Yamaha FZS6W 07 User Manual

							
HANDLEBAR
4-40
EAS22860
REMOVING THE HANDLEBARS
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. Remove: Handlebar grip “1”
NOTE:
Blow compressed air between the left handle-
bar and the handlebar grip, and gradually push 
the grip off the handlebar.
3. Disconnect: Clutch switch connector
4. Remove:  Left handlebar switch “1”
 Clutch cable “2”
 Clutch lever holder “3”
5. Remove:  Right handlebar switch “1”
 Throttle grip “2”
 Throttle cable
6. Disconnect:  Front brake light switch connector
7. Remove:
 Front brake master cylinder holder “3”
 Front brake master cylinder
 Upper handlebar holder
 Handlebar
EAS22880
CHECKING THE HANDLEBAR
1. Check: Handlebar “1”Bends/cracks/damage  → Replace.
WARNING
EWA13690
Do not attempt to straighten a bent handle-
bar as this may dangerously weaken it.
2. Install:
 Handlebar grip
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Apply a thin coat of rubber adhesive onto  the left end of the handlebar.
b. Slide the handlebar grip over the left end of  the handlebar.
c. Wipe off any excess rubber adhesive with a 
clean rag.
WARNING
EWA13700
Do not touch the handlebar grip until the 
rubber adhesive has fully dried.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
EAS22930
INSTALLING THE HANDLEBAR
1. Stand the vehicle on a level surface.
WARNING
EWA13120
Securely support the vehicle so that there 
is no danger of it falling over. 
						

							
HANDLEBAR
4-41
2. Install: Handlebar “1”
 Upper handlebar holders “2”
 Upper handlebar holder caps “3” (Stan-dard)
CAUTION:
ECA14250
 First, tighten the bolts on the front side of the handlebar holder, and then on the rear 
side.
 Turn the handlebar all the way to the left  and right. If there is any contact with the 
fuel tank, adjust the handlebar position.
NOTE:
Align the match marks “a” on the handlebar 
with the upper surface of the lower handlebar 
holders.
3. Install: Throttle cables
 Right handlebar switch “1”
 Throttle grip “2”
NOTE:
Align the projections “a” on the handlebar 
switch with the holes “b” in the handlebar. 4. Install:
 Brake master cylinder “1”
 Brake master cylinder holder “2”Refer to INSTALLING THE FRONT 
BRAKE MASTER CYLINDER on page 4-
25.
NOTE:
Align the mating surfaces of the brake master 
cylinder bracket with the punch mark (right 
handlebar switch side) “a” on the handlebar.
5. Install: Clutch lever holder “1”
Clutch cable
NOTE:
Align the slit on the clutch lever holder with the 
punch mark “a” on the handlebar.
6. Install: Left handlebar switch
Upper handlebar holder bolt23 Nm (2.3 m·kg, 17 ft·lb) 
						

							
HANDLEBAR
4-42
NOTE:
Align the projection “a” on the left handlebar 
switch with the hole “b” on the handlebar.
7. Install: Handlebar grip
 Grip end
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Apply a thin coat of rubber adhesive onto  the left end of the handlebar.
b. Slide the handlebar grip over the left end of 
the handlebar.
c. Wipe off any excess rubber adhesive with a  clean rag.
WARNING
EWA13700
Do not touch the handlebar grip until the 
rubber adhesive has fully dried.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
8. Adjust: Throttle cable free playRefer to ADJUSTING THE THROTTLE 
CABLE FREE PLAY on page 3-8.
9. Adjust:  Clutch cable free playRefer to ADJUSTING THE CLUTCH 
CABLE FREE PLAY on page 3-14.
Grip end
26 Nm (2.6 m·kg, 19 ft·lb)
Throttle cable free play3.0–5.0 mm (0.12–0.20 in) 
						

							
FRONT FORK
4-43
EAS22950
FRONT FORK
Removing the front fork legs
Order Job/Parts to remove Q’ty RemarksFront wheel Refer to FRONT WHEEL on page 4-5.
Front brake calipers Refer to FRONT BRAKE on page 4-15.
1 Front fender 1
2 Cap bolt 1 Loosen.
3 Upper bracket pinch bolt 1 Loosen.
4 Under bracket pinch bolt 1 Loosen.
5Front fork leg 1
For installation, reverse the removal proce-
dure. 
						

							
FRONT FORK
4-44
Disassembling the front fork legs
Order Job/Parts to remove Q’ty Remarks1 Cap bolt 1
2O-ring 1
3Spacer 1
4 Washer 1
5 Front fork spring 1
6 Dust seal 1
7 Oil seal clip 1
8 Damper rod assembly bolt 1
9 Copper washer 1
10 Damper rod assembly 1
11 Oil seal 1
12 Washer 1
13 Inner tube 1
14 Outer tube bushing 1
15 Inner tube bushing 1
16 Oil flow stopper 1
17 Outer tube 1
For assembly, reverse the disassembly pro-
cedure. 
						

							
FRONT FORK
4-45
EAS22970
REMOVING THE FRONT FORK LEGS
The following procedure applies to both of the 
front fork legs.
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. Loosen: Upper bracket pinch bolts “1”
 Cap bolt “2”
 Lower bracket pinch bolts “3”
WARNING
EWA13640
Before loosening the upper and lower 
bracket pinch bolts, support the front fork 
leg.
3. Remove: Front fork leg
EAS22990
DISASSEMBLING THE FRONT FORK LEGS
The following procedure applies to both of the 
front fork legs.
1. Remove:
 Cap bolt
 Washer
Spacer
Fork spring
2. Drain:
 Fork oil
NOTE:
Stroke the inner tube several times while drain-
ing the fork oil.
3. Remove: Dust seal “1”
 Oil seal clip “2” (with a flat-head screwdriver)
CAUTION:
ECA14180
Do not scratch the inner tube.
4. Remove:
 Damper rod assembly bolt
 Damper rod assembly
NOTE:
While holding the damper rod with the damper 
rod holder “1” and T-handle “2”, loosen the 
damper rod assembly bolt.
5. Remove: Inner tube
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Hold the front fork leg horizontally.
b. Securely clamp the brake caliper bracket in 
a vise with soft jaws.
c. Separate the inner tube from the outer tube  by pulling the inner tube forcefully but care-
fully.
Damper rod holder90890-01294
Damping rod holder set YM-01300
T-handle
90890-01326
YM-01326 
						

							
FRONT FORK
4-46
CAUTION:
ECA14190
 Excessive force will damage the oil seal and bushing. A damaged oil seal or bush-
ing must be replaced.
 Avoid bottoming the inner tube into the  outer tube during the above procedure, as 
the oil flow stopper will be damaged.
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EAS23010
CHECKING THE FRONT FORK LEGS
The following procedure applies to both of the 
front fork legs.
1. Check:
 Inner tube “1”
 Outer tube “2”Bends/damage/scratches  → Replace.
WARNING
EWA13650
Do not attempt to straighten a bent inner 
tube as this may dangerously weaken it.
2. Measure:
 Spring free length “a”Out of specification  → Replace. 3. Check:
 Damper rod “1”Damage/wear  → Replace.
Obstruction  → Blow out all of the oil pas-
sages with compressed air.
 Oil flow stopper “2”
Damage  → Replace.
CAUTION:
ECA14200
 The front fork leg has a built-in damper 
adjusting rod and a very sophisticated 
internal construction, which are particu-
larly sensitive to foreign material.
 When disassembling and assembling the  front fork leg, do not allow any foreign 
material to enter the front fork.
4. Check:  Cap bolt O-ringDamage/wear  → Replace.
Fork spring free length
354.0 mm (13.94 in)
Limit 347.0 mm (13.66 in) 
						

							
FRONT FORK
4-47
EAS23020
ASSEMBLING THE FRONT FORK LEGS
The following procedure applies to both of the 
front fork legs.
WARNING
EWA13660
 Make sure the oil levels in both front fork legs are equal.
 Uneven oil levels can result in poor han-
dling and a loss of stability.
NOTE:
 When assembling the front fork leg, be sure 
to replace the following parts:
- Inner tube bushing
- Outer tube bushing
-Oil seal
- Dust seal
 Before assembling the front fork leg, make 
sure all of the components are clean.
1. Install:  Inner tube bushing
 Outer tube bushing
 Oil flow stopper
 Damper rod assembly “1”
 Copper washer 
CAUTION:
ECA14210
Allow the damper rod assembly to slide 
slowly down the inner tube until it pro-
trudes from the bottom of the inner tube. 
Be careful not to damage the inner tube.
2. Lubricate:
 Inner tube’s outer surface 3. Tighten:
 Damper rod assembly bolt “1”
NOTE:
While holding the damper rod assembly with 
the damper rod holder “2” and T-handle “3”, 
tighten the damper rod assembly bolt.
4. Install: Outer tube bushing “1”
(with the fork seal driver “2” and fork seal 
attachment “3”)
New
Recommended lubricantSuspension oil 01 or eqivalent
Damper rod assembly bolt23 Nm (2.3 m·kg, 17 ft·lb)
LOCTITE®
Damper rod holder90890-01294
Damping rod holder set YM-01300
T-handle
90890-01326
YM-01326
Fork seal driver weight90890-01367
Replacement hammer YM-A9409-7
Fork seal driver attachment 
(ø43)
90890-01374
Replacement 43 mm
YM-A5142-3 
						

							
FRONT FORK
4-48
5. Install: Washer
Oil seal “1”(with the fork seal driver and adapter)
CAUTION:
ECA14220
Make sure the numbered side of the oil seal 
faces up.
NOTE:
 Before installing the oil seal, lubricate its lips with lithium soap base grease.
 Lubricate the outer surface of the inner tube  with fork oil.
 Before installing the oil seal, cover the top of 
the front fork leg with a plastic bag “2” to pro-
tect the oil seal during installation.
6. Install:  Oil seal clip “1”
NOTE:
Adjust the oil seal clip so that it fits into the 
outer tube’s groove.
7. Install: Dust seal “1”(with the fork seal driver weight)
8. Fill:  Front fork leg(with the specified amount of the recom-
mended fork oil)
CAUTION:
ECA4S81015
 Be sure to use the recommended fork oil. Other oils may have an adverse effect on 
front fork performance.
 When disassembling and assembling the  front fork leg, do not allow any foreign 
material to enter the front fork.
Fork seal driver weight90890-01367
Replacement hammer YM-A9409-7
Quantity
467.0 cm³ (15.79 US oz) (16.47
Imp.oz)
Recommended oil
Suspension oil 01 or equiva-
lent 
						

							
FRONT FORK
4-49
9. Measure: Front fork leg oil level “a”Out of specification  → Correct.
NOTE:
 While filling the front fork leg, keep it upright.
 After filling, slowly pump the front fork leg up 
and down to distribute the fork oil.
10. Install:  Spring “1”
 Spring seat “2”
 Spacer “3”
 Cap bolt
NOTE:
 Install the spring with the smaller pitch “a” facing down.
 Before installing the cap bolt, lubricate its O- ring with grease.
 Temporarily tighten the cap bolt.
EAS23050
INSTALLING THE FRONT FORK LEGS
The following procedure applies to both of the 
front fork legs.
1. Install: Front fork legTemporarily tighten the upper and lower 
bracket pinch bolts.
NOTE:
Make sure the inner fork tube is flush with the 
top of the handlebar holder.
2. Tighten: Lower bracket pinch bolt “1”
 Cap bolt “2”
 Upper bracket pinch bolt “3”
WARNING
EWA13680
Make sure the brake hoses are routed prop-
erly.
Level
134.0 mm (5.28 in)
b. Lager pitch
Lower bracket pinch bolt30 Nm (3.0 m·kg, 22 ft·lb)
Cap bolt24 Nm (2.4 m·kg, 17 ft·lb)
Upper bracket pinch bolt30 Nm (3.0 m·kg, 22 ft·lb)