brake light YAMAHA XV1600A 2002 Owners Manual

2-1
2
EAU00026
2-DESCRIPTION Left view1. Engine oil drain bolt (crankcase) (page 6-10)
2. Shift pedal (page 3-7)
3. Starter (choke) knob (page 3-12)
4. Fuel cock (page 3-11)
5. Rider seat (page 3-12)
6. Owner’s tool kit (page 6-1)7. Helmet holder (page 3-13)
8. Rear turn signal lights (page 6-38)
9. Tail/brake light (page 6-38)
10. Fuses (page 6-35)
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DESCRIPTION
2-2
2
Right view11. Passenger footrest
12. Passenger seat
13. Engine oil filler cap (page 6-8)
14. Fuel tank (page 3-9)
15. Fuel tank cap (page 3-9)
16. Headlight (page 6-36)
17. Front turn signal lights (page 6-38)
18. Throttle stop screw (page 6-16)19. Brake pedal (page 3-8)
20. Engine oil filter cartridge (page 6-10)
21. Rider footrest
22. Engine oil drain bolt (oil tank) (page 6-9)
23. Transfer case oil drain bolt (page 6-12)
24. Shock absorber assembly spring
preload adjusting nut (page 3-14)
25. Muffler
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3
INSTRUMENT AND CONTROL FUNCTIONS
Main switch/steering lock ..................................... 3-1
Indicator and warning lights ................................ 3-2
Speedometer unit ................................................ 3-3
Self-diagnosis device ........................................... 3-4
Fuel gauge ........................................................... 3-4
Anti-theft alarm (optional) .................................... 3-4
Clock .................................................................... 3-5
Handlebar switches ............................................. 3-6
Clutch lever .......................................................... 3-7
Shift pedal ............................................................ 3-7
Brake lever ........................................................... 3-8
Brake pedal .......................................................... 3-8Fuel tank cap ...................................................... 3-9
Fuel ..................................................................... 3-9
Fuel tank breather hose .................................... 3-10
Fuel cock ........................................................... 3-11
Starter (choke) knob ......................................... 3-12
Locking the steering with a padlock .................. 3-12
Rider seat .......................................................... 3-12
Helmet holder .................................................... 3-13
Adjusting the shock absorber assembly ............ 3-14
Sidestand .......................................................... 3-15
Ignition circuit cut-off system ............................. 3-16
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PRE-OPERATION CHECKS
4-2
4
NOTE:@ Pre-operation checks should be made each time the motorcycle is used. Such an inspection can be accomplished in a very
short time; and the added safety it assures is more than worth the time involved. @
EWA00033
WARNING
@ If any item in the Pre-operation check list is not working properly, have it inspected and repaired before operating
the motorcycle. @Control cablesMake sure that operation is smooth.
Lubricate if necessary.—
Wheels and tiresCheck for damage.
Check tire condition and tread depth.
Check air pressure.
Correct if necessary.6-17–6-20
Brake and shift pedalsMake sure that operation is smooth.
Lubricate pedal pivoting points if necessary.6-29
Brake and clutch leversMake sure that operation is smooth.
Lubricate lever pivoting points if necessary.6-30
SidestandMake sure that operation is smooth.
Lubricate pivot if necessary.6-30
Chassis fastenersMake sure that all nuts, bolts and screws are properly tightened.
Tighten if necessary.—
Instruments, lights, signals
and switchesCheck operation.
Correct if necessary.—
Sidestand switchCheck operation of ignition circuit cut-off system.
If system is defective, have Yamaha dealer check vehicle.3-16 ITEM CHECKS PAGE
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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 ............. 6-23
Checking the brake fluid level ............................ 6-25
Changing the brake fluid .................................... 6-26Drive belt slack .................................................. 6-26
Checking and lubricating the cables ................. 6-28
Checking and lubricating the throttle
grip and cable ................................................. 6-29
Checking and lubricating the brake and
shift pedals ...................................................... 6-29
Checking and lubricating the brake and
clutch levers .................................................... 6-30
Checking and lubricating the sidestand ............ 6-30
Checking the front fork ...................................... 6-31
Checking the steering ....................................... 6-31
Checking the wheel bearings ............................ 6-32
Battery ............................................................... 6-33
Replacing the fuses .......................................... 6-35
Replacing the headlight bulb ............................. 6-36
Replacing a turn signal light bulb or the
tail/brake light bulb .......................................... 6-38
Troubleshooting ................................................. 6-38
Troubleshooting chart ........................................ 6-39
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PERIODIC MAINTENANCE AND MINOR REPAIR
6-5
6
EAU03884
NOTE:_

The air filter needs more frequent service if you are riding in unusually wet or dusty areas.


Hydraulic brake service
Regularly check and, if necessary, correct the brake fluid level.
Every two years replace the internal components of the brake master cylinders and calipers, and change the brake
fluid.
Replace the brake hoses every four years and if cracked or damaged.
_23 Engine oilChange.
Check oil level and vehicle for oil leakage.√√√√√ √
24 Engine oil filter cartridgeReplace.√√√
25
*Transfer case oilCheck oil level.√√
Change.√√√
26*Front and rear brake
switchesCheck operation.√√√√√ √
27 Moving parts and cablesLubricate.√√√√ √
28*Lights, signals and
switchesCheck operation.
Adjust headlight beam.√√√√√ √ NO. ITEM CHECK OR MAINTENANCE JOBODOMETER READING (×1,000 km)
ANNUAL
CHECK
1 10203040
E_5JA_Periodic.fm Page 5 Saturday, August 18, 2001 5:37 PM

PERIODIC MAINTENANCE AND MINOR REPAIR
6-23
6
EW000109
WARNING
@ A soft or spongy feeling in the brake
pedal can indicate the presence of
air in the hydraulic system. If there
is air in the hydraulic system, have a
Yamaha dealer bleed the system be-
fore operating the motorcycle. Air in
the hydraulic system will diminish
the braking performance, which
may result in loss of control and an
accident. @
EAU00713
Adjusting the rear brake light
switch The rear brake light switch, which is ac-
tivated by the brake pedal, is properly
adjusted when the brake light comes
on just before braking takes effect. If
necessary, adjust the brake light switch
as follows.
Turn the adjusting nut while holding the
rear brake light switch in place. To
make the brake light come on earlier,
turn the adjusting nut in direction
a. To
make the brake light come on later,
turn the adjusting nut in direction
b.
EAU00721
Checking the front and rear
brake pads The front and rear brake pads must be
checked for wear at the intervals spec-
ified in the periodic maintenance and
lubrication chart.
1. Rear brake light switch
2. Rear brake light switch adjusting nut
E_5JA.book Page 23 Saturday, August 18, 2001 3:52 PM

PERIODIC MAINTENANCE AND MINOR REPAIR
6-38
6
EAU00855
Replacing a turn signal light
bulb or the tail/brake light
bulb 1. Remove the lens by removing the
screws.
2. Remove the defective bulb by
pushing it in and turning it counter-
clockwise.3. Insert a new bulb into the socket,
push it in, and then turn it clock-
wise until it stops.
4. Install the lens by installing the
screws.
EC000108
CAUTION:@ Do not overtighten the screws, oth-
erwise the lens may break. @
EAU01008
Troubleshooting Although Yamaha motorcycles receive
a thorough inspection before shipment
from the factory, trouble may occur dur-
ing operation. Any problem in the fuel,
compression, or ignition systems, for
example, can cause poor starting and
loss of power.
The following troubleshooting chart
represents a quick and easy procedure
for checking these vital systems your-
self. However, should your motorcycle
require any repair, take it to a Yamaha
dealer, whose skilled technicians have
the necessary tools, experience, and
know-how to service the motorcycle
properly.
Use only genuine Yamaha replace-
ment parts. Imitation parts may look
like Yamaha parts, but they are often
inferior, have a shorter service life and
can lead to expensive repair bills.
1. Screw (× 2)
1. Screw (× 3)
E_5JA.book Page 38 Saturday, August 18, 2001 3:52 PM

MOTORCYCLE CARE AND STORAGE
7-2
7


Do not use any harsh chemical
products on plastic parts. Be
sure to avoid using cloths or
sponges which have been in
contact with strong or abrasive
cleaning products, solvent or
thinner, fuel (gasoline), rust re-
movers or inhibitors, brake flu-
id, antifreeze or electrolyte.


Do not use high-pressure wash-
ers or steam-jet cleaners since
they cause water seepage and
deterioration in the following ar-
eas: seals (of wheel and swing-
arm bearings, fork and brakes),
electric components (couplers,
connectors, instruments,
switches and lights), breather
hoses and vents.


For motorcycles equipped with
a windshield: Do not use strong
cleaners or hard sponges as
they will cause dulling or
scratching. Some cleaning
compounds for plastic may
leave scratches on the wind-
shield. Test the product on a
small hidden part of the wind-
shield to make sure that it does
not leave any marks. If the wind-
shield is scratched, use a quali-
ty plastic polishing compound
after washing.
_
After normal useRemove dirt with warm water, a mild
detergent, and a soft, clean sponge,
and then rinse thoroughly with clean
water. Use a toothbrush or bottlebrush
for hard-to-reach areas. Stubborn dirt
and insects will come off more easily if
the area is covered with a wet cloth for
a few minutes before cleaning.
E_5JA.book Page 2 Saturday, August 18, 2001 3:52 PM

SPECIFICATIONS
8-4
8
Headlight typeQuar tz bulb (halogen)
Bulb voltage, wattage × quantity
Headlight 12 V, 60/55 W × 1
Tail/brake light 12 V, 5/21 W × 1
Turn signal lights 12 V, 21 W × 4
Auxiliary light 12 V, 4 W × 1
Meter lighting 14 V, 0.6 W × 4
Neutral indicator light 12 V, 1 W × 1
High beam indicator light 12 V, 1 W × 1
Turn indicator light 12 V, 1 W × 1
Fuel level warning light LED × 1
Engine trouble warning light LED × 1
Fuses
Main fuse 30 A
Ignition fuse 15 A
Signaling system fuse 10 A
Headlight fuse 15 A
Carburetor heater fuse 10 A
Backup fuse (odometer) 5 A
E_5JA.book Page 4 Saturday, August 18, 2001 3:52 PM