Yamaha FZS6W 07 User Manual

							
6
COOLING SYSTEM
RADIATOR.................................................................................................... 6-1
CHECKING THE RADIATOR.................................................................. 6-3
INSTALLING THE RADIATOR ................................................................ 6-3
OIL COOLER ................................................................................................ 6-4
CHECKING THE OIL COOLER .............................................................. 6-5
INSTALLING THE OIL COOLER ............................................................ 6-5
THERMOSTAT .............................................................................................. 6-6
CHECKING THE THERMOSTAT ............................................................ 6-7
INSTALLING THE THERMOST AT ASSEMBLY ...................................... 6-7
WAT E R  P U M P .............................................................................................. 6-9
DISASSEMBLING THE WATER  PUMP................................................ 6-11
CHECKING THE WATER PUMP .......................................................... 6-11
ASSEMBLING THE WATER PU MP...................................................... 6-12
INSTALLING THE WATER PUMP ........................................................ 6-13 
						

							
RADIATOR
6-1
EAS26380
RADIATOR
Removing the radiator
Order Job/Parts to remove Q’ty RemarksSeat Refer to GENERAL CHASSIS on page 4-1.
Left front cowling inner panel Refer to GENERAL CHASSIS on page 4-1.
Right front cowling inner panel Refer to GENERAL CHASSIS on page 4-1.
Fuel tank Refer to FUEL TANK on page 7-1.
Air filter case Refer to GENERAL CHASSIS on page 4-1.
Coolant Drain.
Refer to CHANGING THE COOLANT on 
page 3-18.
1 Coolant reservoir hose 1
2 Thermo wax outlet hose 1
3 Water pump breather hose 1
4 Radiator outlet hose 1
5 Radiator inlet hose 1
6 Oil cooler outlet hose 1
7 Radiator 1
8 Radiator cap 1
9 Radiator fan 1
10 Coolant reservoir cover 1
11 Coolant reservoir 1
12 Coolant reservoir cap 1 
						

							
RADIATOR
6-2
13 Coolant reservoir drain hose 1For installation, reverse the removal proce-
dure.
Removing the radiator
Order Job/Parts to remove Q’ty Remarks 
						

							
RADIATOR
6-3
EAS26390
CHECKING THE RADIATOR
1. Check: Radiator finsObstruction  → Clean.
Apply compressed air to the rear of the 
radiator.
Damage  → Repair or replace.
NOTE:
Straighten any flattened fins with a thin, flat-
head screwdriver.
2. Check:
 Radiator hoses
 Radiator pipesCracks/damage  → Replace.
3. Measure:  Radiator cap opening pressure
Below the specified pressure  → Replace 
the radiator cap.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Install the radiator cap tester “1” and radia- tor cap tester adapter “2” to the radiator 
cap “3”. b. Apply the specified pressure for ten sec-
onds and make sure there is no drop in 
pressure.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
4. Check:Radiator fanDamage  → Replace.
Malfunction  → Check and repair.
Refer to ELECTRICAL COMPONENTS 
on page 8-59.
EAS26400
INSTALLING THE RADIATOR
1. Fill:  Cooling system
(with the specified amount of the recom-
mended coolant)
Refer to CHANGING THE COOLANT on 
page 3-18.
2. Check:  Cooling system
Leaks  → Repair or replace any faulty part.
3. Measure:  Radiator cap opening pressure
Below the specified pressure  → Replace 
the radiator cap.
Refer to CHECKING THE RADIATOR on 
page 6-3.
Radiator cap opening pressure 93–123 kPa (13.2–17.5 psi)
(0.93–1.23 kgf/cm²)
Radiator cap tester
90890-01325
Radiator pressure tester YU-24460-01
Radiator cap tester adapter 90890-01352
Radiator pressure tester 
adapter
YU-33984 
						

							
OIL COOLER
6-4
EAS26410
OIL COOLER
Removing the oil cooler
Order Job/Parts to remove Q’ty RemarksRadiator assembly Refer to RADIATOR on page 6-1.
Coolant reservoir Refer to RADIATOR on page 6-1.
Engine oil Drain.
Refer to CHANGING THE ENGINE OIL on 
page 3-12.
1 Oil cooler outlet hose 1
2 Union bolt 1
3 Washer 1
4 Oil cooler 1
5O-ring 1
6 Oil cooler inlet hose 1
7 Oil cooler inlet pipe 1
8 Water jacket joint hose 1
9 Water jacket joint 1
10 O-ring 1
11 Water pump outlet hose 1
12 Radiator outlet hose 1 For installation, reverse the removal proce-
dure. 
						

							
OIL COOLER
6-5
EAS26420
CHECKING THE OIL COOLER
1. Check:Oil coolerCracks/damage  → Replace.
2. Check:  Oil cooler inlet hose
 Oil cooler outlet hoseCracks/damage/wear  → Replace.
EAS26430
INSTALLING THE OIL COOLER
1. Clean:
 Mating surfaces of the oil cooler and the crankcase
(with a cloth dampened with lacquer thin-
ner)
2. Install:
 O-ring 
Oil cooler “1”
 Washer “2”
 Union bolt “3”
NOTE:
 Before installing the oil cooler, lubricate the oil cooler bolt and O-ring with a thin coat of 
engine oil.
 Make sure the O-ring is positioned properly.
3. Fill: Cooling system (with the specified amount of the recom-
mended coolant)
Refer to CHANGING THE COOLANT on 
page 3-18.
 Crankcase (with the specified amount of the recom-
mended engine oil)
Refer to CHANGING THE ENGINE OIL 
on page 3-12.
4. Check:
 Cooling systemLeaks  → Repair or replace any faulty part.
5. Measure:
 Radiator cap opening pressureBelow the specified pressure  → Replace 
the radiator cap.
Refer to CHECKING THE RADIATOR on 
page 6-3.
Oil cooler 63 Nm (6.3 m·kg, 46 ft·lb)
New 
						

							
THERMOSTAT
6-6
EAS26440
THERMOSTAT
Removing the thermostat
Order Job/Parts to remove Q’ty RemarksSeat Refer to GENERAL CHASSIS on page 4-1.
Left front cowling inner panel Refer to GENERAL CHASSIS on page 4-1.
Right front cowling inner panel Refer to GENERAL CHASSIS on page 4-1.
Fuel tank Refer to FUEL TANK on page 7-1.
Air filter case Refer to GENERAL CHASSIS on page 4-1.
Coolant Drain.
Refer to CHANGING THE ENGINE OIL on 
page 3-12.
Throttle body assembly Refer to THROTTLE BODIES on page 7-4.
1 Radiator inlet hose 1
2 Thermostat cover 1
3 Thermostat 1 For installation, reverse the removal proce-
dure. 
						

							
THERMOSTAT
6-7
EAS26450
CHECKING THE THERMOSTAT
1. Check: Thermostat “1”Does not open at 71–85 °C (160–185 °F)  → 
Replace.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Suspend the thermostat “3” in a container  “4” filled with water.
b. Slowly heat the water “2”.
c. Place a thermometer “1” in the water.
d. While stirring the water, observe the ther- mostat and thermometer’s indicated tem-
perature.
NOTE:
If the accuracy of the thermostat is in doubt, 
replace it. A faulty thermostat could cause seri-
ous overheating or overcooling.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
2. Check: Thermostat housing cover “1”
 Cracks/damage  → Replace.
EAS26490
INSTALLING THE THERMOSTAT ASSEM-
BLY
1. Install:
Thermostat
NOTE:
Install the thermostat with its breather hole “a” 
facing up.
2. Install: Thermostat cover
NOTE:
Before installing the thermostat cover to the 
cylinder head, lubricate the O-rings with a thin 
coat of lithium-soap-based grease.
3. Fill: Cooling system
(with the specified amount of the recom-
mended coolant)
Refer to CHANGING THE COOLANT on 
page 3-18.
4. Check:  Cooling system
Leaks  → Repair or replace any faulty part.
A. Fully closed
B. Fully open
C. Opening (mm)
D. Temperature
Water jacket outlet joint bolt
12 Nm (1.2 m·kg, 8.7 ft·lb) 
						

							
THERMOSTAT
6-8
5. Measure: Radiator cap opening pressureBelow the specified pressure  → Replace 
the radiator cap.
Refer to CHECKING THE RADIATOR on 
page 6-3. 
						

							
WATER PUMP
6-9
EAS26500
WAT E R  P U M P
Removing the water pump
Order Job/Parts to remove Q’ty RemarksIt is not necessary to remove the water pump 
unless the coolant level is extremely low or 
the coolant contains engine oil.
Coolant Drain.
Refer to CHANGING THE COOLANT on 
page 3-18.
1 Radiator outlet hose 1 Disconnect.
2 Water pump outlet hose 1
3 Water pump breather hose 1 Disconnect.
4 Water pump 1 For installation, reverse the removal proce-
dure.