Yamaha FZS6W 07 User Manual

							
ENGINE REMOVAL
5-2
Removing the exhaust pipe
Order Job/Parts to remove Q’ty Remarks1 Exhaust pipe assembly 1
2 Exhaust pipe gasket 4
3 Catalytic converter pipe 1
4 Muffler cover 1
5Muffler 1 For installation, reverse the removal proce-
dure. 
						

							
ENGINE REMOVAL
5-3
Disconnecting the leads and hoses
Order Job/Parts to remove Q’ty RemarksSeat Refer to GENERAL CHASSIS on page 4-1.
Right front cowling inner panel Refer to GENERAL CHASSIS on page 4-1.
Left front cowling inner panel Refer to GENERAL CHASSIS on page 4-1.
Fuel tank Refer to FUEL TANK on page 7-1.
Battery Refer to GENERAL CHASSIS on page 4-1.
Air filter case Refer to GENERAL CHASSIS on page 4-1.
Battery box Refer to GENERAL CHASSIS on page 4-1.
Battery box bracket Refer to GENERAL CHASSIS on page 4-1.
Throttle body Refer to THROTTLE BODIES on page 7-4.
Engine oil Drain.
Refer to CHANGING THE ENGINE OIL on 
page 3-12.
Oil cooler Refer to OIL COOLER on page 6-4.
Air cut-off valve Refer to AIR INDUCTION SYSTEM on 
page 7-9.
Radiator Refer to RADIATOR on page 6-1.
Starter motor Refer to ELECTRIC STARTER on page 5-
36.
1 Battery negative lead 1
2 Battery positive lead 1
3Clutch cable 1
4 Ground lead 1 
						

							
ENGINE REMOVAL
5-4
5 Starter motor lead 1 Disconnect.
6 Stator coil assembly coupler 1 Disconnect.
7 Oil level switch connector 1 Disconnect.
8 Neutral switch coupler 1 Disconnect.
9 Speed sensor coupler 1 Disconnect.For assembly, reverse the removal proce-
dure.
Disconnecting the leads and hoses
Order Job/Parts to remove Q’ty Remarks 
						

							
ENGINE REMOVAL
5-5
Removing the engine
Order Job/Parts to remove Q’ty Remarks1 Right front engine mounting bolt 1
2 Left front engine mounting bolt 2
3 Self-locking nut 2
4 Rear engine mounting bolt 2
5Engine 1 For installation, reverse the removal proce-
dure. 
						

							
ENGINE REMOVAL
5-6
EAS23720
INSTALLING THE ENGINE
1. Install: Rear engine mounting bolts “1”
NOTE:
Lubricate the rear engine mounting bolt 
threads with engine oil.
2. Install: Right front engine mounting bolt “2”
 Left front engine mounting bolts “3”
NOTE:
Do not fully tighten the bolts.
3. Tighten: Self-locking nut “4”
NOTE:
First tighten the lower self-locking nut.
4. Tighten: Left front engine mounting bolts “5”
5. Tighten:  Right front engine mounting bolt “6”
6. Install:  Shift arm bolt “7”
Self-locking nut55 Nm (5.5 m·kg, 40 ft·lb)
Left front engine mounting bolt55 Nm (5.5 m·kg, 40 ft·lb)
Right front engine mounting 
bolt
55 Nm (5.5 m·kg, 40 ft·lb)
Shift arm bolt10 Nm (1.0 m·kg, 7.2 ft·lb) 
						

							
ENGINE REMOVAL
5-7
NOTE:
 Before installing, make sure to align the punch mark “a” of the shift shaft with the 
punch mark “b” of the shift arm.
 Align the bottom edge of the shift pedal with 
the mark on the frame-to-swingarm bracket. 
						

							
CAMSHAFTS
5-8
EAS23760
CAMSHAFTS
Removing the cylinder head cover
Order Job/Parts to remove Q’ty RemarksBattery Refer to GENERAL CHASSIS on page 4-1.
Air filter case Refer to GENERAL CHASSIS on page 4-1.
Battery box  Refer to FUEL TANK on page 7-1.
Battery box bracket Refer to GENERAL CHASSIS on page 4-1.
Throttle body Refer to THROTTLE BODIES on page 7-4.
Radiator Refer to RADIATOR on page 6-1.
Air cut-off valve Refer to AIR INDUCTION SYSTEM on 
page 7-9.
1 Ignition coil 2
2 Spark plug 4
3 Cylinder head cover 1
4 Cylinder head cover gasket 1
5 Timing chain guide (top side) 1 For installation, reverse the removal proce-
dure. 
						

							
CAMSHAFTS
5-9
Removing the camshafts
Order Job/Parts to remove Q’ty RemarksPickup rotor cover Refer to PICKUP ROTOR on page 5-33.
1 Camshaft sprocket bolt 4
2 Timing chain tensioner 1
3 Timing chain tensioner gasket 1
4 Timing chain guide (exhaust side) 1
5 Intake camshaft cap 3
6Dowel pin 6
7 Exhaust camshaft cap 3
8Dowel pin 6
9 Intake camshaft 1
10 Exhaust camshaft 1
11 Pin 1
12 Timing chain guide (intake side) 1
13 Camshaft sprocket 2 For installation, reverse the removal proce-
dure. 
						

							
CAMSHAFTS
5-10
EAS23810
REMOVING THE CAMSHAFTS
1. Remove: Pickup rotor coverRefer to PICKUP ROTOR on page 5-33.
2. Align:  “T” mark “a” on the pickup rotor(with the crankcase mating surface “b”)
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Turn the crankshaft clockwise.
b. When piston #1 is at TDC on the compres- sion stroke, align the “T” mark “a” on the 
pickup rotor with the crankcase mating sur-
face “b”.
NOTE:
TDC on the compression stroke can be found 
when the camshaft lobes are turned away from 
each other.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
3. Loosen:
 Camshaft sprocket bolts “1”
4. Loosen:  Timing chain tensioner cap bolt “1”
5. Remove:  Timing chain tensioner “2”
Gasket 6. Remove:
 Timing chain guide (exhaust side)
 Camshaft caps “1”
 Dowel pins
CAUTION:
ECA13720
To prevent damage to the cylinder head, 
camshafts or camshaft caps, loosen the 
camshaft cap bolts in stages and in a criss-
cross pattern, working from the outside in.
7. Remove: Intake camshaft “1”
 Exhaust camshaft “2”
NOTE:
To prevent the timing chain from falling into the 
crankcase, fasten it with a wire “a”. 
						

							
CAMSHAFTS
5-11
8. Remove: Camshaft sprockets
EAS23850
CHECKING THE CAMSHAFTS
1. Check: Camshaft lobesBlue discoloration/pitting/scratches  → 
Replace the camshaft.
2. Measure:  Camshaft lobe dimensions “a” and “b”
Out of specification  → Replace the cam-
shaft. 3. Measure:
 Camshaft runout
Out of specification  → Replace.
4. Measure:  Camshaft-journal-to-camshaft-cap clear-
ance
Out of specification  → Measure the cam-
shaft journal diameter.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Install the camshaft into the cylinder head  (without the dowel pins and camshaft 
caps).
b. Position strip of Plastigauge® “1” onto the  camshaft journal as shown.
c. Install the dowel pins and camshaft caps.
Camshaft lobe dimension limit Intake A
32.450–32.550 mm (1.2776–
1.2815 in)
Limit
32.400 mm (1.2756 in)
Intake B 24.950–25.050 mm (0.9823–
0.9862 in)
Limit 24.900 mm (0.9803 in)
Exhaust A 32.450–32.550 mm (1.2776–
1.2815 in)
Limit 32.400 mm (1.2756 in)
Exhaust B
24.950–25.050 mm (0.9823–
0.9862 in)
Limit
24.900 mm (0.9803 in)Camshaft runout limit0.060 mm (0.0024 in)
Camshaft-journal-to-camshaft-
cap clearance
0.028–0.062 mm (0.0011–
0.0024 in)
Limit
0.080 mm (0.0032 in)