Yamaha Fz 09 2014 Manual

							CRANKSHAFT AND BALANCER SHAFT 
e. Install the balancer shaft jou rnal  lower bear­
i ngs 
1 into  the lower crankcase  and assem­
ble the  crankcase halves. 
TIP---------------
• Align the  projections  a of the balancer shaft 
journa l lower bearings  with  the  notc

hes 
b in 
the  crankcase. 
• Do not move  the balancer shaft until the  clear­
ance  measurement  has been 
comp leted. 
f .  Tighten  the bolts to  specification in the  tight­
ening  sequence  cast on the  crankcase.  Refer 
to 
CRANKCASE on  page 5-56. 
g. Remove  the lower  crankcase  and the balanc­
er  shaft  journal lower bearings. 
h.  Measure  t
he compressed Plastigauge® 
w idth a on  each  balancer  shaft journal.  If the 
balancer shaft -journal-to-bala ncer shaft -jour ­
nal-b earing  clearance is out of specif ication, 
se lect  replaceme nt balancer shaft journal 
bearings. 
~/,,~1v-.... 
a~lJ 
••••••••••••••••••\
•••••••••••••• 
4. Select: 
• Balancer 
shaft journa l bearings (J1-J2) 
TIP---------------
• T
he  num bers A stamped  into the balance r 
shaf t web  and  the  numbers 
B stamped  into 
the  lower  crankcase  are  used  to determ ine  the 
rep lacement 
bala ncer shaft journa l bearing siz-
es. 
•  J1 
-  J2 
refer  to the bearings  shown in  the bal­
ancer  shaft and lower cra nkcase  ill u stratio n. 
•  If J(- J2 
are  the same,  use the  same  size for 
all of  the  bea rings. 
For 
examp le, if the  crankcase J , and bal­
ancer  shaft web J ( number s are 5 and 2 re­
spect ive ly, then  the bear ing  size  for J ( is: 
J1  (c
rankcase)  -J1 (ba
la nc er shaft web)= 
5 -2 = 3 (brow n) 
 
Bearing  color code 
1.Blue 2.Black 3.Brown  4.Green 
5.Yellow 
INSTALLING THE CRANKSHAFT 
1. Install: 
• 
Crankshaft journal uppe r bearings 
(into  the upper  crankcase) 
• Crankshaft  journal lower bearings 
(into  the 
lower crankcase) 
• Crankshaft 
TIP--------------~ 
•  Align the  projectio ns a  on  the  crankshaft  jou r-
5-74  
						

							CRANKSHAFT AND BALANCER SHAFT 
nal bearings 1 with th e  notches b in  the 
crankcase. 
• Be s u re  to install each crankshaft journa l bear­
ings 
in i t s orig ina l p la ce . 
, . .,.,., 
INSTALLING THE BALANCER ASSEMBLY 
1 . Inst all: 
•  B ala nc
er journa l upper  bearings 
( in to  the  upper 
crankc ase) 
• B ala ncer journa l lower be arings 
( in to  the 
lower cra n kc ase) 
TIP---------------
• Align the  project ions a o n  the ba lancer journal 
bear ings 1 w ith  the notches b in  the  crank­
cases. 
• Be sure  to install each ba lancer  journal bearing 
i n  its 
original  place. 
2. Install: 
• 
Bala ncer  shaft 
TIP--------------­
lnstall by ali gn ing t h e  crankshaft match  ma rk a  
and  the balance r shaft  match  mark b. 
5-75  
						

							TRANSMISSION 
EA$262-t1 
TRANSMISSION 
Removing the transmission , shift drum assembly , and shift forks 
ii, 12  Nm  (1.2 m. kg!, 8 .7 ft .fbf) 
10 Nm (1.0 m. kgf, 7.2 ft 0 lbf) 
6 
0 1 9 ii, 10 Nm (1.0 m • kgf, 7.2 ft ·lbf) 
Order  Job/Parts to remove Qty Remarks 
Lowe
r crankcase  Refer 
to CRAN KCASE on  page  5-56. 
1 D rive ax le asse mbly , 
2 Oil  seal 1 
3 Bearing 1 
4 Washer 1 
5 Shift drum  r etainer 2 
6 Shift fo rk  gui de  bar 2 
7 Shilt  fo rk ·L 1 
8 Shilt  fo rk ·R 1 
9 Shilt drum assembly 1 
1 0 Shilt  fo rk ·C 1 
, , Ma in axle assembly , 
1 2 Bear ing , 
5-76  
						

							bling the main Disassem . axle assembly 
01·~' 
14 
Order  Job/Part s to remove 
1  2nd pinio n gear 
t h ed 
loc k was he r 
2 
Too  d 
lock was he r ret ain er 
3  T
oo th e 
4  6th  pini on  gear 
5 
Co lla r 
6  Was
her 
7 Circ lip 
8 3 rd  p in io n gear 
9 Circ lip 
10 wash er 
11 Sth pini on  gear 
1 2 
Co llar 
1 3  Bea ring  hou sin g 
14  Bea ring 
1 5  Main 
axle 
TRANSMISSION 
1 
Q ty Remarks 
1 
1 
1 
1 
1 
1 
1 
1 
1 
1 
1 
1 
1 
1 
1 
5-77  
						

							Disassembling the drive axle assembly 
2 
1 
9 
Order 
1 
2 
3  4 
5  6 
7 
8 
9 
1 0 
11 
1 2 
1 3 
14 
15 
1 6 
1 7 
1 8 
1 9 
20 
mm 7 
6 
Job/Pa rts to remove 
Bearing 
Was her 
1
st wheel gear 
Coll a r 
5th wheel gear 
Ci rclip 
Was her 
3rd 
w heel gear 
C olla r 
Toothed lock washe r 
T oothed 
lock washe r reta iner 
4th wheel gear 
Colla r 
Was her 
Circlip  6th 
w heel gea r 
Circ lip 
Was her 
Colla r 
2nd whee l gear 
TRANSMISSION 
Qty Remarks 
1 
1 
1 
1 
1 
1 
1 
1 
1 
1 
1 
1 
1 
1 
1 
1 
1 
1 
1  1 
5-78  
						

							TRANSMISSION 
Disassembling the drive axle assembly 
Order  Job/Parts to remove Qty Remarks 
2 1 
Co lla r 1 
22 Bea ring , 
23 Circlip , 
24 Drive ax le , 
5-79  
						

							REMOVING THE TR ANSMIS SION 
1.  Remove: 
•Drive  axle  assemb ly  1 
• 
Sh ift drum  reta ine rs 2 
• 
Sh ift fork  guide bars 
• Sh ift fork -L 
• Sh ift fork -R 
• Sh ift drum assemb ly 
• 
Sh ift fork -C 
2.  Remove : 
•Bearing hous ing 1 
• 
Mai n axle assemb ly  2 
••••••••••••••••••\
•••••••••••••• 
a. Insert two bo lts  3  of the  proper  size , as 
shown in the illustra tion, in to  the  main axle 
assemb ly 
bearing ho using. 
b.  Tighten  th e bolts  un til they  contact  the  crank­
case surface. 
c .  Con tin ue  tighte
ning  the bolts  unt il t h e  main 
ax le  assemb ly comes free  from  the  upper 
cran kcase  . 
••••••••••••••••••\
•••••••••••••• 
3. Remove: 
• Bearing 1  
TRANSMISSION 
CHECKING THE SHIFT  FORKS 
The following pro cedu re applies to all of  the  sh ift 
forks. 
1. Check : 
• Shift fork  cam follower  1  
•  Shift 
fork pawl  2  
Bends /damage /scorin g/wear ~ Replace th e 
s
hift  fork . 
2 
2. Check: 
•  Shift fork  guide  bar 
Roll the  shift  fork  guide  bar  on a flat surface . 
Bends 
~ Replace. 
EWA 128«1 
A WARN ING 
Do  not  att empt  to straighten  a bent  shift fork 
guid e ba
r. 
3.  Check: 
5-80 
•  Shift fork  movement 
(along the shift fork  guide  bar) 
Rough  movemen t 
~ Replace the  sh ift  forks 
a nd 
s h ift  fork  gui
de bar  as  a set.  
						

							319-0\ 
EAS20270 
CHECKING THE SHIFT DRUM  ASSEMBLY 
1. Check: 
• Sh ift drum  groove 
Damage/sc ratches/wear 
4 Rep lace the  sh ift 
d rum 
assemb ly. 
•Sh ift drum segmen t 1 
Damag e/wear 4 Replace th e  shift  drum as­
semb ly . 
•  Sh ift 
drum  bea rin g 2  
Damage/p itting 4 Replace the shift  dru m as­
semb ly . 
EAS2$2$) 
CHEC KING THE TR AN SMISSION 
1. Measure: 
• Ma

in 
axl e r u n o ut 
(w ith  a cente
ring dev ice  and dia l gauge 1 ) 
Out 
o f specificat ion 4 Replace t h e main ax le . 
M ain a xl e ru n ou t lim it 
0. 08 
m m (0 .0032 in ) 
1 
2.  Meas ure: 
• D rive ax le ru no ut 
(with  a 
centering  device and dial gauge  1) 
5-81 
TRANSMISSION 
Ou1 of spec ificatio n 4 Replace t h e dr ive axle. 
3 .  C heck: 
Driv e axle run out lim it 
0 .
08 mm (0 .0032 In ) 
1 
• Transm iss io n  gea rs 
Blue d iscolora tion/p itting/wear 4 Rep lace 
the  defec tive  gear(s). 
• Transm iss io n  gea r dogs 
Cracks/damage
/rou nded  edges 4 Replace 
the  defec tive  gea r(s). 
4.  Che ck: 
•Transm iss io n gear  engagemen t 
(ea ch  pinion 
gear to  it s  respec tive wheel 
gear) 
Inc orrect 4 Reassem ble the tran smiss ion 
axle  assem blies . 
s. Check: 
•Tra nsm iss ion gear  movement 
Ro ugh  movement 
-) Rep lace the  defective 
part (s). 
6 .  Ch
eck: 
•  C irclips 
Bends /damage /loose ness 4 Replace. 
 A SSE MBLIN G THE MAIN AXLE AND DRI VE 
AXL E 
1. Install: 
• Toothed 
washer 1  
•  C i re lip  2 l@@ii 
• Be  su re  th e circl ip sharp -edged comer   a  is 
pos it io ned  oppos ite  side  to  th e  toothed  washer 
a nd  gear.  
						

							• Align the  openi ng  between  the ends b o f  the 
circlip w ith  a groove c in the ax le. 
• Install th e circl ip so  that  a spli n e d is  in  the 
ce nte r of the  gap  betwee n the circlip ends e 
as  shown. 
2  1 
a 
b 
c 
e 
A. Main ax le 
B . Drive ax le 
2. Install: 
• 
T oot h

e d 
lock washe r r etainer 1 
• Toot h ed lock washer 2 
TIP~~~~~~~~~~~~~~~ 
• With the  toothed lock was her retainer in the 
groove 
 a in  the axle , align the  projection  on 
the  reta iner  with  an 
axle  spline, and th

en insta
ll 
the  toothed lock washer. 
• Be sure  to align the projection on the toothed 
lock washe r that  is between  the alignment 
marks b with  the alignment mark c on  the  re­
tai ner. 
TRANSMISSION 
1 
a 
c 
2 
1 
a 
A. Main axle 
B. Dr ive axle 
....,.,.. 
INSTALLING THE TRANSMISSION 
1 . Install: 
2 
• Bear ing  1  
TIP~~~~~~~~~~~~~~­
Face  the seal side  of bearing  to th e outs ide. 
5-82 
2. Install: 
• Main  axle  assemb ly  1 
• 
Bear ing  housing 2 
Bearin g  ho usi ng bol t 
12 Nm (1 .2 m ·kgf, 8 . 7 ft ·lbf) 
LOCTITE®  
						

							3. Install: 
• Sh ift 
fork -C  1  
•  Sh ift 
drum assemb ly  2 
•  Sh ift 
fork  guide bar 3  
TIP~~~~~~~~~~~~~~-
• The  embossed  marks on  th e  sh ift  forks sho uld 
face  towards  th e  rig ht s ide  of th e 

eng in e a nd  be 
i n  the 
following sequence: R, C , L. 
•  Caref ully 
pos it ion  the shift  fo rks  so that  they 
are 
i n stalle d correctly in to  the tra nsmission 
gears . 
• Install shift  fork-C into the  groove a in  the  3rd 
and  4th p
inion  gear  on the main ax le. 
4. Install: 
• Sh ift 
fork-R 1 
•  Sh ift 
fork- L 2  
•  Sh i
ft fork  guide  bar 
• Sh ift drum  reta iners 3 
• Bearing 
• Oil seal lllllll!@MI 
•  C ircl ip  4 ll@i 
• Drive ax le  assemb ly  5  
Shift drum reta iner bolt 
10 Nm (1.0  m·kgf, 7.2 ft·lbf) 
LOCTITE ® 
TIP~~~~~~~~~~~~~~~ 
• Install sh ift  fork-R in to  the  groove a in  th e 5th 
whee l gear and  sh ift  fork- L into the  gro ove b  
in  th e  6th wheel gear  on the drive axle. 
•  Install 
the shift  drum  retaine r wit h  its OUT 
mark c facing  outward. 
TRANSMISSION 
• To uch  the pro trusio n d on the  sh ift fork  guide 
bar  to the  side 
of t h e s hift drum  reta in er. 
• Make  sure that the drive axle be aring circlip  4 
is 

i n serted  in to  the  grooves 
e  in  the  upper 
c ra nkcase . 
s. Check: 
• Transm is sio n 
Rough  movement -t Repa ir . 
TIP~~~~~~~~~~~~~~~ 
O il each  gear, shaft, a nd  bear in g th oroughly . 
5-83