2002 YAMAHA XV1600A clutch

DESCRIPTION
2-3
2
Controls and instruments1. Clutch lever (page 3-7)
2. Left handlebar switches (page 3-6)
3. Speedometer unit (page 3-3)
4. Main switch/steering lock (page 3-1)5. Right handlebar switches (page 3-6)
6. Throttle grip (page 6-17)
7. Brake lever (page 3-8)
E_5JA.book Page 3 Saturday, August 18, 2001 3:52 PM

3
INSTRUMENT AND CONTROL FUNCTIONS
Main switch/steering lock ..................................... 3-1
Indicator and warning lights ................................ 3-2
Speedometer unit ................................................ 3-3
Self-diagnosis device ........................................... 3-4
Fuel gauge ........................................................... 3-4
Anti-theft alarm (optional) .................................... 3-4
Clock .................................................................... 3-5
Handlebar switches ............................................. 3-6
Clutch lever .......................................................... 3-7
Shift pedal ............................................................ 3-7
Brake lever ........................................................... 3-8
Brake pedal .......................................................... 3-8Fuel tank cap ...................................................... 3-9
Fuel ..................................................................... 3-9
Fuel tank breather hose .................................... 3-10
Fuel cock ........................................................... 3-11
Starter (choke) knob ......................................... 3-12
Locking the steering with a padlock .................. 3-12
Rider seat .......................................................... 3-12
Helmet holder .................................................... 3-13
Adjusting the shock absorber assembly ............ 3-14
Sidestand .......................................................... 3-15
Ignition circuit cut-off system ............................. 3-16
E_5JA.book Page 1 Saturday, August 18, 2001 3:52 PM

INSTRUMENT AND CONTROL FUNCTIONS
3-7
3
EAU00143
Start switch “”
Push this switch to crank the engine
with the starter.
EC000005
CAUTION:@ See page 5-1 for starting instruc-
tions prior to starting the engine. @
EAU00152
Clutch lever The clutch lever is located at the left
handlebar grip. To disengage the
clutch, pull the lever toward the handle-
bar grip. To engage the clutch, release
the lever. The lever should be pulled
rapidly and released slowly for smooth
clutch operation.
The clutch lever is equipped with a
clutch switch, which is part of the ignition
circuit cut-off system. (See page 3-16
for an explanation of the ignition circuit
cut-off system.)
EAU01215
Shift pedal The shift pedal is located on the left
side of the engine and is used in com-
bination with the clutch lever when
shifting the gears of the 5-speed con-
stant-mesh transmission equipped on
this motorcycle.NOTE:@ Use your toes or heel to shift up and
your toes to shift down. @
1. Engine stop switch “/”
2. Light switch “//”
3. Start switch “”
1. Clutch lever
1. Shift pedal
E_5JA.book Page 7 Saturday, August 18, 2001 3:52 PM

INSTRUMENT AND CONTROL FUNCTIONS
3-16
3
EW000044
WARNING
@ The motorcycle must not be ridden
with the sidestand down, or if the
sidestand cannot be properly
moved up (or does not stay up), oth-
erwise the sidestand could contact
the ground and distract the opera-
tor, resulting in a possible loss of
control. Yamaha’s ignition circuit
cut-off system has been designed to
assist the operator in fulfilling the
responsibility of raising the side-
stand before starting off. Therefore,
check this system regularly as de-
scribed below and have a Yamaha
dealer repair it if it does not function
properly. @
EAU03720
Ignition circuit cut-off system The ignition circuit cut-off system (com-
prising the sidestand switch, clutch
switch and neutral switch) has the fol-
lowing functions.

It prevents starting when the trans-
mission is in gear and the side-
stand is up, but the clutch lever is
not pulled.


It prevents starting when the trans-
mission is in gear and the clutch
lever is pulled, but the sidestand is
still down.


It cuts the running engine when
the transmission is in gear and the
sidestand is moved down.
Periodically check the operation of the
ignition circuit cut-off system according
to the following procedure.
EW000045
WARNING
_ If a malfunction is noted, have a
Yamaha dealer check the system
before riding. _
E_5JA.book Page 16 Saturday, August 18, 2001 3:52 PM

INSTRUMENT AND CONTROL FUNCTIONS
3-17
3
CD-01E
With the engine turned off:
1. Move the sidestand down.
2. Make sure that the engine stop switch is set to “”.
3. Turn the key to “ON”.
4. Shift the transmission into the neutral position.
5. Push the start switch.
Does the engine start?
The neutral switch may be defective.
The motorcycle should not be ridden until
checked by a Yamaha dealer.
With the engine still running:
6. Move the sidestand up.
7. Keep the clutch lever pulled.
8. Shift the transmission into gear.
9. Move the sidestand down.
Does the engine stall?After the engine has stalled:
10. Move the sidestand up.
11. Keep the clutch lever pulled.
12. Push the start switch.
Does the engine start?
The sidestand switch may be defective.
The motorcycle should not be ridden until
checked by a Yamaha dealer.The clutch switch may be defective.
The motorcycle should not be ridden until
checked by a Yamaha dealer.
NO
NOTE:This check is most reliable if performed with
a warmed-up engine.
YESYES NO
The system is OK.
The motorcycle can be ridden.
YES NO
E_5JA.book Page 17 Saturday, August 18, 2001 3:52 PM

4-1
4
EAU01114
4-PRE-OPERATION CHECKSThe condition of a vehicle is the owner’s responsibility. Vital components can start to deteriorate quickly and unexpectedly,
even if the vehicle remains unused (for example, as a result of exposure to the elements). Any damage, fluid leakage or loss
of tire air pressure could have serious consequences. Therefore, it is very important, in addition to a thorough visual inspec-
tion, to check the following points before each ride.
EAU03439
Pre-operation check list
CO-01E
ITEM CHECKS PAGE
FuelCheck fuel level in fuel tank.
Refuel if necessary.
Check fuel line for leakage.3-9–3-10
Engine oilCheck oil level in engine.
If necessary, add recommended oil to specified level.
Check vehicle for oil leakage.6-8–6-11
Front brakeCheck operation.
If soft or spongy, have Yamaha dealer bleed hydraulic system.
Check lever free play.
Adjust if necessary.
Check fluid level in reservoir.
If necessary, add recommended brake fluid to specified level.
Check hydraulic system for leakage.6-22, 6-23–6-26
Rear brakeCheck operation.
If soft or spongy, have Yamaha dealer bleed hydraulic system.
Check fluid level in reservoir.
If necessary, add recommended brake fluid to specified level.
Check hydraulic system for leakage.6-22–6-26
ClutchCheck operation.
Lubricate cable if necessary.
Check lever free play.
Adjust if necessary.6-21, 6-30
Throttle gripMake sure that operation is smooth.
Check free play.
If necessary, have Yamaha dealer make adjustment or lubricate.6-17
E_5JA.book Page 1 Saturday, August 18, 2001 3:52 PM

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 cablesMake sure that operation is smooth.
Lubricate if necessary.—
Wheels and tiresCheck for damage.
Check tire condition and tread depth.
Check air pressure.
Correct if necessary.6-17–6-20
Brake and shift pedalsMake sure that operation is smooth.
Lubricate pedal pivoting points if necessary.6-29
Brake and clutch leversMake sure that operation is smooth.
Lubricate lever pivoting points if necessary.6-30
SidestandMake sure that operation is smooth.
Lubricate pivot if necessary.6-30
Chassis fastenersMake sure that all nuts, bolts and screws are properly tightened.
Tighten if necessary.—
Instruments, lights, signals
and switchesCheck operation.
Correct if necessary.—
Sidestand switchCheck operation of ignition circuit cut-off system.
If system is defective, have Yamaha dealer check vehicle.3-16 ITEM CHECKS PAGE
E_5JA.book Page 2 Saturday, August 18, 2001 3:52 PM

5-1
5
EAU00372
5-OPERATION AND IMPORTANT RIDING POINTS
EAU00373
WARNING
@

Become thoroughly familiar
with all operating controls and
their functions before riding.
Consult a Yamaha dealer re-
garding any control or function
that you do not thoroughly un-
derstand.


Never start the engine or oper-
ate it in a closed area for any
length of time. Exhaust fumes
are poisonous, and inhaling
them can cause loss of con-
sciousness and death within a
short time. Always make sure
that there is adequate ventila-
tion.


Before starting out, make sure
that the sidestand is up. If the
sidestand is not raised com-
pletely, it could contact the
ground and distract the opera-
tor, resulting in a possible loss
of control.
@
EAU03515*
Starting the engine In order for the ignition circuit cut-off
system to enable starting, one of the
following conditions must be met:

The transmission is in the neutral
position.


The transmission is in gear with
the clutch lever pulled and the
sidestand up.
EW000054
WARNING
@

Before starting the engine,
check the function of the igni-
tion circuit cut-off system ac-
cording to the procedure
described on page 3-16.


Never ride with the sidestand
down.
@
E_5JA.book Page 1 Saturday, August 18, 2001 3:52 PM