Yamaha Fz 09 2014 Manual

							holde r with the  punch  mark b  on  the hand le­
bar. 
• First,  ti gh ten the  upper bolt, the n the lower  bolt. 
• There should be  more tha n 11 mm (0.43  in)  for 
cleara nce between  the right handleba r sw itch 
and 
the  fron t brake  master cylin de r holde r.  A l­
so , the  punch  mark s ho uld be  seen. 
2. Install: 
• 
Brake  hose gaskets l~IS 
•Brake hose 
• Brake  hose union bo lt 
Brake  hose union bolt 
b 
30 Nm (3 .0 m -k,gf, 22 ft·lbf) 
AwARNING 
Proper  brake  hose routing Is essential to In­
sure safe vehicle operation.  Refer to CABLE 
ROUTING  
on page 2-41. 
TIP~~~~~~~~~~~~~~ 
• Attach  the brake  hose so that  its angle is 3° to 
13° against  the straight line in paralle l with the 
ceiling  plane o f the  master cylinder. 
• W hile  holding the  brake  hose, tighten  the union 
bo lt as  shown. 
• Turn  the ha nd lebar to  the left and  right to make 
sure  th e  brake  hose does not 
touch othe r parts 
(e.g.,  wire harne
ss, cab les,  leads) . Correc t  if 
necessary. 
3. 
Fill: 
• 
Brake  master cylinder reservoir 
4-31 
FRONT BRAKE 
(w ith th e  spec ified amount of the  speci fied 
brake 
f luid) 
Specified  brake fluid 
DOT4 
AwARNING 
• Use only the designated  brake fluid. Other 
brake fluids may  cause  the rubber seals to 
deteriorate,  causing leakage and poor 
brake performance. 
• Refill with  the same  type of brake fluid that 
is  already 
in the system.  Mixing brake fluids 
may result in a harmful  chemical  reaction, 
l ea
ding to poor bra ke  performance. 
• When re filling , be careful  that water  does 
not en ter  the  brake  master  cylinder reser­
voir.  Water will significantly lower th e boil­
ing  poin t of the brake fluid and could cause 
vapo r 
lock. 
NOTICE ~~~~~~~~~~~~~ 
Brake fluid may damage  painted surfaces 
and  plastic  parts. Therefore , always 
clean up 
any 
spli t brake fluid  Immediate ly. 
4 . B leed : 
• Brake  system 
Refe r to BLEEDING THE HYDRAULIC 
BRAKE SYSTEM on page  3-13. 
5. Check : 
• Brake fluid level 
Be low 
the  min imum level mark a--+ Add  the 
spec i
fied brake fluid to the proper level. 
Refer to CHEC KING THE BRAKE FLUID 
LEVE L 
on page 3-11. 
6. Check: 
• Brake leve r operation 
Soft or spongy feeling --+ Bleed the  brake sys­
tem. 
Refer 
to B LEEDING THE HYDRAULIC 
BRAKE SYSTEM on page  3-13.  
						

							EA$2aS50 
REAR BRAKE 
Removing  the rear  brake  pads 
0 0 
0 
0 
0 ,,@ 
Order Job/Parts to remove 
1 Screw plu g 
2 Brake  pad retaining bolt 
3 Rear  brake  caliper 
4 Brake  pad 
5 Brake  pad  shim 
6 B rake  pad  in sulator 
7 B rake  pad  spring 
8 Bleed screw 
REAR  BRAKE 
II. 5 Nm (0.5 m • k f, 3.6 ft ·lb!) 
~ 27 Nm  (2.7  m ·kg!, 20 ft· lb!) 
3 
~ 22 Nm (2.2  m • kgf, 16 ft· lbf) 
17 Nm (1.7  m • kgf, 12 ft· !bf) 
)c. 2.5  Nm (0.25 m • kgf, 1 .8 ft · lb!) 
5 
Qty Remarks 
1 
1 
1 
2 
2 
2 
1 
1 
4-3 2  
						

							REAR BRAKE 
6 
)t 110 Nm (11 m. kgf. 80 ft 0 lbf) 
Order Job/Parts to remove Qty Remarks 
Rider seat  Refer 
to  GE NERAL  CHASSIS  on page 
4-1. 
Air scoop/Fue l tank cove r  Refer 
to GENE RAL  CH ASSIS  on page 
4 -1 . 
F uel tank Refer  to  FUEL  TANK on page  7-1. 
Drain. 
B rake  fluid  Refer to 
 BLEEDING T H E H YORAUL IC 
BRAK E SYST EM  on  page  3-13. 
1  Brake 
fluid rese
rvoir cap 1 
2  Brake 
fluid rese
rvoir diaphragm h older 1 
3 Brake fluid rese rvoir diaphragm 
1 
4  Brake 
fluid reservoir 1 
5 Brake fluid reservoir holder 1 
6 Brake fluid reservoir  hose  1 
7  Brake hose  uni
on bolt 1 
8 B rake  hose  gaske t  2 
9 Brake  hose  1 
10 Rear  brake li gh t switch  couple r 1  Disconnect. 
11 R ig h t footres t assembly 1 
1 2  Wire 
guide 1 
4-33  
						

							REAR BRAKE 
)t 110 Nm (11 m. kgf. 80 ft 0 lbf) 
)t 55 Nm (5.5 m • kgf. 40 ft 0 lbf) 
~ 23 Nm {2.3  m • kgf, 17 ft • lbf) 
Order Job/Parts to remove Qty Remarks 
13  Brake peda l , 
14 Rea r brake  master cylinder asse mbly 1 
15 Rea r brake light switch 1 
4-34  
						

							REAR BRAKE 
Disassembling the rear brake master cylinder 
5 
2 
mm 
2 
mm 
1 
4 
3 mm 
Order  Job/Parts to remove Qty Remarks 
1 Brake  mas ter cyl inde r yoke , 
2 Brake  master cylinder kit , 
3 Hose  joi nt 1 
4 Bush ing 1 
5 Brake  mas ter cylinder body , 
4-35  
						

							REAR BRAKE 
Removing the rear brake caliper 
30 Nm (3.0  m • kgf,  22 ft • lbf) 
4 
~ 22  Nm  (2.2  m • kgf, 16 ft· lbf) 
 
27  Nm  (2.7  m • kgf, 20 ft • lbf) 
Order  Job/Parts to remove Qty Remarks 
1 Brake hose uni on b ott 1 
2 Brake  hose gaske t 2 
3 Brake  hose 1 
4 Rear brake ca liper 1 
4-36  
						

							REAR BRAKE 
Disassembling the rear brake caliper 
5 Nm (0.5 m ·kg!, 3.6 ft • lbf) 
7 
 
9 
8 
mm 9 
mm 
6 
17Nm(1.7m·kgf,12ft·lbl) 1 
~ 2.5  Nm (0.25 m • k I, 1.8 ft·  lbf) 
4 
5 
0 
Order  Job/Parts to remove Qty Remarks 
1 
Screw  plug 1 
2 Brake pad reta ining bol t 1 
3 Brake  pad 2 
4 Brake pad shim 2 
5 Brake  pad insulato r 2 
6 Brake pad spring 1 
7 Brake caliper piston 1 
8 Brake caliper piston  dus t seal 1 
9 Brake cal iper pis ton seal 1 
10 Bleed screw 1 
4-37  
						

							INTRODUCTION 
EWA\4 101 
A WARNING 
Disc brake components rarely require disas­
sembly. Therefore, always follow these pre­
ventive measures: 
• Never disassemble brake components un­
less absolutely necessary. 
• If any connection on the hydraulic brake 
system Is disconnected, the entire brake 
system must be disassembled, drained, 
cleaned, properly filled, and bled after reas ­
sembly. 
• 
Never use solvents on internal brake com­
ponents. 
• Use only clean or new brake fluid for clean­
ing brake components. 
• Brake fluid may damage painted surfaces 
and plastic parts. Therefore, always clean 
up any spilt brake fl uid immediately. 
•Avoid brake fluid coming into contact with 
the eyes as it can cause serious injury. 
FIRST  AID FOR BRAKE FLUID  ENTERING 
THE EYES: 
• 
Flush with water for 1 5 minutes and get im­
mediate medical attention. 
CHECKING THE  REAR BRAKE DISC 
1. Remove: 
•Rear  wheel 
Refer  to  REAR  WHEEL  on page 4-14. 
2. Check : 
• Rear brake  disc 
Damage/galli ng --+ Rep lace. 
3. Measure: 
• Brake  disc runou t 
Out of spec ifica tion --+ Correc t the  brake  disc 
runou t or rep lace the  brake  disc. 
Refer  to 
CHECKING THE FRONT BRAKE 
DISCS  on page 4-25. 
Brake disc runout limit (as mea­
sured on wheel) 
0.15 mm (0.0059 in) 
4. Measure: 
• Brake disc thickness 
Measure  t
he brake disc thick ness  at a few dif ­
ferent  locations. 
Ou t of speci fication --+ Replace. 
Refer  to 
 CHECKING T HE FRONT BRAKE 
DISCS  on page 4-25. 
5 .  Adj ust: 
REAR  BRAKE 
Brake disc thickness limit 
4.5 mm (0.18 in) 
• Brake  disc  runou t 
Re fe r 
to CHECKING THE FRONT BRAKE 
DISCS  on pag e 4-25. 
Rear brake disc bolt 
30 Nm (3.0 m-kgf, 22 ft·lbf) 
LOCTITE® 
6. In stall: 
• Rea r wheel 
Re fer  to REAR  WHEEL  on page 4-14 . 
....,,.., 
REPLACING THE  REAR BRAKE PADS 
TIP~~~~~~~~~~~~~~­
When  replaci ng  th e brake  pads,  it is  not neces­
sary  to discon nect the brake  hose or disassem ­
b le 
th e 

b rake  caliper. 
1. Measure : 
• Brake pad wear lim it  a 
Ou1 of specif icat io n --+ R ep lace the b ra ke 
pads  as a set. 
I 
2. Install: 
Brake pad lining thickness (inner) 
6.0 mm (0.24 in) 
Limit 
1.0 mm (0 .04 in) 
Brake pad lining thickness (outer) 
6.0 mm (0 .24 In) 
Limit 
1.0 mm (0.04 in) 
a 
11  I 
I II II  II Il l 
• Brake  pad  insulators 
• B rake  pad shims 
( o nto  t
he brake  pads) 
• Brake pad  spring 
(into  the re a r  brake  caliper) 
•Brake pads 
TIP~~~~~~~~~~~~~~~ 
Always insta ll new brake  pads,  brake  pad ins u-
4-38  
						

							lators, brake  pad shims , and  brake  pad spring  as 
a  se t. 
••••••••••••••••••\
•••••••••••••• 
a.  Connec t a clear  plast ic h ose 1 tight ly to  the 
bleed screw 2. Put  the other  end of the  hose 
i n to 
an open  container. 
b.  Loosen  the 
bleed screw  and push  the brake 
caliper piston  into the brake caliper with  your 
finger. 
c. T ighten  the bleed screw . 
Brake 
caliper  bleed screw 
5 Nm (0.5 m-kgf, 3.6 ft·lbf) 
d. Install the  brake  pad insulators and  brake  pad 
shims  onto  each  brake  pads. 
TIP~~~~~~~~~~~~~~­
Apply  silicone grease  between the brake  pad in· 
sulator and  brake  pad shim. 
NOTICE ~~~~~~~~~~~~~ 
• Do not allow grease to contact the  brake 
pads. 
• Remove  any excess  grease. 
e. 
Install t h e  brake  pads and brake  pad spring. 
TIP~~~~~~~~~~~~~~~ 
The longer tangs  a of the  brake  pad spring 
m ust  point  in  the  directio n of 
the  brake 
caliper 
piston . 
REAR  BRAKE 
3. Lubricate: 
• Rear  brake cal iper  bolts 
 
NOTICE 
Recommended lubricant 
Siiicone grease 
~~~~~~~~~~~~~ 
• Do not allow grease to contact the brake 
pads . 
• Remove  any excess  grease. 
4. Install: 
• 
Rear  brake caliper 
• 
Brake  pad retain ing bolts 
• Screw  plug 
s. Check:  Rear 
brake 
caliper bolt (front) 
27 Nm (2.7 m-kgf, 20 ft·lbf) 
Rear  brake caliper bolt (rear) 
22 Nm (2.2 m-kgf, 16 ft·lb f) 
LOCTITE® 
Brake  pad retaining bolt 
17 Nm (1.7 m-kg f, 12 ft·lb f) 
Screw  p
lug 
2.5 Nm (0.25 m·kgf, 1.8 ft·lbf) 
• 
Brake flui d  level 
Be low 
the  min imum level mark a-+ Add  the 
spec i
fied brake fluid to the proper level. 
Refer to CHEC KING THE BRAKE FLUID 
LEVEL 
on page 3 · 11. 
6. Check: 
• Brake peda l operation 
Solt or spongy feeling  -+ Bleed the  brake sys· 
tern. 
Refer to BLEEDI NG THE HYDRAULIC 
BRAKE SYSTEM  on page 3·13. 
 REMOVING THE REAR  BRAKE CALIPER 
TIP~~~~~~~~~~~~~~~ 
Before disassembling the brake caliper, drain 
the  brake 
flu id from  the entire  brake  system. 
4-39  
						

							1. Remove : 
• Brake hose union bol t 1 
• Brake  hose gasket s 2 
• Brake hose 3 
TIP~~~~~~~~~~~~~~­
Put the end  of the  brake  hose  in to  a container 
and  pum p ou t the  brake 
fluid  caref ully. 
EAS22001 
DISASSEMBLING THE  REAR  BRAKE 
CALIPER 
1. Remove: 
• Brake caliper piston  1  
• 
Brake cal iper piston  dust seal 2 
• 
Brake cal iper piston seal 3 
0 1 
02 
0-3 
YYYYYYYYYYYYYYYYYYYYYYYYYYYYYYYY 
a. Blo w compressed  air  in to  the brake  hose joi nt 
opening 
 a  to forc e  out  the  piston  fr om  the 
b rake  calip
er. 
AwARNING 
• Cover the brake caliper piston with a  rag. 
Be 
careful not to get injured when  the pis­
ton is expelled from the brake  caliper. 
• Never try to pry out the brake caliper pis­
ton. 
REAR  BRAKE 
b. Remove  the  b rake caliper p ist on  dust sea l 
and  brake caliper piston s eal. 
....,,.., 
CHECKING  THE REAR  BRAKE CALIPER 
Recommended  brake component 
replacement schedule 
Brake pads If necessary 
Pis ton  seal Every  two  years 
Pis ton d us t seal Ev ery  two  years 
Brake  hoses  Every four years 
Brake 
fluid 
Every  two years  and 
w he neve r the  brake 
i s  disassembled 
1 .  Check : 
• Brake caliper p ist on 1 
Rus t/

s cra tches/wea r 
4 Rep lace the brake 
c aliper piston. 
• B rake ca liper cy lind er 2 
Scratches/wear 4 Rep lace the brake caliper 
assemb ly . 
• 
Brake caliper body 3 
Crack s/damage 4 Replace the  brake caliper 
assemb ly . 
• 
Brake flu id  delivery passages 
(bra ke 
caliper body) 
Obs truct ion 
4 B low out  with compressed  air. 
EWA1ACl402 
AwARNJNG 
Whenever  a brake caliper is disassembled , 
replace the brake caliper piston dust seal 
and brake caliper piston seal. 
4-40