Yamaha Fz 09 2014 Manual
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1. Head light asse mbly 2. R ight brak e caliper 3. F ro nt brake hos e 4. Cla mp 5. Left brake cal ipe r 6. L e ft re flecto r 7. Right reflecto r A . To left brake ca liper B . To fron t brake master cylinder C. In st all the fro nt brak e hose with its blue pai nt m ark f ac ing out wa rd. D . In stall the brake hose to the right b ra ke ca lipe r so that the brake pipe touches the pro ject ion on the brake caliper. In sta ll b ra ke hose from th e maste r cylinde r so that it ali gned w ith the direction of th e brake pi pe to the righ t brake caliper. E . In s tall th e brake pipe so that it con tacts th e pro jec · tion on th e brake caliper. F. F ace the catc h of the clamp backward, and then close the cla mp un til three clicks o r m ore are heard. G . Same fo r t hree cla m ps H. Insert the clamp in to the front fender securely . I . When in stalli ng th e reflector, make sure th at the reflector contac ts the brake calipe r. CABLE ROUTING 2-66
1. Rear frame 2 . Clam p 3. Rear brake caliper 4. Rear brake hose 5. Swinga rm assembly A. In stall the clamp facing the direc lion in the illuslra tion. B. Mak e sure to i nsta ll the clamp all the way in the rear fr am e. C . Fas te n the protector of the brake hose with th e c lamp . In s t a ll th e mating section on the top of the veh ic le . D . Make sure to install th e clamp all the way in the swingarm assemb ly. E. Install th e brake pipe so that it aligned with the cut out in the caliper . CABLE ROUTING 2-68
PERIODIC CHECKS AND ADJUSTMENTS PERIODIC MAINTENANCE ....... ............ .... ..... .... .... ................ .... ..... .... .... ........ 3-1 INTRODUCTI ON ..... .... .... ................. .... .... .... .... ............. .... .... .... .... .... ......... 3-1 PERIODIC MAINTE NANCE CHART FOR TH E EMISSION CONTROL SYSTEM . .... .... .... ............. .... .... .... .... .... ..... .... .... .... .... .... .... .... ............. .... .... 3-1 GE NE RAL MAINTENANCE AND LUBR ICATION C HART ..................... 3-2 CHECKING THE FUEL LINE .......................................................... 3-4 CHECKING THE SPARK PLUGS .............................. ........................ 3-4 ADJUSTING THE VALVE CLE ARA NCE .................... .......... ...... ........... 3-5 CHECKING THE ENG INE IDLING SPEED .................................... ............ 3-7 SYNCHRONIZING THE THROTTLE BODIES .............. ............................. 3-8 CHECKING THE THROTTLE BODY JOINTS ................................ ............ 3-9 CHECKING THE CANISTER (fo r Ca li forn ia only) .... ... ........ ..... .... ..... ......... 3-9 CHECKING THE AIR INDUCT ION SYSTEM ....................................... .... 3-10 CHECKING THE CYLINDER HEAD BREATHER HOSE .... ......... ........ .... 3-10 REPLACING THE AIR FIL TER ELEMENT .............. ... ......... ... .......... ... .... 3-10 ADJUS TING THE CLU TCH LEVE R FREE PLA Y ....... ............................. 3-11 C H ECK ING THE BR A KE OPERAT ION ........................ ......... ........ .......... 3-11 CH ECK ING THE BR A KE FLUID LE VEL ............... ........ ......... ........ .......... 3-11 ADJUS TING THE FRONT DISC BRAKE .............. ........ ....... .......... .......... 3-12 CHECKING THE FRONT BRAKE PADS ............ .......................... ........... 3-12 ADJUSTING THE REAR DISC BRAKE ............................... ............ ........ 3-13 CHECKING THE REAR BRAKE PADS ......................................... ........... 3-13 BLEEDING THE HYDRAULIC BRAKE SYSTEM ........................ ........... 3-13 CHECKING THE FRONT BRAKE HOSES ................. ........................... 3-14 CHECKING THE REAR BRAKE HOSE ............. ......... ... ......................... 3-14 CHECKING THE WHEELS .................................. ..... ... ........................ 3 -15 CHECKING THE TIRES ........................................ ......................... .......... 3-15 CHECKING THE WHEEL BEARINGS .................. ......................... .......... 3-16 CHECKING THE SWING ARM OPERATION ................................. .......... 3-16 LUBRICA TING THE SWINGA RM PIVOT .... ......... ... ... ..... ................. ....... 3-16 ADJUS TING THE DRIV E CHA IN SLACK .... .... ... ........ ......... ................ .... 3-16 LUBRICA TING THE DRIVE CHAIN ........... .................. ....... .............. ....... 3-17 CHECKING AND ADJUS TING T HE STEERIN G HEAD ...................... .... 3-18 LUBRICA TING THE STEE RING HEAD ..... ........ ...... .... ....... ..................... 3-19 CH ECKING THE CHASSIS FAST ENERS ............ ................. ........ .......... 3-19 LUBRICAT ING THE BRAKE LEVER ............................................. .......... 3-19 LUBRICAT I NG THE CLUTCH LEV ER .......... ........ ................. ........ .......... 3-19 LUBRICAT I NG THE PEDAL ............. .... .... ........ ......... ........ ................. .... .. 3 -19 ADJ USTING THE SHIFT PEDAL ................................. ................. ... ........ 3-19 CHECKING THE SI DEST AND ...................... ...... .... ..... ... ............. ............ 3-19 LUBRICAT ING THE SIDESTA ND .... .... ..................... ........ ................. .... .. 3-20 CHECKING THE SI DEST AND SWITCH ............................................... 3-20 CHECKING THE FRONT FORK .................................................... 3-20 ADJUSTING THE FRO NT FORK LEGS ........................................... 3-20 CHECKING THE REAR SHOCK ABSORBER ASSEMBL Y ........... .......... 3-21 ADJUS TING THE REAR SHOCK ABSORBER ASSEMBLY ................... 3-21 CHECKING THE CONNECTING ARM AND RELAY ARM ............ .......... 3-22 CHECKING THE ENG INE OIL LE VEL ........ ... .. ... ........ ..... .... .................... 3-22 CHANGING THE ENGINE OIL ............ ... .......... ... ..... ................. ............... 3-23 M EASURI NG THE ENG INE OIL PR ESSURE ......................................... 3-2 4
CHECKING THE COOLANT LEVEL ..... ... ... ..... ...... .. ... ... ... ..... ... ........ ... .... 3-25 CHECKING THE COOLING SYSTEM .......................... ......... ........ .......... 3-25 CHANGING THE COOLANT .... ... ................ ........ ........ .......... ......... .... ...... 3-26 CHECKING THE FRONT B R AKE LIGH T SWI TCH .. ............. ........ .......... 3-27 ADJUS TING THE REAR BRAKE LIGHT SWITCH ........................ .......... 3-27 CHECKING AND LUBRICATING THE CABLES ............ ....... ........ ... ........ 3-28 CHECKING THE THROTTLE GRIP .......... ............ ................ ......... .......... 3-28 CHECKING AND CHARGING THE BATTERY ........................................ 3-29 CHECKING THE FUSES ...... .... .... .... .... ..... .... .... .... .... ................. ........ .... .. 3 -29 REPLACING THE HEADLIGHT BULB ................................. ... ................. 3-29 ADJUSTING THE HEADLIGHT BEAM ............................................... 3-30
PERIODIC MAINTENANCE ,..,,.., PERIODIC MAINTENANCE , . .,,... INTRODUCTION Th is chapter includes all informa tion necessary to perform recomme nded chec ks and adjustmen ts . If f o llowed , th ese prevent ive mainte nance proced ures w ill ens ure more re liable veh ic le operation , a lo n ge r serv ice life and reduce the need for costly overhau l work . Th is informa tion app lies to veh icles al r eady in serv ice as well as to new vehicle s th at are being p rep ared for sale . All serv ice techn ic ia ns should be fam il iar w it h this entire chapter. TIP~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~ • From 24000 m i (37000 km) or 36 month s, repeat the mainte nance in tervals starting from 8000 mi (13000 km ) or 12 mon ths. • It ems m arked with an aster isk requ ire special tools , data and technical sk ills, h ave a Yama ha dea ler perform the serv ice. EA$1 AC1301 PERIODIC MAINTENANCE CHART FOR THE EMISSION CONTROL SYSTEM INITIAL ODOMETER READINGS No. ITEM ROUTINE 600 mi 4000 mi 8000 mi 1 2000 mi 16000 m i 20000 mi (1000 km) (7000 km) (13000 km) (19000 km) (25000 km) (31000 km) or or or or or or 1 month 6 months 12 months 18 months 24 months 30 months • Check fue l hoses fo r c racks or 1 • Fuel line damage . ., ., ., ., ., • Replace it nec essary . • Check condrtion. 2 • Spark plugs • A djust ga p and cle an . ., Repla ce. ., R epla ce. ., • R eplace ev ery 8000 m i (13000 k m ) or 12 months. 3 • Valve clearance • Chec k and ad just valve cle ar-Ev ery 2 660 0 mi (4 200 0 km ) ance whe n engine is cold , Cran kcase • Check breat her hose fo r 4 . cracks or dama ge . ., ., ., ., ., breather system • Replace it nec essary . 5 • Fuel injection • Adjus t syn ch ron iz ation. ., ., ., ., ., ., Evaporative emls· • Check cont ro l sys tem fo r 6 • sion control sys-damage. ., ., tern (for Californi a • Rep lace it necessary . only) • Check the air cut· o ff valve , Air induction sys~ reed valve. and hose tor dam4 7 • age. ., ., tern • Replace an y damaged parts if necess a ry . 3-1
PERIODIC MAINTENANCE
EA$1AC13Q2
GENERA L MAINTENA N CE AN D LUBRICAT IO N CHART
INI TIAL ODOMETER READINGS
No. ITEM ROUTINE 600 mi 4000 mi 8000 mi 1
2000 mi 16000 m i 20000 mi
(1000 km) (7000 km) (13000 km) (19000 km) (25000 km) (31000 km)
or or or or or or
1 month 6 months 12 months 18 months 24 months 30 months
1 • A ir fi lter elemen t • Replace. Evo ry 24000 mi (3700 0 km )
2 • Clutch • Check opera tion .
• Adjust or replace cable.
• C heck opera tion. flu id leve l,
3 • Front brake and for flu id lea kage .
• Replace brak e pa ds ff n eces ·
sary.
• Check opera tion. flu id leve l,
4 • Rear brake and for flu id lea kage .
• Replace brake pads if nece s·
sary.
• Check fo r cracks or damage.
• Check to r correct routing and
5 • Brake hoses damping.
• Replace. Every 4 yea rs
6 . Brake fluid • Replace. Every 2 yea rs
• C heck runout an d fOl dam -
7 • Wheels age .
• Replace If n ece ssary .
• Check tread dep th and tor
damag e.
8 . TI res • Replace If n ece ssary .
• Check air pressure.
• Correc1 if necessary.
• C heck bearings for smoo th
9 . Wheel bearings operation.
• Replace II necessary .
• Check opera tion and for
Swingarm pivot e xcessive play.
0 •
bearings • Moderately repack w ith l it h -
!um-s oap.b a sed grease . E
ve ry 32 000 mi (5000 0 km)
• Check chain slack. alignment
and condition. Eve ry 500 mi (8 00 km) and aft er wash ing the motorcycle. riding in the 1 Drive chain • Adjus1 and lu b ri c a te c ha in
v1ith a specia l 0-ring chain r
a in or riding in vtet a re as
lubricant thoroughl y .
• C heck bear ing assem blie s to r
looseness. 2 • Steer ing bearings
• Moderately repack w ith l it h · E ve ry 1 2 00 0 m i (19000 km) !um-s oap.b a sed grease .
• Check all chassis fittin g and
3 • Chassis fasteners fasteners.
• Correct it neoessary.
14 Brake lever pivot
shaft • Ap ply silicone grease lightl y.
15 Brake pedal pivot • Apply lithium- soap ·b ase d
shaft grease lig htly .
16 C lutch lever pivot • Ap ply lit hi um -soap.b a sed
shaft grease lig htly .
3-2
PERIODIC MAINTENANCE
IN IT IAL ODOMETER READINGS
No. ITEM ROUTINE 600 mi 4000 mi 8000 mi 12000 mi 16000 mi 20000 mi (1000 km) (7000 km) (13000 km) (19000 km) (25000 km) (31000 km)
or or or or or or
1 month 6 months 12 months 18 months 24 months 30 months
7 Shi ft pedal pivot • Apply lit hi um -soap-based
shaft grease lig htly .
• Check operation.
8 Sidestand pivot • Apply lit hi um -soap-based
grease lig htly .
9 • Sldestand switch • Check operation and replace
if necessa(y.
• Check operation and tor oil
0 • Front fork leakage.
• Replace If necessary .
Shock absorber • Check operation and tor oil
1 • assemb ly l eakage.
• Replace If necessary .
2 • Rear suspension • Check operation.
link pivots • Correct rf necessary.
3 Engine oil • Change (warm engine befo re
draining).
24 Eng ine oil fil ter
cartridge
• Replace.
• Check hoses for cracks or
damage.
5 • Cooling system • Replace it necessary.
• Change coo lant.
6 • Front and rear
brake switches
• Check operation .
• Apply Yamaha cable lubricant
7 • Contro l cables or other suitable cable lubri·
cant thoroughly.
• Check operation.
• Check throttte grip free play ,
8 • Throttle grip and adjust if necessary.
• Lubricate ca ble and grip
hou sing.
29 . Lights , signals • Check operation.
and switc hes • Ad just hea dllgh1 be am.
TIP~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~
• Air filter
•Th is mode ls a ir filter i s equ ipped with a disposable oil -coated pape r element , which must not be
cleaned wit h compressed air to avo id damag ing it.
•The ai r filte r elemen t needs to be rep laced more frequently whe n rid ing in un usu ally wet or d usty
areas.
• Hydraulic brake service
• After d isassemblin g th e brake master cylinde rs a nd calipers , always change th e fluid . R egular ly
c heck the brake f luid leve ls a nd fill the reservo irs as re quired.
• Every two years
rep lace the in ternal compo ne nts
of the brake maste r cyl inde rs a nd ca li pers, and
c hange the brake fluid .
• Rep lace the brake hoses every four years and if
c rac ked
or damaged.
3-3
CHECKING THE FUEL LINE The following proced ure applies to all of the fue l, vac uum and breather hoses. 1. Remove: •R ide r seat Refe r to GENERAL CHASSIS on page 4-1. •Fue l tank Refe r to FUEL TANK on page 7-1. 2. Check: • Fue l hose 1 • Fue l tank breather hose 2 • Fue l tank dra in hose 3 C racks/damage -+ Replace. Loose connection -+ Connect properly. ECA14940 NOTICE ~~~~~~~~~~~~ Make sure the fuel tank breather hose is rout ed correctly. TIP~~~~~~~~~~~~~~~ Before r emov ing the fuel hoses , place a few rags in the area u nder where it will be removed. 3. Install: • Fue l tan k Refe r to FUEL TAN K on page 7-1. • R ide r seat Refe r to GENERAL CHASSIS on page 4-1. CHECKING THE SPARK PLUGS The follow ing procedure applies to all of the spark p lugs. 1. Remove: •R ider seat Refer to GENERAL CHASSIS on page 4-1. •Fue l tan k Refer to FUEL TANK on page 7-1. • Air filter case Refe r to GENERAL CHASSIS on page 4-1. • Air cu t- off valve Refe r to AIR INDUCTION SYSTEM on page 7-15. 3-4 PERIODIC MAINTENANCE 2. Remove: • Ig nition coils • Spark plu gs NOTICE ~~~~~~~~~~~~~ Before removing the spark plugs, blow away any dirt accumulated in the spark plug wells with compresse d air to prevent it fro m falling into the cylinders. 3. C heck: • Spark plug type Incorrect-+ Change. 4. C heck: Manufacturer/model NGK/CPR 9EA9 • Electrode 1 Damage/wear -+ Replace the spark plu g. • Insulato r 2 Abnormal colo r -+ Rep lace t h e spa rk plu g. Norma l color is med ium -to -ligh t tan. 5. C le an: • Spark pl ug (with a spark plu g clea ner or w ir e brush) 6. Measure: • Spark plug gap a (with a w ire thickness gauge) Out of specificatio n -+ Regap. Spark plug gap 0.8-0.9 mm (0. 031--0 .035 in) 7. Install: • Spark pl ugs • Ig nition coils Spark plug I 1 2 1 1 3 Nm (1. 3 m·kgf, 9.4 ft·lbf) TIP~~~~~~~~~~~~~~~ Before install ing the spark plu g, clean the spark plug and gasket su rface. 8. Install: • A ir cut-off va lve Re fe r to AIR INDUCTION SYSTEM on