Yamaha FZS6W 07 User Manual

							
OIL PUMP
5-42
Disassembling the oil pump
Order Job/Parts to remove Q’ty Remarks1Oil pump cover 1
2Pin 2
3 Oil pump inner rotor 1
4 Oil pump outer rotor 1
5Pin 1
6 Washer 1
7 Oil pump rotor housing 1
8 Oil pump driven sprocket 1 For assembly, reverse the removal proce-
dure. 
						

							
OIL PUMP
5-43
EAS24930
REMOVING THE OIL PAN
1. Remove: Oil level switch “1”
 Oil pan “2”
 Oil pan gasket
 Dowel pins
NOTE:
Loosen each bolt 1/4 of a turn at a time, in 
stages and in a crisscross pattern. After all of 
the bolts are fully loosened, remove them.
EAS24960
CHECKING THE OIL PUMP
1. Check: Oil pump driven gear “1”
 Oil pump rotor housing “2”
 Oil pump coverCracks/damage/wear  → Replace the 
defective part(s).
2. Measure:  Inner-rotor-to-outer-rotor-tip clearance “a”
 Outer-rotor-to-oil-pump-housing clearance “b” 3. Check:
 Oil pump operationRough movement  → Repeat steps (1) and 
(2) or replace the defective part(s).
EAS24970
CHECKING THE RELIEF VALVE
1. Check:
 Relief valve body “1”
 Relief valve “2”
 Spring “3”
 O-ring “4”Damage/wear  → Replace the defective 
part(s).
Inner-rotor-to-outer-rotor-tip
clearance
0.030–0.090 mm (0.0012–
0.0035 in)
Limit 0.15 mm (0.0059 in)
Outer-rotor-to-oil-pump-hous-
ing clearance 0.030–0.080 mm (0.0012–
0.0032 in)
Limit
0.150 mm (0.0059 in)
1. Inner rotor
2. Outer rotor
3. Oil pump housing 
						

							
OIL PUMP
5-44
EAS24980
CHECKING THE OIL DELIVERY PIPES
1. Check: Oil delivery pipe “1”
Oil pipe “2”Damage  → Replace.
Obstruction  → Wash and blow out with 
compressed air.
EAS24990
CHECKING THE OIL STRAINER
1. Check:  Oil strainer “1”Damage  → Replace.
Contaminants  → Clean with solvent.
EAS4S81016
CHECKING THE OIL NOZZLES
The following procedure applies to all of the oil 
nozzles.
1. Check:
 Oil nozzle “1”
Damage/wear  → Replace the oil nozzle.
 O-ring “2” Damage/wear 
→ Replace.
 Oil nozzle passage Obstruction  → Blow out with compressed 
air.
EAS25010
ASSEMBLING THE OIL PUMP
1. Lubricate:  Inner rotor
 Outer rotor
 Oil pump shaft(with the recommended lubricant)
2. Install:  Oil pump housing “1”
 Oil pump shaft “2”
 Washer “3”
Pin “4”
 Inner rotor “5”
 Outer rotor “6”
 Dowel pins “7”
 Oil pump cover “8”
 Oil pump housing screw
NOTE:
When installing the inner rotor, align the pin “4” 
in the oil pump shaft with the groove “a” in the 
inner rotor “5”.
Recommended lubricant
Engine oil
Oil pump housing screw12 Nm (1.2 m·kg, 8.7 ft·lb) 
						

							
OIL PUMP
5-45
3. Check: Oil pump operationRefer to CHECKING THE OIL PUMP on 
page 5-43.
EAS25030
INSTALLING THE OIL PUMP
1. Install:
 Oil pump drive chain
 Gear cover
 Oil pump
 Oil pump bolts
CAUTION:
ECA4S81018
After tightening the bolts, make sure the oil 
pump turns smoothly.
EAS25040
INSTALLING THE OIL STRAINER
1. Install: Oil strainer “1”
 Relief valve “2”
NOTE:
Make sure to check the arrow mark “a” located 
on the oil strainer housing for the front and rear 
direction of the engine and then install the oil 
strainer so that its arrow mark points to the 
front side of the engine.
EAS25050
INSTALLING THE OIL PAN
1. Install: Oil pipe
 Oil delivery pipe
2. Install:  Dowel pins
Gasket 
 Oil pan “1”
 Oil level switch “2”
 Engine oil drain bolt
WARNING
EWA12820
Always use new copper washers.
NOTE:
 Tighten the oil pan bolts in stages and in a crisscross pattern.
 Lubricate the oil level switch O-ring with 
engine oil.
Oil pump bolt 12 Nm (1.2 m·kg, 8.7 ft·lb)
Oil pan bolt12 Nm (1.2 m·kg, 8.7 ft·lb)
Oil level switch bolt10 Nm (1.0 m·kg, 7.2 ft·lb)
Engine oil drain bolt
43 Nm (4.3 m·kg, 31 ft·lb)
New 
						

							
CLUTCH
5-46
EAS25060
CLUTCH
* Yamaha bond No.1215 (Three Bond No.1215®)
Removing the clutch cover
Order Job/Parts to remove Q’ty RemarksEngine oil Drain
Refer to CHANGING THE ENGINE OIL on 
page 3-12.
Coolant Drain
Refer to CHANGING THE COOLANT on 
page 3-18.
1 Coolant hose 1
2Clutch cable 1
3 Clutch cable holder 1
4Clutch cover 1
5 Clutch cover gasket 1
6Dowel pin 2 For installation, reverse the removal proce-
dure. 
						

							
CLUTCH
5-47
Removing the pull lever shaft
Order Job/Parts to remove Q’ty Remarks1 Circlip 2
2 Washer 1
3 Pull lever 1
4 Pull lever spring 1
5 Washer 1
6 Oil seal 1
7 Bearing 2
8 Pull lever shaft 1
9 Washer 1
For installation, reverse the removal proce-
dure. 
						

							
CLUTCH
5-48
Removing the clutch
Order Job/Parts to remove Q’ty Remarks1 Compression spring 6
2 Pressure plate 1
3 Pull rod 1
4 Bearing 1
5 Friction plate 1 6
6 Clutch plate 1 7
7 Friction plate 2 2
8 Clutch plate 2 1
9 Clutch boss nut 1
10 Lock washer 1
11 Clutch boss 1
12 Thrust plate 1 For assembly, reverse the removal proce-
dure. 
						

							
CLUTCH
5-49
EAS25070
REMOVING THE CLUTCH
1. Remove: Clutch cable holder “1”
 Clutch cover “2”
Gasket
NOTE:
Loosen each bolt 1/4 of a turn at a time, in 
stages and in a crisscross pattern.
After all of the bolts are fully loosened, remove 
them.
2. Remove: Compression spring bolts “1”
 Compression springs
 Pressure plate “2”
 Pull rod “3”
 Friction plates
 Clutch plates
3. Straighten the lock washer tab.
4. Loosen:  Clutch boss nut “1”
NOTE:
While holding the clutch boss “2” with the uni-
versal clutch holder, loosen the clutch boss 
nut. 5. Remove:
 Clutch boss nut “1”
 Lock washer “2”
 Clutch boss “3”
 Thrust plate “4”
EAS25100
CHECKING THE FRICTION PLATES
The following procedure applies to all of the 
friction plates.
1. Check: Friction plate
Damage/wear  → Replace the friction 
plates as a set.
2. Measure:
 Friction plate thicknessOut of specification  → Replace the friction 
plates as a set.
NOTE:
Measure the friction plate at four places.
Universal clutch holder 90890-04086
YM-91042
Friction plate thickness
2.92–3.08 mm (0.115–0.121 in)
Wear limit
2.80 mm (0.1102 in) 
						

							
CLUTCH
5-50
EAS25110
CHECKING THE CLUTCH PLATES
The following procedure applies to all of the 
clutch plates.
1. Check: Clutch plate
Damage  → Replace the clutch plates as a 
set.
2. Measure:
 Clutch plate warpage(with a surface plate and thickness gauge 
“1”)
Out of specification  → Replace the clutch 
plates as a set.
EAS25140
CHECKING THE CLUTCH SPRINGS
The following procedure applies to all of the 
clutch springs.
1. Check: Clutch springDamage  → Replace the clutch springs as a 
set.
2. Measure:  Clutch spring free length “a”Out of specification  → Replace the clutch 
springs as a set.
EAS25150
CHECKING THE CLUTCH HOUSING
1. Check:  Clutch housing dogs “1”Damage/pitting/wear  → Deburr the clutch 
housing dogs or replace the clutch hous-
ing.
NOTE:
Pitting on the clutch housing dogs will cause 
erratic clutch operation.
2. Check:  BearingDamage/wear  → Replace the bearing and 
clutch housing.
EAS25160
CHECKING THE CLUTCH BOSS
1. Check:  Clutch boss splines
Damage/pitting/wear  → Replace the clutch 
boss.
Warpage limit 0.10 mm (0.0039 in)
Clutch spring free length55.00 mm (2.17 in)
Minimum length 54.00 mm (2.13 in)
Limit 52.3 mm (2.06 in) 
						

							
CLUTCH
5-51
NOTE:
Pitting on the clutch boss splines will cause 
erratic clutch operation.
EAS25170
CHECKING THE PRESSURE PLATE
1. Check:
 Pressure plate “1”Cracks/damage  → Replace.
 Bearing “2”
Damage/wear  → Replace.
EAS25220
CHECKING THE PULL LEVER SHAFT AND 
PULL ROD
1. Check:
 Pull lever shaft pinion gear teeth “1”
 Pull rod teeth “2”
Damage/wear  → Replace the pull rod and 
pull lever shaft pinion gear as a set.
2. Check:  Pull rod bearing
Damage/wear  → Replace.
EAS25270
INSTALLING THE CLUTCH
1. Install:
 Thrust plate “1”
 Clutch boss “2”
 Lock washer “3” 
 Clutch boss nut “4”
2. Tighten:  Clutch boss nut
NOTE:
While holding the clutch boss with the univer-
sal clutch holder “1”, tighten the clutch boss 
nut.
3. Bend the lock washer tab along a flat side  of the nut.
4. Lubricate:
 Friction plates
 Clutch plates(with the recommended lubricant)
Clutch boss nut
90 Nm (9.0 m·kg, 65 ft·lb)
Universal clutch holder90890-04086
YM-91042
Recommended lubricantEngine oil
New