Yamaha FZS6W 07 User Manual

CLUTCH
5-52
5. Install: Friction plates
 Clutch plates
NOTE:
First, install a friction plate and then alternate 
between a clutch plate and a friction plate.
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a Install the clutch plate and friction plate as shown in the illustration.
Clutch plate “1”: t=2.3 mm (0.09 in)
Clutch plate “2”: t=2.0 mm (0.08 in)
Friction plate “3”
Friction plate “4”: Color/Brown
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6. Install: Pressure plate “1”
NOTE:
Align the punch mark “a” in the pressure plate...

SHIFT SHAFT
5-53
EAS25410
SHIFT SHAFT
Removing the shift shaft and stopper lever
Order Job/Parts to remove Q’ty RemarksDrive sprocket cover Refer to ENGINE REMOVAL on page 5-1.
1 Shift shaft cover 1
2 Shift shaft cover gasket 1
3Dowel pin 2
4 Oil seal 1
5 Shift shaft 1
6 Shift shaft spring 1
7 Collar 1
8 Stopper lever spring 1
9 Circlip 1
10 Washer 1
11 Stopper lever 1
12 Collar 1
13 Washer 1
14 Shift shaft spring stopper 1 For installation, reverse the removal proce-
dure. 

SHIFT SHAFT
5-54
EAS25420
CHECKING THE SHIFT SHAFT
1. Check: Shift shaft “1”Bends/damage/wear  → Replace.
 Shift shaft spring “2” Damage/wear  → Replace.
EAS25430
CHECKING THE STOPPER LEVER
1. Check:
 Stopper lever “1”
Bends/damage  → Replace.
Roller turns roughly  → Replace the stopper 
lever.
EAS25450
INSTALLING THE SHIFT SHAFT
1. Install:
 Shift shaft spring stopper “1”
 Washers
 Shift shaft “2”
NOTE:
 Apply LOCTITE® to the threads of the shift shaft spring stopper.
 Hook the ends of the...

CRANKCASE
5-55
EAS25540
CRANKCASE
Separating the crankcase
Order Job/Parts to remove Q’ty RemarksEngine Refer to ENGINE REMOVAL on page 5-1.
Cylinder head Refer to CYLINDER HEAD on page 5-16.
Generator Refer to GENERATOR AND STARTER 
CLUTCH on page 5-28.
Starter clutch Refer to GENERATOR AND STARTER 
CLUTCH on page 5-28.
Shift shaft Refer to SHI FT SHAFT on page 5-53.
Crankshaft position sensor Refer to PICKUP ROTOR on page 5-33.
Pickup rotor Refer to PICKUP ROTOR on page 5-33.
Clutch Refer to CLUTCH on...

CRANKCASE
5-56
8Plate 1For installation, reverse the removal proce-
dure.
Separating the crankcase
Order Job/Parts to remove Q’ty Remarks 

CRANKCASE
5-57
EAS25550
DISASSEMBLING THE CRANKCASE
1. Place the engine upside down.
2. Remove: Crankcase bolts
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.
 Loosen the bolts in decreasing numerical 
order (refer to the numbers in the illustration).
 The numbers embossed on the crankcase 
indicate the crankcase tightening sequence.
M8  × 85 mm (3.3 in) bolts: “1”–“7”, “10”
M8  × 115 mm (4.5 in)...

CRANKCASE
5-58
EAS25660
ASSEMBLING THE CRANKCASE
1. Lubricate: Crankshaft journal bearings(with the recommended lubricant)
2. Apply:  Sealant
(onto the crankcase mating surfaces)
NOTE:
Do not allow any sealant to come into contact 
with the oil gallery or crankshaft journal bear-
ings. Do not apply sealant to within 2–3 mm of 
the crankshaft journal bearings.
3. Install:Dowel pin
4. Set the shift drum assembly and transmis- sion gears in the neutral position.
5. Install:
 Lower crankcase “1”(onto...

CRANKCASE
5-59 

CRANKSHAFT
5-60
EAS25950
CRANKSHAFT
Removing the connecting rods and pistons
Order Job/Parts to remove Q’ty RemarksLower crankcase Refer to CRANKCASE on page 5-55.
1 Connecting rod cap 4
2 Big end lower bearing 4
3 Big end upper bearing 4
4 Piston pin clip 8
5 Piston pin 4
6Piston 4
7 Connecting rod 4
8 Top ring 4
9 2nd ring 4
10 Oil ring 4 For installation, reverse the removal proce-
dure. 

CRANKSHAFT
5-61
Removing the crankshaft
Order Job/Parts to remove Q’ty RemarksCrankcase Separate.
Refer to CRANKCASE on page 5-55.
Connecting rods caps Refer to CRANKSHAFT on page 5-60.
1Crankshaft 1
2 Crankshaft journal lower bearing 5
3 Crankshaft journal upper bearing 5 For installation, reverse the removal proce-
dure.