Yamaha FZ09E Manuals

Yamaha FZ09E Manuals

Manuals and User Guides for Yamaha FZ09E. We have 1 Yamaha FZ09E manual available for free PDF download: Service Manual

Yamaha FZ09E Service Manual

Yamaha FZ09E Service Manual (468 pages)

Brand: Yamaha | Category: Motorcycle | Size: 39.27 MB

Table of Contents

Table of Contents

7
- Identification
  10
  - Vehicle Identification Number
    10
  - Model Label
    10
- Features
  11
  - OUTLINE of the Fl SYSTEM
    11
  - Fl SYSTEM
    12
  - Instrument Functions
    13
  - YCC-T (Yamaha Chip Controlled Throttle)
    18
- Important Information
  20
  - Preparation for Removal and Disassembly
    20
  - Replacement Parts
    20
  - Ri Ngs
    20
  - Lock Washers/Plates and Cotter Pins
    20
  - Bear Ing Sand 01 Seals
    20
  - Circlips
    21
  - Rubber Parts
    21
- Basic Service Information
  22
  - Quick Fasteners
    22
  - Electrical System
    22
- Special Tools
  27
Specifications

35
- General Specifications
  36
- Engine Specifications
  37
- Chassis Specifications
  43
- Electrical Specifications
  46
- Tightening Torques
  48
- Lubrication Points and Lubricant Types
  57
  - Engine
    57
  - Chassis
    58
- Lubrication System Chart and Diagrams
  60
  - Engine Oil Lubrication Chart
    60
  - Lubrication Diagrams
    62
- Cooling System Diagrams
  72
- Cable Routing
  76
- Periodic Checks and Adjustments
  105
Table of Contents

106
- Checking the Coolant Level
  131
- Changing the Coolant
  132
- Adjusting the Rear Brake Light Switch
  133
- Checking and Lubricating the Cables
  134
- Checking and Charging the Battery
  135
- Checking the Fuses
  135
- Adjusting the Headlight Beam
  136
- Chassis
  139
Table of Contents

140
- Assembling the Rear Brake Master Cylinder
  183
- Installing the Rear Brake Master Cylinder
  183
- Handlebar
  184
  - Removing the Handlebar
    185
  - Checking the Handlebar
    185
  - Installing the Handlebar
    185
- Front Fork
  188
  - Removing the Front Fork Legs
    188
  - Assembling the Front Fork Legs
    193
  - Installing the Front Fork Legs
    198
- Steering Head
  199
  - Removing the Lower Bracket
    201
  - Installing the Steering Head
    202
- Rear Shock Absorber Assembly
  203
- Swingarm
  207
  - Removing the Swingarm
    208
  - Checking the Swingarm
    208
  - Installing the Swingarm
    209
- Chain Drive
  210
  - Removing the Drive Chain
    211
  - Checking the Drive Chain
    211
  - Installing the Drive Chain
    213
Engine

215
- Engine Inspection
  218
  - Measuring the Compression Pressure
    218
- Engine Removal
  220
  - Removing the Engine
    223
  - Installing Th Eengine
    224
- Camshafts
  226
  - Removing the Camshafts
    228
  - Checking the Camshafts
    229
  - Checking the Timing Chain Guides
    230
  - Checking the Timing Chain Tensioner
    230
  - Installing the Camshafts
    231
- Cylinder Head
  234
  - Removing the Cylinder Head
    236
  - Checking the Timing Chain Guide (Exhaust Side)
    237
- Valves and Valve Springs
  240
  - Removing the Valves
    240
  - Checking the Valve Seats
    242
- Generator and Starter Clutch
  247
  - Removing the Generator
    249
  - Removing the Starter Clutch
    249
  - Checking the Starter Clutch
    249
  - Installing the Starter Clutch
    250
  - Installing the Generator
    250
- Electri Cstarter
  254
  - Assembling the Starter Motor
    255
  - Installing the Starter Motor
    255
- Clutch
  256
  - Removing the Clutch
    259
  - Checking the Friction Plates
    260
  - Checking the Clutch Plates
    260
  - Checking the Clutch Springs
    260
  - Checking the Clutch Housing
    261
  - Checking the Pressure Plate
    261
  - Checking the Primary Driven Gear
    262
  - Checking the Pull Lever Shaft and Pull Rod
    262
  - Installing Th Eclutch
    262
- Shift Shaft
  265
  - Checking the Shift Shaft
    266
  - Installing Th Eshift Shaft
    266
- Oil Pump
  267
  - Checking the Sprocket and Chain
    269
  - Checking the Oil Pump
    269
  - Checking the Relief Valve
    270
  - Assembling the Oil Pump
    270
  - Installing Th Eoil Pump
    270
- Oil Pan
  271
  - Removing the Oil Pan
    272
  - Checking the Oil Strainer
    272
  - Installing Th Eoil Pan
    272
- Crankcase
  273
  - Disassembling the Crankcase
    274
  - Assembling the Crankcase
    274
- Connecting Rods and Pistons
  278
- Crankshaft and Balancer Shaft
  287
  - Removing the Crankshaft and Balancer Shaft
    288
  - Checking the Crankshaft
    288
  - Checking the Balancer Shaft
    290
  - Installing the Crankshaft
    291
  - Installing the Balancer Assembly
    292
- Transmission
  296
  - Removing the Transmission
    297
  - Checking the Shift Forks
    297
Cooling System

301
- Radiator
  302
- Cooling System
  303
  - Installing Th Eradiator
    303
  - Oil Cooler
    305
    
    Checking the Oil Cooler
    306
  - Thermostat
    307
    
    Checking the Thermostat
    308
    
    Radiator
    308
Fuel System

313
- Fuel Tank
  314
  - Removing the Fuel Tank
    316
  - Removing the Fuel Pump
    316
  - Checking the Fuel Pump Body
    316
  - Checking the Fuel Pump Operation
    316
  - Installing the Fuel Tank
    317
- Throttle Bodies
  318
  - Checking the Injectors (before Removing)
    321
  - Removing the Fuel Hose (Fuel Rail Side)
    321
  - Removing the Injectors
    321
  - Checking the Injectors
    321
  - Replacing the Throttle Bodies
    323
  - Installing the Injectors
    323
  - Checking the Fuel Pressure
    324
  - Installing the Fuel Hose (Fuel Rail Side)
    325
  - Adjust Ing the Throttle Position Sensor
    325
  - Adjusting the Accelerator Position Sensor
    326
- Air Induction System
  328
Electrical System

333
- Ignition System
  336
  - Circuit Diagram
    336
  - Troubleshooting
    339
- Electri Cstarting System
  342
  - Circuit Diagram
    342
  - Starting Circuit Cut-Off System Operation
    344
  - Troubleshooting
    346
- Charging System
  348
  - Circuit Diagram
    348
  - Troubleshooting
    350
- Lighting System
  352
  - Circuit Diagram
    352
  - Troubleshooting
    354
- Signaling System
  356
  - Circuit Diagram
    356
  - Troubleshooting
    358
- Cooling System
  362
  - Circuit Diagram
    362
  - Troubleshooting
    364
- Fuel Injection System
  366
  - Circuit Diagram
    366
  - Ecu Self-Diagnostic Function
    368
  - Troubleshooting Method
    370
  - Diagnostic Mode
    371
- Troubleshooting
  372
  - Yamaha Diagnostic Tool
    372
    
    Troubleshooting Details
    373
  - Fuel Pump System
    416
    
    Circuit Diagram
    416
    
    Troubleshooting
    418
  - Electrical Components
    420
    
    Checking the Switches
    424
    
    Checking the Fuses
    428
    
    REPLACING the ECU (Engine Control Unit)
    428
    
    Checking and Charging the Battery
    429
    
    Checking the Relays
    432
    
    Checking the Turn Signauhazard Relay
    433
    
    Checking the Relay Unit (Diode)
    434
    
    Checking the Ignition Coils
    435
    
    Checking the Ignition Spark Gap
    435
    
    Checking the Crankshaft Position Sensor
    436
    
    Checking the Lean Angle Sensor
    436
    
    Checking the Stator Coil
    437
    
    Checking the Rectifier/Regulator
    437
    
    Checking the Engine Oil Level Switch
    439
    
    Checking the Fuel Sender
    439
    
    Checking the Air Induction System Solenoid
    443
    
    Checking the Intake Air Pressure Sensor
    444
    
    Checking the Intake Air Temperatu Re Sensor
    444
    
    Checking the Gear Position Sensor
    445
    
    Checking the Fuel Injectors
    446
Troubleshooting

447
- General Information
  448
- Incorrect Engine Idling Speed
  448
- Starting Failures
  448
- Troubleshooting
  448
- Faul Ty Clutch
  449
- Faulty Gear Shifting
  449
- Jumps out of Gear
  449
- Overheating
  449
- Poor Medium-And-High-Speed Performance
  449
- Faul Ty Lighting or Signaling System
  450
- Faulty Front Fork Legs
  450
- Overcooling
  450
- Poor Braking Performance
  450
- Unstable Handling
  450
- Self-Diagnostic Function and Diagnostic Code Table
  452
- Event Code Table
  459

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