Yamaha FZ-16 User manual

1ES-F8107-E0
2010
FZ 16

FZ 16
ASSEMBLY MANUAL
First Edition
All rights reserved.
Any reproduction or unauthorized use
without the written permission of
India Yamaha Motor Pvt. Ltd.
is expressly prohibited.
Printed in India

This Assembly Manual contains the information required for the correct assembly of this motorcycle prior to
delivery to the customer. Since some external parts of the motorcycle have been removed at the YAMAHA
factory for the convenience of packing, assembly by the YAMAHA dealer is required. It should be noted that the
assembled motorcycle should be thoroughly cleaned, inspected and adjusted prior to delivery to the customer.
FOREWORD
NOTICE
The service specifications given in this assembly manual are based on the model as manufactured. India
Yamaha Motor Pvt. Ltd. is continually striving to improve all of its models. Modifications and significant changes
in specifications or procedures will be forwarded to all authorized YAMAHA dealers and will appear in future
editions of this manual where applicable. The procedures below are described in the order that the procedures
are carried out correctly and completely. Failure to do so can result in poor performance and possible harm to
the motorcycle and/or rider. Particularly important information is distinguished in this manual by the following
notations.
WARNING
NOTICE
TIP:
This is the safety alert symbol. It is used to alert you to potential personal injury hazards.
Obey all safety messages that follow this symbol to avoid possible injury or death.
A WARNING indicates as 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.
ATIP provides key information to make procedures easier or clearer.

INDEX
1. SYMBOLS USED IN THE ASSEMBLY MANUAL …………............................................
2. UNPACKAGING ………………………………………………………………………………..
3. PARTS LOCATION ………………..……………..............................................................
a. Carton A ……………………………………………………………...…….
b. Carton B…………………………………………………………………...…
c. Carton C ……………………………………………………………………..
d. Carton D………………………………………………….……………....….
e. Bubble wrap ………………………………………………..……………….
4. HARDWARE IN CARTON B ………………………………………………………………..
5. SETUP & PRE-DELIVERY CHECKLIST .......................................................................
6. SETUP PROCEDURE …………………….…………………..…………………....…….….
a. Front fender …………………………..……….…………………...............
b. Front wheel …………………………………………………….…………….
c. Handlebar assy. ………………………………………………………….….
d. CDI unit ………………………………………………………………….……
e. Seat ……………………………………………………………..…………….
f. Rear view mirror ………………………………………………………..…….
7. CABLE ROUTING ..........................................................................................................
8. ADJUSTMENTS AND PRE-DELIVERY SERVICE…………………………...………...…
a. Checking and charging the battery .........................................................
b. Measuring the tire pressure ....................................................................
c. Checking the engine oil level ..................................................................
d. Adjusting the engine idling speed ...........................................................
e. Adjusting the throttle cable free play .......................................................
f. Adjusting the rear brake free play ............................................................
g. Adjusting the rear brake light switch .......................................................
h. Adjusting the clutch cable free play ………………………………….......
i. Adjusting the drive chain slack ................................................................
j. Adjusting the headlight beam ...................................................................
9. APPENDICES …………………………………………………………………………………
a. Service data…………………………………………………………………..
10. TIGHTENING TORQUES...............................................................................................
1
2
5
5
5
5
5
5
6
8
9
10
10
12
16
16
16
17
25
26
28
29
30
31
31
32
32
33
33
35
35
36

1
SYMBOLS USED IN THIS MANUAL
In order to simplify descriptions in this assembly manual, the following
symbols are used:
(1): Coat with lithium-soap-based grease.
(2): Tighten to 10 Nm.
(10 Nm = 1.0 m · kg, 7.2 ft · lb)
(3): Towards the front of the motorcycle
(4): Clearance required
(5): Install so that the arrow mark faces upward.
(6): Apply motor oil.
(7): Made of rubber or plastics
(8):
A: Ref. No. (indicating the order of operations.)
B: Place where parts are held
V: Stored in plastic bag/Bubble Sheet
C: Stored in carton box
S: Fixed inside the steel frame/wooden
frame and/or contained in the Styrofoam
tray (upper or lower)
*: Temporarily installed or secured
C: Quantity of parts per motorcycle
D: Size or material of parts
d/D: Diameter of part
l: Length of part
e.g., 5 (0.20)=5mm(0.20 in)
To assemble the motorcycle correctly, supplies (e.g., oils, greases,
and shop rags) and sufficient working space are required.
Workshop
The workshop where the motorcycle is assembled should be clean,
spacious, and have a level floor.
Self-protection
Protect your eyes with suitable safety glasses or goggles when using
compressed air, when grinding or when doing any operation which
may cause particles to fly off.
Protect hands and feet by wearing safety
gloves or shoes.
PREPARATION

2
1. Remove all the strips from all the corners & Top
cover “1”.
2. Remove the Front wheel “2” by untagging Its
cords.“1”.
3. Remove Wooden angles “3”
4. Remove Side covers “4”
5. Remove front cover “5”.
6
6. Remove the nut “6” in order to remove the front
wheel assy. from the packing box..
2
4
4
3
7. Remove the polythene cover “7”.
7
UNPACKAGING
5

3
8. Untag & remove the loosen parts kept on the vehicle.
9. Remove all the carton boxes “8”.
10. Remove the wooden support bracket “9” from the
mounting bracket “10”.
11. Remove mounting bracket by removing the bolt “11”
from seat handle..
10
9
8
8
12. Tighten the bolt”11” at its original position.
11

4
12. Remove carton box “12” from the rear side of the
vehicle by untagging its cord.
13. Remove handlebar “13” from both the side of rear
wheel of both motorcycle.
14. Remove the carton box “14” placed over frame at
the area of rider seat.
12
13
15. Remove the axle nut “15” from the front fork, and
then remove the axle bolt from wooden bracket “16”.
15
16
14

HARDWARE IN CARTON “B”
S. No. PART NO. / DESCRIPTION QTY. Illustration
1. 97027-06020 2 EACH
BOLT HEX
2. 90154-06061 2 EACH
SCREW CROSS RECESS
3. 90387-068C5 4 EACH
COLLAR
4. 90201-6726 2 EACH
WASHER PLAIN
5. 21C-F5183-00 2 nos.
COLLER WHEEL SHAFT
6. 95827-08016 2 nos.
BOLT FLANGE
7. 36L-H3936-00 2 EACH
BAND SWITCH CORD
8. 1ES-F8199-S0 2 nos.
MANUAL OWNERS
9. 21C-F6280-00 2 nos.
MIRROR ASSY 1
10. 21C-F6290-00 2 nos.
MIRROR ASSY 2
11. 21C-H5540-00 2 nos.
CDI UNIT ASSY
5

S. No. PART NO. / DESCRIPTION QTY. Illustration
12. 21C-F8100-10 2 EACH
TOOL KIT
6