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Yamaha FZ6SS FZ6SSC FAZER Service Repair Manual 2004-2005

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Basic Information Identification Make: Yamaha Model: FZ6 Fazer Model Variant: FZ6SS, FZ6SSC Year: 2004-2005 Generation Model Generation: First Generation (RJ14/RJ15) Codes Internal Model Code: RJ14 (FZ6), RJ15 (FZ6 Fazer) Introduction...

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Sku: 135424

Tags: 2004 2005 Fazer FZ6SS FZ6SSC FAZER Motorcycle Motorcycles Yamaha

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Description

Basic Information
Identification
Make:	Yamaha
Model:	FZ6 Fazer
Model Variant:	FZ6SS, FZ6SSC
Year:	2004-2005
Generation
Model Generation:	First Generation (RJ14/RJ15)
Codes
Internal Model Code:	RJ14 (FZ6), RJ15 (FZ6 Fazer)

Introduction
Market Position
Segment:	Mid-weight naked sportbike / sport-tourer.
Target Audience:	Riders seeking a versatile, sporty, and comfortable motorcycle for commuting, touring, and spirited riding.
Competitive Analysis
Competitors:	Kawasaki Z750, Suzuki Bandit 650, Honda CBF600, Triumph Street Triple 675 (later models).
Key Features
Engine Platform:	Derived from the R6 supersport model, offering a strong performance base.
Versatility:	Capable as a commuter, sport-tourer (with Fazer variant's fairings), and engaging naked bike.
Handling:	Praised for its balanced chassis and agile handling characteristics.
Braking:	Equipped with capable braking systems, often featuring dual front discs.

Manual Details
Coverage Areas
Manual Type:	Service Repair Workshop Manual
Language:	English
Format:	PDF
Page Count
Estimated Page Count:	High (typically 300+ pages for this caliber of manual)

Manual Coverage
Systems Covered
Engine Mechanical:	Full engine teardown, rebuild, valve clearance, compression testing, torque specifications, internal component replacement.
Fuel System:	Fuel injection system diagnostics, injector servicing, fuel pump, fuel pressure testing, throttle body synchronization.
Ignition System:	Ignition coil testing, spark plug specifications, ignition timing.
Cooling System:	Radiator, fan, coolant type and capacity, thermostat replacement, troubleshooting leaks.
Exhaust System:	Catalytic converter inspection, muffler replacement, exhaust leak diagnosis.
Transmission Drivetrain:	Clutch inspection and replacement, gearbox disassembly and reassembly, shift linkage adjustment, final drive lubrication.
Suspension Front:	Fork disassembly, seal replacement, oil levels and type, spring rates, steering head bearing adjustment.
Suspension Rear:	Monoshock unit inspection, linkage system maintenance, swingarm bearing service, shock absorber replacement.
Brakes Front:	Brake caliper servicing, pad replacement, disc inspection, master cylinder overhaul, brake fluid specifications and bleeding procedures.
Brakes Rear:	Rear brake caliper servicing, pad replacement, disc inspection, master cylinder overhaul, brake fluid specifications and bleeding procedures.
Wheels Tires:	Wheel bearing inspection and replacement, tire pressure recommendations, wheel balancing.
Electrical System:	Wiring diagrams, battery maintenance, starter motor, alternator, lighting system, horn, fuses, relays.
Instrumentation Controls:	Dashboard component testing, switchgear diagnostics, throttle and clutch cable adjustment.
Frame Bodywork:	Chassis inspection, fairing removal and installation, seat replacement, body panel alignment.
Troubleshooting:	Diagnostic flowcharts for common starting, running, and electrical issues.
Procedures Included
Preventive Maintenance:	Detailed schedules for oil changes, filter replacements, chain adjustment, lubrication points.
Routine Maintenance:	Spark plug replacement, air filter servicing, brake pad checks, coolant level checks.
Major Repairs:	Engine overhaul, transmission rebuild, suspension fork servicing, electrical system diagnostics and repair.
Component Replacement:	Step-by-step guides for replacing key components like clutch, brake calipers, starter motor, fuel pump.
Troubleshooting Guides:	Systematic approaches to identifying and resolving performance issues, starting problems, and electrical faults.
Technical Depth
Depth Level:	Comprehensive Workshop Level - Suitable for professional mechanics and experienced DIY enthusiasts.
Detail Level:	Factory-level detail, including torque values, measurements, and specific tool requirements.

Manual Specifications
File Format
File Type:	PDF
Searchability:	Likely searchable text-based PDF for easy navigation.
Print Quality:	High-resolution scans suitable for printing essential sections or the entire manual.
Binding Type
Binding:	N/A (Digital PDF format)
Paper Type
Paper:	N/A (Digital PDF format)

Engine Specifications
Primary Engine
Engine Type:	Liquid-cooled, four-stroke, DOHC, inline-four cylinder.
Displacement:	599cc (599 cm³).
Bore X Stroke:	65.5 mm x 44.5 mm.
Compression Ratio:	12.2:1.
Valve Train:	DOHC, 4 valves per cylinder.
Fuel Delivery:	Electronic Fuel Injection (Mikuni).
Ignition System:	Digital TCI (Transistor Controlled Ignition).
Performance
Horsepower Peak:	Approximately 96.5 HP (72 kW) @ 12,000 rpm.
Torque Peak:	Approximately 64.1 Nm (47.3 lb-ft) @ 9,500 rpm.
Fuel System
Fuel Type:	Unleaded gasoline, minimum 91 octane (RON).
Fuel Tank Capacity:	19.2 Liters (5.07 US gal).

Transmission
Standard
Transmission Type:	6-speed constant mesh.
Clutch Type:	Wet, multiple-disc.
Final Drive:	O-ring sealed chain.
Features
Gear Ratios:	Specific ratios detailed in manual, typically optimized for sporty performance.

Dimensions
Exterior
Length:	FZ6: 2095 mm (82.5 in) / FZ6 Fazer: 2120 mm (83.5 in)
Width:	FZ6: 755 mm (29.7 in) / FZ6 Fazer: 760 mm (30.0 in)
Height:	FZ6: 1065 mm (42.0 in) / FZ6 Fazer: 1210 mm (47.6 in)
Wheelbase:	1440 mm (56.7 in).
Ground Clearance:	155 mm (6.1 in).
Seat Height:	805 mm (31.7 in).
Weights
Dry Weight:	Approximately 163 kg (359 lbs) for FZ6 / 166 kg (366 lbs) for FZ6 Fazer.
Wet Weight:	Approximately 185 kg (408 lbs) for FZ6 / 188 kg (414 lbs) for FZ6 Fazer (estimated with fluids).

Safety Features
Ratings
Safety Certification:	Compliant with relevant national and international motorcycle safety standards for its production era.
Active Features
Braking System:	Dual hydraulic disc front brakes with dual-piston calipers; Single hydraulic disc rear brake with dual-piston caliper.
Optional ABS:	ABS (Anti-lock Braking System) was an optional feature on some models, particularly the Fazer variants.
Passive Features
Lighting:	Halogen headlight, LED taillight.
Chassis Design:	Rigid diamond-type frame contributing to stable handling.

Technology Features
Infotainment
Instrument Cluster:	Digital speedometer, analog tachometer, fuel gauge, clock, odometer, trip meters, engine warning light.
Driver Assistance
ABS:	Optional ABS system for enhanced braking safety.
Connectivity
ECU:	Engine Control Unit (ECU) manages fuel injection and ignition timing for optimal performance and emissions.

Maintenance
Service Intervals
Oil Change Interval:	Every 6,000 km (3,700 miles) or 6 months, whichever comes first.
Oil Filter Change Interval:	At every oil change (6,000 km / 3,700 miles).
Air Filter Cleaning:	Every 6,000 km (3,700 miles).
Spark Plug Replacement:	Every 18,000 km (11,200 miles).
Valve Clearance Check:	Every 24,000 km (15,000 miles).
Chain Lubrication:	Every 1,000 km (600 miles) or after riding in wet conditions.
Chain Adjustment:	As needed, check slack regularly.
Fluid Specifications
Engine Oil Type:	Yamalube 4 (or equivalent) SAE 10W-40 API SG or higher, JASO MA certified.
Engine Oil Capacity:	3.4 Liters (3.6 US qt) without filter change / 3.5 Liters (3.7 US qt) with filter change.
Coolant Type:	Permanent type antifreeze (ethylene glycol based), 50% solution in distilled water.
Brake Fluid Type:	DOT 4.
Fork Oil Type:	Yamaha Suspension Oil No. 10 or equivalent SAE 5W.
Fork Oil Quantity:	398 cc (13.5 US oz) per fork leg.
Known Issues
Fuel Pump Reliability:	Some early models experienced fuel pump issues, though often addressed under warranty or later revisions.
Stalling At Low Rpm:	Can sometimes occur if the engine is not properly tuned or if there are air leaks in the intake system.
Cam Chain Tensioner:	A known weak point on some Yamaha models of this era, potentially leading to noise if not maintained.
Wiring Harness Corrosion:	In humid or coastal environments, inspect wiring connectors for corrosion.

Vehicle History
Brand Heritage
Yamaha Motorcycles:	Yamaha Motor Company has a long history of producing high-performance and innovative motorcycles across various categories.
Model Evolution
Fz6 Lineage:	The FZ6 series evolved from the successful FZS600 Fazer, utilizing a detuned R1 engine initially, then transitioning to a detuned R6 engine for the 2004+ models, focusing on broader power delivery and refinement.
Design Philosophy:	Designed to offer a blend of R6 performance with increased everyday usability and comfort, especially in the faired Fazer variant.
Production
Manufacturing Location:	Primarily manufactured in Japan by Yamaha Motor Corporation.
Production Period:	2004-2007 for the 599cc R6-derived engine model.

Awards & Recognition
Recognitions
Bike Magazine Reviews:	Consistently received positive reviews from motorcycle publications for its performance, handling, and value proposition.
Ratings
User Satisfaction:	Generally high user satisfaction reported for its reliability and enjoyable riding experience, with common praise for its engine character.