🏷️ Basic Information

Make:

Yamaha

Model:

FZ6 Fazer

Model Variant:

FZ6SS FZ6SSC

Year:

2004-2005

Engine Code Designation:

5VX

Chassis Code Designation:

FZ6SS/FZ6SSC

👋 Introduction

Segment:

Mid-weight naked sportbike / sport-tourer.

Target Audience:

Riders seeking a versatile, sporty motorcycle with a focus on performance and everyday usability.

Competitors:

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

Engine Basis:

Derived from the Yamaha R6 supersport model, offering a potent inline-four engine.

Versatility:

Combines sporty handling with a comfortable riding position, making it suitable for commuting, touring, and spirited riding.

Fueling:

Features Yamaha's Electronic Fuel Injection (FI) system for precise throttle response and emissions control.

📋 Manual Details

Coverage:

All repairs, servicing, maintenance, troubleshooting, diagnostics, and technical specifications.

Page Count:

Not Specified (Implied Comprehensive)

Type:

Factory Service Repair Workshop Manual

Language:

English (Assumed for primary market, typical for factory manuals)

Format:

Digital Download (PDF, compatible with Computer, Tablet, Smartphone)

📖 Manual Coverage

Engine Systems:

Fuel injection system (FI), ignition system, cooling system, lubrication system, engine mechanicals (cylinder head, cylinder block, crankshaft, pistons, valves), timing system, exhaust system.

Drivetrain Systems:

Clutch system (hydraulic), transmission (gearbox), final drive (chain and sprockets), shift mechanism.

Chassis Systems:

Frame and body components, front suspension (telescopic forks, steering system), rear suspension (monoshock absorber, swingarm), front brakes (dual disc, hydraulic calipers), rear brakes (single disc, hydraulic caliper), wheels and tires, braking system diagnostics.

Electrical Systems:

Battery, charging system (stator, regulator/rectifier), starting system (starter motor, starter clutch), lighting system (headlight, taillight, turn signals), instrumentation, wiring harnesses, ECU (Engine Control Unit), sensors (throttle position, crank position, lambda, water temperature, etc.), electrical component testing.

Maintenance Procedures:

Scheduled maintenance, oil changes, filter replacements (oil, air), chain maintenance, brake fluid service, coolant service, spark plug replacement, valve clearance inspection and adjustment, battery maintenance.

Repair Procedures:

Engine disassembly and reassembly, clutch overhaul, transmission repair, suspension overhaul, brake caliper service, carburetor cleaning and adjustment (if applicable to early models or variants not covered), electrical component replacement, fuel injection system diagnostics and repair.

Troubleshooting Diagnostics:

Systematic troubleshooting guides for common and uncommon issues, diagnostic codes (DTCs) for FI system, electrical fault finding, performance issues analysis.

Depth:

Comprehensive, from basic inspections to complete engine and chassis rebuilds, including detailed torque specifications, tolerances, and procedures.

📊 Manual Specifications

File Format:

PDF (Portable Document Format), Digital Download

Print Quality:

High-resolution scans of original factory documentation, suitable for clear printing.

Binding Type:

N/A (Digital Download)

Paper Type:

N/A (Digital Download)

Search Functionality:

Text-searchable PDF (assumed, standard for professional digital manuals).

⚙️ Engine Specifications

Engine Type:

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

Displacement:

599cc

Bore X Stroke:

65.5 mm x 44.5 mm

Compression Ratio:

12.2:1

Horsepower:

Approx. 98 HP (73 kW) @ 12,000 RPM (Rear Wheel)

Torque:

Approx. 65 Nm (48 lb-ft) @ 10,000 RPM (Rear Wheel)

Fuel Delivery:

Electronic Fuel Injection (FI) with Mikuni or Keihin throttle bodies

Fuel Type:

Unleaded gasoline, 95 RON (Octane Rating)

Fuel Tank Capacity:

19.4 Liters (5.1 US gal)

Oil Type:

Yamaha Yamalube or equivalent API SG, JASF G M01 or higher, SAE 10W-40 semi-synthetic or fully synthetic motorcycle oil.

Oil Capacity W Filter:

3.4 Liters (3.6 US qt)

Coolant Type:

Permanent type antifreeze coolant (ethylene glycol based), 50% mixture with distilled water.

Ignition System:

TCI (Transistor Controlled Ignition) with digital ignition control.

Spark Plugs:

NGK CR9E or Denso U27ESR-N (Check manual for exact specifications and gap)

🔧 Transmission

Type:

Constant mesh, 6-speed

Gear Ratios:

1st: 2.750 (33/12), 2nd: 2.000 (32/16), 3rd: 1.571 (33/21), 4th: 1.333 (32/24), 5th: 1.150 (23/20), 6th: 1.043 (24/23)

Final Drive:

Chain drive (525 O-ring type), Gear ratio 17/45 (2.647)

Clutch Type:

Wet, multiple-disc, hydraulically operated

Transmission Oil Type:

Yamaha Yamalube Gear Oil or equivalent API GL-4, SAE 80W-90

Transmission Oil Capacity:

0.80 Liters (0.85 US qt)

📐 Dimensions

Length:

2095 mm (82.5 in)

Width:

750 mm (29.5 in)

Height:

1240 mm (48.8 in)

Wheelbase:

1445 mm (56.9 in)

Ground Clearance:

150 mm (5.9 in)

Seat Height:

805 mm (31.7 in)

Dry Weight:

178 kg (392.4 lbs)

Wet Weight:

201 kg (443 lbs) (Approximate, with fluids)

Front Tire:

120/70ZR17M/C (58W) Tubeless

Rear Tire:

180/55ZR17M/C (73W) Tubeless

Front Wheel:

MT3.50 x 17

Rear Wheel:

MT5.50 x 17

Wheelbase Type:

Aluminum alloy

🛡️ Safety Features

Crash Test Ratings:

N/A (Motorcycle, typically not subject to automotive crash test ratings)

Braking System:

Hydraulic dual disc front brakes (298mm discs), Hydraulic single disc rear brake (245mm disc). Optional ABS available on some variants (FZ6SS ABS / FZ6SSC ABS).

Lighting:

Halogen headlight, LED taillight, front and rear turn signals.

Frame Construction:

Aluminum die-cast diamond frame for rigidity and light weight.

Ergonomics:

Designed for a balance of rider control and comfort, reducing fatigue.

💡 Technology Features

Instrument Cluster:

Digital speedometer, analog tachometer, fuel gauge, odometer, trip meters, clock, engine temperature warning light, FI warning light, neutral indicator.

ABS:

Optional Anti-lock Braking System (ABS) available on specific 'S' models, denoted by 'ABS' in the model name.

ECU Diagnostics:

On-board diagnostics system with fault code retrieval via the FI warning light and diagnostic connector, detailed in the manual.

🔧 Maintenance

Oil Change Interval:

Every 5,000 km (3,000 miles) or 6 months, whichever comes first.

Oil Filter Change Interval:

Every 10,000 km (6,000 miles) or 12 months, often recommended with oil change.

Air Filter Cleaning:

Every 10,000 km (6,000 miles), replacement as needed.

Spark Plug Inspection:

Every 10,000 km (6,000 miles).

Valve Clearance Check:

Every 20,000 km (12,000 miles).

Brake Fluid Replacement:

Every 24 months or as needed.

Coolant Replacement:

Every 24 months or as needed.

Brake Fluid Type:

DOT 4

Fork Oil Type:

SAE 10W (Refer to manual for specific viscosity grade and quantity)

Fuel Injection:

Occasional throttle body synchronization issues or sensor failures, which this manual will address.

Electrical:

Corrosion on connectors or stator issues can occur with age and environmental exposure; comprehensive electrical troubleshooting covered.

Suspension:

Fork seals can wear over time, and rear shock absorbers may lose damping. Manual provides procedures for fork oil changes and shock absorber inspection/replacement.

📚 Vehicle History

Manufacturer:

Yamaha Motor Company

Origins:

Yamaha has a long and successful history in motorcycle manufacturing, known for innovation and performance, particularly with its inline-four engines.

Predecessor:

The FZ6 series evolved from the FZR600 and FZX750, incorporating the more potent 5 valve per cylinder Genesis engine technology.

2004-2005 Generation:

This generation marked a significant redesign with a new chassis and the adoption of fuel injection, moving away from carburetors for improved performance and emissions.

Facelift Post 2005:

Subsequent models (e.g., 2006 onwards) featured updated styling, revised suspension, and potentially higher output engines, but this manual specifically covers the earlier, popular 2004-2005 iteration.

Manufacturing Location:

Japan (Primary)

🏆 Awards & Recognition

Industry Acclaim:

The FZ6 series was generally well-received for its performance, handling, and value proposition in the sport-standard motorcycle market during its production run.