Yamaha FZS6W 07 User Manual
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ENGINE 3-6 Since valve pads of various sizes are origi-nally installed, the valve pad number must be rounded in order to reach the closest equiva- lent to the original. c. Round off the original valve pad number according to the following table. EXAMPLE: Original valve pad number = 148 (thickness = 1.48 mm (0.058 in)) Rounded value = 150 d. Locate the rounded number of the original valve pad and the measured valve clear- ance in the valve pad selection table. The point where the column and row intersect is the new valve pad number. NOTE: The new valve pad number is only an approxi- mation. The valve clearance must be mea- sured again and the above steps should be repeated if the measurement is still incorrect. e. Install the new valve pad “1” and the valve lifter “2”. NOTE: Lubricate the valve pad with molybdenum disulfide grease. Lubricate the valve lifter with molybdenum disulfide oil. The valve lifter must turn smoothly when rotated by hand. Install the valve lifter and the valve pad in the correct place. f. Install the exhaust and intake camshafts, timing chain and camshaft caps. NOTE: Refer to CAMSHAFTS on page 5-8. Lubricate the camshaft bearings, camshaft lobes and camshaft journals. First, install the exhaust camshaft. Align the camshaft marks with the camshaft cap marks. Turn the crankshaft counterclockwise several full turns to seat the parts. g. Measure the valve clearance again. h. If the valve clearance is still out of specifi- cation, repeat all of the valve clearance adjustment steps until the specified clear- ance is obtained. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 7. Install: All removed parts NOTE: For installation, reverse the removal proce- dure. EAS20570 SYNCHRONIZING THE THROTTLE BODIES NOTE: Prior to synchronizing the throttle bodies, the valve clearance and the engine idling speed should be properly adjusted and the ignition timing should be checked. 1. Stand the vehicle on a level surface. NOTE: Place the vehicle on a suitable stand. 2. Remove:Seat Refer to GENERAL CHASSIS on page 4- 1. Fuel tank Refer to FUEL TANK on page 7-1. Last digit Rounded value 0 or 2 0 55 810 Camshaft cap bolt10 Nm (1.0 m·kg, 7.2 ft·lb)
ENGINE 3-7 Air filter caseRefer to GENERAL CHASSIS on page 4- 1. 3. Install: Vacuum gauge “1”(onto the synchronizing hose “2”) 4. Install: Air filter caseRefer to GENERAL CHASSIS on page 4- 1. Fuel tank Refer to FUEL TANK on page 7-1. 5. Start the engine and let it warm up for sev- eral minutes. 6. Check: Engine idling speed Out of specification → Adjust. Refer to ADJUSTING THE ENGINE IDLING SPEED on page 3-8. 7. Adjust: Throttle body synchronization ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. With throttle body #1 “2” as standard, adjust throttle bodies #2 “3”, #3 “4”, and #4 “5” using the air screw “1”. NOTE: After each step, rev the engine two or three times, each time for less than a second, and check the synchronization again. If the air screw is removed, turn the screw 3/ 4 turn in and be sure to synchronize the throttle body. CAUTION: ECA14900 Do not use the throttle valve adjusting screws to adjust the throttle body syncroni- zation. NOTE: The difference in vacuum pressure between two throttle bodies should not exceed 1.33 kPa (10 mmHg). ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 8. Measure: Engine idling speed Out of specification → Adjust. Make sure that the vacuum pressure is within specification. 9. Stop the engine and remove the measuring equipment. 10. Adjust: Throttle cable free playRefer to ADJUSTING THE THROTTLE CABLE FREE PLAY on page 3-8. Vacuum gauge90890-03094 Carburetor synchronizer YU-44456 Engine idling speed1250–1350 r/min Vacuum gauge90890-03094 Carburetor synchronizer YU-44456 Intake vacuum29.0 kPa (8.6 inHg) (218 mmHg)
ENGINE 3-8 11. Install: Fuel tank Refer to FUEL TANK on page 7-1. Seat Refer to GENERAL CHASSIS on page 4- 1. EAS20610 ADJUSTING THE ENGINE IDLING SPEED NOTE: Prior to adjusting the engine idling speed, the throttle bodies synchronization should be adjusted properly, the air filter element should be clean, and the engine should have ade- quate compression. 1. Start the engine and let it warm up for sev- eral minutes. 2. Check: Engine idling speed Out of specification → Adjust. 3. Adjust: Engine idling speed ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Turn the idle adjusting screw “1” in direction “a” or “b” until the specified engine idling speed is obtained. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 4. Adjust: Throttle cable free playRefer to ADJUSTING THE THROTTLE CABLE FREE PLAY on page 3-8. EAS20630 ADJUSTING THE THROTTLE CABLE FREE PLAY NOTE: Prior to adjusting the throttle cable free play, the engine idling speed and throttle bodies synchronization should be adjusted properly. 1. Check: Throttle cable free play “a”Out of specification → Adjust. 2. Remove: Seat Refer to GENERAL CHASSIS on page 4- 1. Fuel tank Refer to FUEL TANK on page 7-1. Air filter case Refer to GENERAL CHASSIS on page 4- 1. Battery Refer to GENERAL CHASSIS on page 4- 1 and CHECKING AND CHARGING THE BATTERY on page 8-68. 3. Adjust: Throttle cable free play NOTE: When the throttle is opened, the accelerator cable “1” is pulled. ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ Throttle body side a. Loosen the locknut “2” on the decelerator cable. Throttle cable free play3.0–5.0 mm (0.12–0.20 in) Engine idling speed1250–1350 r/min Direction “a” Engine idling speed is increased. Direction “b” Engine idling speed is decreased. Throttle cable free play3.0–5.0 mm (0.12–0.20 in) Throttle cable free play3.0–5.0 mm (0.12–0.20 in)
ENGINE 3-9 b. Turn the adjusting nut “3” in direction “a” or “b” to take up any slack on the decelerator cable. c. Tighten the locknuts NOTE: If the specified throttle cable free play cannot be obtained on the throttle body side of the cable, use the adjusting nut on the handlebar side. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ Handlebar side a. Loosen the locknut “1”. b. Turn the adjusting nut “2” in direction “a” or “b” until the specified throttle cable free play is obtained. c. Tighten the locknut ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 4. Install: BatteryRefer to GENERAL CHASSIS on page 4- 1 and CHECKING AND CHARGING THE BATTERY on page 8-68. Air filter case Refer to GENERAL CHASSIS on page 4- 1. Fuel tank Refer to FUEL TANK on page 7-1. Seat Refer to GENERAL CHASSIS on page 4- 1. WARNING EWA4S81001 After adjusting the throttle cable free play, start the engine and turn the handlebar to the right and to the left to ensure that this does not cause the engine idling speed to change. EAS20680 CHECKING THE SPARK PLUGS The following procedure applies to all of the spark plugs. 1. Remove: Radiator lower bolt “1” Radiator lower hose bracket bolt “2” Refer to RADIATOR on page 6-1. 2. Disconnect: Spark plug caps 3. Remove: Spark plugs Direction “a” Throttle cable free play is increased. Direction “b” Throttle cable free play is decreased. Direction “a” Throttle cable free play is increased. Direction “b” Throttle cable free play is decreased.
ENGINE 3-10 CAUTION: ECA13320 Before removing the spark plugs, blow away any dirt accumulated in the spark plug wells with compressed air to prevent it from falling into the cylinders. 4. Check: Spark plug type Incorrect → Change. 5. Check: Electrode “1”Damage/wear → Replace the spark plug. Insulator “2” Abnormal color → Replace the spark plug. Normal color is medium-to-light tan. 6. Clean: Spark plug(with a spark plug cleaner or wire brush) 7. Measure: Spark plug gap “a”(with a wire thickness gauge) Out of specification → Regap. 8. Install: Spark plugs NOTE: Before installing the spark plug, clean the spark plug and gasket surface. 9. Connect: Spark plug caps 10. Install: Radiator lower hose bracket bolt Radiator lower boltRefer to RADIATOR on page 6-1. EAS20710 MEASURING THE COMPRESSION PRES- SURE The following procedure applies to all of the cylinders. NOTE: Insufficient compression pressure will result in a loss of performance. 1. Measure: Valve clearance Out of specification → Adjust. Refer to ADJUSTING THE VALVE CLEARANCE on page 3-4. 2. Start the engine, warm it up for several minutes, and then turn it off. 3. Remove: SeatRefer to GENERAL CHASSIS on page 4- 1. Fuel tank Refer to FUEL TANK on page 7-1. Air filter case Refer to GENERAL CHASSIS on page 4- 1. A. Right side #1, #2 and #3 B. Left side #4 Manufacturer/modelNGK/CR9EK Spark plug gap 0.6–0.7 mm (0.024–0.028 in) Spark plug18 Nm (1.8 m·kg, 13 ft·lb)
ENGINE 3-11 BatteryRefer to GENERAL CHASSIS on page 4- 1 and CHECKING AND CHARGING THE BATTERY on page 8-68. Battery box Battery box bracket Refer to GENERAL CHASSIS on page 4- 1. Heat protector plate Cover Ignition coils 4. Disconnect: Spark plug caps 5. Remove: Spark plugs CAUTION: ECA13340 Before removing the spark plugs, use com- pressed air to blow away any dirt accumu- lated in the spark plug wells to prevent it from falling into the cylinders. 6. Install: Compression gauge “1” 7. Measure: Compression pressure Out of specification → Refer to steps (c) and (d). ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Set the main switch to “ON”. b. With the throttle wide open, crank the engine until the reading on the compres- sion gauge stabilizes. WARNING EWA4S81003 To prevent sparking, ground all spark plug leads before cranking the engine. CAUTION: ECA13340 Before removing the spark plugs, use com- pressed air to blow away any dirt accumu- lated in the spark plug wells to prevent it from falling into the cylinders. NOTE: The difference in compression pressure between cylinders should not exceed 100 kPa (1 kg/cm², 14 psi). c. If the compression pressure is above the maximum specification, check the cylinder head, valve surfaces and piston crown for carbon deposits. Carbon deposits → Eliminate. d. If the compression pressure is below the minimum specification, pour a teaspoonful of engine oil into the spark plug bore and measure again. Refer to the following table. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 8. Install: Spark plugs 9. Connect: Spark plug caps 10. Install: Ignition coils Cover Compression gauge90890-03081 Engine compression tester YU-33223 Standard compression pres- sure (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) Compression pressure (with oil applied into the cylinder) Reading Diagnosis Higher than without oil Piston ring(s) wear or damage → Repair. Same as without oil Piston, valves, cylin- der head gasket or piston possibly defec- tive → Repair. Spark plug 18 Nm (1.8 m·kg, 13 ft·lb)
ENGINE 3-12 Heat protector plate Battery box bracket Battery boxRefer to GENERAL CHASSIS on page 4- 1. Battery Refer to GENERAL CHASSIS on page 4- 1 and CHECKING AND CHARGING THE BATTERY on page 8-68. Air filter case Refer to GENERAL CHASSIS on page 4- 1. Fuel tank Refer to FUEL TANK on page 7-1. Seat Refer to GENERAL CHASSIS on page 4- 1. EAS20730 CHECKING THE ENGINE OIL LEVEL 1. Stand the vehicle on a level surface. NOTE: Place the vehicle on a suitable stand. Make sure the vehicle is upright. 2. Start the engine, warm it up for several minutes, and then turn it off. 3. Check: Engine oil levelThe engine oil level should be between the minimum level mark “a” and maximum level mark “b”. Below the minimum level mark → Add the recommended engine oil to the proper level. CAUTION: ECA4S82001 Engine oil also lubricates the clutch and the wrong oil types or additives could cause clutch slippage. Therefore, do not add any chemical additives. Do not allow foreign materials to enter the crankcase. NOTE: Before checking the engine oil level, wait a few minutes until the oil has settled. 4. Start the engine, warm it up for several minutes, and then turn it off. 5. Check the engine oil level again. NOTE: Before checking the engine oil level, wait a few minutes until the oil has settled. EAS20790 CHANGING THE ENGINE OIL 1. Start the engine, warm it up for several minutes, and then turn it off. 2. Place a container under the engine oil drain bolt. 3. Remove: Engine oil filler cap “1” Engine oil drain bolt “2”(along with the gasket) Ty p eYAMALUBE 4, SAE10W30 or SAE 20W40 Recommended engine oil grade API service SG type or higher, JASO standard MA
ENGINE 3-13 4. Drain: Engine oil(completely from the crankcase) 5. If the oil filter cartridge is also to be replaced, perform the following procedure. ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Remove the oil filter cartridge “1” with an oil filter wrench “2”. b. Lubricate the O-ring “3” of the new oil filter cartridge with a thin coat of engine oil. CAUTION: ECA13390 Make sure the O-ring “3” is positioned cor- rectly in the groove of the oil filter car- tridge. c. Tighten the new oil filter cartridge to speci- fication with an oil filter wrench. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 6. Check: Engine oil drain bolt gasket 7. Install: Engine oil drain bolt(along with the new gasket) 8. Fill: Crankcase (with the specified amount of the recom- mended engine oil) 9. Install: Engine oil filler cap 10. Start the engine, warm it up for several minutes, and then turn it off. 11. Check: Engine(for engine oil leaks) 12. Check: Engine oil levelRefer to CHECKING THE ENGINE OIL LEVEL on page 3-12. EAS20820 MEASURING THE ENGINE OIL PRESSURE 1. Check: Engine oil levelBelow the minimum level mark → Add the recommended engine oil to the proper level. 2. Start the engine, warm it up for several minutes, and then turn it off. Oil filter wrench90890-01426 YU-38411 Oil filter cartridge 17 Nm (1.7 m·kg, 12 ft·lb) Engine oil drain bolt43 Nm (4.3 m·kg, 31 ft·lb) Engine oil quantityTotal amount 3.40 L (3.59 US qt) (2.99 Imp.qt) Without oil filter cartridge replacement 2.50 L (2.64 US qt) (2.20 Imp.qt) With oil filter cartridge replace- ment 2.80 L (2.96 US qt) (2.46 Imp.qt) New
ENGINE 3-14 CAUTION: ECA13410 When the engine is cold, the engine oil will have a higher viscosity, causing the engine oil pressure to increase. Therefore, be sure to measure the engine oil pressure after warming up the engine. 3. Remove: Oil gallery bolt “1” WARNING EWA12980 The engine, muffler and engine oil are extremely hot. 4. Install: Oil pressure gauge “1” Adapter “2” 5. Measure: Engine oil pressure(at the following conditions) Out of specification → Adjust. 6. Install: Main gallery bolt “1” EAS20870 ADJUSTING THE CLUTCH CABLE FREE PLAY 1. Check: Clutch cable free play “a”Out of specification → Adjust. Pressure gauge 90890-03153 YU-03153 Oil pressure adapter H 90890-03139 Engine oil pressure 240 kPa (34.1 psi) (2.4 kg/cm 2) Engine speed Approx 6,600 r/min Oil temperature 75.0–85.0 °C (167.00–185.00 ° F) Engine oil pressure Possible causes Below specification Faulty oil pump Clogged oil filter Leaking oil passage Broken or damaged oil seal Above specification Leaking oil passage Faulty oil filter Oil viscosity too high Main gallery bolt8 Nm (0.8 m·kg, 5.8 ft·lb) Clutch lever free play10.0–15.0 mm (0.39–0.59 in)
ENGINE 3-15 2. Adjust: Clutch cable free play ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ Handlebar side a. Turn the adjusting bolt “1” in direction “a” or “b” until the specified clutch cable free play is obtained. NOTE: If the specified clutch cable free play cannot be obtained on the handlebar side of the cable, use the adjusting nut on the engine side. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ Engine side a. Loosen the locknuts “1”. b. Turn the adjusting nut “2” in direction “a” or “b” until the specified clutch cable free play is obtained. c. Tighten the locknuts. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ EAS20950 CLEANING THE AIR FILTER ELEMENT 1. Remove: SeatRefer to GENERAL CHASSIS on page 4- 1. Fuel tank Refer to FUEL TANK on page 7-1. 2. Remove: Air filter case cover “1” Air filter element “2” 3. Clean: Air filter element(with solvent) 4. Check: Air filter elementDamage → Replace. 5. Install: Air filter element Air filter case cover Direction “a” Clutch cable free play is increased. Direction “b” Clutch cable free play is decreased. Direction “a” Clutch cable free play is increased. Direction “b” Clutch cable free play is decreased.