2002 YAMAHA XV1600A maintenance

TABLE OF CONTENTS
1 GIVE SAFETY THE RIGHT OF WAY
1
2 DESCRIPTION
2
3 INSTRUMENT AND CONTROL FUNCTIONS
3
4 PRE-OPERATION CHECKS
4
5 OPERATION AND IMPORTANT RIDING POINTS
5
6 PERIODIC MAINTENANCE AND MINOR REPAIR
6
7 MOTORCYCLE CARE AND STORAGE
7
8 SPECIFICATIONS
8
9 CONSUMER INFORMATION
9
INDEX
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1
1-1
1-GIVE SAFETY THE RIGHT OF WAY
EAU00021
Motorcycles are fascinating vehicles, which can give you an unsurpassed feeling of power and
freedom. However, they also impose certain limits, which you must accept; even the best motorcycle
does not ignore the laws of physics.
Regular care and maintenance are essential for preserving value and operating condition of your
motorcycle. Moreover, what is true for the motorcycle is also true for the rider: good performance
depends on being in good shape. Riding under the influence of medication, drugs and alcohol is, of
course, out of the question. Motorcycle riders—more than car drivers—must always be at their mental
and physical best. Under the influence of even small amounts of alcohol, there is a tendency to take
dangerous risks.
Protective clothing is as essential for the motorcycle rider as seat belts are for car drivers and
passengers. Always wear a complete motorcycle suit (whether made of leather or tear-resistant
synthetic materials with protectors), sturdy boots, motorcycle gloves and a properly fitting helmet.
Optimum protective wear, however, should not encourage carelessness. Although full-coverage
helmets and suits, in particular, create an illusion of total safety and protection, motorcyclists will
always be vulnerable. Riders who lack critical self-control run the risk of going too fast and are apt to
take chances. This is even more dangerous in wet weather. The good motorcyclist rides safely,
predictably and defensively—avoiding all dangers, including those caused by others.
Enjoy your ride!
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INSTRUMENT AND CONTROL FUNCTIONS
3-10
3
EAU00185
CAUTION:@ Immediately wipe off spilled fuel
with a clean, dry, soft cloth, since
fuel may deteriorate painted surfac-
es or plastic parts. @
EAU04202
ECA00102
CAUTION:_ Use only unleaded gasoline. The
use of leaded gasoline will cause se-
vere damage to internal engine
parts such as the valves and piston
rings, as well as to the exhaust sys-
tem. _
Your Yamaha engine has been de-
signed to use regular unleaded gaso-
line with a research octane number of
91 or higher. If knocking (or pinging)
occurs, use a gasoline of a different
brand or premium unleaded fuel. Use
of unleaded fuel will extend spark plug
life and reduce maintenance costs.
EAU02955
Fuel tank breather hose Before operating the motorcycle:

Check the fuel tank breather hose
connection.


Check the fuel tank breather hose
for cracks or damage, and replace
it if damaged.


Make sure that the end of the fuel
tank breather hose is not blocked,
and clean it if necessary. Recommended fuel:
REGULAR UNLEADED
GASOLINE ONLY
Fuel tank capacity:
Total amount:
20 L
Reserve amount:
3.5 L
1. Fuel tank breather hose
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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
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6-1
6
EAU00462
6-PERIODIC MAINTENANCE AND MINOR REPAIR
EAU00464
Safety is an obligation of the owner.
Periodic inspection, adjustment and lu-
brication will keep your vehicle in the
safest and most efficient condition pos-
sible. The most important points of in-
spection, adjustment, and lubrication
are explained on the following pages.
The intervals given in the periodic
maintenance and lubrication chart
should be simply considered as a gen-
eral guide under normal riding condi-
tions. However, DEPENDING ON THE
WEATHER, TERRAIN, GEOGRAPHI-
CAL LOCATION, AND INDIVIDUAL
USE, THE MAINTENANCE INTER-VALS MAY NEED TO BE SHORT-
ENED.
EW000060
WARNING
@ If you are not familiar with motor-
cycle maintenance work, have a
Yamaha dealer do it for you. @
EAU03711
Owner’s tool kit The owner’s tool kit is located under
the rider seat. (See page 3-12 for rider
seat removal and installation proce-
dures.)
The service information included in this
manual and the tools provided in the
owner’s tool kit are intended to assist
you in the performance of preventive
maintenance and minor repairs. How-
ever, additional tools such as a torque
wrench may be necessary to perform
certain maintenance work correctly.1. Owner’s tool kit
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PERIODIC MAINTENANCE AND MINOR REPAIR
6-2
6
NOTE:_ If you do not have the tools or experi-
ence required for a particular job, have
a Yamaha dealer perform it for you. _
EW000063
WARNING
_ Modifications not approved by
Yamaha may cause loss of perfor-
mance and render the vehicle un-
safe for use. Consult a Yamaha
dealer before attempting any chang-
es. _
E_5JA.book Page 2 Saturday, August 18, 2001 3:52 PM

PERIODIC MAINTENANCE AND MINOR REPAIR
6-3
6
EAU03685
Periodic maintenance and lubrication chart
NOTE:_

The annual checks must be performed every year, except if a kilometer-based maintenance is performed instead.


From 50,000 km, repeat the maintenance intervals starting from 10,000 km.


Items marked with an asterisk should be performed by a Yamaha dealer as they require special tools, data and techni-
cal skills.
_CP-01ENO. ITEM CHECK OR MAINTENANCE JOBODOMETER READING (×1,000 km)
ANNUAL
CHECK
1 10203040
1
*Fuel line• Check fuel hoses for cracks or damage.√√√√ √
2*Fuel filter Check condition.√√
3 Spark plugs Check condition.
 Clean and regap.√√
Replace.√√
4*Valves Check valve clearance.
 Adjust.√√√√
5 Air filter element Clean.√√
Replace.√√
6Clutch Check operation.
 Adjust.√√√√√
7*Front brake Check operation, fluid level and vehicle for fluid leakage.
(See NOTE on page 6-5.)√√ √ √ √ √
 Replace brake pads. Whenever worn to the limit
8*Rear brake Check operation, fluid level and vehicle for fluid leakage.
(See NOTE on page 6-5.)√√ √ √ √ √
 Replace brake pads. Whenever worn to the limit
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PERIODIC MAINTENANCE AND MINOR REPAIR
6-4
6
9
*Brake hosesCheck for cracks or damage.√√√√ √
Replace. (See NOTE on page 6-5.) Every 4 years
10*WheelsCheck runout, spoke tightness and for damage.
Tighten spokes if necessary.√√√√
11*TiresCheck tread depth and for damage.
Replace if necessary.
Check air pressure.
Correct if necessary.√√√√ √
12*Wheel bearingsCheck bearing for looseness or damage.√√√√
13*SwingarmCheck operation and for excessive play.√√√√
Lubricate with lithium-soap-based grease. Every 50,000 km
14*Drive beltCheck belt tension.
Make sure that the rear wheel is properly aligned.Every 4,000 km
15*Steering bearingsCheck bearing play and steering for roughness.√√√√√
Lubricate with lithium-soap-based grease. Every 50,000 km
16*Chassis fastenersMake sure that all nuts, bolts and screws are properly tightened.√√√√ √
17 SidestandCheck operation.
Lubricate.√√√√ √
18*Sidestand switchCheck operation.√√√√√ √
19*Front forkCheck operation and for oil leakage.√√√√
20*Shock absorber
assemblyCheck operation and shock absorber for oil leakage.√√√√
21*Rear suspension relay
arm and connecting arm
pivoting pointsCheck operation.√√√√
Lubricate with lithium-soap-based grease.√√
22*CarburetorCheck starter (choke) operation.
Adjust engine idling speed.√√√√√ √ NO. ITEM CHECK OR MAINTENANCE JOBODOMETER READING (×1,000 km)
ANNUAL
CHECK
1 10203040
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