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FZ (1984-1992)
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Yamaha FZ (1984-1992) [9/200] Maintenance techniques tools and working facilities 0 11

Содержание

Fj fz xj yx600 radian 1
Owners workshop manual 1
Yamaha 1
Chapter 1 2
Chapter 2 2
Chapter 3 2
Chapter 4 2
Chapter 5 2
Chapter 6 2
Chapter 7 2
Chapter 8 2
Contents 2
Conversion factors 2
Introductory pages 2
Wiring diagrams 2
About this manual 3
Caution 3
Introduction to the yamaha fj600 fz600 xj600 and yx600 radian 3
Its purpose 3
Using the manual 3
Warning 3
Identification numbers 4
Identifying model years 4
Buying parts 5
General specifications 5
Basic maintenance techniques 6
Disassembly sequence 6
Fastening systems 6
Gasket sealing surfaces 6
Hose removal tips 6
Maintenance techniques tools and working facilities 6
Tightening sequences and procedures 6
Maintenance techniques tools and working facilities 0 9 7
10 maintenance techniques tools and working facilities 8
Maintenance techniques tools and working facilities 0 11 9
12 maintenance techniques tools and working facilities 10
Buying tools 10
Care and maintenance of tools 10
Maintenance and minor repair tool kit 10
Repair and overhaul tool set 10
Special tools 10
Maintenance techniques tools and working facilities 0 13 11
Working facilities 11
Asbestos 12
Electricity 12
Essential dos and don ts 12
Safety first 12
The battery 12
Motorcycle chemicals and lubricants 13
Abnormal driveline noise 14
Abnormal engine noise 14
Abnormal frame and suspension noise 14
Braking problems 14
Clutch problems 14
Contents 14
Electrical problems 14
Engine doesn t start or is difficult to start 14
Excessive exhaust smoke 14
Gear shifting problems 14
Oil level indicator light comes on 14
Overheating 14
Poor handling or stability 14
Poor running at low speed 14
Poor running or no power at high speed 14
Troubleshooting 14
Compression low 15
Engine doesn t start or is difficult to start 15
Engine flooded 15
No fuel flow 15
No spark or weak spark 15
Starter motor does not rotate 15
Starter motor rotates but engine does not turn over 15
Starter works but engine won t turn over seized 15
Troubleshooting 0 17 15
18 troubleshooting 16
Compression low 16
Fuel air mixture incorrect 16
Poor acceleration 16
Poor running at low speed 16
Rough idle 16
Spark weak 16
Stalls after starting 16
Compression low 17
Engine overheats 17
Firing incorrect 17
Fuel air mixture incorrect 17
Knocking or pinging 17
Miscellaneous causes 17
Overheating 17
Poor running or no power at high speed 17
Troubleshooting 0 19 17
20 troubleshooting 18
Clutch not disengaging completely 18
Clutch problems 18
Clutch slipping 18
Compression too high 18
Engine load excessive 18
Firing incorrect 18
Fuel air mixture incorrect 18
Lubrication inadequate 18
Miscellaneous causes 18
Abnormal driveline noise 19
Abnormal engine noise 19
Clutch noise 19
Doesn t go into gear or lever doesn t return 19
Gear shifting problems 19
Jumps out of gear 19
Knocking or pinging 19
Other noise 19
Overshifts 19
Piston slap or rattling 19
Transmission noise 19
Troubleshooting 0 21 19
Valve noise 19
22 troubleshooting 20
Abnormal frame and suspension noise 20
Black smoke 20
Brake noise 20
Brown smoke 20
Electrical system 20
Engine lubrication system 20
Excessive exhaust smoke 20
Final drive noise 20
Front end noise 20
Oil level indicator light comes on 20
Shock absorber noise 20
White smoke 20
Battery dead or weak 21
Brake lever or pedal pulsates 21
Brakes are spongy don t hold 21
Brakes drag 21
Braking problems 21
Electrical problems 21
Handlebar hard to turn 21
Handlebar pulls to one side 21
Handlebar shakes or vibrates excessively 21
Poor handling or stability 21
Poor shock absorbing qualities 21
Troubleshooting 0 23 21
24 troubleshooting 22
Battery overcharged 22
Chapter 1 tune up and routine maintenance 23
Contents 23
Section 23
2 chapter 1 tune up and routine maintenance 24
Engine 24
Miscellaneous 24
Specifications 24
Brake fluid 25
Chapter 1 tune up and routine maintenance 1 3 25
Engine transmission oil 25
Fork oil 25
Miscellaneous 25
Recommended lubricants and fluids 25
Torque specifications 25
4 chapter 1 tune up and routine maintenance 26
After the initial 500 miles 26
Daily or before riding 26
Every 12 000 km 8 000 miles or 12 months 26
Every 18 000 km 12 000 miles or 18 months 26
Every 24 000 km 16 000 miles or two years 26
Every 500 miles 26
Every 6000 km 4000 miles or 6 months 26
Yamaha fj fz xj yx radian 600 routine maintenance intervals 26
Chapter 1 tune up and routine maintenance 1 5 27
Engine oil 27
Fluid levels check 27
Introduction to tune up and routine maintenance 27
6 chapter 1 tune up and routine maintenance 28
Battery electrolyte level specific gravity check 28
Brake fluid 28
Chapter 1 tune up and routine maintenance 1 7 29
8 chapter 1 tune up and routine maintenance 30
Brake pads check 30
Brake shoes check 30
Brake system general check 30
Brake lever play and pedal position check and adjustment 31
Chapter 1 tune up and routine maintenance 1 9 31
Disc brake models 31
Drum brake models 31
Front brake 31
Rear brake 31
10 chapter 1 tune up and routine maintenance 32
All models 32
Throttle cable adjustment 32
Throttle check 32
Throttle operation grip freeplay check and adjustment 32
Tires wheels general check 32
Chapter 1 tune up and routine maintenance 1 11 33
Clutch check 33
Drive chain and sprockets check adjustment and lubrication 33
12 chapter 1 tune up and routine maintenance 34
Adjustment 34
Chapter 1 tune up and routine maintenance 1 13 35
Engine oil filter change 35
Lubrication 35
14 chapter 1 tune up and routine maintenance 36
Air filter element servicing 36
All models 36
Fj600 xj600 and yx radian models 36
Fz600 models 36
Chapter 1 tune up and routine maintenance 1 15 37
Cylinder compression check 37
Spark plugs replacement 37
16 chapter 1 tune up and routine maintenance 38
Lubrication general 38
Spark plug conditions 39
18 chapter 1 tune up and routine maintenance 40
Valve clearances check and adjustment 40
Chapter 1 tune up and routine maintenance 1 19 41
Early models 41
Later models 41
20 chapter 1 tune up and routine maintenance 42
All models 42
With yamaha valve adjusting tool 42
All models 43
Chapter 1 tune up and routine maintenance 1 21 43
With universal valve adjusting tool 43
22 chapter 1 tune up and routine maintenance 44
A intake valve shim selection chart 44
Carburetor synchronization check and adjustment 44
Does not end in 0 or 5 round it off to the nearest zero or 5 for example if the number on the shim is 258 round it off to 260 if it s 254 round it off to 255 32 if the clearance measured and written down earlier was too large you need a thicker shim if the clearance was too small you need a thinner shim calculate the thickness of tne replacement shim by referring to the accompanying charts see illustrations 33 install the new shim and recheck the clearance if it s within the specifications the valve is properly adjusted 34 adjust any remaining valves that were not within the specifi cations perform the adjustments in the same order as the cylinder firing order 1 2 4 3 35 install the valve cover 36 reconnect the negative cable to the battery 37 install all components removed for access 44
Idle speed check and adjustment 44
Illustration until the idle speed listed in this chapter s specifications is obtained 4 snap the throttle open and shut a few times then recheck the idle speed if necessary repeat the adjustment procedure 5 if a smooth steady idle can t be achieved the fuel air mixture may be incorrect refer to chapter 3 for additional carburetor information 44
Refer to illustration 19 1 the die speed should be checked and adjusted before and after the carburetors are synchronized and when it is obviously too high or too low before adjusting the idle speed make sure the valve clearances and spark plug gaps are correct also turn the handlebars back and forth and see if the idle speed changes as this is done if it does the throttle cable may not be adjusted correctly or it may be worn out this is a dangerous condition that can cause loss of control of the bike be sure to correct this problem before proceeding 2 the engine should be at normal operating temperature which is usually reached after 10 to 15 minutes of stop and go riding place the motorcycle on the centerstand if equipped or prop it securely upright and make sure the transmission is in neutral 3 with the engine idling turn the throttle stop screw see 44
Refer to illustrations 20 1 20 4 20 5 and 20 6 warning gasoline petrol is extremely flammable so fate extra precautions v hen you work on any part of the fuel system don t smoke or allow open flames or bare light bulbs near the work area and don t work in a garage where a natural gas type appliance such as a water heater or clothes dryer is present if you spill any fuel on your skin rinse it off immediately with soap and water when you perform any kind of work on the fuel system wear safety glasses and have a fire extinguisher suitable for a class b type fire flammable liquids on hand 1 carburetor synchronization is simply the process of adjusting the carburetors so they pass the same amount of fuel air mixture to each cylinder this is done by measuring the vacuum produced in each cylinder ca buretors that are out of synchronization will result in decreased fuel mileage increased engine temperature less than ideal throttle response and higher vibration levels 2 to properly synchronize 44
A vacuum gauge setup can also be purchased from a dealer or fabricated from commonly available hardware and automotive vacuum gauges 5 the manometer is the more reliable and accurate instrument and for that reason is preferred over the vacuum gauge setup however since the mercu y used in the manometer is a liquid and extremely toxic extra precautions must be taken during use and storage of the instrument 6 because of the nature of the synchronization procedure and the need for special instruments most owners leave the task to a dealer service department or a reputable motorcycle repair shoo 7 if you re working on an xj600 or an fj600 remove the seat and side covers see chapter 7 if you re working on a 1984 or 1985 45
B exhaust valve shim selection chart 45
Chapter 1 tune up and routine maintenance 1 23 45
Correct idle speed is obtained carburetors removed for clarity 45
Model remove the fuel tank mounting bolt so you can lift the tank for access if you re working on a 1989 or later xj600 remove the fuel tank see chapter 3 and install an auxiliary fuel tank 8 if you re working on an fz600 remove the seat and center and lower fairings see chapter 7 remove the fuel tank see chapter 3 and install an auxiliary fuel tank 9 if you re working on a yx600 radian remove the seat and side covers see chapter 7 remove the fuel tank mounting bolt so you can lift the rear of the tank for access 10 start the engine and let it run until it reaches normal operating temperature then shut it off 11 detach the hoses or caps from the vacuum fittings on the carburetors see illustration then hook up the vacuum gauge set or 45
Remove the vacuum hoses or fitting caps so a test gauge 45
Setup can be installed 45
Turn the throttle stop screw arrow in or out until the 45
24 chapter 1 tune up and routine maintenance 46
Evaporative emission control system california models only check 46
Exhaust system check 46
Steering head bearings check adjustment and lubrication 46
Adjustment 47
Chapter 1 tune up and routine maintenance 1 25 47
26 chapter 1 tune up and routine maintenance 48
Fasteners check 48
Fuel system check and filter cleaning 48
Lubrication 48
Suspension check 48
All models 49
Chapter 1 tune up and routine maintenance 1 27 49
Fork oil replacement 49
Fx xj600 models 49
Fz600 models 49
28 chapter 1 tune up and routine maintenance 50
All models 50
Cam chain adjustment 50
Early models 50
Later models 50
Chapter 2 engine clutch and transmission 51
Contents 51
General 51
Specifications 51
2 chapter 2 engine clutch and transmission 52
Camshaft fj6oo fz600 yx600 radian 52
Camshaft xj600 52
Cylinder head valves and valve springs 52
Chapter 2 engine clutch and transmission 2 3 53
Crankshaft connecting rods and bearings 53
Cylinder block 53
Lubrication system 53
Pistons 53
4 chapter 2 engine clutch and transmission 54
Clutch 54
Lubrication system continued 54
Torque specifications 54
Transmission 54
Chapter 2 engine clutch and transmission 2 5 55
Engine removal and installation 55
General information 55
Major engine repair general note 55
Operations possible with the engine in the frame 55
Operations requiring engine removal 55
Removal 55
6 chapter 2 engine clutch and transmission 56
Fj xj600 and yx600 radian models 56
All models 57
Chapter 2 engine clutch and transmission 2 7 57
Engine disassembly and reassembly general information 57
Fz600 models 57
Installation 57
8 chapter 2 engine clutch and transmission 58
Camshaft chain tensioner removal and installation 58
Installation 58
Removal 58
Valve cover removal and installation 58
Chapter 2 engine clutch and transmission 2 9 59
10 chapter 2 engine clutch and transmission 60
Camshafts valves and cam chain tensioner exploded view 60
Installation 60
See illustration 60
Camshafts 61
Camshafts and lifters removal inspection and installation 61
Chapter 2 engine clutch and transmission 2 11 61
Removal 61
12 chapter 2 engine clutch and transmission 62
Inspection 62
Chapter 2 engine clutch and transmission 2 13 63
14 chapter 2 engine clutch and transmission 64
Installation 64
Chapter 2 engine clutch and transmission 2 15 65
Cylinder head removal and installation 65
Inspection 65
Installation 65
Removal 65
Valve lifters 65
16 chapter 2 engine clutch and transmission 66
Chapter 2 engine clutch and transmission 2 17 67
18 chapter 2 engine clutch and transmission 68
Cylinder head and valves disassembly inspection and reassembly 68
Disassembly 68
Installation 68
Valves valve seats valve guides servicing 68
Chapter 2 engine clutch and transmission 2 19 69
Inspection 69
20 chapter 2 engine clutch and transmission 70
Chapter 2 engine clutch and transmission 2 21 71
Reassembly 71
22 chapter 2 engine clutch and transmission 72
Cylinder block removal inspection and installation 72
Removal 72
Chapter 2 engine clutch and transmission 2 23 73
Inspection 73
Installation 73
24 chapter 2 engine clutch and transmission 74
Chapter 2 engine clutch and transmission 2 25 75
Pistons removal inspection and installation 75
Removal 75
26 chapter 2 engine clutch and transmission 76
Inspection 76
Chapter 2 engine clutch and transmission 2 27 77
Installation 77
Piston rings installation 77
28 chapter 2 engine clutch and transmission 78
Oil pan and relief valves removal relief valve inspection and installation 78
Relief valve inspection 78
Removal 78
Second ring 78
Top ring 78
Chapter 2 engine clutch and transmission 2 29 79
30 chapter 2 engine clutch and transmission 80
Installation 80
Oil pressure check 80
Oil pump pressure check removal inspection and installation 80
Chapter 2 engine clutch and transmission 2 31 81
Removal 81
32 chapter 2 engine clutch and transmission 82
Inspection 82
Installation 82
Oil cooler and hoses removal and installation 82
Chapter 2 engine clutch and transmission 2 33 83
Clutch removal inspection and installation 83
Removal 83
34 chapter 2 engine clutch and transmission 84
Inspection 84
36 chapter 2 engine clutch and transmission 85
Installation 85
Chapter 2 engine clutch and transmission 2 37 86
38 chapter 2 engine clutch and transmission 87
Clutch cable removal and installation 87
Removal 87
Chapter 2 engine clutch and transmission 2 39 88
External shift mechanism removal inspection and installation 88
Shift linkage and pedal 88
Shift mechanism removal 88
40 chapter 2 engine clutch and transmission 89
Shift mechanism inspection 89
Shift mechanism installation 89
Chapter 2 engine clutch and transmission 2 41 90
Crankcase disassembly and reassembly 90
Disassembly 90
42 chapter 2 engine clutch and transmission 91
Reassembly 91
Chapter 2 engine clutch and transmission 2 43 92
Crankcase components inspection and servicing 92
44 chapter 2 engine clutch and transmission 93
Chapter 2 engine clutch and transmission 2 45 94
Crankshaft and main bearings removal inspection main bearing selection and installation 94
Crankshaft removal 94
Inspection 94
Main bearing selection 94
46 chapter 2 engine clutch and transmission 95
Bearing color code 95
Installation 95
No 1 blue 95
No 2 black 95
No 3 brown 95
No 4 green 95
No 5 applies only to the crankshaft main bear ing selection 95
No 5 yellow 95
Chapter 2 engine clutch and transmission 2 47 96
Connecting rods and bearings removal inspection bearing selection and installation 96
Removal 96
48 chapter 2 engine clutch and transmission 97
Connecting rod bearing selection 97
Inspection 97
Chain guides 98
Chapter 2 engine clutch and transmission 2 49 98
Installation 98
Removal 98
Starter chain and camshaft chain 98
Starter chain camshaft chain and guides removal inspection and installation 98
50 chapter 2 engine clutch and transmission 99
Chain guides 99
Inspection 99
Installation 99
Removal 99
Starter chain and camshaft chain 99
Transmission shafts removal and installation 99
Chapter 2 engine clutch and transmission 2 51 100
Mainshaft 100
Transmission shafts disassembly inspection and reassembly 100
52 chapter 2 engine clutch and transmission 101
Inspection 101
Chapter 2 engine clutch and transmission 2 53 102
Disassembly 102
Driveshaft 102
Reassembly 102
54 chapter 2 engine clutch and transmission 103
Inspection 103
Reassembly 103
Removal 103
Shift cam and forks removal inspection and installation 103
Chapter 2 engine clutch and transmission 2 55 104
Installation 104
Removal 104
Starter clutch and drive chain tensioner removal disassembly inspection and installation 104
56 chapter 2 engine clutch and transmission 105
Disassembly inspection and reassembly 105
Initial start up after overhaul 105
Installation 105
Chapter 2 engine clutch and transmission 2 57 106
Recommended break in procedure 106
Warning 106
Carburetor type 107
Chapter 3 fuel and exhaust systems 107
Contents 107
Fuel grade 107
Fuel tank capacity 107
Fuel tank reserve capacity 107
Specifications 107
2 chapter 3 fuel and exhaust systems 108
Carburetor adjustments 108
Jet sizes 108
Tightening torques 108
Chapter 3 fuel and exhaust systems 3 3 109
Fuel tank cleaning and repair 109
Fuel tank removal and installation 109
General information 109
Idle fuel air mixture adjustment general information 109
4 chapter 3 fuel and exhaust systems 110
All models 110
Carburetor overhaul general information 110
Carburetors removal and installation 110
Fz600 models 110
Installation 110
Removal 110
Xj fj600 models 110
Yx600 radian models 110
Carburetors disassembly cleaning and inspection 111
Chapter 3 fuel and exhaust systems 3 5 111
Disassembly 111
6 chapter 3 fuel and exhaust systems 112
Chapter 3 fuel and exhaust systems 3 7 113
8 chapter 3 fuel and exhaust systems 114
Chapter 3 fuel and exhaust systems 3 9 115
10 chapter 3 fuel and exhaust systems 116
Chapter 3 fuel and exhaust systems 3 11 117
Cleaning 117
Inspection 117
12 chapter 3 fuel and exhaust systems 118
Carburetors separation and joining 118
Reassembly 118
Carburetors float height and fuel level adjustment 119
Chapter 3 fuel and exhaust systems 3 13 119
Float height adjustment 119
Fuel level adjustment 119
Removal 119
Throttle cable and grip removal installation and adjustment 119
14 chapter 3 fuel and exhaust systems 120
Adjustment 120
All models 120
Choke cable removal and installation 120
Exhaust system removal and installation 120
Fj600 models 120
Installation 120
Removal 120
Yx600 radian models 120
Chapter 3 fuel and exhaust systems 3 15 121
16 chapter 3 fuel and exhaust systems 122
Chapter 4 ignition system___________________________ 123
Contents 123
Firing order 123
Ignition coil 123
Ignition timing 123
Pickup coil resistance at 20 degrees c 68 degrees f 123
Spark plug caps and spark plugs 123
Specifications 123
Tightening torques 123
2 chapter 4 ignition system 124
Engine starts but misfires 124
Engine will not start 124
General information 124
Ignition system check 124
Chapter 4 ignition system 4 3 125
Ignition coils check removal and installation 125
Pickup coils check removal and installation 125
Removal and installation 125
4 chapter 4 ignition system 126
Dual coil models 126
Igniter check removal and installation 126
Installation 126
Removal 126
Removal and installation 126
Single coil models 126
Chapter 5 frame suspension and final drive 127
Contents 127
Front forks 127
Rear suspension 127
Specifications 127
2 chapter 5 frame suspension and final drive 128
Frame inspection and repair 128
General information 128
Side and centerstand maintenance 128
Torque specifications 128
Chapter 5 frame suspension and final drive 5 3 129
Handlebars removal and installation 129
4 chapter 5 frame suspension and final drive 130
All models 130
Disassembly 130
Fj xj600 models 130
Forks disassembly inspection and reassembly 130
Front forks removal and installation 130
Fz600 models 130
Installation 130
Removal 130
Yx600 radian models 130
Chapter 5 frame suspension and final drive 5 5 131
Front forks fj6o0 and xj600 models exploded view 131
Front forks fz6o0 models exploded view 131
6 chapter 5 frame suspension and final drive 132
Chapter 5 frame suspension and final drive 5 7 133
8 chapter 5 frame suspension and final drive 134
Inspection 134
Chapter 5 frame suspension and final drive 5 9 135
Reassembly 135
Removal 135
Steering head bearings replacement 135
10 chapter 5 frame suspension and final drive 136
Fj600 and xj600 models 136
Fz600 models 136
Yx600 radian models 136
Chapter 5 frame suspension and final drive 5 11 137
12 chapter 5 frame suspension and final drive 138
All models 138
Chapter 5 frame suspension and final drive 5 13 139
Inspection 139
Installation 139
Rear shock absorber removal inspection and installation 139
Removal 139
14 chapter 5 frame suspension and final drive 140
Fj600 and xj600 models 140
Fz600 models 140
Inspection 140
Yx600 radian models 140
Chapter 5 frame suspension and final drive 5 15 141
16 chapter 5 frame suspension and final drive 142
30 mm 0 8 1 8 in 142
Installation 142
Chapter 5 frame suspension and final drive 5 17 143
Rear suspension linkage removal inspection and installation 143
18 chapter 5 frame suspension and final drive 144
Swingarm bearings chock 144
Chapter 5 frame suspension and final drive 5 19 145
Swingarm bearings inspection and replacement 145
Swingarm removal and installation 145
______ ________ 145
Ф bearing bush 3 swingarm 145
20 chapter 5 frame suspension and final drive 146
Cleaning 146
Drive chain removal cleaning and installation 146
Installation 146
Removal 146
Sprockets check and replacement 146
Chapter 5 frame suspension and final drive 5 21 147
Fz600 models 147
22 chapter 5 frame suspension and final drive 148
Fj xj600 and yx600 radian models 148
Brakes 149
Chapter 6 brakes wheels and tires 149
Wheels and tires 149
4 chapter 6 brakes wheels and tires 150
Fz600 models 150
Rear calipers 150
See illustration 150
Warning 150
Brake caliper removal overhaul and installation 151
Chapter 6 brakes wheels and tires 6 5 151
Fj600 and xj600 models 151
Removal 151
6 chapter 6 brakes wheels and tires 152
Overhaul 152
Brake disc s inspection removal and installation 153
Chapter 6 brakes wheels and tires 6 7 153
Front brake master cylinder removal overhaul and installation 153
Inspection 153
Installation 153
Removal 153
8 chapter 6 brakes wheels and tires 154
Overhaul 154
Removal 154
Chapter 6 brakes wheels and tires 6 9 155
Installation 155
10 chapter 6 brakes wheels and tires 156
Overhaul 156
Rear brake master cylinder removal overhaul and installation 156
Removal 156
Brake hoses inspection and replacement 157
Chapters brakes wheels and tires 6 11 157
Inspection 157
Installation 157
12 chapter 6 brakes wheels and tires 158
Brake system bleeding 158
Replacement 158
Chapter 6 brakes wheels and tires 6 13 159
Inspection 159
Installation 159
Rear drum brakes removal inspection and installation 159
Removal 159
14 chapter 6 brakes wheels and tires 160
Wheels alignment check 160
Wheels inspection and repair 160
Chapter 6 brakes wheels and tires 6 15 161
Front wheel removal and installation 161
Installation 161
Removal 161
16 chapter 6 brakes wheels and tires 162
B rear wheel details fj6o0 and xj600 models 163
Chapter 6 brakes wheels and tires 6 17 163
Rear wheel removal and installation 163
Removal 163
See illustrations 163
Warning 163
18 chapter 6 brakes wheels and tires 164
C rear wheel details yx600 radian models 164
Installation 164
See illustration 164
Chapter 6 brakes wheels and tires 6 19 165
Front wheel bearings 165
Wheel bearings inspection and maintenance 165
20 chapter 6 brakes wheels and tires 166
Rear coupling bearing 166
Rear wheel bearings 166
Tubeless tires general information 166
Tire changing sequence tubeless tires 167
Chapter 7 fairings and bodywork 168
Contents 168
Disengage the tab at the front of the seat 168
Fz600 models 168
General information 2 seat removal and installation 168
Illustration 168
See illustration 168
Turn the lock 1 counterclockwise anti clockwise and pull down on the latches 2 168
Xj600 and fj600 models 168
2 chapter 7 fairings and bodywork 169
Ail models 169
All models 169
B and disengage the tab at the top rear 169
Disengage the tab at the front of the seat 3 a remove the mounting bolts 169
Fjixj6oo models 169
Fz600 models 169
Illustration 169
Lower fairing fj xj600 models removal and installation 169
Remove the mounting screws to detach the side cover 4 with the fairing supported from below remove the mounting fasteners on each side 169
See illustration 169
Side covers removal and installation 169
Yx600 radian models 169
Chapter 7 fairings and bodywork 7 3 170
Lower and center fairings fz600 models removal and installation 170
Remove the mounting fasteners along the sides of the fairing panel and two at the front near the fork legs 170
Upper fairing fj xj600 models removal and installation 170
Upper fairing fz600 models removal and installation 170
Battery 171
Chapter 8 electrical system 171
Contents 171
Fuel sender resistance 171
Specifications 171
2 chapter 8 electrical system 172
Alternator 172
Starter motor 172
Torque specifications 172
Battery charging 173
Battery inspection and maintenance 173
Chapter 8 electrical system 8 3 173
Electrical troubleshooting 173
General information 173
4 chapter 8 electrical system 174
Fuses check and replacement 174
Headlight 174
Lighting system check 174
Taillight license plate light 174
Brake light 175
Chapter 8 electrical system 8 5 175
Fj xj600 and yx600 radian models 175
Headlight bulb replacement 175
Neutral indicator light 175
Oil level warning light 175
6 chapter 8 electrical system 176
All models 176
Fj600 and xj600 models 176
Fz600 models 176
Headlight aim check and adjustment 176
Yx600 radian models 176
Chapter 8 electrical system 8 7 177
Fj xj600 177
Fz600 and yx600 radian models 177
Ta ill brake light bulbs 177
Turn signal and taillight bulbs replacement 177
Turn signal bulbs 177
8 chapter 8 electrical system 178
Circuit check 178
Fj600 fz600 and early radian models 178
Front brake lever switch 178
Switch replacement 178
Turn signal circuit check 178
Xj600 and later yx600 radian models 178
10 chapter 8 electrical system 180
Fj600 fz600 and xj600 models 180
Instrument removal and installation 180
Instruments and speedometer cable removal and installation 180
Rear brake pedal switch 180
Speedometer cable removal and installation 180
Yx600 radian models 180
Chapter 8 electrical system 8 11 181
Fuel gauge fj6oo fz600 and xj600 181
Instrument and warning light bulbs replacement 181
Meters and gauges check 181
Sender test 181
Tachometer and speedometer 181
12 chapter 8 electrical system 182
Installation 182
Oil level sender removal check and installation 182
On o o o 182
R br l 182
Removal 182
Replacement 182
Switch position 182
Us models 182
Wire color 182
Chapter 8 electrical system 8 13 183
Handlebar switches check 183
Handlebar switches removal and installation 183
14 chapter 8 electrical system 184
Clutch switch chock and replacement 184
Replacement 184
Sidestand switch check and replacement 184
Chapter 8 electrical system 8 15 185
Fz600 models 185
Horn check and replacement 185
Removal 185
Replacement 185
Starter motor removal and installation 185
Starter relay check and replacement 185
16 chapter 8 electrical system 186
All models 186
Disassembly 186
Installation 186
Starter motor disassembly inspection and reassembly 186
Yx600 radian models 186
Chapter 8 electrical system 8 17 187
18 chapter 8 electrical system 188
Inspection 188
Chapter 8 electrical system 8 19 189
Reassembly 189
20 chapter 8 electrical system 190
Charging system component tests 190
Charging system output test 190
Charging system testing general information and precautions 190
Alternator removal and installation 191
Chapter 8 electrical system 8 21 191
Early models with brushes 191
Later models without brushes 191
22 chapter 8 electrical system 192
Regulator rectifier removal and installation 192
Chapter 8 electrical system 8 23 193
Wiring diagrams 193
26 chapter 8 electrical system 194
Chapter 8 electrical system 8 27 195
Code de couleur 195
Color code 195
Farbenkodierung 195
Conversion factors 196
Fuel consumption 196
Is common practice to convert from miles per gallon mpg to litres 100 kilometres 1 1 00km where mpg limparia x i 100 km 282 and mpg usi x 1 100 km 235 196
Length distance 196
Mass weight 196
Pressure 196
Temoerature 196
Torque moment of force 196
Velocity speed 196
Volume capacity 196
Electrical system 8 1 through 8 29 198
Engine 198
Engine clutch and transmission 02 1 through 02 58 engine 198
Evaporative emission control system california models only check 1 24 198
Exhaust system 198
External shift mechanism removal inspection and instal lation 2 39 198
Fairing and bodywork 198
Fairings and bodywork 7 1 through 7 4 fasteners check 1 26 forks 198
Forks removal and installation 5 4 frame 198
Frame suspension and final drive 5 1 through 5 22 front wheel removal and installation 6 15 fuel and exhaust systems 3 1 through 3 16 fuel system check and fitter cleaning 1 26 fuel tank 198
General information 198
Handlebar switches removal and installation 6 13 handlebar switches check 8 13 handlebars removal and installation 5 3 headlight 198
Hom check and replacement 8 15 198
Idle fuel air mixture adjustment general information 3 3 idle speed check and adjustment 1 22 ignition 198
Ignition main key switch check and replacement 8 12 ignition system 4 1 through 4 4 instrument and warning light bulbs replacement 8 11 198
Ind 2 index 198
Lower fairing fj xj6o0 models removal and installation 7 2 lubrication general 1 16 198
Maintenance schedule 1 4 198
Index ind 3 199
Haynes manuals explain best 200
Isbn 1 56392 1 200
Models covered by this manual 200
Yamaha fj600 598cc us 1984 through 1985 yamaha fz600 598cc us 1986 through 1988 uk 1987 and 1988 yamaha xj600 598cc uk 1984 through 1987 and 1989 through 1992 yamaha yx600 radian 598cc us 1986 through 1990 200

Yamaha FZ (1984-1992) [9/200] Maintenance techniques tools and working facilities 0 11

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