2002 YAMAHA XV1600A maintenance

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 Saturday, August 18, 2001 3:52 PM

PERIODIC MAINTENANCE AND MINOR REPAIR
6-22
6
EAU00696
Adjusting the brake lever free
play The brake lever free play should mea-
sure 2–5 mm as shown. Periodically
check the brake lever free play and, if
necessary, adjust it as follows.
1. Loosen the locknut at the brake le-
ver.
2. To increase the brake lever free
play, turn the adjusting bolt in di-
rection
a. To decrease the brake
lever free play, turn the adjusting
bolt in direction
b.
3. Tighten the locknut.
EW000099
WARNING
@

After adjusting the brake lever
free play, check the free play
and make sure that the brake is
working properly.


A soft or spongy feeling in the
brake lever can indicate the
presence of air in the hydraulic
system. If there is air in the hy-
draulic system, have a Yamaha
dealer bleed the system before
operating the motorcycle. Air in
the hydraulic system will dimin-
ish the braking performance,
which may result in loss of con-
trol and an accident.
@
EAU01746
Adjusting the brake pedal
position The top of the brake pedal should be
positioned approximately 100 mm
above the top of the footrest as shown.
Periodically check the brake pedal po-
sition and, if necessary, have a
Yamaha dealer adjust it.
1. Locknut
2. Brake lever free play adjusting bolt
c. Brake lever free play
a. Distance between brake pedal and footrest
E_5JA.book Page 22 Saturday, August 18, 2001 3:52 PM

PERIODIC MAINTENANCE AND MINOR REPAIR
6-23
6
EW000109
WARNING
@ A soft or spongy feeling in the brake
pedal can indicate the presence of
air in the hydraulic system. If there
is air in the hydraulic system, have a
Yamaha dealer bleed the system be-
fore operating the motorcycle. Air in
the hydraulic system will diminish
the braking performance, which
may result in loss of control and an
accident. @
EAU00713
Adjusting the rear brake light
switch The rear brake light switch, which is ac-
tivated by the brake pedal, is properly
adjusted when the brake light comes
on just before braking takes effect. If
necessary, adjust the brake light switch
as follows.
Turn the adjusting nut while holding the
rear brake light switch in place. To
make the brake light come on earlier,
turn the adjusting nut in direction
a. To
make the brake light come on later,
turn the adjusting nut in direction
b.
EAU00721
Checking the front and rear
brake pads The front and rear brake pads must be
checked for wear at the intervals spec-
ified in the periodic maintenance and
lubrication chart.
1. Rear brake light switch
2. Rear brake light switch adjusting nut
E_5JA.book Page 23 Saturday, August 18, 2001 3:52 PM

PERIODIC MAINTENANCE AND MINOR REPAIR
6-24
6
EAU03938
Front brake pads
Each front brake pad is provided with
wear indicator grooves, which allow
you to check the brake pad wear with-
out having to disassemble the brake.
To check the brake pad wear, check
the wear indicator grooves. If a brake
pad has worn to the point that the wear
indicator grooves have almost disap-
peared, have a Yamaha dealer replace
the brake pads as a set.
EAU03939
Rear brake pads
Each rear brake pad is provided with a
wear indicator groove, which allows
you to check the brake pad wear with-
out having to disassemble the brake.
To check the brake pad wear, check
the wear indicator groove. If a brake
pad has worn to the point that the wear
indicator groove has almost disap-
peared, have a Yamaha dealer replace
the brake pads as a set.
1. Brake pad wear indicator groove (× 2)Front
1. Brake pad wear indicator grooveRear
E_5JA.book Page 24 Saturday, August 18, 2001 3:52 PM

PERIODIC MAINTENANCE AND MINOR REPAIR
6-25
6
EAU03294
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:

When checking the fluid level,
make sure that the top of the brake
fluid reservoir is level.


Use only the recommended quali-
ty brake fluid, otherwise the rubber
seals may deteriorate, causing
leakage and poor braking perfor-
mance.


Refill with the same type of brake
fluid. Mixing fluids may result in a
harmful chemical reaction and
lead to poor braking performance.


Be careful that water does not en-
ter the brake fluid reservoir when
refilling. Water will significantly
lower the boiling point of the fluid
and may result in vapor lock.


Brake fluid may deteriorate paint-
ed surfaces or plastic parts. Al-
ways clean up spilled fluid
immediately.


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 Saturday, August 18, 2001 3:52 PM

PERIODIC MAINTENANCE AND MINOR REPAIR
6-26
6
EAU03976
Changing the brake fluid Have a Yamaha dealer change the
brake fluid at the intervals specified in
the NOTE after the periodic mainte-
nance and lubrication chart. In addition,
have the oil seals of the master cylin-
ders and calipers as well as the brake
hoses replaced at the intervals listed
below or whenever they are damaged
or leaking.

Oil seals: Replace every two
years.


Brake hoses: 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 kgf) 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 Saturday, August 18, 2001 3:52 PM

PERIODIC MAINTENANCE AND MINOR REPAIR
6-27
65. If the drive belt slack is incorrect,
adjust it as follows.
EAU01748
To adjust the drive belt slack
1. Loosen the rear wheel axle nut
and the brake caliper bracket bolt.2. Loosen the drive belt puller lock-
nut on each side of the swingarm. Drive belt slack:
7.5–13 mm1. Wheel axle nut
1. Brake caliper bracket bolt
E_5JA.book Page 27 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
E_5JA.book Page 28 Saturday, August 18, 2001 3:52 PM