Yamaha YZ 2016 Series Manuals

Manuals and User Guides for Yamaha YZ 2016 Series. We have 1 Yamaha YZ 2016 Series manual available for free PDF download: Owner's Service Manual

Yamaha YZ 2016 Series Owner's Service Manual

Yamaha YZ 2016 Series Owner's Service Manual (392 pages)

Brand: Yamaha | Category: Motorcycle | Size: 13.7 MB

Table of Contents

Table of Contents

9
- General Information
  11
- Location of Important Labels
  13
- Description
  14
- Identification
  15
- Vehicle Identification Number
  15
- Engine Serial Number
  15
- Included Parts
  16
- Spark Plug Wrench
  16
- Nipple Wrench
  16
- Handlebar Protector
  16
- Fuel Hose Joint Cover
  16
- Coupler for Connecting Optional Part
  16
- Replacement Parts
  17
- Important Information
  17
- Preparation for Removal and Disassembly
  17
- Gaskets, Oil Seals and O-Rings
  18
- Lock Washers/Plates and Cotter Pins
  18
- Bearings and Oil Seals
  18
- Circlips
  18
- Basic Service Information
  19
- Electrical System
  19
- Special Tools
  23
- Shift Pedal
  29
- Throttle Grip
  29
- Kickstarter Lever
  29
- Start Switch
  29
- Clutch Lever
  29
- Engine Stop Switch
  29
- Control Functions
  29
- Front Brake Lever
  30
- Rear Brake Pedal
  30
- Sidestand
  30
- Starter Knob/Idle Adjusting Screw
  30
- Fuel Tank Cap
  30
- Starting a Cold Engine
  32
- Air Filter Maintenance
  32
- Handling Note
  32
- Fuel
  32
- Starting and Break-In
  32
- Starting a Warm Engine
  34
- Break-In Procedures
  34
- Maintenance after Break-In
  35
- Major Maintenance
  35
- Torque-Check Points
  36
- Motorcycle Care and Storage
  38
- Care
  38
- Storage
  39
Specifications

41
- General Specifications
  42
- Engine Specifications
  43
- Chassis Specifications
  48
- Electrical Specifications
  52
- General Tightening Torque Specifications
  53
- Tightening Torques
  53
- Engine Tightening Torques
  54
- Chassis Tightening Torques
  57
- Engine
  60
- Lubrication Points and Lubricant Types
  60
- Chassis
  61
- Lubrication Diagrams
  64
- Lubrication System Chart and Diagrams
  64
- Cable Routing Diagram
  72
Periodic Checks and Adjustments

87
- Maintenance Intervals
  89
- General Inspection and Maintenance
  95
- Pre-Operation Inspection and Maintenance
  95
- Changing the Coolant
  96
- Checking the Coolant Level
  96
- Checking the Cooling System
  96
- Engine
  96
- Checking the Radiator Cap
  97
- Checking the Radiator Cap Valve Opening Pressure
  97
- Adjusting the Clutch Lever Free Play
  98
- Checking the Coolant Circulatory System for Leaks
  98
- Adjusting the Throttle Grip Free Play
  99
- Lubricating the Throttle Cable
  99
- Cleaning the Air Filter Element
  100
- Checking the Breather Hoses
  101
- Checking the Exhaust System
  101
- Checking the Throttle Body Joint
  101
- Changing the Engine Oil
  102
- Checking the Engine Oil Level
  102
- Checking the Fuel Line
  102
- Adjusting the Engine Idling Speed
  104
- Adjusting the Valve Clearance
  105
- Bleeding the Brake System
  110
- Chassis
  110
- Adjusting the Front Brake
  111
- Checking the Brake Hose
  111
- Adjusting the Rear Brake
  112
- Checking the Front Brake Pads
  112
- Checking the Rear Brake Pads
  114
- Checking the Brake Fluid Level
  115
- Checking the Rear Brake Pad Insulator
  115
- Adjusting the Drive Chain Slack
  116
- Air Bleeding from Front Fork
  117
- Checking the Front Fork Legs
  117
- Checking the Front Fork Protector Guide
  117
- Cleaning the Front Fork Oil Seal and Dust Seal
  117
- Adjusting the Front Fork Legs
  118
- Adjusting the Rear Shock Absorber Assembly
  119
- Checking the Rear Suspension
  119
- Checking the Swingarm Operation
  119
- Checking and Tightening the Spokes
  121
- Checking the Tires
  121
- Checking and Adjusting the Steering Head
  122
- Checking the Wheel Bearings
  122
- Checking the Wheels
  122
- Checking and Lubricating the Cables
  123
- Lubricating the Drive Chain
  123
- Lubricating the Levers
  123
- Lubricating the Pedal
  123
- Checking the Chassis Fasteners
  124
- Lubricating the Sidestand
  124
- Checking the Ignition Timing
  125
- Checking the Spark Plug
  125
- Electrical System
  125
- Checking and Charging the Battery
  126
Chassis

127
- General Chassis
  129
- Removing the Left Side Cover
  130
- Removing the Number Plate
  130
- Removing the Seat
  130
- Front Wheel
  131
- Checking the Front Wheel
  132
- Removing the Front Wheel
  132
- Assembling the Front Wheel
  133
- Disassembling the Front Wheel
  133
- Installing the Front Wheel
  134
- Rear Wheel
  135
- Checking and Replacing the Rear Wheel Sprocket
  136
- Checking the Rear Wheel
  136
- Disassembling the Rear Wheel
  136
- Removing the Rear Wheel
  136
- Assembling the Rear Wheel
  137
- Installing the Rear Wheel
  137
- Front Brake
  139
- Checking the Front Brake Disc
  143
- Disassembling the Front Brake Caliper
  143
- Introduction
  143
- Removing the Front Brake Caliper
  143
- Assembling the Front Brake Caliper
  144
- Checking the Front Brake Caliper
  144
- Installing the Brake Caliper Piston
  144
- Installing the Front Brake Caliper
  145
- Assembling the Front Brake Master Cylinder
  146
- Checking the Front Brake Master Cylinder
  146
- Removing the Front Brake Master Cylinder
  146
- Installing the Front Brake Master Cylinder
  147
- Rear Brake
  149
- Checking the Rear Brake Disc
  153
- Introduction
  153
- Assembling the Rear Brake Caliper
  154
- Checking the Rear Brake Caliper
  154
- Disassembling the Rear Brake Caliper
  154
- Removing the Rear Brake Caliper
  154
- Installing the Brake Caliper Piston
  155
- Installing the Rear Brake Caliper
  155
- Checking the Rear Brake Master Cylinder
  156
- Removing the Rear Brake Master Cylinder
  156
- Assembling the Rear Brake Master Cylinder
  157
- Installing the Rear Brake Master Cylinder
  157
- Checking the Handlebar
  161
- Handlebar
  161
- Installing the Handlebar
  161
- Removing the Handlebar
  161
- Front Fork
  166
- Disassembling the Front Fork Legs
  168
- Removing the Front Fork Legs
  168
- Checking the Front Fork Legs
  169
- Assembling the Front Fork Legs
  170
- Installing the Front Fork Legs
  177
- Steering Head
  179
- Checking the Steering Head
  180
- Installing the Steering Head
  180
- Removing the Lower Bracket
  180
- Rear Shock Absorber Assembly
  183
- Disposing of a Rear Shock Absorber
  186
- Handling the Rear Shock Absorber
  186
- Removing the Bearing
  186
- Removing the Rear Shock Absorber Assembly
  186
- Checking the Connecting Arm and Relay Arm
  187
- Checking the Rear Shock Absorber Assembly
  187
- Installing the Relay Arm
  187
- Installing the Rear Shock Absorber Assembly
  188
- Swingarm
  190
- Checking the Swingarm
  191
- Removing the Bearing
  191
- Removing the Swingarm
  191
- Installing the Swingarm
  192
- Chain Drive
  193
- Checking the Drive Chain
  194
- Removing the Drive Chain
  194
- Checking the Drive Sprocket
  195
- Checking the Rear Wheel Sprocket
  195
- Installing the Drive Chain
  195
Engine

197
- Engine Removal
  200
- Removing the Drive Sprocket
  205
- Removing the Exhaust Pipe 2
  205
- Removing the Silencer
  205
- Changing the Silencer Fiber
  206
- Checking the Silencer and Exhaust Pipe
  206
- Removing the Engine
  206
- Installing the Engine
  207
- Installing the Brake Pedal
  208
- Installing the Drive Sprocket
  208
- Installing the Exhaust Pipe and Muffler
  209
- Camshaft
  211
- Removing the Camshaft
  213
- Checking the Camshaft
  214
- Checking the Timing Chain and Camshaft Sprocket
  215
- Checking the Timing Chain Tensioners
  215
- Checking the Decompression System
  216
- Installing the Camshafts
  216
- Cylinder Head
  218
- Checking the Cylinder Head
  220
- Checking the Timing Chain Guide (Intake Side)
  220
- Removing the Cylinder Head
  220
- Installing the Cylinder Head
  221
- Removing the Valves
  223
- Valves and Valve Springs
  223
- Checking the Valves and Valve Guides
  224
- Checking the Valve Seats
  225
- Checking the Valve Springs
  227
- Checking the Valve Lifters
  228
- Installing the Valves
  228
- Checking the Cylinder and Piston
  231
- Cylinder and Piston
  231
- Removing the Piston
  231
- Checking the Piston Rings
  232
- Checking the Piston Pin
  233
- Installing the Piston and Cylinder
  233
- Electric Starter
  235
- Checking the Starter Motor
  237
- Assembling the Starter Motor
  238
- Checking the Clutch Plates
  243
- Checking the Clutch Springs
  243
- Checking the Friction Plates
  243
- Clutch
  243
- Removing the Clutch
  243
- Checking the Clutch Boss
  244
- Checking the Clutch Housing
  244
- Checking the Clutch Push Rods
  244
- Checking the Pressure Plate
  244
- Checking the Primary Drive Gear
  244
- Checking the Push Lever Shaft
  244
- Checking the Primary Driven Gear
  245
- Installing the Oil Seal
  245
- Installing the Right Crankcase Cover
  245
- Installing the Clutch
  246
- Installing the Kickstarter Lever
  248
- Checking the Kick Gear, Kick Idle Gear and Ratchet Wheel
  250
- Checking the Kick Shaft and Ratchet Wheel
  250
- Installing the Kick Shaft Assembly
  250
- Kickstater
  250
- Removing the Kick Shaft Assembly
  250
- Installing the Kick Idle Gear
  251
- Shift Shaft
  252
- Checking the Shift Guide and Shift Lever Assembly
  254
- Checking the Shift Shaft
  254
- Checking the Stopper Lever
  254
- Removing the Segment
  254
- Removing the Shift Guide and Shift Lever Assembly
  254
- Installing the Segment
  255
- Installing the Shift Guide and Shift Lever Assembly
  255
- Installing the Stopper Lever
  255
- Installing the Shift Pedal
  256
- Installing the Shift Shaft
  256
- Oil Pump and Balancer Gear
  258
- Checking the Balancer
  259
- Checking the Oil Pump
  259
- Checking the Primary Drive Gear, Balancer Shaft Drive Gear, and Balancer Weight Gear
  259
- Removing the Balancer
  259
- Assembling the Oil Pump
  260
- Installing the Oil Pump and Balancer Gear
  261
- Checking the Starter Clutch
  265
- Generator and Starter Clutch
  265
- Removing the Generator
  265
- Installing the Generator
  266
- Installing the Starter Clutch
  266
- Crankcase
  270
- Checking the Crankcase
  272
- Checking the Timing Chain, Timing Chain Guide, Oil Strainer
  272
- Disassembling the Crankcase
  272
- Removing the Crankcase Bearing
  272
- Assembling the Crankcase
  273
- Installing the Oil Seal
  273
- Crankshaft Assembly and Balancer Shaft
  274
- Checking the Crankshaft Assembly
  275
- Removing the Crankshaft Assembly
  275
- Installing the Balancer Shaft
  276
- Installing the Crankshaft Assembly
  276
- Transmission
  277
- Checking the Shift Forks
  278
- Removing the Transmission
  278
- Checking the Shift Drum Assembly
  279
- Checking the Transmission
  279
- Installing the Transmission
  279
- Cooling System
  283
Fuel System

291
- Fuel Tank
  292
- Checking the Fuel Pump Body
  293
- Installing the Fuel Pump
  293
- Removing the Fuel Pump
  293
- Removing the Fuel Tank
  293
- Checking the Fuel Pressure
  294
- Installing the Fuel Tank
  294
- Checking and Replacing the Protector
  295
- Checking the Damper
  295
- Throttle Body
  296
- Checking the Injector
  299
- Checking the Throttle Body
  299
- Checking the Throttle Body Joint
  299
- Adjusting the Throttle Position Sensor
  300
Electrical System

301
- Circuit Diagram
  304
- Ignition System
  304
- Troubleshooting
  306
- Circuit Diagram
  308
- Electric Starting System
  308
- Starting Circuit Cut-Off System Operation
  310
- Troubleshooting
  312
- Charging System
  314
- Circuit Diagram
  314
- Troubleshooting
  316
- Circuit Diagram
  318
- COOLING SYSTEM (for JPN)
  318
- Troubleshooting
  320
- Circuit Diagram
  322
- Fuel Injection System
  322
- Yamaha Diagnostic Tool
  324
- Troubleshooting Details
  327
- Circuit Diagram
  348
- Fuel Pump System
  348
- Troubleshooting
  350
- Electrical Components
  352
- Checking the Switches
  356
- Checking and Charging the Battery
  359
- Checking the Fuses
  359
- Checking the Relays
  362
- Checking the Diode
  363
- Checking the Ignition Coil
  364
- Checking the Ignition Spark Gap
  364
- Checking the Spark Plug Cap
  364
- Checking the Crankshaft Position Sensor
  365
- Checking the Lean Angle Sensor
  365
- Checking the Starter Motor Operation
  366
- Checking the Stator Coil
  366
- Checking the Coolant Temperature Sensor
  367
- CHECKING the RADIATOR FAN MOTOR (for JPN)
  367
- Checking the Rectifier/Regulator
  367
- Checking the Throttle Position Sensor
  368
- Checking the Intake Air Pressure Sensor
  369
- Checking the Throttle Position Sensor Input Voltage
  369
Troubleshooting

371
- General Information
  372
- Incorrect Engine Idling Speed
  372
- Starting Failures
  372
- Troubleshooting
  372
- Clutch Drags
  373
- Clutch Slips
  373
- Jumps out of Gear
  373
- Overheating
  373
- Poor Medium-And-High-Speed Performance
  373
- Shift Pedal Does Not Move
  373
- Shifting Is Difficult
  373
- Faulty Front Fork Legs
  374
- Front Fork Oil Leaking
  374
- Overcooling
  374
- Poor Braking Performance
  374
- Unstable Handling
  374
Tuning

379
- Chassis
  380
- Drive and Rear Wheel Sprockets Setting Parts
  380
- Selection of the Secondary Reduction Ratio (Sprocket)
  380
- Tire Pressure
  380
- Change in Amount and Characteristics of Fork Oil
  381
- Front Fork Setting
  381
- Setting of Spring after Replacement
  381
- Choosing Set Length
  382
- Front Fork Setting Parts
  382
- Rear Suspension Setting
  382
- Setting of Spring after Replacement
  383
- Suspension Setting (Front Fork)
  385
- Suspension Setting (Rear Shock Absorber)
  386

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