Yamaha Fz 09 2014 Manual

							EA$1AC1412 
REMOVING THE FRONT  FORK LEGS 
The following procedure applies to  both  of the 
front fo rk legs. 
TIP~~~~~~~~~~~~~~~ 
Each  front fork leg i s  eq u ipp ed  w ith  a spring pre · 
l oad 
adj ust ing bolt, the  rig ht  fork leg i s  eq u ipp ed 
with  a reboun d da mp in g  force  adjusting screw 
a
nd compress ion  damping  force adjusting 
screw . Pay  attent ion  not  to mistake  the 
right and 
left. 
1. Stand the vehicle on  a leve l surface . 
EWAUl120 
AwARNING 
Securely support the vehicle so that there is 
no danger of it falling over. 
TIP~~~~~~~~~~~~~~­
Place the veh icle on a suitable stand  so tha t the 
fro nt whee l is e levated. 
2.  Remove: 
• Front  brake caliper 
Refer  to  FRONT BRAKE  on page 4-20. 
• 
Front whee l 
Refer to FRONT  WHEEL on page 4-8. 
3. Loose n: 
• Upper bracket  pin ch bol t 1 
• 
Cap 

bol t 2 
• 
Lower  brack et 

pin ch 
bo lts  3  
EWAl$$40 
AwARNING 
Before loosening the upper and lower brack· 
et pinch bolts, support the front fork leg. 
4.  Remove : 
• Fron

t  fork 
leg 
DISASSEMBLING 
THE FRONT  FORK LEGS 
The following procedure applies to  both  of  th e 
fro nt for k 
legs . 
1. Remove: 
• Cap 

bol t 1 
(from  the damper  rod assembly) 
• 
Washer 2 
4-51 
FRONT  FORK 
• Spacer 3 
• 
Lock nu t 4  
TTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTT 
a.  Press  down on the  space r w ith  the  fork  spring 
compressor 
 5 . 
b. Install the  rod holde r 6  betwee n the lock nu t 
4 and  the spacer 3. 
Fork spring compressor 
90890-01441 
YM--01441 
Rod holder 
90890-01434 
Damper rod holder double ended 
YM-01434 
TIP~~~~~~~~~~~~~~~ 
Use the  side of  the  rod holder tha t is  marked B. 
6 
)---1 
~;?J---2 
c. Ho ld th e  cap bo lt and loose n the lock nu t. 
d.  Remove  the cap bolt and  washer. 
e. Remove  the rod holde r and  fork spring com ­
pressor. 
f.  Remove  the spacer  and 
locknut. 
• ••••••••••••••••••\
••••••••••••• 
2. Drain: 
•Fork  oil 
TIP~~~~~~~~~~~~~~­
Strok e the damper  rod assembly  1  sever al 
times whi le dra ining  the fork oil. 
3.  Remove: 
• Dust seal  1 
•  Oi l seal  clip  2  
(with  a flat- head screwdriver)  
						

							£CA1RCl41).l 
NOTICE ~~~~~~~~~~~~-
Do not scratch  the outer tube. 
4. Remove: 
•Outer tu be 
••••••••••••••••••\
•••••••••••••• 
a. Ho ld the  front  fo rk leg  hor izon tally. 
b. Secu re ly  clamp the brake ca liper b racket in a 
v i
se w ith  soft jaws. 
c .  Sepa rate the  oute r tube  from th e 
inner tub e 
by 
p ullin g th e outer  tube forcefully but ca reful­
ly. 
NOTIC•E~-----------­
Excessive  force will damage the bushings. 
Damaged 
bushings must be replaced. 
,. . 
••••••••••••••••••\
•••••••••••••• 
5 .  Remove : 
• Damper rod assembly bolt 
• 
Damper rod assembly 
NOTICE ~~~~~~~~~~~~-
For  the damper rod assembly, the right side 
is used for the rebound  operation . Pay  atten­
tion not to mistake  the right and left. 
TIP------------­
While ho ld in g the  damper  rod  with  the  damper 
ro d 
ho lde r 1,  loosen the  damper rod assemb ly 
bol
t. 
1 
FRONT  FORK 
Damper rod holder 
90890-01423 
Damping rod holder 
VM-01423 
CHECKING 
THE FRONT  FORK LEGS 
The follo wing procedure app lies to both  o f the 
fr ont  fo rk 
legs . 
1. Check: 
•Inner tube  1  
•  Outer tube 2 
Bends /damage /sc ratches ~ Replace . 
EWA13650 
AwARNJNG 
Do not attempt to straighten  a bent inner 
tube as this may dangerously weaken It. 
1 
• • 
(® ) ) )  ) )]) 
 
2 
2. Measu re: 
• Spring  free length  a  
Out of spec if ication ~ Replace . 
Fork spring free length 
300 .3 
mm (11.82 In) 
Limit 
294.3 mm (11.59  in) 
4-52  
						

							3. Check: 
• Dampe r r od 1 
Damage/wear~ Replace. 
Obs tructio n 
~ Blow o ut all o f  the oil passag ­
es  with  com press ed  ai
r. 
£CA1RCl40S 
NOTICE ~~~~~~~~~~~~~ 
• The front fork leg has a very sophisticated 
Internal construction, which are  particular­
ly sensitive to foreign material. 
• When disassembling and assembling the 
front fork leg, do not allow any foreign ma­
terial to enter the front fork. 
1 
I 
8) · I ~l==::::::l[]J~=====·"""" · 
EAS1RClt14 
ASSEMBLING THE FRONT  FORK LEGS 
The follo win g pro ce du re applie s to  both  of the 
f ron t 
f ork 
le gs. 
EWA IRC104 
AwARNING 
• Note that the amount of the fork oil is differ­
ent in the left and right front fork legs. Make 
sure to fill each of the left and right front 
fork legs with the specified amount of the 
fork oil. 
• If both front fork legs are not filled with the 
specified amount of the fork oil, it may 
cause poor handling and a loss of stability. 
TIP~~~~~~~~~~~~~~~ 
• W he n asse mblin g the  front  fo rk le g , be  su re  to 
rep lace the fo llow in g pa rts: 
- Oil  seal 
- Oil  seal clip 
-Dust seal 
FRONT  FORK 
-Copper  washer 
-0-ring 
• B efore  asse mbling  the front  for k leg , ma ke 
su
re all of t h e  compon ents are cl ean . 
1. Install: 
• 
D am per  rod assem bly 1 
NOTICE ~~~~~~~~~~~~~ 
Allow the damper rod assembly to sllde 
slowly down the Inner tube  2  until It pro­
trudes from the bottom of the inner tube.  Be 
careful not to damage the inner tube. 
TIP~~~~~~~~~~~~~~~ 
The left side  dampe r  rod assembly has th e  two 
holes of oil p ath, unlike the right  side. 
1 
A. Left  side 
B. R igh t sid e 
2. Tigh te n : 
• Dampe r 

r
od assembly  bol t 
(a long 
w ith  the copper  washer IUM ) 
Damper rod assembly bolt 
23 Nm (2.3 m·kgf, 17 ft·lbf) 
LOCTITE® 
TIP~~~~~~~~~~~~~~~ 
Wh ile holdi ng th e da mp er  rod assem bly with the 
dampe r rod 
holder 1 , tig hte n the  damper  rod 
assembly  bo lt. 
Damper rod holder 
90890-01423 
Damping rod holder 
YM-01423 
4-53  
						

							3. Lubr icate: 
•  Inner tubes  outer  surface 
Recommended oil 
1-mtl Suspension oil 01 
4. Install: 
• Dust sea l 1  l@IMJ 
• Oil seal clip  2  lf@i 
• Oil seal 3 lt@ii 
• Washer 4 
•  Outer tube bush ing 5 IUM 
• Inner tube bushing 6 l@@ii 
ECA1AC \411 
NOTICE ~~~~~~~~~~~~ 
Make sure the numbered side of the oil seal 
faces b ottom side. 
TIP~~~~~~~~~~~~~~~ 
• Befo re in stalling the oil seal,  lubrica te its lips 
w ith  li thium-soap-based  grease. 
• Lubricate  the outer  surface of the inner tube 
w ith  fork 
o il. 
• Before  installing  the oil  seal , cover  the top  of 
the  front  fork 
leg w ith a plast ic bag  to protect 
the 
oil  sea l during  installatio n. 
FRONT  FORK 
5. Install: 
• Outer 
tube 
(to  the 
inner tube) 
6. Install: 
•  Outer 
tu be  bushing 1 
• Washer 2 
(wi th  the  fork seal driver 3) 
7. Install: 
Fork seal driver 
90890-01442 
Adjustable fork sea l driver (36-46 
mm) 
VM-01442 
• 
Oil  seal 1 
(with the  fork seal driver 2 ) 
Fork seal driver 
90890-01442 
Adjustable fork sea l driver (36-46 
mm) 
VM-01442 
2 
I:>, 
						

							8. Install: 
•  O
il sea l c lip  1 
TIP~~~~~~~~~~~~~~­
Adjust  the oil seal  clip so that it  fits into  the oute r 
tubes  groove. 
I 
~~ 
 
9. Install: 
• 
D ust sea l 1 
(w ith  the fork sea l driver  2) 
1 O.lnstall: 
Fork seal drive r 
90890-01442 
Adjustable 
fork seal driver (36-46 
mm) 
YM-01442 
• Rod p uller  1 
• Rod  puller 
attachment  (M10) 2 
(on to  the  damper  rod 3) 
Rod 
puller 
90890-01437 
Universal 
damping rod bleeding 
tool set 
YM-A8703 
Rod 
puller attachment (M10) 
90890-01436 
Universal 
damping rod bleeding 
tool set 
YM-A8703 
FRONT  FORK 
11.Fill: 
• 
Fro nt fork leg 
(w ith  th e  specified  amo un t  of  the recom ­
mended  fork oil) 
NOTICE 
R ecomme nded oil 
Suspension oil 01 
Quantity (left) 
472.0 
cm3 (15.96 US oz , 16.65 
Imp.oz) 
Quantity (right) 
458.0 cm3 (15.48 US oz , 16.15 
Imp.oz) 
• 
Be sure to use the recommend ed fork oil. 
Other 
oils may  have  an adverse  effect on 
front fork performance. 
• When disassembling and assembling the 
front fork leg, do not allow any foreign  ma­
terial to enter the front fork. 
1 2.After 
filling th e fron t fork leg , s low ly str oke  the 
damper  rod 
 1 u p  and  down  (at least ten 
tim
es)  to  distribute  the fork oil . 
TIP~~~~~~~~~~~~~~~ 
B e  s ure to stroke  the  damper  rod slowly  be ­
cause  the fork oil may  spurt  out. 
t 
13.Before  measuring  the  fork oil leve l, wa it  ten 
m inutes 
unti l the oil has settled and  the  air 
bubbles have  dispersed. 
TIP~~~~~~~~~~~~~~~ 
Be s ure to b lee d th e  fron t fork le g of  any res idua l 
4-55  
						

							air. 
1 4 .M eas ur
e: 
• Fron t fo rk leg  oil level  a 
(from  the top of the  outer  tube,  wit h 

t
he outer 
tube 
f u lly compressed  and witho ut  the  fo rk 
sp
ring) 
Ou t of spe cifica tion -> Correct. 
15.lnstall:  Level 
(left) 
147 mm (5.8 In) 
Level (right) 
148 mm (5.8 in) 
• Fork  spring (Left  side)  1  
• 
Spacer  (Left side)  2  
• 
Loc kn u t  (Left  side) 3 
• 
Washer  (L eft  side) 4 
• 
Cap 

bol t 
(Lef t side)  5  
a 
(alo ng wi th  the 0-rin g 111~1'1![§111& ∀i) 
2 
4 
5 3~~ 
, 
YYTTTYTTTYYTTTYTTTYYTTYYTTTYTTTY 
a.  Remove  the rod puller an d rod puller  attach· 
ment. 
b. Install the for k spring. 
TIP--------------­
lnst all the  fork spr i n g  with  th e sm alle r diam ete r 
a  fa cing up A. 
FRONT  FORK 
---A ----~ -----1 ----  - ----- ·- ,_,_ -~ 
-
J a 
- --
						

							j. Install the  washer  and cap bolt, and  then fin ­
ger  tighten  t
he cap bolt. 
EWAl$$70 
AwARNING 
Always use a new cap bolt 0-rlng. 
k. Hold the  cap bo lt  5 and  tighten  the locknut 
3 
to  spec ific ation. 
Locknut 
15 Nm (1.5 m·kgf, 11 ft·lbf) 
I. Remove  the rod holder and fork  spring com­
pressor. 
••••••••••••••••••\
•••••••••••••• 
16.lns tall: 
• 
Fork  spring  (R ight side)  1  
• 
Spacer  (R ight  side)  2  
• 
Locknut  (Right side) 3  
• 
Damper  adjusting  rod 4 
• 
Washer  (Right  side) 5  
•  Cap 

bol t 
(Right  side) 6 
(alo ng 
wit h the  0-ring IH¥j) 
5 
6 3~~ 
, 
1 
••••••••••••••••••\
•••••••••••••• 
a.  Remove  th e  rod pulle r and  rod puller attach-
ment. 
b. 
Install the  fork  spring . 
TIP---------------
lnstall the fork  spring with  the smaller diameter 
a f acing  up A. 
FRONT  FORK 
---A ----~ -----1 ----- -----·- ,_,_ -~ 
-
Ja 
- --
						

							j. Posi tion  the lockn ut 3 as  spec ified b. 
Distance  b  
12 mm (0.47  In) 
3 
k. Set the cap bolt distance  c  to  spec if icatio n. 
Distance 
c 
13 mm ( 0. 51 in) 
c 
-
I.  Install the  damper  adjusting rod, washer  and 
cap 
bo lt, and  then  finge r tighten  the cap bolt. 
EWAt3610 
AwARNING 
Always use a new  cap bolt 0-ring. 
m. Ho ld the  cap bolt  5 and  tighten  the lockn ut 
3 to  specification. 
Locknut 
15  Nm (1.5 m ·k,gf, 11 ft·lbf) 
n.  Remove  the rod h older and  fo rk spring com ­
presso r. 
FRONT  FORK 
• ••••••••••••••••••\
••••••••••••• 
17.lnstall: 
• Cap  bolt 
(to  the  outer tube) 
TIP~~~~~~~~~~~~~~-
• Temporarily ti gh te n  the  ca p bolt. 
• W hen  to  tig hte n  th e  cap bol t to  the  spec ified 
torqu e is  afte r 
installing the  front f ork leg to  th e 
veh ic le a nd  tig htening  the lowe r bracket  pinch 
bo lts. 
 INSTALLING THE FRONT  FORK LEGS 
The follo wing procedure applies to  both  of the 
front  fo rk 
legs . 
1. Install: 
• 
Fro nt fork leg 
Temporar ily 
tig hten  the upper  and lower 
bracket  pinch bolts. 
TIP~~~~~~~~~~~~~~~ 
Ma ke  sure  the outer  tube  is flu sh w it h  the  top of 
th e 
upp er b rac ke t. 
2 . T ighte n: 
• Lower bracket  pinch bo lts 1 
Lower bracket pinch bolt 
23 Nm (2.3 m·kgf, 17 ft·lbf) 
• 
Cap bolt  2  
Cap bolt 
23 Nm (2.3 m·kgf , 17 ft·lbf) 
•  Upper 
bracket  pinch bo lt  3 
Upper 
bracke t pinch bolt 
26 Nm (2.6 m·kgf, 19 ft·lbf) 
AwARNING 
Make  sure the brake hoses are  routed prop­
erly. 
4-58  
						

							,..,,.., 
STEERING HEAD 
Removing the lower bracket 
110Nm(11 m·kgf,80ft ·lbf) 
~ 7  Nm (0.7 m • kgf, 5.1 ft· lbf} 
10 
g 
~ 7 Nm (0.7 m • kgf, 5 .1 ft· lbf) 
FWD 
Order Job/Parts to remove 
F u el tank 
Air 
fi lter case 
Headlight assemb ly 
Me ter asse mbly 
H a
ndle bar 
Front  fork legs 
1  Pro
tecto r 
2 Rivet 
3 Coupl er cover assemb ly 
4 Clamp 
5 Main  switch cou pler 
6 Wi re harness clamp 
7  Horn lead conne ctor 
8 Horn 
9 Front  brake  hose 
10  Headlight stay 
11 Horn  bracket 
0 0 
4-59 
STEERING HEAD 
1--~1 
1st 52 Nm  (5.2  m • kgf, 38 ft · lbf) 
2nd 18 Nm  (1.8  m • kgf, 13 ft · lbf) 
Qty Remarks 
Refe r  to  F UE L TANK on page  7 -1. 
Refer  to  G ENE RAL 
CHASS IS on  page 
4 -1. 
Refer  to  GENERA L 
CHASSIS on page 
4-1. 
Refe r 

l o  GE NERAL 
CHA SSIS  on page 
4 -1 . 
Refer  to 
HA ND LEBA R on  page  4-44 . 
Refer  to 
 FRON T FORK  on page 4-48 . 
1 
1 
1 
1 
2 Disconnect. 
1  Disconnect. 
2 D isconnect. 
1 
1 
1  1  
						

							Removing the lower bracket 
110Nm(11 m·kgf,80ft ·lb 
7 Nm (0 .7 m • kgf,  5 .1 ft -lbf) 
7  Nm (0.7 m • kgf, 5.1 fl ·lbf) 
Order  Job/Parts to remove 
1 2  L ower b rac k
et ca p 
1 3  S teerin g  ste m  nut 
1 4 
U ppe r brac ke t 
1 5  Lock  was her 
1 6 
U ppe r rin g  nu t 
1 7  R
ubber  washe r 
1 8  Lower ri
ng nut 
1 9  Lower bra ck
et 
20 B earing cov er 
2 1  Low er  bearin g dust 
seal 
22 U pper bearing 
23  Low er  bearin g 
4-60 
STEERING HEAD 
1st 52  Nm  (5.2 m • kgf,  38 ft • lbf) 
2nd  18 Nm (1.8 m . kgf, 13 ft -lbf) 
21 
Qty Remarks 
1 
1 
1 
1 
1 
1 
1 
1 
1 
1 
1 
1