Yamaha FZ6SS FZ6SSC FAZER Shop Manual 2004-2005

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Type: Motorcycle

Vendor:

Sku: 150292

Tags: 2004 2005 FAZER FZ6SS FZ6SSC Motorcycle Motorcycles Yamaha

Product variants

Description

The FZ6 FAZER, produced for the 2004 and 2005 model years, is a versatile middleweight sportbike renowned for its balanced performance and accessible handling. Featuring an inline four-cylinder, DOHC engine derived from the YZF-R6 platform, it delivers approximately 96 horsepower, making it suitable for both spirited riding and daily commuting. The FZ6 FAZER is characterized by its lightweight aluminum frame and a half-fairing design that offers a degree of wind protection. Its engineering prioritizes a blend of sportbike capability with everyday usability, positioning it as a competitive option in its segment. This comprehensive shop and service manual provides detailed guidance for the maintenance and repair of the FZ6 FAZER (FZ6SS / FZ6SSC) models from 2004 and 2005. It covers all essential aspects, including engine mechanicals, fuel and ignition systems, cooling, transmission, chassis, braking, and electrical systems. The manual includes step-by-step procedures for routine maintenance, major repairs, and troubleshooting common issues. With over 500 pages of information, including diagrams, specifications, and diagnostic flowcharts, this resource is an invaluable tool for owners and professional technicians seeking to ensure the optimal performance and longevity of their motorcycle.

🏷️ Basic Information

Identification

Make:

Yamaha

Model:

FZ6 FAZER

Model Variant:

FZ6SS / FZ6SSC

Model Years Covered:

2004, 2005

Codes

Product Code:

YAM-FZ6SS-0405-SM-DL

👋 Introduction

Market Position

Segment:

Middleweight Sportbike / Naked Bike

Purpose:

Versatile performance motorcycle for commuting, sport riding, and touring

Competitive Analysis

Competitors:

Suzuki SV650, Kawasaki ER-6n, Honda CB600F Hornet

Key Features

Engine Layout:

Inline 4-cylinder, DOHC

Chassis Design:

Lightweight aluminum frame, FZ6 FAZER features a half-fairing

Target Audience:

Riders seeking a balance of performance, comfort, and affordability

📋 Manual Details

Coverage Areas

Primary Coverage:

Service, Repair, Maintenance

Included Sections:

Engine, Chassis, Electrical, Troubleshooting, Specifications

Page Count

Estimated Pages:

Manual Type

Type:

Shop Manual / Service Manual

Language

Language:

English

Format

Format:

Digital Download

Device Compatibility:

PC, MAC, Tablets, Smartphones

📖 Manual Coverage

Systems Covered

Engine Mechanical:

Complete disassembly, inspection, repair, and reassembly of engine components

Engine Fuel System:

Fuel injection system, throttle body, injectors, fuel pump, fuel pressure regulation

Engine Ignition System:

Ignition coils, spark plugs, ECU control

Cooling System:

Radiator, fan, thermostat, coolant flow, water pump

Exhaust System:

Catalytic converter, mufflers, lambda sensors

Transmission Mechanical:

Clutch operation, gearbox disassembly and reassembly, gear selection

Chassis Suspension:

Front forks (telescopic, cartridge type), rear shock absorber, linkages, bearings

Chassis Steering:

Handlebar, steering stem, headstock bearings

Braking System:

Front and rear brake calipers, master cylinders, brake lines, fluid replacement, bleeding procedures

Wheel And Tire System:

Wheel bearing inspection, tire pressure recommendations, wheel balancing

Electrical System:

Wiring diagrams, component testing, diagnostic procedures

Bodywork And Fittings:

Fairing removal and installation, seat, fuel tank, body panels

Procedures Included

Routine Maintenance:

Oil changes, filter replacements, spark plug checks, chain adjustment, lubrication points

Troubleshooting:

Diagnostic flowcharts for common problems, electrical faults, engine performance issues

Major Repairs:

Engine rebuild, transmission overhaul, suspension component replacement

Component Testing:

Testing of electrical components, sensors, actuators using multimeter and diagnostic tools

Specifications And Data:

Torque values, clearances, fluid capacities, electrical resistance values

Technical Depth

Depth:

Comprehensive, suitable for professional technicians and experienced DIY mechanics

Detail Level:

Step-by-step instructions with clear diagrams and illustrations

📊 Manual Specifications

File Format

File Type:

Searchability:

Searchable text content for quick information retrieval

Print Quality

Image Resolution:

High-resolution for clear diagram visibility

Readability:

Optimized for digital viewing on various screen sizes

Binding Type

Binding:

N/A (Digital Download)

Paper Type

Paper Type:

N/A (Digital Download)

⚙️ Engine Specifications

Primary Engine

Engine Type:

4-stroke, liquid-cooled, DOHC, 4-valve per cylinder, inline-four

Displacement:

600cc (599 cc)

Bore X Stroke:

65.5 mm x 44.5 mm

Compression Ratio:

12.2:1

Performance

Horsepower Peak:

Approx. 96 hp @ 12,000 rpm

Torque Peak:

Approx. 61 Nm (45 lb-ft) @ 9,500 rpm

Fuel System

Fuel Delivery:

Electronic Fuel Injection (EFI) with dual throttle valves (YCC-T) for improved throttle response

Fuel Type:

Unleaded gasoline, minimum 91 octane

Ignition

Ignition System:

TCI (Transistor Controlled Ignition)

Lubrication

Lubrication System:

Wet sump

Engine Oil

Recommended Oil Viscosity:

10W-40 or 20W-40 (refer to manual for specific climate recommendations)

Oil Capacity With Filter:

Approx. 3.4 Liters (3.6 US qt)

Oil Filter Part Number:

Yamaha 5JX-13440-00-00 or equivalent

🔧 Transmission

Standard

Transmission Type:

Constant mesh, 6-speed

Clutch Type:

Wet, multiple disc

Features

Final Drive:

Chain drive

Transmission Fluid

Transmission Oil Type:

Yamalube 10W-40 or equivalent API SG or higher, JASO MA standard

📐 Dimensions

Exterior

Overall Length:

Approx. 2,095 mm (82.5 in)

Overall Width:

Approx. 775 mm (30.5 in)

Overall Height:

Approx. 1,220 mm (48.0 in)

Seat Height:

Approx. 805 mm (31.7 in)

Wheelbase:

Approx. 1,445 mm (56.9 in)

Weights

Dry Weight:

Approx. 183 kg (403 lbs)

Wet Weight:

Approx. 204 kg (450 lbs) (FZ6 FAZER)

Fuel Tank Capacity:

19.4 Liters (5.1 US gal)

🛡️ Safety Features

Ratings

Safety Features Overview:

ABS (Anti-lock Braking System) was an optional feature on some models (FZ6SSC denotes ABS version)

Active Features

Braking System Type:

Hydraulic dual disc front, hydraulic single disc rear

Brake Disc Diameter Front:

298 mm

Brake Disc Diameter Rear:

245 mm

Passive Features

Lighting:

Halogen headlights, LED taillight

💡 Technology Features

Infotainment

Instrumentation:

Digital speedometer, analog tachometer, fuel gauge, clock, trip meters, warning lights

Driver Assistance

ABS System:

Available as an option (FZ6SSC), enhances braking safety

Connectivity

Diagnostic Ports:

OBD-II compliant diagnostic connector for engine diagnostics (specific connector location detailed in manual)

🔧 Maintenance

Service Intervals

Initial Service:

1,000 km (600 miles) or 6 months

Subsequent Service:

Every 6,000 km (3,700 miles) or 12 months

Valve Clearance Check:

Every 24,000 km (15,000 miles)

Fluid Specifications

Coolant Type:

Yamalube Coolant (Blue) or equivalent ethylene glycol-based antifreeze, 50/50 mix with distilled water

Brake Fluid Type:

DOT 4

Fork Oil Type:

Yamaha Fork Oil G-10 or equivalent SAE 10W (refer to manual for precise fill level)

Known Issues

Common Wear Items:

Clutch plates, chain and sprockets, rear shock absorber seals, steering head bearings

Potential Electrical Faults:

Rectifier/regulator failure, stator winding issues (less common but noted)

Engine Performance Tips:

Regular air filter cleaning/replacement, spark plug condition checks, and proper ECU servicing are crucial for optimal performance

📚 Vehicle History

Brand Heritage

Manufacturer Origin:

Japan

Model Evolution

Predecessor:

FZ6 Fazer (based on the R6 engine platform)

Engine Basis:

Derived from the 1999-2002 YZF-R6 engine, detuned for broader torque and street usability

Production

Production Years:

2004-2010

🏆 Awards & Recognition

Recognitions

Magazine Reviews:

Widely praised for its accessible power delivery, handling, and value for money upon release.

Ratings

Reliability Index:

Generally considered reliable with proper maintenance, sharing components with the R6 platform.