Yamaha FZS600'98 User manual

EB000000
FZS600
SERVICE MANUAL
1997 by Yamaha Motor Co., Ltd.
First edition, December 1997
All rights reserved. Any reproduction or
unauthorized use without the written
permission of Yamaha Motor Co., Ltd.
is expressly prohibited.

NOTE:
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
significantchangesinspecificationsorprocedureswillbeforwardedtoallauthorizedYamahadealers
and will appear in future editions of this manual where applicable.
Designs and specifications ar 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!
FailuretofollowWARNINGinstructionscouldresultinsevereinjuryordeathto
the motorcycle operator, a bystander or a person inspecting or repairing the
motorcycle.
ACAUTIONindicates special precautionsthatmust be takentoavoid 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 Chapter3, “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 descrided
sequentially.

1
3
5
7
9
11
13
15
18
2
4
8
10
12
14
16
6
21
24 25
17
19 20
22 23
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 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
Symbols 24 to 25 in the exploded diagrams
indicate the following:
24 Apply locking agent (LOCTITE)
25 Use new one

GENERAL INFORMATION
SPECIFICATIONS
PERIODIC INSPECTIONS AND
ADJUSTMENTS
ENGINE
COOLING SYSTEM
CARBURETORS
CHASSIS
ELECTRICAL SYSTEM
TROUBLESHOOTING
GEN
INFO 1
SPEC 2
CHK
ADJ 3
ENG 4
COOL 5
CARB 6
CHAS 7
ELEC 8
TRBL
SHTG 9
INDEX

GEN
INFO
1

GEN
INFO
CHAPTER 1
GENERAL INFORMATION
MOTORCYCLE IDENTIFICATION 1-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
VEHICLE IDENTIFICATION NUMBER 1-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
MODEL CODE 1-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
IMPORTANT INFORMATION 1-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PREPARATION FOR REMOVAL AND DISASSEMBLY 1-2. . . . . . . . . . . . . . . . . . . . . .
REPLACEMENT PARTS 1-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
GASKETS, OIL SEALS AND O-RINGS 1-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
LOCK WASHERS/PLATES AND COTTER PINS 1-3. . . . . . . . . . . . . . . . . . . . . . . . . . .
BEARINGS AND OIL SEALS 1-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CIRCLIPS 1-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE CONNECTIONS 1-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SPECIAL TOOLS 1-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

GEN
INFO

1-1
GEN
INFO
MOTORCYCLE IDENTIFICATION
1
1
EB100000
GENERAL INFORMATION
MOTORCYCLE IDENTIFICATION
EB100010
VEHICLE IDENTIFICATION NUMBER
The vehicle identification number 1is stamped
into the right side of the steering head.
EB100020
MODEL CODE
The model code label 1is affixed to the frame.
This information will be needed to order spare
parts.

1-2
spring
lip
oil grease
lip
GEN
INFO
IMPORTANT INFORMATION
EB102000
IMPORTANT INFORMATION
PREPARATION FOR REMOVAL AND
DISASSEMBLY
1. Beforeremovalanddisassembly,removeall
dirt, mud, dust and foreign material.
2. Use only the proper tools and cleaning
equipment.
Refer to the “SPECIAL TOOLS” section.
3. When disassembling, always keep mated
parts together. This includes gears, cylin-
ders,pistons and other parts that have been
“mated” through normal wear.
Mated parts must always be reused or re-
placed as an assembly.
4. During disassembly, clean all of the parts
andplace them intrays in theorder of disas-
sembly. This will speed up assembly and al-
low for the correct installation of all parts.
5. Keep all parts away from any source of fire.
EB102010
REPLACEMENT PARTS
1. Use only genuine Yamaha parts for all re-
placements. Use oil and grease recom-
mended by Yamaha for all lubrication jobs.
Other brands may be similar in-function and
appearance, but inferior in quality.
EB102020
GASKETS, OIL SEALS AND O-RINGS
1. When overhauling the engine, replace all
gaskets, seals and O-rings. All gasket sur-
faces, oil seal lips and O-rings must be
cleaned.
2. During reassembly, properly oil all mating
parts and bearings and apply grease onto
the oil seal lips.

1-3
OR
GEN
INFO
IMPORTANT INFORMATION
CAUTION:
EB102030
LOCK WASHERS/PLATES AND COTTER
PINS
1. After removal, replace all lock washers/
plates
1andcotterpins. Aftertheboltornut
has been tightened to specification, bend
the lock tabs along a flat of the bolt or nut.
EB102040
BEARINGS AND OIL SEALS
1. Install bearings and oil seals so that the
manufacturer’s marks or numbers are vis-
ible. When installing oil seals, apply a light
coat of lithium soap base grease onto the oil
seal lips. Oil bearings liberally when instal-
ling, if appropriate.
1Oil seal
Donot spin thebearingwith compressed
air because this will damage the bearing
surfaces.
1Bearing
EB102050
CIRCLIPS
1. Beforereassembly,checkallcirclipscareful-
lyandreplacedamagedor distortedcirclips.
Always replace piston pin clips after one
use.Wheninstalling a circlips 1, makesure
thatthesharp-edgedcorner 2,ispositioned
opposite the thrust 3that the circlip re-
ceives.
4Shaft

1-4
GEN
INFO
CHECKING THE CONNECTIONS
NOTE:
NOTE:
NOTE:
EB103000
CHECKING THE CONNECTIONS
Check the leads, couplers, and connectors for
stains, rust, moisture, etc.
1.Disconnect:
lead
coupler
connector
2.Check:
lead
coupler
connector
Moisture Dry with an air blower.
Rust/stains Connect and disconnect
several times.
3.Check:
all connections
Loose connection Connect properly.
If the pin 2 on the terminal is flattened, bend
in up.
4.Connect:
lead
coupler
connector
Make sure that all connections are tight.
5.Check:
continuity
(with a pocket tester)
Pocket tester
90590-03112
If there is no continuity, clean the termi-
nals.
When checking the wire harness, perform
steps 1 to 3.
As a quick remedy, use a contact revitaliz-
er available at most part stores.

1-5
GEN
INFO
SPECIAL TOOLS
1
2
12
1
21
EB104000
SPECIAL TOOLS
The following special tools are necessary for
complete and accurate tune-up and assembly.
Useonlytheappropriatespecialtoolsasthiswill
help prevent damage caused by the use of
inappropriate tools or improvised techniques.
When placing an order, refer to the list provided
below to avoid any mistakes.
Tool No. Tool name/Usage Illustration
90890-01268 Ring nut wrench
This tool is used to loosen and tighten the
steering ringnut.
90890-01304 Piston pin puller
This tool is used to remove the piston pin.
90890-01460
-01326 Damper rod holder T-handle
Thesetool ar used for holdingthe damper rod
when removing or installing the damper rod.
90890-01312 Fuel level gauge
This gauge is used to measure the fuel level
in the float chamber.
90890-01325
-01352 Radiator cap tester Adaptor
These tools are used for checking the cooling
system.
90890-01362
-01382 Flywheel puller Crank shaft protector
These tools are used for removing the rotor
and starter clutch.
90890-01367
-01381 Fork seal driver weight Fork seal driver attachment (ø41 mm)
These tools are used when installing the
forkseal.

1-6
GEN
INFO
SPECIAL TOOLS
1
Tool No. Tool name/Usage Illustration
90890-01399 Special thickness gauge
This tool is used to measure the valve
clearance.
90890-01401 Spark plug wrench
This tool is used for removing or installing
the spark plug.
90890-01403 Ring nut wrench
This tool is used to tighten the steering ring
nut.
90890-01469 Oil filter wrench
This tool is used for removing or installing
the oil filter.
90890-01701 Sheave holder
Thistoolisusedforholdingthemagnetorotor.
90890-03081 Compression gauge
This tool is used to measure the engine
compression
90890-03094 Vacuum gauge
This tool is used to measure the
synchronizing the carburetors.
90890-03112 Pocket tester
These instruments are invaluable for
checking the electrical system.
90890-03133 Engine tachometer
This tool is needed for detecting engine rpm.
90890-03153
-03139 Oil pressure gauge Oil pressure adaptor H
These tools are used to measure the engine
oil pressure.

1-7
GEN
INFO
SPECIAL TOOLS
12
1
Tool No. Tool name/Usage Illustration
90890-03141 Timing light
This tool is necessary for checking ignition
timing.
90890-04044 Piston ring compressor
This tool is used to compress piston rings
when installing the cylinder.
90890-03158 Carburetor angle driver
This tool is used to adjust the pilot screw.
90890-04086 Clutch holding tool
This tool is used for holding the clutch boss.
90890-04101 Valve lapper
This tool is used for removing and installing
the valve lifter and for lapping the valve.
90890-04111 Valve guide remover (4.0 mm)
This tool is used to remove the valve guides.
90890-04112 Valve guide installer (4.0 mm)
This tool is needed to install the valve guides
properly.
90890-04113 Valve guide reamer (4.0 mm)
This tool is used to rebore the new valve
guide.
90890-04019
-04114 Valve spring compressor Valve spring compressor attachment
These tools are used when removing or
installing the valve and the valve spring.
90890-06754 Ignition checker
This instrument is necessary for checking
the ignition system components.

1-8
GEN
INFO
SPECIAL TOOLS
Tool No. Tool name/Usage Illustration
90890-85505 Yamaha bond No.1215
This sealant (bond) is used for crankcase
mating surface, etc.

SPEC
2