Yamaha FZS6W 07 User Manual

							
SPECIAL TOOLS
1-12
Pocket tester
90890-03112
Analog pocket tester
YU-03112-C1-9, 5-38, 8-65, 
8-66, 8-67, 8-71, 
8-72, 8-73, 8-74, 
8-75, 8-76, 8-77, 
8-78, 8-79, 8-80, 
8-81, 8-82
Pressure gauge
90890-03153
YU-03153 3-14, 7-6
Oil pressure adapter H
90890-03139 3-14
Fuel pressure adapter
90890-03176
YM-03176 7-6
Valve spring compressor
90890-04019
YM-04019 5-21, 5-27
Valve spring compressor attachment
90890-04108
Valve spring compressor adapter 22 mm
YM-04108 5-21, 5-27
Middle driven shaft bearing driver
90890-04058
Bearing driver 40 mm
YM-04058 6-12
Mechanical seal installer
90890-04078
Water pump seal installer
YM-33221-A 6-12
Tool name/Tool No. Illustration
Reference
pages 
						

							
SPECIAL TOOLS
1-13
Universal clutch holder
90890-04086
YM-910425-49, 5-51
Valve lapper
90890-04101
Valve lapping tool
YM-A8998 3-5
Valve guide remover (ø4)
90890-04111
Valve guide remover (4.0 mm)
YM-04111 5-23
Valve guide installer (ø4)
90890-04112
Valve guide installer (4.0 mm)
YM-04112 5-23
Valve guide reamer (ø4)
90890-04113
Valve guide reamer (4.0 mm)
YM-04113 5-23
Ignition checker
90890-06754
Opama pet-4000 spark checker
YM-34487 8-74
Yamaha bond No. 1215
(Three bond No.1215®)
90890-85505 5-32, 5-35, 5-
58, 6-12
Digital circuit tester
90890-03174
Model 88 Multimeter with tachometer
YU-A1927 7-7
Tool name/Tool No. Illustration
Reference
pages 
						

							
2
SPECIFICATIONS
GENERAL SPECIFICATIONS...................................................................... 2-1
ENGINE SPECIFICATIONS .......................................................................... 2-2
CHASSIS SPECIFICATIONS ........................................................................ 2-9
ELECTRICAL SPECIFICATIONS ............................................................... 2-12
TIGHTENING TORQUES ............................................................................ 2-15
GENERAL TIGHTENING TORQUE SPECIFICATIONS ....................... 2-15
ENGINE TIGHTENING TORQUES ...................................................... 2-16
CHASSIS TIGHTENING TORQUES .................................................... 2-20
LUBRICATION POINTS AND LUBRICANT TYPES .................................. 2-22
ENGINE ................................................................................................ 2-22
CHASSIS .............................................................................................. 2-23
LUBRICATION SYSTEM CHART AND DIAGRAMS ................................. 2-25
ENGINE OIL LUBRICATION CHART ................................................... 2-25
LUBRICATION DIAGRAMS .................................................................. 2-27
COOLING SYSTEM DIAGRAMS ............................................................... 2-39
CABLE ROUTING ...................................................................................... 2-47 
						

							
GENERAL SPECIFICATIONS
2-1
EAS20280
GENERAL SPECIFICATIONS
ModelModel 4S82 (U.S.A.)  4S83 (California)
 
Dimensions
Overall length 2095 mm (82.5 in)
Overall width 750 mm (29.5 in)
Overall height 1210 mm (47.6 in)
Seat height 795 mm (31.3 in)
Wheelbase 1440 mm (56.7 in)
Ground clearance 145 mm (5.71 in)
Minimum turning radius 2800 mm (110.2 in)
 
WeightWith oil and fuel 207.0 kg (456 lb) (FZS6W)  208.0 kg (459 lb) (FZS6WC)
Maximum load 189 kg (417 lb) (FZS6WC)  190 kg (419 lb) (FZS6W)
  
						

							
ENGINE SPECIFICATIONS
2-2
EAS20290
ENGINE SPECIFICATIONS
EngineEngine type Liquid cooled 4-stroke, DOHC
Displacement 600.0 cm³
Cylinder arrangement Forward-inclined parallel 4-cylinder
Bore  × stroke 65.5  × 44.5 mm (2.58  × 1.75 in)
Compression ratio 12.20 :1
Standard compression pressure (at sea level) 1550 kPa/400 r/min (220.5 psi/400 r/min) (15.5 kgf/cm²/400 r/min)
Minimum–maximum 1300–1650 kPa (184.9–234.7 psi) (13.0–16.5 kgf/cm²)
Starting system Electric starter
 
Fuel Recommended fuel Unleaded gasoline only
Fuel tank capacity 19.4 L (5.13 US gal) (4.27 Imp.gal)
Fuel reserve amount 3.6 L (0.95 US gal) (0.79 Imp.gal)
 
Engine oil
Lubrication system Wet sump
Type YAMALUBE 4, SAE10W30 or SAE 20W40
Recommended engine oil grade API service  SG type or higher, JASO standard
MA
Engine oil quantity
Total amount 3.40 L (3.59 US qt) (2.99 Imp.qt)
Without oil filter cartridge replacement 2.50 L (2.64 US qt) (2.20 Imp.qt)
With oil filter cartridge replacement 2.80 L (2.96 US qt) (2.46 Imp.qt)
Oil pressure 240 kPa at 6,600 r/min  (2.4 kg/cm² at 6,600 r/min) 
(2.4 bar at 6,600 r/min) 
(34.1 psi at 6,600 r/min)
 
Oil filter
Oil filter type Formed
 
Oil pumpOil pump type Trochoid
Inner-rotor-to-outer-rotor-tip clearanc e 0.030–0.090 mm (0.0012–0.0035 in)
Limit 0.15 mm (0.0059 in)
Outer-rotor-to-oil-pump-housing clearanc e 0.030–0.080 mm (0.0012–0.0032 in)
Limit 0.150 mm (0.0059 in)
Bypass valve opening pressure 80.0–120.0  kPa  (11.6–17.4  psi)  (0.80–1.20 kgf/cm²)
Relief valve operating pressure 450.0–550.0  kPa  (65.3–79.8  psi)  (4.50–5.50 kgf/cm²)
Pressure check location Main gallery
 
Cooling system Radiator capacity (including all routes ) 2.00 L (2.11 US qt) (1.76 Imp.qt)
Radiator capacity 0.60 L (0.63 US qt) (0.53 Imp.qt)
Coolant reservoir capacity (up to the maximum
level mark) 0.25 L (0.26 US qt) (0.22 Imp.qt)
Radiator cap opening pressure 93–123 kPa (13.2–17.5 psi) (0.93–1.23 kgf/ cm²)
Radiator core
Width 300.0 mm (11.81 in)
Height 188.0 mm (7.40 in)
Depth 24.0 mm (0.94 in) 
						

							
ENGINE SPECIFICATIONS
2-3
Water pumpWater pump type Single su ction centrifugal pump
Reduction ratio 86/44  × 31/31 (1.955)
Max. impeller shaft tilt 0.15 mm (0.006 in)
 
Spark plug (s) Manufacturer/model NGK/CR9EK
Spark plug gap 0.6–0.7 mm (0.024–0.028 in)
 
Cylinder headVolume 10.33–10.93 cm³ (0.63–0.67 cu.in)
Warpage limit 0.05 mm (0.0020 in)
 
CamshaftDrive system Chain drive (right)
Camshaft cap inside diameter 23.008–23.029 mm (0.9058–0.9067 in)
Camshaft journal diameter 22.967–22.980 mm (0.9042–0.9047 in)
Camshaft-journal-to-camshaft-cap clear ance 0.028–0.062 mm (0.0011–0.0024 in)
Limit 0.080 mm (0.0032 in)
Camshaft lobe dimensions 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 limit 0.060 mm (0.0024 in)
 
Timing chain
Model/number of links 92RH2015/120
Tensioning system Automatic
Valve clearance (cold)Intake 0.13–0.20 mm (0.0051–0.0079 in)
Exhaust 0.23–0.30 mm (0.0091–0.0118 in) 
						

							
ENGINE SPECIFICATIONS
2-4
Valve dimensionsValve head diameter A (intake) 24.90–25.10 mm (0.9803–0.9882 in)
Valve head diameter A (exhaust) 21.90–22.10 mm (0.8622–0.8701 in)
Valve face width B (intake) 1.140–1.980 mm (0.0449–0.0780 in)
Valve face width B (exhaust) 1.140–1.980 mm (0.0449–0.0780 in)
Valve seat width C (intake) 0.90–1.10 mm (0.0354–0.0433 in)
Limit 1.6 mm (0.06 in)
Valve seat width C (exhaust) 0.90–1.10 mm (0.0354–0.0433 in)
Limit 1.6 mm (0.06 in)
Valve margin thickness D (intake) 0.60–0.80 mm (0.0236–0.0315 in)
Limit 0.5 mm (0.02 in)
Valve margin thickness D (exhaust) 0.60–0.80 mm (0.0236–0.0315 in)
Limit 0.5 mm (0.02 in)
Valve stem diameter (intake) 3.975–3.990 mm (0.1565–0.1571 in)
Limit 3.950 mm (0.1555 in)
Valve stem diameter (exhaust) 3.960–3.975 mm (0.1559–0.1565 in)
Limit 3.935 mm (0.1549 in)
Valve guide inside diameter (intake) 4.000–4.012 mm (0.1575–0.1580 in)
Limit 4.042 mm (0.1591 in)
Valve guide inside diameter (exhaust) 4.000–4.012 mm (0.1575–0.1580 in)
Limit 4.042 mm (0.1591 in)
Valve-stem-to-valve-guide clearance (intake) 0.010–0.037 mm (0.0004–0.0015 in)
Limit 0.080 mm (0.0032 in)
Valve-stem-to-valve-guide clearance (exhaust) 0.025–0.052 mm (0.0010–0.0020 in)
Limit 0.100 mm (0.0039 in)
Valve stem runout 0.040 mm (0.0016 in)
Cylinder head valve seat width (intake) 0.90–1.10 mm (0.0354–0.0433 in)
Limit 1.6 mm (0.06 in)
Cylinder head valve seat width (exhaust) 0.90–1.10 mm (0.0354–0.0433 in) 
						

							
ENGINE SPECIFICATIONS
2-5
Limit 1.6 mm (0.06 in) 
Valve springInner spring
Free length (intake) 37.04 mm (1.46 in)
Limit 35.20 mm (1.39 in)
Free length (exhaust) 41.79 mm (1.65 in)
Limit 39.70 mm (1.56 in)
Installed length (intake) 30.02 mm (1.18 in)
Installed length (exhaust) 36.12 mm (1.42 in)
Spring rate K1 (intake) 10.50 N/mm (59.96 lb/in) (1.07 kgf/mm)
Spring rate K2 (intake) 17.00 N/mm (97.07 lb/in) (1.73 kgf/mm)
Spring rate K1 (exhaust) 30.26 N/mm (172.78 lb/in) (3.09 kgf/mm)
Spring rate K2 (exhaust) 49.53 N/mm (282.82 lb/in) (5.05 kgf/mm)
Installed compression spring force (intake) 69–79 N (15.51–17.76 lbf) (7.04–8.06 kgf)
Installed compression spring force (exhaust) 160–184  N  (35.97–41.36  lbf)  (16.32–18.76 kgf)
Spring tilt (intake) 2.5  °/1.6 mm (0.06 in)
Spring tilt (exhaust) 2.5  °/1.8 mm (0.07 in)
Winding direction (intake) Counter clockwise
Winding direction (exhaust) Clockwise
Outer spring
Free length (intake) 38.40 mm (1.51 in)
Limit 36.50 mm (1.44 in)
Installed length (intake) 32.52 mm (1.28 in)
Spring rate K1 (intake) 20.80 N/mm (118.77 lb/in) (2.12 kgf/mm)
Spring rate K2 (intake) 33.30 N/mm (190.14 lb/in) (3.40 kgf/mm)
Installed compression spring force (intake) 114–132  N  (25.63–29.67  lbf)  (11.62–13.46 kgf)
Spring tilt (intake) 2.5  °/1.7 mm (0.07 in)
Winding direction (intake) Clockwise
 
Cylinder Bore 65.500–65.510 mm (2.5787–2.5791 in)
Taper limit 0.050 mm (0.0020 in)
Out of round limit 0.050 mm (0.0020 in)
 
Piston
Piston-to-cylinder clearance 0.010–0.035 mm (0.0004–0.0014 in)
Limit 0.05 mm (0.0020 in)
Diameter D 65.475–65.490 mm (2.5778–2.5783 in)
Height H 4.0 mm (0.16 in) 
						

							
ENGINE SPECIFICATIONS
2-6
Offset 0.50 mm (0.0197 in)
Offset direction Intake side
Piston pin bore inside diameter 16.002–16.013 mm (0.6300–0.6304 in)
Limit 16.043 mm (0.6316 in)
Piston pin outside diameter 15.991–16.000 mm (0.6296–0.6299 in)
Limit 15.971 mm (0.6288 in)
Piston-pin-to-piston-pin-bore clearance 0.002–0.022 mm (0.0001–0.0009 in)
Limit 0.072 mm (0.0028 in)
 
Piston ring
Top ringRing type Barrel
Dimensions (B  × T) 0.90  × 2.45 mm (0.04  × 0.10 in)
End gap (installed) 0.25–0.35 mm (0.0098–0.0138 in)
Limit 0.60 mm (0.0236 in)
Ring side clearance 0.030–0.065 mm (0.0012–0.0026 in)
Limit 0.115 mm (0.0045 in)
2nd ring Ring type Taper
Dimensions (B  × T) 0.80  × 2.50 mm (0.03  × 0.10 in)
End gap (installed) 0.70–0.80 mm (0.0276–0.0315 in)
Limit 1.15 mm (0.0453 in)
Ring side clearance 0.030–0.065 mm (0.0012–0.0026 in)
Limit 0.125 mm (0.0049 in)
Oil ring Dimensions (B  × T) 1.50  × 2.00 mm (0.06  × 0.08 in)
End gap (installed) 0.10–0.35 mm (0.0039–0.0138 in)
 
Connecting rod Oil clearance (using plastigauge®) 0 .028–0.052 mm (0.0011–0.0020 in)
Limit 0.08 mm (0.0032 in)
Bearing color code 1.Blue 2.Black 3.Brown 4.Green
  
						

							
ENGINE SPECIFICATIONS
2-7
CrankshaftWidth A 51.850–52.550 mm (2.04–2.06 in)
Width B 268.80–270.00 mm (10.58–10.63 in)
Runout limit C 0.030 mm (0.0012 in)
Big end side clearance D 0.160–0.262 mm (0.0063–0.0103 in)
Big end radial clearance 0.028–0.052 mm (0.0011–0.0020 in)
Small end free play 0.32–0.50 mm (0.01–0.02 in)
Journal oil clearance (using plastigauge®) 0.034–0.058 mm (0.0013–0.0023 in)
Limit 0.10 mm (0.0039 in)
Bearing color code 0.White 1.Black 2.Brown 3.Green 4.Yellow
 
ClutchClutch type Wet, multiple-disc
Clutch release method Outer pull, rack and pinion pull
Clutch release method operation Cable  operation
Clutch lever free play 10.0–15.0 mm (0.39–0.59 in)
Friction plate thickness 2.92–3.08 mm (0.115–0.121 in)
Wear limit 2.80 mm (0.1102 in)
Plate quantity 6 pcs
Friction plate thickness 2.92–3.08 mm (0.115–0.121 in)
Plate quantity 2 pcs
Clutch plate thickness 1.90–2.10 mm (0.075–0.083 in)
Plate quantity 7 pcs
Warpage limit 0.10 mm (0.0039 in)
Clutch plate thickness 2.20–2.40 mm (0.087–0.094 in)
Plate quantity 1 pcs
Warpage limit 0.10 mm (0.0039 in)
Clutch spring free length 55.00 mm (2.17 in)
Limit 52.30 mm (2.06 in)
Spring quantity 6 pcs
 
TransmissionTransmission type Constant mesh 6-speed
Primary reduction system Spur gear
Primary reduction ratio 86/44 (1.955)
Secondary reduction system Chain drive
Secondary reduction ratio 46/16 (2.875)
Operation Left foot operation
Gear ratio1st 37/13 (2.846)
2nd 37/19 (1.947)
3rd 28/18 (1.556)
4th 32/24 (1.333)
5th 25/21 (1.190)
6th 26/24 (1.083)
Main axle runout limit 0.02 mm (0.0008 in)
Drive axle runout limit 0.02 mm (0.0008 in)