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FZ-09
Yamaha FZ-09 User Manual
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THERMOSTAT
,..,...,
THERMOSTAT
Removing
t
he
thermost
at
assembly
4
10
Nm
(1.0
m
.
kgf
,
7.2
ft
-lbf)
Order
Job/Parts
to
r
e
mov
e
Q
'
ty
R
e
marks
Muffler
assembly
Re
f
er
t
o "
EN
G
I
NE
REMOVAL
"
on
page
5·3.
Dra
in
.
Coola
nt
Refer
t
o
"C
H
A
N
G
I
NG
T
HE
COOLA
N
r'
on
page
3
-
26.
1
Radia
t
or
ou
tlet
h
ose
1
2
Wa
t
er
pump
i
nl
e
t
hose
1
3
O
il
coole
r
ou
tl
e
t
hose
1
Di
scon
n
ect.
4
T
h
er
mostat
assemb
l
y
1
6-6
306
308
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
General Tightening Torque Specifications
48
Engine Tightening Torques
49
Chassis Tightening Torques
53
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
Handling the Rear Shock Absorber
204
Installing the Relay Arm
205
Installing the Rear Shock Absorber Assembly
205
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
Removing Th Econnecting Rods and Pistons
278
Checking the Cylinder and Piston
278
Checking the Piston Rings
279
Checking the Piston Pin
280
Installing the Connecting Rod and Piston
283
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
5
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Yamaha FZ-09 Specifications
General
Brand
Yamaha
Model
FZ-09
Category
Motorcycle
Language
English
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