clutch YAMAHA XV1600A 2000 User Guide
[x] Cancel search | Manufacturer: YAMAHA, Model Year: 2000, Model line: XV1600A, Model: YAMAHA XV1600A 2000Pages: 95, PDF Size: 19.02 MB
Page 47 of 95
PERIODIC MAINTENANCE AND MINOR REPAIR
6-3
6
EAU00473
PERIODIC MAINTENANCE AND LUBRICATION
CP-01ENO. ITEM CHECKS AND MAINTENANCE JOBSINITIAL
(1,000 km)EVERY
6,000 km
or
6 months
(whichever
comes first)12,000 km
or
12 months
(whichever
comes first)
1
*Fuel line• Check fuel hoses for cracks or damage.
• Replace if necessary.ÖÖ
2*Fuel filter• Check condition.
• Replace if necessary.Ö
3 Spark plugs• Check condition.
• Clean, regap or replace if necessary.ÖÖÖ
4*Valves• Check valve clearance.
• Adjust if necessary.Every 24,000 km or 24 months
(whichever comes first)
5 Air filter• Clean or replace if necessary.ÖÖ
6Clutch• Check operation.
• Adjust or replace cable.ÖÖÖ
7*Front brake• Check operation, fluid level and vehicle for fluid leakage.
(See NOTE on page 6-5.)
• Correct accordingly.
• Replace brake pads if necessary.ÖÖÖ
8*Rear brake• Check operation, fluid level and vehicle for fluid leakage.
(See NOTE on page 6-5.)
• Correct accordingly.
• Replace brake pads if necessary.ÖÖÖ
9*Wheels• Check balance, runout, spoke tightness and for damage.
• Tighten spokes and rebalance, replace if necessary.ÖÖ
10*Tires• Check tread depth and for damage.
• Replace if necessary.
• Check air pressure.
• Correct if necessary.ÖÖ
E_5ja_Periodic.fm Page 3 Saturday, October 16, 1999 10:12 AM
Page 53 of 95
PERIODIC MAINTENANCE AND MINOR REPAIR
6-9
65. 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 filter.
NOTE:@ 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 2.5 L of oil into the oil fill-
er hole, then install the oil filler cap
and tighten it.
9. Start the engine and rev it several
times.
10. Stop the engine and remove the
oil filler cap.11. Gradually fill the oil tank with the
remainder of the recommended oil
quantity while checking the level
on the dipstick.
EC000066
CAUTION:@ l
Do not put in any chemical addi-
tives. Engine oil also lubricates
the clutch and additives could
cause clutch slippage.
l
Be sure no foreign material en-
ters the crankcase.
@12. Install the oil filler cap.
1. Engine oil drain bolt (engine)Tightening torque:
Drain bolt (oil tank):
43 Nm (4.3 m·kg)
Drain bolt (engine):
43 Nm (4.3 m·kg)
1. Engine oil filter cartridge
Tightening torque:
Oil filter:
17 Nm (1.7 m·kg)
Recommended oil:
See page 8-1.
Oil quantity:
Total amount:
5.0 L
Periodic oil change:
3.7 L
With oil filter replacement:
4.1 L
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Page 61 of 95
PERIODIC MAINTENANCE AND MINOR REPAIR
6-17
6
EAU00685
WheelsTo ensure maximum performance,
long service, and safe operation, note
the following:l
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 dealer.
Do not attempt even small repairs
to the wheel. If a wheel is de-
formed or cracked, it must be re-
placed.
l
Tires and wheels should be bal-
anced whenever either one is
changed or replaced. Failure to
have a wheel balanced can result
in poor performance, adverse han-
dling characteristics, and short-
ened tire life.
l
Ride at moderate speeds after
changing a tire since the tire sur-
face must first be broken in for it to
develop its optimal characteristics.
EAU00694
Clutch lever free play
adjustmentThe clutch lever free play should be ad-
justed to 10 ~ 15 mm.
1. Loosen the locknut at the clutch le-
ver.
2. Turn the adjusting bolt at the
clutch lever in direction
a to in-
crease free play or in direction
b
to decrease free play.
3. Tighten the locknut at the clutch
lever.1. Locknut
2. Adjusting bolt
c. Free play
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Page 62 of 95
PERIODIC MAINTENANCE AND MINOR REPAIR
6-18
6 If the specified free play cannot be ob-
tained, proceed with the following
steps.
4. Loosen the locknut at the clutch le-
ver.
5. Turn the adjusting bolt at the
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 in direction
a to in-
crease free play or in direction
b
to decrease free play.
8. Tighten the locknut at the crank-
case and the clutch lever.
EAU00696
Front brake lever free play
adjustmentThe free play at the front brake lever
should be 2 ~ 5 mm.
1. Loosen the locknut.
2. Turn the adjusting bolt in
direction
a to increase free play
or in direction
b to decrease free
play.
3. After adjusting, tighten the locknut.
EW000099
WARNING
@ l
Check the brake lever free play.
Be sure the brake is working
properly.
l
A soft or spongy feeling in the
brake lever can indicate the
presence of air in the brake sys-
tem. This air must be removed
by bleeding the brake system
before the motorcycle is operat-
ed. Air in the system will cause
greatly diminished braking ca-
pability and can result in loss of
control and an accident. Have a
Yamaha dealer inspect and
bleed the system if necessary.
@
1. Adjusting nut
2. Locknut
1. Locknut
2. Adjusting bolt
c. Free play
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Page 69 of 95
PERIODIC MAINTENANCE AND MINOR REPAIR
6-25
6
EAU02985
Brake and clutch lever
lubricationLubricate the pivoting parts.
EAU02986
Sidestand lubricationLubricate the sidestand pivoting point
and metal-to-metal contact surfaces.
Check that the sidestand moves up
and down smoothly.
EW000113
WARNING
@ If the sidestand does not move
smoothly, consult a Yamaha dealer. @
Recommended lubricant:
Engine oil
Recommended lubricant:
Engine oil
E_5ja_Periodic.fm Page 25 Saturday, October 16, 1999 10:12 AM
Page 85 of 95
8-1
8
EAU01038
8-SPECIFICATIONSSpecifications
Model XV1600A
Dimensions
Overall length 2,500 mm
Overall width 980 mm
Overall 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 full
fuel tank)
332 kg
Engine
Engine type Air-cooled 4-stroke, OHV
Cylinder arrangement V-type 2-cylinder
Displacement 1,602 cm
3
Bore ´ Stroke 95 ´ 113 mm
Compression ratio 8.3:1
Starting system Electric starter
Lubrication system Dry sumpEngine oil
Ty p e
Recommended engine oil
classification API Service SE, SF, SG type or
higher
Quantity
Periodic oil change 3.7 L
With oil filter replacement 4.1 L
Total amount 5.0 L
-20˚ -10˚ 0˚
10˚20˚ 30˚
40˚50˚C
SAE 10W/30
SAE 15W/40SAE 20W/40SAE 20W/50
SAE 10W/40
CAUTION:Be sure to use motor oils that do not contain anti-friction
modifiers. Passenger car motor oils (often labeled
“Energy Conserving”) contain anti-friction additives which
will cause clutch and/or starter clutch slippage, resulting in
reduced component life and poor engine performance.
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Page 86 of 95
SPECIFICATIONS
8-2
8
Transfer case oil
Type SAE80API “GL-4” Hypoid Gear
Oil
Quantity 0.4 L
Air filterDry type element
Fuel
Type Regular unleaded gasoline
Fuel tank capacity 20 L
Reserve amount 3.5 L
Carburetor
Manufacturer MIKUNI
Type ´ quantity BSR40 ´ 1
Spark plug
Manufacturer/type NGK / DPR7EA-9 or
DENSO / X22EPR-U9
Gap 0.8 ~ 0.9 mm
Clutch typeWet, multiple-disc
Transmission
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 operationGear ratio
1st 2.438
2nd 1.579
3rd 1.160
4th 0.906
5th 0.750
Chassis
Frame type Double cradle
Caster angle 32°
Trail 142 mm
Tire
Front
Type With tube
Size 130/90-16 67H
Manufacturer/model Dunlop / D404FL
Bridgestone / G703F
Rear
Type With tube
Size 150/80B-16 71H
Manufacturer/model Dunlop / D404
Bridgestone / G702
E_5ja_Spec.fm Page 2 Saturday, October 16, 1999 10:18 AM
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10-INDEXAAdjusting rear shock absorber
preload ................................................ 3-14
Air filter .................................................. 6-11
Antitheft alarm (optional) ..........................3-4BBattery ................................................... 6-27
Brake and clutch lever lubrication........... 6-25
Brake and shift pedal lubrication ............ 6-24
Brake fluid replacement ......................... 6-22
Brake light switch adjustment ................. 6-19CCarburetor adjustment ........................... 6-13
Care.........................................................7-1
Checking the front and rear brake
pads .................................................... 6-20
Clutch lever ..............................................3-7
Clutch lever free play adjustment ........... 6-17
Controls/Instruments ................................2-3DDiagnosis device......................................3-4
Digital clock..............................................3-5
Dimmer switch .........................................3-6
Drive belt slack adjustment .................... 6-23
Drive belt slack check ............................ 6-22EEngine break-in........................................5-5
Engine oil .................................................6-7
Engine stop switch ...................................3-6
Engine trouble indicator light ....................3-2
FFront brake lever ..................................... 3-8
Front brake lever free play
adjustment .......................................... 6-18
Front fork inspection .............................. 6-26
Fuel ......................................................... 3-9
Fuel cock ............................................... 3-11
Fuel gauge .............................................. 3-4
Fuel level indicator light ........................... 3-2
Fuel tank breather hose ......................... 3-10
Fuel tank cap ........................................... 3-9
Fuse replacement.................................. 6-28GGive safety the right of way ..................... 1-1HHandlebar switches ................................. 3-6
Dimmer switch ................................... 3-6
Engine stop switch ............................. 3-6
Horn switch ........................................ 3-6
Lights switch ...................................... 3-6
Pass switch ........................................ 3-6
Start switch ........................................ 3-7
Turn signal switch .............................. 3-6
Headlight bulb replacement ................... 6-29
Helmet holder ........................................ 3-13
High beam indicator light ......................... 3-2
Horn switch ............................................. 3-6IIdentification number records................... 9-1
Idle speed adjustment ........................... 6-13
Indicator lights ..........................................3-2
Engine trouble indicator light ...............3-2
Fuel level indicator light ......................3-2
High beam indicator light ....................3-2
Neutral indicator light ..........................3-2
Turn indicator light ..............................3-2
Inspecting the brake fluid level ...............6-21KKey identification number .........................9-1LLeft view...................................................2-1
Lights switch ............................................3-6MMain switch/steering lock .........................3-1
Model label ..............................................9-2NNeutral indicator light ...............................3-2PParking.....................................................5-6
Pass switch ..............................................3-6
Periodic maintenance and lubrication .......6-3
Pre-operation check list ............................4-1RRear brake pedal .....................................3-8
Rear brake pedal height adjustment.......6-19
Recommended shift points
(for Switzerland only) .............................5-5
Rider seat ..............................................3-13
Right view ................................................2-2
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INDEX
SShifting .................................................... 5-4
Shift pedal ............................................... 3-7
Sidestand .............................................. 3-15
Sidestand/clutch switch operation
check .................................................. 3-16
Sidestand lubrication ............................. 6-25
Spark plug inspection .............................. 6-6
Specifications .......................................... 8-1
Speedometer ........................................... 3-3
Starter (choke) knob .............................. 3-12
Starting a warm engine ............................ 5-4
Starting the engine .................................. 5-1
Start switch .............................................. 3-7
Steering inspection ................................ 6-26
Steering lock.......................................... 3-12
Storage.................................................... 7-4TThrottle cable free play inspection ......... 6-14
Tips for reducing fuel consumption .......... 5-5
Tires ...................................................... 6-15
Tool kit..................................................... 6-1
Transfer case oil .................................... 6-10
Troubleshooting..................................... 6-31
Troubleshooting chart ............................ 6-32
Turn indicator light ................................... 3-2
Turn signal and tail/brake light bulb
replacement ........................................ 6-31
Turn signal switch .................................... 3-6VValve clearance adjustment................... 6-14
Vehicle identification number ................... 9-1
WWheel bearings ..................................... 6-27
Wheels .................................................. 6-17
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