Yamaha Fz 09 2014 Manual
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SERVICE MANUAL LIT-11616-27-39 FZ09E FZ09EC 1RC-28197-10
FZ09E FZ09EC SERVICE MANUAL ©2013 by Yamaha Motor Corporation , U.S .A . First edition, August 2013 All rights reserved. Any reproduction or unauthorized use without the written permission of Yamaha Motor Corporation, U.S.A. Is expressly prohibited. Printed in U.S.A. PIN LIT-11616 -27-39
EA$20071 IMPORTANT This manual was produced by the Yamaha Motor Company , L td. primarily for use by Yama ha dealers and the ir qualified mecha nics . It is not poss ible to include all the knowledge of a mech anic in one man· ual. Therefore , anyone who uses this book to perform maintenance and repairs on Yamaha vehicles shou ld have a bas ic understanding of mechanics and the techn iques to repa ir these types of veh icles . Repair and maintenance work attempted by anyone without this knowledge is li ke ly to render the vehi· c le u ns afe and un fit for use. Th is model has been des i gned and manufactured to perform within certa in specifica tions in regard to performance and emiss ions. Proper service with the correct tools is necessary to ensure that the vehi · c le w ill operate as des igned. If there i s any question about a serv ice procedure , it is imperative that you contact a Yamaha dealer for any service in format ion changes that app ly to this model. This policy is in tended to prov ide the custome r w ith th e most satisfactio n from his vehicle and to conform to federal envi ro nmen ta l quality objectives. Yamaha Motor Company , Ltd. is cont inually striving to improve all of i ts models. Modifications and sig · nificant changes in spec ifica tions or proced ures will be forwarded to all a ut horized Yamaha dealers and will appear in fu tu re editions of th is man ual where app licable. TIP~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~ • This Service Manual contains informatio n regarding periodic ma intenance to the emission contro l sys· tern. Please read this material carefully. • Designs and spec ifications are subject to change without notice. EA$20081 IMPORTANT MANUAL INFORMATION Part icu larly important information is distinguished in this manual by the follow ing notations. AwARNING NOTICE I TIP This is the safety alert symbol. It is used to alert you to potential per· sonal injury hazards. Obey all safety messages that follow this symbol to avoid possible injury or death. A WARNING indicates a hazardous situation which, if not avoided, could result in death or serious injury. A NOTICE indicates special precautions that must be taken to avoid damage to the vehicle or other property. A T l P provides key information to make procedures easier or clearer.
EA$20Clll1
HOW TO USE THIS MANUAL
This manual is intended as a handy, easy-to-read refere nce book for the mechan ic. Comprehe nsive
explanations of all insta llatio n, remova l, d isassemb ly , assembly, repa ir and check procedures are laid
out with the ind ivid ual steps in sequential order.
• The manual is div ided into chapters and each chapter is divided into sect ions. The current section title
1 is shown at the top of each page.
• Sub-section titles 2 appear in smaller print than the section title.
•
To he lp i dentify parts and clarify procedure steps, there are exploded diagrams 3 at the start of each
removal and disassemb ly section.
• Numbers 4 are g iven in the order of the jobs in the exp loded d iagram. A number indicates a disas
semb ly
step.
• Symbo ls 5 ind icate parts to be lubricated or rep laced .
Refe r to SYMBO LS .
•
A job instr uction chart 6 accompanies the exp loded d iagram , prov id ing the order of jobs, names of
parts , notes in
jobs , etc. This step expla ins remova l and disassembly procedure only. For installa tion
and
assemb ly procedu re, reverse the steps.
•Jobs 7 requir ing more in forma tion (suc h as spec ia l
too ls
and t ech n
ical
data) are
described
seq uen·
tially.
1
CLUTCH
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EA$20101 SYMBOLS The follo wing symbo ls are used in th is man ual for easie r understa nding . TIP~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~ The following symbols are not releva nt to every vehic le. SYMBOL DEFINITION SYMBOL DEFINITION ~ Serviceab le w ith engine mounted 1 Gear oil m ~ F illing flu id 1 Molybdenum disulfide oil ~ B L ubrica nt 1 Brake fluid ~ ~ Spe cial tool ~ Whee l beari ng grease ~ Tightening torque ~ Lithium-soap-based grease ~ Wear limit, clearance ~ Molybdenum disulfide grease [g] Engine speed ~ Silicone grease [iJj] El ectr ical data J. A Apply lock ing agent ( LOCT ITE®). 1 ·~-m Engine oil Replace the part with a new one. 1 Silicone flu id m
EAS20110 TABLE OF CONTENTS GENERAL INFORMATION SPECIFICATIONS PERIODIC CHECKS AND ADJUSTMENTS CHASSIS ENGINE COOLING SYSTEM FUEL SYSTEM ELECTRICAL SYSTEM TROUBLESHOOTING
GENERAL INFORMATION IDENTIFICATION ......................................................................... ........ ............. 1-1 VEHICLE IDENTIFICAT ION NUMBER ........ ............. ........ .... ........ ..... .... .... 1-1 MODEL LABEL .... ............. .... .... .... ............. ........ ........ ........ .... ..... ........ .... .... 1-1 FEATURES ...... .. .... .... .... ..... .... .... ............ ......... ........ ........ ........ ......... ........ ........ 1-2 OUTLINE OF THE Fl SYSTEM .... ............. ........ ........ ................. ........ .... .... 1-2 Fl SYSTEM ............... .... .... .... .... .... ............. .... .... ........ ............ ..... ........ .... .... 1-3 INSTR UMENT FUNC TIONS .... .... .... .... ......... .... ........ .... .... .... ............. .... .... 1-4 YCC-T (Yama ha Chip Controlled Throttle) ... .... .... ............. ........ ........ ......... 1-9 IMPORTANT INFORMATION ...................................................... ........ ........... 1-11 PREP AR AT ION FOR REMOVAL AND DISASSEMBLY .................... .... .. 1-11 REPL ACEMEN T PARTS .......... .... .... .... ..... .... .... .... .... ............ ..... ........ .... .. 1-11 GASKETS , 01 L SEALS AND 0-RI NGS ............ .... .... ................. ........ .... .. 1·11 LOCK WASHERS/PLATES AND COTTER PIN S ........................ ......... 1-11 BEAR I NG S AND 01 L SEAL S . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . .. . . . . . .. . . . . . . . 1 -11 CIRCLIPS .... .... .... .... ............. .... ........ .... ..... ........ ........ ............ ..... ........ .... .. 1-12 RUBBER PARTS ..... .... ............. ........ .... ..... ........ ........ ............ ..... ........ .... .. 1-12 BASIC SERVICE INFORMATION ............ .............................. ................ 1-13 QUICK FASTENERS .......................................................... .... .... ..... 1-13 ELECTRIC AL SYSTEM ................... .... ............................................... 1-13 SPECIAL TOOLS .. .... ............. ........ ........ .... ..... ........ ........ ........ .... ..... ........ .... .. 1-18
EA$20130 IDENTIFICATION EA$201.CO VEHICLE IDE NTIFI CATI ON NUM BER The veh ic le i dent if icat ion number 1 is stamped into t he right s ide of the steering head pipe. EA$20 150 MODEL LABEL The model label 1 is affixed to the frame. This informatio n will be needed to order spare parts. IDENTIFICATION 1-1