Yamaha FZS6W 07 User Manual
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STEERING HEAD 4-51 EAS23090 STEERING HEAD Removing the lower bracket Order Job/Parts to remove Q’ty RemarksFront wheel Refer to FRONT WHEEL on page 4-5. Front fender Refer to FRONT FORK on page 4-43. Front fork Refer to FRONT FORK on page 4-43. Handlebar Refer to HANDLEBAR on page 4-39. Front cowling inner panel (left side) Refer to GENERAL CHASSIS on page 4-1. Front cowling inner panel (right side) Refer to GENERAL CHASSIS on page 4-1. Fuel tank Refer to FUEL TANK on page 7-1. 1 Main switch coupler 2 Disconnect. 2 Steering stem nut 1 3 Washer 1 4 Upper bracket 1 5 Horn stay 1 6 Lock washer 1 7 Upper ring nut 1 8 Rubber washer 1 9 Lower ring nut 1 10 Lower bracket 1 11 Bearing cover 1 12 Bearing inner race 2
STEERING HEAD 4-52 13 Upper bearing 1 14 Lower bearing 1 15 Dust seal 1 16 Bearing outer race 2For installation, reverse the removal proce- dure. Removing the lower bracket Order Job/Parts to remove Q’ty Remarks
STEERING HEAD 4-53 EAS23110 REMOVING THE LOWER BRACKET 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: Steering stem nut Washer Upper ring nut Lock washer Rubber washer Lower ring nut “1”(with the steering nut wrench “2”) Lower bracket NOTE: Hold the lower ring nut with the exhaust and steering nut wrench, and then remove the upper ring nut with the ring nut wrench. WARNING EWA13730 Securely support the lower bracket so that there is no danger of it falling. EAS23130 CHECKING THE STEERING HEAD 1. Wash: Bearing balls Bearing races 2. Check: Bearing balls “1” Bearing races “2”Damage/pitting → Replace. 3. Replace: Bearing balls Bearing races ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Remove the bearing races “1” from the steering head pipe with a long rod “2” and hammer. b. Remove the bearing race “3” from the lower bracket with a floor chisel “4” and hammer. c. Install a new dust seal and new bearing races. CAUTION: ECA14270 If the bearing race is not installed properly, the steering head pipe could be damaged. NOTE: Always replace the bearings and bearing races as a set. Whenever the steering head is disassem- bled, replace the rubber seal. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ Steering nut wrench 90890-01403 Spanner wrench YU-33975 Recommended cleaning solventKerosene
STEERING HEAD 4-54 4. Check: Upper bracket Lower bracket(along with the steering stem) Bends/cracks/damage → Replace. EAS23140 INSTALLING THE STEERING HEAD 1. Lubricate: Upper bearing Lower bearing Bearing races 2. Install: Lower bracket Lower ring nut “1” Rubber washer “2” Upper ring nut “3” Lock washer “4”Refer to CHECKING THE STEERING HEAD on page 4-53. 3. Install: Upper bracket Washer Steering stem nut NOTE: Temporarily tighten the steering stem nut. 4. Install: Front fork legs Refer to INSTALLING THE FRONT FORK LEGS on page 4-49. NOTE: Temporarily tighten the upper and lower bracket pinch bolts. Recommended lubricantLithium-soap-based grease
REAR SHOCK ABSORBER ASSEMBLY 4-55 EAS23160 REAR SHOCK ABSORBER ASSEMBLY Removing the rear shock absorber assembly Order Job/Parts to remove Q’ty RemarksSeat Refer to GENERAL CHASSIS on page 4-1. Side cover Refer to GENERAL CHASSIS on page 4-1. Rear brake caliper Refer to REAR BRAKE on page 4-27. Rear wheel Refer to REAR WHEEL on page 4-10. 1 Self-locking nut/collar/bolt 1/1/1 2 Self-locking nut/washer/bolt 1/1/1 3 Rear shock absorber assembly 1 4 Oil seal/bearing 2/1 For installation, reverse the removal proce- dure.
REAR SHOCK ABSORBER ASSEMBLY 4-56 EAS23180 HANDLING THE REAR SHOCK ABSORBER WARNING EWA13740 This rear shock absorber contains highly compressed nitrogen gas. Before handling the rear shock absorber, read and make sure you understand the following informa- tion. The manufacturer cannot be held responsible for property damage or per- sonal injury that may result from improper handling of the rear shock absorber. Do not tamper or attempt to open the rear shock absorber. Do not subject the rear shock absorber to an open flame or any other source of high heat. High heat can cause an explosion due to excessive gas pressure. Do not deform or damage the rear shock absorber in any way. Rear shock absorber damage will result in poor damping per- formance. EAS23190 DISPOSING OF A REAR SHOCK ABSORBER 1. Gas pressure must be released before dis- posing of a rear shock absorber. To release the gas pressure, drill a 2–3-mm hole through the rear shock absorber at a point 15–20 mm from its end as shown. WARNING EWA13760 Wear eye protection to prevent eye damage from released gas or metal chips. EAS23210 REMOVING THE REAR SHOCK ABSORBER ASSEMBLY 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. Remove: Seat Side cover Refer to GENERAL CHASSIS on page 4- 1. Rear wheel Refer to REAR WHEEL on page 4-10. 3. Remove: Rear shock absorber assembly lower bolt “1” NOTE: While removing the rear shock absorber assembly lower bolt, hold the swingarm so that it does not drop down. 4. Remove: Rear shock absorber assembly upper bolt “2” Rear shock absorber assembly EAS23240 CHECKING THE REAR SHOCK ABSORBER ASSEMBLY 1. Check: Rear shock absorber rodBends/damage → Replace the rear shock absorber assembly. Rear shock absorber Gas leaks/oil leaks → Replace the rear shock absorber assembly. Spring Damage/wear → Replace the rear shock absorber assembly.
REAR SHOCK ABSORBER ASSEMBLY 4-57 BushingsDamage/wear → Replace. Dust seals Damage/wear → Replace. Bolts Bends/damage/wear → Replace. EAS23300 INSTALLING THE REAR SHOCK ABSORBER ASSEMBLY 1. Lubricate: Collar Bearings Oil seals 2. Install: Rear shock absorber assembly NOTE: When installing the rear shock absorber assembly, lift up the swingarm. 3. Tighten: Rear shock absorber assembly upper nut “1” Rear shock absorber assembly lower nut “2” 4. Install: Rear wheelRefer to REAR WHEEL on page 4-10. 5. Adjust: Drive chain slackRefer to ADJUSTING THE DRIVE CHAIN SLACK on page 3-25. Recommended lubricantMolybdenum disulfide grease Rear shock absorber assembly upper nut40 Nm (4.0 m·kg, 29 ft·lb) Rear shock absorber assembly lower nut 40 Nm (4.0 m·kg, 29 ft·lb) Drive chain slack45.0–55.0 mm (1.77–2.17 in)
SWINGARM 4-58 EAS23330 SWINGARM Removing the swingarm Order Job/Parts to remove Q’ty RemarksMuffler assembly Refer to ENGINE REMOVAL on page 5-1. Catalyst assembly Refer to ENGINE REMOVAL on page 5-1. Exhaust pipe assembly Refer to ENGINE REMOVAL on page 5-1. Rear brake caliper Refer to REAR BRAKE on page 4-27. Rear wheel Refer to REAR WHEEL on page 4-10. Rear shock absorber assembly Refer to REAR SHOCK ABSORBER ASSEMBLY on page 4-55. Drive sprocket cover Refer to ENGINE REMOVAL on page 5-1. 1 Locknut 2 Loosen. 2 Adjusting nut 2 Loosen. 3 Rear fender 1 4 Pivot shaft nut/washer 1/1 5 Pivot shaft 1 6 Swingarm 1 7Drive chain 1 8 Drive chain guide 1 9Dust cover 2 10 Bearing 2 11 Spacer 1
SWINGARM 4-59 For installation, reverse the removal proce- dure. Removing the swingarm Order Job/Parts to remove Q’ty Remarks