1989 - 1999 YAMAHA FZR600 FZR 600 Service WORKSHOP Manual - PDF Download
Back to Index................................................................ 0
FZR600/600R W ~ ('89~ ) Service Manual....................................... 1
FZR600W(C) Service Manual................................................ 2
How to use this manual............................................... 4
Illustrated symbols.................................................. 5
Index................................................................ 6
Table of contents.................................................... 7
Chapter 1, General Information....................................... 15
Motorcycle identification........................................ 15
Important information............................................ 16
Special tools.................................................... 18
Chapter 2, Specifications............................................ 24
General specifications........................................... 24
Maintenance specifications - engine.............................. 27
Tightening torque............................................ 33
Maintenance specifications - chassis............................. 35
Tightening torques........................................... 37
Maintenance specifications - electrical.......................... 38
General torque specifications / definition of units.............. 41
Lubrication and grade of lubricant............................... 42
Lubrication diagram.............................................. 44
Coolant diagram.................................................. 45
Cable routing.................................................... 46
Chapter 3, Periodic Inspections and Adjustments...................... 53
Maintenance intervals chart...................................... 53
General maintenance / lubrication................................ 54
Cowlings / covers removal and installation....................... 56
Engine........................................................... 60
Chassis.......................................................... 86
Electrical.......................................................101
Chapter 4, Engine Overhaul...........................................108
Engine removal...................................................108
Engine disassembly...............................................114
Inspection and repair............................................130
Engine assembly and adjustment...................................156
Chapter 5, Cooling System............................................194
Radiator.........................................................194
Thermostatic valve and water pump................................198
Chapter 6, Carburetor................................................204
Carburetor.......................................................204
Removal......................................................206
Disassembly..................................................207
Inspection...................................................210
Assembly.....................................................212
Installation.................................................214
Adjustment...................................................216
Air injection (for california)...................................217
Chapter 7, Chassis...................................................220
Front wheel......................................................220
Rear wheel.......................................................226
Front and rear brake.............................................229
Front fork.......................................................250
Steering head and handlebar......................................258
Rear shock absorber and swingarm.................................269
Drive chain and sprocket.........................................279
Chapter 8, Electrical................................................284
FZR600W/WC circuit diagram.......................................284
Electrical components............................................286
Checking of switches.............................................288
Checking of bulbs................................................291
Ignition system..................................................294
Troubleshooting..............................................297
Electrical starting system.......................................304
Troubleshooting..............................................307
Charging system .................................................316
Troubleshooting..............................................318
Lighting system .................................................322
Troubleshooting..............................................324
Signal system....................................................332
Troubleshooting..............................................334
Cooling system...................................................346
Troubleshooting..............................................348
Fuel pump system ................................................356
Troubleshooting..............................................359
EXUP system (for california only) ...............................364
Troubleshooting..............................................366
Chapter 9, Troubleshooting...........................................372
Starting failure / hard starting.................................372
Poor idle speed performance......................................374
Poor medium and high speed performance / faulty gear shifting....375
Clutch slipping / dragging.......................................376
Overheating or over-cooling......................................377
Faulty brake / front fork oil leakage / malfunction..............378
Instable handling................................................379
Faulty signals and lights........................................380
Wiring diagram...................................................382
FZR600RA(C) Supplementary Service Manual.................................386
How to use this manual...............................................388
Illustrated symbols..................................................389
Table of contents....................................................390
General Information..................................................391
Motorcycle identification........................................391
Specifications.......................................................392
General specifications...........................................392
Maintenance specifications - engine..............................393
Maintenance specifications - electrical..........................394
Chassis..............................................................395
Front and rear brake.............................................395
Electrical...........................................................422
Circuit diagram..................................................422
Wiring diagram...................................................424
FZR600RB(C) Supplementary Service Manual.................................425
How to use this manual...............................................428
Illustrated symbols..................................................429
Table of contents....................................................430
General Information..................................................431
Motorcycle identification........................................431
Special tools....................................................432
Specifications.......................................................433
General specifications...........................................433
Maintenance specifications - engine..............................434
Tightening torques...........................................438
Maintenance specifications - chassis.............................439
Tightening torques...........................................440
Maintenance specifications - electrical..........................441
Lubrication diagram..............................................442
Coolant diagram..................................................445
Cable routing....................................................447
Periodic Inspection and Adjustment...................................455
Cowlings / covers removal and installation.......................455
Engine...........................................................457
Electrical.......................................................463
Engine Overhaul......................................................465
Engine disassembly...............................................465
Engine assembly and adjustment...................................466
Cooling System.......................................................468
Radiator.........................................................468
Thermostatic valve and water pump................................469
Electrical...........................................................470
FZR600RB/FZR600RBC circuit diagram...............................470
Electrical starting system.......................................472
Troubleshooting..............................................474
Fuel pump system.................................................480
Troubleshooting..............................................483
Exup system (for california only) ...............................488
Troubleshooting..............................................490
Wiring diagram...................................................496
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1989 – 1999 YAMAHA FZR600 FZR 600 Service WORKSHOP Manual – PDF Download
$49.00 $14.95
1989 – 1999 YAMAHA FZR600 FZR 600 Service WORKSHOP Manual – PDF Download
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