

  • Page 27: Periodic Inspections And Adjustments

    PERIODIC MAINTENANCE/LUBRICATION INTERVALS EB3000000 PERIODIC INSPECTIONS AND ADJUSTMENTS PERIODIC MAINTENANCE/LUBRICATION INTERVALS EVERY 6,000 km 12,000 km INITIAL ITEM CHECKS AND MAINTENANCE JOBS (1,000 km) 6 months 12 months (whichever (whichever comes first) comes first) S Check fuel hoses for cracks or damage. Fuel line S Replace if necessary.
  • Page 28 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: D The air filter needs more frequent service if you are riding in unusually wet or dusty areas.

  • Page 29: Chassis

    ADJUSTING THE FRONT FORK LEGS EAS00152 CHASSIS ADJUSTING THE FRONT FORK LEGS The following procedure applies to both of the front fork legs. WARNING S Always adjust both front fork legs evenly. Uneven adjustment can result in poor han- dling and loss of stability. S Securely support the motorcycle so that there is no danger of it falling over.

  • Page 30: Chassis

    CHAS FRONT FORK CHASSIS FRONT FORK 30 Nm (3.0 mSkg) 30 Nm (3.0 mSkg) 7 Nm (0.7 mSkg) Order Job name/Part name Q’ty Remarks Removing the front fork Remove the parts in the order listed. Front wheel Refer to “FRONT WHEEL AND BRAKE DISCS”...

  • Page 31: Checking The Front Fork Legs

    CHAS FRONT FORK 23 Nm (2.3 mSkg) 30 Nm (3.0 mSkg) Order Job name/Part name Q’ty Remarks Disassembling the front fork Disassembly the parts in the order listed. Cap bolt O-ring Spacer Washer Front fork spring Refer to “ASSEMBLING THE FRONT Dust seal FORK LEGS”...
  • Page 32 CHAS FRONT FORK 23 Nm (2.3 mSkg) 30 Nm (3.0 mSkg) Order Job name/Part name Q’ty Remarks Outer tube bushing Refer to “ASSEMBLING THE FRONT Oil flow stopper FORK LEGS” section. For assembly, reverse the disassembly procedure. –24–...
  • Page 33 (with the specified amount of the recom- mended fork oil) Quantity (each front fork leg) 0.465 L Yamaha fork and shock oil 10 W or equivalent. Front fork leg oil level a (from the top of the inner tube, with the...

  • Page 34: Electrical

    ELEC SIGNAL SYSTEM EB806000 ELECTRICAL SIGNAL SYSTEM CIRCUIT DIAGRAM –26–...
  • Page 35 ELEC SIGNAL SYSTEM Main switch Battery Fuse (main) Flasher relay Turn switch Hazard switch Front turn signal light Rear turn signal light Fuse (signal) Relay 2 –27–...

  • Page 36: Signal System Check

    ELEC SIGNAL SYSTEM SIGNAL SYSTEM CHECK EB806023 1. If the turn signal light and/or turn indicator light fails to blink: 1. Bulb and bulb socket NO CONTINUITY S Check the bulb and bulb socket for continu- ity. Replace the bulb and/or bulb socket. CONTINUITY 2.
  • Page 37 ELEC SIGNAL SYSTEM 4. Voltage S Connect the pocket tester (DC 20 V) to the flasher relay coupler. Tester (+) lead ! Brown terminal Tester (–) lead ! Frame ground OUT OF SPECIFICATION S Turn the main switch to “ON”. S Check the voltage (12 V) of the “Brown”...
  • Page 38 ELEC SIGNAL SYSTEM 6. Voltage S Connect the pocket tester (DC 20 V) to the bulb socket connector. Flasher light Turn indicator light At the flasher light (left): Tester (+) lead ! Chocolate lead Tester (–) lead ! Frame ground At the flasher light (right): Tester (+) lead ! Dark green lead Tester (–) lead ! Frame ground...

  • Page 39: Clock

    ELEC CLOCK CLOCK EAS00805 The clock fails to come on. 1. Voltage S Connect the pocket tester (DC 20 V) to the clock coupler. Tester (+) read ! Brow Tester (–) read ! Frame ground OUT OF SPECIFICATION S Turn the main switch to “ON”. S Check the voltage (12 V) on the “Brown”...

  • Page 41: Fzs600 2000 Wiring Diagram

    FZS600 2000 WIRING DIAGRAM A.C. magneto Turn indicator light Rectifier/ regulator Meter light Main switch Clutch switch Battery Oil level switch Fuse (back up) Flasher relay Fuse (main) Horn Starter relay Pass switch Starter motor Dimmer switch Starting circuit cut-off relay...

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