Yamaha Wildstar XV1600A (1999) manual

XV1600A OWNER’S MANUAL[...]

EA U00001 INTRODUCTION W elcome to the Y amaha world of motorcycling! As the owner of a Y amaha Wild Star™, y ou are benefiting from Y amaha’ s v ast e xpe- rience in and new est technolog y f or the design and the manuf acture of high-quality products, which ha ve earned Y amaha a reputation f or dependability . Please take the time to read th[...]

EAU00005 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! W ARNING Failure to follow WARNING instructions could result in severe injury or death to the motorcycle operator, a bystander or a perso[...]

IMPORTANT MANUAL INFORMATION EW000002 W ARNING @ PLEASE READ THIS MANUAL CAREFU LLY AND COMPLETELY BEFORE OPERATIN G THIS MOTORCYCLE. @ E_5ja_Info0.fm Page 2 Saturday, Octo ber 16, 1999 10:09 AM[...]

IMPORTANT MANUAL INFORMATION EAU00008 XV1600A OWNER’S MANUAL © 1999 by Yamaha Motor Co., Ltd. 1st Edition, September 1999 All rights reserved. Any reprinti ng or unauthorized use without the written permission of Yamaha Motor Co., Ltd. is expressly prohibited. Printed in Japan. E_5ja_Info0.fm Page 3 Saturday, Octo ber 16, 1999 10:09 AM[...]

TABLE OF CONTENTS 1 GIVE SAFETY THE RIGHT OF W A Y 1 2 DESCRIPTION 2 3 INSTR UMENT AND CONTROL FUNCTIONS 3 4 PRE-OPERA TION CHECKS 4 5 OPERA TION AND IMPOR T ANT RIDING POINTS 5 6 PERIODIC MAINTENANCE AND MINOR REP AIR 6 7 MO T ORCYCLE CARE AND STORA GE 7 8 SPECIFICA TIONS 8 9 CONSUMER I NFORMA TION 9 INDEX E_5ja_Toc0.fm Page 1 Saturday, Octo ber 1[...]

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GIVE SAFETY THE RIGHT OF WAY 1 GIVE SAFETY THE RIGHT OF W A Y ......... .......................... .............. 1-1 E_5ja_LabelTOC.fm Page 1 Saturday, Octo ber 16, 1999 10:09 AM[...]

1 1-1 1- GIVE SAFETY THE RIGHT OF WAY EAU00021 Motorcycles are fascinating vehicles, which can give you an unsurpassed feeling o f power and freedom. Howeve r, they also impose certain limits, which you mu st accept; even the best motorc ycle does not ignore the laws of physics. Regular care and maintenance ar e essential fo r preserving you r moto[...]

DESCRIPTION 2 Left view ............... ...................... .......................... .......................... .... 2-1 Right view ......... .......................... .......................... ....................... ....... 2 -2 Controls/In struments ...................... ......................... .......................... . 2-3 E_5ja_De[...]

2-1 2 EAU00026 2 - DESCRIPTION Left view 1. Shift pedal (page 3-7) 2. Starter (choke) knob (page 3-12) 3. Fuel cock (page 3-11) 4. Rider seat (page 3-13) 5. Tool kit (page 6-1) 6. Helmet holder (page 3-13) 7. Rear turn signal lights (page 6-31) 8. Tail/brake light (page 6-31) 9. Fuses (page 6-28) E_5ja_Description.fm Page 1 Saturday, October 16, 1 [...]

DESCRIPTION 2-2 2 Right view 10. Passenger footrest 11. Passenger seat 12. Fuel tank (page 3-9) 13. Fuel tank cap (page 3-9) 14. Headlight (page 6-29) 15. Front turn signal lights (page 6-31) 16. Throttle stop screw (page 6-14) 17. Rear brake pedal (page 3-8) 18. Rider footrest 19. Rear shock absorber spring preload adjusting nut (page 3-14) 20. Mu[...]

DESCRIPTION 2-3 2 Controls/Instruments 1. Clutch lever (page 3-7) 2. Left handlebar switches (page 3-6) 3. Speedometer (page 3-3) 4. Main switch/steering lock (page 3-1) 5. Right handlebar switches (page 3-6) 6. Throttle grip (page 6-14) 7. Front brake lever (page 3-8) E_5ja_Description.fm Page 3 Saturday, October 16, 1 999 10:10 AM[...]

3 INSTRUMENT AND CONTROL FUNCTIONS Main switch/steering lo c k ................ ...................... 3 -1 Indicator lig hts ...................... .......................... ...... 3-2 Speedomet er ..................... ....................... ............ 3-3 Fuel gauge ................... ......................... ................ 3-4 Diagnosis[...]

3-1 3 EAU00027 3 - INSTRUMENT AND CONTROL FUNCTIONS EAU00029* Main switch/steering lock The main switch controls the ignition and lighting systems. Its operation is described below. EAU00036 ON Electrical circuits are switched on. The engine can be started. The key cannot be removed in this position. EAU00038 OFF All electrical circuits are switche[...]

INSTRUMENT AND CONTROL FUNCTIONS 3-2 3 EAU01590 (Parking) The steering is locked in this position, and the taillight and auxiliary light come on but all other circuits are off. The key can be removed in this position. To use the parking position, first lock the steering, then turn the key to “ ”. Do not use this position for an extend- ed lengt[...]

INSTRUMENT AND CONTROL FUNCTIONS 3-3 3 EAU01734 Speedometer This speedometer is equipped with an odometer and a twin trip meter. Push- ing the mode button (left) will change the display from one mode to the other as follows. In the odometer mode “ODO”, the motorcycle’s total mileage is displayed. In the trip meter modes “TRIP A” or “TRI[...]

INSTRUMENT AND CONTROL FUNCTIONS 3-4 3 EAU00113 Fuel gauge The fuel gauge indicates the quantit y of the remaining gasoline in the tank. The gauge needle moves from “F” (Full) to “E” (Empty) as the fuel level decreases. When the needle moves to the “E” po- sition, add fuel as soon as possible. EAU01735* Diagnosis device This model is eq[...]

INSTRUMENT AND CONTROL FUNCTIONS 3-5 3 EAU01736 Digital clock This digital clock always shows the time regardless of the main switch po- sition. Setting the clock 1. Turn the main switch to “ON”. 2. Press both the set button (right) and the mode button (left) simulta- neously until the hours and min- utes flash. 3. Push the left button and only[...]

INSTRUMENT AND CONTROL FUNCTIONS 3-6 3 EAU00118 Handlebar switches EAU00119 1. Pass switch “ ” Press the switch t o operate the passing light. EAU00121 2. Dimmer switch Turn the switch to “ ” for the high beam and to “ ” for the low beam. EAU00127 3. Turn signal switch To signal a right-hand turn, push the switch to “ ”. To signal a[...]

INSTRUMENT AND CONTROL FUNCTIONS 3-7 3 EAU00143 7. Start switch “ ” The starter motor cranks the engine when pushing the start switch. EC000005 CAUTION: @ See starting instructions prior to starting the engine. @ EAU00152 Clutch lever The clutch lever is located on the left handlebar, and the ignition circuit cut- off system is incorporated in [...]

INSTRUMENT AND CONTROL FUNCTIONS 3-8 3 EAU00158 Front brake lever The front brake lever is located on the right handlebar. Pull it toward the han- dlebar to apply the front brake. EAU00162 Rear brake pedal The rear brake pedal is on the right side of the motorcycle. Press down on the brake pedal to apply the rear brake. 1. Front brake lever 1. Rear[...]

INSTRUMENT AND CONTROL FUNCTIONS 3-9 3 EAU02917 Fuel tank cap To remove Slide the lock cover open, insert the key and turn it 1/4 turn clockwise. The lock will be released and the cap can be removed. To install Make sure the arrow mark on the tank cap is facing forward, then push the tank cap into position. Turn the key counterclockwise to the orig[...]

INSTRUMENT AND CONTROL FUNCTIONS 3-10 3 EAU00185 CAUTION: @ Always wipe off spilled fuel immedi- ately with a dry and clean soft cloth. Fuel may deteriorate painted surfac- es or plastic parts. @ EAU00191 NO TE: @ If knocking or pinging occurs, use a d if- ferent brand of gasoline or hig her oc- tane grade. @ EAU02955 Fuel tank breather hose This m[...]

INSTRUMENT AND CONTROL FUNCTIONS 3-11 3 EAU03050 Fuel cock The fuel cock supplies fuel from the tank to the carburetor while filtering it also. The fuel cock has three positions: OFF With the lever in this position, fuel will not flow. Always return the lever to this position when the engine is not run- ning. ON With the lever in this position, fue[...]

INSTRUMENT AND CONTROL FUNCTIONS 3-12 3 EAU03032 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 t o tu r n o n the starter (choke). Move the knob in direction b to turn off the starter (choke). EAU01214* Steering lock On the right side of t he he[...]

INSTRUMENT AND CONTROL FUNCTIONS 3-13 3 EAU01737 Rider seat To remove Insert the key into the main sw itch and turn it counterclockwise to t he “OPEN” position. Then, remove the seat by pull- ing it upward. NO TE: @ Do not push inward when turning the key. @ To install Insert the projection on the rear of the seat into the holder, then push the[...]

INSTRUMENT AND CONTROL FUNCTIONS 3-14 3 EAU01694 Adjusting rear shock absorber preload This shock absorber is equipped with a spring preload adjusting nut. Use the special wrench located in the owner’s tool kit to adjust the spring pr eload. 1. Loosen the locknut. 2. Turn the adjusting nut in direction a to increase spring pre- load and in direct[...]

INSTRUMENT AND CONTROL FUNCTIONS 3-15 3 3. Tighten the locknut to the speci- fied torque. EC000018 CAUTION: @ Always tighten the locknut against the spring adjusting nut and tighten the locknut to the specified torque. @ EAU00315 W ARNING @ This shock absorber contains high- ly pressurized nitrogen gas. Read and understand the following infor- mati[...]

INSTRUMENT AND CONTROL FUNCTIONS 3-16 3 EAU00331 Sidestand/clutch switch operation check Check the operation of the sidestand switch and clutch switch against the in- formation below. CD-11E CD-11E EW000045 W ARNING @ If improper operation is noted, con- sult a Yamaha dealer immediatel y. @ TURN THE MAIN SWITCH TO “ON” AND THE ENGINE STOP SWITC[...]

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PRE-OPERATION CHECKS 4 Pre-operation check list ..... ......................... ....................... ................. 4-1 E_5ja_PreopTOC.fm Page 1 Saturday, October 16, 1999 10:11 AM[...]

4-1 4 EAU01114 4 - PRE-OPERATION CHECKS Owners are personally responsible for their vehicle’s condition. Your motorcycle’s vital functions can start to deteriorate quickly and unexpectedly, even if it remains unused (for instance, if it is exposed t o the elements). Any damage, fluid le ak or loss of tire pressure could have serious consequence[...]

PRE-OPERATION CHECKS 4-2 4 NO TE: Pre-operation checks should be made each time the motorcycle is used. Such an inspection can be thoroughly accom- plished in a very short time; and the add ed safety it assures is more than worth t he time involved. W ARNING If any item in the PRE-OPERATION CHECK is not working properly, have it inspected and repai[...]

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OPERATION AND IMPORTANT RIDING POINTS 5 Star ting t he engine ........ .......................... ....................... .................... 5-1 Star ting a w ar m engine . .......................... .......................... ................. 5-4 Shifting .... ...................... .......................... .......................... ........[...]

5-1 5 EAU00372 5 - OPERATION AND IMPORTANT RIDING POINTS EAU00373 W ARNING @ ● Before riding thi s motorcycle, become thoroughly familiar with all operating controls and their functions. Consult a Yamaha dealer regarding any control or function that you do not thoroughly understand. ● Never start your eng ine or let it run for any length of tim[...]

OPERATION AND IMPORTANT RIDING POINTS 5-2 5 CF-31E TURN THE MAIN SWITCH TO "ON" AND THE ENGINE STOP SWITCH TO “ ”. IF THE TRANSMISSION IS IN NEUTRAL AND THE SIDESTAND IS DOWN, PUSH THE START SWITCH. THE ENGINE WILL START. RETRACT THE SIDESTAND AND PUT THE TRANSMISSION IN GEAR. IF THE TRANSMISSION IS IN GEAR AND THE SIDESTAND IS UP, PU[...]

OPERATION AND IMPORTANT RIDING POINTS 5-3 5 1. Turn the fuel cock to “ON”. 2. Turn the main switch to “ON” and the engine stop switch to “ ”. 3. Shift the transmission int o neutral. NO TE: @ When the transmission is in neutral, the neutral indicator light should be on. I f the light does not come on, ask a Yamaha dealer to inspect it. [...]

OPERATION AND IMPORTANT RIDING POINTS 5-4 5 EAU01258 Starting a warm engine The starter (choke) is not r equired when the engine is warm. EC000046 CAUTION: @ See the “Engine break-in” section prior to operating the motorcycle for the first time. @ EAU00423 Shifting The transmission lets you control the amount of power you have available at a gi[...]

OPERATION AND IMPORTANT RIDING POINTS 5-5 5 EAU02941 Recommended shift points (for Switzerland only) The recommended shift points are shown in the table below. CF-25E NO TE: @ When shifting two gears down from 4th to 2nd, bring your motorcycle to a speed of 35 km/h. @ EAU00424 Tips for reducing fuel consumption Your motorcycle’s fuel consumption [...]

OPERATION AND IMPORTANT RIDING POINTS 5-6 5 EAU01740 0 ~ 1,000 km Avoid operation above 1/3 throttle. 1,000 ~ 1,600 km Avoid cruising speeds in excess of 1/2 t hrot tle. ECA00026 CAUTION: @ After 1,000 km of operation, be sure to replace the engine oil, oil filter and transfer case oil. @ 1,600 km and beyond Proceed with normal riding. EC000049 CAU[...]

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6 PERIODIC MAINTENANCE AND MINOR REPAIR T ool kit ...................... .......................... ................... 6-1 P erio dic maintenance and lubr ication .......... ......... 6-3 Spar k plug inspection ........... .......................... ...... 6-6 Engine oil .............. .......................... ...................... 6 -7 T ransf[...]

6-1 6 EAU00462 6 - PERIODIC MAINTENANCE AND MINOR REPAIR EAU00464 Periodic inspection, adjustment and lu- brication will keep your motorcycle in the safest and most efficient condition possible. Safety is an obligation of the motorcycle owner. The maintenance and lubrication schedule chart should be considered strictly as a guide to general mainten[...]

PERIODIC MAINTENANCE AND MINOR REPAIR 6-2 6 NO TE: @ If you do not have necessary tools re- quired during a service operation, take your motorcycle to a Yamaha dealer for service. @ EW000063 W ARNING @ Modifications to this motorcycle not approved by Yamaha may cause loss of performance, and render it unsafe for use. Consult a Yamaha dealer before [...]

PERIODIC MAINTENANCE AND MINOR REPAIR 6-3 6 EAU00473 PERIODIC MAINTENANCE AND LUBRICATION CP-01E NO. ITEM CHECKS AND MAINTENANCE JOBS INITIAL (1,000 km) EVERY 6,000 km or 6 months (whichever comes first) 12,000 km or 12 months (whichever comes first) 1 * Fuel lin e • Check fuel hoses for cracks or damage. • Replace if necessary. √√ 2 * Fuel[...]

PERIODIC MAINTENANCE AND MINOR REPAIR 6-4 6 11 * Wheel bearings • Check bearing for looseness or damage. • Replace if necessary. √√ 12 * Swingarm • Check swingarm pivoting point for play. • Correct if necessary. • Lubricate with molybdenum disulfide grease every 24,000 km or 24 months (whichever comes first). √√ 13 * Drive belt ?[...]

PERIODIC MAINTENANCE AND MINOR REPAIR 6-5 6 * Since these items require special t ools, data and tech nical skills, they should be serviced by a Yamaha dealer. EAU02970 NO TE: @ ● 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 c[...]

PERIODIC MAINTENANCE AND MINOR REPAIR 6-6 6 EAU01639 Spark plug inspection The spark plug is an important engine component and should be inspect ed periodically, preferably by a Yamaha dealer. The condition of the spark plug can indicate the condition of the en- gine. Normally, all spark plugs from the same engine should have the same color on the [...]

PERIODIC MAINTENANCE AND MINOR REPAIR 6-7 6 ECA00021 CAUTION: @ Do not use any type of tools to re- move or install t he cap as the i gni- tion coil coupler may get damaged. The spark plug cap may be difficult to remove because a rubber seal on the end of the cap is tightly fit into the cylinder bore. To remove the cap, simply twist it back and for[...]

PERIODIC MAINTENANCE AND MINOR REPAIR 6-8 6 NO TE: @ ● Be sure the motorcycle is posi- tioned straight up when checking the oil level. A slight tilt toward the side can result in false readings. ● When adding oil, be careful not t o overfill the engine; the oil level ris- es faster starting from the half lev- el portion on the dipstick. @ 6. In[...]

PERIODIC MAINTENANCE AND MINOR REPAIR 6-9 6 5. Install the drain bolts and tighten them to the specified torque. 6. Apply a light coat of engine oil to the O-ring of the new oil f ilter. NO TE: @ Make sure the O-ring is seated proper- ly. @ 7. Install the oil filter and tighten it to the specified torque with an oil fil- ter wrench. 8. Pour only 2.[...]

PERIODIC MAINTENANCE AND MINOR REPAIR 6-10 6 13. Start the engine and warm it up for several minutes. While warming up, check for oil leakage. If oil leakage is found, stop the engine immediately and check for the cause. 14. Stop the engine and recheck t he oil level. EAU01828 Transfer case oil Oil level inspection 1. Position the motorcycle u prig[...]

PERIODIC MAINTENANCE AND MINOR REPAIR 6-11 6 5. Remove the oil filler cap and fill the transfer case with sufficient oil. ECA00024 CAUTION: @ Be sure no foreign material enters the transfer case. @ 6. Check the oil level. 7. Install the oil filler cap and tighten it. 8. Check for oil leakage. If oil leak- age is found, check for the cause. EAU01829[...]

PERIODIC MAINTENANCE AND MINOR REPAIR 6-12 6 3. Remove the air filter case cover by removing the screws. 4. Disconnect the ho ses. 5. Remove the air f ilter by removing the screws. 6. Tap the air filter lightly to remove most of the dust and dirt and blow out the remaining dirt with com- pressed air as shown. If the air fil- ter is damaged, replace[...]

PERIODIC MAINTENANCE AND MINOR REPAIR 6-13 6 NO TE: @ Be sure to connect the hoses. @ EC000082 CAUTION: @ ● Make sure the air filter is prop- erly seated in the air filter case. ● The engine should never be run without the air filter installed. Excessive piston and/or cylin- der wear may result. @ EAU00629 Carburetor adjustment The carburetor i[...]

PERIODIC MAINTENANCE AND MINOR REPAIR 6-14 6 2. Set the idle to the specified engine speed by adjusting the throttle stop screw. Turn the screw in di- rection a to increase engine speed and in direction b to de- crease engine speed. NO TE: @ If the specified idle speed cannot be obtained by performing the above ad- justment, consult a Yamaha dealer[...]

PERIODIC MAINTENANCE AND MINOR REPAIR 6-15 6 EAU01745* Tires To ensure maximum performance, long service, and safe operation, note the following: Tire air pressure Always check and adjust the tire pr es- sure before operating the motorcycle. EWA00011 W ARNING @ Tire inflation pressure should be checked and adjusted when the temperature of the tire [...]

PERIODIC MAINTENANCE AND MINOR REPAIR 6-16 6 Tire inspection Always check the tires before operating the motorcycle. If center tread depth reaches the limit as shown, 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. CE-10E CE-11E NO TE: @ These limits ma[...]

PERIODIC MAINTENANCE AND MINOR REPAIR 6-17 6 EAU00685 Wheels To ensure maximum performance, long service, and safe operation, note the following: ● Always inspect the wheels before a ride. Check for cracks, bends or warpage of the wheel. Be sure the spokes are tight and undamaged. If any abnormal condition exists in a wheel, consult a Yamaha deal[...]

PERIODIC MAINTENANCE AND MINOR REPAIR 6-18 6 If the specified free p lay cannot be ob- tained, proceed with the following steps. 4. Loosen the locknut at the clutch le- ver. 5. Turn the adjusting bolt at t he clutch lever in direction a to loos- en the cable. 6. Loosen the locknut at the crank- case side. 7. Turn the adjusting nut at the crankcase [...]

PERIODIC MAINTENANCE AND MINOR REPAIR 6-19 6 EAU01746 Rear brake pedal height adjustment The top of the brake pedal should be positioned 100 mm above the top of the footrest. If not, ask a Yamaha deal- er to adjust it. EW000109 W ARNING @ A soft or spongy feeling in the brake pedal can indicate the presence of air in the brake system. This air must[...]

PERIODIC MAINTENANCE AND MINOR REPAIR 6-20 6 EAU00721 Checking the front and rear brake pads EAU01119 Front brake Wear indicator grooves are provided on each brake pad. These indicators allow checking of brake pad wear with- out disassembling the brake. Inspect the grooves. If they have almost disap- peared, ask a Yamaha dealer to re- place the pad[...]

PERIODIC MAINTENANCE AND MINOR REPAIR 6-21 6 EAU00731 Inspecting the brake fluid level Insufficient brake fluid may let air enter the brake system, possibly causing the brakes to become ineffect ive. Before riding, check that the brake fluid is above the minimum level and replen- ish when necessary. Observe these precautions: ● When checking the [...]

PERIODIC MAINTENANCE AND MINOR REPAIR 6-22 6 EAU00742 Brake fluid replacement The brake fluid should be replaced only by trained Yamaha service personnel. Have the Yamaha dealer replace the following components during periodic maintenance or when they are dam- aged or leaking: ● oil seals (every two years) ● brake hoses (every four years) EAU01[...]

PERIODIC MAINTENANCE AND MINOR REPAIR 6-23 6 EAU01748 Drive belt slack adjustment 1. Loosen the axle nut and caliper bracket bolt. 2. Loosen the locknuts on each side of the swingarm. 3. To tighten the drive belt, turn the adjusting bolts in direction a . To loosen the drive belt, turn the adjusting bolts in direction b and push the wheel forward. [...]

PERIODIC MAINTENANCE AND MINOR REPAIR 6-24 6 EAU02984 Brake and shift pedal lubrication Lubricate the pivoting parts. Recommended lubricant: Engine oil E_5ja_Periodic.fm Page 24 Saturday, October 16, 1 999 10:12 AM[...]

PERIODIC MAINTENANCE AND MINOR REPAIR 6-25 6 EAU02985 Brake and clutch lever lubrication Lubricate the pivoting parts. EAU02986 Sidestand lubrication Lubricate the sidestand pivoting point and metal-to-metal contact surfaces. Check that the sidestand moves up and down smoothly. EW000113 W ARNING @ If the sidestand does not move smoothly, consult a [...]

PERIODIC MAINTENANCE AND MINOR REPAIR 6-26 6 EAU02939 Front fork inspection Visual check EW000115 W ARNING @ Securely support the motorcycle so there is no danger of it falling over. @ Check for scratches or damage on the inner tube and excessive oil leakage from the front fork. Operation check 1. Place the motorcycle on a level place. 2. Hold the [...]

PERIODIC MAINTENANCE AND MINOR REPAIR 6-27 6 EAU01144 Wheel bearings If there is play in the front or rear wheel hub or if the wheel does not turn smoothly, have a Yamaha dealer in- spect the wheel bearings. EAU00800 Battery This motorcycle is equipped with a sealed-type battery. Therefore it is not necessary to check the electrolyte or fill the ba[...]

PERIODIC MAINTENANCE AND MINOR REPAIR 6-28 6 Battery storage When the motorcycle is not used for a month or longer, remove the battery, fully charge it and store it in a cool, dry place. EC000102 CAUTION: @ ● Completely recharge the bat- tery before storing. Storing a discharged battery can cause permanent battery damage. ● Use a battery charge[...]

PERIODIC MAINTENANCE AND MINOR REPAIR 6-29 6 EAU00832 Headlight bulb replacement This motorcycle is equipped with a quartz bulb headlight. If the headlight bulb burns out, replace the bulb as fol- lows: 1. Remove the screws holding the headlight assembly. 2. Remove the headlight connector and the bulb cover. 1. Main fuse 2. Spare fuse Specified fus[...]

PERIODIC MAINTENANCE AND MINOR REPAIR 6-30 6 3. Unhook the bulb holder and re- move the defective bulb. EW000119 W ARNING @ Keep flammable products and your hands away from a bulb while it is on, as it is hot. Do not touch a bulb until it cools down. @ 4. Put a new bulb into position and secure it in place with the bulb holder. EC000105 CAUTION: @ [...]

PERIODIC MAINTENANCE AND MINOR REPAIR 6-31 6 EAU00855* Turn signal and tail/brake light bulb replacement 1. Remove the screws and the lens. 2. Push the bulb inward and turn it counterclockwise. 3. Place a new bulb in the socket. Push the bulb inward and turn it clockwise until it engages into the socket. 4. Install the lens and the screws. EC000108[...]

PERIODIC MAINTENANCE AND MINOR REPAIR 6-32 6 EAU01297 Troubleshooting chart EW000125 W ARNING @ Never check the fuel system while smoking or in the vicinity of an open flame. @ Check if there is fuel in the fuel tank. 1. Fuel Enough fuel. No fuel. Go to compression check. Supply fuel. Use the electric starter. 2. Compression There is compression. N[...]

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MOTORCYCLE CARE AND STORAGE 7 Care ........................ ....................... ......................... .......................... . 7-1 Storage ................. ...................... .......................... .......................... .... 7-4 E_5ja_CleaningTOC.fm Page 1 Saturday, O ctober 16, 1999 10:13 AM[...]

7-1 7 EAU01820 7 - MOTORCYCLE CARE AND STORAGE Care The exposure of its technology makes a motorcycle charming but also vulner- able. Although high-quality compo- nents are used, they are not all rust- resistant. While a rusty exhaust pipe may remain unnoticed on a car, it does look unattractive on a motorcycle. Fre- quent and proper care, however,[...]

MOTORCYCLE CARE AND STORAGE 7-2 7 ECA00010 CAUTION: @ ● Avoid using strong acidic wheel cleaners, especially on spoked wheels. If you do use such products for hard-to-remove dirt, do not leave it on any long- er than instructed, then thor- oughly rinse it off with water, immediately dry the area and apply a corrosion protection spray. ● Imprope[...]

MOTORCYCLE CARE AND STORAGE 7-3 7 After riding in the rain, near the sea or on salt-sprayed roads Since sea salt or salt sprayed on the roads in the winter are extremely corro- sive in combination with water, carry out the following steps after each ride in the rain, near the sea or on salt- sprayed roads. (Salt sprayed in the winter may remain on [...]

MOTORCYCLE CARE AND STORAGE 7-4 7 ECA00033 CAUTION: @ ● Apply spray oil and wax spar- ingly and wipe off any excess. ● Never apply oil or wax on the drive belt. ● Never apply oil or wax on rub- ber and plastic parts, but treat them with a suitable care prod- uct. ● Avoid using abrasive polishing compounds as they wear away the paint. @ NO T[...]

MOTORCYCLE CARE AND STORAGE 7-5 7 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 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 ov[...]

SPECIFICATIONS 8 Specification s ................ ....................... .......................... .................... 8-1 HO W T O USE THE CONVERSION T ABLE ...................... ................. 8-5 E_5ja_SpecTOC.fm Page 1 Saturday, Octo ber 16, 1999 10:18 AM[...]

8-1 8 EAU01038 8 - SPECIFICATIONS Specifications Model XV1600A Dimensions Over all length 2,50 0 mm Over all width 980 mm Over all height 1,140 mm Seat height 710 mm Wheelbase 1,685 mm Ground clearance 145 mm Minimum turning radius 3,200 mm Basic weight (with oil and fu ll fuel tank) 332 kg Engine Engine type Air-cooled 4-stroke , OHV Cylinder arra[...]

SPECIFICATIONS 8-2 8 Transfer case oil T ype SAE80API “GL-4” Hypoid Gear Oil Quantity 0.4 L Air filter Dr y type element Fuel T ype Regular unleaded gasoline Fuel tank capacity 20 L Reser v e amount 3.5 L Carburetor Manuf acture r MIKUNI T ype × quant ity BSR40 × 1 Spark plug Manuf acture r/type NGK / DPR7EA-9 or DENSO / X22EPR-U9 Gap 0.8 ~ 0[...]

SPECIFICATIONS 8-3 8 Maximum load* 196 kg Air pressure (cold tire) Up to 90 kg load* F ront 250 kP a (2.50 kg/cm 2 , 2.50 bar) Rear 250 kP a (2.50 kg/cm 2 , 2.50 bar) 90 kg load ~ maximum load* F ront 250 kP a (2.50 kg/cm 2 , 2.50 bar) Rear 280 kP a (2.80 kg/cm 2 , 2.80 bar) * Load is total weight of cargo , rider, passenger and accessories. Wheels[...]

SPECIFICATIONS 8-4 8 Headlight type Quar tz bulb (halogen) Bulb voltage, wattage × quantity Headlight 12 V , 60/55 W × 1 T ail/brake light 12 V , 5/21 W × 1 T ur n signal lights 12 V , 21 W × 4 A uxiliar y light 12 V , 4 W × 1 Meter light 14 V , 0.6 W × 4 Neutral indicator light 12 V , 1 W × 1 High beam indicator light 12 V , 1 W × 1 T ur n[...]

SPECIFICATIONS 8-5 8 EAU01064 HOW TO USE THE CONVERSION TABLE CS-02E All specification data in this manual are listed in SI and METRIC UNITS. Use this table to convert METRIC unit data t o IMPERIAL unit data. Ex. METRIC MULTIPLIER IMPERIAL **mm × 0.03937 = **in 2 mm × 0.03937 = 0.08 in CONVERSION TA BLE METRIC TO IMPE RIAL Metric unit Multiplier [...]

CONSUMER INFORMATION 9 Identificatio n n u mber records .. ....................... ......................... ........... 9-1 K ey identification number ............... ......................... .......................... . 9-1 V ehicle ident ification number... .......................... .......................... ....... 9 -1 Model labe l .... ...[...]

9-1 9 EAU01039 9 - CONSUMER INFORMATION EAU02944 Identification number records Record the key identification number, vehicle identification number and mod- el label information in the spaces pro- vided for assistance when ordering spare parts from a Yamaha dealer or for reference in case the vehicle is sto- len. 1. KEY IDENTIFICATION NUMBER: CA-02E[...]

CONSUMER INFORMATION 9-2 9 EAU01804 Model label The model label is affixed t o the frame under the rider seat. (See page 3-13 for rider seat removal and installation pro- cedures.) Record the information on this label in the space provided. This information will be needed to order spare parts from your Yamaha dealer. 1. Model label E_5ja_Consumer.f[...]

1 0- INDEX A Adjusting rear shock absorber prel oad ................................................ 3-14 Air f ilte r .................................................. 6-11 Anti the ft ala rm (o ptio nal) ........................ ..3-4 B Batt ery ................................................... 6-27 Brak e and clut ch l ever l ubricatio n ....[...]

INDEX S Shi ftin g .................................................... 5-4 Shift peda l ............................................... 3-7 Sid estan d .............................................. 3-15 Sidestand/clutch switch operation chec k .................................................. 3-16 Sid estan d lu bri cati on .....................[...]

Y AMAHA MO TOR CO., L TD . 5JA-28199-E1 PRINTED ON RECYCLED PAPER PRINTED IN JAPAN 99 · 9 - 0.7 × 1 CR (E)[...]