light YAMAHA XV1600A 2000 User Guide

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-25ENOTE:@ When shifting two gears down from 4th
to 2nd, bring your motorcycle to a
speed of 35 km/h. @
EAU00424
Tips for reducing fuel
consumptionYour motorcycle’s fuel consumption
depends to a large extent on your
riding style. The following tips can help
reduce fuel consumption:l
Warm up the engine before riding.
l
Turn off the starter (choke) as
soon as possible.
l
Shift up swiftly and avoid high en-
gine speeds during acceleration.
l
Do not double-clutch or rev the en-
gine while shifting down and avoid
high engine speeds with no load
on the engine.
l
Turn off the engine instead of let-
ting it idle for an extended length
of time, i.e. in traffic jams, at traffic
lights or railroad crossings.
EAU01128
Engine break-inThere is never a more important period
in the life of your motorcycle than the
period between zero and 1,600 km. For
this reason we ask that you carefully
read the following material. Because
the engine is brand new, you must not
put an excessive load on it for the first
1,600 km. The various parts in the en-
gine wear and polish themselves to the
correct operating clearances. During
this period, prolonged full throttle oper-
ation, or any condition which might re-
sult in excessive heating of the engine,
must be avoided.
Acceleration shift point
(km/h)
1st®2nd
2nd®3rd
3rd®4th
4th®5th23
36
50
60
E_5ja_Operation.fm Page 5 Saturday, October 16, 1999 10:11 AM

6
PERIODIC MAINTENANCE AND MINOR REPAIR
Tool kit................................................................... 6-1
Periodic maintenance and lubrication ................... 6-3
Spark plug inspection ........................................... 6-6
Engine oil .............................................................. 6-7
Transfer case oil .................................................. 6-10
Air filter ............................................................... 6-11
Carburetor adjustment ........................................ 6-13
Idle speed adjustment ........................................ 6-13
Throttle cable free play inspection ...................... 6-14
Valve clearance adjustment ................................ 6-14
Tires .................................................................... 6-15
Wheels ................................................................ 6-17
Clutch lever free play adjustment........................ 6-17
Front brake lever free play adjustment ................ 6-18
Rear brake pedal height adjustment ................... 6-19
Brake light switch adjustment ............................. 6-19
Checking the front and rear brake pads.............. 6-20Inspecting the brake fluid level ........................... 6-21
Brake fluid replacement ..................................... 6-22
Drive belt slack check ........................................ 6-22
Drive belt slack adjustment ................................ 6-23
Brake and shift pedal lubrication ........................ 6-24
Brake and clutch lever lubrication ...................... 6-25
Sidestand lubrication.......................................... 6-25
Front fork inspection ........................................... 6-26
Steering inspection ............................................ 6-26
Wheel bearings .................................................. 6-27
Battery................................................................ 6-27
Fuse replacement .............................................. 6-28
Headlight bulb replacement ............................... 6-29
Turn signal and tail/brake light bulb
replacement ..................................................... 6-31
Troubleshooting .................................................. 6-31
Troubleshooting chart ......................................... 6-32
E_5ja_PeriodicTOC.fm Page 1 Saturday, October 16, 1999 10:12 AM

PERIODIC MAINTENANCE AND MINOR REPAIR
6-6
6
EAU01639
Spark plug inspectionThe spark plug is an important engine
component and should be inspected
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 white insulator around the
center electrode. The ideal color at this
point is a medium-to-light tan color for a
motorcycle that is being ridden normal-
ly. If one spark plug shows a distinctly
different color, there could be some-
thing wrong with the engine.Do not attempt to diagnose such prob-
lems yourself. Instead, take the motor-
cycle to a Yamaha dealer. The spark
plugs should be periodically removed
and inspected because heat and de-
posits will cause any spark plug to
slowly break down and erode. If elec-
trode erosion becomes excessive, or if
carbon and other deposits are exces-
sive, the spark plug should be replaced
with the specified plug.
Before installing any spark plug, mea-
sure the electrode gap with a wire
thickness gauge and adjust it to specifi-
cation.When installing a spark plug, the gas-
ket surface should always be cleaned
and a new gasket used. Any grime
should be wiped off from the threads
and the spark plug tightened to the
specified torque.
NOTE:@ If a torque wrench is not available when
installing a spark plug, a good estimate
of the correct torque is 1/4 to 1/2 turn
past finger tight. The spark plug should
be tightened to the specified torque as
soon as possible. @
a. Spark plug gap
Specified spark plug:
DPR7EA-9/NGK or
X22EPR-U9/DENSO
Spark plug gap:
0.8 ~ 0.9 mm
Tightening torque:
Spark plug:
17.5 Nm (1.75 m·kg)
E_5ja_Periodic.fm Page 6 Saturday, October 16, 1999 10:12 AM

PERIODIC MAINTENANCE AND MINOR REPAIR
6-8
6
NOTE:@ l
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.
l
When adding oil, be careful not to
overfill the engine; the oil level ris-
es faster starting from the half lev-
el portion on the dipstick.
@6. Insert the dipstick into the oil filler
hole and tighten the oil filler cap,
then install the rider seat.
ECA00027
CAUTION:@ Be sure the oil filler cap is securely
tightened as the oil may seep out
when the engine is running. @
Engine oil and oil filter cartridge
replacement
1. Warm up the engine for several
minutes, and then stop the engine.
2. Place an oil pan under the engine
oil drain bolts, and then remove
the rider seat and oil filler cap.
3. Remove the engine oil drain bolts
and drain the oil from the oil tank.
4. Remove the oil filter by using an oil
filter wrench.NOTE:@ An oil filter wrench is available at a
nearby Yamaha dealer. @
1. Maximum level
2. Minimum level
3. Dipstick
1. Engine oil drain bolt (oil tank)
E_5ja_Periodic.fm Page 8 Saturday, October 16, 1999 10:12 AM

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
E_5ja_Periodic.fm Page 9 Saturday, October 16, 1999 10:12 AM

PERIODIC MAINTENANCE AND MINOR REPAIR
6-11
65. 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
Air filterThe air filter should be cleaned at the
specified intervals.
The air filter should be cleaned more
frequently if you are riding in unusually
wet or dusty areas.
1. Remove the air filter case bolts.2. Loosen the carburetor joint screw
and slightly pull the air filter case
outward.
1. Transfer oil level check holeRecommended oil:
See page 8-2.
Oil quantity:
0.4 L
1. Bolt (´ 4)
2. Air filter case cover
1. Carburetor joint screw
E_5ja_Periodic.fm Page 11 Saturday, October 16, 1999 10:12 AM

PERIODIC MAINTENANCE AND MINOR REPAIR
6-12
6 3. Remove the air filter case cover by
removing the screws.
4. Disconnect the hoses.5. Remove the air filter 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 it.
7. Reassemble by reversing the re-
moval procedure.
1. Screw (´ 2)
2. Hose (´ 2)
1. Screw (´ 2)
E_5ja_Periodic.fm Page 12 Saturday, October 16, 1999 10:12 AM

PERIODIC MAINTENANCE AND MINOR REPAIR
6-19
6
EAU01746
Rear brake pedal height
adjustmentThe 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
WARNING
@ A soft or spongy feeling in the brake
pedal can indicate the presence of
air in the brake system. This air
must be removed by bleeding the
brake system before the motorcycle
is operated. Air in the system will
cause greatly diminished braking
capability and can result in loss of
control and an accident. Have a
Yamaha dealer inspect and bleed
the system if necessary. @
EAU00713
Brake light switch adjustmentThe rear brake light switch is activated
by the brake pedal and is properly ad-
justed when the brake light comes on
just before braking takes effect. To ad-
just the rear brake light switch, hold the
switch body so it does not rotate while
turning the adjusting nut.
Turn the adjusting nut in direction
a to
make the brake light come on earlier.
Turn the adjusting nut in direction
b to
make the brake light come on later.
a. Brake pedal height
1. Brake light switch
2. Adjusting nut
E_5ja_Periodic.fm Page 19 Saturday, October 16, 1999 10:12 AM

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:@ l
Completely recharge the bat-
tery before storing. Storing a
discharged battery can cause
permanent battery damage.
l
Use a battery charger designed
for a sealed-type (MF) battery.
Using a conventional battery
charger will cause battery dam-
age. If you do not have a sealed-
type battery charger, contact
your Yamaha dealer.
l
Always make sure the connec-
tions are correct when reinstall-
ing the battery.
@
EAU01749
Fuse replacementThe fuse boxes are located behind the
left side cover. Remove the bolt and
pull outward to remove the cover.
If a fuse is blown, turn off the main
switch and the switch of the circuit in
question. Install a new fuse of proper
amperage. Turn on the switches and
see if the electrical device operates. If
the fuse immediately blows again, con-
sult a Yamaha dealer.
EC000103
CAUTION:@ Do not use fuses of higher amper-
age rating than those recommend-
ed. Substitution of a fuse of
improper rating can cause extensive
electrical system damage and pos-
sibly a fire. @
1. Bolt
1. Signaling system fuse
2. Ignition fuse
3. Headlight fuse
4. Carburetor heater fuse
5. Odometer fuse
6. Spare fuse (´ 3)
E_5ja_Periodic.fm Page 28 Saturday, October 16, 1999 10:12 AM

PERIODIC MAINTENANCE AND MINOR REPAIR
6-29
6
EAU00832
Headlight bulb replacementThis 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 fuseSpecified fuses:
Main fuse: 30 A
Ignition fuse: 15 A
Signaling system fuse: 10 A
Headlight fuse: 15 A
Carburetor heater fuse: 10 A
Odometer fuse: 5 A
1. Screw (´ 2)
1. Connector
2. Bulb holder cover
E_5ja_Periodic.fm Page 29 Saturday, October 16, 1999 10:12 AM