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
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.
EB001000
NOTICE
This manual was produced by the Y amaha Motor Company primarily for use by Yamaha dealers and
their qualified mechanics. 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.
Repairs attempted by anyone without this knowledge are likely to render the scooter unfit for use.
Yamaha Motor Company, Ltd. is continually striving to improve all its models. Modifications and
significant changes in specifications or procedures will be forwarded to all authorized Y amaha 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.
The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR
SAFETY IS INVOLVED!
WARNING
CAUTION:
NOTE: A NOTE provides key information to make procedures easier or clearer.
Failure to follow WARNING instructions could result in severe injury or death
the motorcycle operator, a bystander or a person inspecting or repairing the
motorcycle.
A CAUTION indicates special precautions that must be taken to avoid damage
to the motorcycle.
to
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. An abbreviation and symbol in the upper right corner of each
page indicate the current chapter. Refer to “SYMBOLS” on the following page.
2
Each chapter is divided into sections. The current section title is shown at the top of each page,
except in Chapter 3 (“Periodic Inspections 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
Numbers are given in the order of the jobs in the exploded diagram. A circled number indicates a
disassembly step.
6
Symbols indicate parts to be lubricated or replaced (see “SYMBOLS”).
7
A job instruction chart accompanies the exploded diagram, providing the order of jobs, names of
parts, notes in jobs, etc.
8
Jobs requiring more information (such as special tools and technical data) are described
sequentially.
2
5
7
1
4
6
3
8
1
GEN
INFO
3
CHK
ADJ
5
COOL
7
2
SPEC
4
ENG
6
CARB
8
EB003000
SYMBOLS
The following symbols are not relevant to every
vehicle.
Symbols
chapter.
General information
1
Specifications
2
Periodic inspection and adjustment
3
Engine
4
Cooling system
5
Carburetor(-s)
6
Chassis
7
Electrical system
8
Troubleshooting
9
1
to 9 indicate the subject of each
CHAS
9
10
TRBL
SHTG
11 12
1413
15
16 17
19 2018
22
ELEC
2321
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 indicate the types of lubricants and lubrication
points.
18
Apply engine oil
19
Apply gear oil
20
Apply molybdenum disulfide oil
21
Apply wheel bearing grease
22
Apply lightweight lithium-soap base grease
23
Apply molybdenum disulfide grease
24 25
Symbols 24 to 25 in the exploded diagrams indicate the following:
24
Apply locking agent (LOCTITE)
25
Use new one
CONTENTS
GENERAL INFORMATION
FEA TURES 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SPEEDOMETER 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SPECIFICA TIONS
GENERAL SPECIFICATIONS 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
MAINTENANCE SPECIFICATIONS 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ENGINE 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHASSIS 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
GENERAL INFORMATION
FEATURES
SPEEDOMETER
This speedometer is equipped with:
an odometer
two tripmeters
a clock
FEATURES
Speedometer
1
Odometer/Tripmeter/Clock
2
“SELECT” button
3
“RESET” button
4
GEN
INFO
Odometer and tripmeter modes
When set to “ODO”, the motorcycle’s total mileage is indicated.
When set to “TRIP 1” or “TRIP 2”, the motorcycle’s mileage since the tripmeter was last reset is indicated. Use the tripmeters to estimate how far you can ride on a tank of fuel. This information will enable
you to plan fuel stops in the future.
Selecting a mode
Push the “SELECT” button
“TRIP 1” and “TRIP 2”, 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
“RESET” button
Clock mode
To change the display to the clock mode, push the “SELECT” button
To change the display back to the odometer mode, push the “SELECT” button
To set the clock
1. Push both the “SELECT” button
2. When the hour digits start flashing, push the “RESET” button
3. Push the “SELECT” button
4. When the minute digits start flashing, push the “RESET” button
5. Push the “SELECT” button
4
for at least one second.
3
to change between the odometer mode “ODO”, the tripmeter modes
3
and push the
3
.
3
.
3
and “RESET” button 4 for at least two seconds.
4
to set the hours.
3
to change the minutes.
4
to set the minutes.
3
to start the clock.
NOTE:
After setting the clock, be sure to push the “SELECT” button before turning the main switch to “OFF”,
otherwise the clock will not be set.
–1–
GENERAL SPECIFICATIONS
SPECIFICATIONS
GENERAL SPECIFICATIONS
Model FZS600
Model code: 5DM7
5DM8
5DM9
Fuel:
Type
Fuel tank capacity
Fuel reserve amount
Tire pressure:
Maximum load-except motorcycle
Loading condition A*
front
rear
Loading condition B*
front
rear
High-speed riding
front
rear
Regular unleaded gasoline
20 L
3.5 L
187 kg
0 90 kg
225 kPa (2.25 kg/cm
250 kPa (2.5 kg/cm
90 187 kg
225 kPa (2.25 kg/cm
290 kPa (2.9 kg/cm
225 kPa (2.25 kg/cm
290 kPa (2.9 kg/cm
2
, 2.25 bar)
2
, 2.5 bar)
2
, 2.25 bar)
2
, 2.9 bar)
2
, 2.25 bar)
2
, 2.9 bar)
SPEC
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 light
*Load is the total weight of cargo, rider, passenger and accessories.
12 V 60 W/55 W 1
12 V 5 W 1
12 V 21 W/5 W 2
12 V 21 W 2
12 V 21 W 2
12 V 2 W 3
14 V 1.4 W 1
14 V 1.4 W 1
14 V 1.4 W 1
14 V 1.4 W 2
12 V 2 W 1
LED
–2–
MAINTENANCE SPECIFICATIONS
MAINTENANCE SPECIFICATIONS
ENGINE
SPEC
Item
Valve spring:
Free length IN/EX
Set length (valve closed) IN/EX
Compressed pressure IN/EX
Tilt limit IN/EX
Direction of winding IN/EX
Carburetor:
I.D. mark
Main jet (M.J)
Main air jet (M.A.J)
Jet needle (J.N)
Needle 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
Standard Limit
40.09 mm
34.5 mm
131.4 153.0 N (13.4 15.6 kg)
SSS
Clockwise
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-0
#130
0.95
#12.5
0.9
0.8
0.8
2
1.0
0.6
0.8
#110
3.5 mm
1,150 1,250 r/min
30.7 33.3 kPa (230 250 mmHg)
37.5 mm
SSS
SSS
2.5_/1.8 mm
SSS
SSS
SSS
SSS
SSS
SSS
SSS
SSS
SSS
SSS
SSS
SSS
SSS
SSS
SSS
SSS
SSS
SSS
SSS
SSS
SSS
SSS
–3–
CHASSIS
g
MAINTENANCE SPECIFICATIONS
SPEC
Item
Front suspension:
Front fork travel
Fork spring free length
Fitting length
Collar length
Spring Rate (K1)
(K2)
Stroke (K1)
(K2)
Optional spring
Oil capacity
Oil level
Oil grade
Drive chain:
Type/manufacturer
No. of links
Chain free play
TIGHTENING TORQUES
CHASSIS
Standard Limit
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 cm
132 mm
Fork oil 10W or equivalent
50VA7/DAIDO
110
30 45 mm
3
319 mm
Tightening
Part to be tightened
Holder, clutch lever 1 M6 1.0 11 1.1
Thread size
torque
Nm mkg
Remarks
–4–
ELECTRICAL
MAINTENANCE SPECIFICATIONS
SPEC
Item
Ignition system:
Ignition timing (B.T.D.C.)
Advanced timing (B.T.D.C.)
Advance type
T.C.I.:
Pickup coil resistance
T.C.I. unit model/manufacturer
Charging system:
Type
Model/manufacturer
Standard output
Stator coil resistance
Starter motor:
Model/manufacturer
I.D. number
Output
Armature coil resistance
Brush overall length
Brush spring pressure
Commutator dia.
Mica undercut (depth)
Mica undercut (width)
Standard Limit
10_/1,250 r/min
50_/4,500 r/min
Digital type
189 231 Ω Y-L
J4T095 / MITSUBISHI
A.C. magneto
F4T359/MITSUBISHI
14 V 18 A at 5,000 r/min
0.36 0.44 Ω at 20_C/W-W
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
SSS
SSS
SSS
SSS
SSS
SSS
SSS
SSS
SSS
4 mm
SSS
27 mm
SSS
SSS
Starter relay:
Model/manufacturer
Amperage rating
Coil winding resistance
Horn:
Type
Quantity
Model manufacturer
Maximum amperage
Performance
Coil winding resistance
Flasher/hazard relay:
Type
Model/manufacturer
Self cancelling device
Hazard flasher device
Flasher frequency
Wattage
Thermostat switch:
Model/manufacture
MS5F-631/JIDECO
180 A
4.18 4.62 Ω at 20_C
Plane type
1 pcs
YF-12/NIKKO
3.0 A
105 113 db/2 m
1.15 1.25 Ω at 20_C
Full transistor type
FE246BH/DENSO
No
Yes
75 95 cyl/min
21 W 2 + 3.4 W
4BA/DENSO SSS
SSS
SSS
SSS
SSS
SSS
SSS
SSS
SSS
SSS
SSS
SSS
SSS
SSS
SSS
SSS
–5–
MAINTENANCE SPECIFICATIONS
Item Standard limit
Starting circuit cut-off relay:
Model/manufacture
Coil winding resistance
Fuel pump relay:
Model/manufacture
Coil winding resistance
Amperage for individual circuit:
Main
Headlight
Signal
Ignition
Fan
Parking/Hazard
Back up
Reserve
G8R-30Y-B/OMRON
202.5 247.5 Ω at 20_C
G8R-30Y-B/OMRON
202.5 247.5 Ω at 20_C
30 A
20 A
20 A
20 A
10 A
10 A
5 A
30 A
20 A
10 A
5 A
SPEC
SSS
SSS
SSS
SSS
SSS
SSS
SSS
SSS
SSS
SSS
SSS
SSS
SSS
SSS
SSS
–6–
EB205000
CABLE ROUTING
CABLE ROUTING
SPEC
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)
A Use a plastic band to fasten to-
gether the handlebar switch lead
(L) and the handlebar.
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.
D Pass the brake hose out side of
the speed sensor lead, then use
a plastic clamp to fasten them.
–7–
CABLE ROUTING
SPEC
1 Main switch lead
2 Handlebar switch lead (left)
3 Clutch cable
4 Starter cable
5 Rectifier/regulator
6 Horn lead
7 Box
8 Air guide plate
9 Fan motor lead
10 High tension code
11 Relay assembly
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 Rear fender
–8–
CABLE ROUTING
SPEC
34 Wire harness
35 Relay
36 Fuse box
37 To front brake switch
38 To battery negative (–) lead
39 To starter relay
40 Starter motor lead
41 Pickup coupler
42 Sidestand switch coupler
43 Oil level/neutral switch coupler
44 AC magneto coupler
45 Oil level/neutral switch lead
A Use a plastic clamp to fasten the
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 facing the inside of the body.
E Pass the wire harness, starter
motor lead, AC magneto lead,
sidestand switch lead and oil/
neutral switch lead over the
cross tube.
F Use a plastic clamp to fasten to-
gether the wire harness and the
frame.
–9–
CABLE ROUTING
SPEC
G Use a plastic clamp to fasten to-
gether the wire harness and the
frame.
H Push couplers into the lock stay
of the frame after connecting
wires.
I Use a plastic band to fasten to-
gether wireharness, starter motor lead, AC magneto lead, sidestand switch lead and oil level/neutral switch lead, then hold
the clamp to the frame bracket.
Position the band end to out side
of chassis.
J Use a plastic locking tie to fasten
the starter motor lead, AC magneto 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/neutral switch lead.
M Pass the air cleaner drain hose
in front of the rear arm pivot shaft
and back of the cross tube.
N Pass the air cleaner drain hose
through the pipe holder of rear
shock absorber bracket, then draw
it out to the left side of the body.
–10–
CABLE ROUTING
SPEC
O Use a plastic clamp to fasten to-
gether the sidestand switch lead
and the frame.
P Pass the sidestand switch lead
through the bottom of the coolant
pipe.
Q Do not loosen the fan motor lead
here.
R Pass the clutch cable and starter
cable outside of high tension
code#1.
S Use a steel 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 after 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 connect it at
the back of the horn.
V Pass only the starter lead
through the bottom of the joint of
wire harness.
–11–
CABLE ROUTING
SPEC
1 Rear brake switch lead
2 Battery
3 Reservoir tank over flow hose
4 Cross tube
5 Battery negative (–) lead
6 Reservoir 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
14 Handlebar switch lead (right)
15 Throttle cable
16 Brake hose
17 Guide wire
18 Headlight lead
19 Main switch lead
20 Reservoir tank
21 Air filter box bracket
22 Swingarm bracket
23 Engine bracket
A Pass the fuel tank drain hose,
fuel tank breather hose and reservoir tank over flow pipe between the rear arm and the engine crankcase.
B Pass the fuel tank drain hose
and fuel tank breather hose between air filter joint #3 and #4.
After installing the fuel tank, pull
it down toward the air filter joint
so that there will be no bend of
loosening between them.
–12–
CABLE ROUTING
SPEC
C Pass the T.P.S lead as shown,
then install cover to the air filter
case.
D Use a plastic clamp to fasten to-
gether the throttle cables, headlight lead, handlebar switch
(right) and speed sensor lead.
E Use a plastic locking tie to fasten
the handlebar switch (right) and
brake hose to the right front fork
inner tube.
F Pass the throttle cable, with the
pull side up, through the center
of the clamp.
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 reservoir tank.
M Pass the battery negative (–)
lead inside of the reservoir hose.
N Use the plastic clamp to fasten
together the rear brake switch
lead and the frame.
The latch of the clamp must face
the outside of the body.
–13–
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.
Q Use a clamp to fasten together
the coolant reservoir hose and
the bracket rear arm.
CABLE ROUTING
SPEC
–14–
CABLE ROUTING
SPEC
1 Throttle cable
2 Speed sensor lead
3 Handlebar switch lead (right)
4 Headlight lead
5 Thermostat housing
6 Carburetor heater hose
7 Reservoir tank hose
8 Throttle cable
9 Fuel pump
10 Fuel filter
11 Fuel tank breather hose
12 Fuel tank drain 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 assembly
34 Wire harness
35 Fuel pump lead coupler
36 Ignition coil
–15–
CABLE ROUTING
SPEC
37 Clutch cable
38 Starter cable
39 Ground lead
40 Box
41 Fan motor lead
42 Rectifier/regulator lead13
43 Handlebar switch lead (left)
44 Main switch lead
45 Wire harness
46 To taillight
47 Rear fender
48 Clamp
A Tighten the ground lead and the
thermostat housing together
with a bolt.
B Pass the reservoir hose left side
of thermo stat housing.
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, between 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 rear flasher lead (L)
through the rear fender.
I Pass the wire harness through
the groove of the rear fender.
J Wire harness shouldn’t come
top of the rear fender rib.
–16–
CABLE ROUTING
SPEC
K Pass the wire harness inside of
the rear fender rib.
L Pass the wireharness under the
starter relay.
M Pass the starter motor lead un-
der the joint of the harness, then
pull upward.
N Set the fuel sender coupler in the
cross pipe of the frame.
O Use a plastic clamp to fasten to-
gether the wire harness and
cross pipe of the frame.
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 wire harness, in T-stud of the
frame.
V Put the wire harness into the box
through the groove at the back,
then connect it in the box.
–17–
CABLE ROUTING
SPEC
W Pass the rectifier/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 always under the taillight bracket.
Y Align the connector position of
rear turn signal light leads (left
and right), then bend the rear
–18–
CHK
PERIODIC MAINTENANCE/LUBRICATION INTERVALS
EB3000000
ADJ
PERIODIC INSPECTIONS AND ADJUSTMENTS
PERIODIC MAINTENANCE/LUBRICATION INTERVALS
EVERY
NO. ITEM CHECKS AND MAINTENANCE JOBS
1 * Fuel line
2 * Fuel filter
3 Spark plugs
4 * Valves
5 Air filter Clean or replace if necessary. √ √
6 Clutch
7 * Front brake
8 * Rear brake
9 * Wheels
10 * Tires
11 * Wheel bearings
12 * Swingarm
13 Drive chain
14 * Steering bearings
15 * Chassis fasteners
Check fuel hoses for cracks or damage.
Replace if necessary.
Check condition.
Replace if necessary.
Check condition.
Clean, regap or replace if necessary.
Check valve clearance.
Adjust if necessary.
Check operation.
Adjust or replace cable.
Check operation, fluid level and vehicle for fluid leakage.
(See NOTE)
Correct accordingly.
Replace brake pads if necessary.
Check operation, fluid level and vehicle for fluid leakage.
(See NOTE)
Correct accordingly.
Replace brake pads if necessary.
Check balance, runout and for damage.
Rebalance or replace if necessary.
Check tread depth and for damage.
Replace if necessary.
Check air pressure.
Correct if necessary.
Check bearing for looseness or damage.
Replace if necessary.
Check swingarm pivoting point for play.
Correct if necessary.
Lubricate with molybdenum disulfide grease every 24,000 km or
24 months (whichever comes first).
Check chain slack.
Adjust if necessary. Make sure that the rear wheel is properly
aligned.
Clean and lubricate.
Check bearing play and steering for roughness.
Correct accordingly.
Lubricate with lithium soap base grease every 24,000 km or
24 months (whichever comes first).
Make sure that all nuts, bolts and screws are properly tightened.
Tighten if necessary.
INITIAL
(1,000 km)
√ √ √
Every 42,000 km or 42 months
√ √ √
√ √ √
√ √ √
Every 1,000 km and after washing the
motorcycle or riding in the rain
6,000 km
or
6 months
(whichever
comes first)
√ √
(whichever comes first)
√ √
√ √
√ √
√ √
√ √
√ √
12,000 km
12 months
(whichever
comes first)
or
√
–19–
PERIODIC MAINTENANCE/LUBRICATION INTERVALS
NO. ITEM CHECKS AND MAINTENANCE JOBS
16 Sidestand/centerstand
17 * Sidestand switch
18 * Front fork
Rear shock absorber
19 *
assembly
Rear suspension relay
arm and connecting
20 *
arm pivoting points
21 * Carburetors
22 Engine oil
Engine oil filter
23
cartridge
24 * Cooling system
S Check operation.
S Lubricate and repair if necessary.
S Check operation.
S Replace if necessary.
S Check operation and for oil leakage.
S Correct accordingly.
S Check operation and shock absorber for oil leakage.
S Replace shock absorber assembly if necessary.
S Check operation.
S Lubricate with molybdenum disulfide grease every 24,000 km or
24 months (whichever comes first).
S Check engine idling speed, synchronization and starter operation.
S Adjust if necessary.
S Check oil level and vehicle for oil leakage.
S Correct if necessary.
S Change. (W arm engine before draining.)
S Replace. √ √
S Check coolant level and vehicle for coolant leakage.
S Correct if necessary.
S Change coolant every 24,000 km or 24 months (whichever comes
first).
CHK
ADJ
EVERY
INITIAL
(1,000 km)
√ √ √
√ √ √
√ √ √
6,000 km
or
6 months
(whichever
comes first)
√ √
√ √
√ √
√ √
√ √
12,000 km
or
12 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.
D Hydraulic brake system
S When disassembling the master cylinder or caliper, always replace the brake fluid. Check the brake
fluid level regularly and fill as required.
S Replace the oil seals on the inner parts of the master cylinder and caliper every two years.
S Replace the brake hoses every four years or if cracked or damaged.
–20–
ADJUSTING THE FRONT FORK LEGS
EAS00152
CHASSIS
ADJUSTING THE FRONT FORK LEGS
The following procedure applies to both of the
front fork legs.
WARNING
Always adjust both front fork legs evenly.
Uneven adjustment can result in poor handling and loss of stability.
Securely support the motorcycle so that
there is no danger of it falling over.
CAUTION:
Grooves are provided to indicate the ad-
justment position.
Never go beyond the maximum or mini-
mum adjustment positions.
CHK
ADJ
1. Adjust:
spring preload
a. Turn the adjusting bolt
b
.
Spring preload is
Direction
Direction
Adjusting positions
Standard: 5
Minimum: 7
Maximum: 1
increased (suspension is
a
harder).
Spring preload is
decreased (suspension is
b
softer).
1
in direction a or
–21–
FRONT FORK
30 Nm (3.0 mkg)
CHASSIS
FRONT FORK
CHAS
30 Nm (3.0 mkg)
7 Nm (0.7 mkg)
Order Job name/Part name Q’ty Remarks
Removing the front fork
Front wheel
Front brake calipers
Front fender
1
Bolt (upper bracket)
2
Cap bolt
3
Bolt (lower bracket)
4
Front fork assembly (left/right)
5
Remove the parts in the order listed.
Refer to “FRONT WHEEL AND BRAKE
DISCS” section.
Refer to “FRONT AND REAR BRAKES”
section.
1
Loosen
2
Loosen
2
Loosen
2
Refer to “REMOVING/INSTALLING THE
1/1
FRONT FORK LEGS” section.
For installation, reverse the removal
procedure.
Refer to “REMOVING/
INSTALLING THE FRONT
FORK LEGS” section.
–22–
FRONT FORK
23 Nm (2.3 mkg)
CHAS
30 Nm (3.0 mkg)
Order Job name/Part name Q’ty Remarks
Disassembling the front fork
1
Cap bolt
2
O-ring
3
Spacer
4
Washer
5
Front fork spring
6
Dust seal
7
Oil seal clip
8
Bolt
9
Gasket
10
Damper rod/rebound spring
11
Inner tube/Inner tube bushing
12
Oil seal
13
Washer
Disassembly the parts in the order listed.
1
1
1
1
Refer to “ASSEMBLING THE FRONT
1
FORK LEGS” section.
1
1
1
1
1/1
1
Refer to “DISASSEMBLING/
1
ASSEMBLING THE FRONT FORK
1
LEGS” section.
–23–
FRONT FORK
23 Nm (2.3 mkg)
CHAS
30 Nm (3.0 mkg)
Order Job name/Part name Q’ty Remarks
14
15
Outer tube bushing
Oil flow stopper
1
1/1
Refer to “ASSEMBLING THE FRONT
FORK LEGS” section.
For assembly, reverse the disassembly
procedure.
–24–
FRONT FORK
CHAS
CHECKING THE FRONT FORK LEGS
1. Check:
cap bolt O-ring
1
Damage/wear Replace.
EB703700
ASSEMBLING THE FRONT FORK LEGS
1. Fill:
front fork leg
(with the specified amount of the recommended 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
NOTE:
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.
–25–
EB806000
SIGNAL SYSTEM
CIRCUIT DIAGRAM
SIGNAL SYSTEM
ELECTRICAL
ELEC
–26–
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
SIGNAL SYSTEM
ELEC
–27–
SIGNAL SYSTEM CHECK
EB806023
1. If the turn signal light and / or turn indicator
light fails to blink:
SIGNAL SYSTEM
ELEC
1. Bulb and bulb socket
S Check the bulb and bulb socket for continu-
ity .
CONTINUITY
2. Turn switch
S Disconnect the left handlebar switch cou-
plers from the wire harness.
S Set the hazard switch “OFF”
S Check for continuity as follows:
Brown/White – Chocolate
Brown/White – Dark green
21
31
NO CONTINUITY
Replace the bulb and/or bulb socket.
NO CONTINUITY
CONTINUITY
3. Hazard switch
S Disconnect the left handlebar switch cou-
plers from the wire harness.
S Set the turn switch “Neutral position”
S Check for continuity as follows:
Brown/White – Chocolate
Brown/White – Dark green
Chocolate – Dark green
21
31
32
Replace the left handlebar switch.
NO CONTINUITY
Replace the left handlebar switch.
CONTINUITY
:
–28–
:
4. Voltage
S Connect the pocket tester (DC 20 V) to the
flasher relay coupler.
SIGNAL SYSTEM
ELEC
Tester (+) lead Brown terminal
Tester (–) lead Frame ground
S Turn the main switch to “ON”.
S Check the voltage (12 V) of the “Brown”
lead at the flasher relay terminal.
MEETS
SPECIFICATION
5. Voltage
S Connect the pocket tester (DC 20 V) to the
flasher relay coupler.
Tester (+) lead
Brown/White terminal
Tester (–) lead Frame ground
1
1
1
OUT OF SPECIFICATION
The wiring circuit from the main switch to the
flasher relay connector is faulty, repair it.
S Turn the main switch to “ON”.
S Turn the turn switch to “L” / “R” or push the
hazard switch.
S Check the voltage (12 V) on the
“Brown / White” lead at the flasher relay
terminal.
1
MEETS
SPECIFICATION
:
OUT OF SPECIFICATION
The flasher relay is faulty, replace it.
–29–
:
SIGNAL SYSTEM
ELEC
6. Voltage
S Connect the pocket tester (DC 20 V) to the
bulb socket connector.
Flasher light
A
B
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
S Turn the main switch to “ON”.
S Turn the turn switch 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.
MEETS
SPECIFICATION
1
2
A B
1
OUT OF SPECIFICATION
The wiring circuit from the left handlebar
switch to the bulb socket connector is faulty,
repair it.
2
This circuit is not faulty.
–30–
CLOCK
EAS00805
The clock fails to come on.
1. Voltage
Connect the pocket tester (DC 20 V) to the
clock coupler.
CLOCK
ELEC
Tester (+) read Brow
Tester (–) read Frame ground
Turn the main switch to “ON”.
Check the voltage (12 V) on the “Brown”
lead at the clock terminal.
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
MEETS
SPECIFICATION
MEETS
SPECIFICATION
OUT OF SPECIFICATION
1
The wiring circuit from the main switch to the
clock coupler is faulty, repair it.
OUT OF SPECIFICATION
The clock is faulty, replace it.
This circuit is not faulty.
–31–
FZS600 2000 WIRING DIAGRAM
1 A.C. magneto
2 Rectifier/regulator
3 Main switch
4 Battery
5 Fuse (back up)
6 Fuse (main)
7 Starter relay
8 Starter motor
9 Starting circuit cut-off relay
10 Fuel pump relay
11 Ignitor unit
12 Ignition coil
13 Spark plug
14 Pick up 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 switch
34 Oil level switch
35 Flasher relay
36 Horn
37 Pass switch
38 Dimmer switch
39 Horn switch
40 Turn switch
41 Hazard switch
42 Front turn signal light
43 Rear turn signal light
44 Headlight
45 Tail/Brake light
46 Auxiliary light
47 Fan motor
48 Thermo switch (fan motor)
49 Fuse (fan motor)
50 Fuse (head light)
51 Rear brake switch
52 Fuse (signal)
53 Front brake switch
54 Light switch
55 Engine stop switch
56 Starter switch
57 Fuse
58 Alarm
59 Fuse (parking)
60 Relay 2
COLOR CODE
B Black. . . . . .
Br Brown. . . . .
Ch Chocolate. . . .
Dg Dark green. . . .
G Green. . . . .
Gy Gray. . . .
L Blue. . . . . .
P Pink. . . . . .
Lg Light green. . . . .
O Orange. . . . .
R Red. . . . . .
Sb Sky blue. . . . .
W White. . . . .
Y Y ellow. . . . . .
B/L Black/Blue. . . .
B/R Black/Red. . .
B/W Black/White. . .
B/Y Black/Yellow. . .
Br/L Brown/Blue. . .
Br/W Brown/White. .
G/R Green/Red. . .
G/W Green/White. . .
G/Y Green/Yellow. . .
L/B Blue/Black. . . .
L/R Blue/Red. . .
L/W Blue/White. . .
L/Y Blue/Y ellow. . . .
R/B Red/Black. . .
R/W Red/White. . .
R/Y Red/Y ellow. . .
W/B White/Black. . .
W/G White/Green. . .
W/R White/Red. . .
Y/B Yellow/Black. . .
Y/R Y ellow/Red. . .
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