Yamaha Fz 09 2014 Manual

							2. Meas ure: 
•  C lu tc h spring  free length  a  
O ut 
of spec if icat io n -> Rep lace t h e clutch 
springs as a  set. 
EAS25l50 
Clutch spring free length 
52.50 
mm (2.07 in) 
Limit  49.88 
mm (1.96  in) 
CHECKING THE CLUTCH HOUSING 
1. Check: 
•  C lu tch h ous ing  dogs 
Damage /p ittin
g/wea r -> Deburr  the clutch 
hous ing  dogs  or rep lace t h e clu tch h ous ing. 
TIP~~~~~~~~~~~~~~­
P itting on the c lu tc h hous ing dogs will cause  er­
r a tic 
clutch opera tion . 
2.  Check : 
• Oi l pump  drive  sprocket 1  
Crack
s/damage /wear-> Re place . 
1 
CLUTCH 
3.  C heck: 
•Bear in g 
Damage/wear -> Rep lace t h e  bearing  and 
clutch hous ing. 
 CHECKING THE  CLUTCH BOSS 
1. Check: 
•  C lu tc h bo ss spline s 
Damage /p itt ing/wea r -> Repla ce the clu tch 
boss . 
TIP~~~~~~~~~~~~~~­
Pitting  on  th e clu tc h boss spli nes  will ca use  er­
r
atic c lutc h operat io n . 
 CHECKING THE PRESSURE PLATE 
1 . C heck: 
• Pressure  pla te  1 
C racks/damage -> Rep lace . 
• 
Bear in g 2  
Damage/wear -> Rep lace. 
2 
 
1 
CHECKING THE PRIMARY  DRIVE GEAR 
5-44 
1.  C heck: 
• P rimary  drive  gea r 
Damage/wear 
-> Repla ce the  crankshaft  and 
clutch hous ing  as a set. 
Excess ive  noise 
during operat ion -> Rep lace 
t h e  cranks haft  and clutch ho using as a  set.  
						

							EA$2$~10 
CHECKING THE PRIMARY DRIVEN GEAR 
1. Check: 
• Primary dri ven gear 1 
Damage /wear 4 Replace the cl utch h ous ing 
and  crankshaft  as a set. 
Excess ive noise during operation 4 Replace 
the clutch housin g and  crankshaft as a set. 
EAS25220 
CHECKING THE PULL LEVER SHAFT AND 
PULL ROD 
1. Check: 
• Pull le ver shaft  pin ion  gear  teeth 1 
• 
Pull rod  teeth 2 
Damage/wear 4 Replace th e pu ll rod and 
pull le ver shaft  as a set. 
1 
2.  Check: 
• Pull rod bearing 
Damage /wea r 4 Repla ce. 
° INSTALLING THE CLUTCH 
1 

. 
Install: 
•  Oi l 
pump drive cha in 1 
•  C lu t
ch hous ing 2  
TIP
------------::--­
lnstall th e oil pump drive chain  onto  th e oil pump 
drive  sprocket  a. 
CLUTCH 
2 
a 
2. Install: 
• 
T h rust plate 
•Clu tch boss 1 
•
Wash er 
• 
Con ic al spring washer 2 
•  Cl utch boss  nu t 3  IH4W 
Clutch boss nut 
125 Nm (12. 5 m·kgf, 90 ft·lbf) 
LOCTITE® 
TIP-----------.-~ 
• Ins tall the con ical spri ng  washe r on the main 
axle 

wi th  th e 
OUT mark a fac ing away fro m 
t
he vehic le. 
• 
Whi l e  hol ding the clutch boss 1 with  the uni­
versal  clutc h  holder  4, ti ght en  the clutch bo ss 
n u
t. 
•  Stake the clu tch boss  nu t  at  cu to uts b  in  the 
main axle. 
5-45 
Universal clutch holder 
90890-04086 
YM-91042  
						

							3. In sta ll: 
• 
Fr iction p late 1 
•  C lu tc h  plate 
• 
Fr iction p late 2 
TIP~~~~~~~~~~~~~~ 
• First, in stall a friction p la te a nd  th en a lternate 
between  a clutch  plate and  a frict ion plate. 
•  Install 
the last frict io n plate  1 offset  from the 
o ther  friction 
p la tes 2, ma king sure to align a 
pro ject ion 
on  t
he friction plate w ith  the  punch 
mar k 
a on the clu tch hous ing. 
4. 
Install: 
• Bea
ring 
(in to  the  pressu re plate) 
• Pull 
rod 1 
• 
Pressure plate  2 
•  C lu tch 
spr ings 
•  C lu tch spr ing bolts 3 
Clutch spring bolt 
10 Nm (1.0  m·kgf, 7.2 ft·lbf) 
•  Oil 
pu mp  driven  spro cket 4  
Oil 
pump driven sprocket bolt 
15  Nm (1.5 m ·k,gf, 11 ft·lbf) 
LOCTITE® 
TIP~~~~~~~~~~~~~~ 
• Tig hte n the clu tch s pring b o lts in  stages  and in 
a  cr issc ross  pa
ttern. 
• App ly lithium-soap-based  grease onto th e pull 
rod. 
• Positio n the pull rod so th at the  teeth a face 
towa rds  the 
hole b. T hen, in stall the  clutch 
cove r. 
5. Install: 
• Dowel 
pins 
• Clu tch cover  gaske t IH¥j 
• Clu tch cover 
•Cover 
Clutch 
cover bolt 
CLUTCH 
12 Nm (1.2 m·kgf, 8.7 ft·lbf) 
TIP~~~~~~~~~~~~~~-
• A pply  engine  oil onto t he  bearin g . 
• T ig hten  the clu tch cover  bolts in  sta ges  and in 
a  cri sscross  pattern. 
6. Inst all: 
• 
Pull leve r 
TIP~~~~~~~~~~~~~~ 
• Ins tall the pull  lever with  the O mark  facing to­
ward  lowe r 

side. 
• When installing the p ull lever,  push th e pull  le­
ver  and  ch ec k that  the punch  mark a on th e 
p ull leve r alig ns  with the  mark b on  the  clutch 
cover.  Make su re  that  the 
pull rod  teeth  and 
p ull lever  shaft p inion  gear  are 

engaged. 
5-46  
						

							7. Adjust: 
• C lutch  lever free p lay 
Refer to ADJUSTING THE CLU TCH LEVER 
FREE 
PLAY on  page  3-11. 
Clutch lever free play 
10.0-1 5.0 mm (0.39-0.59 in) 
CLUTCH 
5-47  
						

							SHIFT SHAFT 
EA~IO 
SHIFT SHAFT 
Removing the shift shaft and stopper lever 
22 Nm  (2.2 m. kgf. 16 ft -!bf) 
g 
10 
Order Job/Parts to remove Q ty Remarks 
Clutc h assembly  Refer to C LUTC H on  page  5-39. 
Shift arm  Refer to  C HAIN DRIV E on  page 4-70 . 
1  Circlip  1 
2  Washer  1 
3 Shilt sh aft  1 
4 Washer  1 
5 Circlip 1 
6 Was her  1 
7 
S toppe r lever , 
8 S toppe r lever  spring , 
9 Colla r , 
10  Shilt shaf t spring 
1 
11 Shilt shaf t spring  stoppe r 
1 
12 
O il sea l 1 
1 3  Bearing  1 
5-48  
						

							,..,.... 
CHECKING THE SHIFT  SHAFT 
1.  Check: 
• Sh ift shaft 1 
Bends/damage/wear 4 R ep lace . 
•  Sh i
ft shaft  spring 2 
•Coll a r 
Damage /wear 4 R ep lace . 
, . .,..,. 
CHECKING THE STOPPER LEVER 
1. C heck: 
• Stopper  leve r 1 
Bends/damage 4 Rep lace . 
Rolle r 
turns ro ughly 4 Replace the  stopper 
lever. 
EA,$;2tlol.)1 
INSTALLING THE SHIFT  SHAFT 
1. Install: 
•  Sh i
ft shaft  spring  stoppe r 1  
•  Sh i
ft shaft assemb ly 
•  Stoppe r 
lever spri ng  2  
S h ift s h aft  sprin g  stopper 
22  Nm  (2.2 
m·kgf, 16 ft·lbf) 
LOCTITE ® 
TIP~~~~~~~~~~~~~~~ 
• Hook the  en d  of  the  s hift sh aft sprin g 3  onto 
the  shift  sh aft  spring  stopper  1  . 
• Hoo k the ends o f  the  stopper leve r spring 2 
onto  the stoppe r leve r 4 and  the cra nkcase 
boss 
 5 . 
• 
Mesh  the stoppe r lever w ith 

th e sh ift  d
rum seg ­
ment assemb ly . 
2. Install: 
• Bear ing 
•  O il seal lllf111l4tI 
• Was her 1  
SHIFT  SHAFT 
• C irclip 2 lll@ll!@kI 
TIP~~~~~~~~~~~~~~-
• Lubricate  the oil seal  li ps w ith lit hi­
um-soap-based  grease. 
• L ubricate  the oute r  periphery  of the o il seal  with 
t
he silicone  fl u id. 
) 
5-49  
						

							OIL PUMP 
EA$24Q21 
OIL PUMP 
Removing the oil pump 
0  
~ 
ii, 10 Nm (1.0 m • kgf,  7.2 ft · lbf) 
0 
10 Nm 1.0 m . kgf, 7.2 ft · lbf) 15 Nm  (1.5m.kgf,11 ft ·lbf) 
Order 
Job/Par ts to remove  Qty Remarks 
Clu!c h cover  Refer 10  C LUT CH on  page  5-39 . 
1 Oil p ump  driven sproekel 1 
2 Oil pum p asse mbly 1 
5-50  
						

							OIL PUMP 
Disassembling the oil pump 
II. 3.8  Nm  (0 .38  m • kg!, 2 .8 ft ·lb!) 
1 
mms--.._o 
"~~ 
3 
2 1--0 
I 
OJ---~ 
4 8 
(/) q) 
5 
9-{j  ~. 
m -~ ) Q 
 _/· 
 
., 
Order Job/Parts to remove Qty Remarks 
1 O il pum p  cove r , 
2 Oil pu mp  sh aft 1 
3 Pi n 1 
4 Oil pum p inn er roto r 1 
5 Oil pump  out er  rotor 1 
6 Circ lip 1 Hold dow n  th e  washer  when re m oving t he 
circ lip. 
7  Washer  1 
8 Spring , 
9 Relie f valve , 
10 Dowe l pin 2 
5-5 1  
						

							,..,..., 
CHECKING THE SPROCKET AND CHAIN 
1. Check: 
• Oil pump  drive  sprocket 
Refer  to 
CHECKING T HE CLUTCH  HOUS­
ING 
on page 5-44 . 
2. Check: 
• Oil pump  drive  ch a in 1 
Damage/st iffn ess --+ Rep lace the oil pump 
dr ive  chain  and 
oil pump  drive sprocket 
(clutch hous ing) as a  set. 
 CHECKING THE OIL PUMP 
1. Check: 
•Oi l pump  driven  gear 1 
•  Oi l 
pump  housing  2  
Cracks/damage /wea r 
--+ Replace the  defec ­
t ive  part(s). 
1 
2 
2.  Measure: 
• Inner- rotor- to-outer -ro tor-tip cle arance  a  
• 
Outer-rotor -to -o il - p ump-housing clea ranc e 
b 
• Oi l-pu mp-ho using-to-in ner-rotor-and-ou t­
er-rotor 
clearance  c 
Ou t 
of spec ificatio n --+ Replace the defective 
part(s ). 
OIL  PUMP 
Inner-rotor-to-outer-rotor -tip 
clea rance 
Less than 0.120 mm (0.0047 in) 
Limit 
0.20 mm (0.0079 in) 
Outer-rotor-to-oil-pump-housing 
c learanc e 
0.09-0.19 mm (0 .0035--0 .0075 In) 
Limit 
0.21 mm (0.0083 in) 
Oii-pump-housing-to-in­
ner-and-outer-rotor 
cleara nce 
O.
						

							EAS;.24971 
CHECKING THE RELIEF VALVE 
1. C heck: 
• Relief valve  1 
• 
Sp ring 2 
Damage/we ar ~ R ep lace the oil p um p as­
semb ly. 
EAS2S(ll0 
ASSEMBLING THE OIL PUMP 
1. Lubricate: 
•  Inn er roto r 
• Ou te r rotor 
•  Oil pu mp  shaft 
(w it h  th e reco mmende d 
lubric an t) 
Recommended lubricant 
r--· Engine oil 
2 . Install: 
•  Ou ter 
rotor 1 
•  Inner rotor 2 
• P in 3 
•  Oil pump  cover 4 
• Oil pump  cover  screw 
011 pump cover screw 
3.8 Nm (0.38 m ·kgf, 2.8 ft·lbf) 
TIP--------------­
Ali gn the  pin 3 in  the oil pum p  shaft  with th e 
g roove  in 
the inner rotor 2. 
OIL  PUMP 
3. Check: 
• O il p ump opera tion 
Re fe r  to 
CHECKI NG THE OIL P U M P on 
p age 
5-52. 
 INSTALLING THE OIL PUMP 
1. Install: 
•  Oi l 
pum p 1 
• O il p ump bo lts  2  
Oil pump bolt 
10 Nm (1.0 m ·kgf, 7.2 ft·lbf) 
•  O il p ump driven  sprocket 3 
ECA1ACl508 
NOTICE 
011 pump driven sprocket bolt 
15 Nm (1.5 m -kgf, 11 ft·lbf) 
LOCTITE® 
After installing the oil pump drive chain and 
driven sprocket, make sure the oil pump 
turns smoothly. 
TIP---------------
• 1 RC mark  of  the oil pump drive n sp rocket  is  in­
stalled at oil pump  side. 
•  Install th e oil pump drive  chain  onto  the o il 
p ump driven  sprocket. 
1  .  
5-53