Yamaha FZS600 2000 Service Manual
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–
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