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FZ09E
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Yamaha FZ09E Service Manual
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Contents
Table of Contents
Troubleshooting
Table of Contents
Table of Contents
Identification
Vehicle Identification Number
Model Label
Features
OUTLINE of the Fl SYSTEM
Fl SYSTEM
Instrument Functions
YCC-T (Yamaha Chip Controlled Throttle)
Important Information
Preparation for Removal and Disassembly
Replacement Parts
Ri Ngs
Lock Washers/Plates and Cotter Pins
Bear Ing Sand 01 Seals
Circlips
Rubber Parts
Basic Service Information
Quick Fasteners
Electrical System
Special Tools
Specifications
General Specifications
Engine Specifications
Chassis Specifications
Electrical Specifications
Tightening Torques
General Tightening Torque Specifications
Engine Tightening Torques
Chassis Tightening Torques
Lubrication Points and Lubricant Types
Engine
Chassis
Lubrication System Chart and Diagrams
Engine Oil Lubrication Chart
Lubrication Diagrams
Cooling System Diagrams
Cable Routing
Periodic Checks and Adjustments
Table of Contents
Checking the Coolant Level
Changing the Coolant
Adjusting the Rear Brake Light Switch
Checking and Lubricating the Cables
Checking and Charging the Battery
Checking the Fuses
Adjusting the Headlight Beam
Chassis
Table of Contents
Assembling the Rear Brake Master Cylinder
Installing the Rear Brake Master Cylinder
Handlebar
Removing the Handlebar
Checking the Handlebar
Installing the Handlebar
Front Fork
Removing the Front Fork Legs
Assembling the Front Fork Legs
Installing the Front Fork Legs
Steering Head
Removing the Lower Bracket
Installing the Steering Head
Rear Shock Absorber Assembly
Handling the Rear Shock Absorber
Installing the Relay Arm
Installing the Rear Shock Absorber Assembly
Swingarm
Removing the Swingarm
Checking the Swingarm
Installing the Swingarm
Chain Drive
Removing the Drive Chain
Checking the Drive Chain
Installing the Drive Chain
Engine
Engine Inspection
Measuring the Compression Pressure
Engine Removal
Removing the Engine
Installing Th Eengine
Camshafts
Removing the Camshafts
Checking the Camshafts
Checking the Timing Chain Guides
Checking the Timing Chain Tensioner
Installing the Camshafts
Cylinder Head
Removing the Cylinder Head
Checking the Timing Chain Guide (Exhaust Side)
Valves and Valve Springs
Removing the Valves
Checking the Valve Seats
Generator and Starter Clutch
Removing the Generator
Removing the Starter Clutch
Checking the Starter Clutch
Installing the Starter Clutch
Installing the Generator
Electri Cstarter
Assembling the Starter Motor
Installing the Starter Motor
Clutch
Removing the Clutch
Checking the Friction Plates
Checking the Clutch Plates
Checking the Clutch Springs
Checking the Clutch Housing
Checking the Pressure Plate
Checking the Primary Driven Gear
Checking the Pull Lever Shaft and Pull Rod
Installing Th Eclutch
Shift Shaft
Checking the Shift Shaft
Installing Th Eshift Shaft
Oil Pump
Checking the Sprocket and Chain
Checking the Oil Pump
Checking the Relief Valve
Assembling the Oil Pump
Installing Th Eoil Pump
Oil Pan
Removing the Oil Pan
Checking the Oil Strainer
Installing Th Eoil Pan
Crankcase
Disassembling the Crankcase
Assembling the Crankcase
Connecting Rods and Pistons
Removing Th Econnecting Rods and Pistons
Checking the Cylinder and Piston
Checking the Piston Rings
Checking the Piston Pin
Installing the Connecting Rod and Piston
Crankshaft and Balancer Shaft
Removing the Crankshaft and Balancer Shaft
Checking the Crankshaft
Checking the Balancer Shaft
Installing the Crankshaft
Installing the Balancer Assembly
Transmission
Removing the Transmission
Checking the Shift Forks
Cooling System
Radiator
Cooling System
Installing Th Eradiator
Oil Cooler
Checking the Oil Cooler
Thermostat
Checking the Thermostat
Radiator
Fuel System
Fuel Tank
Removing the Fuel Tank
Removing the Fuel Pump
Checking the Fuel Pump Body
Checking the Fuel Pump Operation
Installing the Fuel Tank
Throttle Bodies
Checking the Injectors (before Removing)
Removing the Fuel Hose (Fuel Rail Side)
Removing the Injectors
Checking the Injectors
Replacing the Throttle Bodies
Installing the Injectors
Checking the Fuel Pressure
Installing the Fuel Hose (Fuel Rail Side)
Adjust Ing the Throttle Position Sensor
Adjusting the Accelerator Position Sensor
Air Induction System
Electrical System
Ignition System
Circuit Diagram
Troubleshooting
Electri Cstarting System
Circuit Diagram
Starting Circuit Cut-Off System Operation
Troubleshooting
Charging System
Circuit Diagram
Troubleshooting
Lighting System
Circuit Diagram
Troubleshooting
Signaling System
Circuit Diagram
Troubleshooting
Cooling System
Circuit Diagram
Troubleshooting
Fuel Injection System
Circuit Diagram
Ecu Self-Diagnostic Function
Troubleshooting Method
Diagnostic Mode
Troubleshooting
Yamaha Diagnostic Tool
Troubleshooting Details
Fuel Pump System
Circuit Diagram
Troubleshooting
Electrical Components
Checking the Switches
Checking the Fuses
REPLACING the ECU (Engine Control Unit)
Checking and Charging the Battery
Checking the Relays
Checking the Turn Signauhazard Relay
Checking the Relay Unit (Diode)
Checking the Ignition Coils
Checking the Ignition Spark Gap
Checking the Crankshaft Position Sensor
Checking the Lean Angle Sensor
Checking the Stator Coil
Checking the Rectifier/Regulator
Checking the Engine Oil Level Switch
Checking the Fuel Sender
Checking the Air Induction System Solenoid
Checking the Intake Air Pressure Sensor
Checking the Intake Air Temperatu Re Sensor
Checking the Gear Position Sensor
Checking the Fuel Injectors
Troubleshooting
General Information
Incorrect Engine Idling Speed
Starting Failures
Troubleshooting
Faul Ty Clutch
Faulty Gear Shifting
Jumps out of Gear
Overheating
Poor Medium-And-High-Speed Performance
Faul Ty Lighting or Signaling System
Faulty Front Fork Legs
Overcooling
Poor Braking Performance
Unstable Handling
Self-Diagnostic Function and Diagnostic Code Table
Event Code Table
Quick Links
1
Engine
SERVICE MANUAL
LIT-11616-27-39
FZ09E
FZ09EC
1RC-28197-10
Table of
Contents
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5
Chapters
Table of Contents
7
Specifications
35
Table of Contents
106
Table of Contents
140
Engine
215
Cooling System
301
Fuel System
313
Electrical System
333
Troubleshooting
447
Table of Contents
Troubleshooting
TROUBLESHOOTING
339
TROUBLESHOOTING
346
TROUBLESHOOTING
350
TROUBLESHOOTING
354
TROUBLESHOOTING
358
TROUBLESHOOTING
364
TROUBLESHOOTING METHOD
370
TROUBLESHOOTING
372
TROUBLESHOOTING DETAILS
373
TROUBLESHOOTING
418
TROUBLESHOOTING
448
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This manual is also suitable for:
Fz09ec
Fz-09
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