Yamaha FZS600 FAZER 1998 Manuals

Manuals and User Guides for Yamaha FZS600 FAZER 1998. We have 1 Yamaha FZS600 FAZER 1998 manual available for free PDF download: Service Manual

Yamaha FZS600 FAZER 1998 Service Manual

Yamaha FZS600 FAZER 1998 Service Manual (360 pages)

Brand: Yamaha | Category: Motorcycle | Size: 7 MB

Table of Contents

Chapter 3 Periodic Inspections and Adjustments

52
- How to Use this Manual
  2
- General Information
  6
- Model Code
  8
- Motorcycle Identification
  8
- Vehicle Identification Number
  8
- Gaskets, Oil Seals and O-Rings
  9
- Preparation for Removal and Disassembly
  9
- Replacement Parts
  9
- Bearings and Oil Seals
  10
- Lock Washers/Plates and Cotter Pins
  10
- Checking the Connections
  11
- Special Tools
  15
- Chapter 2 Specifications
  
  17
  - General Specifications
    19
  - Maintenance Specifications
    23
  - Tightening Torques Engine
    26
  - Tightening Torques Chassis
    30
  - General Tightening Torque Specifications
    35
  - Lubrication Point and Lubrication Types
    37
  - Cooling System Diagrams
    39
  - Lubrication Diagrams
    40
  - Cable Routing
    43
  - Table of Contents
    52
  - Periodic Inspections and Adjustments
    54
  - Introduction
    54
  - Periodic Maintenance/Lubrication Intervals
    54
  - Front Cowling/Seat/Side Cover/Fuel Tank
    56
  - Engine
    58
  - Adjusting the Valve Clearance
    58
  - Synchronizing the Carburetors
    64
  - Adjusting the Engine Idling Speed
    66
  - Adjusting the Throttle Cable Free Play
    67
  - Checking the Spark Plugs
    68
  - Checking the Ignition Timing
    69
  - Measuring the Compression Pressure
    70
  - Checking the Engine Oil Level
    71
  - Changing the Engine Oil
    72
  - Measuring the Engine Oil Pressure
    74
  - Adjusting the Clutch Cable Free Play
    75
  - Cleaning the Air Filter Element
    76
  - Checking the Carburetor Joints and Intake Manifolds
    77
  - Checking the Fuel Hoses and Fuel Filter
    77
  - Checking the Crankcase Breather Hose
    78
  - Checking the Exhaust System
    78
  - Checking the Coolant Level
    79
  - Checking the Cooling System
    79
  - Changing the Coolant
    80
  - Chassis
    83
  - Adjusting the Front Brake
    83
  - Adjusting the Rear Brake
    83
  - Checking the Brake Fluid Level
    84
  - Adjusting the Rear Brake Light Switch
    85
  - Checking the Brake Hoses
    86
  - Bleeding the Hydraulic Brake System
    86
  - Adjusting the Shift Pedal
    87
  - Adjusting the Drive Chain Slack
    88
  - Lubricating the Drive Chain
    89
  - Checking and Adjusting the Steering Head
    90
  - Checking the Front Fork
    91
  - Adjusting the Rear Shock Absorber Assembly
    91
  - Checking the Tires
    93
  - Checking the Wheels
    94
  - Checking and Lubricating the Cables
    95
  - Lubricating the Levers and Pedals
    95
  - Lubricating the Sidestand
    95
  - Lubricating the Center Stand
    95
  - Lubricating the Rear Suspension
    95
  - Electrical Systems
    96
  - Checking and Charging the Battery
    96
  - Checking the Fuses
    101
  - Replacing the Headlight Bulbs
    103
  - Adjusting the Headlight Beams
    103
Chapter 4 Overhauling the Engine

107
- Ac Magneto and Starter Clutch
  108
- Drive Sprocket and Exhaust Pipe
  109
- Overhauling the Engine
  109
- Removing the Engine
  109
- Leads and Hoses
  111
- Engine Bracket and Engine
  112
- Installing the Engine
  113
- Camshaft
  114
- Cylinder Head Covers
  114
- Camshafts
  115
- Removing the Camshafts
  116
- Checking the Camshafts
  117
- Checking the Timing Chain, Camshaft Sprockets, and Timing Chain Guides
  118
- Checking the Timing Chain Tensioner
  119
- Installing the Camshafts
  119
- Cylinder Head
  122
- Checking the Cylinder Heads
  123
- Removing the Cylinder Heads
  123
- Installing the Cylinder Head
  124
- Valves and Valve Springs
  125
- Removing the Valves
  126
  - Checking the Valve
    126
- Checking the Valves and Valve Guides
  127
- Checking the Valve Seats
  128
- Checking the Valve Lifters
  130
- Checking the Valve Springs
  130
- Checking the Camshaft Cap
  131
- Installing the Valves
  131
- Cylinders and Pistons
  133
- Checking the Cylinders and Pistons
  134
- Removing the Cylinders and Pistons
  134
- Checking the Piston Rings
  135
- Checking the Piston Pins
  136
- Installing the Piston and Cylinder
  137
- Clutch
  139
- Clutch Cover
  139
- Clutch
  140
- Checking the Clutch Plates
  142
- Checking the Friction Plates
  142
- Removing the Clutch
  142
- Checking the Clutch Housing
  143
- Checking the Clutch Spring Plate
  143
- Checking the Clutch Springs
  143
- Checking the Clutch Boss
  144
- Checking the Clutch Push Rods
  144
- Checking the Pressure Plate
  144
- Installing the Clutch
  144
- Shift Shaft
  147
- Checking the Shift Shaft
  148
- Installing the Shift Shaft
  148
- Stator Coil
  149
- Starter Clutch
  150
- Ac Magneto Rotor
  151
- Removing the Ac Magneto
  152
- Removing the Starter Clutch
  152
- Checking the Starter Clutch
  153
- Installing the Ac Magneto
  154
- Installing the Starter Clutch
  154
- Oil Pan and Oil Strainer
  155
- Oil Strainer
  155
- Oil Pump
  156
- Checking the Oil Pump
  158
- Checking the Relief Valve
  158
- Removing the Oil Pan
  158
- Assembling the Oil Pump
  159
- Checking the Oil Nozzle
  159
- Checking the Oil Strainer
  159
- Installing the Oil Pan
  160
- Installing the Oil Pump
  160
- Installing the Oil Strainer
  160
- Crankcase
  162
- Disassembling the Crankcase
  162
- Assembling the Crankcase
  163
  - Disassembling the Crankcase
    164
  - Checking the Crankcase
    164
  - Assembling the Crankcase
    165
- Crankshaft
  167
- Connecting Rod
  168
- Checking the Crankshaft and Connecting Rods
  169
- Removing the Connecting Rods
  169
- Removing the Crankshaft Assembly
  169
- Installing the Connecting Rods
  174
- Installing the Crankshaft
  176
- Transmission
  177
- Checking the Transmission
  180
- Installing the Transmission
  181
- Shift Drum and Shift Forks
  182
- Checking the Shift Drum Assembly
  183
- Checking the Shift Forks
  183
- Installing the Shift Forks and Shift Drum Assembly
  183
- Chapter 5 Cooling System
  
  186
  - Checking the Radiator
    189
  - Installing the Radiator
    190
  - Checking the Thermostat
    193
  - Assembling the Thermostat
    194
  - Installing the Thermostat
    194
  - Water Pump
    195
  - Checking the Water Pump
    196
  - Installing the Water Pump
    196
  - Removing the Water Pump
    196
- Chapter 6 Carburetors
  
  199
  - Air Filter Case
    201
  - Checking the Carburetors
    205
  - Assembling the Carburetors
    207
  - Installing the Carburetors
    208
  - Measuring and Adjusting the Fuel Level
    209
  - Checking and Adjusting the Throttle Position Sensor
    210
Chas

214
- Front Wheel and Brake Discs
  216
- Front Wheel
  217
- Checking the Front Wheel
  218
- Removing the Front Wheel
  218
- Checking the Brake Discs
  220
- Installing the Front Wheel
  221
- Adjusting the Front Wheel Static Balance
  222
- Rear Wheel
  223
- Rear Wheel, Brake Disc and Rear Wheel Sprocket
  223
- Brake Disc and Rear Wheel Sprocket
  224
- Checking the Rear Wheel
  226
- Removing the Rear Wheel
  226
- Checking and Replacing the Rear Wheel Sprocket
  227
- Installing the Rear Wheel
  227
- Adjusting the Rear Wheel Static Balance
  228
- Front and Rear Brakes
  229
- Front Brake Pads
  229
- Rear Brake Pads
  230
- Replacing the Front Brake Pads
  231
- Replacing the Rear Brake Pads
  233
- Front Brake Master Cylinder
  235
- Rear Brake Master Cylinder
  237
- Removing the Front Brake Master Cylinder
  239
- Removing the Rear Breake Master Cylinder
  239
- Checking the Front and Rear Brake Master Cylinders
  240
- Assembling and Installing the Front Brake Master Cylinder
  241
- Assembling and Installing the Rear Brake Master Cylinder
  242
- Front Brake Calipers
  244
- Disassembling the Front Brake Caliper
  245
  - Rear Brake Caliper
    246
  - Disassembling the Front Brake Calipers
    248
- Checking the Front and Rear Brake Calipers
  249
- Disassembling the Rear Brake Caliper
  249
- Assembling and Installing the Front Brake Calipers
  250
- Assembling and Installing the Rear Brake Caliper
  252
- Front Fork
  255
- Disassembling the Front Fork Legs
  258
- Removing the Front Fork Legs
  258
- Checking the Front Fork Legs
  259
- Assembling the Front Fork Legs
  260
- Installing the Front Fork Legs
  262
- Handlebar
  263
- Checking the Handlebar
  265
- Removing the Handlebar
  265
- Installing the Handlebar
  266
- Lower Bracket
  268
- Steering Head
  268
- Checking the Steering Head
  270
- Removing the Lower Bracket
  270
- Installing the Steering Head
  271
- Rear Shock Absorber and Relay Arm
  272
- Disposing of a Rear Shock Absorber
  274
- Handling the Rear Shock Absorber
  274
- Removing the Rear Shock Absorber Assembly
  275
- Checking the Rear Shock Absorber Assembly
  276
- Installing the Rear Shock Absorber Assembly
  276
- Swingarm and Drive Chain
  277
- Removing the Swingarm
  279
- Checking the Swingarm
  280
- Checking the Drive Chain
  281
- Installing the Swingarm
  282
- Installing the Drive Chain
  283
- Chapter 8 Electrical
  
  285
  - Electrical Components
    287
  - Circuit Diagram
    288
  - Color Code
    289
  - Checking Steps
    290
  - Switch Connection as Shown in this Manual
    290
  - Checking Switches
    291
  - Switch Position and Terminal Connection
    291
  - Ignition System
    292
  - Troubleshooting
    293
  - Electric Starting System
    300
  - Starting Circuit Operation
    300
  - Starter Motor
    308
  - Checking the Starter Motor
    309
  - Charging System
    311
  - Lighting System
    315
  - Signal System
    322
  - Specification
    330
  - Cooling System
    337
  - Circuit Diagram
    337
  - Troubleshooting
    338
  - Fuel Pump System
    342
  - Fuel Pump Circuit Operation
    343
  - Fuel Pump Test
    347
  - Self-Diagnosis
    348
  - Shift Pedal Does Not Move
    352
  - Starting Failure/Hard Starting
    354
  - Poor Medium-And-High-Speed Performance
    355
  - Faulty Gear Shifting
    356
  - Faulty Clutch Performance
    356
  - Poor Braking
    357
  - Faulty Front Fork Legs
    357
  - Unstable Handling
    358
  - Faulty Lighting and Signal Systems
    358

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