Yamaha Fz 09 2014 Manual

							2 
0 OA-1 
3 
2. Check: 
• Rear  brake caliper bracket  1  
Crack s/damage --+ Replace . 
Refer to REAR WHEEL on pa ge 4- 14. 
1 
0 
EA~1 
ASSEMBLING THE  REAR  BRAKE CALIPER 
EWA1AC1400 
AwARNING 
• Before Installation,  all Internal brake com­
ponents should be cleaned and lubricated 
with clean or new  brake fluid. 
• 
Never  use solvents on internal brake com­
ponents  as they will cause the brake caliper 
piston dust seal and  brake caliper piston 
seal to swell and distort. 
• Whenever  a brake caliper is  disassembled , 
replace 
the brake caliper piston dust seal 
and  brake caliper piston seal. 
Specified brake fluid 
DOT4 
INSTALLING THE  REAR  BRAKE CALIPER 
1. Install: 
• 
Rear  brake caliper  1  
(tem porarily ) 
• 
Brake  hose gaskets l§tiWJ 
• Brake  hose 2 
• 
Brake  hose union bolt 3 
Brake  hose 
union bolt 
30 Nm (3.0  m·kgf, 22 fl·lbf) 
4-41 
REAR  BRAKE 
A WARNING 
Proper  brake hose routing  is essential to in­
sure  safe vehicle  operation . Refer to CABLE 
ROUTING  
on page 2-41. 
NOTICE~~~~~~~~~~~~ 
When Installing the brake hose onto the 
brake  caliper 
1  , make  sure the brake  pipe 
a  passes  between the projections b on 
the brake caliper. 
1 
 b 
2. Remove: 
• Rear brake cal iper 
3. Install: 
• 
Brake  pad insul ators 
• 
Brake  pad shims 
(onto  the brake  pads) 
• Brake  pad spring 
(into  the rear  brake 
caliper) 
• Brake 
pads 
• Rear  brake caliper 
Refer to REPLACING THE REAR  BRAKE 
PADS  on page 4-38. 
Rear  brake caliper bolt (front) 
27 Nm (2.7 m-kgf , 20 fl·lbf) 
Rear brake  caliper bolt (rear) 
22 Nm (2.2 m·kgf, 16 fl·lbf) 
LOCTITE® 
Bra ke pad  retaining bolt 
17 Nm (1.7 m·kgf, 12 fl·lbf) 
Screw 
plug 
2.5 Nm (0.25 m -kgf, 1.8 ft·lbf)  
						

							4. Fill: 
• Brake fluid reservoir 
(with  th e  specif ied amount o f  the  spec ifi ed 
b rake 
fl uid ) 
EWA \3090 
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, 
leading to poor brake performance. 
• When refilling, be careful that water does 
not enter the brake fluid reservoir. Water 
will significantly lower the boiling point of 
the brake fluid and could cause vapor lock. 
£CA1)5.l(l 
NOTICE -----------­
Brake fluid may damage painted surfaces 
and plastic parts. Therefore, always clean up 
any spilt brake fluid immediately. 
5.  Bleed: 
• Brake  system 
Refer  to 
BL

EEDING 
THE HYDRAULIC 
BRAKE SYS TEM on page  3-13. 
6.  Check: 
• Brake flu id  leve l 
Below the min imum level mark "a"~ Add  the 
spec ified  brake 
fluid to  the  proper level. 
Refer  to CHECKING THE BRAKE FLUID 
LEVEL on page  3-11. 
7 .  C h
eck: 
• Brake pedal operation 
Soft o r spongy  feelin g ~ Bleed the  brake sys ­
tem. 
Refer  to BLEED ING THE HYDRAULIC 
BRAKE SYST EM on page 3-13. 
REAR  BRAKE 
....,,,,. 
REMOVING THE REAR BRAKE MASTER 
CYLINDER 
1.  Remove: 
• Bra ke hose  union bol t 1 
• 
Bra ke hose  gaskets 2 
• Bra ke hose 3 
TIP--------------­
To collect  any remain ing  brake fluid,  place a 
con tainer  unde r the  master 
cylinder  and the end 
of the brake  hose. 
....,,,,. 
CHECKING THE REAR BRAKE MASTER 
CYLINDER 
1. C heck: 
• Bra ke master cylinder 
Damage/scratc hes/wea r ~ Replace . 
• 
B ra ke fluid  delivery passages 
( brak e mast er 
cylinder body) 
Obstruction~ Blow out with compressed  air. 
2.  Check: 
• Brake  master cylinder k it 
Damage/scratches/wear~ Replace. 
3.  Check: 
• Brake fluid reservoir  1  
• 
Brake flu id reservo ir  diaphragm h older  2 
Cracks/damage ~ Rep lace. 
• Brake flu id reservo ir  diaphragm 3 
Damage/wear ~ Rep lace. 
4. Check: 
•Brake hose 
• Brake flu id reservoir  hose 
Cracks/damage/wea r ~ Replace. 
4-42  
						

							EA~130 
ASSEMBLING THE REAR  BRAKE MASTER 
CYLINDER 
EWAt 3520 
AwARNING 
• Before  installation, all internal brake com­
ponents should be cleaned and lubricated 
with clean or new brake fluid. 
• Never use solvents on Internal brake com­
ponents. 
1. Install: 
Specified brake fluid 
DOT4 
• Brake  maste r cylin der kit IH@j 
EA~1.CO 
INSTALLING THE  REAR  BRAKE MASTER 
CYLINDER 
1. Install: 
• 
Brake  hose gasket s l~IS 
•Brake hose 
• Brake  fluid  rese rvoir  hose 
• Brake  hose union bolt 
Brake 
hose union bolt 
30 Nm (3 .0  m-k.gf , 22 f1·1bf) 
AwARNING 
Proper brake hose routing is essential to in­
sure safe vehicle operation.  Refer to CABLE 
ROUTING on page 2-41. 
ECA14l«l 
NOTICE~~~~~~~~~~~~ 
When installing the brake hose onto the 
brake master cylinder, make sure the brake 
pipe touches the projection a  as shown. 
2. Fill: 
• 
Brake flu id reservoir 
(with  the specifi ed  amount  of the  spec ified 
b rake 
fl uid ) 
REAR  BRAKE 
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 , 
leading to poor brake performance. 
• When refilling, be careful that water does 
not enter the brake fluid reservoir.  Water 
will significantly lower the boiling point of 
the brake fluid and could cause vapor lock. 
ECA.13~0 
NOTICE 
Brake fluid may damage painted surfaces 
and plastic parts. Therefore, always clean up 
any spilt brake fluid immediately. 
3. Bleed: 
• Brake system 
Re fer  to 
BLEEDING THE HYDRA ULIC 
BRAKE SYSTEM  on pag e 3-13 . 
4.  Check : 
• Brake  fluid l evel 
Below  the m inimum le vel mark  a  ~ Ad d the 
spec ifie d brake  fluid  to  the p rop er 
level. 
Re fe r  to  CHECK ING THE BRAKE FLUID 
LEVE L 
o n  page 3-11. 
5. Adjust: 
• B rake  peda l pos iti on 
Re fe r 

to 
 ADJ USTING THE  REAR DISC 
BRAKE  
on page  3-13. 
6. Adj ust: 
• Rea r brake  ligh t ope ration timing 
Refer  to 
 ADJUSTING THE  REAR  BRAKE 
LIGHT SWITCH on page  3-27. 
4-43  
						

							HANDLEBAR 
EA$22&.c0 
HANDLEBAR 
Removing the handlebar 
17 Nm (1.7 m. kgf,  12 ft dbl) 3.8 Nm (0.38 m • kgf, 2 .8 ft · lbf) 
~ 26 Nm  (2.6 m. kgf, 19 ft dbl) 
9 
11 Nm (1.1 m . kgf, 8.0 ft dbl) 
l~l 2.0 Nm (0.20 m • kgf,  1 .4 ft • lbf) I 
l\l 10 Nm (1.0 m • kgf, 7 .2 ft ·lb!) I 
22 Nm  (2.2 m. kgf,  16 ft · lbf) 
17 Nm  (1.7 m. kgf,  12 ft ·lbf) 
4 16 1 
40 Nm (4.0 m • kgf, 29 ft • lbf) 
Order Job/Parts to remove Qty Remarks 
Me te r  br
acke t  Refer 
to  G ENE RAL CHASS IS• on  page 
4-1. 
1 Rearview mirror 2 
2 Front  brake light sw itch conn ector 2 Disconne ct. 
3 Front master cyli n der  holder 1 
4 Front  brake  mas ter cyli nder assembly 1 
5 Rig ht handl ebar switch 1 
6 Thr ottle  cab le h ous ing 2 
7 
Thr ottle  cab le 2 D isconnect. 
8 G rip  end 2 
9 
Thr ottle g rip 1 
10 Clutc h switch coup le r 1 D isconnect . 
11 Left handle bar sw itc h 1 
12 Handleba r grip 1 
13 C lutc h cab le 1 D isconnect. 
1 4 Clutc h lever  holde r 1 
15 Upper h andlebar  holder 2 
16 
H andl ebar 1 
17 Lower handl ebar holder 2 
4-44  
						

							EA$22&e0 
REMOVING THE HANDLEBAR 
1. 
Stand the vehi c le on  a leve l surface. 
EWAt3 120 
AwARNING 
Securely support the vehicle so that there is 
no danger of it falling over. 
2.  Remove: 
• Hand lebar grip 1 
TIP~~~~~~~~~~~~~~­
Blow compressed  air between  the left handlebar 
and  the handlebar grip, and gradually push  the 
grip  off the 
hand lebar. 
1 
3.  Remove: 
• Thrott le  cab le housings 1 
•  Thro ttle 
grip 2 
TIP~~~~~~~~~~~~~~~ 
While remov in g  the throttle  cable housing, p ull 
bac k the  rubber  cover 3. 
EAS22890 
CHECKING THE  HANDLEBAR 
1.  Chec
k: 
•Hand lebar 
Bends/crac ks/damage --+ Replace. 
EWA llfi90 
A WARNING 
Do not attempt to straighten  a bent handle­
bar as this may dangerously weaken  it. 
HANDLEBAR 
....,,..,, 
INSTALLING THE HANDLEBAR 
1 . 
Stand the vehicle on  a level surface. 
AwARNING 
Securely support the vehicle so that there is 
no danger of it falling over. 
2. 
Install: 
• 
Lower ha ndleba r ho lde rs 
(tem pora rily) 
•  Handlebar  1 
•  Upper  handleba r holders  2 
ECAIRC1407 
NOTICE 
Upper  handlebar  holder bolt 
22 Nm (2.2 m·kgf, 16 fl·lbf) 
• 
First,  tighten  the bolts on the front side of 
the upper handlebar  holder, and then on 
the rear  side. 
• Turn  the handlebar  all the way  to the left 
and  right. If there is any contact with  the 
fuel tank, adjust the handlebar position. 
TIP~~~~~~~~~~~~~~~ 
• Align  the punch  mark a on the hand lebar with 
t
he l eft s ide  upper  surface  of the left  lower  han­
d lebar  ho
lder 3. 
• 
The  upper hand lebar holders  sho uld be in­
stalled 
w ith  the  punc h ma rks b  facing for ­
ward. 
3.  Tigh te n : 
• Lower ha ndlebar  holde r nuts 
4-45  
						

							4. Install: 
Lower handlebar holder nut 
40 Nm (4.0 m-kgf, 29 ft·lbf) 
•  T hro ttle 
grip 1 
•  Thrott le  cab l
es 
• Thrott le  cab le hous ings 2 
• G rip 
end 
Grip  end 
26  Nm  (2.6 
m·kgf, 19 ft·lbf) 
TIP~~~~~~~~~~~~~~~ 
•  Align the pro ject ion  a on  the thrott le  cable 
ho using  wit h the ho le  b in the ha ndleba r. 
•There  should be 1- 3 mm (0.04-0.12 in)  of 
cleara nce c between  the throttle grip  and  the 
grip end. 
c 
~ 
5. Install: 
• 
R ight handlebar swi tch 
Right 
handlebar switch screw 
2.0 Nm (0 .20  m·kgf, 1.4 ft·lbf) 
TIP~~~~~~~~~~~~~~~ 
Al ign the  project ion  a  on  the right hand lebar 
switch  with the hole  b in  th e hand lebar. 
6. Install: 
• 
Front  brake  master cylinde r assembly 
Refe r to INSTALLIN G THE FRO NT BRAKE 
MASTER  CYLINDER  on page  4-30. 
7. 
Install : 
•  Clutch  lever holder  1 
HANDLEBAR 
• C lu tch  cab le 
Clutch  lever 
holder pinch bolt 
11 Nm (1.1  m-kgf, 8.0  ft·lbf ) 
TIP~~~~~~~~~~~~~~~ 
Align the center  of slit on  the clutch  lever ho lder 
w ith the  punch  mark a on  the handlebar. 
8. Install: 
•  Handlebar 
grip 1  
• 
Gri p  end 2 
Grip  end 
26 
Nm (2.6  m-kgf,  19 ft·lbf) 
••••••••••••••••••\
•••••••••••••• 
a. Apply a  thin  coat  of rubbe r ad hesive  onto  the 
e
nd of  the le ft  hand lebar. 
b. S ide the ha ndleba r grip  over  the end  of the 
left  handlebar. 
c. Wipe off  any  excess  rubber adhesive  with a 
clean rag. 
EWA13700 
,A WARN ING 
Do not touch the handlebar grip until the rub­
ber adhesive  has fully dried. 
TIP~~~~~~~~~~~~~~~ 
There sh ould be 1-3 mm (0.04--0.12 in) of clear ­
ance a  betwee n the handleba r grip and  th e grip 
e n d. 
7 
2 1 
4-46  
						

							9. Install: 
• 
Le ft hand leba r sw itch 
Left 
handlebar switch screw 
2. 0 Nm (0 .2 0 m·kgf , 1.4 ft-lbf ) 
TIP~~~~~~~~~~~~~~­
Align the projec tion a on the left handlebar 
sw itch with the ho le b in  the hand leba r. 
1 O.Adjust: 
•  Throttle grip  free play 
Refer  to CHECKI NG THE  THROTTLE 
GRIP on  page  3-28. 
11.Adjust: 
Throttle grip free play 
3.0-5. 0 mm (0.12-0. 20 in) 
•  C lut ch  leve r free pla y 
Refe r 

t o 
ADJ USTING THE CLU TCH LEVE R 
F R
EE PLAY  on  pa ge  3-11. 
Clutch  lever free play 
10.0-15.0 mm (0.39-Q.59 in) 
4-47 
HANDLEBAR  
						

							EA$2a950 
FRONT FORK 
Removing  the front fork legs 
23 Nm  (2.3  m. kgf, 1 7 ft 0 lbf) 
10 
Nm  (1.0 m. kgf,  7.2 ft· lbf) 
Order Job/Parts to remove 
Fr on t 
w heel 
1 Front  fender 
2 Uppe r bracke t pin ch bolt 
3 Cap  bolt 
4 Lowe r bracket  pinc h bolt 
5 F ron t fo rk leg 
4-48 
Q ty 
1 
1 
1 
2 
1 
FRONT  FORK 
23 Nm (2 .3 m . kgf, 17 ft 0 lbf) 
r-~--. -
--3) 
 
 
 , 
, 
, 
 , , 
, 
 
 , , , 
, 
 
 , , , 
  , 
, 
, 
  , 
, 
,l---- 5 , , , 
  , , 
, 
 
 
 , , , 
 
R emarks 
The fo llowing procedu re applies to  bot h of 
th e  fr o nt  fo rk 
legs . 
Refer  to  FRO NT  WHEEL: on  page 4·8 . 
Loose n. 
L oose n. 
L oosen.  
						

							FRONT FORK 
Disassembling the left front fork leg 
II, 23 Nm (2.3 m. kgf,  17 ft· lbf) 
It 15  Nm  (1. 5  m • kgf, 11 ft • lbf) 
0 
0 
i--17 
i---- 9 
i--16 
L. 
• 
Order  Job/Parts to remove Qty Remarks 
1 
Cap  bolt 1 
2 0-rin g 1 
3 Was her 1 
4 Space r 1 
5 Fork spring 1 
6 Locknut 1 
7 Ou st  seal 1 
8 Oi l seal clip 1 
9 Ou ter tube 1 
10 Oi l sea l 1 
11 Was her 1 
12 O ute r tube  bushi ng 1 
13 In ne r tu be  bu shi ng 1 
14 Dam pe r rod asse mbly  boll 1 
15 Copper was her 1 
16 Dam pe r rod asse mbly 1 
1 7 
Inn er tube  1 
4-49  
						

							FRONT FORK 
Disassembling the right front fork leg 
14-123 Nm  (2.3  m. kgf, 17 ft· lbf) I 
~8-r14 
1 LS I>< I 15 Nm (1.5 m • kgf, 11 ft · l b f) 
mlJ2 . ,-, -
6 
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