Yamaha Fz 09 2014 Manual

EA$1AC1412 
REMOVING THE FRONT  FORK LEGS 
The following procedure applies to  both  of the 
front fo rk legs. 
TIP~~~~~~~~~~~~~~~ 
Each  front fork leg i s  eq u ipp ed  w ith  a spring pre · 
l oad 
adj ust ing bolt, the  rig ht  fork leg i s  eq u ipp ed 
with  a reboun d da mp in g  force  adjusting screw 
a
nd compress ion  damping  force adjusting 
screw . Pay  attent ion  not  to mistake  the 
right and 
left. 
1. Stand the vehicle on  a leve l surface . 
EWAUl120 
AwARNING 
Securely support the...

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NOTICE ~~~~~~~~~~~~-
Do not scratch  the outer tube. 
4. Remove: 
•Outer tu be 
••••••••••••••••••\
•••••••••••••• 
a. Ho ld the  front  fo rk leg  hor izon tally. 
b. Secu re ly  clamp the brake ca liper b racket in a 
v i
se w ith  soft jaws. 
c .  Sepa rate the  oute r tube  from th e 
inner tub e 
by 
p ullin g th e outer  tube forcefully but ca reful­
ly. 
NOTIC•E~-----------­
Excessive  force will damage the bushings. 
Damaged 
bushings must be replaced. 
,. . 
••••••••••••••••••\...

3. Check: 
• Dampe r r od 1 
Damage/wear~ Replace. 
Obs tructio n 
~ Blow o ut all o f  the oil passag ­
es  with  com press ed  ai
r. 
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NOTICE ~~~~~~~~~~~~~ 
• The front fork leg has a very sophisticated 
Internal construction, which are  particular­
ly sensitive to foreign material. 
• When disassembling and assembling the 
front fork leg, do not allow any foreign ma­
terial to enter the front fork. 
1 
I 
8) · I ~l==::::::l[]J~=====·"""" · 
EAS1RClt14 
ASSEMBLING THE FRONT...

3. Lubr icate: 
•  Inner tubes  outer  surface 
Recommended oil 
1-mtl Suspension oil 01 
4. Install: 
• Dust sea l 1  l@IMJ 
• Oil seal clip  2  lf@i 
• Oil seal 3 lt@ii 
• Washer 4 
•  Outer tube bush ing 5 IUM 
• Inner tube bushing 6 l@@ii 
ECA1AC \411 
NOTICE ~~~~~~~~~~~~ 
Make sure the numbered side of the oil seal 
faces b ottom side. 
TIP~~~~~~~~~~~~~~~ 
• Befo re in stalling the oil seal,  lubrica te its lips 
w ith  li thium-soap-based  grease. 
• Lubricate  the outer  surface of the inner tube...

8. Install: 
•  O
il sea l c lip  1 
TIP~~~~~~~~~~~~~~­
Adjust  the oil seal  clip so that it  fits into  the oute r 
tubes  groove. 
I 
~~ 
 
9. Install: 
• 
D ust sea l 1 
(w ith  the fork sea l driver  2) 
1 O.lnstall: 
Fork seal drive r 
90890-01442 
Adjustable 
fork seal driver (36-46 
mm) 
YM-01442 
• Rod p uller  1 
• Rod  puller 
attachment  (M10) 2 
(on to  the  damper  rod 3) 
Rod 
puller 
90890-01437 
Universal 
damping rod bleeding 
tool set 
YM-A8703 
Rod 
puller attachment (M10)...

air. 
1 4 .M eas ur
e: 
• Fron t fo rk leg  oil level  a 
(from  the top of the  outer  tube,  wit h 

t
he outer 
tube 
f u lly compressed  and witho ut  the  fo rk 
sp
ring) 
Ou t of spe cifica tion -> Correct. 
15.lnstall:  Level 
(left) 
147 mm (5.8 In) 
Level (right) 
148 mm (5.8 in) 
• Fork  spring (Left  side)  1  
• 
Spacer  (Left side)  2  
• 
Loc kn u t  (Left  side) 3 
• 
Washer  (L eft  side) 4 
• 
Cap 

bol t 
(Lef t side)  5  
a 
(alo ng wi th  the 0-rin g 111~1'1![§111& ∀i) 
2 
4 
5...

j. Install the  washer  and cap bolt, and  then fin ­
ger  tighten  t
he cap bolt. 
EWAl$$70 
AwARNING 
Always use a new cap bolt 0-rlng. 
k. Hold the  cap bo lt  5 and  tighten  the locknut 
3 
to  spec ific ation. 
Locknut 
15 Nm (1.5 m·kgf, 11 ft·lbf) 
I. Remove  the rod holder and fork  spring com­
pressor. 
••••••••••••••••••\
•••••••••••••• 
16.lns tall: 
• 
Fork  spring  (R ight side)  1  
• 
Spacer  (R ight  side)  2  
• 
Locknut  (Right side) 3  
• 
Damper  adjusting  rod 4 
• 
Washer  (Right...

j. Posi tion  the lockn ut 3 as  spec ified b. 
Distance  b  
12 mm (0.47  In) 
3 
k. Set the cap bolt distance  c  to  spec if icatio n. 
Distance 
c 
13 mm ( 0. 51 in) 
c 
-
I.  Install the  damper  adjusting rod, washer  and 
cap 
bo lt, and  then  finge r tighten  the cap bolt. 
EWAt3610 
AwARNING 
Always use a new  cap bolt 0-ring. 
m. Ho ld the  cap bolt  5 and  tighten  the lockn ut 
3 to  specification. 
Locknut 
15  Nm (1.5 m ·k,gf, 11 ft·lbf) 
n.  Remove  the rod h older and  fo rk spring com...

,..,,.., 
STEERING HEAD 
Removing the lower bracket 
110Nm(11 m·kgf,80ft ·lbf) 
~ 7  Nm (0.7 m • kgf, 5.1 ft· lbf} 
10 
g 
~ 7 Nm (0.7 m • kgf, 5 .1 ft· lbf) 
FWD 
Order Job/Parts to remove 
F u el tank 
Air 
fi lter case 
Headlight assemb ly 
Me ter asse mbly 
H a
ndle bar 
Front  fork legs 
1  Pro
tecto r 
2 Rivet 
3 Coupl er cover assemb ly 
4 Clamp 
5 Main  switch cou pler 
6 Wi re harness clamp 
7  Horn lead conne ctor 
8 Horn 
9 Front  brake  hose 
10  Headlight stay 
11 Horn  bracket 
0 0 
4-59...

Removing the lower bracket 
110Nm(11 m·kgf,80ft ·lb 
7 Nm (0 .7 m • kgf,  5 .1 ft -lbf) 
7  Nm (0.7 m • kgf, 5.1 fl ·lbf) 
Order  Job/Parts to remove 
1 2  L ower b rac k
et ca p 
1 3  S teerin g  ste m  nut 
1 4 
U ppe r brac ke t 
1 5  Lock  was her 
1 6 
U ppe r rin g  nu t 
1 7  R
ubber  washe r 
1 8  Lower ri
ng nut 
1 9  Lower bra ck
et 
20 B earing cov er 
2 1  Low er  bearin g dust 
seal 
22 U pper bearing 
23  Low er  bearin g 
4-60 
STEERING HEAD 
1st 52  Nm  (5.2 m • kgf,  38 ft • lbf) 
2nd...