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.

2143

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.

24 25

2321

19 2018

1413

11 12

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 2 W 3

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.

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