Yamaha FZS6W 07 User Manual

							
FRONT BRAKE
4-20
EAS22220
INTRODUCTION
WARNING
EWA14100
Disc brake components rarely require dis-
assembly. Therefore, always follow these 
preventive measures:
 Never disassemble brake components unless absolutely necessary.
 If any connection on the hydraulic brake  system is disconnected, the entire brake 
system must be disassembled, drained, 
cleaned, properly filled, and bled after 
reassembly.
 Never use solvents on internal brake 
components.
 Use only clean or new brake fluid for  cleaning brake components.
 Brake fluid may damage painted surfaces  and plastic parts. Therefore, always clean 
up any spilt brake fluid immediately.
 Avoid brake fluid coming into contact  with the eyes as it can cause serious 
injury.
 FIRST AID FOR BRAKE FLUID ENTERING  THE EYES:
 Flush with water for 15 minutes and get 
immediate medical attention.
EAS22240
CHECKING THE FRONT BRAKE DISCS
The following procedure applies to both brake 
discs.
1. Check: Brake disc
Damage/galling  → Replace.
2. Measure:  Brake disc deflection
Out of specification  → Correct the brake 
disc deflection or replace the brake disc.
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a. Place the vehicle on a suitable stand so  that the front wheel is elevated.
b. Before measuring the front brake disc  deflection, turn the handlebar to the left or 
right to ensure that the front wheel is sta-
tionary.
c. Remove the brake caliper.
d. Hold the dial gauge at a right angle against  the brake disc surface.
e. Measure the deflection 2–3 mm (0.0787– 0.1181 in) below the edge of the brake 
disc.
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3. Measure: Brake disc thicknessMeasure the brake disc thickness at a few 
different locations.
Out of specification  → Replace.
4. Adjust:  Brake disc deflection
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a. Remove the brake disc.
b. Rotate the brake disc by one bolt hole.
c. Install the brake disc.
NOTE:
Tighten the brake disc bolts in stages and in a 
crisscross pattern.
Brake disc deflection limit0.10 mm (0.0039 in)
Brake disc thickness limit4.5 mm (0.18 in) 
						

							
FRONT BRAKE
4-21
d. Measure the brake disc deflection.
e. If out of specification, repeat the adjust-ment steps until the brake disc deflection is 
within specification.
f. If the brake disc deflection cannot be  brought within specification, replace the 
brake disc.
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EAS22270
REPLACING THE FRONT BRAKE PADS
The following procedure applies to both brake 
calipers.
NOTE:
When replacing the brake pads, it is not neces-
sary to disconnect the brake hose or disas-
semble the brake caliper.
1. Measure:
 Brake pad wear limit “a”Out of specification  → Replace the brake 
pads as a set.
2. Install:  Brake pads
 Brake pad spring
NOTE:
Always install new brake pads and a brake pad 
spring as a set.
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a. Connect a clear plastic hose “1” tightly to  the bleed screw “2”. Put the other end of 
the hose into an open container.
b. Loosen the bleed screw and push the  brake caliper pistons into the brake caliper 
with your finger.
c. Tighten the bleed screw.
d. Install new brake pads and a new brake  pad spring.
NOTE:
The arrow mark “b” on the brake pad spring 
must point in the direction of disc rotation.
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3. Install: Brake pad pins
 Brake pad clips
 Brake caliper
4. Check:  Brake fluid level
Brake disc bolt18 Nm (1.8 m·kg, 13 ft·lb)
LOCTITE®
Brake pad lining thickness
(inner)4.5 mm (0.18 in)
Limit
0.5 mm (0.02 in)
Brake pad lining thickness
(outer) 4.5 mm (0.18 in)
Limit 0.5 mm (0.02 in)
Bleed screw6 Nm (0.6 m·kg, 4.3 ft·lb)
Brake caliper bolt40 Nm (4.0 m·kg, 29 ft·lb) 
						

							
FRONT BRAKE
4-22
Below the minimum level mark “c” → Add 
the recommended brake fluid to the proper 
level.
Refer to CHECKING THE BRAKE FLUID 
LEVEL on page 3-22.
5. Check:  Brake lever operationSoft or spongy feeling  → Bleed the brake 
system.
Refer to BLEEDING THE HYDRAULIC 
BRAKE SYSTEM on page 3-24.
EAS22300
REMOVING THE FRONT BRAKE CALIPERS
The following procedure applies to both of the 
brake calipers.
NOTE:
Before removing the brake caliper, drain the 
brake fluid from the entire brake system.
1. Remove:
 Union bolt “1”
 Copper washers “2”
 Brake hose “3”
 Brake caliper
NOTE:
Put the end of the brake hose into a container 
and pump out the brake fluid carefully.
EAS22360
DISASSEMBLING THE FRONT BRAKE 
CALIPERS
The following procedure applies to both of the 
brake calipers.
1. Remove:  Brake caliper pistons “1”
 Brake caliper piston seals “2”
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a. Secure the brake caliper pistons with a 
piece of wood “a”.
b. Blow compressed air into the brake hose 
joint opening “b” to force out the left side 
pistons from the brake caliper.
WARNING
EWA13570
 Cover the brake caliper piston with a lag.BE carefull not the get injured when the 
pistons are expelled from the brake cali-
per.
 Never try to pry out the brake caliper pis-
tons.
 Do not loosen the bolts “3”.
c. Remove the brake caliper piston seals.
d. Repeat the previous steps to force out the  right side pistons from the brake caliper.
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EAS22390
CHECKING THE FRONT BRAKE CALIPERS
Recommended brake component replace-
ment schedule
Brake pads If necessary
Piston seals Every two years
Brake hoses Every four years 
						

							
FRONT BRAKE
4-23
1. Check: Brake caliper pistons “1”Rust/scratches/wear  → Replace the brake 
caliper pistons.
 Brake caliper cylinders “2” Scratches/wear  → Replace the brake cali-
per assembly.
 Brake caliper body “3” Cracks/damage  → Replace the brake cali-
per assembly.
 Brake fluid delivery passages (brake caliper body)
Obstruction  → Blow out with compressed 
air.
WARNING
EWA13600
Whenever a brake caliper is disassembled, 
replace the piston seals.
EAS22410
ASSEMBLING THE FRONT BRAKE CALI-
PERS
WARNING
EWA13620
 Before installation, all internal brake com- ponents should be cleaned and lubricated 
with clean or new brake fluid.
 Never use solvents on internal brake  components as they will cause the piston 
seals to swell and distort.
 Whenever a brake caliper is disassem- bled, replace the brake caliper piston 
seals. 1. Install:
 Brake caliper seals 
 Brake caliper pistons
EAS22440
INSTALLING THE FRONT BRAKE CALI-
PERS
The following procedure applies to both of the 
brake calipers.
1. Install: Brake caliper “1”
(temporarily)
 Copper washers 
 Brake hose “2”
 Union bolt “3”
WARNING
EWA13530
Proper brake hose routing is essential to 
insure safe vehicle operation. Refer to 
CABLE ROUTING on page 2-47.
CAUTION:
ECA14170
When installing the brake hose onto the 
brake caliper “1”, make sure the brake pipe 
“a” touches the projection “b” on the brake 
caliper.
2. Fill:  Brake master cylinder reservoir
(with the specified amount of the recom-
mended brake fluid)
Brake fluid
Every two years and 
whenever the brake is 
disassembled
Recommended fluid
DOT 4
Recommended brake component replace-
ment schedule
Brake hose union bolt
30 Nm (3.0 m·kg, 22 ft·lb)
Recommended fluidDOT 4
New
New 
						

							
FRONT BRAKE
4-24
WARNING
EWA13090
 Use only the designated brake fluid. Other brake fluids may cause the rubber 
seals to deteriorate, causing leakage and 
poor brake performance.
 Refill with the same type of brake fluid 
that is already in the system. Mixing brake 
fluids may result in a harmful chemical 
reaction, leading to poor brake perfor-
mance.
 When refilling, be careful that water does  not enter the brake fluid reservoir. Water 
will significantly lower the boiling point of 
the brake fluid and could cause vapor 
lock.
CAUTION:
ECA13540
Brake fluid may damage painted surfaces 
and plastic parts. Therefore, always clean 
up any spilt brake fluid immediately.
3. Bleed:
 Brake systemRefer to BLEEDING THE HYDRAULIC 
BRAKE SYSTEM on page 3-24.
4. Check:  Brake fluid levelBelow the minimum level mark “c”  → Add 
the recommended brake fluid to the proper 
level.
Refer to CHECKING THE BRAKE FLUID 
LEVEL on page 3-22.
5. Check:  Brake lever operationSoft or spongy feeling  → Bleed the brake 
system.
Refer to BLEEDING THE HYDRAULIC 
BRAKE SYSTEM on page 3-24.
EAS22490
REMOVING THE FRONT BRAKE MASTER 
CYLINDER
NOTE:
Before removing the front brake master cylin-
der, drain the brake fluid from the entire brake 
system.
1. Disconnect:  Brake switch coupler
(from the brake switch)
2. Remove:  Union bolt “1”
 Copper washers “2”
 Brake hoses “3”
NOTE:
To collect any remaining brake fluid, place a 
container under the master cylinder and the 
end of the brake hose.
3. Remove:
Brake lever
 Brake master cylinder holder
 Brake master cylinder
EAS22500
CHECKING THE FRONT BRAKE MASTER 
CYLINDER
1. Check: Brake master cylinder “1”Damage/scratches/wear  → Replace.
 Brake fluid delivery passages (brake master cylinder body)
Obstruction  → Blow out with compressed 
air. 
						

							
FRONT BRAKE
4-25
2. Check: Brake master cylinder kit “1”Damage/scratches/wear  → Replace.
3. Check:  Brake master cylinder reservoir “1”
Cracks/damage  → Replace.
 Brake master cylinder reservoir diaphragm  “2”
Damage/wear  → Replace.
4. Check:  Brake hosesCracks/damage/wear  → Replace.
EAS22520
ASSEMBLING THE FRONT BRAKE MAS-
TER CYLINDER
WARNING
EWA13520
 Before installation, all internal brake com-
ponents should be cleaned and lubricated 
with clean or new brake fluid.
 Never use solvents on internal brake 
components. 1. Install:
 Master cylinder kit
Circlip 
EAS22530
INSTALLING THE FRONT BRAKE MASTER 
CYLINDER
1. Install: Brake master cylinder “1”
NOTE:
 Install the brake master cylinder holder with 
the “UP” mark facing up.
 Align the end of the brake master cylinder 
holder with the punch mark “a” on the han-
dlebar.
 First, tighten the upper bolt, then the lower 
bolt.
2. Install:  Copper washers “1” 
 Brake hose “2”
 Union bolt “3”
WARNING
EWA13530
Proper brake hose routing is essential to 
insure safe vehicle operation. Refer to 
CABLE ROUTING on page 2-47.
Recommended fluidDOT 4
Brake master cylinder holder 
bolt10 Nm (1.0 m·kg, 7.2 ft·lb)
Brake hose union bolt30 Nm (3.0 m·kg, 22 ft·lb)
New
New 
						

							
FRONT BRAKE
4-26
CAUTION:
ECA4S81013
When installing the brake hose onto the 
brake master cylinder, make sure that the 
brake pipe touches the projection “b” on 
the brake master cylinder.
NOTE:
 While holding the brake hose, tighten the union bolt as shown.
 Turn the handlebar to the left and right to  make sure the brake hose does not touch 
other parts (e.g., wire harness, cables, 
leads). Correct if necessary.
3. Fill:  Brake master cylinder reservoir
(with the specified amount of the recom-
mended brake fluid)
WARNING
EWA13540
 Use only the designated brake fluid. Other brake fluids may cause the rubber 
seals to deteriorate, causing leakage and 
poor brake performance.
 Refill with the same type of brake fluid  that is already in the system. Mixing brake 
fluids may result in a harmful chemical 
reaction, leading to poor brake perfor-
mance.
 When refilling, be careful that water does 
not enter the brake master cylinder reser-
voir. Water will significantly lower the 
boiling point of the brake fluid and could 
cause vapor lock.
CAUTION:
ECA13540
Brake fluid may damage painted surfaces 
and plastic parts. Therefore, always clean 
up any spilt brake fluid immediately.
4. Bleed: Brake systemRefer to BLEEDING THE HYDRAULIC 
BRAKE SYSTEM on page 3-24.
5. Check:  Brake fluid levelBelow the minimum level mark “c”  → Add 
the recommended brake fluid to the proper 
level.
Refer to CHECKING THE BRAKE FLUID 
LEVEL on page 3-22.
6. Check:  Brake lever operation
Soft or spongy feeling  → Bleed the brake 
system.
Refer to BLEEDING THE HYDRAULIC 
BRAKE SYSTEM on page 3-24.
Recommended fluid DOT 4 
						

							
REAR BRAKE
4-27
EAS22550
REAR BRAKE
Removing the rear brake pads 
Order Job/Parts to remove Q’ty Remarks1 Screw plug 1
2 Brake pad pin 1
3 Rear brake caliper 1
4 Brake pad shim 4
5 Brake pad 2
6 Brake screw 1
7 Brake pad spring 1 For installation, reverse the removal proce-
dure. 
						

							
REAR BRAKE
4-28
Removing the rear brake master cylinder
Order Job/Parts to remove Q’ty RemarksBrake fluid Drain.
Refer to BLEEDING THE HYDRAULIC 
BRAKE SYSTEM on page 3-24.
1 Brake fluid reservoir cap 1
2 Rear brake fluid reservoir diaphragm holder 1
3 Rear brake fluid reservoir diaphragm 1
4 Brake fluid reservoir 1
5 Brake fluid reservoir hose 1
6 Union bolt 1
7 Copper washer 1
8 Brake hose 1
9 Rear brake master cylinder 1 For installation, reverse the removal proce-
dure. 
						

							
REAR BRAKE
4-29
Disassembling the rear brake master cylinder
Order Job/Parts to remove Q’ty Remarks1 Dust boot 1
2 Circlip 1
3 Brake master cylinder kit 1
4Spring 1
5 Brake master cylinder body 1 For installation, reverse the removal proce-
dure.