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.

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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. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .