Yamaha Fz 09 2014 Manual

							EA$26520 
DISASSEMBLING THE WATER PUMP 
1. Remove: 
• M echanical  seal (housing  side)  1  
TIP~~~~~~~~~~~~~~~ 
Remove  the mechanical  seal (hous ing  side) 
from  the inside  of th e wa ter  pump  hous i
ng 2 . 
1 2 
2. 
Remove: 
• Bearing  1  
•  Oil seal 2  
TIP~~~~~~~~~~~~~~­
Remove  th e o il  seal and  bearing from  the out­
side of the  water  pump  housing  3. 
3 
3.  Remove: 
•Mechanical  seal (impeller s ide) 1 
(from  the impeller, w ith  a  th in , flat-head 
screwdriver) 
TIP~~~~~~~~~~~~~~ 
Do  not  scratch  the impeller shaft. 
1 
• 
• 
WATER PUMP 
.......... 
CHECKING THE WATER PUMP 
1. Check: 
• Water  pump  housing  cover 1 
• Impeller 2  
Crac ks/damage /wea r -> Replace. 
• 
Water  pump  ho using 3  
Crac ks/damage /wea r -> Replace the  wate r 
p ump 
assembly. 
2 
2 . Check: 
• Bear ing 
3 
Rough  movemen t -> Replace. 
3. Check: 
• Water pump inlet p ipe 
Cracks/damage /wea r 
-> Replace . 
......... 
ASSEMBLING THE WATER PUMP 
1. Install: 
In stalled d epth a  
0.5-1.0 mm (0 .0 2-0.0 4 In ) 
1 
TIP~~~~~~~~~~~~~~­
lnstall th e oil  seal w it h  a  socket  th at  matches  its 
outs ide  diameter. 
mm2 
a 
I 
1mm 
2 . Install: 
•
Mech an ical  seal (hous ing  side) 1 IH491 
NOTICE ~~~~~~~~~~~~~ 
Never lubricate the mechanical seal surface 
6-10  
						

							with oil or grease. 
TIP------------:-­
Use the speci al tools  and  a press  to  press  the 
mechan ical seal  (ho usin g s ide)  straigh t in  un til i t 
to uches  th e  water  pu
mp ho using. 
Mechanical seal installer 
90890-04078 
Water pump seal installer 
YM-33221-A 
Middle driven shaft bearing driver 
90890 -04058 
Middle drive bearing installer 40 & 
50mm 
YM-04058 
A 
+ 
2. Water pump hous ing 
3. M echan ica l sea l ins t aller 
4. M idd le d riven shaft  bearing  driver 
A .  P
ush down 
3. Install: 
• 
Mechani cal seal  (im peller  side) 1 U\[4\ll 
TIP----------------
• Bef o re ins t alling th e  mechanic al s e a l (im peller 
s id e),  ap ply  tap 
water or coolan t onto  its  outer 
su rf ac e. 
•  If th e  top  of  the mechanical seal  i s  dirty,  clean 
it. 
4. Measure: 
•  Impeller shaft  tilt 
O ut of specifica tion ~ Repea t steps  (3) and 
6-11 
WATER PUMP 
(4). 
NOTICE -----------­
Make sure the mechanical seal (Impeller 
side) is flush with the impeller. 
Impeller shaft tilt limit 
0 .15 mm (0.006 in) 
1 .  Straightedge 
2 . 
Impeller  
						

							FUEL SYSTEM 
FUEL TANK ................................................ ........ ......................... ........ .............  7-1 
REMOVING THE FUEL TANK  ............. .... ........ .... ............. ........ ........ .........  7-3 
REMOVING THE FUE L PU MP .... .... .... .... .... .... ......... ........ ........ .... ......... ....  7-3 
CHECKING THE FUEL  PUMP  BODY ................... .... .... .... ......... ........ .... .... 7 -3 
CHECKING 
THE FUEL  PUMP  OPERATION ...................................... 7·3 
CHECKING THE ROLLOVER VALVE  (for Californ ia  on ly) ..................... 7 ·3 
INSTALLING 
THE FUEL  PUMP ....................................................... 7·3 
INSTALLING THE FUEL TANK ..................................... .... .................. 7-4 
THROTTL E BODIES .......... .... .... .... .... .... .... ..... .... .... .... .... .... .... .... ..... ........ .... ....  7 ·5 
CHECKING THE INJECTORS  (BEFORE REMOVING) .... .... ..... ........ .... .... 7 -8 
REMOVING 
THE FUE L HOSE  (FUEL  RAIL SIDE) ............... ..... ........ .... .... 7-8 
REMOVING 
THE INJECTORS . ... ..... .... .... .... .... .... .... ......... .... .... ........ .... .... . 7-8 
CHECKING 
THE INJECTORS ...................................................................  7-8 
CHECKING AND CLEANING THE  THROTTLE BODIES ............. .............  7-8 
REPLACING THE  THROTTLE BODI  ES .................................................. 7-10 
INSTALLING 
THE INJECTORS .. ... ...... ............ ... ... .. ... ... ... ..... ......... ..... ....  7 -10 
CHECKING THE IN JECTOR  PRESSURE ............................................... 7-10 
CHECKING 
THE FUEL  PRESSU RE ............................................. ...........  7-11 
INSTALLING THE FUEL  HOSE  (FUEL  RAIL SIDE) ........... .... .............. ... 7-12 
ADJUS TING THE  THROTTLE POSITION  SENSOR ...............................  7-12 
ADJUS TING THE ACC ELER ATOR  POSITION  SENSOR ...... ...... ...........  7-13 
AIR INDUCTION  SYSTEM ............... .... ...... ........ ....... ........ .............................  7-15 
CHECKING THE AIR  INDUCTION  SYSTEM ....................... ........ ............  7-18 
INSTALLING THE AIR  INDUC TION  SYSTEM .........................................  7-18  
						

							,..,,.., 
FUEL TANK 
Removing the fuel tank 
Order 
1 
2 
3 
4 
5 
6 
7 
8 
9 
10 
11 
1 2 
f
						

							FUEL TANK 
Removing the rollover valve and canister (for California only) 
I. 7Nm(0.7m·kgf,5.1 lt·lbl) 
Order Job/Parts to remove Qty Remarks 
Rider  seat  Refer 
to 
GEN ERAL  CHASS IS  on  page 
4-1. 
Air  scoop /F uel  ta nk  cove r  Refer 
to  G ENERAL CH ASS IS  on  page 
4-1 . 
F uel ta nk  Refer  to  F UE L TA NK o n  page  7-1. 
1 Cani ster  pu rge  hos e (ho se  joint  to  cani ster) 1 
2 F u el tank bre athe r h ose (fuel tank to r ollove r 1 valve) 
3 Rollover  valve 1 
4 F u el tank  breathe r h ose (r o llo ve r  valve to  ca nis-1 te r) 
5  C
aniste r 
1 
6 Canister breathe r hose 1 
7  Canister bracke t 1 
7-2  
						

							EA$1AC1101 
REMOVING THE FUEL TANK 
1. 
Ext ract  the fuel in  th e fuel t ank  th rough  the 
fu e l tan k cap with a p ump. 
2. Remov e: 
• R ide r sea t 
•A ir  sc oo p/Fuel tank  co ver 
Refe r 
to GENERAL  CHA SSIS on pag e 4-1. 
3. D iscon nect: 
•  Fu el hose (fuel tank  sid e) 
•  Fu el p um p co up le r 
•  Fue l 
tank drain  hose 
•  Fue l tank breather  hose 
EWAIRClJW 
AwARNING 
Cover fuel hose  connection  with a cloth 
when  disconnecting  them. Residual pres­
sure in the fuel lines  could cause fuel to 
spurt out when  removing  the hose. 
ECA1RC l707 
NOTICE ----------­
Be sure to disconnect the fuel hose by hand. 
Do 
not forcefully disconnect the hose with 
tools. 
TIP-------------
• To  remove the fu el hose  from the fuel pump, 
slide the fue l hose  connecto r  cove r 1 on the 
end  of  the  hose  in  the  directio n of  th e  arrow 
shown,  press 
the  two  buttons 2  on  the  sides 
o f 
the  connector,  and  then  remove the hose. 
• Be fo re  remov ing  the  hose , place a few  rags  in 
the  area  under  where  it 
will be  removed . 
• It is prohibited to  wear  the cotton  work gloves 
or equivalen t coverings. 
t 
2 
4.  Remove: 
•Fue l tank 
TIP------------­
Do not set the fu e l tank  down so that  the instal ­
la ti
on surface  of the fuel pump is directly un der 
the t ank.  Be  sur e to lean the fue l tank in  an  up­
rig ht p
ositio n. 
7-3 
FUEL TANK 
......... 
REMOVING THE FUEL  PUMP 
1.  Remove: 
• Fue l pump 
NOTICE 
~------------• Do not drop the fuel pump or give It a 
strong 
shock. 
• Do not touch  the base  section of the fuel 
sender. 
CHECKING THE FUEL  PUMP  BODY 
1. Check: 
• Fue l pump  body 
Obst
ruction -) C lean. 
Crac ks/damage -) R ep lace  fu e l pump as­
semb ly. 
 CHECKING THE FUEL  PUMP  OPERATION 
1. Check: 
• Fue l pump  operat ion 
Ref e r  t o CHEC KING THE FUEL PRES­
SURE on page 7-11. 
EAS1AC11 18 
CHECKING THE ROLLOVER VALVE (for 
California only) 
1. C heck: 
• Rollo ver  valve  1 
D amag e/fa
ulty -) Rep lace. 
TIP
-------------
• Check  th at a ir f lows  smoothly only in t h e d irec­
tion  of the  arrow  sh own  in  the 
illust ratio n. 
• 
The rollover  valve mus t be in an uprig ht  posi ­
t ion  when  chec
king the a irf low. 
EA.S1FICt103 
INSTALLING THE FUEL  PUMP 
1. Install: 
•  Fue l 
pump  gasket l~fiM 
•Fue l pump 
•  Fue l pump  bracket 
• Fue l pump bo lts  
						

							Fuel pump bolt 
4.0 Nm ( 0 .40  m·kgf, 2.9 ft·lbf) 
TIP~~~~~~~~~~~~~~~ 
• Do  not  damage  the ins talla tion surfaces of th e 
fuel ta nk  when ins talling the fue l pump. 
• Always use  a ne w fuel p ump  gasket. 
• Install the fuel p u mp  gasket  so that  the lip side 
turns  to the ins ide  of the 
fue l tank. 
• Install the fue l pump as  shown  in  the illustra ­
tion . 
• Align the  projection a on th e fue l pump  with 
the 
slot in  th e fu el pump  bracket. 
• T ig hten 

the 
fuel pump bo lts in  the  prope r tigh t­
en ing  seq ue nce  as sh ow n. 
A. Forward 
EA$1AC1104 
INSTALLING THE FUEL TANK 
1.  Connect: 
• Fue l hose (fu el tank  side) 
N O TICE 
0 
0 
~~~~~~~~~~~~~ 
When installing the fu el hose, make sure that 
it is securely connected,  and that the fue l 
hose connector c o ve r on the fu el hose  is in 
the correct position, otherwise the fuel hose 
will not be properly installed. 
TIP~~~~~~~~~~~~~~-
•  Install th e fu el hose sec urely o nto  the fuel 
pump un ti l a 

dis tin ct 
c lick  is heard . 
• To insta ll th e fu el hose  onto  the fue l pump, 
slide the fue l hose  connector  cover 1 on  the 
end  of  the  hose  in  the  dire ctio n  of  the  arrow 
s h own . 
• It is 

pro
hib it ed  to  wea r the  cotto n wo rk gloves 
or equ iva lent coverings . 
FUEL TANK 
1 
2. Connect: 
•  Fue l tank  breather  hose 
• Fue l tank  drain  ho se 
•  Fue l pump co up ler 
7-4  
						

							THROTILE BODIES 
EA$28970 
THROTTLE BODIES 
~ 3.0 Nm (0 .30 m • kgf, 2.2 ft • lbl} 
l 
7 
1 
8 
Order Job/Parts to remove  Qty Remarks 
Rider  se at Refer  to  G ENE RA L C H ASS IS • on  pa ge 
4·1. 
Air scoop/F u el tank c ove r  Refer 
to  G ENERAL CHASS IS  on  page 
4· 1. 
F u el tank  Refe r  to  F U EL  TA N K· o n  page  7 -1. 
Air filter case Refe r  t o GE NERAL C H ASS IS • on pa ge 
4-1 . 
C aniste r  purge  hose  Refe
r to  F U EL  TA N K o n  page  7 -1 . 
F o r Ca lif orn ia  onl y. 
1 F u el h os e 1 
2 Int ak e air  pres sure sen so r 1 co uple r 1 D isconn ect. 
3 Int ak e air  pres sure sen so r 2 co uple r 1 D isconn ect. 
4 Accele ra tor pos ition  se nsor co upler , D isconnect . 
5 Throttle se rvo m oto r cou ple r , Disconnect . 
6 Throttle pos ition sen so r cou ple r , Disconnect. 
7 
Thr ottle  cable  (a ccele rator  cable ) 1 Disconnect. (Black ) 
8 Throttle  cab le  (dece le ra to r  cable ) , D isconnect. 
9 Thr ottle  bocly joint clamp sc rew 6 loosen. 
10 Thrott le b ody asse mbly , 
11 Thr ottle b ody  joint 3 
7 -5  
						

							THROTILE BODIES 
Removing the sensors 
3.5 Nm (0.35 m. kgf, 2.5 ft 0 lbf) 
It 3.5  Nm (0.35 m • kgf, 2 .5 ft • lbf) 8 
7 
5 
• 
2 __ J 
Order  Job/Parts to remove Qty Remarks 
1 Negative  press ure hose 6 
2 Hose  joint 2 
3 Canis ter  purge  hose  5 For Calif orn ia only. 
4 H ose  joint  3 For Californ ia only. 
5 Intake air  press ure senso r 2 1 
6 Intake air  press ure senso r  1 1 
7 
Thr ottle posit ion  senso r 1 
8 Acce lerator pos ition  se nsor 1 
7-6  
						

							THROTILE BODIES 
Removing the injectors 
5 Nm (0.5 m • kgf. 3.6 ft 0 lbf) 
1 
12 Nm  (1.2  m • kgf, 8.7 ft ·I bf) 
Order  Job/Parts 
to remove Qty Remarks 
Throttle bodies/Throttle 
body jo int  Refer to  T HROTT LE  BODIES  on page 7·5 . 
1 Fuel  rail 1 
2 In jector 3 
3 
I njecto r coup ler 2 Disco nnect. 
4 Injector  lead 1 
5 
I njector  lead  coup ler 1 Disco nnect. 
6 Wire  ha rness  1 
7  Ad
apter  1 
7-7