Yamaha Fz 09 2014 Manual

							EA$1ACl106 
CHECKING THE INJECTORS  (BEFORE 
REMOVING) 
1.  Check: 
• Injec tors 
Use 
the  diagnostic  code numbe rs 36 -38. 
Refe r to SELF-DIAGNOSTIC  FUNCTION 
AND DIAGNOS TIC  CODE TAB LE on page 
9-5. 
EAS1 AC1710 
REMOVING THE FUEL  HOSE  (FUEL  RAIL 
SIDE) 
1.  Remove: 
•Fue l ta nk 
Refer  to 
REMOV ING THE FUEL TANK  on 
page  7-3. 
2.  Remove : 
•Fue l hose (fue l rail side) 
£CA 1RCl701 
NOTICE 
-------------Be sure to disconnect the fuel hose by hand . 
Do 
not forcefully disconnect the hose with 
tools. 
TIP-------------~ 
• To  remove  the fue l hose  from the fuel rail joint, 
slide the fuel hose  con nector cover 1 on  the 
e nd 
of the  hose  in  the  dir ection of the  arrow 
shown,  press the two  bu ttons 
2 on  the  sides 
o f the  connector , and  t
hen remove  the hose. 
• Be fore  remov in g  th e hose , place a  few  rags  in 
the  a
rea under  where  it w ill be  removed. 
•  It is  prohib ited  to  wear  the cotton  work gloves 
or  equ iva lent coverings. 
t 
1  2 
EA$1ACl107 
REMOVING THE INJECTORS 
EWAIA C l101 
A WARNING 
• Check the injectors in a well-ventilated area 
free 
of combustible materials . Make sure 
that there is no smoking or use of electric 
tools in the vicinity of the injectors. 
• Be careful when disconnecting the fuel 
hose. Any remaining  pressure In the fuel 
7-8 
THROTILE  BODIES 
hose may cause the fuel to spray out. Place 
a container or rag under the hose to catch 
any fuel that spills. Always clean up any 
spilt fuel  immediately. 
• 
Turn the main switch to OFF and discon­
nect the  negative  battery lead from the bat­
tery terminal before removing  the injectors. 
1. Remove: 
• Th rottle bodies 
•  Fue l rail 1 
••••••••••••••••••\
•••••••••••••• 
a. Remove  the fuel rail  bolts  2  as  shown. 
y1 
8 
~~'\ ~~~=--
CHECKING THE INJECTORS 
1. Check: 
• Injec tors 
Obstruct ion ~ Replace and  check  the fue l 
pump /fuel  supp ly 
system. 
Depos it 
~ Replace . 
Damage 
~ Replace . 
2.  Check: 
• Injecto r resistance 
Refer  to CHECKING T H E FUEL INJEC­
TORS  
on pag e 8-111. 
E.ASIFOC1713 
CHECKING AND CLEANING THE THROTILE 
BODIES 
TIP------------­
Clea n the throttl e bod ies on ly i f  th ey  cannot  be 
synch ron ized  using  the  bypass  air screws . 
Be­
fore cle an ing the  thrott le bod ies,  chec k th e fol­
lowi ng ite ms : 
• Va lve cle arance 
•  Spa rk  plugs 
• 
A ir fil te r ele m ent 
•  Throttle 
body  joints 
•Fue l hose 
• Exhaust  system 
• Cylinder he ad  brea ther hose  
						

							EWAIA C l700 
AwARNING 
If the throttle bodies  are subjected to strong 
shocks or dropped during cleaning,  replace 
them  as a set. 
1. 
Chec k: 
• Throttl e bodie s 
Crack s/
damage 4 Replace  the throttl e bod­
ie s  as  a 

s
et. 
2 . C lea n: 
• 
Thro ttle bodies 
ECA1AC l701 
NOTICE~~~~~~~~~~~~ 
• Observe the following precautions; other­
wise,  the throttle bodies may not operate 
properly. 
• Do not subject the throttle bodies to exces­
sive force. 
• Clean  the throttle bodies in the recom­
mended cleaning  solvent. 
• Do not use any caustic carburetor cleaning 
solution. 
• Do not apply  cleaning solvent directly to 
any plastic parts, sensors, or seals . 
• Be careful not to remove the white paint 
mark that identifies the standard throttle 
body. 
• Do not turn the bypass air screws a; oth­
erwise,  the throttle body synchronization 
will be affected. 
l 
Recommended  cleaning solvent 
Yamaha Oil & Brake  Cleaner 
••••••••••••••••••\
•••••••••••••• 
a. Pla ce th e  thro ttle bodi es on  a flat surface  wit h 
the  air 
filter ca se 

s
ide  facing up. 
b . Ins tall th e  ca ps  (895 -1 4 169 -00)  onto  the  hose 
f itti ngs 
a. 
7-9 
THROTILE  BODIES 
a  a 
c. Hold the thrott le  valves  in  the  open  positio n. 
EWA1FC l104 
AwARNING 
When cleaning  the throttle bodies, be careful 
not to injure yourself on the throttle valves or 
other components of the throttle bodies. 
ECA1ACl700 
NOTICE~~~~~~~~~~~~ 
• Do not  open  the throttle valves by supply­
ing electrical power to the throttle bodies. 
• Do not use tools to open the throttle valves 
or to keep them In the  open position. 
•Do not open  the throttle valves  quickly. 
d . 
App ly the recommen ded  cleaning  solven t to 
the  th rottle 
valves  and  the  ins ide  of  the thro t­
tle 
b odi es  to remove  any carbon  deposi ts. 
TIP~~~~~~~~~~~~~~-
• Do not allow any  clean ing  solven t to  enter  the 
op ening  for the  injectors. 
• Do  not apply any cleani ng  solvent  to the por­
tions  of  th e  throttle va lve shafts  between the 
t h rottle  bodies. 
e. Remove  th e  carbo n deposi ts from  the inside 
of each  throttle  body  in a  downward  direc tion, 
from  the air  fil ter  cas e side of the  th rottle  body 
to  th e  eng ine  sid
e. 
NOTICE ~~~~~~~~~~~~~~ 
• Do not use a  tool, such as a  wire brush, to 
remove  the carbon  deposits;  otherwise,  the 
inside 
of the throttle bodies may be dam­
aged .  
						

							• Do not allow carbon deposit s or other for­
eign 
mater ial s to enter  any of the passages 
in each throttle body or in the space be­
tween 
the throttle  valve shaft and the throt­
tle body. 
f .  Aft
er remov ing the carbo n depos its , clea n the 
i ns ide  of 
the thrott le bod ies with  the recom ­
mended clean ing solvent , and  th en  dry  the 
thrott le bod ies using  compressed  air 
g.  Ma ke s ure  that  there  are 
no carbon  deposits 
or  oth er  fore ign 
mater ia ls in  any  of  the pas ­
sages a in  each throttle body  or in the  space 
b between  the thrott le  va lve s haft  and the 
thro ttle body . 
a 
••••••••••••••••••\
•••••••••••••• 
3. Install th e th rottle bod ies. 
4.  Reset: 
• IS C  (id le speed co ntrol) learning valu es 
Use 
th e 

d ia gnost ic co de  number 
67. 
Refe r 

t o 
SELF -DIAG NOSTIC FUNCT ION 
AND DIAGN OSTIC  COD E TABL E  on  page 
9-5. 
5.  Adjust: 
• Thrott le bod ies synchronizing 
O ut of  specific at io n -+ Replace the throttl e 
bod ies. 
Refe r 

t o 
 SYNCHRONIZ ING THE THROT­
TL E BODIES on  page  3-8. 
EA$1AC171~ 
REPLACING THE  THROTTLE BODIES 
1. Remove  the throttl e bod ies  from  the vehicle. 
2. Ins ta ll a  new throttl e bod ies to  the ve hicle. 
3.  Reset: 
• IS C  (id le speed co ntrol)  learnin g valu es 
Use 
th e dia gnost ic co de  number 67

. 
Refe r to  S E LF-DIAG NOSTIC  FU NCT ION 
AND DIAGN OSTIC  COD E TABL E  on  page 
9-5 . 
4.  Adjust: 
• Thrott le bod ies synchroni zing 
Refer  to 
 SYNCHRONIZ ING TH E THROT-
THROTILE  BODIES 
TLE BODIES  on  page  3-8. 
5 . P lace the vehic le on  a suita ble s tand  so that 
the  rear 
wheel is e lev ated. 
6. Check : 
• Engine idling s p eed 
Sta rt the  engine , warm  it up,  and  then 
mea­
su re  the engin e idli ng spee d. 
Engine 
idling speed 
1100-1300 r/min 
INSTALLING THE INJECTORS 
ECAIRCl702 
NOTICE 
•  Always use  new 0-rings. 
• When installing the injectors, do not allow 
any fore ign material to enter or adhere to 
the injec tors, fuel  rails , or 0-rings. 
• Be careful not to twist or pinch the 0-rings 
when installing the injec tors. 
• When installing the injector , install it at the 
same 
positi on  as the removed cyllnder . 
•  If 
an Injecto r Is subject to strong shocks or 
excessive force , replace  It. 
• If installing the original  fuel rail and bolts, 
remove  the white  paint marks using a 
cleaning  solvent. Otherwise , paint chips on 
the bolt seats could prevent the bolts from 
being tightened to the specified  torque. 
1. Install a new sea l onto  th e  end  of eac h injec ­
tor. 
2. Install the  in jec tors  to  t he fue l rail , ma king 
sure  to 
ins tall them  in  th e correc t d irect ion. 
3. 
Install the  injec tor assemblies to  the  adap ter. 
Fuel  rail bolt 
5 Nm (0.5 m ·kgf, 3.6 ft ·lbf) 
4 .  Check  the inje c tor  press ure afte r the  inje c tors 
are installed to  the thro ttle bod ies. 
Ref e r  to CHECKING T HE INJECTOR 
PRESSURE  
on page 7 -10. 
EA.SIFIC17l5 
CHECKING THE INJECTOR  PRESSURE 
TIP~~~~~~~~~~~~~~-
• After in stalling the injecto rs , perform  the follow ­
ing  steps  to check  the injec to r  pressu re . 
• Do n ot allow a ny  fo re ig n materia ls to  en te r  the 
fuel  li nes. 
1 .  Check: 
• Injector press ure 
7-10  
						

							TTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTT 
a. Connec t the  injec to r  press ure  adapter 1 to 
the fue l rail join t 2, and  th e n  con nect  an  air 
compressor 3 to  the  adapter. 
b. Connect  the pressure  gauge 4 to  the  injec ­
tor  pressure  adapter 
1 . 
Pressure gauge 
90890-03153 
YU-03153 
Fuel 
injector pressure  adapter 
90890-03210 
YU-03210 
4 
1 
3 
~-2 
c. C lose t h e va lve on the injector  pressure 
adapter. 
d. 
Apply a ir  pressu re 

w i
th th e a ir  comp ressor . 
e. 
Open the va lve on the  injector  pressure 
adapter 
u n til the  spec ified pressure  is 
reached. 
Specified  air pressure 
490  kPa  (5.0 kgf/cm2
, 71.1  psi) 
£CA1RC l106 
NOTICE ~~~~~~~~~~~~~ 
Never exceed the specified  air pressure or 
damage could occur. 
f. Clos e the valve on the injecto r  press ure 
adapte r. 
g.  Check  that  the specified  air pressure  is held 
at 
least one  minute. 
Pressure drops ~ Check  the pressure  gauge 
and  adap ter. 
C hec k the 
sea ls and  0-rings  and 

th
en rein ­
stall. 
Out of  spec if ic atio n ~ Replace  the fuel injec­
tors. 
EA$1AC17® 
CHECKING THE FUEL  PRESSURE 
1. Check: 
• Fue l press ure 
7-11 
THROTILE  BODIES 
TTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTT 
a. Remove  the  rider  seat, air  scoop  and fuel 
tan k cover. 
Refer  to 
 GENERAL  CHASSIS on page 4-1. 
b. Remove  the fuel tank bol t a nd  hold  up the  fuel 
tan
k. 
c. D isconnect  the fuel hose 1 from  the  fuel 
pump . 
Refer  to  REMOVING T HE FUEL  TA NK  on 
page  7-
3. 
fWA1RC11(l2 
~WARNING 
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. 
ECA.1RC1101 
NOTICE 
Be sure to disconnect  the fuel hose by hand. 
Do 
not forcefully disconnect the hose  with 
tools. 
d. Connect the pressure  gauge 2  and fuel 
pressure  adapter 
3 to  the fuel hose . 
Pressure gauge 
90890-03153 
YU-03153 
Fuel  pressure  adapter 
90890-03176 
YM-03176 
e. Start the  engine. 
f .  Measure 
the fue l p ressure.  
						

							Faulty --? Rep lace th e fue l pum p. 
EAS1RC1111 
Fuel line pressure at idling 
300-390 kPa (3 .0-3.9 kgf/cm2
, 
43.5 -56.6 psi) 
INSTALLING THE FUEL  HOSE  (FUEL RAIL 
SIDE) 
1. C onnec t: 
• Fue l hose (fuel ra il s ide) 
ECA 1AC I 705 
NOTICE~~~~~~~~~~~~ 
When installing the fuel hose,  make sure that 
it is securely connected , and that the fuel 
hose connector cover on the fuel hose is in 
the correct position, otherwise the fuel hose 
will not be properly installed. 
TIP~~~~~~~~~~~~~~~ 
•  Install the fuel hose se cu re ly on to  th e fuel  rail 
joint u n til a d ist in ct clic k is  heard. 
• To in stall the fue l hose  onto  the fuel  ra il jo int, 
slide th e fuel hose con nector  cove r 1 on the 
en d of  the  hose  in  the  directi on 
of th e  arrow 
shown . 
• It is  prohibi ted  to  wear  the cotton  work gloves 
or equivale nt coverings . 
1 
EAS1RC111G 
ADJUSTING THE THROTILE POSITION 
SENSOR 
EWAIRC170G 
AwARNING 
•  Handle the throttle position sensor with 
special care . 
• Never subject the throttle position sensor 
to strong shocks. If the throttle position 
sensor is dropped, replace it. 
1.  Chec
k: 
• Throttle pos it ion  sensor 
Refer  to 
 CHECKING T HE THROTILE PO ­
SITION  SENSOR  
on  page  8-1 07. 
THROTILE BODIES 
2.  Adjust: 
• Th rott le p os itio n senso r angle 
TIP~~~~~~~~~~~~~~­
B efore  adjusting  the throttle pos it io n  se nso r,  th e 
th rottle bod ies  mus t be  removed  . 
••••••••••••••••••\
•••••••••••••• 
a.  Tempor ary tighten  th e thrott le pos iti on  senso r 
sc rews . 
b. Check  that the thro ttle val ves are fully closed. 
c.  Turn the main swi t c h  to OFF. 
d .  Con nect  the th rott le po siti on  senso r to  the 
w i
re harness . 
e. Simu lt aneous ly p ress  and hold the  S E ­
LECT  button 1 a nd RESET  bu tto n 2 , 
tu
rn the  main switc h to  O N, and  continue  to 
p ress  the butto ns  for 
8 seco nds  or  mo re. 
1 
• , 
7 .. ,,,,, ... @ . ..,, 
d IRC 
TIP~~~~~~~~~~~~~~-
dlAG appears  on the disp lay. 
f. S imu lt aneous ly p ress  the SEL EC T butto n 
1 and RESET button 2  for 2 seconds or 
more  to  set  the  diag nos tic mode. 
cl t IS 
I 
1 
TIP~~~~~~~~~~~~~~~ 
The d iagnostic  code number 1 appears  on the 
disp lay. 
g.  Diagnostic  code num ber 1 is selec ted. 
h.  Adjus t the  pos itio n of the throttl e pos ition sen­
sor ang le so  that  11-21  can  appear  in  t he 
meter 
d isp lay. 
1. A fte r ad just in g  th e throttl e posit ion  senso r an­
g le , 
tig hten  the thrott le positio n  senso r 
screws 3 . 
7-12  
						

							3 
EAS1RC1111 
Throttle position sensor screw 
3.5  Nm (0.35  m·kgf, 2.5 ft·lbf) 
ADJUSTING 
THE ACCELERATOR  POSITION 
SENSOR 
EWAIRC17tlG 
AwARNING 
•  Handle the accelerator position  sensor with 
special care. 
• Never  subject  the accelerator position sen­
sor to strong shocks. If the accelerator po­
sition sensor is  dropped, re place it. 
1. Check: 
•  Acce lera tor pos it ion sen sor 
Refer  to 
CHECKING THE ACCELERATOR 
POSI TION  SENSOR  
on page 8-107. 
2. 
Ad just: 
• Acce lerator pos it ion sen so r ang le 
TIP--------------­
Before  adjusting the accele rator pos itio n sensor, 
the thrott le bod ies must  be removed. 
••••••••••••••••••\
•••••••••••••• 
a.  Temporary  tig h ten  the acce lerator po sition 
sen so r bo lts. 
b.  Check  that the thrott le  va lves are fully  closed. 
c.  Tum  th e  ma in  sw itc h  to OFP . 
d.  Connect  the accele ra tor pos it ion  sensor  to 
the  wire  harness. 
e.  Con nect th e 
th rottle  cables to  the throttl e bod ­
i es. 
f. S im ult aneo usly pr ess  and hold the  S E ­
LECT  butto n 1 and RESET  button 2, 
tum  the ma in  sw it ch  to ON, and  continue  to 
p
ress  the b utto ns  for 8  seconds or more. 
0 ,  
THROTILE  BODIES 
c:llRC 
TIP-------------­
dlAG  appears  on the display . 
g. S imul taneous ly press  the SELECT  butto n 
1 and RESET  butto n 2 for  2 seconds or 
mo re  to  set  the  diagnost ic  mode. 
di 
I 
1 
TIP--------------­
The  diagnos tic  code number 1 appears  on the 
disp lay. 
h .  Diagn ostic  code  numbe r 14 is selected. 
1. Turn  th e th ro ttle grip  to  the fully closed pos i­
tio n. 
J. Adj ust  th e pos iti on  of the acce lerator pos iti on 
sensor 
ang le so that  12-22 can app ear  in the 
meter 
d isp lay. 
k. Af te r  adjust ing the accele rator pos itio n se n­
sor 
ang le, tighte n the accelerator pos iti on 
sensor 
bo lts 3. 
Accelerator 
position sensor bolt 
3.5  Nm (0.35 m·kgf , 2.5 ft·lbf) 
I . 
Turn  the throttle grip  to  the fully open  positio n. 
7-13  
						

							m. C heck  the  meter d isplay va lue.  If th e  meter 
display val ue is  not 97 -107 , adjust  th e acce l­
era tor pos ition  senso r angle . 
n. Se lect the d iagnos tic  code  number 15 . 
o.  Tum the thrott le grip  to  the fu lly  closed  posi­
tio n. 
p .  Ch
eck  the  meter d ispla y  va lue . If th e  meter 
display valu e is  not 10-24, ad ju st  the acce ler­
ato r pos it io n  senso r angle . 
q.  Tum  the th ro

ttl e 
grip to  the fully ope n pos ition. 
r. Chec k the  meter display  value. If t h e  me ter 
display  value is  not 95-109, adjust  the accel­
erator  positio n sensor angle. 
s.  Repeat  steps (h) to (r) until the  meter display 
value s are  wit h in  the  spec ified  ranges . 
t. If the meter display  values are not within  th e 
spec ified  ranges  after repeat ing  steps  (h) to 
( r ) 
severa l times, replace the acce lerato r po ­
sition  senso r. 
7-14 
THROTILE  BODIES  
						

							AIR INDUCTION  SYSTEM 
,..,,.., 
AIR INDUCTION  SYSTEM 
3 
-··-··-
4 
7-15  
						

							1. Air filter case 
2 .  Air  ind uction  system  hose (air 
filter case  to air 
cut -off  valve) 
3 .  Air  cut-off 
valve 
4.  Air  ind uction system  hose (air cut-off valve to reed 
va lv e cover) 
AIR  INDUCTION  SYSTEM 
7-16  
						

							Removing the air cut-off valve assembly and reed valves 
10 Nm (1.0 m. kgl, 7.2 It 0 lbl) 
-• 
AIR  INDUCTION  SYSTEM 
10 -__, 
6~ 
11 
12 
/ 
\. 
1 
Order 
1 
2 
3 
4 
5 
6 
7 
8 
9 
1 0 
11 
12 
Job/Parts to remove 
Rider  seat 
Air 
scoop/Fue l tank cove r 
Fuel ta nk 
A
ir lilt e r c ase 
Radia tor 
Air 
c ut·off  valve co upler 
Air  induct ion  system  hose (air cut·off  valve to 
r eed  valve  cove
r) 
Air in duct ion  system  hose  (air cut-off va lve to 
re
ed valve cover) 
A
ir in duction  system  hose (air fi lter case  to air 
cut-off 
valve) 
Ai r cu t-o ff va lve 
Air cu t-off va lve holde r 
Reed valve cover 
Reed 
va lve  asse mbly 1 
Reed 
va lve  plate 
Reed valve cover 
Reed 
va lve  assemb ly 2 
Reed 
va lve  plate 
7-17 
Qty 
1 
1 
1 
1 
1 
1 
1 
1 
1 
1 
1 
2 
4 
7 
8 
Remarks 
Refer  to  GE NER AL 
CHASS IS  on page 
4· 1. 
Refer  to G ENE RAL CHASS IS  on page 
4 -1 . 
Refer  to 
FUE L 

T A
NK o n  page  7 -1. 
Refer  to  GENERA L 
CHASSIS  on page 
4·1. 
Refe r to RAD IATOR o n  page 6· 1. 
D isconnect.