air filter YAMAHA XV1600A 2001 Owners Manual

6
PERIODIC MAINTENANCE AND MINOR REPAIR
Owner’s tool kit .................................................... 6-1
Periodic maintenance and lubrication chart ......... 6-3
Removing and installing the panel ....................... 6-6
Checking the spark plugs .................................... 6-7
Engine oil and oil filter cartridge .......................... 6-8
Transfer case oil ................................................. 6-12
Cleaning the air filter element ............................ 6-13
Adjusting the carburetor ..................................... 6-16
Adjusting the engine idling speed ...................... 6-16
Adjusting the throttle cable free play .................. 6-17
Adjusting the valve clearance ............................ 6-17
Tires ................................................................... 6-17
Spoke wheels .................................................... 6-20
Adjusting the clutch lever free play .................... 6-21
Adjusting the brake lever free play ..................... 6-22
Adjusting the brake pedal position ..................... 6-22
Adjusting the rear brake light switch .................. 6-23
Checking the front and rear brake pads ............. 6-23Checking the brake fluid level ............................ 6-25
Changing the brake fluid ................................... 6-26
Drive belt slack .................................................. 6-26
Checking and lubricating the brake and
shift pedals ...................................................... 6-28
Checking and lubricating the brake and
clutch levers .................................................... 6-29
Checking and lubricating the sidestand ............ 6-30
Checking the front fork ...................................... 6-30
Checking the steering ....................................... 6-31
Checking the wheel bearings ............................ 6-31
Battery ............................................................... 6-32
Replacing the fuses .......................................... 6-33
Replacing the headlight bulb ............................. 6-35
Replacing a turn signal light bulb or the tail/
brake light bulb ................................................ 6-37
Troubleshooting ................................................. 6-37
Troubleshooting chart ........................................ 6-38
E_5JA.book Page 1 Wednesday, September 13, 2000 6:06 PM

PERIODIC MAINTENANCE AND MINOR REPAIR
6-3
6
EAU03685
Periodic maintenance and lubrication chart
NOTE:_ l
The annual checks must be performed every year, except if a kilometer-based maintenance is performed instead.
l
From 50,000 km, repeat the maintenance intervals starting from 10,000 km.
l
Items marked with an asterisk should be performed by a Yamaha dealer as they require special tools, data and techni-
cal skills.
_CP-01ENO. ITEM CHECK OR MAINTENANCE JOBODOMETER READING (´1,000 km)
ANNUAL
CHECK
1 10203040
1
*Fuel line• Check fuel hoses for cracks or damage.ÖÖÖÖ Ö
2*Fuel filter• Check condition.ÖÖ
3 Spark plugs• Check condition.
• Clean and regap.ÖÖ
•Replace.ÖÖ
4*Valves• Check valve clearance.
• Adjust.Every 20,000 km
5 Air filter element• Clean.ÖÖ
•Replace.ÖÖ
6Clutch• Check operation.
• Adjust.ÖÖÖÖÖ
7*Front brake• Check operation, fluid level and vehicle for fluid leakage.
(See NOTE on page 6-5.)ÖÖÖÖÖ Ö
• Replace brake pads. Whenever worn to the limit
8*Rear brake• Check operation, fluid level and vehicle for fluid leakage.
(See NOTE on page 6-5.)ÖÖÖÖÖ Ö
• Replace brake pads. Whenever worn to the limit
E_5JA_Periodic.fm Page 3 Monday, December 18, 2000 7:28 PM

PERIODIC MAINTENANCE AND MINOR REPAIR
6-5
6
EAU03541
NOTE:@l
The air filter needs more frequent service if you are riding in unusually wet or dusty areas.
l
Hydraulic brake service
• Regularly check and, if necessary, correct the brake fluid level.
• Every two years replace the internal components of the brake master cylinder and caliper, and change the brake fluid.
• Replace the brake hoses every four years and if cracked or damaged.
@23 Engine oil• Change.ÖÖÖÖÖ Ö
24 Engine oil filter cartridge•Replace.ÖÖÖ
25
*Transfer case oil• Check oil level.ÖÖ
• Change.ÖÖÖ
26*Front and rear brake
switches• Check operation.ÖÖÖÖÖ Ö
27 Moving parts and cables• Lubricate.ÖÖÖÖ Ö
28*Lights, signals and
switches• Check operation.
• Adjust headlight beam.ÖÖÖÖÖ Ö NO. ITEM CHECK OR MAINTENANCE JOBODOMETER READING (´1,000 km)
ANNUAL
CHECK
1 10203040
E_5JA_Periodic.fm Page 5 Monday, December 18, 2000 7:28 PM

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
6-10
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
6-13
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

8-1
8
EAU01038
8-SPECIFICATIONSSpecifications CS-01E
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
Without oil filter cartridge
replacement 3.7 L
With oil filter car tridge
replacement 4.1 L
Total amount (dry engine) 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 II”) contain anti-friction additives
which will cause clutch and/or starter clutch slippage, result-
ing in reduced component life and poor engine performance.
E_5JA.book Page 1 Wednesday, September 13, 2000 6:06 PM