Yamaha FZS6W Service Manual
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FZS6W
FZS6WC
SERVICE MANUAL

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  • Page 1 FZS6W FZS6WC SERVICE MANUAL...
  • Page 2 EAS20050 FZS6W/FZS6WC SERVICE MANUAL ©2006 by Yamaha Motor Corporation, U.S.A. First edition, Octover 2006 All rights reserved. Any reproduction or unauthorized use without the written permission of Yamaha Motor Corporation, U.S.A. is expressly prohibited. Printed inU.S.A. P/N LIT-11616-20-60...
  • Page 3 If there is any question about a service procedure, it is imperative that you contact a Yamaha dealer for any service information changes that apply to this model. This policy is intended to provide the customer with the most satisfaction from his vehicle and to conform to federal environmental quality objectives.
  • Page 4: How To Use This Manual

    EAS20090 HOW TO USE THIS MANUAL This manual is intended as a handy, easy-to-read reference book for the mechanic. Comprehensive explanations of all installation, removal, disassembly, assembly, repair and check procedures are laid out with the individual steps in sequential order. •...
  • Page 5 EAS20100 16.Replace the part SYMBOLS The following symbols are used in this manual for easier understanding. NOTE: The following symbols are not relevant to every vehicle. 1. Serviceable with engine mounted 2. Filling fluid 3. Lubricant 4. Special tool 5. Tightening torque 6.
  • Page 7 EAS20110 TABLE OF CONTENTS GENERAL INFORMATION SPECIFICATIONS PERIODIC CHECKS AND ADJUSTMENTS CHASSIS ENGINE COOLING SYSTEM FUEL SYSTEM ELECTRICAL SYSTEM TROUBLESHOOTING...
  • Page 9: Table Of Contents

    GENERAL INFORMATION IDENTIFICATION ..................1-1 VEHICLE IDENTIFICATION NUMBER...........1-1 MODEL LABEL..................1-1 FEATURES ....................1-2 OUTLINE OF FI SYSTEM ..............1-2 FI SYSTEM .....................1-3 INSTRUMENT FUNCTIONS ..............1-4 IMPORTANT INFORMATION ...............1-7 PREPARATION FOR REMOVAL AND DISASSEMBLY......1-7 REPLACEMENT PARTS.................1-7 GASKETS, OIL SEALS AND O-RINGS..........1-7 LOCK WASHERS/PLATES AND COTTER PINS ........1-7 BEARINGS AND OIL SEALS ..............1-8 CIRCLIPS ....................1-8 CHECKING THE CONNECTIONS ...............1-9...
  • Page 10: Identification

    IDENTIFICATION EAS20130 IDENTIFICATION EAS20140 VEHICLE IDENTIFICATION NUMBER The vehicle identification number “1” is stamped into the right side of the steering head pipe. EAS20150 MODEL LABEL The model label “1” is affixed to the frame. This information will be needed to order spare parts.
  • Page 11: Features

    FEATURES EAS20170 FEATURES EAS4S81003 OUTLINE OF FI SYSTEM The main function of a fuel supply system is to provide fuel to the combustion chamber at the opti- mum air-fuel ratio in accordance with the engine operating conditions and the atmospheric tempera- ture.
  • Page 12: Fi System

    FEATURES EAS4S81004 FI SYSTEM The fuel pump delivers fuel to the injector via the fuel filter. The pressure regulator maintains the fuel pressure that is applied to the injector at only 250 kPa (2.5 kg/cm ). Accordingly, when the energiz- ing signal from the ECU energizes the injector, the fuel passage opens, causing the fuel to be injected into the intake manifold only during the time the passage remains open.
  • Page 13: Instrument Functions

    FEATURES EAS4S81005 Tachometer INSTRUMENT FUNCTIONS 1. Tachometer 2. Tachometer red zone. 1. Coolant temperature display/air intake tem- The electric tachometer allows the rider to perature display monitor the engine speed and keep it within 2. Speedometer the ideal power range. 3.
  • Page 14 “E” (Empty), “F” (Full) and symbol “ ” will flash eight times, then go off for approximately 3 seconds. If this occurs, have a Yamaha dealer check the electrical cir- cuit. Coolant temperature mode 1. Odometer/tripmeter/fuel reserve tripmeter Push the “SELECT”...
  • Page 15 FEATURES 4. Push the “RESET” button to select the NOTE: desired brightness level. • Even if the air intake temperature is set to be 5. Push the “SELECT” button to confirm the displayed, the coolant temperature warning selected brightness level. The display will light comes on when the engine overheats.
  • Page 16: Important Information

    EAS20200 REPLACEMENT PARTS Use only genuine Yamaha parts for all replace- ments. Use oil and grease recommended by Yamaha for all lubrication jobs. Other brands may be similar in function and appearance, but...
  • Page 17: Bearings And Oil Seals

    IMPORTANT INFORMATION EAS20230 BEARINGS AND OIL SEALS Install bearings and oil seals so that the manu- facturer’s marks or numbers are visible. When installing oil seals “1”, lubricate the oil seal lips with a light coat of lithium-soap-based grease. Oil bearings liberally when installing, if appro- priate.
  • Page 18: Checking The Connections

    CHECKING THE CONNECTIONS EAS20250 CHECKING THE CONNECTIONS Pocket tester 90890-03112 Check the leads, couplers, and connectors for Analog pocket tester stains, rust, moisture, etc. YU-03112-C 1. Disconnect: • Lead NOTE: • Coupler • If there is no continuity, clean the terminals. •...
  • Page 19: Special Tools

    SPECIAL TOOLS EAS20260 SPECIAL TOOLS The following special tools are necessary for complete and accurate tune-up and assembly. Use only the appropriate special tools as this will help prevent damage caused by the use of inappropri- ate tools or improvised techniques. Special tools, part numbers or both may differ depending on the country.
  • Page 20 SPECIAL TOOLS Reference Tool name/Tool No. Illustration pages Steering nut wrench 3-26, 4-53 90890-01403 Spanner wrench YU-33975 Damper rod holder 4-45, 4-47 90890-01294 Damping rod holder set YM-01300 T-handle 4-45, 4-47 90890-01326 YM-01326 Oil filter wrench 3-13 90890-01426 YU-38411 Fork seal driver weight 4-47, 4-48 90890-01367 Replacement hammer...

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