Yamaha FZS600 2000 Supplementary Service Manual Download Page 31 | Manualshive

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–23–

FRONT FORK

CHAS

Order

Job name / Part name

Q’ty

Remarks

Disassembling the front fork
Cap bolt
O-ring
Spacer
Washer
Front fork spring
Dust seal
Oil seal clip
Bolt
Gasket
Damper rod / rebound spring
Inner tube / Inner tube bushing
Oil seal
Washer

1
1
1
1
1
1
1
1
1

1 / 1

1
1
1

Disassembly the parts in the order listed.

Refer to “ASSEMBLING THE FRONT
FORK LEGS” section.

Refer to “DISASSEMBLING /
ASSEMBLING THE FRONT FORK
LEGS” section.

1
2
3
4
5
6
7
8
9

10

11

12

13

23 Nm (2.3 m

kg)

30 Nm (3.0 m

kg)

«
...
29
30
31
32
33
...
»

Summary of Contents for FZS600 2000

Page 1: ......

Page 2: ......

Page 3: ...ion procedures it is necessary to use this Supplementary Service Manual together with the following manual FZS600 SERVICE MANUAL 5DM1 AE1 FZS600 2000 SUPPLEMENTARY SERVICE MANUAL 1999 by Yamaha Motor Co Ltd First Edition June 1999 Any reproduction or unauthorized use without the written permission of Yamaha Motor Co Ltd is expressly prohibited ...

Page 4: ...l its models Modifications and significant changes in specifications or procedures will be forwarded to all authorized Yamaha dealers and will appear in future editions of this manual where applicable Designs and specifications are subject to change without notice IMPORTANT INFORMATION Particularly important information is distinguished in this manual by the following The Safety Alert Symbol means...

Page 5: ...spections and Adjustments where the sub section title s appear In Chapter 3 Periodic Inspections and Adjustments the sub section title appears at the top of each page instead of the section title 3 Sub section titles appear in smaller print than the section title 4 To help identify parts and clarify procedure steps there are exploded diagrams at the start of each removal and disassembly section 5 ...

Page 6: ...shooting Symbols 10 to 17 indicate the following 10 Serviceable with engine mounted 11 Filling fluid 12 Lubricant 13 Special tool 14 Tightening torque 15 Wear limit clearance 16 Engine speed 17 Electrical data Symbols 18 to 23 in the exploded diagrams indi cate the types of lubricants and lubrication points 18 Apply engine oil 19 Apply gear oil 20 Apply molybdenum disulfide oil 21 Apply wheel bear...

Page 7: ...S 4 CABLE ROUTING 7 PERIODIC INSPECTIONS AND ADJUSTMENTS PERIODIC MAINTENANCE LUBRICATION INTERVALS 19 CHASSIS 21 ADJUSTING THE FRONT FORK LEGS 21 CHASSIS FRONT FORK 22 CHECKING THE FRONT FORK LEGS 23 ASSEMBLING THE FRONT FORK LEGS 23 ELECTRICAL SIGNAL SYSTEM 26 CIRCUIT DIAGRAM 26 SIGNAL SYSTEM CHECK 28 CLOCK 31 FZS600 2000 WIRING DIAGRAM ...

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Page 9: ... and the clock mode in the following order ODO TRIP 1 TRIP 2 Clock ODO Resetting a meter To reset either tripmeter 1 or 2 to 0 0 select either by pushing the SELECT button 3 and push the RESET button 4 for at least one second Clock mode To change the display to the clock mode push the SELECT button 3 To change the display back to the odometer mode push the SELECT button 3 To set the clock 1 Push b...

Page 10: ...kPa 2 25 kg cm2 2 25 bar 290 kPa 2 9 kg cm2 2 9 bar 225 kPa 2 25 kg cm2 2 25 bar 290 kPa 2 9 kg cm2 2 9 bar Bulb voltage wattage quantity Headlight Marker light Brake tail light Front turn signal light Rear turn signal light Meter light Indicator light Neutral indicator light High beam indicator light Oil level warning light Turn indicator light Fuel level warning light Engine temperature warning ...

Page 11: ...le jet N J Pilot air jet P A J 1 Pilot outlet P O Pilot jet P J Bypass 1 B P 1 Bypass 2 B P 2 Bypass 3 B P 3 Pilot screw P S Valve seat size V S Starter jet G S 1 Starter jet G S 2 Throttle valve size TH V Fuel level F L with special tool Engine idle speed Intake vacuum 5DM1 01 GB N SF DK D NL 5DM1 01 B F E P IRL GR 5DM2 11 D F 115 80 5D86 3 5 GB N SF DK D NL 5D86 3 5 B F E P IRL GR 5D92 3 5 D F P...

Page 12: ...ing Oil capacity Oil level Oil grade 120 mm 316 8 mm 309 8 mm 183 mm 7 35 N mm 0 75 kg mm 13 72 N mm 1 4 kg mm 0 70 mm 70 120 mm No 465 cm3 132 mm Fork oil 10W or equivalent 319 mm Drive chain Type manufacturer No of links Chain free play 50VA7 DAIDO 110 30 45 mm TIGHTENING TORQUES CHASSIS Part to be tightened Thread size Tightening torque Remarks g Nm m kg Holder clutch lever 1 M6 1 0 11 1 1 ...

Page 13: ...ing pressure Commutator dia Mica undercut depth Mica undercut width SM 13 MITSUBA SM 13 0 7 kW 0 0015 0 0025 Ω at 20_C 10 mm 7 64 10 00 N 779 1 020 gf 28 mm 0 7 mm 0 8 mm SSS SSS SSS SSS 4 mm SSS 27 mm SSS SSS Starter relay Model manufacturer Amperage rating Coil winding resistance MS5F 631 JIDECO 180 A 4 18 4 62 Ω at 20_C SSS SSS SSS Horn Type Quantity Model manufacturer Maximum amperage Performa...

Page 14: ... B OMRON 202 5 247 5 Ω at 20_C SSS SSS Fuel pump relay Model manufacture Coil winding resistance G8R 30Y B OMRON 202 5 247 5 Ω at 20_C SSS SSS Amperage for individual circuit Main Headlight Signal Ignition Fan Parking Hazard Back up Reserve 30 A 20 A 20 A 20 A 10 A 10 A 5 A 30 A 20 A 10 A 5 A SSS SSS SSS SSS SSS SSS SSS SSS SSS SSS SSS ...

Page 15: ...ar B Use a plastic clamp to fasten to gether the handlebar switch lead left clutch cable and starter cable C Pass the speed sensor lead in side of the clamp code 1 Throttle cable 2 Clutch cable 3 Handlebar switch left 4 Starter cable 5 Main switch 6 Main switch lead 7 Brake hose 8 Speed sensor lead 9 Headlight lead 10 Handlebar switch right CABLE ROUTING SPEC EB205000 CABLE ROUTING ...

Page 16: ...embly 12 Flasher leray 13 Battery 14 Starter relay 15 Battery positive lead 16 Seat lock cable 17 Seat lock stay 18 Cross tube 19 AC magneto lead 20 Starter motor lead 21 Air filter drain hose 22 Neutral switch 23 Sidestand switch lead 24 Neutral switch lead 25 Oil level switch lead 26 Radiator 27 Rectifier regulator lead 28 Horn 29 Speed sensor lead 30 Brake hose 31 Horn lead 32 Horn bracket 33 R...

Page 17: ...handlebar switch lead left main switch lead clutch cable and starter cable to the frame B Pass the fan motor lead through the guide gear then into the box C Use a plastic clamp to fasten the horn lead and air guide plate to the frame D When installing the plug cap the high tension code should be fac ing the inside of the body E Pass the wire harness starter motor lead AC magneto lead sidestand swi...

Page 18: ...ssis J Use a plastic locking tie to fasten the starter motor lead AC mag neto lead sidestand switch lead and oil level neutral switch lead to the frame bracket Cut off the excess end of the tie K Pass the air cleaner drain hose through the engine clamp L Use a steel holder to fasten to gether the AC magneto lead sidestand lead and oil level neu tral switch lead M Pass the air cleaner drain hose in...

Page 19: ...holder to fasten to gether the speed sensor lead and outer tube T Use a plastic clamp to fix the speed sensor lead at 3 points af ter running the lead along the outside of the brake hose First Fasten the bottom end of the speed sensor lead without loosening Second Fasten the lead several times from the bottom end by running along the brake hose U Pass the hom lead under the horn bracket then conne...

Page 20: ...voir tank hose 7 Air filter 8 To fuel tank 9 Fuel tank breather hose 10 Fuel tank drain hose 11 T P S lead 12 Box 13 Speed sensor lead CABLE ROUTING SPEC A Pass the fuel tank drain hose fuel tank breather hose and res ervoir tank over flow pipe be tween the rear arm and the en gine crankcase B Pass the fuel tank drain hose and fuel tank breather hose be tween air filter joint 3 and 4 After install...

Page 21: ...G Pass the throttle cable through the guide wire installed to the handle crown H To front cowling I Pass the main switch lead under the throttle cables headlight lead handlebar switch lead right and speed sensor lead then insert it right side of the box J Pass the throttle cable under the box K Pass the reservoir tank over flow hose and fuel tank drain hose through the cable holder L To coolant re...

Page 22: ...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 Q Use a clamp to fasten together the coolant reservoir hose and the bracket rear arm CABLE ROUTING SPEC ...

Page 23: ... hose 13 Pipe 14 Fuel hose 15 T P S lead 16 Fuel pipe 17 Fuel sender coupler 18 Battery negative lead 19 Battery 20 Rear brake hose 21 Rear brake reservoir tank 22 Rear brake switch lead 23 Fuse box 24 Seat lock cable 25 Ignitor 26 Rear turn signal light lead right 27 Taillight lead 28 Rear turn signal light lead left 29 Taillight bracket 30 Starter motor lead 31 Starter relay 32 Relay 33 Relay as...

Page 24: ...ing C Do not fasten the high tension cord 4 with locking tie D Use a plastic band to fasten the high tension cord 3 4 E Fuel pump lead comes over F Pass the rear brake switch lead and battery negative lead under the coolant reservoir tank be tween the reservoir hose and the battery then are connected at the right side of the battery G Pass the rear flasher lead R through the rear fender H Pass the...

Page 25: ...rame CABLE ROUTING SPEC P Pass the fuel pump lead be tween the ignition coil and fuel fil ter then push under Q Use a plastic clamp to fasten to gether the wire harness and stay R Pass the carburetor inlet hose un der the high tension cord 2 4 S Use a clamp to fasten the clutch cable and starter cable T Use a plastic clamp to fasten high tension code 2 and 4 U Set the clamp which is fixed to the w...

Page 26: ...regulator lead fan motor lead handlebar switch lead left main switch lead headlight lead handlebar switch lead right and speed sensor lead through front side of the box then connecte each coupler in the box X Use a plastic clamp to fasten the wire harness after passing al ways under the taillight bracket CABLE ROUTING SPEC ...

Page 27: ... Check operation fluid level and vehicle for fluid leakage See NOTE Correct accordingly Replace brake pads if necessary 9 Wheels Check balance runout and for damage Rebalance or replace if necessary 10 Tires Check tread depth and for damage Replace if necessary Check air pressure Correct if necessary 11 Wheel bearings Check bearing for looseness or damage Replace if necessary 12 Swingarm Check swi...

Page 28: ...ors S Check engine idling speed synchronization and starter operation S Adjust if necessary 22 Engine oil S Check oil level and vehicle for oil leakage S Correct if necessary S Change Warm engine before draining 23 Engine oil filter cartridge S Replace 24 Cooling system S Check coolant level and vehicle for coolant leakage S Correct if necessary S Change coolant every 24 000 km or 24 months whiche...

Page 29: ...g and loss of stability Securely support the motorcycle so that there is no danger of it falling over Grooves are provided to indicate the ad justment position Never go beyond the maximum or mini mum adjustment positions 1 Adjust spring preload a Turn the adjusting bolt 1 in direction a or b Direction Spring preload is increased suspension is harder Direction Spring preload is decreased suspension...

Page 30: ...ght 1 2 2 2 1 1 Remove the parts in the order listed Refer to FRONT WHEEL AND BRAKE DISCS section Refer to FRONT AND REAR BRAKES section Loosen Loosen Loosen Refer to REMOVING INSTALLING THE FRONT FORK LEGS section For installation reverse the removal procedure Refer to REMOVING INSTALLING THE FRONT FORK LEGS section 30 Nm 3 0 m kg 30 Nm 3 0 m kg 7 Nm 0 7 m kg FRONT FORK CHAS CHASSIS FRONT FORK ...

Page 31: ...seal Oil seal clip Bolt Gasket Damper rod rebound spring Inner tube Inner tube bushing Oil seal Washer 1 1 1 1 1 1 1 1 1 1 1 1 1 1 Disassembly the parts in the order listed Refer to ASSEMBLING THE FRONT FORK LEGS section Refer to DISASSEMBLING ASSEMBLING THE FRONT FORK LEGS section 1 2 3 4 5 6 7 8 9 10 11 12 13 23 Nm 2 3 m kg 30 Nm 3 0 m kg ...

Page 32: ... CHAS Order Job name Part name Q ty Remarks Outer tube bushing Oil flow stopper 1 1 1 Refer to ASSEMBLING THE FRONT FORK LEGS section For assembly reverse the disassembly procedure 14 15 23 Nm 2 3 m kg 30 Nm 3 0 m kg ...

Page 33: ... 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 inner tube fully compressed and without the fork spring 132 mm While filling the front fork leg keep it upright After filling slowly pump the front fork leg up and down to distribute the fork oil ...

Page 34: ... 26 SIGNAL SYSTEM ELEC EB806000 ELECTRICAL SIGNAL SYSTEM CIRCUIT DIAGRAM ...

Page 35: ... 27 SIGNAL SYSTEM ELEC 3 Main switch 4 Battery 6 Fuse main 35 Flasher relay 40 Turn switch 41 Hazard switch 42 Front turn signal light 43 Rear turn signal light 52 Fuse signal 60 Relay 2 ...

Page 36: ...own White Chocolate Brown White Dark green Replace the left handlebar switch CONTINUITY NO CONTINUITY 3 1 2 1 3 Hazard switch SDisconnect the left handlebar switch cou plers from the wire harness SSet the turn switch Neutral position SCheck for continuity as follows Brown White Chocolate Brown White Dark green Chocolate Dark green Replace the left handlebar switch CONTINUITY NO CONTINUITY 3 1 2 1 ...

Page 37: ...ain switch to the flasher relay connector is faulty repair it MEETS SPECIFICATION OUT OF SPECIFICATION 1 STurn the main switch to ON STurn the turn switch to L R or push the hazard switch SCheck the voltage 12 V on the Brown White lead at the flasher relay terminal The flasher relay is faulty replace it MEETS SPECIFICATION OUT OF SPECIFICATION Tester lead Brown White terminal Tester lead Frame gro...

Page 38: ...witch to L R or push the hazard switch S Check the voltage 12 V of the Chocolate lead or Dark green lead on the bulb socket connector The wiring circuit from the left handlebar switch to the bulb socket connector is faulty repair it MEETS SPECIFICATION OUT OF SPECIFICATION This circuit is not faulty 1 At the flasher light right Tester lead Dark green lead Tester lead Frame ground 2 Flasher light T...

Page 39: ... switch to the clock coupler is faulty repair it MEETS SPECIFICATION OUT OF SPECIFICATION 1 This circuit is not faulty 2 Clock Check that the clock is operating properly When setting the clock after its power source has been disconnected e g when the battery is removed first set the clock to 1 00 AM and then to the correct time 1 The clock is faulty replace it MEETS SPECIFICATION OUT OF SPECIFICAT...

Page 40: ......

Page 41: ...coil 15 Throttle position sensor 16 Neutral switch 17 Speed sensor 18 Fuel sender 19 Thermo switch engine temperature 20 Diode 21 Fuel pump 22 Sidestand switch 23 Speedometer 24 Tachometer 25 Fuel meter 26 Fuel level warning light 27 Engine temperature warning light 28 Neutral indicator light 29 Oil level warning light 30 High beam indicator light 31 Turn indicator light 32 Meter light 33 Clutch s...

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