Yamaha FZS600(P) User manual

YAMAHA 2002
FZSBOO(P) 5DM1-SE3
SERVICE
INFORMATION

FOREWORD
This Service information 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 Service information to-
gether with the following manual.
FZS600 '98 ~2002 SERVICE MANUAL: 5DM1-ME3
FZS600 '98 SERVICE INFORMATION: 5DM1-SE1
FZS600 2000 SERVICE INFORMATION: 5DM1-SE2
FZS600 (P) 2002
SERVICE INFORMATION
©2001 by Yamaha Motor Co., Ltd.
First Edition, August 2001
All rights reserved.
Any reproduction or unauthorized use
without the written permission of
Yamaha Motor Co., Ltd. is expressly
prohibited.

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 amechanic in one manual,
so it is assumed that anyone who uses this book to perform maintenance and repairs on Yamaha
motorycle has abasic 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.
NOTE:
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!
AWARNING Failure to follow WARNING instructions could result in severe injury or death to
the motorcycle operator, abystander or aperson inspecting or repairing the
motorcycle.
CAUTION:
NOTE:
ACAUTION indicates special precautions that must be taken to avoid damage
to the motorcycle.
ANOTE provides key information to make procedures easier or clearer.

©GEN
INFO
CHK
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CHAS (^
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SHTG 9
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©
SPEC
©
ENG ID
CARB 9
ELEC JB .
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nNew
EB003000
SYMBOLS
The following symbols are not relevant to every
vehicle.
Symbols (D to (D indicate the subject of each
chapter.
(T) General information
®Specifications
(3) Periodic checks and adjustments
(4) Engine
(§) Cooling system
d) Carburetor(-s)
(2) Chassis
(§) Electrical system
(9) Troubleshooting
Symbols ©to ©indicate the following.
®Serviceable with engine mounted
@Filling fluid
©Lubricant
©Special tool
©Tightening torque
©Wear limit, clearance
@Engine speed
©Electrical data
)in the exploded diagrams indi-
of lubricants and lubrication
Symbols© to<
cate the types
points.
@Apply engine oil
©Apply gear oil
©Apply molybdenum disulfide oil
@Apply wheel bearing grease
©Apply lightweight lithium-soap base grease
©Apply molybdenum disulfide grease
Symbols® to© in the exploded diagrams indi-
cate the following:
®Apply locking agent (LOCTITE®)
@Use new one

CONTENTS
SPECIFICATIONS
GENERAL SPECIFICATIONS 1
MAINTENANCE SPECIFICATIONS 3
ENGINE 3
CHASSIS 4
ELECTRICAL 4
LUBRICATION POINT AND LUBRICATION TYPES 5
ENGINE 5
CABLE ROUTING 6
PERIODIC CHECKS AND ADJUSTMENTS
INTRODUCTION 19
PERIODIC MAINTENANCE/LUBRICATION INTERVALS 19
FZS600 (P) 2002 WIRING DIAGRAM

-1
GENERAL SPECIFICATIONS
SPECIFICATIONS
GENERAL SPECIFICATIONS
SPEC o-
Model FZS600
Model code: 5RT1
5RT2
5RT3
Dimensions:
Overall length 2,080 mm (Except FIN, NOR)
2,175 mm (FIN, NOR)
Overall height 1,180 mm
Basic weight:
With oil and full fuel tank 214 kg
Oil type or grade:
Engine oil
^Temp. c
-20 -10 C'0 20 30 40
'SAE20W40SE or
10 A3C SAE10W30SE
10W/40
20W/40
Periodic oil change
20W/50 |
2.5 L
With oil filter replacement 2.7 L
Total amount 3.5 L
Fuel:
Type Regular unleaded gasoline
Fuel tank capacity 22 L
Fuel reserve amount 3.6 L
Tire:
Type Tubeless
Size front 110/70ZR 17M/C(54W)
110/70ZR 17(54W)
rear 160/60ZR 17M/C(69W)
160/60ZR17(69W)
Manufacturer front BRIDGESTONE/DUNLOP
rear BRIDGESTONE/DUNLOP
Type front BT-57F/D207F
rear BT-57R/D207J
Tire pressure:
Maximum load-except motorcycle 183 kg
Loading condition A* ~90 kg
front 225 kPa (2.25 kg/cm2,2.25 bar)
rear 250 kPa (2.5 kg/cm2,2.5 bar)
Loading condition B* 90 ~183 kg
front 225 kPa (2.25 kg/cm2,2.25 bar)
rear 290 kPa (2.9 kg/cm2,2.9 bar)
High-speed riding
front 225 kPa (2.25 kg/cm2,2.25 bar)
rear 290 kPa (2.9 kg/cm2,2.9 bar)
Load is the total weight of cargo, rider, passenger, and accessories.
-1-

-2-
GENERAL SPECIFICATIONS SPEC
Model FZS600
Bulb voltage, wattage xquantity:
Headlight 12V60W/55W x2
Auxiliary light 12 V5W x2
Tail/brake light 12V5W/21 Wx2
Front turn signal light 12 V21 Wx2
Rear turn signal light 12V21 Wx2
Meter light UV 14W x3
Indicator light
Neutral indicator light 12 V1.4W x1
High beam indicator light 12 V1.4 Wx1
Oil level warning light 12V 1.4W x1
Turn signal indicator light 12V 1.4W x2
Fuel level warning light 12 V2W x1
Engine temperature warning light LED
-2-

-3-
MAINTENANCE SPECIFICATIONS SPEC a—
MAINTENANCE SPECIFICATIONS
ENGINE
Item Standard Limit
Carburetor:
I.D. mark 5DM1 01 •••
Main jet (M.J) #115 •••
Main air jet (M.A.J) #80 •••
Jet needle (J.N) 5D86-3/5 •••
Needle jet (N.J) P-OM •••
Pilot air jet (P.A.J. 1) #130 •••
Pilot outlet (P-O) 0.95 •••
Pilot jet (P.J) #12.5 •••
Bypass 1(B.P.1) 0.9 •••
Bypass 2(B.P.2) 0.8 •••
Bypass 3(B.P.3) 0.8 •••
Pilot screw (P.S) 2-1/2 •••
Valve seat size (V.S) 1.0 •••
Starter jet (G.S.1) 0.6 •••
Starter jet (G.S.2) 0.8 •••
Throttle valve size (TH.V) #110 •••
Fuel level (F.L) (with
special tool)
3.5 mm •••
Engine idle speed 1,150 ~1,250 r/min •••
Intake vacuum 31 .7 ~34.3 kPa (238 ~257 mmHg) ...
TIGHTENING TORQUES
ENGINE
Part to be tightened Part name Thread
size Q'ty
Tightening
torque Remarks
Nm m»kg
Radietor cover Bolt M5 270.7
-3-

-4-
MAINTENANCE SPECIFICATIONS SPEC o-
CHASSIS
Item Standard Limit
Drive chain:
Type/manufacturer 50VA4/DAIDO •••
No. of links 110 •••
Chain free play 30 -45 mm •••
Maximum ten-link section 150 mm •••
TIGHTENING TORQUES
CHASSIS
Part to be tightened Part name Thread
size Q'ty
Tightening
torque Remarks
Nm m»kg
Front cowling stay Nut M8 233 3.3
ELECTRICAL
Item Standard Limit
Charging system:
Type
Model/manufacturer
Standard output
Stator coil resistance
A.C. magneto
F4T377/MITSUBISHI
14 V21 Aat5,000r/min
0.28 ~0.34 Qat 20 CC/W-W
•••
•••
•••
•••
Rectifier:
Model/manufacture
Capacity
Withstand voltage
SH650C-11 /SHINDENGEN
18A
200 V
•••
•••
•••
Fuel gauge:
Model /manufacture
Sender unit resistance -full
-empty
5RT/NIPPON SEIKI
4~10Q
122.5 ~128.5 Q
•••
•••
•••
Amperage for individual circuit:
Main
Headlight
Signal
Ignition
Fan
Back up
Reserve
30 A
20 A
10A
20 A
10A
10A
30 A
20 A
10A
•••
•••
•••
•••
•••
•••
•••
•••
«••
Thermo unit:
Model/manufacture
Resistance 5JJ/NIPPON THERMOSTAT
3413 ~4007Qat80°C
1645 ~1855Qat105°C
•••
•••
•••
_4_

5-
LUBRICATION POINT AND LUBRICATION TYPES
LUBRICATION POINT AND LUBRICATION TYPES
ENGINE
SPEC o-
Lubrication Point Symbol
Cylinder head tightening nut washer -<<D
-5-

6-
CABLE ROUTING
CABLE ROUTING
©Throttle cables
®Clutch cable
©Left handlebar switch lead
©Starter cable
©Main switch
©Main switch lead
©Brake hose
®Speed sensor lead
©Right handlebar switch lead
[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:
•Left handlebar switch lead
•Clutch cable
•Starter cable
\C\ 30 mm or less from the top of
protector.
[Dj Pass speed sensor lead through
clamp code 1
.
OH 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 3lower positions so that
it can not became slack.
[0 1mm or less from the bottom of
protector.
-8-

CABLE ROUTING SPEC g-
Main switch lead ©Starter relay
©Starter cable ©Battery positive lead
®Left handlebar switch lead ©Seat lock cable
Clutch cable ©Seat lock stay
Horn lead ©Cross tube 3
©Rectifier/ regulator ©A.C. magneto lead
©Box ©Starter motor lead
©Air guide ©Cross tube
©Radiator fan motor lead ©Air filter case drain hose
©Spark plug lead 1©Sidestand switch lead
©Starting circuit cut-off relay @Neutral switch
©Battery @Oil level switch lead
©Turn signal relay ©Radiator
U) Rectifier/ regulator lead
>§)Horn
^Brake hose
39) Speed sensor lead
0) Fuse box
§) Rear fender
§) Wire harness
y) Pickup coil lead coupler
§) Sidestand switch lead coupler
3§) Oil level /neutral switch lead cou-
pler
g> A.C. magneto lead coupler
3§> Oil level/neutral switch lead
(T) (2) WsW
3r®
-9-

-8-
CABLE ROUTING SPEC o-
[A] Using clamp, fix:
•Left handlebar switch lead
•Main switch lead
•Clutch cable
•Starter cable
In so doing, locate main switch
lead innermost.
QU To headlight sub-wire harness
[C] Radiator fan motor lead, pass
this lead through hole in air guide
and then into box.
Q5] Install plug cap so that spark
plug lead face toward inside of
vehicle. m
Wire harness, starter motor
lead, A.C. magneto lead, side-
stand switch lead and neutral
switch lead pass the over cross
tube 3.
Using clamp, fix wire harness to
the frame.
Using clamp, fix wire harness to
the frame.
After connecting coupler, push
then on the inside of lock stay on
the frame.
Using clamp, fix to bracket on the
frame:
•Wire harness (at white taping)
•Starter motor lead
•A.C. magneto lead
•Sidestand switch lead
•Oil level switch lead
•Neutral 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.
-10-

CABLE ROUTING SPEC o-
Q] Using clamp, fix to bracket on
frame:
•Stater motor lead
•Sidestand switch lead
•Oil level switch lead
•Neutral switch lead
Locate wire harness outermost.
Locate clamp with its tip down-
ward and cut off excessive
length.
[El 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.
[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.
[0 Using clamp on engine, fix:
•A.C. magneto lead
•Sidestand switch lead
•Oil level switch lead
•Neutral switch lead
ra
Pass on the outside of spark plug
lead 1
•Clutch cable
•Starter cable
Radiator fan motor lead shall
permit no slack in this range.
1mm or less from the bottom of
protector.
1mm or less from the bottom of
protector.
-11-

10-
CABLE ROUTING SPEC o—
\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.
-12-

11 -
CABLE ROUTING
©Right handlebar switch lead @Battery negative lead
©Throttle cables ©Cross tube 3
©Brake hose ©Radiator reservoir tank breather
©Cable guide hose
©Main switch lead ©Air filter
©Radiator reservoir tank ©Throttle position sensor lead
©Rear brake light switch lead ©Box
©Battery ©Speed sensor lead
©Radiator reservoir tank breather ©Engine bracket 3
hose ©Swingarm bracket
SPEC g-
-13-

-12-
CABLE ROUTING SPEC g-
[A] Using clamp, fix to the front fork:
•Right handlebar switch lead
•Brake hose
Locate clamp with its head in-
ward of frame.
[B] Pass throttle cables through
guide.
Throttle cable installed to upper
bracket.
[C] With its pulling side on top. Pass
throttle cable innermost of
clamp.
\D\ Pass main switch lead under:
•Throttle cable (2 pes)
•Right handlebar switch lead
•Speed sensor lead
And them into box at right side. In
so doing, give leads some slack.
[E] Pass throttle cable under box.
0E] Pass through holder on frame:
•Radiator reservoir tank breath-
er hose
•Fuel tank breather hose
[G] To reservoir tank
[F0 Pass battery negative lead on
the inside of radiator reservoir
tank breather hose.
Q] Using clamp, fix stop switch lead
to frame. Locate clamp with its
latch outward of frame.
[J] Pass on the inside of side cover
insertion position.
B
-14-

13-
CABLE ROUTING SPEC o-
IB Pass through hole in bracket bat-
tery and clamp rear brake light
switch lead.
DP Pass on the inside of air filter
bracket, on frame:
•Battery negative lead
•Brake light switch lead
[M] Pass between swingarm head
pipe and engine crankcase:
•Fuel tank drain hose
•Fuel tank breather hose
•Radiator reservoirtank breathe
hose
[N] Fuel tank drain hose install so
that it is not bent or slack.
[Oj After passing throttle position
sensor lead as shown, install
cover 2to air filter.
00 Fix throttle cables, right handle-
bar switch lead and speed sen-
sor lead to the frame with a
clamp.
[Q] Pass radiator reservoir tank
breather hose between air filter
and cross tube 3, and on the out-
side of the engine bracket 3.
[R) Fix radiator reservoir tank
breathe hose to swingarm
bracket on frame with aclamp.
-15-

-14-
CABLE ROUTING
©Throttle cables
(g) Speed sensor lead
(3) Right handlebar switch lead
@Thermostat housing
(5) Carburetor heater hot water
hose
(?) Radiator reservoir tank breather
hose
(7) Fuel pump
(s) Fuel filter
(9) Fuel tank breather hose
@) Fuel tank drain hose
©Pipe 2
©Fuel hose
©Throttle position sensor lead
@Fuel pipe
@Fuel sender coupler
@Battery negative lead
©Battery
([& Rear brake reservoir tank hose
©Rear brake reservoir tank
@) Rear brake right switch lead
©Fuse box
@Seat lock cable
©Ignitor unit
@) Rear turn signal light lead (right)
@Tail/brake light lead
@Rear turn signal light lead (left)
©Tail/brake light bracket
£S Starter motor lead
-16-

-15-
CABLE ROUTING SPEC g- ::-: [
''
:-;\
©Starter relay
@Turn signal relay
©Starting circuit cut-off relay
©Wire harness
©Fuel pump lead coupler
@Ignition coil
@Clutch cable
@Starter cable
©Box
@Horn lead
©Headlight sub-wire harness
©Radiator fan motor lead
©Rectifier/regulator lead
©Left handlebar switch lead
©Main switch lead
@Clamp
^17-