Yamaha YZF600R Thundercat 1996-2003, FZS600 Fazer 1998-2003 Repair Manual

SKU: HYM3702-003
Yamaha YZF600R Thundercat, FZS600 Fazer Repair Manual 1996-2003
Yamaha YZF600R Thundercat, FZS600 Fazer Repair Manual 1996-2003
MSRP: $45.95
Only $36.95
Free Shipping (US48)
In Stock
Item #: HYM3702-003
-
+
Usually ships the next business day
Why Buy From Us?
  • Free Shipping
  • Veteran Owned
  • Secure Shopping
  • Satisfaction Guaranteed
Item Description

The 1996-2003 Yamaha YZF600R Thundercat, FZS600 Fazer sportbike repair manual by Haynes, covers the following models:

  • Yamaha YZF600R Thundercat, 1996-2003
  • Yamaha FZS600 Fazer, 1998-2003
  • Yamaha FZS600S Fazer, 2001

Book Excerpt: 1996-2003 Yamaha YZF600R, FZS600 Fazer Repair Manual

ENGINE, CLUTCH AND TRANSMISSION

CRANKCASE HALVES | INSPECTION AND SERVICING
  1. After the crankcase have been separated, remove the crankshaft, cam chain and tension blade, transmission shafts and selector drum and forks, and any other components or assemblies not already removed, referring to the relevant Sections of this and other Chapters (see Steps 2, 3, 4 and 5 in Section 23).

    Also remove oil passage nozzle and its O-ring (see illustration). Discard the O-ring as a new one must be used.

  2. The crankcase should be cleaned thoroughly with new solvent and dried with compressed air. All oil passages and oil nozzles should be blown out with compressed air.
  3. All traces of old gasket sealant should be removed from the matting surfaces. Minor damage to the surfaces can be cleaned up with a fine sharpening stone or grindstone.

    Check both crankcase halves very carefully for cracks and other damage. Caution: Be very careful not to nick or gouge the crankcase mating surfaces or oil leaks will result.

  4. Small cracks or holes in aluminum castings may be repaired with an epoxy resin adhesive as a temporary measure.

    Permanent repairs can only be effected by argon-arc welding, and only a specialist in the process is in a position to advise on the economy or practical aspect of such a repair.

    If any damage is found that can?t be repaired, replace the crankcase halves as a set.

  5. Damaged threads can be economically reclaimed by using a diamond section wire insert, of the Heli-coil type, which is easily fitted after drilling and re-tapping the affected thread.

ELECTRICAL SYSTEM
STARTER RELAY | CHECK AND REPLACEMENT

CHECK

  1. If the starter circuit is faulty, first check the fuse (see Section 5).
  2. Remove the seat (see Chapter8). The starter relay is located behind the battery. Lift the rubber terminal cover and unscrew the bolt securing the starter motor lead (see illustration); position the lead away from the relay terminal.

    With the ignition switch ?ON?, the engine kill switch in the "RUN" position, and the transmission in neutral, press the starter switch. The relay should be heard to click.

  3. If the relay doesn?t click, switch off the ignition and remove the relay as described below; test it as follows.

Subject: 1996, 1997, 1998, 1999, 2000, 2001, 2002, 2003 Yamaha YZF600R Thundercat, FZS600 Fazer, FZS600S Fazer service, maintenance, repair. ISBN-10: 1844251527 | ISBN-13: 9781844251520 | Haynes 3702

Specifications
  • Publisher: Haynes Manuals
  • Pages: 288 - Hundreds of b&w photos and illustrations
  • Binding: Hardcover - 8.5 x 11 inches
  • ISBN: 978-1-84425-152-0
  • Years: 1996 - 2003
Table of Contents
TABLE of CONTENTS: THE YAMAHA YZF600R, FZS600 FAZER
  • Routine maintenance and servicing
  • Specifications
  • Lubricants and fluids
  • Maintenance schedule
  • Component locations
  • Maintenance procedures
REPAIRS and OVERHAUL
  • Engine, clutch and transmission
  • Fuel and exhaust systems
  • Ignition system
  • Frame and suspension
  • Brakes, wheels and final drive
  • Fairing and bodywork
  • Electrical system
  • Wiring diagrams
REFERENCE
  • Tools and workshop tips
  • Security
  • Storage
  • Troubleshooting
Questions & Answers about Yamaha YZF600R Thundercat, FZS600 Fazer Repair Manual 1996-2003

Questions & Answers about Yamaha YZF600R Thundercat, FZS600 Fazer Repair Manual 1996-2003

Ask a question about Yamaha YZF600R Thundercat, FZS600 Fazer Repair Manual 1996-2003.
Customer Reviews
Yamaha YZF600R Thundercat 1996-2003, FZS600 Fazer 1998-2003 Repair Manual
$36.95
Free Shipping (US48)
In Stock
Close
Top
Close
Open