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Yamaha FZ6SS FZ6SSC FAZER Service Repair Manual 2004-2005
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Basic Information Identification Make: Yamaha Model: FZ6 Fazer Model Variant: FZ6SS, FZ6SSC Year: 2004-2005 Generation Model Generation: First Generation (RJ14/RJ15) Codes Internal Model Code: RJ14 (FZ6), RJ15 (FZ6 Fazer) Introduction...
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| Basic Information | |
| Identification | |
| Make: | Yamaha |
| Model: | FZ6 Fazer |
| Model Variant: | FZ6SS, FZ6SSC |
| Year: | 2004-2005 |
| Generation | |
| Model Generation: | First Generation (RJ14/RJ15) |
| Codes | |
| Internal Model Code: | RJ14 (FZ6), RJ15 (FZ6 Fazer) |
| Introduction | |
| Market Position | |
| Segment: | Mid-weight naked sportbike / sport-tourer. |
| Target Audience: | Riders seeking a versatile, sporty, and comfortable motorcycle for commuting, touring, and spirited riding. |
| Competitive Analysis | |
| Competitors: | Kawasaki Z750, Suzuki Bandit 650, Honda CBF600, Triumph Street Triple 675 (later models). |
| Key Features | |
| Engine Platform: | Derived from the R6 supersport model, offering a strong performance base. |
| Versatility: | Capable as a commuter, sport-tourer (with Fazer variant's fairings), and engaging naked bike. |
| Handling: | Praised for its balanced chassis and agile handling characteristics. |
| Braking: | Equipped with capable braking systems, often featuring dual front discs. |
| Manual Details | |
| Coverage Areas | |
| Manual Type: | Service Repair Workshop Manual |
| Language: | English |
| Format: | |
| Page Count | |
| Estimated Page Count: | High (typically 300+ pages for this caliber of manual) |
| Manual Coverage | |
| Systems Covered | |
| Engine Mechanical: | Full engine teardown, rebuild, valve clearance, compression testing, torque specifications, internal component replacement. |
| Fuel System: | Fuel injection system diagnostics, injector servicing, fuel pump, fuel pressure testing, throttle body synchronization. |
| Ignition System: | Ignition coil testing, spark plug specifications, ignition timing. |
| Cooling System: | Radiator, fan, coolant type and capacity, thermostat replacement, troubleshooting leaks. |
| Exhaust System: | Catalytic converter inspection, muffler replacement, exhaust leak diagnosis. |
| Transmission Drivetrain: | Clutch inspection and replacement, gearbox disassembly and reassembly, shift linkage adjustment, final drive lubrication. |
| Suspension Front: | Fork disassembly, seal replacement, oil levels and type, spring rates, steering head bearing adjustment. |
| Suspension Rear: | Monoshock unit inspection, linkage system maintenance, swingarm bearing service, shock absorber replacement. |
| Brakes Front: | Brake caliper servicing, pad replacement, disc inspection, master cylinder overhaul, brake fluid specifications and bleeding procedures. |
| Brakes Rear: | Rear brake caliper servicing, pad replacement, disc inspection, master cylinder overhaul, brake fluid specifications and bleeding procedures. |
| Wheels Tires: | Wheel bearing inspection and replacement, tire pressure recommendations, wheel balancing. |
| Electrical System: | Wiring diagrams, battery maintenance, starter motor, alternator, lighting system, horn, fuses, relays. |
| Instrumentation Controls: | Dashboard component testing, switchgear diagnostics, throttle and clutch cable adjustment. |
| Frame Bodywork: | Chassis inspection, fairing removal and installation, seat replacement, body panel alignment. |
| Troubleshooting: | Diagnostic flowcharts for common starting, running, and electrical issues. |
| Procedures Included | |
| Preventive Maintenance: | Detailed schedules for oil changes, filter replacements, chain adjustment, lubrication points. |
| Routine Maintenance: | Spark plug replacement, air filter servicing, brake pad checks, coolant level checks. |
| Major Repairs: | Engine overhaul, transmission rebuild, suspension fork servicing, electrical system diagnostics and repair. |
| Component Replacement: | Step-by-step guides for replacing key components like clutch, brake calipers, starter motor, fuel pump. |
| Troubleshooting Guides: | Systematic approaches to identifying and resolving performance issues, starting problems, and electrical faults. |
| Technical Depth | |
| Depth Level: | Comprehensive Workshop Level - Suitable for professional mechanics and experienced DIY enthusiasts. |
| Detail Level: | Factory-level detail, including torque values, measurements, and specific tool requirements. |
| Manual Specifications | |
| File Format | |
| File Type: | |
| Searchability: | Likely searchable text-based PDF for easy navigation. |
| Print Quality: | High-resolution scans suitable for printing essential sections or the entire manual. |
| Binding Type | |
| Binding: | N/A (Digital PDF format) |
| Paper Type | |
| Paper: | N/A (Digital PDF format) |
| Engine Specifications | |
| Primary Engine | |
| Engine Type: | Liquid-cooled, four-stroke, DOHC, inline-four cylinder. |
| Displacement: | 599cc (599 cm³). |
| Bore X Stroke: | 65.5 mm x 44.5 mm. |
| Compression Ratio: | 12.2:1. |
| Valve Train: | DOHC, 4 valves per cylinder. |
| Fuel Delivery: | Electronic Fuel Injection (Mikuni). |
| Ignition System: | Digital TCI (Transistor Controlled Ignition). |
| Performance | |
| Horsepower Peak: | Approximately 96.5 HP (72 kW) @ 12,000 rpm. |
| Torque Peak: | Approximately 64.1 Nm (47.3 lb-ft) @ 9,500 rpm. |
| Fuel System | |
| Fuel Type: | Unleaded gasoline, minimum 91 octane (RON). |
| Fuel Tank Capacity: | 19.2 Liters (5.07 US gal). |
| Transmission | |
| Standard | |
| Transmission Type: | 6-speed constant mesh. |
| Clutch Type: | Wet, multiple-disc. |
| Final Drive: | O-ring sealed chain. |
| Features | |
| Gear Ratios: | Specific ratios detailed in manual, typically optimized for sporty performance. |
| Dimensions | |
| Exterior | |
| Length: | FZ6: 2095 mm (82.5 in) / FZ6 Fazer: 2120 mm (83.5 in) |
| Width: | FZ6: 755 mm (29.7 in) / FZ6 Fazer: 760 mm (30.0 in) |
| Height: | FZ6: 1065 mm (42.0 in) / FZ6 Fazer: 1210 mm (47.6 in) |
| Wheelbase: | 1440 mm (56.7 in). |
| Ground Clearance: | 155 mm (6.1 in). |
| Seat Height: | 805 mm (31.7 in). |
| Weights | |
| Dry Weight: | Approximately 163 kg (359 lbs) for FZ6 / 166 kg (366 lbs) for FZ6 Fazer. |
| Wet Weight: | Approximately 185 kg (408 lbs) for FZ6 / 188 kg (414 lbs) for FZ6 Fazer (estimated with fluids). |
| Safety Features | |
| Ratings | |
| Safety Certification: | Compliant with relevant national and international motorcycle safety standards for its production era. |
| Active Features | |
| Braking System: | Dual hydraulic disc front brakes with dual-piston calipers; Single hydraulic disc rear brake with dual-piston caliper. |
| Optional ABS: | ABS (Anti-lock Braking System) was an optional feature on some models, particularly the Fazer variants. |
| Passive Features | |
| Lighting: | Halogen headlight, LED taillight. |
| Chassis Design: | Rigid diamond-type frame contributing to stable handling. |
| Technology Features | |
| Infotainment | |
| Instrument Cluster: | Digital speedometer, analog tachometer, fuel gauge, clock, odometer, trip meters, engine warning light. |
| Driver Assistance | |
| ABS: | Optional ABS system for enhanced braking safety. |
| Connectivity | |
| ECU: | Engine Control Unit (ECU) manages fuel injection and ignition timing for optimal performance and emissions. |
| Maintenance | |
| Service Intervals | |
| Oil Change Interval: | Every 6,000 km (3,700 miles) or 6 months, whichever comes first. |
| Oil Filter Change Interval: | At every oil change (6,000 km / 3,700 miles). |
| Air Filter Cleaning: | Every 6,000 km (3,700 miles). |
| Spark Plug Replacement: | Every 18,000 km (11,200 miles). |
| Valve Clearance Check: | Every 24,000 km (15,000 miles). |
| Chain Lubrication: | Every 1,000 km (600 miles) or after riding in wet conditions. |
| Chain Adjustment: | As needed, check slack regularly. |
| Fluid Specifications | |
| Engine Oil Type: | Yamalube 4 (or equivalent) SAE 10W-40 API SG or higher, JASO MA certified. |
| Engine Oil Capacity: | 3.4 Liters (3.6 US qt) without filter change / 3.5 Liters (3.7 US qt) with filter change. |
| Coolant Type: | Permanent type antifreeze (ethylene glycol based), 50% solution in distilled water. |
| Brake Fluid Type: | DOT 4. |
| Fork Oil Type: | Yamaha Suspension Oil No. 10 or equivalent SAE 5W. |
| Fork Oil Quantity: | 398 cc (13.5 US oz) per fork leg. |
| Known Issues | |
| Fuel Pump Reliability: | Some early models experienced fuel pump issues, though often addressed under warranty or later revisions. |
| Stalling At Low Rpm: | Can sometimes occur if the engine is not properly tuned or if there are air leaks in the intake system. |
| Cam Chain Tensioner: | A known weak point on some Yamaha models of this era, potentially leading to noise if not maintained. |
| Wiring Harness Corrosion: | In humid or coastal environments, inspect wiring connectors for corrosion. |
| Vehicle History | |
| Brand Heritage | |
| Yamaha Motorcycles: | Yamaha Motor Company has a long history of producing high-performance and innovative motorcycles across various categories. |
| Model Evolution | |
| Fz6 Lineage: | The FZ6 series evolved from the successful FZS600 Fazer, utilizing a detuned R1 engine initially, then transitioning to a detuned R6 engine for the 2004+ models, focusing on broader power delivery and refinement. |
| Design Philosophy: | Designed to offer a blend of R6 performance with increased everyday usability and comfort, especially in the faired Fazer variant. |
| Production | |
| Manufacturing Location: | Primarily manufactured in Japan by Yamaha Motor Corporation. |
| Production Period: | 2004-2007 for the 599cc R6-derived engine model. |
| Awards & Recognition | |
| Recognitions | |
| Bike Magazine Reviews: | Consistently received positive reviews from motorcycle publications for its performance, handling, and value proposition. |
| Ratings | |
| User Satisfaction: | Generally high user satisfaction reported for its reliability and enjoyable riding experience, with common praise for its engine character. |