wheel YAMAHA XV1600A 2000 Owners Manual

4-1
4
EAU01114
4-PRE-OPERATION CHECKSOwners 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 to the elements). Any damage, fluid leak or
loss of tire pressure could have serious consequences. Therefore, it is very important that, in addition to a thorough visual in-
spection, you check the following points before each ride.
EAU00340
PRE-OPERATION CHECK LIST
ITEM CHECKS PAGE
Front brake• Check operation, fluid level and vehicle for fluid leakage.
• Fill with DOT 4 brake fluid if necessary.
6-18 ~ 6-22
Rear brake• Check operation, fluid level and vehicle for fluid leakage.
• Fill with DOT 4 brake fluid if necessary.
Clutch• Check operation, condition and free play.
• Adjust if necessary.6-17 ~ 6-18
Throttle grip and housing• Check for smooth operation.
• Lubricate if necessary.6-14
Engine oil• Check oil level.
• Fill with oil if necessary.6-7 ~ 6-10
Wheels and tires• Check tire pressure, wear, damage and spoke tightness.
• Tighten spokes necessary.6-15 ~ 6-17
Brake and shift pedal
shafts• Check for smooth operation.
• Lubricate if necessary.6-24
Brake and clutch lever
pivots• Check for smooth operation.
• Lubricate if necessary.6-25
Sidestand pivot• Check for smooth operation.
• Lubricate if necessary.6-25
Chassis fasteners• Make sure that all nuts, bolts and screws are properly tightened.
• Tighten if necessary.—
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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
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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
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PERIODIC MAINTENANCE AND MINOR REPAIR
6-4
6
11
*Wheel bearings• Check bearing for looseness or damage.
• Replace if necessary. ÖÖ
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).ÖÖ
13*Drive belt• Check belt tension.
• Adjust if necessary. Make sure that the rear wheel is properly
aligned.ÖEvery 4,000 km
14*Steering bearings• Check bearing play and steering for roughness.
• Correct accordingly.
• Lubricate with lithium soap base grease every 24,000 km
or 24 months (whichever comes first).ÖÖ
15*Chassis fasteners• Make sure that all nuts, bolts and screws are properly tightened.
• Tighten if necessary.ÖÖ
16 Sidestand• Check operation.
• Lubricate and repair if necessary.ÖÖ
17*Sidestand switch• Check operation.
• Replace if necessary.ÖÖÖ
18*Front fork• Check operation and for oil leakage.
• Correct accordingly.ÖÖ
19*Rear shock absorber
assembly• Check operation and shock absorber for oil leakage.
• Replace shock absorber assembly if necessary. ÖÖ
20*Rear suspension relay
arm and connecting arm
pivoting points• Check operation.
• Lubricate with molybdenum disulfide grease every 24,000 km or
24 months (whichever comes first).ÖÖ
21*Carburetor• Check engine idling speed and starter operation.
• Adjust if necessary.ÖÖÖ NO. 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)
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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-11ENOTE:@ These limits may be different by regula-
tion from country to country. If so, con-
form to the limits specified by the
regulations of your own country. @
EAU00681
WARNING
@ l
Operating the motorcycle with
excessively worn tires decrease
riding stability and can lead to
loss of control. Have excessive-
ly worn tires replaced by a
Yamaha dealer immediately.
Brakes, tires, and related wheel
parts replacement should be
left to a Yamaha Service Techni-
cian.
l
Patching a punctured tube is
not recommended. If it is abso-
lutely necessary to do so, use
great care and replace the tube
as soon as possible with a good
quality replacement.
@
1. Sidewall
a. Tread depth
FRONT
Manufacturer Size Type
Dunlop 130/90-16 67H D404FL
Bridgestone 130/90-16 67H G703F
REAR
Manufacturer Size Type
Dunlop 150/80B-16 71H D404
Bridgestone 150/80B-16 71H G702
Minimum tire tread
depth (front and rear)1.6 mm
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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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PERIODIC MAINTENANCE AND MINOR REPAIR
6-22
6
EAU00742
Brake fluid replacementThe 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:l
oil seals (every two years)
l
brake hoses (every four years)
EAU01830
Drive belt slack check1. Put the motorcycle on the side-
stand and make sure that both
wheels are on the ground.
2. Using the reference marks at the
side of the check window, which is
located at the rear left side of the
motorcycle, note the current posi-
tion of the drive belt.3. Apply a force of 45 N (4.5 kg) with
the belt tension gauge to the lower
drive belt run as shown and re-
check the drive belt position in the
check window. The normal drive
belt slack (i.e., the distance be-
tween the original belt position and
its position with the force applied)
is approximately 7.5 ~ 13 mm.
4. If the measured slack exceeds
13 mm, adjust the drive belt.
NOTE:@ The reference marks at the side of the
drive belt check window are 5 mm
apart. @
1. Drive belt
2. Marks
a. Slack
1. Belt tension gauge
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PERIODIC MAINTENANCE AND MINOR REPAIR
6-23
6
EAU01748
Drive belt slack adjustment1. 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. Turn each
adjusting bolt exactly the same
amount to maintain correct axle
alignment.
4. Tighten the locknuts.
ECA00025
CAUTION:@ Too little drive belt slack will over-
load the engine. Keep the drive belt
slack within the specified range. @
5. Tighten the axle nut and caliper
bracket bolt to the specified
torque.
1. Wheel axle nut
1. Caliper bracket bolt
1. Adjusting bolt (´ 2)
2. Locknut (´ 2)
3. Wheel axle
Tightening torque:
Axle nut:
150 Nm (15 m·kg)
Caliper bracket bolt:
48 Nm (4.8 m·kg)
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PERIODIC MAINTENANCE AND MINOR REPAIR
6-26
6
EAU02939
Front fork inspectionVisual check
EW000115
WARNING
@ 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 motorcycle in an upright
position and apply the front brake.
3. Push down hard on the handle-
bars several times and check if the
fork rebounds smoothly.
EC000098
CAUTION:@ If any damage or unsmooth move-
ment is found with the front fork,
consult a Yamaha dealer. @
EAU00794
Steering inspectionPeriodically inspect the condition of the
steering. Worn out or loose steering
bearings may be dangerous. Place a
stand under the engine to raise the
front wheel off the ground. Hold the
lower end of the front forks and try to
move them forward and backward. If
any free play can be felt, ask a Yamaha
dealer to inspect and adjust the steer-
ing. Inspection is easier if the front
wheel is removed.
EW000115
WARNING
@ Securely support the motorcycle so
there is no danger of it falling over. @
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PERIODIC MAINTENANCE AND MINOR REPAIR
6-27
6
EAU01144
Wheel bearingsIf 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
BatteryThis motorcycle is equipped with a
sealed-type battery. Therefore it is not
necessary to check the electrolyte or fill
the battery with distilled water.l
If the battery seems to have dis-
charged, consult a Yamaha dealer.
l
If the motorcycle is equipped with
optional electrical accessories, the
battery tends to discharge more
quickly, so be sure to recharge it
periodically.
EC000101
CAUTION:@ Never try to remove the sealing caps
of the battery cells. The battery will
be damaged. @
EW000116
WARNING
@ Battery electrolyte is poisonous and
dangerous, causing severe burns,
etc. It contains sulfuric acid. Avoid
contact with skin, eyes or clothing.
ANTIDOTE:l
EXTERNAL: Flush with water.
l
INTERNAL: Drink large quanti-
ties of water or milk. Follow with
milk of magnesia, beaten egg,
or vegetable oil. Call a physi-
cian immediately.
l
EYES: Flush with water for
15 minutes and get prompt
medical attention.
Batteries produce explosive gases.
Keep sparks, flame, cigarettes etc.,
away. Ventilate when charging or
using in an enclosed space. Always
shield your eyes when working near
batteries.
KEEP OUT OF REACH OF CHIL-
DREN.
@
1. Battery
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