Yamaha Fz 09 2014 Manual

							CONNECTING RODS AND PISTONS 
Out of spec ificatio n 4 Replace t h e  big  end 
bear ings. 
Oil  clea rance 
0.027-0.051 mm (0.0011- 0.0020 
in) 
TTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTT 
The follow ing procedure applies to all of  the 
connecting  rods. 
£CA1 3000 
NOTICE ~~~~~~~~~~~~~ 
Do not interchange the big end  bearings  and 
connecting  rods. 
To obtain the correct 
crankshaft-pin-to-big-end-bearing 
clear­
ance  and prevent  engine damage, the big 
end  bearings 
must be installed in their origi ­
nal 
positions. 
a . 
C lea n the  big  end  bear ings . cra nkshaft  pin s. 
a n d  the  ins ide 
of the con nectin g rods ha lves. 
b. Install the  big 

e
nd up per  bearing into  th e con ­
necting  rod  and  the big end lower bear ing into 
the  connecting  rod cap . 
TIP~~~~~~~~~~~~~~~ 
Align th e p roject io n s a  on  the  big  en d  bear ings 
w ith  t
he notc hes b  in  th e  connecting  rod  and 
con
nec tin g rod  cap. 
b a 
c. Put  a piece of P last igauge®  1  on  the cran k­
shaft  pin. 
d. 
As semble the  connect ing  rod halves . 
ECA1ACISOI 
NOTICE ~~~~~~~~~~~~ 
Tighten  the connecting rod bolts using the  p
lastic-reg
ion tightening angle method. Al ­
ways install new bolts. 
TIP~~~~~~~~~~~~~~-
• Clean the  connecting  rod bolts and lubricate 
the bol t threads  and seats  with mo lybdenum 
d i
sulfide oil. 
• 
Make  sure that the  project io n a  on  the co n­
necting  ro d cap  faces  the same  direct io n  as  the 
Y  ma rk b on  th e  con necting  rod. 
• After installin g the big  e nd  bearing, assemb le 
the co nne cti n g  rod  an d  co nn ecting  rod  cap 
w ith ou t 
insta lling  them  onto  the  cra nkshaft. 
a 
TIP~~~~~~~~~~~~~~~ 
Inst all by carry ing  out  the follow in g procedures i n 
order  to 
assemble in the  most suitab le con d ition. 
e .  Tigh ten  the  connect ing rod bo lt  wh il e  check ­
ing  that  the sections shown a   and b are 
flus h wi th  each othe r by  to uchin g  th e s urface. 
Connect
ing rod bolt 
30 Nm (3 .0  m·kg f, 22 ft·lbf) 
TIP~~~~~~~~~~~~~~-
To ins tall the  big  end  bearing,  care shou ld be 
t a ken  not  to 
install it  at  an ang le and  the posit ion 
s hou ld not  be out of alignment. 
b 
a . S id e mach ine d  face 
b. Thrust ing faces 
f.  Loo sen  the connecting  rod bolt, remove  the 
connec
ting  rod  and  connecting  rod cap  and 
install these  parts to the  crankshaft  with  the 
5-64  
						

							CONNECTING RODS AND PISTONS 
big  end  bear ing  kept  in the  curre nt condit ion. 
TIP~~~~~~~~~~~~~~-
• Do  not  move  the connect ing rod or c rankshaft 
until the c learance meas uremen t has  been 
comp leted. 
• 
Ma ke  sure  that 

the  projection 
a on the con­
necting rod cap  faces  the  same  direct ion as the 
Y mark  b on the connecting rod. 
• Make  sure  the  Y marks b on the  connecting 
rods 
face towa rds the left s ide  of the cran k­
shaft. 
a 
g. Tig hten the  connect ing ro d bo lts wit h a  torq ue 
w renc h. 
Connecting  rod 
bolt (1st) 
20 Nm (2.0 m·kgf, 14 ft·lbf) 
h.  Put  a mark 1 on the  corner  of the  connecting 
rod 
bolt  2  and  the connecting  rod cap 3. 
2 
 
1--3 
i. Tighten  the connecting  rod bolts further to 
reach the  spec ified angle  175 °- 185 °. 
Connecting  rod bolt (final) 
Specified angle 175°-185° 
A WARN ING 
If the  connecting  rod bolt is tightened more 
than  the specified 
angle, do not loosen the 
bolt and  then  retighten  it .  Instead, replace 
the connecting  rod bolt with a new one and 
perform  the procedure  again. 
NOTICE ~~~~~~~~~~~~~ 
Do not use a torque  wrench to tighten the 
connecting  rod 
bolt to the specified angle. 
J. Af te r  the  installat ion, check that  the  section 
s h own 
a 

i s 
flus h w it h  each  other by tou ching 
the  su rface. 
k. Remove  the connecting  rod  and  b ig  end 
bear ings. 
5-65 
I. Measure the  compressed Plas tigauge® 
w idth  on the  crankshaft  pin . If the crank­
shaft-p in-to-b ig-end-bearing c learance i s  out 
of  specificat i
on, select  replacement b ig  end 
bearings.  
						

							CONNECTING RODS AND PISTONS 
••••••••••••••••••\
•••••••••••••• 
2. Select: 
• B ig 
end  bear ings (P1-P3 ) 
TIP---------------
• The 
numbe rs  fl(  stamped into  the c ranks haft 
web  and the  numbe rs 
 1 o n  the connect in g 
rods  are used  to determ ine  the  replaceme nt 
b ig  end  bearings  s
izes. 
• P1-P3  re
fer  to  the  bea r i
n gs  sh ow n in  the 
c ra nkshaft  ill u stratio n. 
For 
examp le, i f  the  connec ting rod P1  a
nd 
the  crankshaft  web 
P  { numbe rs  are  5 and  2 
respect i
vely , th en  the bearing size for  P 1  is: 
P1 (connecting 
rod)-P1 (cranks
haft) = 5-
2  = 
3 (brown) 
Bea r
ing color code 
1. Blue 2. Black 3. Brown 4. 
Green 
(8) p , P2 p , 
. zzz 322 
~~t:J~===""~~~,·~ 
l~s::-( _1_( a 
1 
......... 
IN STALLING THE CO NNECTING  RO D AND 
PISTON 
The  following  procedure applies to all of th e con ­
nect ing  rods  and  pistons. 
1 . 
Install: 
• 
B ig  end  bear ings 
• Con necting  rod cap 
( onto  t
he connec ti n g  rod) 
TIP---------------
• Be sure  to reinstall each  big  end  bearing  in its 
original place. 
•  Alig n 
the  projections a on  the  big  end bear ­
ings 

with  the  notc hes 
b in 

the  connecting  rods 
and  connect ing  rod  caps. 
• Make sure  that  the pro ject io n c on  the con ­
necting  rod  cap  faces  the same  direct ion  as the 
Y  ma rk d  on  th e  con nect ing  rod. 
c 
2. Tighte n: 
• Co nn ecting  rod bolts 1~@4 
ECAIRCll509 
NOTICE 
Tighten the connecting rod bol t s using th e 
plas tic-region  tighte n ing angle method. Al­
w ays install ne w bolt s . 
TIP--------------­
ln stall by  carry ing  out the  following  procedures in 
o rder  to assemb le in the mos t 
suitable con d iti on . 
TTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTT 
a. Replace t he  con necting  rod bolts with  new 
ones . 
b. Clean th e connecting  rod bolt s and  lubricate 
5-66  
						

							CONNECTING RODS AND PISTONS 
the bolt threads  and seats  wit h  molybdenum 
d i
sulfi de  oil . 
c .  After 
in stalling th e b ig  end  bearing , assemb le 
the  connecting  rod and  con nect ing  rod  cap 
w itho ut 
in stalling them  onto the cranks haft . 
d.  Tig hten  the  connec ting rod  bolt 
whi le  ch

eck­
ing  that the  sectio ns  show n a  a nd  b   are 
flush with  each  other by  touching the  su rface. 
C onne ctin g rod  bol t 
30 Nm (3 .0  m·kgf , 22 ft·lbf) 
TIP~~~~~~~~~~~~~~­
To install the  big  end  bea ring, care  s hou ld  be 
ta ken  not  to 
install it  at  an  ang le  and  the position 
s h ou ld not  be out of alignment. 
b 
a. Side machined face 
b.  Thrusting  faces 
e.  Loose n the 
connecting  rod bolt ,  remove  the 
con nect ing rod  and  connect ing  rod  cap  and 
install t hese  parts  to the  cra nkshaft  with  the 
b ig  end  bear ing  kept  in the 
curre nt cond it io n . 
••••••••••••••••••\
•••••••••••••• 
3. Install: 
• O
il ring  expa nde r 1 
• 
Lowe r o il  rin g rail 2 
•  Uppe r oil  rin g rail  3  
• 2nd  ring 4  
• 
T op ring 5 
(in to  the  piston) 
TIP~~~~~~~~~~~~~~ 
Be  sure to inst all the  p iston  rings  so that  the 
manufacturers  marks  or  numbe
rs a face  up.  4. 
Install: 
• P
iston 1  
(onto  the respect ive connec ti ng  rod 2 ) 
• Piston  pin 3  
• Piston pin clips 411 l@Mll 
TIP~~~~~~~~~~~~~~-
•  App ly eng ine  oil onto  the  piston  pin. 
• Make  su re  that  the Y mark a  on the connec t­
ing  rod  faces le

ft 
whe n the  punch  ma rk b  on 
the p iston  is  pointing up as  show n. 
•  Install the  piston  pin cl ips, so that  the clip  ends 
a re  3  mm 
(0. 12 in) d o r more from the cut ou t 
i n  the  piston . 
• Reinsta ll  eac h pisto n into  it s orig ina l cyl in der . 
5. Lubr icate: 
•Piston 
• 
P iston  rings 
• Cylinder 
4 
(w ith  the  recommended lubricant) 
 
5-67 
R ecommended  l ub ric ant 
E ngi
ne oil 
1  
						

							CONNECTING RODS AND PISTONS 
6. Offset: 
• 
Pi ston  ring  end  gaps 
a. Top r ing 
b. 2nd r ing 
c. Upper oil ring rail 
d . Oil rin g exp ander 
e .  L ower 
oil ring rail 
A. E xhaust  side 
7.  Lubricate : 
• Crankshaft  pins 
[8] 
90  
90 
• Connecting  rod big e nd  bear ing in ner su rface 
(with  t
he recomme nded lu br ican t) 
l 
8. Install: 
R ecommended lubricant 
Engin e oil 
• P is ton  assemb lie s 1 
2  b 
a 1 
3 t 
9. Install: 
• 
Connect ing  rod  caps 
• Connect ing  rod bolts 
TIP~~~~~~~~~~~~~~-
• Make  sure the Y ma rks  a  on  the  connec ting 
rods  face  towa r
ds the left side of th e cra nk· 
sh aft. 
• Make  sure that the project ion b on  the con­
nect ing  rod  cap  faces  the same  direct ion  as the 
 Y  mark a on  the  connecting  rod. 
• Apply Molybdenum  disulfide oil to the bolt 
th reads  and seats. 
( in to  the 
cylinder 2  and  onto  the  crankshaft  b 
p in) 
N O TICE 
Pi ston installing tool 
90 890 -04161 
YM -04161 
~~~~~~~~~~~~~ 
If the projection  a  of the piston installing 
tool damage s, you canno t use it. Plea se  han­
dle with care . 
TIP~~~~~~~~~~~~~~­
Fit  th e  pro ject io n a o f  th e  pis ton ins tallin g  too l 
 3 
and b lu nt- edged part b of the cy lin de r, fix 
the  positio n 
of the  pisto n installing  tool, a nd  the n 
p ush  th e 
p is ton  up to  the 
cylinder . 
1 O.Tighte n: 
• Con necting 

rod 
bolts 1 
TIP~~~~~~~~~~~~~~~ 
Tigh ten  the connec ti n g  rod bo lts u sing the fol· 
l
owi ng procedure . 
a.  Tigh te n  the  connec ting rod 
bolts w ith  a to rque 
wrench. 
5-68  
						

							CONNECTING RODS AND PISTONS 
Connecting rod bolt (1st) 
20 Nm (2.0 m-kgf,  14 ft·lbf) 
b.  Put  a ma rk 1 on th e  co rn e r of  the  connect ing 
rod bolt  2 an d  the  connect ing rod  cap 3. 
----2 
--1 
 
1--3 
c.  Tigh ten  the  connecting  rod bolts furth er  to 
r each  t
he specified ang le 175 °-185°. 
EWAl$400 
Connecting  rod bolt (final) 
Specified  angle 
175°-185° 
I 
ID 
.---ll-+ 
AwARNING 
If the connecting  rod bolt Is tightened more 
than 
the specified  angle, do not loosen the 
bolt and then  retighten  it. Instead, replace 
the  connecting  rod 
bolt with a new one and 
perform  the procedure  again. 
ECAIW..0 
NOTICE~~~~~~~~~~~~ 
Do not use a torque  wrench to tighten  the 
connecting  rod 
bolt to the specified  angle. 
d.  Afte r th e  ins ta
llation , chec k that  the section 
shown 
a is flush w ith  eac h other  by touchi ng 
the 
surface. 
EWAI A C 15JG 
AwARNING 
If the  connecting  rod and  cap are not flush 
with  each 
other, remove  the connecting  rod 
bolts and big end bearing  and restart  from 
step (1 ). In this case , make  sure to replace 
the  connecting  rod 
bolts. 
5-69  
						

							CRANKSHAFT AND BALANCER SHAFT 
EAS;.2$950 
CRANKSHAFT AND BALANCER SHAFT 
Removing  the crankshaft  and balancer shaft 
4 
7 
7 I 
.~~· ~2 
I 1 
Order Job/Parts to remove Qty Remarks 
Lowe r crankcase  Refer 
to CRAN KCASE on page  5-56. 
Connecting  r
od Refer to REMOVING THE CONN ECTING 
RODS  ANO PISTO NS 
on  page  5-61. 
1  Balancer  shaft  1 
2 Balancer shaft journal l ower bear ing 2 
3 Balancer  shaft journa l upper  bearing 2 
4 Cran kshaft 
1 
5  C
ran kshaft 
jo u rn al  lower bear ing 4 
6  C
ran kshaft journ al uppe r bear ing 4 
7 O il nozzfe 3 
5-70  
						

							CRANKSHAFT AND BALANCER SHAFT 
EA$2$lla0 
REMOVING THE CRANKSHAFT AND 
BALANCER 
SHAFT 
1.  Remove: 
• B ala ncer shaft 1  
•  B ala ncer shaft journa l bear ings 
• Crankshaft assemb ly 2 
• C rankshaft jou rna l bearin gs 
TIP~~~~~~~~~~~~~~~ 
Identi fy the  positi o n of eac h balance r shaft jour­
na l 
bearings  and crankshaft journal bea rings so 
that  it  can  be re installed in  it s orig ina l p lac e. 
EAS1 RC l!iOS 
CHECKING THE OIL  NOZZLES 
The followin g p rocedure app lies t o a ll of  th e oil 
nozz les. 
1. C heck: 
• Oil nozz le 1 
Damage /wear --t Rep lace the oil  nozz le. 
• Oil passage 
Obs tructio n 
--t Blow out  with  compr essed  air. 
1 
© 
CHECKING THE CRANKSHAFT 
1. Measu re: 
• Crankshaft  runout 
Out of specificat i on --t Rep lace the cran k­
sh aft. 
Runout limit 
0.030 mm (0.0012 in) 
5-71 
2. C heck: 
• Cra n

kshaf t 
journal surfaces 
• Cra n

ksha ft pin  surf aces 
• Bear ing  su rf a ces 
Scratches /we ar --t Repla ce the crankshaft . 
3. Mea sure: 
• C ra n

kshaft-j ournal-to -c rankshaft -jou r­
nal- bearin g  clea ran ce 
O ut 
of  sp eci fication --t Replace t h e cra nk­
shaft journa l bearings . 
ECA.13920 
NOTICE 
Journal oil clearance 
0.014-0.038 mm (0. 0006-0.0015 
In) 
Do not interchange the crankshaft journal 
bearings. To obtain the correct crank­
shaft-journal-to-crankshaft-journal-bearing 
clearance and prevent engine damage, the 
crankshaft journal bearings must be in­
stalled in their original positions. 
TTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTT 
a. Clean th e  cran ks h aft journa l bearings , cra n k­
sh aft  jo urna ls, and  bearing po rtions  of th e 
c rankcase. 
b. P lac e th e  upper  crankcase  ups ide down  on  a 
bench . 
c . 
Inst all the cran kshaft journa l uppe r  bea ring s 
1 and the  cran ks h aft  into the  upp er crank ­
case. 
TIP~~~~~~~~~~~~~~~ 
Ali gn th e  pro jectio ns a on the  crankshaft jou r­
n al 
uppe r bearings  wit h t he  notc hes b in  th e up ­
per  crankcase .  
						

							CRANKSHAFT AND BALANCER SHAFT 
d. Put  a piece  of P lastigauge® 1 o n each 
cranksha
ft j ou rnal. 
TIP~~~~~~~~~~~~~~­
Do not put the  Plast iga uge® over  th e o il hole in 
the  crankshaft 
journal. 
!(. 
e. Install the  cra nkshaft jou rnal  lower bearings 
1  in to  the lower crankcase and assemb le 
the  crankcase  halves. 
TIP~~~~~~~~~~~~~~-
• Al ign the  project ions a of  the  crankshaft jour­
nal lower bearings  with the notches b in the 
lower crankcase. 
• Do not  move  the crankshaft until the clearance 
measurement  has been  completed. 
f. T ighten  the bolts to  specification  in  the tight­
ening  sequence cast on the  crankcase. 
Refer  to 
CRANKCASE on page  5-56. 
g.  Remove  the 
lower crankcase  and the cran k­
shaft journa l lower bear ings. 
h. Measure  the compressed Plastigauge® 
w id th a on  each  crankshaft journal. 
If the cranks haft-journa l- to-cranksha ft-jour-
nal-bear ing clearance  is out of specifica tion, 
select r ep lacement  crankshaft journal  bear­
ings. 
••••••••••••••••••\
•••••••••••••• 
4. Sel ect: 
• 
Crankshaft journal bearings  (J1-J4) 
TIP~~~~~~~~~~~~~~-
• T
he  numbers A stamped  into  the  cranks haft 
web a nd  the  numbe rs  B stamped  in to  th e 
lower crankcase are used  to determine  the re­
p lacemen t 
crankshaf t journal bearing  siz es. 
• J1- J4  refer 
to the  bearings  sh own  in  t he 
crankshaft 
and lower c rankcase illustra tion. 
•If J1 -J4  are 
the same,  use  the same  size for 
all of the  bearings. 
Fo r example,  if th e 
crankcase Ji a nd cra nk­
sh aft web Ji numbers  are  7  a nd  2 respec­
tively, 
then  the bearing  size  for J1 is: 
J1
 (cran
kcase)  -J 1  (crankshaft 
web) -1 = 7 
- 2  -
1 = 4 (green) 
Bearing color code 
O.Whit e  1.Blu e 2.Bla ck 3. Br own 
4 .Gre en 
5-72  
						

							CRANKSHAFT AND BALANCER SHAFT 
[Al J, J.J , J , 
~i:-.' 
'#:=:-\(~ 
EAS26130 
CHECKING THE  BALANCER SHAFT 
1. Meas ure: 
• Bala ncer shaft run ou t 
Out of  spec if icatio n -) Replace the ba lancer 
shaft. 
2.  Chec
k: 
Balancer shaft runout limit 
0.030 mm (0.0012 in) 
•  Bala ncer shaft journa l su rfaces 
• Beari ng  surfaces 
Scr atches/wear 
-) Repl ace the bal ancer 
shaft. 
3.  M
easure: 
• B ala ncer sh aft jou rnal- to-bal ancer  shaft jour ­
na l 
bearing clear ance 
Ou t 
of specific ati on -) Rep lace the bal ance r 
shaft journal bear in gs . 
ECA.1RC1$11 
NOTICE 
Balancer shaft journal to balancer 
shaft bearing clearance 
0.024-0 .048 
mm (0.0009-0.0019 
in) 
Do 
not interchange  the balancer shaft jour­
nal bearings. To obtain the correct balancer 
shaft-journal-to-balancer  shaft-journal  bear­
ing clearance and prevent engine damage, 
the balancer shaft journal bearings must be 
installed in their original positions. 
TTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTT 
a. Clean the balancer s h aft journa l bearings, 
ba lancer shaft journa ls , and  bearing  portions 
o f the  cran kcase. 
b. Place the u pper  crankcase  upside  dow n on  a 
benc h. 
c. 
Install t h e balance r sh aft journal upper bear­
in gs 1 and th e bala nce r shaft  into  the uppe r 
crankcase. 
TIP~~~~~~~~~~~~~~ 
Ali gn the  proje c tions a on  th e balan cer sh aft 
journa l uppe r bearings  with  the not ches b  in  th e 
u ppe r cra nkcase. 
1 
~8 
d. Put a  piece  of Plast igauge®  1 on each bal-
ance r shaft jo urnal. 
TIP~~~~~~~~~~~~~~ 
Do  not  put  th e Pla st iga uge® ove r the oi l hole in 
th e 
balan ce r shaft journal. 
5-73