Yamaha FZS6W 07 User Manual

							
ENGINE
3-16
CAUTION:
ECA4S81008
Never operate the engine without the air fil-
ter element installed. Unfiltered air will 
cause rapid wear of engine parts and may 
damage the engine. Operating the engine 
without the air filter element will also affect 
throttle bodies synchronization, leading to 
poor engine performance and possible 
overheating.
NOTE:
When installing the air filter element into the air 
filter case cover, make sure their sealing sur-
faces are aligned to prevent any air leaks.
6. Install: Fuel tank
Refer to FUEL TANK on page 7-1.
Seat Refer to GENERAL CHASSIS on page 4-
1.
EAS21010
CHECKING THE THROTTLE BODY JOINTS
The following procedure applies to all of the 
throttle body joints and intake manifolds.
1. Remove: Throttle bodies
Refer to THROTTLE BODIES on page 7-
4.
2. Check:
 Throttle body joints “1”Cracks/damage  → Replace.
3. Install:  Throttle bodiesRefer to THROTTLE BODIES on page 7-
4.
EAS21030
CHECKING THE FUEL LINE
The following procedure applies to all of the 
fuel, vacuum and breather hoses.
1. Remove:Seat Refer to GENERAL CHASSIS on page 4-
1.
Fuel tank
Refer to FUEL TANK on page 7-1.
2. Check:  Breather hose “1”
Fuel hose “2”
Cracks/damage  → Replace.
Loose connection  → Connect properly.
NOTE:
 Before removing the fuel hose, place a few 
rags in the area under where it will be 
removed.
 There is a white mark on the fuel tank 
breather hose.
Refer to CABLE ROUTING on page 2-47.
CAUTION:
ECA14940
Make sure the fuel tank breather hose is 
routed correctly.
3. Install:Fuel tankRefer to FUEL TANK on page 7-1.
Seat
Refer to GENERAL CHASSIS on page 4-
1.
EAS21070
CHECKING THE CRANKCASE BREATHER 
HOSE
1. Remove:Seat
Refer to GENERAL CHASSIS on page 4-
1.
Fuel tank Refer to FUEL TANK on page 7-1.
2. Check:  Crankcase breather hose “1”Cracks/damage  → Replace.
Loose connection  → Connect properly. 
						

							
ENGINE
3-17
CAUTION:
ECA13450
Make sure the crankcase breather hose is 
routed correctly.
3. Install: Fuel tank
Refer to FUEL TANK on page 7-1.
Seat Refer to GENERAL CHASSIS on page 4-
1.
EAS21080
CHECKING THE EXHAUST SYSTEM
The following procedure applies to all of the 
exhaust pipes and gaskets.
1. Remove:Radiator
Refer to RADIATOR on page 6-1.
2. Check:  Exhaust pipe “1”
 Catalytic converter pipe “2”
 Muffler “3”Cracks/damage  → Replace.
Gasket “4” Exhaust gas leaks  → Replace.
3. Check:
 Tightening torque
 Exhaust pipe nut “5”
 Catalytic converter joint bolt “6”
 Muffler joint bolt “7”
 Muffler stay bolt “8”
 Exhaust pipe stay bolt “9”
 Catalytic converter pipe stay bolt “10” 4. Install:
RadiatorRefer to RADIATOR on page 6-1.
EAS21110
CHECKING THE COOLANT LEVEL
1. Stand the vehicle on a level surface.
NOTE:
 Place the vehicle on a suitable stand.
 Make sure the vehicle is upright.
2. Check: Coolant levelThe coolant level should be between the 
maximum level mark “a” and minimum level 
mark “b”.
Below the minimum level mark  → Add the 
recommended coolant to the proper level.
Exhaust pipe nut 20 Nm (2.0 m·kg, 15 ft·lb)
Catalytic converter joint bolt 20 Nm (2.0 m·kg, 15 ft·lb)
Muffler joint bolt 20 Nm (2.0 m·kg, 15 ft·lb)
Muffler stay bolt 20 Nm (2.0 m·kg, 15 ft·lb)
Exhaust pipe stay bolt 20 Nm (2.0 m·kg, 15 ft·lb)
Catalytic converter pipe stay 
bolt
20 Nm (2.0 m·kg, 15 ft·lb) 
						

							
ENGINE
3-18
CAUTION:
ECA13470
 Adding water instead of coolant lowers the antifreeze content of the coolant. If 
water is used instead of coolant check, 
and if necessary, correct the antifreeze 
concentration of the coolant.
 Use only distilled water. However, if dis- tilled water is not available, soft water 
may be used.
3. Start the engine, warm it up for several  minutes, and then turn it off.
4. Check:  Coolant level
NOTE:
Before checking the coolant level, wait a few 
minutes until it settles.
EAS21120
CHECKING THE COOLING SYSTEM
1. Check: Radiator “1”
 Radiator inlet hose “2”
 Radiator outlet hose “3”
Oil cooler “4”
 Oil cooler inlet hose “5”
 Oil cooler outlet hose “6”
 Water jacket joint “7”
 Water jacket joint hose “8”
 Oil cooler inlet pipe “9”
 Water pump outlet hose “10”Cracks/damage  → Replace.
Refer to RADIATOR on page 6-1.
EAS21130
CHANGING THE COOLANT
1. Remove:
 Coolant reservoir “1”
 Coolant reservoir cap “2”
2. Drain:  Coolant
(from the coolant reservoir) 
						

							
ENGINE
3-19
3. Remove: Radiator cap lock bolt “1”
 Radiator cap “2”
WARNING
EWA13030
A hot radiator is under pressure. Therefore, 
do not remove the radiator cap when the 
engine is hot. Scalding hot fluid and steam 
may be blown out, which could cause seri-
ous injury. When the engine has cooled, 
open the radiator cap as follows:
Place a thick rag or a towel over the radia-
tor cap and slowly turn the radiator cap 
counterclockwise toward the detent to 
allow any residual pressure to escape. 
When the hissing sound has stopped, 
press down on the radiator cap and turn it 
counterclockwise to remove.
The following procedure applies to all of the 
coolant drain bolts  and copper washers.
4. Remove:
 Coolant drain bolt (water pump) “1”(along with the copper washer)
5. Drain:  Coolant(from the engine and radiator)
6. Check:
 Copper washer “1” 
7. Install:  Coolant drain bolt (water pump) “2” 8. Install:
 Coolant reservoir
9. Fill:  Cooling system
(with the specified amount of the recom-
mended coolant)
Handling notes for coolant
Coolant is potentially harmful and should 
be handled with special care.
WARNING
EWA13040
 If coolant splashes in your eyes, thor-oughly wash them with water and consult 
a doctor.
 If coolant splashes on your clothes,  quickly wash it away with water and then 
with soap and water.
 If coolant is swallowed, induce vomiting 
and get immediate medical attention.
New
Coolant drain bolt (water pump) 10 Nm (1.0 m·kg, 7.2 ft·lb)
Recommended antifreezeHigh-quality ethylene glycol
antifreeze containing corrosion
inhibitors for aluminum engines
Mixing ratio
1:1 (antifreeze:water)
Radiator capacity (including all
routes)
2.00 L (2.11 US qt) (1.76
Imp.qt)
Coolant reservoir capacity (up
to the maximum level mark) 0.25 L (0.26 US qt) (0.22
Imp.qt) 
						

							
ENGINE
3-20
CAUTION:
ECA13480
 Adding water instead of coolant lowers the antifreeze content of the coolant. If 
water is used instead of coolant check, 
and if necessary, correct the antifreeze 
concentration of the coolant.
 Use only distilled water. However, if dis- tilled water is not available, soft water 
may be used.
 If coolant comes into contact with painted  surfaces, immediately wash them with 
water.
 Do not mix different types of antifreeze.
10. Install:Radiator cap
11. Fill:  Coolant reservoir(with the recommended coolant to the max-
imum level mark “a”)
12. Install:  Coolant reservoir cap
13. Start the engine, warm it up for several  minutes, and then stop it.
14. Check:  Coolant levelRefer to CHECKING THE COOLANT 
LEVEL on page 3-17.
NOTE:
Before checking the coolant level, wait a few 
minutes until the coolant has settled. 
						

							
CHASSIS
3-21
EAS21140
CHASSIS
EAS21160
ADJUSTING THE FRONT DISC BRAKE
1. Adjust: Brake lever position(distance “a” from the throttle grip to the 
brake lever)
NOTE:
 While pushing the brake lever forward, turn the adjusting dial “1” until the brake lever is in 
the desired position.
 Be sure to align the setting on the adjusting 
dial with the arrow mark “2” on the brake 
lever holder.
WARNING
EWA13060
 After adjusting the brake lever position, make sure the pin on the brake lever 
holder is firmly inserted in the hole in the 
adjusting dial.
 A soft or spongy feeling in the brake lever  can indicate the presence of air in the 
brake system. Before the vehicle is oper-
ated, the air must be removed by bleeding 
the brake system. Air in the brake system 
will considerably reduce in loss of control 
and possibly an accident. Therefore, 
check and if necessary, bleed the brake 
system.
CAUTION:
ECA13490
After adjusting the brake lever position, 
make sure there is no brake drag.
EAS21190
ADJUSTING THE REAR DISC BRAKE
1. Check:
 Brake pedal position(distance “a” from the top of the rider foot-
rest to the top of the brake pedal)
Out of specification  → Adjust.
2. Adjust:  Brake pedal position
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Loosen the locknut “1”.
b. Turn the adjusting bolt “2” in direction “a” or  “b” until the specified brake pedal position 
is obtained.
WARNING
EWA13070
After adjusting the brake pedal position, 
check that the end of the adjusting bolt “c” 
is visible through the hole “d”.
c. Tighten the locknut “1” to specification.
Position #1
Distance “a” is the largest.
Position #5 Distance “a” is the smallest.
Brake pedal position (below the
top of the rider footrest)25.8 mm (1.02 in)
Direction “a”
Brake pedal is raised.
Direction “b” Brake pedal is lowered. 
						

							
CHASSIS
3-22
WARNING
EWA4S81005
A soft or spongy feeling in the brake pedal 
can indicate the presence of air in the brake 
system. Before the vehicle is operated, the 
air must be removed by bleeding the brake 
system. Air in the brake system will consid-
erably reduce braking performance.
CAUTION:
ECA13510
After adjusting the brake pedal position, 
make sure there is no brake drag.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
3. Adjust: Rear brake light switch
Refer to ADJUSTING THE REAR BRAKE 
LIGHT SWITCH on page 3-23.
EAS21240
CHECKING THE BRAKE FLUID LEVEL
1. Stand the vehicle on a level surface.
NOTE:
 Place the vehicle on a suitable stand.
 Make sure the vehicle is upright.
2. Check: Brake fluid level
Below the minimum level mark “a”  → Add 
the recommended brake fluid to the proper 
level.
WARNING
EWA13090
 Use only the designated brake fluid.  Other brake fluids may cause the rubber 
seals to deteriorate, causing leakage and 
poor brake performance.
 Refill with the same type of brake fluid  that is already in the system. Mixing brake 
fluids may result in a harmful chemical 
reaction, leading to poor brake perfor-
mance.
 When refilling, be careful that water does 
not enter the brake fluid reservoir. Water 
will significantly lower the boiling point of 
the brake fluid and could cause vapor 
lock.
CAUTION:
ECA13540
Brake fluid may damage painted surfaces 
and plastic parts. Therefore, always clean 
up any spilt brake fluid immediately.
NOTE:
In order to ensure a correct reading of the 
brake fluid level, make sure the top of the 
brake fluid reservoir is horizontal.
EAS21250
CHECKING THE FRONT BRAKE PADS
The following procedure applies to all of the 
brake pads.
1. Operate the brake.
2. Check: Front brake padWear indicators “a” almost touch the brake 
disc  → Replace the brake pads as a set.
Refer to FRONT BRAKE on page 4-15.
Locknut
18 Nm (1.8 m·kg, 13 ft·lb)
Recommended fluidDOT 4
A. Front brake
B. Rear brake 
						

							
CHASSIS
3-23
EAS21260
CHECKING THE REAR BRAKE PADS
The following procedure applies to all of the 
brake pads.
1. Operate the brake.
2. Check: Rear brake padWear indicators “b” almost touch the brake 
disc  → Replace the brake pads as a set.
Refer to REAR BRAKE on page 4-27.
EAS21280
CHECKING THE FRONT BRAKE HOSES
The following procedure applies to all of the 
brake hoses and brake hose clamps.
1. Check:  Brake hoseCracks/damage/wear  → Replace.
2. Check:  Brake hose clamp
Loose  → Tighten the clamp bolt.
3. Hold the vehicle upright and apply the  brake several times.
4. Check:
 Brake hoseBrake fluid leakage  → Replace the dam-
aged hose.
Refer to FRONT BRAKE on page 4-15.
EAS21290
CHECKING THE REAR BRAKE HOSE
1. Check:
 Brake hoseCracks/damage/wear  → Replace.
2. Check:  Brake hose clampLoose Connection  → Tighten the clamp 
bolt.
3. Hold the vehicle upright and apply the rear  brake several times.
4. Check:  Brake hoseBrake fluid leakage  → Replace the dam-
aged hose.
Refer to REAR BRAKE on page 4-27.
EAS21330
ADJUSTING THE REAR BRAKE LIGHT 
SWITCH
NOTE:
The rear brake light switch is operated by 
movement of the brake pedal. The rear brake 
light switch is properly adjusted when the 
brake light comes on just before the braking 
effect starts.
1. Check:  Rear brake light operation timingIncorrect  → Adjust.
2. Adjust:  Rear brake light operation timing
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Hold the main body “1” of the rear brake  light switch so that it does not rotate and 
turn the adjusting nut “2” in direction “a” or 
“b” until the rear brake light comes on at the 
proper time.
Direction “a”
Brake light comes on sooner.
Direction “b” Brake light comes on later. 
						

							
CHASSIS
3-24
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
EAS21340
BLEEDING THE HYDRAULIC BRAKE SYS-
TEM
WARNING
EWA13100
Bleed the hydraulic brake system when-
ever:
 the system is disassembled.
 a brake hose is loosened, disconnected or replaced.
 the brake fluid level is very low.
 brake operation is faulty.
NOTE:
 Be careful not to spill any brake fluid or allow  the brake master cylinder reservoir or brake 
fluid reservoir to overflow.
 When bleeding the hydraulic brake system, 
make sure there is always enough brake fluid 
before applying the brake. Ignoring this pre-
caution could allow air to enter the hydraulic 
brake system, consider ably lengthening the 
bleeding procedure.
 If bleeding is difficult, it may be necessary to 
let the brake fluid settle for a few hours. 
Repeat the bleeding procedure when the tiny 
bubbles in the hose have disappeared.
1. Bleed:  Hydraulic brake system
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Fill the brake fluid reservoir to the proper  level with the recommended brake fluid.
b. Install the diaphragm (brake master cylin- der reservoir or  brake fluid reservoir).
c. Connect a clear plastic hose “1” tightly to 
the bleed screw “2”. d. Place the other end of the hose into a con-
tainer.
e. Slowly apply the brake lever several times.
f. Fully pull the brake lever or fully press  down the brake pedal and hold it in posi-
tion.
g. Loosen the bleed screw.
NOTE:
Loosening the bleed screw will release the 
pressure and cause the brake lever to contact 
the throttle grip or the brake pedal to fully 
extend.
h. Tighten the bleed screw and then release  the brake lever or brake pedal.
i. Repeat steps (e) to (h) until all of the air 
bubbles have disappeared from the brake 
fluid in the plastic hose.
j. Tighten the bleed screw to specification.
k. Fill the brake fluid reservoir to the proper 
level with the recommended brake fluid.
Refer to CHECKING THE BRAKE FLUID 
LEVEL on page 3-22.
A. Front
B. Rear
Bleed screw6 Nm (0.6 m·kg, 4.3 ft·lb) 
						

							
CHASSIS
3-25
WARNING
EWA13110
After bleeding the hydraulic brake system, 
check the brake operation.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
EAS21370
ADJUSTING THE SHIFT PEDAL
1. Check: Shift pedal positionAlign the center of shift pedal “1” and cen-
ter of footrest bracket bolt “2” in a straight 
line.
Incorrect  → Adjust.
2. Adjust:  Shift pedal position
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Loosen both locknuts “1”.
b. Turn the shift rod “2” in direction “a” or “b” to  obtain the correct shift pedal position.
c. Tighten both locknuts.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
EAS21390
ADJUSTING THE DRIVE CHAIN SLACK
NOTE:
The drive chain slack must be checked at the 
tightest point on the chain.
CAUTION:
ECA13550
A drive chain that is too tight will overload 
the engine and other vital parts, and one 
that is too loose can skip and damage the 
swingarm or cause an accident. Therefore, 
keep the drive chain slack within the speci-
fied limits.
1. Stand the vehicle on a level surface.
WARNING
EWA13120
Securely support the vehicle so that there 
is no danger of it falling over.
NOTE:
Place the vehicle on a suitable stand so that 
the rear wheel is elevated.
2. Spin the rear wheel several times and find  the tightest position of drive chain.
3. Check:
 Drive chain slack “a”Out of specification  → Adjust.
4. Adjust:  Drive chain slack
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Loosen the wheel axle nut “1”.
b. Loosen both locknuts “2”.
c. Turn both adjusting nuts “3” in direction “a” 
or “b” until the specified drive chain slack is 
obtained.
Direction “a”
Shift pedal is raised.
Direction “b” Shift pedal is lowered.
Drive chain slack45.0–55.0 mm (1.77–2.17 in)