Yamaha FZS600 2000 Manual

FOREWORD
This Supplementary Service Manual has been prepared to introduce new service and data for the
FZS6002000.ForcompleteserviceinformationproceduresitisnecessarytousethisSupplementary
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.

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
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
significantchangesinspecificationsorprocedureswillbeforwardedtoall 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 ATTENTION! BECOME ALERT! YOUR
SAFETY IS INVOLVED!
FailuretofollowWARNINGinstructionscouldresultin severe injuryordeathto
the motorcycle operator, a bystander or a person inspecting or repairing the
motorcycle.
ACAUTIONindicates special precautions that must betakento avoid damage
to the motorcycle.
NOTE: A NOTE provides key information to make procedures easier or clearer.

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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 inspection and adjustment
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 intheexplodeddiagramsindi-
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 intheexplodeddiagramsindi-
cate the following:
24 Apply locking agent (LOCTITE)
25 Use new one

CONTENTS
GENERAL INFORMATION
FEATURES 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SPEEDOMETER 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SPECIFICATIONS
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

–1–
FEATURES GEN
INFO
NOTE:
GENERAL INFORMATION
FEATURES
SPEEDOMETER
1Speedometer
2Odometer/Tripmeter/Clock
3“SELECT” button
4“RESET” button
This speedometer is equipped with:
an odometer
two tripmeters
a clock
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 indi-
cated.Usethetripmeterstoestimatehowfaryoucanrideonatankoffuel.Thisinformationwillenable
you to plan fuel stops in the future.
Selecting a mode
Push the “SELECT” button 3to change between the odometer mode “ODO”, the tripmeter modes
“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 3and push the
“RESET” button 4for 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 both the “SELECT” button 3and “RESET” button 4for at least two seconds.
2. When the hour digits start flashing, push the “RESET” button 4to set the hours.
3. Push the “SELECT” button 3to change the minutes.
4. When the minute digits start flashing, push the “RESET” button 4to set the minutes.
5. Push the “SELECT” button 3to start the clock.
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.

–2–
GENERAL SPECIFICATIONS SPEC
SPECIFICATIONS
GENERAL SPECIFICATIONS
Model FZS600
Model code: 5DM7
5DM8
5DM9
Fuel:
Type
Fuel tank capacity
Fuel reserve amount
Regular unleaded gasoline
20 L
3.5 L
Tire pressure:
Maximum load-except motorcycle
Loading condition A*
front
rear
Loading condition B*
front
rear
High-speed riding
front
rear
187 kg
0 90 kg
225 kPa (2.25 kg/cm2, 2.25 bar)
250 kPa (2.5 kg/cm2, 2.5 bar)
90 187 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)
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
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
*Load is the total weight of cargo, rider, passenger and accessories.