Yamaha FZS6W 07 User Manual

							
CABLE ROUTING
2-48
1. Left handlebar switch lead
2. Main switch lead
3. Clutch cable
4. Throttle cables
5. Right handlebar switch lead
A. Clamp the right and left handlebar switch leads and handlebars. Point the tip of the 
clamp downward in front of the handlebar.
B. 70–90 mm (2.76–3.54 in)
C. Clamp the horn lead and main switch lead  to the inner tube. Point the binding section 
to the outside of the vehicle body and cut 
the tip down to the length of 1 to 5 mm 
(0.04 to 0.20 in).
D. Route the horn lead by the headmost side.
E. 5–25 mm (0.20–0.98 in)
F. Clamp the horn lead to the inner tube.  Point the binding section to the outside of 
the vehicle body and cut the tip down to the 
length of 1 to 5 mm (0.04 to 0.20 in).
G. Pass the throttle cables, wire harness lead,  clutch cable, main switch lead and left han-
dlebar switch lead in order through the 
frame hole from the lower side of the vehi-
cle.
H. Point the lead, which comes from the ter- minal, to the front side of the vehicle body. 
There should be no slack of leads between 
the band and terminals.
I. Clamp the brake hose to the inner tube.  Point the binding section to the outside of 
the vehicle body and cut the tip down to the 
length of 1 to 5 mm (0.04 to 0.20 in).
J. Pass the throttle cables through the wire  guide. Route the right handlebar switch 
lead by the outside of the wire guide. 
						

							
CABLE ROUTING
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CABLE ROUTING
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1. Rear brake light switch lead
2. Neutral switch lead
3. Fuel tank breather hose
4. Crankshaft position sensor lead
5. Right handlebar switch lead
6. O
2 sensor lead
7. Bracket
8. Fuel tank drain hose
9. Rear brake reservoir hose
A. Pass the fuel tank breather hose, fuel tank  drain hose and brake light switch lead 
through the guide of the stay assembly 2.
B. Clamp the tail/brake light switch lead  together with the O
2 sensor lead and the 
neutral switch lead.
C. To the starter motor
D. Install the right handlebar switch lead cou- pler through the hole of the bracket 2 from 
the downside.
E. Route the starter motor lead by the inner  side of the air cut-off valve hose.
F. Pass the ignition coil leads #1 and #4  through inner side of the air cut-off valve 
hose, and then between the frame and 
bracket 2.
G. Pass the right handlebar switch lead  through the hole located on the right side 
of the frame.
H. Route the right handlebar switch lead  under the bracket 2.
I. Route the coolant reservoir tank hose  under the cover 2. Route the radiator hose 
(outside) outside.
J. Route the radiator hoses (2 pieces) under  the cover 2.
K. Route the crankshaft position sensor lead  inner side of the radiator hose.
L. Pull down the mark-painted sections of the  fuel tank breather hose and fuel tank drain 
hose to be lower than the clamp position of 
the muffler stay. Any order to take out the 
fuel tank breather hose and fuel tank drain 
hose can be accepted.
M. 0–20mm (0–0.79 in)
N. Route the O
2 sensor lead by the outer side 
of the vehicle as viewed from the rear tail/
brake light switch lead.
O. Clamping position should be at the center  of bend-R as shown in the illustration for 
the rear brake reservoir tank hose.
P. Pass the fuel tank breather hose, fuel tank  drain hose and O
2 sensor lead through the 
clamp and insert them to the bracket.
Q. Clamp the O
2 sensor lead to the front side 
of the vehicle.
R. Outside of the vehicle.
S. Attach the clamp so that the opening may  be turned to the Outside of the vehicle. 
						

							
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CABLE ROUTING
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1. Main switch lead
2. Stay assembly
3. Left handlebar switch lead
4. Clutch cable
5. Throttle cables
6. Battery negative lead coupler
7. Starter relay lead
8. Battery negative lead
9. Fuel tank drain hose
10.Rectifier/regulator
11.Turn signal relay
12.Radiator fan motor relay
13.Starting circuit cut-off relay
14.Clamp
15.License plate light lead
16.Rear right turn signal light lead
17.Rear left turn signal light lead
18.Dimmer relay
19.Speed sensor lead
20.Sidestand switch lead
21.Oil level switch lead
22.AC magneto lead
23.Front brake hose
24.Throttle cable (return side)
25.Throttle cable (pull side)
26.Radiator fan motor lead
A. Route the throttle cables above the stay assembly 1.
B. Line up the left handlebar switch lead cou- pler and radiator fan motor lead coupler 
behind the head pipe.
C. Route the clutch cable over the wire har- ness.
D. To the main switch
E. Place three couplers on the flange of the  cover.
F. To the fuel pump
G. Clamp four wire leads. There should be no  excessive slack on the wire leads.
H. To the fuel tank
I. Either installation position can be  accepted, but make sure that the leads are 
not crossed.
J. Clamp the rear turn signal lead and license  plate light lead to the frame. Hook the 
clamp to the bracket. Pull out the lead suffi-
ciently to the frame side and route it along 
with the side of the back stay. Cut the tip of 
the clamp to be between 1 and 5 mm (0.04 
and 0.20 in) upward.
K. Clamp the rear turn signal light lead and  license plate light lead to the frame. Cut the 
tip of the clamp to be between 1 and 5 mm 
(0.04 and 0.20 in).
L. Gap between the lead and muffler should  be 10 mm (0.39 in) or more. M. Coupler should not run on the relay assem-
bly.
N. To the tail/brake light
O. To the license plate light
P. To the rear right turn signal light
Q. To the rear left turn signal light
R. To the engine
S. Route the speed sensor lead behind the  starter motor lead
T. Point the bend-R section of the throttle  cable (pull side) to the inner side horizon-
tally. It is also possible to visually check the 
bend-R section.
U. To the headlight lead
V. Clamp the seat lock cable to the frame as  shown in the illustration. Secure the clamp 
to the weld of the cross member with the 
frame. Position the binding section in front 
of the vehicle body and cut the tip to be 
between 1 and 5 mm (0.04 and 0.20 in).
W. Point the tip of the clamp to the inner side  of the vehicle body. 
						

							
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1. Right handlebar switch lead
2. Throttle cables
3. Battery positive lead
4. Battery cover
5. Connector cover
6. Fuel tank breather hose
7. Lean angle sensor
8. Fuse box
9. Rear right turn signal light lead
10.License plate light lead
11.Rear left turn signal light lead
12.Seat lock cable
13.Rectifier/regulator
14.ECU (engine control unit)
15.Fuel tank drain hose
16.Cover
17.Starter relay lead
18.Battery negative lead
19.Battery negative lead coupler
20.Clutch cable
21.Main switch lead
22.Cover 2
23.Air cut-off valve hose
24.Spark plug lead
A. Either front or rear side arrangement for the left handlebar switch lead coupler and 
radiator fan motor coupler can be 
accepted.
B. Point the L-shape terminal to the front side  of the vehicle.
C. Hook the starter motor lead to the alternate  pawls on the battery cover.
D. To the crankshaft position sensor.
E. Route the crankshaft position sensor lead  above the starter motor leads.
F. Clamp the starter motor lead and crank- shaft position sensor lead. Point the pro-
jected part of the tip to the inner side of the 
vehicle.
G. Pass the radiator hose, wire harness and  starter motor lead in order through the 
lower side of the vehicle.
H. Set the 4 couplers in the connector cover  after wiring it.
I. To the sidestand switch
J. To the speed sensor
K. To the AC magneto
L. To the oil level switch
M. The flap hole is located at the right side of  the vehicle.
N. To the neutral switch. Place the neutral  switch lead coupler under other leads so 
that it is not seen through the frame open-
ings.
O. To the tail/brake light switch
P. To the O
2 sensor Q. Clamp the neutral switch lead, tail/brake 
light lead and O
2 sensor lead. Point the 
clamp opening to the rear side.
R. Push the wire harness in the groove of the  mud guard.
S. Point the opening section of the clamp  upward.
T. To the tail/brake light
U. To the license plate light
V. To the rear left turn signal light
W. To the rear right turn signal light
X. Point the tip of the clamp to the outside of  the vehicle.
Y. Insert the enwinding clamp of the wire har- ness into the hole of the rear frame.
Z. Attach the rectifier/regulator lead with the  clamp of the regulator bracket.
AA.To the engine ground.
AB.To the fuel injection
AC.To the fuel pump
AD.Route the clutch cable under the fuel injec- tion lead.
AE.Pass the clutch cables through the clamp,  and then install the clamp to the cover. 
Position of the clamp is forward of the 
cable stopper.
AF.To the main switch
AG.Place the adjuster of the clutch cable  above the cover.
AH.Route the starter relay lead outside of the  main switch lead and pass forward the fuse 
holder.
AI. Press the battery negative lead into the  space between the ribs of the frame.
AJ.After connecting the coupler of the connec- tor cover, positiion it inside.
AK.Pass the spark plug leads #1 and #4  through the slit of the cover 2.
AL.Pass the spark plug lead #2 through the  inner hole of the cover 2.
AM.Pass the spark plug lead #3 through the  outer hole of the cover 2.
AN.Route the spark plug lead #4 behind the  air cutoff valve hose.
AO.Point the spark plug caps of #1 to #4 to the  direction as shown in the illustration.
AP.Route the spark plug lead #3 under the air  cutoff valve hose.
AQ.Route the spark plug lead #2 behind the  air cutoff valve hose.
AR.Route the spark plug lead #4 by the front  side of the spark plug leads #2 and #3.
AS.Route the spark plug leads #2 and #3  behind the air cut-off valve hose. 
						

							
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CABLE ROUTING
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1. Fuel pump assembly
2. Fuel tank breather hose
3. Fuel tank drain hose
4. Fuel hose
5. Clip
6. Clamp
7. Fuel tank protector
8. Charge hose (FZS6WC)
9. Roll over valve (FZS6WC)
A. Air opening.
B. Install the O-ring with its lip pointed upward.
C. Fuel tank breather hose has a white point  mark. (fuel tank breather hose side)
D. Point the knob of clip front side
a. Fuel piping connector attachment direc- tions. (fuel pump side) Don’t use tool.
1. It is inserted until it makes a click sound the  connector, and it checks that a connector 
does not fall out. It takes care that a foreign 
substance does not enter into a seal por-
tion. (Working groves should not be used 
at the time of work.)
E. It prevents that this portion falls out.
2. The clamp is attached from the bottom  after the work of  “1”. It checks being com-
pletely equipped with, “A”, “B” and “C” sec-
tion. 
						

							
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FZS6WC