Yamaha FZS6W 07 User Manual

							
WATER PUMP
6-10
Disassembling the water pump
Order Job/Parts to remove Q’ty Remarks1 Water pump cover 1
2O-ring 1
3 Impeller shaft 1
4 Circlip 1
5 Water pump seal 1
6 Oil seal 1
7 Bearing 1
8 Water pump housing 1
9O-ring 1
10 Copper washer 1
For assembly, reverse the disassembly pro-
cedure. 
						

							
WATER PUMP
6-11
EAS26510
DISASSEMBLING THE WATER PUMP
1. Remove: Water pump cover
O-ring
 Circlip
 Impeller shaft
2. Remove:  Water pump seal “1”
NOTE:
Remove the water pump seal from the inside 
of the water pump housing “2”.
3. Remove:Oil seal “3”
(with a thin, flat-head screwdriver)
NOTE:
Remove the oil seal from the outside of the 
water pump housing.
4. Remove: Bearing “4”
NOTE:
Remove the bearing from inside of the water 
pump housing. 5. Remove:
 Rubber damper holder “5”
 Rubber damper “6”(from the impeller, with a thin, flat-head 
screwdriver)
NOTE:
Do not scratch the impeller shaft.
EAS26540
CHECKING THE WATER PUMP
1. Check: Water pump housing cover “1”
 Water pump housing cover “2”
 Impeller “3”
 Rubber damper “4”
 Rubber damper holder “5”
 Water pump seals
 Oil sealCracks/damage/wear  → Replace.
2. Check:  Bearing
Rough movement  → Replace. 
						

							
WATER PUMP
6-12
3. Check: Water pump outlet pipe
 Radiator outlet hoseCracks/damage/wear  → Replace.
EAS26560
ASSEMBLING THE WATER PUMP
1. Install:
 Bearing
 Oil seal “1” 
(into the water pump housing “2”)
NOTE:
 Before installing the oil seal, apply tap water or coolant onto its out surface.
 Install the oil seal wi th a socket that matches 
its outside diameter.
2. Install:  Water pump seal “1” 
CAUTION:
ECA14080
Never lubricate the water pump seal sur-
face with oil or grease.
NOTE:
 Install the water pump seal with the special tools.
 Before installing the water pump seal, apply 
Yamaha bond No.1215 or Quick Gasket “2” 
to the water pump housing “3”. 3. Install:
 Rubber damper “1” 
 Rubber damper holder “2” 
NOTE:
Before installing the rubber damper, apply tap 
water or coolant onto its outer surface.
4. Measure: Impeller shaft tilt
Out of specification  → Repeat steps (3) 
and (4).
CAUTION:
ECA14090
Make sure the rubber damper and rubber 
damper holder are flush with the impeller.
Mechanical seal installer 90890-04078
Water pump seal installer YM-33221-A
Middle driven shaft bearing 
driver 90890-04058
Bearing driver 40 mm YM-04058
Yamaha bond No. 1215 (Three 
bond No. 1215®)
90890-85505
New
New
A. Push down
4. Mechanical seal installer
5. Middle driven shaft bearing driver
Impeller shaft tilt limit0.15 mm (0.006 in)
New
New 
						

							
WATER PUMP
6-13
5. Install: Impeller shaft
 Circlip 
 O-ring 
 Water pump cover
EAS26590
INSTALLING THE WATER PUMP
1. Install: O-ring 
 Copper washer 
 Water pump assembly “1”
NOTE:
 Align the slit “a” on the impeller shaft with the projection “b” on the oil pump shaft.
 Lubricate the O-ring with a thin coat of lith-
ium-soap-based grease.
2. Install:  O-ring 
 Water pump inlet hose “1”
 O-rings   Water pump outlet hose “2”
 Copper washer 
NOTE:
 Install the radiator outlet hose with white “a” 
mark positioned outside.
 Install the hose clamp with its screw head 
pointed to the inner side.
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 systemLeaks  → Repair or replace the faulty part.
5. Measure:
 Radiator cap opening pressureBelow the specified pressure  → Replace 
the radiator cap.
Refer to CHECKING THE RADIATOR on 
page 6-3.
1. Straightedge
2. Impeller
Water pump cover bolt 10 Nm (1.0 m·kg, 7.2 ft·lb)
Water pump assembly bolt
10 Nm (1.0 m·kg, 7.2 ft·lb)
New
New
New
New
New
New 
						

							
7
FUEL SYSTEM
FUEL TANK.................................................................................................. 7-1
REMOVING THE FUEL TANK ................................................................ 7-2
REMOVING THE FUEL PUMP............................................................... 7-2
CHECKING THE FUEL PUMP BODY .................................................... 7-2
CHECKING THE FUEL PUMP OPERATION ......................................... 7-2
INSTALLING THE FUEL PUMP.............................................................. 7-2
INSTALLING THE FUEL TANK ............................................................... 7-3
THROTTLE BODIES ..................................................................................... 7-4
CHECKING THE INJECTORS ............................................................... 7-6
CHECKING THE THROTTLE BODIES .................................................. 7-6
CHECKING THE FUEL PRESSURE ...................................................... 7-6
ADJUSTING THE THROTTLE POSITION SENSOR ............................. 7-6
AIR INDUCTION SYSTEM ........................................................................... 7-9
CHECKING THE AIR INDUCTION SYSTEM ....................................... 7-12
INSTALLING THE AIR INDUCTION SYSTEM ..................................... 7-12 
						

							
FUEL TANK
7-1
EAS26620
FUEL TANK
Removing the fuel tank
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.
1 Fuel hose 1
2 Fuel sender coupler 1 Disconnect.
3 Fuel pump coupler 1 Disconnect.
4 Fuel tank drain hose 1
5 Fuel tank breather hose 1
6Fuel tank 1
7Fuel pump 1
8 Roll over valve 1 For installation, reverse the removal proce-
dure. 
						

							
FUEL TANK
7-2
EAS26630
REMOVING THE FUEL TANK
1. Extract the fuel in the fuel tank through the fuel tank cap with a pump.
2. Remove:
 Fuel return hose
 Fuel hose
CAUTION:
ECA4S81003
 Be sure to disconnect the fuel hose by hand. Do not forcefully disconnect the 
hose with tools.
 Although the fuel has been removed from  the fuel tank, be careful when removing 
the fuel hoses, since there may be fuel 
remaining in it.
NOTE:
 To remove the fuel hose from the fuel injec-tion pipe, slide the cover “a” on the end of the 
hose in the direction of the arrow shown and 
then remove the hose.
 Before removing the hoses, place a few rags 
in the area under where it will be removed.
3. Remove:  Fuel tank
NOTE:
Do not set the fuel tank down so that the instal-
lation surface of the fuel pump is directly under 
the tank. Be sure to lean the fuel tank in an 
upright position.
EAS26640
REMOVING THE FUEL PUMP
1. Remove: Fuel pump
CAUTION:
ECA14720
 Do not drop the fuel pump or give it a 
strong shock.
 Do not touch the base section of the fuel 
sender.
EAS26670
CHECKING THE FUEL PUMP BODY
1. Check:  Fuel pump bodyObstruction  → Clean.
Cracks/damage  → Replace fuel pump 
assembly.
2. Check:  Diaphragms and gaskets
Turn/fatigue/cracks  → Replace fuel pump 
assembly.
3. Check:
ValvesCracks/damage  → Replace fuel pump 
assembly.
EAS26690
CHECKING THE FUEL PUMP OPERATION
1. Check:  Fuel pump operation
Refer to CHECKING THE FUEL PRES-
SURE on page 7-6.
EAS26710
INSTALLING THE FUEL PUMP
1. Install:Fuel pump
 Fuel pump bolts
NOTE:
 Do not damage the installation surfaces of the fuel tank when installing the fuel pump.
 Always use a new fuel pump gasket.
 Install the fuel pump as shown in the illustra- tion.
 Tighten the fuel pump bolts in stages in a  crisscross pattern and to the specified 
torque.
Fuel pump bolts4 Nm (0.4 m·kg, 2.9 ft·lb) 
						

							
FUEL TANK
7-3
EAS4S81001
INSTALLING THE FUEL TANK
1. Install: Fuel hose
CAUTION:
ECA4S81001
When installing the fuel hose, make sure 
that it is securely connected, and that the 
fuel hose holders are in the correct posi-
tion, otherwise the fuel hose will not be 
properly installed.
NOTE:
Install the fuel hose connector securely onto 
the fuel tank until a distinct “click” is heard, and 
then make sure that it doed not come loose.
To install the fuel hose from the fuel injection 
hose, slide the cover “a” on the end of the hose 
in the direction of arrow shown.
2. Install: Fuel sender coupler
 Fuel pump coupler
 Fuel tank breather hose (FZS6W)
 Fuel tank drain hose
NOTE:
There is a white paint mark on the fuel tank 
breather hose (FZS6W).
Refer to CABLE ROUTING on page 2-47. 
						

							
THROTTLE BODIES
7-4
EAS26970
THROTTLE BODIES
Removing the throttle bodies
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.
Battery Refer to GENERAL CHASSIS on page 4-1.
Air filter case Refer to GENERAL CHASSIS on page 4-1.
Battery box and battery box bracket Refer to GENERAL CHASSIS on page 4-1.
1 Sub-wire harness coupler 2 Disconnect.
2 Coolant temperature sensor coupler 1 Disconnect.
3 Balance hose 1 Disconnect.
4 Throttle body joint clamp screw 4
5 Throttle bodies 1
6 Throttle cable 2 Disconnect.
7 Throttle body joint 4
8 Heat protector 1
9 Plunger control unit hose 1 Disconnect. For installation, reverse the removal proce-
dure. 
						

							
THROTTLE BODIES
7-5
Removing the injectors
Order Job/Parts to remove Q’ty Remarks1 Throttle position sensor coupler 1 Disconnect.
2 Intake air pressure sensor coupler 1 Disconnect.
3 Cylinder #1 injector coupler 1 Disconnect.
4 Cylinder #2 injector coupler 1 Disconnect.
5 Cylinder #3 injector coupler 1 Disconnect.
6 Cylinder #4 injector coupler 1 Disconnect.
7 Sub-wire harness 1
8 Negative pressure hose 1
9 Intake air pressure sensor 1
10 Fuel distributor 1
11 Injector 4
12 Throttle position sensor 1
13 Fuel pulsation damper 1
14 Throttle bodies 1
For installation, reverse the removal proce-
dure.