Yamaha FZS6W 07 User Manual

WATER PUMP
6-10
Disassembling the water pump
Order Job/Parts to remove Q’ty Remarks1 Water pump cover 1
2O-ring 1
3 Impeller shaft 1
4 Circlip 1
5 Water pump seal 1
6 Oil seal 1
7 Bearing 1
8 Water pump housing 1
9O-ring 1
10 Copper washer 1
For assembly, reverse the disassembly pro-
cedure. 

WATER PUMP
6-11
EAS26510
DISASSEMBLING THE WATER PUMP
1. Remove: Water pump cover
O-ring
 Circlip
 Impeller shaft
2. Remove:  Water pump seal “1”
NOTE:
Remove the water pump seal from the inside 
of the water pump housing “2”.
3. Remove:Oil seal “3”
(with a thin, flat-head screwdriver)
NOTE:
Remove the oil seal from the outside of the 
water pump housing.
4. Remove: Bearing “4”
NOTE:
Remove the bearing from inside of the water 
pump housing. 5. Remove:
 Rubber damper holder “5”
 Rubber damper...

WATER PUMP
6-12
3. Check: Water pump outlet pipe
 Radiator outlet hoseCracks/damage/wear  → Replace.
EAS26560
ASSEMBLING THE WATER PUMP
1. Install:
 Bearing
 Oil seal “1” 
(into the water pump housing “2”)
NOTE:
 Before installing the oil seal, apply tap water or coolant onto its out surface.
 Install the oil seal wi th a socket that matches 
its outside diameter.
2. Install:  Water pump seal “1” 
CAUTION:
ECA14080
Never lubricate the water pump seal sur-
face with oil or grease.
NOTE:
 Install...

WATER PUMP
6-13
5. Install: Impeller shaft
 Circlip 
 O-ring 
 Water pump cover
EAS26590
INSTALLING THE WATER PUMP
1. Install: O-ring 
 Copper washer 
 Water pump assembly “1”
NOTE:
 Align the slit “a” on the impeller shaft with the projection “b” on the oil pump shaft.
 Lubricate the O-ring with a thin coat of lith-
ium-soap-based grease.
2. Install:  O-ring 
 Water pump inlet hose “1”
 O-rings   Water pump outlet hose “2”
 Copper washer 
NOTE:
 Install the radiator outlet hose with...

7
FUEL SYSTEM
FUEL TANK.................................................................................................. 7-1
REMOVING THE FUEL TANK ................................................................ 7-2
REMOVING THE FUEL PUMP............................................................... 7-2
CHECKING THE FUEL PUMP BODY .................................................... 7-2
CHECKING THE FUEL PUMP OPERATION ......................................... 7-2
INSTALLING THE FUEL...

FUEL TANK
7-1
EAS26620
FUEL TANK
Removing the fuel tank
Order Job/Parts to remove Q’ty RemarksSeat Refer to GENERAL CHASSIS on page 4-1.
Left front cowling inner panel Refer to GENERAL CHASSIS on page 4-1.
Right front cowling inner panel Refer to GENERAL CHASSIS on page 4-1.
1 Fuel hose 1
2 Fuel sender coupler 1 Disconnect.
3 Fuel pump coupler 1 Disconnect.
4 Fuel tank drain hose 1
5 Fuel tank breather hose 1
6Fuel tank 1
7Fuel pump 1
8 Roll over valve 1 For installation, reverse the removal proce-
dure. 

FUEL TANK
7-2
EAS26630
REMOVING THE FUEL TANK
1. Extract the fuel in the fuel tank through the fuel tank cap with a pump.
2. Remove:
 Fuel return hose
 Fuel hose
CAUTION:
ECA4S81003
 Be sure to disconnect the fuel hose by hand. Do not forcefully disconnect the 
hose with tools.
 Although the fuel has been removed from  the fuel tank, be careful when removing 
the fuel hoses, since there may be fuel 
remaining in it.
NOTE:
 To remove the fuel hose from the fuel injec-tion pipe, slide the cover “a”...

FUEL TANK
7-3
EAS4S81001
INSTALLING THE FUEL TANK
1. Install: Fuel hose
CAUTION:
ECA4S81001
When installing the fuel hose, make sure 
that it is securely connected, and that the 
fuel hose holders are in the correct posi-
tion, otherwise the fuel hose will not be 
properly installed.
NOTE:
Install the fuel hose connector securely onto 
the fuel tank until a distinct “click” is heard, and 
then make sure that it doed not come loose.
To install the fuel hose from the fuel injection 
hose, slide the cover...

THROTTLE BODIES
7-4
EAS26970
THROTTLE BODIES
Removing the throttle bodies
Order Job/Parts to remove Q’ty RemarksSeat Refer to GENERAL CHASSIS on page 4-1.
Left front cowling inner panel Refer to GENERAL CHASSIS on page 4-1.
Right front cowling inner panel Refer to GENERAL CHASSIS on page 4-1.
Fuel tank Refer to FUEL TANK on page 7-1.
Battery Refer to GENERAL CHASSIS on page 4-1.
Air filter case Refer to GENERAL CHASSIS on page 4-1.
Battery box and battery box bracket Refer to GENERAL CHASSIS on page...

THROTTLE BODIES
7-5
Removing the injectors
Order Job/Parts to remove Q’ty Remarks1 Throttle position sensor coupler 1 Disconnect.
2 Intake air pressure sensor coupler 1 Disconnect.
3 Cylinder #1 injector coupler 1 Disconnect.
4 Cylinder #2 injector coupler 1 Disconnect.
5 Cylinder #3 injector coupler 1 Disconnect.
6 Cylinder #4 injector coupler 1 Disconnect.
7 Sub-wire harness 1
8 Negative pressure hose 1
9 Intake air pressure sensor 1
10 Fuel distributor 1
11 Injector 4
12 Throttle position sensor 1
13...