Yamaha FZS6W 07 User Manual
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ENGINE SPECIFICATIONS 2-8 Shifting mechanismShift mechanism type Shift drum Shift fork guide bar bending limit 0.050 mm (0.0020 in) Shift fork thickness 5.76–5.89 mm (0.2268–0.2319 in) Air filter Air filter element Oil-coated paper element Fuel pumpPump type Electrical Model/manufacturer 5VX/DENSO Maximum consumption amperage 5.5 A Output pressure 250.0 kPa (36.3 psi) (2.50 kgf/cm²) Fuel injectorModel/quantity 0290 x 4 Manufacturer DENSO Throttle bodyType/quantity 36EIDW-B1/1 (FZS6W) 36EIDW-B4/1 (FZS6WC) Manufacturer MIKUNI ID mark 5VX1 03 (FZS6W) 5VX4 12 (FZS6WC) Throttle valve size #50 Throttle position sensor Resistance 4.0–6.0 k Ω Output voltage (at idle) 0.63-0.73 V Adjusted by tachometer Idling condition Engine idling speed 1250–1350 r/min Intake vacuum 29.0 kPa (8.6 inHg) (218 mmHg) Water temperature 95.0–105.0 °C (203.00–221.00 °F) Oil temperature 75.0–85.0 °C (167.00–185.00 °F) Throttle cable free play 3.0–5.0 mm (0.12–0.20 in)
CHASSIS SPECIFICATIONS 2-9 EAS20300 CHASSIS SPECIFICATIONS ChassisFrame type Diamond Caster angle 25.00 ° Trail 97.5 mm (3.84 in) Front wheel Wheel type Cast wheel Rim size 17M/C x MT3.50 Rim material Aluminum Wheel travel 130.0 mm (5.12 in) Radial wheel runout limit 1.0 mm (0.04 in) Lateral wheel runout limit 0.5 mm (0.02 in) Rear wheelWheel type Cast wheel Rim size 17M/C x MT5.50 Rim material Aluminum Wheel travel 130.0 mm (5.12 in) Radial wheel runout limit 1.0 mm (0.04 in) Lateral wheel runout limit 0.5 mm (0.02 in) Front tireType Tubeless Size 120/70 ZR17M/C (58W) Manufacturer/model BRIDGESTONE/BT020F GG Manufacturer/model DUNLOP/D252F Wear limit (front) 0.8 mm (0.03 in) Rear tire Type Tubeless Size 180/55 ZR17M/C (73W) Manufacturer/model BRIDGESTONE/BT020R GG Manufacturer/model DUNLOP/D252 Wear limit (rear) 0.8 mm (0.03 in) Tire air pressure (measured on cold tires)Loading condition 0–90 kg (0–198 lb) Front 225 kPa (33 psi) (2.25 kgf/cm²) (2.25 bar) Rear 250 kPa (36 psi) (2.50 kgf/cm²) (2.50 bar) Loading condition 90–189 kg (198–417 lb) (FZS6WC) 90–190 kg (198–419 lb) (FZS6W) Front 250 kPa (36 psi) (2.50 kgf/cm²) (2.50 bar) Rear 290 kPa (42 psi) (2.90 kgf/cm²) (2.90 bar) High-speed riding Front 225 kPa (33 psi) (2.25 kgf/cm²) (2.25 bar) Rear 250 kPa (36 psi) (2.50 kgf/cm²) (2.50 bar) Front brake Type Dual disc brake Operation Right hand operation
CHASSIS SPECIFICATIONS 2-10 Front disc brakeDisc outside diameter × thickness 298.0 × 5.0 mm (11.73 × 0.20 in) Brake disc thickness limit 4.5 mm (0.18 in) Brake disc deflection limit 0.10 mm (0.0039 in) Brake pad lining thickness (inner) 4.5 mm (0.18 in) Limit 0.5 mm (0.02 in) Brake pad lining thickness (outer) 4.5 mm (0.18 in) Limit 0.5 mm (0.02 in) Master cylinder inside diameter 16.00 mm (0.63 in) Caliper cylinder inside diameter 30.20 mm (1.19 in) Caliper cylinder inside diameter 27.00 mm (1.06 in) Recommended fluid DOT 4 Rear brake Type Single disc brake Operation Right foot operation Brake pedal position (below the bottom of the forest bracket) 25.8 mm (1.02 in) Rear disc brakeDisc outside diameter × thickness 245.0 × 5.0 mm (9.65 × 0.20 in) Brake disc thickness limit 4.5 mm (0.18 in) Brake disc deflection limit 0.15 mm (0.0059 in) Brake pad lining thickness (inner) 6.0 mm (0.24 in) Limit 1.0 mm (0.04 in) Brake pad lining thickness (outer) 6.0 mm (0.24 in) Limit 1.0 mm (0.04 in) Master cylinder inside diameter 12.7 mm (0.50 in) Caliper cylinder inside diameter 38.10 mm (1.50 in) Recommended fluid DOT 4 Steering Steering bearing type Angular bearing Lock to lock angle (left) 35.0 ° Lock to lock angle (right) 35.0 ° Front suspension Type Telescopic fork Spring/shock absorber type Coil spring/oil damper Front fork travel 130.0 mm (5.12 in) Fork spring free length 354.0 mm (13.94 in) Limit 347 mm (13.56 in) Collar length 131.5 mm (5.18 in) Installed length 347.0 mm (13.66 in) Spring rate K1 7.40 N/mm (42.25 lb/in) (0.75 kgf/mm) Spring rate K2 11.80 N/mm (67.38 lb/in) (1.20 kgf/mm) Spring stroke K1 0.0–70.0 mm (0.00–2.76 in) Spring stroke K2 70.0–130.0 mm (2.76–5.12 in) Inner tube outer diameter 43.0 mm (1.69 in) Inner tube bending limit 0.2 mm (0.01 in) Optional spring available No Recommended oil Suspension oil 01 or equivalent Quantity 467.0 cm³ (15.79 US oz) (16.47 Imp.oz) Level 134.0 mm (5.28 in)
CHASSIS SPECIFICATIONS 2-11 Rear suspensionType Swingarm (monocross) Spring/shock absorber type Coil spring/gas-oil damper Rear shock absorber assembly travel 50.0 mm (1.97 in) Spring free length 185.0 mm (7.28 in) Installed length 172.0 mm (6.77 in) Spring rate K1 127.40 N/mm (727.45 lb/in) (12.99 kgf/mm) Spring stroke K1 0.0–50.0 mm (0.00–1.97 in) Optional spring available No Enclosed gas/air pressure (STD) 1200 kPa (170.7 psi) (12.0 kgf/cm²) Spring preload adjusting positions (Minimum) 1 Spring preload adjusting positions (Standard) 3 Spring preload adjusting positions (Maximum) 7 Swingarm radial free play 1.0 mm (0.039 in) Swingarm axial free play 1.0 mm (0.039 in) Drive chain Type/manufacturer 50V4/DAIDO Link quantity 118 Drive chain slack 45.0–55.0 mm (1.77–2.17 in) 15-link length limit 239.3 mm (9.42 in)
ELECTRICAL SPECIFICATIONS 2-12 EAS20310 ELECTRICAL SPECIFICATIONS Vo l t a g eSystem voltage 12 V Ignition systemIgnition system Transistorized coil ignition (digital) Ignition system type DC. TCI Advancer type Digital Ignition timing (B.T.D.C.) 5.0 °/1300 r/min Engine control unit Model/manufacturer FUA0016/MITSUBISHI (FZS6W) FUA0017/MITSUBISHI (FZS6WC) Ignition coil Model/manufacturer JO383/DENSO Minimum ignition spark gap 6.0 mm (0.24 in) Primary coil resistance 1.53–2.07 Ω at 20 °C (68 °F) Secondary coil resistance 12.0–18.0 k Ω at 20 °C (68 °F) Spark plug cap Material Resin Resistance 10.0 k Ω AC magneto Model/manufacturer F5VX/MORIC Stator coil resistance 0.22–0.34 Ω at 20 °C (68 °F) Standard output 14.0 V310 W5000 r/min Rectifier/regulator Regulator type Semi conductor-short circuit Model/manufacturer SH719AA/SHINDENGEN No load regulated voltage 14.1–14.9 V Rectifier capacity 25.0 A Withstand voltage 240.0 V BatteryModel GT12B-4 Voltage, capacity 12 V, 10.0 Ah Specific gravity 1.320 Manufacturer GYM Ten hour rate amperage 1.00 A HeadlightBulb type Halogen bulb Bulb voltage, wattage × quantity Headlight 12 V, 60 W/55W × 1 12 V, 55W × 1 Tail/brake light 12 V, 5.0 W/21W × 1 Front turn signal/position light 12 V, 21 W/5.0 W × 2 Rear turn signal light 12 V, 21W × 2 License plate light 12 V, 5.0 W × 1 Meter lighting LED
ELECTRICAL SPECIFICATIONS 2-13 Indicator lightNeutral indicator light LED Turn signal indicator light LED Oil level warning light LED High beam indicator light LED Coolant temperature warning light LED Engine trouble warning light LED Electric starting systemSystem type Constant mesh Starter motorModel/manufacturer SM-14/MITSUBA Power output 0.60 kW Armature coil resistance 0.0012–0.0022 Ω Brush overall length 10.0 mm (0.39 in) Limit 3.50 mm (0.14 in) Brush spring force 7.16–9.52 N (25.77–34.27 oz) (730–971 gf) Commutator diameter 28.0 mm (1.10 in) Limit 27.0 mm (1.06 in) Mica undercut (depth) 0.70 mm (0.03 in) Starter relay Model/manufacturer MS5F-441/JIDECO Amperage 180.0 A Coil resistance 4.18–4.62 Ω at 20 °C (68 °F) Horn Horn type Plane Quantity 1 pcs Model/manufacturer HF-12/NIKKO Maximum amperage 3.0 A Coil resistance 1.01–1.11 Ω Performance 105–118 dB/2m Turn signal relay Relay type Full transistor Model/manufacturer FE246BH/DENSO Built-in, self-canceling device No Turn signal blinking frequency 75.0–95.0 cycles/min Wattage 21 W × 2 + LED Oil level switch Model/manufacturer 5VX/SOMIC ISHIKAWA Fuel gaugeModel/manufacturer 5VX/DENSO Sender unit resistance (full) 19.0–21.0 Ω Sender unit resistance (empty) 139.0–141.0 Ω Starting circuit cut-off relay Model/manufacturer G8R-30Y-V3/OMRON Coil resistance 162–198 Ω Radiator fan motor relay Model/manufacturer ACM33211M05/MATSUSHITA Coil resistance 86.4–105.6 Ω Headlight relay Model/manufacturer ACM33211M05/MATSUSHITA Coil resistance 86.4–105.6 Ω
ELECTRICAL SPECIFICATIONS 2-14 Fuel injection system relayModel/manufacturer G8R-30Y-R/OMRON Resistance 162–198 Ω Thermo unit Model/manufacturer 8CC/MITSUBISHI Resistance at 80 °C 290.0–354.0 Ω Fuses Main fuse 30.0 A Headlight fuse 20.0 A Taillight fuse 10.0 A Signaling system fuse 10.0 A Ignition fuse 10.0 A Radiator fan fuse 20.0 A Fuel injection system fuse 10.0 A Backup fuse 10.0 A Reserve fuse 30.0 A Reserve fuse 20.0 A Reserve fuse 10.0 A
TIGHTENING TORQUES 2-15 EAS20320 TIGHTENING TORQUES EAS20330 GENERAL TIGHTENING TORQUE SPECIFI- CATIONS This chart specifies tightening torques for stan- dard fasteners with a standard ISO thread pitch. Tightening torque specifications for spe- cial components or assemblies are provided for each chapter of this manual. To avoid warpage, tighten multi-fastener assemblies in a crisscross pattern and progressive stages until the specified tightening torque is reached. Unless otherwise specified, tightening torque specifications require clean, dry threads. Com- ponents should be at room temperature. A. Distance between flats B. Outside thread diameter A (nut) B (bolt)General tightening torques Nm m·kg ft·lb 10 mm 6 mm 6 0.6 4.3 12 mm 8 mm 15 1.5 11 14 mm 10 mm 30 3.0 22 17 mm 12 mm 55 5.5 40 19 mm 14 mm 85 8.5 61 22 mm 16 mm 130 13.0 94
TIGHTENING TORQUES 2-16 EAS20340 ENGINE TIGHTENING TORQUESItem Thread size Q’ty Tightening torque Remarks Spark plugs M10 4 18 Nm (1.8 m·kg, 13 ft·lb) Cylinder head bolt M10 10 See NOTE Cylinder head bolt M6 2 12 Nm (1.2 m·kg, 8.7 ft·lb) Camshaft caps bolt M6 20 10 Nm (1.0 m·kg, 7.2 ft·lb) Cylinder head cover bolt M6 6 12 Nm (1.2 m·kg, 8.7 ft·lb) Camshaft cap oil check bolt M8 1 20 Nm (2.0 m·kg, 14 ft·lb) Air indication system reed valve cover bolt M6 4 10 Nm (1.0 m·kg, 7.2 ft·lb) Air cut-off valve stay bolt M6 1 10 Nm (1.0 m·kg, 7.2 ft·lb) Camshaft sprocket bolt M7 4 20 Nm (2.0 m·kg, 14 ft·lb) Connecting rod cap bolt M7 8 15 Nm (1.5 m·kg, 11 ft·lb) + 120 ° Generator rotor bolt M12 1 75 Nm (7.5 m·kg, 54 ft·lb) Timing chain tensioner bolt M6 2 12 Nm (1.2 m·kg, 8.7 ft·lb) Timing chain tensioner cap bolt M6 1 7 Nm (0.7 m·kg, 5.0 ft·lb) Thermostat cover bolt M6 2 12 Nm (1.2 m·kg, 8.7 ft·lb) Coolant hose joint bolt M6 2 10 Nm (1.0 m·kg, 7.2 ft·lb) Water pump cover bolt M6 2 10 Nm (1.0 m·kg, 7.2 ft·lb) Water pump bolt M6 2 12 Nm (1.2 m·kg, 8.7 ft·lb) Thermo sensor M12 1 18 Nm (1.8 m·kg, 13 ft·lb) Coolant drain bolt M6 1 10 Nm (1.0 m·kg, 7.2 ft·lb) Radiator bolt M6 2 7 Nm (0.7 m·kg, 5.0 ft·lb) Radiator stay and crankcase M6 1 10 Nm (1.0 m·kg, 7.2 ft·lb) Radiator cap stopper bolt M5 1 5 Nm (0.5 m·kg, 3.6 ft·lb) Radiator hose stay bolt M10 1 10 Nm (1.0 m·kg, 7.2 ft·lb) Oil pump cover bolt M6 3 10 Nm (1.0 m·kg, 7.2 ft·lb) Oil pump bolt M6 3 12 Nm (1.2 m·kg, 8.7 ft·lb) Oil pan bolt M6 12 12 Nm (1.2 m·kg, 8.7 ft·lb) Center oil pan bolt M6 1 12 Nm (1.2 m·kg, 8.7 ft·lb) Oil cooler union bolt M20 1 63 Nm (6.3 m·kg, 46 ft·lb) Engine oil drain bolt M14 1 43 Nm (4.3 m·kg, 31 ft·lb) Oil filter union bolt M20 1 70 Nm (7.0 m·kg, 51 ft·lb) Oil filter M20 1 17 Nm (1.7 m·kg, 12 ft·lb) Oil pump chain gui de bolt M6 2 12 Nm (1.2 m·kg, 8.7 ft·lb) Oil pipe bolt M6 2 12 Nm (1.2 m·kg, 8.7 ft·lb) Throttle body joint bolt M6 8 10 Nm (1.0 m·kg, 7.2 ft·lb) Air filter case cover M5 6 1.2 Nm (0.12 m·kg, 0.9 ft·lb) Throttle body and throttle body joint M4 4 3 Nm (0.3 m·kg, 2.2 ft·lb) Throttle body and air filter case M5 4 3 Nm (0.3 m·kg, 2.2 ft·lb) Front exhaust pipe nut M8 8 20 Nm (2.0 m·kg, 14 ft·lb) Rear exhaust pipe bolt M8 1 20 Nm (2.0 m·kg, 14 ft·lb) E M LT LT LT LT E LT LT
TIGHTENING TORQUES 2-17 Catalyst pipe and catalyst pipe stay boltM8 1 20 Nm (2.0 m·kg, 14 ft·lb) Muffler joint bolt M8 1 20 Nm (2.0 m·kg, 14 ft·lb) See NOTE Catalyst joint bolt M8 1 20 Nm (2.0 m·kg, 14 ft·lb) See NOTE Exhaust pipe stay bolt M8 2 20 Nm (2.0 m·kg, 14 ft·lb) Catalyst pipe stay bolt M8 1 20 Nm (2.0 m·kg, 14 ft·lb) Muffler stay bolt M8 2 20 Nm (2.0 m·kg, 14 ft·lb) Muffler protector screw M6 2 9 Nm (0.9 m·kg, 6.5 ft·lb) Crankcase bolt (main journal) M8 10 See NOTE Crankcase bolt M6 2 12 Nm (1.2 m·kg, 8.7 ft·lb) Crankcase bolt M6 12 10 Nm (1.0 m·kg, 7.2 ft·lb) Crankcase bolt M6 1 10 Nm (1.0 m·kg, 7.2 ft·lb) Crankcase bolt M8 2 24 Nm (2.4 m·kg, 17 ft·lb) Generator rotor cover bolt M6 9 12 Nm (1.2 m·kg, 8.7 ft·lb) Clutch cover bolt M6 7 12 Nm (1.2 m·kg, 8.7 ft·lb) Clutch cover bolt M6 1 12 Nm (1.2 m·kg, 8.7 ft·lb) Clutch cable holder bolt M6 2 12 Nm (1.2 m·kg, 8.7 ft·lb) Pickup coil rotor cover bolt M6 7 12 Nm (1.2 m·kg, 8.7 ft·lb) Pickup coil rotor cover bolt M8 1 15 Nm (1.5 m·kg, 11 ft·lb) Shift shaft cover bolt M6 6 12 Nm (1.2 m·kg, 8.7 ft·lb) Breather plate screw M6 3 12 Nm (1.2 m·kg, 8.7 ft·lb) Stator coil screw M6 3 10 Nm (1.0 m·kg, 7.2 ft·lb) Pickup rotor cover clamp screw M6 1 7 Nm (0.7 m·kg, 5.0 ft·lb) Drive sprocket cover bolt M6 3 10 Nm (1.0 m·kg, 7.2 ft·lb) Oil gallery bolt M16 2 8 Nm (0.8 m·kg, 5.8 ft·lb) Generator rotor cover and stator coil lead clamp screw M6 1 10 Nm (1.0 m·kg, 7.2 ft·lb) Breather hose cover bolt M6 4 12 Nm (1.2 m·kg, 8.7 ft·lb) Oil pipe bolt M6 2 12 Nm (1.2 m·kg, 8.7 ft·lb) Crankshaft position sensor bolt M6 2 10 Nm (1.0 m·kg, 7.2 ft·lb) Starter clutch screw M8 3 32 Nm (3.2 m·kg, 23 ft·lb) Starter motor cover bolt M6 2 3.4 Nm (0.34 m·kg, 2.3 ft·lb) Clutch pressure plate screw M6 6 8 Nm (0.8 m·kg, 5.8 ft·lb) Clutch boss nut M20 1 90 Nm (9.0 m·kg, 65 ft·lb) Use a lock washer Drive sprocket nut M20 1 85 Nm (8.5 m·kg, 61 ft·lb) Use a lock washer Transmission bearing housing screw M6 3 12 Nm (1.2 m·kg, 8.7 ft·lb) Shift drum retainer bolt M6 2 10 Nm (1.0 m·kg, 7.2 ft·lb) Item Thread size Q’ty Tightening torque Remarks E E E E LT E LT LT LT LT LT LT