2002 YAMAHA XV1600A check engine light

INSTRUMENT AND CONTROL FUNCTIONS
3-2
3
EAU01590
(Parking)
The steering is locked, and the taillight
and auxiliary light are on, but all other
electrical systems are off. The key can
be removed.
The steering must be locked before the
key can be turned to “”.
ECA00043
CAUTION:@ Do not use the parking position for
an extended length of time, other-
wise the battery may discharge. @
EAU03034
Indicator and warning lights
EAU00079
Fuel level warning light “”
This warning light comes on when the
fuel level drops below approximately
3.5 L. When this occurs, turn the fuel
cock lever to the “RES” position and re-
fuel as soon as possible.
EAU00063
High beam indicator light “”
This indicator light comes on when the
high beam of the headlight is switched
on.
EAU00057
Turn signal indicator light “”
This indicator light flashes when the
turn signal switch is pushed to the left
or right.
EAU00061
Neutral indicator light “”
This indicator light comes on when the
transmission is in the neutral position.
EAU00091
Engine trouble warning light “”
This warning light comes on or flashes
when an electrical circuit monitoring
the engine is defective. When this oc-
curs, have the Yamaha dealer check
the self-diagnosis system.
1. Fuel level warning light “”
2. High beam indicator light “”
3. Turn signal indicator light “”
4. Neutral indicator light “”
5. Engine trouble warning light “”
E_5JA.book Page 2 Saturday, August 18, 2001 3:52 PM

INSTRUMENT AND CONTROL FUNCTIONS
3-4
3
EAU03400
Self-diagnosis device This model is equipped with a self-di-
agnosis device for various electrical
circuits.
If any of those circuits are defective,
the engine trouble warning light will
come on or the fuel level warning light
will flash. If this occurs, have a Yamaha
dealer check the motorcycle.
ECA00061
CAUTION:@ To prevent engine damage, be sure
to consult a Yamaha dealer as soon
as possible if this occurs. @
EAU00113
Fuel gauge The fuel gauge indicates the amount of
fuel in the fuel tank. The needle moves
towards “E” (Empty) as the fuel level
decreases. When the needle reaches
“E”, refuel as soon as possible.NOTE:@ Do not allow the fuel tank to empty it-
self completely. @
EAU00109
Anti-theft alarm (optional) This motorcycle can be equipped with
an optional anti-theft alarm by a
Yamaha dealer. Contact a Yamaha
dealer for more information.
E_5JA.book Page 4 Saturday, August 18, 2001 3:52 PM

OPERATION AND IMPORTANT RIDING POINTS
5-2
5 1. Turn the fuel cock lever to “ON”.
2. Turn the key to “ON” and make
sure that the engine stop switch is
set to “”.
3. Shift the transmission into the neu-
tral position.
NOTE:@ When the transmission is in the neutral
position, the neutral indicator light
should be on, otherwise have a
Yamaha dealer check the electrical
circuit. @
4. Turn the starter (choke) on and
completely close the throttle. (See
page 3-12 for starter (choke)
operation.)
5. Start the engine by pushing the
start switch.NOTE:@ If the engine fails to start, release the
start switch, wait a few seconds, and
then try again. Each starting attempt
should be as short as possible to pre-
serve the battery. Do not crank the en-
gine more than 10 seconds on any one
attempt. @
6. After starting the engine, move the
starter (choke) knob back halfway.
ECA00055
CAUTION:@ For maximum engine life, always
warm the engine up before starting
off. Never accelerate hard when the
engine is cold! @7. When the engine is warm, turn the
starter (choke) off.NOTE:@ The engine is warm when it responds
normally to the throttle with the starter
(choke) turned off. @
E_5JA.book Page 2 Saturday, August 18, 2001 3:52 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 ............. 6-23
Checking the brake fluid level ............................ 6-25
Changing the brake fluid .................................... 6-26Drive belt slack .................................................. 6-26
Checking and lubricating the cables ................. 6-28
Checking and lubricating the throttle
grip and cable ................................................. 6-29
Checking and lubricating the brake and
shift pedals ...................................................... 6-29
Checking and lubricating the brake and
clutch levers .................................................... 6-30
Checking and lubricating the sidestand ............ 6-30
Checking the front fork ...................................... 6-31
Checking the steering ....................................... 6-31
Checking the wheel bearings ............................ 6-32
Battery ............................................................... 6-33
Replacing the fuses .......................................... 6-35
Replacing the headlight bulb ............................. 6-36
Replacing a turn signal light bulb or the
tail/brake light bulb .......................................... 6-38
Troubleshooting ................................................. 6-38
Troubleshooting chart ........................................ 6-39
E_5JA.book Page 1 Saturday, August 18, 2001 3:52 PM

PERIODIC MAINTENANCE AND MINOR REPAIR
6-5
6
EAU03884
NOTE:_

The air filter needs more frequent service if you are riding in unusually wet or dusty areas.


Hydraulic brake service
Regularly check and, if necessary, correct the brake fluid level.
Every two years replace the internal components of the brake master cylinders and calipers, and change the brake
fluid.
Replace the brake hoses every four years and if cracked or damaged.
_23 Engine oilChange.
Check oil level and vehicle for oil leakage.√√√√√ √
24 Engine oil filter cartridgeReplace.√√√
25
*Transfer case oilCheck oil level.√√
Change.√√√
26*Front and rear brake
switchesCheck operation.√√√√√ √
27 Moving parts and cablesLubricate.√√√√ √
28*Lights, signals and
switchesCheck operation.
Adjust headlight beam.√√√√√ √ NO. ITEM CHECK OR MAINTENANCE JOBODOMETER READING (×1,000 km)
ANNUAL
CHECK
1 10203040
E_5JA_Periodic.fm Page 5 Saturday, August 18, 2001 5:37 PM

PERIODIC MAINTENANCE AND MINOR REPAIR
6-7
6
EAU01639
Checking the spark plugs The spark plugs are important engine
components, which should be checked
periodically, preferably by a Yamaha
dealer. Since heat and deposits will
cause any spark plug to slowly erode,
they should be removed and checked
in accordance with the periodic mainte-
nance and lubrication chart. In addition,
the condition of the spark plugs can re-
veal the condition of the engine.
The porcelain insulator around the cen-
ter electrode of each spark plug should
be a medium-to-light tan (the ideal col-
or when the motorcycle is ridden nor-
mally), and all spark plugs installed in
the engine should have the same color.
If any spark plug shows a distinctly dif-
ferent color, the engine could be defec-
tive. Do not attempt to diagnose such
problems yourself. Instead, have a
Yamaha dealer check the motorcycle.
If a spark plug shows signs of electrode
erosion and excessive carbon or other
deposits, it should be replaced.Before installing a spark plug, the spark
plug gap should be measured with a
wire thickness gauge and, if necessary,
adjusted to specification.Clean the surface of the spark plug
gasket and its mating surface, and then
wipe off any grime from the spark plug
threads.
NOTE:@ If a torque wrench is not available when
installing a spark plug, a good estimate
of the correct torque is 1/4–1/2 turn
past finger tight. However, the spark
plug should be tightened to the speci-
fied torque as soon as possible. @
a. Spark plug gap
Specified spark plug:
DPR7EA-9/NGK or
X22EPR-U9/DENSO
Spark plug gap:
0.8–0.9 mm
Tightening torque:
Spark plug:
17.5 Nm (1.75 m·kgf)
E_5JA.book Page 7 Saturday, August 18, 2001 3:52 PM

PERIODIC MAINTENANCE AND MINOR REPAIR
6-8
6
ECA00021
CAUTION:@ Do not use any tools to remove or
install the spark plug cap, otherwise
the ignition coil coupler may get
damaged. The spark plug cap may
be difficult to remove because the
rubber seal on the end of the cap fits
tightly. To remove the spark plug
cap, simply twist it back and forth
while pulling it out; to install it, twist
it back and forth while pushing it in. @
EAU04212
Engine oil and oil filter
cartridge The engine oil level should be checked
before each ride. In addition, the oil
must be changed and the oil filter car-
tridge replaced at the intervals speci-
fied in the periodic maintenance and
lubrication chart.
To check the engine oil level
1. Place the motorcycle on a level
surface and hold it in an upright
position.
NOTE:_ Make sure that the motorcycle is posi-
tioned straight up when checking the oil
level. A slight tilt to the side can result in
a false reading. _2. Remove the rider seat. (See
page 3-12 for rider seat removal
and installation procedures.)
3. Start the engine, warm it up until
the engine oil has reached a nor-
mal temperature of 60°C, let it
continue to idle for ten seconds,
and then turn the engine off.NOTE:_ To achieve the proper engine oil tem-
perature for an accurate oil level read-
ing, the engine must have first
completely cooled down, and then
warmed up again for several minutes to
normal operating temperature. _
1. Engine oil filler cap
E_5JA.book Page 8 Saturday, August 18, 2001 3:52 PM

10-INDEXAAir filter element, cleaning ...................... 6-13
Anti-theft alarm ........................................3-4BBattery ................................................... 6-33
Brake and clutch levers, checking and
lubricating ............................................ 6-30
Brake and shift pedals, checking and
lubricating ............................................ 6-29
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 .............. 6-22CCables, checking and lubricating............ 6-28
Carburetor, 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 ............................... 6-31
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 .................................... 6-35HHandlebar switches ................................. 3-6
Headlight bulb, replacing ....................... 6-36
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 ........................ 9-1LLight switch.............................................. 3-6
MMain 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 ......................................................6-3RRider 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
Starter (choke) knob...............................3-12
Starting a warm engine ............................5-3
Starting the engine ...................................5-1
Start switch ..............................................3-7
Steering, checking..................................6-31
E_5JA.book Page 1 Saturday, August 18, 2001 3:52 PM