Yamaha FZS6W 07 User Manual

							
FEATURES
1-2
EAS20170
FEATURES
EAS4S81003
OUTLINE OF FI SYSTEM
The main function of a fuel supply system is to provide fuel to the combustion chamber at the opti-
mum air-fuel ratio in accordance with the engine  operating conditions and the atmospheric tempera-
ture.
In the conventional carburetor system, the air-fuel ratio of the mixture that is supplied to the combus-
tion chamber is created by the volume of the intake air and the fuel that is metered by the jet used in 
the respective carburetor.
Despite the same volume of intake air, the fuel volume requirement varies by the engine operating 
conditions, such as acceleration, deceleration, or operating under a heavy load. Carburetors that 
meter the fuel through the use of jets have been  provided with various auxiliary devices, so that an 
optimum air-fuel ratio can be achieved to accomm odate the constant changes in the operating con-
ditions of the engine.
As the requirements for the engine to deliver  more performance and cleaner exhaust gases 
increase, it becomes necessary to control the air-fuel ratio in a more precise and finely tuned man-
ner. To accommodate this need, this model has adop ted an electronically controlled fuel injection 
(FI) system, in place of the conventional carburetor system. This system can achieve an optimum 
air-fuel ratio required by the engine at all times by  using a microprocessor that regulates the fuel 
injection volume according to the engine oper ating conditions detected by various sensors.
The adoption of the FI system has resulted in  a highly precise fuel supply, improved engine 
response, better fuel economy, and reduced exhaust  emissions. Furthermore, the air induction sys-
tem (AI system) has been placed under computer control together with the FI system in order to 
realize cleaner exhaust gases.
1. Ignition coil
2. Air filter case
3. Intake air temperature sensor
4. Fuel delivery hose
5. Fuel tank
6. Fuel pump
7. Intake air pressure sensor
8. Throttle position sensor
9. Fuel injector
10.Catalytic converter
11.Crankshaft position sensor 12.Coolant temperature sensor
13.Spark plug
14.Pressure regulator
15.Battery
16.ECU
17.Fuel injection system relay
18.Engine trouble warning light
19.Lean angle sensor
20.O
2 sensor 
						

							
FEATURES
1-3
EAS4S81004
FI SYSTEM
The fuel pump delivers fuel to the injector via the fuel filter. The pressure regulator maintains the fuel 
pressure that is applied to the injector at only 250 kPa (2.5 kg/cm
2). Accordingly, when the energiz-
ing signal from the ECU energizes the injector, th e fuel passage opens, causing the fuel to be 
injected into the intake manifold only during the time the passage remains open. Therefore, the 
longer the length of time the injector is energized (injection duration), the greater the volume of fuel 
that is supplied. Conversely, the shorter the length of time the injector is energized (injection dura-
tion), the lesser the volume of fuel that is supplied.
The injection duration and the injection timing are co ntrolled by the ECU. Signals that are input from 
the throttle position sensor, cranksh aft position sensor, intake air pressure sensor, intake tempera-
ture sensor, coolant temperature sensor and O
2 sensor enable the ECU to determine the injection 
duration. The injection timing is determined through  the signals from the crankshaft position sensor. 
As a result, the volume of fuel that is required  by the engine can be supplied at all times in accor-
dance with the driving conditions.
1. Fuel pump
2. Pressure regulator
3. Fuel injector
4. Throttle body
5. Intake air temperature sensor
6. Throttle position sensor
7. Intake air pressure sensor
8. ECU
9. Coolant temperature sensor
10.Crankshaft position sensor
11.O
2 sensor
A. Fuel system
B. Control system 
						

							
FEATURES
1-4
EAS4S81005
INSTRUMENT FUNCTIONS
WARNING
EWA4S81002
Be sure to stop the vehicle before making 
any setting changes to the multi-function 
meter unit.
The multi-function meter unit is equipped with 
the following:
 a speedometer (which shows the riding speed)
 a tachometer (which shows engine speed)
 an odometer (which shows the total distance  traveled)
 two tripmeters (which show the distance trav- eled since they were last set to zero)
 a fuel reserve tripmeter (which shows the  distance traveled since the left segment of 
the fuel meter started flashing)
a clock
 a fuel meter
 a coolant temperature display
 an air intake temperature displaya self-diag- nosis device
 an LCD and tachometer brightness control 
mode
NOTE:
 Be sure to turn the key to “ON” before using the “SELECT” and “RESET” buttons.
 To switch the speedometer and odometer/
tripmeter displays between kilometers and 
miles, press the “SELECT” button for at least 
one second.
Tachometer
The electric tachometer allows the rider to 
monitor the engine speed and keep it within 
the ideal power range.
When the key is turned to “ON”, the tachome-
ter needle will sweep once across the r/min 
range and then return to zero r/min in order to 
test the electrical circuit.
CAUTION:
ECA4S81004
Do not operate the engine in the tachome-
ter red zone.
Red zone: 14000 r/min and above
Clock mode
The clock is displayed when the key is turned 
to “ON”. In addition, the clock can be displayed 
for 10 seconds by pushing the “SELECT” but-
ton when the main switch is in the “OFF” or 
“LOCK” position.
To set the clock
1 Turn the key to “ON”.
2. Push the “SELECT” button and “RESET”  button together for at least two seconds.
3. When the hour digits start flashing, push 
the “RESET” button to set the hours.
4. Push the “SELECT” button, and the minute  digits will start flashing.
5. Push the “RESET” button to set the min- utes.
6. Push the “SELECT” button and then 
release it to start the clock.
1. Coolant temperature display/air intake tem-perature display
2. Speedometer
3. Tachometer
4. Odometer/tripmeter/fuel reserve tripmeter
5. “SELECT” button
6. “RESET” button
7. Clock
8. Fuel meter
1. Tachometer
2. Tachometer red zone.
1. Clock
2. Speedometer 
						

							
FEATURES
1-5
Odometer and tripmeter modes
Push the “SELECT” button to switch the dis-
play between the odometer mode “ODO” and 
the tripmeter modes “TRIP A” and “TRIP B” in 
the following order:
“TRIP A” → “TRIP B”  → “ODO”  → “TRIP A”
When the fuel amount in the fuel tank 
decreases to 3.4 L (0.90 US gal) (0.75 
Imp.gal), the left segment of the fuel meter will 
start flashing, and the odometer display will 
automatically change to the fuel reserve trip-
meter mode “F TRIP” and start counting the 
distance traveled from that point. In that case, 
push the “SELECT” button to switch the dis-
play between the various tripmeter and odom-
eter modes in the following order:
“F-TRIP”  → “TRIP A”  → “TRIP B”  → “ODO”  → 
“F-TRIP”
To reset a tripmeter, select it by pushing the 
“SELECT” button, and then push the “RESET” 
button for at least one second. If you do not 
reset the fuel reserve tripmeter manually, it will 
reset itself automatically and the display will 
return to the prior mode after refueling and 
traveling 5 km (3 mi).
Fuel meter
The fuel meter indicates the amount of fuel in 
the fuel tank. The display segments of the fuel 
meter disappear towards “E” (Empty) as the 
fuel level decreases. When only one segment 
is left near “E”, refuel as soon as possible.
NOTE:
This fuel meter is equipped with a self-diagno-
sis system. If the electrical circuit is defective, 
the following cycle will be repeated until the 
malfunction is corrected:  “E” (Empty), “F” (Full) 
and symbol “ ” will flash eight times, then go 
off for approximately 3 seconds. If this occurs, 
have a Yamaha dealer check the electrical cir-
cuit.
Coolant temperature mode
The coolant temperature display indicates the 
temperature of the coolant.
Push the “RESET” button to switch the coolant 
temperature display to the air intake tempera-
ture display.
NOTE:
When the coolant temperature display is 
selected, “C” is displayed for one second, and 
then the coolant temperature is displayed.
CAUTION:
ECA4S81009
Do not operate the engine if it is over-
heated.
Air intake temperature mode
The air intake temperature display indicates 
the temperature of the air drawn into the air fil-
ter case. Push the “RESET” button to switch 
the coolant temperature display to the air 
intake temperature display.
1. Odometer/tripmeter/fuel reserve tripmeter
1. Fuel meter
1. Coolant temperature display
1. Air intake temperature display 
						

							
FEATURES
1-6
NOTE:
 Even if the air intake temperature is set to be displayed, the coolant temperature warning 
light comes on when the engine overheats.
 When the key is turned to “ON”, the coolant 
temperature is automatically displayed, even 
if the air intake temperature was displayed 
prior to turning the key to “OFF”.
 When the air intake temperature display is  selected, “A” is displayed for one second, 
and then the air intake temperature is dis-
played.
Self-diagnosis device
This model is equipped with a self-diagnosis 
device for various electrical circuits.
If any of those circuits are defective, the engine 
trouble warning light will come on, and then the 
display will indicate a two-digit error code (e.g., 
11, 12, 13).
LCD and tachometer brightness control mode
This function allows you to adjust the bright-
ness of the LCD and the tachometer panel and 
needle to suit the outside lighting conditions.
To set the brightness
1. Turn the key to “OFF”.
2. Push and hold the “SELECT” button.
3. Turn the key to “ON”, and then release the  “SELECT” button after five seconds. 4. Push the “RESET” button to select the 
desired brightness level.
5. Push the “SELECT” button to confirm the 
selected brightness level. The display will 
return to the odometer or tripmeter mode.
1. Error code display
1. Tachometer panel
2. Tachometer needle
3. LCD
4. Brightness level 
						

							
IMPORTANT INFORMATION
1-7
EAS20180
IMPORTANT INFORMATION
EAS20190
PREPARATION FOR REMOVAL AND DISAS-
SEMBLY
1. Before removal and disassembly, remove all dirt, mud, dust and foreign material.
2. Use only the proper tools and cleaning  equipment.
Refer to SPECIAL TOOLS on page 1-10.
3. When disassembling, always keep mated 
parts together. This includes gears, cylin-
ders, pistons and other parts that have 
been “mated” through normal wear. Mated 
parts must always be reused or replaced 
as an assembly.
4. During disassembly, clean all of the parts  and place them in trays in the order of dis-
assembly. This will speed up assembly and 
allow for the correct installation of all parts.
5. Keep all parts away from any source of fire.
EAS20200
REPLACEMENT PARTS
Use only genuine Yamaha parts for all replace-
ments. Use oil and grease recommended by 
Yamaha for all lubrication jobs. Other brands 
may be similar in function and appearance, but 
inferior in quality.
EAS20210
GASKETS, OIL SEALS AND O-RINGS
1. When overhauling the engine, replace all  gaskets, seals and O-rings. All gasket sur-
faces, oil seal lips and O-rings must be 
cleaned.
2. During reassembly, properly oil all mating  parts and bearings and lubricate the oil 
seal lips with grease.
EAS20220
LOCK WASHERS/PLATES AND COTTER 
PINS
After removal, replace all lock washers/plates 
“1” and cotter pins. After the bolt or nut has 
been tightened to specification, bend the lock 
tabs along a flat of the bolt or nut.
1. Oil
2. Lip
3. Spring
4. Grease 
						

							
IMPORTANT INFORMATION
1-8
EAS20230
BEARINGS AND OIL SEALS
Install bearings and oil seals so that the manu-
facturer’s marks or numbers are visible. When 
installing oil seals “1”, lubricate the oil seal lips 
with a light coat of lithium-soap-based grease. 
Oil bearings liberally when installing, if appro-
priate.
CAUTION:
ECA13300
Do not spin the bearing with compressed 
air because this will damage the bearing 
surfaces.
EAS20240
CIRCLIPS
Before reassembly, check all circlips carefully 
and replace damaged or distorted circlips. 
Always replace piston pin clips after one use. 
When installing a circlip “1”, make sure the 
sharp-edged corner “2” is positioned opposite 
the thrust “3” that the circlip receives. 
						

							
CHECKING THE CONNECTIONS
1-9
EAS20250
CHECKING THE CONNECTIONS
Check the leads, couplers, and connectors for 
stains, rust, moisture, etc.
1. Disconnect: Lead
 Coupler
 Connector
2. Check:  Lead
 Coupler
 ConnectorMoisture  → Dry with an air blower.
Rust/stains  → Connect and disconnect 
several times.
3. Check:  All connectionsLoose connection  → Connect properly.
NOTE:
If the pin “1” on the terminal is flattened, bend 
it up.
4. Connect:
 Lead
 Coupler
 Connector
NOTE:
Make sure all connections are tight.
5. Check:Continuity(with the pocket tester)
NOTE:
 If there is no continuity, clean the terminals.
 When checking the wire harness, perform steps (1) to (3).
 As a quick remedy, use  a contact revitalizer 
available at most part stores.
Pocket tester
90890-03112
Analog pocket tester YU-03112-C 
						

							
SPECIAL TOOLS
1-10
EAS20260
SPECIAL TOOLS
The following special tools are necessary for complete and accurate tune-up and assembly. Use 
only the appropriate special tools as this will help prevent damage caused by the use of inappropri-
ate tools or improvised techniques. Special tools, part numbers or both may differ depending on the 
country.
When placing an order, refer to the list provided below to avoid any mistakes.
NOTE:
 For U.S.A. and Canada, use part number starting with “YM-”, “YU-”, or “ACC-”.
 For others, use part number starting with “90890-”.
Tool name/Tool No. Illustration Reference
pages
Flywheel puller
90890-01362
Heavy duty puller
YU-33270-B 5-30
Flywheel puller attachment
90890-04089
Crankshaft protector
YM-33282 5-30
Sheave holder
90890-01701
Primary clutch holder
YS-01880-A 5-30, 5-31, 5-
32, 5-34
Piston pin puller set
90890-01304
Piston pin puller
YU-01304 5-62
Radiator cap tester
90890-01325
Radiator pressure tester
YU-24460-01 6-3
Radiator cap tester adapter
90890-01352
Radiator pressure tester adapter
YU-33984 6-3 
						

							
SPECIAL TOOLS
1-11
Steering nut wrench
90890-01403
Spanner wrench
YU-339753-26, 4-53
Damper rod holder
90890-01294
Damping rod holder set
YM-01300 4-45, 4-47
T-handle
90890-01326
YM-01326 4-45, 4-47
Oil filter wrench
90890-01426
YU-38411 3-13
Fork seal driver weight
90890-01367
Replacement hammer
YM-A9409-7 4-47, 4-48
Fork seal driver attachment (ø43)
90890-01374
Replacement 43 mm
YM-A5142-3 4-47
Vacuum gauge
90890-03094
Carburetor synchronizer
YU-44456 3-7
Compression gauge
90890-03081
Engine compression tester
YU-33223 3-11
Tool name/Tool No. Illustration
Reference
pages