Yamaha Fz 09 2014 Manual

EA$1AC15Q2 
OIL PAN 
Removing the oil pan 
Orde r 
1 
2 
3 
4 
5 
6 
7 
___...,(13) 
1 0 Nm (1 .0 m • kgf,  7. 2 ft ·lbf) 
43 Nm (4.3 m • kgf, 31 ft • lbf) 
10 
Nm ( 1.0 m . kgf, 7.2 ft ·lbf) 
Job/Pa rts to remove Qty 
Rider seal 
A
ir s c oop /F u el lank  cover 
Fu el lan k 
Muffle r asse mbly 
Engine oil 
O il  level 
switc h lead  coupler 1 
Oil  level switc h lead  holde r 1 
Oil level switc h  1 
02 sensor lead  holde r 1 
Oil pan 1 
O il pan gasket 1 
O il stra in e r 1 
5-54 
OIL PAN 
7 
Remark s...

REMOVING THE OIL PAN 
1. Remove: 
• Oil level switch 1 
• Oil pan 2 
• Oil pan  gasket 
TIP~~~~~~~~~~~~~~­
Loosen  each bolt 1/4  of a tur n at a  time, in stag­
es  and  in  a crisscross  pattern.  After all of the 
bolts are fully  loosened , remove them. 
EA~990 
CHECKING THE OIL STRAINER 
1. Check: 
• Oil stra iner 1 
Damage -+ Replace. 
1 
Con taminan ts -+ Clean wi th so lvent. 
1 
INSTALLING THE OIL PAN 
1. 
Install: 
• Gasket l@@ll 
• Oil pa n 1 
Oil 
pan bolt 
10 Nm (1.0 m·kgf, 7.2 ft·lbf) 
•...

EA$2$S.C0 
CRANKCASE 
Separating  the crankcase 
II, 24 Nm (2.4  m • kgf, 17 ft · lbf) 
lll,J 10 Nm (1.0 m • kgf,  7.2 ft • lbf) I 
1st  25 Nm 2.5  m • kgf, 18 ft 0 lbf 
2nd  15  Nm  (1.5  m • kgf, 11 ft • lbf) 
3rd  Spec ified angle 60 
Jll,J 24 Nm  (2.4  m . kgf, 17 ft · lbf) [ 
(2) ,,_,., .... 
(6) 
Orde r  Job/Pa
rts to remove 
Engine 
Cylinder head 
Water  pump 
S tart
er clutch 
Starter  moto r 
Clutch housing 
O il stra in e r 
, O il filter cartr idge 
2 Oil filter cartr idge  unio n bolt 
3 Gea...

EA$2$S50 
DISASSEMBLING THE CRANKCASE 
1. 
P lace the  engine  upside down. 
2.  Remove: 
• Crankcase bolts 
TIP~~~~~~~~~~~~~~~ 
• Loose n each bo lt 1/4  of a tum  at a time,  in stag ­
es and in a  crisscross  pattern. Aft er all of the 
bolts are fully  loosened, remove  them. 
• Loosen  the bolts in  the  proper  sequence  as 
shown . 
• The numbers  embossed on the crankcase in­
dicate the  cran kcase  tighten ing  sequence. 
3.  Remove: 
• Lowe r crankcase 
NOTICE ~~~~~~~~~~~~~ 
Tap on one side of...

4. Set the shift drum assemb ly and  tr a nsmiss io n 
gears  in t he 
ne utr al pos it io n . 
5. 
Inst all: 
• 
Lowe r cran kcase 1  
(on to 

t h e  uppe r cr ankcase 
2 ) 
N O TICE ~~~~~~~~~~~~~ 
Before tightening the crankca se bolts,  make 
sure the transmission gears shift correctly 
when  the shift drum assembly  is tu rned by 
hand. 
6. 
Insta ll: 
• 
C ran kcase bo lt s 
TIP~~~~~~~~~~~~~~-
• L ubr icate  th e bo lts 1 - B  th re ad ,  mating  su r­
f a ces  an d  was he rs w ith  eng ine 
oil....

8. Tig hten: 
• C rankcase bolts  9-30 
Crankcase bolts 9-14  
24  Nm  (2.4 m·kgf, 17 fl·lbf) 
Crankcase bolts  15 - 30  
10 
Nm (1.0  m·kgf, 7.2 fl·lbf) 
TIP~~~~~~~~~~~~~~­
Tigh te n  th e bol ts in  the tigh tening  sequence  cast 
on  the  crankcase. 
CRANKCASE 
5-59  

CONNECTING RODS AND PISTONS 
EA$1AC1503 
CONNECTING RODS AND PISTONS 
Removing the connecting rods and pistons 
1st 20 Nm (2.0 m • kg l,  14 It · lbl) 
2nd Specified  angle 175-1 85  
Order  Job/Parts 
to remove Qty Remarks 
Lowe r crankcase  Refer 
to 
CRA N KCASE on  page 5-56. 
1 C onnect ing  rod  cap 3 
2  Big 
en d lowe r bearin g 3 
3 
Pist o n  pin clip 6 
4 Pisto n  pin 3 
5 Pisto n 3 
6 Connect ing  rod 3 
7 Big  end  uppe r bearing 3 
8 
Top r in g 3 
9 2nd  ring 3 
10 O il rin g 3 
5-60  

CONNECTING RODS AND PISTONS 
,..,,.., 
REMOVING THE CONNECTING RODS AND 
PISTONS 
The follow ing  procedure applies to all of the con ­
n ect in g  rods  and p
istons. 
1.  Remove: 
•Connec ting rod cap 1 
• Connect ing  rod 
• Big  end bearings 
TIP~~~~~~~~~~~~~~-
• Ide ntify the position of each  big  end  bear ing so 
that it  can  be reinstalled in  its orig inal  place. 
• 
After  removing  the connecting  rods  and  con­
necting  rod caps,  care 
should be  ta ken  not  to 
damage  the 
mating...

CONNECTING RODS AND PISTONS 
and front-to-b ack  measurements  of the cylinder . 
Then,  find the  average 
of the  meas urement s. 
Bore 
78.000-78.010 mm 
(3.0709-3.0713 in) 
Taper limit 
0.050 mm (0.0020 in) 
Out of round limit 
0 .050 mm (0 .002 0 In) 
 C  
=  max imum of D1-D6 
Taper  limit  =  max imum  of  D1 or  D2 -max
i­
mum  of 
D s or Ds 
O ut of ro und lim it= maximum  of D1 , D3 o
r D5 
-m in im um of D2 , D4 o
r D5 
~ ... 04 ... ------
• 
b. If o ut  of  specifica tion , re p la ce the...

CONNECTING RODS AND PISTONS 
TIP~~~~~~~~~~~~~~­
Use the piston  crown to level the piston  ring near 
bottom of cylinder  a , whe re  cyl inde r wear  is 
lowest. 
3 .  Measure: 
• Piston  ring end  gap 
Out of specification -> Rep lace  the piston 
ring . 
TIP~~~~~~~~~~~~~~ 
Th e oil ring  expander  spa cers  en d  gap  cannot 
be measured. If th e oil ring ra ils gap  is exces­
s ive , rep lace 
all three  piston  rings. 
Top ring 
End 
gap (installed) 
0.15-0.25 mm (0.0059-0.0098 in) 
Limit 
0.50 mm...