Yamaha Fz 09 2014 Manual

							b.  Kee p pre ssing  the timin g chain ten sioner rod 
by  han d,  remove  th e  hex ag on  w rench  a nd 
slo wly r elea se  the  timi ng 

c h ain  tens ion er  rod. 
c .  Make  sure  t
hat the timing  chain  tens io ner  rod 
comes  out 
of th e timi ng  cha in  tens ioner ho us­
i n g  smoo th ly. 
I f there  is  rough  moveme nt,  re­
p

la ce 
the  tim ing  chai n te ns ion er. 
INSTALLING THE CAMSHAFTS 
1 . Remove : 
• Timing 

mark  acc ess ing 
bo lt  1  
• 
Cra n ks h aft  end cover 2  
-_J 
2. Align : 
• 
Mark  a  on th e  generato r rotor 
(wi th  the generato r roto r cover  mark b ) 
••••••••••••••••••\
•••••••••••••• 
a .  Tur n  the  cran kshaft cou nte rc lockwise. 
b .  W hen pist on  #1  is  at BTDC1 25° on  the  co m ­
p ress i
on stro k e, alig n the BTDC1 25° ma rk a  
o n  the generator roto r w it h  the genera tor roto r 
cover mark b. 
CAMSHAFTS 
&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&& 
3 . Inst all: 
•  In tak e 
cam shaft  sprocke t 1 
• E xha ust  cams haft  spr ocket 2 
Camshaft  sprock et bolt 
24  Nm  (2.4 m·kgf , 17 ft·lbf ) 
NOTICE ~~~~~~~~~~~~~ 
Be sure  to tighten  the camshaft  sprocket 
bolts to the  spec ified  torque  to avoid  the 
possibility of the bolts coming loose and 
damaging  the eng
ine. 
TIP~~~~~~~~~~~~~~~ 
• Ins tall the  camshaft projection a  at th e  p osi­
t i on  shown  in the  i
llustr ation. 
• T ig h ten  the  cams ha ft  sproc ket bo l

t 
with  the 
cams ha ft  wre nc h 
3 . 
5-14 
Camshaft  wrench 
90890-04162 
YM-04162 
a 
3 
a  
						

							4. Install: 
• 
Exhaust  camshaft 1  
•  In ta ke 
c amshaft 2 
TIP~~~~~~~~~~~~~~-
• Ma ke s ure  th e  pu nch  mar k a on each cam­
shaft  faces  up. 
• When installi ng the  camshaft , no  need to alig n 
the  mark  b on the  camshaft  sprocket. 
5. Install: 
• 
Camshaft  cap 
• In ta ke c amshaft  cap 
• Exhaus t cams haft ca p 
TIP~~~~~~~~~~~~~~~ 
• Ma ke  sure  each  camshaft  cap  is ins talled in  it s 
orig ina l place. Refer  to  the  identifica tion marks 
as follows: 
IL: Intake left side  cams haft  cap  mark 
EL: Exhaus t left s ide  cams haft cap  mark 
• Make  sure the arrow  mark a on each cam­
shaft  points 

t oward  the right side  of the  engine. 
CAMSHAFTS 
6. Tigh te n : 
• C amshaft  cap bolts 
Camshaft  cap bolt 
10 Nm (1.0 m·kgf , 7.2 ft·lbf ) 
TIP~~~~~~~~~~~~~~­
Tigh ten the  cams haft  cap bolts in  the  tighten ing 
sequence  as shown. 
ECA.1RC11Wt1 
NOTICE 
• Lubricate the camshaft  cap bolts with the 
engine 
oil. 
• 
The  camshaft cap bolts must be tightened 
evenly or damage to the cylinder head , 
camshaft  caps, and  camshafts 
will result. 
• 
Do not  turn the  crankshaft  when installing 
the  camshaft to avoid  damage or improper 
valve timing. 
7. Tigh ten: 
• Camshaft  cap bolts  1 
Camshaft  cap bolt 
10 Nm (1.0 m ·kgf, 7.2 ft·lbf) 
TIP~~~~~~~~~~~~~~­
T igh ten the  camsha ft  cap bo lts in  stages  and  in 
a  cri sscross  patt e
rn, wo rking from the inne r caps 
out. 
NOTICE 
• Lubricate the camshaft  cap bolts with the 
engine 
oil. 
• 
The  camshaft cap bolts must be tightened 
evenly or damage to the cylinder head , 
camshaft  caps, and  camshafts 
will result. 
• 
Do not turn  the crankshaft  when installing 
the camshaft to avoid  damage or improper 
valve timing. 
5-15  
						

							8. Check: 
• Camshaft  punch mark  a  
Make  su re  the  punch  mark 
a  on  the cam ­
shaft  is 

a ligned  wit h  the  cams haft  cap 
align ­
me nt mark b. 
9. Install: 
• 
T im ing chain  tens ioner 
• T im ing chain  tens ioner  gasket IHM 
••••••••••••••••••\
•••••••••••••• 
a. Apply a  few  drops  of  engine oil to  th e  ins ide 
a  o f th e t iming  ch ain tensione r. 
~-"'7:S?< a 
b . W hile li ghtly  pressing  the  timin g chain ten ­
sioner  rod by hand, turn the tim ing  chain ten ­
sione r rod fully co unte rc lockw ise with  a 
h exagon  wrench 
 1 . 
CAMSHAFTS 
c.  Keep  pressin g  the  tim ing  cha in  tens ioner  rod 
by hand,  remove  the hexagon  wrench, and 
th en  ins e
rt the  hexago n wrench 2 (Pa rts 
No.:  1 
RC-12228 -00)  into  the timing  ch ain ten ­
sioner  rod. 
d . 
Install the  tim ing  chain  te nsi oner  gasket 3, 
the  ti m in g 

ch a in  te nsione r 
4 , a nd 

th e  t im
ing 
c h a in  tens io ne r 
bolts  5  on the cy linde r 
b loc k 
. 
TIP~~~~~~~~~~~~~~­
Face  the sect io n b  of the  gaske t inwa rd. 
4 
I 
e .  Tighte n the  tim ing  cha in  tens ioner bol ts to  the 
spec ified  torq ue. 
T im ing chain tensioner bolt 
10 Nm (1 .0  m-kgt , 7.2 fl·lbt ) 
LOCTITE® 
f. Screw the  hexago n wrenc h by han d  unti l th e 
timing  ch ain  tensio ner  rod  t
ouches the timing 
c h a in 
guide,  an d t hen  tigh ten  1/4  tu rn by tool. 
TIP~~~~~~~~~~~~~~~ 
The  timing  chain  tens ioner  rod is exte nded  by 
5-16  
						

							turni ng  the  hexagon  wrench clockwise. 
I 
g. Remove  the hexagon  wrench,  and check  the 
tim ing  chain  tensio
n. 
I 
h. Install the timing  ch ain  tens io ner cap bol t and 
gasket , and  then  tight en  the  timing  ch ain 
t en· 
sioner  cap bolt to  the  spec ifie d torque. 
T i
ming chain tensioner cap bolt 
7 Nm (0 .7 m·kgf, 5.1 ft·lbf) 
••••••••••••••••••\
•••••••••••••• 
10.Tum: 
• 
Cranks haft 
(severa l turns coun terc lockw ise) 
11.Check: 
• Mark  a 
Make  sure the mark a on the  generator  rotor 
i s 
aligned w it h  the  generator  rotor cover  mark 
b. 
• Cam shaft  punch  mark c 
Make  sure th e 

punch  mark 
c on th e cam · 
sh aft  is aligned w it h  the  camshaft  cap align· 
ment mark d . 
Out 
o f alignmen t ~ Adju st. 
Refe r 
to the installatio n steps  above . 
5-17 
CAMSHAFTS 
12.Measure: 
• Va lve  clearance 
Out of spec if icat ion ~ Adjus t. 
Re fer  to 
 ADJUSTING T HE  VALVE CLE AR · 
ANCE  
on page  3-5. 
13 .ln stall: 
• Tim in g 
mark  access ing bo lt  1 
Timing mark accessing bolt 
15 Nm (1.5 m·kgf, 11 ft·lbf) 
• 
C ra nks haf t end  cover 2  
Crankshaft end cover 
10 Nm (1.0  m-kgf, 7.2 ft·lbf) 
..--..J 
14.lnstall: 
• 
Timing  chain  gu ide  (top  side) 
• Cylinder head  cover  gasket 1 IH¥j 
• Cylinder head  cover 
Cylinder head cover bolt 
10 Nm (1.0 m·kgf, 7.2 ft·lbf)  
						

							TIP~~~~~~~~~~~~~~­
Afte r installing the  cylinder  head gaske t 1 to the 
cylinde r head  cove r,  c u t off  the a  sect io n. 
a 
15.lnstall: 
• 
Spark plugs 
• Ignit io n  co
ils 1 
Spark  plug 
13 Nm (1.3 m-kgf, 9.4 fl·lbf) 
TIP~~~~~~~~~~~~~~-
lnstall t h e  ign itio n coi ls  1  in  the  direction  shown 
in  the  illustrat ion. 
CAMSHAFTS 
5-18  
						

							EAs,24100 
CYLINDER HEAD 
Removing the cylinder head 
ii. 1 O Nm (1.0 m • kgf, 7 .2 ft • lbl~ 
16  Nm  1 .6 m . kgl, 12 ft ·lbf 
,.....,;r,.-,< 
2 
Order  Job/Parts to remove 
Engine 
I nt a

k e 
camshaft 
Ex ha

u st camshaft 
1 C oola nt temperature  senso r 
2 Cylin de r head 
3 
Cy lin der head  gaske t 
4 Dowe l p in 
5  T
im in g c hai n guide (exhaus t side) 
Qty 
1 
1 
1 
2 
1 
5-19 
CYLINDER HEAD 
1st 25  Nm  (2.5  m. kgf. 18 ft dbl) 
2nd 16  Nm  (1.6  m • kgl, 12 ft • lbf), 
Specified angle  90 • 
ii. 10 Nm (1.0 m • kgf, 7 .2 ft -lbf) 
Remarks 
Refer  to  E NGINE R EMOVAL on  page  5-3. 
Re fer  to 
CAMSHA FT S on  page  5-9. 
Refer  to 
CAMSHA FT S on  page  5-9.  
						

							REMOVING THE CYLINDER HEAD 
1. Remove: 
• Inta ke camshaft 
• Exhaust  camshaft 
Refe r to 
RE MOVING THE CAMSHAFTS 
on page  5-11. 
2.  Remove: 
• Cy lin de r head bo lts 
TIP~~~~~~~~~~~~~~-
• Loosen  the bolts in  the  proper  sequence as 
shown. 
• Loosen  each bolt 1/2 of a  turn  at a time.  After 
all of the bolts are fully  loosened, remove  them. 
EA$1AC 1508 
CHECKING THE TIMING  CHAIN GUIDE 
(EXHAUST  SIDE ) 
1. Check: 
•Timing chain guide (e xhaus t side) 
Damage/wear 4Replace . 
EA~1$) 
CHECKING THE CYLINDER HEAD 
1. Eliminate: 
• 
Combust ion  chamber  carbon deposits 
(with  a rounded  scrape r) 
TIP~~~~~~~~~~~~~~~ 
Do  not  use  a sharp  instr ume nt  to  avoid damag­
ing or scratching: 
• Spark plug bore  threads 
• Valve seats 
2.  Check: 
• Cylinder he ad 
Damage/scratches 
~ Replace. 
CYLINDER HEAD 
•  Cylinder head  water  jacket 
M ineral deposits/rust~ E liminate. 
3.  Measure: 
• Cylinder head  warpage 
Out of specif icat ion 4 Res urface  the 

cylinde r 
head. 
Warpage limit 
0.10 mm (0.0039 in) 
• ••••••••••••••••••\
••••••••••••• 
a. Place a  stra ightedge  1  and  a thickness 
gau ge 2 across  the cylinder head . 
Thickness gauge 
90890-03180 
Feeler 
gauge  set 
YU-26900-9 
b. Measure  the warpage. 
c. 
If the limit i s  exceeded,  resurface the  cylinder 
head as follows. 
d. Place a 4~0 gri t we t sandpaper on the 
s u rface 
p late and  resurface  the 

cy lin de r 
head 
using  a fig ur e-e ig ht sanding  pattern. 
TIP~~~~~~~~~~~~~~~ 
To ensure  an even  surface,  rotate  the cylinder 
head severa l times. 
5-20  
						

							EA$2>12-CO 
INSTALLING THE CYLINDER HEAD 
1. 
Install: 
•Tim ing cha in  guide  (exhaust  side) 1 
•  Cyli nde r 
head  gasket 2 i~t:WJ 
• Dowel pins 3 
2. Install: 
•  Cy lin de r 
head 
•  Cy lin de r head bo lts (M6) 
• Cy lin de r head bo lts (M9) 1nHl!ll..l!llj 
TIP---------------
• Pass  the timing  ch ain  thro ugh  the  timing  chain 
cavity. 
• Lubr icate  the cylinder head bo lt (M9)  thread 
and  mating  surface  with  eng ine 
oil. 
3. T ig hten: 
•  Cyli nde r head bo lts 1 - 8  
•  Cylinder 
head bo lts 9-12 
Cylinder 
head bolt  1 - 8 
1st:  25  Nm (2.5 m·kgf , 18 ft·lbf ) 
*2nd: 16 Nm (1.6 m·kgf, 12 ft-lbf) 
+90° 
Cylinder 
head bolt  9-12  
10 
Nm (1. 0  m·kgf, 7.2 ft·lbf) 
•  Fo
llow ing the  tightening  order , loose n the bolt 
one  by one  an d  th en retigh ten  it  to  the  specific 
torq ue a nd  th e spec ific 
angle. 
TIP--------------­
Tigh ten  th e  cylinder  head bo lt s  1 -8 in the 
tig hte
ning  seq uence  as sh own  and torque  them 
in  2 stages. 
5-21 
CYLINDER HEAD 
4. Install: 
• 
Exh a ust  camshaft 
• Intake cams haft 
Refe r  to IN STALLING THE CAMSHAFTS  
o n  page 
5-14.  
						

							VALVES AND VALVE SPRINGS 
EA$2>1VO 
VALVES AND  VALVE SPRINGS 
Removing the valves and valve springs 
10~10 
11~ 
12 -~ 19 
13~ 
0 1 
14~~19 01-mm1s---e 
11~ & 911 ....... , ,.. 
L~ ~ 
R .I~ 0 ~~ 1 2 ; 
,\)• ,;... 0  ) \ 
~  \...< ,-
						

							EA$2>12$) 
REMOVING THE VALVES 
The following procedure applies to all of  the 
va lves and related components. 
TIP~~~~~~~~~~~~~~­
Before  removing  the inter nal parts of the cylinder 
head  (e.g., valves,  valve springs,  valve  seats), 
make  sure  the 
va lves  properly  seal. 
1. Remove: 
• Valve  lifter 1 
• Va Ive pad 2 
TIP~~~~~~~~~~~~~~­
Make  a note of the  position of each va lve  lifter 
and valve pad  so that  they  can be reinstalled  in 
the ir 
orig inal  place. 
1 3 
EX 
IN 
2 1 
2.  Check : 
• Valve  sealing 
Leakage  at the valve seat --t C heck  the valve 
face, valve seat,  and valve seat  width. 
Refer  to 
CHECKING THE VALVE SEATS 
on page  5-25. 
••••••••••••••••••\
•••••••••••••• 
a. Pour  a clean  solven t a in to  the  in take  and 
exhaust  ports. 
b.  Chec k that  the 
valves  proper ly  seal. 
TIP~~~~~~~~~~~~~~ 
There shou ld be no leakage at the valve seat 1. 
1 
••••••••••••••••••\
•••••••••••••• 
3.  Remove: 
• Valve cotters 
VALVES AND  VALVE SPRINGS 
TIP~~~~~~~~~~~~~~ 
Remove  the valve co tters  by compressing the 
valve spring  with  the valve spr ing compresso r 
1 and the va lve spring  compresso r attac hment 
2. 
Valve spring compressor 
90890-04019 
YM-04019 
Valve spring compressor attach­
ment 
90890-04108 
Valve spring compressor adapter 
22mm 
YM-04108 
1 
4.  Remove: 
• Va lve spring  retainer 1 
•  Va lve spri ng 2 
•  Va lve  3 
•  Va lve 
stem seal  4 
• Va lve spring  seat 5 
TIP~~~~~~~~~~~~~~­
lden tify the pos it ion  of eac h part  very care fully so 
that  it can  be 
reinstalled in  its original  place. 
· --._ 
I  ·--._ 
----- ©-1 
I ®-4 
i ~ -2 
......... _____ ~ 
.__, 
3 
,_,,. 
CHECKING THE VALVES AND VALVE 
GUIDES 
T he follow ing procedure applies to all of the 
valves and va lve guides . 
1. Measure: 
•  Va lve-stem-to-valve -gu ide  clearance 
Out 
of  spec ification --t Replace the va lve 
5-23