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
ADJ <a
COOL X
®
CHAS (^
TRBL
SHTG 9
•
©
SPEC
©
ENG ID
CARB 9
ELEC JB .
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®\\
f^t
®1i@I
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-