Yamaha FZ6-S 2004 Manuals

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

Yamaha FZ6-S 2004 Service Manual

Yamaha FZ6-S 2004 Service Manual (456 pages)

Brand: Yamaha | Category: Motorcycle | Size: 19.22 MB

Table of Contents

Table of Contents

7
- Important Manual Information
  4
- How to Use this Manual
  5
- Chassis
  6
- Cooling System
  6
- Electrical System
  6
- Engine
  6
- Fuel Injection System
  6
- Info
  6
- Periodic Checks and Adjustments
  6
- Spec
  6
  - Table of Contents
    7
- Troubleshooting
  6
- Chapter 1 General Information
  12
- Motorcycle Identification
  12
  - Vehicle Identification Number
    12
  - Model Label
    12
- Features
  13
  - Outline of Fi System
    13
  - Fi System
    14
  - Instrument Function
    15
- Important Information
  17
  - Preparation for Removal and Disassembly
    17
  - Replacement Parts
    17
  - Gaskets, Oil Seals and O-Rings
    17
  - Lock Washers/Plates and Cotter Pins
    18
  - Bearings and Oil Seals
    18
  - Circlips
    18
- Checking the Connections
  19
- Special Tools
  20
Specifications Spec

25
- Chapter 2 Specifications
  27
- General Specifications
  27
- Engine Specifications
  28
- Chassis Specifications
  36
- Electrical Specifications
  40
- Conversion Table
  43
- General Tightening Torque Specifications
  43
- Tightening Torques
  44
  - Engine Tightening Torques
    44
  - Chassis Tightening Torques
    47
- Lubrication Points and Lubricant Types
  49
  - Engine
    49
  - Chassis
    50
- Cooling System Diagrams
  51
- Engine Oil Lubrication Chart
  55
- Lubrication Diagrams
  56
- Cable Routing
  62
Chk Adj

74
- Chapter 3 Periodic Checks and Adjustments
  76
- Introduction
  76
- Periodic Maintenance and Lubrication Intervals
  76
- Seat
  78
- Fuel Tank
  79
  - Removing the Fuel Tank
    80
  - Removing the Fuel Pump
    80
  - Installing the Fuel Pump
    81
  - Installing the Fuel Tank
    81
- Cowlings
  82
- Air Filter Case
  83
- Battery Box and Battery Box Bracket
  84
- Engine
  85
  - Adjusting the Valve Clearance
    85
- Chassis
  116
  - Adjusting the Front Brake
    116
  - Adjusting the Rear Brake
    117
  - Checking the Brake Fluid Level
    118
  - Checking the Front and Rear Brake Pads
    119
  - Adjusting the Rear Brake Light Switch
    120
  - Checking the Front and Rear Brake Hoses
    120
  - Bleeding the Hydraulic Brake System
    121
  - Adjusting the Shift Pedal
    122
  - Adjusting the Drive Chain Slack
    123
  - Lubricating the Drive Chain
    124
  - Checking and Adjusting the Steering Head
    125
  - Checking the Front Fork
    127
  - Adjusting the Rear Shock Absorber Assembly
    128
  - Checking the Tires
    129
  - Checking the Wheels
    131
  - Checking and Lubricating the Cables
    132
  - Lubricating the Levers and Pedals
    132
  - Lubricating the Sidestand
    132
  - Lubricating the Centerstand
    132
  - Lubricating the Rear Suspension
    133
- Electrical System
  134
  - Checking and Charging the Battery
    134
  - Checking the Fuses
    140
  - Replacing the Headlight Bulbs
    142
  - Adjusting the Headlight Beams
    143
Chas

145
- Front Wheel and Brake Discs
  147
- Chapter 4
  149
- Checking the Front Wheel
  149
- Removing the Front Wheel
  149
- Checking the Brake Discs
  151
- Installing the Front Wheel
  152
- Adjusting the Front Wheel Static Balance
  153
- Rear Wheel and Brake Disc Rear Wheel
  155
- Front and Rear Brakes
  162
- Front Fork
  191
  - Front Fork Legs
    191
  - Removing the Front Fork Legs
    194
  - Disassembling the Front Fork Legs
    194
  - Checking the Front Fork Legs
    196
  - Assembling the Front Fork Legs
    197
  - Installing the Front Fork Legs
    200
- Handlebar
  201
  - Removing the Handlebar
    202
  - Checking the Handlebar
    202
- Steering Head
  205
  - Under Bracket
    205
  - Removing the under Bracket
    207
  - Checking the Steering Head
    207
  - Installing the Steering Head
    208
- Rear Shock Absorber Assembly
  210
- Swingarm and Drive Chain
  214
  - Removing the Swingarm
    216
  - Removing the Drive Chain
    217
  - Checking the Swingarm
    217
  - Installing the Swingarm
    218
  - Checking the Drive Chain
    219
Eng

222
- Chapter 5
  226
- Drive Sprocket
  226
- Engine
  226
- Exhaust Pipe
  227
- Engine
  228
- Leads and Hoses
  228
- Installing the Engine
  231
- Camshafts
  233
  - Cylinder Head Cover
    233
  - Removing the Camshafts
    236
  - Checking the Camshafts
    237
  - Checking the Timing Chain, Camshaft Sprockets
    239
  - And Timing Chain Guides
    239
  - Checking the Timing Chain Tensioner
    239
  - Installing the Camshafts
    240
- Cylinder Head
  244
  - Removing the Cylinder Head
    245
  - Checking the Cylinder Head
    245
  - Installing the Cylinder Head
    246
- Valves and Valve Springs
  247
  - Removing the Valves
    249
  - Checking the Valves and Valve Guides
    250
  - Checking the Valve Seats
    252
  - Checking the Valve Springs
    254
- Starter Clutch and Generator
  257
  - Stator Coil Assembly
    257
  - Removing the Generator
    259
  - Removing the Starter Clutch
    260
  - Checking the Starter Clutch
    261
  - Installing the Starter Clutch
    261
  - Installing the Generator
    262
- Shift Shaft
  264
  - Shift Shaft and Stopper Lever
    264
  - Checking the Shift Shaft
    266
  - Checking the Stopper Lever
    266
  - Installing the Shift Shaft
    266
  - Removing the Pickup Rotor
    269
  - Installing the Pickup Rotor
    269
- Clutch
  271
  - Clutch Cover
    271
  - Checking the Clutch Plates
    275
  - Checking the Clutch Springs
    275
  - Checking the Clutch Housing
    276
  - Checking the Clutch Boss
    276
  - Checking the Pressure Plate
    276
  - Checking the Pull Lever Shaft and Pull Rod
    277
  - Installing the Clutch
    277
- Oil Pan and Oil Pump
  280
  - Removing the Oil Pan
    283
  - Checking the Oil Pump
    283
  - Checking the Oil Delivery Pipe and Oil Pipe
    284
  - Assembling the Oil Pump
    285
  - Installing the Oil Pump
    285
  - Installing the Oil Strainer
    286
  - Installing the Oil Pan
    286
- Crankcase
  287
  - Checking the Crankcase
    290
  - Checking the Bearings and Oil Seals
    290
  - Checking the Timing Chain
    290
  - Assembling the Crankcase
    290
- Connecting Rods and Pistons
  292
  - Removing the Connecting Rods and Pistons
    293
  - Removing the Crankshaft Assembly
    294
  - Checking the Cylinder and Piston
    294
  - Checking the Piston Rings
    295
  - Checking the Piston Pins
    296
  - Checking the Big End Bearings
    297
  - Installing the Connecting Rod and Piston
    300
- Crankshaft
  304
  - Checking the Crankshaft
    305
  - Checking the Crankshaft Journal Bearings
    305
  - Installing the Crankshaft
    308
- Transmission
  309
  - Transmission, Shift Drum Assembly and Shift Forks
    309
  - Removing the Transmission
    315
  - Checking the Shift Forks
    315
  - Checking the Shift Drum Assembly
    316
  - Checking the Transmission
    316
  - Installing the Transmission
    317
- Cool
  320
6 Cool

321
- Chapter 6 Cooling System
  323
- Radiator
  323
  - Checking the Radiator
    325
  - Installing the Radiator
    326
- Oil Cooler
  327
  - Checking the Oil Cooler
    329
  - Installing the Oil Cooler
    329
- Thermostat
  330
  - Checking the Thermostat
    331
  - Installing the Thermostat
    332
- Water Pump
  333
  - Disassembling the Water Pump
    335
  - Checking the Water Pump
    336
  - Assembling the Water Pump
    336
  - Installing the Water Pump
    338
Throttle Bodies/Air Induction System

340
- Chapter 7 Fuel Injection System
  342
- Wiring Diagram
  343
- Ecu's Self-Diagnostic Function
  344
- Alternate Instructions Operation Control (Fail-Safe Action)
  345
- Fail-Safe Actions Table
  345
- Troubleshooting Chart
  347
- Diagnostic Mode
  348
- Troubleshooting Details
  354
- Throttle Bodies
  366
- Air Induction System
  372
  - Air Injection
    372
  - Air Cut-Off Valve
    372
  - Air Induction System Diagrams
    373
  - Checking the Air Induction System
    374
- Elec
  376
8 Elec

377
- Chapter 8 Electrical System
  379
- Electrical Components
  379
- Checking Switch Continuity
  381
- Checking the Switches
  382
- Checking the Bulbs and Bulb Sockets
  383
  - Types of Bulbs
    383
  - Checking the Condition of the Bulbs
    383
  - Checking the Condition of the Bulb Sockets
    384
  - CHECKING the Leds
    385
- Ignition System
  386
  - Circuit Diagram
    386
  - Troubleshooting
    387
- Electric Starting System
  392
  - Circuit Diagram
    392
  - Starting Circuit Cut-Off System Operation
    393
  - Troubleshooting
    394
- Starter Motor
  397
  - Checking the Starter Motor
    399
  - Assembling the Starter Motor
    400
- Charging System
  402
  - Circuit Diagram
    402
  - Troubleshooting
    403
- Lighting System
  405
  - Circuit Diagram
    405
  - Troubleshooting
    407
  - Checking the Lighting System
    409
- Signaling System
  412
  - Circuit Diagram
    412
  - Checking the Signaling System
    414
  - Troubleshooting
    414
- Cooling System
  421
  - Circuit Diagram
    421
  - Troubleshooting
    422
- Fuel Pump System
  425
  - Circuit Diagram
    425
  - Troubleshooting
    427
  - Checking the Fuel Pump
    429
- Immobilizer System
  430
  - System Diagram
    430
  - Circuit Diagram
    431
  - General Information
    432
  - Key ID Registration Method
    433
  - Self-Diagnosis Error Code Indication
    435
  - Troubleshooting
    436
  - Checking the Immobilizer System
    437
  - Replacement Parts on Troubles
    439
- Self-Diagnosis
  440
- Trbl Shtg
  443
Trbl Shtg

444
- Troubleshooting
  444
- Chapter 9
  446
- Electrical Systems
  446
- Engine
  446
- Fuel System
  446
- Starting Failures
  446
- Incorrect Engine Idling Speed
  447
  - Engine
    447
  - Fuel System
    447
  - Electrical Systems
    447
- Poor Medium-And-High-Speed Performance
  447
- Faulty Clutch
  448
  - Clutch Slips
    448
  - Clutch Drags
    448
- Faulty Gear Shifting
  448
  - Shifting Is Difficult
    448
  - Shift Pedal Does Not Move
    448
  - Jumps out of Gear
    448
- Overcooling
  449
- Overheating
  449
  - Engine
    449
  - Cooling System
    449
  - Fuel System
    449
  - Chassis
    449
  - Electrical Systems
    449
- Poor Braking Performance
  449
- Faulty Front Fork Legs
  450
  - Leaking Oil
    450
  - Malfunction
    450
- Unstable Handling
  450

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