Yamaha 2002 FZS600 Manual

FOREWORD
This Supplementary Service Manual has been prepared to introduce new service and data for the
FZS600 (P) 2002. For complete service information procedures it is necessary to use this Supplemen-
tary Service Manual together with the following manual.
FZS600 SERVICE MANUAL: 5DM1-AE1
FZS600 SUPPLEMENTARY SERVICE MANUAL: 5DM1-AE2
FZS600 (P) 2002
SUPPLEMENTARY
SERVICE MANUAL
E2001 by Yamaha Motor Co., Ltd.
First Edition, August 2001
Any reproduction or unauthorized use
without the written permission of
Yamaha Motor Co., Ltd. is expressly
prohibited.

NOTE:
WARNING
CAUTION:
EB001000
NOTICE
This manual was produced by the Yamaha 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
motorycle has a basic understanding of the mechanical ideas and the procedures of motorcycle repair.
Repairs attempted by anyone without this knowledge are likely to render the motorcycle unsafe and
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 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 notations.
The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR
SAFETY IS INVOLVED!
Failure to follow WARNING instructions could result in severe injury or death to
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.
NOTE: A NOTE provides key information to make procedures easier or clearer.

7
2143
8
6
5
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.
1The 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.
2Each 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.)
3Sub-section titles appear in smaller print than the section title.
4To help identify parts and clarify procedure steps, there are exploded diagrams at the start of each
removal and disassembly section.
5Numbers are given in the order of the jobs in the exploded diagram. A circled number indicates a
disassembly step.
6Symbols indicate parts to be lubricated or replaced (see “SYMBOLS”).
7A job instruction chart accompanies the exploded diagram, providing the order of jobs, names of
parts, notes in jobs, etc.
8Jobs requiring more information (such as special tools and technical data) are described
sequentially.

22
1
3
5
7
9
2
4
8
6
24 25
2321
19 2018
15
1413
11 12
10
GEN
INFO SPEC
ENG
CARB
ELEC
CHK
ADJ
TRBL
SHTG
16 17
COOL
CHAS
EB003000
SYMBOLS
The following symbols are not relevant to every
vehicle.
Symbols 1to 9indicate the subject of each
chapter.
1General information
2Specifications
3Periodic checks and adjustments
4Engine
5Cooling system
6Carburetor(-s)
7Chassis
8Electrical system
9Troubleshooting
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 bearing grease
22 Apply lightweight lithium-soap base grease
23 Apply molybdenum disulfide grease
Symbols 24 to 25 in the exploded diagrams indi-
cate the following:
24 Apply locking agent (LOCTITE)
25 Use new one

CONTENTS
SPECIFICATIONS
GENERAL SPECIFICATIONS 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
MAINTENANCE SPECIFICATIONS 3. . . . . . . . . . . . . . . . . . . . . . . . . . .
ENGINE 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHASSIS 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ELECTRICAL 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
LUBRICATION POINT AND LUBRICATION TYPES 5. . . . . . . . . . . .
COOLING SYSTEM DIAGRAMS 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CABLE ROUTING 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PERIODIC CHECKS AND ADJUSTMENTS
INTRODUCTION 21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PERIODIC MAINTENANCE/LUBRICATION INTERVALS 21. . . . . . .
FRONT COWLING/SEAT/SIDE COVER/FUEL TANK 23. . . . . . . . . .
FRONT COWLING 23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SEAT, SIDE COVER, AND FUEL TANK 24. . . . . . . . . . . . . . . . . . . .
CHASSIS 25. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ADJUSTING THE FRONT BRAKE 25. . . . . . . . . . . . . . . . . . . . . . . . .
ELECTRICAL SYSTEM 25. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
REPLACING THE HEADLIGHT BULBS 25. . . . . . . . . . . . . . . . . . . .
ADJUSTING THE HEADLIGHT BEAMS 26. . . . . . . . . . . . . . . . . . . .
ENGINE
CYLINDER HEAD 27. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CLUTCH 28. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
INSTALLING THE CLUTCH 30. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
AC MAGNETO AND STARTER CLUTCH 32. . . . . . . . . . . . . . . . . . . . . .
STARTER CLUTCH 32. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
COOLING SYSTEM
RADIATOR 33. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
THERMOSTAT 34. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ASSEMBLING THE THERMOSTAT 35. . . . . . . . . . . . . . . . . . . . . . . .
WATER PUMP 36. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DISASSEMBLING THE WATER PUMP 37. . . . . . . . . . . . . . . . . . . . .
CHECKING THE WATER PUMP 37. . . . . . . . . . . . . . . . . . . . . . . . . . .
ASSEMBLING THE WATER PUMP 38. . . . . . . . . . . . . . . . . . . . . . . .
CHASSIS
FRONT FORK 40. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
REMOVING THE FRONT FORK LEGS 41. . . . . . . . . . . . . . . . . . . . .
INSTALLING THE FRONT FORK LEGS 41. . . . . . . . . . . . . . . . . . . .
HANDLEBAR 42. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
STEERING HEAD 44. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
LOWER BRACKET 44. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SWINGARM AND DRIVE CHAIN 46. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ELECTRICAL SYSTEM
INSTRUMENT FUNCTION 48. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DIGITAL CLOCK 48. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CIRCUIT DIAGRAM 49. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING SWITCHES 51. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SWITCH POSITION AND TERMINAL CONNECTION 51. . . . . . . .
LIGHTING SYSTEM 52. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CIRCUIT DIAGRAM 52. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
LIGHTING SYSTEM CHECK 53. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SIGNAL SYSTEM 56. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CIRCUIT DIAGRAM 56. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SIGNAL SYSTEM CHECK 58. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
COOLING SYSTEM 60. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CIRCUIT DIAGRAM 60. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TROUBLESHOOTING 61. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FZS600 (P) 2002 WIRING DIAGRAM

–1–
GENERAL SPECIFICATIONS SPEC
SAE20W40SE or
SAE10W30SE
SPECIFICATIONS
GENERAL SPECIFICATIONS
Model FZS600
Model code: 5RT1
5RT2
5RT3
Dimensions:
Overall length
Overall height
2,080 mm (Except FIN, NOR)
2,175 mm (FIN, NOR)
1,180 mm
Basic weight:
With oil and full fuel tank 214 kg
Oil type or grade:
Engine oil
Periodic oil change
With oil filter replacement
Total amount
2.5 L
2.7 L
3.5 L
Fuel:
Type
Fuel tank capacity
Fuel reserve amount
Regular unleaded gasoline
22 L
3.6 L
Tire:
Type
Size front
rear
Manufacturer front
rear
Type front
rear
Tubeless
110/70ZR 17 M/C (54W)
110/70ZR 17 (54W)
160/60ZR 17 M/C (69W)
160/60ZR 17 (69W)
BRIDGESTONE/DUNLOP
BRIDGESTONE/DUNLOP
BT-57F/D207F
BT-57R/D207J
Tire pressure:
Maximum load-except motorcycle
Loading condition A*
front
rear
Loading condition B*
front
rear
High-speed riding
front
rear
183 kg
0 X90 kg
225 kPa (2.25 kg/cm2, 2.25 bar)
250 kPa (2.5 kg/cm2, 2.5 bar)
90 X183 kg
225 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)
* Load is the total weight of cargo, rider, passenger, and accessories.

–2–
GENERAL SPECIFICATIONS SPEC
Model FZS600
Bulb voltage, wattage quantity:
Headlight
Auxiliary light
Tail/brake 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 signal indicator light
Fuel level warning light
Engine temperature warning light
12 V 60 W/55 W 2
12 V 5 W 2
12 V 5 W/21 W 2
12 V 21 W 2
12 V 21 W 2
14 V 14 W 3
12 V 1.4 W 1
12 V 1.4 W 1
12 V 1.4 W 1
12 V 1.4 W 2
12 V 2 W 1
LED

–3–
MAINTENANCE SPECIFICATIONS SPEC
MAINTENANCE SPECIFICATIONS
ENGINE
Item Standard Limit
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
5DM1 01
#115
#80
5D86-3/5
P-0M
#130
0.95
#12.5
0.9
0.8
0.8
2-1/2
1.0
0.6
0.8
#110
3.5 mm
1,150 X1,250 r/min
31.7 X34.3 kPa (238 X257 mmHg)
SSS
SSS
SSS
SSS
SSS
SSS
SSS
SSS
SSS
SSS
SSS
SSS
SSS
SSS
SSS
SSS
SSS
SSS
SSS
TIGHTENING TORQUES
ENGINE
Part to be tightened Part name Thread
size
Q’ty
Tightening
torque Remarks
g
size
y
Nm mSkg
Radietor cover Bolt M5 2 7 0.7

–4–
MAINTENANCE SPECIFICATIONS SPEC
CHASSIS
Item Standard Limit
Drive chain:
Type/manufacturer
No. of links
Chain free play
Maximum ten-link section
50VA4/DAIDO
110
30 X45 mm
150 mm
SSS
SSS
SSS
SSS
TIGHTENING TORQUES
CHASSIS
Part to be tightened Part name Thread
size
Q’ty
Tightening
torque Remarks
g
size
y
Nm mSkg
Front cowling stay Nut M8 2 33 3.3
ELECTRICAL
Item Standard Limit
Charging system:
Type
Model/manufacturer
Standard output
Stator coil resistance
A.C. magneto
F4T377/MITSUBISHI
14 V 21 A at 5,000 r/min
0.28 X0.34 Ωat 20_C/W-W
SSS
SSS
SSS
SSS
Rectifier:
Model/manufacture
Capacity
Withstand voltage
SH650C-11/SHINDENGEN
18 A
200 V
SSS
SSS
SSS
Fuel gauge:
Model/manufacture
Sender unit resistance-full
-empty
5RT/NIPPON SEIKI
4 X10 Ω
122.5 X128.5 Ω
SSS
SSS
SSS
Amperage for individual circuit:
Main
Headlight
Signal
Ignition
Fan
Back up
Reserve
30 A
20 A
10 A
20 A
10 A
10 A
30 A
20 A
10 A
SSS
SSS
SSS
SSS
SSS
SSS
SSS
SSS
SSS
Thermo unit:
Model/manufacture
Resistance
5JJ/NIPPON THERMOSTAT
3413 X4007 Ωat 80_C
1645 X1855 Ωat 105_C
SSS
SSS
SSS

–5–
LUBRICATION POINT AND LUBRICATION TYPES SPEC
LUBRICATION POINT AND LUBRICATION TYPES
ENGINE
Lubrication Point Symbol
Cylinder head tightening nut washer

–6–
COOLING SYSTEM DIAGRAMS SPEC
8Radiator outlet hose
9Radiator
10 Radiator inlet hose
1Engine outlet hose
2Engine outlet hose
3Carburetor inlet hose
4Carburetor outlet hose
5Water pump
6Coolant drain bolt
7Water pump outlet hose
EB203000
COOLING SYSTEM DIAGRAMS

–7–
COOLING SYSTEM DIAGRAMS SPEC
1Radiator
2Water pump outlet hose
3Oil cooler inlet hose
4Oil cooler outlet hose
5Carburetor outlet hose

–8–
CABLE ROUTING SPEC
D Pass speed sensor lead through
clamp code 1.
E 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 became slack.
F 10 mm or less from the bottom of
protector.
A Using clamp, left handlebar
switch lead to crimpled part of
clutch cable fitting. After clamp-
ing, cut excessive portion from
tip.
B Using clamp, bundle:
SLeft handlebar switch lead
SClutch cable
SStarter cable
C 30 mm or less from the top of
protector.
1Throttle cables
2Clutch cable
3Left handlebar switch lead
4Starter cable
5Main switch
6Main switch lead
7Brake hose
8Speed sensor lead
9Right handlebar switch lead
EB205000
CABLE ROUTING

–9–
CABLE ROUTING SPEC
27 Rectifier/regulator lead
28 Horn
29 Brake hose
30 Speed sensor lead
31 Fuse box
32 Rear fender
33 Wire harness
34 Pickup coil lead coupler
35 Sidestand switch lead coupler
36 Oil level/neutral switch lead cou-
pler
37 A.C. magneto lead coupler
38 Oil level/neutral switch lead
14 Starter relay
15 Battery positive lead
16 Seat lock cable
17 Seat lock stay
18 Cross tube 3
19 A.C. magneto lead
20 Starter motor lead
21 Cross tube
22 Air filter case drain hose
23 Sidestand switch lead
24 Neutral switch
25 Oil level switch lead
26 Radiator
1Main switch lead
2Starter cable
3Left handlebar switch lead
4Clutch cable
5Horn lead
6Rectifier/regulator
7Box
8Air guide
9Radiator fan motor lead
10 Spark plug lead 1
11 Starting circuit cut-off relay
12 Battery
13 Turn signal relay

–10–
CABLE ROUTING SPEC
SWire harness (at white taping)
SStarter motor lead
SA.C. magneto lead
SSidestand switch lead
SOil level switch lead
SNeutral switch lead
Locate wire harness outermost.
Locate clamp with its tip outward
of frame so that it does not pro-
trude through clearance be-
tween side cover and frame.
E Wire harness, starter motor
lead, A.C. magneto lead, side-
stand switch lead and neutral
switch lead pass the over cross
tube 3.
F Using clamp, fix wire harness to
the frame.
G Using clamp, fix wire harness to
the frame.
H After connecting coupler, push
then on the inside of lock stay on
the frame.
I Using clamp, fix to bracket on the
frame:
A Using clamp, fix:
SLeft handlebar switch lead
SMain switch lead
SClutch cable
SStarter cable
In so doing, locate main switch
lead innermost.
B To headlight sub-wire harness
C Radiator fan motor lead, pass
this lead through hole in air guide
and then into box.
D Install plug cap so that spark
plug lead face toward inside of
vehicle.

–11–
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.
P Using clamp on engine, fix:
SA.C. magneto lead
SSidestand switch lead
SOil level switch lead
SNeutral switch lead
J Using clamp, fix to bracket on
frame:
SStater motor lead
SSidestand switch lead
SOil level switch lead
SNeutral switch lead
Locate wire harness outermost.
Locate clamp with its tip down-
ward and cut off excessive
length.
K Pass air filter drain hose through
clamp on engine.
L Air filter case drain hose in front
of swingarm pivot shaft and in
rear of cross tube.
CABLE ROUTING SPEC
Q Pass on the outside of spark plug
lead 1
SClutch cable
SStarter cable
R Radiator fan motor lead shall
permit no slack in this range.
S 10 mm or less from the bottom of
protector.
T 10 mm or less from the bottom of
protector.

–12–
U Using holder, fix speed sensor
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.
CABLE ROUTING SPEC

–13–
CABLE ROUTING SPEC
1Right handlebar switch lead
2Throttle cables
3Brake hose
4Cable guide
5Main switch lead
6Radiator reservoir tank
7Rear brake light switch lead
8Battery
9Radiator reservoir tank breather
hose
10 Battery negative lead
11 Cross tube 3
12 Radiator reservoir tank breather
hose
13 Air filter
14 Throttle position sensor lead
15 Box
16 Speed sensor lead
17 Engine bracket 3
18 Swingarm bracket