Table Of Contents - Yamaha FZ-16 Service Manual

Table of Contents

How To Use This Manual4
Symbols5
Table Of Contents6
General Information7
Vehicle Identification Number (Chassis Number)8
Engine Serial Number8
Features9
Multifunction Display9
Fuel Gauge9
Important Information10
Preparing For The Removal And Disassembly10
Replacement Parts10
Packing, Oil Seals And O-Rings10
And Pins10
Bearings And Oil Seals11
Locking Ring11
Inspection Of Connections12
Special Tools13
Specifications17
General18
Specifications Engine19
Carb25
Chassis Specifications26
Electrical29
Turn Signal Relay30
Torque31
Torque Motor32
Sequence Cylinder Head Tightening34
Tightening Sequence Of The Magneto Cover34
Tightening Sequence Of The Clutch Cover34
Crankcase Tightening Sequence35
Lubrication Points And Lubricant Types38
Tables And Diagrams Lubrication System41
Table Of Engine Oil Lubrication41
Lubrication Charts42
Guiding Cables44
Troubleshooting53
Periodic Maintenance54
Table Of Lubrication And Routine Maintenance54
Engine56
Adjusting The Clearance Valves56
Adjusting The Engine Idle57
Engine Idle Adjustment57
Measurement And Adjustment Co58
Set Cable Free Play Throttle59
Checking The Spark60
On Inspection Time60
Spark Plug Inspection60
Measurement Of Pressure Compression61
Checking The Engine Oil Level62
Change Engine Oil62
Set Cable Free Play Clutch63
Motor Oil Change63
Free Play Adjustment Clutch Cable63
Cleaning The Air Filter Element64
Check Carburetor And Unon Connection Filter Housing65
Check The Breath Of The Head Tube65
Check The Exhaust System65
Check The Filter Wrench Fuel66
Chassis67
Adjusting The Rear Brake Drum67
Checking The Brake Fluid Level67
Checking The Front Brake Pads68
Checking The Front Brake Hose68
Bleeding The Hydraulic Brake System68
Adjusting The Rear Brake Light Switch68
Adjusting The Transmission Slack Chain69
Transmission Chain Lubrication70
Inspection And Adjustment Column Address71
Verification Of The Front Fork72
Inspection Of Tires72
Inspection Of The Wheels73
Inspection And Lubrication Cables73
Lubrication Lever Clutch73
Lubricating The Brake Lever74
Pedal Lubrication74
Lubrication Sidestand74
Lubricating The Rear Suspension74
Adjusting The Rear Shock74
Electrical System75
Beam Adjustment Of Farola76
Auxiliary Light Replacement76
Change Bulb Rear / Bulb Brake76
To Replace The Rear Light77
Change Indicator Light Bulb Drawing77
General Chassis80
Removing The Fuel Tank81
Removing The Lamp And The Meter82
Removing The Air Filter83
Installing The Air Filter Housing84
Removing The Front Wheel And Brake Disc85
Disassembly Of The Front Wheel86
Removing The Front Wheel87
Verification Of Front Wheel87
Front Wheel Assembly88
Front Wheel Assembly (Disco)88
Removing The Rear Wheel And Brake Bands Holder91
Disassembly Of The Rear Wheel92
Removing The Rear Wheel93
Verification Of Rear Wheel93
Checking The Rear Wheel93
Check And Replace The Rear Wheel Gear93
Rear Wheel Assembly (Drum)94
Disassembly Of The Front Brake Pads95
Removing The Front Brake Master Cylinder96
Disassemble The Front Brake Master Cylinder97
Checking The Front Brake Disc98
Removing The Front Brake Caliper100
Disassembly Of The Brake Caliper100
Checking The Brake Caliper100
Assembly Of The Front Brake Caliper101
Front Brake Master Cylinder Disassembly102
Check The Front Brake Master Cylinder102
Front Brake Master Cylinder Assembly102
Rear Brake105
Disassembly Of The Bands105
Rear Drum Brake Wheel107
Testing The Limits Of Wear107
Removing The Handle109
Removing The Handlebar111
Check The Handle111
Handlebar Assembly111
Front Fork114
Removing The Fork Legs114
Disassembly Of The Front Fork Legs115
Removing The Front Fork Bars117
Verification Of Front Fork Bars118
Assembly Of The Front Fork Bars118
Steering122
Disassembly Of The Steering Column122
Disassembly Of Lower Bracket124
Checking The Address Column124
Fitting The Steering Column124
Removing The Rear Shock126
Verification Of Rear Shock127
Rear Shock Mounting127
Swing128
Removing The Rocker128
Verification Of Overhead130
Tilt Assembly130
Removing The Transmission Chain132
Check Transmission Chain133
Assembly Of The Chain134
Removing The Silencer138
Disconnect Cables And Connectors139
Removing The Motor140
Motor Assembly141
Arm Assembly Of Changes141
Removing The Head142
Inspection Of The Head144
Inspection Of Gear Tree And Guide Cam Chain Distribution145
Checking The Timing Chain Tensioner Distribution145
Inspection System Decompression146
Head Assembly146
Removing The Rocker Arms And Camshaft149
Removing The Rocker And Camshaft150
Camshaft Inspection150
Checking The Rocker And Axles150
Dimensions Of The Lobes Of Camshaft150
Camshaft And Rocker Assembly151
Removing The Valves And Valve Springs152
Removing The Valves153
Valves And Valve Guide Inspection153
Inspection Of The Seats Of The Valves154
Checking The Valve Springs155
Valve Assembly156
Removal Of The Cylinder And Piston158
Removing The Cylinder And Piston159
Inspection Of Cylinder And Piston159
Checking The Piston Rings160
Checking The Piston Pin161
Assembly Piston And Cylinder161
Removing The Magneto And Starter Clutch163
Magnet Removal165
Removing The Starter Clutch165
Checking The Starter Clutch165
Starting Clutch Assembly166
Mounting Magneto166
Electric Start168
Removing The Starter Motor168
Disassemble The Starter169
Starter Inspection170
Starter Assembly171
Clutch172
Removing The Clutch Cover172
Removing The Clutch173
Removing The Push Lever174
Inspection Of Records Of Friction175
Inspection Of Clutch Discs175
Inspection Of Clutch Springs176
Inspection Of The Clutch Hood176
Inspection Of Caddy Clutch176
Inspection Of Pressure Plate176
Driven Gear Inspection177
Clutch Assembly177
Removing The Oil Pump180
Disassembly Of The Oil Pump181
Checking The Oil Pump182
Assembling The Oil Pump182
Axis Of Changes184
Removing The Shift Shaft And Lever Stop184
Shaft Inspection Of Changes185
Top Lever Inspection185
Assembly Shaft Changes185
Pinion Balancer186
Removing The Sprocket And Balancer Primary Drive Gear186
Inspection Pinion Gears The Balancer And Gear Primary Driver188
Driven Gear Assembly188
Mount The Gears188
Carter190
Separation Of The Crankcase190
Dismantling Of Bearings And Oil Seals192
Crankcase Separation193
Crankcase Inspection193
Inspection Of The Supply Chain Guide193
Checking The Oil Strainer193
Bearing Retainer Assembly194
Crankcase Assembly194
Crankshaft195
Removing The Crankshaft And The Balancer195
Removing The Crankshaft196
Crankshaft Inspection196
Crankshaft Assembly196
Transmission198
Removing The Transmission, The Drum Changes And Changes The Hairpin198
Disassemble The Main Axis199
Disassembly Of The Coupling Pin200
Inspection Of Forks Changes201
Inspection Of Change Drum201
Inspection Of Transmission201
Inspection Of The Push Rod202
Main Shaft Assy, Spindle Traction202
Assembly Of The Forks Changes And Change Drum202
Fuel System204
Removing The Carburetor205
Disassemble The Carburetor206
Carburetor Disassembly209
Carburetor Assy210
Carburetor Assembly212
Measuring And Adjusting The Fuel212
Inspection Of The Fuel Wrench212
Air Induction System213
Removing The Air Induction System214
Induction System Inspection215
Air Injection215
Air Switching Valve215
Ignition System Circuit Diagram218
Ignition System Troubleshooting220
Electric Starting System222
System Operation Starting Circuit Court224
Electric Starting System Troubleshooting226
Charging System Circuit Diagram228
Charging System Troubleshooting230
Lighting System Circuit Diagram231
Lighting System Troubleshooting233
Signalling System Circuit Diagram234
Signalling System Troubleshooting236
Self-Diagnosis Function240
Fault Code Table241
Verification Of The Light Bulb Warning Of Engine Failure241
Method Of Solution Of Problems241
Troubleshooting Details242
Fault Code No. 15 Symptom Throttle Position Sensor: Open Circuit Or Short Circuit Detected242
Fault Code No. 16 The Throttle Position Sensor Is Attached243
Symptom: Cable Primary Ignition Coil: Open Circuit Detected243
Symptom: The Signals Received From The Speed Sensor Is Not Normal244
Electrical Components245
Switch Inspection247
Verification Of Bulbs And Sockets Of Bulbs250
Types Of Bulbs250
Checking The Condition Of The Bulbs250
Checking The Status Of Sockets Of Bulbs251
Checking The Fuse251
Checking The Relays254
Starter Cut Relay255
Verification Of Signal Relay Giro255
Checking The Spark Plug Hood256
Checking The Ignition Coil256
Verification Of The Distance Between Spark Plug Electrode257
Verification Of The Position Sensor Crankshaft257
Verification Of Operation Starter257
Checking The Stator Coil258
Verification Regulator / Rectifier258
Speaker Verification259
Verification Fuel Meter259
Verification Of Position Sensor Throttle260
Checking The Speed Sensor260
Starting Failures262
Improper Engine Idling262
Poor Performance In Middle And High Speed263
Failure To Gear263
Shift Pedal Does Not Move263
Skip Gears263
Overcooling264
Poor Performance Brake264
Failure Of The Front Fork264
Unstable Handling264
Failure Of Lighting System O Signaling265
Light Turn Signal Flashes Slowly265
Signal Light Remains On Rotation265
Horn Does Not Sound265
Wiring Diagram266
Color Code267