Yamaha Fz 09 2014 Manual

							Removing the front brake master cylinder 
1.5 Nm (0.15 m. kgf, 1.1 ft ·lbf) 
1.0 Nm (0.10 m· kgf, 0 .72 ft ·lbf) 
4 
9 
30 Nm (3.0 m. kgf,  22 ft 0 lbf) 
Order 
1 
2 
3 
4 
5  6 
7 
8 
9 
1 0 
11 
Job/Parts to remove 
R ig h t rea r vie\V mirro r 
B rake Huid 
B rake  mas ter cyl in de r re servo ir cap 
B rake  mas ter 
cyl in de

r 
re servo ir dia

phr agm 
holde r 
Brake  mas te

r 
cylinde r reservo ir diap hragm 
B rake 
lever 
Front  brake lig h t sw itch lead conn ecto r 
Fr ont  brake 
lig h t sw itch 
B rake  hose  uni on  bo tt 
B rake  hose  gaske t 
B rake  hose 
Front  brake  mas ter 
cyli n de r h olde r 
Front  brake  mas ter cyli n de r as sem bly 
FRONT BRAKE 
10 Nm (1.0 m. kgf.  7.2 ft -lbf) 
~ 6 Nm (0 .6 m • kgf,  4 .3 ft • lbf) 
5 
1 .2  Nm (0 .12 m • kgf, 0.87 ft· lbf) 
Qty 
1 
1 
1 
1 
2 
1 
1 
2 
1 
1 
1  Remarks 
Re fer  to 
 H AN OLEBAR on  pag e 4-44 . 
D rain . 
Refer  to 
 BL EE DIN G TH E HYDRA ULIC 
BRA KE S YSTEM  on pa ge 3-13 . 
D isconnect. 
4 -2 1  
						

							FRONT BRAKE 
Disassembling the front brake master cylinder 
Order Job/Parts to remove Qty Remarks 
1 Brake  maste r cyl inder ktt 1 
2 B rake  maste r cyl in der b ody 1 
4-22  
						

							Removing the front brake calipers 
·:----. 
-----
15!;] 30  Nm  (3.0  m • kgf, 22 ft • lbf) I 
Order  Job/Parts to remove Qty 
Brake fluid 
1 Brake  hose  union bolt 1 
2 B rake  hose  gaske t  1 
3 Brake  hose 2 
4 
B rake  hose  gaske t 2 
5 Reflec tor 1 
6 Front brake caliper 1 
4 -23 
FRONT BRAKE 
~ 35  Nm  (3.5 m. kgf. 25 ft 0 lbf) 
5 
6 
Remarks 
The fo llow ing procedu re a p plies to  both  of 
t h e  fro nt  brake 
calipers . 
Drain. 
Refe r to 
BLEE DIN G THE HYDRA ULIC 
BRA KE SYS TEM on page  3-1 3.  
						

							Disassembling the front brake calipers 
it 5 Nm (0.5 m • kgf, 3.6 ft 0 lbf) 
2 1 
mm 
6  5 
7 
e mm 
Orde
r  Job/Parts to remove 
1 Brake pad Clip 
2 B rake  pad  pin 
3 Brake  pad spring 
4 B rake  pad 
5 Brake cal ipe r piston 
6 Brake cal ipe r piston  dust seal 
7 Brake caliper piston seal 
8 Bleed screw 
mm 
6 
Q ty 
2 
1 
1 
2 
4 
4 
4 
, 
4-24 
FRONT BRAKE 
3 
6 
5 
mm 
Re marks 
The follow ing procedure app li es to  both  of 
the  front  brake 
calipers .  
						

							,.,,,,,., 
INTRODUCTION 
EWA\4 101 
A WARNING 
Disc  brake  components rarely require disas­
semb ly. 
Therefore , always follow these pre­
ventive measures : 
• Never disassemble brake components un­
less absolutely necessary . 
• If any connection on the hydraulic brake 
system 
Is disconnected , the  entire  brake 
system 
must be disassembled , drained, 
cleaned, properly filled, and bled after reas­
semb ly. 
• 
Never  use solvents on internal brake com­
ponents . 
• Use only clean or new brake fluid for clean­
ing brake components. 
• Brake fluid may  damage  painted surfaces 
and 
plastic parts.  Therefore , always clean 
up any spilt brake fluid immediately. 
•Avoid brake fluid coming into contact  with 
the  eyes  as 
it can cause  serious  injury. 
FIRST AID FOR BRAKE FLUID  ENTERING 
THE EYES: 
•  Flush 
with  water for 15 minutes  and get im­
mediate medical attention . 
EA5WO 
CHECKING THE FRONT BRAKE DISCS 
The following procedure applies to both  brake 
d i
scs. 
1. Remove: 
• Fron t wheel 
Refer  to FRONT  WHEEL on page 4-8. 
2. Check: 
• Front brake  disc 
Damage/galling --+ Replace. 
3. Measure: 
• Brake  disc runou t 
Out of specifica tion --+ Correct the  brake  disc 
runo ut or rep lace the  brake  disc. 
Brake 
disc runout limit (as mea­
sured on wheel) 
0.10 
mm (0.0039 in) 
••••••••••••••••••\
•••••••••••••• 
a. P la ce the vehicle on a  suitab le  stand so that 
the  front 
wheel is  eleva ted. 
b.  Befo re  measuring  the brake  disc runou
t, turn 
the  handleba r to 
the  left  or right to  ens ure  that 
the  front 
wheel is  stationary. 
c. Remove  the brake  caliper. 
FRONT BRAKE 
d. Hold  the dial gauge  at a rig ht  ang le against 
the  brake  disc  surface. 
e. Measure  the runou t 1.5 mm (0.06 in) below 
the  edge  of the  brake  disc. 
• ••••••••••••••••••\
••••••••••••• 
4. Measure: 
• Brake  disc thickness 
Measure  the brake  disc thickness  at a few 
dif ­
ferent  locations. 
Out of  specification --+ Replace. 
5. Adjust:  Brake 
disc thickness limit 
4.0 mm (0.
16 in) 
• Brake  disc runou t 
TTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTT 
a. Remove  the brake  disc. 
b. Rotate  the brake  disc by one  bolt  ho le. 
c. Install the  brake  disc. 
NOTICE 
Front brake disc bolt 
18 Nm (1.8  m-kgf, 13 ft·lbf) 
LOCTITE® 
~~~~~~~~~~~~~ 
Replace the  brake disc bolts with  new ones. 
TIP~~~~~~~~~~~~~~~ 
Tigh ten the  brake  disc bolts  in  stages  and in a 
cr isscross  pattern. 
4-25  
						

							/ 
I 
d. Measu re the brake  disc  runou t. 
e. 
If out of spec ificatio n,  repe at the  adjustment 
s teps 
unt il the  brake  disc  runou t  is  within 
spec ificat ion . 
f. If the  brake  disc  runou t cannot  be bro ug ht 
w it h in  spec if i
cati on , rep lace the  brake  disc. 
••••••••••••••••••\
•••••••••••••• 
6. Install: 
• 
Front whee l 
Refer  to F RONT  WHEEL on page 4-8 . 
EAS?2211 
REPLA CIN G THE FRONT BRAKE PADS 
The follow ing p roc edu re app lies to  both  brake 
calipers. 
TIP~~~~~~~~~~~~~~ 
When rep lac ing the  brake  pads,  it  is  not  neces ­
sary  to disconnect  the brake 
hose 
or disassem ­
ble th e 

b
rake caliper. 
1. Remove: 
• Brake  pad clips 1 
• 
Brake  pad pin 2 
• Brake  pad spring  3  
2 
2.  Remove : 
•B ra ke pads 1 
3 
~ 
1 
} 
FRONT BRAKE 
1 
3.  Measure: 
• Brake  pad wear limit a  
Ou1 of spec if icati o n ~ R ep lace the b rake 
pads  as a se
t. 
Brake pad lining thickness (inner) 
4.5 mm ( 0 .18 In ) 
Lim it 
0. 5 m m (0. 02 in ) 
Brake  pa d llnlng thickness (outer) 
4.5 mm (0 .1 8 in ) 
L im it 
0 .5 mm ( 0 .0 2 In ) 
& 1 
4. Remove : 
• Brake caliper bolts 
5 . Inst all: 
• Brake 
pads 
• Brake  pad spring 
II 
a 
10+ 
TIP~~~~~~~~~~~~~~-
Always  install new  brake  pads and new  brake 
pad  spring 
as a set. 
••••••••••••••••••\
•••••••••••••• 
a. Connect  a cle ar  plast ic hose 1  tig htly to  th e 
blee d screw 2. Pu t the  other  end of the  hose 
in to  an  open  conta iner. 
b. Loosen  the blee d screw  and  push  the brake 
caliper pis to ns  into  the brake caliper wit h your 
fi
nge r. 
4-26  
						

							c. Tigh ten  the bleed screw. 
Brake 
caliper  bleed screw 
5 Nm (0.5  m·kgf, 3.6 ft· lbf) 
d. Ins tall the  brake  pads and bra ke  pad  spring. 
TIP~~~~~~~~~~~~~~~ 
The arro w  mark a  on  the  brake  pad spring 
must  poin t in  the  directi on of disc  rotation. 
••••••••••••••••••\
•••••••••••••• 
6. Install: 
• 
Brake  pad pin 
• Brake  pad clips 
• 
Front  brake calipe r 
Front  brake caliper bolt 
35 Nm  (3.5 m ·k.gf, 25 ft·lbf) 
FRONT BRAKE 
8.  Check : 
• Br

ake 
lever operat ion 
Soft or spongy fee ling --? Bleed the  brake  sys­
tem. 
Ref e r  to BLEED ING THE HYDRAULIC 
BRAKE SYSTEM  on pag e 3-13. 
 REMOVING THE FRONT BRAKE CALIPERS 
The following procedure applies to  both of th e 
b rake 
calipers. 
TIP~~~~~~~~~~~~~~­
B efo re  re mov ing  the  b rake caliper , drain  the 
b ra ke 
flu id fr om  the entire b ra ke  sys tem. 
1.  Remove: 
• Br

ake hose  union 
bol

ts 1 
• 
Br

ake hose  gaskets 
2 
• 
Brake  hoses 3 
TIP~~~~~~~~~~~~~~-
Put  the end of the brake  hose  into a container 
a nd  pump  out the  brake 
fluid carefully . 
7. 
Check: 1 ~Wr-~-rn 
• Brake flu id  leve l 
Be l
ow the  minimum level mark  a --? Add  the 
specified  brake 
flu id to  the  prope r level. 
Refer to CHECKING THE  BRAKE FLUID 
LEVEL  on  page  3-11.  
DISASSEMBLING 
THE FRONT BRAKE 
CALIPERS 
The follo wing procedure app lies to both  o f the 
b rake 
calipers. 
1. Remove: 
• Br

ake 
ca liper p is tons  1 
• 
Br

ake 
ca liper p is ton  dust sea ls  2 
• 
Br

ake 
ca liper p is ton sea ls  3  
4-27  
						

							••••••••••••••••••\
•••••••••••••• 
a. Sec ure  the  right  side  brake caliper pistons 
w i
th a p iece  of wo od a. 
b. B low compressed  air  into the  brake  hose joint 
ope nin g 
b to force  out  the left side  pistons 
from 
the  brake 
cal iper. 
EWA IRC1401 
AwARNING 
• Never try to pry out the brake caliper pis­
tons. 
• Do not loosen the bolts  4. 
4 
b 
c .  Remove the  brake c a li per p iston  dust sea ls 
and  brake caliper pis ton sea ls. 
d. Repeat  the previous  steps to force out the 
right side  pis to ns  from t h e  brake ca liper. 
EASZ!391 
CHECKING THE FRONT B RAKE CALIPER S 
The following procedure applies to both of  the 
brake 
calipers. 
FRONT BRAKE 
Recommended  brake component 
replacement schedule 
Brake pads If necessary 
P is ton 
seals Every  two years 
P is ton  dus t 
seals Eve ry  two  years 
Brake  hoses  Every four years 
Bra ke 
fluid 
Every  two years  and 
w heneve r the  brake 
i s 
disassemb led 
1.  Check : 
•Brake  caliper p is to ns 1 
Rust/scra tc h es/wea r 4 Rep lace t he  brake 
cal iper pisto ns. 
• Brake cal iper  cylinde rs  2  
Sc ratc hes/wear 4 Rep lace t he  bra ke calipe r 
assemb ly . 
• 
Brake cal iper body 3 
Cracks/damage 4 Rep lace the  brake cal iper 
assemb ly . 
• 
Brake fluid  delivery passages 
(bra ke 
cal iper body) 
Obstr uc
tion 4 B low o ut wit h compressed  air. 
EWA13611 
AwARNING 
Whenever a brake caliper is d is ass embled , 
replace 
the  brake caliper piston dus t seal s 
and brake cal iper piston se als . 
3 
l!ASZZ< 
ASSEMBLING THE FRONT BRAKE 
CALIPERS 
AwARNING 
• Before installation , all  in ternal brake  com­
ponents 
s hould be cleaned and lu bricated 
with clean or n ew  brake fluid. 
• 
Never  use solvent s on internal brake  com­
pon ents  as 
they will caus e the brake calip er 
pi ston dust se als and  brake caliper piston 
seals to swell and  distort. 
• Whenever  a brake caliper is disa ss embled , 
4-28  
						

							replace the  brake caliper piston dust seal s 
and brake caliper piston s eals . 
Specifi ed  brake fluid 
DOT4 
INSTALLING THE FRONT BRAKE CALIPER S 
The following procedure applies to both  of  the 
brake 
calipers. 
1 

. 
Install: 
• 
Front  brake caliper 1 
(tempora ril
y) 
• Brake  hose gaskets l~IS 
• Brake  hose 2 
• 
Brake  hose unio n bo lt 3 
Brake  hose uni
on bolt 
30 Nm (3.0 m -k,gf, 22 ft·lbf) 
AwARNING 
Prope r brake  hose  rou ting Is essential to In­
sure safe vehicle operation . Refer  to CABLE 
ROUTING  
on page 2-41. 
N O TICE ~~~~~~~~~~~~~ 
• When installing the  brake hose onto the 
brake 
caliper  1 , make  sure the brake  pipe 
a touches  the projection b  on the  brake 
caliper. 
•  Install 
the  brake pipe c  so that it is 
aligned with the brake pipe a . 
1 
2 .  Remove: 
• Front b ra ke c a lipe r 
3. Inst all: 
•
Brak e pads 
• Brake  pad spring 
• Brake  pad pin 
• Brake  pad clips 
• 
Fron t b ra ke cal ipe r 
FRONT BRAKE 
Front  brake caliper bolt 
35 Nm (3.5 m·kgf, 25 ft-lbf) 
Refer to R EPLACING THE FRONT BRAKE 
PADS on page  4-26. 
4. 
Fill: 
• 
Brake  master  cylinder  reservo ir 
(w i
th th e  specified amo unt  of  the  specified 
brake fluid) 
EWA13000 
Spec if ied  brake fluid 
DOT4 
AwARNING 
•  U se only the  designated  brake flui d. Other 
brake fluids may  cause  the rubber seal s to 
dete riorate , cau sing leakage and poor 
brake  performance . 
• Refill w it h  the  same  type of brake fluid that 
is 
already in the system.  Mixing  brake fluids 
may res ult in a harmful  chemical reaction , 
leading to poor brake performance . 
• When refilling, be careful that water  does 
not enter the brake fluid re servoir.  Water 
will significantly lower the boiling point of 
the  brake fluid and could caus e vapor lock. 
ECA1l540 
NOTICE 
Brake fluid may damage  painted surfaces 
and 
plast ic parts.  Therefore, always  clean up 
any 
spilt brake fluid immed iately . 
5 . 
Bleed: 
• Brak e system 
Refe r to BLEEDING THE HYDRAULI C 
BRAKE SYSTEM on pa ge  3-13. 
6. Check : 
• Brake fluid  level 
Be low 
the  m inim um le vel mark  a  --+ A dd  the 
s p ec i
fied bra ke flu id to  the prope r level. 
Refe r  t o CHECKING THE  BRAK E FLUID 
LEVE L on p age  3-11 . 
4-29  
						

							7. Check: 
• Brake lever operat ion 
Soft or spongy fee ling -t Bleed the  brake  sys­
tem. 
Refe r 
t o 
BLEED ING THE HYDRAULIC 
BRAKE SYSTEM  on page  3-13. 
REMOVING THE  FRONT  BRAKE MASTER 
CYLINDER 
TIP~~~~~~~~~~~~~~­
Bef ore removing  the front b rake  master cylinder , 
dra in  the  brake fluid from  the entire brake  sys­
tem. 
1.  Disconnect: 
• Brake light switch  connectors 
(from  the fron t b rake 
lig ht switc h) 
2.  Remove: 
• Brake  hose union bolt 1 
• Brake  hose gaskets 2 
• 
Brake  hose 3 
TIP~~~~~~~~~~~~~~-
To collect any remain ing brake fluid,  place a 
conta iner  under  the master 
cylinder and  the end 
of th e  brake  hose. 
EAS?l:m 
CHECKING THE FRONT  BRAKE MASTER 
CYLINDER 
1.  Check: 
• Brake  maste r cylin de r 
Damage/sc ratc hes/wear -t Replace. 
• 
Brake flu id delivery passages 
(brake  master 
cylinder body) 
FRONT BRAKE 
Obstruct ion -t B low o ut  wit h comp ressed  air. 
2.  Check: 
• Bra ke master cylinder k it 
Damage/scratc hes/wea r 
-t Replace. 
3. Check: 
• Brake  master cylin de r reservoi r 1 
• 
Brake  master cylin de r reservo ir  diaphragm 
holde r 2 
Cracks/damage -t Replace . 
• 
Brake  master cylin de r reservo ir  diaphragm 
 3 
Damage/wear -t Replace. 
4.  Check: 
• Brake  hoses 
Cracks/damage /wear 
-t Replace. 
....,,.,. 
ASSEMBLING THE  FRONT  BRAKE MASTER 
CYLINDER 
AwARNJNG 
• Before  installation , all internal brake com­
ponents 
should be cleaned and  lubricated 
with clean or new brake fluid. 
• 
Never  use solvents on Internal brake com­
ponents. 
 
Specified  brake fluid 
DOT4 
INSTALLING THE FRONT  BRAKE MASTER 
CYLINDER 
1. Install: 
• 
Front  brake  master cylinder 
• 
Front  brake  master cylinder holder 
Front  brake master cylinder holder 
bolt 
10 Nm (1.0 m·kgf, 7.2 ft·lbf) 
TIP~~~~~~~~~~~~~~~ 
• Ins tall the  front  b rake  master cylin de r ho lde r 
wi

t h  the 
U P mar1< a  facing  up. 
• Align the  en d  of the  front brake  master cylinde r 
4-30