Yamaha Fz 09 2014 Manual

2. Meas ure: 
•  C lu tc h spring  free length  a  
O ut 
of spec if icat io n -> Rep lace t h e clutch 
springs as a  set. 
EAS25l50 
Clutch spring free length 
52.50 
mm (2.07 in) 
Limit  49.88 
mm (1.96  in) 
CHECKING THE CLUTCH HOUSING 
1. Check: 
•  C lu tch h ous ing  dogs 
Damage /p ittin
g/wea r -> Deburr  the clutch 
hous ing  dogs  or rep lace t h e clu tch h ous ing. 
TIP~~~~~~~~~~~~~~­
P itting on the c lu tc h hous ing dogs will cause  er­
r a tic 
clutch opera tion . 
2.  Check : 
• Oi l...

EA$2$~10 
CHECKING THE PRIMARY DRIVEN GEAR 
1. Check: 
• Primary dri ven gear 1 
Damage /wear 4 Replace the cl utch h ous ing 
and  crankshaft  as a set. 
Excess ive noise during operation 4 Replace 
the clutch housin g and  crankshaft as a set. 
EAS25220 
CHECKING THE PULL LEVER SHAFT AND 
PULL ROD 
1. Check: 
• Pull le ver shaft  pin ion  gear  teeth 1 
• 
Pull rod  teeth 2 
Damage/wear 4 Replace th e pu ll rod and 
pull le ver shaft  as a set. 
1 
2.  Check: 
• Pull rod bearing 
Damage /wea r 4 Repla...

3. In sta ll: 
• 
Fr iction p late 1 
•  C lu tc h  plate 
• 
Fr iction p late 2 
TIP~~~~~~~~~~~~~~ 
• First, in stall a friction p la te a nd  th en a lternate 
between  a clutch  plate and  a frict ion plate. 
•  Install 
the last frict io n plate  1 offset  from the 
o ther  friction 
p la tes 2, ma king sure to align a 
pro ject ion 
on  t
he friction plate w ith  the  punch 
mar k 
a on the clu tch hous ing. 
4. 
Install: 
• Bea
ring 
(in to  the  pressu re plate) 
• Pull 
rod 1 
• 
Pressure plate...

7. Adjust: 
• C lutch  lever free p lay 
Refer to ADJUSTING THE CLU TCH LEVER 
FREE 
PLAY on  page  3-11. 
Clutch lever free play 
10.0-1 5.0 mm (0.39-0.59 in) 
CLUTCH 
5-47  

SHIFT SHAFT 
EA~IO 
SHIFT SHAFT 
Removing the shift shaft and stopper lever 
22 Nm  (2.2 m. kgf. 16 ft -!bf) 
g 
10 
Order Job/Parts to remove Q ty Remarks 
Clutc h assembly  Refer to C LUTC H on  page  5-39. 
Shift arm  Refer to  C HAIN DRIV E on  page 4-70 . 
1  Circlip  1 
2  Washer  1 
3 Shilt sh aft  1 
4 Washer  1 
5 Circlip 1 
6 Was her  1 
7 
S toppe r lever , 
8 S toppe r lever  spring , 
9 Colla r , 
10  Shilt shaf t spring 
1 
11 Shilt shaf t spring  stoppe r 
1 
12 
O il sea l 1 
1 3  Bearing...

,..,.... 
CHECKING THE SHIFT  SHAFT 
1.  Check: 
• Sh ift shaft 1 
Bends/damage/wear 4 R ep lace . 
•  Sh i
ft shaft  spring 2 
•Coll a r 
Damage /wear 4 R ep lace . 
, . .,..,. 
CHECKING THE STOPPER LEVER 
1. C heck: 
• Stopper  leve r 1 
Bends/damage 4 Rep lace . 
Rolle r 
turns ro ughly 4 Replace the  stopper 
lever. 
EA,$;2tlol.)1 
INSTALLING THE SHIFT  SHAFT 
1. Install: 
•  Sh i
ft shaft  spring  stoppe r 1  
•  Sh i
ft shaft assemb ly 
•  Stoppe r 
lever spri ng  2  
S h ift s h aft  sprin g...

OIL PUMP 
EA$24Q21 
OIL PUMP 
Removing the oil pump 
0  
~ 
ii, 10 Nm (1.0 m • kgf,  7.2 ft · lbf) 
0 
10 Nm 1.0 m . kgf, 7.2 ft · lbf) 15 Nm  (1.5m.kgf,11 ft ·lbf) 
Order 
Job/Par ts to remove  Qty Remarks 
Clu!c h cover  Refer 10  C LUT CH on  page  5-39 . 
1 Oil p ump  driven sproekel 1 
2 Oil pum p asse mbly 1 
5-50  

OIL PUMP 
Disassembling the oil pump 
II. 3.8  Nm  (0 .38  m • kg!, 2 .8 ft ·lb!) 
1 
mms--.._o 
"~~ 
3 
2 1--0 
I 
OJ---~ 
4 8 
(/) q) 
5 
9-{j  ~. 
m -~ ) Q 
 _/· 
 
., 
Order Job/Parts to remove Qty Remarks 
1 O il pum p  cove r , 
2 Oil pu mp  sh aft 1 
3 Pi n 1 
4 Oil pum p inn er roto r 1 
5 Oil pump  out er  rotor 1 
6 Circ lip 1 Hold dow n  th e  washer  when re m oving t he 
circ lip. 
7  Washer  1 
8 Spring , 
9 Relie f valve , 
10 Dowe l pin 2 
5-5 1  

,..,..., 
CHECKING THE SPROCKET AND CHAIN 
1. Check: 
• Oil pump  drive  sprocket 
Refer  to 
CHECKING T HE CLUTCH  HOUS­
ING 
on page 5-44 . 
2. Check: 
• Oil pump  drive  ch a in 1 
Damage/st iffn ess --+ Rep lace the oil pump 
dr ive  chain  and 
oil pump  drive sprocket 
(clutch hous ing) as a  set. 
 CHECKING THE OIL PUMP 
1. Check: 
•Oi l pump  driven  gear 1 
•  Oi l 
pump  housing  2  
Cracks/damage /wea r 
--+ Replace the  defec ­
t ive  part(s). 
1 
2 
2.  Measure: 
• Inner- rotor- to-outer -ro...

EAS;.24971 
CHECKING THE RELIEF VALVE 
1. C heck: 
• Relief valve  1 
• 
Sp ring 2 
Damage/we ar ~ R ep lace the oil p um p as­
semb ly. 
EAS2S(ll0 
ASSEMBLING THE OIL PUMP 
1. Lubricate: 
•  Inn er roto r 
• Ou te r rotor 
•  Oil pu mp  shaft 
(w it h  th e reco mmende d 
lubric an t) 
Recommended lubricant 
r--· Engine oil 
2 . Install: 
•  Ou ter 
rotor 1 
•  Inner rotor 2 
• P in 3 
•  Oil pump  cover 4 
• Oil pump  cover  screw 
011 pump cover screw 
3.8 Nm (0.38 m ·kgf, 2.8 ft·lbf)...