🏷️ Basic Information

Make:

Yamaha

Model:

FZ6 Fazer

Model Code:

FZ6-S (Fazer) / FZ6-N (Naked)

Production Years Covered:

2004, 2005

Vin Code Prefix:

5VX

👋 Introduction

Category:

Sport Touring / Naked Sportbike

Target Audience:

Owners seeking to perform routine maintenance, diagnostics, and repairs on their Yamaha FZ6 Fazer.

Competitors 2004 2005:

Honda CBF600, Suzuki Bandit 600/1200, Kawasaki Z750, Triumph Speed Four/Sprint ST.

Engine Type:

In-line four-cylinder, DOHC, 4 valves per cylinder

Frame Type:

Diamond-type, die-cast aluminum

Advantage Over Paper:

Instant access, searchability, no physical wear and tear, easily accessible on multiple devices.

📋 Manual Details

Major Systems:

Engine, Fuel System, Ignition System, Cooling System, Lubrication System, Exhaust System, Transmission, Clutch, Drivetrain, Frame, Suspension (Front and Rear), Braking System (Front and Rear), Electrical System, Lighting, Instrumentation, Fuel Tank, Bodywork, Wheels and Tires, Troubleshooting, Maintenance

Specific Procedures:

Engine removal/installation, Cylinder head inspection/overhaul, Piston and connecting rod service, Crankshaft inspection, Carburetor overhaul and synchronization, Fuel injection system diagnosis (if applicable to specific models covered), Spark plug replacement, Oil filter and oil change, Coolant flush and replacement, Valve clearance adjustment, Chain adjustment and lubrication, Clutch adjustment and inspection, Brake pad replacement, Brake fluid flush and replacement, Suspension fork oil change and seal replacement, Wheel bearing replacement, Electrical component testing and replacement, Lighting system diagnostics, Instrument cluster troubleshooting

Estimated Pages:

Estimated 400-600 pages (typical for comprehensive service manuals)

Type:

Service Repair Manual

Language:

English

Format:

PDF

📖 Manual Coverage

Engine Mechanical:

Detailed disassembly, inspection, repair, and reassembly procedures for all internal engine components. Includes torque specifications for critical fasteners.

Fuel System:

Carburetor system diagnosis, cleaning, rebuilding, and synchronization. Fuel pump testing (if applicable), fuel filter replacement, and fuel line routing.

Ignition System:

Ignition coil testing, spark plug specification and replacement, CDI unit troubleshooting, and ignition timing procedures.

Cooling System:

Radiator service, coolant type and capacity, thermostat testing and replacement, water pump inspection, and fan operation.

Lubrication System:

Oil type and viscosity, oil filter part numbers, oil change intervals, oil pump inspection, and oil pressure testing.

Transmission Drivetrain:

Gearbox disassembly and assembly, clutch operation and adjustment, chain and sprocket wear inspection and replacement, and final drive oil specifications.

Suspension Steering:

Front fork overhaul (oil level, seal replacement), rear shock absorber inspection, steering head bearing adjustment, and wheel bearing maintenance.

Braking System:

Brake caliper service, brake pad replacement, brake disc inspection, brake fluid type and bleeding procedures, and master cylinder inspection.

Electrical Lighting:

Wiring diagrams, battery specifications, starter motor and charging system testing, fuse identification and replacement, headlight, taillight, and turn signal bulb types and replacement.

Chassis Bodywork:

Frame inspection, fairing removal and installation, seat removal, fuel tank mounting, and general body panel maintenance.

Routine Maintenance:

Oil changes, filter replacements, chain maintenance, tire pressure checks, brake fluid checks, coolant level checks, spark plug checks, air filter cleaning/replacement.

Troubleshooting Guides:

Systematic diagnostic flowcharts for common issues like starting problems, poor performance, electrical faults, and braking system anomalies.

Component Overhaul:

Detailed step-by-step instructions for rebuilding carburetors, brake calipers, suspension forks, and other wear-prone components.

Electrical Diagnostics:

Testing of charging system, ignition system components, lighting circuits, and instrument panel functions using appropriate diagnostic tools.

Specifications Data:

Torque values, clearances, fluid capacities, resistance readings, and other critical technical data for proper assembly and adjustment.

Depth:

Comprehensive from basic maintenance to complete engine and chassis rebuilds. Suitable for both home mechanics and professional technicians.

Diagnostic Level:

Advanced diagnostic procedures for identifying and rectifying complex mechanical and electrical issues.

Rebuild Procedures:

Full rebuild instructions for major components like the engine, gearbox, and suspension.

📊 Manual Specifications

File Type:

PDF (Portable Document Format)

Searchability:

Searchable text content allowing quick access to specific information.

Printability:

Printable pages for offline use and hands-on work.

Image Resolution:

High-resolution images and diagrams for clarity.

Binding:

N/A (Digital PDF format)

Paper Quality:

N/A (Digital PDF format)

⚙️ Engine Specifications

Engine Code:

5VX

Displacement:

600 cc (599.4 cc)

Bore X Stroke:

65.5 mm x 44.5 mm

Compression Ratio:

12.2:1

Valve Mechanism:

DOHC, 4 valves per cylinder, shim-under-bucket adjustment

Horsepower Peak:

Approx. 96.5 hp (71.9 kW) @ 12,000 rpm

Torque Peak:

Approx. 61.1 Nm (45.0 lb-ft) @ 10,000 rpm

Fuel Delivery:

Carbureted (Mikuni BSR37 semi-down draft carburetors, 4x)

Fuel Type:

Unleaded gasoline, minimum 91 octane (RON+MON)/2

Fuel Tank Capacity:

19.7 L (5.2 US gal)

Oil Capacity With Filter:

3.4 L (3.6 US qt)

Oil Type Recommended:

Yamalube 4 (or equivalent) SAE 10W-40 API SG or higher

Coolant Type:

Ethylene glycol-based coolant, 50% mixture with distilled water

Coolant Capacity:

1.8 L (1.9 US qt)

🔧 Transmission

Transmission Type:

Constant mesh 6-speed sequential

Clutch Type:

Wet, multiple disc

Final Drive:

Chain drive

Gear Ratios:

1st: 2.750, 2nd: 2.056, 3rd: 1.625, 4th: 1.333, 5th: 1.136, 6th: 1.000

Transmission Oil Type:

Yamalube Gear Oil (or equivalent) SAE 80 API GL-4

Transmission Oil Capacity:

0.7 L (0.74 US qt)

📐 Dimensions

Length:

2,095 mm (82.5 in)

Width:

765 mm (30.1 in)

Height:

1,220 mm (48.0 in)

Wheelbase:

1,445 mm (56.9 in)

Ground Clearance:

150 mm (5.9 in)

Dry Weight:

182 kg (401 lbs)

Wet Weight:

Approx. 202 kg (445 lbs)

Load Capacity:

Typically 180-200 kg (rider + luggage)

🛡️ Safety Features

Crash Test Ratings:

Motorcycles are not subjected to standardized crash testing like automobiles.

Brakes:

Front: Dual 298mm discs with 4-piston calipers. Rear: Single 245mm disc with 2-piston caliper. ABS was optional on some models.

Tires Front:

120/70 ZR17

Tires Rear:

180/55 ZR17

Lighting:

Halogen headlight, LED taillight

💡 Technology Features

Instrument Cluster:

Analog tachometer, digital speedometer, fuel gauge, clock, trip meters, and indicator lights.

ABS Availability:

Optional on some markets/trims.

Connectivity Features:

N/A (standard for the era - no Bluetooth or integrated navigation)

🔧 Maintenance

Oil Change Interval:

Every 6,000 km (3,700 mi) or 6 months, whichever comes first.

Chain Lubrication Interval:

Every 1,000 km (600 mi) or after riding in rain.

Valve Clearance Check:

Every 24,000 km (15,000 mi)

Coolant Replacement Interval:

Every 2 years or 24,000 km (15,000 mi)

Brake Fluid Type:

DOT 4

Fork Oil Viscosity:

SAE 10W

Fork Oil Level:

151 mm (5.94 in)

Common Wear Items:

Clutch plates, brake pads, chain and sprockets, fork seals.

Potential Faults:

Carburetor synchronization can drift over time, leading to rough idling or uneven power delivery. Regulator/rectifier failures are not uncommon on Yamaha models of this era.

📚 Vehicle History

Yamaha Legacy:

Yamaha Motor Company, established in 1955, is a global leader in motorcycles, marine products, and musical instruments. Known for performance, innovation, and reliability.

Fz6 Lineage:

The FZ6 Fazer was introduced as a more touring-oriented version of the FZ6-N (naked) model. Both shared a detuned R6 engine, offering a blend of sporty performance and everyday usability.

Manufacturing Location:

Japan (primarily)

Generation Details:

This generation (2004-2006) featured the 600cc inline-four derived from the R6, replacing the older FZS600 Fazer.

🏆 Awards & Recognition

Performance Reviews:

Praised for its accessible performance, comfortable ergonomics for a sportbike, and versatile nature for commuting and touring.

Reliability Reputation:

Generally considered reliable with proper maintenance, benefiting from the robust R6-derived engine.