Yamaha FZS6W 07 User Manual

REAR BRAKE
4-30
Removing the rear brake caliper
Order Job/Parts to remove Q’ty RemarksBrake fluid Drain.
Refer to BLEEDING THE HYDRAULIC 
BRAKE SYSTEM on page 3-24.
1 Union bolt 1
2 Copper washer 2
3 Brake hose 1
4 Rear brake caliper 1 For installation, reverse the removal proce-
dure. 

REAR BRAKE
4-31
Disassembling the rear brake caliper
Order Job/Parts to remove Q’ty Remarks1 Screw plug 1
2 Brake pad pin 1
3 Brake pad 2
4 Brake pad shim 4
5 Brake pad spring 1
6 Brake caliper piston 1
7 Brake caliper piston seal 2
8 Bleed screw 1 For assembly, reverse the disassembly pro-
cedure. 

REAR BRAKE
4-32
EAS22560
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...

REAR BRAKE
4-33
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 a new brake pad shim “3” onto each  new brake pad “4”.
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3. Install: Brake caliper
 Brake pad pin
 Screw plug
4. Check:  Brake fluid level
Below the minimum level mark “a”  → Add 
the recommended brake fluid to the proper 
level.
Refer to CHECKING THE BRAKE FLUID 
LEVEL on page 3-22. 5. Check:
 Brake pedal...

REAR BRAKE
4-34
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a. Blow compressed air into the brake hose joint opening “a” to force out the piston from 
the brake caliper.
WARNING
EWA13550
 Cover the brake caliper piston with a rag. 
Be careful not to get injured when the pis-
ton is expelled from the brake caliper.
 Never try to pry out the brake caliper pis-
ton.
b. Remove the brake caliper piston seals.
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EAS22640
CHECKING THE REAR BRAKE CALIPER
1. Check:  Brake caliper pistons...

REAR BRAKE
4-35
1. Install: Brake caliper seals 
 Brake caliper piston
EAS22670
INSTALLING THE REAR BRAKE CALIPER
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....

REAR BRAKE
4-36
7. Check: Brake pedal operationSoft or spongy feeling  → Bleed the brake 
system.
Refer to BLEEDING THE HYDRAULIC 
BRAKE SYSTEM on page 3-24.
EAS22700
REMOVING THE REAR BRAKE MASTER 
CYLINDER
1. Remove:  Union bolt “1”
 Copper washers “2”
 Brake hose “3”
NOTE:
To collect any remaining brake fluid, place a 
container under the master cylinder and the 
end of the brake hose.
2. Disconnect: Brake fluid reservoir hose
3. Remove:  Pin (from the brake pedal link)
4. Remove:
 Rear brake...

REAR BRAKE
4-37
EAS22730
ASSEMBLING THE REAR BRAKE MASTER 
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 
EAS22740
INSTALLING THE REAR BRAKE MASTER 
CYLINDER
1. Install:
 Copper washers 
 Brake hoses
 Union bolt
WARNING
EWA13530
Proper brake hose routing is essential to 
insure safe vehicle operation. Refer...

REAR BRAKE
4-38
6. Adjust: Rear brake light operation timingRefer to ADJUSTING THE REAR BRAKE 
LIGHT SWITCH on page 3-23.
Brake pedal position25.8 mm (1.02 in) 

HANDLEBAR
4-39
EAS22840
HANDLEBAR
Removing the handlebar
Order Job/Parts to remove Q’ty Remarks1 Grip end 2
2 Handlebar grip 1
3 Clutch switch connector 1 Disconnect.
4 Left handlebar switch 1
5Clutch cable 1
6 Clutch lever 1
7 Right handlebar switch 1
8 Throttle grip 1
9 Throttle cable 2
10 Front brake light switch connector 1 Disconnect.
11 Front brake master cylinder holder 1
12 Front brake master cylinder 1
13 Upper handlebar holder 1
14 Handlebar 1
For installation, reverse the removal proce-
dure.