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
Ó
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.

1-4
INFORMACI
Ó
NIMPOR
T
A
NTE
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BEARINGS AND OIL SEALS
Assemble the bearings and oil seals so that the
manufacturer's mark or numbers are visible.
When installing oil seals "1", lubricate the edges
of oil seals with a thin layer of grease lithium soap
base. In bearings, apply oil, if requested.
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PREACAUCIÓN
Donotturnthebearingwithcompressedair,and
this will damage the surfaces
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Sealing rings
Before assembling, carefully check all sealing
rings and replace that are damaged or twisted.
Always replace the sealing rings of the piston pin,
after one use. When installing a sealing ring "1",
make sure that the sharp corners "2" are placed
on the opposite side "3" to the force received by
the closing ring.

1-5
INSPECCI
Ó
N DE LAS CONEXIONES
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CHECKING THE CONNECTIONS
Verify on the cables, couplers and connectors stains,
oxidation, moisture, etc.
1.
Disconnect:
•
Cable
•
Coupler
•
Connector
2.
Verify
•
Cable
•
Coupler
•
Connector
Moisture Dry airjet
Oxidation / stains Connect and disconnect
several times.
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3.
Check:
•Allconnections
Loose connection Connect adequately
NOTE:
If crimp the pin "1" of the terminal, fold
up.
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4.Connect:
•
Cable
•
Coupler
•
Connector
NOTE:
Make sure all connections are tight.
5.
Check:
•
Continuity
(With the multimeter)
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NOTE:
• If there is no continuity, clean the terminals
• When checking the wire harness, perform steps
(1) through (3).
• As a quick fix, use a spray contact cleaner,
available at most parts stores.

1-6
HERRAMIEN
T
A
S ESPECIALES
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SPECIAL TOOLS
Special tools shown below, are necessary for mounting and precise adjustments. Use only the
appropriate special tools, that will help to prevent damage caused by the use of inappropriate tools or
improvised techniques.
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Tool name / nr Tool
Illustration
Tappet screw holder
YSST-706
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This tool is used to hold the tappet screw to adjust valve
clearance
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Tappet adjustment wrench
YSST-806A
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This tool is used to loosen and tighten the nut on the
tappet
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Thickness gauges
YSST-815
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This tool is used to adjust the valve clearance in an engine
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Adjuster rear shock
YSST-821
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This tool is used for adjusting the rear shock preload
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Magneto Holder
YSST-601B
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This tool is used to hold the magnet to remove or install
magneto securing nut and main gear nut
Magneto Puller
YSST-628
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This tool is used to remove the magnet with the help of
the magnet holder
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1-7
HERRAMIEN
T
A
S ESPECIALES
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Tool name / nr Tool
Illustration
Tool to install the crankshaft spacer.
(A) YSST-
266 (b)
YSST-267
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These tools are using to install the crankshaft.
(A) (B)
Tool for removing the crankshaft. YSST-
265
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This tool is used to remove the crankshaft from the
crankcase
Clutch Hub Fixer
YSST-733
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This tool is used to lock the clutch hub while installing or
removing the locking nut of the clutch hub.
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Lamp flicker
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This instrument is used to check the ignition timing.
Manometer
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This instrument is used to measure the compression of
the engine
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Scraper
YSST-612
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This tool is used to scrape the tip seal crankcase mating
surface.
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Compressor valve spring
YSST-603
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This tool is used to remove and install the valve and valve
spring.
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1-8
HERRAMIEN
T
A
S ESPECIALES
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Tool name / nr Tool
Illustration
Adapter valve spring compressor
A-803 YSST
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This tool is used to remove and install the valve and the
valve spring using YSST 603.
Set gauge pump vacuum / pressure
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This instrument is used to test and verify the vacuum of air
induction system.
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Nut wrench address
YSST-721
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This tool is used to loosen and tighten the stem nut.
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Key in T-
813 YSST
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This tool is used to hold the plunger of the front fork to
loosen or tighten the hex bolt.
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Assembly tool oil seal front fork
YSST-875
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This tool helps you to install the oil seal of the front fork.
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Dynamic spark tester
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This instrument is used to verify the efficiency of the spark
from the spark plug.

1-9
HERRAMIEN
T
A
S ESPECIALES
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Tool name / nr Tool
Illustration
Multimeter
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ThEste instrument is used to verify the electrical
circuits or components.
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Yamaha Adhesive No. 1215
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This adhesive is used on the contact surfaces, while the
housings assembled # 1 and # 2 of the engine.
Loctite
Three Bond 1322
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This adhesive is used for added strength Torx screws for
adjustment.
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Base for piston
YSST-604
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This tool is necessary to support the piston in the cylinder
mounting.
Crankshaft key cap
YSST-625
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This tool is used to remove / install the plug left crankcase
cover # 1 (LH).
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SPECIFICATIONS
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SPECIFICATION ................................................ 2-1 ........
ENGINE SPECIFICATIONS ............................................... 2-2 .........
CHASSIS SPECIFICATIONS ............................................... 2-9 ........
ELECTRICAL ................................................ 2-12 ....
TORQUE ............................................... ............................... 2-14
SPECIFICATIONS TORQUE ON .... 2-14
ENGINE TORQUE ............................................. 2-16 ......
TORQUE CHASSIS .............................................2-19......
LUBRICATION POINTS AND LUBRICANT TYPES .................... 2-21
LUBRICATION SYSTEM TABLES AND CHARTS ........... 2-24
ENGINE LUBRICATION TABLE ...................................... 2-24
LUBRICATION DIAGRAMS ............................................... 2-25 .......
Cable routing ............................................... ............................. 2-27

ESPECIFICACIONES GENERALES
2-1
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GENERAL
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MODEL
Model
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21C1
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Dimensions
Total length
1973mm
Total width 770mm
Height totall 1045mm
Seat Height 790mm
Wheelbase 1334mm Ground
clearance
160mm Minimum
turning radius
2340mm
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Weight
With gasoline and oil
135.0kg
Peak load 195.0kg

2-2
ESPECIFICACIONES DE MOTOR
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ENGINE SPECIFICATIONS
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Engine
EngineType 4-stroke, air-cooled SOHC
Displacem
ent
153.0cm
3
Cylinder Layout A cylinder leaning forward
Bore x stroke 58.0 x 57.9mm
Compression Ratio 9.50:1
Compression pressure (at sea level) 1200kPa
Starting System Electric start, Kickstarter (According
the
Country)
Fuel
Recommended fuel Regular unleaded regular gasoline
Fuel Tank Capacity 12.0
L
Reserve capacity 1.4 L
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Motor oil
Lubrication system Wet sump
Type
SAE20W50
Recommended grade of motor oil
Quantity of engine oil
Periodic change
YAMALUBE(Grade-SG)
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1.00 L
Total change 1.20 L
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Oil filter
Type oil filter
Paper
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Oil pump
Type of oil pump
Troco-ide
Internal rotor clearance to the outer rotor Less than 0.15mm
Limit
Clearance external rotor casing to the oil
pump
Limit
Clearance of the casing until the oil pump
inner rotor and outer rotor
Limit
0.20mm
0.13-0.19mm
0.15
mm
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0.06 0.11
mm
0.15mm

2-3
ESPECIFICACIONES DE MOTOR
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Spark plug (s)
Manufacturer / Model NGK / CPR8EA-9
Electrode gap 0.8-0.9mm
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Butt
Volume
13.40-14.00cm ³
Maximum deformation 0.03mm
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Camshaft
Traction system Transmission chain (left) Dimensions of
camshaft lobes
Admission 31,342 - 31.44 2mm
Limit 31.342mm
Admission B 25,166 - 25.26 6mm
Limit
Escape A
Limit
Escape B
Limit
25.136mm
31,110 - 31.210mm
31.080mm
25,096 - 25.19 6mm
25.066mm
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B
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A
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Strain Limit 0.03 mm camshaft
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