Yamaha FZ09E 2014 Manuals

Yamaha FZ09E 2014 Manuals

Manuals and User Guides for Yamaha FZ09E 2014. We have 1 Yamaha FZ09E 2014 manual available for free PDF download: Service Manual

Yamaha FZ09E 2014 Service Manual

Yamaha FZ09E 2014 Service Manual (468 pages)

Brand: Yamaha | Category: Motorcycle | Size: 18.08 MB

Table of Contents

Table of Contents

7
- How to Use this Manual
  5
- Symbols
  6
- Identification
  10
- Vehicle Identification Number
  10
  - Model Label
    10
- Features
  11
  - Outline of the Fi System
    11
  - Fi System
    12
  - Instrument Functions
    13
  - YCC-T (Yamaha Chip Controlled Throttle)
    18
- Important Information
  20
- Preparation for Removal and Disassembly
  20
  - Replacement Parts
    20
  - Gaskets, Oil Seals and O-Rings
    20
  - Lock Washers/Plates and Cotter Pins
    20
  - Bearings and Oil 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
  42
- Electrical Specifications
  46
- Tightening Torques
  48
- Lubrication Points and Lubricant Types
  57
  - Engine
    57
  - Chassis
    58
  - Three Bond
    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
- Introduction
  107
- Periodic Maintenance
  107
- Periodic Maintenance Chart for the Emission Control System
  107
- General Maintenance and Lubrication Chart
  108
- Checking the Fuel Line
  110
- Checking the Spark Plugs
  110
- Adjusting the Valve Clearance
  111
- Checking the Engine Idling Speed
  113
- Synchronizing the Throttle Bodies
  114
- CHECKING the CANISTER (for California Only)
  115
- Checking the Throttle Body Joints
  115
- Checking the Air Induction System
  116
- Checking the Cylinder Head Breather Hose
  116
- Replacing the Air Filter Element
  116
- Adjusting the Clutch Lever Free Play
  117
- Checking the Brake Fluid Level
  117
- Checking the Brake Operation
  117
- Adjusting the Front Disc Brake
  118
- Checking the Front Brake Pads
  118
- Adjusting the Rear Disc Brake
  119
- Bleeding the Hydraulic Brake System
  119
- Checking the Rear Brake Pads
  119
- Checking the Front Brake Hoses
  120
- Checking the Rear Brake Hose
  120
- Checking the Tires
  121
- Checking the Wheels
  121
- Adjusting the Drive Chain Slack
  122
- Checking the Swingarm Operation
  122
- Checking the Wheel Bearings
  122
- Lubricating the Swingarm Pivot
  122
- Lubricating the Drive Chain
  123
- Checking and Adjusting the Steering Head
  124
- Adjusting the Shift Pedal
  125
- Checking the Chassis Fasteners
  125
- Checking the Sidestand
  125
- Lubricating the Brake Lever
  125
- Lubricating the Clutch Lever
  125
- Lubricating the Pedal
  125
- Lubricating the Steering Head
  125
- Adjusting the Front Fork Legs
  126
- Checking the Front Fork
  126
- Checking the Sidestand Switch
  126
- Lubricating the Sidestand
  126
- Adjusting the Rear Shock Absorber Assembly
  127
- Checking the Rear Shock Absorber Assembly
  127
- Checking the Connecting Arm and Relay Arm
  128
- Checking the Engine Oil Level
  128
- Changing the Engine Oil
  129
- Measuring the Engine Oil Pressure
  130
- Checking the Coolant Level
  131
- Checking the Cooling System
  131
- Changing the Coolant
  132
- Adjusting the Rear Brake Light Switch
  133
- Checking the Front Brake Light Switch
  133
- Checking and Lubricating the Cables
  134
- Checking the Throttle Grip
  134
- Checking and Charging the Battery
  135
- Checking the Fuses
  135
- Replacing the Headlight Bulb
  135
- Adjusting the Headlight Beam
  136
Chassis

139
- General Chassis
  
  145
  - Installing the Air Scoops
    145
  - Installing the Fuel Tank Moles
    145
  - Removing the Air Scoops
    145
  - Front Wheel
    150
- Removing the Front Wheel
  
  150
  - Disassembling the Front Wheel
    150
  - Checking the Front Wheel
    150
  - Assembling the Front Wheel
    151
  - Adjusting the Front Wheel Static Balance
    151
  - Installing the Front Wheel (Front Brake Discs)
    152
  - Rear Wheel
    157
- Removing the Rear Wheel
  
  157
- Front Brake
  
  161
  - Introduction
    165
  - Checking the Front Brake Discs
    165
  - Replacing the Front Brake Pads
    166
  - Removing the Front Brake Calipers
    167
  - Disassembling the Front Brake Calipers
    167
  - Checking the Front Brake Calipers
    168
  - Assembling the Front Brake Calipers
    168
  - Installing the Front Brake Calipers
    169
  - Removing the Front Brake Master Cylinder
    170
  - Checking the Front Brake Master Cylinder
    170
  - Assembling the Front Brake Master Cylinder
    170
  - Installing the Front Brake Master Cylinder
    170
  - Rear Brake
    172
  - Introduction
    178
  - Checking the Rear Brake Disc
    178
  - Replacing the Rear Brake Pads
    178
  - Removing the Rear Brake Caliper
    179
  - Disassembling the Rear Brake Caliper
    180
  - Checking the Rear Brake Caliper
    180
  - Assembling the Rear Brake Caliper
    181
  - Installing the Rear Brake Caliper
    181
  - Removing the Rear Brake Master Cylinder
    182
  - Checking the Rear Brake Master Cylinder
    182
  - 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
    191
  - Disassembling the Front Fork Legs
    191
  - Checking the Front Fork Legs
    192
  - Assembling the Front Fork Legs
    193
  - Installing the Front Fork Legs
    198
- Steering Head
  
  199
  - Removing the Lower Bracket
    201
  - Checking the Steering Head
    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
  - Checking the Drive Sprocket
    212
  - Checking the Rear Wheel Sprocket
    212
  - Checking the Rear Wheel Drive Hub
    212
  - Installing the Drive Chain
    213
Engine

215
- Engine Inspection
  
  218
  - Extension
    218
  - Measuring the Compression Pressure
    218
- Engine Removal
  
  220
  - Removing the Engine
    224
  - Installing the Engine
    224
  - Camshafts
    226
  - Removing the Camshafts
    228
  - Checking the Camshafts
    229
  - Checking the Timing Chain and Camshaft Sprocket
    230
  - Checking the Timing Chain Guides
    230
  - Checking the Timing Chain Tensioner
    230
  - Installing the Camshafts
    231
  - Cylinder Head
    236
- Removing the Cylinder Head
  
  237
- Valves and Valve Springs
  
  240
  - Removing the Valves
    240
  - Checking the Valves and Valve Guides
    240
  - Checking the Valve Seats
    242
  - Checking the Valve Springs
    243
  - Checking the Valve Lifters
    244
  - Installing the Valves
    244
- 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
  - Electric Starter
    252
  - Checking the Starter Motor
    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 Clutch Boss
    261
  - Checking the Pressure Plate
    261
  - Checking the Primary Drive Gear
    261
  - Checking the Primary Driven Gear
    262
  - Checking the Pull Lever Shaft and Pull Rod
    262
  - Installing the Clutch
    262
- Shift Shaft
  
  265
  - Checking the Shift Shaft
    266
  - Checking the Stopper Lever
    266
  - Installing the Shift 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 the Oil Pump
    270
- Oil Pan
  
  271
  - Removing the Oil Pan
    272
  - Checking the Oil Strainer
    272
  - Installing the Oil Pan
    272
- Crankcase
  
  273
  - Disassembling the Crankcase
    274
  - Checking the Crankcase
    274
  - Assembling the Crankcase
    274
- Connecting Rods and Pistons
  
  278
  - Removing the Connecting Rods and Pistons
    278
  - Checking the Cylinder and Piston
    278
  - Checking the Piston Rings
    279
  - Checking the Piston Pin
    280
  - Checking the Connecting Rods
    280
  - Installing the Connecting Rod and Piston
    283
  - Piston Installing Tool
    285
- Crankshaft and Balancer Shaft
  
  288
  - Removing the Crankshaft and Balancer Shaft
    288
  - Checking the Oil Nozzles
    288
  - Checking the Crankshaft
    288
  - Checking the Balancer Shaft
    290
  - Installing the Crankshaft
    291
  - Installing the Balancer Assembly
    292
- Transmission
  
  293
  - Removing the Transmission
    297
  - Checking the Shift Forks
    297
Cooling System

301
- Radiator
  
  302
  - Checking the Radiator
    303
    
    Installing the Radiator
    303
- Oil Cooler
  
  305
  - Cooling System
    303
  - Checking the Oil Cooler
    306
  - Installing the Oil Cooler
    306
- Thermostat
  
  307
  - Checking the Thermostat
    308
  - Installing the Thermostat Assembly
    308
- Water Pump
  
  309
  - Disassembling the Water Pump
    311
  - Checking the Water Pump
    311
  - Assembling the Water Pump
    311
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
  - CHECKING the ROLLOVER VALVE (for California Only)
    316
  - Installing the Fuel Pump
    316
  - Installing the Fuel Tank
    317
- Throttle Bodies
  
  321
  - Checking the Injectors (before Removing)
    321
  - Removing the Fuel Hose (Fuel Rail Side)
    321
  - Removing the Injectors
    321
  - Checking the Injectors
    321
  - Checking and Cleaning the Throttle Bodies
    321
  - Replacing the Throttle Bodies
    323
  - Installing the Injectors
    323
  - Checking the Injector Pressure
    323
  - Checking the Fuel Pressure
    324
  - Installing the Fuel Hose (Fuel Rail Side)
    325
  - Adjusting the Throttle Position Sensor
    325
  - Adjusting the Accelerator Position Sensor
    326
  - Air Induction System
    328
- Checking the Air Induction System
  
  331
  - Installing the Air Induction System
    331
  - Electrical System
    333
    
    Electric Starting System
    342
    
    Ignition Checker
    392
  - Troubleshooting
    447
    
    General Information
    447
    
    Wiring Diagram
    463

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