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Yamaha FZS6W Manuals
Manuals and User Guides for Yamaha FZS6W. We have
2
Yamaha FZS6W manuals available for free PDF download: Service Manual
Yamaha FZS6W Service Manual (394 pages)
Brand:
Yamaha
| Category:
Motorcycle
| Size: 14.64 MB
Table of Contents
Table of Contents
7
How to Use this Manual
4
General Information
9
Identification
10
Vehicle Identification Number
10
Model Label
10
Features
11
Outline of Fi System
11
Fi System
12
Instrument Functions
13
Important Information
16
Preparation for Removal and Disassembly
16
Replacement Parts
16
Gaskets, Oil Seals and O-Rings
16
Lock Washers/Plates and Cotter Pins
16
Bearings and Oil Seals
17
Circlips
17
Checking the Connections
18
Special Tools
19
Specifications
23
General Specifications
24
Engine Specifications
25
Chassis Specifications
32
Electrical Specifications
35
Tightening Torques
38
General Tightening Torque Specifications
38
Engine Tightening Torques
39
Chassis Tightening Torques
43
Lubrication Points and Lubricant Types
45
Engine
45
Chassis
46
Lubrication System Chart and Diagrams
48
Engine Oil Lubrication Chart
48
Lubrication Diagrams
50
Cooling System Diagrams
62
Cable Routing
70
Periodic Checks and Adjustments
83
Periodic Maintenance
86
Introduction
86
Engine
89
Adjusting the Valve Clearance
89
Synchronizing the Throttle Bodies
91
Adjusting the Engine Idling Speed
93
Adjusting the Throttle Cable Free Play
93
Checking the Spark Plugs
94
Measuring the Compression Pressure
95
Checking the Engine Oil Level
97
Changing the Engine Oil
97
Measuring the Engine Oil Pressure
98
Adjusting the Clutch Cable Free Play
99
Cleaning the Air Filter Element
100
Checking the Throttle Body Joints
101
Checking the Fuel Line
101
Checking the Crankcase Breather Hose
101
Checking the Exhaust System
102
Checking the Coolant Level
102
Checking the Cooling System
103
Changing the Coolant
103
Chassis
106
Adjusting the Front Disc Brake
106
Adjusting the Rear Disc Brake
106
Checking the Brake Fluid Level
107
Checking the Front Brake Pads
107
Checking the Rear Brake Pads
108
Checking the Front Brake Hoses
108
Checking the Rear Brake Hose
108
Adjusting the Rear Brake Light Switch
108
Bleeding the Hydraulic Brake System
109
Adjusting the Shift Pedal
110
Adjusting the Drive Chain Slack
110
Lubricating the Drive Chain
111
Checking and Adjusting the Steering Head
111
Checking the Front Fork
113
Adjusting the Rear Shock Absorber Assembly
113
Checking the Tires
113
Checking the Wheels
116
Checking and Lubricating the Cables
116
Lubricating the Levers
116
Lubricating the Pedal
116
Lubricating the Sidestand
116
Lubricating the Centerstand
116
Lubricating the Rear Suspension
116
Chassis
119
General Chassis
122
Front Wheel
126
Removing the Front Wheel
128
Checking the Front Wheel
128
Adjusting the Front Wheel Static Balance
129
Installing the Front Wheel
130
Rear Wheel
131
Removing the Rear Wheel
134
Checking the Rear Wheel
134
Checking the Rear Wheel Drive Hub
134
Checking and Replacing the Rear Wheel Sprocket
135
Adjusting the Rear Wheel Static Balance
135
Installing the Rear Wheel
135
Front Brake
136
Introduction
141
Checking the Front Brake Discs
141
Replacing the Front Brake Pads
142
Removing the Front Brake Calipers
143
Disassembling the Front Brake Calipers
143
Checking the Front Brake Calipers
143
Assembling the Front Brake Calipers
144
Installing the Front Brake Calipers
144
Removing the Front Brake Master Cylinder
145
Checking the Front Brake Master Cylinder
145
Assembling the Front Brake Master Cylinder
146
Installing the Front Brake Master Cylinder
146
Rear Brake
148
Introduction
153
Checking the Rear Brake Disc
153
Replacing the Rear Brake Pads
153
Removing the Rear Brake Caliper
154
Disassembling the Rear Brake Caliper
154
Checking the Rear Brake Caliper
155
Assembling the Rear Brake Caliper
155
Installing the Rear Brake Caliper
156
Removing the Rear Brake Master Cylinder
157
Checking the Rear Brake Master Cylinder
157
Assembling the Rear Brake Master Cylinder
158
Installing the Rear Brake Master Cylinder
158
Handlebar
160
Removing the Handlebars
161
Checking the Handlebar
161
Installing the Handlebar
161
Front Fork
164
Removing the Front Fork Legs
166
Disassembling the Front Fork Legs
166
Checking the Front Fork Legs
167
Assembling the Front Fork Legs
168
Installing the Front Fork Legs
170
Steering Head
172
Removing the Lower Bracket
174
Checking the Steering Head
174
Installing the Steering Head
175
Rear Shock Absorber Assembly
176
Handling the Rear Shock Absorber
177
Disposing of a Rear Shock Absorber
177
Removing the Rear Shock Absorber Assembly
177
Checking the Rear Shock Absorber Assembly
177
Installing the Rear Shock Absorber Assembly
178
Swingarm
179
Removing the Swingarm
181
Checking the Swingarm
181
Installing the Swingarm
182
Chain Drive
183
Removing the Drive Chain
184
Checking the Drive Chain
184
Checking the Drive Sprocket
185
Checking the Rear Wheel Sprocket
185
Checking the Rear Wheel Drive Hub
185
Installing the Drive Chain
185
Engine
187
Engine Removal
190
Installing the Engine
195
Camshafts
197
Removing the Camshafts
199
Checking the Camshafts
200
Checking the Timing Chain and Camshaft Sprocket
201
Checking the Timing Chain Guides
201
Checking the Timing Chain Tensioner
202
Installing the Camshafts
202
Cylinder Head
205
Removing the Cylinder Head
206
Checking the Cylinder Head
206
Installing the Cylinder Head
206
Valves and Valve Springs
209
Removing the Valves
210
Checking the Valves and Valve Guides
211
Checking the Valve Seats
212
Checking the Valve Springs
214
Checking the Valve Lifters
215
Installing the Valves
215
Generator and Starter Clutch
217
Removing the Generator
219
Removing the Starter Clutch
219
Checking the Starter Clutch
220
Installing the Starter Clutch
220
Installing the Generator
221
Pickup Rotor
222
Removing the Pickup Rotor
223
Installing the Pickup Rotor
223
Electric Starter
225
Checking the Starter Motor
227
Assembling the Starter Motor
228
Installing the Starter Motor
228
Oil Pump
229
Removing the Oil Pan
232
Checking the Oil Pump
232
Checking the Relief Valve
232
Checking the Oil Delivery Pipes
233
Checking the Oil Strainer
233
Checking the Oil Nozzles
233
Assembling the Oil Pump
233
Installing the Oil Pump
234
Installing the Oil Strainer
234
Installing the Oil Pan
234
Clutch
235
Removing the Clutch
238
Checking the Friction Plates
238
Checking the Clutch Plates
239
Checking the Clutch Springs
239
Checking the Clutch Housing
239
Checking the Clutch Boss
239
Checking the Pressure Plate
240
Checking the Pull Lever Shaft and Pull Rod
240
Installing the Clutch
240
Shift Shaft
242
Checking the Shift Shaft
243
Checking the Stopper Lever
243
Installing the Shift Shaft
243
Crankcase
244
Disassembling the Crankcase
246
Checking the Crankcase
246
Checking the Bearings and Oil Seals
246
Checking the Oil Pump Drive Chain
246
Assembling the Crankcase
247
Crankshaft
249
Removing the Connecting Rods and Pistons
251
Removing the Crankshaft Assembly
251
Checking the Cylinder and Piston
252
Checking the Piston Rings
252
Checking the Piston Pins
253
Checking the Big End Bearings
254
Installing the Connecting Rod and Piston
257
Checking the Crankshaft
259
Checking the Crankshaft Journal Bearings
259
Installing the Crankshaft
261
Transmission
263
Removing the Transmission
267
Checking the Shift Forks
267
Checking the Shift Drum Assembly
267
Checking the Transmission
268
Installing the Transmission
268
Cooling System
271
Radiator
274
Checking the Radiator
274
Installing the Radiator
274
Oil Cooler
276
Checking the Oil Cooler
276
Installing the Oil Cooler
276
Thermostat
277
Checking the Thermostat
278
Installing the Thermostat Assembly
278
Water Pump
280
Disassembling the Water Pump
282
Checking the Water Pump
282
Assembling the Water Pump
283
Installing the Water Pump
284
Fuel System
285
Fuel Tank
287
Checking the Fuel Pump Body
287
Checking the Fuel Pump Operation
287
Installing the Fuel Pump
287
Removing the Fuel Pump
287
Removing the Fuel Tank
287
Installing the Fuel Tank
288
Throttle Bodies
290
Checking the Injectors
291
Checking the Throttle Bodies
291
Checking the Fuel Pressure
291
Adjusting the Throttle Position Sensor
291
Air Induction System
294
Checking the Air Induction System
297
Installing the Air Induction System
297
Electrical System
299
Ignition System
302
Circuit Diagram
302
Troubleshooting
304
Electric Starting System
306
Circuit Diagram
306
Starting Circuit Cut-Off System Operation
308
Troubleshooting
309
Charging System
312
Circuit Diagram
312
Troubleshooting
314
Lighting System
316
Circuit Diagram
316
Troubleshooting
318
Signaling System
320
Circuit Diagram
320
Troubleshooting
322
Cooling System
328
Circuit Diagram
328
Troubleshooting
330
Fuel Injection System
332
Circuit Diagram
332
Ecu Self-Diagnostic Function
334
Fail-Safe Actions (Substitute Characteristics Operation Control)
335
Troubleshooting Method
337
Diagnostic Mode
338
Troubleshooting Details
344
Fuel Pump System
356
Circuit Diagram
356
Troubleshooting
358
Electrical Components
360
Checking the Switches
364
Checking the Bulbs and Bulb Sockets
367
Checking the Leds
368
Checking the Fuses
368
Checking and Charging the Battery
369
Checking the Relays
372
Checking the Turn Signal/Hazard Relay
373
Checking the Relay Unit (Diode)
373
Checking the Spark Plug Caps
374
Checking the Ignition Coils
375
Checking the Crankshaft Position Sensor
376
Checking the Lean Angle Sensor
376
Checking the Startor Motor Operation
376
Checking the Stator Coil
377
Checking the Rectifier/Regulator
377
Checking the Horn
378
Checking the Engine Oil Level Gauge
378
Checking the Fuel Sender
379
Checking the Speed Sensor
379
Checking the Radiator Fan Motor
380
Checking the Coolant Temperature Sensor
380
Checking the Throttle Position Sensor
380
Checking the Fuel Pump
381
Checking the Air Induction System Solenoid
382
Checking the Intake Air Pressure Sensor
382
Checking the Intake Air Temperature Sensor
382
Troubleshooting
385
General Information
385
General Information
386
Incorrect Engine Idling Speed
386
Starting Failures
386
Troubleshooting
386
Faulty Clutch
387
Faulty Gear Shifting
387
Jumps out of Gear
387
Overheating
387
Poor Medium-And-High-Speed Performance
387
Shift Pedal Does Not Move
387
Faulty Front Fork Legs
388
Overcooling
388
Poor Braking Performance
388
Unstable Handling
388
Faulty Lighting or Signaling System
389
Wiring Diagram
390
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Yamaha FZS6W Service Manual (20 pages)
Brand:
Yamaha
| Category:
Motorcycle
| Size: 0.47 MB
Table of Contents
How to Use this Manual
4
Table of Contents
9
Identification
10
Vehicle Identification Number
10
Model Label
10
Features
11
Outline of Fi System
11
Fi System
12
Instrument Functions
13
Important Information
16
Preparation for Removal and Disassembly
16
Replacement Parts
16
Gaskets, Oil Seals and O-Rings
16
Lock Washers/Plates and Cotter Pins
16
Bearings and Oil Seals
17
Circlips
17
Checking the Connections
18
Special Tools
19
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