🏷️ Basic Information

Make:

Yamaha

Model:

FZ6 Fazer

Model Codes:

FZ6SS, FZ6SSC

Model Years Covered:

2004, 2005

👋 Introduction

Segment:

Middleweight Naked/Sportbike

Target Audience:

Enthusiast owners, independent repair shops, Yamaha dealerships

Competitors:

Suzuki SV650, Kawasaki ER-6f, Honda CBF600

Key Selling Points:

Versatile performance, comfortable ergonomics for a sportbike, reliable Yamaha engineering.

Manual Value Proposition:

Empowers owners and technicians with the knowledge to perform all necessary maintenance, diagnostics, and repairs, ensuring longevity and optimal performance of the FZ6 Fazer.

Vehicle Strengths:

Punchy parallel-twin engine, balanced chassis, comfortable riding position for its class.

📋 Manual Details

Primary Focus:

Workshop Repair and Maintenance

Diagnostic Coverage:

Comprehensive diagnostic procedures

Repair Coverage:

All repair and rebuild procedures

Maintenance Coverage:

Detailed maintenance schedules and procedures

Restoration Coverage:

Procedures for refurbishment and restoration

Estimated Pages:

Likely 300-500+ pages (typical for comprehensive workshop manuals)

Type:

Digital Workshop Repair Manual

Language:

English

Format:

Digital (PDF assumed)

📖 Manual Coverage

Engine:

Complete engine overhaul, tuning, component testing, lubrication system, cooling system, fuel system, ignition system, emissions control

Transmission:

Clutch system, gearbox operation, internal components, lubrication, servicing

Chassis:

Frame, suspension (front and rear), steering system, wheel bearings, swingarm

Brakes:

Front and rear brake systems, hydraulic components, ABS (if applicable), brake pad and disc replacement, bleeding procedures

Electrical System:

Wiring diagrams, charging system (alternator, rectifier/regulator, battery), starting system (starter motor, solenoid), lighting system, instrument cluster, ECU (Engine Control Unit) diagnostics and repair, sensors, relays, fuses

Fuel System:

Fuel injection system (throttle bodies, injectors, fuel pump, fuel pressure regulator), fuel tank, lines

Exhaust System:

Exhaust manifold, catalytic converter (if applicable), muffler, lambda sensors

Bodywork And Trim:

Fairings, seat removal, tank cover, fenders, mirrors, lights removal and installation

Maintenance Procedures:

Oil and filter changes, air filter replacement, spark plug replacement, coolant flush and replacement, chain adjustment and lubrication, brake fluid replacement, general inspection points

Diagnostic Procedures:

Troubleshooting guides based on symptoms, fault code interpretation (if OBD-II compliant or similar), component testing methods

Repair Procedures:

Step-by-step instructions for component removal, disassembly, inspection, repair, and reassembly for all major systems

Rebuild Procedures:

Detailed instructions for engine and gearbox rebuilds, including torque specifications and clearances

Calibration Procedures:

Throttle body synchronization, idle speed adjustment, ignition timing checks (if applicable)

Depth:

Comprehensive: Covers basic maintenance to complete engine and transmission rebuilds, including in-depth electrical diagnostics.

Diagnostic Focus:

Advanced diagnostic strategies and fault finding

Repair Scope:

Full repair manual, not a condensed guide

📊 Manual Specifications

Format:

Digital (PDF recommended for searchability and portability)

Searchability:

High (if properly OCR'd PDF)

Printability:

Likely printable page by page

Image Resolution:

High resolution, clear diagrams and illustrations

Type:

N/A (Digital Format)

Type:

N/A (Digital Format)

⚙️ Engine Specifications

Engine Type:

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

Displacement:

600cc (approx.)

Bore X Stroke:

65.5 mm x 44.5 mm (typical for this generation)

Compression Ratio:

12.2:1 (typical)

Ignition System:

TCBI (Transistor Controlled Ignition) with electronic advance

Horsepower:

Approx. 95-98 hp at 12,000 rpm

Torque:

Approx. 61-63 Nm (45-47 lb-ft) at 10,000 rpm

Fuel Delivery:

Fuel Injection (FI), typically with 4-hole injectors and Mikuni throttle bodies

Fuel Type:

Unleaded gasoline, 95-98 RON

Fuel Tank Capacity:

19.4 Liters (5.1 US gal)

Type:

Wet sump

Oil Type And Capacity:

Yamalube 4 (or equivalent) 10W-40, approx. 3.4 Liters (3.6 US qt) with filter change. Manual will specify exact capacity and grade.

Type:

Liquid-cooled

Coolant Capacity:

Approx. 2.1 Liters (2.2 US qt). Manual will specify exact type (e.g., Yamaha Blue)

🔧 Transmission

Type:

6-speed, constant mesh

Clutch Type:

Wet, multiple disc

Final Drive:

O-ring sealed chain

Gear Ratios:

Manual will detail specific gear ratios for each speed.

Transmission Oil Type:

Manual will specify gear oil grade and quantity (typically SAE 80W-90 GL-4)

📐 Dimensions

Length:

Approx. 2,105 mm (82.9 in)

Width:

Approx. 750 mm (29.5 in)

Height:

Approx. 1,250 mm (49.2 in)

Wheelbase:

Approx. 1,445 mm (56.9 in)

Dry Weight:

Approx. 195 kg (430 lbs)

Wet Weight:

Approx. 222 kg (489 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 bolted hubs)

Front Brake Type:

Dual hydraulic disc, 298 mm diameter

Rear Brake Type:

Hydraulic disc, 245 mm diameter

🛡️ Safety Features

Crash Test Data:

Motorcycles are not typically subjected to standardized crash testing like automobiles. Safety data would be limited to manufacturer-provided information on safety features and handling characteristics.

Braking System:

Dual front discs and single rear disc provide significant stopping power. Optional ABS may have been available and would be detailed in the manual.

Suspension:

Well-tuned suspension contributes to stability and rider control.

Lighting:

Adequate headlight, taillight, and turn signals for visibility.

Ergonomics:

Designed for a balance of sporty feel and rider comfort, aiding in fatigue reduction.

💡 Technology Features

Features:

Basic analogue tachometer with digital speedometer and multi-function display. No advanced infotainment systems.

ABS:

Optional Anti-lock Braking System (ABS) was available on some models (FZ6SSC designation often indicates ABS). The manual will cover its function and diagnostics.

Features:

No modern connectivity features like Bluetooth or smartphone integration.

ECU:

Engine Control Unit (ECU) manages fuel injection, ignition timing, and other engine parameters. The manual provides diagnostic procedures for ECU faults and sensor readings.

🔧 Maintenance

Oil Filter Change:

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

Air Filter Cleaning Replacement:

Inspection every 6,000 km (3,700 miles), cleaning/replacement as needed, typically at 12,000-18,000 km (7,500-11,200 miles).

Spark Plug Replacement:

Typically at 20,000-30,000 km (12,500-18,700 miles) or as per manual recommendation. Manual will specify plug type (e.g., NGK CR9E).

Chain Lubrication Adjustment:

Lubricate every 1,000 km (600 miles) or after riding in rain/wet conditions. Adjust slack every 6,000 km (3,700 miles) or as needed.

Valve Clearance Check:

Initial check typically at 20,000 km (12,500 miles), then every 40,000 km (25,000 miles). Manual will provide exact intervals and specifications.

Engine Oil:

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

Coolant:

Permanent type antifreeze, 50% mixture with distilled water. Yamaha Blue coolant is recommended.

Brake Fluid:

DOT 4 SAE J1703 or FMVSS No. 116 DOT 4.

Fork Oil:

SAE 10W (Manual will specify exact type and quantity per fork leg).

Common Wear Items:

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

Potential Electrical Issues:

Rectifier/regulator failures, stator coil issues can occur with age and heat cycling.

Fuel System Concerns:

Throttle body synchronization may drift over time, requiring adjustment for smooth running.

Suspension Notes:

While generally well-regarded, riders may opt for aftermarket upgrades for enhanced performance.

📚 Vehicle History

Heritage:

Yamaha Motor Company has a long and successful history in motorsports and motorcycle manufacturing, known for innovation and performance.

Predecessors:

The FZ6 Fazer is a successor to the FZR600 and FZX750, evolving into a more modern and user-friendly sport-touring/naked bike.

Engine Origin:

The engine is derived from the R6 supersport, but de-tuned and re-geared for broader usability and torque.

Production Period:

The FZ6 Fazer model line was produced from 2004 through 2010, with various updates. This manual specifically covers the initial 2004-2005 models.

Manufacturing Location:

Typically manufactured in Japan by Yamaha.

🏆 Awards & Recognition

Awards:

Specific awards for the 2004-2005 FZ6 Fazer are not widely documented as major accolades, but the model was generally well-received by motorcycle publications for its performance and value proposition.

Publication Reviews:

Motorcycle reviews of the period often praised its balanced handling, tractable engine performance, and versatility for commuting and light touring.