Yamaha Fz 09 2014 Manual

							,..,,... 
CHECKING THE AIR INDUCTION  SYSTEM 
Air Injection 
The air  induction  system burns unburned  ex­
haust  gases 
by inject ing  fresh  air (secondary  air) 
into  th e  ex haust  port,  reduc
ing  the  emission of 
hydrocarbons.  When there  is  negative pressure 
at the exhaust  port,  th e  reed va lve opens, allow ­
ing  secondary  air to flow in to  the  exhaust  port. 
The  requir
ed tempera ture for bur ning  the  un­
bur ned  exhaust  gases is approx imately 
600 to 
700 • c (1112 to 1292 ° F). 
A ir  cut-off valve 
The  air cut-off valve is controlled by  the signals 
from  the ECU in accordance  with the combus­
tion  cond itions. 
Ord inarily, the  air  cut-off valve 
opens  to allow the  air  to flow during id le and 
c loses to  cut-off  the flow when the vehicle is  be­
in g  driven.  However,  if  the 

coolant 
temperature 
i s 
below the  specified value , the air 

cu t- off 
va lve 
remains  open and allows the air to flow into  the 
exha u
st pipe u n til the  temperat ure becomes 
h igher  th an  the  spec ifi ed 
value. 
A .  From  th e  air filter case 
B. 
To t he cyli nder head 
1. Check: 
• Hoses 
Loose  connections -t Connect properly. 
Cracks/damage -t Replace. 
2.  Check: 
•Reed  valve 
• 
Reed  valve  stopper 
• Reed valve  seat 
AIR INDUCTION  SYSTEM 
Cracks/damage -t Replace the reed valve 
assemb l
y. 
3.  Measure: 
• Reed va lve bend ing li mi t a 
Ou1 of  spec ification -t Rep lace t he  reed 
va lve assemb ly. 
~:. 
4. Check : 
Reed valve bending limit 
0.4 
mm (0.02 in) 
• A ir  cul-off va lve 
Cracks/damage -t Rep lace. 
5. Check 
• Air ind uctio n system solenoid 
a 
! 
f 
Refer  to CHECKING THE AIR  INDUCTION 
SYSTEM  SOLENOID 
on  page  8-108. 
7-18  
						

							0 d 
d 
0 
2. Install: 
• 
Reed valve  assembly 1 
• Reed valve assembly 2 
TIP~~~~~~~~~~~~~~-
• Install th e  reed valve  assemb ly 1 so  that  th e 
open  side  turn s to  t he  exha ust  side 
of the en · 
gine . 
• Install th e  reed valve  assemb ly 2  so  th at  th e 
open  side turns  to the  intake  side  of th e  engine. 
A. Reed va lve assemb ly 1 
B . Reed va lve assemb ly 2 
C . Exhaust  side 
3 . 
Install: 
• 
Reed  valve cover 
Reed valve co ver bolt 
10 Nm (1.0  m·kgf,  7.2 ft·lbf) 
LOCTITE® 
7-19 
AIR  INDUCTION  SYSTEM  
						

							ELECTRICAL SYSTEM 
IG NITION SYSTEM .... ......... .... .... ............ .... ..... .... .... ................ .... ..... .... .... ........  8-1 
CIRCUIT  DIAGRAM ..... .... .... .... .... ............. .... .... .... .... .... .... .... ..... ........ .... ....  8-1 
ENGINE  STOPPING  DUE TO SIDESTAND  OPER ATI ON ........................  8-3 
TROUBLESHOOTING ..... ..... .... .... .... .... .... .... .... ..... .... .... .... .... .... .... ......... ....  8-4 
ELE CTRI C START ING SYSTEM ......................................................... .... ........  8-7 
CIRCUIT  DIAGRAM ..... .... .... .... .... ............. .... .... .... .... .... .... ......... ........ .... ....  8-7 
STARTING  CIRCUIT  CUT -OFF SYSTEM  OPERATION ...........................  8-9 
TROUBLESHOOTING .............. .... .... .... ..... .... .... .... .... ................. ........ .... ..  8-11 
CHARGING  SYS TE M ......... .... .... ........ .... ......... .... .... ............ .... ......... .... .... ...... 8-13 
CIRCUIT  DIAGRAM ..... .... ........ ................. ........ ........ ........ ......... ........ .... ..  8-13 
TROUBLESHOOTING .............. ........ ......... ........ ........ ................. ........ .... ..  8 -15 
LIGHTIN G SYSTEM ........... .... .... ........ .... ......... .... .... ............ .... ......... .... .... ...... 8-17 
C IR CU IT DIAGRAM ..... .... .... ........ ............. .... .... ......................... .... ..........  8-17 
TROUBLESHOOTING .............. ........ ......... ........ ........ ................. ........ .... ..  8-19 
S IGNALIN G SY STEM ......... .... .... ............ ......... .... .... ............ .... ......... .... .... ...... 8-21 
C IR CU IT DIAGRAM ..... .... .... ........ ............. .... .... ......................... .... ..........  8-21 
TROUBLESHOO TING .......... ........ ........ ......... .... .... ......................... ..........  8-23 
COOLING  SYS TEM ... ......... .... .... ..................... ................ ..... .... .... .... ..............  8-27 
C IR CU IT DIAGRAM ..... .... .... ........ ............. .... .... ......................... .... ..........  8-27 
TROUBLESHOO TING .......... ........ ........ ......... .... .... ......................... ..........  8-29 
FUEL  INJECTION  SYSTEM ....... ..... ....... .... ..... .... .... ................ ......... .... .... ...... 8-31 
C IR CUIT  DIAGRAM ..... .... .... ..................... .... .... ......................... .... ..........  8-31 
ECU SEL F-D IAGN OSTIC  FUNCT ION .................. ......................... ..........  8-33 
TROUBLESHOO TING  METHOD .......................... ..................... ..............  8-35 
DIAGNOSTIC  MODE ............................ .... .... ................. ........ ........ ...........  8-36 
YAMAHA 
DIAGNOSTIC  TOOL ................................................................  8-37 
TROUBLESHOOTING  DETAILS ...... ......... ........ ........ ................. ........ .... .. 8 -38 
FUEL  PUMP  SYS TEM ........ .... .... ............ ......... .... .... ................ ......... .... .... ...... 8-81 
C IR CUIT  DIAGRAM ..... .... .... ........ ............. .... .... ......................... .... ..........  8-81 
TROUBLESHOOTING ...................... .... ..... ........ ........ ............ ..... ........ .... .. 8 -83 
ELE CTRI CAL COMP ONENT S ........ ................ ................ ......... .... .... ..............  8-85 
CHECKING THE SWITCH ES ............................................ ......... .... .... .... .. 8-89 
CHECKING THE BU LBS AND BULB  SOCKETS .......... ...........................  8-92 
CHECKING THE FUSES .......... .... .... .... ..... .... .... .... .... ................. ........ .... .. 8 -93 
REPL ACING THE ECU (eng ine c o ntro l unit) .............. .............................  8-93 
CHECKING AND CHARGING THE  BATTERY .................................. 8-94 
CHECKING THE RE LAYS ... .... .... .... .... ......... .... .... .... .... .... ......... ........ .... .. 8 -97 
CHECKING THE TUR N SIGNAUHAZARD RELAY ............................ 8-98  
						

							CHECKING THE RELAY UNIT  (DIODE) .... .... .......... ........ ... ... ... ..... ... ... ....  8-99 
CHECKING THE IGNI TION COILS .... .... .... ...... ........ ... .... .... ...... ..... ... ... .. 8 -100 
CHECKING 
THE IGNI TION SPARK GAP .. .......... ... .... .... ....... ... ..... ... .... . 8-100 
CHECKING 
THE  CRANKSHAFT POSITION  SENSOR .............. .. ........ . 8-101 
CHECKING THE  LEAN  ANGLE SENSOR ... ...... ................. ............. ...... 8-101 
CHECKING THE  START ER MOTOR  OPERATION ........... ............. ...... 8-102 
CHECKING THE STATOR  COI

L 
. .. ..... ........ .... .... ........ .............. ... .......... . 8-102 
CHECKING THE RECTIF IER/REGULATOR .... .... .... ............ ..... ........ ....  8-102 
CHECKING THE HORN ....... .... .... .... .... ................. .... ........ .... ..... ........ ....  8-103 
CHECKING THE ENG I

NE  OIL 
LEVEL SWITCH ....... .... .... .... .... ......... .... 8-104 
CHECKING 
THE FUEL SENDER ................................................ 8-104 
CHECKING 
THE FUEL  METER/FUEL LEVEL WARNING  LIGHT ....... 8-105 
CHECKING THE OIL LEVEL WARNING  LIGHT ............................... 8-105 
CHECKING THE  SPEED SENSOR .............................................  8-105 
CHECKING THE RADIATOR FAN MOTORS .... ........ ......... ........ ...........  8-106 
CHECKING THE COOLAN T TEMPERATURE  SENSOR ......................  8-106 
CHECKING THE  THROTTLE POSITION  SENSOR ................... ...........  8-107 
CHECKING THE  ACCELE RATOR POS ITION  SENSOR ....... ....... ... ... .. 

8-107 
CHECKING THE  THROTTLE SERVO  MOTOR ........... ... .... .... ....... ... ... .. 8 -108 
CHECKING THE AIR  INDUCTION SYSTEM SOLENOID ...... ....... ... ... .. 

8-108 
CHECKING THE INTAKE  AIR PRESSURE  SENSOR .... .... ...... ..... ... .... . 

8-109 
CHECKING THE INTAKE  AIR TEMPERATU RE  SENSO R ........... ...... .. 8 -109 
CHECKING THE  GEAR POSITION  SENSOR ........................ .... ..... ......  8-110 
CHECKING THE FUEL  INJEC TORS ......... .... .... ......... ......... .... ... ..... ......  8-111  
						

							,..,,.., 
IGNITION SYSTEM 
EA$27110 
CIRCUIT DIAGRAM 
Ill I 
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li:I I 
€ I I I 
e I 
• 
9• I 
! 
Ii} · I I 
,.®-. I_@-_~-®--;• . ·1 
 t~'. . · 1 ~ ~~ - --..... . 
mi , ml· Ill· . .. .. . m I · 
i .i-• ;u_ --
, 
 !1 i 
·~ --
'--~ 0 
IGNITION  SYSTEM 
-
G:;:>( l 1· • 
® ~ T 
r-:== 
® 
!El·© @ 
-~-jl:.t. 
~llll: :: : . . . --
. ==i=oi>J 
. . -----------· 
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8-1  
						

							3.  Ma in  switch 
4 .  Ma in  fuse 
9 . 
Ign it ion fuse 
13 .Ba
ttery 
14 .Eng ine  ground 
15. 
Fuel inj ect ion  system  fuse 
18.Jo i
nt connector 
19.Jo i
nt coupler 
20.Re lay 
un it 
23. ECU (eng ine contro l unit) 
24. lgn it ion coil #1 
25. I gn it ion coil #2 
26 . 
Ign it ion coil #3 
27 .Spa rk 
p lug 
33 . C rankshaft  posit ion senso r 
38 . Lean 
an gle senso r 
58 . Gea r pos iti
on senso r 
61.S idestand swi tch 
62.  Right 
hand le ba r 

switch 
64 . Start/e ngi
ne stop  switch 
IGNITION  SYSTEM 
8-2  
						

							IGNITION SYSTEM 
EA$1AC18M 
ENGINE  STOPPING DUE TO SID ESTAND OPERATION 
When  the engine  is  running  and the transmiss ion  is in gear,  the  engine  will  stop  if  the  sidestand  is 
moved  down. This is because  the 
electr ic current  from the ignit ion coils does not f low to  the ECU when 
both  th e  gear  position  sensor 
(neutral circu it) and sidestand  switch are set to OFP, thereby  preventing 
the  spa rk 
plugs from  producing a  spark.  Howeve r,  the eng ine  con tinues  to run  unde r the follow ing  con ­
dit ions: 
• The  transm iss ion  is in gear  (the neutral circ uit of the  gear  position  sensor  is open)  and t he s ides ta nd 
i s  up  ( the sidestand  switc h  circui t  is 
closed). 
• 
T he  transm iss ion  is in ne utral (th e neutral circui t of the  gear pos ition sensor  is closed) and  the sides­
tand  is down  (the sides tand  swit
ch circui t is  open). 
1.  Ba ttery 
2 .  Ma in  fuse 
3 .  Ma in  switch 
4 . 
Ignit ion fuse 
5 .  Start/e ngine  stop  switch 
6. I gn it ion coil 
7. Spark p lug 
8. ECU (eng ine cont ro l unit) 
9. S idestand  switch 
1 0.Re lay uni t (diode) 
10 
• 
11 
 
..:-
11. Gear  posit ion sensor (neutra l circuit) 
12.Battery  negative lead 
12 2 
..------, I 
.,: 
= @ 
1 
i 
I 3 I 
4 
~ 
,\5 
• 
8 J 
1
6 
l  9 14. 
 
-~ 
1 7 
8-3  
						

							IGNITION SYSTEM 
EA$27150 
TROUBLESHOOTING 
The ignition  system fails to operate  (no spark or intermittent  spark). 
TIP~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~ 
• Before troubleshooting,  remove the following part(s): 
1.  Ri
der seat 
2. Air scoop 
3. Fuel tank cover 
4. Fuel tank 
5. Air filter case 
1. Check  the fuses. 
(Main,  i
gnition and fue l injectio n 
system)  Refer  to 
CHEC KING THE FUSES 
on page 8-93. 
OK.!. 
2 . Check  the battery. 
Refer  to 
CHECKING AND 
CHARGING THE BATTERY on 
page 8 -94. 
OK.!. 
3 . Check  the spark plugs. 
Refer  to CHECKING T H E SPARK 
PLUGS on page 3-4. 
OK.I. 
4. Check  the ignitio n spark gap. 
Refer  to 
CHECKING T H E IGNI­
TION SPARK GAP on page 8-100. 
NG.!. 
5.  Check the  ignition coils. 
Refer  to CHECKING THE IGNI ­
TION COILS  on page 8-100. 
OK.!. 
6. Check  the crankshaft position sen­
sor. 
Refer 
to CHECKING THE CRANK­
SHAFT POSITION  SENSOR on 
page 8-101 . 
OK.!. 
7. Check  the main switch. 
Refer  to 
CHECKI NG THE 
SWITCHES  on page 8-89. 
OK.!. 
8. Check th e starVe ngin e stop swit ch. 
Refer  to 
CHECKI NG T H E 
SWITCHES  on page 8-89. 
OK.I. 
NG~ 
NG~ 
NG~ 
OK~ 
NG~ 
NG~ 
NG~ 
NG~ 
8-4 
Replace th e  fuse(s) . 
• C lean the battery terminals . 
• Recharge or replace the battery. 
Re-gap 
or replace th e spark plugs. 
Ignit ion system is OK. 
Replace the ignition coils. 
Replace the crankshaft position sensor. 
Replace the main switch. 
Replace th e right  ha ndlebar switch .  
						

							9. Check the  gear  position sensor 
Refer  to  CH ECK ING THE  GEAR 
POSITION  SENSOR on page 
8-11  o. 
OKt 
1 o.Check  the sidestand  switch. 
Refer  to 
 CHECK ING THE 
SWITCHES on  page  8-89. 
OKt 
11.Check  the relay unit  (d iode). 
Refer  to 
CHECK ING T H E  RELAY 
UNIT  (DIO DE) on  page  8-99. 
OKt 
12.Check  the lean  angle sensor . 
Refer  to 
CHEC KING THE  LEAN 
ANGLE 
SENSOR on  page 8-101. 
13.Check  the entire ign ition  systems 
wiring. 
Refer  to 
CIRCUIT  DIAGRAM  on 
page  8-1. 
Replace the ECU. 
Re fer  to  REPLAC ING THE ECU (en­
g ine control  unit) on page 8-93. 
NG~ 
NG~ 
NG~ 
NG~ 
NG~ 
8-5 
IGNITION  SYSTEM 
Replace the gear  position  sensor. 
Replace the  sides tand swit ch. 
Replace the re lay unit. 
Rep lace the lean  angle sensor. 
Proper ly con nec t or repai r th e  ignition sys­
tems  wiring.