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FZS600'98
Yamaha FZS600'98 Manuals
Manuals and User Guides for Yamaha FZS600'98. We have
1
Yamaha FZS600'98 manual available for free PDF download: Service Manual
Yamaha FZS600'98 Service Manual (364 pages)
Brand:
Yamaha
| Category:
Motorcycle
| Size: 7.63 MB
Table of Contents
Gen Info
10
Important Information
4
Periodic Inspections and
5
Table of Contents
10
Chapter 1
12
Motorcycle Identification
12
Important Information
13
Lock Washers/Plates and Cotter Pins
14
Checking the Connections
15
Special Tools
16
Specifications
23
General Specifications
23
Maintenance Specifications
26
General Tightening Torque Specifications
39
Cable Routing
50
Table of Contents
56
Chapter 3 Periodic Inspections and Adjustments
58
Introduction
58
Periodic Maintenance/Lubrication Intervals
58
Brake Fluid Replacement
59
Front Cowling/Seat/Side Cover/Fuel Tank
60
Engine
62
Adjusting the Valve Clearance
62
Synchronizing the Carburetors
68
Adjusting the Engine Idling Speed
70
Adjusting the Throttle Cable Free Play
71
Checking the Spark Plugs
72
Checking the Ignition Timing
73
Measuring the Compression Pressure
74
Checking the Engine Oil Level
75
Changing the Engine Oil
76
Measuring the Engine Oil Pressure
78
Adjusting the Clutch Cable Free Play
79
Cleaning the Air Filter Element
80
Checking the Carburetor Joints and Intake Manifolds
81
Checking the Fuel Hoses and Fuel Filter
81
Checking the Crankcase Breather Hose
82
Checking the Exhaust System
82
Checking the Coolant Level
83
Checking the Cooling System
83
Changing the Coolant
84
Chassis
87
Adjusting the Front Brake
87
Adjusting the Rear Brake
87
Checking the Brake Fluid Level
88
Adjusting the Rear Brake Light Switch
89
Checking the Brake Hoses
90
Bleeding the Hydraulic Brake System
90
Adjusting the Shift Pedal
91
Adjusting the Drive Chain Slack
92
Lubricating the Drive Chain
93
Checking and Adjusting the Steering Head
94
Checking the Front Fork
95
Adjusting the Rear Shock Absorber Assembly
95
Checking the Tires
97
Checking the Wheels
98
Checking and Lubricating the Cables
99
Lubricating the Levers and Pedals
99
Lubricating the Sidestand
99
Lubricating the Center Stand
99
Lubricating the Rear Suspension
99
Electrical System
100
Checking and Charging the Battery
100
Checking the Fuses
105
Replacing the Headlight Bulbs
107
Adjusting the Headlight Beams
107
Table of Contents
111
Chapter 4 Overhauling the Engine
113
Removing the Engine
113
Drive Sprocket and Exhaust Pipe
113
Leads and Hoses
115
Engine Bracket and Engine
116
Installing the Engine
117
Camshaft
118
Cylinder Head Covers
118
Camshafts
119
Removing the Camshafts
120
Checking the Camshafts
121
Checking the Timing Chain, Camshaft Sprockets, and Timing Chain Guides
122
Checking the Timing Chain Tensioner
123
Installing the Camshafts
123
Cylinder Head
126
Removing the Cylinder Heads
127
Checking the Cylinder Heads
127
Installing the Cylinder Head
128
Valves and Valve Springs
129
Removing the Valves
130
Checking the Valves and Valve Guides
131
Checking the Valve Seats
132
Checking the Valve Springs
134
Checking the Valve Lifters
134
Checking the Camshaft Cap
135
Installing the Valves
135
Cylinder and Piston
137
Removing the Cylinders and Pistons
138
Checking the Cylinders and Pistons
138
Checking the Piston Rings
139
Checking the Piston Pins
140
Installing the Piston and Cylinder
141
Clutch
143
Clutch Cover
143
Clutch
144
Removing the Clutch
146
Checking the Friction Plates
146
Checking the Clutch Plates
146
Checking the Clutch Springs
147
Checking the Clutch Spring Plate
147
Checking the Clutch Housing
147
Checking the Clutch Boss
148
Checking the Pressure Plate
148
Checking the Clutch Push Rods
148
Installing the Clutch
148
Shift Shaft
151
Checking the Shift Shaft
152
Installing the Shift Shaft
152
Stator Coil
153
Ac Magneto and Starter Clutch
153
Starter Clutch
154
Ac Magneto Rotor
155
Removing the Starter Clutch
156
Removing the Ac Magneto
156
Checking the Starter Clutch
157
Installing the Ac Magneto
158
Installing the Starter Clutch
158
Oil Pan and Oil Strainer
159
Oil Strainer
159
Oil Pump
160
Removing the Oil Pan
162
Checking the Oil Pump
162
Checking the Relief Valve
162
Checking the Oil Strainer
163
Checking the Oil Nozzle
163
Assembling the Oil Pump
163
Installing the Oil Pump
164
Installing the Oil Strainer
164
Installing the Oil Pan
164
Crankcase
166
Disassembling the Crankcase
166
Assembling the Crankcase
167
Crankshaft
171
Connecting Rod
172
Removing the Crankshaft Assembly
173
Removing the Connecting Rods
173
Checking the Crankshaft and Connecting Rods
173
Installing the Connecting Rods
178
Installing the Crankshaft
180
Transmission
181
Checking the Transmission
184
Installing the Transmission
185
Shift Drum and Shift Forks
186
Checking the Shift Forks
187
Checking the Shift Drum Assembly
187
Installing the Shift Forks and Shift Drum Assembly
187
Cooling System
192
Water Pump
199
Table of Contents
218
Front Wheel and Brake Discs
220
Chapter 7
221
Front Wheel
221
Checking the Front Wheel
222
Removing the Front Wheel
222
Checking the Brake Discs
224
Installing the Front Wheel
225
Adjusting the Front Wheel Static Balance
226
Rear Wheel, Brake Disc and Rear Wheel Sprocket
227
Rear Wheel
227
Brake Disc and Rear Wheel Sprocket
228
Removing the Rear Wheel
230
Checking the Rear Wheel
230
Checking and Replacing the Rear Wheel Sprocket
231
Installing the Rear Wheel
231
Adjusting the Rear Wheel Static Balance
232
Front and Rear Brakes
233
Front Brake Pads
233
Rear Brake Pads
234
Replacing the Front Brake Pads
235
Replacing the Rear Brake Pads
237
Front Brake Master Cylinder
239
Removing the Front Brake Master Cylinder
239
Checking the Front and Rear Brake Master Cylinders
244
Assembling and Installing the Front Brake Master Cylinder
245
Assembling and Installing the Rear Brake Master Cylinder
246
Front Brake Calipers
248
Disassembling the Front Brake Caliper
249
Disassembling the Rear Brake Caliper
253
Checking the Front and Rear Brake Calipers
253
Assembling and Installing the Front Brake Calipers
254
Assembling and Installing the Rear Brake Caliper
256
Front Fork
259
Removing the Front Fork Legs
262
Disassembling the Front Fork Legs
262
Checking the Front Fork Legs
263
Assembling the Front Fork Legs
264
Installing the Front Fork Legs
266
Handlebar
267
Removing the Handlebar
269
Checking the Handlebar
269
Installing the Handlebar
270
Steering Head
272
Lower Bracket
272
Removing the Lower Bracket
274
Checking the Steering Head
274
Installing the Steering Head
275
Rear Shock Absorber and Relay Arm
276
Handling the Rear Shock Absorber
278
Disposing of a Rear Shock Absorber
278
Removing the Rear Shock Absorber Assembly
279
Checking the Rear Shock Absorber Assembly
280
Installing the Rear Shock Absorber Assembly
280
Swingarm and Drive Chain
281
Removing the Swingarm
283
Checking the Swingarm
284
Checking the Drive Chain
285
Installing the Swingarm
286
Installing the Drive Chain
287
Circuit Diagram
293
Electric Starting System
305
Charging System
316
Lighting System
323
Signal System
326
Fuel Pump System
349
Troubleshooting
358
Faulty Gear Shifting
360
Unstable Handling
362
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