Yamaha FZS6W 07 User Manual

							
REAR BRAKE
4-30
Removing the rear brake caliper
Order Job/Parts to remove Q’ty RemarksBrake fluid Drain.
Refer to BLEEDING THE HYDRAULIC 
BRAKE SYSTEM on page 3-24.
1 Union bolt 1
2 Copper washer 2
3 Brake hose 1
4 Rear brake caliper 1 For installation, reverse the removal proce-
dure. 
						

							
REAR BRAKE
4-31
Disassembling the rear brake caliper
Order Job/Parts to remove Q’ty Remarks1 Screw plug 1
2 Brake pad pin 1
3 Brake pad 2
4 Brake pad shim 4
5 Brake pad spring 1
6 Brake caliper piston 1
7 Brake caliper piston seal 2
8 Bleed screw 1 For assembly, reverse the disassembly pro-
cedure. 
						

							
REAR BRAKE
4-32
EAS22560
INTRODUCTION
WARNING
EWA14100
Disc brake components rarely require dis-
assembly. Therefore, always follow these 
preventive measures:
 Never disassemble brake components unless absolutely necessary.
 If any connection on the hydraulic brake  system is disconnected, the entire brake 
system must be disassembled, drained, 
cleaned, properly filled, and bled after 
reassembly.
 Never use solvents on internal brake 
components.
 Use only clean or new brake fluid for  cleaning brake components.
 Brake fluid may damage painted surfaces  and plastic parts. Therefore, always clean 
up any spilt brake fluid immediately.
 Avoid brake fluid coming into contact  with the eyes as it can cause serious 
injury.
 FIRST AID FOR BRAKE FLUID ENTERING  THE EYES:
 Flush with water for 15 minutes and get 
immediate medical attention.
EAS22570
CHECKING THE REAR BRAKE DISC
1. Check:
Brake discDamage/galling  → Replace.
2. Measure:
 Brake disc deflectionOut of specification  → Correct the brake 
disc deflection or replace the brake disc.
Refer to CHECKING THE FRONT BRAKE 
DISCS on page 4-20.
3. Measure:  Brake disc thicknessMeasure the brake disc thickness at a few 
different locations.
Out of specification  → Replace.
Refer to CHECKING THE FRONT BRAKE 
DISCS on page 4-20. 4. Adjust:
 Brake disc deflectionRefer to CHECKING THE FRONT BRAKE 
DISCS on page 4-20.
EAS22580
REPLACING THE REAR BRAKE PADS
NOTE:
When replacing the brake pads, it is not neces-
sary to disconnect the brake hose or disas-
semble the brake caliper.
1. Measure: Brake pad wear limit “a”
Out of specification  → Replace the brake 
pads as a set.
2. Install:  Brake pad spring
 Brake pad shims(onto the brake pads)
 Brake pads
NOTE:
Always install new brake pads, brake pad 
shims, and a brake pad spring as a set.
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a. Connect a clear plastic hose “1” tightly to  the bleed screw “2”. Put the other end of 
the hose into an open container.
Brake disc deflection limit
0.15 mm (0.0059 in)
Brake disc thickness limit4.5 mm (0.18 in)
Brake disc bolt
30 Nm (3.0 m·kg, 22 ft·lb)
LOCTITE®
Brake pad lining thickness
(inner)6.0 mm (0.24 in)
Limit 1.0 mm (0.04 in)
Brake pad lining thickness
(outer) 6.0 mm (0.24 in)
Limit 1.0 mm (0.04 in) 
						

							
REAR BRAKE
4-33
b. Loosen the bleed screw and push the brake caliper pistons into the brake caliper 
with your finger.
c. Tighten the bleed screw.
d. Install a new brake pad shim “3” onto each  new brake pad “4”.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
3. Install: Brake caliper
 Brake pad pin
 Screw plug
4. Check:  Brake fluid level
Below the minimum level mark “a”  → Add 
the recommended brake fluid to the proper 
level.
Refer to CHECKING THE BRAKE FLUID 
LEVEL on page 3-22. 5. Check:
 Brake pedal operationSoft or spongy feeling  → Bleed the brake 
system.
Refer to BLEEDING THE HYDRAULIC 
BRAKE SYSTEM on page 3-24.
EAS22590
REMOVING THE REAR BRAKE CALIPER
NOTE:
Before disassembling the brake caliper, drain 
the brake fluid from the entire brake system.
1. Remove:  Union bolt “1”
 Copper washers “2”
 Brake hose “3”
 Brake caliper “4”
NOTE:
Put the end of the brake hose into a container 
and pump out the brake fluid carefully.
EAS22600
DISASSEMBLING THE REAR BRAKE CALI-
PER
1. Remove:
 Brake caliper piston “1”
 Brake caliper piston seals “2”
Bleed screw6 Nm (0.6 m·kg, 4.3 ft·lb)
Brake caliper bolt (front side)27 Nm (2.7 m·kg, 20 ft·lb)
Brake caliper bolt (rear side) 22 Nm (2.2 m·kg, 16 ft·lb)
Brake pad pin 17 Nm (1.7 m·kg, 12 ft·lb)
Screw plug 3 Nm (0.3 m·kg, 22 ft·lb) 
						

							
REAR BRAKE
4-34
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Blow compressed air into the brake hose joint opening “a” to force out the piston from 
the brake caliper.
WARNING
EWA13550
 Cover the brake caliper piston with a rag. 
Be careful not to get injured when the pis-
ton is expelled from the brake caliper.
 Never try to pry out the brake caliper pis-
ton.
b. Remove the brake caliper piston seals.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
EAS22640
CHECKING THE REAR BRAKE CALIPER
1. Check:  Brake caliper pistons “1”Rust/scratches/wear  → Replace the brake 
caliper pistons.
 Brake caliper cylinders “2” Scratches/wear 
→ Replace the brake cali-
per assembly.
 Brake caliper body “3”
Cracks/damage  → Replace the brake cali-
per assembly.
 Brake fluid delivery passages
(brake caliper body)
Obstruction  → Blow out with compressed 
air.
WARNING
EWA13610
Whenever a brake caliper is disassembled, 
replace the brake caliper piston seals.
2. Check:  Rear brake caliper bracket “1”
Cracks/damage  → Replace.
EAS22650
ASSEMBLING THE REAR BRAKE CALIPER
WARNING
EWA13620
 Before installation, all internal brake com-
ponents should be cleaned and lubricated 
with clean or new brake fluid.
 Never use solvents on internal brake  components as they will cause the piston 
seals to swell and distort.
 Whenever a brake caliper is disassem-
bled, replace the brake caliper piston 
seals.
Recommended brake component
replacement schedule
Brake pads If necessary
Piston seals Every two years
Brake hoses Every four years
Brake fluid
Every two years and 
whenever the brake is 
disassembled
Recommended fluid
DOT 4 
						

							
REAR BRAKE
4-35
1. Install: Brake caliper seals 
 Brake caliper piston
EAS22670
INSTALLING THE REAR BRAKE CALIPER
1. Install: Brake caliper “1”
(temporarily)
 Copper washers 
 Brake hose “2”
 Union bolt “3”
WARNING
EWA13530
Proper brake hose routing is essential to 
insure safe vehicle operation. Refer to 
CABLE ROUTING on page 2-47.
CAUTION:
ECA14170
When installing the brake hose onto the 
brake caliper “1”, make sure the brake pipe 
“a” touches the projection “b” on the brake 
caliper.
2. Remove:  Brake caliper
3. Install:  Brake pad spring  Brake pad shims (on to the brake pads)
 Brake pads
 Brake caliper
4. Fill:  Brake fluid reservoir(with the specified amount of the recom-
mended brake fluid)
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.
5. Bleed: Brake systemRefer to BLEEDING THE HYDRAULIC 
BRAKE SYSTEM on page 3-24.
6. Check:  Brake fluid levelBelow the minimum level mark “c”  → Add 
the recommended brake fluid to the proper 
level.
Refer to CHECKING THE BRAKE FLUID 
LEVEL on page 3-22.
Brake hose union bolt
30 Nm (3.0 m·kg, 22 ft·lb)
New
New
Brake caliper bolt (front side)27 Nm (2.7 m·kg, 20 ft·lb)
Brake caliper bolt (rear side) 22 Nm (2.2 m·kg, 16 ft·lb)
Brake pas pin
17 Nm (1.7 m·kg, 12 ft·lb)
Screw plug 3 Nm (0.3 m·kg, 2.2 ft·lb)
Recommended fluid
DOT 4 
						

							
REAR BRAKE
4-36
7. Check: Brake pedal operationSoft or spongy feeling  → Bleed the brake 
system.
Refer to BLEEDING THE HYDRAULIC 
BRAKE SYSTEM on page 3-24.
EAS22700
REMOVING THE REAR BRAKE MASTER 
CYLINDER
1. Remove:  Union bolt “1”
 Copper washers “2”
 Brake hose “3”
NOTE:
To collect any remaining brake fluid, place a 
container under the master cylinder and the 
end of the brake hose.
2. Disconnect: Brake fluid reservoir hose
3. Remove:  Pin (from the brake pedal link)
4. Remove:
 Rear brake master cylinder
5. Remove:  Circlip (from the rear brake master cylinder)
 Master cylinder kit
EAS22720
CHECKING THE REAR BRAKE MASTER 
CYLINDER
1. Check: Brake master cylinder “1”
Damage/scratches/wear  → Replace.
 Brake fluid delivery passages (brake master cylinder body)
Obstruction  → Blow out with compressed 
air.
2. Check:  Brake master cylinder kit “1”Damage/scratches/wear  → Replace.
3. Check:  Brake fluid reservoir “1”Cracks/damage  → Replace.
 Brake fluid reservoir diaphragm “2” Cracks/damage  → Replace.
4. Check:  Brake hosesCracks/damage/wear  → Replace. 
						

							
REAR BRAKE
4-37
EAS22730
ASSEMBLING THE REAR BRAKE MASTER 
CYLINDER
WARNING
EWA13520
 Before installation, all internal brake com-ponents should be cleaned and lubricated 
with clean or new brake fluid.
 Never use solvents on internal brake 
components.
1. Install:  Master cylinder kit
 Circlip 
EAS22740
INSTALLING THE REAR BRAKE MASTER 
CYLINDER
1. Install:
 Copper washers 
 Brake hoses
 Union bolt
WARNING
EWA13530
Proper brake hose routing is essential to 
insure safe vehicle operation. Refer to 
CABLE ROUTING on page 2-47.
CAUTION:
ECA14160
When installing the brake hose onto the 
brake master cylinder, make sure the brake 
pipe touches the projection “a” as shown.
2. Fill: Brake fluid reservoir
(to the maximum level mark “a”)
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.
3. Bleed: Brake system
Refer to BLEEDING THE HYDRAULIC 
BRAKE SYSTEM on page 3-24.
4. Check:
 Brake fluid levelBelow the minimum level mark “b”  → Add 
the recommended brake fluid to the proper 
level.
Refer to CHECKING THE BRAKE FLUID 
LEVEL on page 3-22.
5. Adjust:  Brake pedal position “c”Refer to ADJUSTING THE REAR DISC 
BRAKE on page 3-21.
Recommended fluidDOT 4
Brake hose union bolt
30 Nm (3.0 m·kg, 22 ft·lb)
New
New
Recommended fluidDOT 4 
						

							
REAR BRAKE
4-38
6. Adjust: Rear brake light operation timingRefer to ADJUSTING THE REAR BRAKE 
LIGHT SWITCH on page 3-23.
Brake pedal position25.8 mm (1.02 in) 
						

							
HANDLEBAR
4-39
EAS22840
HANDLEBAR
Removing the handlebar
Order Job/Parts to remove Q’ty Remarks1 Grip end 2
2 Handlebar grip 1
3 Clutch switch connector 1 Disconnect.
4 Left handlebar switch 1
5Clutch cable 1
6 Clutch lever 1
7 Right handlebar switch 1
8 Throttle grip 1
9 Throttle cable 2
10 Front brake light switch connector 1 Disconnect.
11 Front brake master cylinder holder 1
12 Front brake master cylinder 1
13 Upper handlebar holder 1
14 Handlebar 1
For installation, reverse the removal proce-
dure.