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FZ-16
Yamaha FZ-16 Manuals
Manuals and User Guides for Yamaha FZ-16. We have
2
Yamaha FZ-16 manuals available for free PDF download: Service Manual, Assembly Manual
Yamaha FZ-16 Service Manual (268 pages)
Brand:
Yamaha
| Category:
Motorcycle
| Size: 14.26 MB
Table of Contents
How to Use this Manual
4
Symbols
5
Table of Contents
6
General Information
7
Vehicle Identification Number (Chassis Number)
8
Engine Serial Number
8
Features
9
Fuel Gauge
9
Multifunction Display
9
And Pins
10
Important Information
10
Packing, Oil Seals and O-Rings
10
Preparing for the Removal and Disassembly
10
Replacement Parts
10
Bearings and Oil Seals
11
Locking Ring
11
Inspection of Connections
12
Special Tools
13
2 Specifications
17
General
18
Specifications Engine
19
Carb
25
Chassis Specifications
26
Electrical
29
Turn Signal Relay
30
Torque
31
Torque Motor
32
Sequence Cylinder Head Tightening
34
Tightening Sequence of the Clutch Cover
34
Tightening Sequence of the Magneto Cover
34
Crankcase Tightening Sequence
35
Lubrication Points and Lubricant Types
38
Tables and Diagrams Lubrication System
41
Table of Engine Oil Lubrication
41
Lubrication Charts
42
Guiding Cables
44
Troubleshooting
53
Periodic Maintenance
54
Table of Lubrication and Routine Maintenance
54
Adjusting the Clearance Valves
56
Engine
56
Adjusting the Engine Idle
57
Engine Idle Adjustment
57
Measurement and Adjustment CO
58
Set Cable Free Play Throttle
59
Checking the Spark
60
On Inspection Time
60
Spark Plug Inspection
60
Measurement of Pressure Compression
61
Change Engine Oil
62
Checking the Engine Oil Level
62
Free Play Adjustment Clutch Cable
63
Motor Oil Change
63
Set Cable Free Play Clutch
63
Cleaning the Air Filter Element
64
Check Carburetor and Unon Connection Filter Housing
65
Check the Breath of the Head Tube
65
Check the Exhaust System
65
Check the Filter Wrench Fuel
66
Adjusting the Rear Brake Drum
67
Chassis
67
Checking the Brake Fluid Level
67
Bleeding the Hydraulic Brake System
68
Checking the Front Brake Hose
68
Checking the Front Brake Pads
68
Adjusting the Rear Brake Light Switch
68
Adjusting the Transmission Slack Chain
69
Transmission Chain Lubrication
70
Specifications
70
Inspection and Adjustment Column Address
71
Inspection of Tires
72
Verification of the Front Fork
72
Inspection and Lubrication Cables
73
Inspection of the Wheels
73
Lubrication Lever Clutch
73
Engine
73
Adjusting the Rear Shock
74
Lubricating the Brake Lever
74
Lubricating the Rear Suspension
74
Lubrication Sidestand
74
Pedal Lubrication
74
Electrical System
75
Beam Adjustment of Farola
76
Auxiliary Light Replacement
76
Change Bulb Rear / Bulb Brake
76
Electrical System
76
To Replace the Rear Light
77
Change Indicator Light Bulb Drawing
77
General Chassis
80
Removing the Fuel Tank
81
Removing the Lamp and the Meter
82
Removing the Air Filter
83
Installing the Air Filter Housing
84
General Chassis
84
Removing the Front Wheel and Brake Disc
85
Disassembly of the Front Wheel
86
Removing the Front Wheel
87
Verification of Front Wheel
87
Front Wheel Assembly
88
Front Wheel Assembly (Disco)
88
Removing the Rear Wheel and Brake Bands Holder
91
Disassembly of the Rear Wheel
92
Removing the Rear Wheel
93
Verification of Rear Wheel
93
Checking the Rear Wheel
93
Check and Replace the Rear Wheel Gear
93
Rear Wheel Assembly (Drum)
94
Disassembly of the Front Brake Pads
95
Removing the Front Brake Master Cylinder
96
Disassemble the Front Brake Master Cylinder
97
Checking the Front Brake Disc
98
Removing the Front Brake Caliper
100
Disassembly of the Brake Caliper
100
Checking the Brake Caliper
100
Assembly of the Front Brake Caliper
101
Front Brake Master Cylinder Disassembly
102
Check the Front Brake Master Cylinder
102
Front Brake Master Cylinder Assembly
102
Rear Brake
105
Disassembly of the Bands
105
Rear Drum Brake Wheel
107
Testing the Limits of Wear
107
Removing the Handle
109
Removing the Handlebar
111
Check the Handle
111
Handlebar Assembly
111
Front Fork
114
Removing the Fork Legs
114
Disassembly of the Front Fork Legs
115
Removing the Front Fork Bars
117
Verification of Front Fork Bars
118
Assembly of the Front Fork Bars
118
Assembly of the Front Fork Bars
121
Steering
122
Disassembly of the Steering Column
122
Disassembly of Lower Bracket
124
Checking the Address Column
124
Fitting the Steering Column
124
Removing the Rear Shock
126
Verification of Rear Shock
127
Rear Shock Mounting
127
Swing
128
Removing the Rocker
128
Verification of Overhead
130
Tilt Assembly
130
Removing the Transmission Chain
132
Check Transmission Chain
133
Assembly of the Chain
134
Removing the Silencer
138
Disconnect Cables and Connectors
139
Removing the Motor
140
Motor Assembly
141
Arm Assembly of Changes
141
Removing the Head
142
Inspection of the Head
144
Inspection of Gear Tree and Guide Cam Chain Distribution
145
Checking the Timing Chain Tensioner Distribution
145
Inspection System Decompression
146
Head Assembly
146
Removing the Rocker Arms and Camshaft
149
Removing the Rocker and Camshaft
150
Camshaft Inspection
150
Checking the Rocker and Axles
150
Dimensions of the Lobes of Camshaft
150
Camshaft and Rocker Assembly
151
Camshaft Inspection
151
Removing the Valves and Valve Springs
152
Removing the Valves
153
Valves and Valve Guide Inspection
153
Inspection of the Seats of the Valves
154
Checking the Valve Springs
155
Valve Assembly
156
Removal of the Cylinder and Piston
158
Removing the Cylinder and Piston
159
Inspection of Cylinder and Piston
159
Checking the Piston Rings
160
Checking the Piston Pin
161
Assembly Piston and Cylinder
161
Removing the Magneto and Starter Clutch
163
Magnet Removal
165
Removing the Starter Clutch
165
Checking the Starter Clutch
165
Starting Clutch Assembly
166
Mounting Magneto
166
Electric Start
168
Removing the Starter Motor
168
Disassemble the Starter
169
Starter Inspection
170
Electric Start
170
Starter Assembly
171
Clutch
172
Removing the Clutch Cover
172
Removing the Clutch
173
Removing the Push Lever
174
Inspection of Records of Friction
175
Inspection of Clutch Discs
175
Inspection of Clutch Springs
176
Inspection of the Clutch Hood
176
Inspection of Caddy Clutch
176
Inspection of Pressure Plate
176
Driven Gear Inspection
177
Clutch Assembly
177
Removing the Oil Pump
180
Disassembly of the Oil Pump
181
Checking the Oil Pump
182
Assembling the Oil Pump
182
Axis of Changes
184
Removing the Shift Shaft and Lever Stop
184
Shaft Inspection of Changes
185
Top Lever Inspection
185
Assembly Shaft Changes
185
Pinion Balancer
186
Removing the Sprocket and Balancer Primary Drive Gear
186
Inspection Pinion Gears the Balancer and Gear Primary Driver
188
Driven Gear Assembly
188
Mount the Gears
188
Carter
190
Separation of the Crankcase
190
Dismantling of Bearings and Oil Seals
192
Crankcase Separation
193
Crankcase Inspection
193
Inspection of the Supply Chain Guide
193
Checking the Oil Strainer
193
Bearing Retainer Assembly
194
Crankcase Assembly
194
Crankshaft
195
Removing the Crankshaft and the Balancer
195
Removing the Crankshaft
196
Crankshaft Inspection
196
Crankshaft Assembly
196
Transmission
198
Removing the Transmission, the Drum Changes and Changes the Hairpin
198
Disassemble the Main Axis
199
Disassembly of the Coupling Pin
200
Inspection of Forks Changes
201
Inspection of Change Drum
201
Inspection of Transmission
201
Inspection of the Push Rod
202
Main Shaft Assy, Spindle Traction
202
Assembly of the Forks Changes and Change Drum
202
Fuel System
204
Removing the Carburetor
205
Disassemble the Carburetor
206
Carburetor Disassembly
209
Carburetor Assy
210
Carburetor Assembly
212
Measuring and Adjusting the Fuel
212
Inspection of the Fuel Wrench
212
Air Induction System
213
Removing the Air Induction System
214
Induction System Inspection
215
Air Injection
215
Air Switching Valve
215
Ignition System Circuit Diagram
218
Ignition System Troubleshooting
220
Electric Starting System
222
System Operation Starting Circuit Court
224
Electric Starting System Troubleshooting
226
Charging System Circuit Diagram
228
Charging System Troubleshooting
230
Lighting System Circuit Diagram
231
Lighting System Troubleshooting
233
Signalling System Circuit Diagram
234
Signalling System Troubleshooting
236
Self-Diagnosis Function
240
Fault Code Table
241
Verification of the Light Bulb Warning of Engine Failure
241
Method of Solution of Problems
241
Troubleshooting Details
242
Fault Code No. 15 Symptom Throttle Position Sensor: Open Circuit or Short Circuit Detected
242
Fault Code No. 16 the Throttle Position Sensor Is Attached
243
Symptom: Cable Primary Ignition Coil: Open Circuit Detected
243
Symptom: the Signals Received from the Speed Sensor Is Not Normal
244
Electrical Components
245
Switch Inspection
247
Verification of Bulbs and Sockets of Bulbs
250
Types of Bulbs
250
Checking the Condition of the Bulbs
250
Checking the Status of Sockets of Bulbs
251
Checking the Fuse
251
Checking the Relays
254
Starter Cut Relay
255
Verification of Signal Relay Giro
255
Checking the Spark Plug Hood
256
Checking the Ignition Coil
256
Verification of the Distance between Spark Plug Electrode
257
Verification of the Position Sensor Crankshaft
257
Verification of Operation Starter
257
Checking the Stator Coil
258
Verification Regulator / Rectifier
258
Speaker Verification
259
Verification Fuel Meter
259
Verification of Position Sensor Throttle
260
Checking the Speed Sensor
260
General Information
261
Starting Failures
262
Improper Engine Idling
262
Poor Performance in Middle and High Speed
263
Failure to Gear
263
Shift Pedal Does Not Move
263
Skip Gears
263
Overcooling
264
Poor Performance Brake
264
Failure of the Front Fork
264
Unstable Handling
264
Failure of Lighting System O Signaling
265
Light Turn Signal Flashes Slowly
265
Signal Light Remains on Rotation
265
Horn Does Not Sound
265
Wiring Diagram
266
Color Code
267
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Yamaha FZ-16 Assembly Manual (42 pages)
Brand:
Yamaha
| Category:
Motorcycle
| Size: 1.5 MB
Table of Contents
Table of Contents
4
1 Symbols Used in the Assembly Manual
5
2 Unpackaging
6
Bubble Wrap
9
4 Hardware in Carton B
10
3 Parts Location
11
Carton a
11
Carton B
11
Carton C
11
Carton D
11
5 Setup & Pre-Delivery Checklist
12
6 Setup Procedure
13
Front Fender
14
Front Wheel
14
Handlebar Assy
16
CDI Unit
20
Seat
20
Rear View Mirror
20
7 Cable Routing
21
8 Adjustments and Pre Deliveryservice
29
Checking and Charging the Battery
30
Measuring the Tire Pressure
32
Checking the Engine Oil Level
33
Adjusting the Engine Idling Speed
34
Adjusting the Throttle Cable Free Play
35
Adjusting the Rear Brake Free Play
35
Adjusting the Rear Brake Light Switch
36
Adjusting the Clutch Cable Free Play
36
Adjusting the Drive Chain Slack
37
Adjusting the Headlight Beam
38
9 Appendices
39
Service Data
39
10 Tightening Torques
40
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