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Yamaha_FZ6_SS_SSC_‘04_ 2 in 1 Owner‘s_manual ( user giude) + Service Repair Manual
YAMAHA_FZ6_SS_SSC_2004_OWNER‘S_MANUAL
TOTAL 100 PAGES
CONTENTS
SAFETY INFORMATION
LOCATION OF IMPORTANT LABELS
DESCRIPTION
LEFT VIEW RIGHT VIEW CONTROLS AND INSTRUMENTS
INSTRUMENT AND CONTROL FUNCTIONS
MAIN SWITCH/STEERING LOCK INDICATOR AND WARNING LIGHTS LCD TACHOMETER MULTIFUNCTION DISPLAY HANDLEBAR SWITCHES CLUTCH LEVER SHIFT PEDAL BRAKE LEVER BRAKE PEDAL FUEL TANK CAP FUEL CATALYTIC CONVERTER SEAT STORAGE COMPARTMENT ADJUSTING THE SHOCK ABSORBER
ASSEMBLY SIDE STAND IGNITION CIRCUIT CUTOFF SYSTEM
PREOPERATION CHECKS
PREOPERATIONAL CHECK LIST
OPERATION AND IMPORTANT RIDING POINTS
STARTING THE ENGINE SHIFTING ENGINE BREAK-IN PARKING
PERIODIC MAINTENANCE AND MINOR REPAIR
PERIODIC MAINTENANCE OWNER‘S TOOL KIT PERIODIC MAINTENANCE CHART FOR THE
EMISSION CONTROL SYSTEM GENERAL MAINTENANCE AND
LUBRICATION CHART REMOVING AND INSTALLING PANELS CHECKING THE SPARK PLUGS CANISTER (FOR CALIFORNIA ONLY) ENGINE OIL AND OIL FILTER CARTRIDGE COOLANT REPLACING THE AIR FILTER ELEMENT ADJUSTING THE THROTTLE CABLE
FREE PLAY ADJUSTING THE VALVE CLEARANCE
TIRES CAST WHEELS ACCESSORIES AND REPLACEMENT
PARTS ADJUSTING THE CLUTCH LEVER FREE PLAY
ADJUSTING THE BRAKE PEDAL POSITION ADJUSTING THE REAR BRAKE LIGHT SWITCH CHECKING THE FRONT AND REAR
PADS CHECKING THE BRAKE FLUID LEVEL CHANGING THE BRAKE FLUID DRIVE CHAIN SLACK LUBRICATING THE DRIVE CHAIN CHECKING AND LUBRICATING THE
CABLES CHECKING AND LUBRICATING THE THROTTLE GRIP AND CABLE CHECKING AND LUBRICATING THE BRAKE AND SHIFT PEDALS
CHECKING AND LUBRICATING THE BRAKE AND CLUTCH LEVERS CHECKING AND LUBRICATING THE
CENTERSTAND AND SIDESTAND CHECKING THE FRONT FORK CHECKING THE STEERING CHECKING THE WHEEL BEARINGS BATTERY REPLACING THE FUSES REPLACING THE HEADLIGHT BULB REPLACING THE TAIL/BRAKE LIGHT
BULB REPLACING A TURN SIGNAL LIGHT BULB
YAMAHA_FZ6_SS_SSC_2004 SERVICE REPAIR MANUAL
TOTAL 432 PAGES
CONTENTS
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
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
CHAPTER 3
PERIODIC CHECKS AND ADJUSTMENTS ,INTRODUCTION ,PERIODIC MAINTENANCE CHART FOR THE EMISSION CONTROL SYSTEM
GENERAL MAINTENANCE AND LUBRICATION CHART,SEAT ,FUEL TANK ,
STALLING THE FUEL PUMP INSTALLING THE FUEL TANK
COWLINGS
AIR FILTER CASE
BATTERY BOX AND BATTERY BOX BRACKET
ENGINE
ADJUSTING THE VALVE CLEARANCE SYNCHRONIZING THE THROTTLE BODIES ADJUSTING THE ENGINE IDLING SPEED ADJUSTING THE THROTTLE CABLE FREE PLAY CHECKING THE SPARK PLUGS MEASURING THE COMPRESSION PRESSURE CHECKING THE ENGINE OIL LEVEL CHANGING THE ENGINE OIL MEASURING THE ENGINE OIL PRESSURE ADJUSTING THE CLUTCH CABLE FREE PLAY CLEANING THE AIR FILTER ELEMENT ,CHANGING THE COOLANT
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
CHAPTER 4 CHASSIS
FRONT WHEEL AND BRAKE DISCS
REMOVING THE FRONT WHEEL CHECKING 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
FRONT AND REAR BRAKES
FRONT BRAKE PADS REAR BRAKE PADS REPLACING THE FRONT BRAKE PADS REPLACING THE REAR BRAKE PADS FRONT BRAKE MASTER CYLINDER REAR 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 INSTALLING THE HANDLEBAR
STEERING HEAD
UNDER BRACKET REMOVING THE UNDER BRACKET CHECKING THE STEERING HEAD INSTALLING THE STEERING HEAD
SWINGARM AND DRIVE CHAIN
REMOVING THE SWINGARM REMOVING THE DRIVE CHAIN CHECKING THE SWINGARM INSTALLING THE SWINGARM CHECKING THE DRIVE CHAIN
CHAPTER 5 ENGINE
ENGINE
DRIVE SPROCKET EXHAUST PIPE LEADS AND HOSES ENGINE INSTALLING THE ENGINE
CAMSHAFTS
CYLINDER HEAD COVER CAMSHAFTS 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 CHECKING THE VALVE LIFTERS INSTALLING THE VALVES
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
CRANKSHAFT POSITION SENSOR AND PICKUP ROTOR
REMOVING THE PICKUP ROTOR INSTALLING THE PICKUP ROTOR
CLUTCH
CLUTCH COVER CLUTCH REMOVING THE CLUTCH CHECKING THE FRICTION PLATES 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 RELIEF VALVE CHECKING THE OIL DELIVERY PIPE AND OIL PIPE CHECKING THE OIL STRAINER CHECKING THE OIL NOZZLES ASSEMBLING THE OIL PUMP INSTALLING THE OIL PUMP INSTALLING THE OIL STRAINER INSTALLING THE OIL PAN
CRANKCASE
DISASSEMBLING THE 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 (EXCEPT FOR CAL) INSTALLING THE CONNECTING ROD AND PISTON (FOR CAL)
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
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
WATERPUMP
DISASSEMBLING THE WATER PUMP CHECKING THE WATER PUMP ASSEMBLING THE WATER PUMP INSTALLING THE WATER PUMP CHAPTER 7 FUEL INJECTION SYSTEM
FUEL INJECTION SYSTEM
WIRING DIAGRAM ECU‘S SELF-DIAGNOSTIC FUNCTION ALTERNATE INSTRUCTIONS OPERATION CONTROL (FAIL-SAFE ACTION)
FAIL,SAFE ACTIONSTABLE ,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
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 LED‘S
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 TROUBLESHOOTING CHECKING THE SIGNALING SYSTEM
COOLING SYSTEM
CIRCUIT DIAGRAM TROUBLESHOOTING
FUEL PUMP SYSTEM
CIRCUIT DIAGRAM FUEL PUMP SYSTEM TROUBLESHOOTING CHECKING THE FUEL PUMP
SELF-DIAGNOSIS
TROUBLESHOOTING
CHAPTER 9 TROUBLESHOOTING
STARTING FAILURES
ENGINE FUEL SYSTEM ELECTRICAL SYSTEMS
INCORRECT ENGINE IDLING SPEED
SYSTEMS
POOR MEDIUM-AND-HIGH-SPEED PERFORMANCE
ENGINE FUEL SYSTEM
FAULTY GEAR SHIFTING
SHIFTING IS DIFFICULT SHIFT PEDAL DOES NOT MOVE JUMPS OUT OF GEAR
FAULTY CLUTCH
CLUTCH SLIPS CLUTCH DRAGS
OVERHEATING
ENGINE COOLING SYSTEM FUEL SYSTEM CHASSIS ELECTRICAL SYSTEMS
OVERCOOLING
COOLING SYSTEM
POOR BRAKING PERFORMANCE
FAULTY FRONTFORK LEGS
LEAKING OIL MALFUNCTION
UNSTABLE HANDLING
FAULTY LIGHTING OR SIGNALING SYSTEM
HEADLIGHT DOES NOT COME ON HEADLIGHT BULB BURNT OUT TAIL,BRAKELIGHTDOES NOTCOME ON ,BRAKELIGHTBULB BURNT OUT
TURN SIGNAL DOES NOT COME ON TURN SIGNAL BLINKS SLOWLY TURN SIGNAL REMAINS LIT TURN SIGNAL BLINKS QUICKLY HORN DOES NOT SOUND
IMPORTANT MANUAL INFORMATION
THIS OWNERS MANUAL SHOULD BE CONSIDERED A PERMANENT PART OF THIS MOTORCYCLE AND SHOULD REMAIN WITH IT EVEN IF THE MOTORCYCLE IS SUBSEQUENTLY https://www.tradebit.comAHA CONTINUALLY SEEKS ADVANCEMENTS IN PRODUCT DESIGN AND QUALITY. THEREFORE, WHILE THIS MANUAL CONTAINS THE MOSTCURRENT PRODUCT INFORMATION AVAILABLE AT THE TIME OF PRINTING, THERE MAY BE MINOR DISCREPANCIES BETWEEN YOUR MOTORCYCLE.
THIS SERVICE MANUAL CONTAINS INFORMATION REGARDING PERIODIC MAINTENANCE TO THE EMISSION CONTROLSYSTEM. PLEASE READ THIS MATERIAL https://www.tradebit.comIGNS AND SPECIFICATIONS ARE SUBJECT TO CHANGE WITHOUT NOTICE.
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