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Yamaha FZS6W FZS6WC 2006-2009 Workshop Service Repair Manual

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🏷️ Basic Information Identification Make: Yamaha Model: FZS6W / FZS6WC Model Nickname: FZS600 Fazer Chassis Codes: FZS6W (standard), FZS6WC (California/US Market specific) Product Type: Workshop Service Repair Manual 👋 Introduction Market Position Category: Mid-weight naked sportbike/standard motorcycle Target Audience: Riders seeking a versatile, sporty, and reliable motorcycle for commuting, touring, and spirited riding. Competitive Analysis Key Competitors: Honda CB600F Hornet, Suzuki Bandit 600/650, Kawasaki Z750 Key Features Engine Type: Liquid-cooled, 4-stroke, DOHC, 5-valve, inline-four cylinder Frame Type: Steel diamond frame Suspension: Telescopic front forks, rear monoshock suspension Braking: Dual front discs, single rear disc (often with optional ABS in some markets) Styling: Sleek, aggressive naked styling with a functional bikini fairing for wind deflection 📋 Manual Details Coverage Areas Years Covered: 2006, 2007, 2008, 2009 Page Count Estimated Pages: Hundreds (precise number not specified, implies comprehensive) Manual Type Type: Official Factory Service Manual Language Language: English Format Format: PDF Download 📖 Manual Coverage Systems Covered Engine: Complete engine overhaul, diagnosis, tuning, lubrication, cooling system, fuel system, ignition system, exhaust system Transmission: Clutch, gearbox, internal components, operation, maintenance, lubrication Chassis: Frame, front fork, rear suspension, steering system, wheel bearings, hubs Brakes: Front and rear brake systems, hydraulic lines, calipers, master cylinders, bleeding procedures, disc and pad replacement Electrical: Wiring diagrams, lighting system, ignition system, starter system, charging system, battery, fuses, relays, ECU diagnostics Fuel System: Carburetor (likely 4x CV type), fuel pump, fuel lines, fuel filter, fuel tank maintenance Cooling System: Radiator, coolant hoses, thermostat, water pump, coolant specifications and flush procedures Bodywork And Trim: Fairings, seat, body panels, fasteners, removal and installation procedures Procedures Included Routine Maintenance: Oil changes, filter replacement, spark plug checks/replacement, chain adjustment and lubrication, brake fluid checks, coolant level checks Troubleshooting: Step-by-step diagnostic flowcharts for common and uncommon problems across all systems Major Repairs: Engine rebuilds (top-end and bottom-end), transmission overhauls, suspension component replacement, electrical system repairs Component Removal Installation: Detailed instructions for removing and installing virtually every component on the motorcycle Specifications Data: Torque values, clearances, fluid capacities, electrical specifications, timing settings Technical Depth Depth: Comprehensive, covering everything from basic checks to full engine disassembly and reassembly. Suitable for both amateur and professional technicians. 📊 Manual Specifications File Format File Type: PDF Searchability: Likely text-searchable PDF for efficient information retrieval Print Quality Printability: Printable, allowing for hard copy reference in a workshop environment Binding Type Binding Recommendation: Recommended for spiral or comb binding for ease of use during repairs Paper Type Paper Type Recommendation: Glossy or semi-gloss paper recommended for durability and clarity of diagrams ⚙️ Engine Specifications Primary Engine Engine Code: 47X (common for this generation FZS600) Engine Type: 90-degree V-twin (Correction: FZS600 is Inline-4. This product information is for FZS600 Fazer, which is Inline-4. The V-twin is incorrect for this model.) Engine Type Correct: Liquid-cooled, 4-stroke, DOHC, 5-valve per cylinder, Inline-four Displacement: 599 cc (600 cc class) Bore X Stroke: 62.0 mm x 49.6 mm (typical for this engine) Compression Ratio: 12.2:1 (typical) Performance Horsepower Peak: Approximately 95-98 hp @ 11,000 rpm (factory figures) Torque Peak: Approximately 64-66 Nm @ 9,500 rpm (factory figures) Fuel System Fuel Delivery: Carburetor, likely Mikuni BDSR32 (4x CV-type) or similar Fuel Type: Unleaded gasoline, minimum 91 octane (RON+MON)/95 AKI Fuel Tank Capacity: 19 Liters (approx.) Lubrication System Oil Type: Yamalube 4-stroke motorcycle oil or equivalent API SG/SH/SJ/SL, JASO MA certified Oil Grade: 10W-40 or 20W-50 depending on ambient temperature (refer to manual for specific recommendations) Oil Capacity W Filter: Approximately 3.4 Liters Oil Capacity Wo Filter: Approximately 3.0 Liters 🔧 Transmission Standard Type: 6-speed constant mesh Features Clutch Type: Wet, multiple-disc Final Drive: Chain drive Fluid Specifications Transmission Oil Type: Yamalube Gear Oil API GL-4, SAE 80W or equivalent (refer to manual for specific type/capacity) 📐 Dimensions Exterior Length: Approximately 2,085 mm Width: Approximately 770 mm Height: Approximately 1,160 mm Wheelbase: Approximately 1,430 mm Weights Dry Weight: Approximately 183 kg Wet Weight: Approximately 198 kg (fully fueled, ready to ride) Suspension Travel Front Fork Travel: 130 mm Rear Suspension Travel: 135 mm 🛡️ Safety Features Ratings Safety Certification: Meets or exceeds all applicable national and international motorcycle safety standards for its production era. Active Features Braking System: Dual 298mm front discs with 2-piston calipers, single 245mm rear disc with 1-piston caliper. Optional ABS available on some models/markets. Lighting: Halogen headlight, LED tail light, clear lens front turn signals. Passive Features Frame Construction: High-tensile steel diamond frame for rigidity and rider feedback. Ergonomics: Comfortable, upright riding position designed for rider control and fatigue reduction. 💡 Technology Features Infotainment Instrument Cluster: Analog tachometer, digital speedometer, fuel gauge, coolant temperature gauge, trip meters, clock. Basic and functional for the era. Driver Assistance ABS: Optional Anti-lock Braking System (ABS) available on select models, enhancing braking safety. Connectivity Connectivity Features: No integrated smart connectivity features (e.g., Bluetooth, smartphone integration) typical of modern...
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Yamaha FZS6W FZS6WC 2006-2009 Workshop Service Repair Manual
🏷️ Basic Information
Identification
Make:
Yamaha
Model:
FZS6W / FZS6WC
Model Nickname:
FZS600 Fazer
Chassis Codes:
FZS6W (standard), FZS6WC (California/US Market specific)
Product Type:
Workshop Service Repair Manual
👋 Introduction
Market Position
Category:
Mid-weight naked sportbike/standard motorcycle
Target Audience:
Riders seeking a versatile, sporty, and reliable motorcycle for commuting, touring, and spirited riding.
Competitive Analysis
Key Competitors:
Honda CB600F Hornet, Suzuki Bandit 600/650, Kawasaki Z750
Key Features
Engine Type:
Liquid-cooled, 4-stroke, DOHC, 5-valve, inline-four cylinder
Frame Type:
Steel diamond frame
Suspension:
Telescopic front forks, rear monoshock suspension
Braking:
Dual front discs, single rear disc (often with optional ABS in some markets)
Styling:
Sleek, aggressive naked styling with a functional bikini fairing for wind deflection
📋 Manual Details
Coverage Areas
Years Covered:
2006, 2007, 2008, 2009
Page Count
Estimated Pages:
Hundreds (precise number not specified, implies comprehensive)
Manual Type
Type:
Official Factory Service Manual
Language
Language:
English
Format
Format:
PDF Download
📖 Manual Coverage
Systems Covered
Engine:
Complete engine overhaul, diagnosis, tuning, lubrication, cooling system, fuel system, ignition system, exhaust system
Transmission:
Clutch, gearbox, internal components, operation, maintenance, lubrication
Chassis:
Frame, front fork, rear suspension, steering system, wheel bearings, hubs
Brakes:
Front and rear brake systems, hydraulic lines, calipers, master cylinders, bleeding procedures, disc and pad replacement
Electrical:
Wiring diagrams, lighting system, ignition system, starter system, charging system, battery, fuses, relays, ECU diagnostics
Fuel System:
Carburetor (likely 4x CV type), fuel pump, fuel lines, fuel filter, fuel tank maintenance
Cooling System:
Radiator, coolant hoses, thermostat, water pump, coolant specifications and flush procedures
Bodywork And Trim:
Fairings, seat, body panels, fasteners, removal and installation procedures
Procedures Included
Routine Maintenance:
Oil changes, filter replacement, spark plug checks/replacement, chain adjustment and lubrication, brake fluid checks, coolant level checks
Troubleshooting:
Step-by-step diagnostic flowcharts for common and uncommon problems across all systems
Major Repairs:
Engine rebuilds (top-end and bottom-end), transmission overhauls, suspension component replacement, electrical system repairs
Component Removal Installation:
Detailed instructions for removing and installing virtually every component on the motorcycle
Specifications Data:
Torque values, clearances, fluid capacities, electrical specifications, timing settings
Technical Depth
Depth:
Comprehensive, covering everything from basic checks to full engine disassembly and reassembly. Suitable for both amateur and professional technicians.
📊 Manual Specifications
File Format
File Type:
PDF
Searchability:
Likely text-searchable PDF for efficient information retrieval
Print Quality
Printability:
Printable, allowing for hard copy reference in a workshop environment
Binding Type
Binding Recommendation:
Recommended for spiral or comb binding for ease of use during repairs
Paper Type
Paper Type Recommendation:
Glossy or semi-gloss paper recommended for durability and clarity of diagrams
⚙️ Engine Specifications
Primary Engine
Engine Code:
47X (common for this generation FZS600)
Engine Type:
90-degree V-twin (Correction: FZS600 is Inline-4. This product information is for FZS600 Fazer, which is Inline-4. The V-twin is incorrect for this model.)
Engine Type Correct:
Liquid-cooled, 4-stroke, DOHC, 5-valve per cylinder, Inline-four
Displacement:
599 cc (600 cc class)
Bore X Stroke:
62.0 mm x 49.6 mm (typical for this engine)
Compression Ratio:
12.2:1 (typical)
Performance
Horsepower Peak:
Approximately 95-98 hp @ 11,000 rpm (factory figures)
Torque Peak:
Approximately 64-66 Nm @ 9,500 rpm (factory figures)
Fuel System
Fuel Delivery:
Carburetor, likely Mikuni BDSR32 (4x CV-type) or similar
Fuel Type:
Unleaded gasoline, minimum 91 octane (RON+MON)/95 AKI
Fuel Tank Capacity:
19 Liters (approx.)
Lubrication System
Oil Type:
Yamalube 4-stroke motorcycle oil or equivalent API SG/SH/SJ/SL, JASO MA certified
Oil Grade:
10W-40 or 20W-50 depending on ambient temperature (refer to manual for specific recommendations)
Oil Capacity W Filter:
Approximately 3.4 Liters
Oil Capacity Wo Filter:
Approximately 3.0 Liters
🔧 Transmission
Standard
Type:
6-speed constant mesh
Features
Clutch Type:
Wet, multiple-disc
Final Drive:
Chain drive
Fluid Specifications
Transmission Oil Type:
Yamalube Gear Oil API GL-4, SAE 80W or equivalent (refer to manual for specific type/capacity)
📐 Dimensions
Exterior
Length:
Approximately 2,085 mm
Width:
Approximately 770 mm
Height:
Approximately 1,160 mm
Wheelbase:
Approximately 1,430 mm
Weights
Dry Weight:
Approximately 183 kg
Wet Weight:
Approximately 198 kg (fully fueled, ready to ride)
Suspension Travel
Front Fork Travel:
130 mm
Rear Suspension Travel:
135 mm
🛡️ Safety Features
Ratings
Safety Certification:
Meets or exceeds all applicable national and international motorcycle safety standards for its production era.
Active Features
Braking System:
Dual 298mm front discs with 2-piston calipers, single 245mm rear disc with 1-piston caliper. Optional ABS available on some models/markets.
Lighting:
Halogen headlight, LED tail light, clear lens front turn signals.
Passive Features
Frame Construction:
High-tensile steel diamond frame for rigidity and rider feedback.
Ergonomics:
Comfortable, upright riding position designed for rider control and fatigue reduction.
💡 Technology Features
Infotainment
Instrument Cluster:
Analog tachometer, digital speedometer, fuel gauge, coolant temperature gauge, trip meters, clock. Basic and functional for the era.
Driver Assistance
ABS:
Optional Anti-lock Braking System (ABS) available on select models, enhancing braking safety.
Connectivity
Connectivity Features:
No integrated smart connectivity features (e.g., Bluetooth, smartphone integration) typical of modern motorcycles. Focus is on mechanical and electrical systems.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Every 3,000 km or 3 months, whichever comes first (typical recommendation, refer to manual)
Air Filter Check:
Every 6,000 km or 6 months (typical recommendation, refer to manual)
Spark Plug Replacement:
Every 12,000 km or 12 months (typical recommendation, refer to manual)
Valve Clearance Check:
Every 12,000 km or 12 months (critical maintenance item, refer to manual for precise interval)
Fluid Specifications
Coolant Type:
Permanent type antifreeze coolant (ethylene glycol based) with demineralized water, 50:50 mixture.
Brake Fluid Type:
DOT 4 hydraulic brake fluid
Known Issues
Common Wear Items:
Chain and sprockets, brake pads, tires, fork seals (depending on mileage and care).
Potential Electrical Issues:
Wiring harness integrity, stator output (less common but possible on older bikes).
Carburetor Cleaning:
Periodic cleaning and synchronization of carburetors may be required for optimal performance, especially if fuel quality varies.
📚 Vehicle History
Brand Heritage
Manufacturer Reputation:
Yamaha is renowned for its high-quality engines, reliability, and sport-oriented motorcycles. The 'Fazer' lineage is well-established.
Model Evolution
Predecessor:
FZS600 Fazer (pre-2004 model, with different engine and styling)
Generation:
This generation (2004-2009) received updates including revised styling, improved chassis components, and engine refinements compared to the original FZS600 Fazer.
Production
Production Period:
2004-2009 (for this specific generation)
Production Location
Manufacturing Plants:
Primarily manufactured in Japan by Yamaha Motor Corporation.
🏆 Awards & Recognition
Recognitions
Press Reviews:
The FZS600 Fazer generation was generally well-received by motorcycle publications for its balanced performance, comfort, and value for money, often praised as a competent all-rounder.
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