Yamaha Fz 09 2014 Manual

							e. Meas ure  the coo lant tempera ture sensor re­
s istance. 
••••••••••••••••••\
•••••••••••••• 
3. Install: 
•  Coo lant 
tem pera ture  senso r 
,. 
Coolant temperature sensor 
16 Nm  (1.6 m·kgf, 12 ft·lbf) 
CHECKING 
THE  THROTTLE POSITION 
SENSOR 
1.  Remove : 
• T hrott le position sen so r 
(from  the 
thro ttle bod ies) 
EWA1AC1106 
A WARNING 
• Handle the throttle position sensor with 
special care. 
• Never  subject  the throttle position sensor 
to strong shocks. If the throttle position 
sensor is dropped , replace it. 
2.  Check: 
• Throttle pos it ion  sensor  maximum  resistance 
Out of spec ificatio n 4 Replace the thrott le 
posi tion sensor. 
l~I 
Resistance 
1.20-2.so  kn 
••••••••••••••••••\
•••••••••••••• 
a.  Con nect  the  pocket  tester (Q x  1 k) to  the 
thrott le pos it io n  senso r 

term ina ls 
as  sho wn. 
Pocket  tester 
90890-03112 
Analog 
pocket tester 
YU-03112-C 
• 
Pos itiv e tes ter  probe 4 
blu e  1  
• 
N egative  teste r probe 4 
black/b lue  2  
ELECTRICAL  COMPONENTS 
b. Measure  the throttle po sition  sensor  maxi­
m um  resi stance  . 
••••••••••••••••••\
•••••••••••••• 
3. Install: 
•  Th rottle 
pos itio n senso r 
TIP~~~~~~~~~~~~~~­
When installing th e thrott le pos iti on sen sor , ad ­
just  its 
angl e  proper ly . Refe r to ADJUSTING 
T HE  THROTTLE POS ITION  SENSOR  on  page 
7-12. 
, ... , ... ,. 
CHECKING THE ACCELERATOR  POSITION 
SENSOR 
1. Remove: 
•  Accelerator posi tion sensor 
(fr
om the thrott le bod ies) 
EWA1FCl106 
A WARN ING 
•  Handle the accelerator position sensor with 
special care. 
• Never  subject the accelerator position sen­
sor to strong  shocks. If the accelerator  po­
sition sensor is dropped, replace it. 
2.  Check : 
• Accelera tor posit ion  sensor  maxim um  res is­
ta nce 
Out of  specif icat ion 4 Repla ce the acce lera­
tor pos iti on  sensor. 
l~I 
Resistance 
1.08-2.52  kQ 
••••••••••••••••••\
•••••••••••••• 
a .  Co nn ect  th e  pocke t teste r (!1 x 1 k) to  the ac-
cele rato r pos iti on  senso r termina ls as s h own . 
Pocket  tester 
90890-03112 
Analog 
pocket  tester 
YU-03112-C 
• Pos it iv e  tester  probe 4 
blue  1  
• 
Nega tive  tester  probe 4 
black/b lu e  2 
8-107  
						

							b. Measure  the accelerator pos it ion  sensor 
maximum  resistance. 
••••••••••••••••••\
•••••••••••••• 
3. Install: 
•  Acce lera tor 
posit ion  sensor 
TIP~~~~~~~~~~~~~~­
When installing the accelerato r position  sensor , 
ad just  its 
ang le  proper ly . Re fe r  to ADJ USTING 
THE  ACCELERATOR POSITION  SENSOR on 
page 
7-13. 
EAS1RCl81» 
CHECK ING THE THROTILE SERVO  MOTOR 
1. Remove: 
• Air f il ter case 
Refer  to 
GE

NERAL  CHASSIS 
on page  4-1. 
2.  Chec
k: 
•Throttle  valve operation 
Throttle  valves do not fully close -t Replace 
the throttle bodies . 
••••••••••••••••••\
•••••••••••••• 
a. Connec t two  C-size  batteries  to the thro ttle 
servo  motor  termina ls 1 as  show n. 
ECA IRC\802 
NOTICE ~~~~~~~~~~~~-
Do not use a  12  V battery to operate the throt­
tle servo motor. 
TIP--------------­
Do  not use old batteries  to opera te  the throttle 
servo  motor. 
ELECTRICAL  COMPONENTS 
+ 
3V 
+ 
3V 
A. Check that  the th rott le  va lves  2  open . 
B . 
Check tha t the thrott le  va lves  2  fully close . 
CHECKING  THE AIR INDUCTION SYSTEM 
SOLENO
ID 
1. Check: 
• A ir induction system soleno id res istance 
Out of spec ification -t Rep lace. 
'~' 
Solenoid resistance 
20-240 
TTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTT 
a.  Remove  the air induct ion  system soleno id 
coup ler 
from  the air ind uctio n system sole­
noid . 
b. Connect  the pocket tester (n x 1) to the  air in ­
d uction  system soleno id  termina l as shown. 
Pocket 
tester 
90890-03112 
Analog pocket tester 
YU- 03112 -C 
• 
Positive  tester probe -t 
Air  in d uct ion  system sole no id  terminal  1  
• 
Nega tive  tester  probe -t 
Air  induct ion  system so leno id  terminal  2 
8-108  
						

							2 1 
D 
c. Meas ure  the a ir  in du ction  system  sole no id  re ­
sista nce. 
EAS2&11 
CHECKING THE INTAKE  AIR PRESSURE 
SENSOR 
1. Chec k: 
•  In ta ke air  pre ssu re  se nsor ou tp ut vol ta g e 
Ou t of sp eci fica tion -> Rep lace. 
Intake air pressure sensor output 
voltage 
3.57-3.71 V @ 101.3 kPa 
TTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTT 
a.  Connec t the  test  harness S-pressu re  sensor 
(3P) 
1 to  the intake  air  p ressure  sensor  and 
w ire  har ness  as shown. 
£CA 1RCl&OS 
NOTICE ~~~~~~~~~~~~~ 
Pay attention to the installing direction of the 
test harness S-pressure sensor (3P) cou­
pler. 
b.  Conne ct th e  digi ta l c ir cu it 

tes ter  (
DCV) to  th e 
t e st  ha
rness S-pressu re  se ns or  (3P). 
Digital 
circuit tester 
90890-031 74 
Model 
88 Multlmeter with tachom ­
eter 
YU-A1927 
Test harness S -pressure sensor 
(3P) 
90890-03207 
YU- 03207 
• 
P ositive tes ter  probe 
p in k  (w i
re harne ss co lor) (inta ke  air pres­
su re  sensor  1) 
p ink/w hite  (wi
re harness  co lo r) (int ake  air 
pressure  sensor  2) 
• N ega tive  tes te r  probe 
b lack/blue (w ire harness colo r) 
ELECTRICAL  COMPONENTS 
 
A. In take a ir  pressure  se nsor 1 
B. Intak e air  pressure sensor 2 
c. Se t th e  ma in  switch  to ON . 
d.  Measu re  the  inta ke  air  pressu re  senso r out­
put vo ltage. 
••••••••••••••••••\
•••••••••••••• 
....,..,. 
CHECKING THE INTAKE  AIR 
TEMPERATURE  SENSOR 
1.  Rem ove: 
• Inta ke a ir  tem perature sensor 
EW14110 
A wARNING 
• Handle the Intake air temperature sensor 
with special care. 
• Never subject the Intake air temperature 
sensor to strong shocks. If the  intake air 
temperature sensor is dropped,  replace it. 
2. C heck: 
• Inta k e a ir t emperature senso r res is tance 
O ut of specifi catio n -> Rep la ce. 
Intake air temperature sensor re­
sistance 
540~6oo n@o 0c (32 °F) 
290-390 
n@8o • c (176 ° F) 
TTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTT 
a.  Con nec t the pocke t tester (n x 100) to the  in ­
ta ke  air  tempera tu re  sensor  te rmi nal  as 
s h own. 
8-109  
						

							Pocket tester 
90890-03112 
Analog 
pocket tester 
YU-03 112 -C 
b. Immerse the  intake 

air  temperatu
re sensor 
1  in  a con ta ine r filled with  wate r 2. 
TIP~~~~~~~~~~~~~~~ 
Make  sure that the intake  air  tem perature sensor 
termina ls do  not 

get wet. 
c. 
P lace a 

th ermometer 
3 in the  wa ter. 
3 
1 
2 
d. 
S low ly heat  the wa te r,  th en let it coo l dow n to 
the  specified  tempera
ture. 
e. Measure  the in take  air  temperature  sensor 
resistance. 
••••••••••••••••••\
•••••••••••••• 
3. Install: 
•  In ta ke 
air  tempe rature  sensor 
EA$1ACHllS 
CHECKING THE  GEAR POSITION  SENSOR 
1. Remove: 
•Fue l ta n k 
Refer  to 
FUEL TANK  on  page  7-1. 
• Gear  positio n sensor 
Refer  to 
CRANKCASE  on page  5-56. 
2.  Check: 
• Gear  positio n sensor 
Out of specif icat ion-+ Replace the gea r posi ­
tion  sensor . 
Pocket tester 
90890-03112 
Analog 
pocket tester 
YU-03112-C 
8-110 
ELECTRICAL  COMPONENTS 
Result 
Neutral 
position 
Continuity 
Positive tester  probe 
sky blue 1  
Negative  tester probe 
Sensor  terminal  a 
1st position 
Continuity 
Positive tester probe 
white 
 2  
Negative  tester probe 
Sensor  terminal  b  
2nd position 
Continuity 
Positive tester  probe 
pink 3 
Negative  tester probe 
Sensor  terminal  c 
3rd position 
Continuity 
Positive tester probe 
yellow/white  4  
Negative  tester probe 
Sensor  terminal  d  
4th position 
Continuity 
Positive tester  probe 
white/red 
 5 
Negative  tester probe 
Sensor  terminal  e 
5th position 
Continuity 
Positive tester probe 
orange 
 6  
Negative  tester probe 
Sensor  terminal f 
6th position 
Continuity 
Positive tester  probe 
gray 
 7  
Negative  tester probe 
Sensor  terminal  g   
						

							EA$1ACHll7 
CHECKING THE FUEL INJECTORS 
The following procedure applies to all of the fue l 
injectors. 
1.  Remove: 
• Fue l injector 
Refe r 
to THROTTLE  BODIES on page  7-5. 
2.  Check: 
•  Fue l injector  res istance 
Out of  specif icat ion -+ Replace the fue l injec­
tor. 
l~I 
Resistance 
12.0 Q 
••••••••••••••••••\
•••••••••••••• 
a.  Disconnect  the fue l injector coupler from  the 
fuel injector. 
b.  Connect  the pocket  tester (Q x 10) to the fue l 
injector coupler as  shown. 
Pocket tester 
90890-03112 
Analog pocket tester 
YU-03112-C 
• Pos itive tester probe -+ 
Injector  terminal  1  
• 
Negat ive teste r probe -+ 
In jecto r te rminal  2 
1  2 
c. Measure  the fuel injector  resistance. 
8-111 
ELECTRICAL  COMPONENTS  
						

							TROUBLESHOOTING 
TROUBLESHOOTIN G ........................................ ......................... ........ .............  9-1 
GENERAL 
INFORMATION .............. .... .... ........ .... ............. ........ ........ .... .... . 9-1 
STARTING  FAILURES ..... .... .... .... .... .... ..... .... .... .... .... .... .... .... ..... ........ .... ....  9-1 
INCORRECT  ENGINE IDLING SPEED ........ .... .... .... .... ........ ..... ........ .... ....  9-1 
POOR  MEDIUM -AND -HIGH-SPEED  PERFORMANCE ......................... 9-2 
FAUL TY GEAR SHIFTING ... ........................................ .................. 9-2 
SHIFT PEDAL DOES NOT MOVE ...... .... .... .................... .... ........ ............  9-2 
JUMPS  OUT OF GEAR ........ .... .... .... ........ .... .... ......... ........ ........ .... ......... ....  9-2 
FAUL TY CLUTCH ........................................ ................................. .............  9-2 
OVERHEATING ............................................ ................................. .............  9-2 
OVERCOOL ING ........ ........... .............. ........ ............... .................... .............  9-3 
POOR  BRAKING PERFORMANCE ......... .................... ........ ......................  9-3 
FAUL T Y FRON T FORK  LEGS .... ........ ....... ........ ...... ................ ..................  9-3 
UNSTABLE  HANDLING ..... ........ ........ ......... .... .... .......................................  9-3 
FAUL T Y LIGHTING  OR SIGNALING  SYSTEM ......................................... 9-3 
SELF -DIAGNOSTIC  FUNCTION AND DIAGNOSTIC CODE TABLE ............. 9 -5 
EVENT C O DE TABL E ....................................................................................  9-12  
						

							EA~1 
TROUBLESHOOTING 
, ....... 
GENERAL INFORMATION 
TIP--------------­
The following guide for troubl eshooting does  not 
cover 
all the poss ible causes  of tro ub le. It shou ld 
be h elpful, how ever, as a gu ide to basic troub le­
shooting.  Refer to the relat ive procedure in this 
manual for checks , adjustments,  and rep lace ­
ment of parts. 
EAS3Q.l.10 
STARTING  FAILURES 
Engine 
1. Cylinder(s) and cylinder h ead(s) 
• Loose  spark plug 
• 
Loose cylinder head or cylinder 
• 
Damaged 

cylinder 
head  gasket 
• Worn  or damaged cylinder 
•  Incorrect  valve  cleara nce 
•  Imp roperly  sealed  valve 
•  Incorrect  valve-to-va lve-seat 
con tact 
•  Incorrect valve tim ing 
•  Fau lty  valve spring 
• Seized valve 
2.  Piston(s)  and piston  ring(s) 
• Imp roperly inst alled piston  ring 
• Damaged , worn or fa tig ued  piston  ring 
• Se ized  piston  ring 
• Se ize d or  damaged  piston 
3.  Air 
filter 
•  Improper ly 
installed air filter 
•  C logged 
air filter  element 
4.  Crankcase  and crankshaft 
• Improper ly  assemb led crankcase 
• Seized  crankshaft 
Fuel system 
1. Fue l tank 
• Empty fuel tank 
•  C logged  fu el tank  cap breather hole 
• 
Deteriorated  or contaminated fuel 
•  C logged 
or  damaged fu el hos e 
2. 
Fue l pump 
• Fau lty  fuel pump 
• Fau lty  fuel pump relay 
3. Thrott le body  (-ies) 
• Deteriorated or contaminated fuel 
• 
Sucked-in  air 
Electrical system 
1.  Battery 
• Discharged  battery 
• Fau lty battery 
9-1 
TROUBLESHOOTING 
2.  Fuse(s) 
• Blown, damaged or incorrect  fuse 
•  Improper ly  installed fuse 
3. Spark  plug(s) 
•  Incorrect 
spark plug gap 
• Incorrect spark plug heat range 
•  Fouled spark plug 
• Worn or damaged elec trode 
• 
Worn or damaged in sulator 
4. Ignitio n coil(s) 
• 
Cracked or brok en  ignition coil body 
• Broken or shorted  primary  or secondary coils 
5. Ign ition system 
• Fau lty ECU 
• Faulty crankshaft  position  sensor 
• Broken  generator  rotor woodruff  key 
6. Switches  and wiring 
• Faulty ma in swi tc h 
• Fa ulty start/eng ine  stop switch 
• Bro ken or shorted  wiring 
•  Fau lty gear  posit ion sensor 
•  Fa ulty sidestand  switch 
• Fau lty clutch switch 
•  Improper ly grounded  circu it 
• Loose  connec ti ons 
7. Starting  system 
• Fa ulty starter  motor 
• Fa ulty starter relay 
•  Fau l
ty start ing  circuit  cut-off relay 
•  Fau l
ty starter clutch 
....,..,. 
INCORRECT  ENGINE IDLING SPEED 
Engine 
1. Cylinder(s) a nd cylinder head(s) 
•  Incorrect  valve clearance 
• 
Damaged valve trai n  componen ts 
2 .  Air 
fil te r 
•  C logged 
a ir fil te r element 
Fuel system 
1. Th rottle body  (-ies) 
• Damaged or loose  throttle body joint 
• Improper ly synchronized thrott le bod ies 
•  Improper  throttle grip  tree play 
•  Flooded  throttle 
body 
• Fau lty air induction  system 
Electrical system 
1. Battery 
• Discharged  battery 
• Faulty battery 
2. 
Spark  plug(s) 
•  Incorrect 
spark plug gap 
•  Incorrect spark plug heat  range 
• Fou led spark p lug  
						

							• Worn or damaged  elect rode 
• Worn  or damaged  ins u

lato r 
3. 
Ign it io n  coil(s) 
• 
Broken  or sh orted  primary or secondary coil s 
• 
C racked  or broken  ig n

it io n 
coil 
4. Ign it io n sys tem 
•Fau lty ECU 
•  Fau lty 
cranks haft  pos it io n  se nsor 
• Broken gene rator  rotor woodruff  key 
, . .,.,.., 
POOR MEDIUM -AND-HIGH -SPEED 
PERFORMANCE 
Refe r  to STARTING  FAILURES on page 9-1. 
Engine 
1  . A ir filter 
•  C logged 
a ir filte r e lemen t 
Fuel sy stem 
1. T hrott le body (- ies) 
•  Fau l

ty  thro tt
le body 
2. Fue l pump 
• Fau l

ty fuel 
pump 
EA$29530 
FAULTY GEAR SHIFTING 
Shift ing Is d iff ic u lt 
Refer  to Clutch  drags. 
EA~~ 
SHIFT PEDAL DOES NOT MOVE 
Shift 
s haft 
•  Improper ly adj usted  shift  rod 
• Bent s hift  sh aft 
Shift drum  and  shift  fork s 
• Fore ign  object  in a shift  drum  groove 
• Seized shift fork 
• Bent  shift  fork  guide bar 
Transmi ssi on 
• Seized transmiss ion  gear 
• Fore ign  object  between  tra nsm issio n gears 
• Improper ly  assembled tran sm is s ion 
JUMPS OUT OF GEAR 
Shift s haft 
•  Incorrect shift peda l positi on 
•  Improper ly r eturned  stopper lever 
Shift fork s 
• Worn  shift  fork 
Shift dru m 
•  Incorrect  axial  play 
• 
Worn  shift  drum  groove 
Trans missi on 
• Worn  gear dog 
9-2 
TROUBLESHOOTING 
 FAUL TY CLUTCH 
C lutch  slip s 
1. C lu tc h 
•  Improper ly  assemb led  clut
ch 
• Improper ly adj usted cl utch cab le 
• 
Loose  or fatig ued clu tc h spri ng 
• Worn frict ion p late 
• 
Worn clutch  plate 
2 .  Eng ine o il 
•  Incorrect  o
il level 
•  Incorrect  o
il viscos ity (low) 
• 
De teriora ted oil 
C lutch dra g s 
1. C lu tc h 
•  Uneven ly 
tens ioned clutch springs 
• W arped  pressure plate 
• 
Ben t clu tch  plate 
•  Swollen 
friction p late 
• 
Bent c lu tch  pull rod 
• Broken clutch 

boss 
• Burnt  primary driven  gear bus hing 
• Matc h marks  not aligned 
2.  Eng in e oil 
•  Incorrect  o
il level 
•  Incorrect  o
il viscos ity  (hig h) 
• De teriora ted oil 
O VERH EATIN G 
Engine 
1 . Clogged  coolant passages 
• Cylinder head(s)  and piston(s) 
• Heavy  carbon build up 
2.  Eng in e oil 
•  Incorrect  o
il level 
•  Incorrect  oil 
v iscos ity 
•  In fer io r o il  q ua li ty 
Coo ling system 
1 . Coo la nt 
• 
Low cool a nt level 
2 .  Rad ia to r 
• Damaged  or leaking r ad iato r 
• Fa ulty rad iator  cap 
• Bent or damaged  rad iato r fin 
3.  Wate r p ump 
• Damaged or faulty water  pump 
• Thermos tat 
• Thermostat stays closed 
• O il  coo ler 
•  C logged 
or  damaged oil  cooler 
• 
Hose(s)  and p

ipe(s) 
• Damaged  hose 
• Improper ly connected  hose  
						

							• Damaged pipe 
• Improperly connected  pipe 
Fuel system 
1. T hrott le body  (-ies) 
• Damaged  or loose thro ttle body join t 
2 .  Air 
filter 
•  Clogg ed 
air filter  elemen t 
Chassis 
1. Brake(s) 
• Dragg ing  brake 
Electrical system 
1. Spark plug(s) 
•  Incorrect 
spar k plug gap 
•  Incorrect spar k plug heat  range 
2. 
Ign it ion sys tem 
•Fau lty  EC U 
EA.~10 
OVERCOOLING 
Cooling system 
1. Thermosta t 
• Thermostat stays  open 
, . .,_ 
POOR BRAKING PERFORMANCE 
• Worn  brake  pad 
• Worn brake  disc 
• A ir in hydrau lic brake  system 
• Leaking  brake flu id 
•  Faul ty 
brake caliper k it 
•  Faul ty brake caliper  seal 
• 
Loose  union bol t 
• 
Damaged bra ke  hos e 
• Oil or grease  on  the  brake  disc 
• Oil or grease  on  the  brake  pad 
• Incorrect brake fluid  level 
, . .,_ 
FAULTY  FRONT FORK LEGS 
Leaking oil 
• Bent, damaged or rusty inner  tube 
• C ra cked or damaged outer tube 
•  Improper ly ins talled  oil sea l 
• 
Damaged oil sea l lip 
•  Incorrect  oil  leve l 
(high ) 
• Loose  dampe r 

r od 
assemb ly bol t 
• 
Damaged  damper rod assemb ly  bol t copper 
washer 
• Cracked or damaged cap bo lt  0 -ring 
Malfunction 
• Bent or damaged  in ner  tube 
• Ben t or damaged  outer  tube 
• Damaged  fork spring 
• Worn or damaged  outer tube bush ing 
• Ben t or damaged  damper rod 
9-3 
TROUBLESHOOTING 
• Inco rrect  oil v iscos it y 
•  Inco rrec t oil leve l 
......,. 
UNSTABLE HANDLING 
1. Hand leba r 
• 
Ben t or improperly installed ha ndlebar 
2. Steer ing  head  componen ts 
•  Improper ly  installed upper  bracket 
• Improper ly  installed  lower bracket 
(improperly tightened  ring nut) 
• Bent  steering  stem 
• Damaged ball bearing or bear ing  race 
3.  Fro nt fork 
leg(s) 
•  Uneven  o
il leve ls (bo th fro nt fork legs) 
•  Uneven ly 
tensioned  fork spring  (both  front 
fo rk 
legs) 
• 
Bro ken for k spring 
• Bent  or damaged  inner  tu be 
• Bent  or damaged  outer tube 
4 . 
Swin garrn 
• Worn  bearing or b ush ing 
• Bent or damaged  swin garm 
5. Rea r shock  absorber assembly( -ies) 
• Fau lty rear  shock  absorber  spring 
• Leaking o il or gas 
6. Tire(s) 
•  Uneven tire  pressures  (front and  rear) 
• Incorrect tire press ure 
• Uneven tir e  wear 
7. W he el(s) 
•  Inco rre
ct wheel  balance 
• 
De formed  cast wheel 
• 
Damaged wheel be aring 
• Be nt or loose  wheel axle 
• 
Excess ive wheel runou t 
8.  Frame 
•Bent frame 
• Damaged  steering head  pipe 
•  Improper ly  installed bea ring race 
,,.,.,,, 
FAUL TY LIGHTING  OR SIGNALING  SYSTEM 
Headlight does not come on 
• Wrong headlight b ulb 
• 
Too  many electrical accessor ies 
• Hard charg ing 
• Inco rrec t connect ion 
•  Imprope rly grounded  circu it 
• Poor con tacts  (main or light sw it ch) 
• Burnt-out h eadligh t b ulb 
Headlight bulb burnt out 
• Wrong h eadlig ht b ulb 
•  Fau lt y 
battery