Yamaha Road Star XV1600A 2000 Owner'S Manual Download Page 68 | Manualshive

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PERIODIC MAINTENANCE AND MINOR REPAIR

6-20

6

EAU00696

Adjusting the brake lever free
play

The brake lever free play should mea-
sure 2–5 mm as shown. Periodically
check the brake lever free play and, if
necessary, adjust it as follows.

1. Loosen the locknut at the brake le-

ver.

2. To increase the brake lever free

play, turn the adjusting bolt in di-
rection

a

. To decrease the brake

lever free play, turn the adjusting
bolt in direction

b

.

3. Tighten the locknut.

EW000099

WARNING

@

●

After adjusting the brake lever
free play, check the free play
and make sure that the brake is
working properly.

●

A soft or spongy feeling in the
brake lever can indicate the
presence of air in the hydraulic
system. If there is air in the hy-
draulic system, have a Yamaha
dealer bleed the system before
operating the motorcycle. Air in
the hydraulic system will dimin-
ish the braking performance,
which may result in loss of con-
trol and an accident.

@

1. Locknut
2. Adjusting bolt
c. Brake lever free play

E_5ja.book Page 20 Thursday, August 24, 2000 8:53 AM

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Summary of Contents for Road Star XV1600A 2000

Page 1: ...PRINTED IN JAPAN 2000 3 0 3 1 CR E YAMAHA MOTOR CO LTD 5JA 28199 21 PRINTED ON RECYCLED PAPER XV1600A OWNER S MANUAL ProCarManuals com ...

Page 2: ...s It represents the high degree of craftsmanship and reliability that have made Yamaha a leader in these fields This manual will give you an understanding of the operation inspection and basic maintenance of this motorcycle If you have any questions concerning the operation or maintenance of your motorcycle please consult a Yamaha dealer E_5ja book Page 1 Thursday August 24 2000 8 53 AM ProCarManu...

Page 3: ...n to avoid damage to the motorcycle NOTE A NOTE provides key information to make procedures easier or clearer NOTE This manual should be considered a permanent part of this motorcycle and should remain with it even if the motorcycle is subsequently sold Yamaha continually seeks advancements in product design and quality Therefore while this manual contains the most current product information avai...

Page 4: ...IMPORTANT MANUAL INFORMATION EW000002 WARNING PLEASE READ THIS MANUAL CAREFULLY AND COMPLETELY BEFORE OPERATING THIS MOTORCYCLE E_5ja book Page 2 Thursday August 24 2000 8 53 AM ProCarManuals com ...

Page 5: ...00 by Yamaha Motor Co Ltd 1st Edition March 2000 All rights reserved Any reprinting or unauthorized use without the written permission of Yamaha Motor Co Ltd is expressly prohibited Printed in Japan E_5ja book Page 3 Thursday August 24 2000 8 53 AM ProCarManuals com ...

Page 6: ...ONTROL FUNCTIONS 3 4 PRE OPERATION CHECKS 4 5 OPERATION AND IMPORTANT RIDING POINTS 5 6 PERIODIC MAINTENANCE AND MINOR REPAIR 6 7 MOTORCYCLE CARE AND STORAGE 7 8 SPECIFICATIONS 8 9 CONSUMER INFORMATION 9 INDEX E_5ja book Page 1 Thursday August 24 2000 8 53 AM ProCarManuals com ...

Page 7: ...E_5ja book Page 2 Thursday August 24 2000 8 53 AM ProCarManuals com ...

Page 8: ...N 1 Safe riding 1 1 Protective apparel 1 3 Modifications 1 3 Loading and accessories 1 3 Gasoline and exhaust gas 1 5 Location of important labels 1 7 E_5ja book Page 1 Thursday August 24 2000 8 53 AM ProCarManuals com ...

Page 9: ...L CONDITIONS Safe riding 1 Always make pre operation checks Careful checks may help prevent an accident 2 This motorcycle is designed to carry the operator and a passenger 3 The failure of motorists to detect and recognize motorcycles in traffic is the predominating cause of automobile motorcycle accidents Many accidents have been caused by an automobile driver who did not see the motorcycle Makin...

Page 10: ...fficient lean angle for the speed a Always obey the speed limit and never travel faster than warranted by road and traffic conditions b Always signal before turning or changing lanes Make sure that other motorists can see you 6 The posture of the operator and passenger is important for proper control a The operator should keep both hands on the handlebar and both feet on the operator footrests dur...

Page 11: ...come very hot and can cause burns Always wear protective clothing that covers your legs ankles and feet 6 Passengers should also observe the precautions mentioned above Modifications Modifications made to this motorcycle not approved by Yamaha or the removal of original equipment may render the motorcycle unsafe for use and may cause severe personal injury Modifications may also make your motorcyc...

Page 12: ... cargo as sleeping bags duffel bags or tents can create unstable handling or slow steering response Accessories Genuine Yamaha accessories have been specifically designed for use on this motorcycle Since Yamaha cannot test all other accessories that may be available you must personally be responsible for the proper selection installation and use of non Yamaha accessories Use extreme caution when s...

Page 13: ...ore such accessories are not recommended 2 Use caution when adding electrical accessories If electrical accessories exceed the capacity of the motorcycle s electrical system an electric failure could result which could cause a dangerous loss of lights or engine power Gasoline and exhaust gas 1 GASOLINE IS HIGHLY FLAMMABLE a Always turn the engine off when refueling b Take care not to spill any gas...

Page 14: ...n transporting the motorcycle in another vehicle make sure that it is kept upright and that the fuel cock is turned either to ON or to RES for vacuum fuel cocks or OFF for manual fuel cocks If it should lean over gasoline may leak out of the carburetor or fuel tank 5 If you should swallow any gasoline inhale a lot of gasoline vapor or allow gasoline to get into your eyes see your doctor immediatel...

Page 15: ...bels Please read the following important labels carefully before operating this motorcycle WARNING Before you operate this vehicle read the owner s manual English 3HP 21568 00 4AA 22259 40 1 2 E_5ja book Page 7 Thursday August 24 2000 8 53 AM ProCarManuals com ...

Page 16: ...DESCRIPTION 2 Left view 2 1 Right view 2 2 Controls and instruments 2 3 E_5ja book Page 1 Thursday August 24 2000 8 53 AM ProCarManuals com ...

Page 17: ...r choke knob page 3 10 3 Fuel cock page 3 9 4 Rider seat page 3 11 5 Owner s tool kit page 6 1 6 Helmet holder page 3 12 7 Rear turn signal lights page 6 34 8 Tail brake light page 6 34 9 Fuses page 6 31 E_5ja book Page 1 Thursday August 24 2000 8 53 AM ProCarManuals com ...

Page 18: ...el tank cap page 3 8 14 Headlight page 6 32 15 Front turn signal lights page 6 34 16 Throttle stop screw page 6 16 17 Brake pedal page 3 7 18 Rider footrest 19 Rear shock absorber spring preload adjusting nut page 3 13 20 Mufflers E_5ja book Page 2 Thursday August 24 2000 8 53 AM ProCarManuals com ...

Page 19: ...age 3 6 2 Left handlebar switches page 3 5 3 Speedometer unit page 3 3 4 Main switch steering lock page 3 1 5 Right handlebar switches page 3 6 6 Throttle grip page 6 16 7 Brake lever page 3 7 E_5ja book Page 3 Thursday August 24 2000 8 53 AM ProCarManuals com ...

Page 20: ...switches 3 5 Clutch lever 3 6 Shift pedal 3 7 Brake lever 3 7 Brake pedal 3 7 Fuel tank cap 3 8 Fuel 3 9 Fuel cock 3 9 Starter choke knob 3 10 Locking the steering with a padlock 3 11 Rider seat 3 11 Helmet holder 3 12 Adjusting the shock absorber assembly 3 13 Sidestand 3 15 Ignition circuit cut off system 3 15 E_5ja book Page 1 Thursday August 24 2000 8 53 AM ProCarManuals com ...

Page 21: ... steering is locked and all electrical systems are off The key can be re moved To lock the steering 1 Turn the handlebars all the way to the left 2 Push the key in from the OFF po sition and then turn it to LOCK while still pushing it 3 Remove the key To unlock the steering Push the key in and then turn it to OFF while still pushing it EW000016 WARNING Never turn the key to OFF or LOCK while the m...

Page 22: ... high beam of the headlight is switched on EAU00057 Turn signal indicator light This indicator light flashes when the turn signal switch is pushed to the left or right EAU00061 Neutral indicator light This indicator light comes on when the transmission is in the neutral position EAU00091 Engine trouble warning light This warning light comes on or flashes when an electrical circuit monitoring the e...

Page 23: ...ng order CB 27E To reset a tripmeter select it by push ing the mode button left and then hold down the set button right for at least one second The tripmeters can be used to estimate the distance that can be traveled with a full tank of fuel This information will enable you to plan future fuel stops NOTE This motorcycle is not equipped with a tachometer however it has a built in engine speed limit...

Page 24: ...is device This model is equipped with a self di agnosis device for various electrical cir cuits If any of those circuits are defective the engine trouble warning light will come on or the fuel level warning light will flash If this occurs have a Yamaha dealer check the motorcycle ECA00061 CAUTION To prevent engine damage be sure to consult a Yamaha dealer as soon as possible if this occurs EAU0173...

Page 25: ...e hours 5 Push the left button and only the minute display will flash 6 Push the right button to change the minutes 7 Push the left button and both the hours and minutes will flash 8 Push the right button for two sec onds to set the clock EAU00118 Handlebar switches EAU00119 1 Pass switch Press this switch to flash the headlight EAU00121 2 Dimmer switch Set this switch to for the high beam and to ...

Page 26: ...n the throttle cable is stuck EAU00143 2 Start switch Push this switch to crank the engine with the starter EC000005 CAUTION See page 5 1 for starting instruc tions prior to starting the engine EAU00152 Clutch lever The clutch lever is located at the left handlebar grip To disengage the clutch pull the lever toward the handle bar grip To engage the clutch release the lever The lever should be pull...

Page 27: ...orcycle NOTE Use your toes or heel to shift up and your toes to shift down EAU00158 Brake lever The brake lever is located at the right handlebar grip To apply the front brake pull the lever toward the handle bar grip EAU00162 Brake pedal The brake pedal is on the right side of the motorcycle To apply the rear brake press down on the brake pedal 1 Shift pedal 1 Brake lever 1 Brake pedal E_5ja book...

Page 28: ...p into the tank opening with the key inserted in the lock and with the mark facing forward 2 Turn the key counterclockwise to the original position remove it and then close the lock cover NOTE The fuel tank cap cannot be installed unless the key is in the lock In addition the key cannot be removed if the cap is not properly installed and locked EW000024 WARNING Make sure that the fuel tank cap is ...

Page 29: ...lean dry soft cloth since fuel may deteriorate painted surfac es or plastic parts EAU00192 EAU03050 Fuel cock The fuel cock supplies fuel from the tank to the carburetor while filtering it also The fuel cock has three positions OFF With the lever in this position fuel will not flow Always return the lever to this position when the engine is not run ning 1 Filler tube 2 Fuel level Recommended fuel ...

Page 30: ...ition Fill the tank at the first oppor tunity Be sure to set the lever back to ON after refueling EAU03032 Starter choke knob Starting a cold engine requires a richer air fuel mixture which is supplied by the starter choke Move the knob in direction a to turn on the starter choke Move the knob in direction b to turn off the starter choke ON normal position RES reserve position E_5ja book Page 10 T...

Page 31: ...remove the rider seat 1 Insert the key into the main switch and then turn it counterclockwise to OPEN NOTE Do not push inward when turning the key 2 Pull the rider seat off To install the rider seat 1 Insert the projection on the rear of the rider seat into the seat holder as shown and then push the front of the seat down to lock it in place 2 Remove the key from the main switch if the scooter wil...

Page 32: ...ttach the helmet to the helmet holder and then securely install the seat EW000030 WARNING Never ride with a helmet attached to the helmet holder since the helmet may hit objects causing loss of control and possibly an accident To release the helmet from the hel met holder Remove the rider seat remove the hel met from the helmet holder and then install the seat 1 Helmet holder E_5ja book Page 12 Th...

Page 33: ...n sion turn the adjusting nut in di rection a To decrease the spring preload and thereby soften the suspension turn the adjusting nut in direction b NOTE The spring preload setting is deter mined by measuring distance A shown in the illustration The shorter distance A is the higher the spring preload the longer distance A is the lower the spring preload 1 Locknut 2 Adjusting nut 1 Special wrench A...

Page 34: ...bsorber The manufacturer cannot be held re sponsible for property damage or personal injury that may result from improper handling Do not tamper with or attempt to open the gas cylinder Do not subject the shock ab sorber to an open flame or other high heat sources otherwise it may explode due to excessive gas pressure Do not deform or damage the gas cylinder in any way as this will result in poor ...

Page 35: ... in fulfilling the responsibility of raising the side stand before starting off Therefore check this system regularly as de scribed below and have a Yamaha dealer repair it if it does not function properly EAU00331 Ignition circuit cut off system The ignition circuit cut off system com prising the sidestand switch clutch switch and neutral switch has the fol lowing functions It prevents starting w...

Page 36: ... lever pulled 8 Shift the transmission into gear 9 Move the sidestand down Does the engine stall After the engine has stalled 10 Move the sidestand up 11 Keep the clutch lever pulled 12 Push the start switch Does the engine start The sidestand switch may be defective The motorcycle should not be ridden until checked by a Yamaha dealer The clutch switch may be defective The motorcycle should not be...

Page 37: ...E_5ja book Page 17 Thursday August 24 2000 8 53 AM ProCarManuals com ...

Page 38: ...PRE OPERATION CHECKS 4 Pre operation check list 4 1 E_5ja book Page 1 Thursday August 24 2000 8 53 AM ProCarManuals com ...

Page 39: ...brake fluid if necessary 6 20 6 24 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 19 6 20 Throttle grip and housing Check operation Lubricate if necessary 6 16 Engine oil Check oil level Add oil if necessary 6 8 6 9 Wheels and tires Check tire air pressure for wear an...

Page 40: ...afety 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 Fuel Check fuel level Add fuel if necessary 3 9 Lights signals and switches Check operation ITEM CHECKS PAGE E_5ja book Page 2 Thursday August 24 2000 8 53 AM ProCarManuals com ...

Page 41: ...E_5ja book Page 3 Thursday August 24 2000 8 53 AM ProCarManuals com ...

Page 42: ...G POINTS 5 Starting and warming up a cold engine 5 1 Starting a warm engine 5 3 Shifting 5 3 Tips for reducing fuel consumption 5 4 Engine break in 5 4 Parking 5 5 E_5ja book Page 1 Thursday August 24 2000 8 53 AM ProCarManuals com ...

Page 43: ... out make sure that the sidestand is up If the sidestand is not raised com pletely it could contact the ground and distract the opera tor resulting in a possible loss of control EAU01860 Starting and warming up a cold engine In order for the ignition circuit cut off system to enable starting one of the following conditions must be met The transmission is in the neutral position The transmission is...

Page 44: ...art the engine by pushing the start switch NOTE If the engine fails to start release the start switch wait a few seconds and then try again Each starting attempt should be as short as possible to pre serve the battery Do not crank the en gine more than 10 seconds on any one attempt 6 After starting the engine move the starter choke knob back halfway ECA00045 CAUTION For maximum engine life never a...

Page 45: ...sition press the shift pedal down repeatedly until it reaches the end of its travel and then slightly raise it EC000048 CAUTION Even with the transmission in the neutral position do not coast for long periods of time with the engine off and do not tow the motorcycle for long dis tances The transmission is properly lubricated only when the engine is running Inade quate lubrication may damage the tr...

Page 46: ...For this rea son you should read the following ma terial carefully Since the engine is brand new do 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 that might result in engine overheating must be avoided EAU01740 0 1 000 km Av...

Page 47: ...then turn the fuel cock lever to OFF EW000058 WARNING Since the engine and exhaust system can become very hot park in a place where pedestri ans or children are not likely to touch them Do not park on a slope or on soft ground otherwise the mo torcycle may overturn E_5ja book Page 5 Thursday August 24 2000 8 53 AM ProCarManuals com ...

Page 48: ...lay 6 20 Adjusting the brake pedal position 6 21 Adjusting the rear brake light switch 6 21 Checking the front and rear brake pads 6 22 Checking the brake fluid level 6 23 Changing the brake fluid 6 24 Drive belt slack 6 24 Checking and lubricating the brake and shift pedals 6 26 Checking and lubricating the brake and clutch levers 6 27 Checking and lubricating the sidestand 6 27 Checking the fron...

Page 49: ...PHI CAL LOCATION AND INDIVIDUAL USE THE MAINTENANCE INTER VALS MAY NEED TO BE SHORT ENED EW000060 WARNING If you are not familiar with motor cycle maintenance work have a Yamaha dealer do it for you EAU03394 Owner s tool kit The owner s tool kit is located under the rider seat See page 3 11 for rider seat removal and installation proce dures The service information included in this manual and the ...

Page 50: ...r a particular job have a Yamaha dealer perform it for you EW000063 WARNING Modifications not approved by Yamaha may cause loss of perfor mance and render the vehicle un safe for use Consult a Yamaha dealer before attempting any chang es E_5ja book Page 2 Thursday August 24 2000 8 53 AM ProCarManuals com ...

Page 51: ...Clean or replace if necessary 6 Clutch Check operation Adjust or replace cable 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 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 9 Brake hoses Check for cracks o...

Page 52: ...ten if necessary 17 Sidestand Check operation Lubricate and repair if necessary 18 Sidestand switch Check operation Replace if necessary 19 Front fork Check operation and for oil leakage Correct accordingly 20 Rear shock absorber assembly Check operation and shock absorber for oil leakage Replace shock absorber assembly if necessary 21 Rear suspension relay arm and connecting arm pivoting points C...

Page 53: ... caliper and change the brake fluid Replace the brake hoses every four years and if cracked or damaged 24 Engine oil filter cartridge Replace 25 Transfer case oil Check oil level and vehicle for oil leakage Correct accordingly Change oil at initial 1 000 km and thereafter every 24 000 km or 24 months whichever comes first 26 Front and rear brake switches Check operation Correct accordingly 27 Movi...

Page 54: ...bs described in this chapter Refer to this section each time the pan el needs to be removed and installed EAU00491 Panel A To remove the panel Remove the bolt and then pull the pan el off as shown To install the panel Place the panel in the original position and then install the bolt 1 Panel A 1 Bolt E_5ja book Page 6 Thursday August 24 2000 8 53 AM ProCarManuals com ...

Page 55: ... engine could be defec tive Do not attempt to diagnose such problems yourself Instead have a Yamaha dealer check the motorcycle If a spark plug shows signs of electrode erosion and excessive carbon or other deposits it should be replaced Before installing a spark plug the spark plug gap should be measured with a wire thickness gauge and if necessary adjusted to specification Clean the surface of t...

Page 56: ... 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 11 for rider seat removal and in stallation procedures 3 Start the e...

Page 57: ... 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 To change the engine oil with or without oil filter cartridge replace me...

Page 58: ... new oil filter cartridge and then tighten it to the specified torque with a torque wrench 7 Install the engine oil drain bolts and then tighten them to the spec ified torques 8 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 9 Start the engine rev it several times and then turn it off 1 Engine oil dr...

Page 59: ...cause 13 Turn the engine off and then check the oil level and correct it if necessary 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 positi...

Page 60: ... the specified torque 5 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 6 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 chec...

Page 61: ...nt more fre quently if you are riding in unusually wet or dusty areas 1 Remove the air filter case bolts 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 1 Bolt 4 2 Air filter case cover 1 Air filter joint clamp screw 1 Screw 2 2 Hose 2 E_5ja book Page 13 Thursday August 2...

Page 62: ...own 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 8 Install the air filter case cover by installing the screws 9 Connect the hoses 10 Install the air filter by pushing it onto the air filter joint then tighten ing the air filter joint clamp screw 1 Screw 2 2 Hose 1 Hose...

Page 63: ...ne EAU03397 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 occasiona...

Page 64: ... 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 Engine idling speed 850 950...

Page 65: ...d keep the following precautions in mind NEVER OVERLOAD THE MOTORCYCLE Operation of an overloaded motorcycle may re sult in tire damage loss of con trol or severe injury Make sure that the total weight of rider pas senger cargo and accessories does not exceed the specified maximum load for the vehicle Do not carry along loosely packed items which can shift during a ride Securely pack the heaviest ...

Page 66: ...mediately The replacement of all wheel and brake related parts includ ing the tires should be left to a Yamaha dealer who has the necessary professional knowl edge and experience It is not recommended to patch a punctured tube If unavoid able however patch the tube very carefully and replace it as soon as possible with a high quality product 1 Tire tread depth 2 Wear indicators a Sidewall FRONT Ma...

Page 67: ...usting the clutch lever free play The clutch lever free play should mea sure 10 15 mm as shown Periodically check the clutch lever free play and if necessary adjust it as follows 1 Loosen the locknut at the clutch le ver 2 To increase the clutch lever free play turn the adjusting bolt in di rection a To decrease the clutch lever free play turn the adjusting bolt in direction b 3 If the specified c...

Page 68: ...in direction b 3 Tighten the locknut EW000099 WARNING After adjusting the brake lever free play check the free play and make sure that the brake is working properly A soft or spongy feeling in the brake lever can indicate the presence of air in the hydraulic system If there is air in the hy draulic system have a Yamaha dealer bleed the system before operating the motorcycle Air in the hydraulic sy...

Page 69: ...draulic 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 re...

Page 70: ...If a brake pad has worn to the point that the wear indicators have almost disappeared have a Yamaha dealer replace the brake pads as a set EAU01198 Rear brake pads Each rear brake pad is provided with a wear indicator groove which allows you to check the brake pad for wear without having to disassemble the brake To check the brake pad wear check the wear indicator groove If a brake pad has worn to...

Page 71: ...ty brake fluid otherwise the rubber seals may deteriorate causing leakage and poor braking perfor mance Refill with the same type of brake fluid Mixing fluids may result in a harmful chemical reaction and lead to poor braking performance Be careful that water does not en ter the master cylinder when refill ing Water will significantly lower the boiling point of the fluid and may result in vapor lo...

Page 72: ...ide and adjusted if neces sary To check the drive belt slack 1 Place the motorcycle on a level surface and hold it in an upright position 2 Note the current position of the drive belt using the marks near the check hole NOTE The marks near the drive belt check hole are 5 mm apart 3 Note the position of the drive belt with a force of 45 N 4 5 kg ap plied to the belt with a belt tension gauge as sho...

Page 73: ...ive belt turn the adjusting bolt on each side of the swingarm in direction a To loos en the drive belt turn the adjusting bolt on each side of the swingarm in direction b and then push the rear wheel forward NOTE Turn each adjusting bolt the same amount for proper wheel alignment 4 Tighten the locknuts 1 Wheel axle nut 1 Caliper bracket bolt 1 Adjusting bolt 2 2 Locknut 2 E_5ja book Page 25 Thursd...

Page 74: ...specified torques EAU03199 Checking and lubricating the brake and shift pedals The operation of the brake and shift pedals should be checked before each ride and the pedal pivots should be lu bricated if necessary Tightening torques Axle nut 150 Nm 15 m kg Brake caliper bracket bolt 48 Nm 4 8 m kg Recommended lubricant Lithium soap based grease all purpose grease E_5ja book Page 26 Thursday August...

Page 75: ... sidestand The operation of the sidestand should be checked before each ride and the sidestand pivot and metal to metal contact surfaces should be lubricated if necessary EW000113 WARNING If the sidestand does not move up and down smoothly have a Yamaha dealer check or repair it Recommended lubricant Lithium soap based grease all purpose grease Recommended lubricant Lithium soap based grease all p...

Page 76: ...e applying the front brake push down hard on the handle bars several times to check if the front fork compresses and re bounds smoothly EC000098 CAUTION If any damage is found or the front fork does not operate smoothly have a Yamaha dealer check or re pair it EAU00794 Checking the steering Worn or loose steering bearings may cause danger Therefore the operation of the steering must be checked as ...

Page 77: ... periodic maintenance and lubrica tion chart If there is play in the wheel hub or if the wheel does not turn smoothly have a Yamaha dealer check the wheel bearings EAU00800 Battery This motorcycle is equipped with a sealed type MF battery which does not require any maintenance There is no need to check the electrolyte or to add distilled water EC000101 CAUTION Never attempt to remove the battery c...

Page 78: ...tilation when charging it in an enclosed space KEEP THIS AND ALL BATTER IES OUT OF THE REACH OF CHILDREN To charge the battery Have a Yamaha dealer charge the bat tery as soon as possible if it seems to have discharged Keep in mind that the battery tends to discharge more quickly if the motorcycle is equipped with op tional electrical accessories To store the battery 1 If the motorcycle will not b...

Page 79: ...The fuse boxes are located behind panel A See page 6 6 for panel re moval and installation procedures If a fuse is blown replace it as follows 1 Turn the key to OFF and turn off the electrical circuit in question 2 Remove the blown fuse and then install a new fuse of the specified amperage 1 Signaling system fuse 2 Ignition fuse 3 Headlight fuse 4 Carburetor heater fuse 5 Odometer fuse 6 Spare fus...

Page 80: ...ce operates 4 If the fuse immediately blows again have a Yamaha dealer check the electrical system EAU03188 Replacing the headlight bulb This motorcycle is equipped with a quartz bulb headlight If the headlight bulb burns out replace it as follows 1 Remove the headlight unit by removing the screws 2 Disconnect the headlight coupler and then remove the headlight unit and bulb cover 1 Screw 2 1 Head...

Page 81: ... the glass part of the headlight bulb to keep it free from oil otherwise the transparency of the glass the luminosity of the bulb and the bulb life will be adversely af fected Thoroughly clean off any dirt and fingerprints on the headlight bulb using a cloth moistened with alcohol or thinner 5 Install the bulb cover and then connect the coupler 6 Install the headlight unit by install ing the screw...

Page 82: ...pment 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 ne...

Page 83: ...ve a Yamaha dealer check the vehicle Remove the spark plugs and check the electrodes 3 Ignition Wipe off with a dry cloth and correct the spark plug gaps or replace the spark plugs Have a Yamaha dealer check the vehicle The engine does not start Have a Yamaha dealer check the vehicle The engine does not start Check the battery Operate the electric starter 4 Battery The engine turns over quickly Th...

Page 84: ...MOTORCYCLE CARE AND STORAGE 7 Care 7 1 Storage 7 4 E_5ja book Page 1 Thursday August 24 2000 8 53 AM ProCarManuals com ...

Page 85: ...ical couplers and connectors including the spark plug caps are tightly in stalled 3 Remove extremely stubborn dirt like oil burnt onto the crankcase with a degreasing agent and a brush but never apply such prod ucts onto seals gaskets the drive belt and wheel axles Always rinse the dirt and degreaser off with wa ter Cleaning ECA00010 CAUTION Avoid using strong acidic wheel cleaners especially on s...

Page 86: ... 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 use Remove dirt with warm water a mild detergent and a soft clean sponge and then rinse thoroughly with clean water Us...

Page 87: ...in duced discoloring of stainless steel exhaust systems can be re moved through polishing 3 To prevent corrosion it is recom mended to apply a corrosion pro tection spray on all metal including chrome and nickel plat ed surfaces 4 Use spray oil as a universal clean er to remove any remaining dirt 5 Touch up minor paint damage caused by stones etc 6 Wax all painted surfaces 7 Let the motorcycle dry...

Page 88: ... allow water and humid ity to seep in and cause rust To prevent corrosion avoid damp cellars stables because of the presence of ammonia and areas where strong chemi cals are stored Long term Before storing your motorcycle for sev eral months 1 Follow all the instructions in the Care section of this chapter 2 For motorcycles equipped with a fuel cock that has an OFF posi tion Turn the fuel cock lev...

Page 89: ... the engine over 6 Lubricate all control cables and the pivoting points of all levers and pedals as well as of the sidestand centerstand 7 Check and if necessary correct the tire air pressure and then lift the motorcycle so that both of its wheels are off the ground Alterna tively turn the wheels a little every month in order to prevent the tires from becoming degraded in one spot 8 Cover the muff...

Page 90: ...SPECIFICATIONS 8 Specifications 8 1 Conversion table 8 5 E_5ja book Page 1 Thursday August 24 2000 8 53 AM ProCarManuals com ...

Page 91: ...rication system Dry sump Engine oil Type Recommended engine oil classification API Service SE SF SG type or higher Quantity Without oil filter cartridge replacement 3 7 L With oil filter cartridge 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 40 SAE 20W 40 SAE 20W 50 SAE 10W 40 CAUTION Be sure to use motor oils that do not contain anti friction modifie...

Page 92: ...sc Transmission Primary reduction system Spur gear Primary reduction ratio 1 532 Secondary reduction system Belt drive Secondary reduction ratio 2 320 Transmission type Constant mesh 5 speed Operation Left foot Gear ratio 1st 2 438 2nd 1 579 3rd 1 160 4th 0 906 5th 0 750 Chassis Frame type Double cradle Caster angle 32 Trail 142 mm Tires Front Type With tube Size 130 90 16 67H Manufacturer model D...

Page 93: ...el Size 16 MT 3 50 Brakes Front Type Dual disc brake Operation Right hand Fluid DOT 4 Rear Type Single disc brake Operation Right foot Fluid DOT 4 Suspension Front Type Telescopic fork Rear Type Swingarm link suspension Spring shock absorber Front Coil spring oil damper Rear Coil spring gas oil damper Wheel travel Front 140 mm Rear 110 mm Electrical Ignition system T C I digital Charging system Ty...

Page 94: ...21 W 2 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 signal indicator light 12 V 1 W 1 Fuel level warning light LED Engine trouble warning light LED 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 E_5ja book Page 4 Thursday August 24 2000 8 53 AM ProCarMan...

Page 95: ...t Multiplier Imperial unit Torque m kg m kg cm kg cm kg 7 233 86 794 0 0723 0 8679 ft lb in lb ft lb in lb Weight kg g 2 205 0 03527 lb oz Speed km h 0 6214 mi h Distance km m m cm mm 0 6214 3 281 1 094 0 3937 0 03937 mi ft yd in in Volume Capacity cc cm3 cc cm3 L liter L liter 0 03527 0 06102 0 8799 0 2199 oz IMP liq cu in qt IMP liq gal IMP liq Miscellaneous kg mm kg cm2 Centigrade C 55 997 14 2...

Page 96: ...9 Identification numbers 9 1 Key identification number 9 1 Vehicle identification number 9 1 Model label 9 2 Motorcycle noise regulation for Australia 9 2 E_5ja book Page 1 Thursday August 24 2000 8 53 AM ProCarManuals com ...

Page 97: ...41 Key identification number The key identification number is stamped into the key tag Record this number in the space provided and use it for reference when ordering a new key EAU01043 Vehicle identification number The vehicle identification number is stamped into the steering head pipe Record this number in the space pro vided NOTE The vehicle identification number is used to identify your motor...

Page 98: ... NOISE CON TROL SYSTEM PROHIBITED Owners are warned that the law may prohibit a The removal or rendering inopera tive by any person other than for purposes of maintenance repair or replacement of any device or element of design incorporated into any new vehicle for the pur pose of noise control prior to its sale or delivery to the ultimate pur chaser or while it is in use and b The use of the vehi...

Page 99: ...ng 5 4 Fuel gauge 3 4 Fuel tank cap 3 8 Fuses replacing 6 31 H Handlebar switches 3 5 Dimmer switch 3 5 Engine stop switch 3 6 Horn switch 3 6 Pass switch 3 5 Start switch 3 6 Turn signal switch 3 6 Headlight bulb replacing 6 32 Helmet holder 3 12 I Identification numbers 9 1 Ignition circuit cut off system 3 15 Indicator and warning lights 3 2 Engine trouble warning light 3 2 Fuel level warning l...

Page 100: ...cold engine 5 1 Starting a warm engine 5 3 Steering checking 6 28 Steering locking with a padlock 3 11 Storage 7 4 T Throttle cable free play adjusting 6 16 Tires 6 17 Tool kit 6 1 Transfer case oil 6 11 Troubleshooting 6 34 Troubleshooting chart 6 35 Turn signal light bulb or the tail brake light bulb replacing 6 34 V Valve clearance adjusting 6 16 Vehicle identification number 9 1 W Wheel bearin...

Page 101: ...H_5KS_Toc0 fm Page 2 Monday August 21 2000 11 11 AM ProCarManuals com ...

Page 102: ...H_5KS_Toc0 fm Page 2 Monday August 21 2000 11 11 AM ProCarManuals com ...

Page 103: ...PRINTED IN JAPAN 2000 3 0 3 1 CR E YAMAHA MOTOR CO LTD 5JA 28199 21 PRINTED ON RECYCLED PAPER XV1600A OWNER S MANUAL ProCarManuals com ...

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