2001 YAMAHA XV1600A tires

PRE-OPERATION CHECKS
4-2
4
NOTE:@ Pre-operation checks should be made each time the motorcycle is used. Such an inspection can be accomplished in a very
short time; and the added safety it assures is more than worth the time involved. @
EWA00033
WARNING
@ If any item in the Pre-operation check list is not working properly, have it inspected and repaired before operating
the motorcycle. @Control cables• Make sure that operation is smooth.
• Lubricate if necessary.—
Wheels and tires• Check for damage.
• Check tire condition and tread depth.
• Check air pressure.
• Correct if necessary.6-17–6-20, 6-31
Brake and shift pedals• Make sure that operation is smooth.
• Lubricate pedal pivoting points if necessary.6-28–6-29
Brake and clutch levers• Make sure that operation is smooth.
• Lubricate lever pivoting points if necessary.6-29
Sidestand• Make sure that operation is smooth.
• Lubricate pivot if necessary.6-30
Chassis fasteners• Make sure that all nuts, bolts and screws are properly tightened.
• Tighten if necessary.—
Instruments, lights, signals
and switches• Check operation.
• Correct if necessary.— ITEM CHECKS PAGE
E_5JA.book Page 2 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
6-4
6
9
*Brake hoses• Check for cracks or damage.ÖÖÖÖ Ö
• Replace. (See NOTE on page 6-5.) Every 4 years
10*Wheels• Check runout, spoke tightness and for damage.
• Tighten spokes if necessary.ÖÖÖÖ
11*Tires• Check tread depth and for damage.
• Replace if necessary.
• Check air pressure.
• Correct if necessary.ÖÖÖÖ
12*Wheel bearings• Check bearing for looseness or damage.ÖÖÖÖ
13*Swingarm• Check operation and for excessive play.ÖÖÖÖ
• Lubricate with molybdenum disulfide grease. Every 50,000 km
14*Drive belt• Check belt tension.
• Make sure that the rear wheel is properly aligned.Every 4,000 km
15*Steering bearings• Check bearing play and steering for roughness.ÖÖÖÖÖ
• Lubricate with lithium-soap-based grease. Every 20,000 km
16*Chassis fasteners• Make sure that all nuts, bolts and screws are properly tightened.ÖÖÖÖ Ö
17 Sidestand• Check operation.
• Lubricate.ÖÖÖÖ Ö
18*Sidestand switch• Check operation.ÖÖÖÖÖ Ö
19*Front fork• Check operation and for oil leakage.ÖÖÖÖ
20*Rear shock absorber
assembly• Check operation and shock absorber for oil leakage.ÖÖÖÖ
21*Rear suspension relay
arm and connecting arm
pivoting points• Check operation.ÖÖÖÖ
• Lubricate with molybdenum disulfide grease.ÖÖ
22*Carburetors• Check starter (choke) operation.
• Adjust engine idling speed and synchronization.ÖÖÖÖÖ Ö NO. ITEM CHECK OR MAINTENANCE JOBODOMETER READING (´1,000 km)
ANNUAL
CHECK
1 10203040
E_5JA_Periodic.fm Page 4 Monday, December 18, 2000 7:28 PM

PERIODIC MAINTENANCE AND MINOR REPAIR
6-17
6
EAU00635
Adjusting the throttle cable
free play The throttle cable free play should
measure 4–6 mm at the throttle grip.
Periodically check the throttle cable
free play and, if necessary, have a
Yamaha dealer adjust it.
EAU00637
Adjusting the valve clearance The valve clearance changes with use,
resulting in improper air-fuel mixture
and/or engine noise. To prevent this
from occurring, the valve clearance
must be adjusted by a Yamaha dealer
at the intervals specified in the periodic
maintenance and lubrication chart.
EAU01848
Tires To maximize the performance, durabil-
ity, and safe operation of your motor-
cycle, note the following points
regarding the specified tires.
Tire air pressure
The tire air pressure should be
checked and, if necessary, adjusted
before each ride.
a. Throttle cable free playE_5JA.book Page 17 Wednesday, September 13, 2000 6:06 PM

PERIODIC MAINTENANCE AND MINOR REPAIR
6-18
6
EW000082
WARNING
@ l
The tire air pressure must be
checked and adjusted on cold
tires (i.e., when the temperature
of the tires equals the ambient
temperature).
l
The tire air pressure must be
adjusted in accordance with the
riding speed and with the total
weight of rider, passenger, car-
go, and accessories approved
for this model.
@CE-01E
CE-07EEWA00012
WARNING
@ Because loading has an enormous
impact on the handling, braking,
performance and safety characteris-
tics of your motorcycle, you should
keep the following precautions in
mind. l
NEVER OVERLOAD THE
MOTORCYCLE! Operation of an
overloaded motorcycle may re-
sult in tire damage, loss of con-
trol, or severe injury. Make sure
that the total weight of rider,
passenger, cargo, and accesso-
ries does not exceed the speci-
fied maximum load for the
vehicle.
l
Do not carry along loosely
packed items, which can shift
during a ride.
l
Securely pack the heaviest
items close to the center of the
motorcycle and distribute the
weight evenly on both sides.
l
Adjust the suspension and tire
air pressure with regard to the
load.
l
Check the tire condition and air
pressure before each ride.
@
Tire air pressure
(measured on cold tires)
Load* Front Rear
Up to 90 kg250 kPa
2.50 kg/cm
2
2.50 bar250 kPa
2.50 kg/cm
2
2.50 bar
90 kg–maximum250 kPa
2.50 kg/cm
2
2.50 bar280 kPa
2.80 kg/cm
2
2.80 bar
Maximum load* 196 kg
* Total weight of rider, passenger, cargo and
accessories
E_5JA.book Page 18 Wednesday, September 13, 2000 6:06 PM

PERIODIC MAINTENANCE AND MINOR REPAIR
6-19
6Tire inspection
The tires must be checked before each
ride. If the center tread depth reaches
the specified limit, if the tire has a nail
or glass fragments in it, or if the side-
wall is cracked, have a Yamaha dealer
replace the tire immediately.
CE-08ENOTE:@ The tire tread depth limits may differ
from country to country. Always comply
with the local regulations. @
EW000079
WARNING
@ l
Have a Yamaha dealer replace
excessively worn tires. Besides
being illegal, operating the
motorcycle with excessively
worn tires decreases riding sta-
bility and can lead to loss of
control.
l
The replacement of all wheel-
and brake-related parts, includ-
ing the tires, should be left to a
Yamaha dealer, who has the
necessary professional knowl-
edge and experience.
@
Tire information
This motorcycle is equipped with tube
tires.
EW000078
WARNING
@ l
The front and rear tires should
be of the same make and de-
sign, otherwise the handling
characteristics of the motor-
cycle cannot be guaranteed.
l
After extensive tests, only the
tires listed below have been ap-
proved for this model by
Yamaha Motor Co., Ltd.
@CE-10E
1. Tire sidewall
a. Tire tread depthMinimum tire tread depth
(front and rear)1.6 mm
FRONT
Manufacturer Size Model
Dunlop 130/90-16 67H D404FL
Bridgestone 130/90-16 67H G703F
REAR
Manufacturer Size Model
Dunlop 150/80B-16 71H D404
Bridgestone 150/80B-16 71H G702
E_5JA.book Page 19 Wednesday, September 13, 2000 6:06 PM

PERIODIC MAINTENANCE AND MINOR REPAIR
6-20
6
EAU00681
WARNING
@ l
Have a Yamaha dealer replace
excessively worn tires. Besides
being illegal, operating the
motorcycle with excessively
worn tires decreases riding sta-
bility and can lead to loss of
control.
l
The replacement of all wheel-
and brake-related parts, includ-
ing the tires, should be left to a
Yamaha dealer, who has the
necessary professional knowl-
edge and experience.
l
It is not recommended to patch
a punctured tube. If unavoid-
able, however, patch the tube
very carefully and replace it as
soon as possible with a high-
quality product.
@
EAU00685
Spoke wheels To maximize the performance, durabil-
ity, and safe operation of your motor-
cycle, note the following points
regarding the specified wheels.l
The wheel rims should be checked
for cracks, bends or warpage, and
the spokes for looseness or dam-
age before each ride. If any dam-
age is found, have a Yamaha
dealer replace the wheel. Do not
attempt even the smallest repair to
the wheel. A deformed or cracked
wheel must be replaced.
l
The wheel should be balanced
whenever either the tire or wheel
has been changed or replaced. An
unbalanced wheel can result in
poor performance, adverse han-
dling characteristics, and a short-
ened tire life.
l
Ride at moderate speeds after
changing a tire since the tire sur-
face must first be “broken in” for it
to develop its optimal characteris-
tics.
E_5JA.book Page 20 Wednesday, September 13, 2000 6:06 PM

MOTORCYCLE CARE AND STORAGE
7-3
7After riding in the rain, near the sea or
on salt-sprayed roadsSince sea salt or salt sprayed on roads
during winter are extremely corrosive in
combination with water, carry out the
following steps after each ride in the
rain, near the sea or on salt-sprayed
roads.NOTE:@ Salt sprayed on roads in the winter may
remain well into spring. @1. Clean the motorcycle with cold
water and a mild detergent, after
the engine has cooled down.
ECA00012
CAUTION:@ Do not use warm water since it in-
creases the corrosive action of the
salt. @2. After drying the motorcycle, apply
a corrosion protection spray on all
metal, including chrome- and nick-
el-plated, surfaces to prevent cor-
rosion.After cleaning
1. Dry the motorcycle with a chamois
or an absorbing cloth.
2. Use a chrome polish to shine
chrome, aluminum and stainless-
steel parts, including the exhaust
system. (Even the thermally in-
duced discoloring of stainless-
steel exhaust systems can be re-
moved through polishing.)
3. To prevent corrosion, it is recom-
mended to apply a corrosion pro-
tection spray on all metal,
including chrome- and nickel-plat-
ed, surfaces.
4. Use spray oil as a universal clean-
er to remove any remaining dirt.
5. Touch up minor paint damage
caused by stones, etc.
6. Wax all painted surfaces.
7. Let the motorcycle dry completely
before storing or covering it.
EWA00001
WARNING
@ l
Make sure that there is no oil or
wax on the brakes or tires. If
necessary, clean the brake
discs and brake linings with a
regular brake disc cleaner or ac-
etone, and wash the tires with
warm water and a mild deter-
gent.
l
Before operating the motor-
cycle test its braking perfor-
mance and cornering behavior.
@
E_5JA.book Page 3 Wednesday, September 13, 2000 6:06 PM