Segment:
Middleweight Naked/Sportbike
Target Audience:
Enthusiast owners, independent repair shops, Yamaha dealerships
Competitors:
Suzuki SV650, Kawasaki ER-6f, Honda CBF600
Key Selling Points:
Versatile performance, comfortable ergonomics for a sportbike, reliable Yamaha engineering.
Manual Value Proposition:
Empowers owners and technicians with the knowledge to perform all necessary maintenance, diagnostics, and repairs, ensuring longevity and optimal performance of the FZ6 Fazer.
Vehicle Strengths:
Punchy parallel-twin engine, balanced chassis, comfortable riding position for its class.
Primary Focus:
Workshop Repair and Maintenance
Diagnostic Coverage:
Comprehensive diagnostic procedures
Repair Coverage:
All repair and rebuild procedures
Maintenance Coverage:
Detailed maintenance schedules and procedures
Restoration Coverage:
Procedures for refurbishment and restoration
Estimated Pages:
Likely 300-500+ pages (typical for comprehensive workshop manuals)
Type:
Digital Workshop Repair Manual
Format:
Digital (PDF assumed)
Engine:
Complete engine overhaul, tuning, component testing, lubrication system, cooling system, fuel system, ignition system, emissions control
Transmission:
Clutch system, gearbox operation, internal components, lubrication, servicing
Chassis:
Frame, suspension (front and rear), steering system, wheel bearings, swingarm
Brakes:
Front and rear brake systems, hydraulic components, ABS (if applicable), brake pad and disc replacement, bleeding procedures
Electrical System:
Wiring diagrams, charging system (alternator, rectifier/regulator, battery), starting system (starter motor, solenoid), lighting system, instrument cluster, ECU (Engine Control Unit) diagnostics and repair, sensors, relays, fuses
Fuel System:
Fuel injection system (throttle bodies, injectors, fuel pump, fuel pressure regulator), fuel tank, lines
Exhaust System:
Exhaust manifold, catalytic converter (if applicable), muffler, lambda sensors
Bodywork And Trim:
Fairings, seat removal, tank cover, fenders, mirrors, lights removal and installation
Maintenance Procedures:
Oil and filter changes, air filter replacement, spark plug replacement, coolant flush and replacement, chain adjustment and lubrication, brake fluid replacement, general inspection points
Diagnostic Procedures:
Troubleshooting guides based on symptoms, fault code interpretation (if OBD-II compliant or similar), component testing methods
Repair Procedures:
Step-by-step instructions for component removal, disassembly, inspection, repair, and reassembly for all major systems
Rebuild Procedures:
Detailed instructions for engine and gearbox rebuilds, including torque specifications and clearances
Calibration Procedures:
Throttle body synchronization, idle speed adjustment, ignition timing checks (if applicable)
Depth:
Comprehensive: Covers basic maintenance to complete engine and transmission rebuilds, including in-depth electrical diagnostics.
Diagnostic Focus:
Advanced diagnostic strategies and fault finding
Repair Scope:
Full repair manual, not a condensed guide
Engine Type:
Liquid-cooled, 4-stroke, DOHC, 4-valve inline-four
Displacement:
600cc (approx.)
Bore X Stroke:
65.5 mm x 44.5 mm (typical for this generation)
Compression Ratio:
12.2:1 (typical)
Ignition System:
TCBI (Transistor Controlled Ignition) with electronic advance
Horsepower:
Approx. 95-98 hp at 12,000 rpm
Torque:
Approx. 61-63 Nm (45-47 lb-ft) at 10,000 rpm
Fuel Delivery:
Fuel Injection (FI), typically with 4-hole injectors and Mikuni throttle bodies
Fuel Type:
Unleaded gasoline, 95-98 RON
Fuel Tank Capacity:
19.4 Liters (5.1 US gal)
Oil Type And Capacity:
Yamalube 4 (or equivalent) 10W-40, approx. 3.4 Liters (3.6 US qt) with filter change. Manual will specify exact capacity and grade.
Coolant Capacity:
Approx. 2.1 Liters (2.2 US qt). Manual will specify exact type (e.g., Yamaha Blue)
Length:
Approx. 2,105 mm (82.9 in)
Width:
Approx. 750 mm (29.5 in)
Height:
Approx. 1,250 mm (49.2 in)
Wheelbase:
Approx. 1,445 mm (56.9 in)
Dry Weight:
Approx. 195 kg (430 lbs)
Wet Weight:
Approx. 222 kg (489 lbs) (with all fluids)
Front Tire Size:
120/70ZR17 M/C (58W)
Rear Tire Size:
180/55ZR17 M/C (73W)
Wheel Bolt Pattern:
N/A (Cast wheels, not bolted hubs)
Front Brake Type:
Dual hydraulic disc, 298 mm diameter
Rear Brake Type:
Hydraulic disc, 245 mm diameter
Crash Test Data:
Motorcycles are not typically subjected to standardized crash testing like automobiles. Safety data would be limited to manufacturer-provided information on safety features and handling characteristics.
Braking System:
Dual front discs and single rear disc provide significant stopping power. Optional ABS may have been available and would be detailed in the manual.
Suspension:
Well-tuned suspension contributes to stability and rider control.
Lighting:
Adequate headlight, taillight, and turn signals for visibility.
Ergonomics:
Designed for a balance of sporty feel and rider comfort, aiding in fatigue reduction.
Features:
Basic analogue tachometer with digital speedometer and multi-function display. No advanced infotainment systems.
ABS:
Optional Anti-lock Braking System (ABS) was available on some models (FZ6SSC designation often indicates ABS). The manual will cover its function and diagnostics.
Features:
No modern connectivity features like Bluetooth or smartphone integration.
ECU:
Engine Control Unit (ECU) manages fuel injection, ignition timing, and other engine parameters. The manual provides diagnostic procedures for ECU faults and sensor readings.
Oil Filter Change:
Every 6,000 km (3,700 miles) or 6 months.
Air Filter Cleaning Replacement:
Inspection every 6,000 km (3,700 miles), cleaning/replacement as needed, typically at 12,000-18,000 km (7,500-11,200 miles).
Spark Plug Replacement:
Typically at 20,000-30,000 km (12,500-18,700 miles) or as per manual recommendation. Manual will specify plug type (e.g., NGK CR9E).
Chain Lubrication Adjustment:
Lubricate every 1,000 km (600 miles) or after riding in rain/wet conditions. Adjust slack every 6,000 km (3,700 miles) or as needed.
Valve Clearance Check:
Initial check typically at 20,000 km (12,500 miles), then every 40,000 km (25,000 miles). Manual will provide exact intervals and specifications.
Engine Oil:
Yamalube 4 (or equivalent) 10W-40 SAE API SG or higher, JASO MA.
Coolant:
Permanent type antifreeze, 50% mixture with distilled water. Yamaha Blue coolant is recommended.
Brake Fluid:
DOT 4 SAE J1703 or FMVSS No. 116 DOT 4.
Fork Oil:
SAE 10W (Manual will specify exact type and quantity per fork leg).
Common Wear Items:
Clutch plates, chain and sprockets, brake pads, fork seals, swingarm bearings.
Potential Electrical Issues:
Rectifier/regulator failures, stator coil issues can occur with age and heat cycling.
Fuel System Concerns:
Throttle body synchronization may drift over time, requiring adjustment for smooth running.
Suspension Notes:
While generally well-regarded, riders may opt for aftermarket upgrades for enhanced performance.
Heritage:
Yamaha Motor Company has a long and successful history in motorsports and motorcycle manufacturing, known for innovation and performance.
Predecessors:
The FZ6 Fazer is a successor to the FZR600 and FZX750, evolving into a more modern and user-friendly sport-touring/naked bike.
Engine Origin:
The engine is derived from the R6 supersport, but de-tuned and re-geared for broader usability and torque.
Production Period:
The FZ6 Fazer model line was produced from 2004 through 2010, with various updates. This manual specifically covers the initial 2004-2005 models.
Manufacturing Location:
Typically manufactured in Japan by Yamaha.
