Yamaha 2004 FZ6-SS Manuals

Manuals and User Guides for Yamaha 2004 FZ6-SS. We have 1 Yamaha 2004 FZ6-SS manual available for free PDF download: Service Manual

Yamaha 2004 FZ6-SS Service Manual (435 pages)

Yamaha Motorcycle Service manual

Brand: Yamaha | Category: Motorcycle | Size: 14.51 MB

Specifications

5
- Table of Contents
  6
Important Manual Information
3
How to Use this Manual
4
Periodic Checks and Adjustments

5
Chassis

5
Engine

5
Cooling System

5
Fuel Injection System

5
Electrical System

5
Troubleshooting

15
Chapter 1 General Information

17
Motorcycle Identification

17
- Vehicle Identification Number
  17
- Model Label
  17
Gen Info

17
Features

18
- Outline of Fi System
  18
- Fi System
  19
- Instrument Function
  20
Important Information

22
- Preparation for Removal and Disassembly
  22
- Replacement Parts
  22
- Gaskets, Oil Seals and O-Rings
  22
- Lock Washers/Plates and Cotter Pins
  23
- Bearings and Oil Seals
  23
- Circlips
  23
Checking the Connections

24
Special Tools

25
Chapter 2 Specifications

28
Spec

28
General Specifications

28
Engine Specifications

29
Chassis Specifications

37
Electrical Specifications

41
Conversion Table

44
General Tightening Torque Specifications

44
Tightening Torques

45
- Engine Tightening Torques
  45
- Chassis Tightening Torques
  48
Lubrication Points and Lubricant Types

50
- Engine
  50
- Chassis
  51
Cooling System Diagrams

52
Engine Oil Lubrication Chart

56
Lubrication Diagrams

57
Cable Routing

63
Chapter 3 Periodic Checks and Adjustments

78
Introduction

78
Periodic Maintenance Chart for the Emission Control System

78
General Maintenance and Lubrication Chart

78
Chk Adj

78
Seat

80
Fuel Tank

81
- Removing the Fuel Tank
  83
- Removing the Fuel Pump
  83
- Installing the Fuel Pump
  84
- Installing the Fuel Tank
  84
Cowlings

85
Air Filter Case

86
Battery Box and Battery Box Bracket

87
Engine

88
- Adjusting the Valve Clearance
  88
- Synchronizing the Throttle Bodies
  94
- Adjusting the Engine Idling Speed
  96
- Adjusting the Throttle Cable Free Play
  97
- Checking the Spark Plugs
  99
- Measuring the Compression Pressure
  100
- Checking the Engine Oil Level
  103
- Changing the Engine Oil
  104
- Measuring the Engine Oil Pressure
  106
- Adjusting the Clutch Cable Free Play
  108
- Cleaning the Air Filter Element
  109
- Checking the Throttle Body Joints
  110
- Checking the Fuel and Breather Hoses
  111
- Checking the Crankcase Breather Hose
  111
- Checking the Exhaust System
  112
- Checking the Coolant Level
  113
- Checking the Cooling System
  114
- Changing the Coolant
  115
Chassis

118
- Adjusting the Front Brake
  118
- Adjusting the Rear Brake
  119
- Checking the Brake Fluid Level
  120
- Checking the Front and Rear Brake Pads
  121
- Adjusting the Rear Brake Light Switch
  122
- Checking the Front and Rear Brake Hoses
  122
- Bleeding the Hydraulic Brake System
  124
- Adjusting the Shift Pedal
  124
- Adjusting the Drive Chain Slack
  125
- Lubricating the Drive Chain
  126
- Checking and Adjusting the Steering Head
  127
- Checking the Front Fork
  129
- Adjusting the Rear Shock Absorber Assembly
  130
- Checking the Tires
  131
- Checking and Lubricating the Cables
  134
- Lubricating the Levers and Pedals
  134
- Lubricating the Sidestand
  134
- Lubricating the Centerstand
  134
- Lubricating the Rear Suspension
  135
Electrical System

136
- Checking and Charging the Battery
  136
- Checking the Fuses
  142
- Replacing the Headlight Bulbs
  144
- Adjusting the Headlight Beams
  145
Chapter 4 Chassis

146
Chas

146
Front Wheel and Brake Discs

146
- Removing the Front Wheel
  148
- Checking the Front Wheel
  148
- Checking the Brake Discs
  150
- Installing the Front Wheel
  151
- Adjusting the Front Wheel Static Balance
  152
- Rear Wheel and Brake Disc
  154
Rear Wheel and Brake Disc Rear Wheel

154
Front and Rear Brakes

161
- Front Brake Pads
  161
- Replacing the Front Brake Pads
  164
- Replacing the Rear Brake Pads
  166
- Front Brake Master Cylinder
  168
- Disassembling the Front Brake Master Cylinder
  170
- Disassembling the Rear Brake Master Cylinder
  172
- Master Cylinder
  173
- Disassembling the Front Brake Calipers
  173
- Disassembling the Rear Brake Caliper
  182
- Calipers
  183
- Caliper
  184
Front Fork

190
- Front Fork Legs
  190
- Removing the Front Fork Legs
  193
- Disassembling the Front Fork Legs
  193
- Checking the Front Fork Legs
  195
- Assembling the Front Fork Legs
  196
- Installing the Front Fork Legs
  199
Handlebar

200
- Removing the Handlebar
  201
- Checking the Handlebar
  201
- Installing the Handlebar
  202
Steering Head

204
- Under Bracket
  204
- Removing the under Bracket
  206
- Checking the Steering Head
  206
- Installing the Steering Head
  207
Rear Shock Absorber Assembly

209
Swingarm and Drive Chain

213
- Removing the Swingarm
  215
- Removing the Drive Chain
  216
- Checking the Swingarm
  216
- Installing the Swingarm
  217
- Checking the Drive Chain
  218
Chapter 5 Engine

220
- Drive Sprocket
  220
- Exhaust Pipe
  221
- Leads and Hoses
  222
- Engine
  222
- Installing the Engine
  225
Eng

220
Camshafts

227
- Cylinder Head Cover
  227
- Removing the Camshafts
  230
- Checking the Camshafts
  231
- Checking the Timing Chain, Camshaft Sprockets
  233
- And Timing Chain Guides
  233
- Checking the Timing Chain Tensioner
  233
- Installing the Camshafts
  234
Cylinder Head

238
- Removing the Cylinder Head
  239
- Checking the Cylinder Head
  239
- Installing the Cylinder Head
  240
Valves and Valve Springs

241
- Removing the Valves
  243
- Checking the Valves and Valve Guides
  244
- Checking the Valve Seats
  246
- Checking the Valve Springs
  248
Starter Clutch and Generator

251
- Stator Coil Assembly
  251
- Removing the Generator
  253
- Removing the Starter Clutch
  254
- Checking the Starter Clutch
  255
- Installing the Starter Clutch
  255
- Installing the Generator
  256
Shift Shaft

258
- Shift Shaft and Stopper Lever
  258
- Checking the Shift Shaft
  260
- Checking the Stopper Lever
  260
- Installing the Shift Shaft
  260
Crankshaft Position Sensor and Pickup Rotor

261
- Removing the Pickup Rotor
  263
- Installing the Pickup Rotor
  263
Clutch

265
- Clutch Cover
  265
- Checking the Clutch Plates
  269
- Checking the Clutch Springs
  269
- Checking the Clutch Housing
  270
- Checking the Clutch Boss
  270
- Checking the Pressure Plate
  270
- Checking the Pull Lever Shaft and Pull Rod
  271
- Installing the Clutch
  271
Oil Pan and Oil Pump

274
- Removing the Oil Pan
  277
- Checking the Oil Pump
  277
- Installing the Oil Strainer
  280
- Installing the Oil Pan
  280
Crankcase

281
- Checking the Crankcase
  284
- Checking the Bearings and Oil Seals
  284
- Checking the Timing Chain
  284
- Assembling the Crankcase
  284
Connecting Rods and Pistons

286
- Removing the Connecting Rods and Pistons
  287
- Removing the Crankshaft Assembly
  288
- Checking the Cylinder and Piston
  288
- Checking the Piston Rings
  289
- Checking the Piston Pins
  290
- CHECKING the BIG END BEARINGS (Except for CAL)
  292
- CHECKING the BIG END BEARINGS (for CAL)
  295
- (For CAL)
  295
Crankshaft

306
- Checking the Crankshaft
  307
- Checking the Crankshaft Journal Bearings
  307
- Installing the Crankshaft
  310
Transmission

311
- Transmission, Shift Drum Assembly and Shift Forks
  311
- Removing the Transmission
  317
- Checking the Shift Forks
  317
- Checking the Shift Drum Assembly
  318
- Checking the Transmission
  318
- Installing the Transmission
  319
Chapter 6 Cooling System

321
Cool

321
Radiator

321
- Checking the Radiator
  323
- Installing the Radiator
  324
Oil Cooler

325
- Checking the Oil Cooler
  327
- Installing the Oil Cooler
  327
Thermostat

328
- Checking the Thermostat
  329
- Installing the Thermostat
  330
Water Pump

331
- Disassembling the Water Pump
  333
- Checking the Water Pump
  334
- Assembling the Water Pump
  334
- Installing the Water Pump
  336
Chapter 7 Fuel Injection System

337
- Wiring Diagram
  338
- Ecu's Self-Diagnostic Function
  339
- Fail-Safe Action
  340
- Fail-Safe Actions Table
  340
- Troubleshooting Chart
  342
- Diagnostic Mode
  343
- Troubleshooting Details
  349
Throttle Bodies

361
Air Induction System

368
- Air Injection
  368
- Air Cut-Off Valve
  368
- Air Induction System Diagrams
  369
- Checking the Air Induction System
  370
Chapter 8 Electrical System

372
Elec

372
Electrical Components

372
Checking Switch Continuity

374
Checking the Switches

375
Checking the Bulbs and Bulb Sockets

376
- Types of Bulbs
  376
- Checking the Condition of the Bulbs
  376
- Checking the Condition of the Bulb Sockets
  377
- CHECKING the Leds
  378
Ignition System

379
- Circuit Diagram
  379
- Troubleshooting
  380
Electric Starting System

385
- Circuit Diagram
  385
- Starting Circuit Cut-Off System Operation
  386
- Troubleshooting
  387
Starter Motor

390
- Checking the Starter Motor
  392
- Assembling the Starter Motor
  393
Charging System

395
- Circuit Diagram
  395
- Troubleshooting
  396
Lighting System

398
- Circuit Diagram
  398
- Troubleshooting
  400
- Checking the Lighting System
  402
Signaling System

405
- Circuit Diagram
  405
- Troubleshooting
  407
- Checking the Signaling System
  407
Cooling System

414
- Circuit Diagram
  414
- Troubleshooting
  415
Fuel Pump System

418
- Circuit Diagram
  418
- Troubleshooting
  420
- Checking the Fuel Pump
  422
Self-Diagnosis

423
- Troubleshooting
  426
Starting Failures

426
- Engine
  426
- Fuel System
  426
- Electrical Systems
  426
Chapter 9

427
- Engine
  427
- Fuel System
  427
- Electrical Systems
  427
Poor Medium-And-High-Speed Performance

427
Trbl Shtg

427
Incorrect Engine Idling Speed

427
Faulty Gear Shifting

428
- Shifting Is Difficult
  428
- Shift Pedal Does Not Move
  428
- Jumps out of Gear
  428
Faulty Clutch

428
- Clutch Slips
  428
- Clutch Drags
  428
Overheating

429
- Engine
  429
- Cooling System
  429
- Fuel System
  429
- Chassis
  429
- Electrical Systems
  429
Overcooling

429
Poor Braking Performance

429
Faulty Front Fork Legs

430
- Leaking Oil
  430
- Malfunction
  430
Unstable Handling

430
Faulty Lighting or Signaling System

431
- Headlight Does Not Come on
  431
- Headlight Bulb Burnt out
  431
- Tail/Brake Light Does Not Come on
  431
- Tail/Brake Light Bulb Burnt out
  431
- Turn Signal Does Not Come on
  431
- Turn Signal Blinks Slowly
  431
- Turn Signal Remains Lit
  431
- Turn Signal Blinks Quickly
  431
- Horn Does Not Sound
  431

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Yamaha 2004 FZ6-SS Manuals

Yamaha 2004 FZ6-SS Service Manual (435 pages)

Table of Contents

Specifications

Periodic Checks and Adjustments

Chassis

Engine

Cooling System

Fuel Injection System

Electrical System

Troubleshooting

Chapter 1 General Information

Motorcycle Identification

Gen Info

Features

Important Information

Checking the Connections

Special Tools

Chapter 2 Specifications

Spec

General Specifications

Engine Specifications

Chassis Specifications

Electrical Specifications

Conversion Table

General Tightening Torque Specifications

Tightening Torques

Lubrication Points and Lubricant Types

Cooling System Diagrams

Engine Oil Lubrication Chart

Lubrication Diagrams

Cable Routing

Chapter 3 Periodic Checks and Adjustments

Introduction

Periodic Maintenance Chart for the Emission Control System

General Maintenance and Lubrication Chart

Chk Adj

Seat

Fuel Tank

Cowlings

Air Filter Case

Battery Box and Battery Box Bracket

Engine

Chassis

Electrical System

Chapter 4 Chassis

Chas

Front Wheel and Brake Discs

Rear Wheel and Brake Disc Rear Wheel

Front and Rear Brakes

Front Fork

Handlebar

Steering Head

Rear Shock Absorber Assembly

Swingarm and Drive Chain

Chapter 5 Engine

Eng

Camshafts

Cylinder Head

Valves and Valve Springs

Starter Clutch and Generator

Shift Shaft

Crankshaft Position Sensor and Pickup Rotor

Clutch

Oil Pan and Oil Pump

Crankcase

Connecting Rods and Pistons

Crankshaft

Transmission

Chapter 6 Cooling System

Cool

Radiator

Oil Cooler

Thermostat

Water Pump

Chapter 7 Fuel Injection System

Throttle Bodies

Air Induction System

Chapter 8 Electrical System

Elec