Yamaha FZ-16 2015 User manual

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MANUAL
SERVICE
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FZ-16
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21C-F8197-EO

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FZ-16
SERVICE MANUAL All rights
reserved.
Anyreprintingorunauthorizeduse without the
writtenpermission of YAMAHA MOTOR INDIA
PVT.LTD.isexpresslyprohibited.

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ATTENTION
This manual has been prepared by IYM, primarily for use by dealers and their qualified mechanics.
Unable to gather in a manual all the knowledge of a mechanic. Any person carrying out maintenance
and repairs on Yamaha vehicles should have basic mechanical skills and techniques needed to repair
these vehicles. Repair work and maintenance performed by a person who lacks such knowledge, the
vehicle probably will not be safe or suitable for use. Yamaha Motor India Pvt Ltd. is continually striving to
improve all its models. All authorized Yamaha dealers will be informed of any amendments and
substantial changes occur in specifications or procedures, and these will be included in future editions of
this manual, when necessary.
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NOTE:
Designs and specifications subject to change without notice.
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IMPORTANT INFORMATION HEREIN
Particularly important information is distinguished in this manual by the following symbols:
Safety alert symbol means ATTENTION! BE ALERT! YOUR SAFETY IS INVOLVED!
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WARNING
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CAUTION
NOTE:
A WARNING indicates a hazardous situation which could result in death or serious
injury to the vehicle operator, a bystander or a person who is inspecting or repairing
the vehicle.
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A CAUTION indicates special precautions that must be taken to avoid damage to the
vehicle.
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A NOTE provides key information to facilitate or clarify procedures.

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37
Using this Guide
This book is intended as a practical tool, easy to read reference book for the mechanic. Includes
explanations of all installation, removal, disassembly, assembly, repair and check procedures are set out
in individual steps in sequential order.
The manual is divided into chapters and each chapter is divided into sections. The current section title
"1" appears at the top of every page.
Sub-section titles "2" appear in smaller print than the section title.
To help identify parts and clarify procedure steps, there are diagrams exploited "3" at the start of each
removal and disassembly section.
The numbers "4" are given in the order of jobs in diagrams exploited. A number indicates a
disassembly step.
Symbols "5" indicates the parts to be lubricated or replaced. See
"SYMBOLS".
A table of work instructions "6" accompanies the exploded diagram, providing the order of jobs, names
of parts, notes in jobs, etc..
Jobs "7" that require more information (such as special tools and technical data) are described in sequential
order.
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1
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ClutchHu bHolder
YSST-733
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4
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5
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6
2

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SYMBOLS
The following symbols are used in this manual to
facilitate understanding.
NOTE:
The following symbols are not relevant
each vehicle.
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1 2
3
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4 5
6
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8
1. Serviceable with engine mounted
2. Type of liquid
3. Lubricant
4. Special Tool
5. Torque
6. Wear limit, tolerance
7. Engine speed
8. Electrical
9. Motor oil
10. Gear oil
11.Molybdenumdisulfideoil
12. Brake fluid
13. Bearing Grease
14. Grease with lithium soap base
15. Molybdenum disulfide grease
16. Silicone Grease
17. Apply locking agent (LOCTITE ®).
18. Replace the part with a new one.
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9 10
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E
G
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11 12
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M BF
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13 14
B
LS
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15 16
M
S
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17 18
LT
New

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3
TABLEOFCONTENTS
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GENERAL INFORMATION
1
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SPECIFICATIONS
2
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INSPECTIONS
And adjustments
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CHASSIS
4
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MOTOR
5
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CARBURETOR
6
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ELECTRICAL
7
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TROUBLESHOOTING
8

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GENERAL INFORMATION
IDENTIFICATION OF MOTORCYCLE .............................................. 1-1 .......
VEHICLE IDENTIFICATION NUMBER .......................................... 1-1
ENGINE SERIAL NUMBER ............................................. .................... 1-1
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LCD METER ................................................ ................................... 1-2
IMPORTANT INFORMATION ................................................ ....................... 1-3
PREPARATION FOR REMOVAL AND DISASSEMBLY ......... 1-3
REPLACEMENT PARTS ............................................... ............... 1-3
GASKETS, OIL SEALS RINGS I ................................. 1-3
SAFETY WASHERS / LOCKNUTS
AND PINS ................................................ ................................... 1-3
BEARINGS AND OIL SEALS ........................................... 1 - 4
Sealing rings ............................................... ......................... 1-4
CHECKING THE CONNECTIONS .............................................. 1-5 ..............
SPECIAL TOOLS ................................................ ..................... 1-6

IDENTIFICACI
Ó
N
1-1
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IDENTIFICATION
VEHICLE IDENTIFICATION NUMBER (chassis
number)
The vehicle identification number "1" is stamped
on the chassis.
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ENGINE SERIAL NUMBER
The engine serial number "1" is stamped on the
crankcase.
NOTE:
Designs and specifications are subject to change
without notice.
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1

1-2
CARACTER
Í
STICAS
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Multi-function display
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2
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SELECT
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1. Multi-function
display
2. "Select" button (select)
The Multi-function display is
equipped with the following:
• A speedometer (which shows the speed)
• An odometer (which shows the total distance
traveled)
• An odometer (which shows the distance
traveled since it was last reset in)
• A fuel gauge (which indicates the level of fuel
available in the fuel anque)
NOTE
Be sure to turn the key to "ON" before using
the "SELECT" button.
MODE odometer and tripmeter.
A light pulse (less than one second) in the
"SELECT" button switches the display between
odometer and tripmeter.
Fuel meter
1
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1. Fuel meter
The fuel gauge indicates the amount of fuel in the
fuel tank. The sec com ments fuel meter
disappear towards "E" (Empty) as the fuel level
decreases. When the last segment fuel gauge
starts flashing, refuel as soon as possible.

1-3
INFORMACI
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NIMPOR
T
A
NTE
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lubrication.
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PREPARATION FOR REMOVAL AND
DISASSEMBLY
1. Before removal and disassembly, clean all dirt,
mud, dust and foreign material.
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2. Use only the proper tools and equipment
clean.
See "SPECIAL TOOL S" on page 1-8.
3. When disassembling, always hold together
parts of the same whole. This includes gears,
cylinders, pistons and other parts that work
"grouped" for normal use. The parts should
always be grouped reused or replaced
altogether.
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4. During disassembly, clean all parts and place
them in trays in the order of disassembly. This
will speed up the assembly and ensure the
correct assembly of the pieces
5. Keep all parts away from any
fire source.
REPLACEMENT PARTS
Use only genuine Yamaha parts in all changes.
Use oil and grease recommended by Yamaha,
for all
services .Other brands may
be similar in function and appearance, but
inferior in quality.
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GASKETS, OIL SEALS AND O RINGS
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1. When assembling the engine, replace all
gaskets, oil seals and O-rings. All packaging
surfaces, edges of oil seals and O-rings must be
cleaned.
2. During assembly, place the oil specified in all
parts and bearings, and carefully lubricate the
edges of oil grease them.
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Lockwashers, locknuts and PINS
After disassembly, replace all lock washers and pins
"1". After it has set the screw or nut to the specified
torque, double side edges against the side of the
screw or nut.