FZ 16 Manual de Desembalaje

1ES-F8107-E0

2010

FZ 16

FZ 16

ASSEMBLY MANUAL

First EditionAll rights reserved.

Any reproduction or unauthorized usewithout 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 todelivery to the customer. Since some external parts of the motorcycle have been removed at the YAMAHAfactory for the convenience of packing, assembly by the YAMAHA dealer is required. It should be noted that theassembled 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. IndiaYamaha Motor Pvt. Ltd. is continually striving to improve all of its models. Modifications and significant changesin specifications or procedures will be forwarded to all authorized YAMAHA dealers and will appear in futureeditions of this manual where applicable. The procedures below are described in the order that the proceduresare carried out correctly and completely. Failure to do so can result in poor performance and possible harm tothe motorcycle and/or rider. Particularly important information is distinguished in this manual by the followingnotations.

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 orserious injury.

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

5

5

5

5

5

6

8

9

10

10

12

16

16

16

17

25

262829

30

31

3132

3233

33

3535

36

1

SYMBOLS USED IN THIS MANUAL

In order to simplify descriptions in this assembly manual, the followingsymbols 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 heldV: Stored in plastic bag/Bubble SheetC: Stored in carton boxS: Fixed inside the steel frame/woodenframe and/or contained in the Styrofoamtray (upper or lower)*: Temporarily installed or securedC: Quantity of parts per motorcycleD: Size or material of partsd/D: Diameter of partl: Length of parte.g., 5 (0.20) = 5 mm (0.20 in)

To assemble the motorcycle correctly, supplies (e.g., oils, greases,and shop rags) and sufficient working space are required.

WorkshopThe workshop where the motorcycle is assembled should be clean,spacious, and have a level floor.

Self-protectionProtect your eyes with suitable safety glasses or goggles when usingcompressed air, when grinding or when doing any operation whichmay cause particles to fly off.

Protect hands and feet by wearing safetygloves or shoes.

PREPARATION

2

1. Remove all the strips from all the corners & Topcover “1”.

2. Remove the Front wheel “2” by untagging Itscords.“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 frontwheel assy. from the packing box..

2

4

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 themounting bracket “10”.

11. Remove mounting bracket by removing the bolt “11”from seat handle..

10

9

8

8

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

4

12. Remove carton box “12” from the rear side of thevehicle by untagging its cord.

13. Remove handlebar “13” from both the side of rearwheel of both motorcycle.

14. Remove the carton box “14” placed over frame atthe area of rider seat.

12

13

15. Remove the axle nut “15” from the front fork, andthen 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 A2. Carton B3. 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

1

2

1. Bubble wrap2. 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)

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 fender2. Front wheel3. Handlebar4. Left handlebar switch5. Right handlebar switch6. CDI unit7. Seat8. Rear view mirror

1 23 867 45

FRONT FENDER

1. Seat the Front fender assy. “1” between the Front forkleg “2” .

2. Install the Screw cross recess “3” along with the collar“4”.

3. Install the hex bolt “5” along with the washer “6” fromthe inner side of fender.

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

Screw3.0 Nm, 0.3Kg.m, 2 ft.lbBolt6.0 N.m, 0.6 Kg.m, 5 ft.lb

Be careful not to scratch to the front fender with thefront fork outer tube.

Proper cable routing is essential to safe motorcycleoperation.

1

1

4 3

56

FRONT WHEEL

1 C 1

2 C 2

3 C 4

4 C 2

5 C 2

2

2

1. Install the speed sensor gear unit into the wheel hub sothat the projection “1” on the wheel hub fits in either slot ofthe speed sensor gear unit.

2. Lift the wheel up between the fork legs.

TIPMake sure that there is enough space between the brakepads before inserting the brake disc and that the retainerin the speedometer gear unit fits over the slot on the forkleg.

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 offront fork on the front wheel “6” hub.

5. Apply a thin coat of lithium soap based grease andthen 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 nut60 Nm, 6.0 m.Kg, 43 ft.lb.

3

4

5

6

5 C 1 D=15, =14

6 C 1

7 * 1

�

D=14, =241.7

9 C 1 d=14

�

11

7

985

a

b6

HANDLE BAR ASSY.

a

1

2

2

3

4

3. Install the clutch cable “3” onto the clutch lever “4” asshown 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 withthe holes “b” in the handlebar.

Left handlebar

5a

1. Install handlebar “1” and then upper handlebar holder“2”.

2. Tighten at the specified torque.Bolt26 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 allthe way to the left and right. If there is any contactwith the fuel tank, adjust the handlebar position.

TIP:Align the mark “a” on the handlebar with the uppersurfaces 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.

Screw7 Nm (0.7 Kg.m, 5 ft.lb)

13

9 C 1

Right handlebar

1. Install brake master cylinder holder “1” and thentighten its bolts at specified torque.

Bolt10Nm, 1.0m.Kg, 7 ft.lb.

3. Install throttle grip “1”, throttle cable “2” and thenright handlebar switch “3”.

TIP:Align the projection “a” on the right handlebar switch withthe hole “b” in the handlebar.

4. Install the switch mounting screws “6” & tighten themat specified torque.

Screw

2. Install the throttle cable “4” inside the hole “5” asshown 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 handlebar end cap “2”.

TIP:Tighten the end cap bolt gradually until it reaches toplastic legs of the end cap assy.

2. Insert the end cap assy into the handlebar hole thentighten its bolt at specified torque.

End cap bolt4Nm (0.4m.Kg, 3 ft.lb)

TIP:There should be less than 3mm of clearance “a” betweenthe 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

5 C 1

C.D.I. UNIT

1

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

1 C 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

1 C 1

REAR VIEW MIRROR

Install the mirror assy 1 “1” & mirror assy 2 “2” andadjust according to need.

1 C 1

2 C 1

12

1

2

16

CABLE ROUTING

RR

3 1 410

9 65

8G

11

7

6

5

8

7

5

6

11

9

D9

H

I

14

13

1

2

12

F

2

3

2

14A

1

4

3

12

B

A

C

D

C

BR-R

17

1. Front brake hose

2. Throttle Cable

3. Front brake light switch lead

4. Right handlebar switch lead

5. Left handlebar switch lead

6. Clutch switch lead

7. Clutch cable

8. Starter cable

9. Main switch lead

10. Meter lead

11. LH Front turn signal lead

12. RH Front lead

13. Headlight lead

14. Pilot light lead

A. Pass through the guide in headlight stay RHS

B. Pass through the guide in headlight stay RHS

C. Pass through the guide in headlight stay LHS

D. Pass through the guide in headlight stay LHS

E. Hold with the clamp to headlight stay

F. Pass the RH Fr. lead through the guide

G. Pass the LH Fr. lead through the guide

H. Pass the wire harness, handle switches lead, sensor unit leadthrough the guide in headlight stay

I. Sensor unit lead through guide in headlight stay

turn signal

turn signal

turn signal

18

13

13

52

B

B

L

M

C

C

D

D

E

JS

S

F

31 2 4B

C

A

5

D6

7

8

9

E

10

2F

11

HG

I

14

15

16

NMM

EE C B

BS

111413

1615

2

L

2 12

13

14

16

15

J

12

S-S

6

M-M

6

N

E-E B-B D-D C-C

3

4

171717

19

1. Clutch cable

2. Overflow pipe

3. Throttle cable

4. Starter cable

5. Carburetor air bend

6. AC magneto generator lead

7. Wire minus lead

8. Battery breather hose

9. Carburetor drain hose

10. Fuel pipe

11. Horn lead

12. Connector cover

13. Wire harness

14. Sensor unit lead

15. Switch handle (LH) lead wire

16. Switch handle (RH)

A. Clutch cable and Starter cable through the guide

B. Overflow pipe through flange in left of fuel tank

C. Throttle cable and Starter cable through the guide

D. Hold theAC Magneto generator assembly lead with the clamp to frame

E. Pass battery breather hose and carburetor drain hose through to hole in joint hose

F. Pass the overflow pipe through the guide

G. Pass wire harness, sensor unit lead, handle switches lead through the guide

H. Pass horn lead after overflow pipe is passed through the guide

I. Pass wire harness, sensor unit lead, handle switches lead through the guide

J. Insert projection in connector cover to hole in frame

K. After wiring is connected, all the leads are encompassed by cover, connecter. Naked leads not protrudefrom cover, connecter.

lead wire

17. AIS hose pipe

20

A

14

2 3

5

6 910

8

11

103

13

2122

20

14

15

12

16

17

18

19

A

A-A

7

15

A

21

1. LH Handle switch

2. Clutch switch lead

3. Clutch cable

4. LH Handle switch lead

5. Starter cable

6. Main switch lead

7. RH Handle switch lead

8. Brake hose

9. Front stop switch assembly lead

10. Throttle cable

11. RH Handle switch

12. Rear lead (LH)

13. relay assembly

14. Tail light unit assembly lead

15. Rear lead (RH)

16. Seat lock cover

17. Seat lock cable

18. Starting circuit cut off relay

19. CDI unit assembly

20. Carburetor air bend

21. Rear fender

22. Rear fender cover

A. Insert carburetor air bend in the hole of air filter assembly.

B. Hold clutch and handle switch leads with clamp to handle bar.

C. Hold front stop and handle switch leads with clamp to handle bar.

D. Pass tail light assembly, both rear leads through to hole of rear fender

E. Fix high tension cord and bend hose 1 by clamp.

F. Fix clutch cable and vacuum sensing hose 1 by clamp.

turn signal

Turn signal

turn signal

turn signal .

22

2917

16

H-H

1628

10

K-K

30

25

U-U

31

5

T-T

PP16

A 18 19 B 10 C 21 2226 E

24 27 23

251

5

6

7

8

F

G9

HI

J

K 1211

10

13L

14

29

15

MN

H

31

30

K

KK

U

UUTT

TT

O

23

1. Throttle cable

2. Sensor unit lead

3. Brake hose

4. Horn lead

5. HT lead

6. Spark plug cap

7. Starting motor lead

8. Starter relay lead

9. Fuse holder assembly

10. Wire minus lead

11. Carburetor drain hose

12. Battery breather hose

13. Starter relay assembly

14. Stop switch assembly

15. Battery

16. Wire harness lead

17. Regulator, Rectifier assembly lead

18. Air filter cover

19. Regulator, Rectifier assembly

20. Carburetor air bend

21. Wire plus lead

22. AC Magneto generator assembly lead

23. Ignition coil

24. Ignition coil lead

25. Clutch cable

26. Throttle position sensor lead

27. Sender assembly lead

28. Battery box

29. Stop switch assy. lead wire

30. Vacuum sensing hose

31. Bend hose, AIS unit

A. Pass wire harness through to guide of air filterassembly.

B. Pass wire harness, minus lead through tobackside hook in battery box.

C. Fit white marking of wire harness to clamp.D. Fit clamp to rear end of engine bracket 1 of frame .E. Match clamp to white paint of vacuum sensing

hose 1.

F. Pass starting motor lead and starter relay leadthrough to clamp in battery box.

G. Pass battery breather hose and carburetor drainhose through to outside of engine.

H. Pass battery breather hose and carburetor drainhose through to inside from here.

I. Hold plus lead and fuse holder assembly lead tobattery band.

J. Pass wire harness through to hook in batterybox.

K. Hold rectifier regulator assembly lead, wireharness and stop switch assembly lead withclamp to frame .

L. Pass wire harness through to backside of batterybox.

M. Pass wire harness through to slit of air filtercover.

N. Fit white marking of wire harness to right end inbattery box clamp.

O. Hold minus & fuse assy. plus lead with batteryband.

24

ADJUSTMENTS AND PRE DELIVERYSERVICE

Perform the pre delivery service in the order indicated by the letters. Always follow the order as shown.

A. Checking & charging the battery

B. Measuring the tire pressure

C. Checking the Engine Oil Level

D. Adjusting the engine idle speed

E. Adjusting the throttle cable free play

F. Adjusting the rear brake.

G. Adjusting rear brake light switch

H. Adjusting Clutch Cable free play

I. Adjusting Chain Slack

J. Adjusting Head Light Beam

A E H J

BDCGIF

25

NOTICE

A. CHECKING AND CHARGING THE BATTERY

1. Charging:The battery must be charged properly before using for thefirst time. This initial charge will prolong the life of thebattery.(a) Upper level line(b) Lower level line

a. Remove all filler caps from the battery and remove thebreather hose cap (1).

TIP:Place the battery on a level place.

b. Cool the electrolyte .c. Pour electrolyte into each cell little by little up to theupper level line (a), and leave it for a while. When thebattery fluid permeates the plates and separators, thefluid level begins to lower. Add electrolyte and bring backto upper level line (a).

TIP:Fill the battery with electrolyte (diluted sulfuric acid).

Never try to add battery electrolyte to a battery that isinstalled on a motorcycle. Even a skilled mechanicwill spill enough acid to damage metal parts. Alwaysremove the battery before filling with electrolyte andduring charging. Always completely clean theexterior of the battery before installing.

Battery electrolyte is dangerous; it contain sulfuricacid and therefore is poisonous and highly caustic.Always follow these preventive measures:

1. Avoid bodily contact with electrolyte as it cancause severe burns or permanent eyeinjury.2. Wear protective eye gear when handling orworking near batteries.

Antidote (EXTERNAL):• SKIN-Flush with water.

Antidote (INTERNAL):Drink large quantities of water or milk follow with

milk of magnesia, beaten egg, orvegetable oil. Getimmediate medicalAttention.

• EYES-Flush with water for 15 minutes and getimmediate medical attention.

•

1

a

b

WARNING

26

Batteries also generate explosive hydrogen gas,therefore you should always follow these preventivemeasures:

Charge batteries in a well-ventilated area. Keepbatteries away from fire, sparks, or open flames (e.g.,welding equipment, lighted cigarettes, etc.).

Batteries.

KEEP BATTERIES AND ELECTROLYTE OUT OF THEREACH OF CHILDREN.

•

• DO NOT SMOKE when charging or handling

d. Connect the battery to a battery charger.e. Set the battery charger rate at 1/10 of the battery

capacity and charge the battery for 5-10 hours.

F. Turn the battery charger off, then disconnect it fromthe battery.

g. Check the specific gravity of each cell with a hydro-meter. If the hydrometer readings are below thespecification, charging is necessary.

h. Install the filler caps, and thoroughly wipe off thefluid around the filler caps. Wipe off the batterycompletely before installation

Charging rate0.5 Ah X 5-10 hours

Battery capacity12 V, 5.0 Ah

Specific gravity1.280

2. Installation:a. The breather hose should be connected and routed

Properly.

b. Make sure that the main switch is turned off, andinstall the battery in the battery box.

c. Connect the positive lead first, and then connectthe negative lead.

When inspecting the battery, be sure the breatherhose is routed correctly. If the battery breather hosetouches the frame in such a way as to cause batteryelectrolyte or gas to exit onto the frame, structuraland cosmetic damage to the machine can occur.

WARNING

27

Make sure that the battery leads are connectedcorrectly. Reversing leads can seriously damagethe electrical system.

NOTICE

1. Measure tire pressure, If found out of specification,maintain the tire pressure.

• The tire pressure should only be checked andregulated when the tire temperature equals theambient air temperature.

causetire damage, an accident, or an injury.

NEVER OVERLOAD THE MOTORCYCLE.

Maximum load* 195Kg

• The tire pressure and the suspension must beadjusted according to the total weight (includingcargo, rider, passenger, and accessories) and theanticipated riding speed.

• Operation of an overloaded motorcycle could

WARNING

Cold tire pressure:

Front: 28psi (2.0Kgf/cm )

Rear: 33psi (2.25kgf/cm )

2

2

* Maximum load is the total weight of rider, passanger,cargo and accessories.

B. MEASURING THE TIRE PRESSURE

28

1. Stand the motorcycle on a level surface.

TIP:Place the motorcycle on a suitable stand.

2. Start the engine, warm it up for several minutes, andthen turn it off.3. Remove dipstick “1”.4. Check:• Engine oil levelThe engine oil level should be between the minimumlevel mark (a) and maximum level mark (b).

Below the minimum level mark Add the recommendedengine oil to the proper level.

TIP:Before checking the engine oil level, wait a few minutes

until the oil has settled.Do not screw the dipstick “1” in when checking the oil

level.

Periodic oil change1.00 L

Total amount of Engine Oil1.20 L

•

Engine OilAmount/Quantity

• Make sure that the motorcycle is upright

•

•

C. CHECKING THE ENGINE OIL LEVEL

Do not allow foreign materials to enter the crankcase.

5. Start the engine, warm it up for several minutes,and then turn it off.

6. Check the engine oil level again.

TIP:Before checking the engine oil level, wait a few minutesuntil the oil has settled.

7. Install dipstick.

NOTICE

29

D. ADJUSTING THE ENGINE IDLING SPEED

TIP:Prior to adjusting the engine idling speed, the Carburetorsynchronization should be adjusted properly, the air filtershould be clean, and the engine should have adequatecompression.

1. Start the engine and let it warm up for several minutes.

2. Install:• Digital tachometer (onto the spark plug lead)

3. Check:

If out of specification, adjust it.

4.Adjust:

a. Turn the throttle stop screw “1” in direction “a” or “b”until the specified engine idling speed is obtained.

8. Remove:

9.Adjust:

• Engine idling speed

• Engine idling speed

• Digital tachometer

• Throttle cable free play

Engine idling speed 1300–1500 r/min

Direction “a”Engine idling speed is increased.

Direction “b”Engine idling speed is decreased.

Throttle cable free play 3.0–5.0 mm

30

E. ADJUSTING THE THROTTLE CABLE FREE PLAY

Direction “a”Throttle cable free play is increased.

Direction “b”Throttle cable free play is decreased.

After adjusting the throttle cable free play, start theengine and turn the handlebar to the right or left toensure that this does not cause the engine idlingspeed to change.

TIP:Prior to adjusting the throttle cable free play, the engineidling speed should be adjusted.

1. Check:Throttle cable free play “a”

Out of specification ! Adjust.a. Slide back the rubber cover “1”b. Loosen the locknut “2”.c. Turn the adjusting nut “3” in direction “a” or “b” until

the specified carburetor cable free play is obtained.d. Tighten the locknute. Slide the rubber cover to its original position.

•

F. ADJUSTING THE REAR BRAKE FREE PLAY

Free Play: 15 ~ 20 mm

Direction “a”Brake pedal free play is increased.

Direction “b”Brake pedal free play is decreased.

After adjusting the brake pedal free play, make surethere is no brake drag.

1. Measure:brake pedal free play (a)Out of specification → Adjust.

2. Adjust:Brake pedal free play

a. Turn the adjusting nut “1” in direction “a” or “b”until the specified brake pedal free play is obtained.

3. Adjust:Rear brake light switch

•

•

31

WARNING

NOTICE

G. ADJUSTING THE REAR BRAKE LIGHT SWITCH

Direction “a”Brake light comes on sooner.

Direction “b”Brake light comes on later.

TIP:The rear brake light switch is operated by movement ofthe brake pedal. The rear brake light switch is properlyadjusted when the brake light comes on just before thebraking effect starts.

1. Check:• Rear brake light operation timing Incorrect Adjust.2. Adjust:

a. Hold the main body “1” of the rear brake lightswitch so that it does not rotate and turn theadjusting nut “2” in direction “a” or “b” until therear brake light comes on at the proper time.

• Rear brake light operation timing

H. ADJUSTING THE CLUTCH CABLE FREE PLAY

Direction “a”Clutch cable free play is increased.

Direction “b”Clutch cable free play is decreased.

The clutch lever free play should be adjusted to10 ~ 15 mm. If the free play is incorrect, adjust asfollows.

a. Pull back the rubber cover “1”b. Loosen the locknut “2”.c. Turn the adjusting bolt “3” in direction “a” or “b” until

the specified clutch cable free play is obtained.d. Tighten the locknut.e. Place the rubber cover in its original position.

32

I. ADJUSTING THE DRIVE CHAIN SLACK

A drive chain that is too tight will overload the engineand other vital parts, and one that is too loose canskip and damage the swingarm or cause an accident.Therefore, keep the drive chain slack within thespecified limits.

Securely support the vehicle so that there is nodanger of it falling over.

Drive chain slack 30-40 mm

Direction “a”Drive chain is tightened.

Direction “b”Drive chain is loosened.

TIPThe drive chain slack must be checked at the tightestpoint on the chain.

1. Stand the vehicle on a level surface.

TIP:Place the vehicle on the centerstand so that the rearwheel is elevated.

2. Spin the rear wheel several times and find thetightest position of drive chain.

3. Check:• Drive chain slack “a”Out of specification Adjust.

TIP:Measure the drive chain slack halfway between the driveaxle and the rear wheel axle.

4. Adjust:• Drive chain slacka. Loosen the brake rod adjusting nut “1”.b. Loosen the wheel axle nut “2”c. Turn the adjusting nut "3” to adjust the chainSlackness.

TIP:To maintain the proper wheel alignment, adjust both sidesevenly.

e. Tighten the wheel axle nut.

33

WARNING

NOTICE

J. ADJUSTING HEADLIGHT BEAM

Direction “a”Headlight beam is lowered.

Direction “b”Headlight beam is raised.

1. Loosen:• Head light mounting bolt “1” from both the end.• Head light beam adjustment bolt “2”.

2. Adjust :Loosen the headlight adjusting screw and move theheadlight in the following manner to adjust the headlightbeam.

3. Tighten Bolt 1 & 2

4. Tighten the adjusting bolt “2” upto the specified torque.

5.Adjust:• Brake pedal free play

6.Align the rear axlea. To maintain correct axle alignment. Reference lines “1”on the swingarm should be matched with an outerdiameter of the washer ”2”at both the sides.b. After adjusting, be sure to tighten each chain adjustinglocknut. Then tighten the axle nut to the specified torque.

34

a

b

2

1

SERVICE DATA

Engine idling speed:

Spark plug:

Fuel:

Valve clearance (cold):

Maximum load*:

Tire pressure:

STANDARD EQUIPMENT

1,300 ~ 1,500 r/min

Type (manufacturer)NGK/CPR8EA-9Gap 0.8 ~0.9

Recommended fuelunleaded gasoline onlyFuel tank capacityTotal:12.0 L

IN0.08 ~ 0.12 mmEX0.12 ~ 0.16 mm

195 kg

Single riding/Double RidingFront2.00 kgf/cm2, 28 psiRear2.25 kgf/cm2, 33 psi

*Load is the total weight of rider, passenger,cargo and accessories.

1. Owner’s manual 2 pc.2. Owner’s tool kit 2 pc.

OWNER’S TOOL KIT1. Tool Bag2. Screw driver Plus / Minus3. Grip4. Spanner (14 X 17 mm)5. Spanner (10 X 12 mm)6. Spanner (8 X10 mm)7. Box Spanner Spark Plug (16 mm)8. Allan key (4 mm)

APPENDICES

35

36

TIGHTENING TORQUE

ItemThread

sizeQty Tightening torque Remarks

E

E

Crown handle bolt M8 2 16 Nm (1.6 m kg, 12ft Ib)

Crown handle nut M22 1 110 Nm (11.0 m kg, 80ft Ib)

. .

. .

Steering shaft and ring nut (Initial) M25 1 33 Nm (3.3 m.kg, 24ft.Ib)

Steering shaft and ring nut (final) M25 1 22 Nm (2.2 m.kg, 16ft.Ib)

FR. Fender comp. M6 1 6 Nm (0.6 m.kg, 4ft.Ib)

Steering lock/Main switch M6 2 7 Nm (0.7 m.kg, 5ft.Ib)

Head light stay M6 2 7 Nm (0.7 m.kg, 5ft.Ib)

Lever holder assy. M6 2 7 Nm (0.7 m.kg, 5ft.Ib)

Handle switch screw M5 2 10 Nm (1.0 m.kg, 7ft.Ib)

Meter and head light stay screw M5 3 1 Nm (0.1 m.kg, 1ft.Ib)

No. plate stay bolt M5 2 4 Nm (0.4 m.kg, 3ft.Ib)

Head light bolt M6 3 7 Nm (0.7 m.kg, 5ft.Ib)

Head light side cover M4 4 2 Nm (0.2 m.kg, 1ft.Ib)

Front Engine mounting M10 2 55 Nm (5.5 m.kg, 40ft.Ib)

Engine mounting front bracket bolt M8 2 55 Nm (5.5 m.kg, 40ft.Ib)

Engine mounting nut stay bolt M8 3 30 Nm (3.0 m.kg, 22ft.Ib)

Pivot shaft nut M12 1 46 Nm (4.6 m.kg, 33ft.Ib)

Rear cushion lower nut M12 1 60 Nm (6.0 m.kg, 43ft.Ib)

Rear cushion upper nut M12 1 40 Nm (4.0 m.kg, 29ft.Ib)

Bar tension and rear arm M8 1 20 Nm (2.0 m.kg, 14ft.Ib)

Fuel cock screw M6 2 7 Nm (0.7 m.kg, 5ft.Ib)

Ignition coil bolt M6 2 7 Nm (0.7 m.kg, 5ft.Ib)

Side cover bolt M6 1 2 Nm (0.2 m.kg, 1ft.Ib)

Battery Box Bolt M6 3 7 Nm (0.7 m.kg, 5ft.Ib)

Fuel sender unit bolt M5 4 4 Nm (0.4 m.kg, 3ft.Ib)

Rectifier, regulator nut M6 1 7 Nm (0.7 m.kg, 5ft.Ib)

Seat lock assy. M6 1 4 Nm (0.4 m.kg, 3ft.Ib)

Side Cover Bolt M6 4 2 Nm (0.2 m.kg, 1ft.Ib)

Seat Handle bolt M8 4 25 Nm (2.5 m.kg, 18ft.Ib)

Tail light assy. M5 2 2 Nm (0.2 m.kg, 1ft.Ib)

Rear reflector nut M5 1 2 Nm (0.2 m.kg, 1ft.Ib)

Fuel tank top cover screw M5 10 2 Nm (0.2 m.kg, 1ft.Ib)

Fuel tank side cover screw M5 2 2 Nm (0.2 m.kg, 1ft.Ib)

Guide air ½ and air shroud bolt M5 2 2 Nm (0.2 m.kg, 1ft.Ib)

Air shroud bolt M6 2 2 Nm (0.2 m.kg, 1ft.Ib)

Horn nut M6 1 7 Nm (0.7 m.kg, 5ft.Ib)

37

ItemThread

sizeQty Tightening torque Remarks

E

E

Front wheel axle nut M14 1 60 Nm (6.0 m.kg, 43ft.Ib)

Rear wheel axle nut M14 1 90 Nm (9.0 m.kg, 65ft.Ib)

M8 6 43 Nm (4.3 m.kg, 31ft.Ib)

Tension bar and brake shoe plate M8 1 20 Nm (2.0 m.kg, 14ft.Ib)

Camshaft and lever cam shaft M6 1 10 Nm (1.0 m.kg, 7ft.Ib)

Calliper bolt M10 2 35 Nm (3.5 m.kg, 25ft.Ib)

Disk brake bolt M8 6 30 Nm (3.0 m.kg, 22ft.Ib)

Master cylinder bolt M6 2 10 Nm (1.0 m.kg, 7ft.Ib)

Brake pedal and footrest assy. M10 1 30 Nm (3.0 m.kg, 22ft.Ib)

Footrest assy and frame bolt M8 2 35 Nm (3.5 m.kg, 25ft.Ib)

Sidestand nut M10 1 44 Nm (4.4 m.kg, 32ft.Ib)

Main stand nut M10 2 46 Nm (4.6 m.kg, 33ft.Ib)

Shift pedal nut M8 1 2 Nm (3.0 m.kg, 22ft.Ib)

Bracket side stand and frame nut M10 1 44 Nm (4.4 m.kg, 32ft.Ib)

Footrest bracket plate nut M6 2 8 Nm (0.8 m.kg, 6ft.Ib)

Shift arm installation nut M6 1 10 Nm (1.0 m.kg, 7ft.Ib)

Rear brake switch nut M6 1 7 Nm (0.7 m.kg, 5ft.Ib)

Sprocket wheel and clutch hub bolt

INDIA YAMAHA MOTOR PVT. LTD.