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Yamaha Manuals
Motorcycle
FZ6-SS 2004
Service manual
Yamaha FZ6-SS 2004 Service Manual
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Contents
Table of Contents
Troubleshooting
Bookmarks
Table of Contents
Table of Contents
Important Manual Information
How to Use this Manual
Chassis
Cooling System
Electrical System
Engine
Fuel Injection System
Info
Periodic Checks and Adjustments
Spec
Table of Contents
Troubleshooting
Chapter 1 General Information
Motorcycle Identification
Vehicle Identification Number
Model Label
Features
Outline of Fi System
Fi System
Instrument Function
Important Information
Preparation for Removal and Disassembly
Replacement Parts
Gaskets, Oil Seals and O-Rings
Lock Washers/Plates and Cotter Pins
Bearings and Oil Seals
Circlips
Checking the Connections
Special Tools
Specifications Spec
Chapter 2 Specifications
General Specifications
Engine Specifications
Chassis Specifications
Electrical Specifications
Conversion Table
General Tightening Torque Specifications
Tightening Torques
Engine Tightening Torques
Chassis Tightening Torques
Lubrication Points and Lubricant Types
Engine
Chassis
Cooling System Diagrams
Engine Oil Lubrication Chart
Lubrication Diagrams
Cable Routing
Chk Adj
Chapter 3 Periodic Checks and Adjustments
Introduction
Periodic Maintenance and Lubrication Intervals
Seat
Fuel Tank
Removing the Fuel Tank
Removing the Fuel Pump
Installing the Fuel Pump
Installing the Fuel Tank
Cowlings
Air Filter Case
Battery Box and Battery Box Bracket
Engine
Adjusting the Valve Clearance
Chassis
Adjusting the Front Brake
Adjusting the Rear Brake
Checking the Brake Fluid Level
Checking the Front and Rear Brake Pads
Adjusting the Rear Brake Light Switch
Checking the Front and Rear Brake Hoses
Bleeding the Hydraulic Brake System
Adjusting the Shift Pedal
Adjusting the Drive Chain Slack
Lubricating the Drive Chain
Checking and Adjusting the Steering Head
Checking the Front Fork
Adjusting the Rear Shock Absorber Assembly
Checking the Tires
Checking the Wheels
Checking and Lubricating the Cables
Lubricating the Levers and Pedals
Lubricating the Sidestand
Lubricating the Centerstand
Lubricating the Rear Suspension
Electrical System
Checking and Charging the Battery
Checking the Fuses
Replacing the Headlight Bulbs
Adjusting the Headlight Beams
Chas
Front Wheel and Brake Discs
Chapter 4
Checking the Front Wheel
Removing the Front Wheel
Checking the Brake Discs
Installing the Front Wheel
Adjusting the Front Wheel Static Balance
Rear Wheel and Brake Disc Rear Wheel
Rear Brake Disc and Rear Wheel Sprocket
Removing the Rear Wheel
Checking the Rear Wheel
Checking the Rear Wheel Drive Hub
Checking and Replacing the Rear Wheel Sprocket
Installing the Rear Wheel
Adjusting the Rear Wheel Static Balance
Front and Rear Brakes
Front Brake Pads
Rear Brake Pads
Replacing the Front Brake Pads
Replacing the Rear Brake Pads
Front Brake Master Cylinder
Disassembling the Front Brake Master Cylinder
Checking the Front and Rear Brake Master Cylinders
Disassembling the Rear Brake Master Cylinder
Assembling and Installing the Front Brake Master Cylinder
Assembling the Rear Brake Master Cylinder
Front Brake Calipers
Rear Brake Caliper
Disassembling the Front Brake Calipers
Disassembling the Rear Brake Caliper
Checking the Front and Rear Brake Calipers
Assembling and Installing the Front Brake Calipers
Assembling and Installing the Rear Brake Caliper
Front Fork
Front Fork Legs
Removing the Front Fork Legs
Disassembling the Front Fork Legs
Checking the Front Fork Legs
Assembling the Front Fork Legs
Installing the Front Fork Legs
Handlebar
Removing the Handlebar
Checking the Handlebar
Steering Head
Under Bracket
Removing the under Bracket
Checking the Steering Head
Installing the Steering Head
Rear Shock Absorber Assembly
Removing the Rear Shock Absorber Assembly
Handling the Rear Shock Absorber
Disposing of a Rear Shock Absorber
Checking the Rear Shock Absorber Assembly
Installing the Rear Shock Absorber Assembly
Swingarm and Drive Chain
Removing the Swingarm
Removing the Drive Chain
Checking the Swingarm
Installing the Swingarm
Checking the Drive Chain
Eng
Chapter 5
Drive Sprocket
Engine
Exhaust Pipe
Engine
Leads and Hoses
Installing the Engine
Camshafts
Cylinder Head Cover
Removing the Camshafts
Checking the Camshafts
Checking the Timing Chain, Camshaft Sprockets
And Timing Chain Guides
Checking the Timing Chain Tensioner
Installing the Camshafts
Cylinder Head
Removing the Cylinder Head
Checking the Cylinder Head
Installing the Cylinder Head
Valves and Valve Springs
Removing the Valves
Checking the Valves and Valve Guides
Checking the Valve Seats
Checking the Valve Springs
Starter Clutch and Generator
Stator Coil Assembly
Removing the Generator
Removing the Starter Clutch
Checking the Starter Clutch
Installing the Starter Clutch
Installing the Generator
Shift Shaft
Shift Shaft and Stopper Lever
Checking the Shift Shaft
Checking the Stopper Lever
Installing the Shift Shaft
Removing the Pickup Rotor
Installing the Pickup Rotor
Clutch
Clutch Cover
Checking the Clutch Plates
Checking the Clutch Springs
Checking the Clutch Housing
Checking the Clutch Boss
Checking the Pressure Plate
Checking the Pull Lever Shaft and Pull Rod
Installing the Clutch
Oil Pan and Oil Pump
Removing the Oil Pan
Checking the Oil Pump
Checking the Oil Delivery Pipe and Oil Pipe
Assembling the Oil Pump
Installing the Oil Pump
Installing the Oil Strainer
Installing the Oil Pan
Crankcase
Checking the Crankcase
Checking the Bearings and Oil Seals
Checking the Timing Chain
Assembling the Crankcase
Connecting Rods and Pistons
Removing the Connecting Rods and Pistons
Removing the Crankshaft Assembly
Checking the Cylinder and Piston
Checking the Piston Rings
Checking the Piston Pins
Checking the Big End Bearings
Installing the Connecting Rod and Piston
Crankshaft
Checking the Crankshaft
Checking the Crankshaft Journal Bearings
Installing the Crankshaft
Transmission
Transmission, Shift Drum Assembly and Shift Forks
Removing the Transmission
Checking the Shift Forks
Checking the Shift Drum Assembly
Checking the Transmission
Installing the Transmission
Cool
6 Cool
Chapter 6 Cooling System
Radiator
Checking the Radiator
Installing the Radiator
Oil Cooler
Checking the Oil Cooler
Installing the Oil Cooler
Thermostat
Checking the Thermostat
Installing the Thermostat
Water Pump
Disassembling the Water Pump
Checking the Water Pump
Assembling the Water Pump
Installing the Water Pump
Throttle Bodies/Air Induction System
Chapter 7 Fuel Injection System
Wiring Diagram
Ecu's Self-Diagnostic Function
Alternate Instructions Operation Control (Fail-Safe Action)
Fail-Safe Actions Table
Troubleshooting Chart
Diagnostic Mode
Troubleshooting Details
Throttle Bodies
Injectors
Checking the Injectors
Checking the Throttle Bodies
Checking the Fuel Pump and Pressure Regulator Operation
Checking and Adjusting the Throttle Position Sensor
Air Induction System
Air Injection
Air Cut-Off Valve
Air Induction System Diagrams
Checking the Air Induction System
Elec
8 Elec
Chapter 8 Electrical System
Electrical Components
Checking Switch Continuity
Checking the Switches
Checking the Bulbs and Bulb Sockets
Types of Bulbs
Checking the Condition of the Bulbs
Checking the Condition of the Bulb Sockets
CHECKING the Leds
Ignition System
Circuit Diagram
Troubleshooting
Electric Starting System
Circuit Diagram
Starting Circuit Cut-Off System Operation
Troubleshooting
Starter Motor
Checking the Starter Motor
Assembling the Starter Motor
Charging System
Circuit Diagram
Troubleshooting
Lighting System
Circuit Diagram
Troubleshooting
Checking the Lighting System
Signaling System
Circuit Diagram
Checking the Signaling System
Troubleshooting
Cooling System
Circuit Diagram
Troubleshooting
Fuel Pump System
Circuit Diagram
Troubleshooting
Checking the Fuel Pump
Immobilizer System
System Diagram
Circuit Diagram
General Information
Key ID Registration Method
Self-Diagnosis Error Code Indication
Troubleshooting
Checking the Immobilizer System
Replacement Parts on Troubles
Self-Diagnosis
Trbl Shtg
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Table of
Contents
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Chapters
Table of Contents
7
Specifications Spec
25
Chk Adj
74
Chas
145
Eng
222
6 Cool
321
Throttle Bodies/Air Induction System
340
8 Elec
377
Trbl Shtg
444
Table of Contents
Troubleshooting
PERIODIC CHECKS AND ADJUSTMENTS
6
TROUBLESHOOTING CHART
347
TROUBLESHOOTING DETAILS
354
TROUBLESHOOTING
387
TROUBLESHOOTING
394
TROUBLESHOOTING
403
TROUBLESHOOTING
407
CHECKING THE SIGNALING SYSTEM
414
TROUBLESHOOTING
422
TROUBLESHOOTING
427
TROUBLESHOOTING
436
TROUBLESHOOTING
444
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Fz6-s 2004
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