Yamaha FZ09E User manual

SERVICE MANUAL
LIT-11616-27-39
FZ09E
FZ09EC
1RC -28197-10

FZ09E
FZ09EC
SERVICE MANUAL
©2013
by Yamaha Motor Corporation, U.S.A.
First edition, August 2013
All
rights reserved.
Any reproduction or unauthorized use
without the written permission of
Yamaha Motor Corporation, U.S.A.
Is expressly prohibited .
Printed
in U.S.A.
PIN LIT-11616-27-39

EA$20071
IMPORTANT
This manual was produced by the Yamaha Motor Company, Ltd. primarily for use by Yamaha deale rs
a nd their qua li fied mechanics. It is not possible to i nc ludeall the k now ledge of a mec ha ni c inone man·
ua l. Therefore, anyone who uses this book to perform maintenance and repairs on Yamaha vehicles
should have a basic understanding
of mechanics and the techniques to repair these types of vehicles.
Repairand maintenance work attempted
by anyone without this k now ledge is likely to render the vehi·
cle unsafe and unfit for use.
This model has been designed and manufactured to perform within certa
in specificatio ns in regard to
performance and emissions. Proper service with the correct tools
is necessary to ensure that the vehi·
clewill operate
as designed. If the re is anyquestion abouta service procedure, it is imperative that you
contact a Yamaha dealer for any service information changes that app
ly to this model. This policy is
intended to provide the customer with the most
sa tisfaction fr om h is vehicle and to conform to federal
environmental quality objectives.
Yamaha Motor Company, Ltd. is continually striving
to improve a ll of its models. Modificationsand sig·
nificantchanges
in specificationsorprocedures w ill beforwarded to a ll authorized Yamahadealersand
wi
ll appear in future editions of this manual where applicable.
TIP ~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~
• ThisService Manualcontains information regarding periodic maintenance tot he emission controlsys·
tern. Please read this material carefully.
• Designs and specifications are subject to change without notice.
EA$20081
IMPORTANT MANUAL INFORMATION
Particularly important information is distinguished in this manual
by the followi ng notations.
AwARNING
'NOTICEI
TIP
This is the safety alert symbol. It is used to alert you to potential per ·
sonal injury hazards. Obey all safety messages that follow this symbol
to avoid possible injury or death.
A WARNING
indicates a hazardous situation which, if not avoided, could
result in death or serious injury.
A NOTICE
indicates special precautions that must be taken to avoid
damage to the vehicle or other property.
A TlP provides key information to make procedures easi er or clearer.

EA$20Clll1
HOW TO USE THIS MANUAL
This manual is intended as a handy, easy-to-read reference book for the mechanic. Comprehensive
explanations of all installation, removal, disassembly, assembly, repair and check procedures are laid
out with the individual steps in sequential order.
• The manual is dividedinto chapters and each chapter isdivided intosections. Thecurrent section title
"1" is shown at the top of each page.
• Sub-section titles "2" appearin sma ll er print t han the section title.
• To help identifyparts and clarify proceduresteps, the re are exploded diagrams"3" at thesta rt of each
removal anddisassembly section.
• Numbers "4" are given in the order of the jobs in the exploded diagram. A number indicates a disas-
sembly step.
• Symbols "5" indicate parts to be lub ri cated or replaced.
Refer to "SYMBOLS".
• A job instru ct ion chart "6" accompa ni es t he exploded diagram, providing the order of jobs, names of
parts, notes in jo bs, etc. This step explai ns removal and disassembly procedu re only. For insta ll ation
and assembly procedure, reverse the steps.
•Jobs"7" requiring more information (such as special tools and technical data) are described sequen·
tia
ll y. 1
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EA$201 01
SYMBOLS
The following symbols are used in this manual for easier understand in g.
TIP ~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~
The fo ll owing symbols are not relevant to every vehicl e.
SYMBOL DEFINITION SYMBOL DEFINITION
~
Serviceable with engine mounted 1 Gearoil
m
~
Filling fluid 1 Molybdenum di su lfide oil
~
B Lubricant 1 Brake fluid ~
~
Special tool
~
Wheel bearing grease
~
Tightening to rq ue
~
Lithium-soap-based grease
~
Wearlimit, clearance
~
Molybdenum disulfi de grease
[g] Engine speed
~
Sil ic one grease
[iJj]
Electrical data J.
A Apply locking agent (LOCTITE®).
1
·~-
m Engine oil Replace the part with a new one.
1
Si licone fluid
m

EAS20 110 TABLE OF CONTENTS
GENERAL INFORMATION
SPECIFICATIONS
PERIODIC CHECKS
AND
ADJUSTMENTS
CHASSIS
ENGINE
COOLING SYSTEM
FUEL SYSTEM
ELECTRICAL SYSTEM
TROUBLESHOOTING

GENERAL INFORMATION
IDENTIFICATION........................................................ .. ...... .. ............................1-1
VEHICLE IDENTIFICATION NUMBER ................
.. ...... .. ............................ 1-1
MODE L LABEL............................................. .. ...... .. ...... .. ............... .. ...........1-1
FEATURES....................
.. ................. .. ........................................................ .. ....1-2
OUTLINE OF THE Fl SYSTEM..................................................................1-2
Fl SYSTEM........................................................... .. ...... .. ............... .. ...........1-3
INSTRUMENT FUNCTIONS ................................
.. ....................... .. ...........1-4
YCC-T (Yamaha
Ch ip Con tr olled Throttle) ................... .. ...... .. ...... .. ............1-9
IMPORTANT
INFORMAT ION.........................................................................1-11
PREPARATION FOR REMOVAL AND DISASSEMBLY....... .. ...... .. .........1-11
REPLACEMENT PARTS............................................................... .. .........1-11
G ASKE TS, 01 L SEALSAND 0-RINGS ....................... .. ....... .. ...... .. .........1·11
LOCK WASHERS/PLATES AND COTTER PINS ........ .. ..... .. ........ ........ 1-11
BEARINGS AND 01 L SE ALS ... ... ....... ............ ... ... .. .. ....... .. ... .. .. ... ... .1 -11
CIRCLIPS .................................... .. ............... .. ...... .. ...... .. ............... .. .........1-12
RUBBER PARTS................. .. ...... .. ............... .. ...... .. ...... .. ............... .. .........1-12
BASIC SERVICE INFORMATION ........ ..... ...... .. ..... .. ...... ......... ...... .. ....... 1-13
QUICK FASTENERS ....................... .. ..... .. ...... ........ .. ..... .. ............ .... 1-13
ELECTRICAL SYSTEM....... .. ..... .. ............... .. ..... .. ...... ........ .. ..... .. ....... 1-13
SPEC IAL TOOLS .......... .. .. .. ...... .. ...... .. ............... .. ...... .. ...... .. ............... .. .........1-18

EA$201 30
IDENTIFICATION
EA$201 .CO
VEHI CLE IDENTIFICATION NUMBER
The vehicle identification number "1" is stamped
into t
he ri ght side of the steering head pipe.
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MODEL LA BEL
The model l abe l "1" is affixed to the frame. This
information will be needed
to order spare parts.
IDENTIFICATION
1-1