Yamaha FZR600 W WC - Service Repair Manual - Wiring Diagrams

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YAMAHA FZR600 (W-WC) - WORKSHOP, SERVICE, REPAIR MANUAL - WIRING DIAGRAMS

- English Service Manual / Repair Manual and Wiring Diagrams, for motorcycles Yamaha FZR600 W WC.

 
CONTENTS:

- Chapter 1.
- General information
- Motorcycle identification  1-1
- Vehicle identification number . 1-1
- Engine serial number . 1-1
- Important information  1-2
- Preparation for removal  1-2
- All replacement parts . 1-2
- Gasket, oil seals, and 0-rings  1-2
- Lock washer/plates and cotter pins  1-3
- Bearings and oil seals . 1-3
- Cl rc lips . 1-3
- Special tools  1-4
- For tune up . 1-4
- For engine service . 1-5
- For chassis service . 1-8
- For electrical components  1-8
- Chapter 2.
- Specifications
- Specifications  2-1
- General specifications  2-1
- Maintenance specifications . 2-4
- Engine. 2-4
- Chassis  2-12
- Electrical  2-15
- General torque specifications  2-18
- Definition of units  2-18
- Lubrication point and grade of lubricant  2-19
- Engine  2-19
- Chassis  2-20
- Lubrication diagram . 2-21
- Coolant diagram . 2-22
- Cable routing  2-23
- Chapter 3.
- Periodic inspection and adjustment
- Introduction . 3-1
- Maintenance interval chart  3-1
- General maintenance/lubrication  3-2
- Cowlings/covers removal and installation  3-4
- Removal . 3-4
- Installation . 3-6
- Engine . 3-8
- Exup cable adjustment (for california only)  3-8
- Valve clearance adjustment . 3-9
- Carburetor synchronization . 3-16
- Idle speed adjustment  3-18
- Throttle cable free play adjustment . 3-19
- Spafik plug inspection . 3-20
- Ignition timing check . 3-21
- Compression pressure measurement . 3-22
- Engine oil level inspection . 3-24
- Engine 01 l replacement . 3-24
- Engine oil filter replacement . 3-25
- Clutch adjustment  3-27
- Air filter cleaning . 3-28
- Carburetor joint inspection  3-29
- Fuel line inspection . 3-29
- Crankcase ventilation hose inspection  3-29
- Exhaust system inspection  3-30
- Coolant level inspection . 3-30
- Coolant replacement . 3-31
- Chassis  3-34
- Front brake adjustment  3-34
- Rear brake adjustment . 3-34
- Brake fluid inspection  3-35
- Brake pad inspection  3-36
- Brake light switch adjustment  3-36
- Brake hose inspection . 3-37
- Al r bleeding . 3-37
- Dr ive chain slack adjustment  3-38
- Drive chain lubrication  3-40
- Change pedal adjustment  3-40
- Front fork inspection  3-41
- Steering head inspection . 3-41
- Rear shock absorber adjustment  3-44
- Tl re inspection  3-45
- Wheel inspection  3-46
- Cable inspection . 3-47
- Lubrication  3-47
- Electrical  3-49
- Battery inspection  3-49
- Fuse inspection  3-51
- Headlight beam adjustment  3-53
- Headlight bulb replacement . 3-53
- Tail/brake bulb replacement  3-55
- Chapter 4.
- Engine overhaul
- Engine removal . 4-1
- Side cowlings and top cover. . 4-1
- Fuel tank . 4-1
- Engine oil  4-1
- Coo lant  . 4-1
- Air fil tea case and carburetor  4-1
- Radiator . 4-2
- Muffler assembly  4-2
- Clutch cable and drive chain  4-3
- Leads . 4-4
- Engine removal  4-5
- Engine disassembly  4-7
- Cylinder head cover, camshaft and
- Cylinder head . 4-7
- Cylinder and piston  4-10
- Starter clutch . 4-12
- Clutch  4-13
- Starter motor and a.c. Generator . 4-14
- Oil pan and 01 l strainer  4-15
- Oil pump and shift shaft  4-16
- Water pump . 4-17
- Crankcase disassembly . 4-17
- Transmission, shifter and shift cam  4-18
- Crankshaft . 4-19
- Valve pad and valve . 4-20
- Connecting rod . 4-22
- Inner rotor (oil pump)  4-22
- Inspection and repair . 4-23
- Cylinder head  4-23
- Valve and valve guide . 4-24
- Valve seat . •  4-26
- Valve spring  4-29
- Valve lifter . ••. 4-30
- Camshaft, timing chain and cam sprocket . 4-30
- Cylinder and piston . 4-32
- Piston ring and piston pin . 4-34
- Piston pin  4-35
- Crankshaft and connecting rod  4-36
- Oil pump  4-40
- Primary drive . 4-41
- Starter drives  4-42
- Clutch . 4-43
- Transmission  4-45
- Shift shaft and stopper lever.  4-46
- Oil jet nozzle . 4-47
- Relief valve and pipe  4-47
- Crankcase . 4-47
- Bearing and oil seal  4-48
- Exup valve and cables (fzr600wc only)  4-48
- Engine assembly and adjustment . 4-49
- Inner rotor (oil pump) . 4-49
- Connecting rod  4-49
- Valve pad and valve  4-50
- Crankshaft  4-53
- Transmission, shifter and shift cam . 4-56
- Crankcase assembly . 4-57
- Water pump  4-60
- Shift shaft and oil pump . 4-60
- Oil pan and oil strainer . 4-61
- A.c. Magneto and starter motor  4-62
- Clutch . 4-64
- Starter clutch  4-67
- Piston and cylinder . 4-70
- Cylinder head and camshaft  4-74
- Timing chain tensioner  4-79
- Remounting engine  4-80
- Chapter 5.
- Cooling system
- Radiator  5-1
- Removal  5-2
- Inspection  5-3
- Installation . 5-4
- Thermostatic valve . 5-6
- Removal  5-6
- Inspection  5-7
- Installation . 5-7
- Water pump  . 5-8
- Removal  5-8
- Inspection  5-9
- Installation . 5-9
- Chapter 6.
- Carburetor
- Carburetor . 6-1
- Section view  6-2
- Removal . 6-3
- Disassembly  6-4
- Inspection  6-7
- Assembly . 6-9
- Installation . 6-11
- Adjustment  6-13
- Air injection (for california)  6-14
- Air injection (al r induction system)  6-14
- Air cut valve . 6-14
- Air induction system inspection  6-15
- Chapter 7.
- Chassis
- Front wheel  7-1
- Removal . 7-2
- Inspection  7-2
- Installation . 7-4
- Static wheel balance adjustment . 7-5
- Rear wheel  7-7
- Removal . 7-8
- Inspection  7-8
- Installation . 7-9
- Static wheel balance adjustment . 7-9
- Front and rear brake  7-10
- Brake pad replacement  7-12
- Caliper disassembly  7-16
- Master cylinder disassembly  7-19
- Inspection and repair  7-20
- Assembly . 7-24
- Front fork  7-31
- Removal . 7-32
- Disassembly  7-33
- Inspection  7-34
- Assembly . 7-35
- Installation . 7-37
- Steering head and handlebar  7-39
- Removal . 7-41
- Inspection  7-44
- Installation . 7-45
- Rear shock absorber and swingarm  7-50
- Handling notes  7-52
- Disposal notes . 7-52
- Removal . 7-52
- Inspection  7-56
- Installation . 7-57
- Drive chain and sprocket . 7-60
- Removal . 7-60
- Inspection and cleaning . 7-60
- Installation . 7-62
- Chapter 8.
- Electrical
- Fzr600w/wc circuit diagram . 8-1
- Color code . 8-2
- Electrical components . 8-3
- Checking of switches  8-5
- Switch connection as shown in manual  8-5
- Checking switch for terminal connection . 8-5
- Checking of bulbs (for headlight, tail/brake light,
- Flasher light, meter light, etc.) . 8-8
- Kinds of bulbs  8-8
- Checking bulb condition . 8-8
- Ignition system . 8-11
- Circuit diagram  8-11
- Digital ignition control system . 8-13
- Troubleshooting . 8-14
- Electrical starting system . 8-21
- Circuit diagram  8-21
- Starting circuit operation  8-23
- Troubleshooting . 8-24
- Starter motor . 8-30
- Charging system . 8-33
- Circuit diagram  8-33
- Troubleshooting . 8-35
- Lighting system  •8-39
- Circuit diagram . -8-39
- Troubleshooting  8-41
- Lighting system check . 8-44
- Signal system . 8-50
- Circuit diagram  8-50
- Troubleshooting  8-51
- Signal system check . 8-53
- Cooling system  8-63
- Circuit diagram  8-63
- Troubleshooting  8-65
- Fuel pump system  8-73
- Circuit diagram  8-73
- Fuel pump circuit operation . 8-75
- Troubleshooting  8-76
- Fuel pump test . 8-80
- Exup system (for carifornia only)  8-81
- Circuit diagram  8-81
- Troubleshooting . 8-83
- Chapter 9.
- Troubleshooting
- Starting failure/hard starting  9-1
- Fuel system  9-1
- Electrical system . 9-2
- Compression system  9-2
- Poor idle speed performance . 9-3
- Poor idle speed performance  9-3
- Poor medium and high speed performance  9-4
- Poor medium and high speed performance . 9-4
- Faul ty gear shifting . 9-4
- Hard shifting  9-4
- Shift pedal does not move . 9-4
- Jump-out gear  • • • • • . 9-4
- Clutch slipping/dragging . 9-5
- Clutch slipping . 9-5
- Clutch dragging . 9-5
- Overheating or over-cooling  9-6
- Overheating . 9-6
- Over-cooling . 9-6
- Faul ty brake . 9-7
- Poor braking effect . 9-7
- Front fork oil leakage/malfunction  9-7
- 01 l leakage  9-7
- Malfunction . 9-7
- Instable handling  9-8
- Handlebars  9-8
- Steering . 9-8
- Front forks  9-8
- Wheels . 9-8
- Frame  9-8
- Rear arm . 9-8
- Rear cushion . 9-8
- Drive chain  9-8
- Fairing . 9-8
- Faul ty signals and lights  9-9
- Headlight dark  9-9
- Bulb burnt out . 9-9
- Flasher does not light  9-9
- Flasher keeps on . 9-9
- Flasher winks slower  9-10
- Flasher winks quicker . 9-10
- Horn is inoperative  9-10
- Fzr600 w/wc wiring diagram