1989 – 1999 YAMAHA FZR600 FZR 600 Service WORKSHOP Manual – PDF Download

Description

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