Yamaha Fz 09 2014 Manual

							EA~IO 
REMOVING THE DRIVE CHAIN 
1. Stand the vehic le on  a leve l surface. 
EWAt3 120 
AwARNING 
Securely support the vehicle so that there is 
no danger of it falling over. 
TIP~~~~~~~~~~~~~~­
Place th e veh ic le on a suitable s tand  so that  the 
rea r wheel is eleva ted . 
2.  Straighten the  drive  sprocke t  nut rib a. 
a 
3. Remove : 
• Drive chain 
N O TICE 
~------------~ Be su re to put on safety goggles when work-
ing. 
TIP~~~~~~~~~~~~~~~ 
Cut th e drive chain  with  the drive chain  cut & riv­
et 
tool. 
EAS2344 1 
Drive chain cut  & rivet tool 
90890-01550 
YM-01550 
CHECKING THE DRIVE CHAIN 
1.  Measure: 
• 15 -link sectio n a of the drive chain 
Ou t of specifica tion ~ Replace th e 
chain. 
15-link l ength limit 
239. 3 mm (9. 42 In) 
drive 
TTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTT 
a. Meas ure  the length  b  betwee n the inner 
sides  of the  p
ins and  the le ngth c between 
the  ou
ter sides of the  pins on a 15-link sect ion 
of the drive chain as shown  in  th e illustr atio n. 
b. Calc u late the le ngth  a  of the 15 -li n k sect io n 
of the drive chain  using  the follow ing fo rmul a. 
Drive chain 15- li nk section length  a  = 
4-71 
CHAIN  DRIVE 
(length  b  between pin  inner  sides + length 
 c  
between p in  ou ter sides)/2 
TIP~~~~~~~~~~~~~~ 
• W hen  meas urin g a 15-link section of the  drive 
chain , make  su re  that  the drive 
chain is taut. 
• Perform this procedure 2- 3 times,  at a diff eren t 
locat ion each  time. 
1 

2  3  4 5 6 
1213141516 
--,-,  .   •  • •     
 • • 
(o 0)\0 OJ lO 0  0 0)\0 OJ r OJ 0) 
a 
1  2  3  4  5 61213141516 
  • •       •    
(o OJ\0 OJ lO 0  0 0)\0 OJ OJ 0) 
b 
c 
&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&& 
2.  Check: 
• Dr ive chain 
S tiffn ess ~ Clea n and lubricate or rep lace. 
3. Clean: 
• 
Dr ive chain 
• • 
• • 
••••••••••••••••••\
•••••••••••••• 
a.  Wip e  th e  drive chain w ith  a clean clo th. 
b.  Put the  drive chain  in  ke rosene and remove 
a ny  rema inin g dirt. 
c.  Remove  the  dri
ve chain from th e  ke rose ne 
a nd 
comple te ly dry  it.  
						

							CHAIN DRIVE 
£CA1RCl403 
NOnCE .-'G~~~3::s;:,.~....cs~~---, 
• This vehicle has a drive chain with small 
rubber 0-rlngs 1  between the drive chain 
side plates. Never use high-pressure water 
or air,  steam, gasoline, certain solvents 
(e. g.,  benzine) , or a coarse brush to clean 
the drive chain. High-pressure methods 
could force dirt or water into the drive 
chains internals, and solvents will deterio-
rate the 0-rings. A coarse brush can also 
damage the 0-rings. Therefore, use only 
kerosene to clean the drive chain. 
• Do not soak the drive chain in kerosene for 
more than ten minutes, otherwise the 
0-rings can be  damaged. 
I 
I 
-
I I 
1 
••••••••••••••••••\
•••••••••••••• 
4.  Check: 
• 0-rings 1  
Damage -+ Re place the  drive  cha in. 
• Drive chain rollers  2 
Damage/wear -+ Replace the drive  chain. 
• Drive chain s ide plates  3 
Damage/wear /c rac ks -+ Rep lace the  drive 
chain. 
L--===- L..-==-==1 
DD 
1 
5. L ub ricate: 
• Dri

ve  cha in 
Recommended lubricant 
l Chain lubricant suitable for 
0-rlng chains 
.,..,. .. 
CHECKING THE DRIVE  SPROCKET 
1. Check: 
• Dri

ve  sproc ke t 
More  than  1 
/4 toot h a wear -+ Rep lace the 
d rive  sproc k
et, the rea r wheel sproc ket and 
the  drive  cha
in as a set. 
Be nt tee th 
-+ Replace the drive  sproc ket,  the 
rea r 
whee l sprocket  and  the  drive chain  as  a 
s et. 
1 
 l  
  
2 
b. Correct 
1  .  D
rive ch ain roller 
2. Dr ive sprocket 
a 
CHECKING THE  REAR  WHEEL SPROCKET 
Refer to C HE CKIN G AND REPL ACI NG THE 
R EA R 

WHEE L 
SPR OCKET on page 4·18. 
......... 
CHECKING THE  REAR  WHEEL DRIVE HUB 
Refer  to CHEC KIN G THE  REAR  WHEEL 
DRIVE  HUB on page  4-17. 
4-72  
						

							EA$1AC1«l3 
INSTALLING THE DRIVE  CHAIN 
1. Install: 
• 
Drive chai n 
£CA1 7410 
NOTICE ~~~~~~~~~~~~~ 
Be sure to put on safety goggles when work­
ing. 
TIP~~~~~~~~~~~~~~-
lnstall the  drive chain  joint  with  the  drive  chain 
cu t 
& rivet t ool . 
Drive chain cut & rivet tool 
90890-01550 
YM-01550 
••••••••••••••••••\
•••••••••••••• 
a.  Whe n press  fitt ing the connecting plat e 1 , 
make  su re  th e  space  a between  the end of 
the  connect ing pin 
2  and  the  con necting 
pla te i s 1.2- 1.4 mm (0.05--0.06 in). 
2 
1 ----t_c:,t.,·,·:.7·1_-_-:_t:=J t====:::::;::I a 
I 
b.  After  rive ting , make  sure the diameter be­
tween  the edges b  of the  connect ing p in 2 
is 5 .5-5.8 mm (0.22-0.23 in ). 
2 
b 
c.  After rivetin g, make  sure  the space c, wh ich 
is  insi
de o f th e  connectin g link 3 and  ins ide 
of the  connect ing plat e 1 , is 14.1-14.3 mm 
(0.56-Q.65 i n ). 
3~---~ 
c 
1 
CHAIN  DRIVE 
2. Lubricate: 
• Drive cha in 
Recommended lubricant 
 
Chain lubricant suitable for 
0-ring chains 
3. Install: 
• 
D rive sprocke t 
• Washer 1  
• 
Drive sprocket  nut 2  l@@W 
Drive sprocket nut 
95 Nm (9.5 m·kgf, 69 ft-lbf) 
TIP~~~~~~~~~~~~~~-
• Whil e  applying the  rear bra ke , tig hten  the drive 
sprocket  nut. 
• Ins tall washe r 1 with the OUT mark  a  fac ­
ing out. 
• S take the  drive  sprocket nut 2 at cu tou ts b  
in  the drive axle. 
4. Install: 
•  Shift 
arm 1 
TIP~~~~~~~~~~~~~~­
B efo re installing , make sure  to align the mark a 
of th e  sh ift shaft  with  the punch  mark b  of th e 
shift a rm. 
Shift arm bolt 
14 Nm (1.4 m·kgf, 10 ft-lbf) 
5.  Adjust: 
• Drive cha in s lack 
4-73  
						

							Refer to ADJUSTING THE DRIVE CHAIN 
SLACK  
on page 3-16. 
Drive  chain slack 
5.0-15.0 mm (0 .20-0.59 In) 
N O TICE ~~~~~~~~~~~~-
A drive  chain that is too tight will overload 
the engine  and other vital parts, and one that 
is too loose can skip and damage the swing­
arm 
or cause  an accident.  There fore , keep 
the  drive  chain 
slack within the specified lim­
its. 
4-74 
CHAIN  DRIVE  
						

							ENGINE 
ENGINE INSPECTION ......................................................................... .............  5-1 
MEASURING THE COMPRESSION  PRESSURE ............ ............ ..... .... ....  5-1 
ENGINE  REMOVAL ............................................ ......................... ........ .............  5-3 
REMOVING TH E ENGINE ......... ...................... ......... ........ ........ ........ .........  5-7 
INSTALLING THE ENGINE ........ ............... ........ ........ ................. ........ .... ....  5-7 
C AMSHAFTS .............................................. ........ ......................... ........ .............  5-9 
REMOVING THE CAMSHAFTS ....... .................. ........... ............ .... ...... ..... 5-11 
CHECKING THE CAMSHAFTS ... .............. ...... ..... .... .... .............. ...... .......  5-12 
CHECKING THE TIMING  CHAIN AND CAMSHA FT SP ROC KET ...........  5-13 
CHECKING THE TIMING  CHAIN GUIDES ............... .... .... ......... .... .... .... ..  5-13 
CHECKING THE TIMING  CHAIN TENSIONER .... .... ........ .... ..... ........ .... ..  5-13 
INSTALLING THE CAMSHAFTS .............. .... .... .... .... .... ............. ........ .... ..  5-14 
C YLINDER HEAD  ........................................................................\
........ ...........  5-19 
REMOVING THE CYLINDER HEAD  .... .... .... .... .... .... ......... .... .... ........ .... ... 5 -20 
CHECKING 
THE TIMING  CHAIN GUIDE (EXHAUST  SIDE) ..... ........ .... .. 5-20 
CHECKING 
THE CYLINDER HEAD  .... .... .... .... ..... .... .... .... .... ..... ........ .... .. 5-20 
INSTALLING 
THE CYLINDER HEAD ......... .............................. ......... 5·21 
VALVES AND VALVE SPRING S ....... .... ......... .... .... .... .... ............ ..... ........ .... ..  5-22 
REMOVING THE VALVES ... .... .... .... .... .... .... ......... .... ........ ............ ..... .... ..  5-23 
CHECKING THE VALVES AND  VALVE GUIDES ..... ........ .... ..... ........ .... ..  5-23 
CHECKING THE  VALVE SEATS ................................................... 5·25 
CHECKING 
THE  VALVE SPRINGS .................................. ................ 5·26 
CHECKING 
THE  VALVE LIFTERS ....................................................  5-27 
INSTALLING THE VALVES ...... .... .... .... ..... ........ ........ ........ .... ..... ........ .... ..  5-27 
G EN E
RATO R  AND STARTER CLUTCH ................................ ................ 5·30 
REMOVING 
THE  GENERATOR ................................... .... ................ 5·32 
REMOVING 
THE STARTER  CLUTCH ....................................... ......... 5·32 
CHECKING 
THE STARTER  CLUTCH ........................... .... ................ 5·32 
INSTALLING 
THE STARTER  CLUTCH ....... ......................... ...................  5-33 
INSTALLING THE  GENERATO R .......................................... ...................  5-33 
ELECTRI C START ER  ............ .... .... .... .... .... ..... .... .... ........ ........ .... ..... ........ .... ..  5-35 
CHECKING THE STARTER  MOTOR ................................. ................ 5·37 
ASSEMBLING 
THE STARTER  MOTOR ..................................................  5-38 
INSTALLING THE STARTER  MOTOR ..................... ...............................  5-38 
CLUTCH ..... .... .... .... .... ......... .... .... .... .... .... .... ..... ........ ........ ........ .... ..... ........ .... ..  5-39 
REMOVING THE CLUTCH ...... .... .... .... ..... ........ ........ ............ ..... ........ ......  5-42 
CHECKING THE FRICT ION PLATES ................................... ...................  5-43 
CHECKING THE CLUTCH  PLATES ........................................................  5-43 
CHECKING THE CLUTCH  SPRINGS ................................... ...................  5-43  
						

							CHECKING THE CLUTCH HOUSING ....... ... ... ........... ... ... ..... ... ........... ... . 5 -44 
CHECKING THE CLUTCH  BOSS ...... .... .... ...... ...... ........... ..... ........... .......  5-44 
CHECKING THE PR ESSURE PLATE  ... .......... ... ... .. ... ... ... ..... ... ........... .... 5 -44 
CHECKING THE PR I

MARY  DRIVE 
GEAR ...... ... .... .... .... ...... .... ........ .......  5-44 
C H EC KING THE PRI MARY DRIVEN GEAR ............................................ 5-45 
CH EC KING THE PULL LEV ER  SHAFT  AND PULL ROD .............. ..........  5-45 
INSTALLING THE CLUTC H .......................................................... ...........  5-45 
SHIFT  SHAFT ..................... .... .... ............ .... ..... ........ ........ ........ ......... ........ ...... 5-48 
C H EC KING THE SHIFT  SHAFT ...... .... ..................... ........ ................. ...... 5-49 
C H EC KING THE STOPPER LEVER  .... ............. ........ ................. ........ .... .. 5-49 
INSTALLING TH E SHIFT SHA FT ............. ........ ........ ................. ........ .... .. 5-49 
OIL PUMP ................ ........... .... .... ............ .... ..... .... .... ........ ........ ......... ........ ...... 5-50 
C H EC KING THE SPROC KET AND CHAIN .............. ................. ........ .... .. 5-52 
C H EC KING THE OIL PUMP .... ........ .... ..... .... ...... ...... ......... ........ ......... .... . 5-52 
C H EC KING THE RELIEF VALVE  ........................ ................. ........ ...........  5-53 
ASSEMBLING THE OIL  PUMP .... .... .... ............. ........ ........ .... ..... ........ .... ..  5-53 
INSTALLING TH E OIL  PUMP ...... .... .... ..... ........ .... .... ......... ........ ............. . 5-53 
OIL PAN ...................................................... ........ ......................... ........ ...........  5-54 
REMOVING THE OIL  PAN ............... ........ ........ ........ .... ... ..... ....................  5-55 
CHECKING THE OIL STRAINER ..... ............ ............. ............ ..... ........ .... ..  5-55 
INSTALLING TH E OIL  PAN ..... .... ........ ..... ........ ........ .... ............. ........ .... ..  5-55 
CRANKCASE .......... ........... .... .... ............ .... ..... ........ ........ ........ ......... ........ ...... 5-56 
DISASSEMBLING T H E  CRANKCASE  ... ........... ........ ........ ......... ........ .... .. 5-57 
CHECKING THE  CRANKCASE  ....... .... ........ ............. ........ .... ..... ........ .... ..  5-5 7 
ASSEMBLING THE  CRANKCASE  ....... .... .... ........ ..... ........ ........ .... ..... .... ..  5-57 
CONNEC TIN G  RODS AND PISTONS ................................................ ...........  5-60 
REMOVING THE CONNECT ING RODS AND PISTONS ........................  5-61 
CHECKING THE CYLINDER AND PISTON .......... .... .... .... .... ........ ..... .... ..  5-61 
CHECKING THE PISTON  RINGS .... .... ......... .... ........ ............ ..... ........ .... ..  5-62 
CHECKING THE PISTON  PIN ..... .... .... ......... .... .... .... ............ ..... ........ .... ..  5-63 
CHECKING THE CONNECTING  RODS ........................ .... ................ 5-63 
INSTALLING THE CO NNECTING  ROD AND PISTON ..........................  5-66 
CRANKSHAFT AND BALANCER SHAFT ..... .... .... .... .... ................. ........ .... ..  5- 70 
REMOVING T HE  CRANKS HAFT  AND BALANCER  SHAFT ..... ........ .... ..  5- 71 
CHECKING THE OI L NOZZLES ..................................................... 5-71 
CHECKING THE  CRANK SHAFT  ..... .... ..................... ........ ......... ........ .... ..  5-71 
CHECKING THE  BALANCER SHAFT .............................................. 5-73 
INSTALLING THE CRANKS HAFT ....... ..................... ........ ......... ........ .... ..  5-74 
INSTALLING THE  BALA NCER ASSEMBLY ............................................  5-75 
TRANSMISSION .... .... ......... .... .... .... .... .... .... ..... ........ ........ ........ .... ..... ........ .... ..  5-76 
REMOVING T HE TRA NSMISSION ...... .... ................. ........ ......... ........ .... ..  5-80 
CHECKING THE SHIFT  FORKS ...................................................... 5-80  
						

							CHECKING THE SHIFT DRUM ASSEMBLY  ... .... ... .... .... ....... ........ .. .... ... . 5 -81 
CHECKING THE TRANSMISS ION . ... .... .... .......... ... .... .... ....... .......... .... .... 5 -81 
ASSEMBLING THE MAIN AXLE  AND DRIVE AXLE  ...... ...... .... ............ ...  5-81 
INSTALLING THE T RANSMISSION .... ................ ... .... .... ....... ........... ... ....  5-82  
						

							EA$1AC1506 
ENGINE  INSPECTION 
EA$20110 
MEASURING THE COMPRESSION 
PRESSURE 
The following p rocedure app lies to all of  the cyl ­
inders . 
TIP-------------:-­
lnsufficient compress io n  pressure will  result in  a 
loss of performance. 
1.  Measu re: 
• Valve  clearance 
Ou t 
of speci ficat ion -+Adjust. 
Refe r to ADJUST IN G THE VALVE CLEAR ­
ANCE  
on page 3·5. 
2.  Start  the engine , warm  it  up  for several 

min · 
utes,  and  then turn  it  off . 
3.  Remove: 
•R ider seat 
Refer  to 
GENERAL  CHASSIS  on page 4· 1. 
• Fue l tank 
Refer  to 
FUEL TANK  on  page  7

-
1. 
• Air filter case 
Refer  to 
GENERAL  CHASSIS on page  4-1. 
• Air cut- off valve 
Refer  to AIR  INDUCTION  SYSTEM on 
page 7-15. 
• Ign ition  coils 
• 
Spar1< plugs 
Refe r 

t o 
 CAMSHAFTS  on page 5·9. 
NOTICE ___________ _ 
Before removing the spark plugs, use com· 
pressed air to blow away any dirt accumulat· 
ed in the spark plug wells to prevent it from 
falling into the cylinders. 
4. Install: 
• 
Compress ion  gauge 1 
• 
Ex tensi on 2 
Compression gauge 
90890-03081 
Engine compression tester 
YU-33223 
Extension 
90890-04136 
5-1 
ENGINE  INSPECTION 
1 2 
5. Measure: 
• Compression  pressu re 
Out of specifica tion -+ Re fe r  to  steps  (c) and 
(d) . 
Standard compression pressure 
(at sea level) 
1530  kPa/680 r/min (15.3 
kgf/cm2/680 r/min,  217.6 psi/680 
r/min) 
Minimum-maximum 
1330-171 O kPa/680 r/min 
(13.3-17.1 kgf/cm2/680 r/min, 
189 .
2-243.2 psi/680 r/min) 
• ••••••••••••••••••\
••••••••••••• 
a . Set the  main  sw itch  to ON . 
b. W ith the thro ttle wide  open , cran k  the  eng ine 
unti l the  read in g  on  the  compress ion  gauge 
stab iliz es. 
A WARN ING 
To prevent sparking the plug, remove all ig­
nition coil couplers and fuel injector cou­
plers before cranking the engine. 
TIP
-------------
T he  difference  in  comp ress ion  pressure  be­
t ween 
cy lin ders  should not exceed 100 kPa (1 
kg/cm2
, 15 psi). 
c. 
If t he  compress ion  pressure  is above  the 
maximum  specification , chec k the 
cylinder 
head , val

ve 
s u rfaces  and 

piston  crown  for 
carbon  deposits. 
Carbon  deposits 
-+ Eliminate. 
d. If the  comp ressio n pressure  is be low the min ­
imum  specificati on , po ur  a teaspoon ful of en­
gine oil into  the spark plug bore  and  meas ure 
aga in. 
Reier  to t
he follow ing table.  
						

							Compression  pressu re  (w ith oil appl ie d into 
the 
cylinder) 
Reading  Diagnosis 
H ig h
er than  without  Piston ring(s)  wear or 
oil damage --+ Repair. 
Piston , valves,  cylin -
Same 
as  witho ut oil der head  gasket  pos-
sibly defec tive --+ 
R epa ir . 
••••••••••••••••••\
•••••••••••••• 
6. Install: 
•  Spark  plu gs 
Spark plug 
13 Nm (1.3 m·kgf, 9.4 fl·lbf) 
7. Install: 
•  Ign it io n  co
ils 
Refer  to  CAMSHAFTS  on page 5-9. 
• Air  cut -off valve 
Refer  to  AIR  INDUCTION  SYSTEM  on 
page 7-15. 
• Air filter case 
Refer  to 
GENERAL  CHASSIS on page  4-1. 
• Fue l tank 
Re f
er to  FUEL TANK  on page  7-1. 
• R ider s eat 
Re f
er to GE NERAL  CHASSIS on page  4-1. 
ENGINE  INSPECTION 
5-2  
						

							ENGINE REMOVAL 
EA$2:)111 
ENGINE  REMOVAL 
Removing  the muffler  and exhaust  pipe 
~ 10 Nm (1.0 m • kgf, 7.2 ft· lbf) 
~ 10 Nm (1.0 m. kgf,  7.2 ft -lbf) 
3 
Order Job/Parts to remove  Qty Remarks 
1 02 senso r couple r bracket 1 
2 0
2 sensor coup le r 1  Disco nnect. 
3 
Muffle r assem bly 1 
4 Ex haus t gaske t 3 
5 Muffle r protector 1 
5-3