Yamaha FZ-16 Standard Motorcycle Manuals

Manuals and User Guides for Yamaha FZ-16 Standard Motorcycle. We have 2 Yamaha FZ-16 Standard Motorcycle manuals available for free PDF download: Service Manual, Assembly Manual

Yamaha FZ-16 Service 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
- 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
- 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

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
9 Appendices

39
- Service Data
  39
10 Tightening Torques

40

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