Yamaha FZS600(P) Service Manual Download | Manualshive

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Summary of Contents for FZS600(P)

Page 1: ...YAMAHA 2002 FZSBOO P 5DM1 SE3 SERVICE INFORMATION ...

Page 2: ...information to gether with the following manual FZS600 98 2002 SERVICE MANUAL 5DM1 ME3 FZS600 98 SERVICE INFORMATION 5DM1 SE1 FZS600 2000 SERVICE INFORMATION 5DM1 SE2 FZS600 P 2002 SERVICE INFORMATION 2001 by Yamaha Motor Co Ltd First Edition August 2001 All rights reserved Any reproduction or unauthorized use without the written permission of Yamaha Motor Co Ltd is expressly prohibited ...

Page 3: ...ions 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 NOTE Designs and specifications are subject to change without notice IMPORTANT INFORMATION Particularly important information is distinguished in this manual by the following notations The Safety Alert Symbol means ATTENT...

Page 4: ...m 9 Troubleshooting Symbols to indicate the following Serviceable with engine mounted Filling fluid Lubricant Special tool Tightening torque Wear limit clearance Engine speed Electrical data in the exploded diagrams indi of lubricants and lubrication Symbols to cate the types points Apply engine oil Apply gear oil Apply molybdenum disulfide oil Apply wheel bearing grease Apply lightweight lithium ...

Page 5: ...MAINTENANCE SPECIFICATIONS 3 ENGINE 3 CHASSIS 4 ELECTRICAL 4 LUBRICATION POINT AND LUBRICATION TYPES 5 ENGINE 5 CABLE ROUTING 6 PERIODIC CHECKS AND ADJUSTMENTS INTRODUCTION 19 PERIODIC MAINTENANCE LUBRICATION INTERVALS 19 FZS600 P 2002 WIRING DIAGRAM ...

Page 6: ...d gasoline Fuel tank capacity 22 L Fuel reserve amount 3 6 L Tire Type Tubeless Size front 110 70ZR 17M C 54W 110 70ZR 17 54W rear 160 60ZR 17M C 69W 160 60ZR17 69W Manufacturer front BRIDGESTONE DUNLOP rear BRIDGESTONE DUNLOP Type front BT 57F D207F rear BT 57R D207J Tire pressure Maximum load except motorcycle 183 kg Loading condition A 90 kg front 225 kPa 2 25 kg cm2 2 25 bar rear 250 kPa 2 5 k...

Page 7: ...21 W x 2 Front turn signal light 12 V 21 W x 2 Rear turn signal light 12V21 W x 2 Meter light UV 14W x 3 Indicator light Neutral indicator light 12 V 1 4W x 1 High beam indicator light 12 V 1 4 W x 1 Oil level warning light 12V 1 4W x 1 Turn signal indicator light 12V 1 4W x 2 Fuel level warning light 12 V2W x 1 Engine temperature warning light LED 2 ...

Page 8: ...Pilot jet P J 12 5 Bypass 1 B P 1 0 9 Bypass 2 B P 2 0 8 Bypass 3 B P 3 0 8 Pilot screw P S 2 1 2 Valve seat size V S 1 0 Starter jet G S 1 0 6 Starter jet G S 2 0 8 Throttle valve size TH V 110 Fuel level F L with special tool 3 5 mm Engine idle speed 1 150 1 250 r min Intake vacuum 31 7 34 3 kPa 238 257 mmHg TIGHTENING TORQUES ENGINE Part to be tightened Part name Thread size Q ty Tightening tor...

Page 9: ...ng system Type Model manufacturer Standard output Stator coil resistance A C magneto F4T377 MITSUBISHI 14 V 21 Aat5 000r min 0 28 0 34 Q at 20 C C W W Rectifier Model manufacture Capacity Withstand voltage SH650C 11 SHINDENGEN 18A 200 V Fuel gauge Model manufacture Sender unit resistance full empty 5RT NIPPON SEIKI 4 10Q 122 5 128 5 Q Amperage for individual circuit Main Headlight Signal Ignition ...

Page 10: ...5 LUBRICATION POINT AND LUBRICATION TYPES LUBRICATION POINT AND LUBRICATION TYPES ENGINE SPEC o Lubrication Point Symbol Cylinder head tightening nut washer D 5 ...

Page 11: ...ch cable fitting After clamp ing cut excessive portion from tip B Using clamp bundle Left handlebar switch lead Clutch cable Starter cable C 30 mm or less from the top of protector Dj Pass speed sensor lead through clamp code 1 OH Fix speed sensor lead with clamp so that brake hose is on the outside of frame Clamp the speed sensor lead after clam pipng at 3 lower positions so that it can not becam...

Page 12: ... Radiator fan motor lead Air filter case drain hose Spark plug lead 1 Sidestand switch lead Starting circuit cut off relay Neutral switch Battery Oil level switch lead Turn signal relay Radiator U Rectifier regulator lead Horn Brake hose 39 Speed sensor lead 0 Fuse box Rear fender Wire harness y Pickup coil lead coupler Sidestand switch lead coupler 3 Oil level neutral switch lead cou pler g A C m...

Page 13: ...r lead A C magneto lead side stand switch lead and neutral switch lead pass the over cross tube 3 Using clamp fix wire harness to the frame Using clamp fix wire harness to the frame After connecting coupler push then on the inside of lock stay on the frame Using clamp fix to bracket on the frame Wire harness at white taping Starter motor lead A C magneto lead Sidestand switch lead Oil level switch...

Page 14: ...d in rear of cross tube M Pass air filter case drain hose through the rear suspension bracket holder and out on left side of vehicle N Using clamp fix sidestand switch lead to frame O Pass sidestand switch lead be hind water pipe 0 Using clamp on engine fix A C magneto lead Sidestand switch lead Oil level switch lead Neutral switch lead ra Pass on the outside of spark plug lead 1 Clutch cable Star...

Page 15: ...ensor lead to outer tube V Pass speed sensor lead along brake hose on the outside of frame and fix it with clamp at 3 positions W To stop switch X To battery negative lead Y To starter relay Z Pass only starter motor lead be hind wire harness branch 12 ...

Page 16: ...tube 3 Brake hose Radiator reservoir tank breather Cable guide hose Main switch lead Air filter Radiator reservoir tank Throttle position sensor lead Rear brake light switch lead Box Battery Speed sensor lead Radiator reservoir tank breather Engine bracket 3 hose Swingarm bracket SPEC g 13 ...

Page 17: ...under Throttle cable 2 pes Right handlebar switch lead Speed sensor lead And them into box at right side In so doing give leads some slack E Pass throttle cable under box 0E Pass through holder on frame Radiator reservoir tank breath er hose Fuel tank breather hose G To reservoir tank F0 Pass battery negative lead on the inside of radiator reservoir tank breather hose Q Using clamp fix stop switch...

Page 18: ...se Radiator reservoirtank breathe hose N Fuel tank drain hose install so that it is not bent or slack Oj After passing throttle position sensor lead as shown install cover 2 to air filter 00 Fix throttle cables right handle bar switch lead and speed sen sor lead to the frame with a clamp Q Pass radiator reservoir tank breather hose between air filter and cross tube 3 and on the out side of the eng...

Page 19: ... tank breather hose Fuel tank drain hose Pipe 2 Fuel hose Throttle position sensor lead Fuel pipe Fuel sender coupler Battery negative lead Battery Rear brake reservoir tank hose Rear brake reservoir tank Rear brake right switch lead Fuse box Seat lock cable Ignitor unit Rear turn signal light lead right Tail brake light lead Rear turn signal light lead left Tail brake light bracket S Starter moto...

Page 20: ...lay Starting circuit cut off relay Wire harness Fuel pump lead coupler Ignition coil Clutch cable Starter cable Box Horn lead Headlight sub wire harness Radiator fan motor lead Rectifier regulator lead Left handlebar switch lead Main switch lead Clamp 17 ...

Page 21: ... water hose for carbure tor heater D Place fuel pump lead so that it comes on top Ej Pass brake light switch lead and battery negative lead under ra diator reservoir tank and be tween radiator reservoir hose and battery and connect them at right side of battery OS Pass rear turn signal light lead right through hole in rear fend er G Pass rear turn signal light lead left through hole in rear fender...

Page 22: ...pe on frame Locate clamp tip forward of vehicle 0 Pass fuel pump lead between ignition coil and filter and push it downward P Using clamp fix wire harness to the stay Q Pass under 2 and 4 spark plug leads for layout R Using clamp fix clutch cable and starter cable S Using clamp fix 2 and 4 spark plug leads T Fit clamp fastened to wire har ness onto T stud on frame U Pass wire harenss through cut i...

Page 23: ...d right handlebar switch lead AD Clamp rear turn signal light and speed sensor lead through leads L and R without slack cut in box front and connect them AE Mate turn signal light reads L inside box and R at coupler position Y Using clamp fix wire harness af bend them and clamp them to ter making sure to pass it under gether with wire harness taillight bracket AF Into turn signal light lAGI Mate a...

Page 24: ...el hoses for cracks or damage V V V 2 Fuel filter Check condition V 3 Spark plugs Check condition Clean and regap V V Replace V V 4 Valves Check valve clearance Adjust Every 40 000 km 5 Air filter element Clean V V Replace V V 6 Clutch Check operation Adjust V V V 7 Front brake Check operation fluid level and vehicle for fluid leakage V V V V Replace brake pads Whenever worn to the limit 8 Rear br...

Page 25: ...choke operation Adjust engine idling speed and synchronization s V V V 23 Engine oil Change Check oil level and vehicle for oil leakage V V 24 Engine oil filter cartridge Replace V 25 Cooling system Check coolant level and vehicle for coolant leakage I Change Every 3 years 26 Front and rear brake switches Check operation 27 Moving parts and cables Lubricate V 28 Lights signals and switches Check o...

Page 26: ... B G Black Green B L Black Blue B R Black Red B Y Black Yellow light Oil level switch Fuel sender Alarm Signaling system fuse Hedlight fuse Rdiator fan motor fuse Right handlebar switch Front brake light switch Light switch Engine stop switch Start switch Rear brake light switch Left handlebar switch Pass switch Dimmer switch Horn switch Clutch switch Hazard switch Turn signal switch Horn Turn sig...

Page 27: ...YAMAHA YAMAHA MOTOR CO LTD 2500 SHINGAI IWATA SH1ZUOKA JAPAN PRINTED IN BELGIUM ...

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