maintenance YAMAHA XV1600A 2001 User Guide

PERIODIC MAINTENANCE AND MINOR REPAIR
6-8
6
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. @
EAU03679
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 car-
tridge replaced at the intervals speci-
fied 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.NOTE:@ Make sure that the motorcycle is posi-
tioned straight up when checking the oil
level. A slight tilt to the side can result in
a false reading. @2. Remove the rider seat. (See page
3-12 for rider seat removal and in-
stallation procedures.)3. Start the engine, warm it up until
the engine oil has reached a nor-
mal temperature of 60 °C, let it
continue to idle for ten seconds,
and then turn the engine off.
NOTE:@ To achieve the proper engine oil tem-
perature for an accurate oil level read-
ing, the engine must have first
completely cooled down, and then
warmed up again for several minutes to
normal operating temperature. @4. Wait a few minutes until the oil set-
tles, 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.NOTE:@ The engine oil should be between the
minimum and maximum level marks. @
E_5JA.book Page 8 Wednesday, September 13, 2000 6:06 PM

PERIODIC MAINTENANCE AND MINOR REPAIR
6-9
65. If the engine oil is below the mini-
mum level mark, add sufficient oil
of the recommended type to raise
it to the correct level.
NOTE:@ When adding oil, be careful not to over-
fill the engine; the oil level rises faster
starting from the half level portion on
the dipstick. @6. Insert the dipstick into the oil filler
hole, and then tighten the oil filler
cap.
7. Install the rider seat.
ECA00027
CAUTION:@ Make sure that the oil filler cap is se-
curely tightened, otherwise oil may
seep out when the engine is
running. @
1. Engine oil filler cap
1. Maximum level
2. Minimum level
3. Dipstick
E_5JA.book Page 9 Wednesday, September 13, 2000 6:06 PM

PERIODIC MAINTENANCE AND MINOR REPAIR
6-10
6 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:@ Skip steps 4–8 if the oil filter cartridge is
not being replaced. @4. Place an oil pan under the engine
to correct the used oil.
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. @
7. Apply a thin coat of engine oil to
the O-ring of the new oil filter car-
tridge.NOTE:@ Make sure that the O-ring is properly
seated. @8. Install the new oil filter cartridge,
and then tighten it to the specified
torque with a torque wrench.
1. Engine oil drain bolt (oil tank)
1. Engine oil drain bolt (crankcase)
1. Engine oil filter cartridgeTightening torque:
Oil filter cartridge:
17 Nm (1.7 m·kg)
E_5JA.book Page 10 Wednesday, September 13, 2000 6:06 PM

PERIODIC MAINTENANCE AND MINOR REPAIR
6-11
69. Install the engine oil drain bolts,
and then tighten them to the spec-
ified torque.
10. Pour only 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.
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.
EC000072
CAUTION:@ l
In order to prevent clutch slip-
page (since the engine oil also
lubricates the clutch), do not
mix any chemical additives with
the oil or use oils of a higher
grade than “CD”. In addition, do
not use oils labeled “ENERGY
CONSERVING II” or higher.
l
Make sure that no foreign mate-
rial 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. Tightening torque:
Engine oil drain bolt:
43 Nm (4.3 m·kg)
Recommended engine oil:
See page 8-1.
Oil quantity:
Without oil filter cartridge
replacement:
3.7 L
With oil filter cartridge
replacement:
4.1 L
Total amount (dry engine):
5.0 L
E_5JA.book Page 11 Wednesday, September 13, 2000 6:06 PM

PERIODIC MAINTENANCE AND MINOR REPAIR
6-12
6
EAU03395
Transfer case oil 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.
NOTE:@ Make sure that the motorcycle is posi-
tioned 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.NOTE:@ The oil should be at the brim of the
check hole. @3. If the oil is below the brim of the
check hole, remove the oil filler
cap, add sufficient oil of the rec-
ommended 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.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.
1. Transfer case oil filler cap
2. Transfer case oil check bolt
Tightening torque:
Transfer case oil check bolt:
7.5 Nm (0.75 m·kg)
1. Transfer case oil drain boltTightening torque:
Transfer case oil drain bolt:
17.5 Nm (1.75 m·kg)
E_5JA.book Page 12 Wednesday, September 13, 2000 6:06 PM

PERIODIC MAINTENANCE AND MINOR REPAIR
6-13
64. Remove the oil filler cap, add the
specified amount of the recom-
mended transfer case oil, and then
install and tighten the oil filler cap.
ECA00024
CAUTION:@ Make sure that no foreign material
enters the transfer case. @
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.
EAU03707
Cleaning the air filter element The air filter element should be cleaned
at the intervals specified in the periodic
maintenance and lubrication chart.
Clean the air filter element more fre-
quently if you are riding in unusually
wet or dusty areas.
1. Remove the air filter case bolts.
1. Transfer case oil check holeRecommended transfer case oil:
See page 8-2.
Oil quantity:
0.4 L
1. Bolt (´ 4)
2. Air filter case
E_5JA.book Page 13 Wednesday, September 13, 2000 6:06 PM

PERIODIC MAINTENANCE AND MINOR REPAIR
6-14
6 2. Loosen the air filter joint clamp
screw, and then slightly pull the air
filter case out.3. Remove the air filter case cover by
removing the screws.
4. Disconnect the hoses shown.5. Remove the air filter element by
removing the screws, and then
disconnect the hose shown.
1. Air filter joint clamp screw
1. Screw (´ 2)
2. Hose (´ 2)
3. Air filter case cover
1. Screw (´ 2)
2. Hose
E_5JA.book Page 14 Wednesday, September 13, 2000 6:06 PM

PERIODIC MAINTENANCE AND MINOR REPAIR
6-15
66. 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 in-
serting 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.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 install-
ing the bolts.
1. Screw (´ 2)
2. Hose
1. Hose (´ 2)
E_5JA.book Page 15 Wednesday, September 13, 2000 6:06 PM

PERIODIC MAINTENANCE AND MINOR REPAIR
6-16
6
EAU00629
Adjusting the carburetor The carburetor is an important part of
the engine and requires very sophisti-
cated adjustment. Therefore, most car-
buretor adjustments should be left to a
Yamaha dealer, who has the neces-
sary professional knowledge and expe-
rience. The adjustment described in
the following section, however, may be
serviced by the owner as part of routine
maintenance.
EC000094
CAUTION:@ The carburetor has been set and ex-
tensively tested at the Yamaha fac-
tory. Changing these settings
without sufficient technical knowl-
edge may result in poor perfor-
mance of or damage to the engine. @
EAU01168
Adjusting the engine idling
speed The engine idling speed must be
checked and, if necessary, adjusted as
follows at the intervals specified in the
periodic maintenance and lubrication
chart.NOTE:@ A diagnostic tachometer is needed to
make this adjustment. @1. Attach the tachometer to the spark
plug lead.
2. Start the engine and warm it up for
several minutes at 1,000–
2,000 r/min while occasionally rev-
ving it to 4,000–4,400 r/min.NOTE:@ The engine is warm when it quickly re-
sponds to the throttle. @
3. Check the engine idling speed
and, if necessary, adjust it to spec-
ification by turning the throttle stop
screw. To increase the engine
idling speed, turn the screw in di-
rection
a. To decrease the engine
idling speed, turn the screw in di-
rection
b.NOTE:@ If the specified idling speed cannot be
obtained as described above, have a
Yamaha dealer make the adjustment. @1. Throttle stop screwEngine idling speed:
850–950 r/min
E_5JA.book Page 16 Wednesday, September 13, 2000 6:06 PM

PERIODIC MAINTENANCE AND MINOR REPAIR
6-17
6
EAU00635
Adjusting the throttle cable
free play The throttle cable free play should
measure 4–6 mm at the throttle grip.
Periodically check the throttle cable
free play and, if necessary, have a
Yamaha dealer adjust it.
EAU00637
Adjusting the valve clearance 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.
EAU01848
Tires To maximize the performance, durabil-
ity, and safe operation of your motor-
cycle, note the following points
regarding the specified tires.
Tire air pressure
The tire air pressure should be
checked and, if necessary, adjusted
before each ride.
a. Throttle cable free playE_5JA.book Page 17 Wednesday, September 13, 2000 6:06 PM