Yamaha FZS6W 07 User Manual
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CABLE ROUTING 2-58 1. Clip 2. Roll over valve assembly 3. Canister hose 4. Balance hose 5. Clamp 6. Canister assembly 7. Upper bracket 8. Hose 9. Canister bracket 10.Fuel tank drain hose 11.Roll over valve hose A. Front side B. Point the paint marking upward. C. Pass the canister hose outside, pass the balance hose inside. D. Point the knob of clamp front side. The application of water is possible at the time of attachment. E. Point the knob of clamp upward. The appli- cation of water is possible at the time of attachment. F. Pass the balance hose under the canister hose. G. Insert to the back, but the tip of the nipple should not come out from the hose. H. Point the knob of clamp downward. I. Install the part poin ting the white paint mark to the front side of the vehicle. The application of water is possible at the time of attachment. J. Clamp the fuel tank drain hose so that the distance between the paint mark and the edge of the clamp may become 430–440 mm (16.9–17.3 in).
3 PERIODIC CHECKS AND ADJUSTMENTS PERIODIC MAINTENANCE......................................................................... 3-1 INTRODUCTION ........................... ......................................................... 3-1 ENGINE ......................................................................................................... 3-4 ADJUSTING THE VALVE CLEARANCE ................................................ 3-4 SYNCHRONIZING THE THROTTLE BODIES ....................................... 3-6 ADJUSTING THE ENGINE ID LING SPEED .......................................... 3-8 ADJUSTING THE THROTTLE CABLE FREE PLAY .............................. 3-8 CHECKING THE SPARK PLUGS ........................................................... 3-9 MEASURING THE COMPRESSION PRESSURE ............................... 3-10 CHECKING THE ENGINE OI L LEVEL ................................................. 3-12 CHANGING THE ENGINE OIL............................................................. 3-12 MEASURING THE ENGINE OI L PRESSURE ..................................... 3-13 ADJUSTING THE CLUTCH CABLE FREE PLAY ................................ 3-14 CLEANING THE AIR FILTER ELEMENT ............................................. 3-15 CHECKING THE THROTTLE BODY JOINTS ...................................... 3-16 CHECKING THE FUEL LINE ............................................................... 3-16 CHECKING THE CRANKCASE BREATHER HOSE ............................ 3-16 CHECKING THE EXHAUST SYSTEM ................................................. 3-17 CHECKING THE COOLANT LEVEL .................................................... 3-17 CHECKING THE COOLING SYSTEM ................................................. 3-18 CHANGING THE COOLANT ................................................................ 3-18 CHASSIS .................................................................................................... 3-21 ADJUSTING THE FRONT DISC BRAKE ............................................. 3-21 ADJUSTING THE REAR DISC BRAKE ............................................... 3-21 CHECKING THE BRAKE FLUID LEVEL .............................................. 3-22 CHECKING THE FRONT BRAKE PADS .............................................. 3-22 CHECKING THE REAR BRAKE PADS ................................................ 3-23 CHECKING THE FRONT BRAKE HOSES........................................... 3-23 CHECKING THE REAR BRAKE HOSE ............................................... 3-23 ADJUSTING THE REAR BRAKE LIGHT SWITCH .............................. 3-23 BLEEDING THE HYDRAULIC BRAKE SYSTEM ................................. 3-24 ADJUSTING THE SHIFT PEDAL ......................................................... 3-25 ADJUSTING THE DRIVE CHAIN SLACK ............................................ 3-25 LUBRICATING THE DRIVE CHAIN ...................................................... 3-26 CHECKING AND ADJUSTING THE STEERING HEAD ...................... 3-26 CHECKING THE FRONT FORK .......................................................... 3-28 ADJUSTING THE REAR SHOCK ABSORBER ASSEMBLY................ 3-28 CHECKING THE TIRES ....................................................................... 3-28 CHECKING THE WHEELS .................................................................. 3-31 CHECKING AND LUBRICATING THE CABLES .................................. 3-31 LUBRICATING THE LEVER S ............................................................... 3-31 LUBRICATING THE PEDAL ................................................................. 3-31 LUBRICATING THE SIDESTAND ......................................................... 3-31 LUBRICATING THE CENTERSTAND .................................................. 3-31 LUBRICATING THE REAR SUSPENSION .......................................... 3-31
ELECTRICAL SYSTEM.............................................................................. 3-32 REPLACING THE HEADLIGHT BULBS............................................... 3-32 ADJUSTING THE HEADLIGHT BEAMS .............................................. 3-32
PERIODIC MAINTENANCE 3-1 EAS20450 PERIODIC MAINTENANCE EAS20460 INTRODUCTION This chapter includes all information necessary to perform recommended checks and adjustments. If followed, these preventive maintenance procedures will ensure more reliable vehicle operation, a longer service life and reduce the need for costly ov erhaul work. This information applies to vehicles already in service as well as to new vehicles that are being prepared for sale. All service technicians should be familiar with this entire chapter. Periodic maintenance chart for the emission control system * Since these items require special tools, data an d technical skills, have a Yamaha dealer perform the service. General maintenance and lubrication chart NO. ITEM ROUTINE INITIAL ODOMETER READINGS 600 mi (1000 km) or 1 month 4000 mi (7000 km) or 6 months 8000 mi (13000 km) or 12 months 12000 mi (19000 km) or 18 months 16000 mi (25000 km) or 24 months 20000 mi (31000 km) or 30 months 1 * Fuel line Check fuel hoses for cracks or damage. Replace if necessary. √√√√√ 2 * Spark plugs Check condition. Adjust gap and clean. Replace every 8000 mi (13000 km) or 12 months. √ Replace. √Replace. √ 3 * Valve clearance Check and adjust valve clear- ance when engine is cold. Every 26600 mi (42000 km) 4* Crankcase breather system Check breather hose for cracks or damage. Replace if necessary. √√√√√ 5 *Fuel injection Check and adjust engine idle speed and synchronization. √√√√√√ 6 * Exhaust system Check for leakage. Tighten if necessary. Replace gasket(s) if neces- sary. √√√√√√ 7* Evaporative emis- sion control sys- tem (For California only) Check control system for dam- age. Replace if necessary. √√ 8* Air induction sys- tem Check the air cut-off valve, reed valve, and hose for dam- age. Replace any damaged parts if necessary. √√ NO. ITEM ROUTINE INITIAL ODOMETER READINGS 600 mi (1000 km) or 1 month 4000 mi (7000 km) or 6 months 8000 mi (13000 km) or 12 months 12000 mi (19000 km) or 18 months 16000 mi (25000 km) or 24 months 20000 mi (31000 km) or 30 months 1 * Air filter element Check condition and damage. √√ Replace if necessary. √ 2*Clutch Check operation. Adjust or replace cable. √√√√√√ 3 * Front brake Check operation, fluid level, and for fluid leakage. Replace brake pads if neces- sary. √√√√√√
PERIODIC MAINTENANCE 3-2 4 * Rear brake Check operation, fluid level, and for fluid leakage. Replace brake pads if neces- sary. √√√√√√ 5 * Brake hoses Check for cracks or damage. √√√√√ Replace. Every 4 years 6 * Wheels Check runout and for damage. Replace if necessary. √√√√√ 7*Tires Check tread depth and for damage. Replace if necessary. Check air pressure. Correct if necessary. √√√√√ 8 * Wheel bearings Check bearings for smooth operation. Replace if necessary. √√√√√ 9* Swingarm pivot bearings Check bearing assemblies for looseness. Moderately repack with lithium- soap-based grease. √ Repack. 10 Drive chain Check chain slack, alignment and condition. Adjust and lubricate chain with a special O-ring chain lubricant thoroughly. Every 500 mi (800 km) and after washing the vehicle or riding in the rain 11 * Steering bearings Check bearing assemblies for looseness. √√√√√√ Moderately repack with lithium- soap-based grease. Every 12000 mi (19000 km) 12 * Chassis fasteners Check all chassis fitting and fasteners. Correct if necessary. √√√√√ 13 Brake and clutch lever pivot shafts Apply lithium-soap-based grease (all-purpose grease) lightly. √√√√√ 14 Brake and shift pedal pivot shafts Apply lithium-soap-based grease (all-purpose grease) lightly. √√√√√ 15 * Centerstand and sidestand pivots Check operation. Apply lithium-soap-based grease (all-purpose grease) lightly. √√√√√ 16 * Sidestand switch Check operation and replace if necessary. √√√√√√ 17 * Front fork Check operation and for oil leakage. Replace if necessary. √√√√√ 18 * Shock absorber assembly Check operation and for oil leakage. Replace if necessary. √√√√√ 19 Engine oil Change (warm engine before draining). √√√√√√ 20 * Engine oil filter cartridge Replace. √√√ NO. ITEM ROUTINE INITIAL ODOMETER READINGS 600 mi (1000 km) or 1 month 4000 mi (7000 km) or 6 months 8000 mi (13000 km) or 12 months 12000 mi (19000 km) or 18 months 16000 mi (25000 km) or 24 months 20000 mi (31000 km) or 30 months
PERIODIC MAINTENANCE 3-3 * Since these items require special tools, data and technical skills, have a Yamaha dealer perform the service. NOTE: From 24000 mi (37000 km) or 36 months, repeat the maintenance intervals starting from 8000 mi (13000 km) or 12 months. NOTE: Air filter This model’s air filter is equipped with a disposable oil-coated paper element, which must not be cleaned with compressed air to avoid damaging it. The air filter element needs to be replaced more frequently when riding in unusually wet or dusty areas. Hydraulic brake service After disassembling the brake master cylinders and calipers, always change the fluid. Regularly check the brake fluid levels and fill the reservoirs as required. Every two years replace the internal components of the brake master cylinders and calipers, and change the brake fluid. Replace the brake hoses every four years and if cracked or damaged. 21 * Cooling system Check hoses for cracks or damage. Replace if necessary. √√√√√ Change with ethylene glycol antifreeze coolant every 24 months. Change. 22 * Front and rear brake switches Check operation. √√√√√√ 23 * Control cables Apply Yamaha chain and cable lube or engine oil SAE 10W-30 thoroughly. √√√√√√ 24 * Throttle grip hous- ing and cable Check operation and free play. Adjust the throttle cable free play if necessary. Lubricate the throttle grip housing and cable. √√√√√ 25 * Lights, signals and switches Check operation. Adjust headlight beam. √√√√√√ NO. ITEM ROUTINE INITIAL ODOMETER READINGS 600 mi (1000 km) or 1 month 4000 mi (7000 km) or 6 months 8000 mi (13000 km) or 12 months 12000 mi (19000 km) or 18 months 16000 mi (25000 km) or 24 months 20000 mi (31000 km) or 30 months
ENGINE 3-4 EAS20470 ENGINE EAS20490 ADJUSTING THE VALVE CLEARANCE The following procedure applies to all of the valves. NOTE: Valve clearance adjustment should be made on a cold engine, at room temperature. When the valve clearance is to be measured or adjusted, the piston must be at top dead center (TDC) on the compression stroke. 1. Remove: SeatRefer 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 and CHECKING AND CHARGING THE BATTERY on page 8-68. Air filter case Refer to GENERAL CHASSIS on page 4- 1. Battery box Battery box bracket Refer to GENERAL CHASSIS on page 4- 1. Throttle bodies Refer to THROTTLE BODIES on page 7- 4. Air cut-off valve Refer to AIR INDUCTION SYSTEM on page 7-9. Radiator Radiator fan motor Refer to RADIATOR on page 6-1. 2. Remove: Ignition coils Spark plugs Cylinder head cover Cylinder head cover gasket Refer to CAMSHAFTS on page 5-8. 3. Remove: Pickup rotor cover “1” 4. Measure: Valve clearanceOut of specification → Adjust. ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Turn the crankshaft counterclockwise. b. When piston #1 is at TDC on the compres- sion stroke, align the TDC mark “a” on the pickup rotor with the crankcase mating sur- face “b”. NOTE: TDC on the compression stroke can be found when the camshaft lobes are turned away from each other. c. Measure the valve clearance with a thick- ness gauge “1”. NOTE: If the valve clearance is incorrect, record the measured reading. Measure the valve clearance in the following sequence. 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 3-5 d. To measure the valve clearances of the other cylinders, starting with cylinder #1 at TDC, turn the crankshaft counterclockwise as specified in the following table. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 5. Remove: Camshafts NOTE: Refer to CAMSHAFTS on page 5-8. When removing the timing chain and cam- shafts, fasten the timing chain with a wire to retrieve it if it falls into the crankcase. 6. Adjust: Valve clearance ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Remove the valve lifter “1” and the valve pad “2” with a valve lapper “3”. NOTE: Cover the timing chain opening with a rag to prevent the valve pad from falling into the crankcase. Make a note of the position of each valve lifter “1” and valve pad “2” so that they can be installed in the correct place. b. Select the proper valve pad from the follow- ing table. NOTE: The thickness “a” of each valve pad is marked in hundredths of millimeters on the side that touches the valve lifter. Valve clearance measuring sequence Cylinder #1 → #2 → #4 → #3 A. Front A. Degrees that the crankshaft is turned counterclockwise B. Cylinder C. Combustion cycle Cylinder #2 180 ° Cylinder #4 360 ° Cylinder #3 540 ° Valve lapper 90890-04101 Valve lapping tool YM-A8998 Valve pad range Nos. 120–240 Valve pad thickness 1.20–2.40 mm (0.0472–0.0945 in) Available valve pads 25 thicknesses in 0.05 mm (0.002 in) increments