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

First Edition, August 2001

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 .

<®

®\\

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

30 A

20 A

10A

•••

«••

Thermo unit:

Model/manufacture

Resistance 5JJ/NIPPON THERMOSTAT

3413 ~4007Qat80°C

1645 ~1855Qat105°C

•••

_4_

LUBRICATION POINT AND LUBRICATION TYPES

ENGINE

SPEC o-

Lubrication Point Symbol

Cylinder head tightening nut washer -<<D

-5-

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