Yamaha FZS6W 07 User Manual
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TIGHTENING TORQUES 2-18 NOTE: Cylinder head bolt1. First, tighten the bolts to approximately 19 Nm (1.9 m·kg, 14 ft·lb) with a torque wrench follow- ing the tightening order. 2. Retighten the bolts 50 Nm (5.0 m·kg, 36 ft·lb) with a torque wrench. Crankcase bolt (main journal) 1. First, tighten the bolts to approximately 12 Nm (1.2 m·kg, 8.7 ft·lb) with a torque wrench follow- ing the tightening order. 2. Retighten the bolts 25 Nm (2.5 m·kg, 18 ft·lb) with a torque wrench. 3. Loosen the all bolts one by one following the tightening order and then tighten them to 27 Nm (2.7 m·kg, 20 ft·lb) again. Muffler joint bolt Retighten the bolt at 1000 km (600 ml). Catalyst joint bolt Retighten the bolt at 1000 km (600 ml). O 2 sensor M18 1 45 Nm (4.5 m·kg, 33 ft·lb) Shift shaft spring stopper screw M8 1 22 Nm (2.2 m·kg, 16 ft·lb) Shift rod nut M6 1 7 Nm (0.7 m·kg, 5.0 ft·lb) Left thread Shift rod nut M6 1 7 Nm (0.7 m·kg, 5.0 ft·lb) Shift rod joint M6 1 10 Nm (1.0 m·kg, 7.2 ft·lb) Shift arm bolt M6 1 10 Nm (1.0 m·kg, 7.2 ft·lb) Pickup coil rotor bolt M8 1 35 Nm (3.5 m·kg, 25 ft·lb) Starter motor bolt M6 2 10 Nm (1.0 m·kg, 7.2 ft·lb) Neutral switch M10 1 20 Nm (2.0 m·kg, 14 ft·lb) Oil level switch bolt M6 2 10 Nm (1.0 m·kg, 7.2 ft·lb) Speed sensor bolt M6 1 10 Nm (1.0 m·kg, 7.2 ft·lb) Item Thread size Q’ty Tightening torque Remarks LT LT
TIGHTENING TORQUES 2-19 Cylinder head tightening sequence. Crankcase tightening sequence.
TIGHTENING TORQUES 2-20 EAS20350 CHASSIS TIGHTENING TORQUESItem Thread size Q’ty Tightening torque Remarks Upper bracket pinch bolt M8 2 30 Nm (3.0 m·kg, 22 ft·lb) Steering stem nut M22 1 110 Nm (11 m·kg, 80 ft·lb) Upper bracket and upper handle- bar holder M8 4 23 Nm (2.3 m·kg, 17 ft·lb) Lower bracket pinch bolt – 2 30 Nm (3.0 m·kg, 22 ft·lb) Lower ring nut M25 1 18 Nm (1.8 m·kg, 13 ft·lb) See NOTE Front fork cap bolt M35 2 24 Nm (2.4 m·kg, 17 ft·lb) Damper rod assembly bolt M10 2 23 Nm (2.3 m·kg, 17 ft·lb) Front wheel axle pinch bolt M8 1 23 Nm (2.3 m·kg, 17 ft·lb) Front brake master cylinder bolt M6 2 10 Nm (1.0 m·kg, 7.2 ft·lb) Front brake master cylinder cap screw M4 2 2 Nm (0.2 m·kg, 1.4 ft·lb) Front brake hose union blot M10 2 30 Nm (3.0 m·kg, 22 ft·lb) Front brake hose holder and front fork M6 1 7 Nm (0.7 m·kg, 5.0 ft·lb) Front cowling stay and frame M8 2 33 Nm (3.3 m·kg, 24 ft·lb) Front cowling bracket and frame M6 2 7 Nm (0.7 m·kg, 5.0 ft·lb) Front fender and front fork M6 2 6 Nm (0.6 m·kg, 4.3 ft·lb) Clutch lever holder pinch bolt M6 1 11 Nm (1.1 m·kg, 8.0 ft·lb) Engine mount bolts (left of front side) M10 1 55 Nm (5.5 m·kg, 40 ft·lb) See NOTE Engine mount bolts (left of rear side) M10 1 55 Nm (5.5 m·kg, 40 ft·lb) See NOTE Engine mount bolts (right of front side) M10 1 55 Nm (5.5 m·kg, 40 ft·lb) See NOTE Engine mount self locking nut (upper) M10 1 55 Nm (5.5 m·kg, 40 ft·lb) See NOTE Engine mount self locking nut (lower) M10 1 55 Nm (5.5 m·kg, 40 ft·lb) See NOTE Pivot shaft and frame M18 1 120 Nm (12 m·kg, 87 ft·lb) Rear shock absorber and frame M10 1 40 Nm (4.0 m·kg, 29 ft·lb) Rear shock absorber and rear arm M10 1 40 Nm (4.0 m·kg, 29 ft·lb) Seal guard and rear arm M6 2 7 Nm (0.7 m·kg, 5.0 ft·lb) Rear fender and rear arm M6 3 7 Nm (0.7 m·kg, 5.0 ft·lb) Rear brake hose holder and rear arm M6 1 7 Nm (0.7 m·kg, 5.0 ft·lb) Fuel tank bracket and frame M6 2 7 Nm (0.7 m·kg, 5.0 ft·lb) Fuel tank bracket and fuel tank M6 2 7 Nm (0.7 m·kg, 5.0 ft·lb) Fuel tank and rear frame M6 1 7 Nm (0.7 m·kg, 5.0 ft·lb) Fuel tank and fuel tank cap M5 5 6 Nm (0.6 m·kg, 4.3 ft·lb) Fuel pump and fuel tank M5 6 4 Nm (0.4 m·kg, 2.9 ft·lb) Ignition coil and battery box M6 2 7 Nm (0.7 m·kg, 5.0 ft·lb)
TIGHTENING TORQUES 2-21 NOTE: Lower ring nut1. First, tighten the ring nut to approximately 52 Nm (5.2 m·kg, 38 ft·lb) with a torque wrench, then loosen the ring nut completely. 2. Retighten the lower ring nut to specification. Engine mount bolts and engine mount self locking nut Refer to INSTALLING THE ENGINE on page 5-6. Seat lock and frame M6 2 7 Nm (0.7 m·kg, 5.0 ft·lb) Licence plate light screw M5 2 4 Nm (0.4 m·kg, 2.9 ft·lb) Rear reflector bolt M5 2 4 Nm (0.4 m·kg, 2.9 ft·lb) Flap and bracket 6 M6 2 7 Nm (0.7 m·kg, 5.0 ft·lb) Blacket 6 and rear frame M6 2 19 Nm (1.9 m·kg, 14 ft·lb) Tail/brake right unit screw M6 2 3 Nm (0.3 m·kg, 2.2 ft·lb) Rear fender cover bolt M5 4 4 Nm (0.4 m·kg, 2.9 ft·lb) Seat handle bolt M8 4 23 Nm (2.3 m·kg, 17 ft·lb) Muffler and rear fender bolt M6 4 7 Nm (0.7 m·kg, 5.0 ft·lb) Side cover bolt M6 2 10 Nm (1.0 m·kg, 7.2 ft·lb) Lean angle sensor bolt M4 2 2 Nm (0.2 m·kg, 1.4 ft·lb) Coolant reserver tank cover bolt M6 2 4 Nm (0.4 m·kg, 2.9 ft·lb) Front wheel axle shaft bolt M18 1 72 Nm (7.2 m·kg, 52 ft·lb) Front brake caliper bolt M10 4 40 Nm (4.0 m·kg, 29 ft·lb) Front brake disc bolt M6 10 18 Nm (1.8 m·kg, 13 ft·lb) Brake caliper bleed screw M7 3 6 Nm (0.6 m·kg, 4.3 ft·lb) Rear wheel axle nut M24 1 120 Nm (12 m·kg, 87 ft·lb) Rear brake disc and rear wheel M8 5 30 Nm (3.0 m·kg, 22 ft·lb) Rear brake caliper bolt front and rear brake caliper bracket M8 1 27 Nm (2.7 m·kg, 20 ft·lb) Rear brake caliper bolt rear and rear brake caliper bracket M8 1 22 Nm (2.2 m·kg, 16 ft·lb) Rear wheel sprocket and rear wheel drive hub M10 6 100 Nm (10 m·kg, 72 ft·lb) Chain adjusting bolt lock nut M8 2 16 Nm (1.6 m·kg, 12 ft·lb) Rear brake hose union bolt M10 1 30 Nm (3.0 m·kg, 22 ft·lb) Sidestand bolt M10 1 46 Nm (4.6 m·kg, 33 ft·lb) Sidestand bracket and frame M10 2 63 Nm (6.3 m·kg, 46 ft·lb) Sidestand switch screw M5 2 4 Nm (0.4 m·kg, 2.9 ft·lb) Footrest bracket and frame M8 4 30 Nm (3.0 m·kg, 22 ft·lb) Rear brake reserver tank and bracket M6 1 3 Nm (0.3 m·kg, 2.2 ft·lb) Rear master cylinder and footrest bracket M8 2 23 Nm (2.3 m·kg, 17 ft·lb) Mainstand bolt M10 2 73 Nm (7.3 m·kg, 53 ft·lb) Upper bracket and canister bracket (FZS6WC) M6 2 7 Nm (0.7 m·kg, 5.0 ft·lb) Canister bolt (FZS6WC) M6 2 7 Nm (0.7 m·kg, 5.0 ft·lb) Item Thread size Q’ty Tightening torque Remarks LT LT
LUBRICATION POINTS AND LUBRICANT TYPES 2-22 EAS20360 LUBRICATION POINTS AND LUBRICANT TYPES EAS20370 ENGINE Lubrication point Lubricant Oil seal lips O-rings Bearings and bushes Crankshaft pins Piston surfaces Piston pins Connecting rod bolts Crankshaft journals Camshaft lobes Camshaft journals Valve stems (intake and exhaust) Valve stem ends (intake and exhaust) Valve lifter surface Piston cooler (O-ring) Oil pump rotors (inner and outer) Oil pump housing Oil strainer Clutch (pull rod) Starter clutch idle gear inner surface Starter clutch assembly Primary driven gear Transmission gears (wheel and pinion) Main axle and drive axle Shift drum Shift forks and shift fork guide bars Shift shaft Shift shaft boss Cylinder head cover mating surface Yamaha bond No.1215 Cylinder head cover semicircular Yamaha bond No.1215 Crankcase mating surface Yamaha bond No.1215 Generator rotor cover (stator coil assembly lead grommet) Yamaha bond No.1215 Pickup rotor cover (crankshaft position sensor lead grommet) Yamaha bond No.1215 LS LS E E E E M E M M M E E E E E E LS E E E M M E E E E
LUBRICATION POINTS AND LUBRICANT TYPES 2-23 EAS20380 CHASSISLubrication point Lubricant Steering bearings and bearing races (upper and lower) Front wheel oil seal (right and left) Rear wheel oil seal Rear wheel drive hub oil seal Rear wheel drive hub mating surface Rear brake pedal shaft Sidestand pivoting point and metal-to-metal moving parts Link and sidestand switch contact point Throttle grip inner surface Brake lever pivoting point and metal-to-metal moving parts Clutch lever pivoting point and metal-to-metal moving parts Rear shock absorber collar Pivot shaft Swingarm pivot bearing Swingarm head pipe end, oil seal and bush Engine mount bolts (rear upper and lower) Shift pedal shaft Shift shaft joint Rear footrest ball and metal-to-metal moving parts Main stand metal-to-metal moving parts LS LS LS LS LS LS LS LS LS LS LS LS LS LS LS LS LS LS LS LS
LUBRICATION SYSTEM CHART AND DIAGRAMS 2-25 EAS20390 LUBRICATION SYSTEM CHART AND DIAGRAMS EAS20400 ENGINE OIL LUBRICATION CHART
LUBRICATION SYSTEM CHART AND DIAGRAMS 2-26 1. Oil strainer 2. Oil pump 3. Relief valve 4. Oil filter 5. Oil cooler 6. Main axle 7. Mission cooler 8. Drive axle 9. Main gallery 10.Piston cooler 11.Intake camshaft 12.Exhaust camshaft
LUBRICATION SYSTEM CHART AND DIAGRAMS 2-27 EAS20410 LUBRICATION DIAGRAMS