Yamaha Fz 09 2014 Manual

							EA$1AC15Q2 
OIL PAN 
Removing the oil pan 
Orde r 
1 
2 
3 
4 
5 
6 
7 
___...,(13) 
1 0 Nm (1 .0 m • kgf,  7. 2 ft ·lbf) 
43 Nm (4.3 m • kgf, 31 ft • lbf) 
10 
Nm ( 1.0 m . kgf, 7.2 ft ·lbf) 
Job/Pa rts to remove Qty 
Rider seal 
A
ir s c oop /F u el lank  cover 
Fu el lan k 
Muffle r asse mbly 
Engine oil 
O il  level 
switc h lead  coupler 1 
Oil  level switc h lead  holde r 1 
Oil level switc h  1 
02 sensor lead  holde r 1 
Oil pan 1 
O il pan gasket 1 
O il stra in e r 1 
5-54 
OIL PAN 
7 
Remark s 
Refer  lo  G E
NERAL CHASSIS  on page 
4· 1. 
Refe r lo GE NERAL CH ASS IS  on page 
4-1. 
Refer  lo  FUEL TANK  on  page  7-1 . 
Refer  lo  E NG INE REMOVAi: on page  5-3. 
Dra in. 
Refer  to 
CHA NG IN G TH E EN G IN E  Oil: on 
page  3-23. 
D isconnect  
						

							REMOVING THE OIL PAN 
1. Remove: 
• Oil level switch 1 
• Oil pan 2 
• Oil pan  gasket 
TIP~~~~~~~~~~~~~~­
Loosen  each bolt 1/4  of a tur n at a  time, in stag­
es  and  in  a crisscross  pattern.  After all of the 
bolts are fully  loosened , remove them. 
EA~990 
CHECKING THE OIL STRAINER 
1. Check: 
• Oil stra iner 1 
Damage -+ Replace. 
1 
Con taminan ts -+ Clean wi th so lvent. 
1 
INSTALLING THE OIL PAN 
1. 
Install: 
• Gasket l@@ll 
• Oil pa n 1 
Oil 
pan bolt 
10 Nm (1.0 m·kgf, 7.2 ft·lbf) 
•  O
il level swi tch 2 
Oil  level 
switch bolt 
10 Nm (1.0 m·kgf, 7.2 ft·lbf) 
• 
Engine o il drain bolt  3 
OIL PAN 
Engine oil drain bo lt 
43 Nm (4.3 m ·kgf, 31 ft·lbf) 
A wARNING 
Always use  new copper washers. 
TIP~~~~~~~~~~~~~~-
• Tighten  the oil pan bolts in stages  and in a 
cr isscross  pattern. 
• Lubricate  the oil level sw itch 0-ring with lithi­
um-soap-based  grease. 
2 
5-55  
						

							EA$2$S.C0 
CRANKCASE 
Separating  the crankcase 
II, 24 Nm (2.4  m • kgf, 17 ft · lbf) 
lll,J 10 Nm (1.0 m • kgf,  7.2 ft • lbf) I 
1st  25 Nm 2.5  m • kgf, 18 ft 0 lbf 
2nd  15  Nm  (1.5  m • kgf, 11 ft • lbf) 
3rd  Spec ified angle 60 
Jll,J 24 Nm  (2.4  m . kgf, 17 ft · lbf) [ 
(2) ,,_,., .... 
(6) 
Orde r  Job/Pa
rts to remove 
Engine 
Cylinder head 
Water  pump 
S tart
er clutch 
Starter  moto r 
Clutch housing 
O il stra in e r 
, O il filter cartr idge 
2 Oil filter cartr idge  unio n bolt 
3 Gea r posit ion sensor 
4 Speed senso r 
5 Clutch  cable hol der 
6 L owe r crankcase 
7 Dowe l pin 
Qty 
1 
1 
1 
1 
, 
, 
3 
5- 56 
CRANKCASE 
1st 25 Nm (2.5  m. k  f, 18 ft · lbf) 
ii. 2nd 18 Nm  (1 .8  m • kgf, 13 ft ·lbf) 
3rd  Specified angle 60 
II, 17 Nm  (1.7 m. kgf, 12 ft -lbf) 
II, 70 Nm (7.0 m. k  f, 51 ft 0 lbf 
Remarks 
Refer  to E NGINE REMOVAL  on page  5-3. 
Refer  to 
CYLI NDER HEAD on  page 5· 19. 
Refer  to 
WATER PUMP on  page 6·8 . 
Refer  to G ENE RATO R AN D START ER 
CL UTCH  on page 5·30. 
Refer  to  EL ECTR IC STARTER o n  page 
5·35. 
Refer  to C LU TCH on  page 5·39 . 
Refer  to O IL PAN on  page 5·5 4 .  
						

							EA$2$S50 
DISASSEMBLING THE CRANKCASE 
1. 
P lace the  engine  upside down. 
2.  Remove: 
• Crankcase bolts 
TIP~~~~~~~~~~~~~~~ 
• Loose n each bo lt 1/4  of a tum  at a time,  in stag ­
es and in a  crisscross  pattern. Aft er all of the 
bolts are fully  loosened, remove  them. 
• Loosen  the bolts in  the  proper  sequence  as 
shown . 
• The numbers  embossed on the crankcase in­
dicate the  cran kcase  tighten ing  sequence. 
3.  Remove: 
• Lowe r crankcase 
NOTICE ~~~~~~~~~~~~~ 
Tap on one side of  the  crankcase  with a 
soft-face  hammer.  Tap only on reinforced 
portions of the crankcase, not on the crank· 
case  mating  surfaces . Work slowly and care ­
fully and  make  sure the crankcase halves 
separate evenly. 
4. Remove: 
•Dowel pins 
5.  Remove: 
• Crankshaft journal lower bear ing 
•  Balancer shaft journa l bearings 
(from  the 
lower crankcase) 
TIP~~~~~~~~~~~~~~­
ldentify the  pos itio n of  each  part very carefully so 
that  it  can  be 
re installed in  it s orig ina l place. 
CRANKCASE 
......... 
CHECKING THE  CRANKCASE 
1 . 
Thoroughly wash  the crankcase halves in  a 
mild solvent. 
2 . Thoroughly  clean  all the  gasket  surfaces  and 
cran kcase  mating  surfaces . 
3. Check: 
•Crankcase 
Cracks/damage ~ Replace. 
•  Oi l d elivery 
passag es 
Obstruction~ Blow o ut  wit h comp ressed  air. 
650 
ASSEMBLING THE  CRANKCASE 
1 . 
Lub ricate: 
• Crankshaft 

journal 
bearing  inner surface 
(w i
th the  recommended lubricant) 
Recommended lubricant 
l-1911l Eng ine oil 
2 . App ly: 
• Sealant 
(onto  the  crankcase  mating su rfaces) 
Yamaha 
bond No.1215 
(Three 
bond No.1215®) 
9089().85505 
TIP~~~~~~~~~~~~~~-
Do n ot allow any sea lant to  come  into contact 
with  the 
oil gallery or crankshaf t journal  bear­
ings, or bala ncer shaft journal bearings. 
3. 
Install: 
•Dowe l pins 
5-57  
						

							4. Set the shift drum assemb ly and  tr a nsmiss io n 
gears  in t he 
ne utr al pos it io n . 
5. 
Inst all: 
• 
Lowe r cran kcase 1  
(on to 

t h e  uppe r cr ankcase 
2 ) 
N O TICE ~~~~~~~~~~~~~ 
Before tightening the crankca se bolts,  make 
sure the transmission gears shift correctly 
when  the shift drum assembly  is tu rned by 
hand. 
6. 
Insta ll: 
• 
C ran kcase bo lt s 
TIP~~~~~~~~~~~~~~-
• L ubr icate  th e bo lts 1 - B  th re ad ,  mating  su r­
f a ces  an d  was he rs w ith  eng ine 
oil. 
• L ubr icate  th e bo lts  9 - 12  th read,  mating  su r­
f a ces  an d 
0-rin gs wit h  eng ine o il . 
• Lubr icat e 
the bolts 13 - 30  thread  an d  mat ­
i n g 
s urf aces  with  engin e 
oil. 
• M B x 100 mm (3.9 4 in) bo lts w ith  washe rs: 
7  B  ... I -~CWI 
• M B x B5 mm (3.35  in) bo lts w it h  was he rs: 
1   6   ... --~Pf" 
• M B x 7B mm (3.0 7 i n) bo lts wit h  new  0-rings: 
9  - 12  
• MB x 60 mm (2.36  in ) b olts: 13 , 14  
• 
M6 x B5 mm ( 3 .35  in ) bo lt: 1 B 
• M6 x 65 mm (2 .56  in ) bo lts: 15,  16  
• 
M6 x 65 mm ( 2 .56  in ) bo lt: 26  
• 
M6  x 50 mm (1.97  in ) bo lt s :  17 ,  19-2 1 , 
23-25, 271
-30  
• M6 x 40 mm (1 .57  in ) bo lt: 22  
-19 20 21 
=-22 
CRANKCASE 
7.  Ti gh te n : 
• C ra nkcase bo lts 1 -B  
Crankcase bolts  1  - S  
1st: 25  Nm  (2.5 m ·kgf, 18 ft·lbf) 
•2nd : 15 Nm (1.5 m·kgf, 11 ft· lbf) 
3rd: +so• 
Crankcase bolts  7 - 8  
1st:  25  Nm  (2.5 m·kgf, 18 ft·lbf) 
•2nd : 
18 Nm (1.8 m ·kgf , 13 ft·lbf) 
3rd: +so• 
* Following the t ig h ten in g  order, loo sen the b olt 
one  by one  and  then  retigh te n 

i t  to  the  spec i
fic 
torque . 
EWA1FC ISCM 
AwARNING 
If the crankcase bolt is tightened  more than 
the spec ified  angle, do not loosen  the bolt 
and then  retighten  it .  Instead , replace  the 
crankcase 
bolt with  a new one and perform 
the procedure  again . 
NOTICE ~~~~~~~~~~~~~ 
Do not use  a torque  wrench to tighten  the 
crankcase 
bolt to the speci fied angle . 
TIP~~~~~~~~~~~~~~­
Tig h ten  the bo lts in t he t ig h te ning  sequence  cast 
on  th e  cr ankca s
e. 
5-58  
						

							8. Tig hten: 
• C rankcase bolts  9-30 
Crankcase bolts 9-14  
24  Nm  (2.4 m·kgf, 17 fl·lbf) 
Crankcase bolts  15 - 30  
10 
Nm (1.0  m·kgf, 7.2 fl·lbf) 
TIP~~~~~~~~~~~~~~­
Tigh te n  th e bol ts in  the tigh tening  sequence  cast 
on  the  crankcase. 
CRANKCASE 
5-59  
						

							CONNECTING RODS AND PISTONS 
EA$1AC1503 
CONNECTING RODS AND PISTONS 
Removing the connecting rods and pistons 
1st 20 Nm (2.0 m • kg l,  14 It · lbl) 
2nd Specified  angle 175-1 85  
Order  Job/Parts 
to remove Qty Remarks 
Lowe r crankcase  Refer 
to 
CRA N KCASE on  page 5-56. 
1 C onnect ing  rod  cap 3 
2  Big 
en d lowe r bearin g 3 
3 
Pist o n  pin clip 6 
4 Pisto n  pin 3 
5 Pisto n 3 
6 Connect ing  rod 3 
7 Big  end  uppe r bearing 3 
8 
Top r in g 3 
9 2nd  ring 3 
10 O il rin g 3 
5-60  
						

							CONNECTING RODS AND PISTONS 
,..,,.., 
REMOVING THE CONNECTING RODS AND 
PISTONS 
The follow ing  procedure applies to all of the con ­
n ect in g  rods  and p
istons. 
1.  Remove: 
•Connec ting rod cap 1 
• Connect ing  rod 
• Big  end bearings 
TIP~~~~~~~~~~~~~~-
• Ide ntify the position of each  big  end  bear ing so 
that it  can  be reinstalled in  its orig inal  place. 
• 
After  removing  the connecting  rods  and  con­
necting  rod caps,  care 
should be  ta ken  not  to 
damage  the 
mating surfaces of  the  conne cting 
ro
ds and  connecting  rod caps. 
2.  Remove: 
• Pi

s ton  pin 
c lips 1 
• P i ston  pin  2  
• 
P i

ston 
 3  
ECA 1RCISCM 
NOTICE ~~~~~~~~~~~~~ 
Do not use a hammer to drive the piston pin 
out. 
TIP~~~~~~~~~~~~~~-
• For reference  during installat ion , p ut id entifica· 
ti on  marks  on the  p iston  crown . 
• Befo re  remov ing  the piston  pin, d eburr  the pi s· 
ton  pin clip groove  and the pist on  pin  bore ar­
ea. If both  areas  are debarred  and the pis to n 
p in  is 
still diff icu lt to  remove,  remove  it wi th  the 
pist on  pin puller set 4. 
Piston pin puller set 
90890-01304 
Piston pin puller 
YU-01304 
5-61 
3 . Remove : 
•Top rin g 
• 2nd rin g 
• Oil ring 
4 
TIP~~~~~~~~~~~~~~-
When  removing  a  pist on  ring,  open  the en d gap 
with your fingers and lift the other  side of the ring 
ove r the  pis t
on crown . 
,,_,.. 
CHECKING THE CYLINDER AND PISTON 
1. Check: 
• P iston wall 
• 
Cylinder wall 
Vert ical  scratc hes ~ Replace the cylinder, 
a nd rep lace the  piston and p is ton rings as a 
set. 
2.  Measure: 
• Piston- to-cy linder c learance 
TTYTTTYYTTTYTTTYYTTTYTTTYTTTYYTT 
a.  Measure cylinder bore C with  the cylinde r 
bore  gauge. 
TIP~~~~~~~~~~~~~~­
Measure cylinder bore C  by tak ing side -to -s ide  
						

							CONNECTING RODS AND PISTONS 
and front-to-b ack  measurements  of the cylinder . 
Then,  find the  average 
of the  meas urement s. 
Bore 
78.000-78.010 mm 
(3.0709-3.0713 in) 
Taper limit 
0.050 mm (0.0020 in) 
Out of round limit 
0 .050 mm (0 .002 0 In) 
 C  
=  max imum of D1-D6 
Taper  limit  =  max imum  of  D1 or  D2 -max
i­
mum  of 
D s or Ds 
O ut of ro und lim it= maximum  of D1 , D3 o
r D5 
-m in im um of D2 , D4 o
r D5 
~ ... 04 ... ------
• 
b. If o ut  of  specifica tion , re p la ce the  cylinder, 
and replace th e  pis to n  and pist on  rings  as a 
set. 
c.  Meas ure p is ton 
ski rt  diameter P wi th  the mi­
crome ter. 
a 
Piston 
Diameter 
77.975-77.990 
mm 
(3 .0699-3.0705  In) 
p 
a. 12.0 mm ( 0.47 in) from  the bottom edge of 
the  piston 
d. If out of specification , rep lace the  pis ton  and 
p iston  rings  as a se
t. 
e. Ca lc u late the  pis ton -to- cylinde r clearance 
with  the fo llowing form ula. 
Pis ton -t o -cy li nder cleara nce = Cy lin d er bor e 
C  -P iston skirt  dia mete r P  
Piston-to-cylinder 
clearance 
0.010-0 .035 mm (0.0004-0.0014 
in) 
Limit 
0.150 mm (0.0059 in) 
f . 
If o ut of specificat ion , replace  the cylin der, 
and 
r ep lace th e 

p iston  and piston  rings  as  a 
se
t. 
...... ,,. 
CHECKING THE PISTON  RINGS 
1. Measu re: 
•  Piston ring  side clearance 
Out of  speci fication -> Rep lace  the piston 
and  pis ton  rings  as  a set. 
TIP~~~~~~~~~~~~~~­
Before meas uring  the  piston  ring  side  clearance, 
e li mi nate  any carbo n deposits  from  the  piston 
rin g g rooves  and piston rings  . 
Piston ring 
Top ring 
Ring  side clearance 
0.030-0 .065 mm (0.0012-0.0026 
in) 
Limit 
0.115 mm (0.0045 in) 
2nd ring 
2. Install: 
Ring  side clearance 
0.020-0 .055 mm (0.0008-0.0022 
in) 
Limit 
0.115 mm (0.0045 in) 
•  Piston rin g 
(in to the  cy linde r) 
5-62  
						

							CONNECTING RODS AND PISTONS 
TIP~~~~~~~~~~~~~~­
Use the piston  crown to level the piston  ring near 
bottom of cylinder  a , whe re  cyl inde r wear  is 
lowest. 
3 .  Measure: 
• Piston  ring end  gap 
Out of specification -> Rep lace  the piston 
ring . 
TIP~~~~~~~~~~~~~~ 
Th e oil ring  expander  spa cers  en d  gap  cannot 
be measured. If th e oil ring ra ils gap  is exces­
s ive , rep lace 
all three  piston  rings. 
Top ring 
End 
gap (installed) 
0.15-0.25 mm (0.0059-0.0098 in) 
Limit 
0.50 mm (0.0197 in) 
2nd ring 
End 
gap (Installed) 
0.30-0.45 mm (0.0118-0.0177 in) 
Limit 
0 .80 mm (0 .0315 In) 
Oil ring 
End gap (installed) 
0 .10-0.40 mm (0 .0039-0.0157 In) 
-­, 
b . Upper of cylinder 
CHECKING  THE PISTON PIN 
Th e  follow ing procedu re  appl ies  to all  of the  pis­
to n p ins. 
1. Check: 
• P iston p in 
Blue disco loration /g rooves -> Replace  the 
piston  pin  and  then ch eck  the lubricat ion  sys­
tem . 
2 .  Measure: 
• Piston  pin  outs ide  diame ter  a  
Out 
of specification -> Rep lace  the piston  pin . 
/ 
Piston  pin outside  diameter 
16.990-16.995 mm 
(0.6689-0.6691 in) 
Limit 
16.970 mm (0.668 1 in) 
3. Measure: 
• Pisto n pin bore  insid e  diame ter b  
Out of spec ification -> Replace the  piston. 
Piston  pin bore inside diameter 
17.002-17.013 mm 
(0 .6694-0.6698 in) 
Limit 
17.043 mm (0.6710 in) 
__ __:._vrip!....l::...J_j J 
, 
4. Calcul ate: 
• 
P iston -p in-to- p isto n-p in-b ore  clea ranc e 
Out of speci ficati on -> Replace  the pisto n pin 
and  pisto n 
as a set. 
Pis ton-pin -to -p is ton-pin -bore  clearance  = 
P iston  pin bore  inside  diameter 
 b   • Piston 
pin  outside  diameter 
a  
EAS  1AC1!K).t 
Piston-pin -to-piston-pin -bore 
clearance 
0.007-0.023 mm (0.0003-0.0009 
in) 
CHECKING  THE CONNECTING  RODS 
1. Measure: 
• Cra nkshaft-pin-to·b ig-e nd·bearing clea rance 
5-63