OWNER’S MANUAL XV16AR(C) XV16ALER(C) XV16ASR(C) XV16ATR(C) XV16ATLER(C) LIT-11626-16-44 4WM-28199-15
EAU03438
EAU00002 INTRODUCTION Congratulations on your purchase of the Yamaha Road Star™/Road Star™ Silverado™. This model is the result of Yamaha’s vast experience in the production of fine sporting, touring, and pacesetting racing machines. It represents the high degree of craftsmanship and reliability that have made Yamaha a leader in these fields. This manual will give you an understanding of the operation, inspection, and basic maintenance of this motorcycle.
IMPORTANT MANUAL INFORMATION Particularly important information is distinguished in this manual by the following notations: 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 or a person inspecting or repairing the motorcycle. WARNING CAUTION: A CAUTION indicates special precautions that must be taken to avoid damage to the motorcycle.
IMPORTANT MANUAL INFORMATION EW000000 WARNING PLEASE READ THIS MANUAL AND THE “YOU AND YOUR MOTORCYCLE: RIDING TIPS” BOOKLET CAREFULLY AND COMPLETELY BEFORE OPERATING THIS MOTORCYCLE. DO NOT ATTEMPT TO OPERATE THIS MOTORCYCLE UNTIL YOU HAVE ATTAINED ADEQUATE KNOWLEDGE OF ITS CONTROLS AND OPERATING FEATURES AND UNTIL YOU HAVE BEEN TRAINED IN SAFE AND PROPER RIDING TECHNIQUES.
IMPORTANT MANUAL INFORMATION AFFIX DEALER LABEL HERE EAU04247 XV16AR(C)/XV16ALER(C)/XV16ASR(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.
TABLE OF CONTENTS EAU00009 1 SAFETY INFORMATION 1 2 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 SPECIFICATIONS 8 9 CONSUMER INFORMATION 9 INDEX
SAFETY INFORMATION Safe riding .......................................................................................... 1-1 Protective apparel .............................................................................. 1-3 Modifications ...................................................................................... 1-3 Loading and accessories ................................................................... 1-3 Gasoline and exhaust gas...........................................................
SAFETY INFORMATION EAU03633 1- 1 MOTORCYCLES ARE SINGLE TRACK VEHICLES. THEIR SAFE USE AND OPERATION ARE DEPENDENT UPON THE USE OF PROPER RIDING TECHNIQUES AS WELL AS THE EXPERTISE OF THE OPERATOR. EVERY OPERATOR SHOULD KNOW THE FOLLOWING REQUIREMENTS BEFORE RIDING THIS MOTORCYCLE. HE OR SHE SHOULD: 1. OBTAIN THOROUGH INSTRUCTIONS FROM A COMPETENT SOURCE ON ALL ASPECTS OF MOTORCYCLE OPERATION. 2. OBSERVE THE WARNINGS AND MAINTENANCE REQUIREMENTS IN THE OWNER’S MANUAL. 3.
SAFETY INFORMATION 4. Many motorcycle accidents involve inexperienced operators. In fact, many operators who have been involved in accidents do not even have a current motorcycle license. a. Make sure that you are qualified and that you only lend your motorcycle to other qualified operators. b. Know your skills and limits. Staying within your limits may help you to avoid an accident. c.
SAFETY INFORMATION Protective apparel 1 The majority of fatalities from motorcycle accidents are the result of head injuries. The use of a safety helmet is the single most critical factor in the prevention or reduction of head injuries. 1. Always wear an approved helmet. 2. Wear a face shield or goggles. Wind in your unprotected eyes could contribute to an impairment of vision which could delay seeing a hazard. 3. The use of a jacket, heavy boots, trousers, gloves, etc.
SAFETY INFORMATION Loading The total weight of the operator, passenger, accessories and cargo must not exceed the maximum load limit of XV16A(C), XV16ALE(C), XV16AS(C): 432 lb (196 kg) / XV16AT(C), XV16ATLE(C): 399 lb (181 kg). When loading within this weight limit, keep the following in mind: 1. Cargo and accessory weight should be kept as low and close to the motorcycle as possible.
SAFETY INFORMATION 1 a. Accessories fitted to the handlebar or the front fork area can create instability due to improper weight distribution or aerodynamic changes. If accessories are added to the handlebar or front fork area, they must be as lightweight as possible and should be kept to a minimum. b. Bulky or large accessories may seriously affect the stability of the motorcycle due to aerodynamic effects. Wind may attempt to lift the motorcycle, or the motorcycle may become unstable in cross winds.
SAFETY INFORMATION a. The engine and exhaust system may be hot, therefore, park the motorcycle in a place where pedestrians or children are not likely to touch these hot areas. b. Do not park the motorcycle on a slope or soft ground, otherwise it may fall over. c. Do not park the motorcycle near a flammable source (e.g. a kerosene heater, or near an open flame), otherwise it could catch fire. 4.
SAFETY INFORMATION EAU02977 Location of important labels Please read the following important labels carefully before operating this motorcycle.
SAFETY INFORMATION 2 1 1 XV16AT/XV16ATLE California only 3 4 5 6 XV16AT/XV16ATLE (5GA-F8446-00) 1-8
DESCRIPTION XV16A(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 .................................................................
DESCRIPTION EAU00026 2- Road Star™ XV16A(C)/XV16ALE(C)/XV16AS(C) Left view 2 (XV16A) 1. Shift pedal 2. Starter (choke) knob 3. Fuel cock 4. Rider seat 5. Owner’s tool kit 6. Helmet holder 7. Rear turn signal lights 8. Tail/brake light 9.
DESCRIPTION Road Star™ XV16A(C)/XV16ALE(C)/XV16AS(C) Right view 2 (XV16A) 10. Passenger footrest 11. Passenger seat 12. Fuel tank 13. Fuel tank cap 14. Headlight 15. Front turn signal/position lights 16. Brake pedal 17. Rider footrest 18. Shock absorber spring preload adjusting nut 19.
DESCRIPTION Road Star™/Silverado™ XV16AT(C)/XV16ATLE(C) Left view 2 (XV16AT) 1. Shift pedal 2. Starter (choke) knob 3. Fuel cock 4. Rider seat 5. Owner’s tool kit 6. Helmet holder 7. Rear turn signal lights 8. Tail/brake light 9. Saddlebag 10.
DESCRIPTION Road Star™/Silverado™ XV16AT(C)/XV16ATLE(C) Right view 2 (XV16AT) 11. Passenger seat 12. Fuel tank 13. Fuel tank cap 14. Windshield 15. Headlight 16. Front turn signal/position lights 17. Brake pedal 18. Rider footrest 19. Shock absorber spring preload adjusting nut 20. Passenger footrest 21.
DESCRIPTION Road Star™/Road Star™ Silverado™ XV16A(C)/XV16ALE(C)/XV16AS(C)/XV16AT(C)/XV16ATLE(C) Controls and instruments XV16A(C)/XV16ALE(C)/XV16AS(C) XV16AT(C)/XV16ATLE(C) 2 (XV16A) 1. Clutch lever 2. Left handlebar switches 3. Speedometer unit 4. Main switch/steering lock (XV16AT) 5. Right handlebar switches 6. Throttle grip 7.
INSTRUMENT AND CONTROL FUNCTIONS Main switch/steering lock .....................................3-1 Indicator and warning lights ................................3-2 Speedometer unit ................................................3-3 Self-diagnosis device ...........................................3-4 Fuel gauge ...........................................................3-4 Clock ....................................................................3-5 Handlebar switches ......................................
INSTRUMENT AND CONTROL FUNCTIONS EAU00027 3- 3 EAU00029 Main switch/steering lock The main switch/steering lock controls the ignition and lighting systems, and is used to lock the steering. The various positions are described below. EAU00032 ON All electrical systems are supplied with power, the headlight, meter lighting, taillight and front position lights come on, and the engine can be started. The key cannot be removed. EAU00038 OFF All electrical systems are off. The key can be removed.
INSTRUMENT AND CONTROL FUNCTIONS EAU00063 High beam indicator light “ ” This indicator light comes on when the high beam of the headlight is switched on. EAU00057 1. 2. 3. 4. 5. Turn signal indicator light “ ” This indicator light flashes when the turn signal switch is pushed to the left or right.
INSTRUMENT AND CONTROL FUNCTIONS Pushing the mode button (left) switches the display between the odometer mode “ODO” and the tripmeter modes “TRIP A” and “TRIP B” in the following order: CB-27E ODO TRIP A TRIP B 3 1. 2. 3. 4. 5. Odometer/tripmeter/clock Speedometer Fuel gauge Set button Mode button To reset a tripmeter, select it by pushing the mode button (left), and then hold down the set button (right) for at least one second.
INSTRUMENT AND CONTROL FUNCTIONS EAU01735 EAU00113 Self-diagnosis device Fuel gauge This model is equipped with a self-diagnosis device for various electrical circuits. If any of those circuits are defective, the engine trouble warning light will come on or the fuel level warning light will flash. If this occurs, have a Yamaha dealer check the motorcycle. The fuel gauge indicates the amount of fuel in the fuel tank. The needle moves towards “E” (Empty) as the fuel level decreases.
INSTRUMENT AND CONTROL FUNCTIONS 4. Push the right button to change the hours. 5. Push the left button and only the minute display will flash. 3 1. Clock 2. Set button 3. Mode button EAU01736 Clock The digital clock shows the time regardless of the main switch position. To set the clock: 1. Turn the key to “ON”. 2. Press both the set button (right) and the mode button (left) simultaneously until the hours and minutes flash. 6. Push the right button to change the minutes. 3.
INSTRUMENT AND CONTROL FUNCTIONS 1. Dimmer switch “ / 2. Turn signal switch “ 3. Horn switch “ ” Since this model is equipped with a self-canceling system, the turn signal lights will self-cancel after the motorcycle has traveled both about 150 m (490 ft) and for approximately 15 seconds. However, the turn signal lights can also be canceled manually by pushing the switch in after it has returned to the center position.
INSTRUMENT AND CONTROL FUNCTIONS 3 1. Clutch lever 1. Shift pedal 1. Brake lever EAU00152 EAU01215 EAU00158 Clutch lever Shift pedal Brake lever The clutch lever is located at the left handlebar grip. To disengage the clutch, pull the lever toward the handlebar grip. To engage the clutch, release the lever. The lever should be pulled rapidly and released slowly for smooth clutch operation. The clutch lever is equipped with a clutch switch, which is part of the ignition circuit cut-off system.
INSTRUMENT AND CONTROL FUNCTIONS 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. 1. Brake pedal EAU00162 Brake pedal The brake pedal is on the right side of the motorcycle. To apply the rear brake, press down on the brake pedal. 1. 2. a. b. Fuel tank cap lock cover “ ” mark Unlock. Lock.
INSTRUMENT AND CONTROL FUNCTIONS EAU00185 CAUTION: Immediately wipe off spilled fuel with a clean, dry, soft cloth, since fuel may deteriorate painted surfaces or plastic parts. @ @ EAU04265 3 Recommended fuel: UNLEADED GASOLINE ONLY Fuel tank capacity: Total amount: 5.3 US gal (4.4 Imp gal, 20 L) Reserve amount: 0.9 US gal (0.8 Imp gal, 3.5 L) 1. Fuel tank filler tube 2. Fuel level EAU03753 Fuel Make sure that there is sufficient fuel in the tank.
INSTRUMENT AND CONTROL FUNCTIONS OFF: closed position ON: normal position RES: reserve position 3 Pointed end positioned over “OFF” EAU03050 Fuel cock The fuel cock supplies fuel from the tank to the carburetor while filtering it also. The fuel cock has three positions: Pointed end positioned over “ON” Pointed end positioned over “RES” 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.
INSTRUMENT AND CONTROL FUNCTIONS 3 EAU04038 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).
INSTRUMENT AND CONTROL FUNCTIONS EW000030 WARNING Never ride with a helmet attached to the helmet holder, since the helmet may hit objects, causing loss of control and possibly an accident. _ _ 1. Projection 2. Seat holder 1. Helmet holder 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 will be left unattended.
INSTRUMENT AND CONTROL FUNCTIONS 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 screws. 3 1. Windshield 2. Bolt (× 4) 1. Headlight cover 2. Screw (× 4) EAU01231 Windshield [XV16AT(C)/XV16ATLE(C)] To suit the rider’s preference, the windshield angle can be adjusted and the height can be changed to one of two positions. To adjust the windshield angle 1.
INSTRUMENT AND CONTROL FUNCTIONS EW000134 WARNING After adjusting the windshield: ● Securely tighten the windshield bolts. ● Turn the handlebar to the left and right to make sure that the handlebar is not obstructed and that the windshield does not contact any other parts. ● Open the throttle and make sure that the throttle grip returns properly when released, otherwise an accident or injury could result.
INSTRUMENT AND CONTROL FUNCTIONS 3 1. Locknut 2. Spring preload adjusting nut 1. Special wrench EAU03591 Adjusting the shock absorber assembly This shock absorber assembly is equipped with a spring preload adjusting nut. EC000015 A. Distance A 2. To increase the spring preload and thereby harden the suspension, turn the adjusting nut in direction a. To decrease the spring preload and thereby soften the suspension, turn the adjusting nut in direction b.
INSTRUMENT AND CONTROL FUNCTIONS EAU00315 Spring preload: Minimum (soft): Distance A = 1.67 in (42.5 mm) Standard: XV16A(C)/XV16ALE(C)/ XV16AS(C) Distance A = 1.67 in (42.5 mm) XV16AT(C)/XV16ATLE(C) Distance A = 1.79 in (45.5 mm) Maximum (hard): Distance A = 2.02 in (51.5 mm) CAUTION: Always tighten the locknut against the adjusting nut, and then tighten the locknut to the specified torque. WARNING This shock absorber contains highly pressurized nitrogen gas.
INSTRUMENT AND CONTROL FUNCTIONS EAU00330 Sidestand The sidestand is located on the left side of the frame. Raise the sidestand or lower it with your foot while holding the motorcycle upright. NOTE: The built-in sidestand switch is part of the ignition circuit cut-off system, which cuts the ignition in certain situations. (See further down for an explanation of the ignition circuit cut-off system.
INSTRUMENT AND CONTROL FUNCTIONS CD-01E With the engine turned off: 1. Move the sidestand down. 2. Make sure that the engine stop switch is set to “ 3. Turn the key to “ON”. 4. Shift the transmission into the neutral position. 5. Push the start switch. Does the engine start? YES NOTE: This check is most reliable if performed with a warmed-up engine. ”. NO The neutral switch may be defective. The motorcycle should not be ridden until checked by a Yamaha dealer.
PRE-OPERATION CHECKS Pre-operation check list .....................................................................
PRE-OPERATION CHECKS EAU01114 4- The condition of a vehicle is the owner’s responsibility. Vital components can start to deteriorate quickly and unexpectedly, even if the vehicle remains unused (for example, as a result of exposure to the elements). Any damage, fluid leakage or loss of tire air pressure could have serious consequences. Therefore, it is very important, in addition to a thorough visual inspection, to check the following points before each ride.
PRE-OPERATION CHECKS ITEM Control cables CHECKS • Make sure that operation is smooth. • Lubricate if necessary. Check for damage. Check tire condition and tread depth. Check air pressure. Correct if necessary. PAGE — Wheels and tires • • • • 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.
OPERATION AND IMPORTANT RIDING POINTS Starting and warming up a cold engine ............................................. 5-1 Starting a warm engine ..................................................................... 5-3 Shifting .............................................................................................. 5-3 Engine break-in ................................................................................. 5-5 Parking .......................................................................
OPERATION AND IMPORTANT RIDING POINTS EAU00372 5- ● Before starting out, make sure that the sidestand is up. If the sidestand is not raised completely, it could contact the ground and distract the operator, resulting in a possible loss of control. @ EAU00376 @ EAU00373 5 @ WARNING ● Become thoroughly familiar with all operating controls and their functions before riding. Consult a Yamaha dealer regarding any control or function that you do not thoroughly understand.
OPERATION AND IMPORTANT RIDING POINTS 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 throttle with the starter (choke) turned off. To avoid the possibility of excessive exhaust emissions, never leave the starter (choke) on longer than necessary.
OPERATION AND IMPORTANT RIDING POINTS EAU01258 EC000048 Starting a warm engine @ Follow the same procedure as for starting a cold engine with the exception that the starter (choke) is not required when the engine is warm. EAU00423 Shifting 5 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 illustration.
OPERATION AND IMPORTANT RIDING POINTS EAU02988* EAU02974 To start out and accelerate 1. Pull the clutch lever to disengage the clutch. 2. Shift the transmission into first gear. The neutral indicator light should go out. 3. Open the throttle gradually, and at the same time, release the clutch lever slowly. 4. At the recommended shift points shown in the following table, close the throttle, and at the same time, quickly pull the clutch lever in. 5. Shift the transmission into second gear.
OPERATION AND IMPORTANT RIDING POINTS 1,000 mi (1,600 km) and beyond The vehicle can now be operated normally. EAU01128 Engine break-in 5 There is never a more important period in the life of your engine than the period between 0 and 1,000 mi (1,600 km). For this reason, you should read the following material carefully. Since the engine is brand new, do not put an excessive load on it for the first 1,000 mi (1,600 km).
OPERATION AND IMPORTANT RIDING POINTS EAU00457 Parking 5 When parking, stop the engine, remove 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 pedestrians or children are not likely to touch them. ● Do not park on a slope or on soft ground, otherwise the motorcycle may overturn.
PERIODIC MAINTENANCE AND MINOR REPAIR Periodic maintenance ..........................................6-1 Owner’s tool kit ....................................................6-2 Periodic maintenance chart for the emission control system ...................................................6-3 General maintenance and lubrication chart .........6-4 Removing and installing the panel .......................6-7 Checking the spark plugs ....................................6-8 Canister (for California only) ........
PERIODIC MAINTENANCE AND MINOR REPAIR EAU00462 6- TROL ARE GROUPED SEPARATELY. THESE SERVICES REQUIRE SPECIALIZED DATA, KNOWLEDGE, AND EQUIPMENT. YAMAHA DEALERS ARE TRAINED AND EQUIPPED TO PERFORM THESE PARTICULAR SERVICES. EAU01790 Safety is an obligation of the owner. Periodic inspection, adjustment and lubrication will keep your vehicle in the safest and most efficient condition possible.
PERIODIC MAINTENANCE AND MINOR REPAIR NOTE: If you do not have the tools or experience required for a particular job, have a Yamaha dealer perform it for you. _ _ EW000062 WARNING Modifications not approved by Yamaha may cause loss of performance, excessive emissions, and render the vehicle unsafe for use. Consult a Yamaha dealer before attempting any changes. _ 1. Owner’s tool kit EAU03644 Owner’s tool kit The owner’s tool kit is located under the rider seat.
PERIODIC MAINTENANCE AND MINOR REPAIR EAU00471 Periodic maintenance chart for the emission control system No. 1 * 2 6 ITEM ROUTINE INITIAL 600 mi (1,000 km) or 1 month 4,000 mi (7,000 km) or 6 months ODOMETER READINGS 8,000 mi 12,000 mi 16,000 mi (13,000 km) (19,000 km) (25,000 km) or or or 12 months 18 months 24 months 20,000 mi (31,000 km) or 30 months Valve clearance • Check valve clearance when engine is cold. • Adjust if necessary. Spark plug • Check condition. • Adjust gap and clean.
PERIODIC MAINTENANCE AND MINOR REPAIR EAU00472 General maintenance and lubrication chart No. 1 ITEM ROUTINE Engine oil • Replace TYPE 4,000 mi (7,000 km) or 6 months √ √ See page 8-1. 2 * Oil filter • Replace - 3 * Air filter (See NOTE on page 6-6.) • Clean with compressed air. • Replace if necessary. - 4 * Front brake • Check operation and fluid leakage. (See NOTE page 6-6.) • Correct if necessary. - 5 * Rear brake • Check operation and fluid leakage. (See NOTE page 6-6.
PERIODIC MAINTENANCE AND MINOR REPAIR No. ROUTINE TYPE 4,000 mi (7,000 km) or 6 months ODOMETER READINGS 8,000 mi 12,000 mi 16,000 mi (13,000 km) (19,000 km) (25,000 km) or or or 12 months 18 months 24 months 20,000 mi (31,000 km) or 30 months 10 Brake/ Clutch lever pivot shaft • Apply chain lube lightly. Yamaha chain and cable lube or SAE 10W30 motor oil √ √ √ √ √ 11 Brake pedal and shift pedal shaft • Lubricate • Apply chain lube lightly.
PERIODIC MAINTENANCE AND MINOR REPAIR EAU03907 NOTE: From 24,000 mi (37,000 km) or 36 months, repeat the maintenance intervals starting from 4,000 mi (7,000 km) or 6 months. _ _ EAU03057 NOTE: ● The air filter needs 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.
PERIODIC MAINTENANCE AND MINOR REPAIR 1. Panel A 1. Bolt EAU01777 Removing and installing the panel 6 The panel shown above needs to be removed to perform some of the maintenance jobs described in this chapter. Refer to this section each time the panel needs to be removed and installed. EAU00491 Panel A To remove the panel Remove the bolt, and then pull the panel off as shown. 6-7 To install the panel Place the panel in the original position, and then install the bolt.
PERIODIC MAINTENANCE AND MINOR REPAIR a. Spark plug gap EAU01639 Checking the spark plugs The spark plugs are important engine components, which should be checked periodically, preferably by a Yamaha dealer. Since heat and deposits will cause any spark plug to slowly erode, they should be removed and checked in accordance with the periodic maintenance and lubrication chart. In addition, the condition of the spark plugs can reveal the condition of the engine.
PERIODIC MAINTENANCE AND MINOR REPAIR ECA00021 CAUTION: Do not use any tools to remove or install the spark plug cap, otherwise the ignition coil coupler may get damaged. The spark plug cap may be difficult to remove because the rubber seal on the end of the cap fits tightly. To remove the spark plug cap, simply twist it back and forth while pulling it out; to install it, twist it back and forth while pushing it in. @ @ 6 1.
PERIODIC MAINTENANCE AND MINOR REPAIR NOTE: Make sure that the motorcycle is positioned straight up when checking the oil level. A slight tilt to the side can result in a false reading. NOTE: When adding oil, be careful not to overfill the engine; the oil level rises faster starting from the half level portion on the dipstick. _ _ _ 2. Remove the rider seat. (See page 3-11 for rider seat removal and installation procedures.) 3.
PERIODIC MAINTENANCE AND MINOR REPAIR 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. _ _ 1. Engine oil drain bolt (oil tank) 6 1. Engine oil drain bolt (crankcase) 7. Apply a thin coat of engine oil to the O-ring of the new oil filter cartridge. To change the engine oil (with or without oil filter cartridge replacement) 1.
PERIODIC MAINTENANCE AND MINOR REPAIR 12. Remove the engine oil filler cap, and then gradually fill the oil tank with the remaining oil quantity while regularly checking the oil level on the dipstick. 1. Engine oil filter cartridge 9. Install the engine oil drain bolts, and then tighten them to the specified torque. Tightening torque: Engine oil drain bolt: 31 ft·lbf (4.3 m·kgf, 43 Nm) Recommended engine oil: See page 8-1. Oil quantity: Without oil filter cartridge replacement: 3.9 US qt (3.3 Imp qt, 3.
PERIODIC MAINTENANCE AND MINOR REPAIR NOTE: Make sure that the motorcycle is positioned straight up when checking the oil level. A slight tilt to the side can result in a false reading. _ _ 2. Remove the oil check bolt, and then check the oil level in the transfer case. 1. Transfer case oil filler cap 2. Transfer case oil level check bolt 1. Transfer case oil drain bolt _ EAU04251 Transfer case oil 6 NOTE: The oil should be at the brim of the check hole.
PERIODIC MAINTENANCE AND MINOR REPAIR 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 4. Remove the oil filler cap, add the specified amount of the recommended transfer case oil, and then install and tighten the oil filler cap. 6 Recommended transfer case oil: See page 8-2. Oil quantity: 0.42 US qt (0.35 Imp qt, 0.
PERIODIC MAINTENANCE AND MINOR REPAIR 1. Bolt (× 4) 2. Air filter case 1. Air filter joint clamp screw EAU03707 Cleaning the air filter element 6 The air filter element should be cleaned at the intervals specified in the periodic maintenance and lubrication chart. Clean the air filter element more frequently 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. 6-15 1.
PERIODIC MAINTENANCE AND MINOR REPAIR 1. Screw (× 2) 2. Hose 5. Remove the air filter element by removing the screws, and then disconnect the hose shown. 1. Hose (× 2) 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, replace it. 7. Install the air filter element by inserting it into the air filter case, then installing the screws, and then connect the hose shown. 8.
PERIODIC MAINTENANCE AND MINOR REPAIR EAU01752 EAU00637 Adjusting the carburetor Adjusting the valve clearance The carburetor is an important part of the engine and its emission control system, which requires very sophisticated adjustment. Therefore, carburetor adjustments should be left to Yamaha dealer, who has the necessary professional knowledge and experience. The valve clearance changes with use, resulting in improper air-fuel mixture and/or engine noise.
PERIODIC MAINTENANCE AND MINOR REPAIR rider, passenger, and accessories (windshield, saddlebags, etc. if approved for this model). _ CE-05E Tire air pressure (measured on cold tires) Load* EAU01846 Tires Rear Up to 198 lb (90 kg) 198 lb (90 kg)– maximum 36 psi 41 psi (2.50 kgf/cm2, (2.80 kgf/cm2, 250 kPa) 280 kPa) CE-16E To ensure maximum performance, long service, and safe operation, note the following: Tire air pressure Always check and adjust the tire pressure before operating the motorcycle.
PERIODIC MAINTENANCE AND MINOR REPAIR combinations other than what is approved are used on this motorcycle. The front and rear tires should be of the same manufacture and design. EAU00680 _ _ CE-10E FRONT Manufacturer Dunlop 1. Tire sidewall 2. Tire wear indicator a. Tire tread depth 6 Bridgestone Size 130/90-16 M/C 67H 130/90-16 67H 130/90-16 M/C 67H D404FL G703F REAR Tire inspection Always check the tires before operating the motorcycle.
PERIODIC MAINTENANCE AND MINOR REPAIR EAU00685 Spoke wheels To maximize the performance, durability, and safe operation of your motorcycle, note the following points regarding the specified wheels. ● The wheel rims should be checked for cracks, bends or warpage, and the spokes for looseness or damage before each ride. If any damage is found, have a Yamaha dealer replace the wheel. Do not attempt even the smallest repair to the wheel. A deformed or cracked wheel must be replaced.
PERIODIC MAINTENANCE AND MINOR REPAIR 1. Locknut 2. Clutch lever free play adjusting bolt c. Clutch lever free play 1. Clutch lever free play adjusting nut 2. Locknut EAU00694 6 Adjusting the clutch lever free play The clutch lever free play should measure 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 direction a.
PERIODIC MAINTENANCE AND MINOR REPAIR 3. Tighten the locknut. EW000109 EW000099 WARNING A soft or spongy feeling in the brake pedal can indicate the presence of air in the hydraulic system. If there is air in the hydraulic system, have a Yamaha dealer bleed the system before operating the motorcycle. Air in the hydraulic system will diminish the braking performance, which may result in loss of control and an accident.
PERIODIC MAINTENANCE AND MINOR REPAIR EAU00721 Checking the front and rear brake pads Front The front and rear brake pads must be checked for wear at the intervals specified in the periodic maintenance and lubrication chart. 1. Rear brake light switch 2. Rear brake light switch adjusting nut 1. Brake pad wear indicator groove (× 2) EAU03938 Front brake pads Each front brake pad is provided with wear indicator grooves, which allow you to check the brake pad wear without having to disassemble the brake.
PERIODIC MAINTENANCE AND MINOR REPAIR Rear Front 1. Brake pad wear indicator groove Rear 1. Minimum level mark EAU03939 Rear brake pads Each rear brake pad is provided with a wear indicator groove, which allows you to check the brake pad wear without having to disassemble the brake. To check the brake pad wear, check the wear indicator groove. If a brake pad has worn to the point that the wear indicator groove has almost disappeared, have a Yamaha dealer replace the brake pads as a set. 1.
PERIODIC MAINTENANCE AND MINOR REPAIR ● 6 Be careful that water does not enter the brake fluid reservoir when refilling. Water will significantly lower the boiling point of the fluid and may result in vapor lock. ● Brake fluid may deteriorate painted surfaces or plastic parts. Always clean up spilled fluid immediately. ● As the brake pads wear, it is normal for the brake fluid level to gradually go down. However, if the brake fluid level goes down suddenly, have a Yamaha dealer check the cause.
PERIODIC MAINTENANCE AND MINOR REPAIR 1. Belt tension gauge 3. Note the position of the drive belt with a force of 10 lbf (4.5 kg, 45 N) applied to the belt with a belt tension gauge as shown. 1. Wheel axle nut 1. Brake caliper bracket bolt EAU01748 To adjust the drive belt slack 1. Loosen the rear wheel axle nut and the brake caliper bracket bolt. 6 NOTE: A belt tension gauge is available at a Yamaha dealer. _ _ 4.
PERIODIC MAINTENANCE AND MINOR REPAIR ECA00025 CAUTION: Improper drive belt slack will overload 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. 1. Drive belt slack adjusting bolt (× 2) 2. Locknut (× 2) 3. Wheel axle 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.
PERIODIC MAINTENANCE AND MINOR REPAIR EAU03370 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 lubricated if necessary.
PERIODIC MAINTENANCE AND MINOR REPAIR EAU03164 6 EAU03165 Checking and lubricating the brake and clutch levers Checking and lubricating the sidestand The operation of the brake and clutch levers should be checked before each ride, and the lever pivots should be lubricated if necessary. 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.
PERIODIC MAINTENANCE AND MINOR REPAIR EAU02939 Checking the front fork The condition and operation of the front fork must be checked as follows at the intervals specified in the periodic maintenance and lubrication chart. To check the condition EW000115 WARNING Securely support the 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.
PERIODIC MAINTENANCE AND MINOR REPAIR EAU00794 Checking the wheel bearings Worn or loose steering bearings may cause danger. Therefore, the operation of the steering must be checked as follows at the intervals specified in the periodic maintenance and lubrication chart. 1. Place a stand under the engine to raise the front wheel off the ground. The front and rear wheel bearings must be checked at the intervals specified in the periodic maintenance and lubrication chart.
PERIODIC MAINTENANCE AND MINOR REPAIR EW000116 @ 1. Battery EAU00800 Battery This motorcycle is equipped with a sealed-type (MF) battery, which does not require any maintenance. There is no need to check the electrolyte or to add distilled water. EC000101 CAUTION: Never attempt to remove the battery cell seals, as this would permanently damage the battery. @ @ WARNING ● Electrolyte is poisonous and dangerous since it contains sulfuric acid, which causes severe burns.
PERIODIC MAINTENANCE AND MINOR REPAIR EC000102 @ 6 @ CAUTION: keep the battery ● Always charged. Storing a discharged battery can cause permanent battery damage. ● To charge a sealed-type (MF) battery, a special (constantvoltage) battery charger is required. Using a conventional battery charger will damage the battery. If you do not have access to a sealed-type (MF) battery charger, have a Yamaha dealer charge your battery. 1.
PERIODIC MAINTENANCE AND MINOR REPAIR EC000103 CAUTION: Do not use a fuse of a higher amperage rating than recommended to avoid causing extensive damage to the electrical system and possibly a fire. _ _ 1. Main fuse 2. Spare main fuse Specified fuses: Main fuse: Headlight fuse: Signaling system fuse: Ignition fuse: Odometer fuse: Carburetor heater fuse: 30 A 15 A 10 A 15 A 5A 10 A 3. Turn the key to “ON” and turn on the electrical circuit in question to check if the device operates. 4.
PERIODIC MAINTENANCE AND MINOR REPAIR 1. Screw (× 2) EAU04189 Replacing the headlight bulb 6 This motorcycle is equipped with a quartz bulb headlight. If the headlight bulb burns out, replace it as follows. 1. Remove the headlight unit by removing the screws. 1. Headlight coupler 2. Headlight bulb cover 2. Disconnect the headlight coupler, and then remove the bulb cover. 6-35 1. Headlight bulb holder 3. Unhook the headlight bulb holder, and then remove the defective bulb.
PERIODIC MAINTENANCE AND MINOR REPAIR EC000105 CAUTION: 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 affected. Thoroughly clean off any dirt and fingerprints on the headlight bulb using a cloth moistened with alcohol or thinner. _ 1. Do not touch this area. EW000119 WARNING Headlight bulbs get very hot.
PERIODIC MAINTENANCE AND MINOR REPAIR EAU01579 Supporting the motorcycle 1. Screw (× 2) 1. Screw (× 3) 3. Insert a new bulb into the socket, push it in, and then turn it clockwise until it stops. 4. Install the lens by installing the screws. EAU00855 Replacing a turn signal light bulb or the tail/brake light bulb 6 1. Remove the lens by removing the screws. 2. Remove the defective bulb by pushing it in and turning it counterclockwise.
PERIODIC MAINTENANCE AND MINOR REPAIR To service the rear wheel Raise the rear wheel off the ground by using a motorcycle stand or, if a motorcycle 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. EAU01008 Troubleshooting Although Yamaha motorcycles receive a thorough inspection before shipment from the factory, trouble may occur during operation.
PERIODIC MAINTENANCE AND MINOR REPAIR EAU01297 Troubleshooting chart EW000125 WARNING Keep away open flames and do not smoke while checking or working on the fuel system. @ @ 1. Fuel There is enough fuel. Check the compression. There is no fuel. Supply fuel. There is compression. Check the ignition. There is no compression. Have a Yamaha dealer check the vehicle. Check the fuel level in the fuel tank. The engine does not start. Check the compression. 2.
MOTORCYCLE CARE AND STORAGE Care .................................................................................................. 7-1 Storage ..............................................................................................
MOTORCYCLE CARE AND STORAGE EAU03708 7- Care 7 While the open design of a motorcycle reveals the attractiveness of the technology, it also makes it more vulnerable. Rust and corrosion can develop even if high-quality components are used. A rusty exhaust pipe may go unnoticed on a car, however, it detracts from the overall appearance of a motorcycle.
MOTORCYCLE CARE AND STORAGE thinner, fuel (gasoline), rust removers or inhibitors, brake fluid, antifreeze or electrolyte. ● Do not use high-pressure washers or steam-jet cleaners since they cause water seepage and deterioration in the following areas: seals (of wheel and swingarm bearings, fork and brakes), electric components (couplers, connectors, instruments, switches and lights), breather hoses and vents.
MOTORCYCLE CARE AND STORAGE 6. Wax all painted and chrome-plated 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. windshield. Before using them, make a test by polishing an area which does not affect your visibility. 7 After cleaning 1. Dry the motorcycle with a chamois or an absorbing cloth. 2.
MOTORCYCLE CARE AND STORAGE Saddlebag cleaning and care (for XV16AT(C)/XV16ATLE(C) only) Clean the saddlebag on each side using a high-quality saddle soap. Rub the surface of the soap using a damp cloth or sponge to produce a lather, and then apply it to the surface of the saddlebags. Allow the lather to dry, and then polish the saddlebags with a soft cloth.
MOTORCYCLE CARE AND STORAGE Storage Short-term Always store your motorcycle in a cool, dry place and, if necessary, protect it against dust with a porous cover. ECA00014 7 _ _ CAUTION: ● Storing the motorcycle in a poorly ventilated room or covering it with a tarp, while it is still wet, will allow water and humidity to seep in and cause rust. ● To prevent corrosion, avoid damp cellars, stables (because of the presence of ammonia) and areas where strong chemicals are stored.
MOTORCYCLE CARE AND STORAGE 6. Lubricate all control cables and the pivoting points of all levers and pedals as well as of the sidestand/ centerstand. 7. Check and, if necessary, correct the tire air pressure, and then lift the motorcycle so that both of its wheels are off the ground. Alternatively, 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 plastic bags to prevent moisture from entering them. 9.
SPECIFICATIONS Specifications ....................................................................................
SPECIFICATIONS EAU01038 8- Specifications CS-01E Model Compression ratio XV16A(C)/XV16ALE(C)/ XV16AS(C)/XV16AT(C)/ XV16ATLE(C) Dimensions Overall length 98.4 in (2,500 mm) Overall width 38.6 in (980 mm) Starting system Electric starter Lubrication system Dry sump Engine oil Type 0 Overall height XV16A(C)/XV16ALE(C)/ XV16AS(C) 44.9 in (1,140 mm) XV16AT(C)/XV16ATLE(C) 59.1 in (1,500 mm) Seat height 28.0 in (710 mm) Wheelbase 66.
SPECIFICATIONS Quantity Transmission Without oil filter cartridge replacement 3.9 US qt (3.3 lmp qt, 3.7 L) With oil filter cartridge replacement 4.3 US qt (3.6 lmp qt, 4.1 L) Total amount (dry engine) 5.3 US qt (4.4 lmp qt, 5.0 L) Transfer case oil Type SAE80API “GL-4” Hypoid Gear Oil 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 ratio 0.
SPECIFICATIONS Rear Rear Type Tube tire Type Spoke wheel Size 150/80B-16 71H Size 16 × MT 3.50 150/80B-16 M/C 71H Manufacturer/ model 16 M/C × MT 3.50 Brakes Dunlop / D404 Front Bridgestone / G702 Type Maximum load* XV16A(C)/XV16ALE(C)/ XV16AS(C) 432 lb (196 kg) XV16AT(C)/XV16ATLE(C) 399 lb (181 kg) Up to 198 lb (90 kg)* Rear 36 psi (2.50 kgf/cm2, 250 kPa) Right hand Fluid DOT 4 Type Single disc brake 36 psi (2.50 kgf/cm , 250 kPa) 2 Front 36 psi (2.
SPECIFICATIONS Electrical Fuses Ignition system Transistorized coil ignition (digital) Charging system Type A.C.
CONSUMER INFORMATION Identification numbers ....................................................................... 9-1 Key identification number .................................................................. 9-1 Vehicle identification number ............................................................. 9-1 Model label ........................................................................................ 9-2 Reporting safety defects ...................................................................
CONSUMER INFORMATION EAU01039 9- EAU02944 Identification numbers Record the key identification number, vehicle identification number and model label information in the spaces provided below for assistance when ordering spare parts from a Yamaha dealer or for reference in case the vehicle is stolen. 1. Key identification number 1. KEY IDENTIFICATION NUMBER: CA-02E 2.
CONSUMER INFORMATION 1. Model label EAU01804 Model label The model label is affixed to the frame under the rider seat. (See page 3-11 for rider seat removal and installation procedures.) Record the information on this label in the space provided. This information will be needed when ordering spare parts from a Yamaha dealer.
CONSUMER INFORMATION EAU01051 Reporting safety defects If you believe that your vehicle has a defect which could cause a crash or could cause injury or death, you should immediately inform the National Highway Traffic Safety Administration (NHTSA) in addition to notifying Yamaha Motor Corporation, U.S.A. If NHTSA receives similar complaints, 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.
CONSUMER INFORMATION EAU01053 Motorcycle noise regulation TAMPERING WITH NOISE CONTROL SYSTEM PROHIBITED: Federal law prohibits the following acts or the causing thereof: (1) The removal or rendering inoperative 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 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 d
CONSUMER INFORMATION EAU01325 Maintenance record Copies of work orders and/or receipts for parts purchased and installed on your motorcycle will be required to document that maintenance has been completed in accordance with the emissions warranty. The chart below is printed only as a reminder that maintenance work is required. It is not acceptable proof of maintenance work.
CONSUMER INFORMATION Maintenance interval Date of service Servicing dealer name and address Mileage Remarks 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 9 9-6
CONSUMER INFORMATION EAU02918 YAMAHA MOTOR CORPORATION, U.S.A.
CONSUMER INFORMATION 9 9-8
CONSUMER INFORMATION EAU01063 YAMAHA EXTENDED SERVICE (Y.E.S.
CONSUMER INFORMATION 9 9-10
INDEX 10- A E M Accessories and replacement parts .......6-20 Air filter element, cleaning ......................6-15 Engine break-in ....................................... 5-5 Engine oil and oil filter cartridge ............... 6-9 Engine stop switch................................... 3-6 Engine trouble warning light .................... 3-2 Main switch/steering lock .........................3-1 Maintenance and lubrication, periodic ......6-4 Maintenance, emission control system.....
INDEX Spark plugs, checking ............................. 6-8 Specifications .......................................... 8-1 Speedometer unit .................................... 3-3 Starter (choke) knob .............................. 3-11 Starting and warming up a cold engine.... 5-1 Starting a warm engine............................ 5-3 Start switch.............................................. 3-6 Steering, checking ................................. 6-31 Steering, locking with a padlock.............
YAMAHA MOTOR CO., LTD. PRINTED ON RECYCLED PAPER PRINTED IN JAPAN 2002.08-0.
