2001 YAMAHA XV1600A brake fluid

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
E_5JA.book Page 1 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
6-5
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
E_5JA_Periodic.fm Page 5 Monday, December 18, 2000 7:28 PM

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
E_5JA.book Page 25 Wednesday, September 13, 2000 6:06 PM

PERIODIC MAINTENANCE AND MINOR REPAIR
6-26
6
EAU03238
Changing the brake fluid Have a Yamaha dealer change the
brake fluid at the intervals specified in
the periodic maintenance and lubrica-
tion chart. In addition, have the oil seals
of the brake master cylinder and caliper
as well as the brake hose replaced at
the intervals listed below or whenever
they are damaged or leaking.l
Oil seals: Replace every two
years.
l
Brake hose: Replace every four
years.
EAU01830
Drive belt slack The drive belt slack should be checked
before each ride and adjusted if neces-
sary.
To check the drive belt slack
1. Place the motorcycle on a level
surface and hold it in an upright
position.
2. Note the current position of the
drive belt using the marks near the
check hole.
NOTE:@ The marks near the drive belt check
hole are 5 mm apart. @3. Note the position of the drive belt
with a force of 45 N (4.5 kg) ap-
plied to the belt with a belt tension
gauge as shown.
4. Calculate the drive belt slack by
subtracting the measurement not-
ed in step 2 from the measure-
ment noted in step 3.
1. Drive belt
2. Marks
a. Drive belt slack
1. Belt tension gauge
E_5JA.book Page 26 Wednesday, September 13, 2000 6:06 PM

SPECIFICATIONS
8-3
8
Maximum load* 196 kg
Tire air pressure (measured on
cold tires)
Up to 90 kg*
Front 250 kPa (2.50 kg/cm
2, 2.50 bar)
Rear 250 kPa (2.50 kg/cm2, 2.50 bar)
90 kg–maximum*
Front 250 kPa (2.50 kg/cm2, 2.50 bar)
Rear 280 kPa (2.80 kg/cm2, 2.80 bar)
* Total weight of rider, passenger, cargo and accessories
Wheels
Front
Type Spoke wheel
Size 16 ´ MT 3.00
Rear
Type Spoke wheel
Size 16 ´ MT 3.50
Brakes
Front
Type Dual disc brake
Operation Right hand
Fluid DOT 4Rear
Type Single disc brake
Operation Right foot
Fluid DOT 4
Suspension
Front Telescopic fork
Rear Swingarm (link suspension)
Spring/shock absorber
Front Coil spring / oil damper
Rear Coil spring / gas-oil damper
Wheel travel
Front 140 mm
Rear 110 mm
Electrical
Ignition system Transistorized coil ignition
(digital)
Charging system
Type A.C. magneto
Standard output 14 V, 21 A @ 5,000 r/min
Battery
Type YTX20L-BS
Voltage, capacity 12 V, 18 Ah
E_5JA.book Page 3 Wednesday, September 13, 2000 6:06 PM

10-INDEXAAir filter element, cleaning ...................... 6-13
Anti-theft alarm ........................................3-4BBattery ................................................... 6-32
Brake and clutch levers, checking and
lubricating ............................................ 6-29
Brake and shift pedals, checking and
lubricating ............................................ 6-28
Brake fluid, changing ............................. 6-26
Brake fluid level, checking...................... 6-25
Brake lever...............................................3-8
Brake lever free play, adjusting .............. 6-22
Brake light switch (rear), adjusting ......... 6-23
Brake pads, checking............................. 6-23
Brake pedal..............................................3-8
Brake pedal position, adjusting .............. 6-22CCarburetor, adjusting ............................. 6-16
Care.........................................................7-1
Clock .......................................................3-5
Clutch lever ..............................................3-7
Clutch lever free play, adjusting ............. 6-21
Conversion table ......................................8-5DDimmer switch .........................................3-6
Drive belt slack ...................................... 6-26
Adjusting .......................................... 6-27
Checking .......................................... 6-26
EEngine break-in ....................................... 5-5
Engine oil and oil filter cartridge ............... 6-8
Engine stop switch................................... 3-6
Engine trouble warning light .................... 3-2FFront fork, checking ............................... 6-30
Fuel ......................................................... 3-9
Fuel cock ............................................... 3-11
Fuel consumption, tips for reducing ......... 5-4
Fuel gauge .............................................. 3-4
Fuel level warning light ............................ 3-2
Fuel tank breather hose ......................... 3-10
Fuel tank cap ........................................... 3-9
Fuses, replacing .................................... 6-33HHandlebar switches ................................. 3-6
Headlight bulb, replacing ....................... 6-35
Helmet holder ........................................ 3-13
High beam indicator light ......................... 3-2
Horn switch ............................................. 3-6IIdentification numbers ............................. 9-1
Idling speed, adjusting ........................... 6-16
Ignition circuit cut-off system.................. 3-16
Indicator and warning lights ..................... 3-2KKey identification number ........................ 9-1
LLight switch ..............................................3-6MMain switch/steering lock .........................3-1
Model label ..............................................9-2NNeutral indicator light ...............................3-2PPanel, removing and installing..................6-6
Parking.....................................................5-6
Part locations ...........................................2-1
Pass switch ..............................................3-6
Periodic maintenance and
lubrication chart ....................................... 6-3
Pre-operation check list ............................4-1RRider seat ..............................................3-12SSafety information ....................................1-1
Self-diagnosis device ...............................3-4
Shifting .....................................................5-3
Shift pedal ................................................3-7
Shift points (for Switzerland only) .............5-4
Shock absorber assembly, adjusting ......3-14
Sidestand ...............................................3-15
Sidestand, checking and lubricating .......6-30
Spark plugs, checking ..............................6-7
Specifications ...........................................8-1
Speedometer unit.....................................3-3
E_5JA.book Page 1 Wednesday, September 13, 2000 6:06 PM