Yamaha FZS6W 07 User Manual
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CHASSIS 3-26 NOTE: To maintain the proper wheel alignment, adjust both sides evenly. d. Tighten both locknuts to specification. e. Tighten the wheel axle nut to specification. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ EAS21440 LUBRICATING THE DRIVE CHAIN The drive chain consists of many interacting parts. If the drive chain is not maintained prop- erly, it will wear out quickly. Therefore, the drive chain should be serviced, especially when the vehicle is used in dusty areas. This vehicle has a drive chain with small rub- ber O-rings between each side plate. Steam cleaning, high-pressure washing, certain sol- vents, and the use of a coarse brush can dam- age these O-rings. Therefore, use only kerosene to clean the drive chain. Wipe the drive chain dry and thoroughly lubricate it with engine oil or chain lubricant that is suitable for O-ring chains. Do not use any other lubricants on the drive chain since they may contain sol- vents that could damage the O-rings. EAS21500 CHECKING AND ADJUSTING THE STEER- ING HEAD 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 front wheel is elevated. 2. Check: Steering headGrasp the bottom of the front fork legs and gently rock the front fork. Binding/looseness → Adjust the steering head. 3. Remove: Upper bracketRefer to STEERING HEAD on page 4-51. 4. Adjust: Steering head ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Remove the lock washer “1”, the upper ring nut “2”, and the rubber washer “3”. b. Tighten the lower ring nut “4” with a steer- ing nut wrench “5”. NOTE: Set the torque wrench at a right angle to the steering nut wrench. Direction “a” Drive chain is tightened. Direction “b” Drive chain is loosened. Locknut16 Nm (1.6 m·kg, 12 ft·lb) Wheel axle nut120 Nm (12 m·kg, 87 ft·lb) Recommended lubricant Engine oil or chain lubricant suitable for O-ring chains Steering nut wrench90890-01403 Spanner wrench YU-33975 Lower ring nut (initial tightening torque) 52 Nm (5.2 m·kg, 38 ft·lb)
CHASSIS 3-27 c. Loosen the lower ring nut “4” completely and then tighten it to specification with a steering nut wrench. WARNING EWA13140 Do not overtighten the lower ring nut. d. Check the steering head for looseness or binding by turning the front fork all the way in both directions. If any binding is felt, remove the lower bracket and check the upper and lower bearings. Refer to STEERING HEAD on page 4-51. e. Install the rubber washer “2”. f. Install the upper ring nut “3”. g. Finger tighten the upper ring nut “3”, then align the slots of both ring nuts. If neces- sary, hold the lower ring nut and tighten the upper ring nut until their slots are aligned. h. Install the lock washer “1”. NOTE: Make sure the lock washer tabs “a” sit correctly in the ring nut slots “b”. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 5. Install: Upper bracketRefer to STEERING HEAD on page 4-51. 6. Measure: Steering head tension ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ NOTE: Make sure all of the cables and wires are prop- erly routed. a. Point the front wheel straight ahead. b. Install a plastic locking tie “1” loosely around the end of the handlebar as shown. c. Hook a spring gauge “2” onto the plastic locking tie. d. Hold the spring gauge at a 90 ° angle from the handlebar, pull the spring gauge, and then record the measurement when the handlebar starts to run. e. Repeat the above procedure on the oppo- site handlebar. f. If the steering head tension is out of specifi- cation (both handlebars should be within specification), remove the upper bracket and loosen or tighten the upper ring nut. g. Reinstall the upper bracket and measure the steering head tension again as described above. h. Repeat the above procedure until the steer- ing head tension is within specification. i. Grasp the bottom of the front fork legs and gently rock the front fork. Binding/looseness → Adjust the steering head. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ Lower ring nut (final tightening torque) 18 Nm (1.8 m·kg, 13 ft·lb) Steering head tension200–500g
CHASSIS 3-28 EAS21530 CHECKING THE FRONT FORK 1. Stand the vehicle on a level surface. WARNING EWA13120 Securely support the vehicle so that there is no danger of it falling over. 2. Check: Inner tube “1”Damage/scratches → Replace. Oil seal “2” Oil leakage → Replace. 3. Hold the vehicle upright and apply the front brake. 4. Check: Front fork operationPush down hard on the handlebar several times and check if the front fork rebounds smoothly. Rough movement → Repair. Refer to FRONT FORK on page 4-43. EAS21590 ADJUSTING THE REAR SHOCK ABSORBER ASSEMBLY WARNING EWA13120 Securely support the vehicle so that there is no danger of it falling over. Spring preload CAUTION: ECA13590 Never go beyond the maximum or minimum adjustment positions. 1. Adjust: Spring preload ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Adjust the spring preload with the special wrench and extension bar included in the owner’s tool kit. b. Turn the adjusting ring “1” in direction “a” or “b”. c. Align the desired position on the adjusting ring with the stopper “2”. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ EAS21650 CHECKING THE TIRES The following procedure applies to both of the tires. 1. Check: Tire pressureOut of specification → Regulate. Direction “a” Spring preload is increased (suspension is harder). Direction “b” Spring preload is decreased (suspension is softer). Spring preload adjusting posi- tions Minimam1 Standard 3 Maximum 7
CHASSIS 3-29 WARNING EWA13180 The tire pressure should only be checked and regulated when the tire temperature equals the ambient air temperature. The tire pressure and the suspension must be adjusted according to the total weight (including cargo, rider, passenger and accessories) and the anticipated riding speed. Operation of an overloaded vehicle could cause tire damage, an accident or an injury. NEVER OVERLOAD THE VEHICLE. WARNING EWA13190 It is dangerous to ride with a worn-out tire. When the tire tread reaches the wear limit, replace the tire immediately. 2. Check: Tire surfacesDamage/wear → Replace the tire. Tire air pressure (measured on cold tires) Loading condition* 0–90 kg (0–198 lb) Front 225 kPa (33 psi) (2.25 kgf/cm²) (2.25 bar) Rear 250 kPa (36 psi) (2.50 kgf/cm²) (2.50 bar) Loading condition* 90–189 kg (198–417 lb) (FZS6WC) 90–190 kg (198–419 lb) (FZS6W) Front 250 kPa (36 psi) (2.50 kgf/cm²) (2.50 bar) Rear 290 kPa (42 psi) (2.90 kgf/cm²) (2.90 bar) High-speed riding Front 225 kPa (33 psi) (2.25 kgf/cm²) (2.25 bar) Rear 250 kPa (36 psi) (2.50 kgf/cm²) (2.50 bar) Maximum load* 189 kg (417 lb) (FZS6WC) 190 kg (419 lb) (FZS6W) * Total weight of rider, passenger, cargo and accessories
CHASSIS 3-30 WARNING EWA14080 Do not use a tubeless tire on a wheel designed only for tube tires to avoid tire failure and personal injury from sudden deflation. When using a tube tire, be sure to install the correct tube. Always replace a new tube tire and a new tube as a set. To avoid pinching the tube, make sure the wheel rim band and tube are centered in the wheel groove. Patching a punctured tube is not recom- mended. If it is absolutely necessary to do so, use great care and replace the tube as soon as possible with a good quality replacement. WARNING EWA14090 After extensive tests, the tires listed below have been approved by Yamaha Motor Co., Ltd. for this model. The front and rear tires should always be by the same manufac- turer and of the same design. No guarantee concerning handling characteristics can be given if a tire combination other than one approved by Yamaha is used on this vehi- cle. WARNING EWA13210 New tires have a relatively low grip on the road surface until they have been slightly worn. Therefore, approximately 100 km should be traveled at normal speed before any high-speed riding is done. NOTE: For tires with a direction of rotation mark “1”: Install the tire with the mark pointing in the direction of wheel rotation. Align the mark “2” with the valve installation point. 1. Tire tread depth 2. Side wall 3. Wear indicator Wear limit (front) 0.8 mm (0.03 in) Wear limit (rear) 0.8 mm (0.03 in) A. Tire B. Wheel Tube wheel Tube tire only Tubeless wheel Tube or tubeless tire Front tireSize 120/70 ZR17M/C (58W) Manufacturer/model BRIDGESTONE/BT020F GG Manufacturer/model DUNLOP/D252F Rear tireSize 180/55 ZR17M/C (73W) Manufacturer/model BRIDGESTONE/BT020R GG Manufacturer/model DUNLOP/D252
CHASSIS 3-31 EAS21670 CHECKING THE WHEELS The following procedure applies to both of the wheels. 1. Check: WheelDamage/out-of-round → Replace. WARNING EWA13260 Never attempt to make any repairs to the wheel. NOTE: After a tire or wheel has been changed or replaced, always balance the wheel. EAS21690 CHECKING AND LUBRICATING THE CABLES The following procedure applies to all of the inner and outer cables. WARNING EWA13270 Damaged outer cable may cause the cable to corrode and interfere with its movement. Replace damaged outer cable and inner cables as soon as possible. 1. Check: Outer cableDamage → Replace. 2. Check: Cable operationRough movement → Lubricate. NOTE: Hold the cable end upright and pour a few drops of lubricant into the cable sheath or use a suitable lubricating device. EAS21700 LUBRICATING THE LEVERS Lubricate the pivoting point and metal-to-metal moving parts of the levers. EAS21710 LUBRICATING THE PEDAL Lubricate the pivoting point and metal-to-metal moving parts of the pedal. EAS21720 LUBRICATING THE SIDESTAND Lubricate the pivoting point and metal-to-metal moving parts of the sidestand. EAS21730 LUBRICATING THE CENTERSTAND Lubricate the pivoting point and metal-to-metal moving parts of the centerstand. EAS21740 LUBRICATING THE REAR SUSPENSION Lubricate the pivoting point and metal-to-metal moving parts of the rear suspension. Recommended lubricant Engine oil or a suitable cable lubricant Recommended lubricantLithium-soap-based grease Recommended lubricantLithium-soap-based grease Recommended lubricantLithium-soap-based grease Recommended lubricant Lithium-soap-based grease Recommended lubricantMolybdenum disulfide grease
ELECTRICAL SYSTEM 3-32 EAS21750 ELECTRICAL SYSTEM EAS21790 REPLACING THE HEADLIGHT BULBS The following procedure applies to both of the headlight bulbs. 1. Disconnect: Headlight coupler “1” 2. Remove: Headlight bulb cover “2” 3. Remove: Headlight bulb holder “1” 4. Remove: Headlight bulb “2” WARNING EWA13320 Since the headlight bulb gets extremely hot, keep flammable products and your hands away from the bulb until it has cooled down. 5. Install: Headlight bulb Secure the new headlight bulb with the headlight bulb holder. CAUTION: ECA13690 Avoid touching the glass part of the head- light bulb to keep it free from oil, otherwise the transparency of the glass, the life of the bulb and the luminous flux will be adversely affected. If the headlight bulb gets soiled, thoroughly clean it with a cloth moistened with alcohol or lacquer thinner. 6. Install: Headlight bulb holder 7. Install: Headlight bulb cover 8. Connect: Headlight coupler EAS21810 ADJUSTING THE HEADLIGHT BEAMS The following procedure applies to both of the headlights. 1. Adjust: Headlight beam (vertically) ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Turn the adjusting screw “1” in direction “a” or “b”. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 2. Adjust: Headlight beam (horizontally) ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Turn the adjusting screw “1” in direction “a” or “b”. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ New Direction “a” Headlight beam is raised. Direction “b” Headlight beam is lowered. Direction “a” Headlight beam moves to the right. Direction “b” Headlight beam moves to the left.
4 CHASSIS GENERAL CHASSIS.................................................................................... 4-1 FRONT WHEEL ............................................................................................ 4-5 REMOVING THE FRONT WHEEL ......................................................... 4-7 CHECKING THE FRONT WHEEL.......................................................... 4-7 ADJUSTING THE FRONT WHEEL STATIC BALANCE ......................... 4-8 INSTALLING THE FRONT WHEEL ........................................................ 4-9 REAR WHEEL ............................................................................................ 4-10 REMOVING THE REAR WHEEL ......................................................... 4-13 CHECKING THE REAR WHEEL .......................................................... 4-13 CHECKING THE REAR WHEEL DRIVE HUB ..................................... 4-13 CHECKING AND REPLACING THE REAR WHEEL SPROCKET ....... 4-14 ADJUSTING THE REAR WHEEL STATIC BALANCE .......................... 4-14 INSTALLING THE REAR WHEEL ........................................................ 4-14 FRONT BRAKE .......................................................................................... 4-15 INTRODUCTION ........................... ....................................................... 4-20 CHECKING THE FRONT BRAKE DISCS ............................................ 4-20 REPLACING THE FRONT BR AKE PADS ............................................ 4-21 REMOVING THE FRONT BRAKE CALIPERS ..................................... 4-22 DISASSEMBLING THE FRONT BRAKE CALIPERS ........................... 4-22 CHECKING THE FRONT BRAKE CALIPERS ..................................... 4-22 ASSEMBLING THE FRONT BRAKE CALIPERS ................................. 4-23 INSTALLING THE FRONT BRAKE CALIPERS .................................... 4-23 REMOVING THE FRONT BRAKE MASTER CYLINDER..................... 4-24 CHECKING THE FRONT BRAKE MASTER CYLINDER ..................... 4-24 ASSEMBLING THE FRONT BRAKE MASTER CYLINDER................. 4-25 INSTALLING THE FRONT BRAKE MASTER CYLINDER ................... 4-25 REAR BRAKE ............................................................................................ 4-27 INTRODUCTION ........................... ....................................................... 4-32 CHECKING THE REAR BRAKE DISC ................................................. 4-32 REPLACING THE REAR BRAKE PADS .............................................. 4-32 REMOVING THE REAR BR AKE CALIPER.......................................... 4-33 DISASSEMBLING THE REAR BRAKE CALIPER ................................ 4-33 CHECKING THE REAR BRAKE CALIPER .......................................... 4-34 ASSEMBLING THE REAR BRAK E CALIPER ...................................... 4-34 INSTALLING THE REAR BRAKE CALIPER......................................... 4-35 REMOVING THE REAR BRAKE MASTER CYLINDER ....................... 4-36 CHECKING THE REAR BRAKE MASTER CYLINDER ....................... 4-36 ASSEMBLING THE REAR BRAKE MASTER CYLINDER ................... 4-37 INSTALLING THE REAR BRAKE MASTER CYLINDER ...................... 4-37 HANDLEBAR .............................................................................................. 4-39 REMOVING THE HANDLEBARS ......................................................... 4-40 CHECKING THE HANDLEBAR ............................................................ 4-40
INSTALLING THE HANDLEBAR ................................... ....................... 4-40 FRONT FORK ............................................................................................. 4-43 REMOVING THE FRONT FORK LEGS ............................................... 4-45 DISASSEMBLING THE FRONT FO RK LEGS ..................................... 4-45 CHECKING THE FRONT FORK LEGS ................................................ 4-46 ASSEMBLING THE FRONT FORK LEGS ........................................... 4-47 INSTALLING THE FRONT FORK LEGS .............................................. 4-49 STEERING HEAD ....................................................................................... 4-51 REMOVING THE LOWER BRACKET .................................................. 4-53 CHECKING THE STEERING HEAD .................................................... 4-53 INSTALLING THE STEERING HEAD ................................................... 4-54 REAR SHOCK ABSORBER ASSEMBLY .................................................. 4-55 HANDLING THE REAR SHOC K ABSORBER ..................................... 4-56 DISPOSING OF A REAR SHOCK ABSORBER ................................... 4-56 REMOVING THE REAR SHOCK ABSORBER ASSEMBLY................. 4-56 CHECKING THE REAR SHOCK ABSO RBER ASSEMBLY ................. 4-56 INSTALLING THE REAR SHOCK ABSORBER ASSEMBLY ............... 4-57 SWINGARM ................................................................................................ 4-58 REMOVING THE SWINGARM ............................................................. 4-60 CHECKING THE SWINGARM ............................................................. 4-60 INSTALLING THE SWINGARM ............................................................ 4-61 CHAIN DRIVE ............................................................................................. 4-62 REMOVING THE DRIVE CHAIN .......................................................... 4-63 CHECKING THE DRIVE CHAIN .......................................................... 4-63 CHECKING THE DRIVE SPROCKET .................................................. 4-64 CHECKING THE REAR WHEEL SPROCKET ..................................... 4-64 CHECKING THE REAR WHEEL DRIVE HUB ..................................... 4-64 INSTALLING THE DRIVE CHAIN ......................................................... 4-64