Yamaha FZS6W 07 User Manual
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SWINGARM 4-60 EAS23340 REMOVING THE SWINGARM 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 rear wheel is elevated. 2. Measure: Swingarm side play Swingarm vertical movement ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Measure the tightening torque of the swing- arm pivot shaft bolt and nut. b. Measure the swingarm side play “A” by moving the swingarm from side to side. c. If the swingarm side play is out of specifica- tion, check the spacers, bearings, washers and dust covers. d. Check the swingarm vertical movement “B” by moving the swingarm up and down. If swingarm vertical movement is not smooth or if there is binding, check the spacers, bearings and dust covers. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ EAS23370 CHECKING THE SWINGARM 1. Check: Swingarm Bends/cracks/damage → Replace. 2. Check: Pivot shaftRoll the pivot shaft on a flat surface. Bends → Replace. WARNING EWA4S81007 Do not attempt to straighten a bent pivot shaft. 3. Wash: Pivot shaft Dust covers Spacer Washers Bearings 4. Check: Dust covers “1” Spacer “2”Damage/wear → Replace. Bearings Damage/pitting → Replace.Pivot shaft nut 120 Nm (12.0 m·kg, 87 ft·lb) Swingarm side play (at the end of the swingarm) 1.0 mm (0.039 in) Recommended cleaning solventKerosene
SWINGARM 4-61 EAS23380 INSTALLING THE SWINGARM 1. Lubricate: Bearings Spacers Dust covers Pivot shaft “1” 2. Install: Swingarm Pivot shaft nut “2” 3. Install: Rear shock absorber assemblyRefer to INSTALLING THE REAR SHOCK ABSORBER ASSEMBLY on page 4-57. Rear wheel Refer to INSTALLING THE REAR WHEEL on page 4-14. 4. Adjust: Drive chain slack Refer to ADJUSTING THE DRIVE CHAIN SLACK on page 3-25. Recommended lubricantLithium-soap-based grease Pivot shaft nut120 Nm (12.0 m·kg, 87 ft·lb) Drive chain slack 45.0–55.0 mm (1.77–2.17 in)
CHAIN DRIVE 4-62 EAS23400 CHAIN DRIVE Removing the drive chain Order Job/Parts to remove Q’ty RemarksDrive sprocket cover Refer to ENGINE REMOVAL on page 5-1. Swingarm Refer to REMOVING THE SWINGARM on page 4-60. 1 Rear fender 1 2Drive chain 1 3 Chain protector 1 For installation, reverse the removal proce- dure.
CHAIN DRIVE 4-63 EAS23410 REMOVING THE DRIVE CHAIN 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 rear wheel is elevated. 2. Remove: Drive chain (with the drive chain cutter) EAS23440 CHECKING THE DRIVE CHAIN 1. Measure: Measure the dimension between 15-links on the inner side “a” and outer side “b” of the roller and calculate the dimension between pin centers. Dimension “c” between pin centers = (Inner dimension “a” + Outer dimension “b”)/2 15-link section “c” of the drive chain Out of specification → Replace the drive chain, front drive sprocket and rear drive sprocket as a set. NOTE: While measuring the 15-link section, push down on the drive chain to increase its ten- sion. Perform this measurement at two or three dif- ferent places. 2. Check: Drive chainStiffness → Clean and lubricate or replace. 3. Clean: Drive chain ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Wipe the drive chain with a clean cloth. b. Put the drive chain in kerosene and remove any remaining dirt. c. Remove the drive chain from the kerosene and completely dry it. CAUTION: ECA14290 This vehicle has a drive chain with small rubber O-rings “1” between the drive chain side plates. Never use high-pres- sure water or air, steam, gasoline, certain solvents (e.g., benzine), or a coarse brush to clean the drive chain. High-pressure methods could force dirt or water into the drive chain’s internals, and solvents will deteriorate the O-rings. A coarse brush can also damage the O-rings. Therefore, use only kerosene to clean the drive chain. Do not soak the drive chain in kerosene for more than ten minutes, otherwise the O-rings can be damaged. 15-link drive chain section limit (maximum)239.3 mm (9.42 in)
CHAIN DRIVE 4-64 ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 4. Check: O-rings “1”Damage → Replace the drive chain. Drive chain rollers “2” Damage/wear → Replace the drive chain. Drive chain side plates “3” Damage/wear → Replace the drive chain. Cracks → Replace the drive chain and make sure the battery breather hose is properly routed away from the drive chain and below the swingarm. 5. Lubricate: Drive chain EAS23460 CHECKING THE DRIVE SPROCKET 1. Check: Drive sprocket More than 1/4 tooth “a” wear → Replace the drive chain sprockets as a set. Bent teeth → Replace the drive chain sprockets as a set. EAS23470 CHECKING THE REAR WHEEL SPROCKET Refer to CHECKING AND REPLACING THE REAR WHEEL SPROCKET on page 4-14. EAS23480 CHECKING THE REAR WHEEL DRIVE HUB Refer to CHECKING THE REAR WHEEL DRIVE HUB on page 4-13. EAS28800 INSTALLING THE DRIVE CHAIN 1. Lubricate: Drive chain 2. Install: Drive chain 3. Install: SwingarmRefer to INSTALLING THE SWINGARM on page 4-61. Recommended lubricant Engine oil or chain lubricant suitable for O-ring chains a. Correct 1. Drive chain roller 2. Drive chain sprocket Recommended lubricantEngine oil or chain lubricant suitable for O-ring chains
5 ENGINE ENGINE REMOVAL...................................................................................... 5-1 INSTALLING THE ENGINE .................................................................... 5-6 CAMSHAFTS ................................................................................................ 5-8 REMOVING THE CAMSHAFTS ........................................................... 5-10 CHECKING THE CAMSHAFTS ........................................................... 5-11 CHECKING THE TIMING CHAIN AND CAMSHAFT SPROCKET ....... 5-12 CHECKING THE TIMING CHAIN GUIDES .......................................... 5-12 CHECKING THE TIMING CHAIN TENSIONER ................................... 5-13 INSTALLING THE CAMSHAFTS .......................................................... 5-13 CYLINDER HEAD ....................................................................................... 5-16 REMOVING THE CYLINDER HEAD .................................................... 5-17 CHECKING THE CYLINDER HEAD .................................................... 5-17 INSTALLING THE CYLINDER HEAD ................................................... 5-17 VALVES AND VALVE SPRINGS ................................................................ 5-19 REMOVING THE VALVES .................................................................... 5-21 CHECKING THE VALVES AND VALVE GUIDES ................................. 5-22 CHECKING THE VALVE SEATS .......................................................... 5-23 CHECKING THE VALVE SPRINGS...................................................... 5-25 CHECKING THE VALVE LIFTERS ....................................................... 5-26 INSTALLING THE VALVES ................................................................... 5-26 GENERATOR AND STARTER CLUTCH .................................................... 5-28 REMOVING THE GENERATOR ........................................................... 5-30 REMOVING THE STARTER CLUTCH ................................................. 5-30 CHECKING THE STARTER CLUTCH .................................................. 5-31 INSTALLING THE STARTER CLUTCH ................................................ 5-31 INSTALLING THE GENERATOR .......................................................... 5-32 PICKUP ROTOR ......................................................................................... 5-33 REMOVING THE PICKUP ROTOR ...................................................... 5-34 INSTALLING THE PICKUP ROTOR ..................................................... 5-34 ELECTRIC STARTER ................................................................................. 5-36 CHECKING THE STARTER MOTOR ................................................... 5-38 ASSEMBLING THE STARTER MO TOR ............................................... 5-39 INSTALLING THE STARTER MOTOR .................................................. 5-39 OIL PUMP ................................................................................................... 5-40 REMOVING THE OIL PAN ................................................................... 5-43 CHECKING THE OIL PUMP ................................................................ 5-43 CHECKING THE RELIEF VALVE ......................................................... 5-43 CHECKING THE OIL DELIVERY PIPES.............................................. 5-44 CHECKING THE OIL STRAINER ......................................................... 5-44
CHECKING THE OIL NOZZLES .......................................................... 5-44 ASSEMBLING THE OIL PUMP............................................................ 5-44 INSTALLING THE OIL PUMP ............................................................... 5-45 INSTALLING THE OIL STRAINER ....................................................... 5-45 INSTALLING THE OIL PAN .................................................................. 5-45 CLUTCH ...................................................................................................... 5-46 REMOVING THE CLUTCH................................................................... 5-49 CHECKING THE FRICTION PLATES .................................................. 5-49 CHECKING THE CLUTCH PLATES ..................................................... 5-50 CHECKING THE CLUTCH SPRINGS .................................................. 5-50 CHECKING THE CLUTCH HOUSING ................................................. 5-50 CHECKING THE CLUTCH BOSS ........................................................ 5-50 CHECKING THE PRESSURE PLATE .................................................. 5-51 CHECKING THE PULL LEVER SHAFT AND PULL ROD.................... 5-51 INSTALLING THE CLUTCH.................................................................. 5-51 SHIFT SHAFT ............................................................................................. 5-53 CHECKING THE SHIFT SHAFT .......................................................... 5-54 CHECKING THE STOPPER LEVER .................................................... 5-54 INSTALLING THE SHIFT SHAFT ......................................................... 5-54 CRANKCASE ............................................................................................. 5-55 DISASSEMBLING THE CRANKC ASE ................................................. 5-57 CHECKING THE CRANKCASE ........................................................... 5-57 CHECKING THE BEARINGS A ND OIL SEALS ................................... 5-57 CHECKING THE OIL PUMP DRIVE CHAIN ........................................ 5-57 ASSEMBLING THE CRANKCAS E ....................................................... 5-58 CRANKSHAFT ........................................................................................... 5-60 REMOVING THE CONNECTING RODS AND PISTONS..................... 5-62 REMOVING THE CRANKSHA FT ASSEMBLY ..................................... 5-62 CHECKING THE CYLINDER AND PISTON......................................... 5-63 CHECKING THE PISTON RINGS ........................................................ 5-63 CHECKING THE PISTON PINS ........................................................... 5-64 CHECKING THE BIG END BEAR INGS ............................................... 5-65 INSTALLING THE CONNECTING ROD AND PISTON ........................ 5-68 CHECKING THE CRANKSHAFT ......................................................... 5-70 CHECKING THE CRANKSHAFT JO URNAL BEARINGS .................... 5-70 INSTALLING THE CRANKSHAFT ........................................................ 5-72 TRANSMISSION ......................................................................................... 5-74 REMOVING THE TRANSMISSION ...................................................... 5-78 CHECKING THE SHIFT FORKS .......................................................... 5-78 CHECKING THE SHIFT DRUM ASSEMBLY ........................................ 5-78 CHECKING THE TRANSMISSION ...................................................... 5-79 INSTALLING THE TRANSMISSION ..................................................... 5-79
ENGINE REMOVAL 5-1 EAS23710 ENGINE REMOVAL Removing the drive sprocket Order Job/Parts to remove Q’ty RemarksDrive chain Loosen Refer to ADJUSTING THE SHIFT PEDAL on page 3-25. 1 Locknut 1 2 Shift rod 1 3 Shift arm 1 4 Drive sprocket cover 1 5 Drive sprocket nut 1 6 Lock washer 1 7 Drive sprocket 1 For installation, reverse the removal proce- dure.