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.

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 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.

–3–
MAINTENANCE SPECIFICATIONS SPEC
MAINTENANCE SPECIFICATIONS
ENGINE
Item Standard Limit
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
40.09 mm
34.5 mm
131.4 153.0 N (13.4 15.6 kg)
SSS
Clockwise
37.5 mm
SSS
SSS
2.5_/1.8 mm
SSS
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 (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)
SSS
SSS
SSS
SSS
SSS
SSS
SSS
SSS
SSS
SSS
SSS
SSS
SSS
SSS
SSS
SSS
SSS
SSS
SSS
SSS
SSS

–4–
MAINTENANCE SPECIFICATIONS SPEC
CHASSIS
Item Standard Limit
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
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 cm3
132 mm
Fork oil 10W or equivalent

319 mm










Drive chain:
Type/manufacturer
No. of links
Chain free play
50VA7/DAIDO
110
30 45 mm



TIGHTENING TORQUES
CHASSIS
Part to be tightened Thread size Tightening
torque Remarks
g
Nm mkg
Holder, clutch lever 1 M6 1.0 11 1.1

–5–
MAINTENANCE SPECIFICATIONS SPEC
ELECTRICAL
Item Standard Limit
Ignition system:
Ignition timing (B.T.D.C.)
Advanced timing (B.T.D.C.)
Advance type
10_/1,250 r/min
50_/4,500 r/min
Digital type
SSS
SSS
SSS
T.C.I.:
Pickup coil resistance
T.C.I. unit model/manufacturer 189 231 ΩY-L
J4T095/MITSUBISHI SSS SSS
Charging system:
Type
Model/manufacturer
Standard output
Stator coil resistance
A.C. magneto
F4T359/MITSUBISHI
14 V 18 A at 5,000 r/min
0.36 0.44 Ωat 20_C/W-W
SSS
SSS
SSS
SSS
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)
SM-13/MITSUBA
SM-13
0.7 kW
0.0015 0.0025 Ωat 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
4 mm
SSS
27 mm
SSS
SSS
Starter relay:
Model/manufacturer
Amperage rating
Coil winding resistance
MS5F-631/JIDECO
180 A
4.18 4.62 Ωat 20_C
SSS
SSS
SSS
Horn:
Type
Quantity
Model manufacturer
Maximum amperage
Performance
Coil winding resistance
Plane type
1 pcs
YF-12/NIKKO
3.0 A
105 113 db/2 m
1.15 1.25 Ωat 20_C
SSS
SSS
SSS
SSS
SSS
SSS
Flasher/hazard relay:
Type
Model/manufacturer
Self cancelling device
Hazard flasher device
Flasher frequency
Wattage
Full transistor type
FE246BH/DENSO
No
Yes
75 95 cyl/min
21 W 2 + 3.4 W
SSS
SSS
SSS
SSS
SSS
SSS
Thermostat switch:
Model/manufacture 4BA/DENSO SSS

–6–
MAINTENANCE SPECIFICATIONS SPEC
Item Standard limit
Starting circuit cut-off relay:
Model/manufacture
Coil winding resistance G8R-30Y-B/OMRON
202.5 247.5 Ωat 20_CSSS SSS
Fuel pump relay:
Model/manufacture
Coil winding resistance G8R-30Y-B/OMRON
202.5 247.5 Ωat 20_CSSS SSS
Amperage for individual circuit:
Main
Headlight
Signal
Ignition
Fan
Parking/Hazard
Back up
Reserve
30 A
20 A
20 A
20 A
10 A
10 A
5 A
30 A
20 A
10 A
5 A
SSS
SSS
SSS
SSS
SSS
SSS
SSS
SSS
SSS
SSS
SSS

–7–
D Pass the brake hose out side of
the speed sensor lead, then use
a plastic clamp to fasten them.
A Use a plastic band to fasten to-
getherthehandlebarswitchlead
(L) and the handlebar.
B Use a plastic clamp to fasten to-
getherthehandlebarswitchlead
(left), clutch cable and starter
cable
C Pass the speed sensor lead in-
side of the clamp code.
1Throttle cable
2Clutch cable
3Handlebar switch (left)
4Starter cable
5Main switch
6Main switch lead
7Brake hose
8Speed sensor lead
9Headlight lead
10 Handlebar switch (right)
CABLE ROUTING SPEC
EB205000
CABLE ROUTING

–8–
CABLE ROUTING SPEC
1Main switch lead
2Handlebar switch lead (left)
3Clutch cable
4Starter cable
5Rectifier/regulator
6Horn lead
7Box
8Air guide plate
9Fan 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

–9–
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
theguidegear,thenintothebox.
C Use a plastic clamp to fasten the
horn lead and air guide plate to
the frame.
D Wheninstalling the plugcap, the
high tension code should be fac-
ing 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.

–10–
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 mo-
tor lead, AC magneto lead, side-
stand switch lead and oil lev-
el/neutral switch lead, then hold
the clamp to the frame bracket.
Positionthebandendto out side
of chassis.
J Useaplasticlocking tietofasten
the starter motor lead, AC mag-
neto 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,
sidestandleadandoillevel/neu-
tral switch lead.
M Pass the air cleaner drain hose
infrontofthereararmpivotshaft
and back of the cross tube.
N Pass the air cleaner drain hose
through the pipe holder of rear
shockabsorberbracket, thendraw
it out to the left side of the body.

–11–
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
throughthebottomofthecoolant
pipe.
Q Donot loosenthe fanmotor lead
here.
R Passthe clutchcableandstarter
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
speedsensor leadat 3points af-
ter 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.

–12–
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
1Rear brake switch lead
2Battery
3Reservoir tank over flow hose
4Cross tube
5Battery negative (–) lead
6Reservoir tank hose
7Air filter
8To fuel tank
9Fuel tank breather hose
10 Fuel tank drain hose
11 T.P.S. lead
12 Box
13 Speed sensor lead
CABLE ROUTING SPEC
A Pass the fuel tank drain hose,
fuel tank breather hose and res-
ervoir tank over flow pipe be-
tween the rear arm and the en-
gine crankcase.
B Pass the fuel tank drain hose
and fuel tank breather hose be-
tween 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.