Yamaha FZ-16 Assembly Manual

1ES-F8107-E0

2010

FZ 16

ASSEMBLY MANUAL

First Edition

Any reproduction or unauthorized use

without the written permission of

India Yamaha Motor Pvt. Ltd.

is expressly prohibited.

Printed in India

This Assembly Manual contains the information required for the correct assembly of this motorcycle prior to

delivery to the customer. Since some external parts of the motorcycle have been removed at the YAMAHA

factory for the convenience of packing, assembly by the YAMAHA dealer is required. It should be noted that the

assembled motorcycle should be thoroughly cleaned, inspected and adjusted prior to delivery to the customer.

FOREWORD

NOTICE

The service specifications given in this assembly manual are based on the model as manufactured. India

Yamaha Motor Pvt. Ltd. is continually striving to improve all of its models. Modifications and significant changes

in specifications or procedures will be forwarded to all authorized YAMAHA dealers and will appear in future

editions of this manual where applicable. The procedures below are described in the order that the procedures

are carried out correctly and completely. Failure to do so can result in poor performance and possible harm to

the motorcycle and/or rider. Particularly important information is distinguished in this manual by the following

notations.

WARNING

NOTICE

TIP:

This is the safety alert symbol. It is used to alert you to potential personal injury hazards.

Obey all safety messages that follow this symbol to avoid possible injury or death.

A WARNING indicates as hazardous situation which, if not avoided, could result in death or

serious injury.

A NOTICE indicates special precautions that must be taken to avoid damage to the vehicle

or other property.

ATIP provides key information to make procedures easier or clearer.

INDEX

1. SYMBOLS USED IN THE ASSEMBLY MANUAL …………............................................

2. UNPACKAGING ………………………………………………………………………………..

3. PARTS LOCATION ………………..……………..............................................................

a. Carton A ……………………………………………………………...…….

b. Carton B…………………………………………………………………...…

c. Carton C ……………………………………………………………………..

d. Carton D………………………………………………….……………....….

e. Bubble wrap ………………………………………………..……………….

4. HARDWARE IN CARTON B ………………………………………………………………..

5. SETUP & PRE-DELIVERY CHECKLIST .......................................................................

6. SETUP PROCEDURE …………………….…………………..…………………....…….….

a. Front fender …………………………..……….…………………...............

b. Front wheel …………………………………………………….…………….

c. Handlebar assy. ………………………………………………………….….

d. CDI unit ………………………………………………………………….……

e. Seat ……………………………………………………………..…………….

f. Rear view mirror ………………………………………………………..…….

7. CABLE ROUTING ..........................................................................................................

8. ADJUSTMENTS AND PRE-DELIVERY SERVICE…………………………...………...…

a. Checking and charging the battery .........................................................

b. Measuring the tire pressure ....................................................................

c. Checking the engine oil level ..................................................................

d. Adjusting the engine idling speed ...........................................................

e. Adjusting the throttle cable free play .......................................................

f. Adjusting the rear brake free play ............................................................

g. Adjusting the rear brake light switch .......................................................

h.

Adjusting the clutch cable free play ………………………………….......

i. Adjusting the drive chain slack ................................................................

j. Adjusting the headlight beam ...................................................................

9. APPENDICES …………………………………………………………………………………

a. Service data…………………………………………………………………..

10. TIGHTENING TORQUES...............................................................................................

1

2

5

6

8

9

10

12

16

17

25

26

28

29

30

31

32

33

35

36

1

SYMBOLS USED IN THIS MANUAL

In order to simplify descriptions in this assembly manual, the following

symbols are used:

(1): Coat with lithium-soap-based grease.

(2): Tighten to 10 Nm.

(10 Nm = 1.0 m · kg, 7.2 ft · lb)

(3): Towards the front of the motorcycle

(4): Clearance required

(5): Install so that the arrow mark faces upward.

(6): Apply motor oil.

(7): Made of rubber or plastics

(8):

A: Ref. No. (indicating the order of operations.)

B: Place where parts are held

V: Stored in plastic bag/Bubble Sheet

C: Stored in carton box

S: Fixed inside the steel frame/wooden

frame and/or contained in the Styrofoam

tray (upper or lower)

*: Temporarily installed or secured

C: Quantity of parts per motorcycle

D: Size or material of parts

d/D: Diameter of part

l: Length of part

e.g., 5 (0.20)=5mm(0.20 in)

To assemble the motorcycle correctly, supplies (e.g., oils, greases,

and shop rags) and sufficient working space are required.

Workshop

The workshop where the motorcycle is assembled should be clean,

spacious, and have a level floor.

Self-protection

Protect your eyes with suitable safety glasses or goggles when using

compressed air, when grinding or when doing any operation which

may cause particles to fly off.

Protect hands and feet by wearing safety

gloves or shoes.

PREPARATION

2

1. Remove all the strips from all the corners & Top

cover “1”.

2. Remove the Front wheel “2” by untagging Its

cords.“1”.

3. Remove Wooden angles “3”

4. Remove Side covers “4”

5. Remove front cover “5”.

6

6. Remove the nut “6” in order to remove the front

wheel assy. from the packing box..

2

4

3

7. Remove the polythene cover “7”.

7

UNPACKAGING

5

3

8. Untag & remove the loosen parts kept on the vehicle.

9. Remove all the carton boxes “8”.

10. Remove the wooden support bracket “9” from the

mounting bracket “10”.

11. Remove mounting bracket by removing the bolt “11”

from seat handle..

10

9

8

12. Tighten the bolt”11” at its original position.

11

4

12. Remove carton box “12” from the rear side of the

vehicle by untagging its cord.

13. Remove handlebar “13” from both the side of rear

wheel of both motorcycle.

14. Remove the carton box “14” placed over frame at

the area of rider seat.

12

13

15. Remove the axle nut “15” from the front fork, and

then remove the axle bolt from wooden bracket “16”.

15

16

14

HARDWARE IN CARTON “B”

S. No. PART NO. / DESCRIPTION QTY. Illustration

1. 97027-06020 2 EACH

BOLT HEX

2. 90154-06061 2 EACH

SCREW CROSS RECESS

3. 90387-068C5 4 EACH

COLLAR

4. 90201-6726 2 EACH

WASHER PLAIN

5. 21C-F5183-00 2 nos.

COLLER WHEEL SHAFT

6. 95827-08016 2 nos.

BOLT FLANGE

7. 36L-H3936-00 2 EACH

BAND SWITCH CORD

8. 1ES-F8199-S0 2 nos.

MANUAL OWNERS

9. 21C-F6280-00 2 nos.

MIRROR ASSY 1

10. 21C-F6290-00 2 nos.

MIRROR ASSY 2

11. 21C-H5540-00 2 nos.

CDI UNIT ASSY

5

S. No. PART NO. / DESCRIPTION QTY. Illustration

12. 21C-F8100-10 2 EACH

TOOL KIT

6

7

1. Carton A

2. Carton B

3. Carton C

Carton box A content

Rider seat (2nos, 1 for each vehicle)

Carton box B content

Carton box C content

1. Owner’s manual (2nos, 1 for each vehicle)

2. Tool kit (2nos, 1 for each vehicle)

3. Installation hardware.

4. Mirror assy 1 (2nos, 1 for each vehicle)

5. Mirror assy 2 (2nos, 1 for each vehicle)

6. CDI unit (2nos, 1 for each vehicle)

Front fender (1no.)

1

2

1. Bubble wrap

2. Carton D

Carton box D content

Bubble wrap content

Front fender (1no.)

Handle bar (2nos, 1 for each vehicle)

3

1

2

PART LOCATION

8

SETUP AND PREDILIVERY CHECK LIST

TIP:

Check the following items again after setup and predelivery service have been completed.

A: INSTALLATION OF THE PARTS INCLUDED IN THE CRATE

Front wheel Rearview Mirrors

Front fender Seat

Handlebar

B: TIGHTENING TORQUE OF EACH PART

Flange bolt (front fender)

Front wheel axle nut

Flange bolt (Handlebar holder)

Front fender screw

Grip eng cap bolt

Master cylinder holding cap bolt

Right / Left handle switch screw

07 Nm (0.7 m · kg, 05 ft · lb)

60 Nm (6.0 m · kg, 43 ft · lb)

26 Nm (2.6 m · kg, 19 ft · lb)

06 Nm (0.6 m · kg, 04 ft · lb)

04 Nm (0.4 m · kg, 03 ft · lb)

10 Nm (1.0 m · kg, 07 ft · lb)

C: ROUTING OF WIRE, CABLES, ETC.

Clutch switch lead Right handlebar switch lead

Clutch cable Throttle cable

Left handlebar switch lead

Front brake light switch lead

D: ADJUSTMENTS

Adjusting the clutch cable free play

Checking the engine oil level

Adjusting the engine idling speed

Adjusting the throttle cable free play

Adjusting the rear brake light switch

Adjusting the rear brake

Measuring the tire pressure

Adjusting the drive chain slack

Adjusting the headlight beam

E: FUNCTION AND PERFORMANCE

Check the function of the headlight, meter light and

taillight

Check the function of the brake light

Check the function of the turn signals and indicator

lights

Check the tone quality of the horn

Check the function of the

indicator on the speedometer

Check the feel of the brakes

Check engine for irregular noise

(Yes/No)

Check for exhaust leak (Yes/No)

F: ACCESSORIES, ETC. FOR DELIVERY

Owner’s manual Owner’s tool kit

9

SETUP PROCEDURE

Perform the setup procedures in the order indicated by the numbers. Always follow the order asshown.

1. Front fender

2. Front wheel

3. Handlebar

4. Left handlebar switch

5. Right handlebar switch

6. CDI unit

7. Seat

8. Rear view mirror

1 2

3 86

7

45

FRONT FENDER

1. Seat the Front fender assy. “1” between the Front fork

leg “2” .

2. Install the Screw cross recess “3” along with the collar

“4”.

3. Install the hex bolt “5” along with the washer “6” from

the inner side of fender.

4. Tighten the screws and bolts as per the specification.

Screw

3.0 Nm, 0.3Kg.m, 2 ft.lb

Bolt

6.0 N.m, 0.6 Kg.m, 5 ft.lb

Be careful not to scratch to the front fender with the

front fork outer tube.

Proper cable routing is essential to safe motorcycle

operation.

1

4

3

5

6

FRONT WHEEL

1C 1

2C 2

3C 4

4C 2

5C 2

2

1. Install the speed sensor gear unit into the wheel hub so

that the projection “1” on the wheel hub fits in either slot of

the speed sensor gear unit.

2. Lift the wheel up between the fork legs.

TIP

Make sure that there is enough space between the brake

pads before inserting the brake disc and that the retainer

in the speedometer gear unit fits over the slot on the fork

leg.

10

NOTICE

WARNING

3. Align the speed sensor slot “3” on the protruded part

“4” of the front fork, then install it .

4. Install the Collar “5” between wheel & left side leg of

front fork on the front wheel “6” hub.

5. Apply a thin coat of lithium soap based grease and

then insert the axle bolt “7” through front fork leg (left),

speed sensor unit, wheel hub, collar then front for leg

(right).

6. Install the washer “8” and then nut”9”.

Axle nut

60 Nm, 6.0 m.Kg, 43 ft.lb.

3

4

5

6

5 C 1 D=15, =14

6C1

7* 1

l

D=14, =241.7

9 C 1 d=14

l

11

7

9

8

5

a

b

6

HANDLE BAR ASSY.

a

1

2

3

4

3. Install the clutch cable “3” onto the clutch lever “4” as

shown in illustration.

4. Install clutch lever holder”5”.

TIP:

Align the slit of the clutch lever holder with the mark “a”

on the handlebar.

5. Install left handlebar switch “6”

TIP:

Align the projection “a” on the left handlebar switch with

the holes “b” in the handlebar.

Left handlebar

5

a

1. Install handlebar “1” and then upper handlebar holder

“2”.

2. Tighten at the specified torque.

Bolt

26 Nm (2.6 M.Kg, 19 ft.lb)

First install the bolts on the both side of the handle-

bar holder, and then rear side. Turn the handlebar all

the way to the left and right. If there is any contact

with the fuel tank, adjust the handlebar position.

TIP:

Align the mark “a” on the handlebar with the upper

surfaces of the lower handlebar holder.

NOTICE

12

7. Install the clutch switch “8” by pushing it in.

8. Install the band cord “9”.

9

8

7

6. Install the handle switch screws “7” at specified torque.

Screw

7 Nm (0.7 Kg.m, 5 ft.lb)

13

9C1

Right handlebar

1. Install brake master cylinder holder “1” and then

tighten its bolts at specified torque.

Bolt

10Nm, 1.0m.Kg, 7 ft.lb.

3. Install throttle grip “1”, throttle cable “2” and then

right handlebar switch “3”.

TIP:

Align the projection “a” on the right handlebar switch with

the hole “b” in the handlebar.

4. Install the switch mounting screws “6” & tighten them

at specified torque.

Screw

2. Install the throttle cable “4” inside the hole “5” as

shown in illustration.

7 Nm (0.7 Kg.m, 5 ft.lb)

4

5

6

1

14

Handlebar end cap

1. Install the the handle bar grip “1” and then handle

bar end cap “2”.

TIP:

Tighten the end cap bolt gradually until it reaches to

plastic legs of the end cap assy.

2. Insert the end cap assy into the handlebar hole then

tighten its bolt at specified torque.

End cap bolt

4Nm (0.4m.Kg, 3 ft.lb)

TIP:

There should be less than 3mm of clearance “a” between

the handlebar grip & grip end.

7

5. Install brake switch “7” then cover it.

6. Tighten the band cord “8” at specified position.

TIP:

Ensure the proper cable routing.

8

15

5C1

C.D.I. UNIT

1

Install CDI unit “1” and connect its all the couplers.

1C 1

SEAT

1. Insert the key in the lock.

2. Insert the projection “1” of the seat into the set holder

“2” and slide the seat forward.

3. Push the seat down to lock it in its place.

4. Turn the key counter clock wise and remove it

1C 1

REAR VIEW MIRROR

Install the mirror assy 1 “1” & mirror assy 2 “2” and

adjust according to need.

1C 1

2C 1

1

2

1

2

16

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Yamaha FZ-16 Assembly Manual

Yamaha FZ-16 Assembly Manual

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