Yamaha FZS6W 07 User Manual

							
CLUTCH
5-52
5. Install: Friction plates
 Clutch plates
NOTE:
First, install a friction plate and then alternate 
between a clutch plate and a friction plate.
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a Install the clutch plate and friction plate as shown in the illustration.
Clutch plate “1”: t=2.3 mm (0.09 in)
Clutch plate “2”: t=2.0 mm (0.08 in)
Friction plate “3”
Friction plate “4”: Color/Brown
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6. Install: Pressure plate “1”
NOTE:
Align the punch mark “a” in the pressure plate 
with the punch mark “b” in the clutch boss.
7. Install: Bearing “1”
 Pill rod “2”
 Pressure plate “3”
 Clutch springs
 Clutch spring bolts
NOTE:
Tighten the clutch spring bolts in stages and in 
a crisscross pattern.
8. Install:
Pull lever
9. Install:
Clutch cover
Gasket 
 Clutch cable holder
NOTE:
 Install the pull rod so that the teeth a face towards the rear of the vehicle. Then, install 
the clutch cover.
 Apply oil onto the bearing.
 Apply molybdenum disulfide grease onto the  pull rod.
 When installing the clutch cover, push the  pull lever and check that the punch mark “a” 
on the pull lever aligns with the mark “b” on 
the clutch cover. Make sure that the pull rod 
teeth and pull lever shaft pinion gear are 
engaged.
 Tighten the clutch cover bolts in stages and 
in a crisscross pattern.
10. Adjust:  Clutch cable free play
Refer to ADJUSTING THE CLUTCH 
CABLE FREE PLAY on page 3-14.
Clutch spring bolt8 Nm (0.8 m·kg, 5.8 ft·lb)
New 
						

							
SHIFT SHAFT
5-53
EAS25410
SHIFT SHAFT
Removing the shift shaft and stopper lever
Order Job/Parts to remove Q’ty RemarksDrive sprocket cover Refer to ENGINE REMOVAL on page 5-1.
1 Shift shaft cover 1
2 Shift shaft cover gasket 1
3Dowel pin 2
4 Oil seal 1
5 Shift shaft 1
6 Shift shaft spring 1
7 Collar 1
8 Stopper lever spring 1
9 Circlip 1
10 Washer 1
11 Stopper lever 1
12 Collar 1
13 Washer 1
14 Shift shaft spring stopper 1 For installation, reverse the removal proce-
dure. 
						

							
SHIFT SHAFT
5-54
EAS25420
CHECKING THE SHIFT SHAFT
1. Check: Shift shaft “1”Bends/damage/wear  → Replace.
 Shift shaft spring “2” Damage/wear  → Replace.
EAS25430
CHECKING THE STOPPER LEVER
1. Check:
 Stopper lever “1”
Bends/damage  → Replace.
Roller turns roughly  → Replace the stopper 
lever.
EAS25450
INSTALLING THE SHIFT SHAFT
1. Install:
 Shift shaft spring stopper “1”
 Washers
 Shift shaft “2”
NOTE:
 Apply LOCTITE® to the threads of the shift shaft spring stopper.
 Hook the ends of the stopper lever spring “3” 
onto the stopper lever “4” and the crankcase 
boss.
 Mesh the stopper lever with the shift drum 
segment assembly. 2. Install:
 Shift shaft cover
NOTE:
Lubricate the oil seal lips with lithium-soap-
based grease. 
						

							
CRANKCASE
5-55
EAS25540
CRANKCASE
Separating the crankcase
Order Job/Parts to remove Q’ty RemarksEngine Refer to ENGINE REMOVAL on page 5-1.
Cylinder head Refer to CYLINDER HEAD on page 5-16.
Generator Refer to GENERATOR AND STARTER 
CLUTCH on page 5-28.
Starter clutch Refer to GENERATOR AND STARTER 
CLUTCH on page 5-28.
Shift shaft Refer to SHI FT SHAFT on page 5-53.
Crankshaft position sensor Refer to PICKUP ROTOR on page 5-33.
Pickup rotor Refer to PICKUP ROTOR on page 5-33.
Clutch Refer to CLUTCH on page 5-46.
Water pump Refer to WATER PUMP on page 6-9.
Oil pan Refer to OIL PUMP on page 5-40.
Oil pump Refer to OIL PUMP on page 5-40.
1 Timing chain 1
2 Oil pump drive chain 1
3 Oil pump drive chain guide 1
4 Lower crankcase 1
5Dowel pin 3
6 Thrust plate 1
7 Washer 1 
						

							
CRANKCASE
5-56
8Plate 1For installation, reverse the removal proce-
dure.
Separating the crankcase
Order Job/Parts to remove Q’ty Remarks 
						

							
CRANKCASE
5-57
EAS25550
DISASSEMBLING THE CRANKCASE
1. Place the engine upside down.
2. Remove: Crankcase bolts
NOTE:
 Loosen each bolt 1/4 of a turn at a time, in 
stages and in a crisscross pattern. After all of 
the bolts are fully loosened, remove them.
 Loosen the bolts in decreasing numerical 
order (refer to the numbers in the illustration).
 The numbers embossed on the crankcase 
indicate the crankcase tightening sequence.
M8  × 85 mm (3.3 in) bolts: “1”–“7”, “10”
M8  × 115 mm (4.5 in) bolts: “8”, “9”
M8  × 65 mm (2.6 in) bolts: “11”, “12”
M6  × 65 mm (2.6 in) bolts: “13”, “14”
M6  × 55 mm (2.2 in) bolts: “15”, “22”–“26”
M6  × 45 mm (1.8 in) bolts: “16”, “19”, “20”
M6  × 65 mm (2.6 in) bolts: “17”, “27”
M6  × 75 mm (3.0 in) bolt: “18”
M6  × 100 mm (3.9 in) bolt: “21”
3. Remove:  Lower crankcase
CAUTION:
ECA13900
Tap on one side of the crankcase with a 
soft-face hammer. Tap only on reinforced 
portions of the crankcase, not on the 
crankcase mating surfaces. Work slowly 
and carefully and make sure the crankcase 
halves separate evenly.
4. Remove:
 Dowel pins
5. Remove:  Crankshaft journal lower bearing
(from the lower crankcase)
NOTE:
Identify the position of each crankshaft jour-
nal  lower bearing so that it can be reinstalled 
in its original place.
EAS25580
CHECKING THE CRANKCASE
1. Thoroughly wash the crankcase halves in a  mild solvent.
2. Thoroughly clean all the gasket surfaces  and crankcase mating surfaces.
3. Check:
 CrankcaseCracks/damage  → Replace.
 Oil delivery passages
Obstruction  → Blow out with compressed 
air.
EAS4S81034
CHECKING THE BEARINGS AND OIL 
SEALS
1. Check:  Bearings
Clean and lubricate the bearings, then 
rotate the inner race with your finger.
Rough movement  → Replace.
2. Check:  Oil sealsDamage/wear  → Replace.
EAS25620
CHECKING THE OIL PUMP DRIVE CHAIN
1. Check:
 Oil pump drive chain “1”
Damage/stiffness  → Replace the oil pump 
drive chain, oil pump drive sprocket and oil 
pump shaft as a set.
2. Check:  Oil pump drive sprocketCracks/damage/wear  → Replace the oil 
pump drive sprocket and the oil pump drive 
chain as a set. 
						

							
CRANKCASE
5-58
EAS25660
ASSEMBLING THE CRANKCASE
1. Lubricate: Crankshaft journal bearings(with the recommended lubricant)
2. Apply:  Sealant
(onto the crankcase mating surfaces)
NOTE:
Do not allow any sealant to come into contact 
with the oil gallery or crankshaft journal bear-
ings. Do not apply sealant to within 2–3 mm of 
the crankshaft journal bearings.
3. Install:Dowel pin
4. Set the shift drum assembly and transmis- sion gears in the neutral position.
5. Install:
 Lower crankcase “1”(onto the upper crankcase “2”)
CAUTION:
ECA13980
Before tightening the crankcase bolts, 
make sure the transmission gears shift cor-
rectly when the shift drum assembly is 
turned by hand. 6. Install:
 Crankcase bolts
NOTE:
 Lubricate the bolt threads with engine oil.
 Install a washer on bolts “1”–”10” 
 Seal bolt “18”
 Tighten the bolts in the tightening sequence 
cast on the crankcase.
M8  × 85 mm (3.3 in) bolts: “1”–“7”, “10”
M8  × 115 mm (4.5 in) bolts: “8”, “9”
M8  × 65 mm (2.6 in) bolts: “11”, “12”
M6  × 65 mm (2.6 in) bolts: “13”, “14”
M6  × 55 mm (2.2 in) bolts: “15”, “22”–“26”
M6  × 45 mm (1.8 in) bolts: “16”, “19”, “20”
M6  × 65 mm (2.6 in) bolts: “17”, “27”
M6  × 75 mm (3.0 in) bolt: “18” LOCTITE®
M6  × 100 mm (3.9 in) bolt: “21”
*Loosen the bolts following the tightening 
order and then tighten to specification 
torque.
Recommended lubricant Engine oil
Yamaha bond No. 1215(Three bond No. 1215®)
90890-85505
Crankcase boltBolt “1”–“10”
1st: 12 Nm (1.2 m·kg, 8.7 ft·lb)
2nd: 25 Nm (2.5 m·kg, 18 ft·lb)
3rd*: 27 Nm (2.7 m·kg, 20 ft·lb)
Bolt “11”, “12”
24 Nm (2.4 m·kg, 17 ft·lb)
Bolt “13”, “14”
14 Nm (1.4 m·kg, 1.0 ft·lb)
Bolt “15”–“27”
12 Nm (1.2 m·kg, 8.7 ft·lb) 
						

							
CRANKCASE
5-59 
						

							
CRANKSHAFT
5-60
EAS25950
CRANKSHAFT
Removing the connecting rods and pistons
Order Job/Parts to remove Q’ty RemarksLower crankcase Refer to CRANKCASE on page 5-55.
1 Connecting rod cap 4
2 Big end lower bearing 4
3 Big end upper bearing 4
4 Piston pin clip 8
5 Piston pin 4
6Piston 4
7 Connecting rod 4
8 Top ring 4
9 2nd ring 4
10 Oil ring 4 For installation, reverse the removal proce-
dure. 
						

							
CRANKSHAFT
5-61
Removing the crankshaft
Order Job/Parts to remove Q’ty RemarksCrankcase Separate.
Refer to CRANKCASE on page 5-55.
Connecting rods caps Refer to CRANKSHAFT on page 5-60.
1Crankshaft 1
2 Crankshaft journal lower bearing 5
3 Crankshaft journal upper bearing 5 For installation, reverse the removal proce-
dure.