Yamaha FZS6W 07 User Manual

							
GENERAL CHASSIS
4-1
EAS21830
GENERAL CHASSIS
Removing the seat
Order Job/Parts to remove Q’ty Remarks1Seat 1 For installation, reverse the removal proce-
dure. 
						

							
GENERAL CHASSIS
4-2
Removing the cowlings
Order Job/Parts to remove Q’ty RemarksSeat Refer to GENERAL CHASSIS on page 4-1.
1 Left front cowling inner panel (with cowling) 1
2 Right front cowling inner panel (with cowling) 1
3 Front turn signal light coupler 2 Disconnect.
4 Front cowling 1
5 Front cowling inner panel (center) 1
6 Rear view mirrors  2
7 Windshield 1
8 Side cover  2
9 Rear cowling  1 For installation, reverse the removal proce-
dure. 
						

							
GENERAL CHASSIS
4-3
Removing the air filter case and battery
Order Job/Parts to remove Q’ty RemarksSeat Refer to GENERAL CHASSIS on page 4-1.
Left front cowling inner panel Refer to GENERAL CHASSIS on page 4-1.
Right front cowling inner panel Refer to GENERAL CHASSIS on page 4-1.
Fuel tank Refer to FUEL TANK on page 7-1.
1 Intake air temperature sensor coupler 1 Disconnect.
2 Throttle body hose 2 Disconnect.
3 Air induction system hose 1 Disconnect.
4 Clamp 4 Loosen.
5 Crankcase breather hose 1 Disconnect.
6 Starter relay 1
7 Battery negative lead 1 Disconnect.
8 Battery positive lead 1 Disconnect.
9Battery cover 1
10 Battery 1
11 Air filter case 1 For installation, reverse the removal proce-
dure. 
						

							
GENERAL CHASSIS
4-4
Removing the battery box
Order Job/Parts to remove Q’ty RemarksSeat Refer to GENERAL CHASSIS on page 4-1.
Left front cowling inner panel Refer to GENERAL CHASSIS on page 4-1.
Right front cowling inner panel Refer to GENERAL CHASSIS on page 4-1.
Fuel tank Refer to FUEL TANK on page 7-1.
Battery Refer to GENERAL CHASSIS on page 4-1.
Air filter case Refer to GENERAL CHASSIS on page 4-1.
1Battery box 1
2 Battery box bracket 3
3 Ignition coil 2 For installation, reverse the removal proce-
dure. 
						

							
FRONT WHEEL
4-5
EAS21880
FRONT WHEEL
Removing the front wheel and brake discs
Order Job/Parts to remove Q’ty Remarks1 Brake hose holder 1
2 Reflector stay 2
3 Reflector 2
4 Front brake caliper  2
5 Front wheel axle pinch bolt 1 Loosen.
6 Front wheel axle 1
7 Collar 2
8 Front wheel 1
9 Front brake disc  2 For installation, reverse the removal proce-
dure. 
						

							
FRONT WHEEL
4-6
Disassembling the front wheel
Order Job/Parts to remove Q’ty Remarks1 Oil seal 2
2 Wheel bearing 2
3Spacer 1
For assembly, reverse the disassembly pro-
cedure. 
						

							
FRONT WHEEL
4-7
EAS21900
REMOVING THE FRONT WHEEL
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. Remove: Left brake caliper
 Right brake caliper
NOTE:
Do not apply the brake lever when removing 
the brake calipers.
3. Loosen: Front wheel pinch bolt
 Front wheel axle
4. Elevate:  Front wheel
NOTE:
Place the vehicle on a suitable stand so that 
the front wheel is elevated.
5. Remove:
 Front wheel axle
 Front wheel
6. Remove:
Collers
EAS21920
CHECKING THE FRONT WHEEL
1. Check: Wheel axleRoll the wheel axle on a flat surface.
Bends  → Replace.
WARNING
EWA13460
Do not attempt to straighten a bent wheel 
axle.
2. Check:
Tire
 Front wheel
Damage/wear  → Replace.
Refer to CHECKING THE TIRES on page 
3-28 and CHECKING THE WHEELS on 
page 3-31.
3. Measure:
 Radial wheel runout “1”
 Lateral wheel runout “2”Over the specified limits  → Replace. 4. Check:
 Wheel bearingsFront wheel turns roughly or is loose  → 
Replace the wheel bearings.
 Oil seals Damage/wear  → Replace.
5. Replace:  Wheel bearings 
 Oil seals 
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a. Clean the outside of the front wheel hub.
b. Remove the oil seals “1” with a flat-head  screwdriver.
NOTE:
To prevent damaging the wheel, place a rag “2” 
between the screwdriver and the wheel sur-
face.
Radial wheel runout limit
1.0 mm (0.04 in)
Lateral wheel runout limit 0.5 mm (0.02 in)
New
New 
						

							
FRONT WHEEL
4-8
c. Remove the wheel bearings “3” with a gen-eral bearing puller.
d. Install the new wheel bearings and oil seals  in the reverse order of disassembly.
CAUTION:
ECA14130
Do not contact the wheel bearing inner race 
“4” or balls “5”. Contact should be made 
only with the outer race “6”.
NOTE:
Use a socket “7” that matches the diameter of 
the wheel bearing outer race and oil seal.
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EAS21970
ADJUSTING THE FRONT WHEEL STATIC 
BALANCE
NOTE:
 After replacing the tire, wheel or both, the front wheel static balance should be 
adjusted.  Adjust the front wheel static balance with the 
brake disc installed.
1. Remove:  Balancing weight(s)
2. Find:
 Front wheel’s heavy spot
NOTE:
Place the front wheel on a suitable balancing 
stand.
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a. Spin the front wheel.
b. When the front wheel stops, put an “X
1” 
mark at the bottom of the wheel.
c. Turn the front wheel 90 ° so that the “X
1” 
mark is positioned as shown.
d. Release the front wheel.
e. When the wheel stops, put an “X
2” mark at 
the bottom of the wheel.
f. Repeat steps (d) through (f) several times  until all the marks come to rest at the same 
spot.
g. The spot where all the marks come to rest 
is the front wheel’s heavy spot “X”.
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3. Adjust: Front wheel static balance
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a. Install a balancing weight “1” onto the rim  exactly opposite the heavy spot “X”. 
						

							
FRONT WHEEL
4-9
NOTE:
Start with the lightest weight.
b. Turn the front wheel 90° so that the heavy 
spot is positioned as shown.
c. If the heavy spot does not stay in that posi- tion, install a heavier weight.
d. Repeat steps (b) and (c) until the front  wheel is balanced.
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4. Check:
 Front wheel static balance
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a. Turn the front wheel and make sure it stays  at each position shown.
b. If the front wheel does not remain station- ary at all of the positions, rebalance it.
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EAS22000
INSTALLING THE FRONT WHEEL
The following procedure applies to both of the 
brake discs. 1. Lubricate:
 Wheel axle
 Oil seal lips
2. Install: Coller
 Wheel axle
NOTE:
Install the tire and wheel with the mark “1” 
pointing in the direction of wheel rotation.
3. Tighten:
 Wheel axle
 Wheel axle pinch bolt
CAUTION:
ECA14140
Before tightening the wheel axle nut, push 
down hard on the handlebar(s) several 
times and check if the front fork rebounds 
smoothly.
4. Install: Brake calipers
WARNING
EWA13490
Make sure the brake cable is routed prop-
erly.
Recommended lubricantLithium-soap-based grease
Wheel axle nut72 Nm (7.2 m·kg, 52 ft·lb)
Wheel axle pinch bolt19 Nm (1.9 m·kg, 14 ft·lb)
Front brake caliper bolt40 Nm (4.0 m·kg, 29 ft·lb)