Yamaha FZ 16 Assembly Manual
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Yamaha FZ 16 Assembly Manual

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2010
FZ 16
1ES-F8107-E0

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Summary of Contents for Yamaha FZ 16

  • Page 1 2010 FZ 16 1ES-F8107-E0...
  • 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 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.

  • Page 4: Table Of Contents

    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.

  • Page 5: Symbols Used In The Assembly Manual

    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.

  • Page 6: Unpackaging

    UNPACKAGING 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. Remove the nut “6” in order to remove the front wheel assy.
  • Page 7 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.. 12.
  • Page 8 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.

  • Page 9: Bubble Wrap

    HARDWARE IN CARTON “B” S. No. PART NO. / DESCRIPTION QTY. Illustration 97027-06020 2 EACH BOLT HEX 90154-06061 2 EACH SCREW CROSS RECESS 90387-068C5 4 EACH COLLAR 90201-6726 2 EACH WASHER PLAIN 21C-F5183-00 2 nos. COLLER WHEEL SHAFT 95827-08016 2 nos. BOLT FLANGE 36L-H3936-00 2 EACH...

  • Page 10: Hardware In Carton B

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

  • Page 11: Parts Location

    PART LOCATION Carton box A content Rider seat (2nos, 1 for each vehicle) Carton box B content 1. Owner’s manual (2nos, 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.

  • Page 12: Setup & Pre-Delivery Checklist

    SETUP AND PREDILIVERY CHECK LIST TIP: predelivery service have been completed. Check the following items again after setup and A: INSTALLATION OF THE PARTS INCLUDED IN THE CRATE Front wheel Rearview Mirrors Front fender Seat Handlebar B: TIGHTENING TORQUE OF EACH PART Flange bolt (front fender) 07 Nm (0.7 m ·...

  • Page 13: Setup Procedure

    SETUP PROCEDURE Perform the 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...

  • Page 14: Front Fender

    FRONT FENDER 1. Seat the Front fender assy. “1” between the Front fork leg “2” . 2. Install the Screw cross recess “3” along with the collar “4”. NOTICE Be careful not to scratch to the front fender with the front fork outer tube.
  • Page 15 3. Align the speed sensor slot “3” on the protruded part “4” of the front fork, then install it . 4. Install the Collar “5” between wheel & left side leg of front fork on the front wheel “6” hub. 5.

  • Page 16: Handlebar Assy

    HANDLE BAR ASSY. 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) NOTICE 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.
  • Page 17 6. Install the handle switch screws “7” at specified torque. Screw 7 Nm (0.7 Kg.m, 5 ft.lb) 7. Install the clutch switch “8” by pushing it in. 8. Install the band cord “9”.
  • Page 18 Right handlebar 1. Install brake master cylinder holder “1” and then tighten its bolts at specified torque. Bolt 10Nm, 1.0m.Kg, 7 ft.lb. 2. Install the throttle cable “4” inside the hole “5” as shown in illustration. 3. Install throttle grip “1”, throttle cable “2” and then right handlebar switch “3”.
  • Page 19 5. Install brake switch “7” then cover it. 6. Tighten the band cord “8” at specified position. TIP: Ensure the proper cable routing. Handlebar end cap 1. Install the the handle bar grip “1” and then handle bar end cap “2”. TIP: Tighten the end cap bolt gradually until it reaches to plastic legs of the end cap assy.

  • Page 20: Cdi Unit

    C.D.I. UNIT Install CDI unit “1” and connect its all the couplers. SEAT 1. Insert the key in the lock. 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.

  • Page 21: Cable Routing

    CABLE ROUTING...
  • Page 22 Front brake hose Throttle Cable Front brake light switch lead Right handlebar switch lead Left handlebar switch lead Clutch switch lead Clutch cable Starter cable Main switch lead 10. Meter lead 11. LH Front turn signal lead 12. RH Front turn signal lead 13.
  • Page 23 2 12...
  • Page 24 Clutch cable Overflow pipe Throttle cable Starter cable Carburetor air bend AC magneto generator lead Wire minus lead Battery breather hose Carburetor drain hose 10. Fuel pipe 11. Horn lead 12. Connector cover 13. Wire harness 14. Sensor unit lead 15.
  • Page 26 LH Handle switch Clutch switch lead Clutch cable LH Handle switch lead Starter cable Main switch lead RH Handle switch lead Brake hose Front stop switch assembly lead 10. Throttle cable 11. RH Handle switch 12. Rear turn signal lead (LH) Turn signal relay assembly 14.
  • Page 27 25 1 24 27 A 18 19 B 10 C K 12...
  • Page 28 Throttle cable Pass starting motor lead and starter relay lead through to clamp in battery box. Sensor unit lead G. Pass battery breather hose and carburetor drain Brake hose hose through to outside of engine. H. Pass battery breather hose and carburetor drain Horn lead hose through to inside from here.

  • Page 29: Adjustments And Pre Deliveryservice

    ADJUSTMENTS AND PRE DELIVERYSERVICE Perform the pre delivery service in the order indicated by the letters. Always follow the order as shown. A. Checking & charging the battery B. Measuring the tire pressure C. Checking the Engine Oil Level D. Adjusting the engine idle speed E.

  • Page 30: Checking And Charging The Battery

    A. CHECKING AND CHARGING THE BATTERY 1. Charging: The battery must be charged properly before using for the first time. This initial charge will prolong the life of the battery. (a) Upper level line (b) Lower level line NOTICE Never try to add battery electrolyte to a battery that is installed on a motorcycle.
  • Page 31 Batteries also generate explosive hydrogen gas, therefore you should always follow these preventive measures: • Charge batteries in a well-ventilated area. Keep batteries away from fire, sparks, or open flames (e.g., welding equipment, lighted cigarettes, etc.). • DO NOT SMOKE when charging or handling Batteries.

  • Page 32: Measuring The Tire Pressure

    NOTICE Make sure that the battery leads are connected correctly. Reversing leads can seriously damage the electrical system. B. MEASURING THE TIRE PRESSURE 1. Measure tire pressure, If found out of specification, maintain the tire pressure. WARNING • The tire pressure should only be checked and regulated when the tire temperature equals the ambient air temperature.

  • Page 33: Checking The Engine Oil Level

    C. CHECKING THE ENGINE OIL LEVEL 1. Stand the motorcycle on a level surface. TIP: • Place the motorcycle on a suitable stand. • Make sure that the motorcycle is upright 2. Start the engine, warm it up for several minutes, and then turn it off.

  • Page 34: Adjusting The Engine Idling Speed

    D. ADJUSTING THE ENGINE IDLING SPEED TIP: Prior to adjusting the engine idling speed, the Carburetor synchronization should be adjusted properly, the air filter should be clean, and the engine should have adequate compression. 1. Start the engine and let it warm up for several minutes. 2.

  • Page 35: Adjusting The Throttle Cable Free Play

    E. ADJUSTING THE THROTTLE CABLE FREE PLAY TIP: Prior to adjusting the throttle cable free play, the engine idling speed should be adjusted. 1. Check: • Throttle cable free play “a” Out of specification ! Adjust. a. Slide back the rubber cover “1” b.

  • Page 36: Adjusting The Rear Brake Light Switch

    G. ADJUSTING THE REAR BRAKE LIGHT SWITCH TIP: The rear brake light switch is operated by movement of the brake pedal. The rear brake light switch is properly adjusted when the brake light comes on just before the braking effect starts. 1.

  • Page 37: Adjusting The Drive Chain Slack

    I. ADJUSTING THE DRIVE CHAIN SLACK The drive chain slack must be checked at the tightest point on the chain. WARNING A drive chain that is too tight will overload the engine and other vital parts, and one that is too loose can skip and damage the swingarm or cause an accident.

  • Page 38: Adjusting The Headlight Beam

    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.

  • Page 39: Appendices

    APPENDICES SERVICE DATA Engine idling speed: 1,300 ~ 1,500 r/min Spark plug: Type (manufacturer) NGK/CPR8EA-9 Gap 0.8 ~0.9 Fuel: Recommended fuel unleaded gasoline only Fuel tank capacity Total: 12.0 L Valve clearance (cold): 0.08 ~ 0.12 mm 0.12 ~ 0.16 mm Maximum load*: 195 kg Tire pressure:...

  • Page 40: Tightening Torques

    TIGHTENING TORQUE Thread Item Tightening torque Remarks size Crown handle bolt 16 Nm (1.6 m kg, 12ft Ib) Crown handle nut 110 Nm (11.0 m kg, 80ft Ib) 33 Nm (3.3 m . kg, 24ft . Ib) Steering shaft and ring nut (Initial) M25 22 Nm (2.2 m .
  • Page 41 Thread Item Tightening torque Remarks size 60 Nm (6.0 m . kg, 43ft . Ib) Front wheel axle nut 90 Nm (9.0 m . kg, 65ft . Ib) Rear wheel axle nut 43 Nm (4.3 m . kg, 31ft . Ib) Sprocket wheel and clutch hub bolt 20 Nm (2.0 m .
  • Page 42 INDIA YAMAHA MOTOR PVT. LTD.

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