🏷️ Basic Information

Make:

Yamaha

Model:

YZFR6S

Year:

2004

Product Type:

Master Service Repair Manual Supplement

Model Code:

RM02

Engine Code:

5FL1

👋 Introduction

Segment:

Supersport Motorcycle

Target Audience:

Enthusiasts and professional mechanics seeking detailed repair and maintenance information for the 2004 Yamaha YZFR6S.

Competitors:

Honda CBR600RR, Kawasaki ZX-6R, Suzuki GSX-R600

Yzfr6S Distinction:

The YZFR6S, for 2004, represented a slightly more accessible variant or evolution of the YZF-R6 platform, often sharing core components but potentially with minor differences in tuning or features compared to the primary R6 model of the same year. This manual supplement focuses on those specific distinctions.

📋 Manual Details

Primary Focus:

2004 Yamaha YZFR6S (RM02)

Supplementary Nature:

This is a SUPPLEMENTAL manual, intended to be used in conjunction with the main service manual for the YZFR6 series. It details specific updates or differences for the 2004 YZFR6S model.

Estimated Pages:

200-300 (typical for a supplemental manual of this type, exact count not provided but described as 'FULL/COMPLETE VERSION' for the supplement)

Type:

Service Repair Manual Supplement

Language:

English

File Format:

PDF

📖 Manual Coverage

Engine:

Detailed diagnostics, disassembly, assembly, and repair procedures for the 4-cylinder, liquid-cooled, DOHC, 20-valve engine, including timing chain, valve train, lubrication system, cooling system, and fuel injection.

Fuel System:

Yamaha Electronic Fuel Injection (YEC-FI) system: fuel pump, injectors, throttle body assembly, sensors (TPS, MAP, IAT, MAT, etc.), ECU diagnosis, and troubleshooting.

Ignition System:

CDI ignition system, spark plugs, ignition coils, timing, and troubleshooting.

Transmission:

6-speed constant mesh gearbox: clutch operation, gear selection mechanism, internal transmission components, lubrication, and repair.

Chassis:

Frame, subframe, swingarm, suspension (front telescopic forks, rear monoshock), steering system, and wheel bearings.

Suspension Front:

Adjustable telescopic front forks (preload, compression, rebound damping), fork seal replacement, oil level and type specifications.

Suspension Rear:

Monoshock rear suspension system: linkage, shock absorber adjustment, spring preload, and damping settings.

Brakes:

Hydraulic disc brakes: front dual discs, rear single disc, brake caliper maintenance, master cylinders, brake lines, fluid replacement (DOT 4), bleeding procedures, and pad replacement.

Electrical System:

Battery, charging system (stator, rectifier/regulator), starter motor, lighting, instrumentation, wiring diagrams, fuses, relays, and diagnostic connector.

Cooling System:

Radiator, fan, water pump, thermostat, coolant type and capacity, flushing, and bleeding procedures.

Exhaust System:

Exhaust manifold, catalytic converter (if applicable), muffler, and lambda sensor (oxygen sensor) diagnosis.

Body And Trim:

Fairings, seat, fuel tank, handlebars, footpegs, and cosmetic component removal/installation.

Maintenance:

Scheduled maintenance, oil changes, filter replacements, chain adjustment and lubrication, brake fluid changes, coolant flushes, and spark plug replacement intervals.

Troubleshooting:

Comprehensive diagnostic flowcharts and symptom-based troubleshooting for engine performance, electrical issues, starting problems, and braking concerns.

Repair:

Step-by-step disassembly, inspection, repair, and reassembly instructions for all major vehicle components.

Overhaul:

Detailed procedures for complete engine and transmission rebuilds, including torque specifications and clearances.

Wiring Diagrams:

Detailed electrical system wiring schematics for accurate diagnosis and repair.

Depth:

Comprehensive, covering everything from basic fluid changes and adjustments to complete engine and transmission overhauls, including advanced electronic diagnostics.

📊 Manual Specifications

File Type:

PDF

Searchability:

Searchable text within the PDF document for quick information retrieval.

Quality:

High-resolution graphics and text, ensuring clarity for printing and on-screen viewing.

Printability:

Yes, fully printable for creating a physical copy.

Digital Binding:

N/A (Digital PDF)

Digital Paper Type:

N/A (Digital PDF)

⚙️ Engine Specifications

Engine Type:

Inline 4-cylinder, 4-stroke, DOHC, 5 valves per cylinder

Displacement:

599 cc (Cubic Centimeters)

Bore X Stroke:

65.5 mm x 44.5 mm

Compression Ratio:

12.8:1

Horsepower Est:

Approx. 123 hp @ 13000 rpm (at crank, may vary slightly based on specific model tune for YZFR6S)

Torque Est:

Approx. 48.5 lb-ft @ 11500 rpm (at crank)

Fuel Delivery:

Fuel Injection (YEC-FI)

Fuel Type:

Unleaded gasoline, minimum 91 octane (RON+MON)/95 Research Octane

Oil Type:

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

Oil Capacity W Filter:

3.2 Liters (3.4 US qt)

Coolant Type:

High-quality ethylene glycol-based coolant with demineralized water (50:50 mix recommended)

Coolant Capacity:

1.9 Liters (2.0 US qt)

🔧 Transmission

Type:

6-speed constant mesh

Final Drive:

O-ring sealed chain

Clutch Type:

Wet, multiple disc, cable operated

Transmission Oil Type:

Yamalube 4 (or equivalent) SAE 10W-40 API SG or higher, JASO MA certified (shared engine/transmission oil)

📐 Dimensions

Length:

2040 mm (80.3 in)

Width:

720 mm (28.3 in)

Height:

1135 mm (44.7 in)

Wheelbase:

1405 mm (55.3 in)

Ground Clearance:

130 mm (5.1 in)

Seat Height:

820 mm (32.3 in)

Dry Weight:

164 kg (361.5 lbs)

Wet Weight:

183 kg (403.4 lbs) (approx., with all fluids)

Fuel Capacity:

17 Liters (4.5 US gal)

🛡️ Safety Features

Safety Certification:

Meets applicable safety standards for its class; specific crash test ratings not typically applicable to motorcycles in the same way as cars.

Braking System:

Dual front disc brakes, single rear disc brake providing strong stopping power.

Suspension Control:

Adjustable front and rear suspension for optimal handling and stability.

Frame Construction:

Aluminum Deltabox frame designed for rigidity and rider feedback.

Lighting:

Halogen headlights and LED taillight for visibility.

💡 Technology Features

Dashboard:

Digital speedometer, analog tachometer, fuel gauge, clock, trip meters, indicator lights.

ABS:

N/A (ABS was not a standard or common option for this model year YZFR6S).

Data Port:

Diagnostic connector for accessing engine control unit (ECU) data and fault codes.

🔧 Maintenance

Oil Change Interval:

Every 6,000 km (3,700 miles) or 6 months, whichever comes first. Inspect more frequently if used in severe conditions.

Air Filter Cleaning:

Every 12,000 km (7,500 miles). Replace if damaged.

Spark Plug Replacement:

Every 18,000 km (11,200 miles) or 18 months.

Brake Fluid Replacement:

Every 24 months or as needed if contaminated.

Coolant Replacement:

Every 24 months or 24,000 km (15,000 miles), whichever comes first.

Engine Oil Viscosity:

SAE 10W-40

Engine Oil Standard:

API SG or higher, JASO MA certified

Brake Fluid:

DOT 4

Coolant Mixture:

50% Ethylene Glycol, 50% Demineralized Water

Typical Concerns:

Potential for stator failure (common on many Yamahas of this era), occasional fuel injection sensor issues, clutch lever adjustment for smooth engagement. These are general, and the manual provides diagnostic steps for any performance anomalies.

Oil Filter Example:

Yamaha Genuine Part: 3FV-13440-30-00 (Note: Always verify exact part number for your VIN)

Spark Plug Example:

NGK CR9E (verify for specific model variant)

📚 Vehicle History

Yamaha Legacy:

Yamaha Motor Company has a rich history in motorsports and performance motorcycles, known for innovation, engine technology, and racing success.

Yzf R6 Lineage:

The YZF-R6 line has consistently been a benchmark in the 600cc supersport class, known for its high-revving engines and track-focused performance since its inception.

Production Year Focus:

2004 model year, with specific notes for the YZFR6S variant.

🏆 Awards & Recognition

Motorcycle Class:

The YZF-R6 series has consistently been lauded by motorcycle journalists and industry publications for its performance, handling, and technological advancements within the 600cc supersport segment.