2001 YAMAHA XV1600A clutch

OPERATION AND IMPORTANT RIDING POINTS
5-3
5
EAU01258
Starting a warm engine Follow the same procedure as for start-
ing a cold engine with the exception
that the starter (choke) is not required
when the engine is warm.
EAU00423
Shifting Shifting gears lets you control the
amount of engine power available for
starting off, accelerating, climbing hills,
etc.
The gear positions are shown in the il-
lustration.NOTE:@ To shift the transmission into the neu-
tral position, press the shift pedal down
repeatedly until it reaches the end of its
travel, and then slightly raise it. @
EC000048
CAUTION:@ l
Even with the transmission in
the neutral position, do not
coast for long periods of time
with the engine off, and do not
tow the motorcycle for long dis-
tances. The transmission is
properly lubricated only when
the engine is running. Inade-
quate lubrication may damage
the transmission.
l
Always use the clutch while
changing gears to avoid dam-
aging the engine, transmission,
and drive train, which are not
designed to withstand the
shock of forced shifting.
@
1. Shift pedal
N. Neutral position
E_5JA.book Page 3 Wednesday, September 13, 2000 6:06 PM

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
E_5JA.book Page 1 Wednesday, September 13, 2000 6:06 PM

PERIODIC MAINTENANCE AND MINOR REPAIR
6-3
6
EAU03685
Periodic maintenance and lubrication chart
NOTE:_ l
The annual checks must be performed every year, except if a kilometer-based maintenance is performed instead.
l
From 50,000 km, repeat the maintenance intervals starting from 10,000 km.
l
Items marked with an asterisk should be performed by a Yamaha dealer as they require special tools, data and techni-
cal skills.
_CP-01ENO. ITEM CHECK OR MAINTENANCE JOBODOMETER READING (´1,000 km)
ANNUAL
CHECK
1 10203040
1
*Fuel line• Check fuel hoses for cracks or damage.ÖÖÖÖ Ö
2*Fuel filter• Check condition.ÖÖ
3 Spark plugs• Check condition.
• Clean and regap.ÖÖ
•Replace.ÖÖ
4*Valves• Check valve clearance.
• Adjust.Every 20,000 km
5 Air filter element• Clean.ÖÖ
•Replace.ÖÖ
6Clutch• Check operation.
• Adjust.ÖÖÖÖÖ
7*Front brake• Check operation, fluid level and vehicle for fluid leakage.
(See NOTE on page 6-5.)ÖÖÖÖÖ Ö
• Replace brake pads. Whenever worn to the limit
8*Rear brake• Check operation, fluid level and vehicle for fluid leakage.
(See NOTE on page 6-5.)ÖÖÖÖÖ Ö
• Replace brake pads. Whenever worn to the limit
E_5JA_Periodic.fm Page 3 Monday, December 18, 2000 7:28 PM

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
E_5JA.book Page 11 Wednesday, September 13, 2000 6:06 PM

PERIODIC MAINTENANCE AND MINOR REPAIR
6-21
6
EAU00694
Adjusting the clutch lever free
play The clutch lever free play should mea-
sure 10–15 mm as shown. Periodically
check the clutch lever free play and, if
necessary, adjust it as follows.
1. Loosen the locknut at the clutch le-
ver.
2. To increase the clutch lever free
play, turn the adjusting bolt in di-
rection
a. To decrease the clutch
lever free play, turn the adjusting
bolt in direction
b.3. If the specified clutch lever free
play could be obtained as de-
scribed above, tighten the locknut
and skip the rest of the procedure,
otherwise proceed as follows.
4. Fully turn the adjusting bolt at the
clutch lever in direction
a to loos-
en the clutch cable.
5. Loosen the locknut at the crank-
case.
6. To increase the clutch lever free
play, turn the adjusting nut in di-
rection
a. To decrease the clutch
lever free play, turn the adjusting
nut in direction
b.7. Tighten the locknut at the clutch
lever and the crankcase.1. Locknut
2. Clutch lever free play adjusting bolt
c. Clutch lever free play
1. Clutch lever free play adjusting nut
2. Locknut
E_5JA.book Page 21 Wednesday, September 13, 2000 6:06 PM

PERIODIC MAINTENANCE AND MINOR REPAIR
6-29
6
EAU03164
Checking and lubricating the
brake and clutch levers The operation of the brake and clutch
levers should be checked before each
ride, and the lever pivots should be lu-
bricated if necessary.
Recommended lubricant:
Lithium-soap-based grease
(all-purpose grease)
E_5JA.book Page 29 Wednesday, September 13, 2000 6:06 PM

8-1
8
EAU01038
8-SPECIFICATIONSSpecifications CS-01E
Model XV1600A
Dimensions
Overall length 2,500 mm
Overall width 980 mm
Overall height 1,140 mm
Seat height 710 mm
Wheelbase 1,685 mm
Ground clearance 145 mm
Minimum turning radius 3,200 mm
Basic weight (with oil and full
fuel tank)
332 kg
Engine
Engine type Air-cooled 4-stroke, OHV
Cylinder arrangement V-type 2-cylinder
Displacement 1,602 cm
3
Bore ´ Stroke 95 ´ 113 mm
Compression ratio 8.3:1
Starting system Electric starter
Lubrication system Dry sumpEngine oil
Ty p e
Recommended engine oil
classification API Service SE, SF, SG type or
higher
Quantity
Without oil filter cartridge
replacement 3.7 L
With oil filter car tridge
replacement 4.1 L
Total amount (dry engine) 5.0 L
-20 -10 0
10 20 30
40
50 ˚C
SAE 10W-30
SAE 15W-40SAE 20W-40SAE 20W-50
SAE 10W-40
CAUTION:Be sure to use motor oils that do not contain anti-friction
modifiers. Passenger car motor oils (often labeled
“ENERGY CONSERVING II”) contain anti-friction additives
which will cause clutch and/or starter clutch slippage, result-
ing in reduced component life and poor engine performance.
E_5JA.book Page 1 Wednesday, September 13, 2000 6:06 PM

SPECIFICATIONS
8-2
8
Transfer case oil
Type SAE80API “GL-4” Hypoid Gear
Oil
Quantity 0.4 L
Air filterDry type element
Fuel
Type Regular unleaded gasoline
Fuel tank capacity 20 L
Reserve amount 3.5 L
Carburetor
Manufacturer MIKUNI
Model ´ quantity BSR40 ´ 1
Spark plug
Manufacturer/model NGK / DPR7EA-9 or
DENSO / X22EPR-U9
Gap 0.8–0.9 mm
Clutch typeWet, multiple-disc
Transmission
Primary reduction system Spur gear
Primary reduction ratio 1.532
Secondary reduction system Belt
Secondary reduction ratio 2.320
Transmission type Constant mesh 5-speed
Operation Left footGear ratio
1st 2.438
2nd 1.579
3rd 1.160
4th 0.906
5th 0.750
Chassis
Frame type Double cradle
Caster angle 32°
Trail 142 mm
Tire
Front
Type Tube tire
Size 130/90-16 67H
Manufacturer/model Dunlop / D404FL
Bridgestone / G703F
Rear
Type Tube tire
Size 150/80B-16 71H
Manufacturer/model Dunlop / D404
Bridgestone / G702
E_5JA.book Page 2 Wednesday, September 13, 2000 6:06 PM