2004 Yamaha FZ6-ST/FZ6-STC Service & Repair Manual with Supplement (P/N LIT-11616-18-43)

Covers the 2004 Yamaha FZ6-ST and FZ6-STC, including specific data for USA and California (CAL) emissions variants. The set combines Yamaha supplement P/N LIT-11616-18-43, first edition August 2004, with the FZ6-SS/FZ6-SSC base service manual, P/N LIT-11616-17-50.

A 469-page English PDF with searchable service text. Some diagram lettering and the base manual's covers are not searchable.

• Engine repair: Engine removal, cylinder-head and valve service, camshaft installation, crankcase separation, piston inspection, and crankshaft and connecting-rod bearing checks.

• Clutch and transmission: Wet-clutch disassembly and inspection, transmission shaft service, shift-fork and shift-drum checks, and starter-clutch repair.

• Fuel injection: ECU self-diagnosis, fault-code troubleshooting, sensor and actuator tests, throttle-body synchronization, fuel-pressure testing, and throttle position sensor adjustment.

• Brakes and chassis: Master-cylinder and caliper overhaul, hydraulic brake bleeding, front-fork rebuilding, steering-head service, and swingarm and drive-chain inspection.

• Cooling and lubrication: Radiator-cap pressure testing, thermostat checks, water-pump seal replacement, oil-cooler service, and oil-pump inspection.

• Electrical diagnosis: Ignition, starting, charging, lighting, and signaling circuit tests, supported by wiring diagrams, connector views, and cable and wire harness routing.

Written primarily for Yamaha dealers and qualified mechanics, these manuals assume an understanding of mechanics and motorcycle repair techniques.

Model Codes and Supplement Updates

The supplement identifies 5VX8 (USA except CAL) and 5VX9 (CAL); the included base manual identifies 5VX3 and 5VX4, respectively. California coverage includes evaporative-emission canister, rollover-valve, and hose-routing details.

Updated pages address piston measurement, connecting-rod and big-end-bearing procedures, engine installation, drive-chain wear inspection, and cable routing. The electrical specifications distinguish Mitsubishi F8T812 and F8T813 ignition units and identify the G8R-30Y-V3 starting circuit cut-off relay.

Engine Repair and Factory Specifications

The DOHC parallel four-cylinder sections cover valve-guide replacement, valve-seat inspection and lapping, intake and exhaust valve-clearance shim selection, and timing-chain and tensioner checks. Cylinder head torque values are documented in a multi-stage tightening sequence alongside the assembly procedures.

Bottom-end coverage includes Plastigauge checks of crankshaft-pin-to-big-end-bearing clearance and bearing selection using stamped identification numbers and color codes. The manual warns that mixing connecting rods and big-end bearings can produce incorrect clearances and engine damage.

Transmission coverage extends to shaft runout, gear-dog wear, shift-fork positioning, and gear engagement. Periodic maintenance schedules for the engine, chassis, and cooling system accompany lubrication charts, fluid capacities, wear limits, and electrical test specifications.

Fuel Injection and Electrical Troubleshooting

The document outlines detailed fuel injection system operation and pairs fault codes with probable causes, inspection tables, and reinstatement methods. Its instrument-panel diagnostic mode covers sensor readings, actuator operation, stored malfunction history, and history erasure.

These tables help distinguish wiring and connector problems from sensor faults before parts are replaced. Fuel-pump and pressure-regulator tests specify pressure gauge YU-03153 and adapter YM-03176.

Throttle-body removal, cleaning, synchronization, and injector checks are covered; the throttle bodies themselves are not intended for internal disassembly. Air-induction coverage includes the ECU-controlled air cut-off valve, reed valves, and solenoid testing.

Electrical fault tracing includes the starting circuit cut-off system and starter-motor inspection and assembly. Observe the manual's fire precautions during fuel-system testing and its warnings for electrical checks that can produce sparks.

Chassis and Cooling-System Service

Front-fork procedures cover bushings, seals, damper rods, and oil-level setting. The manual warns that bottoming the inner tube during disassembly can damage the oil flow stopper.

Brake coverage includes piston and seal inspection, hose routing, and post-assembly bleeding. Rear-shock coverage addresses removal, inspection, preload adjustment, and replacement; the pressurized shock is not intended to be opened for internal repair.

Cooling-system sections cover the radiator, thermostat, oil cooler, and water pump, including mechanical-seal installation and impeller-shaft inspection. Reference drawings include Cooling System Diagrams and the Engine Oil Lubrication Chart, alongside the FI Wiring Diagram, Electric Starting System Circuit Diagram, and FZ6-SS/FZ6-SSC Wiring Diagram.

File Contents and Readability

The PDF contains the 34-page supplement and a 435-page base-manual section. All covers, two full wiring-diagram sheets (including a color-coded version), and the component legend page are already included in the total.

PDF bookmarks cover both manuals and their main sections. The separate “Back to Index” link requires an index file that is not included. Small wiring labels and connector details require zooming for comfortable reading.