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...

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...

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....

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-...

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...

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...

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-...

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.