Yamaha FZS6W 07 User Manual

							
EAS20050
FZS6W/FZS6WC
SERVICE MANUAL
©2006 by Yamaha Motor 
 Corporation, U.S.A.
First edition, Octover 2006
All rights reserved. Any reproduction 
or unauthorized use without the written 
permission of  Yamaha Motor Corporation,  U.S.A. is expressly prohibited.
Printed inU.S.A.
P/N LIT-11616-20-60 
						

							
EAS20070
NOTICE
This manual was produced by the Yamaha Motor Company, Ltd. primarily for use by Yamaha deal-
ers and their qualified mechanics. It is not possible to include all the knowledge of a mechanic in one 
manual. Therefore, anyone who uses this book to perform maintenance and repairs on Yamaha 
vehicles should have a basic understanding of mechanics and the techniques to repair these types 
of vehicles. Repair and maintenance work attempted by anyone without this knowledge is likely to 
render the vehicle unsafe and unfit for use.
This model has been designed and manufactured to pe rform within certain specifications in regard 
to performance and emissions. Proper service with the correct tools is necessary to ensure that the 
vehicle will operate as designed. If there is any qu estion about a service procedure, it is imperative 
that you contact a Yamaha dealer for any service information changes that apply to this model. This 
policy is intended to provide the customer with the  most satisfaction from his vehicle and to conform 
to federal environmental quality objectives.
Yamaha Motor Company, Ltd. is continually strivi ng to improve all of its models. Modifications and 
significant changes in specificati ons or procedures will be forwarded to all authorized Yamaha deal-
ers and will appear in future editions of this manual where applicable.
NOTE:
• This Service Manual contains information regarding periodic maintenance to the emission control 
system. Please read this material carefully.
 Designs and specifications are  subject to change without notice.
EAS20080
IMPORTANT MANUAL INFORMATION
Particularly important information is disti nguished in this manual by the following.
The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR 
SAFETY IS INVOLVED!
Failure to follow WARNING instructions could result in severe injury or death
 to 
the vehicle operator, a bystander or a  person checking or repairing the vehicle.
A CAUTION indicates special precautions that must be taken to avoid damage 
to the vehicle.
A NOTE provides key information to make procedures easier or clearer.WARNING
CAUTION:
NOTE: 
						

							
EAS20090
HOW TO USE THIS MANUAL
This manual is intended as a handy, easy-to-read reference book for the mechanic. Comprehensive 
explanations of all installation, removal, disassembly, assembly, repair and check procedures are 
laid out with the individual steps in sequential order.
 The manual is divided into chapters and each chapter is divided into sections. The current section  title is shown at the top of each page “1”.
 Sub-section titles appear in smaller print than the section title “2”.
 To help identify parts and clarify procedure steps, there are exploded diagrams at the start of each 
removal and disassembly section “3”.
 Numbers are given in the order of the jobs in  the exploded diagram. A number indicates a disas-
sembly step “4”.
 Symbols indicate parts to be lubricated or replaced “5”. Refer to “SYMBOLS”.
 A job instruction chart accompanies the exploded diagram, providing the order of jobs, names of  parts, notes in jobs, etc “6”.
 Jobs requiring more information (such as special tools and technical data) are described sequen-
tially “7”. 
						

							
EAS20100
SYMBOLS
The following symbols are used in this manual 
for easier understanding.
NOTE:
The following symbols are not relevant to every 
vehicle.
1. Serviceable with engine mounted
2. Filling fluid
3. Lubricant
4. Special tool
5. Tightening torque
6. Wear limit, clearance
7. Engine speed
8. Electrical data
9. Engine oil
10.Gear oil
11.Molybdenum-disulfide oil
12.Wheel-bearing grease
13.Lithium-soap-based grease
14.Molybdenum-disulfide grease
15.Apply locking agent (LOCTITE®)
GME
BLSM
91011
12 13 14
15 16
LTNew
T R..
123
456
78
16.Replace the part 
						

							
1
2
3
4
5
6
7
8
9
EAS20110
TABLE OF CONTENTS
GENERAL INFORMATION
SPECIFICATIONS
PERIODIC CHECKS AND ADJUSTMENTS
CHASSIS
ENGINE
COOLING SYSTEM
FUEL SYSTEM
ELECTRICAL SYSTEM
TROUBLESHOOTING 
						

							
1
GENERAL INFORMATION
IDENTIFICATION.......................................................................................... 1-1
VEHICLE IDENTIFICATION NUMBER ................................................... 1-1
MODEL LABEL .............................. ......................................................... 1-1
FEATURES ................................................................................................... 1-2
OUTLINE OF FI SYSTEM ...................................................................... 1-2
FI SYSTEM ............................................................................................. 1-3
INSTRUMENT FUNCTIONS .................................................................. 1-4
IMPORTANT INFORMATION ....................................................................... 1-7
PREPARATION FOR REMOVAL AND DISASSEMBLY .......................... 1-7
REPLACEMENT PARTS......................................................................... 1-7
GASKETS, OIL SEALS AND O- RINGS.................................................. 1-7
LOCK WASHERS/PLATES AND COTTER PINS ................................... 1-7
BEARINGS AND OIL SEAL S ................................................................. 1-8
CIRCLIPS ............................................................................................... 1-8
CHECKING THE CONNECTIONS ............................................................... 1-9
SPECIAL TOOLS ........................................................................................ 1-10 
						

							
IDENTIFICATION
1-1
EAS20130
IDENTIFICATION
EAS20140
VEHICLE IDENTIFICATION NUMBER
The vehicle identification number “1” is 
stamped into the right side of the steering 
head pipe.
EAS20150
MODEL LABEL
The model label “1” is affixed to the frame. This 
information will be needed to order spare 
parts.