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”
...

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...

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...

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-...

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
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...