Yamaha RoadStan XV17AWC Owner`s manual

OWNER’S MANUAL
XV16AR(C)
XV16ALER(C)
XV16ASR(C)
XV16ATR(C)
XV16ATLER(C)
LIT-11626-16-44
4WM-28199-15
EAU03438
EAU00002
INTRODUCTION
Congratulations on your purchase of the Yamaha Road Star™/Road Star™ Silverado™.
This model is the result of Yamaha’s vast experience in the production of fine sporting,
touring, and pacesetting racing machines. It represents the high degree of craftsmanship and reliability that have made Yamaha a leader in these fields.
This manual will give you an understanding of the operation, inspection, and basic
maintenance of this motorcycle. If you have any questions concerning the operation
or maintenance of your motorcycle, please consult a Yamaha dealer.
The design and manufacture of this Yamaha motorcycle fully comply with the emissions standards for clean air applicable at the date of manufacture. Yamaha has met
these standards without reducing the performance or economy of operation of the
motorcycle. To maintain these high standards, it is important that you and your
Yamaha dealer pay close attention to the recommended maintenance schedules and
operating instructions contained within this manual.
IMPORTANT MANUAL INFORMATION
Particularly important information is distinguished in this manual by the following notations:
The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR SAFETY IS
INVOLVED!
Failure to follow WARNING instructions could result in severe injury or death to the
motorcycle operator, a bystander or a person inspecting or repairing the motorcycle.
WARNING
CAUTION:
A CAUTION indicates special precautions that must be taken to avoid damage to the
motorcycle.
NOTE:
A NOTE provides key information to make procedures easier or clearer.
NOTE:
● This manual should be considered a permanent part of this motorcycle and should remain
with it even if the motorcycle is subsequently sold.
● Yamaha continually seeks advancements in product design and quality. Therefore, while
this manual contains the most current product information available at the time of printing,
there may be minor discrepancies between your motorcycle and this manual. If you have
any questions concerning this manual, please consult your Yamaha dealer.
@
@
EAU00003
IMPORTANT MANUAL INFORMATION
EW000000
WARNING
PLEASE READ THIS MANUAL AND THE “YOU AND YOUR MOTORCYCLE: RIDING
TIPS” BOOKLET CAREFULLY AND COMPLETELY BEFORE OPERATING THIS MOTORCYCLE. DO NOT ATTEMPT TO OPERATE THIS MOTORCYCLE UNTIL YOU HAVE ATTAINED ADEQUATE KNOWLEDGE OF ITS CONTROLS AND OPERATING FEATURES
AND UNTIL YOU HAVE BEEN TRAINED IN SAFE AND PROPER RIDING TECHNIQUES.
REGULAR INSPECTIONS AND CAREFUL MAINTENANCE, ALONG WITH GOOD RIDING
SKILLS, WILL ENSURE THAT YOU SAFELY ENJOY THE CAPABILITIES AND THE RELIABILITY OF THIS MOTORCYCLE.
@
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IMPORTANT MANUAL INFORMATION
AFFIX DEALER
LABEL HERE
EAU04247
XV16AR(C)/XV16ALER(C)/XV16ASR(C)/
XV16ATR(C)/XV16ATLER(C)
OWNER’S MANUAL
©2002 by Yamaha Motor Corporation, U.S.A.
1st edition, August 2002
All rights reserved.
Any reprinting or unauthorized use
without the written permission of
Yamaha Motor Corporation, U.S.A.
is expressly prohibited.
Printed in Japan.
P/N LIT-11626-16-44
TABLE OF CONTENTS
EAU00009
1 SAFETY INFORMATION
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
SAFETY INFORMATION
Safe riding .......................................................................................... 1-1
Protective apparel .............................................................................. 1-3
Modifications ...................................................................................... 1-3
Loading and accessories ................................................................... 1-3
Gasoline and exhaust gas.................................................................. 1-5
Location of important labels .............................................................. 1-7
1
SAFETY INFORMATION
EAU03633
1-
1
MOTORCYCLES ARE SINGLE TRACK VEHICLES. THEIR SAFE USE AND OPERATION ARE
DEPENDENT UPON THE USE OF PROPER RIDING TECHNIQUES AS WELL AS THE EXPERTISE
OF THE OPERATOR. EVERY OPERATOR SHOULD KNOW THE FOLLOWING REQUIREMENTS
BEFORE RIDING THIS MOTORCYCLE.
HE OR SHE SHOULD:
1. OBTAIN THOROUGH INSTRUCTIONS FROM A COMPETENT SOURCE ON ALL ASPECTS OF
MOTORCYCLE OPERATION.
2. OBSERVE THE WARNINGS AND MAINTENANCE REQUIREMENTS IN THE OWNER’S MANUAL.
3. OBTAIN QUALIFIED TRAINING IN SAFE AND PROPER RIDING TECHNIQUES.
4. OBTAIN PROFESSIONAL TECHNICAL SERVICE AS INDICATED BY THE OWNER’S MANUAL
AND/OR WHEN MADE NECESSARY BY MECHANICAL CONDITIONS.
Safe riding
1. Always make pre-operation checks. Careful checks may help prevent an accident.
2. This motorcycle is designed to carry the operator and a passenger.
3. The failure of motorists to detect and recognize motorcycles in traffic is the predominating cause of
automobile/motorcycle accidents. Many accidents have been caused by an automobile driver who
did not see the motorcycle. Making yourself conspicuous appears to be very effective in reducing the
chance of this type of accident.
Therefore:
a. Wear a brightly colored jacket.
b. Use extra caution when approaching and passing through intersections, since intersections are
the most likely places for motorcycle accidents to occur.
c. Ride where other motorists can see you. Avoid riding in another motorist’s blind spot.
1-1
SAFETY INFORMATION
4. Many motorcycle accidents involve inexperienced operators. In fact, many operators who have been
involved in accidents do not even have a current motorcycle license.
a. Make sure that you are qualified and that you only lend your motorcycle to other qualified operators.
b. Know your skills and limits. Staying within your limits may help you to avoid an accident.
c. We recommend that you practice riding your motorcycle where there is no traffic until you have
become thoroughly familiar with the motorcycle and all of its controls.
5. Many motorcycle accidents have been caused by error of the motorcycle operator. A typical error
made by the operator is veering wide on a turn due to EXCESSIVE SPEED or undercornering (insufficient lean angle for the speed).
a. Always obey the speed limit and never travel faster than warranted by road and traffic conditions.
b. Always signal before turning or changing lanes. Make sure that other motorists can see you.
6. The posture of the operator and passenger is important for proper control.
a. The operator should keep both hands on the handlebar and both feet on the operator footrests
during operation to maintain control of the motorcycle.
b. The passenger should always hold onto the operator, seat strap, or grab bar, if equipped, with
both hands and keep both feet on the passenger footrests.
c. Never carry a passenger unless he or she can firmly place both feet on the passenger footrests.
7. Never ride under the influence of alcohol or other drugs.
8. This motorcycle is designed for on-road use only, therefore, it is not suitable for off-road use.
1-2
1
SAFETY INFORMATION
Protective apparel
1
The majority of fatalities from motorcycle accidents are the result of head injuries. The use of a safety
helmet is the single most critical factor in the prevention or reduction of head injuries.
1. Always wear an approved helmet.
2. Wear a face shield or goggles. Wind in your unprotected eyes could contribute to an impairment of vision which could delay seeing a hazard.
3. The use of a jacket, heavy boots, trousers, gloves, etc., is effective in preventing or reducing abrasions or lacerations.
4. Never wear loose-fitting clothes, otherwise they could catch on the control levers, footrests, or wheels
and cause injury or an accident.
5. Never touch the engine or exhaust system during or after operation. They become very hot and can
cause burns. Always wear protective clothing that covers your legs, ankles, and feet.
6. Passengers should also observe the precautions mentioned above.
Modifications
Modifications made to this motorcycle not approved by Yamaha, or the removal of original equipment,
may render the motorcycle unsafe for use and may cause severe personal injury. Modifications may
also make your motorcycle illegal to use.
Loading and accessories
Adding accessories or cargo to your motorcycle can adversely affect stability and handling if the
weight distribution of the motorcycle is changed. To avoid the possibility of an accident, use extreme
caution when adding cargo or accessories to your motorcycle. Use extra care when riding a
motorcycle that has added cargo or accessories. Here are some general guidelines to follow if loading
cargo or adding accessories to your motorcycle:
1-3
SAFETY INFORMATION
Loading
The total weight of the operator, passenger, accessories and cargo must not exceed the maximum
load limit of XV16A(C), XV16ALE(C), XV16AS(C): 432 lb (196 kg) / XV16AT(C), XV16ATLE(C):
399 lb (181 kg). When loading within this weight limit, keep the following in mind:
1. Cargo and accessory weight should be kept as low and close to the motorcycle as possible. Make
sure to distribute the weight as evenly as possible on both sides of the motorcycle to minimize imbalance or instability.
2. Shifting weights can create a sudden imbalance. Make sure that accessories and cargo are securely
attached to the motorcycle before riding. Check accessory mounts and cargo restraints frequently.
3. Never attach any large or heavy items to the handlebar, front fork, or front fender. These items, including such cargo as sleeping bags, duffel bags, or tents, can create unstable handling or slow
steering response.
Accessories
Genuine Yamaha accessories have been specifically designed for use on this motorcycle. Since
Yamaha cannot test all other accessories that may be available, you must personally be responsible
for the proper selection, installation and use of non-Yamaha accessories. Use extreme caution when
selecting and installing any accessories.
Keep the following guidelines in mind, as well as those provided under “Loading” when mounting
accessories.
1. Never install accessories or carry cargo that would impair the performance of your motorcycle. Carefully inspect the accessory before using it to make sure that it does not in any way reduce ground
clearance or cornering clearance, limit suspension travel, steering travel or control operation, or obscure lights or reflectors.
1-4
1
SAFETY INFORMATION
1
a. Accessories fitted to the handlebar or the front fork area can create instability due to improper
weight distribution or aerodynamic changes. If accessories are added to the handlebar or front
fork area, they must be as lightweight as possible and should be kept to a minimum.
b. Bulky or large accessories may seriously affect the stability of the motorcycle due to aerodynamic
effects. Wind may attempt to lift the motorcycle, or the motorcycle may become unstable in cross
winds. These accessories may also cause instability when passing or being passed by large vehicles.
c. Certain accessories can displace the operator from his or her normal riding position. This improper position limits the freedom of movement of the operator and may limit control ability, therefore,
such accessories are not recommended.
2. Use caution when adding electrical accessories. If electrical accessories exceed the capacity of the
motorcycle’s electrical system, an electric failure could result, which could cause a dangerous loss of
lights or engine power.
Gasoline and exhaust gas
1. GASOLINE IS HIGHLY FLAMMABLE:
a. Always turn the engine off when refueling.
b. Take care not to spill any gasoline on the engine or exhaust system when refueling.
c. Never refuel while smoking or in the vicinity of an open flame.
2. Never start the engine or let it run for any length of time in a closed area. The exhaust fumes are poisonous and may cause loss of consciousness and death within a short time. Always operate your
motorcycle in an area that has adequate ventilation.
3. Always turn the engine off before leaving the motorcycle unattended and remove the key from the
main switch. When parking the motorcycle, note the following:
1-5
SAFETY INFORMATION
a. The engine and exhaust system may be hot, therefore, park the motorcycle in a place where pedestrians or children are not likely to touch these hot areas.
b. Do not park the motorcycle on a slope or soft ground, otherwise it may fall over.
c. Do not park the motorcycle near a flammable source (e.g. a kerosene heater, or near an open
flame), otherwise it could catch fire.
4. When transporting the motorcycle in another vehicle, make sure that it is kept upright and that the fuel
cock is turned to “ON” or “RES” (for vacuum type) / “OFF” (for manual type). If it should lean over,
gasoline may leak out of the carburetor or fuel tank.
5. If you should swallow any gasoline, inhale a lot of gasoline vapor, or allow gasoline to get into your
eyes, see your doctor immediately. If any gasoline spills on your skin or clothing, immediately wash
the affected area with soap and water and change your clothes.
1-6
1
SAFETY INFORMATION
EAU02977
Location of important labels
Please read the following important labels carefully before operating this motorcycle.
1
1-7
SAFETY INFORMATION
2
1
1
XV16AT/XV16ATLE
California only
3
4
5
6
XV16AT/XV16ATLE
(5GA-F8446-00)
1-8
DESCRIPTION
XV16A(C)/XV16ALE(C)/XV16AS(C) Left view................................... 2-1
XV16A(C)/XV16ALE(C)/XV16AS(C) Right view ................................ 2-2
XV16AT(C)/XV16ATLE(C) Left view ................................................... 2-3
XV16AT(C)/XV16ATLE(C) Right view ................................................ 2-4
XV16A(C)/XV16ALE(C)/XV16AS(C)/XV16AT(C)/XV16ATLE(C)
Controls and instruments ................................................................. 2-5
2
DESCRIPTION
EAU00026
2-
Road Star™
XV16A(C)/XV16ALE(C)/XV16AS(C) Left view
2
(XV16A)
1. Shift pedal
2. Starter (choke) knob
3. Fuel cock
4. Rider seat
5. Owner’s tool kit
6. Helmet holder
7. Rear turn signal lights
8. Tail/brake light
9. Fuses
(page 3-7)
(page 3-11)
(page 3-10)
(page 3-11)
(page 6-2)
2-1
(page 3-12)
(page 6-37)
(page 6-37)
(page 6-33)
DESCRIPTION
Road Star™
XV16A(C)/XV16ALE(C)/XV16AS(C) Right view
2
(XV16A)
10. Passenger footrest
11. Passenger seat
12. Fuel tank
13. Fuel tank cap
14. Headlight
15. Front turn signal/position lights
16. Brake pedal
17. Rider footrest
18. Shock absorber spring preload
adjusting nut
19. Muffler
(page 3-9)
(page 3-8)
(page 6-35)
(page 6-37)
2-2
(page 3-8)
(page 3-15)
DESCRIPTION
Road Star™/Silverado™
XV16AT(C)/XV16ATLE(C) Left view
2
(XV16AT)
1. Shift pedal
2. Starter (choke) knob
3. Fuel cock
4. Rider seat
5. Owner’s tool kit
6. Helmet holder
7. Rear turn signal lights
8. Tail/brake light
9. Saddlebag
10. Fuses
(page 3-7)
(page 3-11)
(page 3-10)
(page 3-11)
(page 6-2)
2-3
(page 3-12)
(page 6-37)
(page 6-37)
(page 3-14)
(page 6-33)
DESCRIPTION
Road Star™/Silverado™
XV16AT(C)/XV16ATLE(C) Right view
2
(XV16AT)
11. Passenger seat
12. Fuel tank
13. Fuel tank cap
14. Windshield
15. Headlight
16. Front turn signal/position lights
17. Brake pedal
18. Rider footrest
19. Shock absorber spring preload
adjusting nut
20. Passenger footrest
21. Muffler
(page 3-9)
(page 3-8)
(page 3-13)
(page 6-35)
(page 6-37)
2-4
(page 3-8)
(page 3-15)
DESCRIPTION
Road Star™/Road Star™ Silverado™
XV16A(C)/XV16ALE(C)/XV16AS(C)/XV16AT(C)/XV16ATLE(C) Controls and instruments
XV16A(C)/XV16ALE(C)/XV16AS(C)
XV16AT(C)/XV16ATLE(C)
2
(XV16A)
1. Clutch lever
2. Left handlebar switches
3. Speedometer unit
4. Main switch/steering lock
(XV16AT)
5. Right handlebar switches
6. Throttle grip
7. Brake lever
(page 3-7)
(page 3-6)
(page 3-3)
(page 3-1)
2-5
(page 3-6)
(page 6-17)
(page 3-7)
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
Clock ....................................................................3-5
Handlebar switches .............................................3-6
Clutch lever ..........................................................3-7
Shift pedal ............................................................3-7
Brake lever ...........................................................3-7
Brake pedal ..........................................................3-8
Fuel tank cap .......................................................3-8
Fuel ..................................................................... 3-9
Fuel cock ........................................................... 3-10
Starter (choke) knob ......................................... 3-11
Locking the steering with a padlock .................. 3-11
Rider seat .......................................................... 3-11
Helmet holder .................................................... 3-12
Windshield [XV16AT(C)/XV16ATLE(C)] ............. 3-13
Saddlebags [XV16AT(C)/XV16ATLE(C)] ........... 3-14
Adjusting the shock absorber assembly ............ 3-15
Sidestand .......................................................... 3-17
Ignition circuit cut-off system ............................. 3-17
3
INSTRUMENT AND CONTROL FUNCTIONS
EAU00027
3-
3
EAU00029
Main switch/steering lock
The main switch/steering lock controls
the ignition and lighting systems, and is
used to lock the steering. The various
positions are described below.
EAU00032
ON
All electrical systems are supplied with
power, the headlight, meter lighting,
taillight and front position lights come
on, and the engine can be started. The
key cannot be removed.
EAU00038
OFF
All electrical systems are off. The key
can be removed.
EAU00040
LOCK
The steering is locked, and all electrical
systems are off. The key can be
removed.
To lock the steering
1. Turn the handlebars all the way to
the left.
2. Push the key in from the “OFF” position, and then turn it to “LOCK”
while still pushing it.
3. Remove the key.
To unlock the steering
Push the key in, and then turn it to
“OFF” while still pushing it.
3-1
1. Push.
2. Turn.
EW000016
WARNING
Never turn the key to “OFF” or
“LOCK” while the motorcycle is
moving, otherwise the electrical
systems will be switched off, which
may result in loss of control or an
accident. Make sure that the motorcycle is stopped before turning the
key to “OFF” or “LOCK”.
@
@
INSTRUMENT AND CONTROL FUNCTIONS
EAU00063
High beam indicator light “
”
This indicator light comes on when the
high beam of the headlight is switched
on.
EAU00057
1.
2.
3.
4.
5.
Turn signal indicator light “
”
This indicator light flashes when the
turn signal switch is pushed to the left
or right.
Fuel level warning light “ ”
High beam indicator light “
”
Turn signal indicator light “
”
Neutral indicator light “ ”
Engine trouble warning light “
”
EAU00061
EAU03034
Indicator and warning lights
Neutral indicator light “ ”
This indicator light comes on when the
transmission is in the neutral position.
EAU00079
EAU04241
Fuel level warning light “ ”
This warning light comes on when the
fuel level drops below approximately
0.9 US gal (0.8 Imp gal, 3.5 L). When
this occurs, turn the fuel cock lever to
the “RES” position and refuel as soon
as possible.
Engine trouble warning light “
”
This warning light comes on or flashes
when an electrical circuit monitoring
the engine is defective. When this occurs, have a Yamaha dealer check the
self-diagnosis system.
3-2
3
INSTRUMENT AND CONTROL FUNCTIONS
Pushing the mode button (left) switches the display between the odometer
mode “ODO” and the tripmeter modes
“TRIP A” and “TRIP B” in the following
order:
CB-27E
ODO
TRIP A
TRIP B
3
1.
2.
3.
4.
5.
Odometer/tripmeter/clock
Speedometer
Fuel gauge
Set button
Mode button
To reset a tripmeter, select it by pushing the mode button (left), and then
hold down the set button (right) for at
least one second. The tripmeters can
be used to estimate the distance that
can be traveled with a full tank of fuel.
This information will enable you to plan
future fuel stops.
EAU03393
Speedometer unit
The speedometer unit is equipped with
a speedometer, an odometer and two
tripmeters. The speedometer shows
riding speed. The odometer shows the
total distance traveled. The tripmeters
show the distance traveled since they
were last set to zero.
NOTE:
This motorcycle is not equipped with a
tachometer; however, it has a built-in
engine speed limiter, which prevents
the engine speed from exceeding approximately 4,400 r/min.
@
@
3-3
INSTRUMENT AND CONTROL FUNCTIONS
EAU01735
EAU00113
Self-diagnosis device
Fuel gauge
This model is equipped with a self-diagnosis 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.
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.
EC000004
NOTE:
Do not allow the fuel tank to empty itself completely.
@
@
CAUTION:
When the tachometer displays an
error code, the motorcycle should
be checked as soon as possible in
order to avoid engine damage.
@
@
3-4
3
INSTRUMENT AND CONTROL FUNCTIONS
4. Push the right button to change
the hours.
5. Push the left button and only the
minute display will flash.
3
1. Clock
2. Set button
3. Mode button
EAU01736
Clock
The digital clock shows the time regardless of the main switch position.
To set the clock:
1. Turn the key to “ON”.
2. Press both the set button (right)
and the mode button (left) simultaneously until the hours and minutes flash.
6. Push the right button to change
the minutes.
3. Push the left button and only the
hour display will flash.
8. Push the right button for two seconds to set the clock.
3-5
7. Push the left button and both the
hours and minutes will flash.
INSTRUMENT AND CONTROL FUNCTIONS
1. Dimmer switch “
/
2. Turn signal switch “
3. Horn switch “
”
Since this model is equipped with a
self-canceling system, the turn signal
lights will self-cancel after the motorcycle has traveled both about 150 m
(490 ft) and for approximately 15 seconds. However, the turn signal lights
can also be canceled manually by
pushing the switch in after it has returned to the center position.
”
”
NOTE:
The self-canceling system only operates when the motorcycle is moving, so
that the turn signal lights will not selfcancel while you are stopped at an intersection.
3
4. Engine stop switch “
5. Start switch “
”
/
”
_
EAU00118
Handlebar switches
EAU03888
Dimmer switch “
/
”
Set this switch to “
” for the high
beam and to “
” for the low beam.
EAU04218
Turn signal switch “
/
”
To signal a right-hand turn, push this
switch to “
”. To signal a left-hand
turn, push this switch to “
”. When
released, the switch returns to the center position.
_
EAU00129
Horn switch “
”
Press this switch to sound the horn.
EAU03890
Engine stop switch “ / ”
Set this switch to “ ” before starting
the engine. Set this switch to “ ” to
stop the engine in case of an emergency, such as when the motorcycle overturns or when the throttle cable is
stuck.
EAU00143
Start switch “ ”
Push this switch to crank the engine
with the starter.
EC000005
CAUTION:
See page 5-1 for starting instructions prior to starting the engine.
@
@
3-6
INSTRUMENT AND CONTROL FUNCTIONS
3
1. Clutch lever
1. Shift pedal
1. Brake lever
EAU00152
EAU01215
EAU00158
Clutch lever
Shift pedal
Brake lever
The clutch lever is located at the left
handlebar grip. To disengage the
clutch, pull the lever toward the handlebar 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 3-17 for an explanation of the ignition circuit cut-off system.)
The shift pedal is located on the left
side of the engine and is used in combination with the clutch lever when
shifting the gears of the 5-speed constant-mesh transmission equipped on
this motorcycle.
The brake lever is located at the right
handlebar grip. To apply the front
brake, pull the lever toward the handlebar grip.
NOTE:
Use your toes or heel to shift up and
your toes to shift down.
@
@
3-7
INSTRUMENT AND CONTROL FUNCTIONS
To install the fuel tank cap
1. Insert the fuel tank cap into the
tank opening with the key inserted
in the lock and with the “ ” mark
facing forward.
2. Turn the key counterclockwise to
the original position, remove it,
and then close the lock cover.
1. Brake pedal
EAU00162
Brake pedal
The brake pedal is on the right side of
the motorcycle. To apply the rear
brake, press down on the brake pedal.
1.
2.
a.
b.
Fuel tank cap lock cover
“ ” mark
Unlock.
Lock.
NOTE:
The fuel tank cap cannot be installed
unless the key is in the lock. In addition,
the key cannot be removed if the cap is
not properly installed and locked.
@
EAU02917
Fuel tank cap
@
EW000024
To remove the fuel tank cap
Slide the lock cover open, insert the
key into the lock, and then turn it
1/4 turn clockwise. The lock will be released and the fuel tank cap can be
removed.
3-8
WARNING
Make sure that the fuel tank cap is
properly installed before riding.
@
@
3
INSTRUMENT AND CONTROL FUNCTIONS
EAU00185
CAUTION:
Immediately wipe off spilled fuel
with a clean, dry, soft cloth, since
fuel may deteriorate painted surfaces or plastic parts.
@
@
EAU04265
3
Recommended fuel:
UNLEADED GASOLINE ONLY
Fuel tank capacity:
Total amount:
5.3 US gal (4.4 Imp gal, 20 L)
Reserve amount:
0.9 US gal (0.8 Imp gal, 3.5 L)
1. Fuel tank filler tube
2. Fuel level
EAU03753
Fuel
Make sure that there is sufficient fuel in
the tank. Fill the fuel tank to the bottom
of the filler tube as shown.
EW000130
_
_
WARNING
● Do not overfill the fuel tank, otherwise it may overflow when the
fuel warms up and expands.
● Avoid spilling fuel on the hot
engine.
ECA00104
CAUTION:
Use only unleaded gasoline. The
use of leaded gasoline will cause severe damage to internal engine
parts, such as the valves and piston
rings, as well as to the exhaust system.
_
_
3-9
Your Yamaha engine has been designed to use regular unleaded gasoline with a pump octane number
[(R+M)/2] of 86 or higher, or 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.
Gasohol
There are two types of gasohol: gasohol containing ethanol and that containing methanol. Gasohol containing
ethanol can be used if the ethanol content does not exceed 10%. Gasohol
containing methanol is not recommended by Yamaha because it can
cause damage to the fuel system or vehicle performance problems.
INSTRUMENT AND CONTROL FUNCTIONS
OFF: closed position
ON: normal position
RES: reserve position
3
Pointed end positioned over “OFF”
EAU03050
Fuel cock
The fuel cock supplies fuel from the
tank to the carburetor while filtering it
also.
The fuel cock has three positions:
Pointed end positioned over “ON”
Pointed end positioned over “RES”
ON
With the lever in this position, fuel flows
to the carburetor. Normal riding is done
with the lever in this position.
RES
This indicates reserve. If you run out of
fuel while riding, move the lever to this
position. Fill the tank at the first opportunity. Be sure to set the lever back to
“ON” after refueling!
OFF
With the lever in this position, fuel will
not flow. Always return the lever to this
position when the engine is not running.
3-10
INSTRUMENT AND CONTROL FUNCTIONS
3
EAU04038
Starter (choke) knob “
”
Starting a cold engine requires a richer
air-fuel mixture, which is supplied by
the starter (choke).
Move the knob in direction a to turn on
the starter (choke).
Move the knob in direction b to turn off
the starter (choke).
EAU03372
EAU03785*
Locking the steering with a
padlock
Rider seat
In addition to the main switch/steering
lock, there are brackets on the right
side of the steering head pipe for locking the steering with a padlock. To do
so, turn the handlebar until the holes in
the two brackets are aligned, and then
lock the steering with a suitable padlock.
To remove the rider seat
1. Insert the key into the main switch,
and then turn it counterclockwise
to “OPEN”.
NOTE:
Do not push inward when turning the
key.
_
_
2. Pull the rider seat off.
3-11
INSTRUMENT AND CONTROL FUNCTIONS
EW000030
WARNING
Never ride with a helmet attached to
the helmet holder, since the helmet
may hit objects, causing loss of
control and possibly an accident.
_
_
1. Projection
2. Seat holder
1. Helmet holder
To install the rider seat
1. Insert the projection on the rear of
the rider seat into the seat holder
as shown, and then push the front
of the seat down to lock it in place.
2. Remove the key from the main
switch if the motorcycle will be left
unattended.
Helmet holder
NOTE:
Make sure that the rider seat is properly secured before riding.
_
_
EAU00264
The helmet holder is located under the
rider seat.
To secure a helmet to the helmet
holder
1. Remove the rider seat. (See page
3-11 for rider seat removal and installation procedures.)
2. Attach the helmet to the helmet
holder, and then securely install
the seat.
3-12
To release the helmet from the helmet holder
Remove the rider seat, remove the helmet from the helmet holder, and then
install the seat.
3
INSTRUMENT AND CONTROL FUNCTIONS
4. Loosen the screws holding the
windshield cover located above the
headlight, position the cover close
to the headlight without touching it,
and then tighten the screws.
3
1. Windshield
2. Bolt (× 4)
1. Headlight cover
2. Screw (× 4)
EAU01231
Windshield
[XV16AT(C)/XV16ATLE(C)]
To suit the rider’s preference, the windshield angle can be adjusted and the
height can be changed to one of two
positions.
To adjust the windshield angle
1. Loosen the bolts on each side of
the windshield.
2. Move the windshield to the desired
angle.
3. Tighten the bolts to the specified
torque.
To change the windshield height
1. Remove the bolts on each side of
the windshield.
2. Move the windshield to the other
position.
3. Install the bolts and tighten them
to the specified torque.
Tightening torque:
Windshield bolts:
12 ft·lbf (1.6 m·kgf, 16 Nm)
3-13
INSTRUMENT AND CONTROL FUNCTIONS
EW000134
WARNING
After adjusting the windshield:
● Securely tighten the windshield
bolts.
● Turn the handlebar to the left
and right to make sure that the
handlebar is not obstructed and
that the windshield does not
contact any other parts.
● Open the throttle and make sure
that the throttle grip returns
properly when released, otherwise an accident or injury could
result.
@
@
3
EAU04263*
Saddlebags
[XV16AT(C)/XV16ATLE(C)]
To open a saddlebag
Unbuckle the belts and fold up the flap.
To close a saddlebag
Fold the flap down and buckle both
belts securely.
NOTE:
For saddlebag cleaning and care, see
page 7-4.
_
_
EWA00027
WARNING
Improper loading or overloading
can cause loss of control and possibly an accident or personal injury.
● Always securely close each
saddlebag before riding.
● Distribute weight evenly on
each side of the motorcycle.
● Do not exceed the load limit of
11 lb (5 kg) for each saddlebag.
● Do not exceed the maximum
load of XV16A(C), XV16ALE(C),
XV16AS(C): 432 lb (196 kg) /
XV16AT(C),
XV16ATLE(C):
399 lb (181 kg) for the vehicle.
_
_
3-14
INSTRUMENT AND CONTROL FUNCTIONS
3
1. Locknut
2. Spring preload adjusting nut
1. Special wrench
EAU03591
Adjusting the shock absorber
assembly
This shock absorber assembly is
equipped with a spring preload adjusting nut.
EC000015
A. Distance A
2. To increase the spring preload
and thereby harden the suspension, turn the adjusting nut in direction a. To decrease the spring
preload and thereby soften the
suspension, turn the adjusting nut
in direction b.
NOTE:
The spring preload setting is determined by measuring distance A, shown
in the illustration. The shorter distance
A is, the lower the spring preload; the
longer distance A is, the higher the
spring preload.
_
_
CAUTION:
Never attempt to turn an adjusting
mechanism beyond the maximum
or minimum settings.
_
_
Adjust the spring preload as follows.
1. Loosen the locknut.
3-15
INSTRUMENT AND CONTROL FUNCTIONS
EAU00315
Spring preload:
Minimum (soft):
Distance A = 1.67 in (42.5 mm)
Standard:
XV16A(C)/XV16ALE(C)/
XV16AS(C)
Distance A = 1.67 in (42.5 mm)
XV16AT(C)/XV16ATLE(C)
Distance A = 1.79 in (45.5 mm)
Maximum (hard):
Distance A = 2.02 in (51.5 mm)
CAUTION:
Always tighten the locknut against
the adjusting nut, and then tighten
the locknut to the specified torque.
WARNING
This shock absorber contains highly pressurized nitrogen gas. For
proper handling, read and understand the following information before handling the shock absorber.
The manufacturer cannot be held responsible for property damage or
personal injury that may result from
improper handling.
● Do not tamper with or attempt to
open the gas cylinder.
● Do not subject the shock absorber to an open flame or other
high heat sources, otherwise it
may explode due to excessive
gas pressure.
● Do not deform or damage the
gas cylinder in any way, as this
will result in poor damping performance.
● Always have a Yamaha dealer
service the shock absorber.
_
@
3. Tighten the locknut to the specified torque.
Tightening torque:
Locknut:
25 ft·lbf (3.5 m·kgf, 35 Nm)
EC000018
_
@
3-16
3
INSTRUMENT AND CONTROL FUNCTIONS
EAU00330
Sidestand
The sidestand is located on the left side
of the frame. Raise the sidestand or
lower it with your foot while holding the
motorcycle upright.
NOTE:
The built-in sidestand switch is part of
the ignition circuit cut-off system, which
cuts the ignition in certain situations.
(See further down for an explanation of
the ignition circuit cut-off system.)
@
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), otherwise the sidestand could contact
the ground and distract the operator, 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 sidestand before starting off. Therefore,
check this system regularly as described 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 (comprising the sidestand switch, clutch
switch and neutral switch) has the following functions.
● It prevents starting when the transmission is in gear and the sidestand is up, but the clutch lever is
not pulled.
● It prevents starting when the transmission 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.
_
_
3-17
INSTRUMENT AND CONTROL FUNCTIONS
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?
YES
NOTE:
This check is most reliable if performed with
a warmed-up engine.
”.
NO
The neutral switch may be defective.
The motorcycle should not be ridden until
checked by a Yamaha dealer.
NO
The sidestand switch may be defective.
The motorcycle should not be ridden until
checked by a Yamaha dealer.
NO
The clutch 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?
YES
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?
YES
The system is OK. The motorcycle can be ridden.
3-18
3
PRE-OPERATION CHECKS
Pre-operation check list ..................................................................... 4-1
4
PRE-OPERATION CHECKS
EAU01114
4-
The 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 inspection, to check the following points before each ride.
EAU03439
Pre-operation check list
ITEM
CHECKS
PAGE
Fuel
• Check fuel level in fuel tank.
• Refuel if necessary.
• Check fuel line for leakage.
Engine oil
• Check oil level in engine.
• If necessary, add recommended oil to specified level.
• Check vehicle for oil leakage.
6-9–6-12
Front brake
•
•
•
•
•
•
•
Check 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.
6-21–6-25
Rear brake
•
•
•
•
•
Check 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.
6-22–6-25
Clutch
•
•
•
•
Check operation.
Lubricate cable if necessary.
Check lever free play.
Adjust if necessary.
Throttle grip
• Make sure that operation is smooth.
• Check cable free play.
• If necessary, have Yamaha dealer adjust cable free play and lubricate cable and
grip housing.
4
3-9
6-21
4-1
6-17
PRE-OPERATION CHECKS
ITEM
Control cables
CHECKS
• Make sure that operation is smooth.
• Lubricate if necessary.
Check for damage.
Check tire condition and tread depth.
Check air pressure.
Correct if necessary.
PAGE
—
Wheels and tires
•
•
•
•
Brake and shift pedals
• Make sure that operation is smooth.
• Lubricate pedal pivoting points if necessary.
6-28
Brake and clutch levers
• Make sure that operation is smooth.
• Lubricate lever pivoting points if necessary.
6-29
Sidestand
• Make sure that operation is smooth.
• Lubricate pivot if necessary.
6-29
Chassis fasteners
• Make sure that all nuts, bolts and screws are properly tightened.
• Tighten if necessary.
—
Instruments, lights, signals
and switches
• Check operation.
• Correct if necessary.
—
Sidestand switch
• Check operation of ignition circuit cut-off system.
• If system is defective, have Yamaha dealer check vehicle.
6-18–6-20
4
3-17
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.
@
@
4-2
OPERATION AND IMPORTANT RIDING POINTS
Starting and warming up a cold engine ............................................. 5-1
Starting a warm engine ..................................................................... 5-3
Shifting .............................................................................................. 5-3
Engine break-in ................................................................................. 5-5
Parking .............................................................................................. 5-6
5
OPERATION AND IMPORTANT RIDING POINTS
EAU00372
5-
●
Before starting out, make sure
that the sidestand is up. If the
sidestand is not raised completely, it could contact the
ground and distract the operator, resulting in a possible loss
of control.
@
EAU00376
@
EAU00373
5
@
WARNING
● Become thoroughly familiar with
all operating controls and their
functions before riding. Consult
a Yamaha dealer regarding any
control or function that you do
not thoroughly understand.
● Never start the engine or operate
it in a closed area for any length
of time. Exhaust fumes are poisonous, and inhaling them can
cause loss of consciousness
and death within a short time. Always make sure that there is adequate ventilation.
CAUTION:
● Make sure not to store personal
items near the air cleaner intake, otherwise air intake will be
blocked and performance will
suffer.
● Make sure not to put anything
near the battery and its terminals, otherwise electrical failure
and acid corrosion may result.
EAU01751*
Starting and warming up a
cold 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
@
@
@
5-1
WARNING
Before starting the engine,
check the function of the ignition circuit cut-off system according to the procedure
described on page 3-18.
● Never ride with the sidestand
down.
●
OPERATION AND IMPORTANT RIDING POINTS
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. To avoid the possibility of excessive exhaust emissions,
never leave the starter (choke) on longer than necessary. The time necessary
for starter (choke) use depends upon
the ambient temperature. Temperatures above 50°F (10°C) require about
7 seconds of starter (choke) use and
temperatures below 50°F (10°C) require about 35 seconds with the starter
(choke) turned on, then about
2.5 minutes with the starter (choke) in
the halfway position.
@
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 neutral position.
4. Turn the starter (choke) on and
completely close the throttle. (See
page 3-11 for starter (choke) operation.)
5. Start the engine by pushing the
start switch.
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.
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 preserve the battery. Do not crank the engine more than 10 seconds on any one
attempt.
@
@
@
@
6. After starting the engine, move the
starter (choke) knob back halfway.
5-2
@
5
OPERATION AND IMPORTANT RIDING POINTS
EAU01258
EC000048
Starting a warm engine
@
Follow the same procedure as for starting a cold engine with the exception
that the starter (choke) is not required
when the engine is warm.
EAU00423
Shifting
5
Shifting gears lets you control the
amount of engine power available for
starting off, accelerating, climbing hills,
etc.
The gear positions are shown in the illustration.
@
NOTE:
To shift the transmission into the neutral position, press the shift pedal down
repeatedly until it reaches the end of its
travel, and then slightly raise it.
@
@
5-3
CAUTION:
● Even with the transmission in
the neutral position, do not
coast for long periods of time
with the engine off, and do not
tow the motorcycle for long distances. The transmission is
properly lubricated only when
the engine is running. Inadequate lubrication may damage
the transmission.
● Always use the clutch while
changing gears to avoid damaging the engine, transmission,
and drive train, which are not
designed to withstand the
shock of forced shifting.
OPERATION AND IMPORTANT RIDING POINTS
EAU02988*
EAU02974
To start out and accelerate
1. Pull the clutch lever to disengage
the clutch.
2. Shift the transmission into first
gear. The neutral indicator light
should go out.
3. Open the throttle gradually, and at
the same time, release the clutch
lever slowly.
4. At the recommended shift points
shown in the following table, close
the throttle, and at the same time,
quickly pull the clutch lever in.
5. Shift the transmission into second
gear. (Make sure not to shift the
transmission into the neutral position.)
6. Open the throttle part way and
gradually release the clutch lever.
7. Follow the same procedure when
shifting to the next higher gear.
Recommended shift points
The recommended shift points during
acceleration and deceleration are
shown in the table below.
NOTE:
Always shift gears at the recommended shift points.
@
CF-04E
EAU00427
To decelerate
1. Apply both the front and the rear
brakes to slow the motorcycle.
2. Shift the transmission into first
gear when the motorcycle reaches
16 mi/h (25 km/h). If the engine is
about to stall or runs very roughly,
pull the clutch lever in and use the
brakes to stop the motorcycle.
3. Shift the transmission into the neutral position when the motorcycle
is almost completely stopped. The
neutral indicator light should come
on.
@
5-4
1st
2nd
3rd
4th
→
→
→
→
2nd
3rd
4th
5th
Acceleration
shift point
mi/h (km/h)
Deceleration
shift point
mi/h (km/h)
13 (20)
19 (30)
25 (40)
31 (50)
16 (25)
16 (25)
16 (25)
16 (25)
5
OPERATION AND IMPORTANT RIDING POINTS
1,000 mi (1,600 km) and beyond
The vehicle can now be operated
normally.
EAU01128
Engine break-in
5
There is never a more important period
in the life of your engine than the period
between 0 and 1,000 mi (1,600 km).
For this reason, you should read the
following material carefully.
Since the engine is brand new, do not
put an excessive load on it for the first
1,000 mi (1,600 km). The various parts
in the engine wear and polish themselves to the correct operating clearances. During this period, prolonged
full-throttle operation or any condition
that might result in engine overheating
must be avoided.
EC000049
CAUTION:
If any engine trouble should occur
during the engine break-in period,
immediately have a Yamaha dealer
check the vehicle.
@
@
EAU01740*
0–600 mi (0–1,000 km)
Avoid prolonged operation
1/3 throttle.
above
600–1,000 mi (1,000–1,600 km)
Avoid prolonged operation above
1/2 throttle.
ECA00026*
CAUTION:
After 600 mi (1,000 km) of operation,
the engine oil and transfer case oil
must be changed, and the oil filter
cartridge replaced.
@
@
5-5
OPERATION AND IMPORTANT RIDING POINTS
EAU00457
Parking
5
When parking, stop the engine, remove the key from the main switch,
and then turn the fuel cock lever to
“OFF”.
EW000058
@
WARNING
Since the engine and exhaust
system can become very hot,
park in a place where pedestrians or children are not likely to
touch them.
● Do not park on a slope or on
soft ground, otherwise the
motorcycle may overturn.
●
@
5-6
PERIODIC MAINTENANCE AND MINOR REPAIR
Periodic maintenance ..........................................6-1
Owner’s tool kit ....................................................6-2
Periodic maintenance chart for the emission
control system ...................................................6-3
General maintenance and lubrication chart .........6-4
Removing and installing the panel .......................6-7
Checking the spark plugs ....................................6-8
Canister (for California only) ................................6-9
Engine oil and oil filter cartridge ..........................6-9
Transfer case oil .................................................6-13
Cleaning the air filter element ............................6-15
Adjusting the carburetor .....................................6-17
Adjusting the throttle cable free play ..................6-17
Adjusting the valve clearance ............................6-17
Tires....................................................................6-18
Spoke wheels ....................................................6-20
Accessories and replacement parts ..................6-20
Adjusting the clutch lever free play ....................6-21
Adjusting the brake lever free play .....................6-21
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 ............................ 6-24
Changing the brake fluid ................................... 6-25
Drive belt slack .................................................. 6-25
Checking and lubricating the throttle grip and
cable ............................................................... 6-27
Checking and lubricating the brake and
shift pedals ...................................................... 6-28
Checking and lubricating the brake and
clutch levers .................................................... 6-29
Checking and lubricating the sidestand ............ 6-29
Checking the front fork ...................................... 6-30
Checking the steering ....................................... 6-31
Checking the wheel bearings ............................ 6-31
Battery ............................................................... 6-32
Replacing the fuses .......................................... 6-33
Replacing the headlight bulb ............................. 6-35
Replacing a turn signal light bulb or
the tail/brake light bulb .................................... 6-37
Supporting the motorcycle ................................ 6-37
Troubleshooting ................................................. 6-38
Troubleshooting chart ........................................ 6-39
6
PERIODIC MAINTENANCE AND MINOR REPAIR
EAU00462
6-
TROL ARE GROUPED SEPARATELY. THESE SERVICES REQUIRE
SPECIALIZED DATA, KNOWLEDGE,
AND EQUIPMENT. YAMAHA DEALERS ARE TRAINED AND EQUIPPED
TO PERFORM THESE PARTICULAR
SERVICES.
EAU01790
Safety is an obligation of the owner.
Periodic inspection, adjustment and lubrication will keep your vehicle in the
safest and most efficient condition possible. The most important points of
motorcycle inspection, adjustment, and
lubrication are explained on the following pages.
Maintenance, replacement, or repair
of the emission control devices and
systems may be performed by any
repair establishment or individual
that is certified (if applicable).
EW000060
6
WARNING
If you are not familiar with motorcycle maintenance work, have a
Yamaha dealer do it for you.
@
@
EAU00467
PERIODIC MAINTENANCE
PROPER PERIODIC MAINTENANCE
OF YOUR MOTORCYCLE IS IMPORTANT IN ORDER TO ENJOY LONG,
PLEASURABLE SERVICE. ESPECIALLY IMPORTANT ARE THE
MAINTENANCE SERVICES RELATED TO EMISSIONS CONTROL.
THESE CONTROLS NOT ONLY
FUNCTION TO ENSURE CLEANER
AIR, BUT ARE ALSO VITAL TO
PROPER ENGINE OPERATION AND
MAXIMUM PERFORMANCE. IN THE
FOLLOWING PERIODIC MAINTENANCE CHARTS, THE SERVICES
RELATED TO EMISSIONS CON6-1
PERIODIC MAINTENANCE AND MINOR REPAIR
NOTE:
If you do not have the tools or experience required for a particular job, have
a Yamaha dealer perform it for you.
_
_
EW000062
WARNING
Modifications not approved by
Yamaha may cause loss of performance, excessive emissions, and
render the vehicle unsafe for use.
Consult a Yamaha dealer before attempting any changes.
_
1. Owner’s tool kit
EAU03644
Owner’s tool kit
The owner’s tool kit is located under
the rider seat. (See page 3-11 for rider
seat removal and installation procedures.)
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. However, additional tools such as a torque
wrench may be necessary to perform
certain maintenance work correctly.
_
6
6-2
PERIODIC MAINTENANCE AND MINOR REPAIR
EAU00471
Periodic maintenance chart for the emission control system
No.
1
*
2
6
ITEM
ROUTINE
INITIAL
600 mi
(1,000 km)
or
1 month
4,000 mi
(7,000 km)
or
6 months
ODOMETER READINGS
8,000 mi
12,000 mi
16,000 mi
(13,000 km)
(19,000 km)
(25,000 km)
or
or
or
12 months
18 months
24 months
20,000 mi
(31,000 km)
or
30 months
Valve clearance
• Check valve clearance when engine is
cold.
• Adjust if necessary.
Spark plug
• Check condition.
• Adjust gap and clean.
• Replace at 8,000 mi (13,000 km) or
12 months and thereafter every
8,000 mi (13,000 km) or 12 months.
√
Replace
√
Replace
√
Every 16,000 mi (25,000 km)
3
*
Crankcase
ventilation system
• Check ventilation hose for cracks or
damage.
• Replace if necessary.
√
√
√
√
√
4
*
Fuel line
• Check fuel hose for cracks or damage.
• Replace if necessary.
√
√
√
√
√
5
*
Fuel filter
• Replace initial 20,000 mi (31,000 km) or
30 months and thereafter every 20,000 mi
(31,000 km) or 30 months.
6
*
Exhaust system
• Check for leakage.
• Retighten if necessary.
• Replace gasket(s) if necessary.
7
*
Idle speed
• Check and adjust engine idle speed.
• Adjust cable free play.
*
Evaporative
Emission control
system (For
California only)
• Check control system for damage.
• Replace if necessary.
8
Replace
√
√
√
√
√
√
√
√
√
√
√
√
* Since these items require special tools, data and technical skills, have a Yamaha dealer perform the service.
6-3
√
PERIODIC MAINTENANCE AND MINOR REPAIR
EAU00472
General maintenance and lubrication chart
No.
1
ITEM
ROUTINE
Engine oil
• Replace
TYPE
4,000 mi
(7,000 km)
or
6 months
√
√
See page 8-1.
2
*
Oil filter
• Replace
-
3
*
Air filter
(See NOTE on
page 6-6.)
• Clean with compressed
air.
• Replace if necessary.
-
4
*
Front brake
• Check operation and fluid
leakage. (See NOTE page
6-6.)
• Correct if necessary.
-
5
*
Rear brake
• Check operation and fluid
leakage. (See NOTE page
6-6.)
• Correct if necessary.
6
*
Clutch
• Check operation and free
play.
• Correct if necessary.
7
*
• Check vehicle for leakage.
SAE 80 API “GL-4”
Transfer case oil • Replace every 16,000 mi
hypoid gear oil
(25,000 km) or 24 months.
8
*
Control cable
• Apply chain lube
thoroughly.
Yamaha chain and
cable lube or
SAE 10W30 motor oil
*
Rear arm pivot
bearing
• Check bearing assembly
for looseness.
• Moderately repack every
16,000 mi (25,000 km) or
24 months.
Medium weight wheel
bearing grease
9
INITIAL
600 mi
(1,000 km)
or
1 month
√
ODOMETER READINGS
8,000 mi
12,000 mi
16,000 mi
(13,000 km) (19,000 km) (25,000 km)
or
or
or
12 months
18 months
24 months
√
√
√
√
20,000 mi
(31,000 km)
or
30 months
√
√
√
√
√
√
√
√
√
√
√
Replace
brake fluid
√
-
√
√
√
√
Replace
brake fluid
√
-
√
√
√
√
√
√
Replace
√
Check
√
√
√
* Since these items require special tools, data and technical skills, have a Yamaha dealer perform the service.
6-4
Replace
√
√
Repack
√
6
PERIODIC MAINTENANCE AND MINOR REPAIR
No.
ROUTINE
TYPE
4,000 mi
(7,000 km)
or
6 months
ODOMETER READINGS
8,000 mi
12,000 mi
16,000 mi
(13,000 km) (19,000 km) (25,000 km)
or
or
or
12 months
18 months
24 months
20,000 mi
(31,000 km)
or
30 months
10
Brake/
Clutch lever
pivot shaft
• Apply chain lube lightly.
Yamaha chain and
cable lube or
SAE 10W30 motor oil
√
√
√
√
√
11
Brake pedal
and shift
pedal shaft
• Lubricate
• Apply chain lube lightly.
Yamaha chain and
cable lube or
SAE 10W30 motor oil
√
√
√
√
√
Yamaha chain and
cable lube or
SAE 10W30 motor oil
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
Repack
√
√
√
√
√
√
12
*
Sidestand pivot
• Check operation and
lubricate.
• Apply chain lube lightly.
13
*
Sidestand switch
• Check and clean or
replace if necessary.
-
*
Front fork
• Check operation and for
leakage.
-
15
*
Steering
bearings
• Check bearing assembly
for looseness.
• Moderately repack every
16,000 mi (25,000 km) or
24 months.
16
*
Wheel bearings
• Check bearings for
smooth rotation.
*
Rear suspension link pivots
• Apply grease lightly.
Drive belt
• Check for belt tension
• Adjust if necessary
14
6
ITEM
INITIAL
600 mi
(1,000 km)
or
1 month
17
18
*
√
Lithium soap base
grease
Molybdenum disulfide
grease
√
√
-
Every 2,500 mi (4,000 km)
* Since these items require special tools, data and technical skills, have a Yamaha dealer perform the service.
6-5
PERIODIC MAINTENANCE AND MINOR REPAIR
EAU03907
NOTE:
From 24,000 mi (37,000 km) or 36 months, repeat the maintenance intervals starting from 4,000 mi (7,000 km) or 6 months.
_
_
EAU03057
NOTE:
● The air filter needs more frequent service if you are riding in unusually wet or dusty areas.
● Hydraulic brake system
• When disassembling the master cylinder or caliper cylinder, always replace the brake fluid. Check the brake fluid level
regularly and fill as required.
• Replace the oil seals on the inner parts of the master cylinder and caliper cylinder every two years.
• Replace the brake hoses every four years or if cracked or damaged.
@
@
6
6-6
PERIODIC MAINTENANCE AND MINOR REPAIR
1. Panel A
1. Bolt
EAU01777
Removing and installing the
panel
6
The panel shown above needs to be
removed to perform some of the maintenance jobs described in this chapter.
Refer to this section each time the panel needs to be removed and installed.
EAU00491
Panel A
To remove the panel
Remove the bolt, and then pull the panel off as shown.
6-7
To install the panel
Place the panel in the original position,
and then install the bolt.
PERIODIC MAINTENANCE AND MINOR REPAIR
a. Spark plug gap
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 maintenance and lubrication chart. In addition,
the condition of the spark plugs can reveal the condition of the engine.
The porcelain insulator around the center electrode of each spark plug should
be a medium-to-light tan (the ideal color when the motorcycle is ridden normally), and all spark plugs installed in
the engine should have the same color.
If any spark plug shows a distinctly different color, the engine could be defective. 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.
Specified spark plug:
DPR7EA-9/NGK or
X22EPR-U9/DENSO
Before installing a spark plug, the spark
plug gap should be measured with a
wire thickness gauge and, if necessary,
adjusted to specification.
Spark plug gap:
0.03–0.04 in (0.8–0.9 mm)
6-8
Clean the surface of the spark plug
gasket and its mating surface, and then
wipe off any grime from the spark plug
threads.
Tightening torque:
Spark plug:
12.5 ft·lbf (1.75 m·kgf, 17.5 Nm)
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 specified torque as soon as possible.
@
@
6
PERIODIC MAINTENANCE AND MINOR REPAIR
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.
@
@
6
1. Engine oil filler cap
EAU00499
Canister (for California only)
This model is equipped with a canister
to prevent the discharging of fuel vapor
into the atmosphere. Before operating
this motorcycle, make sure to check
the following:
● Check each hose connection.
● Check each hose and canister for
cracks or damage. Replace if
damaged.
● Make sure that the canister
breather is not blocked, and if necessary, clean it.
6-9
EAU04628
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 cartridge replaced at the intervals specified 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.
PERIODIC MAINTENANCE AND MINOR REPAIR
NOTE:
Make sure that the motorcycle is positioned straight up when checking the oil
level. A slight tilt to the side can result in
a false reading.
NOTE:
When adding oil, be careful not to overfill the engine; the oil level rises faster
starting from the half level portion on
the dipstick.
_
_
_
2. Remove the rider seat. (See page
3-11 for rider seat removal and installation procedures.)
3. Start the engine, warm it up until
the engine oil has reached a normal temperature of 140 °F (60 °C),
let it continue to idle for ten seconds, and then turn the engine off.
NOTE:
To achieve the proper engine oil temperature for an accurate oil level reading, the engine must have first
completely cooled down, and then
warmed up again for several minutes to
normal operating temperature.
_
1. Maximum level mark
2. Minimum level mark
3. Dipstick
ECA00027
CAUTION:
Make sure that the oil filler cap is securely tightened, otherwise oil may
seep out when the engine is running.
_
4. Wait a few minutes until the oil settles, remove the oil filler cap, wipe
the dipstick clean, insert it back
into the oil filler hole (without
screwing it in), and then remove it
again to check the oil level.
_
_
6. Insert the dipstick into the oil filler
hole, and then tighten the oil filler
cap.
7. Install the rider seat.
NOTE:
The engine oil should be between the
minimum and maximum level marks.
_
_
5. If the engine oil is below the minimum level mark, add sufficient oil
of the recommended type to raise
it to the correct level.
6-10
_
6
PERIODIC MAINTENANCE AND MINOR REPAIR
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.
_
_
1. Engine oil drain bolt (oil tank)
6
1. Engine oil drain bolt (crankcase)
7. Apply a thin coat of engine oil to
the O-ring of the new oil filter cartridge.
To change the engine oil (with or
without oil filter cartridge replacement)
1. Start the engine, warm it up for
several minutes, and then turn it
off.
2. Place an oil pan under the oil tank
to collect the used oil.
3. Remove the engine oil filler cap
and drain bolt to drain the oil from
the oil tank.
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.
NOTE:
Skip steps 4–8 if the oil filter cartridge is
not being replaced.
Tightening torque:
Oil filter cartridge:
12 ft·lbf (1.7 m·kgf, 17 Nm)
_
_
4. Place an oil pan under the engine
to collect the used oil.
6-11
PERIODIC MAINTENANCE AND MINOR REPAIR
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 filter cartridge
9. Install the engine oil drain bolts,
and then tighten them to the specified torque.
Tightening torque:
Engine oil drain bolt:
31 ft·lbf (4.3 m·kgf, 43 Nm)
Recommended engine oil:
See page 8-1.
Oil quantity:
Without oil filter cartridge
replacement:
3.9 US qt (3.3 Imp qt, 3.7 L)
With oil filter cartridge
replacement:
4.3 US qt (3.6 Imp qt, 4.1 L)
Total amount (dry engine):
5.3 US qt (4.4 Imp qt, 5.0 L)
10. Pour only 2.6 US qt (2.2 Imp qt,
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.
6-12
ECA00133
_
CAUTION:
● In order to prevent clutch slippage (since the engine oil also
lubricates the clutch), do not
mix any chemical additives. Do
not use oils with a diesel specification of “CD” or oils of a
higher quality than specified. In
addition, do not use oils labeled
“ENERGY CONSERVING II” or
higher.
● Make sure that no foreign material 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.
6
PERIODIC MAINTENANCE AND MINOR REPAIR
NOTE:
Make sure that the motorcycle is positioned 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.
1. Transfer case oil filler cap
2. Transfer case oil level check bolt
1. Transfer case oil drain bolt
_
EAU04251
Transfer case oil
6
NOTE:
The oil should be at the brim of the
check hole.
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.
_
3. If the oil is below the brim of the
check hole, remove the oil filler
cap, add sufficient oil of the recommended 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.
Tightening torque:
Transfer case oil check bolt:
5 ft·lbf (0.75 m·kgf, 7.5 Nm)
6-13
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.
Tightening torque:
Transfer case oil drain bolt:
13 ft·lbf (1.75 m·kgf, 17.5 Nm)
PERIODIC MAINTENANCE AND MINOR REPAIR
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.
1. Transfer case oil level check hole
4. Remove the oil filler cap, add the
specified amount of the recommended transfer case oil, and then
install and tighten the oil filler cap.
6
Recommended transfer case oil:
See page 8-2.
Oil quantity:
0.42 US qt (0.35 Imp qt, 0.4 L)
ECA00024
CAUTION:
Make sure that no foreign material
enters the transfer case.
_
_
6-14
PERIODIC MAINTENANCE AND MINOR REPAIR
1. Bolt (× 4)
2. Air filter case
1. Air filter joint clamp screw
EAU03707
Cleaning the air filter element
6
The air filter element should be cleaned
at the intervals specified in the periodic
maintenance and lubrication chart.
Clean the air filter element more frequently if you are riding in unusually
wet or dusty areas.
1. Remove the air filter case bolts.
2. Loosen the air filter joint clamp
screw, and then slightly pull the air
filter case out.
6-15
1. Screw (× 2)
2. Hose (× 2)
3. Air filter case cover
3. Remove the air filter case cover by
removing the screws.
4. Disconnect the hoses shown.
PERIODIC MAINTENANCE AND MINOR REPAIR
1. Screw (× 2)
2. Hose
5. Remove the air filter element by
removing the screws, and then
disconnect the hose shown.
1. Hose (× 2)
6. Lightly tap the air filter element to
remove most of the dust and dirt,
and then blow the remaining dirt
out with compressed air as shown.
If the air filter element is damaged,
replace it.
7. Install the air filter element by inserting it into the air filter case,
then installing the screws, and
then connect the hose shown.
8. Install the air filter case cover by
installing the screws.
6-16
9. Connect the hoses shown.
10. Install the air filter case by pushing
it onto the air filter joint, and then
tighten the air filter joint clamp
screw.
11. Install the air filter case by installing the bolts.
6
PERIODIC MAINTENANCE AND MINOR REPAIR
EAU01752
EAU00637
Adjusting the carburetor
Adjusting the valve clearance
The carburetor is an important part of
the engine and its emission control system, which requires very sophisticated
adjustment. Therefore, carburetor adjustments should be left to Yamaha
dealer, who has the necessary professional knowledge and experience.
The valve clearance changes with use,
resulting in improper air-fuel mixture
and/or engine noise. To prevent this
from occurring, the valve clearance
must be adjusted by a Yamaha dealer
at the intervals specified in the periodic
maintenance and lubrication chart.
a. Throttle cable free play
EAU00635
Adjusting the throttle cable
free play
6
The throttle cable free play should
measure 0.16–0.24 in (4–6 mm) at the
throttle grip. Periodically check the
throttle cable free play and, if necessary, have a Yamaha dealer adjust it.
6-17
PERIODIC MAINTENANCE AND MINOR REPAIR
rider, passenger, and accessories
(windshield, saddlebags, etc. if approved for this model).
_
CE-05E
Tire air pressure
(measured on cold tires)
Load*
EAU01846
Tires
Rear
Up to 198 lb (90 kg)
198 lb (90 kg)–
maximum
36 psi
41 psi
(2.50 kgf/cm2, (2.80 kgf/cm2,
250 kPa)
280 kPa)
CE-16E
To ensure maximum performance,
long service, and safe operation, note
the following:
Tire air pressure
Always check and adjust the tire pressure before operating the motorcycle.
EWA00011
WARNING
Tire inflation pressure should be
checked and adjusted when the
temperature of the tire equals the
ambient air temperature. Tire inflation pressure must be adjusted according to total weight of cargo,
_
Front
36 psi
36 psi
(2.50 kgf/cm2, (2.50 kgf/cm2,
250 kPa)
250 kPa)
Maximum load*
XV16A(C)/XV16ALE(C)/
XV16AS(C): 432 lb (196 kg)
XV16AT(C)/XV16ATLE(C):
399 lb (181 kg)
* Total weight of rider, passenger, cargo and
accessories
EWA00012
WARNING
Proper loading of your motorcycle
is important for several characteristics of your motorcycle, such as
handling, braking, performance and
safety. Do not carry loosely packed
items that can shift. Securely pack
your heaviest items close to the
center of the motorcycle, and dis_
6-18
tribute the weight evenly from side
to side. Properly adjust the suspension for your load, and check the
condition and pressure of your tires.
NEVER OVERLOAD YOUR MOTORCYCLE. Make sure the total weight
of the cargo, rider, passenger, and
accessories (windshield, saddlebags, etc. if approved for this model)
does not exceed the maximum load
of the motorcycle. Operation of an
overloaded motorcycle could cause
tire damage, an accident, or even injury.
_
6
PERIODIC MAINTENANCE AND MINOR REPAIR
combinations other than what is approved are used on this motorcycle.
The front and rear tires should be of
the same manufacture and design.
EAU00680
_
_
CE-10E
FRONT
Manufacturer
Dunlop
1. Tire sidewall
2. Tire wear indicator
a. Tire tread depth
6
Bridgestone
Size
130/90-16 M/C 67H
130/90-16 67H
130/90-16 M/C 67H
D404FL
G703F
REAR
Tire inspection
Always check the tires before operating
the motorcycle. If a tire tread shows
crosswise line (minimum tread depth),
if the tire has a nail or glass fragments
in it, or if the side wall is cracked, contact a Yamaha dealer immediately and
have the tire replaced.
EW000078
Manufacturer
Dunlop
Bridgestone
Size
WARNING
After extensive tests, the tires mentioned below have been approved
by Yamaha Motor Co., Ltd. for this
model. No guarantee for handling
characteristics can be given if tire
Model
150/80B-16 71H
150/80B-16 M/C 71H
150/80B-16 71H
150/80B-16 M/C 71H
D404
G702
CE-23E
Minimum tire tread depth
(front and rear)
0.04 in (1.0 mm)
_
NOTE:
These limits may be different by regulation from country to country. If so, conform to the limits specified by the
regulations of your own country.
_
_
Model
130/90-16 67H
_
6-19
WARNING
It is dangerous to ride with a
worn-out tire. When a tire tread
begins to show crosswise lines,
have a Yamaha dealer replace
the tire immediately.
● The replacement of all wheeland brake-related parts, including the tires, should be left to a
Yamaha dealer, who has the
necessary professional knowledge and experience.
● It is not recommended to patch
a punctured tube. If unavoidable, however, patch the tube
very carefully and replace it as
soon as possible with a highquality product.
●
PERIODIC MAINTENANCE AND MINOR REPAIR
EAU00685
Spoke wheels
To maximize the performance, durability, and safe operation of your motorcycle, note the following points
regarding the specified wheels.
● The wheel rims should be checked
for cracks, bends or warpage, and
the spokes for looseness or damage before each ride. If any damage is found, have a Yamaha
dealer replace the wheel. Do not
attempt even the smallest repair to
the wheel. A deformed or cracked
wheel must be replaced.
● The wheel should be balanced
whenever either the tire or wheel
has been changed or replaced. An
unbalanced wheel can result in
poor performance, adverse handling characteristics, and a shortened tire life.
● Ride at moderate speeds after
changing a tire since the tire surface must first be “broken in” for it to
develop its optimal characteristics.
EAU00691
Accessories and replacement
parts
by the use of items which have not
been approved by Yamaha.
@
EW000098
WARNING
This motorcycle is not designed to
pull a trailer or to be attached to a
sidecar. The accessories or replacement parts you choose for your
motorcycle should be designed specifically for this model, and they
must be securely mounted to maintain the inherent stability of the original design. Genuine Yamaha Parts
and Accessories are designed and
tested to be compatible with your
motorcycle. Please consider Genuine Yamaha Parts and Accessories
before making a purchase. Use of
non-Yamaha-approved accessories
or replacement parts may cause
loss of handling stability and riding
safety. Since Yamaha cannot control the quality of accessories or
parts manufactured by other companies, Yamaha cannot be held liable for any consequences caused
@
6-20
6
PERIODIC MAINTENANCE AND MINOR REPAIR
1. Locknut
2. Clutch lever free play adjusting bolt
c. Clutch lever free play
1. Clutch lever free play adjusting nut
2. Locknut
EAU00694
6
Adjusting the clutch lever free
play
The clutch lever free play should measure 0.4–0.6 in (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
lever.
2. To increase the clutch lever free
play, turn the adjusting bolt in direction 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 described 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 loosen the clutch cable.
5. Loosen the locknut at the
crankcase.
6. To increase the clutch lever free
play, turn the adjusting nut in direction 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.
6-21
1. Locknut
2. Brake lever free play adjusting bolt
c. Brake lever free play
EAU00696
Adjusting the brake lever free
play
The brake lever free play should measure 0.08–0.2 in (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
lever.
2. To increase the brake lever free
play, turn the adjusting bolt in direction a. To decrease the brake
lever free play, turn the adjusting
bolt in direction b.
PERIODIC MAINTENANCE AND MINOR REPAIR
3. Tighten the locknut.
EW000109
EW000099
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 before operating the motorcycle. Air in
the hydraulic system will diminish
the braking performance, which
may result in loss of control and an
accident.
@
@
@
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 hydraulic system, have a Yamaha
dealer bleed the system before
operating the motorcycle. Air in
the hydraulic system will diminish the braking performance,
which may result in loss of control and an accident.
a. Distance between brake pedal and footrest
EAU01746
Adjusting the brake pedal
position
The top of the brake pedal should be positioned approximately 3.9 in (100 mm)
above the top of the footrest as shown.
Periodically check the brake pedal position and, if necessary, have a Yamaha
dealer adjust it.
6-22
@
6
PERIODIC MAINTENANCE AND MINOR REPAIR
EAU00721
Checking the front and rear
brake pads
Front
The front and rear brake pads must be
checked for wear at the intervals specified in the periodic maintenance and
lubrication chart.
1. Rear brake light switch
2. Rear brake light switch adjusting nut
1. Brake pad wear indicator groove (× 2)
EAU03938
Front brake pads
Each front brake pad is provided with
wear indicator grooves, which allow
you to check the brake pad wear without 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 disappeared, have a Yamaha dealer replace
the brake pads as a set.
EAU00713
Adjusting the rear brake light
switch
6
The rear brake light switch, which is activated 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.
6-23
PERIODIC MAINTENANCE AND MINOR REPAIR
Rear
Front
1. Brake pad wear indicator groove
Rear
1. Minimum level mark
EAU03939
Rear brake pads
Each rear brake pad is provided with a
wear indicator groove, which allows
you to check the brake pad wear without 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 disappeared, have a Yamaha dealer replace
the brake pads as a set.
1. Minimum level mark
EAU03294
Checking the brake fluid level
Insufficient brake fluid may allow air to
enter the brake system, possibly causing it to become ineffective.
Before riding, check that the brake fluid
is above the minimum level mark and
replenish if necessary. A low brake fluid 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 system for leakage.
6-24
Observe these precautions:
● When checking the fluid level,
make sure that the top of the brake
fluid reservoir is level.
● Use only the recommended quality brake fluid, otherwise the rubber
seals may deteriorate, causing
leakage and poor braking performance.
Recommended brake fluid: DOT 4
●
Refill with the same type of brake
fluid. Mixing fluids may result in a
harmful chemical reaction and
lead to poor braking performance.
6
PERIODIC MAINTENANCE AND MINOR REPAIR
●
6
Be careful that water does not enter 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 painted surfaces or plastic parts. Always clean up spilled fluid
immediately.
● As the brake pads wear, it is normal for the brake fluid level to
gradually go down. However, if the
brake fluid level goes down suddenly, have a Yamaha dealer
check the cause.
EAU03976
Changing the brake fluid
Have a Yamaha dealer change the
brake fluid at the intervals specified in
the NOTE after the periodic maintenance and lubrication chart. In addition,
have the oil seals of the master cylinders 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.
1. Drive belt
2. Marks
a. Drive belt slack
EAU04452
Drive belt slack
The drive belt slack should be checked
and adjusted at the intervals specified
in the periodic maintenance and lubrication chart.
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
drive belt check hole.
NOTE:
The marks near the drive belt check
hole are 0.2 in (5 mm) apart.
_
_
6-25
PERIODIC MAINTENANCE AND MINOR REPAIR
1. Belt tension gauge
3. Note the position of the drive belt
with a force of 10 lbf (4.5 kg, 45 N)
applied to the belt with a belt tension gauge as shown.
1. Wheel axle nut
1. Brake caliper bracket bolt
EAU01748
To adjust the drive belt slack
1. Loosen the rear wheel axle nut
and the brake caliper bracket bolt.
6
NOTE:
A belt tension gauge is available at a
Yamaha dealer.
_
_
4. Calculate the drive belt slack by
subtracting the measurement noted in step 2 from the measurement noted in step 3.
Drive belt slack:
0.3–0.5 in (7.5–13 mm)
5. If the drive belt slack is incorrect,
adjust it as follows.
6-26
PERIODIC MAINTENANCE AND MINOR REPAIR
ECA00025
CAUTION:
Improper drive belt slack will overload 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.
1. Drive belt slack adjusting bolt (× 2)
2. Locknut (× 2)
3. Wheel axle
2. Loosen the drive belt puller locknut on each side of the swingarm.
3. To tighten the drive belt, turn the
adjusting bolt on each side of the
swingarm in direction a. To loosen the drive belt, turn the adjusting
bolt on each side of the swingarm
in direction b, and then push the
rear wheel forward.
6
Tightening torques:
Axle nut:
108.5 ft·lbf (15 m·kgf, 150 Nm)
Brake caliper bracket bolt:
34.7 ft·lbf (4.8 m·kgf, 48 Nm)
NOTE:
Turn each adjusting bolt the same
amount for proper wheel alignment.
@
@
4. Tighten the locknuts.
6-27
EAU04034
Checking and lubricating the
throttle grip and cable
The operation of the throttle grip should
be checked before each ride. In addition, the cable should be lubricated or
replaced at the intervals specified in
the periodic maintenance chart.
PERIODIC MAINTENANCE AND MINOR REPAIR
EAU03370
Checking and lubricating the
brake and shift pedals
The operation of the brake and shift
pedals should be checked before each
ride, and the pedal pivots should be lubricated if necessary.
6
Recommended lubricant:
Lithium-soap-based grease
(all-purpose grease)
6-28
PERIODIC MAINTENANCE AND MINOR REPAIR
EAU03164
6
EAU03165
Checking and lubricating the
brake and clutch levers
Checking and lubricating the
sidestand
The operation of the brake and clutch
levers should be checked before each
ride, and the lever pivots should be lubricated if necessary.
The operation of the sidestand should
be checked before each ride, and the
sidestand pivot and metal-to-metal
contact surfaces should be lubricated if
necessary.
EW000113
Recommended lubricant:
Lithium-soap-based grease
(all-purpose grease)
WARNING
If the sidestand does not move up
and down smoothly, have a Yamaha
dealer check or repair it.
@
@
Recommended lubricant:
Lithium-soap-based grease
(all-purpose grease)
6-29
PERIODIC MAINTENANCE AND MINOR REPAIR
EAU02939
Checking the front fork
The condition and operation of the front
fork must be checked as follows at the
intervals specified in the periodic maintenance and lubrication chart.
To check the condition
EW000115
WARNING
Securely support the motorcycle so
that there is no danger of it falling
over.
@
@
Check the inner tubes for scratches,
damage and excessive oil leakage.
To check the operation
1. Place the motorcycle on a level
surface and hold it in an upright
position.
2. While applying the front brake,
push down hard on the handlebars several times to check if the
front fork compresses and rebounds smoothly.
EC000098
CAUTION:
If any damage is found or the front
fork does not operate smoothly,
have a Yamaha dealer check or repair it.
@
@
6-30
6
PERIODIC MAINTENANCE AND MINOR REPAIR
EAU00794
Checking the wheel bearings
Worn or loose steering bearings may
cause danger. Therefore, the operation
of the steering must be checked as follows at the intervals specified in the periodic maintenance and lubrication
chart.
1. Place a stand under the engine to
raise the front wheel off the
ground.
The front and rear wheel bearings must
be checked at the intervals specified in
the periodic maintenance and lubrication chart. If there is play in the wheel
hub or if the wheel does not turn
smoothly, have a Yamaha dealer
check the wheel bearings.
EW000115
WARNING
Securely support the motorcycle so
that there is no danger of it falling
over.
@
6
EAU01144
Checking the steering
2. Hold the lower ends of the front
fork legs and try to move them forward and backward. If any free
play can be felt, have a Yamaha
dealer check or repair the steering.
@
6-31
PERIODIC MAINTENANCE AND MINOR REPAIR
EW000116
@
1. Battery
EAU00800
Battery
This motorcycle is equipped with a
sealed-type (MF) battery, which does
not require any maintenance. There is
no need to check the electrolyte or to
add distilled water.
EC000101
CAUTION:
Never attempt to remove the battery
cell seals, as this would permanently damage the battery.
@
@
WARNING
● Electrolyte is poisonous and
dangerous since it contains sulfuric acid, which causes severe
burns. Avoid any contact with
skin, eyes or clothing and always shield your eyes when
working near batteries. In case
of contact, administer the following FIRST AID.
• EXTERNAL: Flush with plenty
of water.
• INTERNAL: Drink large quantities of water or milk and immediately call a physician.
• EYES: Flush with water for
15 minutes and seek prompt
medical attention.
● Batteries produce explosive hydrogen gas. Therefore, keep
sparks, flames, cigarettes, etc.,
away from the battery and provide sufficient ventilation when
charging it in an enclosed space.
● KEEP THIS AND ALL BATTERIES OUT OF THE REACH OF
CHILDREN.
@
6-32
To charge the battery
Have a Yamaha dealer charge the battery as soon as possible if it seems to
have discharged. Keep in mind that the
battery tends to discharge more quickly
if the motorcycle is equipped with optional electrical accessories.
To store the battery
1. If the motorcycle will not be used
for more than one month, remove
the battery, fully charge it, and
then place it in a cool, dry place.
2. If the battery will be stored for
more than two months, check it at
least once a month and fully
charge it if necessary.
3. Fully charge the battery before installation.
4. After installation, make sure that
the battery leads are properly connected to the battery terminals.
6
PERIODIC MAINTENANCE AND MINOR REPAIR
EC000102
@
6
@
CAUTION:
keep the battery
● Always
charged. Storing a discharged
battery can cause permanent
battery damage.
● To charge a sealed-type (MF)
battery, a special (constantvoltage) battery charger is required. Using a conventional
battery charger will damage the
battery. If you do not have access to a sealed-type (MF) battery charger, have a Yamaha
dealer charge your battery.
1. Bolt
EAU04190*
Replacing the fuses
The main fuse and the fuse box, which
contains the fuses for the individual circuits, are located behind panel A. (See
page 6-7 for panel removal and installation procedures.)
6-33
1.
2.
3.
4.
5.
6.
Signaling system fuse
Ignition fuse
Headlight fuse
Carburetor heater fuse
Odometer fuse
Spare fuse (× 3)
If a fuse is blown, replace it as follows.
1. Turn the key to “OFF” and turn off
the electrical circuit in question.
2. Remove the blown fuse, and then
install a new fuse of the specified
amperage.
PERIODIC MAINTENANCE AND MINOR REPAIR
EC000103
CAUTION:
Do not use a fuse of a higher amperage rating than recommended to
avoid causing extensive damage to
the electrical system and possibly a
fire.
_
_
1. Main fuse
2. Spare main fuse
Specified fuses:
Main fuse:
Headlight fuse:
Signaling system fuse:
Ignition fuse:
Odometer fuse:
Carburetor heater fuse:
30 A
15 A
10 A
15 A
5A
10 A
3. Turn the key to “ON” and turn on
the electrical circuit in question to
check if the device operates.
4. If the fuse immediately blows
again, have a Yamaha dealer
check the electrical system.
6
6-34
PERIODIC MAINTENANCE AND MINOR REPAIR
1. Screw (× 2)
EAU04189
Replacing the headlight bulb
6
This motorcycle is equipped with a
quartz bulb headlight. If the headlight
bulb burns out, replace it as follows.
1. Remove the headlight unit by removing the screws.
1. Headlight coupler
2. Headlight bulb cover
2. Disconnect the headlight coupler,
and then remove the bulb cover.
6-35
1. Headlight bulb holder
3. Unhook the headlight bulb holder,
and then remove the defective
bulb.
PERIODIC MAINTENANCE AND MINOR REPAIR
EC000105
CAUTION:
Do not touch the glass part of the
headlight bulb to keep it free from
oil, otherwise the transparency of
the glass, the luminosity of the bulb,
and the bulb life will be adversely affected. Thoroughly clean off any dirt
and fingerprints on the headlight
bulb using a cloth moistened with
alcohol or thinner.
_
1. Do not touch this area.
EW000119
WARNING
Headlight bulbs get very hot. Therefore, keep flammable products away
from a lit headlight bulb, and do not
touch the bulb until it has cooled
down.
_
_
_
5. Install the headlight bulb cover,
and then connect the coupler.
6. Install the headlight unit by installing the screws.
7. Have a Yamaha dealer adjust the
headlight beam if necessary.
4. Place a new headlight bulb into
position, and then secure it with
the bulb holder.
6-36
6
PERIODIC MAINTENANCE AND MINOR REPAIR
EAU01579
Supporting the motorcycle
1. Screw (× 2)
1. Screw (× 3)
3. Insert a new bulb into the socket,
push it in, and then turn it clockwise until it stops.
4. Install the lens by installing the
screws.
EAU00855
Replacing a turn signal light
bulb or the tail/brake light
bulb
6
1. Remove the lens by removing the
screws.
2. Remove the defective bulb by
pushing it in and turning it counterclockwise.
EC000108
CAUTION:
Do not overtighten the screws, otherwise the lens may break.
@
@
6-37
Since this model is not equipped with a
centerstand, follow these precautions
when removing the front and rear
wheel or performing other maintenance requiring the motorcycle to
stand upright. Check that the motorcycle is in a stable and level position
before starting any maintenance. A
strong wooden box can be placed under the engine for added stability.
To service the front wheel
1. Stabilize the rear of the motorcycle
by using a motorcycle stand or, if
an additional motorcycle stand is
not available, by placing a jack under the frame in front of the rear
wheel.
2. Raise the front wheel off the
ground by using a motorcycle
stand.
PERIODIC MAINTENANCE AND MINOR REPAIR
To service the rear wheel
Raise the rear wheel off the ground by
using a motorcycle stand or, if a motorcycle stand is not available, by placing
a jack either under each side of the
frame in front of the rear wheel or under
each side of the swingarm.
EAU01008
Troubleshooting
Although Yamaha motorcycles receive
a thorough inspection before shipment
from the factory, trouble may occur during operation. Any problem in the fuel,
compression, or ignition systems, for
example, can cause poor starting and
loss of power.
The following troubleshooting chart
represents a quick and easy procedure
for checking these vital systems yourself. However, should your motorcycle
require any repair, take it to a Yamaha
dealer, whose skilled technicians have
the necessary tools, experience, and
know-how to service the motorcycle
properly.
Use only genuine Yamaha replacement parts. Imitation parts may look
like Yamaha parts, but they are often
inferior, have a shorter service life and
can lead to expensive repair bills.
6-38
6
PERIODIC MAINTENANCE AND MINOR REPAIR
EAU01297
Troubleshooting chart
EW000125
WARNING
Keep away open flames and do not smoke while checking or working on the fuel system.
@
@
1. Fuel
There is enough fuel.
Check the compression.
There is no fuel.
Supply fuel.
There is compression.
Check the ignition.
There is no compression.
Have a Yamaha dealer
check the vehicle.
Check the fuel level in
the fuel tank.
The engine does not start.
Check the compression.
2. Compression
Operate the electric starter.
6
3. Ignition
Wet
Wipe off with a dry cloth and correct the
spark plug gaps, or replace the spark plugs.
Open the throttle halfway and operate
the electric starter.
Dry
Have a Yamaha dealer check the vehicle.
The engine does not start.
Check the battery.
Remove the spark plugs
and check the electrodes.
4. Battery
The engine turns over
quickly.
The battery is good.
The engine turns over
slowly.
Check the battery lead connections,
and charge the battery if necessary.
Operate the electric starter.
6-39
The engine does not start.
Have a Yamaha dealer
check the vehicle.
MOTORCYCLE CARE AND STORAGE
Care .................................................................................................. 7-1
Storage .............................................................................................. 7-5
7
MOTORCYCLE CARE AND STORAGE
EAU03708
7-
Care
7
While the open design of a motorcycle
reveals the attractiveness of the technology, it also makes it more vulnerable. Rust and corrosion can develop
even if high-quality components are
used. A rusty exhaust pipe may go unnoticed on a car, however, it detracts
from the overall appearance of a
motorcycle. Frequent and proper care
does not only comply with the terms of
the warranty, but it will also keep your
motorcycle looking good, extend its life
and optimize its performance.
Before cleaning
1. Cover the muffler outlets with plastic bags after the engine has
cooled down.
2. Make sure that all caps and covers
as well as all electrical couplers
and connectors, including the
spark plug caps, are tightly installed.
3. Remove extremely stubborn dirt,
like oil burnt onto the crankcase,
with a degreasing agent and a
brush, but never apply such products onto seals, gaskets, the drive
belt and wheel axles. Always rinse
the dirt and degreaser off with
water.
7-1
Cleaning
ECA00010
_
CAUTION:
● Avoid using strong acidic wheel
cleaners, especially on spoked
wheels. If such products are
used on hard-to-remove dirt, do
not leave the cleaner on the affected area any longer than instructed. Also, thoroughly rinse
the area off with water, immediately dry it, and then apply a
corrosion protection spray.
● Improper cleaning can damage
windshields, cowlings, panels
and other plastic parts. Use
only a soft, clean cloth or
sponge with mild detergent and
water to clean plastic.
● Do not use any harsh chemical
products on plastic parts. Be
sure to avoid using cloths or
sponges which have been in
contact with strong or abrasive
cleaning products, solvent or
MOTORCYCLE CARE AND STORAGE
thinner, fuel (gasoline), rust removers or inhibitors, brake fluid, antifreeze or electrolyte.
● Do not use high-pressure washers or steam-jet cleaners since
they cause water seepage and
deterioration in the following areas: seals (of wheel and swingarm bearings, fork and brakes),
electric components (couplers,
connectors, instruments, switches and lights), breather hoses
and vents.
● For motorcycles equipped with
a windshield: Do not use strong
cleaners or hard sponges as
they will cause dulling or
scratching. Some cleaning
compounds for plastic may
leave scratches on the windshield. Test the product on a
small hidden part of the windshield to make sure that it does
not leave any marks. If the wind-
shield is scratched, use a quality plastic polishing compound
after washing.
1. Clean the motorcycle with cold
water and a mild detergent, after
the engine has cooled down.
ECA00012
_
After normal use
Remove dirt with warm water, a mild
detergent, and a soft, clean sponge,
and then rinse thoroughly with clean
water. Use a toothbrush or bottlebrush
for hard-to-reach areas. Stubborn dirt
and insects will come off more easily if
the area is covered with a wet cloth for
a few minutes before cleaning.
After riding in the rain, near the sea or
on salt-sprayed roads
Since sea salt or salt sprayed on roads
during winter are extremely corrosive in
combination with water, carry out the
following steps after each ride in the
rain, near the sea or on salt-sprayed
roads.
NOTE:
Salt sprayed on roads in the winter may
remain well into spring.
_
_
7-2
CAUTION:
Do not use warm water since it increases the corrosive action of the
salt.
_
_
2. After drying the motorcycle, apply
a corrosion protection spray on all
metal, including chrome- and nickel-plated, surfaces to prevent corrosion.
Windshield cleaning
(for XV16AT(C)/XV16ATLE(C) only)
Avoid using any alkaline or strong acid
cleaner, gasoline, brake fluid, or any
other solvent. Clean the windshield
with a cloth or sponge dampened with
a neutral detergent, and after cleaning,
thoroughly wash it off with water. For
additional cleaning, use Yamaha Windshield Cleaner or other quality cleaner.
Some cleaning compounds for plastics
may leave scratches on surfaces of the
7
MOTORCYCLE CARE AND STORAGE
6. Wax all painted and chrome-plated surfaces. Avoid combination
cleaner waxes, many of which
contain abrasives that may mar
the paint or protective finish.
7. Let the motorcycle dry completely
before storing or covering it.
windshield. Before using them, make a
test by polishing an area which does
not affect your visibility.
7
After cleaning
1. Dry the motorcycle with a chamois
or an absorbing cloth.
2. Use a chrome polish to shine
chrome, aluminum and stainlesssteel parts, including the exhaust
system. (Even the thermally induced discoloring of stainlesssteel exhaust systems can be removed through polishing.)
3. To prevent corrosion, it is recommended to apply a corrosion protection spray on all metal,
including chrome- and nickel-plated, surfaces.
4. Use spray oil as a universal cleaner to remove any remaining dirt.
5. Touch up minor paint damage
caused by stones, etc.
ECA00033
_
EWA00001
_
WARNING
● Make sure that there is no oil or
wax on the brakes or tires. If
necessary, clean the brake
discs and brake linings with a
regular brake disc cleaner or acetone, and wash the tires with
warm water and a mild detergent.
● Before operating the motorcycle test its braking performance and cornering behavior.
_
7-3
CAUTION:
● Apply spray oil and wax sparingly and make sure to wipe off
any excess.
● Never apply oil or wax to the
drive belt.
● Never apply oil or wax to any
rubber and plastic parts, but
treat them with a suitable care
product.
● Avoid using abrasive polishing
compounds as they will wear
away the paint.
_
NOTE:
Consult a Yamaha dealer for advice on
what products to use.
_
_
MOTORCYCLE CARE AND STORAGE
Saddlebag cleaning and care (for
XV16AT(C)/XV16ATLE(C) only)
Clean the saddlebag on each side using a high-quality saddle soap. Rub the
surface of the soap using a damp cloth
or sponge to produce a lather, and then
apply it to the surface of the saddlebags. Allow the lather to dry, and then
polish the saddlebags with a soft cloth.
If the saddlebags have been exposed
to severe weather conditions and have
become faded, or been scuffed, use a
fine boot creme to return the leather to
its original rich, even color.
Exposure to the elements can dry out
the leather over time. Therefore, an occasional application of a good quality
mink oil is recommended to restore the
leather and lift its water resistance.
Make sure that the saddlebags are
clean and dry before applying the mink
oil. Using a soft cloth or a dauber, work
a thin coat of mink oil into the leather
surface of the saddlebags. Wipe off
any excess oil immediately and allow
the saddlebags to dry for several
hours.
7
7-4
MOTORCYCLE CARE AND STORAGE
Storage
Short-term
Always store your motorcycle in a cool,
dry place and, if necessary, protect it
against dust with a porous cover.
ECA00014
7
_
_
CAUTION:
● Storing the motorcycle in a
poorly ventilated room or covering it with a tarp, while it is still
wet, will allow water and humidity to seep in and cause rust.
● To prevent corrosion, avoid
damp cellars, stables (because
of the presence of ammonia)
and areas where strong chemicals are stored.
Long-term
Before storing your motorcycle for
several months:
1. Follow all the instructions in the
“Care” section of this chapter.
2. For motorcycles equipped with a
fuel cock that has an “OFF” position: Turn the fuel cock lever to
“OFF”.
3. Drain the carburetor float chambers by loosening the drain bolts;
this will prevent fuel deposits from
building up. Pour the drained fuel
into the fuel tank.
4. Fill up the fuel tank and add fuel
stabilizer (if available) to prevent
the fuel tank from rusting and the
fuel from deteriorating.
5. Perform the following steps to protect the cylinders, piston rings, etc.
from corrosion.
a. Remove the spark plug caps and
spark plugs.
b. Pour a teaspoonful of engine oil
into each spark plug bore.
c. Install the spark plug caps onto the
spark plugs, and then place the
spark plugs on the cylinder head
so that the electrodes are grounded. (This will limit sparking during
the next step.)
d. Turn the engine over several times
with the starter. (This will coat the
cylinder walls with oil.)
e. Remove the spark plug caps from
the spark plugs, and then install
the spark plugs and the spark plug
caps.
EWA00003
WARNING
To prevent damage or injury from
sparking, make sure to ground the
spark plug electrodes while turning
the engine over.
_
_
7-5
MOTORCYCLE CARE AND STORAGE
6. Lubricate all control cables and
the pivoting points of all levers and
pedals as well as of the sidestand/
centerstand.
7. Check and, if necessary, correct
the tire air pressure, and then lift
the motorcycle so that both of its
wheels are off the ground. Alternatively, turn the wheels a little every
month in order to prevent the tires
from becoming degraded in one
spot.
8. Cover the muffler outlets with plastic bags to prevent moisture from
entering them.
9. Remove the battery and fully
charge it. Store it in a cool, dry
place and charge it once a month.
Do not store the battery in an excessively cold or warm place (less
than 30 °F [0 °C] or more than
90 °F [30 °C]). For more information on storing the battery, see
page 6-32.
NOTE:
Make any necessary repairs before
storing the motorcycle.
_
_
7
7-6
SPECIFICATIONS
Specifications .................................................................................... 8-1
8
SPECIFICATIONS
EAU01038
8-
Specifications
CS-01E
Model
Compression ratio
XV16A(C)/XV16ALE(C)/
XV16AS(C)/XV16AT(C)/
XV16ATLE(C)
Dimensions
Overall length
98.4 in (2,500 mm)
Overall width
38.6 in (980 mm)
Starting system
Electric starter
Lubrication system
Dry sump
Engine oil
Type
0
Overall height
XV16A(C)/XV16ALE(C)/
XV16AS(C)
44.9 in (1,140 mm)
XV16AT(C)/XV16ATLE(C)
59.1 in (1,500 mm)
Seat height
28.0 in (710 mm)
Wheelbase
66.3 in (1,685 mm)
Ground clearance
Minimum turning radius
-20 -10
Recommended engine oil
classification
126.0 in (3,200 mm)
732 lb (332 kg)
XV16AT(C)/XV16ATLE(C)
765 lb (347 kg)
Air-cooled 4-stroke, OHV
Cylinder arrangement
V-type 2-cylinder
Displacement
1,602 cm3
Bore × Stroke
3.74 × 4.45 in (95 × 113 mm)
50
70
90
110 130 ˚F
0
10
20
30
40
50 ˚C
API Service SE, SF, SG type or
higher
CAUTION:
In order to prevent clutch slippage (since the engine oil also
lubricates the clutch), do not mix any chemical additives. Do
not use oils with a diesel specification of “CD” or oils of a
higher quality than specified. In addition, do not use oils labeled “ENERGY CONSERVING II” or higher.
Engine
Engine type
30
YAMALUBE 4 (20W-40)
or SAE 20W-40
5.7 in (145 mm)
XV16A(C)/XV16ALE(C)/
XV16AS(C)
10
YAMALUBE 4 (10W-30)
or SAE 10W-30
Basic weight (with oil and full
fuel tank)
8
8.3:1
8-1
SPECIFICATIONS
Quantity
Transmission
Without oil filter cartridge
replacement
3.9 US qt (3.3 lmp qt, 3.7 L)
With oil filter cartridge
replacement
4.3 US qt (3.6 lmp qt, 4.1 L)
Total amount (dry engine)
5.3 US qt (4.4 lmp qt, 5.0 L)
Transfer case oil
Type
SAE80API “GL-4” Hypoid Gear
Oil
Primary reduction system
Spur gear
Primary reduction ratio
1.532
Secondary reduction system
Belt
Secondary reduction ratio
2.320
Transmission type
Constant mesh 5-speed
Operation
Left foot
Gear ratio
0.42 US qt (0.35 lmp qt, 0.4 L)
1st
2.438
Dry type element
2nd
1.579
3rd
1.160
UNLEADED GASOLINE ONLY
4th
0.906
Fuel tank capacity
5.3 US gal (4.4 lmp gal, 20 L)
5th
0.750
Reserve amount
0.9 US gal (0.8 lmp gal, 3.5 L)
Quantity
Air filter
Fuel
Type
Chassis
Frame type
Carburetor
Manufacturer
Model × quantity
MIKUNI
Caster angle
32°
BSR40 × 1
Trail
5.6 in (142 mm)
Tire
Spark plug
Manufacturer/model
NGK / DPR7EA-9 or
DENSO / X22EPR-U9
Gap
0.03–0.04 in (0.8–0.9 mm)
Clutch type
Double cradle
Front
Type
Tube tire
Size
130/90-16 67H
Wet, multiple-disc
130/90-16 M/C 67H
Manufacturer/
model
Dunlop / D404FL
Bridgestone / G703F
8-2
8
SPECIFICATIONS
Rear
Rear
Type
Tube tire
Type
Spoke wheel
Size
150/80B-16 71H
Size
16 × MT 3.50
150/80B-16 M/C 71H
Manufacturer/
model
16 M/C × MT 3.50
Brakes
Dunlop / D404
Front
Bridgestone / G702
Type
Maximum load*
XV16A(C)/XV16ALE(C)/
XV16AS(C)
432 lb (196 kg)
XV16AT(C)/XV16ATLE(C)
399 lb (181 kg)
Up to 198 lb (90 kg)*
Rear
36 psi (2.50 kgf/cm2, 250 kPa)
Right hand
Fluid
DOT 4
Type
Single disc brake
36 psi (2.50 kgf/cm , 250 kPa)
2
Front
36 psi (2.50 kgf/cm , 250 kPa)
Rear
41 psi (2.80 kgf/cm2, 280 kPa)
Operation
Right foot
Fluid
DOT 4
Suspension
2
198 lb (90 kg)–maximum*
8
Operation
Rear
Tire air pressure
(measured on cold tires)
Front
Dual disc brake
Front
Telescopic fork
Rear
Swingarm (link suspension)
Spring/Shock absorber
* Total weight of rider, passenger, cargo and accessories
Front
Coil spring / oil damper
Rear
Coil spring / gas-oil damper
Wheel travel
Wheels
Front
Type
Size
Spoke wheel
16 × MT 3.00
16 M/C × MT 3.00
8-3
Front
5.5 in (140 mm)
Rear
4.3 in (110 mm)
SPECIFICATIONS
Electrical
Fuses
Ignition system
Transistorized coil ignition
(digital)
Charging system
Type
A.C. magneto
Standard output
14 V, 21 A @ 5,000 r/min
Battery
Main fuse
30 A
Ignition fuse
15 A
Signaling system fuse
10 A
Headlight fuse
15 A
Carburetor heater fuse
10 A
Odometer fuse
Type
YTX20L-BS
Voltage, capacity
12 V, 18 Ah
Headlight type
5A
Quartz bulb (halogen)
Bulb voltage, wattage × quantity
Headlight
12 V, 60/55 W × 1
Tail/brake light
12 V, 8/27 W × 1
Front turn signal /
Front position light
12 V, 27/8 W × 2
Rear turn signal light
12 V, 27 W × 2
Meter lighting
14 V, 0.6 W × 4
Neutral indicator light
12 V, 1 W × 1
High beam indicator light
12 V, 1 W × 1
Turn indicator light
12 V, 1 W × 1
Fuel level warning light
LED × 1
Engine trouble warning light
LED × 1
8
8-4
CONSUMER INFORMATION
Identification numbers ....................................................................... 9-1
Key identification number .................................................................. 9-1
Vehicle identification number ............................................................. 9-1
Model label ........................................................................................ 9-2
Reporting safety defects ................................................................... 9-3
Motorcycle noise regulation .............................................................. 9-4
Maintenance record .......................................................................... 9-5
YAMAHA MOTOR CORPORATION, U.S.A. STREET AND
ENDURO MOTORCYCLE LIMITED WARRANTY ........................... 9-7
YAMAHA EXTENDED SERVICE (Y.E.S.) ......................................... 9-9
9
CONSUMER INFORMATION
EAU01039
9-
EAU02944
Identification numbers
Record the key identification number,
vehicle identification number and model label information in the spaces provided below for assistance when
ordering spare parts from a Yamaha
dealer or for reference in case the vehicle is stolen.
1. Key identification number
1. KEY IDENTIFICATION NUMBER:
CA-02E
2. VEHICLE IDENTIFICATION
NUMBER:
EAU01043
EAU01041
Key identification number
Vehicle identification number
The key identification number is
stamped into the key tag. Record this
number in the space provided and use
it for reference when ordering a new
key.
The vehicle identification number is
stamped into the steering head pipe.
Record this number in the space provided.
CA-02E
9
1. Vehicle identification number
NOTE:
The vehicle identification number is
used to identify your motorcycle and
may be used to register your motorcycle with the licensing authority in
your area.
@
3. MODEL LABEL INFORMATION:
CA-01E
@
9-1
CONSUMER INFORMATION
1. Model label
EAU01804
Model label
The model label is affixed to the frame
under the rider seat. (See page 3-11 for
rider seat removal and installation procedures.) Record the information on
this label in the space provided. This information will be needed when ordering
spare parts from a Yamaha dealer.
9
9-2
CONSUMER INFORMATION
EAU01051
Reporting safety defects
If you believe that your vehicle has a defect which could cause a crash or could cause injury or death, you should immediately inform the National Highway Traffic Safety Administration (NHTSA) in addition to notifying Yamaha Motor Corporation,
U.S.A. If NHTSA receives similar complaints, it may open an investigation, and if it finds that a safety defect exists in a group
of vehicles, it may order a recall and remedy campaign. However, NHTSA cannot become involved in individual problems
between you, your dealer, or Yamaha Motor Corporation, U.S.A.
To contact NHTSA, you may either call the Auto Safety Hotline toll-free at 1-800-424-9393 (or 366-0123 in Washington, D.C.
area) or write to: NHTSA, U.S. Department of Transportation, Washington, D.C. 20590. You can also obtain other information about motor vehicle safety from the Hotline.
9
9-3
CONSUMER INFORMATION
EAU01053
Motorcycle noise regulation
TAMPERING WITH NOISE CONTROL SYSTEM PROHIBITED:
Federal law prohibits the following acts or the causing thereof: (1) The removal or rendering inoperative by any person other
than for purposes of maintenance, repair, or replacement of any device or element of design incorporated into any new vehicle for the purpose of noise control prior to its sale or delivery to the ultimate purchaser or while it is in use or (2) the use of
the vehicle after such device or element of design has been removed or rendered inoperative by any person.
“AMONG THOSE ACTS PRESUMED TO CONSTITUTE TAMPERING ARE THE ACTS LISTED BELOW”.
These acts include tampering with the following systems; i.e., modification, removal, etc.
CL-01E
Exhaust system
Muffler
Exhaust pipe
Silencer
Intake system
Air cleaner case
Air cleaner element
Intake duct
9
9-4
CONSUMER INFORMATION
EAU01325
Maintenance record
Copies of work orders and/or receipts for parts purchased and installed on your motorcycle will be required to document that
maintenance has been completed in accordance with the emissions warranty. The chart below is printed only as a reminder
that maintenance work is required. It is not acceptable proof of maintenance work.
CL-04E
Maintenance
interval
Date of
service
Servicing dealer
name and address
Mileage
600 mi
(1,000 km) or
1 month
4,000 mi
( 7,000 km) or
6 months
8,000 mi
(13,000 km) or
12 months
12,000 mi
(19,000 km) or
18 months
16,000 mi
(25,000 km) or
24 months
9
20,000 mi
(31,000 km) or
30 months
24,000 mi
(37,000 km) or
36 months
9-5
Remarks
CONSUMER INFORMATION
Maintenance
interval
Date of
service
Servicing dealer
name and address
Mileage
Remarks
28,000 mi
(43,000 km) or
42 months
32,000 mi
(49,000 km) or
48 months
36,000 mi
(55,000 km) or
54 months
40,000 mi
(61,000 km) or
60 months
9
9-6
CONSUMER INFORMATION
EAU02918
YAMAHA MOTOR CORPORATION, U.S.A. STREET
AND ENDURO MOTORCYCLE LIMITED WARRANTY
9
9-7
CONSUMER INFORMATION
9
9-8
CONSUMER INFORMATION
EAU01063
YAMAHA EXTENDED SERVICE (Y.E.S.)
9
9-9
CONSUMER INFORMATION
9
9-10
INDEX
10-
A
E
M
Accessories and replacement parts .......6-20
Air filter element, cleaning ......................6-15
Engine break-in ....................................... 5-5
Engine oil and oil filter cartridge ............... 6-9
Engine stop switch................................... 3-6
Engine trouble warning light .................... 3-2
Main switch/steering lock .........................3-1
Maintenance and lubrication, periodic ......6-4
Maintenance, emission control system.....6-3
Maintenance, periodic ..............................6-1
Maintenance record .................................9-5
Model label ..............................................9-2
B
Battery ...................................................6-32
Brake and clutch levers, checking and
lubricating ............................................6-29
Brake and shift pedals, checking and
lubricating ............................................6-28
Brake fluid, changing .............................6-25
Brake fluid level, checking......................6-24
Brake lever...............................................3-7
Brake lever free play, adjusting ..............6-21
Brake light switch (rear), adjusting .........6-23
Brake pedal..............................................3-8
Brake pedal position, adjusting ..............6-22
C
Canister (for California only).....................6-9
Carburetor, adjusting .............................6-17
Care.........................................................7-1
Clock .......................................................3-5
Clutch lever..............................................3-7
Clutch lever free play, adjusting .............6-21
D
Dimmer switch .........................................3-6
Drive belt slack ......................................6-25
Adjusting ..........................................6-26
Checking ..........................................6-25
F
Front and rear brake pads, checking ..... 6-23
Front fork, checking ............................... 6-30
Fuel ......................................................... 3-9
Fuel cock............................................... 3-10
Fuel gauge .............................................. 3-4
Fuel level warning light ............................ 3-2
Fuel tank cap........................................... 3-8
Fuses, replacing .................................... 6-33
H
Handlebar switches ................................. 3-6
Headlight bulb, replacing ....................... 6-35
Helmet holder ........................................ 3-12
High beam indicator light ......................... 3-2
Horn switch ............................................. 3-6
I
Identification numbers ............................. 9-1
Ignition circuit cut-off system.................. 3-17
Indicator and warning lights ..................... 3-2
K
Key identification number ........................ 9-1
L
Labels, location ....................................... 1-7
N
Neutral indicator light ...............................3-2
Noise regulation .......................................9-4
P
Panel, removing and installing..................6-7
Parking.....................................................5-6
Part locations ...........................................2-1
Pre-operation check list............................4-1
R
Rider seat ..............................................3-11
S
Saddlebags
[XV16AT(C)/XV16ATLE(C)].................3-14
Safety defects, reporting ..........................9-3
Safety information ....................................1-1
Self-diagnosis device ...............................3-4
Shifting.....................................................5-3
Decelerating .......................................5-4
Shift points..........................................5-4
Starting out and accelerating ..............5-4
Shift pedal................................................3-7
Shock absorber assembly, adjusting......3-15
Sidestand...............................................3-17
Sidestand, checking and lubricating .......6-29
INDEX
Spark plugs, checking ............................. 6-8
Specifications .......................................... 8-1
Speedometer unit .................................... 3-3
Starter (choke) knob .............................. 3-11
Starting and warming up a cold engine.... 5-1
Starting a warm engine............................ 5-3
Start switch.............................................. 3-6
Steering, checking ................................. 6-31
Steering, locking with a padlock............. 3-11
Storage.................................................... 7-5
Supporting the motorcycle ..................... 6-37
T
Throttle cable free play, adjusting .......... 6-17
Throttle grip and cable, checking and
lubricating............................................ 6-27
Tires ...................................................... 6-18
Tool kit..................................................... 6-2
Transfer case oil .................................... 6-13
Troubleshooting..................................... 6-38
Troubleshooting chart............................ 6-39
Turn signal indicator light ......................... 3-2
Turn signal light or tail/brake light bulb,
replacing ............................................. 6-37
Turn signal switch.................................... 3-6
V
Valve clearance, adjusting..................... 6-17
Vehicle identification number ................... 9-1
W
Warranty, extended................................. 9-9
Warranty limited ...................................... 9-7
Wheel bearings, checking ..................... 6-31
Wheels.................................................. 6-20
Windshield
[XV16AT(C)/XV16ATLE(C)] ................ 3-13
YAMAHA MOTOR CO., LTD.
PRINTED ON RECYCLED PAPER
PRINTED IN JAPAN
2002.08-0.3×1 CR
(E)