Yamaha Fz 09 2014 Manual

							guide. 
• Va lve -stem -to -va lve -guide clea rance = 
Va lve  guide  inside  diameter a  · 
Valve stem  diameter b 
Valve-stem-to-valve-guide  clear· 
ance (intake) 
0.010-0.037 mm (0.0004-0.00 15 
in) 
Limit 
0.080 mm (0.0032 in) 
Valve-stem-to-valve-guide  clear· 
ance (exhaust) 
0.025-o.052 mm (0.0010-0.0020 
in) 
Limit 
0.100 mm (0.0039 in) 
2.  Rep l
ace: 
• Valve  guide 
TIP~~~~~~~~~~~~~~-
To  ease  valve  guide remova l and installation, 
and 
to maintain  the  correct  fit, hea t the cylinder 
h ead  to 100 •c (212 °F) in an oven. 
YYTTTYTTTYYTTTYTTTYYTTYYTTTYTTTY 
a.  Remove  the valve gu ide  with  the  valve  guid e 
r emove r 
1. 
VALVES AND  VALVE SPRINGS 
b. Install the new  valve  guide  with the  valve 
g
uide inst aller 2 and  valve  guide remover 
11.1. 
Valve guide  position 
13.3-13 .7 
mm (0.52-0.54 in) 
a. Val ve guide  posit io n 
c. After in stalling the valve guide, bore the valve 
g uid e 

w i
th  the valve gu ide  reamer 3  to ob· 
lain the  proper va lve-ste m-to-valve-gu ide 
c learance. 
TIP~~~~~~~~~~~~~~­
After  replac ing the val ve gu ide , reface  the valve 
seat. 
5-24  
						

							Valve guide remover (04.5) 
90890-04116 
Val ve guide remover (4.5 mm) 
YM-0411 6 
Valve guide install er (0 4.5) 
90890-04117 
Valve guide installe r (4.5 mm) 
YM-04117 
Val ve guide re am er (04.5) 
90890-0411 8 
Valve guid e r eamer (4.5 mm) 
YM-0411 8 
••••••••••••••••••\
•••••••••••••• 
3. Eliminate: 
• Carbo n depos its 
(from  the 
valve face and valve seat) 
4. Check: 
•Va lve face 
P itti ng/wear 
4 Grind  the valve face. 
• Va lve stem  end 
Mus hroom  shape 
or diameter large r than  the 
body 
of the valve stem 4 Rep lace the va lve. 
5. Meas ure: 
•  Valve stem  runou t 
O ut of speci fica tion 4 Replace th e valve. 
TIP~~~~~~~~~~~~~~-
• When  installing  a new va lve,  always  replace 
the valve guide . 
• If the valve is  removed or rep laced , always  re­
place 
the valve stem seal. 
EA~XO 
Valv e s te m runou t 
0.01 O mm (0.0004 in ) 
C HECKING THE VALVE  SEATS 
// 
The following  procedure applies to all o f  the 
va lves and va lve seats . 
1. Elim inate: 
• Carbon  deposits 
(from  the 
valve face and valve seat) 
VALVES AND  VALVE SPRINGS 
2. Check : 
•Va lve seat 
P itting/wear 
4 Rep lace the  cylinder  head. 
3. Measure: 
• Va lve seat  wid th a 
Ou1 o f  specifica tion 4 Replace th e  cy linde r 
head. 
V alve sea t 

w i
dth 
Valve seat width (intak e) 
0 .90-1.10 mm (0. 0354--0 .0433 In) 
Lim it 
1.60 mm (0.06 i n) 
Val v e s e a t  w id th  (exhaust) 
1.10-1. 30 mm (0 .04 33--0 .0512 in ) 
L im it 
1 .80 mm (0 .07 In) 
TTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTT 
a. App ly  blue  layout  fluid  b onto  the valve face. 
b 
b. Install the valve i n to  the cylinder  head. 
c.  Press  the 
valve throug h the valve gu ide  and 
onto  th e 
va lve seat to make  a clea r impres ­
sion. 
d .  Measure  the 
valve sea t w idth. 
TIP~~~~~~~~~~~~~~-
Where the va lve seat  and valve face contacted 
one  another,  the 
blue  layout  fluid  will have  been 
removed. 
AAA..AAAAA£AAA£AAAA£AAA£AA..t...AAAAA£A 
4 . Lap: 
• Va lve face 
5-25  
						

							•Valve sea t 
TIP~~~~~~~~~~~~~~­
Afte r rep laci ng  the cylind er head or replacing  the 
va lve and va lve guide , th e va lve seat  and valve 
face 
should be  lapped  . 
••••••••••••••••••\
•••••••••••••• 
a. Apply a coar se  lapp ing  compo un d a to  the 
valve f ace . 
NOTICE ~~~~~~~~~~~~~ 
Do not let the lapping compound enter the 
gap between the valve stem and the valve 
guide. 
b. 
App ly mo lybdenum  disulf ide oil on to  the 
va lve s tem. 
c. Install the  valve into the cylinder  head. 
d.  Tur n t
he va lve unt il  th e va lve face  and valve 
seat  are 
even ly po li shed,  then clean o ff all of 
the lappin g compound . 
TIP~~~~~~~~~~~~~~­
For the  best lapp ing results, light ly tap  the va lve 
sea t 
whil e rot ating  the valve  back  and forth be· 
twee n your  hands. 
e. 
App ly a  fine  lapp ing  compound  to the  valve 
f ace  and  repe
at the  abo ve  steps. 
f. After  every  lapping  procedu re , be sure to 
clean  off 
all of the lapp ing com poun d from  the 
va lve f ac e and va lve seat. 
g. App ly  blue layo ut flu id  b onto  the valve  face. 
VALVES AND  VALVE SPRINGS 
h. Install the va lve in to  the cylind er he ad. 
1. Press  the valve  th rough the  valve  guide  and 
o nto  the  valve  seat to  make  a clea r 
impres · 
sion. 
J . Measure  the va lve sea t w idth  c  aga in. If the 
va lve sea t width  is out  of  spec if ication , re face 
a
nd l ap  the valve seat. 
c 
f.o\S2-1:110 
CHECKING THE VALVE SPRINGS 
T he follow ing p roced ure applies to all of  the 
va lve  springs. 
1. Measure: 
• Va lve  spri ng free le ngth a  
Ou1 of  spec ificat io n ~ Rep lace  the valve 
spr ing . 
5-26 
Free length (intake) 
39.31 
mm (1.55 in) 
Lim it 
37. 34 mm (1.47 in) 
Free 
length  (exhaust) 
37.78 mm (1. 49 In) 
Limit 
35.89 mm (1.41 in)  
						

							i 
f o..ia 
2. Measure: 
• Compressed valve spring  force a 
Out 
of speci ficat ion 4 Rep lace the  valve 
spr
ing. 
t 
b. I ns talled le n gth 
Installed compression spring 
force (intake) 
192.00-220.00 N  (19 .58-22.43 
kgf, 43.16-49.46 lbf) 
Installed compression spring 
force (exhaust ) 
162.00-186.00 N (16 .52-18.97 
kgf, 36.42-41.81 lbf) 
Installed length (intake) 
32.90 mm (1 .30 in) 
Installe d length (e xhau st) 
32.00 mm (1.26 in) 
3. Meas ure: 
• Valve  spring tilt a 
Out 
of specification 4 Rep lace the  valve 
spring. 
Spring tilt (i ntake ) 
1. 7 mm (0.0 7 in) 
Spring tilt (exhau st) 
1 .6 mm (0.06 in) 
VALVES AND  VALVE SPRINGS 
---a 
...... ,,. 
CHECKING THE VALVE  LIFTERS 
The following procedure applies to all of the 
valve 
lifters. 
1 . Check: 
•  Va lve lifter 
Damage/scra tc hes 4 Replace  the valve  lift­
ers  and cylinder head . 
....,.,.. 
INSTALLING THE VALVES 
The following procedure applies to all of the 
valves  and related  components. 
1. Deb urr: 
• Va lve  stem  end 
(with an oil stone) 
2. Lubr icate: 
• Valve  stem 1 
• Valve  stem seal 2 
(with  the  recommended lubricant) 
Recommended lubricant 
1-~l Molybdenum disulfide oil 
5-27  
						

							3. Install: 
•Valve spring seat 1 
• Valve stem seal 2 ljnt4•;,l•1 
•Valve 3 
• Valve 
spring 4  
•  Valve 
spring  reta iner 5 
( into  the cylinde r head) 
TIP---------------
• Ma ke  sure  each valve is installed in  its original 
place. 
•  Install 
the valve springs wit h the larger pitch a 
fac ing  up. 
j-. 
---. -5 
b. Smaller pitc h 
4. Install: 
3 
• Valve cotte rs 1 
I 
i ®-2mm 
! ~ - 4 
......... ~ 
---.... 
TIP---------------
lnstall the valve cotters by compressi ng the 
va lve spring  with the valve spr ing  compressor 
2 and  the valve spring  compressor  attachment 
31. 
VALVES AND VALVE SPRINGS 
Valve spring  compressor 
90890-04019 
YM-04019 
Valve spring compressor attach­
ment 
90890-04108 
Valve spring compressor  adapter 
22mm 
YM-04108 
5. To  secure  the valve cotters  onto the valve 
stem,  lightly tap the valve tip with a soft-face 
hammer. 
NOTICE 
Hitting the valve tip with  excessive  force 
could damage the valve. 
6. Lubricate: 
•Valve pad 
(w i
th the  recommended lubricant) 
l 
Recommended  lubricant 
Molybdenum  disulfide 
oil 
• Valve lifter 
(w ith the  reco mmen ded lub ricant) 
I--. Recommended  lubricant 
l Engine oil 
5-28 
7. Install: 
•Valve pad 
• Valve lifte r  
						

							TIP~~~~~~~~~~~~~~ 
• The valve  li fter m ust  move smoo th ly whe n ro· 
lated  with  a finge r. 
• Eac h valve  lifter and valve pad  must  be rein· 
stalled in i ts original pos itio n. 
VALVES AND  VALVE SPRINGS 
5-29  
						

							GENERATOR AND STARTER CLUTCH 
,..,_, 
GENERATOR  AND STARTER CLUTCH 
~ 32 Nm (3 .2 m • kgf, 23 ft ·lbf) , 
~ 75 Nm  7.5 m . kgf, 54 ft · lbl) 
l~l 15  Nm  (1.5 m • kgf, 11 ft -lbl) V 
l~l 1 O Nm (1.0 m • kgf, 7 .2  ft • lbf) l~ 
~ 12 Nm (1.2  m • kgf, 8.7  ft • lbf) 
Orde r  Job/Pa
rts to remove 
Rider seat 
A
ir s c oop /F u el tank  cover 
Fu el ta nk 
Rear  side  cove r 
(left) 
Wa ter  pump 
Eng ine 
oil 
1  Sta tor coi l co up le r 
2 C ra nkshaft  posit io n  senso r couple r 
3 Holder  (fuel tan k overflow hose  and breat her 
hose) 
4 
5  6 
7 
8 
Gen era to r cove r 
Genera to r cove r gas ket 
Dowe l pin 
S tato r 
coil lead  holder 
S tato r coil 

assembly  (s tato r coil/cra nkshaft 
posi· 
lio n  se nsor) 
5-30 
Qty 
1 
1 
1 
1 
1 
2 
1 
1 
~) 
id 
( 3) 
8 
-., ~ 14 N m (1.4 m . kgl, 10 ft -lbf) 
(6) 
12 Nm (1 .2 m . kgf, 8.7 ft · lbl) 
12 Nm (1 .2 m • kgf, 8 .7  ft • lbf) 
Rema rk s 
Refer  to  G E
NERAL CHASSIS  on page 
4· 1. 
Refe r  to GE NERAL CH ASS IS  on page 
4· 1. 
Refer  to  FUEL TANK  on  page 7·1 . 
Refer  to  G ENERAL CHASSIS  on page 
4·1. 
Refer  to WAT ER  PUMP on  page 6·8. 
D ra in . 
Refer  to 
 C HAN G IN G TH E ENG IN E  OIL.: on 
p age 
3 ·23. 
D isconnect. 
Dis conne c
t.  
						

							GENERATOR AND STARTER CLUTCH 
10 
32  Nm  (3.2  m • kgf, 23 ft • lbf) 
~ 75 Nm  (7.5 m. kgf, 54 ft -lbf) :, 14Nm(1.4m·kgf,10ft·lbf) 
12  Nm  (1.2  m. kgf,  8.7 ft· lbf) 
\!, 12  Nm  (1.2  m • kgf, 8.7 ft • lbf) 
12 Nm (1.2  m • kgf, 8.7 ft 0 lbf) 
Order  Job/Parts to remove  Qty Remarks 
9 Gener ator rotor  1 
10 Start er clutc h 1 
1 
1  Start
er clut ch gear  1 
1 2  Woodruff  key  1 
1 3 
S tarte r 
clut ch  id le gea r sh aft  1 
1 4 

S tarte r 
clut ch  idle gea r  1 
1 5 

C ranks haft  end  cove r  1 
1 6  Ti
ming  mark  access
ing bolt 1 
17 Water  pump  outlet  pipe 
1 
5-31  
						

							GENERATOR AND STARTER CLUTCH 
,..,..., 
REMOVING THE GENERATOR 
1.  Remove: 
• Gene rator  rotor bolt 1 
• Washer 
TIP~~~~~~~~~~~~~~~ 
While  ho lding th e  generator  rotor 2 with  the 
sheave 
holder 3,  loos en the  generator  rotor 
bolt. 
Sheave holder 
90890 -01701 
Primary clutch holder 
YS-01880-A 
2.  Remove: 
• Generator  rotor 1 
(wit h the flyw heel  puller 2) 
• Woodruff  key 
NOTICE ~~~~~~~~~~~~~ 
To protect the end of the crankshaft, place an 
appropriate sized socket between the fly­
wheel puller set center bolt and the crank­
shaft. 
TIP~~~~~~~~~~~~~~~ 
• Inst all the flyw heel  puller bolts to  the  threaded 
ho les of  the starter clutch. 
• 
Make  sure the flywheel  puller is  centered  over 
the  genera t
or rotor. 
Flywheel puller 
90890-01362 
Heavy duty puller 
YU-33270 -B 
...... ,.. 
REMOVING THE  STARTER CLUTCH 
1.  Remove: 
• Sta rter clutc h  bo lts 
•  Starter  c
lutch 
TIP~~~~~~~~~~~~~~­
Wh ile hold ing the  generator  rotor 1 wit h  the 
sheave 
hol der  2 , loos en th e sta rt er clutch 
bol ts. 
1 
.,...,,. 
Sheave holder 
90890-01701 
Primary clutch holder 
YS-01880-A 
CHECKING 
THE  STARTER CLUTCH 
1. Check: 
• Starter  clutch  rollers 
Damage/Wear -t Replace. 
2. Check: 
• Sta rter clutc h  idle gear 
•  Sta rter clutch gear 
Bu rrs/c hips/roug hness/wear 
-t Re place the 
defect ive  part (s). 
3 .  C heck: 
• S ta rte r clu tch gear  contact  surfaces 
Damage/pitt ing /wear 
-t Rep lace the  starter 
clutch gear. 
4 .  Check : 
• S ta rter  clu tch o per ation 
••••••••••••••••••\
•••••••••••••• 
a. Inst all the starter clutch gear  1  onto  the gen-
5-32  
						

							GENERATOR AND STARTER CLUTCH 
erator rotor 2 and  hold  the generator  rotor . 
b.  When  tu
rning  the  starter  clutch gear clock­
w ise 
 fl( , the  starter  clutch  and the starter 
clutch  gear should  engage, otherw ise  the 
s tarter  clutch  is  fau lty  and  must  be rep laced. 
c .  When  turning the starter  clutch  gear  counter­
c lockwise 
B, i t  shou ld  turn freely,  otherw ise 
the  starter  clu tc h  is  fau lty  and  must 
be re­
p la ced. 
A 
1 
1 
 
B 
2 
 INSTALLING THE  STARTER CLUTCH 
1 . Install: 
• 
Starter  clu tch 1  
Starter clutch bolt 
32  Nm  (3.2 m·kgf, 23 ft·lbf) 
LOCTITE® 
TIP~~~~~~~~~~~~~~ 
•  Install the  starter  clutch so that  the side of the 
starter  clu tc h  roller  assembly  with  the  arrow 
mark 
a i s  toward the  generator  rotor 2. 
• W hile  hold ing  the  gene rator  rotor  with the 
sheave  holder 
3, ti ghten  the starter  clu tch 
bo lts. 
Sheave 
holder 
90890-01701 
Primary  clutch holder 
YS-01880-A 
...... 500 
INSTALLING THE GENERATOR 
1. Install: 
• 
Wood ruff key 
• Generator  rotor 
• Washer lf@ii 
• Generator rotor bolt 
TIP~~~~~~~~~~~~~~~ 
• Clean the  tapered  portion  of the  crankshaft  and 
t
he generator  rotor  hub. 
• Whe n insta lling the  generator  rotor, make  sure 
the  woodruff  key is properly  seated in the  key­
way  of the  crankshaft . 
• Lub rica te the  washer  with  eng ine  oil. 
• L ub rica te the  generator  rotor  bolt threads  and 
washer  mating  surfaces  with engine  oil. 
2. Tighten: 
• Generator  rotor bolt 1 
Generator rotor bolt 
75 Nm (7.5 m ·kgf, 54 ft·lbf) 
TIP~~~~~~~~~~~~~~­
Wh ile hold ing  the  generator  rotor 2  wi th  the 
sheave  holder 
3, tighten  the  genera tor  rotor 
bol t. 
5-33 
Sheave holder 
90890-01701 
Primary clutch holder 
YS-01880-A