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Yamaha FZ6-SSC 2004 2005 Workshop Repair Service Manual

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🏷️ Basic Information Identification Make: Yamaha Model: FZ6-SSC Year: 2004, 2005 Codes Chassis Code: FZ600 👋 Introduction Market Position Market Segment: Middleweight Naked Sportbike / Standard Motorcycle Target Audience: Enthusiast...

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标签: 2004 2005 FZ6-SSC Misc Motorcycle Motorcycles Yamaha

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Description

🏷️ Basic Information

Identification

Make:

Yamaha

Model:

FZ6-SSC

Year:

2004, 2005

Codes

Chassis Code:

FZ600

👋 Introduction

Market Position

Market Segment:

Middleweight Naked Sportbike / Standard Motorcycle

Target Audience:

Enthusiast riders, DIY mechanics, and professional service technicians.

Competitive Analysis

Key Competitors:

Honda CBF600, Suzuki Bandit 600/650, Kawasaki Z750, Triumph Street Triple (later models).

Key Features

Engine Basis:

Derived from the R6 supersport engine, offering a good blend of performance and everyday usability.

Handling Characteristics:

Known for its agile handling and comfortable riding position, making it suitable for both commuting and spirited riding.

📋 Manual Details

Coverage Areas

Manual Type:

Workshop Repair Service Manual

Language:

English

Format:

PDF Download

Coverage Scope:

All Models, Engines, Trim, Transmissions

📖 Manual Coverage

Systems Covered

Engine Mechanical:

Full engine disassembly, inspection, repair, and reassembly for the FZ6's inline-four engine.

Fuel System:

Fuel injection system (EFI), throttle bodies, injectors, fuel pump, fuel pressure regulator, and evaporative emission control.

Cooling System:

Radiator, cooling fan, water pump, thermostat, coolant passages, and fluid specifications.

Lubrication System:

Oil pump, oil passages, oil filter replacement, oil type, and capacity.

Ignition System:

Ignition coils, spark plugs, CDI unit, and timing specifications.

Exhaust System:

Exhaust pipes, mufflers, catalytic converter, and emissions controls.

Transmission Drivetrain:

Clutch operation, gearbox internal components, shifting mechanism, final drive (chain and sprockets).

Suspension Front:

Front fork (conventional or upside-down), fork oil type, capacity, seal replacement, spring rates, and adjustments.

Suspension Rear:

Monoshock rear suspension, linkage system, shock absorber adjustment, and bushing maintenance.

Braking System Front:

Dual front disc brakes, calipers, brake pads, rotors, brake fluid type, bleeding procedures, and master cylinder.

Braking System Rear:

Rear disc brake, caliper, brake pads, rotor, brake fluid type, bleeding procedures, and master cylinder.

Wheels Tires:

Wheel bearing inspection and replacement, tire types, recommended pressures, and wheel mounting procedures.

Electrical System Charging:

Stator, rectifier/regulator, battery, and troubleshooting charging system issues.

Electrical System Ignition:

ECU (Engine Control Unit), wiring diagrams, sensors (crankshaft position, throttle position, etc.).

Electrical System Lighting:

Headlight, taillight, turn signals, brake light, and dashboard illumination.

Electrical System Instruments:

Speedometer, tachometer, warning lights, and diagnostic indicators.

Chassis Frame:

Frame inspection, frame integrity checks, and mounting points.

Bodywork:

Fairings, fuel tank, seat, fenders, and associated fasteners.

Troubleshooting Diagnostics:

Systematic troubleshooting guides for common and uncommon problems, fault code interpretation (if applicable).

Procedures Included

Scheduled Maintenance:

Detailed instructions for routine maintenance tasks like oil changes, filter replacements, chain adjustment, brake checks, and valve clearance checks.

Disassembly Reassembly:

Step-by-step instructions for the complete removal and reinstallation of major components and sub-assemblies.

Torque Specifications:

Precise torque values for all critical fasteners and bolts, ensuring proper assembly and preventing damage.

Wiring Diagrams:

Comprehensive electrical system wiring diagrams for easy diagnosis and repair of electrical faults.

Diagnostic Troubleshooting:

Guided procedures for diagnosing and resolving performance issues, starting problems, and unusual noises.

Special Tools:

Identification and usage instructions for specialized tools required for certain repair or maintenance procedures.

Technical Depth

Depth Level:

Comprehensive (from basic maintenance to complete engine rebuilds and electrical system diagnosis).

Diagnostic Capabilities:

Advanced diagnostic procedures, including sensor testing, ECU diagnostics, and fault code interpretation.

Reference Data:

Includes detailed specifications, measurements, and tolerances for all components.

📊 Manual Specifications

File Format

File Format:

PDF

Searchable Text:

Yes

Printable:

Yes

Digital Quality:

High Resolution

Binding Type

Binding Type:

N/A (Digital Download)

Paper Type

Paper Type:

N/A (Digital Download)

⚙️ Engine Specifications

Primary Engine

Engine Type:

Liquid-cooled, 4-stroke, DOHC, 4-valve inline-four cylinder

Displacement:

599 cc

Bore X Stroke:

65.5 mm x 44.5 mm

Compression Ratio:

12.2:1

Performance

Horsepower Max:

Approx. 85.8 hp (63.1 kW) @ 11,000 rpm (manufacturer claimed, may vary slightly by region/testing)

Torque Max:

Approx. 58.5 Nm (43.2 lb-ft) @ 9,500 rpm (manufacturer claimed, may vary slightly by region/testing)

Fuel System

Fuel Induction:

Electronic Fuel Injection (Mikuni 38mm throttle bodies x 4)

Fuel Type:

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

Fuel Tank Capacity:

19.2 L (5.07 US gal)

🔧 Transmission

Standard

Transmission Type:

6-speed constant mesh

Optional

Optional Transmissions:

N/A

Features

Clutch Type:

Wet, multiple disc, cable operated

Final Drive:

O-ring sealed chain

📐 Dimensions

Exterior

Length:

2,095 mm (82.5 in)

Width:

760 mm (29.9 in)

Height:

1,095 mm (43.1 in)

Wheelbase:

1,440 mm (56.7 in)

Ground Clearance:

150 mm (5.9 in)

Weights

Dry Weight:

177 kg (390 lbs)

Wet Weight:

Approx. 196 kg (432 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 bolt-on spokes)

🛡️ Safety Features

Ratings

Safety Ratings:

N/A (Motorcycles are not typically subjected to the same crash testing as cars).

Active Features

Braking System:

Dual disc front, single disc rear with braided steel brake lines for improved feel and performance.

Passive Features

Lighting:

Halogen headlight, LED taillight, and standard signaling systems.

💡 Technology Features

Infotainment

Infotainment System:

N/A (Basic analog tachometer, digital speedometer, fuel gauge, and indicator lights)

Driver Assistance

Rider Aids:

None (No ABS or traction control on this model).

Connectivity

Connectivity Features:

N/A

🔧 Maintenance

Service Intervals

Oil Change Interval:

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

Chain Lubrication Adjustment:

Every 1,000 km (600 miles) or after washing/rain.

Air Filter Inspection:

Every 12,000 km (7,500 miles).

Spark Plug Replacement:

Every 12,000 km (7,500 miles).

Valve Clearance Check:

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

Fluid Specifications

Engine Oil Type:

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

Engine Oil Capacity:

3.40 L (3.59 US qt) without filter change, 3.70 L (3.91 US qt) with filter change

Coolant Type:

Permanent type anti-freeze coolant (ethylene glycol based) with deionized water at a 1:1 ratio

Brake Fluid Type:

DOT 4 (FMVSS No. 116)

Fork Oil Type:

Yamaha Suspension Fluid No. 10 or equivalent SAE 10W fork oil

Known Issues

Common Wear Items:

Chain and sprockets, brake pads, clutch plates (under heavy use), fork seals, wheel bearings.

Electrical Gremlins:

Occasional issues with the side stand switch or regulator/rectifier failures are not uncommon in older bikes, though not specific widespread problems for this model.

Engine Performance Quirks:

Some owners report a slight hesitation or flatness in the powerband between 5,000-7,000 RPM, which can sometimes be mitigated with ECU flashing or minor tuning adjustments.

📚 Vehicle History

Brand Heritage

Yamaha Legacy:

Yamaha Motor Company, a division of Yamaha Corporation, has a long-standing reputation for producing high-quality motorcycles and musical instruments, with a history dating back to the 1950s.

Model Evolution

Fz6 Lineage:

The FZ6 line evolved from the FZS600 Fazer, which itself was derived from the Yamaha YZF-R6 sportbike engine. The FZ6-SSC represents a significant update with fuel injection and revised styling.

Production

Production Years:

2004-2007 (for this generation)

Manufacturing Location:

Japan

🏆 Awards & Recognition

Recognitions

Motorcycle Awards:

While specific awards for the FZ6-SSC model are not widely publicized, the FZ6 platform was generally well-received for its value proposition and performance in its class.