Yamaha Road Star XV1600AT 2004 Owner'S Manual Download Page 51 | Manualshive

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PERIODIC MAINTENANCE AND MINOR REPAIR

6-13

6

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 in-

stalling 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.

EAU21280

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 ser-
viced by the owner as part of routine
maintenance.

CAUTION:

ECA10550

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.

1. Hose

U5JA26E0.book Page 13 Tuesday, May 18, 2004 3:32 PM

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Summary of Contents for Road Star XV1600AT 2004

Page 1: ...PRINTED ON RECYCLED PAPER YAMAHA MOTOR CO LTD PRINTED IN JAPAN 2004 05 0 3 1 CR E 5JA 28199 26 XV1600AT OWNER S MANUAL ProCarManuals com ...

Page 2: ...U5JA26E0 book Page 2 Tuesday May 18 2004 3 32 PM ProCarManuals com ...

Page 3: ...y all advantages of your XV1600A The owner s manual does not only instruct you in how to operate inspect and maintain your motorcycle but also in how to safeguard yourself and others from trouble and injury In addition the many tips given in this manual will help keep your motorcycle in the best possible condition If you have any further questions do not hesitate to contact your Yamaha dealer The ...

Page 4: ...torcycle and this manual If you have any questions concerning this manual please consult your Yamaha dealer WARNING EWA10030 PLEASE READ THIS MANUAL CAREFULLY AND COMPLETELY BEFORE OPERATING THIS MOTORCYCLE The Safety Alert Symbol means ATTENTION BECOME ALERT YOUR SAFETY IS INVOLVED Failure to follow WARNING instructions could result in severe injury or death to the motorcycle operator a bystander...

Page 5: ...004 by Yamaha Motor Co Ltd 1st edition May 2004 All rights reserved Any reprinting or unauthorized use without the written permission of Yamaha Motor Co Ltd is expressly prohibited Printed in Japan U5JA26E0 book Page 2 Tuesday May 18 2004 3 32 PM ProCarManuals com ...

Page 6: ...IR 6 1 Owner s tool kit 6 1 Periodic maintenance and lubrication chart 6 2 Removing and installing the panel 6 6 Checking the spark plugs 6 6 Engine oil and oil filter cartridge 6 7 Transfer case oil 6 10 Cleaning the air filter element 6 12 Adjusting the carburetor 6 13 Adjusting the engine idling speed 6 14 Adjusting the throttle cable free play 6 14 Adjusting the valve clearance 6 15 Tires 6 15...

Page 7: ... 31 Supporting the motorcycle 6 32 Troubleshooting 6 32 Troubleshooting chart 6 33 MOTORCYCLE CARE AND STORAGE 7 1 Care 7 1 Storage 7 3 SPECIFICATIONS 8 1 CONSUMER INFORMATION 9 1 Identification numbers 9 1 Motorcycle noise regulation for Australia 9 2 U5JA26E0 book Page 2 Tuesday May 18 2004 3 32 PM ProCarManuals com ...

Page 8: ... been caused by an automobile driver who did not see the motorcycle Making yourself conspicuous appears to be very effective in reducing the chance of this type of accident Therefore Wear a brightly colored jacket Use extra caution when ap proaching and passing through intersections since intersec tions are the most likely places for motorcycle accidents to oc cur Ride where other motorists can se...

Page 9: ...d or goggles Wind in your unprotected eyes could contribute to an impairment of vision which could delay seeing a hazard The use of a jacket heavy boots trousers gloves etc is effective in preventing or reducing abrasions or lacerations Never wear loose fitting clothes otherwise they could catch on the control levers footrests or wheels and cause injury or an accident Never touch the engine or exh...

Page 10: ...eme caution when selecting and installing any ac cessories Keep the following guidelines in mind as well as those provided under Load ing when mounting accessories Never install accessories or carry cargo that would impair the perfor mance of your motorcycle Care fully inspect the accessory before using it to make sure that it does not in any way reduce ground clearance or cornering clearance limi...

Page 11: ...re leaving the motorcycle unattended and remove the key from the main switch When parking the motor cycle note the following The engine and exhaust system may be hot therefore park the motorcycle in a place where pe destrians or children are not like ly to touch these hot areas Do not park the motorcycle on a slope or soft ground otherwise it may fall over Do not park the motorcycle near a flammab...

Page 12: ...this vehicle read the owner s manual Prima di usare il veicolo leggete il manuale di istruzioni Lire le manuel du propriétaire avant d utiliser ce véhicule Lesen Sie die Bedienungsanleitung bevor Sie dieses Fahrzeug fahren Antes de conducir este vehículo lea el Manual del Propietario 5PA 21568 00 2 3 U5JA26E0 book Page 5 Tuesday May 18 2004 3 32 PM ProCarManuals com ...

Page 13: ...SAFETY INFORMATION 1 6 1 2 3 U5JA26E0 book Page 6 Tuesday May 18 2004 3 32 PM ProCarManuals com ...

Page 14: ...ob page 3 9 3 Fuel cock page 3 8 4 Rider seat page 3 10 5 Battery page 6 27 6 Owner s tool kit page 6 1 7 Helmet holder page 3 11 8 Rear turn signal light page 6 31 9 Tail brake light page 6 31 10 Fuses page 6 29 U5JA26E0 book Page 1 Tuesday May 18 2004 3 32 PM ProCarManuals com ...

Page 15: ... cap page 3 7 5 Headlight page 6 30 6 Front turn signal light page 6 31 7 Throttle stop screw page 6 14 8 Brake pedal page 3 6 9 Rider footrest 10 Air filter element page 6 12 11 Shock absorber assembly spring preload adjusting nut page 3 11 12 Muffler U5JA26E0 book Page 2 Tuesday May 18 2004 3 32 PM ProCarManuals com ...

Page 16: ...ver page 3 5 2 Left handlebar switches page 3 4 3 Speedometer unit page 3 2 4 Main switch steering lock page 3 1 5 Right handlebar switches page 3 4 6 Throttle grip page 6 14 7 Brake lever page 3 6 U5JA26E0 book Page 3 Tuesday May 18 2004 3 32 PM ProCarManuals com ...

Page 17: ...ng 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 WARNING EWA10060 Never turn the key to OFF or LOCK while the vehicle ...

Page 18: ...ight This warning light comes on or flashes when an electrical circuit monitoring the engine is defective When this occurs have a Yamaha dealer check the self diagnosis system EAU11701 Speedometer unit The speedometer unit is equipped with a speedometer an odometer and two tripmeters The speedometer shows riding speed The odometer shows the total distance traveled The tripmeters show the distance ...

Page 19: ...is model is equipped with a self diag nosis 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 vehicle CAUTION ECA10040 When the tachometer displays an er ror code the vehicle should be checked as soon as possible in or der to avoid engi...

Page 20: ...ill flash 4 Push the right button to change the 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 EAU12343 Handlebar switches Left Right 1 Clock 2 Set button 3 Mode button 1 Pass switch 2 Dimmer switch 3 Turn sign...

Page 21: ...arting the engine Set this switch to to stop the engine in case of an emergen cy such as when the vehicle overturns or when the throttle cable is stuck EAU12710 Start switch Push this switch to crank the engine with the starter CAUTION ECA10050 See page 5 1 for starting instruc tions prior to starting the engine EAU12820 Clutch lever The clutch lever is located at the left handlebar grip To diseng...

Page 22: ...orcycle NOTE Use your toes or heel to shift up and your toes to shift down EAU12890 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 EAU12941 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 U5JA26E0 b...

Page 23: ... 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 WARNING EWA10130 Make sure that the fuel tank cap is properly installed before riding EAU13210 Fuel Make sure that there is sufficient fuel in the tank Fill the fuel tank to the bottom of the filler tube as shown WARNING EWA10880 Do n...

Page 24: ...or higher If knocking or pinging oc curs use a gasoline of a different brand or premium unleaded fuel Use of un leaded fuel will extend spark plug life and reduce maintenance costs EAU13560 Fuel cock The fuel cock supplies fuel from the tank to the carburetor while filtering it al so The fuel cock has three positions OFF With the lever in this position fuel will not flow Always return the lever to...

Page 25: ...e tank at the first oppor tunity Be sure to set the lever back to ON after refueling EAU13600 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 1 Pointed end positioned over ON 1 Pointed end positioned over RES U5JA26...

Page 26: ...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 motorcycle ...

Page 27: ... the hel met holder Remove the rider seat remove the hel met from the helmet holder and then install the seat EAU14811 Adjusting the shock absorber assembly This shock absorber assembly is equipped with a spring preload adjust ing nut CAUTION ECA10100 Never attempt to turn an adjusting mechanism beyond the maximum or minimum settings Adjust the spring preload as follows 1 Loosen the locknut 2 To i...

Page 28: ... handling read and understand the following information before handling the shock absorber 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 pressu...

Page 29: ...rcuit cut off system WARNING EWA10240 The vehicle must not be ridden with the sidestand down or if the side stand cannot be properly moved up or does not stay up otherwise the sidestand could contact the ground and distract the operator resulting in a possible loss of control Yamaha s ignition circuit cut off system has been designed to assist the operator in fulfilling the respon sibility of rais...

Page 30: ...h lever is not pulled It prevents starting when the trans mission is in gear and the clutch le ver is pulled but the sidestand is still down It cuts the running engine when the transmission is in gear and the sid estand is moved down Periodically check the operation of the ignition circuit cut off system according to the following procedure WARNING EWA10250 If a malfunction is noted have a Yamaha ...

Page 31: ...ngine has stalled 10 Move the sidestand up 11 Keep the clutch lever pulled 12 Push the start switch Does the engine start The system is OK The motorcycle can be ridden This check is most reliable if performed with a warmed up engine The neutral switch may be defective The motorcycle should not be ridden until checked by a Yamaha dealer The sidestand switch may be defective The motorcycle should no...

Page 32: ...Therefore it is very important in addition to a thorough visual inspec tion to check the following points before each ride NOTE Pre operation checks should be made each time the vehicle 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 WARNING EWA11150 If any item in the Pre operation check list is not working p...

Page 33: ...play Adjust if necessary Check brake pads for wear Replace if necessary Check fluid level in reservoir If necessary add recommended brake fluid to specified level Check hydraulic system for leakage 6 18 6 19 6 20 Rear brake Check operation If soft or spongy have Yamaha dealer bleed hydraulic system Check brake pads for wear Replace if necessary Check fluid level in reservoir If necessary add recom...

Page 34: ...ion is smooth Lubricate pedal pivoting points if necessary 6 24 Brake and clutch levers Make sure that operation is smooth Lubricate lever pivoting points if necessary 6 25 Sidestand Make sure that operation is smooth Lubricate pivot if necessary 6 25 Chassis fasteners Make sure that all nuts bolts and screws are properly tightened Tighten if necessary Instruments lights signals and switches Check...

Page 35: ... position The transmission is in gear with the clutch lever pulled and the sid estand up WARNING EWA10290 Before starting the engine check the function of the igni tion circuit cut off system ac cording to the procedure described on page 3 14 Never ride with the sidestand down 1 Turn the fuel cock lever to ON 2 Turn the key to ON and make sure that the engine stop switch is set to 3 Shift the tran...

Page 36: ...same procedure as for start ing a cold engine with the exception that the starter choke is not required when the engine is warm EAU16671 Shifting Shifting gears lets you control the amount of engine power available for starting off accelerating climbing hills etc The gear positions are shown in the il lustration NOTE To shift the transmission into the neu tral position press the shift pedal down r...

Page 37: ...tion Do not rev the engine while shifting down and avoid high engine speeds with no load on the engine Turn the engine off instead of let ting it idle for an extended length of time e g in traffic jams at traffic lights or at railroad crossings EAU16841 Engine break in There is never a more important period in the life of your engine than the period between 0 and 1600 km 1000 mi For this reason yo...

Page 38: ...uld occur during the engine break in period immediately have a Yamaha dealer check the vehicle EAU17170 Parking When parking stop the engine remove the key from the main switch and then turn the fuel cock lever to OFF WARNING EWA10310 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...

Page 39: ...amiliar with mainte nance work have a Yamaha dealer do it for you EAU17360 Owner s tool kit The owner s tool kit is located under the rider seat See page 3 10 The service information included in this manual and the tools provided in the owner s tool kit are intended to assist you in the performance of preventive maintenance and minor repairs How ever additional tools such as a torque wrench may be...

Page 40: ...MAINTENANCE JOB ODOMETER READING 1000 km ANNUAL CHECK 1 10 20 30 40 1 Fuel line Check fuel hoses for cracks or damage 2 Fuel filter Check condition 3 Spark plugs Check condition Clean and regap Replace 4 Valves Check valve clearance Adjust Every 20000 km 5 Air filter element Clean Replace 6 Clutch Check operation Adjust 7 Front brake Check operation fluid level and vehicle for fluid leakage Replac...

Page 41: ... is properly aligned Every 4000 km 15 Steering bearings Check bearing play and steering for roughness Lubricate with lithium soap based grease Every 50000 km 16 Chassis fasteners Make sure that all nuts bolts and screws are properly tightened 17 Sidestand Check operation Lubricate 18 Sidestand switch Check operation 19 Front fork Check operation and for oil leakage 20 Shock absorber assem bly Chec...

Page 42: ...car tridge Replace 25 Transfer case oil Check oil level Change 26 Front and rear brake switches Check operation 27 Moving parts and ca bles Lubricate 28 Throttle grip housing and cable Check operation and free play Adjust the throttle cable free play if necessary Lubricate the throttle grip housing and cable 29 Mufflers and exhaust pipes Check the screw clamps for looseness 30 Lights signals and s...

Page 43: ...ry 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 U5JA26E0 book Page 5 Tuesday May 18 2004 3 32 PM ProCarManuals com ...

Page 44: ... cause any spark plug to slowly erode they should be removed and checked in accordance with the periodic mainte nance and lubrication chart In addition the condition of the spark plugs can re veal the condition of the engine The porcelain insulator around the cen ter electrode of each spark plug should be a medium to light tan the ideal color when the vehicle is ridden normally and all spark plugs...

Page 45: ... 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 vehicle on a level sur face and hold it in an upright posi tion NOTE Make sure that the vehicle is positioned straight up when checking the oil level A slight tilt to the side can result in a false reading 2...

Page 46: ...ect 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 CAUTION ECA10900 Make sure that the oil filler cap is se curely tightened otherwise oil may seep out when the engine is run ning To change the...

Page 47: ...o the specified torque with a torque wrench 9 Install the engine oil drain bolts and then tighten them to the spec ified torque 10 Pour only 2 5 L 2 6 US qt 2 2 Imp qt 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 ...

Page 48: ... must be checked for oil leakage before each ride If any leakage is found have a Yamaha deal er check and repair the vehicle In addi tion the transfer case oil level should be checked and 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 vehicle on a level sur face and hold it in an upright posi tio...

Page 49: ...emove the oil filler cap add the specified amount of the recom mended transfer case oil and then install and tighten the oil filler cap CAUTION ECA10870 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 en gine off and check for the cause 1 Transf...

Page 50: ...hen 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 dis connect the hose shown 6 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 repl...

Page 51: ...sting 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 ser viced by the owner as part of routine maintenance CAUTION ECA10550 The carburetor...

Page 52: ... 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 en gine idling speed turn the screw in direction b NOTE If the specified idling speed cannot be obtained as described above have a Yamaha dealer make the adjustment EAU21380 Adjusting the throttle cable free play The throttle cable free play s...

Page 53: ...ire air pressure must be ad justed in accordance with the riding speed and with the total weight of rider passenger car go and accessories approved for this model WARNING EWA10510 Proper loading of your vehicle is im portant for several characteristics of your vehicle such as handling braking performance and safety Do not carry loosely packed items that can shift Securely pack your heavi est items...

Page 54: ...ut tire When a tire tread begins to show crosswise lines have a Yamaha dealer replace the tire immediately 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...

Page 55: ...ened tire life Ride at moderate speeds after changing a tire since the tire sur face must first be broken in for it to develop its optimal characteris tics EAU22041 Adjusting the clutch lever free play The clutch lever free play should mea sure 10 0 15 0 mm 0 39 0 59 in as shown Periodically check the clutch le ver free play and if necessary adjust it as follows 1 Loosen the locknut at the clutch ...

Page 56: ...ction b 6 Tighten the locknut at the clutch le ver and the crankcase EAU22092 Adjusting the brake lever free play The brake lever free play should mea sure 2 0 5 0 mm 0 08 0 20 in as shown Periodically check the brake le ver 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 screw in di rection a To de...

Page 57: ...cessary 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 EAU22390 Checking the front and rear brake pads The front and rear brake pads must be checked for wear at the intervals spe...

Page 58: ... to become ineffective Before riding check that the brake fluid is above the minimum level mark and replenish if necessary A low brake fluid level may indicate worn brake pads and or brake system leakage If the brake fluid level is low be sure to check the brake pads for wear and the brake system for leakage Observe these precautions When checking the fluid level make sure that the top of the brak...

Page 59: ...he NOTE after the periodic mainte nance and lubrication chart In addition have the oil seals of the master cylin ders and calipers as well as the brake hoses replaced at the intervals listed below or whenever they are damaged or leaking Oil seals Replace every two years Brake hoses Replace every four years EAU23040 Drive belt slack The drive belt slack should be checked and adjusted at the interva...

Page 60: ...lt slack is incorrect adjust it as follows EAU23070 To adjust the drive belt slack 1 Loosen the rear wheel axle nut and the brake caliper bracket bolt 2 Loosen the drive belt puller locknut on each side of the swingarm 3 To tighten the drive belt turn the adjusting bolt on each side of the swingarm in direction a To loos en the drive belt turn the adjusting 1 Drive belt 2 Marks 3 Drive belt slack ...

Page 61: ...ll control cables and the condition of the cables should be checked before each ride and the ca bles and cable ends should be lubricat ed if necessary If a cable is damaged or does not move smoothly have a Yamaha dealer check or replace it WARNING EWA10720 Damage to the outer sheath may in terfere with proper cable operation and will cause the inner cable to rust Replace a damaged cable as soon as...

Page 62: ...bricated or replaced at the intervals specified in the periodic maintenance chart EAU23131 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 Recommended lubricant Lithium soap based grease all pur pose grease U5JA26E0 book Page 24 Tuesday May 18 2004 3 32 PM ProC...

Page 63: ...ricating the 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 WARNING EWA10730 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 pur pose grease Recommended lubricant Lithium soap based...

Page 64: ... if the front fork compresses and rebounds smoothly CAUTION ECA10590 If any damage is found or the front fork does not operate smoothly have a Yamaha dealer check or re pair it EAU23280 Checking the steering Worn or loose steering bearings may cause danger Therefore the operation of the steering must be checked as fol lows at the intervals specified in the pe riodic maintenance and lubrication cha...

Page 65: ...smoothly have a Yamaha dealer check the wheel bearings EAU23370 Battery This model is equipped with a sealed type MF battery which does not re quire any maintenance There is no need to check the electrolyte or to add distilled water CAUTION ECA10620 Never attempt to remove the battery cell seals as this would permanent ly damage the battery 1 Battery 2 Negative battery terminal 3 Positive battery ...

Page 66: ...ossible if it seems to have discharged Keep in mind that the battery tends to discharge more quickly if the vehicle is equipped with optional electrical accessories To store the battery 1 If the vehicle will not be used for more than one month remove the battery fully charge it and then place it in a cool dry place 2 If the battery will be stored for more than two months check it at least once a m...

Page 67: ...recommended to avoid causing extensive damage to the electrical system and possibly a fire 3 Turn the key to ON and turn on the electrical circuit in question to check if the device operates 4 If the fuse immediately blows again have a Yamaha dealer check the electrical system 1 Screw 1 Signaling system fuse 2 Ignition fuse 3 Headlight fuse 4 Carburetor heater fuse 5 Backup fuse for odometer 6 Spa...

Page 68: ...able products away from a lit headlight bulb and do not touch the bulb until it has cooled down 4 Place a new headlight bulb into po sition and then secure it with the bulb holder CAUTION ECA10660 Do not touch 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 clea...

Page 69: ... 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 CAUTION ECA10680 Do not overtighten the screws oth erwise the lens may break 1 Do not touch the glass part of the bulb 1 Scr...

Page 70: ...orcycle stand or if a motor cycle stand is not available by placing a jack either under each side of the frame in front of the rear wheel or under each side of the swingarm EAU25850 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 cau...

Page 71: ...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 72: ...eave the cleaner on the af fected area any longer than in structed Also thoroughly rinse the area off with water immedi ately dry it and then apply a cor rosion protection spray Improper cleaning can damage windshields cowlings panels and other plastic parts Use only a soft clean cloth or sponge with mild detergent and water to clean plastic Do not use any harsh chemical products on plastic parts ...

Page 73: ... 1 Dry the motorcycle with a chamois or an absorbing cloth 2 Use a chrome polish to shine chrome aluminum and stainless steel parts including the exhaust system Even the thermally 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 ...

Page 74: ...ion of this chapter 2 For motorcycles equipped with a fuel cock that has an OFF posi tion Turn the fuel cock lever to OFF 3 Drain the carburetor float cham bers by loosening the drain bolts this will prevent fuel deposits from building up Pour the drained fuel into the fuel tank 4 Fill up the fuel tank and add fuel stabilizer if available to prevent the fuel tank from rusting and the fuel from det...

Page 75: ...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 muffler outlets with plas tic bags to prevent moisture from entering them 9 Remove the battery and fully charge it Store it in a cool dry place and charge it once a month Do not store the battery in an ex cessively cold or warm place less than 0 C 30 F or ...

Page 76: ...Imp qt With oil filter cartridge replacement 4 10 L 4 33 US qt 3 61 Imp qt Transfer gear oil Type SAE80 API GL 4 Hypoid gear oil Quantity 0 40 L 0 42 US qt 0 35 Imp qt Air filter Air filter element Dry element Fuel Recommended fuel Unleaded gasoline only Fuel tank capacity 20 0 L 5 28 US gal 4 40 Imp gal Fuel reserve amount 3 5 L 0 92 US gal 0 77 Imp gal Carburetor Manufacturer MIKUNI Type x quant...

Page 77: ... kgf cm Loading condition 90 196 kg 198 432 lb Front 250 kPa 36 psi 2 50 kgf cm Rear 280 kPa 41 psi 2 80 kgf cm Front wheel Wheel type Spoke wheel Rim size 16M C x MT3 00 Rear wheel Wheel type Spoke wheel Rim size 16M C x MT3 50 Front brake Type Dual disc brake Operation Right hand operation Recommended fluid DOT 4 Rear brake Type Single disc brake Operation Right foot operation Recommended fluid ...

Page 78: ...light 12 V 21 0 W 2 Meter lighting 14 V 0 6 W 4 Neutral indicator light 12 V 1 0 W 1 High beam indicator light 12 V 1 0 W 1 Turn signal indicator light 12 V 1 0 W 1 Fuel level warning light LED Engine trouble warning light LED Fuses Main fuse 30 0 A Headlight fuse 15 0 A Signaling system fuse 10 0 A Ignition fuse 15 0 A Carburetor heater fuse 10 0 A Backup fuse 5 0 A U5JA26E0 book Page 3 Tuesday M...

Page 79: ...ion 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 EAU26400 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 motorcycle and may be u...

Page 80: ...HIBITED 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 vehicle after such device or e...

Page 81: ...t cut off system 3 14 Indicator and warning lights 3 2 K Key identification number 9 1 L Labels location of 1 5 M Main switch steering lock 3 1 Model label 9 2 N Neutral indicator light 3 2 Noise regulation for Australia 9 2 P Panel removing and installing 6 6 Parking 5 4 Part locations 2 1 Pass switch 3 5 Periodic maintenance and lubrication chart 6 2 Pre operation check list 4 2 R Rear brake lig...

Page 82: ...DEX Turn signal switch 3 5 V Valve clearance adjusting 6 15 Vehicle identification number 9 1 W Wheel bearings checking 6 27 Wheels 6 17 U5JA26E0 book Page 2 Tuesday May 18 2004 3 32 PM ProCarManuals com ...

Page 83: ...U5JA26E0 book Page 3 Tuesday May 18 2004 3 32 PM ProCarManuals com ...

Page 84: ...PRINTED ON RECYCLED PAPER YAMAHA MOTOR CO LTD PRINTED IN JAPAN 2004 05 0 3 1 CR E 5JA 28199 26 XV1600AT OWNER S MANUAL ProCarManuals com ...

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