Yamaha FZS6W 07 User Manual

CAMSHAFTS
5-12
NOTE:
 Tighten the camshaft cap bolts in stages and in a crisscross pattern, working from the 
inner caps out.
 Do not turn the camshaft when measuring 
the camshaft journal-to-camshaft cap clear-
ance with the Plastigauge®.
d. Remove the camshaft caps and then mea- sure the width of the Plastigauge® “2”.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
5. Measure: Camshaft journal diameter “a”Out of specification  → Replace the cam-
shaft.
Within specification  → Replace the cylinder 
head and the...

CAMSHAFTS
5-13
 Timing chain guide (top side) “3”Damage/wear  → Replace the defective 
part(s).
EAS23970
CHECKING THE TIMING CHAIN TEN-
SIONER
1. Check:
 Timing chain tensionerCracks/damage  → Replace.
2. Check:  One-way camRough movement  → Replace the timing 
chain tensioner assembly.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Lightly press the timing chain tensioner rod  into the timing chain tensioner housing by 
hand.
NOTE:
While pressing the timing chain tensioner rod, 
wind it clockwise with a thin...

CAMSHAFTS
5-14
3. Install: Dowel pins
 Intake camshaft caps
 Exhaust camshaft caps
NOTE:
 Make sure each camshaft cap is installed in its original place. Refer to the identification 
marks as follows:
“I1”, “I2”: Intake side camshaft cap mark
“E1”, “E2”: Exhaust side camshaft cap mark
 Make sure the arrow mark “a” on each cam-
shaft points towards the right side of the 
engine.
4. Install:  Camshaft cap bolts
NOTE:
Tighten the camshaft cap bolts in stages and 
in a crisscross pattern,  working...

CAMSHAFTS
5-15
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
7. Turn: Crankshaft(several full turns clockwise)
8. Check:
“T” mark “a”Make sure the “T” mark on the pickup rotor 
is aligned with the crankcase mating sure 
face “b”.
 Camshaft sprocket  match mark “c”
Make sure the match marks on the cam-
shaft sprockets are aligned with the edge of 
the cylinder head “d”.
Out of alignment  → Adjust.
Refer to the installation steps above.
9. Tighten:  Camshaft sprocket bolts “1”
CAUTION:
ECA4S81017
Be sure to tighten...

CYLINDER HEAD
5-16
EAS24100
CYLINDER HEAD
Removing the cylinder head
Order Job/Parts to remove Q’ty RemarksIntake camshaft Refer to CAMSHAFTS on page 5-8.
Exhaust camshaft Refer to CAMSHAFTS on page 5-8.
1 Cylinder head 1
2 Cylinder head gasket 1
3Dowel pin 2 For installation, reverse the removal proce-
dure. 

CYLINDER HEAD
5-17
EAS24120
REMOVING THE CYLINDER HEAD
1. Remove: Cylinder head bolts
NOTE:
 Loosen the bolts in the proper sequence as shown.
 Loosen each bolts 1/2 of a turn at a time.  After all of the bolts are fully loosened, 
remove them.
EAS24160
CHECKING THE CYLINDER HEAD
1. Eliminate: Combustion chamber carbon deposits
(with a rounded scraper)
NOTE:
Do not use a sharp instrument to avoid damag-
ing or scratching:
 Spark plug bore threads
Valve seats
2. Check: Cylinder...

CYLINDER HEAD
5-18
NOTE:
Pass the timing chain through the timing chain 
cavity.
3. Tighten: Cylinder head bolts “1” – “10”
 Cylinder head bolts “11” “12”
NOTE:
 Lubricate the cylinder head bolts with engine oil.
 Tighten the cylinder head bolts in the proper 
tightening sequence as shown and torque 
them in two stages.
 First, tighten the bolts “1” – ”10” to approxi-
mately 19 Nm (1.9 m·kg, 14 ft·lb) with a 
torque wrench and then tighten the 50 Nm 
(5.0 m·kg, 36 ft·lb).
4. Install:  Exhaust...

VALVES AND VALVE SPRINGS
5-19
EAS24270
VALVES AND VALVE SPRINGS
Removing the valves and valve springs
Order Job/Parts to remove Q’ty RemarksCylinder head Refer to CYLINDER HEAD on page 5-16.
1 Intake valve lifter 8
2 Intake valve pad 8
3 Intake valve cotter 16
4 Intake valve upper spring seat 8
5 Intake valve spring outer 8
6 Intake valve spring inner 8
7 Intake valve stem seal 8
8 Intake valve lower spring seat 8
9 Intake valve 8
10 Intake valve guide 8
11 Exhaust valve lifter 8
12 Exhaust valve pad 8...

VALVES AND VALVE SPRINGS
5-20
For installation, reverse the removal proce-
dure.
Removing the valves and valve springs
Order Job/Parts to remove Q’ty Remarks 

VALVES AND VALVE SPRINGS
5-21
EAS24280
REMOVING THE VALVES
The following procedure applies to all of the 
valves and related components.
NOTE:
Before removing the internal parts of the cylin-
der head (e.g., valves, valve springs, valve 
seats), make sure the valves properly seal.
1. Remove: Valve lifter “1”
 Valve pad “2”
NOTE:
Make a note of the position of each valve lifter 
and valve pad so that they can be reinstalled in 
their original place.
2. Check: Valve sealing
Leakage at the valve seat  →...