Yamaha FZ-16 2015 Service Manual
  1. Manuals
  2. Brands
  3. Yamaha Manuals
  4. Motorcycle
  5. FZ-16 2015
  6. Service manual

Yamaha FZ-16 2015 Service Manual

Hide thumbs
Table of Contents

Advertisement

Quick Links

 
 
 
 
 
 
 
 
 
 
 
 
MANUAL
SERVICE
 
 
FZ-16
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
21C-F8197-EO

Advertisement

Table of Contents
loading

Related Manuals for Yamaha FZ-16 2015

Summary of Contents for Yamaha FZ-16 2015

  • Page 1                         MANUAL SERVICE     FZ-16                                                ...
  • Page 2                                 FZ-16 SERVICE MANUAL All rights reserved. Any reprinting or unauthorized use without the written permission of YAMAHA MOTOR INDIA PVT. LTD. is expressly prohibited.

  • Page 3: Specification

    Repair work and maintenance performed by a person who lacks such knowledge, the vehicle probably will not be safe or suitable for use. Yamaha Motor India Pvt Ltd. is continually striving to improve all its models. All authorized Yamaha dealers will be informed of any amendments and substantial changes occur in specifications or procedures, and these will be included in future editions of this manual, when necessary.
  • Page 4     Using this Guide This book is intended as a practical tool, easy to read reference book for the mechanic. Includes explanations of all installation, removal, disassembly, assembly, repair and check procedures are set out in individual steps in sequential order.  ...
  • Page 5     SYMBOLS 1. Serviceable with engine mounted 2. Type of liquid The following symbols are used in this manual to 3. Lubricant facilitate understanding. 4. Special Tool NOTE: 5. Torque The following symbols are not relevant 6. Wear limit, tolerance each vehicle.
  • Page 6     TABLE OF CONTENTS       GENERAL INFORMATION       SPECIFICATIONS       INSPECTIONS And adjustments       CHASSIS       MOTOR       CARBURETOR       ELECTRICAL       TROUBLESHOOTING...

  • Page 7: Table Of Contents

      GENERAL INFORMATION   IDENTIFICATION OF MOTORCYCLE ..........1-1 ..VEHICLE IDENTIFICATION NUMBER .......... 1-1 ENGINE SERIAL NUMBER ..............1-1   LCD METER ................... 1-2   IMPORTANT INFORMATION ............... 1-3 PREPARATION FOR REMOVAL AND DISASSEMBLY ..1-3 REPLACEMENT PARTS ..........

  • Page 8: Vehicle Identification Number

      IDENTIFICACIÓN   IDENTIFICATION   VEHICLE IDENTIFICATION NUMBER (chassis number) The vehicle identification number "1" is stamped on the chassis.                                 ENGINE SERIAL NUMBER The engine serial number "1" is stamped on the crankcase.

  • Page 9: Fuel Meter

      CARACTERÍSTICAS   Multi-function display                   SELECT         Multi-function display 2. "Select" button (select)   The Multi-function display is equipped with the following: • A speedometer (which shows the speed) •...

  • Page 10: Preparation For Removal And Disassembly

    5. Keep all parts away from any fire source.   REPLACEMENT PARTS Use only genuine Yamaha parts in all changes. Use oil and grease recommended by Yamaha, for all services Other brands may lubrication.

  • Page 11: Bearings And Oil Seals

      INFORMACIÓN IMPORTANTE   BEARINGS AND OIL SEALS Assemble the bearings and oil seals so that the manufacturer's mark or numbers are visible. When installing oil seals "1", lubricate the edges of oil seals with a thin layer of grease lithium soap base.

  • Page 12: Checking The Connections

      INSPECCIÓN DE LAS CONEXIONES     CHECKING THE CONNECTIONS NOTE: Verify on the cables, couplers and connectors stains, • If there is no continuity, clean the terminals oxidation, moisture, etc. • When checking the wire harness, perform steps (1) through (3). Disconnect: •...

  • Page 13: Special Tools

      HERRAMIENTAS ESPECIALES   SPECIAL TOOLS   Special tools shown below, are necessary for mounting and precise adjustments. Use only the appropriate special tools, that will help to prevent damage caused by the use of inappropriate tools or improvised techniques.  ...

  • Page 14: Herramientas Especiales

      HERRAMIENTAS ESPECIALES   Tool name / nr Tool Illustration Tool to install the crankshaft spacer. (A) YSST- 266 (b) YSST-267       These tools are using to install the crankshaft. Tool for removing the crankshaft. YSST-      ...
  • Page 15   HERRAMIENTAS ESPECIALES   Tool name / nr Tool Illustration Adapter valve spring compressor A-803 YSST         This tool is used to remove and install the valve and the valve spring using YSST 603.   Set gauge pump vacuum / pressure  ...
  • Page 16         ThEste instrument is used to verify the electrical circuits or components. Yamaha Adhesive No. 1215           This adhesive is used on the contact surfaces, while the housings assembled # 1 and # 2 of the engine.

  • Page 17: Table Of Contents

        SPECIFICATIONS     SPECIFICATION ..........2-1 ..  ENGINE SPECIFICATIONS ..........2-2 ..  CHASSIS SPECIFICATIONS ..........2-9 ..  ELECTRICAL ..........2-12 ..  TORQUE ................2-14 SPECIFICATIONS TORQUE ON ..2-14 ENGINE TORQUE ..........2-16 ..TORQUE CHASSIS ..........

  • Page 18: Especificaciones Generales

      ESPECIFICACIONES GENERALES   GENERAL       MODEL Model 21C1   Dimensions Total length 1973mm Total width 770mm Height totall 1045mm Seat Height 790mm Wheelbase Ground 1334mm clearance 160mm Minimum turning radius 2340mm   Weight With gasoline and oil 135.0kg Peak load 195.0kg...

  • Page 19: Engine Specifications

      ESPECIFICACIONES DE MOTOR   ENGINE SPECIFICATIONS   Engine Engine Type 4-stroke, air-cooled SOHC 153.0cm Displacem Cylinder Layout A cylinder leaning forward Bore x stroke 58.0 x 57.9mm Compression Ratio 9.50:1 Compression pressure (at sea level) 1200kPa Starting System Electric start, Kickstarter (According Country) Fuel Recommended fuel...
  • Page 20   ESPECIFICACIONES DE MOTOR   Spark plug (s) Manufacturer / Model NGK / CPR8EA-9 Electrode gap 0.8-0.9mm   Butt Volume 13.40-14.00cm ³ Maximum deformation 0.03mm               Camshaft Traction system Transmission chain (left) Dimensions of camshaft lobes Admission 31,342 - 31.44 2mm...
  • Page 21   ESPECIFICACIONES DE MOTOR   Timing Chain Model Silent Chain Tensioning System Automatic   Rocker / Rocker Bore rocker 9985-10.000mm Limit 10.030mm Outside diameter of rocker 9966-9.976mm Limit 9.950mm   Valves, valve seats, valve guides Valve clearance (cold) Admission 0.08-0.12mm Exhaust 0.12-0.16mm Valve Dimensions...
  • Page 22   ESPECIFICACIONES DE MOTOR   Limit 0.080mm Tolerance between the valve stem and the guide (Escape) Limit 0.025-0.052mm 0.100mm Limit deformation of the valve stem 0.010mm                   Valve Spring Free length (Admission) 39.40mm Limit 37.40mm...
  • Page 23   ESPECIFICACIONES DE MOTOR                       Deviation   0.25 mm Direction of deviation Side A-dmission 15.002 15.013 mm Diameter hole for the piston pin 15,043 mm Limit 14.995 15.000 mm Outer diameter of piston pin 14,975 mm Limit  ...
  • Page 24   ESPECIFICACIONES DE MOTOR     Small end bore 14090-15028 mm Large end bore 36000-36009 mm   Crankshaft Width A 47.95-48.00 mm Maximum deformation C Side clearance 0.030 mm large side D 0110-0140 mm              ...
  • Page 25   ESPECIFICACIONES DE MOTOR Change mechanism Type shifting mechanism Rod drive mechanism and guide Thickness shift fork 4.76-4.89 mm   Decompression device Type of device Auto-decompressor   Air filter Air filter element Dry element Carburetor Type X Quantity BS26X1 Identification mark 21C1110 Main jet # 112.5...

  • Page 26: Chassis Specifications

      ESPECIFICACIONES DE CHASIS   CHASSIS SPECIFICATIONS   Chassis Chassis type Diamond Angle 25.00 º Avance 101.2 mm Front Wheel Wheel Type Casting wheel Rim size 17 M/CXMT2.50 Material of rim Aluminum wheel travel 130.0 mm radi a l devi a ti o n l i m i t wheel 1.0 mm lateral deviation limit wheel...
  • Page 27   ESPECIFICACIONES DE CHASIS   Front brake disc Thickness and outer diameter of the disc 267.0 x 4.0 mm Limit brake disc thickness 3.5 mm deviation limit of the brake disc 0.10 mm thickness covering brake pads (interior) 4.5 mm Limit 0.8 mm coating thickness of the brake pads (outside) 4.5 mm Limit 0.8 mm bore...
  • Page 28   ESPECIFICACIONES DE CHASIS Spring Free Length 187.0 mm i n stal l e d l e ngth 178.0 mm spring tension K1 120.0 N / mm spri n g K1 Race 0.0-20.0 mm   Rocker Free game at the end of the swingarm (Limit axial) 2.4 mm  ...

  • Page 29: Electrical

      ESPECIFICACIONES ELÉCTRICAS   ELECTRICAL   Voltage System voltage   Ignition system Ignition system DC, CDI feed type Digital Ignition advance (B.T.D.C.) 7.0 ° / 1400r/min Coil Resistance Pulse 192-288Ù at 20 ° C   Ignition Coil Primary coil resistance 0.32-0.48Ù...
  • Page 30   ESPECIFICACIONES ELÉCTRICAS   Electric Power System System Type Constant mesh   Starter Output power 0.25 kW     Starter relay Amperage 100 A coil resistance 3.51-4.29 Ù   Horn Horn type Fl a t Amount Maxim um Amperage 1 pc 1.5 A  ...

  • Page 31: Torque

      PARES DE APRIETE   TORQUE   GENERAL OF TORQUE   This chart specifies tightening torques for standard fasteners with thread ISO normalized. torque specifications special components or assemblies mentioned in each chapter of this manual. To prevent distortion, cross-clamping sets with multiple attachment points, in progressive stages, until the specified torque.
  • Page 32   PARES DE APRIETE DE MOTOR   MOTOR TORQUE       Size Item Amount Torque Observations threa 22 Nm (2.2 m kg, 16ft Ib) Head screws (interior) 10 Nm (1.0 m kg, 7ft Ib) Head screws (side chain)   13 Nm (1.3 m.kg, 9ft.Ib) Plug  ...
  • Page 33   PARES DE APRIETE DE MOTOR         Size Item Amount Torque Observations threa 10 Nm (1.0 m.kg, 7ft.Ib) Screw crankcase 1 and 2 50 Nm (5.0 m.kg, 36ft.Ib) Kickstarter Nut   12 Nm (1.2 m.kg, 9ft.Ib) Screw guide sprocket Screw engine clutch  ...
  • Page 34   PARES DE APRIETE DE MOTOR   Sequence cylinder head tightening                     Torque Sequence magneto cover                 2.10 Tightening sequence clutch cover      ...
  • Page 35   PARES DE APRIETE DE MOTOR   Crankcase tightening sequence         2.12   3.13   A. Carter left B. Right side crankcase 2-18  ...

  • Page 36: Pares De Apriete

      PARES DE APRIETE   TORQUE     Size Item Amount Torque Observations thread 16 Nm (1.6 m kg, 12ft Ib) Screw steering column 110 Nm (11.0 m kg, 80ft Ib) Nut of the steering column 33 Nm (3.3 m.kg, 24ft.Ib)  ...
  • Page 37   PARES DE APRIETE       Size Item Amount Torque Observations thread Nut front wheel axle 60 Nm (6.0 m.kg, 43ft.Ib) Nut rear wheel axle 90 Nm (9.0 m.kg, 65ft.Ib) Screw crown and hub   clutch 43 Nm (4.3 m.kg, 31ft.Ib)  ...

  • Page 38: Lubrication Points And Lubricant Types

      PUNTOS DE LUBRICACIÓN Y TIPOS DE LUBRICANTE   LUBRICATION POINTS AND LUBRICANT TYPES     Point Lubrication Lubricant Edge oil seals Bearings O-rings Head screws and washers Thrust surface of the large end of the rod Piston, piston rings and the inner surface of the cylinder Inner surface of the balancer sprocket Camshaft Lobe Decompression cam...
  • Page 39   PUNTOS DE LUBRICACIÓN Y TIPOS DE LUBRICANTE   Point Lubrication Lubricant   Yamaha Adhesive Crankshaft Position Sensor / washer assembly stator lead No. 1215 (Three Bond No.1215R)   Yamaha Adhesive Contact surface of carcasses No. 1215 (Three Bond No.1215R)  ...
  • Page 40   PUNTOS DE LUBRICACIÓN Y TIPOS DE LUBRICANTE     Point Lubrication Lubricant Seal edges of the front wheel (left and right) Outer surface of the front wheel shaft Speed Sensor Unit Seal edges of the rear wheel hub Contact surface of the rear wheel hub Outer surface of the rear wheel axle Rear wheel axle and the threads of the nut Pivot point of the brake pedal shaft...

  • Page 41: Lubrication System Tables And Charts

      PUNTOS DE LUBRICACIÓN Y TIPOS DE LUBRICANTE   LUBRICATION SYSTEM TABLES AND CHARTS   TABLE OF ENGINE OIL LUBRICATION                                          ...

  • Page 42: Lubrication Diagrams

      PUNTOS DE LUBRICACIÓN Y TIPOS DE LUBRICANTE   LUBRICATION DIAGRAMS                                                            ...
  • Page 43   PUNTOS DE LUBRICACIÓN Y TIPOS DE LUBRICANTE   LUBRICATION DIAGRAMS                                                            ...
  • Page 44   GUIADO DE CABLES                       9 6 5                                   2-27  ...
  • Page 45   GUIADO DE CABLES     1. Front brake hose 2. Throttle Cable 3. Cable front brake switch 4. Cable right handlebar switch 5. Cable left handlebar switch 6. Clutch switch lead 7. Clutch Cable 8. Cable boot 9. Main switch lead 10.
  • Page 46   GUIADO DE CABLES                                                                          ...
  • Page 47   GUIADO DE CABLES     1. Clutch Cable 2. Overflow pipe 3. Throttle Cable 4. Cable boot 5. Carburetor vent hose 6. Magneto Cable CA 7. Negative cable 8. Breather hose battery 9. Carburetor drain hose 10. Fuel Hose 11.
  • Page 48   GUIADO DE CABLES           February 3                                                           2-31  ...
  • Page 49   GUIADO DE CABLES     Left Handlebar switches Clutch switch lead Clutch cable Cable left handlebar switch Cable Boot Main switch lead Cable right handlebar switch Brake Hose Cable front brake switch 10. Accelerator cable 11. Handlebar switches right 12.
  • Page 50   GUIADO DE CABLES                                 24 27 23 10 C 21 18 19 26 22 E               J 10 K Dec.
  • Page 51   GUIADO DE CABLES   1. Accelerator cable G. Pass the breather hose from the battery and 2. Cable sensor unit the carburetor drain hose through the engine 3. Brake Hose exterior 4. Speaker wire H. Pass the breather hose from the battery and 5.

  • Page 52: Inspections

        PERIODIC MAINTENANCE AND ADJUSTMENT     PERIODIC MAINTENANCE ..........3-1 ......Periodic maintenance and lubrication intervals ... 3-1 ADJUSTMENT valve clearance ........3-3 ENGINE IDLE ADJUSTMENT ..........3-3 .... CO measurement and adjustment ..............3-5 ADJUSTING THE THROTTLE CABLE SLACK ....3-6 SPARK PLUG INSPECTION ..........
  • Page 53     TROUBLESHOOTING       ELECTRICAL ..................3-22 INSPECTION AND CHARGING ..........3-22 ..Fuse inspection ..............3-22 BULB REPLACEMENT FAROLA ........... 3 - 22 SETTING THE BEAM BULB FAROLA ......... 3-23 AUXILIARY BULB REPLACEMENT ..........3-23 BULB REPLACEMENT TAILLIGHT / BRAKE LIGHT ..

  • Page 54: Periodic Maintenance

    All maintenance must be performed according to routine maintenance program (discussed below) to maintain the best performance of the vehicle. The items marked with an asterisk should be performed by a Yamaha dealer as they require special tools, data and technical skills.
  • Page 55   MANTENIMIENTO PERIÓDICO       READING     ODOMETER (x 1000 OR MAINTENANCE INSPECTION NOT. ELEMENT     • Check bearing for play and if the 䌮 䌮 䌮 䌮 䌮 䌮 Bearing steering for roughness direction • Lubricating grease based on Every 12000 km Fasteners •...
  • Page 56   MOTOR     MOTOR   a. Rotate the crankshaft in the opposite direction of the b. When the piston is at top dead center (TDC) of the ADJUSTING THE VALVE CLEARANCE compression stroke, align the "a" in the magnet with The following procedure applies to all valves.
  • Page 57   MOTOR 8. Assembly: Barrette Gasket head cover Head cover See "HEAD" on page 5-5   9. Assembly: Hose air induction system   Refer to "AIR INDUCTION SYSTEM" on page 6-9   10. Assemble c. Turn the adjustment screw "3" in direction "a" or "b" Fuel tank to obtain the specified valve clearance.
  • Page 58   MOTOR     3. Check: Engine idling If out of specification? Adjust. See "ENGINE IDLE ADJUSTMENT" on page 3-4.   4. Insert: Probe "2" meter CO (Calibrated) by the exhaust pipe "3", using the appropriate adapter "4"      ...
  • Page 59   MOTOR   CAUTION c. Tighten the locknut.   Do not alter carburetor adjustments, if engine performance is good. If necessary, you must register the existing settings (# of turns) mixture screw. To check the configuration of the screw c a r b u r e t o r m i x i n g , f o l l o w t h e CO adjustment procedure "...
  • Page 60   MOTOR     CHECKING THE SPARK NOTE:   Before installing the spark plug, clean the spark 1. Disconnect: Spark plug and gasket. plug     8. Connect: The spark plug cap Remov   ON INSPECTION TIME Spark NOTE:   CAUTION Before checking the ignition timing, check the  ...
  • Page 61   MOTOR       CAUTION a. Start the engine and warm it up for a few   Before removing the spark plug, clean with minutes and then leave the engine running at compressed air dirt that may have accumulated specified idle in the spark plug hole to prevent it from falling  ...
  • Page 62   MOTOR     Compression pressure (with oil applied into Type the cylinder) SAE 20W50 (Engine Oil Reading Diagnosis YAMALUBE-4 times)   Piston rings are worn or Greater than without damaged ‫וי‬   CAUTION Repair       Piston, valves, cylinder Do not allow foreign matter entering the  ...
  • Page 63   MOTOR     verification oil. If no engine oil comes out after one Assemble the new oil filter element and cover minute, turn the engine so that no damage the oil filter element. occurs.   Cover Screw oil filter element Check the engine oil passages, the oil filter element and 10 Nm (1.0 m ·...
  • Page 64   MOTOR     Tighten the locknut. Slide the rubber cover to its original position. NOTE: If the free play specified clutch cable, can not be obtained on the handlebar side, the adjusting nut used in the motor side.    ...
  • Page 65   MOTOR   CAUTION: Never run the engine without the air filter element installed. The unfiltered air will cause rapid wear of engine parts and may damage it.     NOTE:   Make sure the air filter element is properly  ...
  • Page 66   MOTOR   Check the filter of the fuel cock   Check: •Fuel pipe "1" Replace ‫וי‬ Cracks / damage                             •Fuel filter "1" Replace ‫וי‬ Contaminated / Damaged Fuel wash.
  • Page 67   CHASIS     CHECKING THE BRAKE FLUID LEVEL CHASSIS Place the vehicle on a flat surface.   NOTE: ADJUSTING THE REAR BRAKE DRUM   Place the vehicle on the center support Check: Adjust ‫וי‬ Make sure the vehicle is vertical  ...
  • Page 68   CHASIS   CHECKING THE FRONT BRAKE PADS The procedure applies to all brake pads. Apply the front brake. Check: Front brake pads Wear indicators "1" almost touching the brake disc Replace ‫ וי‬play brake pads. See "FRONT BRAKE" on page 4-20  ...
  • Page 69   CHASIS     Loosen the bleed screw. Remove: Cover the brake master cylinder "1" NOTE:   When you release the bleed screw, the pressure   will be released and cause contact with the brake   lever the throttle.    ...
  • Page 70   CHASIS     Rotate the rear wheel to find the point of NOTE: greater tension in the drive chain. To maintain proper alignment of the wheel, Check: adjusting both sides equally. Clearance transmission chain "a" OOS Adjust ‫.וי‬ Secure the axle nut with the torque wheel specified.
  • Page 71   CHASIS       Tighten the lower ring nut "4" wrench nut steering column "5". NOTE: Set the torque wrench at a right angle to the nut wrench the steering column.               Spray the lubricant within the chain between  ...
  • Page 72   CHASIS                               Assemble:   upper fork WARNING Refer to "STEERING" pressure should checked on page 4-43 corrected when the tire temperature is equal to CHECKING THE FRONT FORK room temperature.
  • Page 73 There is no guarantee on handling   characteristics that can be given if combined NOTE: tires have not been approved by Yamaha for After a tire or wheel has been changed, it must this vehicle. balance the wheel.  ...
  • Page 74   CHASIS     LUBRICATING THE BRAKE LEVER   Adjuster rear shock Lubricate the pivot point and the metal-metal YSST-821 moving parts of the lever.   Recommended lubricant Silicone Grease     LUBRICATION PEDALS Lubricate the pivot point and the metal-metal moving parts of the lever.
  • Page 75   SISTEMA ELECTRICO     ELECTRICAL 4. Remove:   • Lamp "1" lamp holder "2" INSPECTION AND CHARGING See   "ELECTRICAL COMPONENTS" on page 7-       Fuse inspection   See "ELECTRICAL COMPONENTS" on   page 7-34      ...
  • Page 76   SISTEMA ELECTRICO     Assembly: CHANGE OF LIGHT AUXILIARY •Lamp bulb The following procedure applies to the low beam Secure the new lamp bulb holder with bulb and high beam. bulb lamp Remove: CAUTION: •Side Covers (see Changing the bulb of the Avoid touching the glass part of the bulb to keep lamp) on page 3-22 it free Cembran oil, otherwise the transparency...
  • Page 77   SISTEMA ELECTRICO         TO REPLACE THE REAR LIGHT 3. Remove: • Coupler taillight "1" •Screws "2" from inside the fender                               CHANGING THE LIGHT BULB turn indicator Remove: •Screw "1"...
  • Page 78   CHASIS     GENERAL CHASSIS ASSEMBLY OF THE AIR FILTER BOX   FRONT WHEEL REMOVING THE FRONT WHEEL FRONT WHEEL DISASSEMBLY CHECKING THE FRONT WHEEL FRONT WHEEL ASSEMBLY TERA FRONT WHEEL ASSEMBLY (DISC)   REAR WHEEL 4-12 REAR WHEEL REMOVAL 4-14 CHECKING THE REAR WHEEL 4-14...
  • Page 79   CHASIS     STEERING COLUMN 4-43 LOWER BRACKET REMOVAL 4-45 VERIFICATION OF THE STEERING 4-45 COLUMN MOUNT DIRECTION N 4-45     REAR SHOCK 4-47 REMOVING THE REAR SHOCK 4-48 CHECKING THE REAR SHOCK 4-48 Rear shock mounting 4-48  ...

  • Page 80: General Chassis

      GENERAL DEL CHASIS   GENERAL CHASSIS   2 Nm (0.2 m kg, 1ft 25 Nm (2.5 m kg, 18 ft   2 Nm (0.2 m kg, 1ft   2 Nm (0.2 m kg, 1ft       7 Nm (0.7 m kg, 5ft 2 Nm (0.2 m kg, 1ft...

  • Page 81: Removing The Fuel Tank

      GENERAL DEL CHASIS   Removing the fuel tank 2 Nm (0.2 m kg, 1ft                   4 Nm (0.4 m kg, 3ft   4 Nm (0.4 m kg, 3ft   Order Procedure / Parts to remove Amount Observations  ...
  • Page 82   GENERAL DEL CHASIS     Removing the lamp and the meter   2 Nm (0.2 m kg, 1ft     2 Nm (0.2 m kg, 1ft   2 Nm (0.2 m kg, 1ft   2 Nm (0.2 m kg, 1ft  ...
  • Page 83   GENERAL DEL CHASIS     Removing the air filter full   2 Nm (0.2 m kg, 1ft                                 23 Nm (2.3 m kg, 17 ft  ...
  • Page 84   GENERAL DEL CHASIS   INSTALLING THE AIR FILTER BOX Install: • NOTE; Align the projection "a" on the air filter box with slot "b" at the junction of the air filter.                  ...

  • Page 85: Front Wheel

      RUEDA DELANTERA   FRONT WHEEL   Removing the front wheel and the brake disc           30 Nm (3.0 m kg, 22 ft           7 Nm (0.7 m kg, 5ft      ...
  • Page 86   RUEDA DELANTERA   Disassembly of the front wheel                                                   Order Procedure / Parts to remove Amount Observations Oil Seal...
  • Page 87   RUEDA DELANTERA       REMOVING THE FRONT WHEEL Place the vehicle on a flat surface.   WARNING Securely support the vehicle so there is no risk of falling.   Survey: • Front Wheel NOTE: Place the vehicle on a suitable stand so that the  ...
  • Page 88   RUEDA DELANTERA       FRONT WHEEL ASSEMBLY (DISC)   Assemble: l • front brake.   Screws front brake disc 30 Nm (3.0 m · kg, 22 ft · lb) LOCTITE ®   NOTE: Tighten the brake disc bolts in stages and in a 4.
  • Page 89   RUEDA DELANTERA   Assembly: • speed sensor   NOTE: Make sure the speed sensor and the hub of the wheel is installed with the two projections meshed into the two slots respectively.                ...
  • Page 90   RUEDA DELANTERA     4-11...

  • Page 91: Rueda Trasera

      RUEDA TRASERA   Removal of the rear wheel and the brake band carrier   July 6 90 Nm (9.0 m kg, 65 ft lb)                                ...
  • Page 92   RUEDA TRASERA   Disassembly of the rear wheel Order Procedure / Parts to remove Amount Observations Rear wheel sprocket Necklace Oil Seal Tread RWD Cube Shock rear drive hub Tread Spacer Oil Seal       For assembly, reverse the disassembly procedure.
  • Page 93   RUEDA TRASERA       REMOVING THE REAR WHEEL (DRUM) Measure: Place the vehicle on a flat surface.   Radial deflection of the wheel WARNING Windage wheel Refer to "CHECKING THE FRONT WHEEL" Securely support the vehicle so there is no risk on page 4-8 of falling.
  • Page 94   RUEDA TRASERA   NOTE: Tighten: Nut wheel axle Assemble the sprocket on the rear wheel with   the maker's mark out.   Nut wheel axle 90 Nm (8.0 m · kg, 58 ft · lb) Tighten the self-locking nuts in stages and in a  ...

  • Page 95: Freno Delantero

      FRENO DELANTERO     FRONT BRAKE   Disassembly of the front brake pads Order Procedure / Parts to remove Amount Observations Fastener brake hose Screw the front brake caliper Front Caliper Clip of brake pads Brake Pad Pin Front brake pads Spring brake  ...
  • Page 96   FRENO DELANTERO   Removing the front brake master cylinder   10 Nm (1.0 m kg, 7ft Ib)                 7 Nm (0.7 m kg, 5ft Ib)                ...
  • Page 97   FRENO DELANTERO     Disassemble the front brake master cylinder                                 Order Procedure / Parts to remove Amount Observations Smock Pushrod Spring Pin lock Complete piston Spring  ...
  • Page 98   FRENO DELANTERO     INTRODUCTION Place the vehicle on a suitable stand so that the   front wheel is lifted. WARNING Before measuring the deformation of the front The disc brake components rarely require brake disc, rotating the handlebar to the left or disassembly.
  • Page 99   FRENO DELANTERO         NOTE: Assemble the new brake pads and new brake pads spring. Securely attach clear plastic hose "1" in the bleed screw "2". Place the other end of the hose into a container.    ...
  • Page 100   FRENO DELANTERO   REMOVING THE FRONT BRAKE Disassemble dust seals and brake caliper CALIPER   NOTE:   Before disassembling the brake caliper, drain all CHECKING THE BRAKE CALIPER   the brake fluid from the brake system. Plan recommended replacement brake components Disassembly: Combination screw brake hose...
  • Page 101   FRENO DELANTERO     ASSEMBLY FRONT BRAKE CALIPER Assembly: WARNING Spring brake pads Brake pads Before installation, internal brake Caliper components should be cleaned and lubricated Fastener brake hose with a liquid cleaner or brake again.   Never solvents internal brake Assembly:...
  • Page 102   FRENO DELANTERO     CHECKING THE FRONT BRAKE MASTER Max.   CYLINDER Check: Brake Master Cylinder "1" Damage / scratches / wear R e p l a c e ‫.ו י‬ Flights distribution brake fluid "2" (Body brake caliper) Obstructed ‫...
  • Page 103   FRENO DELANTERO   Fill: Deposit brake master cylinder (with the and recommended specified amount of brake fluid)   Recommended fluid: DOT 3 or DOT 4         WARNING         Nte solame Use the recommended brake  ...
  • Page 104   FRENO DELANTERO   See "PURGING hydraulic brake system" on page 3-15.   4-25...

  • Page 105: Freno Trasero

      FRENO TRASERO   REAR BRAKE   Disassembly of the bands 10 Nm (1.0 m kl g, 7ft Brake                                            ...
  • Page 106   FRENO TRASERO   REAR BRAKE Check:     • Lining Brake Shoe   Crystallized areas ‫ וי‬Repair.   Sand crystallized areas with coarse   sandpaper.     NOTE:   After sanding crystallized surfaces, clean the   brake bands with a cloth.  ...
  • Page 107   FRENO TRASERO                                         Align the slot "c" in the lever brake camshaft   with the slot in the brake camshaft.  ...
  • Page 108   FRENO TRASERO   While pressing the brake pedal all the way down, push lever brake camshaft completely in the direction of the arrow and check that the wear indicator brake bands not wear indicator reaches the drum brake. Not enough ‫ וי‬still can be used. Reach Replace ‫...
  • Page 109   MANILLAR   HANDLEBAR   Removing the handlebar   10 Nm (1.0 m kg, 7ft • • Ib) 26 Nm (2.6 m kg, 19 ft • • Ib)                   7 Nm (0.7 m kg, 5ft •...
  • Page 110   MANILLAR   Removing the handlebar   10 Nm (1.0 m kg, 7ft • • Ib) 26 Nm (2.6 m kg, 19 ft • • Ib)               Nov. 14     7 Nm (0.7 m kg, 5ft •...
  • Page 111   MANILLAR     HANDLE REMOVAL HANDLE ASSY Place the vehicle on a flat surface Place the vehicle on a flat surface   WARNING WARNING Securely support the vehicle so there is no risk Securely support the vehicle so there is no risk of falling.
  • Page 112   MANILLAR                       Assembly: Switch front brake light "1" • Assembly: NOTE: • Clutch Cable Align the projection "a" on the left handlebar switch NOTE: with the hole "b" on the handlebars. Lubricate the clutch cable end with a thin layer of  ...
  • Page 113   MANILLAR                                 Fit: Cable free play Refer clutch • "FREE PLAY ADJUSTMENT CABLE CLUTCH" on page 3-   Free play the clutch lever 10.0-15.0 mm  ...

  • Page 114: Horquilla Delantera

      HORQUILLA DELANTERA   FRONT FORK   Removing the fork legs 25 Nm (2.5 m k • g, 18 ft • Ib) lead               25 Nm (2.5 m • k g, 18 ft • Ib)  ...
  • Page 115   HORQUILLA DELANTERA     Disassemble the front fork legs                                         Order Procedure / Parts to remove Amount Observations     The following procedure applies to both front fork legs Screw cap...
  • Page 116   HORQUILLA DELANTERA     Disassemble the front fork legs                                         Order Procedure / Parts to remove Amount Observations Outer tube  ...
  • Page 117   HORQUILLA DELANTERA     Strip the FRONT FORK   The following procedure applies to both front fork Drain: legs • Fork Oil Place the vehicle on a flat surface NOTE:   Press the outer tube several times while leaving WARNING the fork oil Securely support the vehicle so there is no risk...
  • Page 118   HORQUILLA DELANTERA   Check: NOTE: While holding the damper rod with the clip of the • Damper rod damper rod "2" and the T-wrench "3", loosen Damage / wear Replace ‫.וי‬ the damper rod. Obstructed Blow compressed air ‫ וי‬all oil passages •...
  • Page 119   HORQUILLA DELANTERA       Recommended oil Assembly tool oil seal front fork Oil suspension YSST-875 10W or equivalent       Tighten: CAUTION • Screw the damper rod "1" Be sure to assemble the oil seal with the Screw the damper rod number up.
  • Page 120   HORQUILLA DELANTERA             Assembly: Dust "1" • (With the Mounting tool seal Front fork oil "2") Assembly tool oil seal front fork YSST-875           10.Antes to measure the oil level of the fork, wait ten  ...
  • Page 121   HORQUILLA DELANTERA     WARNING Assembly: Make sure the brake hose, cable O-ring • clutch, and the cables are guided (The screw cap of the front fork) correctly. • Screw the top of the front fork • Clip   BLACK: •...
  • Page 122   COLUMNA DE LA DIRECCIÓN   STEERING   Disassembly of the steering column 110 Nm (11.0m kg, 80 ft • •     22 Nm (2.2 m kg, 16 ft • •                  ...
  • Page 123   COLUMNA DE LA DIRECCIÓN       Disassembly of the steering column 22 Nm (2.2 m kg, 16 ft • • lb)     22 Nm (2.2 m kg, 16 ft • • lb)            ...
  • Page 124   COLUMNA DE LA DIRECCIÓN   BOTTOM BRACKET REMOVAL Remove the bottom bracket bearing with a   chisel "2" and the hammer. Place the vehicle on a flat surface Install bearing races and a new coat.   WARNING CAUTION Securely support the vehicle so there is no risk If the bearing races are not installed properly, of falling.
  • Page 125   COLUMNA DE LA DIRECCIÓN   • Upper ring nut • Lockwasher Refer to "CHECKING AND ADJUSTING THE STEERING HEAD" on page 3-18 Assemble: • Upper Bracket • Nut of the steering column   Assemble: • Front fork bars Refer to "FRONT FORK"...

  • Page 126: Amortiguador Trasero

      AMORTIGUADOR TRASERO   REAR SHOCK   Removing the rear shock                             60 Nm (6.0 m kg, 43 ft • •              ...
  • Page 127   AMORTIGUADOR TRASERO   REMOVING THE REAR SHOCK Place the vehicle on a flat surface   WARNING Securely support the vehicle so there is no risk of falling.   NOTE: Place the vehicle on a suitable stand so that the rear wheel is elevated.  ...
  • Page 128   BASCULANTE   TILTING   Removing the rocker     60 Nm (6.0 m kg, 43 ft • •   10 Nm (1.0 m kg, 7 ft • •                        ...
  • Page 129   BASCULANTE   Removing the rocker   60 Nm (6.0 m kg, 43 ft • •   10 Nm (1.0 m kg, 7 ft • •                              ...
  • Page 130   BASCULANTE     SWINGARM REMOVAL WARNING   Place the vehicle on a flat surface Do not attempt to straighten the pivot axis.   WARNING Securely support the vehicle so there is no risk of falling.   NOTE: Securely support the vehicle so there is no risk of falling.
  • Page 131   BASCULANTE         to 121st             Rocker Left Right side                         Assembly: • Rear Shock • • Rear Wheel See section "SHOCK BACK "on page 4-47 and"...

  • Page 132: Drive Chain

      CADENA DE TRANSMISIÓN   DRIVE CHAIN   Removing the drive chain                                                         10 Nm (1.0 m kg, 7 ft •...
  • Page 133   CADENA DE TRANSMISIÓN   CHECKING THE DRIVE CHAIN   Measure: 15 links of the drive chain • OOS Replace ‫ וי‬the chain.   Link length limit of 15 191.5 mm     Measure the length "a" between the inner faces of the roller and the length "b"...
  • Page 134   CADENA DE TRANSMISIÓN     Check: Gear • Refer to "REAR WHEEL" on page 4-12   ASSEMBLY DRIVE CHAIN Lubricate: Drive chain •   Recommended lubricant chain lubricant suitable for O-ring chains   Assemble: • Drive chain • Drive sprocket Retention of the drive sprocket •...
  • Page 135   MOTOR     ENGINE REMOVAL ENGINE MOUNTING CHANGES Arm Mount   HEAD REMOVING THE HEAD HEAD INSPECTION GEAR INSPECTION AND DISTRIBUTION GUIDE TO THE TIMING CHAIN INSPECTION OF TENSION DISTRIBUTION CHAIN INSPECTION SYSTEM DECOMPRESSION CYLINDER ASSEMBLY   CAMSHAFT 5-12 REMOVING THE ROCKER ARMS AND CAMSHAFT 5-13 CAMSHAFT INSPECTION...
  • Page 136       CLUTCH 5-35 CLUTCH REMOVAL 5-38 INSPECTION OF RECORDS OF FRICTION 5-38 CHECKING THE CLUTCH PLATES 5-38 CHECKING THE CLUTCH SPRINGS 5-39 INSPECTION Caddy 5-39 INSPECTION OF PRESSURE PLATE 5-39 CHECKING THE CLUTCH PUSH LEVER SHORT AND PUSH ROD 5-39 PRIMARY DRIVE GEAR INSPECTION 5-39...
  • Page 137       CRANKSHAFT 5-58 Remove Crankshaft 5-59 CRANKSHAFT INSPECTION 5-59 CRANKSHAFT ASSEMBLY 5-59   TRANSMISSION 5-61 CHECKING THE SHIFT FORKS 5-64 CHANGE DRUM INSPECTION 5-64 Transmission Inspection 5-64 MOUNT push rods 5-65 MAIN SHAFT ASSEMBLY AND DRIVE SHAFT 5-65 FITTING THE DRUM FORKS AND CHANGES 5-65...

  • Page 138: Desmontaje Del Motor

      DESMONTAJE DEL MOTOR   ENGINE REMOVAL   Muffler Removal                                       12 Nm (1.2 m kg, 9 ft • •      ...
  • Page 139   DESMONTAJE DEL MOTOR   Disconnect cables and connectors                                             10 Nm (1.0 m kg, 7 ft • • 10 Nm (1.0 m kg, 7 ft •...
  • Page 140   DESMONTAJE DEL MOTOR     Engine removal 30 Nm (3.4 m kg, 22 ft • •                                           55 Nm (5.5 m kg, 40 ft •...
  • Page 141   DESMONTAJE DEL MOTOR       ENGINE MOUNTING ARM ASSEMBLY OF CHANGES   1. Urge: 1. Install: • Motor "1" • changes Arm "1"   •Motor mounting screw (upper side) "2"   •Motor mounting nut (rear upper side) "3" Screw changes arm •Motor mounting screw (rear lower side) "4"...
  • Page 142   CULATA   HEAD   Removing the cylinder head 22 Nm (1.0 m kg, 16 ft • •   10 Nm (1.0 m kg, 7 ft 13 Nm (1.3 m kg, 9 ft 8 Nm (0.8 m kg, 6 ft •...
  • Page 143 Tensor distribution chain Tensioner Gasket chain Camshaft sprocket Decompression cam Butt Cylinder head gasket Dowel pin Guide the distribution chain (exhaust side)       For assembly, reverse the disassembly procedure. Yamaha Adhesive No. 1215 (Three Bond No. 1215)  ...
  • Page 144   CULATA   REMOVING THE HEAD 1. Align: "I" in the magneto rotor "a" • The brand (With the stationary mark "b" on the cover Magneto) Turn the crankshaft counterclockwise. When the piston is in neutral   higher (PMS) on the compression stroke, Remove: align the "I"...
  • Page 145   CULATA     Check:   Butt. • ¼ tooth → Replace. Damage / scratches Correct Water jacket of the cylinder head • Contact roller chain Mineral deposits oxide / ‫ וי‬Delete. Camshaft sprocket Measure: Check: •Deformation of the cylinder head. Guide chain •...
  • Page 146   CULATA   INSPECTION SYSTEM DECOMPRESSION   1. Check: • Decompression System a. Check the decompression system with camshaft sprocket and the decompression cam installed on the camshaft. b. Check that the decompression lever "1" moves smoothly.   c. Without operate the decompression lever, check that the decompression cam "2"...
  • Page 147   CULATA   Align the "I" of the timing sprocket "c" with the tighten the tensioner timing chain "3" to the stationary mark "d" on the plate holding the specified torque. camshaft. Screws chain tensioner distribution Install the timing chain on the sprocket 9 Nm (0.9 m ·...
  • Page 148   CULATA                     Tighten: • Screw camshaft sprocket   Screw camshaft sprocket 20 Nm (2.0 m · kg, 14 ft · lb)     PRCAUCIÓN Be sure to tighten the screw on the camshaft sprocket with the specified torque to avoid the possibility that...
  • Page 149   ÁRBOL DE LEVAS   CAMSHAFT   Removing the rocker arms and camshaft 22 Nm (2.2 m kg, 16 ft • •   10 Nm (1.0 m kg, 7 ft • •   13 Nm (1.3 m kg, 9 ft •...
  • Page 150   ÁRBOL DE LEVAS     REMOVING THE ROCKER ARMS AND Dimensions of the camshaft CAMSHAFT lobes   Loosen: Admission • Locknut "1" 31342-31442 mm • Adjustment screw valve clearance "2" Limit • Rocker "3" 31,342 mm   Admission B  ...
  • Page 151   INSPECCIÓN DEL ÁRBOL DE LEVAS       Check: Clearance between the rocker • Rocker Shaft arm and rocker aje Blue discoloration / pitting excessive wear / scratches Replace ‫ וי‬to verify 0009-0034 mm Limit lubrication system. 0.08 mm Measure:  ...

  • Page 152: Valves And Valve Springs

      VÁLVULAS Y RESORTES DE VÁLVULAS   VALVES AND VALVE SPRINGS   Removing the valves and valve springs   6New                         Order Procedure / Parts to remove Amount Observations  ...
  • Page 153   VÁLVULAS Y RESORTES DE VÁLVULAS       REMOVING THE VALVES NOTE: The following procedure applies to all valves and Identify the position of each part very carefully so that it can be reinstalled in its original place. related components.  ...
  • Page 154   VÁLVULAS Y RESORTES DE VÁLVULAS     Delete: CHECKING THE VALVE SEATS Carbon deposits • (From the valve face and valve seat) The following procedure applies to all valves and valve seats. Check: Delete: Valve face • Pitting / wear Rectify ‫ וי‬face Carbon deposits •...
  • Page 155   VÁLVULAS Y RESORTES DE VÁLVULAS   Grind: • Valve face • Valve Seat NOTE: After replacing the head or replace the valve and the valve guide, should be lapped the valve seat and valve face     Apply lapping compound secondary  ...
  • Page 156   VÁLVULAS Y RESORTES DE VÁLVULAS         Tilting the compression Free length (Admission)   spring (Admission) 39.40 mm   2.5 ° / 1.7 mm Tilting the compression   Limit spring (Escape)   37.40 mm 2.5 ° / 1.7 mm  ...
  • Page 157   VÁLVULAS Y RESORTES DE VÁLVULAS     • Seal valve stem "2"   • Valve "3" Valve spring "4" •   • Upper spring seat valve "5" (in the butt)   NOTE:     • Ensure that each valve is installed in its original  ...

  • Page 158: Cylinder And Piston

      CILINDRO Y PISTÓN   CYLINDER AND PISTON   Removing the cylinder and piston                                     Order Procedure / Parts to remove Amount Observations Butt See "HEAD"...
  • Page 159   CILINDRO Y PISTÓN       REMOVAL cylinder and piston   Remove: • Piston pin "1" Piston pin "2" • • Piston "3"   CAUTION Do not use a hammer to remove the piston pin   NOTE: • Before removing the piston pin, cover the  ...
  • Page 160   CILINDRO Y PISTÓN     "C" = maximum of D1-D2 CHECKING THE PISTON RINGS Measure: "T" = maximum of D1 or D2 - Up to D5 or D6 • Ring Side Clearance OOS R e p l a c e ‫ ו י‬piston "R"...
  • Page 161   CILINDRO Y PISTÓN   Measure: Measure: • Inner diameter of the piston pin hole "a" Out of specification Replace piston ‫וי‬ • Distance between centers of rings OOS R e p l a c e ‫ ו י‬the   piston rings.
  • Page 162   CILINDRO Y PISTÓN         120 °         120 ° 120 °       90 º     d 45 ° 45 º   Install: Top Ring • Piston "1" Oil ring expander •...
  • Page 163   MAGNETO Y EMBRAGUE DEL ARRANQUE   MAGNETO AND STARTER CLUTCH   Removing the magneto and starter clutch       10 Nm (1.0 m kg, 7ft   10 Nm (1.0 m kg, 7ft 7New            ...
  • Page 164   MAGNETO Y EMBRAGUE DEL ARRANQUE   Removing the magneto and starter clutch     10 Nm (1.0 m kg, 7ft   10 Nm (1.0 m kg, 7ft           14 Nm (1.4 m kg, 10 ft  ...
  • Page 165   MAGNETO Y EMBRAGUE DEL ARRANQUE   MAGNETO REMOVAL Remove: •Magneto rotor nut Washer • NOTE: •While holding the magneto rotor using the rotor magnet holder "1", loosen the rotor magnet.   STARTER CLUTCH REMOVAL Remove: •Starter clutch bolts "1" NOTE: •While holding the rotor magnet with magnet holder, remove the starter clutch bolts "1"...
  • Page 166   MAGNETO Y EMBRAGUE DEL ARRANQUE     NOTE: • While holding the rotor magnet, tighten the starter clutch "1". Mark end "A" of each screw • starter clutch.     Check: Freewheel starter clutch • • Starter Clutch Sprocket Burrs / chips / roughness Replace ‫וי‬...
  • Page 167       2.10       Apply: • Sealant (In the crankshaft position sensor / the buttonhole for mounting the stator wire)   Yamaha Adhesive No. 1215 TG-1215                      ...

  • Page 168: Electric Start

      ARRANQUE ELÉCTRICO   ELECTRIC START   Removing the starter motor       2 Nm (0.2 m kg, 1ft • • Ib)     10 Nm (1.0 m kg, 7ft • • Ib)              ...
  • Page 169   ARRANQUE ELÉCTRICO     Disassemble the starter                                       Order Procedure / Parts to remove Amount Observations Starter Cover Package Set of carbon brushes Support carbon brushes Oil Seal Pin lock...
  • Page 170   ARRANQUE ELÉCTRICO     NOTE: STARTER REMOVAL To ensure proper operation of the switch must be lowered mica. Remove: • Starter "1" • Motor front cover start / brush holder assembly "2"   NOTE: Before disassembling the starter, make alignment marks "a"...
  • Page 171   ARRANQUE ELÉCTRICO             Check: Pinion Teeth • Damage / wear Replace ‫ וי‬pinion. Check: • Tread • Oil Seal Damage / wear Replace ‫ וי‬cover front starter / brush holder assembly STARTER ASSY Install: Front cover starter / •...
  • Page 172   EMBRAGUE   CLUTCH   Removing the clutch cover   9 Nm (0.9 m kg, 7ft • • Ib)                                           10 Nm (1.0 m kg, 7ft 10 Nm (1.0 m...
  • Page 173   EMBRAGUE   Clutch Removal   70 Nm (7.0 m kg, 51 ft lb)         8 Nm (0.8 m kg, 6ft Ib)                 Order Procedure / Parts to remove Amount Observations Locknut Clutch Spring...
  • Page 174   EMBRAGUE   Removing the push lever             3New     4New   Order Procedure / Parts to remove Amount Observations Clutch Refer to "CLUTCH" on page 5-35   Clutch thrust lever Spring clutch push lever Pin lock Oil Seal Tread...
  • Page 175   EMBRAGUE   CLUTCH REMOVAL   Straighten the lock washer. Loosen: • The clutch disc holder nut "1" NOTE: While holding the tray clutch "2" with the clutch holder "3", loosen the nut on the clutch disc holders.   Clutch Holder YSST-733  ...
  • Page 176   EMBRAGUE         Thickness of clutch discs     1.85-2.15 mm   Strain Limit   0.20 mm               Check: • Tread Damage / wear Replace ‫ וי‬bearing and the clutch.   CLUTCH INSPECTION caddy CHECKING THE CLUTCH SPRINGS Check:...
  • Page 177   EMBRAGUE   Check: NOTE: • Primary drive gear Make sure the corners with sharp edges of the thrust Damage / wear Replace ‫ וי‬gear washer "a" is placed opposite the clutch disc primary drive and clutch as a whole. holders.
  • Page 178   EMBRAGUE                             Fold the tab washer along a flat side of the nut. Fit: Lubricate: Free play of the clutch mechanism • • Friction Plates   Clutch discs •...
  • Page 179   EMBRAGUE   Install: Oil Seal "1" • Oil Seal "2" •                                         Install: • Clutch cover   Clutch cover screw 10 Nm (1.0 m ·...

  • Page 180: Bomba De Aceite

      BOMBA DE ACEITE   OIL PUMP   Removing the oil pump                                             4 Nm (0.4 m kg, 3ft •...
  • Page 181   BOMBA DE ACEITE   Disassembly of the oil pump                                               Order Procedure / Parts to remove Amount Observations Housing cover oil pump Primary driven gear oil pump...
  • Page 182   BOMBA DE ACEITE     CHECKING THE OIL PUMP Clearance between the inner Check: rotor and the outer rotor Primary drive gear oil pump • Less than 0.15 mm Primary driven gear oil pump • Limit • Pump housing oil 0.20 mm Cracks / damage / wear Replace ‫...
  • Page 183   BOMBA DE ACEITE                   Check: • Operation of the oil pump Refer to "CHECKING THE OIL PUMP" on page 5-   MOUNT OIL PUMP Install: • Oil pump   Screw oil bulges 4 Nm (0.4 m ·...

  • Page 184: Shift Shaft

      EJE DE CAMBIOS   SHIFT SHAFT   Removing the shift shaft and lever stop                                               9 Nm (0.9 m kg, 7ft •...
  • Page 185   EJE DE CAMBIOS   SHIFT SHAFT INSPECTION Check: • Axis of changes Curves / damage / wear Replace ‫.וי‬ • Changes shaft spring Damage / wear Replace ‫.וי‬     INSPECTION STOP LEVER Check: • Lever cap Curves / damage Replace ‫.וי‬ Roller turns roughly Replace ‫...
  • Page 186   PIÑÓN DEL BALANCEADOR   BALANCER SPROCKET   Removing the balancer sprocket and primary drive gear                                           60 Nm (6.0 m kg, 43 ft •...
  • Page 187   PIÑÓN DEL BALANCEADOR   Removing the balancer sprocket and primary drive gear                                         60 Nm (6.0 m kg, 43 ft •...
  • Page 188   PIÑÓN DEL BALANCEADOR   BALANCER SPROCKET ASSEMBLY PRIMARY BALANCER DRIVEN   GEAR Loosen: Assembly: Primary drive gear nut "1" Dowel pin "1" • • Springs "2" • NOTE: Place a sheet of leather or a leather "a" between (With the glass ceiling) the primary drive gear anceador bal "2"...
  • Page 189   PIÑÓN DEL BALANCEADOR             Fold the tab washer along a flat side of the nut.               Tighten: Nut primary balancer driven gear • "1" Primary drive gear "2" •...

  • Page 190: Crankcase Separation

      CÁRTER   CARTER   Crankcase separation     10 Nm (1.0 m kg, 7 ft • •   10 Nm (1.0 m kg, 7 ft • •                          ...
  • Page 191   CÁRTER   Crankcase separation   kg, 7 ft 10 Nm (1.0 m • •   10 Nm (1.0 m kg, 7 ft • •                 10 Nm (1.0 m kg, 7 ft •...
  • Page 192   CÁRTER   Dismantling of bearings and oil seals               7 Nm (0.7 m kg, 5 ft • •                     Order Procedure / Parts to remove Amount Observations See "Crankshaft"...
  • Page 193   CÁRTER   CRANKCASE SEPARATION CAUTION Tap on one side of the pan with a soft-faced Remove: hammer. Tap reinforced only on portions of the Crankcase Bolts • crankcase, not the contacting surfaces of the crankcase. Work slowly and carefully and make NOTE: sure the pan is separated into halves evenly.
  • Page 194 Clean all contact surfaces of the seals and   crankcase. Apply:   •Sealant (On the crankcase mating surfaces)     Yamaha Adhesive No. 2.12 1215   3.13 NOTE:   Do not allow product to come in contact   with the oil passage.
  • Page 195   CIGÜEÑAL   CRANKSHAFT   Remove Crankshaft and balancer                                   Order Procedure / Parts to remove Amount Observations     Refer to "CRANKCASE" on page Sump 5-53 Balancer...
  • Page 196   CIGÜEÑAL       Remove Crankshaft Remove: • Crankshaft "1" NOTE: • Remove the crankshaft with the tool to remove the crankshaft "2". • Be sure to remove the tool crankshaft is centered on the crankshaft.   CAUTION Measure: •...
  • Page 197   CIGÜEÑAL                               CAUTION To avoid scratching the crankshaft and to facilitate the process, assembly, lubricate the edges of oil seals with grease lithium soap base and each bearing with engine oil.
  • Page 198   TRANSMISIÓN   TRANSMISSION   Removing the transmission, the shift drum and changes forks                                     Order Procedure / Parts to remove Amount Observations Refer to "CRANKCASE"...
  • Page 199   TRANSMISIÓN     Disassembly of the main shaft                                           Order Procedure / Parts to remove Amount Observations Second Pinion Fifth gear Sprocket third Pin lock...
  • Page 200   TRANSMISIÓN     Drive Shaft Disassembly                                 Order Procedure / Parts to remove Amount Observations Pin lock   Washer Second gear Fifth Gear Washer First gear Necklace Washer...
  • Page 201   TRANSMISIÓN   CHECKING THE SHIFT FORKS DRUM INSPECTION OF CHANGES Check: Grooves changes in the drum The following procedure applies to all changes Damage / scratches / wear Replace ‫וי‬ forks. the drum changes. Check: The drum segment changes "1" Damage / wear Cam pin fork changes "1"...
  • Page 202   TRANSMISIÓN   MAIN SHAFT ASSEMBLY AND DRIVE SHAFT Install: Toothed washer "1" Pin lock "2" NOTE: Be sure to install the lock pin so that its sharp edge "to" be back to the ring gear and the gear. Check: Make sure the ends of the pin lock Transmission gears "B"...
  • Page 203   TRANSMISIÓN   NOTE: The markings on the shift forks should be facing the right side of the engine and be in the following sequence: "R", "C", "L".                         Check: Transmission Rough movement ‫...

  • Page 204: Fuel System

            FUEL SYSTEM     CARBURETOR CARBURETOR REMOVAL CARBURETOR DISASSEMBLY CARBURETOR INSPECTION CARBURETOR ASSY CARBURETOR ASSEMBLY MEASURING AND ADJUSTING THE FUEL BLE INSPECTION FUEL WRENCH       AIR INDUCTION SYSTEM AIR INDUCTION SYSTEM REMOVAL AIR INDUCTION SYSTEM 6-10 INSPECTION SYSTEM AIR INDUCTION 6-11...
  • Page 205   CARBURADOR   CARBURETOR   Disassembling the carburetor Order Procedure / Parts to remove Amount Observations     Seat, side covers 1 & 2, fuel hose Refer to "GENERAL CHASSIS" on page 4-1   Fuel overflow hose Disconnect     Fuel Hose  ...
  • Page 206   CARBURADOR   Disassemble the carburetor     Order Procedure / Parts to remove Amount Observations   Disassemble the carburetor Remove the parts in the order listed   Diaphragm cover Diaphragm spring   Needle Valve   Piston valve Diaphragm   Ring Drain bolt  ...
  • Page 207   CARBURADOR   Disassemble the carburetor                                                                 Order Procedure / Parts to remove Amount Observations  ...
  • Page 208   CARBURADOR   Disassemble the carburetor                                                                      ...
  • Page 209   CARBURADOR     CARBURETOR DISASSEMBLY 4.Verificar: Camera body float "1" Dirt - Clean. • Check:   •Carburetor Body "1"   •Float chamber "2" Accommodation supplier "3" • Cracks / damage-Replace.     5.Verificar: Rubber gasket float chamber "1" • Cracks / damage / wear - Replace.
  • Page 210   CARBURADOR       8. Check: • Filter mesh "1" Damaged / Replace clogged ----               9. Check: • Main jet "1" / accommodation supplier "2" / O-ring "3" / main nozzle "4" Damage / obstruction - Replace  ...
  • Page 211   CARBURADOR           2.Install: Install: • mixture screw "1" • Float "1" • Filter mesh "2" • Float Pin "2"   • Screw "3"   • Packaging of the float chamber "4"   • Float chamber "5"  ...
  • Page 212   CARBURADOR     6. Install: • Diaphragm Spring "1" • Cover the Iris "2", tighten the screws                               2.Ajustar:   Fuel Level •     CARBURETOR ASSEMBLY a.
  • Page 213   SISTEMA DE INDUCCIÓN DE AIRE   AIR INDUCTION SYSTEM                                                              ...
  • Page 214   SISTEMA DE INDUCCIÓN DE AIRE   Removing the air induction system                 Order Procedure / Parts to remove Amount Observations       Seat, side cover Side cover 1 & 2 Refer to "GENERAL CHASSIS" on page 4-1  ...
  • Page 215   SISTEMA DE INDUCCIÓN DE AIRE     Cracks / damage Replace ‫.וי‬ INSPECTION SYSTEM AIR INDUCTION 3-way junction • Air injection Cracks / damage Replace ‫.וי‬ The air induction system of burning the unburnt Check: exhaust gases by injecting fresh air (secondary •...
  • Page 216   SISTEMA DE INDUCCIÓN DE AIRE       Air Switching Valve Replace valve opens air cutting. Air shutoff valve closed The air cut valve is OK                            ...
  • Page 217     ELECTRICAL     IGNITION SYSTEM CIRCUIT DIAGRAM TROUBLESHOOTING   ELECTRIC STARTING SYSTEM CIRCUIT DIAGRAM OPERATION starter cut TROUBLESHOOTING   CHARGING SYSTEM 7-11 CIRCUIT DIAGRAM 7-11 TROUBLESHOOTING 7-13   LIGHT SYSTEM 7-14 CIRCUIT DIAGRAM 7-14 TROUBLESHOOTING 7-16   SIGNAL SYSTEM 7-17 CIRCUIT DIAGRAM 7-17...
  • Page 218         G BL       B Br R   W - W (BLACK) R CRK + IG                     LY G               W W BL LY 26 START STOP...

  • Page 219: Sistema De Encendido

      SISTEMA DE ENCENDIDO         1. Magneto CA 3. Unit Regulator / Rectifier 4. Main fuse 5. Battery 6. Main switch 7. CDI Unit 8. Ignition Coil 19. TPS 20. Plug 21. Cable Positive + 22. Negative cable - 30.
  • Page 220   SISTEMA DE ENCENDIDO     TROUBLESHOOTING   The ignition system is not working (no spark or intermittent spark).   NOTE: • Before troubleshooting, remove the following parts: Seat Side cover 1 and 2 Fuel tank       Check the fuse.  ...
  • Page 221   SISTEMA DE ENCENDIDO       The engine stop switch is faulty. Check the engine stop switch. See the "Verifying SWITCHES" on page   Replace the switch 7-30.   㻚 right handlebar   OK t          ...
  • Page 222         G BL       B Br R   W - W (BLACK) R CRK + IG                     LY G               W W BL LY 26 START 30 LIGHT...
  • Page 223   SISTEMA DE ARRANQUE ELÉCTRICO     2. Neutral switch 4. Main fuse 5. Battery 6. Main switch 21. Cable Positive + 22. Negative cable - 23. Starter relay 24. Starter 26. Start switch 27. Starter cut relay 28. Clutch switch 30.
  • Page 224   SISTEMA DE ARRANQUE ELÉCTRICO   SYSTEM OPERATION START CIRCUIT COURT   If the engine cutoff switch is set to "" and the ignition switch is positioned to "ON" (both switches are closed), the starter may work if one of the following conditions is served: •...
  • Page 225   SISTEMA DE ARRANQUE ELÉCTRICO   a. When the transmission is in neutral b. When the lever is pulled CLUTCH HANDLEBAR 1. Battery 2. Fuse 3. Main switch 4. Engine stop switch 5. Starter cut relay 6. Clutch switch 7. Neutral switch 8.
  • Page 226   SISTEMA DE ARRANQUE ELÉCTRICO   TROUBLESHOOTING The starter does not turn.   NOTE: • Before troubleshooting, remove the following parts: Seat Side cover 1 and 2       Check the fuse.   Replace the fuse. See "Checking the Fuse" on page 7-34.  ...
  • Page 227   SISTEMA DE ARRANQUE ELÉCTRICO       Check the engine stop switch. See the The engine stop switch is faulty. "Verifying SWITCHES" on page 7-30.   Replace r i n t e r u p t o r OK t  ...
  • Page 228         G BL     B Br R   W - W (BLACK) R CRK + IG                     LY G               W W BL LY 26 START 30 LIGHT STOP...

  • Page 229: Sistema De Carga

      SISTEMA DE CARGA   1. Magneto CA 3. Regulator / rectifier 4. Main fuse 5. Battery 21. Cable Positive + 22. Negative cable -   7-12...
  • Page 230   SISTEMA DE CARGA   TROUBLESHOOTING The battery is not charging. NOTE: • Before troubleshooting, remove the following parts: Seat Panel on the left side / side cover.     Check the fuse.   Replace the fuse See "Checking the Fuse" on page 7-34  ...
  • Page 231         G BL     B Br R   W - W2 (BLACK) R CRK + IG                       BL G LY              ...
  • Page 232   SISTEMA DE LUCES     4. Main fuse 5. Battery 6. Main switch 13. Meter 15. Streetlight 18. Taillight 21. Cable Positive + 22. Negative cable - 31 Light Switch 34. Light switch...
  • Page 233   SISTEMA DE LUCES   TROUBLESHOOTING Any of the following lights fails: Street Light, light beam indicator, tail light, auxiliary light or light meter. NOTE: • Before to solve problems, remove the following parts: 1. Seat 2. One side cover and side cover 2 3.
  • Page 234               B Br R     W - W ( B L A C K ) R CRK + IG                     LY G      ...
  • Page 235   SISTEMA DE SEÑALIZACIÓN   2. Neutral switch 4. Main fuse 5. Battery 6. Main switch 7. CDI 9. Horn 10. Relay turn signal 11. Front brake switch 12. Rear brake switch 13. Meter 16. Front turn indicator light (LH) 17.
  • Page 236   SISTEMA DE SEÑALIZACIÓN   TROUBLESHOOTING • Any of the following fault lights: turn indicator lights, brake light or indicator lights. • The horn does not sound. • The fuel gauge does not work.   NOTE: • Before troubleshooting, remove the following parts: 1.
  • Page 237   SISTEMA DE SEÑALIZACIÓN     Check the wiring of the signaling system.   Connect or repair wiring 㻚 signaling See section "CIRCUIT DIAGRAM" on system page 7-17. The system circuit is OK 㻚       The brake light / rear does not light.  ...
  • Page 238   SISTEMA DE SEÑALIZACIÓN     3.Verificar switch indicator light turn. The horn switch is faulty. Replace the See the "Verifying SWITCHES" on   switch left page 7-30.   Handlebar 㻚       4.Verificar r e l a y s h i f t i n d i c a t o r  ...
  • Page 239   SISTEMA DE SEÑALIZACIÓN       2.Check the signaling system wiring. Connect or repair wiring 㻚 signaling See section "CIRCUIT DIAGRAM" on page 7-17. system Replace the meter 㻚 . 7-22  ...
  • Page 240   FUNCIÓN DE AUTO-DIAGNÓSTICO   SELF-DIAGNOSIS FUNCTION The vehicle is equipped with a self-diagnostic function. If this function detects a malfunction in the system, immediately operate the engine under substitute characteristics and illuminates the warning light Engine trouble to alert the driver that a fault has occurred in the system. Once it has detected a malfunction, an error code will be stored in the memory of CDI.
  • Page 241   FUNCIÓN DE AUTO-DIAGNÓSTICO   FAULT CODE TABLE       Can / can Can / Fault Item Symptom not boot can not Code drive     Throttle Position Sensor Throttle position sensor: You can (Open or short) open or short circuit detected.  ...
  • Page 242   FUNCIÓN DE AUTO-DIAGNÓSTICO   TROUBLESHOOTING DETAILS   This section describes the steps to the fault code number displayed on the meter. Check and service elements or components that are the likely cause of the failure.       Symptom throttle position sensor: open or short circuit detected Fault Code No.
  • Page 243   FUNCIÓN DE AUTO-DIAGNÓSTICO           Fault Code No. The throttle position sensor is attached Component: Throttle Position Sensor   Element / components and Method Order Check or maintenance job probable cause reintegration Condition sensor assembly Arran •...
  • Page 244   FUNCIÓN DE AUTO-DIAGNÓSTICO       Symptom: The signals received from the speed sensor is not normal.   Component: Vehicle Speed Sensor   Element / components and Method Order Check or maintenance job probable cause reintegration Condition sensor assembly S t a r t t h e •...

  • Page 245: Electrical Components

      COMPONENTES ELÉCTRICOS   ELECTRICAL COMPONENTS                                                                      ...
  • Page 246   COMPONENTES ELÉCTRICOS   1. Front brake switch 2. Fuel Gauge 3. Starter cut relay 4. CDI Unit 5. Main switch 6. Horn 7. Starter relay 8. Neutral switch 9. Rear brake switch 10. Battery 11. Regulator / rectifier 12. Fuse 13.

  • Page 247: Switch Inspection

      COMPONENTES ELÉCTRICOS   SWITCH INSPECTION 1234   R / B   (BLACK) B R Br Br YY   (RED)                                          ...
  • Page 248   COMPONENTES ELÉCTRICOS     1. Clutch switch 2. Main switch 3. Front brake switch 4. Rear brake switch 5. Neutral switch 6. Switch turn signal 7. Horn switch 8. Light switch 9. Light Switch step 10. Engine stop switch 11.
  • Page 249   COMPONENTES ELÉCTRICOS   Check continuity of each switch with the multimeter. If the continuity reading is incorrect, check the connections, and if necessary, replace the switch. CAUTION: Never insert the tester probes into the slots of the coupling terminal "a". Always insert probes for the opposite end of the coupler, being careful not to loosen or damage the cables.
  • Page 250   COMPONENTES ELÉCTRICOS   CHECKING THE BULBS AND SOCKETS WARNING OF BULBS Since the streetlight bulbs get very hot, keep Check each bulb and bulb socket for damage or wear, flammable products and your hands away from proper connections and continuity between terminals. them until they have cooled.
  • Page 251   COMPONENTES ELÉCTRICOS     Checking the condition of the bulbs sockets   The following procedure applies to all of the light a. Set the main switch to "OFF". bulb sockets. b. Install a new fuse of the correct amperage. c. 1.
  • Page 252   COMPONENTES ELÉCTRICOS     INTERNA   Example • Drink plenty of water or milk followed by milk Open circuit voltage = 12.0 V Charging of magnesia, beaten egg or vegetable oil. Get = 5-10 hours time Charging the immediate medical attention. = 20-30% battery  ...
  • Page 253   COMPONENTES ELÉCTRICOS       WARNING     Do not charge a battery quickly.     Charging method with a charger CAUTION: (voltage) variable Do not use a battery charger quick charge, a. Measuring the open circuit voltage prior to and requiring a high amperage in the battery charging.
  • Page 254   COMPONENTES ELÉCTRICOS       Check:   •Battery terminals Charging method with a constant voltage Sulfation → Clean with hot water. Loose charger connection Connect ‫ וי‬correctly. Measure the open circuit voltage, before Lubricate: loading. •Battery terminals NOTE:   Recommended lubricant The voltage should be measured after 30 Dielectric grease...
  • Page 255   COMPONENTES ELÉCTRICOS   b. Turn the ignition switch to "ON". Starter cut relay c. Measure the input voltage signal relay of rotation.   Output voltage relay turn signal 12 V 2. Check: LB RB   • The output voltage relay turn signal. OOS Replace ‫.וי‬...
  • Page 256   COMPONENTES ELÉCTRICOS     VERIFICATION plug cap a. Disconnect connectors of the ignition coil, the   terminals of the ignition coil. 1.Check: b. Connect the multimeter (Ù × 1) to the ignition • plug cap resistance OOS Replace ‫.וי‬ coil, as shown.
  • Page 257   COMPONENTES ELÉCTRICOS   • Positive tester probe ‫וי‬ Sensor check crankshaft position High voltage cable 1 .. Disconnect: • Negative tester probe ‫וי‬ • Coupling crankshaft position sensor land (From the wire harness)     2.Check:   • Reliability of crankshaft position sensor  ...
  • Page 258   COMPONENTES ELÉCTRICOS   a. Connect the positive battery terminal "1" and the starter cable "2" with a jumper wire "3". WARNING • The cable used for the bridge must have at least the same capacity of the cable battery, otherwise, the jumper cable may be burned.
  • Page 259   COMPONENTES ELÉCTRICOS       CHECKING THE FUEL GAUGE   1. Remove:   • Fuel Tank SPEAKER VERIFICATION 2. Remove: 1.Check: • Fuel Gauge • Resistance of the horn OOS Replace ‫וי‬     3. Check: Coil Resistance • Resistance fuel gauge OOS Replace ‫...
  • Page 260   COMPONENTES ELÉCTRICOS   CHECKING THE THROTTLE POSITION SENSOR CHECKING THE SPEED SENSOR 1. Check: Check: • Throttle Position Sensor • Voltage output speed sensor OOS Replace ‫.וי‬   a. Connect the digital circuit tester to the terminals   of the throttle sensor body, as shown. Reading cycle of the output voltage •...
  • Page 261   TROUBLESHOOTING       TROUBLESHOOTING GENERAL INFORMATION Misfires INCORRECT ENGINE IDLE Poor performance in medium and high speed GEAR FAILURE ELBCIAOMDE SHIFT PEDAL DOES NOT MOVE JUMPING GEARS CLUTCH FAILURE OVERHEATING Supercooling PERFORMANCE POBREFREENNEALDO FAILURE HORQEULILALNATEDRA UNSTABLE HANDLING FAILURE OF LIGHTING SYSTEM OR SIGNALLING WIRING DIAGRAM...
  • Page 262   SOLUCIÓN DE PROBLEMAS     Electrical System TROUBLESHOOTING Battery   • Battery discharged   • Battery failure GENERAL INFORMATION Fuse NOTE: • Blown, damaged or incorrect The following troubleshooting guide does not cover • improperly installed fuse all possible causes. It should be useful, Plug however, as a basic guide to the •...
  • Page 263   SOLUCIÓN DE PROBLEMAS   Electrical System JUMPING GEARS Battery   • Battery discharged Axis of changes • Defective battery • Shift Pedal Position incorrect Plug • The return lever stop improperly • Distance between the spark plug electrodes Forks of changes incorrect •...
  • Page 264   SOLUCIÓN DE PROBLEMAS   • Grease or oil on the brake disc Fuel System • Grease or oil on brake pads • Improper carburetor adjustment • Brake fluid level incorrect • Setting the wrong fuel level • Blocked air filter element FRONT FORK FAILURE oil leak  ...
  • Page 265   SOLUCIÓN DE PROBLEMAS   Rear Shock • Light Bulb melt rotation • Bad connection • Faulty rear shock spring • Oil Leaks • Damaged or faulty wiring harness Tire (s) • Grounding circuit • Battery failure • Unequal tire pressures (front and rear) •...
  • Page 266           B Br R   W - W ( B L A C K ) R CRK + IG                       LY G          ...

  • Page 267: Diagrama De Cableado

      DIAGRAMA DE CABLEADO       FZ-16 COLOR CODE 1. Magneto CA B Br Black Neutral switch Coffee 3. Regulator / Rectifier ChChocolate 4. Main fuse Dark green Dg 5. Battery G Green 6. Main switch GyGris 7. CDI Unit LgVerde clear 8.

Table of Contents