Yamaha FZ-16 User manual

SERVICE MANUAL
FZ-16
21C-F8197-EO

FZ-16
SERVICE MANUAL
All rights reserved.
Any reproduction or unauthorized use
without the written consent of
YAMAHA MOTOR INDIA PVT. LTD.
is strictly prohibited.

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

HOW TO USE THIS MANUAL
This manual is intended as a practical tool, easy to read, a book of reference for the
mechanic. Includes explanations of all installation, removal, disassembly, assembly, repair,
and testing procedures are set out in individual steps in sequential order.
The manual is divided into chapters and each chapter is divided into sections. The section title
current "1" appears at the top of each page.
Sub-headings in the "2" appear in smaller print than the section title.
To help identify parts and clarify procedure steps, there are diagrams exploited "3"
at the beginning of each of the sections of removal and disassembly.
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
work, names of parts, notes in jobs, etc..
Work "7" that require more information (such as special tools and technical data) are
described in sequential order.
1
3
4
ClutchHubHolder
YSST-733
7
5
6
2

SYMBOLS
The following symbols are used in this manual
to facilitate understanding.
NOTE:
The following symbols are not relevant to
each vehicle.
1
2
3
4
5
6
1. Serviceable with engine mounted
2. Liquid fill
3. Lubricant
4. Special Tool
5. Torque
6. Wear limit, tolerance
7. Engine speed
8. Electrical data
9. Motor oil
10. Gear oil
11. Molybdenum disulfide oil
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 new one.
T.
R.
7
8
9
E
10
G
11
M
12
BF
13
B
14
LS
15
M
16
S
17
LT
18
New

TABLE OF CONTENTS
GENERAL INFORMATION
1
2
3
4
5
6
7
8
SPECIFICATIONS
INSPECTIONS
NEWSPAPERS AND
ADJUSTMENTS
CHASSIS
ENGINE
CARB
ELECTRICAL
TROUBLESHOOTING

GENERAL INFORMATION
IDENTIFICATION OF MOTORCYCLE .............................................. 1-1 .......
VEHICLE IDENTIFICATION NUMBER .......................................... 1-1
ENGINE SERIAL NUMBER ............................................. 1-1 ....................
LCD METER ................................................ ................................... 1-2
INFORMATION IMPORTANT ................................................. 1-3 ......................
PREPARATION FOR REMOVAL AND DISASSEMBLY ......... 1-3
REPLACEMENT PARTS ............................................... 1-3 ...............
PACKING, OIL SEALS RINGS I ................................. 1-3
LOCK WASHERS / LOCKNUTS
AND PINS ................................................ 1-3 ...................................
BEARINGS AND OIL SEALS ........................................... 1 - 4
RING CLOSING ............................................... 1-4 .........................
INSPECTION CONNECTION .............................................. 1-5 ..............
SPECIAL TOOLS ................................................ 1-6 .....................

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

FEATURES
MULTIFUNCTION DISPLAY
1
2
SELECT
1. Multi-function display
2. "SELECT" button (select)
The Multi-function display is equipped
with the following:
• A speedometer (which shows the speed
offset)
• An odometer (which shows the
total distance traveled)
• An odometer (indicating the
distance traveled since it was in
last reset)
• A fuel gauge (indicating the
available fuel level within the
anque fuel)
NOTE
Be sure to turn the key to "ON"
before using the "SELECT".
TOTAL ODOMETER MODE
Odometer.
A light pulse (less than one second) on the button
"SELECT" the display changes between
odometer and tripmeter.
Fuel Gauge
1
1. Fuel Gauge
The fuel gauge indicates the amount of
fuel in the fuel tank.
Segments fuel meter
disappear towards "E" (Empty) as
fuel level decreases. When the
last segment of the fuel gauge
starts flashing, refuel as soon
possible.
1-2

IMPORTANT INFORMATION
IMPORTANT INFORMATION
PREPARING FOR THE REMOVAL AND
DISASSEMBLY
1. Before you remove and disassemble, clean
all dirt, mud, dust and material
strangers.
PACKING, OIL SEALS AND O RINGS
1. When assembling the engine, replace all
gaskets, oil seals and O-rings. All
surfaces of packaging, seal edges
Oil and O-rings must be cleaned.
2. Use only the proper tools and
clean equipment.
See "TOOLS
SPECIAL "on page 1-8.
3. When disassembling, always keep
together the pieces of the same whole. This
includes gears, cylinders, pistons and other
working parts "grouped" by the use
normal. The parts must always grouped
be reused or replaced altogether.
2. During assembly, place the oil
specified on all parts and bearings
carefully and lubricate the edges of the
oil them with grease.
4. During disassembly, clean all
pieces and place them in trays in the order of
removal. This will speed up assembly and allow
the correct assembly of all parts
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
.
lubrication services. Other brands may
be similar in function and appearance, but
inferior in quality.
WASHER SAFETY LOCKNUTS
AND PINS
After disarming, replace all washers
safety pins and "1". After which
set screw or nut to the torque
specified, fold the side edges against
side of the screw or nut.
1-3