2001 YAMAHA XV1600A oil level

4-1
4
EAU01114
4-PRE-OPERATION CHECKSThe condition of a vehicle is the owner’s responsibility. Vital components can start to deteriorate quickly and unexpectedly,
even if the vehicle remains unused (for example, as a result of exposure to the elements). Any damage, fluid leakage or loss
of tire air pressure could have serious consequences. Therefore, it is very important, in addition to a thorough visual inspec-
tion, to check the following points before each ride.
EAU03439
Pre-operation check list
ITEM CHECKS PAGE
Fuel• Check fuel level in fuel tank.
• Refuel if necessary.
• Check fuel line for leakage.3-9–3-10
Engine oil• Check oil level in engine.
• If necessary, add recommended oil to specified level.
• Check vehicle for oil leakage.6-8–6-11
Front brake• Check operation.
• If soft or spongy, have Yamaha dealer bleed hydraulic system.
• Check lever free play.
• Adjust if necessary.
• Check fluid level in reservoir.
• If necessary, add recommended brake fluid to specified level.
• Check hydraulic system for leakage.6-22–6-26
Rear brake• Check operation.
• If soft or spongy, have Yamaha dealer bleed hydraulic system.
• Check fluid level in reservoir.
• If necessary, add recommended brake fluid to specified level.
• Check hydraulic system for leakage.6-22–6-26
Clutch• Check operation.
• Lubricate cable if necessary.
• Check lever free play.
• Adjust if necessary.6-21, 6-29
Throttle grip• Make sure that operation is smooth.
• Lubricate throttle grip, housing and cables if necessary.
• Check free play.
• If necessary, have Yamaha dealer make adjustment.6-17
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6
PERIODIC MAINTENANCE AND MINOR REPAIR
Owner’s tool kit .................................................... 6-1
Periodic maintenance and lubrication chart ......... 6-3
Removing and installing the panel ....................... 6-6
Checking the spark plugs .................................... 6-7
Engine oil and oil filter cartridge .......................... 6-8
Transfer case oil ................................................. 6-12
Cleaning the air filter element ............................ 6-13
Adjusting the carburetor ..................................... 6-16
Adjusting the engine idling speed ...................... 6-16
Adjusting the throttle cable free play .................. 6-17
Adjusting the valve clearance ............................ 6-17
Tires ................................................................... 6-17
Spoke wheels .................................................... 6-20
Adjusting the clutch lever free play .................... 6-21
Adjusting the brake lever free play ..................... 6-22
Adjusting the brake pedal position ..................... 6-22
Adjusting the rear brake light switch .................. 6-23
Checking the front and rear brake pads ............. 6-23Checking the brake fluid level ............................ 6-25
Changing the brake fluid ................................... 6-26
Drive belt slack .................................................. 6-26
Checking and lubricating the brake and
shift pedals ...................................................... 6-28
Checking and lubricating the brake and
clutch levers .................................................... 6-29
Checking and lubricating the sidestand ............ 6-30
Checking the front fork ...................................... 6-30
Checking the steering ....................................... 6-31
Checking the wheel bearings ............................ 6-31
Battery ............................................................... 6-32
Replacing the fuses .......................................... 6-33
Replacing the headlight bulb ............................. 6-35
Replacing a turn signal light bulb or the tail/
brake light bulb ................................................ 6-37
Troubleshooting ................................................. 6-37
Troubleshooting chart ........................................ 6-38
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PERIODIC MAINTENANCE AND MINOR REPAIR
6-5
6
EAU03541
NOTE:@l
The air filter needs more frequent service if you are riding in unusually wet or dusty areas.
l
Hydraulic brake service
• Regularly check and, if necessary, correct the brake fluid level.
• Every two years replace the internal components of the brake master cylinder and caliper, and change the brake fluid.
• Replace the brake hoses every four years and if cracked or damaged.
@23 Engine oil• Change.ÖÖÖÖÖ Ö
24 Engine oil filter cartridge•Replace.ÖÖÖ
25
*Transfer case oil• Check oil level.ÖÖ
• Change.ÖÖÖ
26*Front and rear brake
switches• Check operation.ÖÖÖÖÖ Ö
27 Moving parts and cables• Lubricate.ÖÖÖÖ Ö
28*Lights, signals and
switches• Check operation.
• Adjust headlight beam.ÖÖÖÖÖ Ö NO. ITEM CHECK OR MAINTENANCE JOBODOMETER READING (´1,000 km)
ANNUAL
CHECK
1 10203040
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PERIODIC MAINTENANCE AND MINOR REPAIR
6-8
6
ECA00021
CAUTION:@ Do not use any tools to remove or
install the spark plug cap, otherwise
the ignition coil coupler may get
damaged. The spark plug cap may
be difficult to remove because the
rubber seal on the end of the cap fits
tightly. To remove the spark plug
cap, simply twist it back and forth
while pulling it out; to install it, twist
it back and forth while pushing it in. @
EAU03679
Engine oil and oil filter
cartridge The engine oil level should be checked
before each ride. In addition, the oil
must be changed and the oil filter car-
tridge replaced at the intervals speci-
fied in the periodic maintenance and
lubrication chart.
To check the engine oil level
1. Place the motorcycle on a level
surface and hold it in an upright
position.NOTE:@ Make sure that the motorcycle is posi-
tioned straight up when checking the oil
level. A slight tilt to the side can result in
a false reading. @2. Remove the rider seat. (See page
3-12 for rider seat removal and in-
stallation procedures.)3. Start the engine, warm it up until
the engine oil has reached a nor-
mal temperature of 60 °C, let it
continue to idle for ten seconds,
and then turn the engine off.
NOTE:@ To achieve the proper engine oil tem-
perature for an accurate oil level read-
ing, the engine must have first
completely cooled down, and then
warmed up again for several minutes to
normal operating temperature. @4. Wait a few minutes until the oil set-
tles, remove the oil filler cap, wipe
the dipstick clean, insert it back
into the oil filler hole (without
screwing it in), and then remove it
again to check the oil level.NOTE:@ The engine oil should be between the
minimum and maximum level marks. @
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PERIODIC MAINTENANCE AND MINOR REPAIR
6-9
65. If the engine oil is below the mini-
mum level mark, add sufficient oil
of the recommended type to raise
it to the correct level.
NOTE:@ When adding oil, be careful not to over-
fill the engine; the oil level rises faster
starting from the half level portion on
the dipstick. @6. Insert the dipstick into the oil filler
hole, and then tighten the oil filler
cap.
7. Install the rider seat.
ECA00027
CAUTION:@ Make sure that the oil filler cap is se-
curely tightened, otherwise oil may
seep out when the engine is
running. @
1. Engine oil filler cap
1. Maximum level
2. Minimum level
3. Dipstick
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PERIODIC MAINTENANCE AND MINOR REPAIR
6-11
69. Install the engine oil drain bolts,
and then tighten them to the spec-
ified torque.
10. Pour only 2.5 L of the specified
amount of recommended engine
oil through the filler hole, insert the
dipstick, and then tighten the oil
filler cap.
11. Start the engine, rev it several
times, and then turn it off.
12. Remove the engine oil filler cap,
and then gradually fill the oil tank
with the remaining oil quantity
while regularly checking the oil
level on the dipstick.
EC000072
CAUTION:@ l
In order to prevent clutch slip-
page (since the engine oil also
lubricates the clutch), do not
mix any chemical additives with
the oil or use oils of a higher
grade than “CD”. In addition, do
not use oils labeled “ENERGY
CONSERVING II” or higher.
l
Make sure that no foreign mate-
rial enters the crankcase.
@
13. Install the engine oil filler cap.
14. Start the engine, and then let it idle
for several minutes while checking
it for oil leakage. If oil is leaking,
immediately turn the engine off
and check for the cause.
15. Turn the engine off, and then
check the oil level and correct it if
necessary. Tightening torque:
Engine oil drain bolt:
43 Nm (4.3 m·kg)
Recommended engine oil:
See page 8-1.
Oil quantity:
Without oil filter cartridge
replacement:
3.7 L
With oil filter cartridge
replacement:
4.1 L
Total amount (dry engine):
5.0 L
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PERIODIC MAINTENANCE AND MINOR REPAIR
6-12
6
EAU03395
Transfer case oil The transfer case oil level should be
checked before each ride. In addition,
the oil must be changed at the intervals
specified in the periodic maintenance
and lubrication chart.
To check the transfer case oil level
1. Place the motorcycle on a level
surface and hold it in an upright
position.
NOTE:@ Make sure that the motorcycle is posi-
tioned straight up when checking the oil
level. A slight tilt to the side can result in
a false reading. @2. Remove the oil check bolt, and
then check the oil level in the
transfer case.NOTE:@ The oil should be at the brim of the
check hole. @3. If the oil is below the brim of the
check hole, remove the oil filler
cap, add sufficient oil of the rec-
ommended type to raise it to the
correct level, and then install the
oil filler cap.
4. Install the oil check bolt, and then
tighten it to the specified torque.To change the transfer case oil
1. Place an oil pan under the transfer
case to collect the used oil.
2. Remove the drain bolt and the
check bolt to drain the oil from the
transfer case.
3. Install the drain bolt and the check
bolt, and then tighten the drain bolt
to the specified torque.
1. Transfer case oil filler cap
2. Transfer case oil check bolt
Tightening torque:
Transfer case oil check bolt:
7.5 Nm (0.75 m·kg)
1. Transfer case oil drain boltTightening torque:
Transfer case oil drain bolt:
17.5 Nm (1.75 m·kg)
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PERIODIC MAINTENANCE AND MINOR REPAIR
6-25
6
EAU03196
Checking the brake fluid level Insufficient brake fluid may allow air to
enter the brake system, possibly caus-
ing it to become ineffective.
Before riding, check that the brake fluid
is above the minimum level mark and
replenish if necessary. A low brake flu-
id level may indicate worn brake pads
and/or brake system leakage. If the
brake level is low, be sure to check the
brake pads for wear and the brake sys-
tem for leakage.
Observe these precautions:l
When checking the fluid level,
make sure that the top of the mas-
ter cylinder or brake fluid reservoir
is level.
l
Use only the recommended quali-
ty brake fluid, otherwise the rubber
seals may deteriorate, causing
leakage and poor braking perfor-
mance.
l
Refill with the same type of brake
fluid. Mixing fluids may result in a
harmful chemical reaction and
lead to poor braking performance.
l
Be careful that water does not en-
ter the master cylinder when refill-
ing. Water will significantly lower
the boiling point of the fluid and
may result in vapor lock.
l
Brake fluid may deteriorate paint-
ed surfaces or plastic parts. Al-
ways clean up spilled fluid
immediately.
l
As the brake pads wear, it is nor-
mal for the brake fluid level to
gradually go down. However, if the
brake fluid level goes down sud-
denly, have a Yamaha dealer
check the cause.
1. Minimum level markFront
1. Minimum level mark
Recommended brake fluid: DOT 4Rear
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