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Yamaha ROAD STAR XV16A, Owner'S Manual

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PERIODIC MAINTENANCE AND MINOR REPAIR

6-21

6

EAU00694

Adjusting the clutch lever free
play

The clutch lever free play should mea-
sure 0.4–0.6 in (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

lever.

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 clutch lever free

play could be obtained as de-
scribed above, tighten the locknut
and skip the rest of the procedure,
otherwise proceed as follows.

4. Fully turn the adjusting bolt at the

clutch lever in direction

a

to loos-

en the clutch cable.

5. Loosen the locknut at the

crankcase.

6. To increase the clutch lever free

play, turn the adjusting nut in di-
rection

a

. To decrease the clutch

lever free play, turn the adjusting
nut in direction

b

.

7. Tighten the locknut at the clutch

lever and the crankcase.

EAU00696

Adjusting the brake lever free
play

The brake lever free play should mea-
sure 0.08–0.2 in (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

lever.

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

.

1. Locknut
2. Clutch lever free play adjusting bolt
c. Clutch lever free play

1. Clutch lever free play adjusting nut
2. Locknut

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

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Summary of Contents for ROAD STAR XV16A

Page 1: ......

Page 2: ......

Page 3: ...and basic maintenance of this motorcycle If you have any questions concerning the operation or maintenance of your motorcycle please consult a Yamaha dealer The design and manufacture of this Yamaha m...

Page 4: ...al precautions that must be taken 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...

Page 5: ...OTOR CYCLE DO NOT ATTEMPT TO OPERATE THIS MOTORCYCLE UNTIL YOU HAVE AT TAINED ADEQUATE KNOWLEDGE OF ITS CONTROLS AND OPERATING FEATURES AND UNTIL YOU HAVE BEEN TRAINED IN SAFE AND PROPER RIDING TECHNI...

Page 6: ...600AS C XV16ATP C OWNER S MANUAL 2001 by Yamaha Motor Corporation U S A 1st Edition May 2001 All rights reserved Any reprinting or unauthorized use without the written permission of Yamaha Motor Corpo...

Page 7: ...DESCRIPTION 2 3 INSTRUMENT AND CONTROL 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 SPECI...

Page 8: ...SAFETY INFORMATION 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...

Page 9: ...WHEN MADE NECESSARY BY MECHANICAL 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 passe...

Page 10: ...e to EXCESSIVE SPEED or undercornering insuf ficient 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...

Page 11: ...during or after operation They become 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 abov...

Page 12: ...r front fork or front fender These items in cluding such cargo as sleeping bags duffel bags or tents can create unstable handling or slow steering response Accessories Genuine Yamaha accessories have...

Page 13: ...may limit control ability therefore such accessories are not recommended 2 Use caution when adding electrical accessories If electrical accessories exceed the capacity of the motorcycle s electrical...

Page 14: ...pen flame otherwise it could catch fire 4 When transporting the motorcycle in another vehicle make sure that it is kept upright and that the fuel cock is turned to ON or RES for vacuum type OFF for ma...

Page 15: ...SAFETY INFORMATION 1 1 7 EAU02977 Location of important labels Please read the following important labels carefully before operating this motorcycle...

Page 16: ...SAFETY INFORMATION 1 1 8 1 California only XV16AT C 2 3 4 5 6 XV16AT C...

Page 17: ...DESCRIPTION 2 XV16A C XV16AS C Left view 2 1 XV16A C XV16AS C Right view 2 2 XV16AT C Left view 2 3 XV16AT C Right view 2 4 XV16A C XV16AS C XV16AT C Controls and instruments 2 5...

Page 18: ...C Left view 1 Shift pedal page 3 7 2 Starter choke knob page 3 11 3 Fuel cock page 3 10 4 Rider seat page 3 11 5 Owner s tool kit page 6 2 6 Helmet holder page 3 12 7 Rear turn signal lights page 6 35...

Page 19: ...Passenger footrest 11 Passenger seat 12 Fuel tank page 3 9 13 Fuel tank cap page 3 8 14 Headlight page 6 33 15 Front turn signal position lights page 6 35 16 Brake pedal page 3 8 17 Rider footrest 18...

Page 20: ...Shift pedal page 3 7 2 Starter choke knob page 3 11 3 Fuel cock page 3 10 4 Rider seat page 3 11 5 Owner s tool kit page 6 2 6 Helmet holder page 3 12 7 Rear turn signal lights page 6 35 8 Tail brake...

Page 21: ...12 Fuel tank page 3 9 13 Fuel tank cap page 3 8 14 Windshield page 3 13 15 Headlight page 6 33 16 Front turn signal position lights page 6 35 17 Brake pedal page 3 8 18 Rider footrest 19 Shock absorb...

Page 22: ...T C Controls and instruments 1 Clutch lever page 3 7 2 Left handlebar switches page 3 6 3 Speedometer unit page 3 3 4 Main switch steering lock page 3 1 5 Right handlebar switches page 3 6 6 Throttle...

Page 23: ...ndlebar switches 3 6 Clutch lever 3 7 Shift pedal 3 7 Brake lever 3 7 Brake pedal 3 8 Fuel tank cap 3 8 Fuel 3 9 Fuel cock 3 10 Starter choke knob 3 11 Locking the steering with a padlock 3 11 Rider s...

Page 24: ...off The key can be removed EAU00040 LOCK The steering is locked and all electrical systems are off The key can be removed To lock the steering 1 Turn the handlebars all the way to the left 2 Push the...

Page 25: ...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...

Page 26: ...TRIP A and TRIP B in the following 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 u...

Page 27: ...t will flash If this occurs have a Yamaha dealer check the motorcycle EC000004 CAUTION When the tachometer displays an error code the motorcycle should be checked as soon as possible in order to avoid...

Page 28: ...t simulta neously until the hours and min utes flash 3 Push the left button and only the hour display will flash 4 Push the right button to change the hours 5 Push the left button and only the minute...

Page 29: ...e canceled manually by pushing the switch in after it has re turned to the center position NOTE _ The self canceling system only oper ates when the motorcycle is moving so that the turn signal lights...

Page 30: ...tion circuit cut off system See page 3 17 for an explanation of the ig nition circuit cut off system EAU01215 Shift pedal The shift pedal is located on the left side of the engine and is used in com...

Page 31: ...be removed To install the fuel tank cap 1 Insert the fuel tank cap into the tank opening with the key inserted in the lock and with the mark facing forward 2 Turn the key counterclockwise to the orig...

Page 32: ...etc _ Your Yamaha engine has been de signed to use regular unleaded gaso line with a pump octane number R M 2 of 86 or higher or a research octane number of 91 or higher If knocking or pinging occurs...

Page 33: ...engine is not run ning ON With the lever in this position fuel flows to the carburetor Normal riding is done with the lever in this position RES This indicates reserve If you run out of fuel while rid...

Page 34: ...steering with a padlock In addition to the main switch steering lock there are brackets on the right side of the steering head pipe for lock ing the steering with a padlock To do so turn the handleba...

Page 35: ...e helmet holder is located under the rider seat To secure a helmet to the helmet holder 1 Remove the rider seat See page 3 11 for rider seat removal and in stallation procedures 2 Attach the helmet to...

Page 36: ...gle 3 Tighten the bolts to the specified torque To change the windshield height 1 Remove the bolts on each side of the windshield 2 Move the windshield to the other position 3 Install the bolts and ti...

Page 37: ...could result EAU01739 Saddlebags XV16AT C To open Unbuckle the belts and fold up the flap To close Fold the flap down and buckle both belts securely NOTE For saddlebag cleaning and care see page 7 4...

Page 38: ...oosen the locknut 2 To increase the spring preload and thereby harden the suspen sion turn the adjusting nut in di rection a To decrease the spring preload and thereby soften the suspension turn the a...

Page 39: ...roperty 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 s...

Page 40: ...ist the operator 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...

Page 41: ...he sidestand up 7 Keep the clutch 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 clut...

Page 42: ...PRE OPERATION CHECKS 4 Pre operation check list 4 1...

Page 43: ...l in engine If necessary add recommended oil to specified level Check vehicle for oil leakage 6 9 6 12 Front brake Check operation If soft or spongy have Yamaha dealer bleed hydraulic system Check lev...

Page 44: ...ondition and tread depth Check air pressure Correct if necessary 6 18 6 19 Brake and shift pedals Make sure that operation is smooth Lubricate pedal pivoting points if necessary 6 28 Brake and clutch...

Page 45: ...OPERATION AND IMPORTANT RIDING POINTS 5 Starting and warming up a cold engine 5 1 Starting a warm engine 5 3 Shifting 5 3 Engine break in 5 5 Parking 5 6...

Page 46: ...round and distract the opera tor resulting in a possible loss of control EAU00376 CAUTION Make sure not to store personal items near the air cleaner in take otherwise air intake will be blocked and pe...

Page 47: ...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 ECA00055 CAUTION For maximum engine life always...

Page 48: ...the transmission into the neu tral position 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 n...

Page 49: ...rocedure when shifting to the next higher gear NOTE Always shift gears at the recommend ed shift points EAU00427 To decelerate 1 Apply both the front and the rear brakes to slow the motorcycle 2 Shift...

Page 50: ...ear ances During this period prolonged full throttle operation or any condition that might result in engine overheating must be avoided EAU01740 0 600 mi 0 1 000 km Avoid prolonged operation above 1 3...

Page 51: ...the key from the main switch and 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 li...

Page 52: ...free play 6 21 Adjusting the brake lever free play 6 21 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 bra...

Page 53: ...le EW000060 WARNING If you are not familiar with motor cycle maintenance work have a Yamaha dealer do it for you EAU00467 PERIODIC MAINTENANCE PROPER PERIODIC MAINTENANCE OF YOUR MOTORCYCLE IS IMPOR T...

Page 54: ...he performance of preventive maintenance and minor repairs How ever additional tools such as a torque wrench may be necessary to perform certain maintenance work correctly NOTE _ If you do not have th...

Page 55: ...s and thereafter every 8 000 mi 13 000 km or 12 months Replace Replace 3 Crankcase ventilation system Check ventilation hose for cracks or damage Replace if necessary 4 Fuel line Check fuel hose for c...

Page 56: ...age 6 6 Correct if necessary Replace brake fluid 5 Rear brake Check operation and fluid leakage See NOTE page 6 6 Correct if necessary Replace brake fluid 6 Clutch Check operation and free play Correc...

Page 57: ...e 15 Steering bearings Check bearing assembly for looseness Moderately repack every 16 000 mi 25 000 km or 24 months Lithium soap base grease Repack 16 Wheel bearings Check bearings for smooth rotatio...

Page 58: ...more frequent service if you are riding in unusually wet or dusty areas Hydraulic brake system When disassembling the master cylinder or caliper cylinder always replace the brake fluid Check the brak...

Page 59: ...rform some of the main tenance jobs 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...

Page 60: ...if ferent color the 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...

Page 61: ...ter to prevent the discharging of fuel vapor into the atmosphere Before operating this motorcycle make sure to check the following Check each hose connection Check each hose and canister for cracks or...

Page 62: ...perature _ 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 chec...

Page 63: ...under the engine to collect 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...

Page 64: ...do not mix any chemical additives with the oil or use oils of a CD grade or higher In addition do not use oils labeled ENERGY CONSERVING II or higher Make sure that no foreign mate rial enters the cr...

Page 65: ...e brim of the check hole 3 If the oil is below the brim of the check hole remove the oil filler cap add sufficient oil of the rec ommended type to raise it to the correct level and then install the oi...

Page 66: ...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 leaki...

Page 67: ...ean the air filter element 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 ai...

Page 68: ...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...

Page 69: ...justing the throttle cable free play The throttle cable free play should measure 0 16 0 24 in 4 6 mm at the throttle grip Periodically check the throttle cable free play and if neces sary have a Yamah...

Page 70: ...and safety Do not carry loosely packed items that can shift Securely pack your heaviest items close to the center of the motorcycle and dis tribute the weight evenly from side to side Properly adjust...

Page 71: ...fied by the regulations of your own country _ EAU00680 WARNING _ It is dangerous to ride with a worn out tire When a tire tread begins to show crosswise lines have a Yamaha dealer replace the tire imm...

Page 72: ...ire sur face must first be broken in for it to develop its optimal characteristics EAU00691 Accessories and replacement parts EW000098 WARNING This motorcycle is not designed to pull a trailer or to b...

Page 73: ...a to loos en the clutch cable 5 Loosen the locknut at the crankcase 6 To increase the clutch lever free play turn the adjusting nut in di rection a To decrease the clutch lever free play turn the adju...

Page 74: ...esult in loss of con trol and an accident EAU01746 Adjusting the brake pedal position The top of the brake pedal should be po sitioned approximately 3 9 in 100 mm above the top of the footrest as show...

Page 75: ...djusting 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 lubricati...

Page 76: ...ing check that the brake fluid is above the minimum level mark and replenish if necessary A low brake flu id level may indicate worn brake pads and or brake system leakage If the brake level is low be...

Page 77: ...he brake fluid at the intervals specified in the 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 ho...

Page 78: ...te the drive belt slack by subtracting the measurement not ed in step 2 from the measure ment noted in step 3 5 If the drive belt slack is incorrect adjust it as follows EAU01748 To adjust the drive b...

Page 79: ...knuts ECA00025 CAUTION Improper drive belt slack will over load the engine Keep the drive belt slack within the specified range 5 Tighten the axle nut and the brake caliper bracket bolt to the specifi...

Page 80: ...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 l...

Page 81: ...3165 Checking and lubricating 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 necess...

Page 82: ...otorcycle so that there is no danger of it falling over Check the inner tubes for scratches damage and excessive oil leakage To check the operation 1 Place the motorcycle on a level surface and hold i...

Page 83: ...W000115 WARNING Securely support the motorcycle so that there is no danger of it falling over 2 Hold the lower ends of the front fork legs and try to move them for ward and backward If any free play c...

Page 84: ...nutes and seek prompt medical attention Batteries produce explosive hy drogen gas Therefore keep sparks flames cigarettes etc away from the battery and pro vide sufficient ventilation when charging it...

Page 85: ...ery charger have a Yamaha dealer charge your battery EAU04190 Replacing the fuses The main fuse and the fuse box which contains the fuses for the individual cir cuits are located behind panel A See pa...

Page 86: ...em 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 electr...

Page 87: ...headlight If the headlight bulb burns out replace it as follows 1 Remove the headlight unit by re moving the screws 2 Disconnect the headlight coupler and then remove the bulb cover 3 Unhook the head...

Page 88: ...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...

Page 89: ...the motorcycle Since this model is not equipped with a centerstand follow these precautions when removing the front and rear wheel or performing other mainte nance requiring the motorcycle to stand up...

Page 90: ...y 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...

Page 91: ...compression Check the ignition Have 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 th...

Page 92: ...MOTORCYCLE CARE AND STORAGE 7 Care 7 1 Storage 7 5...

Page 93: ...ps 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 wh...

Page 94: ...rt and insects will come off more easily if the area is covered with a wet cloth for a few minutes before cleaning After riding in the rain near the sea or on salt sprayed roads Since sea salt or salt...

Page 95: ...chrome plat ed surfaces Avoid combination cleaner waxes many of which contain abrasives that may mar the paint or protective finish 7 Let the motorcycle dry completely before storing or covering it E...

Page 96: ...e weather conditions and have become faded or been scuffed use a fine boot creme to return the leather to its original rich even color Exposure to the elements can dry out the leather over time Theref...

Page 97: ...rain 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...

Page 98: ...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...

Page 99: ...SPECIFICATIONS 8 Specifications 8 1...

Page 100: ...ression ratio 8 3 1 Starting system Electric starter Lubrication system Dry sump Engine oil Type Recommended engine oil classification API Service SE SF SG type or higher Quantity Without oil filter c...

Page 101: ...n 0 8 0 9 mm Clutch type Wet multiple disc Transmission Primary reduction system Spur gear Primary reduction ratio 1 532 Secondary reduction system Belt Secondary reduction ratio 2 320 Transmission ty...

Page 102: ...t Type Spoke wheel Size 16 MT 3 00 16 M C MT 3 00 Rear Type Spoke wheel Size 16 MT 3 50 16 M C MT 3 50 Brakes Front Type Dual disc brake Operation Right hand Fluid DOT 4 Rear Type Single disc brake Op...

Page 103: ...gnal Front position light 12 V 27 8 W 2 Rear turn signal light 12 V 27 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 indicator light 12 V...

Page 104: ...tion number 9 1 Vehicle identification number 9 1 Model label 9 2 Reporting safety defects 9 3 Motorcycle noise regulation 9 4 Maintenance record 9 5 YAMAHA MOTOR CORPORATION U S A STREET AND ENDURO M...

Page 105: ...L LABEL INFORMATION CA 01E EAU01041 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...

Page 106: ...is affixed to the frame under the rider seat See page 3 11 for rider seat removal and installation pro cedures Record the information on this label in the space provided This in formation will be need...

Page 107: ...ints it may open an investigation and if it finds that a safety defect exists in a group of vehicles it may order a recall and remedy campaign However NHTSA cannot become involved in individual proble...

Page 108: ...ed into any new ve hicle for the purpose of noise control prior to its sale or delivery to the ultimate purchaser or while it is in use or 2 the use of the vehicle after such device or element of desi...

Page 109: ...ranty The chart below is printed only as a reminder that maintenance work is required It is not acceptable proof of maintenance work CL 04E Maintenance interval Date of service Mileage Servicing deale...

Page 110: ...6 9 28 000 mi 43 000 km or 42 months 32 000 mi 49 000 km or 48 months 36 000 mi 55 000 km or 54 months 40 000 mi 61 000 km or 60 months Maintenance interval Date of service Mileage Servicing dealer na...

Page 111: ...CONSUMER INFORMATION 9 7 9 EAU02918 YAMAHA MOTOR CORPORATION U S A STREET AND ENDURO MOTORCYCLE LIMITED WARRANTY...

Page 112: ...CONSUMER INFORMATION 9 8 9...

Page 113: ...CONSUMER INFORMATION 9 9 9 EAU01063 YAMAHA EXTENDED SERVICE Y E S...

Page 114: ...CONSUMER INFORMATION 9 10 9...

Page 115: ...t 3 2 Fuel tank cap 3 8 Fuses replacing 6 33 H Handlebar switches 3 6 Headlight bulb replacing 6 35 Helmet holder 3 12 High beam indicator light 3 2 Horn switch 3 6 I Identification numbers 9 1 Igniti...

Page 116: ...hrottle grip and cable checking and lubricating 6 27 Tires 6 18 Tool kit 6 2 Transfer case oil 6 13 Troubleshooting 6 38 Troubleshooting chart 6 39 Turn signal indicator light 3 2 Turn signal light or...

Page 117: ...INVESTMENT Use Genuine YAMAHA Parts and Accessories See your Authorized YAMAHA Dealer for a Genuine YAMAHA Service Manual Printed on recycled paper LIT 11626 15 18 4WM 28199 13 PRINTED IN JAPAN 2001...

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