Yamaha Fazer FZ6SS FZ6SSC 2004-06 Motorcycle Service Repair Manual

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Tipo: Motorcycle

Proveedor:

SKU: 151481

Etiquetas: 2004 2005 2006 Fazer Fazer FZ6SS FZ6SSC Motorcycle Motorcycles Yamaha

Variantes de producto

Descripción

This manual covers the Fazer FZ6SS / FZ6SSC, a first-generation middleweight sport-touring motorcycle produced between 2004 and 2006. Featuring a 599 cc inline-four engine derived from the R6 platform and a semi-full fairing for enhanced wind protection, this model offers a versatile blend of sporty performance and touring comfort. Known for its reliable engineering and rider-focused design, the Fazer is well-suited for a range of riding activities, from daily commuting to longer journeys. The RJ07 chassis code identifies this iteration, a model that generally received positive reviews for its balanced capabilities and engaging riding experience. This comprehensive Service Repair Technical Maintenance Manual provides detailed information essential for the upkeep and repair of your Fazer. It covers all major systems, including engine, fuel, transmission, brakes, and electrical components, with thorough instructions for disassembly, assembly, inspection, and diagnosis. Included are regular maintenance procedures, troubleshooting guides, critical torque specifications, and clear wiring diagrams. This manual is designed to assist owners, mechanics, and technicians in maintaining the Fazer’s optimal performance, ensuring its longevity, and addressing any potential issues with precision and accuracy.

🏷️ Basic Information

Identification

Make:

Yamaha

Model:

Fazer FZ6SS / FZ6SSC

Model Designation:

FZ6-S Semicomplete Fairing (Fazer), FZ6-S Compact Fairing (Fazer)

Model Suffix Ssc:

Likely denotes a specific market variant or minor equipment difference, possibly related to ABS or emissions for certain regions.

Generation

Generation:

First Generation FZ6

Codes

Chassis Codes:

RJ07 (common for this era FZ6 platform)

👋 Introduction

Market Position

Segment:

Middleweight Sport-Touring Motorcycle

Target Audience:

Riders seeking a versatile, reliable, and performance-oriented motorcycle for commuting, touring, and spirited riding.

Competitive Analysis

Competitors:

Suzuki Bandit 600S/1200S, Honda CBF600S/CBR600F, Kawasaki ZZR600/Ninja 650R.

Key Features

Engine Source:

Derived from the potent R6 supersport engine, retuned for broader power delivery.

Fairing:

Semi-full fairing offering wind protection for touring comfort.

Versatility:

Balances sporty performance with the comfort and practicality of a sport-tourer.

📋 Manual Details

Coverage Areas

Covered Years:

2004, 2005, 2006

Page Count

Page Count:

Manual Type

Manual Type:

Service Repair Technical Maintenance Manual

Language

Language:

English (Assumed, typical for this market)

Format

Format:

Print (Implied by physical page count, though digital copies are common)

📖 Manual Coverage

Systems Covered

Engine:

Complete disassembly, assembly, inspection, diagnosis, and repair of the 4-cylinder engine, including timing, valve clearance, ignition, lubrication, and cooling systems.

Fuel System:

Detailed coverage of the fuel injection system (EFI), throttle body, injectors, fuel pump, pressure regulator, and emissions control components.

Transmission:

Service and repair of the 6-speed gearbox, clutch assembly, internal components, and shift mechanism.

Chassis Suspension:

Front fork (telescopic, cartridge type) overhaul, rear shock absorber (monoshock) service, linkage maintenance, and swingarm inspection.

Brakes:

Front and rear brake system service, including hydraulic lines, master cylinders, calipers, brake pads, discs, and bleeding procedures. Potential coverage for ABS systems if equipped.

Electrical System:

Comprehensive wiring diagrams, charging system (alternator, regulator/rectifier, battery), starting system (starter motor, solenoid), lighting, ignition system, instrumentation, and fault diagnosis.

Cooling System:

Radiator, cooling fan, thermostat, water pump, coolant passages, and flushing/refilling procedures.

Exhaust System:

Inspection and replacement of exhaust pipes, catalytic converter (if applicable), and muffler.

Bodywork And Trim:

Fairing removal and installation, seat, fuel tank, body panels, and associated fasteners.

Troubleshooting:

Extensive diagnostic flowcharts and common problem identification for various systems.

Procedures Included

Maintenance:

Regular scheduled maintenance tasks, including oil changes, filter replacements, chain adjustment, lubrication points, and safety checks.

Repair:

Step-by-step instructions for component disassembly, repair, reassembly, and adjustment for all major motorcycle systems.

Diagnostics:

Methods for identifying malfunctions, reading diagnostic codes (if applicable via diagnostic tool connection), and performance testing.

Installation:

Guidance on installing genuine Yamaha parts and accessories, as well as proper fitting of replacement components.

Torque Specifications:

Precise torque values for all critical fasteners and assembly points.

Technical Depth

Depth:

Comprehensive from basic maintenance to complete engine rebuilds and detailed electrical system troubleshooting.

Detail Level:

Highly detailed, suitable for professional technicians and experienced DIY enthusiasts.

📊 Manual Specifications

File Format

Digital Format Quality:

PDF (Assumed - high resolution for printability and readability, searchable text likely)

Print Quality

Print Quality:

Professional, clear illustrations and text (if printed version)

Binding Type

Binding Type:

Spiral Bound or Perfect Bound (Typical for workshop manuals)

Paper Type

Paper Type:

Durable, high-quality paper stock resistant to shop grease and fluids.

⚙️ Engine Specifications

Primary Engine

Type:

Inline-Four Cylinder, DOHC, 16-valve

Displacement:

599 cc

Bore X Stroke:

65.5 mm x 44.5 mm

Compression Ratio:

12.2:1

Performance

Horsepower:

Approx. 96 hp @ 11,000 rpm (varies slightly by market/tuning)

Torque:

Approx. 61 Nm (45 lb-ft) @ 9,500 rpm (varies slightly by market/tuning)

Redline:

Approx. 13,000 rpm

Fuel System

Induction:

Fuel Injection (Yamaha's EFI system, YCC-T often present in later models but may be early EFI here)

Fuel Type:

Unleaded gasoline, minimum 91 RON (Octane Rating)

Cooling System

Type:

Liquid-cooled

🔧 Transmission

Standard

Type:

6-speed constant mesh

Features

Clutch:

Wet, multiple-disc, cable-actuated

Final Drive:

O-ring sealed chain

📐 Dimensions

Exterior

Length:

Approx. 2,095 mm (82.5 in)

Width:

Approx. 770 mm (30.3 in)

Height:

Approx. 1,215 mm (47.8 in)

Wheelbase:

Approx. 1,440 mm (56.7 in)

Weights

Dry Weight:

Approx. 188 kg (414.5 lbs)

Wet Weight:

Approx. 205 kg (452 lbs) (fully fueled and ready to ride)

Fuel Capacity:

20.5 Liters (5.4 US gal)

🛡️ Safety Features

Ratings

Optional ABS system available on some FZ6SSC variants.

Active Features

Brakes:

Dual 298mm discs front, Single 245mm disc rear. ABS optional.

Lighting:

Halogen headlights, LED taillight.

💡 Technology Features

Infotainment

Instrument Cluster:

Digital speedometer, analog tachometer, fuel gauge, clock, trip meters, coolant temperature indicator, and various warning lights.

Driver Assistance

Optional Anti-lock Braking System provides enhanced safety during braking.

Connectivity

Diagnostic Port:

Likely equipped with a diagnostic connector for ECU access and fault code retrieval using appropriate tools.

🔧 Maintenance

Service Intervals

Oil Change:

Every 6,000 km (3,750 miles) or 6 months, whichever comes first.

Oil Filter Change:

At every oil change.

Air Filter Inspection:

Every 6,000 km (3,750 miles); clean or replace as needed.

Spark Plug Replacement:

Every 18,000 km (11,250 miles) or as per manual recommendation.

Valve Clearance Check:

Every 24,000 km (15,000 miles) or 24 months.

Fluid Specifications

Engine Oil Type:

Yamalube 4 (or equivalent) SAE 10W-40 API SG or higher, JASO MA certified.

Engine Oil Capacity:

3.00 L (3.17 US qt) without filter; 3.40 L (3.59 US qt) with filter change.

Coolant Type:

Permanent antifreeze coolant (ethylene glycol-based) with distilled water, 50:50 mixture.

Brake Fluid Type:

DOT 4.

Fork Oil Type:

Yamaha Fork Oil 10W or equivalent.

Fork Oil Capacity:

485 cc (16.4 US fl oz) per leg.

Known Issues

Fuel Pump Reliability:

Some owners have reported premature fuel pump failure, particularly in early models. The manual would detail testing procedures.

Regulator Rectifier:

As with many motorcycles of this era, the regulator/rectifier can be a potential failure point due to heat management. The manual provides testing and replacement.

Rear Shock Preload Adjuster:

The remote preload adjuster mechanism can sometimes seize or become difficult to operate with age and exposure. Proper lubrication and care are advised.

📚 Vehicle History

Brand Heritage

Yamaha Legacy:

Yamaha has a long history of producing high-performance and reliable motorcycles across various categories.

Model Evolution

Fz6 Lineage:

The FZ6 was Yamaha's successful entry into the middleweight sport-touring segment, evolving from earlier naked bike designs and borrowing heavily from the R6 platform for its powertrain.

Production

Production Era:

First Generation: 2004-2007 (FZ6-N and FZ6-S/Fazer models). The 2004-2006 models represent the initial phase of this generation.

Manufacturing Location:

Typically manufactured in Japan or facilities approved by Yamaha Motor Company.

🏆 Awards & Recognition

Recognitions

Bike Magazine Reviews:

Generally well-received by motorcycle publications for its blend of performance and practicality, often praised for its R6-derived engine character.