2002 YAMAHA XV1600A check engine

PERIODIC MAINTENANCE AND MINOR REPAIR
6-11
6
EC000072*
CAUTION:_

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 “CD”
grade or higher. In addition, do
not use oils labeled “ENERGY
CONSERVING II” or higher.


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. 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 Saturday, August 18, 2001 3:52 PM

PERIODIC MAINTENANCE AND MINOR REPAIR
6-13
64. Remove the oil filler cap, add the
specified amount of the recom-
mended transfer case oil, and then
install and tighten the oil filler cap.
ECA00024
CAUTION:@ Make sure that no foreign material
enters the transfer case. @
5. Start the engine and let it idle for
several minutes while checking
the transfer case for oil leakage. If
oil is leaking, immediately turn the
engine off and check for the
cause.
EAU03707
Cleaning the air filter element The air filter element should be cleaned
at the intervals specified in the periodic
maintenance and lubrication chart.
Clean the air filter element more fre-
quently if you are riding in unusually
wet or dusty areas.
1. Remove the air filter case bolts.
1. Transfer case oil check holeRecommended transfer case oil:
See page 8-2.
Oil quantity:
0.4 L
1. Bolt (× 4)
2. Air filter case
E_5JA.book Page 13 Saturday, August 18, 2001 3:52 PM

PERIODIC MAINTENANCE AND MINOR REPAIR
6-16
6
EAU00629
Adjusting the carburetor The carburetor is an important part of
the engine and requires very sophisti-
cated adjustment. Therefore, most car-
buretor adjustments should be left to a
Yamaha dealer, who has the neces-
sary professional knowledge and expe-
rience. The adjustment described in
the following section, however, may be
serviced by the owner as part of routine
maintenance.
EC000094
CAUTION:@ The carburetor has been set and ex-
tensively tested at the Yamaha fac-
tory. Changing these settings
without sufficient technical knowl-
edge may result in poor perfor-
mance of or damage to the engine. @
EAU01168
Adjusting the engine idling
speed The engine idling speed must be
checked and, if necessary, adjusted as
follows at the intervals specified in the
periodic maintenance and lubrication
chart.NOTE:@ A diagnostic tachometer is needed to
make this adjustment. @1. Attach the tachometer to the spark
plug lead.
2. Start the engine and warm it up for
several minutes at 1,000–
2,000 r/min while occasionally rev-
ving it to 4,000–4,400 r/min.NOTE:@ The engine is warm when it quickly re-
sponds to the throttle. @
3. Check the engine idling speed
and, if necessary, adjust it to spec-
ification by turning the throttle stop
screw. To increase the engine
idling speed, turn the screw in di-
rection
a. To decrease the engine
idling speed, turn the screw in di-
rection
b.NOTE:@ If the specified idling speed cannot be
obtained as described above, have a
Yamaha dealer make the adjustment. @1. Throttle stop screwEngine idling speed:
850–950 r/min
E_5JA.book Page 16 Saturday, August 18, 2001 3:52 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 Saturday, August 18, 2001 3:52 PM

PERIODIC MAINTENANCE AND MINOR REPAIR
6-28
6 3. To tighten the drive belt, turn the
adjusting bolt on each side of the
swingarm in direction
a. To loos-
en the drive belt, turn the adjusting
bolt on each side of the swingarm
in direction
b, and then push the
rear wheel forward.
NOTE:@ Turn each adjusting bolt the same
amount for proper wheel alignment. @4. Tighten the locknuts.
ECA00025
CAUTION:@ Improper drive belt slack will over-
load the engine. Keep the drive belt
slack within the specified range. @5. Tighten the axle nut and the brake
caliper bracket bolt to the specified
torques.
EAU02962
Checking and lubricating the
cables The operation of all control cables and
the condition of the cables should be
checked before each ride, and the ca-
bles and cable ends should be lubricat-
ed if necessary. If a cable is damaged
or does not move smoothly, have a
Yamaha dealer check or replace it.
EW000112
WARNING
_ Damage to the outer sheath may in-
terfere with proper cable operation
and will cause the inner cable to
rust. Replace a damaged cable as
soon as possible to prevent unsafe
conditions. _
1. Drive belt slack adjusting bolt (× 2)
2. Drive belt puller locknut (× 2)
3. Wheel axle
Tightening torques:
Axle nut:
150 Nm (15 m·kgf)
Brake caliper bracket bolt:
48 Nm (4.8 m·kgf)
Recommended lubricant:
Engine oil
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PERIODIC MAINTENANCE AND MINOR REPAIR
6-31
6
EAU02939
Checking the front fork The condition and operation of the front
fork must be checked as follows at the
intervals specified in the periodic main-
tenance and lubrication chart.
To check the condition
EW000115
WARNING
@ Securely support the motorcycle so
that there is no danger of it falling
over. @Check the inner tubes for scratches,
damage and excessive oil leakage.To check the operation
1. Place the motorcycle on a level
surface and hold it in an upright
position.
2. While applying the front brake,
push down hard on the handle-
bars several times to check if the
front fork compresses and re-
bounds smoothly.
EC000098
CAUTION:@ If any damage is found or the front
fork does not operate smoothly,
have a Yamaha dealer check or re-
pair it. @
EAU00794
Checking the steering Worn or loose steering bearings may
cause danger. Therefore, the operation
of the steering must be checked as fol-
lows at the intervals specified in the pe-
riodic maintenance and lubrication
chart.
1. Place a stand under the engine to
raise the front wheel off the
ground.
EW000115
WARNING
@ Securely support the motorcycle so
that there is no danger of it falling
over. @
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PERIODIC MAINTENANCE AND MINOR REPAIR
6-39
6
EAU01297
Troubleshooting chart
EW000125
WARNING
@ Keep away open flames and do not smoke while checking or working on the fuel system. @
Check the fuel level in
the fuel tank.1. Fuel
There is enough fuel.
There is no fuel.
Check the compression.
Supply fuel.
The engine does not start.
Check the compression.
Operate the electric starter.2. Compression
There is compression.
There is no compression.
Check the ignition.
Have a Yamaha dealer
check the vehicle.
Remove the spark plugs
and check the electrodes.3. Ignition
Wipe off with a dry cloth and correct the
spark plug gaps, or replace the spark plugs.
Have a Yamaha dealer check the vehicle.
The engine does not start.
Have a Yamaha dealer
check the vehicle.
The engine does not start.
Check the battery.
Operate the electric starter.4. Battery
The engine turns over
quickly.
The engine turns over
slowly.
The battery is good.Check the battery lead connections,
and charge the battery if necessary.
DryWet
Open the throttle halfway and operate
the electric starter.
E_5JA.book Page 39 Saturday, August 18, 2001 3:52 PM

MOTORCYCLE CARE AND STORAGE
7-5
75. Perform the following steps to pro-
tect the cylinders, piston rings, etc.
from corrosion.
a. Remove the spark plug caps and
spark plugs.
b. Pour a teaspoonful of engine oil
into each spark plug bore.
c. Install the spark plug caps onto the
spark plugs, and then place the
spark plugs on the cylinder head
so that the electrodes are ground-
ed. (This will limit sparking during
the next step.)
d. Turn the engine over several times
with the starter. (This will coat the
cylinder walls with oil.)
e. Remove the spark plug caps from
the spark plugs, and then install
the spark plugs and the spark plug
caps.
EWA00003
WARNING
_ To prevent damage or injury from
sparking, make sure to ground the
spark plug electrodes while turning
the engine over. _
6. Lubricate all control cables and
the pivoting points of all levers and
pedals as well as of the sidestand/
centerstand.
7. Check and, if necessary, correct
the tire air pressure, and then lift
the motorcycle so that both of its
wheels are off the ground. Alterna-
tively, turn the wheels a little every
month in order to prevent the tires
from becoming degraded in one
spot.
8. Cover the muffler outlets with plas-
tic bags to prevent moisture from
entering them.9. Remove the battery and fully
charge it. Store it in a cool, dry
place and charge it once a month.
Do not store the battery in an ex-
cessively cold or warm place (less
than 0°C or more than 30°C). For
more information on storing the
battery, see page 6-34.
NOTE:_ Make any necessary repairs before
storing the motorcycle. _
E_5JA.book Page 5 Saturday, August 18, 2001 3:52 PM