Yamaha FZS6W 07 User Manual

SPECIAL TOOLS
1-12
Pocket tester
90890-03112
Analog pocket tester
YU-03112-C1-9, 5-38, 8-65, 
8-66, 8-67, 8-71, 
8-72, 8-73, 8-74, 
8-75, 8-76, 8-77, 
8-78, 8-79, 8-80, 
8-81, 8-82
Pressure gauge
90890-03153
YU-03153 3-14, 7-6
Oil pressure adapter H
90890-03139 3-14
Fuel pressure adapter
90890-03176
YM-03176 7-6
Valve spring compressor
90890-04019
YM-04019 5-21, 5-27
Valve spring compressor attachment
90890-04108
Valve spring compressor adapter 22 mm
YM-04108 5-21, 5-27
Middle driven shaft bearing...

SPECIAL TOOLS
1-13
Universal clutch holder
90890-04086
YM-910425-49, 5-51
Valve lapper
90890-04101
Valve lapping tool
YM-A8998 3-5
Valve guide remover (ø4)
90890-04111
Valve guide remover (4.0 mm)
YM-04111 5-23
Valve guide installer (ø4)
90890-04112
Valve guide installer (4.0 mm)
YM-04112 5-23
Valve guide reamer (ø4)
90890-04113
Valve guide reamer (4.0 mm)
YM-04113 5-23
Ignition checker
90890-06754
Opama pet-4000 spark checker
YM-34487 8-74
Yamaha bond No. 1215
(Three bond No.1215®)
90890-85505 5-32,...

2
SPECIFICATIONS
GENERAL SPECIFICATIONS...................................................................... 2-1
ENGINE SPECIFICATIONS .......................................................................... 2-2
CHASSIS SPECIFICATIONS ........................................................................ 2-9
ELECTRICAL SPECIFICATIONS ............................................................... 2-12
TIGHTENING TORQUES ...............................................................................

GENERAL SPECIFICATIONS
2-1
EAS20280
GENERAL SPECIFICATIONS
ModelModel 4S82 (U.S.A.)  4S83 (California)
 
Dimensions
Overall length 2095 mm (82.5 in)
Overall width 750 mm (29.5 in)
Overall height 1210 mm (47.6 in)
Seat height 795 mm (31.3 in)
Wheelbase 1440 mm (56.7 in)
Ground clearance 145 mm (5.71 in)
Minimum turning radius 2800 mm (110.2 in)
 
WeightWith oil and fuel 207.0 kg (456 lb) (FZS6W)  208.0 kg (459 lb) (FZS6WC)
Maximum load 189 kg (417 lb) (FZS6WC)  190 kg (419 lb) (FZS6W)
  

ENGINE SPECIFICATIONS
2-2
EAS20290
ENGINE SPECIFICATIONS
EngineEngine type Liquid cooled 4-stroke, DOHC
Displacement 600.0 cm³
Cylinder arrangement Forward-inclined parallel 4-cylinder
Bore  × stroke 65.5  × 44.5 mm (2.58  × 1.75 in)
Compression ratio 12.20 :1
Standard compression pressure (at sea level) 1550 kPa/400 r/min (220.5 psi/400 r/min) (15.5 kgf/cm²/400 r/min)
Minimum–maximum 1300–1650 kPa (184.9–234.7 psi) (13.0–16.5 kgf/cm²)
Starting system Electric starter
 
Fuel Recommended fuel Unleaded...

ENGINE SPECIFICATIONS
2-3
Water pumpWater pump type Single su ction centrifugal pump
Reduction ratio 86/44  × 31/31 (1.955)
Max. impeller shaft tilt 0.15 mm (0.006 in)
 
Spark plug (s) Manufacturer/model NGK/CR9EK
Spark plug gap 0.6–0.7 mm (0.024–0.028 in)
 
Cylinder headVolume 10.33–10.93 cm³ (0.63–0.67 cu.in)
Warpage limit 0.05 mm (0.0020 in)
 
CamshaftDrive system Chain drive (right)
Camshaft cap inside diameter 23.008–23.029 mm (0.9058–0.9067 in)
Camshaft journal diameter 22.967–22.980 mm...

ENGINE SPECIFICATIONS
2-4
Valve dimensionsValve head diameter A (intake) 24.90–25.10 mm (0.9803–0.9882 in)
Valve head diameter A (exhaust) 21.90–22.10 mm (0.8622–0.8701 in)
Valve face width B (intake) 1.140–1.980 mm (0.0449–0.0780 in)
Valve face width B (exhaust) 1.140–1.980 mm (0.0449–0.0780 in)
Valve seat width C (intake) 0.90–1.10 mm (0.0354–0.0433 in)
Limit 1.6 mm (0.06 in)
Valve seat width C (exhaust) 0.90–1.10 mm (0.0354–0.0433 in)
Limit 1.6 mm (0.06 in)
Valve margin thickness D (intake) 0.60–0.80...

ENGINE SPECIFICATIONS
2-5
Limit 1.6 mm (0.06 in) 
Valve springInner spring
Free length (intake) 37.04 mm (1.46 in)
Limit 35.20 mm (1.39 in)
Free length (exhaust) 41.79 mm (1.65 in)
Limit 39.70 mm (1.56 in)
Installed length (intake) 30.02 mm (1.18 in)
Installed length (exhaust) 36.12 mm (1.42 in)
Spring rate K1 (intake) 10.50 N/mm (59.96 lb/in) (1.07 kgf/mm)
Spring rate K2 (intake) 17.00 N/mm (97.07 lb/in) (1.73 kgf/mm)
Spring rate K1 (exhaust) 30.26 N/mm (172.78 lb/in) (3.09 kgf/mm)
Spring rate K2...

ENGINE SPECIFICATIONS
2-6
Offset 0.50 mm (0.0197 in)
Offset direction Intake side
Piston pin bore inside diameter 16.002–16.013 mm (0.6300–0.6304 in)
Limit 16.043 mm (0.6316 in)
Piston pin outside diameter 15.991–16.000 mm (0.6296–0.6299 in)
Limit 15.971 mm (0.6288 in)
Piston-pin-to-piston-pin-bore clearance 0.002–0.022 mm (0.0001–0.0009 in)
Limit 0.072 mm (0.0028 in)
 
Piston ring
Top ringRing type Barrel
Dimensions (B  × T) 0.90  × 2.45 mm (0.04  × 0.10 in)
End gap (installed) 0.25–0.35 mm...

ENGINE SPECIFICATIONS
2-7
CrankshaftWidth A 51.850–52.550 mm (2.04–2.06 in)
Width B 268.80–270.00 mm (10.58–10.63 in)
Runout limit C 0.030 mm (0.0012 in)
Big end side clearance D 0.160–0.262 mm (0.0063–0.0103 in)
Big end radial clearance 0.028–0.052 mm (0.0011–0.0020 in)
Small end free play 0.32–0.50 mm (0.01–0.02 in)
Journal oil clearance (using plastigauge®) 0.034–0.058 mm (0.0013–0.0023 in)
Limit 0.10 mm (0.0039 in)
Bearing color code 0.White 1.Black 2.Brown 3.Green 4.Yellow
 
ClutchClutch type Wet,...