Yamaha Fz 09 2014 Manual

							ENGINE REMOVAL 
Disconnecting the leads and hoses 
3 4 
~ 12 Nm (1.2  m • kgf.  8.7 ft 0 lbf) 
7  6 
--10 • 
• 
2 
7 Nm (0.7  m • kgf, 5.1 ft -lbl) 
Order Job/Parts to remove Qty Remarks 
Rider  seat  Refe
r to  GE NERAL  CHASS IS  on page 
4· 1. 
Ai r 
sc oop/Fuel tank cove r/Rear side  cove r (left) Refer  to  G ENE RAL  CHASS IS  on page 
4· 1. 
F uel tan k Refer  to  FUEL  TANK o n  page 7·1. 
Air filt er c ase  Refer 
to  GENERA L CHASSIS  on page 
4·1. 
Thrott le bod ies  Refer to THROTTLE BODIE S on  page 7·5. 
Fu el rail Refer  to THROTTLE BODIE S on  page 7·5. 
Radia tor Refer to  RAD IATOR o n  page 6· 1. 
A
ir cu t-off va lv e Refe r to A IR  IN DUC TION  SYSTEM on 
page  7-1 5. 
Rig ht f
ootres t asse mbly Refer  to  RE AR  BRAKE on page  4-32. 
Drive  sprocket  Refer to 
 C HAIN DRIV E on  page 4-70. 
1 Clutc h 

cab le 
1  Disconnect. 
2 S tar te r  motor lead 1  Disconne ct. 
3  Negative 
ba
ttery lead 1 Disconnect . 
4 Ign itio n coi l co uple r 3 Disconnect. 
5 
Coola nt te m pera ture se nso r coupler 1 Dis connect. 
6 Speed senso r coupler 1 D isconnect. 
7 
O il level switch co upl er 1 Disconnect. 
5-4  
						

							ENGINE REMOVAL 
Disconnecting the leads and hoses 
~ 12 Nm (1.2 m • kgf. 8.7 ft 0 lbl) 
9  8 
--10 
7 Nm (0.7 m • kgf, 5.1 ft - lbl) 
Order  Job/Parts to remove Qty Remarks 
8 Gear posit ion  senso r coup ler 2  Disconne ct. 
9 Cranks hatt  posi tion sensor couple r 1 Disconnect. 
10 Sta to r coi l co upl er 1 Disco nnect. 
5-5  
						

							ENGINE REMOVAL 
Removing the engine 
~ 7 Nm (0.7 m • kgf,  5.1 ft · lbf) 
~ 45  Nm  (4.5 m. kgf, 33 ft· lbf) 
3 
8 
.. . -----@ -aui;:.il( ...... 
3 
45  Nm  (4.5 m · kgf, 33 ft· lbf) 
1.2  m . kgf,  8.7 ft · lbf) 
7  Nm (0.7 m. kgf,  5.1 ft· lbf) 
Order  Job/Parts to remove Qty Remarks 
1 Eng ine  mount in g  bo tt  (ri gh t fr o nt  upper  side) 1 
2 Ad apt er bolt (ri ght) 1 
3 
Engi ne  moun ting bolt (right fr o nt low er 
side)/e ng ine 

mo un ti
ng b o tt (le ft fr on t lower 
side)/en gine  moun tin g bolt  (lett f ro n t u pper  sid e) 
1/1/1 
4 Ad apt er bott (lef t) 1 
5 Eng ine  mounti ng bolt (rea r lowe r side) /e n gi ne 
m oun
ting n ut ( re ar low er sid e) 1/ 1 
6 E ng in e  m ount ing bolt (re ar uppe r sid e)/e ngin e 
m ou n
ting  nu t (re ar  upper side ) 1/ 1 
7 E ng ine 1 
8 Eng ine  mount in g  ad ju st b olt 3 
5 -6  
						

							EA$1AC 1501 
REMOVING THE ENGINE 
1. Loosen: 
• Engine  mounting  adjust bo lt (front) 
TIP~~~~~~~~~~~~~~~ 
Loosen  the engine  moun ti ng  adjust bolt w ith  the 
p ivo t shaft  wrench 
1. 
Pivot  shaft wrench 
90890-01485 
Frame  mount insert wrench 
YM-01485 
2. Loosen: 
• Engine mounting  adjust bo lts (rear) 
TIP~~~~~~~~~~~~~~~ 
Loosen  the engine  mounting  adjust bolts wi th 
the  pivot  sha ft  w renc h 
1 and  pivot  shaft  wrench 
adap ter 
2. 
Pivot  shaft wrench 
90890-01518 
Frame  spanner  socket 
YM-01518 
Pivot shaft wrench  adapter 
90890-01476 
1 
5-7 
ENGINE  REMOVAL 
1 2 
INSTALLING THE ENGINE 
1. Install: 
• 
Eng ine  mounting  adjust bolt (front) 1 
(temporarily tighten) 
• Eng ine  mounting  adjust bolts (rear) 2  
(temporar i
ly tighten) 
2. 
Install: 
• Eng ine 
3 . Install: 
• 
Eng ine mounting bolt ( rear  upper  side) 3 
• Eng ine 
mounting bolt (rear low er side)  4 
4 . 
Install: 
• 
Adapte r bolt (left)  5 
(tem porari
ly tighte n) 
5. Install: 
• 
Engine  mounting bolt (left fro nt  up per  side) 
6 
• Eng ine  moun ting bolt  (left front lo wer side) 7  
• 
Eng ine  mount ing bolt (r ig ht  fro nt lower side) 
8 
Temporarily tighten  the engine mounting bolts 
6. Tighten: 
• Engine  mounting  adjust bolt (front) 1  
TIP~~~~~~~~~~~~~~-
• T ig hten  the  engi ne  mo un ti n g  adjust bolt to 
spec ifica ti on  with  the  pivo t shaft  wrenc h. 
• Make  su re  that  the flange on  the  engine 
mounting  adjust 
bolt co ntacts  the en gine . 
Engine  mounting  adjust bolt 
(front) 
7 Nm (0.7 m ·kgf , 5.1 ft·lbf) 
Pivot  shaft wrench 
90890-01485 
Frame  mount Insert wrench 
YM-01485 
7. Tighten: 
• Engine  mounting  adjust bolts (rear) 2  
						

							TIP~~~~~~~~~~~~~~-
• Tig hte n  the eng in e  mo unt in g  ad ju st b o lts to 
spe
cif ic at ion  with  th e pivot shaft  wrench and 
p ivo t sha ft w rench  ad ap t
er. 
• Ma ke sure  that  the fla nge on  the  eng in e 
mounting  adjust 
bolt contac ts  the eng ine. 
8. Install: 
Engine mounting adjust bolt 
(rear ) 
7  Nm 
(0.

7 m·kgf , 
5.1 ft·lbf) 
Pivot  shaft wrench 
90890-01518 
Frame  spanner  socket 
YM-01518 
Pivot shaft wrench  adapter 
90890-01476 
• Ad apter  bolt 
(right) 9 
(tem po ra
rily tigh ten) 
9. 
Install: 
• 
Engine  mou nting bolt (right  front  upper  side) 
 1  O  
1 O.Tig hten: 
• Engine mou nting  nut (rear  lower  side)  1 1 
• Eng
ine mou nting  nut (rear  upper  side)  12  
Engine mounting nut 
45  Nm  (4.5 m·kgf, 33 ft·lbf) 
11. Tighten: 
• Engine  mount ing bolt (ri ght  front  upper  side) 
1  O  
• Engine mo un tin g bo lt  (le ft  fro nt  up pe r  sid e) 
6  
• Engine mo unt in g bo lt  (left fr ont  lower  side) 7 
• Eng
ine mo un ti n g bo lt (righ t fron t lowe r sid e) 
Engine 
mounting bolt 
45  Nm  (4.5 m·kgf, 33 ft·lbf) 
12.  Tig hten: 
• Adapter  bolt (left)  5  
• 
Adap

t
er bo lt  (rig ht) 9 
Adapter bolt 
12  Nm  (1.2 m·kgf, 8.7 ft·lbf) 
ENGINE  REMOVAL 
5-8  
						

							CAMSHAFTS 
EA$2:)1$) 
CAMSHAFTS 
Removing the cylinder head cover 
~ 10 Nm (1.0 m • kgf, 7.2 ft ·lbf) 
1 
4 
13 Nm (1.3 m • kgf, 9.4  ft • lbf) 
Order Job/Parts to remove Q ty Remarks 
Ride r sea t  Refer 
to  G ENE RAL CHASS IS • on page 
4-1. 
A
ir scoop/Fuel tank  cove r  Refer 
to  GE NERAL CHASS IS  on pa ge 
4· 1. 
F u el tank Refe r  to  FUEL  TANK · on  page 7·1. 
Air filt er case Reie r to  GE NERAL CHASSIS • on page 
4 -1 . 
Radi ator  Refer to 
 RA DIATOR on  page 6-1 . 
Ai r cu t-
off va lve Refer  to A IR  IN DUC TIO N  SYST EM on 
pag e 7·1 5 . 
1 Ig n itio n 

coi l co uple r 
3 Disconnect. 
2 I gn itio n coi l 3 
3 Spark  plug 3 
4 Cylinder head  cover  1 
5 
Cyli nder head cover  gas ke t  1 
6 Timin g chain  guide (top  side ) 
1 
5-9  
						

							Removing the camshafts 
II, 7 Nm (0.7 m. k gf, 5.1 ft ·lbf) 
1 O Nm (1.0 m · kgf, 7.2 ft • lbf) 
d 
,,..........,,
,(;] 
II, 12  Nm  (1.2 m. kgf,  8.7 ft -lbf) 
10 Nm (1.0 m . kgf, 7.2 ft -lbf) 
Order  Job/Parts to remove 
I 
13 
Crankshaft end cove r/Timing mark  accessing 
bolt 
1 T im in g chain cover 
2 T iming chain cover gas k et 
3 T iming c hain  te nsio n er 
4 
T im in g chain  t en sio ner  gasket 
5 Int ake camshaft cap 
6 Exh au st  camsh aft  cap 
7 Cams haft  cap 
8 Intak e camshaft 
9 Exh au st cam sh aft 
10 Int ake camshaft  sprocket 
11 Ex haust cams hatt  sprocket 
12 Timin g ch ain bol t 
13 Dowe l pin 
14 Ti min g c hain  guide (in take  side) 
15 Ti min g c hai n 
5-10 
14 
Qty 
1 
1 
1 
1 
1 
1 
1 
1 
1 
1 
1 
1 
1 
1 
1 
CAMSHAFTS 
~ 10 Nm (1.0 m. kgf, 7.2 ft -lbf) 
8~ 10 
~~-, I 
,~-f&\tm:mU; 
. ~ ~ T ~i~L
						

							EA$2:)810 
REMOVING TH E CAMS HAFTS 
1.  Remove: 
• Tim in g  ma rk access ing 

bolt  1  
• 
Cran kshaft  end cover 2 
2. Align: 
• 
Mark  a  on th e  ge ner ator  rotor 
-.J 
(with  the generato r rotor  cover  mark b) 
TTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTT 
a. Tum  the crankshaft  counte rc lockw ise. 
b.  Whe n pis t
on #1 is  at BTDC125 ° on the com­
p ress ion  stroke, al ign t he BTDC125 ° mark a 
on  the genera tor rotor  wit h  the  generato r rotor 
cover  mark 
b. 
TIP~~~~~~~~~~~~~~~ 
BTDC  125° on the  compress ion str oke  can be 
f ound  when the  cam shaft 
lobes are turned  away 
fro m each  other. 
-.J 
••••••••••••••••••\
•••••••••••••• 
3. Remove : 
• Timing  ch ain  tens ione r 1 
• 
Tim in g  cha in  ten sio ner  gasket 
a 
5-11 
4.  Remove: 
•Cams haft cap 1 
•  In take 
ca ms haft  cap 2 
CAMSHAFTS 
• E xh a ust  cams haft  cap 3 
NOTICE ~~~~~~~~~~~~~ 
To prevent damage to the cylinder hea d, 
camshafts or camshaft caps, loosen th e 
camshaft cap bolts in stages and in a criss­
cross patte rn , w orking from th e outs ide in . 
5 .  Remove: 
•Intake camshaft 1 
• 
Exhaust  camshaft 2  
TIP~~~~~~~~~~~~~~­
To p reve nt  t he  tim ing  chain  from falling  into the 
cran kcase , fasten  it  w ith  a  w ir e 
3. 
2 
~-
~ 
I 
~ 
I H • • >-~  ~ 
-
• 
• 
1 
6. Remove: 
• Camshaft sproc ket 1  
TIP~~~~~~~~~~~~~~~ 
Us e th e  cams haft wrench 2  and loos en the 
cams haft  sprocket 
bo lt.  
						

							,..,,.., 
Camshaft wrench 
90890-04162 YM-04162 
2 
CHECKING THE CAMSHAFTS 
1. Check : 
• Camshaft lobes 
1 
Blue dis co lo ra tion/ pittin g/scratches -> Re ­
p lace 
th e camshaft. 
2. Measu re: 
• Cam shaft lobe dim ensions  a  an d b 
Ou t 
of sp eci fica tion -> Re place the  camshaft. 
Camshaft lobe dimensions 
Lobe height (Intake ) 
36.290-36.390 mm 
(1.4287 -1.4327 in) 
Limit 
36.190 mm (1.4248 in) 
Base circle diameter (Intake) 
27.950-28. 050 mm 
(1.1004-1.1043 In) 
Limit 
27.850 mm ( 1.0965 in) 
Lobe height (Exhaust) 
35.720-35.820 mm 
(1.4063 -1.4102 in) 
Limit 
35.620 mm (1.4024 in) 
Base circle diameter (Exhaust) 
27 .978-28.078 mm 
(1.1015-1.1054 in) 
Limit 
27 .878 mm (1. 0976 in) 
a 
1· ~I 
CAMSHAFTS 
3.  Measure: 
• Camshaft runou t 
Ou1 of spe cific ation -> Rep lace. 
Camshaft runout limit 
0. 030 mm (0.0012 in) 
4. Measure: 
• Camshaft-jo urna l-to- camshaft-cap cleara nce 
O
u1 o f spec ificatio n -> Measure  the camshaft 
journa l diameter. 
Camshaft- journal-to-cam­
shaft-cap clearance 
0.028--0.062 mm (0. 0011--0.0024 
in) 
TTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTT 
a. Install the  cams haft  in to  the cylinder head 
(withou t the camshaft  caps). 
b. Position  strip of Plastigauge®  1 onto  the 
camshaft 
j o urn al as  shown. 
1 
c. Install the dowe l pins  and  cams haft  caps. 
5-12  
						

							TIP~~~~~~~~~~~~~~-
• Tig hte n the  camshaft c a p bolts in  stages  and  in 
a  crisscross  patte
rn, wo rking from  the in ner 
caps out. 
• Do not  tum  the camshaft  when  meas uring  the 
camshaft  journal-to-camshaft  cap 
clearance 
w ith the P last iga uge®. 
Camshaft cap bolt 
10 Nm (1.0  m·kgf, 7.2 ft·lbf) 
d. Remove  the camshaft  caps and then mea­
su re  the  wid th  of  the Plas ti gauge®  2. 
2 
••••••••••••••••••\
•••••••••••••• 
5.  Meas ure: 
• Camshaft jou rn al diame ter  a  
Out 
of spec ifi cation ~ Replace the  camshaft. 
W it h in  spec ifica ti on 
~ Rep lace the cylinder 
h ead  and  the camshaft  caps as a set. 
 
Camshaft journal diameter 
24.459-24.472 mm 
(0 .9630-0.9635 in) 
a 
0 ---
CHECKING  THE TIMING CHAIN AND 
CAMSHAFT 
SPROCKET 
1. C heck: 
• Tim ing chain 
Damage /st iffn ess 
~ Rep lace the timin g 
chain  and  camshaft  and  camshaft  sprocket 
as  a set. 
CAMSHAFTS 
2.  C heck: 
• Cams haft sprocket 
More  than 1 
/4 toot h wear a ~ R ep lace the 
camsh aft sproc kets  and  th e 
t i m in g  cha
in as  a 
set. 
a 
   
b-.;· 
• • • 
a. 1 /4 tooth 
b . Correct 
1 .  Ti
ming chain 
2 .  Camshaft 
sprocket 
.....,... 
1 
,. 
• 2 •  •  
CHECKING  THE TIMING CHAIN GUIDES 
The following p rocedure applies to all of the 
camshaft  sprockets  and  timing  cha in  gu ides. 
1 .  C heck: 
•Timing chain gu ide  (intake  side)  1  
• Timing 
cha in  guide  (top sid e) 2 
Damage/wea r ~ Rep lace the  defec tive 
part(s). 
2 
1 
....,,.,. 
CHECKING  THE TIMING CHAIN TENSIONER 
1.  Check : 
• Timing  chain  tensi oner 
Cracks/damage/rough  movement 
~ Re­
plac e 
. 
••••••••••••••••••\
•••••••••••••• 
a. Ligh tly press  the tim ing  cha in  te nsi one r rod 
into 
the  timin g chain tens io ner  housing  by 
hand. 
TIP~~~~~~~~~~~~~~-
Wh ile press ing  the  timing  ch ain  tens io ner rod, 
w in d  it counterclockw ise  with  a hexagon  wrench 
1 until it  stops. 
5-13