Yamaha Fz 09 2014 Manual

							EA$2:)110 
REMOVING THE LOWER BRACKET 
1. Stand the ve hicle on  a leve l su rface. 
EWAt3120 
AwARNING 
Securely support the vehicle so that there is 
no danger of it falling over. 
2. Remove: 
•  U pp er ring nu t 
• Rubber was he r 
• Lowe r ring nu t 1 
• 
Lowe r 

b ra cke t 
EWAl31)) 
AwARNING 
Securely support the lower bracket so that 
there is no danger of it falling. 
TIP~~~~~~~~~~~~~~ 
•  Hold the lower ring nut with  steering  nu t 
wrench,  and then remove  th e  upper  ring nu t 
w ith  the 
ring  nu t wrench. 
• Remove  the lower ring nut wi th  the steeri ng nu t 
wrench 
2. 
Ring nut wrench 
90890-01268 
Spanner wrench 
YU-0 1268 
Steering nut wrench 
90890-0140 3 
Exhaust flange nut wrench 
YU-A9472 
CHECKING THE STEERING HEAD 
1.  Wash : 
•Bearings 
• 
Beari ng  races 
• 
2.  Check: 
Recommended cleaning solvent 
Kerosene 
• Bearings 1  
• 
Bearin g races 2 
4-61 
STEERING HEAD 
Dam age/pitt ing ~ Replace th e  bearings and 
bea ring  races as  a set. 
2 --@) 
1~ 
2-
3. Rep lace: 
• Bear i
ngs 
® 
tg;J 2 
®SS!> 1 
E j -2 
• Bearing races 
TTYTTTYYTTTYTTTYYTTTYTTTYTTTYYTT 
a.  Remove  the bearing  rac es  from  the steering 
head  pipe 1 with a lo ng ro d 2 and hamme r. 
b.  Remove  the bear i
ng race 3 from  the lowe r 
bracket  with  a floor  ch isel 4 and  hammer. 
c. 
Install a  new dust sea l and new beari ng rac­
es. 
ECA.14:270 
NOTICE 
If the bearing race is not installed properly, 
the steering head pipe could be damaged. 
TIP~~~~~~~~~~~~~~~ 
•  Always  replace the  bear in gs  and  bearing race s 
as a  se t. 
• Wheneve r 

t
he steering  head  is disassemb led, 
rep lace the d ust seal. 
1 
3  
						

							••••••••••••••••••\
•••••••••••••• 
4. Check: 
• Upper  bracke t 
• Lower bracke t 
(along with  the steering  stem) 
Bends/crac ks/damage 
--+ Replace. 
INSTALLING 
THE STEERING HEAD 
1.  Lubr icate: 
• U pp er 

b ea
ring 
• Lowe r 

b ea
ring 
Recommended 
lubrican t 
I-mt• Lithium-soap-based  grease 
2. 
Install: 
• Lower 
ring  nut 1 
• 
Rubber  washer 2  
• 
Upper  r

i ng  nut 
3 
• 
Lock  washer 4  
Refer  to CHECKING AND ADJUSTING 
THE STEERING  HEAD on page  3-18. 
4 
2 
3. Install: 
• 
Upper  bracket 
• Stee ring  stem  nut 
TIP~~~~~~~~~~~~~~­
Temporarily tighte n the  steering stem  nut. 
4. 
Install: 
• 
Fron t fork legs 
Refe r to  FRONT  FORK on page  4-48. 
TIP~~~~~~~~~~~~~~-
Temporarily tig hten  the  upper  and lower bracket 
p
inc h bo lts. 
5.  Tig hten: 
• Steering  stem  nut 
Steering  stem 
nut 
11 O Nm (11 m·kgf,  80 ft·lbf) 
4-62 
STEERING HEAD  
						

							REAR SHOCK ABSORBER  ASSEMBLY 
EASZ)l(IO 
REAR SHOCK ABSORBER  ASSEMBLY 
Removing the rear shock absorber  assembly 
~ 61 Nm (6.1 m • kgf,  44 ft · lbf) \ 44 Nm (4.4  m . kgf, 32 ft · lbf) 
44 Nm (4.4  m · kgf, 32 ft· lbf) 
55 Nm (5.5 m. kgf, 40 ft · lbf) 
Order Job/Parts to remove Qty Remarks 
Ride r sea t  Refer 
to  G ENE RAL CHASsrs · on page 
4·1. 
Air scoop/F u el  tank  cove r  Refer 
to  G ENERAL CHASS IS  on pa ge 
4-1. 
F u el ta nk Refer  to  FUEL  TANK · on  page  7 -1. 
Muffle r asse mbly Refe r  t o ENG IN E  REMOV AL on page 5 ·3 . 
1  Connecting  arm lowe r nu Vbolt 1/ 1 
2 Re lay arm n uV colla r/bolt 111/1 
3  Rear 
sh oc k absorbe r assemb ly uppe r 
nuVwas her
/bolt 1/1/1 
4 Rear sh oc k absorbe r assembly  lowe r 
nuVwas her/bolt 1/211 
5 Re ar sh oc k absorber assemb ly 1 
6 Connect ing  arm  uppe r nuVbo lt 1/1 
7  Connecting  arm 
2 
8 Rel ay a rm 
1 
9 Collar/oi l se al/b earing  1/2/2 
1 0  Collar/ oil sea l/bearing 2/4 /2 
4-63  
						

							REAR SHOCK ABSORBER  ASSEMBLY 
HANDLING THE REAR SHOCK  ABSORBER 
EWAl37.CO 
A WARNING 
This rear shock absorber  contains highly 
compressed  nitrogen gas. Before handling 
the rear shock absorber,  read and make  sure 
you understand the following information. 
The  manufacturer  cannot be 
held responsi­
ble for property  damage or personal Injury 
that may result from Improper handling of 
the rear shock absorber. 
• Do not tamper or attempt  to open  the rear 
shock absorber. 
• Do not subject the rear shock absorber to 
an open flame or any other  source  of high 
heat.  High heat can cause  an 
explosion due 
to excessive gas pressure. 
• Do not deform or damage  the rear shock 
absorber in any  way.  Rear shock absorber 
damage 
will result in poor damping  perfor­
mance. 
EAs::-3190 
DISPOSING  OF A REAR SHOCK  ABSORBER 
1. Gas press ure  must  be released befor e dis­
po sin g  of  a re a r  sho ck  absor be r.  To  release 
the  gas  pressu re , 
drill a 2- 3 m m (0.08 -0.12 
in) h ole thro ugh  the  rear shock  absorber  at  a 
p o
int 20-25 mm (0. 79--0.98 in )  from  its end 
as show n. 
AwARNING 
Wear eye  protection to prevent eye damage 
from released gas or metal chips. 
EAS23210 
20-25 mm 
(0.79-0 .98 in) 
I Q) 
REMOVING THE REAR SHOCK  ABSORBER 
ASSEMBLY 
1. Stan d the vehicle on a leve l su rface . 
AwARNING 
Securely support the vehicle so that there is 
no danger of it falling over. 
TIP~~~~~~~~~~~~~~­
Pla ce the  vehic le on a suitab le  stan d so  that  th e 
r ear 
wheel is  elevated. 
2. Remove: 
• C onn ectin g arm lowe r nu t 1 
• 
Con nectin g 

a
rm lo we r bo lt 
•  Relay 
arm nut 2  
•  Relay arm bolt 
TIP~~~~~~~~~~~~~~­
W hen removing  the bolt, hold t he  swingarm so 
t ha t it  does  not drop  dow n. 
1 
3.  Remove: 
• Rear shock  absorber  assemb ly  upper  nu t 
• Rear  shock  absorber  assemb ly  upper bolt 
• 
Rear  shock  absorber  assemb ly 
TIP~~~~~~~~~~~~~~~ 
R em ove  th e  rea r sho ck  absor be r asse mbly  from 
betwee n the  swinga
rm and frame. 
l!ASZ>200 
CHECKING THE  REAR SHOCK  ABSORBER 
ASSEMBLY 
1 . Check: 
• Rear  shock  absorber  rod 
Be nds/damage 
~ Rep lace  the rear shoc k 
absorber  assembly. 
• Rear  shock  absorber 
Gas 
l ea ks/oil  leaks ~ Rep lace the  rear  shoc k 
absorber  assembl
y. 
•Spring 
• Bushings 
Dam ag e/wear ~ Replace  the  rea r shock ab­
sor be r ass em bly. 
•Bolts 
Ben ds/da mage/w ea r ~ Replace. 
 CHECKING THE CONNECTING ARM  AND 
RELAY  ARM 
1. Check: 
• Connecting  arms 1 
•  Relay arm  2  
Damage/wea r ~ Replace. 
4-64  
						

							REAR SHOCK ABSORBER  ASSEMBLY 
1 
2. Check: 
•Bearings 
• Oi l seals 
Damage/p itting 4 Replace. 
3. Check: 
•Collars 
Damage/sc ratches -> Replace. 
INSTALLING THE RELAY ARM 
1. Lubricate: 
• Collars 
• Oi l seals 
• 
2. Install: 
Recommended lub ricant 
Lithium-soap-based  grease 
• Bearings 1  
(to  the relay arm) 
• Oil seals 2 l@IMi 
(to  the relay arm) 
Installed depth a 
6.0 mm (0 .24 In) 
Installed 
depth  b  
7.0 mm (0.28 in) 
Installed depth c 
1.5-2.5 mm (0.06-0.10 in) 
Installed depth d 
0.5-1.5 mm (0 .02 -0.06 In) 
TIP--------------
• When installing the oi l sea ls  2 to  the relay 
arm , face  the character  stamp of the oil seals 
outside. 
• When  install ing  the  connecting  arms 4 to the 
relay arm,  face  the 1 RC mark of the connecting 
arms  outs ide. 
3. Relay a rm 
d-----d 
b-+-i.-
4 . Connecting  arm 
5. Rear  shock  absorber assemb ly 
A. Left  side 
B. R ight  side 
......,,, 
INSTALLING THE REAR SHOCK 
ABSORBER  ASSEMBL V 
1. Inst all: 
• 
Rear  shock  absorbe r assembly 
5 
• Rear  shock  absorbe r assembly upper bolt 
• 
Rear  shock  absorbe r assembly upper nut 
•  Relay arm bolt 
•  Relay 
arm  nut 
• Con necting  arm lowe r bolt 
• 
Connecting  arm lower n u t 
TIP--------------
•  Install the  rear  shock  absorber assembly upper 
bolt, relay arm bolt and  connect ing  arm lower 
bol t from the left. 
• 
When installing  the rea r shock  absorbe r as ­
semb ly,  lift up  the swingarm. 
• Install the rear  shock  absorber assemb ly w ith 
t
he rebo und  dampi ng adjus ti n g  screw  facing 
t
he left s ide of the vehicle. 
2 .  Tighten: 
• Rear  shock  absorbe r assembly upper nut 
•  Relay arm  nut 
• Con necting  arm lower n u t 
4-65  
						

							REAR SHOCK ABSORBER  ASSEMBLY 
Rear shock absorber assembly 
upper nut 
44 Nm  (4.4 m·kgf, 32 ft· lbf) 
Relay 
arm nut 
61 Nm (6.1 m ·kgf, 44 ft· lbf) 
Connecting  arm lower nut 
55 Nm  (5.5 m·kgf,  40 ft·lbf) 
4-66  
						

							SWINGARM 
EASZ)S30 
SWINGARM 
Removing the swingarm 
1 1 0 Nm (11 m . kgf, 80 ft -lbf) 
3 
-
4 
7 Nm (0.7 m • kgf, 5 .1 f t •  lbl) 
Orde r  Job/Part s to remove Q ty Remarks 
Rear  brake cal ipe r Refe r  t o RE .AR  BRAKE  on page 4·32. 
Rear w heel Refe r 

t o 
 REAR  WHEEL: on  page 4·14 . 
Muffle r asse mbly 
Refer  to EN G IN E  REMOVAL: on page 5·3 . 
Chai n  Refer to CHAIN  DRIVE on page 4·70. 
, Connect ing  arm lower nut , 
2 Connect ing  arm lower bolt 1 
3 Pivo t shaft  nut 1 
4 Pivo t shaft 1 
5 Was her 
1 
6 Swingarm 
1 
7 Drive  ch ain g uard 
1 
8 Drive  ch ain g uide 
1 
9 Rear fe n de r 
1 
10 D us t cover 4 
11 Coll a r 3 
12 O il  sea l 4 
13  Bearing 4 
4-67  
						

							EASZ)~ 
REMOVING THE SWINGARM 
1. Stand the vehic le on  a leve l surface. 
EWAt3120 
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 th at  the 
rea r wheel is eleva ted . 
2.  Remove: 
• Connecting  arm lower nut 1 
• 
Connecting  arm lower bolt 
TIP~~~~~~~~~~~~~~ 
When  removing the bolt, hold the swingarm  so 
that  it  does  not drop  down. 
1 
3. Meas ure: 
• Swingarm  side play 
• 
Sw ingarm vertical movement 
YYYYYYYYYYYYYYYYYYYYYYYYYYYYYYYY 
a.  Measure  the  tightening  torque of the  pivot 
shaft  nu
t. 
Pivot  shaft nut 
11 O Nm (11 m·kgf, 80  ft·lbf) 
b. Check  the swingarm  side play A  by  moving 
the  swingarm  from side to side. 
If the  swingarm  has side-to-side p lay , check 
the  spacer , bear ings,  and dust  covers. 
c.  Check  the 
swingarm vert ical movement B 
by  moving  the swingarm up and  down . 
If the swingarm vert ical movement  is  not 
smoo th 
or if  there is b ind ing,  check  the pivot 
shaft , 
collar , bearings,  and dust  covers . 
SWINGARM 
AA ....... AAAA£AAA£AAAA£AAA£AA...._...AAAA£A 
4. Remove: 
• Drive  cha in 
Ref er  to RE MOVING THE DRIVE  CHAIN 
on page 4-71. 
• Swingarm 
....,,,., 
CHECKING THE SWINGARM 
1. Check : 
• Sw ingarm 
Bends /cracks/damage ~ R ep lace. 
2.  Check: 
• Pivo t shaft 
Roll the  pivot  shaft  on a fla t surf ace. 
Ben ds ~ Replace. 
EWA13770 
A WARN ING 
Do not attempt to straighten  a bent pivot 
shaft. 
3.  Wash: 
• Pivo t shaft 
• Dust  covers 
•Collars 
• Washer 
l 
4.  Check:  Recommended 
cleaning solvent 
Kerosene 
• Dust 
covers 1 
•  O il  sea ls  2 
Damage/wear ~ Replace. 
4-68  
						

							• Colla rs  3  
Damage /s cr atc hes 
-> Replace. 
• 
Be arin gs 4  
Damage /pittin g 4 Rep lace. 
4  2 
2  3 \~ 
\b() 
 INSTALLING THE SWINGARM 
1. Lub ricate: 
• Dust  covers 
• P ivot  sh aft 
• Oil sea ls 
• Co lla rs 
• 
2. Insta ll: 
Recommended lubrican t 
Lithium-soap-based  grease 
• Bearings 1  
(to  the swingarm) 
• Oil seals 21 l@t@i 
(to  the swingarm) 
Installed depth a  
2.0 mm (0.08 in) 
Installed depth b  
9.0 mm (0.35 in) 
Installed depth  c  
0.5-1 .5 mm (0.02-0.06 in) 
Installed depth  d  
7.0 mm (0.28 in) 
Installed depth e  
1.5-2.5 mm ( 0.06-0.1  O in) 
TIP~~~~~~~~~~~~~~ 
W hen inst alling the oil  sea ls to th e  sw in ga r m, 
f ace  the  ch a rac ter  stamp 
of th e oil sea ls o utside. 
SWINGARM 
e-.....= --e 
fl 
A.  Le ft side 
B .  Righ t side 
3. In stall: 
• 
Sw ingarm 
• Pivo t shaft 
Pivot shaft nut 
11 O Nm (11 m-kgf , 80 ft-I bf) 
4 . Inst all: 
• 
Dr ive  ch a in 
Ref e r  to  IN ST ALLI NG THE DRIVE  CHAIN 
on  pa ge 4 -7 3. 
• C on nectin g  arm lowe r bolt 
• 
C on nectin g 

a
rm l owe r nu t 
Connecting 
arm lower nut 
55 Nm (5 .5 m-kgf , 40 ft-lbf) 
•
Rear  w hee l 
Refe r  to  R EAR SHO CK  ABSORB ER AS­
SEMBLY  o n  page 4-63 a n d REAR W HEEL  
o n  page 
4-14. 
5. Adjust: 
• Dr ive  ch a in s lac k 
Refe r  t o A DJUSTING TH E DRIVE  CHAIN 
SLACK  
on  page 3-16. 
Drive  chain slack 
5.0-15.0 mm (0.20--0.59 in) 
4-69  
						

							CHAIN DRIVE 
,......., 
CHAIN DRIVE 
Removing  the drive  chain 
~ 14 Nm  (1.4  m · kgf, 10 ft· lbf) 
Order Job/Parts to remove Qty Remarks 
1 Locknut 2 
2 Shift  rod 1 
3 Shift a rm 1 
4 
Drive sprock et cove r 1 
5 Drive  ch ain  gu ide 1 
6 Drive sprock et nu t 1 
7 
Was her 1 
8 Drive sprock et 1 
9 Drive  chai n , 
4-70