Yamaha FZS6W 07 User Manual

HANDLEBAR
4-40
EAS22860
REMOVING THE HANDLEBARS
1. Stand the vehicle on a level surface.
WARNING
EWA13120
Securely support the vehicle so that there 
is no danger of it falling over.
2. Remove: Handlebar grip “1”
NOTE:
Blow compressed air between the left handle-
bar and the handlebar grip, and gradually push 
the grip off the handlebar.
3. Disconnect: Clutch switch connector
4. Remove:  Left handlebar switch “1”
 Clutch cable “2”
 Clutch lever holder “3”
5. Remove:  Right handlebar switch “1”
...

HANDLEBAR
4-41
2. Install: Handlebar “1”
 Upper handlebar holders “2”
 Upper handlebar holder caps “3” (Stan-dard)
CAUTION:
ECA14250
 First, tighten the bolts on the front side of the handlebar holder, and then on the rear 
side.
 Turn the handlebar all the way to the left  and right. If there is any contact with the 
fuel tank, adjust the handlebar position.
NOTE:
Align the match marks “a” on the handlebar 
with the upper surface of the lower handlebar 
holders.
3. Install: Throttle cables
...

HANDLEBAR
4-42
NOTE:
Align the projection “a” on the left handlebar 
switch with the hole “b” on the handlebar.
7. Install: Handlebar grip
 Grip end
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Apply a thin coat of rubber adhesive onto  the left end of the handlebar.
b. Slide the handlebar grip over the left end of 
the handlebar.
c. Wipe off any excess rubber adhesive with a  clean rag.
WARNING
EWA13700
Do not touch the handlebar grip until the 
rubber adhesive has fully dried.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
8....

FRONT FORK
4-43
EAS22950
FRONT FORK
Removing the front fork legs
Order Job/Parts to remove Q’ty RemarksFront wheel Refer to FRONT WHEEL on page 4-5.
Front brake calipers Refer to FRONT BRAKE on page 4-15.
1 Front fender 1
2 Cap bolt 1 Loosen.
3 Upper bracket pinch bolt 1 Loosen.
4 Under bracket pinch bolt 1 Loosen.
5Front fork leg 1
For installation, reverse the removal proce-
dure. 

FRONT FORK
4-44
Disassembling the front fork legs
Order Job/Parts to remove Q’ty Remarks1 Cap bolt 1
2O-ring 1
3Spacer 1
4 Washer 1
5 Front fork spring 1
6 Dust seal 1
7 Oil seal clip 1
8 Damper rod assembly bolt 1
9 Copper washer 1
10 Damper rod assembly 1
11 Oil seal 1
12 Washer 1
13 Inner tube 1
14 Outer tube bushing 1
15 Inner tube bushing 1
16 Oil flow stopper 1
17 Outer tube 1
For assembly, reverse the disassembly pro-
cedure. 

FRONT FORK
4-45
EAS22970
REMOVING THE FRONT FORK LEGS
The following procedure applies to both of the 
front fork legs.
1. Stand the vehicle on a level surface.
WARNING
EWA13120
Securely support the vehicle so that there 
is no danger of it falling over.
NOTE:
Place the vehicle on a suitable stand so that 
the front wheel is elevated.
2. Loosen: Upper bracket pinch bolts “1”
 Cap bolt “2”
 Lower bracket pinch bolts “3”
WARNING
EWA13640
Before loosening the upper and lower 
bracket pinch bolts, support...

FRONT FORK
4-46
CAUTION:
ECA14190
 Excessive force will damage the oil seal and bushing. A damaged oil seal or bush-
ing must be replaced.
 Avoid bottoming the inner tube into the  outer tube during the above procedure, as 
the oil flow stopper will be damaged.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
EAS23010
CHECKING THE FRONT FORK LEGS
The following procedure applies to both of the 
front fork legs.
1. Check:
 Inner tube “1”
 Outer tube “2”Bends/damage/scratches  → Replace.
WARNING
EWA13650
Do not attempt...

FRONT FORK
4-47
EAS23020
ASSEMBLING THE FRONT FORK LEGS
The following procedure applies to both of the 
front fork legs.
WARNING
EWA13660
 Make sure the oil levels in both front fork legs are equal.
 Uneven oil levels can result in poor han-
dling and a loss of stability.
NOTE:
 When assembling the front fork leg, be sure 
to replace the following parts:
- Inner tube bushing
- Outer tube bushing
-Oil seal
- Dust seal
 Before assembling the front fork leg, make 
sure all of the components are clean....

FRONT FORK
4-48
5. Install: Washer
Oil seal “1”(with the fork seal driver and adapter)
CAUTION:
ECA14220
Make sure the numbered side of the oil seal 
faces up.
NOTE:
 Before installing the oil seal, lubricate its lips with lithium soap base grease.
 Lubricate the outer surface of the inner tube  with fork oil.
 Before installing the oil seal, cover the top of 
the front fork leg with a plastic bag “2” to pro-
tect the oil seal during installation.
6. Install:  Oil seal clip “1”
NOTE:
Adjust the...

FRONT FORK
4-49
9. Measure: Front fork leg oil level “a”Out of specification  → Correct.
NOTE:
 While filling the front fork leg, keep it upright.
 After filling, slowly pump the front fork leg up 
and down to distribute the fork oil.
10. Install:  Spring “1”
 Spring seat “2”
 Spacer “3”
 Cap bolt
NOTE:
 Install the spring with the smaller pitch “a” facing down.
 Before installing the cap bolt, lubricate its O- ring with grease.
 Temporarily tighten the cap bolt.
EAS23050
INSTALLING THE FRONT...