Yamaha Fz 09 2014 Manual

							5. Meas ure: 
• Engine o il p ressure 
(a t the 
following co nd iti ons) 
Oil pressure 
230.0  kPa/5000  r/ min @100  °C 
(2.3  kgf/cm2tsooo r/min,  33.4 
psi/5000 r/min@ 212 °F) 
Out of specificati on ~ C heck. 
Engine o il pressure Po ssible causes 
•  Faulty  oil pump 
• C logged  oil fil t e r 
Be low 
spec if icat ion • Leaking oil pas -
sage 
• B ro ke n  or  dam -
age d 
oil sea l 
• 
Leak ing o il pas -
sage 
Above  specifica tio n 
•  Faulty  oil fi lter 
•  O il viscosity  too 
h ig h 
6. 
Install: 
• 
M ain gallery  bolt 
Main gallery  bolt 
8 Nm (0.8  m·kgf , 5.8 ft·lbf) 
ECA1AC1301 
NOTICE~~~~~~~~~~~~ 
Be careful not to  tighten too much. 
EA$21110 
CHECKING THE COOLANT LEVEL 
1.  Stand  the 
vehicle on  a leve l su rface. 
TIP~~~~~~~~~~~~~~-
•  P lace th e veh ic le o n  a suitab le sta nd. 
• Make  sure  the vehicle is  up r ight. 
2.  Chec k: 
•  C oo lan t leve l 
The coo la n t  level sh ou ld be  betwee n the 
max imum 
le ve l mark a and 

min imum 
l eve l 
PERIODIC  MAINTENANCE 
mark b. 
Below th e minimum leve l mar k ~ Add the 
r ecomme nded 
coo lant t o  the  proper leve l. 
NOTICE ~~~~~~~~~~~~~ 
• Adding w ate r Instead of coolant lower s the 
antifreeze  concentration 
of the coolant. If 
water Is u sed Inste ad of coolan t check, and 
if necessary , correct the antifreeze concen­
tration of the coolant. 
•  Use 
only distilled water.  However , if dis ­
tilled water  is not available , soft water may 
be used. 
3.  Start  the engine,  warm  it up  f
or several min­
u
tes, and  th en  tum it off. 
4.  Check: 
•  Coo lant  level 
TIP~~~~~~~~~~~~~~­
Befo re  check ing  the coo la nt  le ve l, wa it  a  few 
m in utes 
until it settl es. 
eA.$21120 
CHECKING THE COOLING  SYSTEM 
1. Che ck: 
3-25 
• Radia to r 1  
• 
Radi a to r in le t hose 2  
• 
Radi ator ou tlet hos e 3 
•  O il  coo ler  4 
•  O il  coo ler  inlet 
h ose 5 
•  O il  coo ler  outlet 
hose 6  
• 
Wa ter jacket joint 7 
• Wate r p ump inl et p ipe  8  
Cracks/damage ~ Replace . 
Refe r  to RADIATOR  on page  6-1, OIL 
C O OLER  
on page  6-4 , THERMOSTAT  on 
page  6-6  and  WATER 
PU MP on  page  6-8 .  
						

							1 
3 
CHANGING THE COOLANT 
1. Remove : 
• Radiato r cap bo lt  1 
• 
Rad iator  cap 2 
• 
Rad iato r cap  stoppe r 3 
EWAIOO:)) 
AwARNING 
A hot radiator  is under pressure.  Therefore , 
do not remove the radiator cap when  the en­
gine is hot. Scalding hot fluid and  steam  may 
be 
blown out, which could cause serious in­
jury.  When 
the engine  has cooled, open the 
radiat or  cap  as 
follows: 
Place 
a thick rag or a towel ove r  the  radiator 
cap and slowly turn  the radiator cap counter­
clockwise toward the  detent to allow any  re­
sidual pressu re to escape . When the hissing 
s ound  has stopped, press down on  the  radi­
a
tor c ap  and  turn it countercl ockwise  to re­
mo ve . 
2.  Remove: 
• Coo lant reservo ir bolts  1 
PERIODIC  MAINTENANCE 
• Coo lan t reservoi r cover 2  
•  Coo lant 
r eservo ir  3  
• Collars  4  
3 .  Remove: 
• Coo lan t reservoi r cap 1 
4.  Drain: 
• Coo lant 
(from  the coola nt reservo ir) 
5.  Remove: 
• Water  pump  drain bolt  1 
• 
Copper  washer 2 
6.  Dra in : 
• Coo lant 
(from  the engine  and  radiato r) 
7. Install: 
• 
Water  pump  drain b o lt 
• Copper washer l@@W 
8. Install: 
• Collars 
3-26 
Water pump drain bolt 
10 Nm (1. 0 m·kgf , 7.2 ft·lbf)  
						

							• Coolant reservo ir 
•  Coolant reservo ir  cover 
•  Coolant reservo ir bolts 
9.  Fill: 
Coolant reservoir bolt (MS) 
0.5 Nm (0.05  m·kgf,  0.3 7 ft·lbf) 
Coolant 
reservoir bolt (M6) 
9  Nm 
(0 .

9  m·kgf , 
6.5 ft·lbf) 
•  Cooling 
system 
(with  the spec i
fied amount  of the recom ­
mended coolant) 
Recommended  antifreeze 
High-quality ethylene glycol anti­
freeze containing  corrosion 
inhibitors for aluminum engines 
Mixing  ratio 
1 
:1 (antifreeze:  water) 
Radiator  capacity 
(including  all 
routes) 
1.93  L 
(2.04  US qt, 1. 70 Imp.qt) 
Coolant 
reservoir  capacity (up to 
the maximum level mark) 
0.25 L (0.26  US qt, 0.22 Imp.qt) 
Handling 
notes  for coolant 
Coolant 
i s  potent ially harmful and shou ld be 
h andled with spec ial care . 
EWA13CMO 
A WARNING 
• If coolant  splashes in your eyes, thorough­
ly wash them with  water  and consult a doc­
tor. 
• If coolant splashes on your clothes, quickly 
wash it away with water and then with soap 
and  water. 
• If coolant Is swallowed , Induce vomiting 
and get Immediate  medical attention. 
NOTICE ~~~~~~~~~~~~~ 
• Adding water instead of coolant  lowers the 
antifreeze  concentration 
of the coolant. If 
water is used instead of coolant check,  and 
if necessary,  correct the antifreeze concen­
tration of the coolant. 
•  Use 
only distilled water.  However, if dis­
tilled 
water is not ava ilable , soft water may 
be used. 
• If coolant comes into contact  with painted 
surfaces , 
immediately wash them with wa­
ter. 
• Do not mix different  types of antifreeze . 
PERIODIC  MAINTENANCE 
1 O.lnstall: 
• 
Radi a tor cap  stopper 
• Radia tor cap 
• Radia tor cap bolt 
Radiator cap bolt 
5  Nm (0 .5  m·kgf, 3.6 ft·lbf) 
11.Fill: 
• Coo lant r eservo ir 
(w i
th  the recomme nded coo la nt to the maxi­
mum level mark a) 
12.lnstall: 
•  Coo lant 
r eservo ir cap 
13.Start the  eng ine, wa rm  it  up  for several  min­
utes,  and then tum  it off. 
14.Check: 
•  Coo lant  level 
Ref er to CHECKING THE COOLANT  LEV­
EL on page  3-25. 
TIP~~~~~~~~~~~~~~­
Before  checking  the coolant  leve l, wai t a  few 
minutes 
un til the coo lant has settled. 
EA.SIRC13l3 
CHECKING THE FRONT BRAKE LIGHT 
SWITCH 
Refer to  ELECTRICAL  COMPONENTS on 
page  8-85. 
 ADJUSTING THE  REAR  BRAKE LIGHT 
SWITCH 
TIP~~~~~~~~~~~~~~­
T he  rear  brake ligh t switch  is  operated  by move­
ment  of the brake pedal. The  rea r brake ligh t 
switch is proper ly adjusted  when the  brake light 
comes on just  before  the brak ing eff ect  starts. 
1 .  Check: 
• Rear brake ligh t operation timing 
Incorrect~ Adjust. 
2.  Adjust: 
• Rear  brake light operat ion timing 
3-27  
						

							TTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTT 
a. Hold t h e  main  body 1 of the  rear brake lig ht 
swi

tch  so  th a t it d oes  not  ro tate  and  tum 
the 
ad jus ting  nut 
2 in  direc tion a o r b  un til th e 
r e a r b ra k e 
lig ht comes  on  at  th e  proper  time. 
Dire c
tion a  
Brake light come s on so oner. 
Dir ec
tion b  
Brake light com es  on la ter. 
EA.$?1090 
C HECKING AND LUBRICATING THE 
C ABLE S 
PERIODIC  MAINTENANCE 
Dam age /dete rioration -> Replace . 
•  Th rottl e cab le 
insta llation 
Inc orre ct-> R einst all the th rottl e ca bles . 
Refe r to HA NDLEB AR on  page  4-44. 
2. C he ck: 
•  Th rottle grip mov em en t 
Rough  mo veme nt -> Lub ricate  or rep la ce th e 
defe cti
ve pa rt (s). 
Reco mmen ded 
lubrican t 
1--aa Suita bl e cable lubrica nt 
TIP~~~~~~~~~~~~~~­
W ith  the  eng ine  stop ped , turn the th rott le g rip 
s lo wly an d release it.  Make  sure tha t th e th rott le 
grip  tu rn s smoo thly a nd  ret urns p ro p erly w he n 
rele ase d. 
Repe

at  th is c hec k wi th  th e 
han d leb ar  turn e d all 
th e 

w ay t o th e 
left a nd right. 
3. C hec k: 
•Th rottl e grip free pla y  a  
Out 
o f specif icati on -> Adj ust. 
Thro ttle grip free pl ay 
3 .0-5.0 mm (0 .12-0. 2 0 In) 
The follo wing pro cedu re applies to all of  the  in- / 
ne r 
a n d o uter 
c a bles. 
E W A\3VO 
AwARNING 
Dam ag ed oute r ca ble may cause th e ca ble to 
corrode and interfere  with its moveme nt.  Re­
place d ama ged  outer cable and  inner cables 
as soon as possible . 
1.  Chec k: 
•  O uter  cable 
Damage ->  Replace. 
2.  Check: 
•  Cab le o p era tion 
Rou gh  mov emen t 
-> Lubrica te. 
R ecom mende d 
lubricant 
l Eng in e oil or a suita ble  cabl e lu -
bricant 
TIP~~~~~~~~~~~~~~~ 
H old t he  ca ble end  uprig ht a nd  po ur  a few  drops 
of 
lub ric a nt in to 

t h e 
cab le sheath or use  a  suit­
ab le  lub rica ti n g d ev ice. 
 C HEC KIN G THE THROTILE  GRIP 
1.  Check: 
•  Throttle  cab les 
4.  Adjust: 
• Th rottle  grip free pla y 
TIP~~~~~~~~~~~~~~­
Prior to  adjus ti n g  the th rott le grip  free play, th ro t­
tle body  synchronizat ion should be  adjusted 
p rope rly . 
••••••••••••••••••\
•••••••••••••• 
a. S lide b ack  the rub be r cover 1  . 
b. Loo sen  the locknu t 2. 
c.  Turn  the  ad ju sti ng  nu t 3  in 

dire ctio n 
a  or b 
u ntil  th e sp ecified  thr ottle  grip free  play  is 

ob­
ta
ine d . 
D ir ec tion 
a 
Th

r
ottle grip free p lay is i nc re a sed . 
Direction b  
Th
rottle grip free pl ay is  decreas ed . 
3-28  
						

							1 2 3 
d. Tigh ten the  lo ck nut. 
e. 
S li d e the  rub ber  cove r to  it s 

orig ina l posit ion. 
TIP
--------------­
Make  su re  that  the adjus ting nut  is  covered  com­
p lete ly 
by the  rubber  cover. 
EAW700 
CHECKING  AND CHARGING THE  BATTERY 
Re fe r  t o 
C H ECKING AND CHARGI NG THE 
BATTER Y o n  page  8-94. 
EAS:tl770 
CHECK ING THE FUSES 
Re

fe r  to 
CHECK IN G THE FU SE S on  pag e 
8-93. 
EAW700 
REPLACING THE HEADLIGHT BULB 
1. Remove: 
• Headlight un it  side  cover bolts  1  
TIP--------------­
Li ft up  the  hea dli gh t unit 2, and  then remove  it 
f rom  the headligh t stay 
3. 
PERIODIC  MAINTENANCE 
2. Disconnect: 
•Head light coup ler 1 
3.  Remove: 
• Head light bulb  cover 1 
4. Unhook: 
• 
Head light bulb  holder 1 
5.  Remove: 
• Head light bulb 2 
A WARN ING 
3-29 
Since the headlight bulb gets extremely hot, 
keep 
flammable products and your hands 
away from the bulb until it has cooled down.  
						

							6. Insta ll: 
•  He adligh t b ulb 
IH4W 
Secu re the  new headlight  bulb with  the head ­
li g ht bulb  ho lder. 
NOTICE ~~~~~~~~~~~~~ 
Avoid touching the glass part of the head ­
light bulb to keep it free from oil, otherwise 
the  transparency 
of the glass, the life of the 
bulb and  the luminous flux will be adversely 
affected. If the headlight bulb gets soiled , 
thoroughly clean it with a cloth moistened 
with 
alcohol or lacquer thinner. 
7 . Hook: 
•  Headlight  bulb  ho lder 
8 . Install: 
•  Head
light  bulb cover 
9.  Connect: 
• He adligh t co uple r 1 
1 O.lnstall: 
•  He adligh t 
unit 1 
TIP~~~~~~~~~~~~~~­
lnstall the head ligh t unit  as  show n. 
1 
11.lns tall: 
•  He adligh t 
unit  side  cove r bolts 
EA.$?18 10 
Headlight unit side cover bolt 
7  Nm (0. 7 m·kgf , 5.1 ft·lbf) 
ADJUSTING 
THE HEADLIGHT BEAM 
1.  Adjus
t: 
• Hea dligh t beam (vertically) 
PERIODIC  MAINTENANCE 
TTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTT 
a. Tum the adjusting  screw 1 in  directio n a or 
 b. 
D irection  a 
Headlight 
beam is raised . 
Direction 
b 
Headlight beam Is lowered . 
= = 
&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&& 
2. Adjust: 
• Head light beam  (horizontally) 
••••••••••••••••••\
•••••••••••••• 
TIP~~~~~~~~~~~~~~­
To adjust  the headligh t beam  (horizontally), in­
sert  a crosshead  screwdriver  into  t
he hole a 
and  turn  the ad ju sti ng  screw. 
a.  Tu
rn the  adjus ting screw 1 in  direction b or 
c . 
Direction b 
Headlight beam moves to the right. 
Direction 
 c 
H ea
dlight beam moves to the left. 
3-30  
						

							PERIODIC MAINTENANCE 
3-31  
						

							PERIODIC MAINTENANCE 
3-32  
						

							CHASSIS 
GENERAL CHASSIS ... ....... .... .... ............ .... ........ ......................... ........ ............  .4-1 
REMOVING THE AIR SCOOPS ....... .... .... .... .... ........ ......... ........ ........ .... .... . 4-5 
INSTALLING THE AIR  SCOOPS ..... .... ..................... ........ ..................... ....  4-5 
INSTALLING THE FUEL TAN K MOLES ........................... ................. .... ....  4-5 
FRONT WHEEL  .................................................. ......................... ........ ............  .4-8 
REMOVING THE FRONT WHEE L ... .... .... .... .... ................. ........ ........ ....... 4-10 
DISASSEMBLING 
THE FRONT WHEEL  .................. ................. ........ .... .. 4 -10 
CHECKING 
THE FRONT WHEEL  ....... .... .... .... ......... .... .... ................. .... .. 4 -10 
ASSEMBLING 
THE FRONT WHEE L ............................................ 4-11 
ADJUSTING THE FRONT WHEEL STATIC BALANCE  ....................... 4-11 
INSTALLING THE FRONT WHEEL (FRONT BRAKE DISCS) ........... .... ..  4-12 
REAR  WHEEL  ... .... .... ....
..... .... .... .... .... .... .... ..... ........ ........ ........ ......... ........ .... ..  4 -14 
REMOVING THE  REAR  WHEEL ...................................................... 4-17 
DISASSEMBLING THE  REAR  WHEEL ............................................ 4-17 
CHECKING THE REAR  WHEEL ...... .... ................. .... .... ............. .... .... .... ..  4 -17 
CHECKING THE  REAR  WHEEL DRIVE  HUB ...... .... .... .... .... ..... .... .... .... ..  4-17 
CHECKING AND REPLACING THE  REAR  WHEEL SPROCKET ..........  .4-18 
ASSEMBLING THE  REAR WHEEL  ........................................................  .4-18 
ADJUS TING THE  REAR  WHEEL STATIC BALANCE  .................. ..........  .4-18 
INSTALLING THE  REAR  WHEEL  (REAR BRAKE DISC) .... .... .... ... .. ... ... .4 -18 
FRONT BRAKE  ............................................................................................. .4 -20 
INT RODUCTION .................................................. ....................................  4-25 
CHECKING THE FRONT B R AKE DISCS .... ...... ........ ....... .......................  4-25 
REPLACING THE F RONT BRAKE PADS ...... .... .... ...... .... .............. ..... ... .4 -26 
REMOVING THE FRONT BRAKE CALIPERS ........ .... .... ....... ......... ..... ... .4 -27 
DISASSEMBLING THE FRONT BR A KE CALIPE RS .... .... ..... ... ........ ...... .4 -27 
CH ECKING THE FRO NT B RA KE CALIPE RS ...................... ........ ..........  .4-28 
ASSEMBLING TH E FR ONT BRAK E CALIPERS .......................... ..... .....  .4-28 
INSTALLING TH E FRONT BRAKE CALI PERS .... .... ................. .............  .4-29 
REMOVING TH E FRONT BRAKE MAS TER  CYLIND ER ............. .......... .4-30 
CH ECKING 
THE FRO NT B RA KE MAST ER  CYLIND ER ...... ..... ... ..... ..... .4-30 
ASSE MBLING 
THE FRONT BRAKE MASTER  CYLINDER ....... ... ..... .... .. 4 -3 0 
INSTALLING 
THE FRONT BRAKE M ASTER  CYLINDER .... ..... ... ..... .... .. 4 -3 0 
REAR  BRAKE  .................................................... ..... ........... ......... ........ ..... .....  .4-32 
INTR ODUCTION .......................................... ........ ........ ........ ........ ............  4-38 
CHECKING THE REAR  BRAKE DISC ................. ..... ... ..... ... ..... ... .......... ..  4-38 
REPLACING THE  REAR  BRAKE PADS ................... ... .............. ... ..... .... ..  4 -3 8 
REMOVING THE  REAR  BRAKE CALIPER ...... .... .... ... ..... ......... ... ..... .... ..  4 -39 
DISASSEMBLING THE  REAR  BRAKE CALIPER ..................... ... ..... ..... 4-40 
CHECKING 
THE  REAR  BRAKE CALIPER ....... ................ ........ ... ........... 4-40 
ASSEMBLING 
THE  REAR  BRAKE CALIPER .......................... ........ ..... 4-41 
INSTALLING THE  REAR  BRAKE CALIPER ..... ........................ ... ..... ..... 4-41 
REMOVING THE  REAR  BRAKE MASTER  CYLINDER .......................... .4-42 
CHECKING THE  REAR  BRAKE MASTER  CYLINDER ..........................  .4-42  
						

							ASSEMBLING THE REAR BRAKE  MASTER CYLINDER ........ ........... ... .4-43 
INSTALLIN G THE REAR  BRAKE  MASTER CYLINDER ...... ............ ...... .4-43 
HANDLEBAR .............................................. ................................. ...................  4-44 
REMOVING THE HANDLEBAR  ...............................................................  4-4 5 
CHE CKING THE  HANDLEBAR  ..................... ........ ......................... .........  .4-45 
INSTALLIN G THE HANDLEBAR  ........................... ........ ................. .........  .4-45 
FRONT  FORK .................. ........ ................. ........ ........... ................ ...................  4-48 
REMOVING THE FRONT  FORK LEGS  ......................................... .........  .4-51 
DISASSEMBLING THE FRONT  FORK LE GS  ............................... .........  .4-51 
CHE CKING THE FRONT  FORK LE GS  ...... .............. ......................... ......  .4-52 
ASSEM BLING THE FRONT  FORK LEGS ................................. ....... ...... .4-53 
IN STALLING THE FRONT  FORK LEGS ................................................. .4-58 
STEERING HEAD ......... ............. ....... ..... .... ....... ....... ................ ............. .........  .4-59 
REMOVING THE LOWER B R ACKET  ................... ......................... ......... .4-61 
CHECKING THE STEERING HEAD  .... ...... ....... ....... ...............................  .4-61 
INSTALLING THE ST EE RING HEAD  ........ ...... .......................................  .4-62 
REAR 
SHOCK ABSORBER ASSEMBLY ............... .......... ...................... ......  .4-63 
HANDLI NG THE  REAR SHOCK  ABSORBER ............................... .........  .4-64 
DISPOSING OF A REAR SHOCK  ABSORB ER .......................... ...... ...... .4-64 
REMOVING THE REAR SHOCK  ABSORB ER ASS EMBLY  ............. ...... .4-64 
CHECKING THE  REAR SHOCK  ABSORBER ASSEMBL  Y ........ ...... ...... .4-64 
CHECKING THE CONNECT ING ARM AND RELAY  ARM ..................... .4-64 
INSTALLING THE  RELAY  ARM .................. .................. .............. ........... .. 4-65 
INST ALLING THE  REAR SH OCK  ABSORBER ASSEMB LY  ...................  4-65 
SWINGARM ................................................ ........ ......................... ........ ...........  4-67 
REMOVING THE SWINGARM .................... ................................. ............  4-68 
CHECKING THE SWINGARM ............ ......... ................ ...........................  .4-68 
INST ALLING THE SWIN GARM ........... ................................. ...................  4-69 
CHAIN  DRIVE ..................... .... .... ............ ......... ........ ........ ........ ......... ........ ..... .4-70 
REMOVING TH E DRIV E CHAIN ........ ........................................ .............  .4-71 
CHECKING THE DRIVE  CHAIN ................ ............................................. .4-71 
CHECKING THE DRIVE SPROCKET ................... ................ ...................  4-72 
CHECKING THE  REAR  WHEEL SPROCKET ...................... ...................  4-72 
CHECKING THE  REAR  WHEEL DRIVE  HUB ...... ................ ...................  4-72 
INSTALLING T HE DRIVE  CHAIN ...................... ............................... 4-73