Yamaha FZ-16, Assembly Manual

Page 1: ...1ES F8107 E0 2010 FZ 16 ...

Page 2: ...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 ...

Page 3: ...ill 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 fol...

Page 4: ...S 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 Se...

Page 5: ... 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 5 mm 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 ...

Page 6: ... 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 ...

Page 7: ...n 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 ...

Page 8: ...ng 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 ...

Page 9: ...SS 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 ...

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

Page 11: ...s 1 for each vehicle 2 Tool kit 2nos 1 for each vehicle 3 Installation hardware 4 Mirror assy 1 2nos 1 for each vehicle 5 Mirror assy 2 2nos 1 for each vehicle 6 CDI unit 2nos 1 for each vehicle Front fender 1no 1 1 2 1 Bubble wrap 2 Carton D Carton box D content Bubble wrap content Front fender 1no Handle bar 2nos 1 for each vehicle 3 1 2 PART LOCATION ...

Page 12: ...d Right handlebar switch lead Clutch cable Throttle cable Left handlebar switch lead Front brake light switch lead D ADJUSTMENTS Adjusting the clutch cable free play Checking the engine oil level Adjusting the engine idling speed Adjusting the throttle cable free play Adjusting the rear brake light switch Adjusting the rear brake Measuring the tire pressure Adjusting the drive chain slack Adjustin...

Page 13: ... setup procedures in the order indicated by the numbers Always follow the order asshown 1 Front fender 2 Front wheel 3 Handlebar 4 Left handlebar switch 5 Right handlebar switch 6 CDI unit 7 Seat 8 Rear view mirror 1 2 3 8 6 7 4 5 ...

Page 14: ...he front fender with the front fork outer tube Proper cable routing is essential to safe motorcycle operation 1 1 4 3 5 6 FRONT WHEEL 1 C 1 2 C 2 3 C 4 4 C 2 5 C 2 2 2 1 Install the speed sensor gear unit into the wheel hub so that the projection 1 on the wheel hub fits in either slot of the speed sensor gear unit 2 Lift the wheel up between the fork legs TIP Make sure that there is enough space b...

Page 15: ... front fork on the front wheel 6 hub 5 Apply a thin coat of lithium soap based grease and then insert the axle bolt 7 through front fork leg left speed sensor unit wheel hub collar then front for leg right 6 Install the washer 8 and then nut 9 Axle nut 60 Nm 6 0 m Kg 43 ft lb 3 4 5 6 5 C 1 D 15 14 6 C 1 7 1 l D 14 241 7 9 C 1 d 14 l 11 7 9 8 5 ...

Page 16: ...ndlebar switch with the holes b in the handlebar Left handlebar 5 a 1 Install handlebar 1 and then upper handlebar holder 2 2 Tighten at the specified torque Bolt 26 Nm 2 6 M Kg 19 ft lb First install the bolts on the both side of the handle bar holder and then rear side Turn the handlebar all the way to the left and right If there is any contact with the fuel tank adjust the handlebar position TI...

Page 17: ...7 Install the clutch switch 8 by pushing it in 8 Install the band cord 9 9 8 7 6 Install the handle switch screws 7 at specified torque Screw 7 Nm 0 7 Kg m 5 ft lb 13 9 C 1 ...

Page 18: ...throttle grip 1 throttle cable 2 and then right handlebar switch 3 TIP Align the projection a on the right handlebar switch with the hole b in the handlebar 4 Install the switch mounting screws 6 tighten them at specified torque Screw 2 Install the throttle cable 4 inside the hole 5 as shown in illustration 7 Nm 0 7 Kg m 5 ft lb 4 5 6 1 14 ...

Page 19: ...he end cap assy 2 Insert the end cap assy into the handlebar hole then tighten its bolt at specified torque End cap bolt 4Nm 0 4m Kg 3 ft lb TIP There should be less than 3mm of clearance a between the handlebar grip grip end 7 5 Install brake switch 7 then cover it 6 Tighten the band cord 8 at specified position TIP Ensure the proper cable routing 8 15 5 C 1 ...

Page 20: ...ock 2 Insert the projection 1 of the seat into the set holder 2 and slide the seat forward 3 Push the seat down to lock it in its place 4 Turn the key counter clock wise and remove it 1 C 1 REAR VIEW MIRROR Install the mirror assy 1 1 mirror assy 2 2 and adjust according to need 1 C 1 2 C 1 1 2 1 2 16 ...

Page 21: ...CABLE ROUTING R R 3 1 4 10 9 6 5 8 G 11 7 6 5 8 7 5 6 11 9 D 9 H I 14 13 1 2 12 F 2 3 2 1 4 A 1 4 3 12 B A C D C B R R 17 ...

Page 22: ... A Pass through the guide in headlight stay RHS B Pass through the guide in headlight stay RHS C Pass through the guide in headlight stay LHS D Pass through the guide in headlight stay LHS E Hold with the clamp to headlight stay F Pass the RH Fr lead through the guide G Pass the LH Fr lead through the guide H Pass the wire harness handle switches lead sensor unit lead through the guide in headligh...

Page 23: ...13 13 5 2 B B L M C C D D E J S S F 3 1 2 4 B C A 5 D 6 7 8 9 E 10 2 F 11 H G I 14 15 16 N M M E E C B B S 11 14 13 16 15 2 L 2 12 13 14 16 15 J 12 S S 6 M M 6 N E E B B D D C C 3 4 17 17 17 19 ...

Page 24: ...able through the guide D Hold theAC Magneto generator assembly lead with the clamp to frame E Pass battery breather hose and carburetor drain hose through to hole in joint hose F Pass the overflow pipe through the guide G Pass wire harness sensor unit lead handle switches lead through the guide H Pass horn lead after overflow pipe is passed through the guide I Pass wire harness sensor unit lead ha...

Page 25: ...A 1 4 2 3 5 6 9 10 8 11 10 3 13 21 22 20 14 15 12 16 17 18 19 A A A 7 15 A 21 ...

Page 26: ...able 18 Starting circuit cut off relay 19 CDI unit assembly 20 Carburetor air bend 21 Rear fender 22 Rear fender cover A Insert carburetor air bend in the hole of air filter assembly B Hold clutch and handle switch leads with clamp to handle bar C Hold front stop and handle switch leads with clamp to handle bar D Pass tail light assembly both rear leads through to hole of rear fender E Fix high te...

Page 27: ...29 17 16 H H 16 28 10 K K 30 25 U U 31 5 T T P P 16 A 18 19 B 10 C 21 22 26 E 242723 251 5 6 7 8 F G 9 H I J K 12 11 10 13 L 14 29 15 M N H 31 30 K K K U U U T T T T O 23 ...

Page 28: ...embly B Pass wire harness minus lead through to backside hook in battery box C Fit white marking of wire harness to clamp D Fit clamp to rear end of engine bracket 1 of frame E Match clamp to white paint of vacuum sensing hose 1 F Pass starting motor lead and starter relay lead through to clamp in battery box G Pass battery breather hose and carburetor drain hose through to outside of engine H Pas...

Page 29: ...A Checking charging the battery B Measuring the tire pressure C Checking the Engine Oil Level D Adjusting the engine idle speed E Adjusting the throttle cable free play F Adjusting the rear brake G Adjusting rear brake light switch H Adjusting Clutch Cable free play I Adjusting Chain Slack J Adjusting Head Light Beam A E H J B D C G I F 25 ...

Page 30: ...try to add battery electrolyte to a battery that is installed on a motorcycle Even a skilled mechanic will spill enough acid to damage metal parts Always remove the battery before filling with electrolyte and during charging Always completely clean the exterior of the battery before installing Battery electrolyte is dangerous it contain sulfuric acid and therefore is poisonous and highly caustic A...

Page 31: ...ith a hydro meter If the hydrometer readings are below the specification charging is necessary h Install the filler caps and thoroughly wipe off the fluid around the filler caps Wipe off the battery completely before installation Charging rate 0 5 Ah X 5 10 hours Battery capacity 12 V 5 0 Ah Specific gravity 1 280 2 Installation a The breather hose should be connected and routed Properly b Make su...

Page 32: ...ent air temperature cause tire damage an accident or an injury NEVER OVERLOAD THE MOTORCYCLE Maximum load 195Kg The tire pressure and the suspension must be adjusted according to the total weight including cargo rider passenger and accessories and the anticipated riding speed Operation of an overloaded motorcycle could WARNING Cold tire pressure Front 28psi 2 0Kgf cm Rear 33psi 2 25kgf cm 2 2 Maxi...

Page 33: ... Before checking the engine oil level wait a few minutes until the oil has settled Do not screw the dipstick 1 in when checking the oil level Periodic oil change 1 00 L Total amount of Engine Oil 1 20 L Engine OilAmount Quantity Make sure that the motorcycle is upright C CHECKING THE ENGINE OIL LEVEL Do not allow foreign materials to enter the crankcase 5 Start the engine warm it up for several mi...

Page 34: ...s 2 Install Digital tachometer onto the spark plug lead 3 Check If out of specification adjust it 4 Adjust a Turn the throttle stop screw 1 in direction a or b until the specified engine idling speed is obtained 8 Remove 9 Adjust Engine idling speed Engine idling speed Digital tachometer Throttle cable free play Engine idling speed 1300 1500 r min Direction a Engine idling speed is increased Direc...

Page 35: ...the rubber cover 1 b Loosen the locknut 2 c Turn the adjusting nut 3 in direction a or b until the specified carburetor cable free play is obtained d Tighten the locknut e Slide the rubber cover to its original position F ADJUSTING THE REAR BRAKE FREE PLAY Free Play 15 20 mm Direction a Brake pedal free play is increased Direction b Brake pedal free play is decreased After adjusting the brake peda...

Page 36: ...o that it does not rotate and turn the adjusting nut 2 in direction a or b until the rear brake light comes on at the proper time Rear brake light operation timing H ADJUSTING THE CLUTCH CABLE FREE PLAY Direction a Clutch cable free play is increased Direction b Clutch cable free play is decreased The clutch lever free play should be adjusted to 10 15 mm If the free play is incorrect adjust as fol...

Page 37: ...must be checked at the tightest point on the chain 1 Stand the vehicle on a level surface TIP Place the vehicle on the centerstand so that the rear wheel is elevated 2 Spin the rear wheel several times and find the tightest position of drive chain 3 Check Drive chain slack a Out of specification Adjust TIP Measure the drive chain slack halfway between the drive axle and the rear wheel axle 4 Adjus...

Page 38: ...ht in the following manner to adjust the headlight beam 3 Tighten Bolt 1 2 4 Tighten the adjusting bolt 2 upto the specified torque 5 Adjust Brake pedal free play 6 Align the rear axle a To maintain correct axle alignment Reference lines 1 on the swingarm should be matched with an outer diameter of the washer 2 at both the sides b After adjusting be sure to tighten each chain adjusting locknut The...

Page 39: ...acity Total 12 0 L IN 0 08 0 12 mm EX 0 12 0 16 mm 195 kg Single riding Double Riding Front 2 00 kgf cm2 28 psi Rear 2 25 kgf cm2 33 psi Load is the total weight of rider passenger cargo and accessories 1 Owner s manual 2 pc 2 Owner s tool kit 2 pc OWNER S TOOL KIT 1 Tool Bag 2 Screw driver Plus Minus 3 Grip 4 Spanner 14 X 17 mm 5 Spanner 10 X 12 mm 6 Spanner 8 X10 mm 7 Box Spanner Spark Plug 16 m...

Page 40: ...55 Nm 5 5 m kg 40ft Ib Engine mounting nut stay bolt M8 3 30 Nm 3 0 m kg 22ft Ib Pivot shaft nut M12 1 46 Nm 4 6 m kg 33ft Ib Rear cushion lower nut M12 1 60 Nm 6 0 m kg 43ft Ib Rear cushion upper nut M12 1 40 Nm 4 0 m kg 29ft Ib Bar tension and rear arm M8 1 20 Nm 2 0 m kg 14ft Ib Fuel cock screw M6 2 7 Nm 0 7 m kg 5ft Ib Ignition coil bolt M6 2 7 Nm 0 7 m kg 5ft Ib Side cover bolt M6 1 2 Nm 0 2 ...

Page 41: ... Nm 3 0 m kg 22ft Ib Master cylinder bolt M6 2 10 Nm 1 0 m kg 7ft Ib Brake pedal and footrest assy M10 1 30 Nm 3 0 m kg 22ft Ib Footrest assy and frame bolt M8 2 35 Nm 3 5 m kg 25ft Ib Sidestand nut M10 1 44 Nm 4 4 m kg 32ft Ib Main stand nut M10 2 46 Nm 4 6 m kg 33ft Ib Shift pedal nut M8 1 2 Nm 3 0 m kg 22ft Ib Bracket side stand and frame nut M10 1 44 Nm 4 4 m kg 32ft Ib Footrest bracket plate ...

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