Yamaha Road Star XV16ALER Owner'S Manual Download

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PERIODIC MAINTENANCE AND MINOR REPAIR

6-14

4. Remove the oil filler cap, add the

specified amount of the recom-
mended transfer case oil, and then
install and tighten the oil filler cap.

ECA00024

CAUTION:

Make sure that no foreign material
enters the transfer case.

5. Start the engine and let it idle for

several minutes while checking
the transfer case for oil leakage. If
oil is leaking, immediately turn the
engine off and check for the
cause.

1. Transfer case oil level check hole

Recommended transfer case oil:

See page 8-2.

Oil quantity:

0.42 US qt (0.35 Imp qt, 0.4 L)

Summary of Contents for Road Star XV16ALER

Page 1: ...4WM 28199 15 LIT 11626 16 44 XV16AR C XV16ALER C XV16ASR C XV16ATR C XV16ATLER C OWNER S MANUAL ...

Page 2: ...EAU03438 ...

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 motorcycle fully comply with the emis sions standards for clean air applicable at the date of manufacture Yamaha has met these standards without reducing the performance or economy of operation of the...

Page 4: ...ial 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 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...

Page 5: ...MOTOR 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 TECHNIQUES REGULAR INSPECTIONS AND CAREFUL MAINTENANCE ALONG WITH GOOD RIDING SKILLS WILL ENSURE THAT YOU SAFELY ENJOY THE CAPABILITIES AND THE RELI ABILITY OF THIS MOTORCYCLE ...

Page 6: ...6ASR C XV16ATR C XV16ATLER C OWNER S MANUAL 2002 by Yamaha Motor Corporation U S A 1st edition August 2002 All rights reserved Any reprinting or unauthorized use without the written permission of Yamaha Motor Corporation U S A is expressly prohibited Printed in Japan P N LIT 11626 16 44 ...

Page 7: ...CRIPTION 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 SPECIFICATIONS 8 9 CONSUMER INFORMATION 9 INDEX EAU00009 ...

Page 8: ......

Page 9: ...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 10: ...R 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 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 wh...

Page 11: ...ue 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 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 handleba...

Page 12: ... 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 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 Modific...

Page 13: ...the handlebar 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 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 insta...

Page 14: ...d 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 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 refuelin...

Page 15: ...open 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 manual type 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 y...

Page 16: ...SAFETY INFORMATION 1 1 7 EAU02977 Location of important labels Please read the following important labels carefully before operating this motorcycle ...

Page 17: ...SAFETY INFORMATION 1 1 8 1 California only XV16AT XV16ATLE 2 3 4 5 6 XV16AT XV16ATLE 5GA F8446 00 ...

Page 18: ......

Page 19: ...C XV16ALE C XV16AS C Left view 2 1 XV16A C XV16ALE C XV16AS C Right view 2 2 XV16AT C XV16ATLE C Left view 2 3 XV16AT C XV16ATLE C Right view 2 4 XV16A C XV16ALE C XV16AS C XV16AT C XV16ATLE C Controls and instruments 2 5 ...

Page 20: ...V16AS 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 37 8 Tail brake light page 6 37 9 Fuses page 6 33 XV16A ...

Page 21: ...ew 10 Passenger footrest 11 Passenger seat 12 Fuel tank page 3 9 13 Fuel tank cap page 3 8 14 Headlight page 6 35 15 Front turn signal position lights page 6 37 16 Brake pedal page 3 8 17 Rider footrest 18 Shock absorber spring preload adjusting nut page 3 15 19 Muffler ...

Page 22: ...w 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 37 8 Tail brake light page 6 37 9 Saddlebag page 3 14 10 Fuses page 6 33 XV16AT ...

Page 23: ...eat 12 Fuel tank page 3 9 13 Fuel tank cap page 3 8 14 Windshield page 3 13 15 Headlight page 6 35 16 Front turn signal position lights page 6 37 17 Brake pedal page 3 8 18 Rider footrest 19 Shock absorber spring preload adjusting nut page 3 15 20 Passenger footrest 21 Muffler XV16AT ...

Page 24: ...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 grip page 6 17 7 Brake lever page 3 7 XV16A C XV16ALE C XV16AS C XV16AT C XV16ATLE C XV16A XV16AT ...

Page 25: ...itches 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 seat 3 11 Helmet holder 3 12 Windshield XV16AT C XV16ATLE C 3 13 Saddlebags XV16AT C XV16ATLE C 3 14 Adjusting the shock absorber assembly 3 15 Sidestand 3 17 Ignition circuit cut off system 3 17 ...

Page 26: ... 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 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 N...

Page 27: ...ht 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 EAU04241 Engine trouble warning light This warning light comes on or flashes when an electrical circuit monitoring the engine is defective When t...

Page 28: ...s 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 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...

Page 29: ...ht 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 engine damage EAU00113 Fuel gauge The fuel gauge indicates the amount of fuel in the fuel tank The needle moves towards E Empty as the fuel level decreases When the needle reaches E refuel as soon a...

Page 30: ...ft 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 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 1 Clock 2 S...

Page 31: ...d 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 will not self cancel while you are stopped at an in tersection _ EAU00129 Horn switch Press this switch to sound the horn EAU03890 Engine stop switch Set this switch to before starting the engine Set this swit...

Page 32: ...i 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 bination with the clutch lever when shifting the gears of the 5 speed con stant mesh transmission equipped on this motorcycle NOTE Use your toes or heel to shift up and your toes to shift down EAU001...

Page 33: ...n 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 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 install...

Page 34: ...xhaust sys tem _ 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 use a gasoline of a different brand or premi um unleaded fuel Use of unleaded fuel will extend spark plug life and reduce maintenance costs Gasohol There are two types of gasohol gaso hol c...

Page 35: ... 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 riding move the lever to this position Fill the tank at the first oppor tunity Be sure to set the lever back to ON after refueling Pointed end positioned over OFF OFF closed position Pointed end positio...

Page 36: ...e 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 handlebar until the holes in the two brackets are aligned and then lock the steering with a suitable pad lock EAU03785 Rider seat To remove the rider seat 1 Insert the key into the main switch and then turn ...

Page 37: ...he 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 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 a...

Page 38: ...red angle 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 tighten them to the specified torque 4 Loosen the screws holding the windshield cover located above the headlight position the cover close to the headlight without touching it and then tighten the...

Page 39: ...gs XV16AT C XV16ATLE C To open a saddlebag Unbuckle the belts and fold up the flap To close a saddlebag Fold the flap down and buckle both belts securely NOTE _ For saddlebag cleaning and care see page 7 4 _ EWA00027 WARNING _ Improper loading or overloading can cause loss of control and possi bly an accident or personal injury Always securely close each saddlebag before riding Distribute weight e...

Page 40: ...Loosen 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 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 lower the spring preload the longer distan...

Page 41: ...e 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 damping per formance Always have a Yamaha dealer service the shock abso...

Page 42: ...sist 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 not function properly EAU03720 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 pr...

Page 43: ...the 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 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 defe...

Page 44: ......

Page 45: ...PRE OPERATION CHECKS 4 Pre operation check list 4 1 ...

Page 46: ...essary 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 lever free play Adjust if necessary Check fluid level in reservoir If necessary add recommended brake fluid to specified level Check hydraulic system for leakage 6 21 6 25 Rear brake Check operation If soft or spongy have...

Page 47: ...condition and tread depth Check air pressure Correct if necessary 6 18 6 20 Brake and shift pedals Make sure that operation is smooth Lubricate pedal pivoting points if necessary 6 28 Brake and clutch levers Make sure that operation is smooth Lubricate lever pivoting points if necessary 6 29 Sidestand Make sure that operation is smooth Lubricate pivot if necessary 6 29 Chassis fasteners Make sure ...

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Page 49: ...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 50: ...ground 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 performance will suffer Make sure not to put anything near the battery and its termi nals otherwise electrical failure and acid corrosion may result EAU01751 Starting and warming up a cold engine In or...

Page 51: ... 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 warm the engine up before starting off Never accelerate hard when the engine is cold 7 When the engine is warm turn the starter choke off NOTE The engine is warm when it responds normally to the thro...

Page 52: ... 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 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 Ina...

Page 53: ...procedure 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 the transmission into first gear when the motorcycle reaches 16 mi h 25 km h If the engine is about to stall or runs very roughly pull the clutch lever in and use the brakes to stop the motorcycle 3...

Page 54: ...lear 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 throttle 600 1 000 mi 1 000 1 600 km Avoid prolonged operation above 1 2 throttle ECA00026 CAUTION After 600 mi 1 000 km of operation the engine oil and transfer case oil must be changed and the oil...

Page 55: ... 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 likely to touch them Do not park on a slope or on soft ground otherwise the motorcycle may overturn ...

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Page 57: ...r 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 brake fluid level 6 24 Changing the brake fluid 6 25 Drive belt slack 6 25 Checking and lubricating the throttle grip and cable 6 27 Checking and lubricating the brake and shift pedals 6 28 Checking and...

Page 58: ...ble 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 TANT IN ORDER TO ENJOY LONG PLEASURABLE SERVICE ESPE CIALLY IMPORTANT ARE THE MAINTENANCE SERVICES RELAT ED TO EMISSIONS CONTROL THESE CONTROLS NOT ONLY FUNCTION TO ENSURE CLEANER AIR BUT ARE ALSO VIT...

Page 59: ...the 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 the tools or experi ence required for a particular job have a Yamaha dealer perform it for you _ EW000062 WARNING _ Modifications not approved by Yamaha may cause loss of perfor mance excessive emissio...

Page 60: ...hs 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 cracks or damage Replace if necessary 5 Fuel filter Replace initial 20 000 mi 31 000 km or 30 months and thereafter every 20 000 mi 31 000 km or 30 months Replace 6 Exhaust system Check for leakage Re...

Page 61: ...page 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 Correct if necessary 7 Transfer case oil Check vehicle for leakage Replace every 16 000 mi 25 000 km or 24 months SAE 80 API GL 4 hypoid gear oil Replace Check Replace 8 Control cable Apply chain lube thor...

Page 62: ...ge 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 rotation 17 Rear suspen sion link pivots Apply grease lightly Molybdenum disulfide grease 18 Drive belt Check for belt tension Adjust if necessary Every 2 500 mi 4 000 km No ITEM ROUTINE TYPE INITIAL ODOMET...

Page 63: ...s 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 brake fluid level regularly and fill as required Replace the oil seals on the inner parts of the master cylinder and caliper cylinder every two years Replace the brake hoses every four years or if cracke...

Page 64: ...erform 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 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 ...

Page 65: ...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 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 Cle...

Page 66: ...ster 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 damage Replace if damaged Make sure that the canister breather is not blocked and if nec essary clean it EAU04628 Engine oil and oil filter cartridge The engine oil level should be checked before ea...

Page 67: ...mperature _ 4 Wait a few minutes until the oil set tles remove the oil filler cap wipe the dipstick clean insert it back into the oil filler hole without screwing it in and then remove it again to check the oil level NOTE _ The engine oil should be between the minimum and maximum level marks _ 5 If the engine oil is below the mini mum level mark add sufficient oil of the recommended type to raise ...

Page 68: ... 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 is available at a Yamaha dealer _ 7 Apply a thin coat of engine oil to the O ring of the new oil filter car tridge NOTE _ Make sure that the O ring is properly seated _ 8 Install the new oil filter c...

Page 69: ...al additives Do not use oils with a diesel speci fication of CD or oils of a higher quality than specified In addition do not use oils labeled ENERGY CONSERVING II or higher Make sure that no foreign mate rial enters the crankcase _ 13 Install the engine oil filler cap 14 Start the engine and then let it idle for several minutes while checking it for oil leakage If oil is leaking immediately turn ...

Page 70: ...the 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 oil filler cap 4 Install the oil check bolt and then tighten it to the specified torque To change the transfer case oil 1 Place an oil pan under the transfer case to collect the used oil 2 Remove th...

Page 71: ...ap ECA00024 CAUTION _ Make sure that no foreign material enters the transfer case _ 5 Start the engine and let it idle for several minutes while checking the transfer case for oil leakage If oil is leaking immediately turn the engine off and check for the cause 1 Transfer case oil level check hole Recommended transfer case oil See page 8 2 Oil quantity 0 42 US qt 0 35 Imp qt 0 4 L ...

Page 72: ...lean 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 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 1 Air filter joint clamp screw 1 Screw 2 2 Hose 2 3 Air filter case...

Page 73: ...n If the air filter element is damaged replace it 7 Install the air filter element by in serting it into the air filter case then installing the screws and then connect the hose shown 8 Install the air filter case cover by installing the screws 9 Connect the hoses shown 10 Install the air filter case by pushing it onto the air filter joint and then tighten the air filter joint clamp screw 11 Insta...

Page 74: ...djusting 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 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 clea...

Page 75: ...o 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 the suspen sion for your load and check the condition and pressure of your tires NEVER OVERLOAD YOUR MOTOR CYCLE Make sure the total weight of the cargo rider passenger and accessories windshield saddle bags etc ...

Page 76: ... so con form to the limits specified 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 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 e...

Page 77: ...tire 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 be attached to a sidecar The accessories or replace ment parts you choose for your motorcycle should be designed spe cifically for this model and they must be securely mounted to main tain the inheren...

Page 78: ... 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...

Page 79: ...result 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 shown Periodically check the brake pedal posi tion and if necessary have a Yamaha dealer adjust it EW000109 WARNING A soft or spongy feeling in the brake pedal can indicate the presence of air in the hyd...

Page 80: ...adjusting nut in direction b EAU00721 Checking the front and rear brake pads The front and rear brake pads must be checked for wear at the intervals spec ified in the periodic maintenance and lubrication chart EAU03938 Front brake pads Each front brake pad is provided with wear indicator grooves which allow you to check the brake pad wear with out having to disassemble the brake To check the brake...

Page 81: ...ding 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 sure to check the brake pads for wear and the brake sys tem for leakage Observe these precautions When checking the fluid level make sure that the top of the brake fluid reservoir is level Use only ...

Page 82: ... 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 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 EAU04452 Drive belt slack The drive belt slack should be checked and adjusted...

Page 83: ...e at a Yamaha dealer _ 4 Calculate 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 belt slack 1 Loosen the rear wheel axle nut and the brake caliper bracket bolt 1 Belt tension gauge Drive belt slack 0 3 0 5 in 7 5 13 mm 1 Wheel axle nut 1 Brake calipe...

Page 84: ...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 specified torques EAU04034 Checking and lubricating the throttle grip and cable The operation of the throttle grip should be checked before each ride In addi tion the cable should be lubricated or replaced a...

Page 85: ... 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 purpose grease ...

Page 86: ...03165 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 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 lubrica...

Page 87: ...motorcycle 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 it in an upright position 2 While 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 i...

Page 88: ...EW000115 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 can be felt have a Yamaha dealer check or repair the steering EAU01144 Checking the wheel bearings The front and rear wheel bearings must be checked at the intervals specified in the periodic maintena...

Page 89: ...inutes 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 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 ...

Page 90: ...tery 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 page 6 7 for panel removal and instal lation 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 i...

Page 91: ...tem 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 Main fuse 2 Spare main fuse Specified fuses Main fuse 30 A Headlight fuse 15 A Signaling system fuse 10 A Ignition fuse 15 A Odometer fuse 5 A Carburetor heater fuse 10 A ...

Page 92: ...b 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 headlight bulb holder and then remove the defective bulb 1 Screw 2 1 Headlight coupler 2 Headlight bulb cover 1 Headlight bulb holder ...

Page 93: ..._ 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 clean off any dirt and fingerprints on the headlight bulb using a cloth moistened with alcohol or thinner _ 5 Install the headlight bulb cover and then connect the coupler 6 Install the headlight uni...

Page 94: ... 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 upright Check that the motor cycle is in a stable and level position before starting any maintenance A strong wooden box can be placed un der the engine for added stability To service the front wheel 1...

Page 95: ...ay occur dur ing operation Any problem in the fuel compression or ignition systems for example can cause poor starting and loss of power The following troubleshooting chart represents a quick and easy procedure for checking these vital systems your self However should your motorcycle require any repair take it to a Yamaha dealer whose skilled technicians have the necessary tools experience and kno...

Page 96: ... 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 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 Batter...

Page 97: ...MOTORCYCLE CARE AND STORAGE 7 Care 7 1 Storage 7 5 ...

Page 98: ...aps 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 water Cleaning ECA00010 CAUTION _ Avoid using strong acidic wheel cleaners especially on spoked wheels If such products are used on hard to remo...

Page 99: ...d 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 sprayed on roads during winter are extremely corrosive in combination with water carry out the following steps after each ride in the rain near the sea or on salt sprayed roads NOTE _ Salt sprayed on road...

Page 100: ...d 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 EWA00001 WARNING _ Make sure that there is no oil or wax on the brakes or tires If necessary clean the brake discs and brake linings with a regular brake disc cleaner or ac etone and wash the tires wi...

Page 101: ...o severe 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 Therefore an oc casional application of a good quality mink oil is recommended to restore the leather and lift its water resistance Make sure that the saddlebags are clean and dry before applying the...

Page 102: ...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 deteriorating 5 Perform the following steps to pro tect the cylinders piston rings etc from corrosion a Remove the spark plug caps and spark plugs b Pour a teaspoonful of engine oil...

Page 103: ...e 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 30 F 0 C or more than 90 F 30 C For more informa ...

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Page 105: ...SPECIFICATIONS 8 Specifications 8 1 ...

Page 106: ... Engine Engine type Air cooled 4 stroke OHV Cylinder arrangement V type 2 cylinder Displacement 1 602 cm3 Bore Stroke 3 74 4 45 in 95 113 mm Compression 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 0 10 30 50 70 90 110 130 F YAMALUBE 4 20W 40 or SAE 20W 40 20 10 0 10 20 30 40 50 C ...

Page 107: ...l 0 8 lmp gal 3 5 L Carburetor Manufacturer MIKUNI Model quantity BSR40 1 Spark plug Manufacturer model NGK DPR7EA 9 or DENSO X22EPR U9 Gap 0 03 0 04 in 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 type Constant mesh 5 speed Operation Left foot Gear...

Page 108: ...um Front 36 psi 2 50 kgf cm2 250 kPa Rear 41 psi 2 80 kgf cm2 280 kPa Total weight of rider passenger cargo and accessories Wheels Front 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 Operation Right foot Fluid DOT 4 Suspension Front Telescopic fork R...

Page 109: ...Headlight 12 V 60 55 W 1 Tail brake light 12 V 8 27 W 1 Front turn signal 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 1 W 1 Fuel level warning light LED 1 Engine trouble warning light LED 1 Fuses Main fuse 30 A Ignition fuse 15 A Signaling system f...

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Page 111: ...ation 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 MOTORCYCLE LIMITED WARRANTY 9 7 YAMAHA EXTENDED SERVICE Y E S 9 9 ...

Page 112: ...EL 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 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 num...

Page 113: ... 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 needed when ordering spare parts from a Yamaha dealer 1 Model label ...

Page 114: ...aints 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 problems between you your dealer or Yamaha Motor Corporation U S A To contact NHTSA you may either call the Auto Safety Hotline toll free at 1 800 424 9393 or 366 0123 in Washington D C area or write to NH...

Page 115: ...ted 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 design has been removed or rendered inoperative by any person AMONG THOSE ACTS PRESUMED TO CONSTITUTE TAMPERING ARE THE ACTS LISTED BELOW These acts include tampering with the following systems i e modif...

Page 116: ...rranty 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 dealer name and address Remarks 600 mi 1 000 km or 1 month 4 000 mi 7 000 km or 6 months 8 000 mi 13 000 km or 12 months 12 000 mi 19 000 km or 18 months 16 000 mi 25 000 km or 24 months 20 000 mi 31 000 ...

Page 117: ... 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 name and address Remarks ...

Page 118: ...CONSUMER INFORMATION 9 7 9 EAU02918 YAMAHA MOTOR CORPORATION U S A STREET AND ENDURO MOTORCYCLE LIMITED WARRANTY ...

Page 119: ...CONSUMER INFORMATION 9 8 9 ...

Page 120: ...CONSUMER INFORMATION 9 9 9 EAU01063 YAMAHA EXTENDED SERVICE Y E S ...

Page 121: ...CONSUMER INFORMATION 9 10 9 ...

Page 122: ...cock 3 10 Fuel gauge 3 4 Fuel level warning light 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 Ignition circuit cut off system 3 17 Indicator and warning lights 3 2 K Key identification number 9 1 L Labels location 1 7 M Main switch steering lock 3 1 Ma...

Page 123: ...hrottle cable free play adjusting 6 17 Throttle 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 tail brake light bulb replacing 6 37 Turn signal switch 3 6 V Valve clearance adjusting 6 17 Vehicle identification number 9 1 W Warranty extended 9 9 Warranty...

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Page 126: ...PRINTED IN JAPAN 2002 08 0 3 1 CR E PRINTED ON RECYCLED PAPER YAMAHA MOTOR CO LTD ...

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Yamaha Road Star XV16ALER, Owner'S Manual

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