2002 YAMAHA XV1600A checking oil
[x] Cancel search: checking oilPage 45 of 104
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
Page 53 of 104
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
Page 55 of 104
PERIODIC MAINTENANCE AND MINOR REPAIR
6-10
6
NOTE:_ Skip steps 4–8 if the oil filter cartridge is
not being replaced. _4. Place an oil pan under the engine
to collect the used oil.
5. Remove the engine oil drain bolt to
drain the oil from the crankcase.
6. Remove the oil filter cartridge with
an oil filter wrench.NOTE:_ An oil filter wrench is available at a
Yamaha dealer. _
7. Apply a thin coat of engine oil to
the O-ring of the new oil filter car-
tridge.NOTE:_ Make sure that the O-ring is properly
seated. _8. Install the new oil filter cartridge
with an oil filter wrench, and then
tighten it to the specified torque
with a torque wrench.9. Install the engine oil drain bolts,
and then tighten them to the spec-
ified torque.
10. Pour only 2.5 L of the specified
amount of recommended engine
oil through the filler hole, insert the
dipstick, and then tighten the oil
filler cap.
11. Start the engine, rev it several
times, and then turn it off.
12. Remove the engine oil filler cap,
and then gradually fill the oil tank
with the remaining oil quantity
while regularly checking the oil
level on the dipstick.
1. Engine oil drain bolt (crankcase)
1. Engine oil filter cartridgeTightening torque:
Oil filter cartridge:
17 Nm (1.7 m·kgf)
Tightening torque:
Engine oil drain bolt:
43 Nm (4.3 m·kgf)
E_5JA.book Page 10 Saturday, August 18, 2001 3:52 PM
Page 56 of 104
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
Page 57 of 104
PERIODIC MAINTENANCE AND MINOR REPAIR
6-12
6
EAU03395
Transfer case oil The transfer case oil level should be
checked before each ride. In addition,
the oil must be changed at the intervals
specified in the periodic maintenance
and lubrication chart.
To check the transfer case 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 oil check bolt, and
then check the oil level in the
transfer case.NOTE:@ The oil should be at the brim of the
check hole. @3. If the oil is below the brim of the
check hole, remove the oil filler
cap, add sufficient oil of the rec-
ommended type to raise it to the
correct level, and then install the
oil filler cap.
4. Install the oil check bolt, and then
tighten it to the specified torque.To change the transfer case oil
1. Place an oil pan under the transfer
case to collect the used oil.
2. Remove the drain bolt and the
check bolt to drain the oil from the
transfer case.
3. Install the drain bolt and the check
bolt, and then tighten the drain bolt
to the specified torque.
1. Transfer case oil filler cap
2. Transfer case oil check bolt
Tightening torque:
Transfer case oil check bolt:
7.5 Nm (0.75 m·kgf)
1. Transfer case oil drain boltTightening torque:
Transfer case oil drain bolt:
17.5 Nm (1.75 m·kgf)
E_5JA.book Page 12 Saturday, August 18, 2001 3:52 PM
Page 58 of 104
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
Page 70 of 104
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
Page 73 of 104
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