1ES-F8107-E0: Downloaded From Manuals Search Engine

2010
FZ 16
1ES-F8107-E0
Downloaded from www.Manualslib.com manuals search engine

FZ 16
ASSEMBLY MANUAL
First Edition
All rights reserved.
Any reproduction or unauthorized use
without the written permission of
India Yamaha Motor Pvt. Ltd.
is expressly prohibited.
Printed in India

FOREWORD
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.
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.
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.
WARNING A WARNING indicates as hazardous situation which, if not avoided, could result in death or
serious injury.
NOTICE A NOTICE indicates special precautions that must be taken to avoid damage to the vehicle
or other property.
TIP: ATIP provides key information to make procedures easier or clearer.

INDEX
1. SYMBOLS USED IN THE ASSEMBLY MANUAL …………............................................1
2. UNPACKAGING ………………………………………………………………………………..2
3. PARTS LOCATION ………………..…………….............................................................. 5

a. Carton A ……………………………………………………………...……. 5
b. Carton B…………………………………………………………………...… 5
c. Carton C …………………………………………………………………….. 5
d. Carton D………………………………………………….……………....…. 5
e. Bubble wrap ………………………………………………..………………. 5
4. HARDWARE IN CARTON B ……………………………………………………………….. 6
5. SETUP & PRE-DELIVERY CHECKLIST ....................................................................... 8
6. SETUP PROCEDURE …………………….…………………..…………………....…….…. 9

a. Front fender …………………………..……….…………………............... 10
b. Front wheel …………………………………………………….……………. 10
c. Handlebar assy. ………………………………………………………….…. 12
d. CDI unit ………………………………………………………………….…… 16
e. Seat ……………………………………………………………..……………. 16
f. Rear view mirror ………………………………………………………..……. 16
7. CABLE ROUTING .......................................................................................................... 17
8. ADJUSTMENTS AND PRE-DELIVERY SERVICE…………………………...………...… 25
a. Checking and charging the battery ......................................................... 26

b. Measuring the tire pressure .................................................................... 28
c. Checking the engine oil level .................................................................. 29
d. Adjusting the engine idling speed ........................................................... 30
e. Adjusting the throttle cable free play ....................................................... 31
f. Adjusting the rear brake free play ............................................................ 31
g. Adjusting the rear brake light switch ....................................................... 32
h. Adjusting the clutch cable free play …………………………………....... 32
i. Adjusting the drive chain slack ................................................................ 33
j. Adjusting the headlight beam ................................................................... 33
9. APPENDICES ………………………………………………………………………………… 35
a. Service data………………………………………………………………….. 35
10. TIGHTENING TORQUES............................................................................................... 36

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) = 5 mm (0.20 in)
PREPARATION
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.
1
UNPACKAGING
1. Remove all the strips from all the corners & Top
cover “1”.
2. Remove the Front wheel “2” by untagging Its

2
cords.“1”.
4
3. Remove Wooden angles “3”
3 4. Remove Side covers “4”
5. Remove front cover “5”.

4
5
6. Remove the nut “6” in order to remove the front
wheel assy. from the packing box..
7
7. Remove the polythene cover “7”.
2
8. Untag & remove the loosen parts kept on the vehicle.
8
9. Remove all the carton boxes “8”.
10
10. Remove the wooden support bracket “9” from the
mounting bracket “10”.
9 11. Remove mounting bracket by removing the bolt “11”
from seat handle..
12. Tighten the bolt”11” at its original position.

11
3
12. Remove carton box “12” from the rear side of the
14
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”.
16
15
4
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
PART LOCATION
Carton box A content

1
Rider seat (2nos, 1 for each vehicle)
Carton box B content
1. Owner’s manual (2nos, 1 for each vehicle)

2. Tool kit (2nos, 1 for each vehicle)
3. Installation hardware.
3 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)
2
Carton box C content
Front fender (1no.)
1. Carton A
2. Carton B
3. Carton C
Carton box D content

Front fender (1no.)
Bubble wrap content

Handle bar (2nos, 1 for each vehicle)
1
1
2
1. Bubble wrap
2. Carton D
7
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) 07 Nm (0.7 m · kg, 05 ft · lb)

Front wheel axle nut 60 Nm (6.0 m · kg, 43 ft · lb)
Flange bolt (Handlebar holder) 26 Nm (2.6 m · kg, 19 ft · lb)
Front fender screw 06 Nm (0.6 m · kg, 04 ft · lb)
Grip eng cap bolt 04 Nm (0.4 m · kg, 03 ft · lb)
Master cylinder holding cap bolt 10 Nm (1.0 m · kg, 07 ft · lb)
Right / Left handle switch screw 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 Adjusting the rear brake
Checking the engine oil level Measuring the tire pressure
Adjusting the engine idling speed Adjusting the drive chain slack
Adjusting the throttle cable free play Adjusting the headlight beam
Adjusting the rear brake light switch
E: FUNCTION AND PERFORMANCE
Check the function of the headlight, meter light and Check the function of the
taillight indicator on the speedometer
Check the function of the brake light Check the feel of the brakes
Check the function of the turn signals and indicator Check engine for irregular noise
lights (Yes/No)
Check the tone quality of the horn Check for exhaust leak (Yes/No)
F: ACCESSORIES, ETC. FOR DELIVERY
Owner’s manual Owner’s tool kit
8
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
7 6 35 8 4 1 2
9
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”.
1
NOTICE
Be careful not to scratch to the front fender with the
front fork outer tube.
3. Install the hex bolt “5” along with the washer “6” from
the inner side of fender.
2 4. Tighten the screws and bolts as per the specification.
5
1 6 Screw
3.0 Nm, 0.3Kg.m, 2 ft.lb
Bolt
6.0 N.m, 0.6 Kg.m, 5 ft.lb
WARNING
Proper cable routing is essential to safe motorcycle
operation.
1 C 1
4 3 2 C 2
3 C 4
4 C 2
5 C 2
FRONT WHEEL
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
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
3. Align the speed sensor slot “3” on the protruded part
“4” of the front fork, then install it .
4
4. Install the Collar “5” between wheel & left side leg of
front fork on the front wheel “6” hub.
5 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 6. Install the washer “8” and then nut”9”.
Axle nut
60 Nm, 6.0 m.Kg, 43 ft.lb.
5 C 1 D=15, l=14
6 C 1
7 7 * 1 D=14, l=241.7
5
8 9 9 C 1 d=14
11
HANDLE BAR ASSY.
2 1. Install handlebar “1” and then upper handlebar holder

“2”.
2
2. Tighten at the specified torque.
1
Bolt
a 26 Nm (2.6 M.Kg, 19 ft.lb)
NOTICE
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.
Left handlebar
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
a
a 5. Install left handlebar switch “6”

b
6 TIP:
Align the projection “a” on the left handlebar switch with
the holes “b” in the handlebar.
12
6. Install the handle switch screws “7” at specified torque.
Screw
7 Nm (0.7 Kg.m, 5 ft.lb)
8 7. Install the clutch switch “8” by pushing it in.
8. Install the band cord “9”.

9 9 C 1
13
Right handlebar
1. Install brake master cylinder holder “1” and then

tighten its bolts at specified torque.
1
Bolt
10Nm, 1.0m.Kg, 7 ft.lb.
2. Install the throttle cable “4” inside the hole “5” as

shown in illustration.
5
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
7 Nm (0.7 Kg.m, 5 ft.lb)
14
5. Install brake switch “7” then cover it.
6. Tighten the band cord “8” at specified position.
TIP:
Ensure the proper cable routing.
5 C 1
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.
15
C.D.I. UNIT
Install CDI unit “1” and connect its all the couplers.
1 C 1
SEAT
1. Insert the key in the lock.

1 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
2
REAR VIEW MIRROR
2 1 Install the mirror assy 1 “1” & mirror assy 2 “2” and
adjust according to need.
1 C 1
2 C 1
16
CABLE ROUTING
3 1 A 10
4
9 6 5
3 7
C
8 6
F G
11
2 12 5
2
R R C 8
1
A 4 7
5
4 13 D
6
2 14 11
3 9
1 B 9 D
R-R
12
B
H
1
I
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 turn signal 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. turn signal lead through the guide
G. Pass the LH Fr. turn signal lead through the guide
H. Pass the wire harness, handle switches lead, sensor unit lead
through the guide in headlight stay
I. Sensor unit lead through guide in headlight stay
18
17
17 17 13 2
3 5
4
13
E-E B-B D-D C-C
1 A3 2 4
B
C
5
F
E DC
B
B
14 S
S D B
C B
15 J E
16 L
N
I M
D
6
G H M 7
11 8
F 2
E
10
9
13 1411 2 12
13
14
16
15 16 6
12 6
2 15
L J S-S N M-M
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) lead wire
17. AIS hose pipe
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 the AC 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 protrude
from cover, connecter.
20
6 9
10
8
5 11
2 3
4
1
10
3
20
A
19 13
18
17
16
15
22
21
12
A A
14
15 A-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 turn signal lead (LH)
13. Turn signal relay assembly
14. Tail light unit assembly lead
15. Rear turn signal lead (RH)
16. Seat lock cover
17. Seat lock cable
18. Starting circuit cut off relay
19. CDI unit assembly
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 turn signal 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.
22
25 31
16
17 28
29
16 5
10 30
H-H K-K U-U T-T
30
251 31
24 27
A 18 19 B 10 C 23
2126 22 E
U 5
T
U
T
K
16 6
P K
O
8
N 7
M
15 H
F
9
G
I
29 H
14 10
L 11 J
13 K 12
23
1. Throttle cable F. Pass starting motor lead and starter relay lead
2. Sensor unit lead through to clamp in battery box.
G. Pass battery breather hose and carburetor drain
3. Brake hose hose through to outside of engine.
4. Horn lead H. Pass battery breather hose and carburetor drain
hose through to inside from here.
5. HT lead I. Hold plus lead and fuse holder assembly lead to
6. Spark plug cap battery band.
7. Starting motor lead J. Pass wire harness through to hook in battery
box.
8. Starter relay lead K. Hold rectifier regulator assembly lead, wire
9. Fuse holder assembly harness and stop switch assembly lead with
clamp to frame .
10. Wire minus lead L. Pass wire harness through to backside of battery
11. Carburetor drain hose box.
12. Battery breather hose M. Pass wire harness through to slit of air filter
cover.
13. Starter relay assembly N. Fit white marking of wire harness to right end in
14. Stop switch assembly battery box clamp.
O. Hold minus & fuse assy. plus lead with battery
15. Battery band.
16. Wire harness lead
17. Regulator, Rectifier assembly lead
18. Air filter cover
19. Regulator, Rectifier assembly
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 filter
assembly.
B. Pass wire harness, minus lead through to
backside 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.
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
F I G C D B
25
A. CHECKING AND CHARGING THE BATTERY
1 1. Charging:
The battery must be charged properly before using for the
a first time. This initial charge will prolong the life of the
battery.
b (a) Upper level line
(b) Lower level line
NOTICE
Never try to add battery electrolyte to a battery that is
installed on a motorcycle. Even a skilled mechanic
will spill enough acid to damage metal parts. Always
remove the battery before filling with electrolyte and
during charging. Always completely clean the
exterior of the battery before installing.
a. Remove all filler caps from the battery and remove the
breather 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 the
upper level line (a), and leave it for a while. When the
battery fluid permeates the plates and separators, the
fluid level begins to lower. Add electrolyte and bring back
to upper level line (a).
TIP:
Fill the battery with electrolyte (diluted sulfuric acid).
WARNING
Battery electrolyte is dangerous; it contain sulfuric
acid and therefore is poisonous and highly caustic.
Always follow these preventive measures:
1. Avoid bodily contact with electrolyte as it can

cause severe burns or permanent eye
injury.
2. Wear protective eye gear when handling or
working near batteries.
Antidote (EXTERNAL):
• SKIN-Flush with water.
• EYES-Flush with water for 15 minutes and get
immediate medical attention.
Antidote (INTERNAL):
• Drink large quantities of water or milk follow with
milk of magnesia, beaten egg, orvegetable oil. Get
immediate medical
Attention.
26
Batteries also generate explosive hydrogen gas,
therefore you should always follow these preventive
measures:
• Charge batteries in a well-ventilated area. Keep

batteries away from fire, sparks, or open flames (e.g.,
welding equipment, lighted cigarettes, etc.).
• DO NOT SMOKE when charging or handling

Batteries.
KEEP BATTERIES AND ELECTROLYTE OUT OF THE

REACH OF CHILDREN.
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.
Charging rate
0.5 Ah X 5-10 hours
Battery capacity
12 V, 5.0 Ah
F. Turn the battery charger off, then disconnect it from

the battery.
g. Check the specific gravity of each cell with a hydro-
meter. If the hydrometer readings are below the
specification, charging is necessary.
Specific gravity
1.280
h. Install the filler caps, and thoroughly wipe off the

fluid around the filler caps. Wipe off the battery
completely before installation
2. Installation:
a. The breather hose should be connected and routed
Properly.
WARNING
When inspecting the battery, be sure the breather
hose is routed correctly. If the battery breather hose
touches the frame in such a way as to cause battery
electrolyte or gas to exit onto the frame, structural
and cosmetic damage to the machine can occur.
b. Make sure that the main switch is turned off, and

install the battery in the battery box.
c. Connect the positive lead first, and then connect
the negative lead.
27
NOTICE
Make sure that the battery leads are connected
correctly. Reversing leads can seriously damage
the electrical system.
B. MEASURING THE TIRE PRESSURE
1. Measure tire pressure, If found out of specification,

maintain the tire pressure.
WARNING
• The tire pressure should only be checked and
regulated when the tire temperature equals the
ambient air temperature.
• The tire pressure and the suspension must be

adjusted according to the total weight (including
cargo, rider, passenger, and accessories) and the
anticipated riding speed.
• Operation of an overloaded motorcycle could cause

tire damage, an accident, or an injury.
NEVER OVERLOAD THE MOTORCYCLE.
Maximum load* 195Kg
Cold tire pressure:

Front: 28psi (2.0Kgf/cm2 )
Rear: 33psi (2.25kgf/cm2 )
* Maximum load is the total weight of rider, passanger,

cargo and accessories.
28
C. CHECKING THE ENGINE OIL LEVEL
1. Stand the motorcycle on a level surface.
TIP:
• Place the motorcycle on a suitable stand.
• Make sure that the motorcycle is upright
2. Start the engine, warm it up for several minutes, and

then turn it off.
3. Remove dipstick “1”.
4. Check:
• Engine oil level
The engine oil level should be between the minimum
level mark (a) and maximum level mark (b).
Below the minimum level mark Add the recommended

engine 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.
Engine Oil Amount/Quantity

Periodic oil change
1.00 L
Total amount of Engine Oil
1.20 L
NOTICE
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 minutes
until the oil has settled.
7. Install dipstick.
29
D. ADJUSTING THE ENGINE IDLING SPEED
TIP:
Prior to adjusting the engine idling speed, the Carburetor
synchronization should be adjusted properly, the air filter
should be clean, and the engine should have adequate
compression.
1. Start the engine and let it warm up for several minutes.
2. Install:
• Digital tachometer (onto the spark plug lead)
3. Check:
• Engine idling speed
If out of specification, adjust it.
Engine idling speed 1300–1500 r/min

4. Adjust:
• Engine idling speed
a. Turn the throttle stop screw “1” in direction “a” or “b”

until the specified engine idling speed is obtained.
Direction “a”
Engine idling speed is increased.
Direction “b”
Engine idling speed is decreased.
8. Remove:
• Digital tachometer
9. Adjust:
• Throttle cable free play
Throttle cable free play 3.0–5.0 mm
30
E. ADJUSTING THE THROTTLE CABLE FREE PLAY
TIP:
Prior to adjusting the throttle cable free play, the engine
idling 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 locknut
e. Slide the rubber cover to its original position.
Direction “a”
Throttle cable free play is increased.
Direction “b”
Throttle cable free play is decreased.
WARNING
After adjusting the throttle cable free play, start the
engine and turn the handlebar to the right or left to
ensure that this does not cause the engine idling
speed to change.
F. ADJUSTING THE REAR BRAKE FREE PLAY

1. Measure:
brake pedal free play (a)
Out of specification → Adjust.
Free Play: 15 ~ 20 mm
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.
Direction “a”
Brake pedal free play is increased.
Direction “b”
Brake pedal free play is decreased.
NOTICE
After adjusting the brake pedal free play, make sure
there is no brake drag.
3. Adjust:
• Rear brake light switch
31
G. ADJUSTING THE REAR BRAKE LIGHT SWITCH
TIP:
The rear brake light switch is operated by movement of
the brake pedal. The rear brake light switch is properly
adjusted when the brake light comes on just before the
braking effect starts.
1. Check:
• Rear brake light operation timing Incorrect Adjust.
2. Adjust:
• Rear brake light operation timing
a. Hold the main body “1” of the rear brake light
switch so that it does not rotate and turn the
adjusting nut “2” in direction “a” or “b” until the
rear brake light comes on at the proper time.
Direction “a”
Brake light comes on sooner.
Direction “b”
Brake light comes on later.
H. ADJUSTING THE CLUTCH CABLE FREE PLAY
The clutch lever free play should be adjusted to

10 ~ 15 mm. If the free play is incorrect, adjust as
follows.
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.
Direction “a”
Clutch cable free play is increased.
Direction “b”
Clutch cable free play is decreased.
32
I. ADJUSTING THE DRIVE CHAIN SLACK
TIP
The drive chain slack must be checked at the tightest
point on the chain.
WARNING
A drive chain that is too tight will overload the engine
and other vital parts, and one that is too loose can
skip and damage the swingarm or cause an accident.
Therefore, keep the drive chain slack within the
specified limits.
1. Stand the vehicle on a level surface.

NOTICE
Securely support the vehicle so that there is no
danger of it falling over.
TIP:
Place the vehicle on the centerstand so that the rear
wheel is elevated.
2. Spin the rear wheel several times and find the

tightest position of drive chain.
3. Check:
• Drive chain slack “a”
Out of specification Adjust.
Drive chain slack 30-40 mm
TIP:
Measure the drive chain slack halfway between the drive
axle and the rear wheel axle.
4. Adjust:
• Drive chain slack
a. Loosen the brake rod adjusting nut “1”.
b. Loosen the wheel axle nut “2”
c. Turn the adjusting nut "3” to adjust the chain
Slackness.
Direction “a”
Drive chain is tightened.
Direction “b”
Drive chain is loosened.
TIP:
To maintain the proper wheel alignment, adjust both sides
evenly.
e. Tighten the wheel axle nut.
33
5. Adjust:
• Brake pedal free play
6. Align the rear axle

a. To maintain correct axle alignment. Reference lines “1”
on the swingarm should be matched with an outer
diameter of the washer ”2”at both the sides.
b. After adjusting, be sure to tighten each chain adjusting
locknut. Then tighten the axle nut to the specified torque.
J. ADJUSTING HEADLIGHT BEAM
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 the
headlight in the following manner to adjust the headlight
b beam.
3. Tighten Bolt 1 & 2
Direction “a”
Headlight beam is lowered.
a Direction “b”
Headlight beam is raised.
4. Tighten the adjusting bolt “2” upto the specified torque.
34
APPENDICES
SERVICE DATA
Engine idling speed:

1,300 ~ 1,500 r/min
Spark plug:
Type (manufacturer)
NGK/CPR8EA-9
Gap 0.8 ~0.9
Fuel:
Recommended fuel
unleaded gasoline only
Fuel tank capacity
Total:
12.0 L
Valve clearance (cold):

IN
0.08 ~ 0.12 mm
EX
0.12 ~ 0.16 mm
Maximum load*:
195 kg
Tire pressure:
Single riding/Double Riding
Front
2.00 kgf/cm2, 28 psi
Rear
2.25 kgf/cm2, 33 psi
*Load is the total weight of rider, passenger,
cargo and accessories.
STANDARD EQUIPMENT
1. Owner’s manual 2 pc.
2. Owner’s tool kit 2 pc.
OWNER’S TOOL KIT

1. Tool Bag
2. Screw driver Plus / Minus
3. Grip
4. 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)
35
TIGHTENING TORQUE
Thread
Item Qty Tightening torque Remarks
size
Crown handle bolt M8 2 16 Nm (1.6 m.kg, 12ft.Ib) E
Crown handle nut M22 1 110 Nm (11.0 m.kg, 80ft.Ib) E
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)
36
Thread
Item Qty Tightening torque Remarks
size
Front wheel axle nut M14 1 60 Nm (6.0 m.kg, 43ft.Ib) E
Rear wheel axle nut M14 1 90 Nm (9.0 m.kg, 65ft.Ib) E
Sprocket wheel and clutch hub bolt 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)
37
INDIA YAMAHA MOTOR PVT. LTD.

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TIP: ATIP provides key information to make procedures easier or clearer.

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

3. PARTS LOCATION ………………..…………….............................................................. 5

4. HARDWARE IN CARTON B ……………………………………………………………….. 6

5. SETUP & PRE-DELIVERY CHECKLIST ....................................................................... 8

6. SETUP PROCEDURE …………………….…………………..…………………....…….…. 9

7. CABLE ROUTING .......................................................................................................... 17

8. ADJUSTMENTS AND PRE-DELIVERY SERVICE…………………………...………...… 25

a. Checking and charging the battery ......................................................... 26

10. TIGHTENING TORQUES............................................................................................... 36

Downloaded from www.Manualslib.com manuals search engine

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

Protect hands and feet by wearing safety

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

3 4. Remove Side covers “4”

5. Remove front cover “5”.

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

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

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

10. 21C-F6290-00 2 nos.

11. 21C-H5540-00 2 nos.

12. 21C-F8100-10 2 EACH

Carton box A content

Carton box B content

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

Carton box D content

Bubble wrap content

A: INSTALLATION OF THE PARTS INCLUDED IN THE CRATE

Front wheel Rearview Mirrors

B: TIGHTENING TORQUE OF EACH PART

Flange bolt (front fender) 07 Nm (0.7 m · kg, 05 ft · lb)

C: ROUTING OF WIRE, CABLES, ETC.

Clutch switch lead Right handlebar switch lead

E: FUNCTION AND PERFORMANCE

F: ACCESSORIES, ETC. FOR DELIVERY

Owner’s manual Owner’s tool kit

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

4. Install clutch lever holder”5”.

a 5. Install left handlebar switch “6”

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

8. Install the band cord “9”.

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

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

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

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

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

Handlebar end cap

End cap bolt

1. Insert the key in the lock.

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

4. Turn the key counter clock wise and remove it

REAR VIEW MIRROR

A. Checking & charging the battery

b. Cool the electrolyte .

1. Avoid bodily contact with electrolyte as it can

• Charge batteries in a well-ventilated area. Keep

• DO NOT SMOKE when charging or handling

KEEP BATTERIES AND ELECTROLYTE OUT OF THE