Tappet (Valve Clearance) Adjustment for Yamaha FZ16 / FZ-S / Fazer (150)

Yamaha FZ-16 or Fazer 153cc shares the same 153cc two valve engine. Its time tasted and proves to be highly reliable and smooth offering from this Japaneses manufacturer. One of the factor, due to the engines nature of being reliable is highly over looked by the users, that’s the tappet adjustment of valve clearance settings.

What is Tappet / Valve Clearance ?

The engine comes with two valve. One inlet and one exhaust. The inlet valve allow air and fuel mixture from carburetor to come into the engine combustion chamber and the after combustion, the exhaust valve allows the burnt gases to go out via the exhaust.

Tappet Clearance

There is a specified gap, as you may see in the above illustration, which may needs to be adjusted over time, since the tension of the springs may increase of decrease.

What happens with wrong settings ?

Over time of usage, due to wear and tear, the valve sprint may lose tension or the rocker arm may lose its edge, hence allowing the gap to unsettle. If the value drops below specified limit, you may find starting trouble in cold weather, but usually the gap increases, and when it does, you would face host of issues.

  • Vibration from engine.
  • Noise from engine..
  • Power loss in high RPM
  • Effects in fuel economy as the bike starts to give low mileage
  • With time, it would effect the valve and may cause valve damage and lead to engine seize !!

How often you may need to look into the issue ?

As per the Yamaha Service Manual, both user and service center, company recommends to check and adjust at every 12,000 kms, meaning once in every 4 service. But from our experience, we would say, you can safely do it at every 15,000 kms or once every year.

How do one adjust the valve / tappet clearance ?

Yamaha service center is the best place to get it done, but we advice Cold Engineyou stand there with your bike and make sure they do it right. You may get it done from any experience mechanic also, but do supervise the process via this below guide on how to adjust the valve / tappet clearance of the engine.

Cold engine

Always make sure, the engine is dead code. Since metal expands in heat, so if one carries out the process of adjusting in warm or hot engine, the setup values wont be correct, so make sure there is at-least a 2 hour rest given to the engine to cool down before the work is done in the valve clearance adjustment.

Valve / Tappet Clearance valuesTappet_Value_FZ16

Following are the values to set the gap,

Inlet -> 0.08 mm to 0.12 mm
Exhaust -> 0.12 mm to 0.16 mm

Open up the engine top cover

The top cover is right on top of the engine and can be removed easily by removing few screws to access the valve / tappet adjustment area.

Opening the Head Cover Head cover removed

Set the piston to TDC mark via the adjuster provided in starter clutch side.

TDC_01 Adjusting the TDC

Now one may use the filler gauge to slide into the gap and set into right value.

Filler Gauge for right value Tappet Adjustment Process

Once done, simply put the cover back on, and there you go, its done.


Its simple straight forward job, costs Rs. 100/- in service center and even less when done from outside, but helps to keep the bike in good condition so always make sure to adjust the tappet, once a year or once every 15,000 kms.

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  1. How to ask in service center about this valve clearance.

    • Hey,

      Technically the work is called “checking of tappet or valve clearance”

      This work is listed as work to be done for every service. You may check that behind the service booklet page for service.


      • Mukesh Solanki


        This issue is very informative. Currently my bike (fazer 2011, 40k kms clocked) is heating like oven if i ride like for 6-7 kms in normal traffice condition and take huge time to hit 100.

        Over heat (can feel even from 2 feet distance)
        loss in power
        continues tic-tac sound after engine shut (higher than when it was normal)
        mileage havent measured yet but its in process

        irony is i have showed it to Pearl Yamaha service center in kothaguda, near Hitec City in Hyderabad. They said valves gone bad and need to be replaced, so i made them do. Now i see more heat, noise, cant go high speed due to low power generation, unusual and intermittent sound from engine.

        Not sure what these guys have done but i don’t see like before. I didn’t understood sketch diagram explaining rotation of crank shaft to fullest.

        Any suggestions how this can be fixed or can it be done at home performing every step to perfection.

        Now i don’t trust Yamaha as they screw bike more every time i submit there. Not sure if they perform it with gauge tool.

        Any suggestions would be appreciated.


        • Hey Mukesh,

          No matter how good a maker is, it an unwritten rule or so that religion for the mechanics to lag when there is no one to supervise.. Specially the owner.. No matter how trusted the mechanics are, be it service center or local guys, they will lag in work.

          Yes but I agree, certain service centers are really bad, may be you have uncounted one your self there.. Here in India, those numbers are majority !!

          Coming to your issue, Engine oil plays a major role in all those problem you have mentioned, so may I know what is the engine oil used ?? Secondly what is the last time you changed your clutch plates, sprocket kit along with wheel bearings ??


  2. Same problem with My Fazer 2012 . Engine some times stall working after few 10s of KMS and again starts itself . Consuming high engine oil . Average is about 20-25 KMS . Smoke black in early startup and again a white smoke too coming . Mechanic said engine head needs to be check and may be carb need to be change . Please help !

  3. What is PMS

  4. the way he put the piston on TDC is wrong.

  5. This issue is very informative. Currently my bike (fz16 2013, 40k kms clocked) and take huge time to hit 100.tictic sound from engine please tell me tappet setting values for this ride

  6. Jayant Gandhani


    I have fazer 2009 model. Since past 6 months I have been facing a similar issue.
    My bike knocks,Power loss,Doesnt accelerate, Sudden power drop, Black smoke, Unusual firing.

    I got it serviced thrice, also got carborator cleaned, changed air fliter, engine oil.
    Once its serviced it works fine for some days but then back to the same all issues.

    Yamaha service center near my place in Kharadi, Pune sucks.
    Now he is telling me to get Engine head work done.
    Change valves,rings and what not which would cost me around 6000-7000 according to him!

    I have no idea what should i do. Kindly suggest.
    Is it advisable to change these valves and other parts in engine head? Even if we do so how much does it cost approximately? Is it worth it?

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