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Manuals
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Yamaha Manuals
Motorcycle
FZS600'98
Service manual
Yamaha FZS600'98 Service Manual
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Contents
Table of Contents
Troubleshooting
Bookmarks
Table of Contents
Gen Info
Important Information
Periodic Inspections and
Table of Contents
Chapter 1
Motorcycle Identification
Important Information
Lock Washers/Plates and Cotter Pins
Checking the Connections
Special Tools
Specifications
General Specifications
Maintenance Specifications
General Tightening Torque Specifications
Cable Routing
Table of Contents
Chapter 3 Periodic Inspections and Adjustments
Introduction
Periodic Maintenance/Lubrication Intervals
Brake Fluid Replacement
Front Cowling/Seat/Side Cover/Fuel Tank
Engine
Adjusting the Valve Clearance
Synchronizing the Carburetors
Adjusting the Engine Idling Speed
Adjusting the Throttle Cable Free Play
Checking the Spark Plugs
Checking the Ignition Timing
Measuring the Compression Pressure
Checking the Engine Oil Level
Changing the Engine Oil
Measuring the Engine Oil Pressure
Adjusting the Clutch Cable Free Play
Cleaning the Air Filter Element
Checking the Carburetor Joints and Intake Manifolds
Checking the Fuel Hoses and Fuel Filter
Checking the Crankcase Breather Hose
Checking the Exhaust System
Checking the Coolant Level
Checking the Cooling System
Changing the Coolant
Chassis
Adjusting the Front Brake
Adjusting the Rear Brake
Checking the Brake Fluid Level
Adjusting the Rear Brake Light Switch
Checking the Brake Hoses
Bleeding the Hydraulic Brake System
Adjusting the Shift Pedal
Adjusting the Drive Chain Slack
Lubricating the Drive Chain
Checking and Adjusting the Steering Head
Checking the Front Fork
Adjusting the Rear Shock Absorber Assembly
Checking the Tires
Checking the Wheels
Checking and Lubricating the Cables
Lubricating the Levers and Pedals
Lubricating the Sidestand
Lubricating the Center Stand
Lubricating the Rear Suspension
Electrical System
Checking and Charging the Battery
Checking the Fuses
Replacing the Headlight Bulbs
Adjusting the Headlight Beams
Table of Contents
Chapter 4 Overhauling the Engine
Removing the Engine
Drive Sprocket and Exhaust Pipe
Leads and Hoses
Engine Bracket and Engine
Installing the Engine
Camshaft
Cylinder Head Covers
Camshafts
Removing the Camshafts
Checking the Camshafts
Checking the Timing Chain, Camshaft Sprockets, and Timing Chain Guides
Checking the Timing Chain Tensioner
Installing the Camshafts
Cylinder Head
Removing the Cylinder Heads
Checking the Cylinder Heads
Installing the Cylinder Head
Valves and Valve Springs
Removing the Valves
Checking the Valves and Valve Guides
Checking the Valve Seats
Checking the Valve Springs
Checking the Valve Lifters
Checking the Camshaft Cap
Installing the Valves
Cylinder and Piston
Removing the Cylinders and Pistons
Checking the Cylinders and Pistons
Checking the Piston Rings
Checking the Piston Pins
Installing the Piston and Cylinder
Clutch
Clutch Cover
Clutch
Removing the Clutch
Checking the Friction Plates
Checking the Clutch Plates
Checking the Clutch Springs
Checking the Clutch Spring Plate
Checking the Clutch Housing
Checking the Clutch Boss
Checking the Pressure Plate
Checking the Clutch Push Rods
Installing the Clutch
Shift Shaft
Checking the Shift Shaft
Installing the Shift Shaft
Stator Coil
Ac Magneto and Starter Clutch
Starter Clutch
Ac Magneto Rotor
Removing the Starter Clutch
Removing the Ac Magneto
Checking the Starter Clutch
Installing the Ac Magneto
Installing the Starter Clutch
Oil Pan and Oil Strainer
Oil Strainer
Oil Pump
Removing the Oil Pan
Checking the Oil Pump
Checking the Relief Valve
Checking the Oil Strainer
Checking the Oil Nozzle
Assembling the Oil Pump
Installing the Oil Pump
Installing the Oil Strainer
Installing the Oil Pan
Crankcase
Disassembling the Crankcase
Assembling the Crankcase
Crankshaft
Connecting Rod
Removing the Crankshaft Assembly
Removing the Connecting Rods
Checking the Crankshaft and Connecting Rods
Installing the Connecting Rods
Installing the Crankshaft
Transmission
Checking the Transmission
Installing the Transmission
Shift Drum and Shift Forks
Checking the Shift Forks
Checking the Shift Drum Assembly
Installing the Shift Forks and Shift Drum Assembly
Cooling System
Water Pump
Table of Contents
Front Wheel and Brake Discs
Chapter 7
Front Wheel
Checking the Front Wheel
Removing the Front Wheel
Checking the Brake Discs
Installing the Front Wheel
Adjusting the Front Wheel Static Balance
Rear Wheel, Brake Disc and Rear Wheel Sprocket
Rear Wheel
Brake Disc and Rear Wheel Sprocket
Removing the Rear Wheel
Checking the Rear Wheel
Checking and Replacing the Rear Wheel Sprocket
Installing the Rear Wheel
Adjusting the Rear Wheel Static Balance
Front and Rear Brakes
Front Brake Pads
Rear Brake Pads
Replacing the Front Brake Pads
Replacing the Rear Brake Pads
Front Brake Master Cylinder
Removing the Front Brake Master Cylinder
Checking the Front and Rear Brake Master Cylinders
Assembling and Installing the Front Brake Master Cylinder
Assembling and Installing the Rear Brake Master Cylinder
Front Brake Calipers
Disassembling the Front Brake Caliper
Disassembling the Rear Brake Caliper
Checking the Front and Rear Brake Calipers
Assembling and Installing the Front Brake Calipers
Assembling and Installing the Rear Brake Caliper
Front Fork
Removing the Front Fork Legs
Disassembling the Front Fork Legs
Checking the Front Fork Legs
Assembling the Front Fork Legs
Installing the Front Fork Legs
Handlebar
Removing the Handlebar
Checking the Handlebar
Installing the Handlebar
Steering Head
Lower Bracket
Removing the Lower Bracket
Checking the Steering Head
Installing the Steering Head
Rear Shock Absorber and Relay Arm
Handling the Rear Shock Absorber
Disposing of a Rear Shock Absorber
Removing the Rear Shock Absorber Assembly
Checking the Rear Shock Absorber Assembly
Installing the Rear Shock Absorber Assembly
Swingarm and Drive Chain
Removing the Swingarm
Checking the Swingarm
Checking the Drive Chain
Installing the Swingarm
Installing the Drive Chain
Circuit Diagram
Electric Starting System
Charging System
Lighting System
Signal System
Fuel Pump System
Troubleshooting
Faulty Gear Shifting
Unstable Handling
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Quick Links
1
Adjusting the Valve Clearance
2
Synchronizing the Carburetors
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Table of Contents
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This manual is also suitable for:
1998 fzs600 5dm1-ae1
Fazer 600 1998
Fzs 600 1998
5dm1-ae1 1998
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