Yamaha FZ-16 User manual

SERVICE MANUAL

FZ-16

21C-F8197-EO

FZ-16

SERVICE MANUAL

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.

ClutchHubHolder

YSST-733

SYMBOLS

The following symbols are used in this manual

to facilitate understanding.

NOTE:

The following symbols are not relevant to

each vehicle.

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.

New

TABLE OF CONTENTS

GENERAL INFORMATION

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

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

FEATURES

MULTIFUNCTION DISPLAY

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. 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

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

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