Yamaha ROAD STAR XV16AR, ROAD STAR XV16ATLER, ROAD STAR XV16ALER, ROAD STAR XV16ATR, ROAD STAR XV16ASR User Manual

OWNER’S MANUAL

XV16AR(C)

XV16ALER(C)

XV16ASR(C)

XV16ATR(C)

XV16ATLER(C)

4WM-28199-15LIT-11626-16-44

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 spor ting,
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. 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 emis­sions 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
motorcycle. To maintain these high standards, it is important that you and your
Yamaha dealer pay close attention to the recommended maintenance schedules and
operating instructions contained within this manual.

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!

EAU00003

WARNING

CAUTION:

NOTE:

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.

A CAUTION indicates special precautions that must be taken to avoid damage to the
motorcycle.

A NOTE provides key information to make procedures easier or clearer.

NOTE:

@

This manual should be considered a permanent part of this motorcycle and should remain

●

with it even if the motorcycle is subsequently sold.
Yamaha continually seeks advancements in product design and quality. Therefore, while

●

this manual contains the most current product information available at the time of printing,
there may be minor discrepancies between your motorcycle and this manual. If you have
any questions concerning this manual, please consult your Yamaha dealer.

@

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.
REGULAR INSPECTIONS AND CAREFUL MAINTENANCE, ALONG WITH GOOD RIDING
SKILLS, WILL ENSURE THAT YOU SAFELY ENJOY THE CAPABILITIES AND THE RELI­ABILITY OF THIS MOTORCYCLE.

@

IMPORTANT MANUAL INFORMATION

AFFIX DEALER

LABEL HERE

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.

P/N LIT-11626-16-44

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EAU00009

TABLE OF CONTENTS

1SAFETY INFORMATION

2DESCRIPTION

3INSTRUMENT AND CONTROL FUNCTIONS

4PRE-OPERATION CHECKS

5OPERATION AND IMPORTANT RIDING POINTS

6PERIODIC MAINTENANCE AND MINOR REPAIR

7MOTORCYCLE CARE AND STORAGE

8SPECIFICATIONS

9CONSUMER INFORMATION

INDEX

1

2

3

4

5

6

7

8

9

SAFETY INFORMATION

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

1

1-

SAFETY INFORMATION

EAU03633

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

1

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. OBTAIN QUALIFIED TRAINING IN SAFE AND PROPER RIDING TECHNIQUES.

4. OBTAIN PROFESSIONAL TECHNICAL SERVICE AS INDICATED BY THE OWNER’S MANUAL
AND/OR 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 who
did not see the motorcycle. Making yourself conspicuous appears to be very effective in reducing the
chance of this type of accident.

Therefore:

a. Wear a brightly colored jacket.
b. Use extra caution when approaching and passing through intersections, since intersections are

the most likely places for motorcycle accidents to occur.

c. Ride where other motorists can see you. Avoid riding in another motorist’s blind spot.

1-1

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 opera-

tors.
b. Know your skills and limits. Staying within your limits may help you to avoid an accident.
c. We recommend that you practice riding your motorcycle where there is no traffic until you have

become thoroughly familiar with the motorcycle and all of its controls.

5. Many motorcycle accidents have been caused by error of the motorcycle operator. A typical error
made by the operator is veering wide on a turn due to EXCESSIVE SPEED or undercornering (insuf­ficient lean angle for the speed).
a. Always obey the speed limit and never travel faster than warranted by road and traffic conditions.
b. Always signal before turning or changing lanes. Make sure that other motorists can see you.

6. The posture of the operator and passenger is important for proper control.
a. The operator should keep both hands on the handlebar and both feet on the operator footrests

during operation to maintain control of the motorcycle.

b. The passenger should always hold onto the operator, seat strap, or grab bar, if equipped, with

both hands and keep both feet on the passenger footrests.

c. Never carry a passenger unless he or she can firmly place both feet on the passenger footrests.

7. Never ride under the influence of alcohol or other drugs.

8. This motorcycle is designed for on-road use only, therefore, it is not suitable for off-road use.

1

1-2

SAFETY INFORMATION

Protective apparel

The majority of fatalities from motorcycle accidents are the result of head injuries. The use of a safety

1

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., is effective in preventing or reducing abra­sions or lacerations.

4. Never wear loose-fitting clothes, otherwise they could catch on the control levers, footrests, or wheels
and cause injury or an accident.

5. Never touch the engine or exhaust system 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. Modifications may
also make your motorcycle illegal to use.

Loading and accessories

Adding accessories or cargo to your motorcycle can adversely affect stability and handling if the
weight distribution of the motorcycle is changed. To avoid the possibility of an accident, use extreme
caution when adding cargo or accessories to your motorcycle. Use extra care when riding a
motorcycle that has added cargo or accessories. Here are some general guidelines to follow if loading
cargo or adding accessories to your motorcycle:

1-3

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. Make
sure to distribute the weight as evenly as possible on both sides of the motorcycle to minimize imbal­ance or instability.

2. Shifting weights can create a sudden imbalance. Make sure that accessories and cargo are securely
attached to the motorcycle before riding. Check accessory mounts and cargo restraints frequently.

3. Never attach any large or heavy items to the handlebar, front fork, or front fender. These items, in­cluding 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, installation and use of non-Yamaha accessories. Use extreme caution when
selecting and installing any accessories.
Keep the following guidelines in mind, as well as those provided under “Loading” when mounting
accessories.

1. Never install accessories or carry cargo that would impair the performance of your motorcycle. Care­fully inspect the accessory before using it to make sure that it does not in any way reduce ground
clearance or cornering clearance, limit suspension travel, steering travel or control operation, or ob­scure lights or reflectors.

1

1-4

SAFETY INFORMATION

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.

1

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. These accessories may also cause instability when passing or being passed by large ve­hicles.

c. Certain accessories can displace the operator from his or her normal riding position. This improp-

er position limits the freedom of movement of the operator and 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 refueling.
b. Take care not to spill any gasoline on the engine or exhaust system when refueling.
c. Never refuel while smoking or in the vicinity of an open flame.

2. Never start the engine or let it run for any length of time in a closed area. The exhaust fumes are poi­sonous and may cause loss of consciousness and death within a short time. Always operate your
motorcycle in an area that has adequate ventilation.

3. Always turn the engine off before leaving the motorcycle unattended and remove the key from the
main switch. When parking the motorcycle, note the following:

1-5

SAFETY INFORMATION

a. The engine and exhaust system may be hot, therefore, park the motorcycle in a place where pe-

destrians 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. 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 your doctor immediately. If any gasoline spills on your skin or clothing, immediately wash
the affected area with soap and water and change your clothes.

1

1-6

SAFETY INFORMATION

Location of important labels

Please read the following important labels carefully before operating this motorcycle.

1

EAU02977

1-7

SAFETY INFORMATION

1

34

5

2

California onlyXV16AT/XV16ATLE

XV16AT/XV16ATLE

6

1

1-8

(5GA-F8446-00)

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................................................................. 2-5

2

2-

DESCRIPTION

EAU00026

Road Star

™

XV16A(C)/XV16ALE(C)/XV16AS(C) Left view

2

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)

(XV16A)

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)

2-1

Road Star™
XV16A(C)/XV16ALE(C)/XV16AS(C) Right view

DESCRIPTION

2

(XV16A)

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

2-2

DESCRIPTION

Road Star™/Silverado™
XV16AT(C)/XV16ATLE(C) Left view

2

(XV16AT)

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)

2-3

Road Star™/Silverado™
XV16AT(C)/XV16ATLE(C) Right view

DESCRIPTION

2

(XV16AT)

11.Passenger seat

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

2-4

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 (page 3-7)

2. Left handlebar switches (page 3-6)

3. Speedometer unit (page 3-3)

4. Main switch/steering lock (page 3-1)

(XV16AT)

5.Right handlebar switches (page 3-6)

6.Throttle grip (page 6-17)

7.Brake lever (page 3-7)

2-5

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 .............................................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

3

3-

INSTRUMENT AND CONTROL FUNCTIONS

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

LOCK

The steering is locked, and all electrical
systems are off. The key can be
removed.

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.

To lock the steering

1. Turn the handlebars all the way to
the left.

2. Push the key in from the “OFF” po­sition, and then turn it to “LOCK”
while still pushing it.

3. Remove the key.

EAU00040

EAU00027

1. Push.

2. Turn.

EW000016

WARNING

@

Never turn the key to “OFF” or
“LOCK” while the motorcycle is
moving, otherwise the electrical
systems will be switched off, which
may result in loss of control or an
accident. Make sure that the motor­cycle is stopped before turning the
key to “OFF” or “LOCK”.

@

EAU00038

OFF

All electrical systems are off. The key
can be removed.

To unlock the steering
Push the key in, and then turn it to
“OFF” while still pushing it.

3-1

1. Fuel level warning light “ ”

2. High beam indicator light “ ”

3. Turn signal indicator light “ ”

4. Neutral indicator light “ ”

5. Engine trouble warning light “ ”

EAU03034

Indicator and warning lights

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

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.

3

EAU00079

Fuel level warning light “ ”

This warning light comes on when the
fuel level drops below approximately

0.9 US gal (0.8 Imp gal, 3.5 L). When
this occurs, turn the fuel cock lever to
the “RES” position and refuel as soon
as possible.

EAU04241

Engine trouble warning light “ ”

This warning light comes on or flashes
when an electrical circuit monitoring
the engine is defective. When this oc­curs, have a Yamaha dealer check the
self-diagnosis system.

3-2

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. Odometer/tripmeter/clock

2. Speedometer

3. Fuel gauge

4. Set button

5. Mode button

EAU03393

Speedometer unit

The speedometer unit is equipped with
a speedometer, an odometer and two
tripmeters. The speedometer shows
riding speed. The odometer shows the
total distance traveled. The tripmeters
show the distance traveled since they
were last set to zero.

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. The tripmeters can
be used to estimate the distance that
can be traveled with a full tank of fuel.
This information will enable you to plan
future fuel stops.

NOTE:

@

This motorcycle is not equipped with a
tachometer; however, it has a built-in
engine speed limiter, which prevents
the engine speed from exceeding ap­proximately 4,400 r/min.

@

3-3

INSTRUMENT AND CONTROL FUNCTIONS

EAU01735

Self-diagnosis device

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.

CAUTION:

@

When the tachometer displays an
error code, the motorcycle should
be checked as soon as possible in
order to avoid engine damage.

@

EC000004

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 as possible.

NOTE:

@

Do not allow the fuel tank to empty it­self completely.

@

3

3-4

INSTRUMENT AND CONTROL FUNCTIONS

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.

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.

3. Push the left button and only the
hour display will flash.

3-5

8. Push the right button for two sec­onds to set the clock.

1. Dimmer switch “ / ”

2. Turn signal switch “ ”

3. Horn switch “ ”

EAU00118

Handlebar switches

EAU03888

Dimmer switch “ / ”

Set this switch to “ ” for the high
beam and to “ ” for the low beam.

EAU04218

Turn signal switch “ / ”

To signal a right-hand turn, push this
switch to “ ”. To signal a left-hand
turn, push this switch to “ ”. When
released, the switch returns to the cen­ter position.

INSTRUMENT AND CONTROL FUNCTIONS

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.

NOTE:

_

The self-canceling system only oper­ates when the motorcycle is moving, so
that the turn signal lights will not self­cancel while you are stopped at an in­tersection.

_

EAU00129

Horn switch “ ”

Press this switch to sound the horn.

3-6

4. Engine stop switch “ / ”

5. Start switch “ ”

Engine stop switch “ / ”

Set this switch to “ ” before starting
the engine. Set this switch to “ ” to
stop the engine in case of an emergen­cy, such as when the motorcycle over­turns or when the throttle cable is
stuck.

Start switch “ ”

Push this switch to crank the engine
with the starter.

CAUTION:

@

See page 5-1 for starting instruc­tions prior to starting the engine.

@

3

EAU03890

EAU00143

EC000005

INSTRUMENT AND CONTROL FUNCTIONS

3

1. Clutch lever 1. Shift pedal 1. Brake lever

EAU00152

Clutch 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. (See
page 3-17 for an explanation of the ig­nition circuit cut-off system.)

Shift pedal

The shift pedal is located on the left
side of the engine and is used in com­bination with the clutch lever when
shifting the gears of the 5-speed con­stant-mesh transmission equipped on
this motorcycle.

NOTE:

@

Use your toes or heel to shift up and
your toes to shift down.

@

EAU01215

EAU00158

Brake lever

The brake lever is located at the right
handlebar grip. To apply the front
brake, pull the lever toward the handle­bar grip.

3-7

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.

3

1. Brake pedal 1. Fuel tank cap lock cover

EAU00162

Brake pedal

2. “ ” mark
a. Unlock.
b. Lock.

The brake pedal is on the right side of
the motorcycle. To apply the rear

Fuel tank cap

brake, press down on the brake pedal.

To remove the fuel tank cap

Slide the lock cover open, insert the
key into the lock, and then turn it
1/4 turn clockwise. The lock will be re­leased and the fuel tank cap can be
removed.

3-8

EAU02917

NOTE:

@

The fuel tank cap cannot be installed
unless the key is in the lock. In addition,
the key cannot be removed if the cap is
not properly installed and locked.

@

@

WARNING

EW000024

Make sure that the fuel tank cap is
properly installed before riding.

@

INSTRUMENT AND CONTROL FUNCTIONS

3

1. Fuel tank filler tube

2. Fuel level

Fuel

Make sure that there is sufficient fuel in
the tank. Fill the fuel tank to the bottom
of the filler tube as shown.

WARNING

_

Do not overfill the fuel tank, oth-

●

erwise it may overflow when the
fuel warms up and expands.
Avoid spilling fuel on the hot

●

engine.

_

EAU03753

EW000130

EAU00185

CAUTION:

@

Immediately wipe off spilled fuel
with a clean, dry, soft cloth, since
fuel may deteriorate painted surfac­es or plastic parts.

@

EAU04265

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)

ECA00104

CAUTION:

_

Use only unleaded gasoline. The
use of leaded gasoline will cause se­vere damage to internal engine
parts, such as the valves and piston
rings, as well as to the exhaust sys­tem.

_

Your Yamaha engine has been de­signed to use regular unleaded gaso­line 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 premi­um unleaded fuel. Use of unleaded fuel
will extend spark plug life and reduce
maintenance costs.

Gasohol

There are two types of gasohol: gaso­hol containing ethanol and that contain­ing methanol. Gasohol containing
ethanol can be used if the ethanol con­tent does not exceed 10%. Gasohol
containing methanol is not recom­mended by Yamaha because it can
cause damage to the fuel system or ve­hicle performance problems.

3-9

INSTRUMENT AND CONTROL FUNCTIONS

OFF: closed position

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:

OFF

With the lever in this position, fuel will
not flow. Always return the lever to this
position when the engine is not run­ning.

ON: normal position

Pointed end positioned over “ON”

ON

With the lever in this position, fuel flows
to the carburetor. Normal riding is done
with the lever in this position.

RES: reserve position

3

Pointed end positioned over “RES”

RES

This indicates reserve. If you run out of
fuel while riding, move the lever to this
position. Fill the tank at the first oppor­tunity. Be sure to set the lever back to
“ON” after refueling!

3-10

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).

EAU03372

Locking the 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 lock­ing 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 pad­lock.

3-11

EAU03785*

Rider seat

To remove the rider seat

1. Insert the key into the main switch,
and then turn it counterclockwise
to “OPEN”.

NOTE:

_

Do not push inward when turning the
key.

_

2. Pull the rider seat off.

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

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.

NOTE:

_

Make sure that the rider seat is proper­ly secured before riding.

_

1. Helmet holder

EAU00264

Helmet holder

The 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 in­stallation procedures.)

2. Attach the helmet to the helmet
holder, and then securely install
the seat.

3-12

To release the helmet from the hel­met holder

Remove the rider seat, remove the hel­met from the helmet holder, and then
install the seat.

3

INSTRUMENT AND CONTROL FUNCTIONS

3

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.

1. Windshield

2. Bolt (× 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. Loosen the bolts on each side of
the windshield.

2. Move the windshield to the desired
angle.

3. Tighten the bolts to the specified
torque.

1. Headlight cover

2. Screw (× 4)

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.

Tightening torque:

Windshield bolts:

12 ft·lbf (1.6 m·kgf, 16 Nm)

3-13

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.

@

EW000134

INSTRUMENT AND CONTROL FUNCTIONS

EAU04263*

Saddlebags
[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.

_

WARNING

_

Improper loading or overloading
can cause loss of control and possi­bly an accident or personal injury.

Always securely close each

●

saddlebag before riding.
Distribute weight evenly on

●

each side of the motorcycle.
Do not exceed the load limit of

●

11 lb (5 kg) for each saddlebag.
Do not exceed the maximum

●

load of XV16A(C), XV16ALE(C),
XV16AS(C): 432 lb (196 kg) /
XV16AT(C), XV16ATLE(C):
399 lb (181 kg) for the vehicle.

_

3

EWA00027

3-14

INSTRUMENT AND CONTROL FUNCTIONS

3

1. Locknut

2. Spring preload adjusting nut

EAU03591

Adjusting the shock absorber
assembly

This shock absorber assembly is
equipped with a spring preload adjust­ing nut.

CAUTION:

_

Never attempt to turn an adjusting
mechanism beyond the maximum
or minimum settings.

_

Adjust the spring preload as follows.

1. Loosen the locknut.

EC000015

1. Special wrench A. Distance A

2. To increase the spring preload
and thereby harden the suspen­sion, turn the adjusting nut in di­rectiona. To decrease the spring
preload and thereby soften the
suspension, turn the adjusting nut
in direction b.

3-15

NOTE:

_

The spring preload setting is deter­mined by measuring distance A, shown
in the illustration. The shorter distance
A is, the lower the spring preload; the
longer distance A is, the higher the
spring preload.

_

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)

3. Tighten the locknut to the speci­fied torque.

Tightening torque:

Locknut:

25 ft·lbf (3.5 m·kgf, 35 Nm)

EC000018

CAUTION:

_

Always tighten the locknut against
the adjusting nut, and then tighten
the locknut to the specified torque.

_

INSTRUMENT AND CONTROL FUNCTIONS

EAU00315

WARNING

@

This shock absorber contains high­ly pressurized nitrogen gas. For
proper handling, read and under­stand the following information be­fore handling the shock absorber.
The manufacturer cannot be held re­sponsible for property damage or
personal injury that may result from
improper handling.

Do not tamper with or attempt to

●

open the gas cylinder.
Do not subject the shock ab-

●

sorber to an open flame or other
high heat sources, otherwise it
may explode due to excessive
gas pressure.
Do not deform or damage the

●

gas cylinder in any way, as this
will result in poor damping per­formance.
Always have a Yamaha dealer

●

service the shock absorber.

@

3

3-16

INSTRUMENT AND CONTROL FUNCTIONS

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:

@

3

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.)

@

EAU00330

EW000044

WARNING

@

The motorcycle must not be ridden
with the sidestand down, or if the
sidestand cannot be properly
moved up (or does not stay up), oth­erwise the sidestand could contact
the ground and distract the opera­tor, resulting in a possible loss of
control. Yamaha’s ignition circuit
cut-off system has been designed to
assist the operator in fulfilling the
responsibility of raising the side­stand before starting off. Therefore,
check this system regularly as de­scribed 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 (com­prising the sidestand switch, clutch
switch and neutral switch) has the fol­lowing functions.

It prevents starting when the trans-

●

mission is in gear and the side­stand is up, but the clutch lever is
not pulled.
It prevents starting when the trans-

●

mission is in gear and the clutch
lever is pulled, but the sidestand is
still down.
It cuts the running engine when

●

the transmission is in gear and the

sidestand is moved down.
Periodically check the operation of the
ignition circuit cut-off system according
to the following procedure.

WARNING

_

If a malfunction is noted, have a
Yamaha dealer check the system
before riding.

_

EW000045

3-17

CD-01E

INSTRUMENT AND CONTROL FUNCTIONS

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

With the engine still running:

6. Move the sidestand up.

7. Keep the clutch lever pulled.

8. Shift the transmission into gear.

9. Move the sidestand down.

Does the engine stall?

YES NO

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?

YES NO

The system is OK.

The motorcycle can be ridden.

NO

NOTE:

This check is most reliable if performed with
a warmed-up engine.

The neutral switch may be defective.

The motorcycle should not be ridden

checked by a Yamaha dealer.

The sidestand switch may be defective.

The motorcycle should not be ridden

checked by a Yamaha dealer.

The clutch switch may be defective.

The motorcycle should not be ridden

checked by a Yamaha dealer.

until

until

until

3

3-18

PRE-OPERATION CHECKS

Pre-operation check list .......................... ... .... ... ... ... .... ... ... ... ... .... ... ... . 4 -1

4

4-

PRE-OPERATION CHECKS

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 check list

ITEM CHECKS PAGE

•Check fuel level in fuel tank.

4

Fuel

Engine oil

Front brake

Rear brake

Clutch

Throttle grip

• Refuel if necessary.

• Check fuel line for leakage.

• Check oil level in engine.

• If necessary, add recommended oil to specified level.

• Check vehicle for oil leakage.

•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.

•Check operation.

• If soft or spongy, have Yamaha dealer bleed hydraulic system.

•Check fluid level in reservoir.

• If necessary, add recommended brake fluid to specified level.

•Check hydraulic system for leakage.

•Check operation.

•Lubricate cable if necessary.

• Check lever free play.

•Adjust if necessary.

•Make sure that operation is smooth.

•Check cable free play.

• If necessary, have Yamaha dealer adjust cable free play and lubricate cable and
grip housing.

4-1

3-9

6-9–6-12

6-21–6-25

6-22–6-25

6-21

6-17

EAU01114

EAU03439

PRE-OPERATION CHECKS

ITEM CHECKS PAGE

Control cables

Wheels and tires

Brake and shift pedals

Brake and clutch levers

Sidestand

Chassis fasteners
Instruments, lights, signals

and switches
Sidestand switch

NOTE:

@

Pre-operation checks should be made each time the motorcycle is used. Such an inspection can be accomplished in a very
short time; and the added safety it assures is more than worth the time involved.

@

WARNING

@

If any item in the Pre-operation check list is not working properly, have it inspected and repaired before operating
the motorcycle.

@

•Make sure that operation is smooth.

• Lubricate if necessary.

•Check for damage.

• Check tire condition and tread depth.

• Check air pressure.

• Correct if necessary.

•Make sure that operation is smooth.

• Lubricate pedal pivoting points if necessary.

•Make sure that operation is smooth.

• Lubricate lever pivoting points if necessary.

•Make sure that operation is smooth.

• Lubricate pivot if necessary.

•Make sure that all nuts, bolts and screws are properly tightened.

•Tighten if necessary.

•Check operation.

• Correct if necessary.

•Check operation of ignition circuit cut-off system.

• If system is defective, have Yamaha dealer check vehicle.

—

6-18–6-20

6-28

6-29

6-29

—

—

3-17

EWA00033

4

4-2

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 .............................................................................................. 5-6

5

5-

OPERATION AND IMPORTANT RIDING POINTS

EAU00372

● 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.

@

CAUTION:

@

EAU00373

WARNING

@

5

● 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.

● Never start the engine or operate

● Make sure not to store personal

items near the air cleaner in­take, otherwise air intake will be
blocked and performance will
suffer.

● Make sure not to put anything

near the battery and its termi­nals, otherwise electrical failure
and acid corrosion may result.

@

EAU00376

it in a closed area for any length
of time. Exhaust fumes are poi-

Starting and warming up a
cold engine

In order for the ignition circuit cut-off
system to enable starting, one of the
following conditions must be met:

The transmission is in the neutral

●

position.
The transmission is in gear with

●

the clutch lever pulled and the
sidestand up.

WARNING

@

● Before starting the engine,

check the function of the igni­tion circuit cut-off system ac­cording to the procedure
described on page 3-18.

● Never ride with the sidestand

down.

@

EAU01751*

EW000054

sonous, and inhaling them can
cause loss of consciousness
and death within a short time. Al­ways make sure that there is ad­equate ventilation.

5-1

1. Turn the fuel cock lever to “ON”.

2. Turn the key to “ON” and make
sure that the engine stop switch is
set to “ ”.

3. Shift the transmission into the neu­tral position.

NOTE:

@

When the transmission is in the neutral
position, the neutral indicator light
should be on, otherwise have a
Yamaha dealer check the electrical
circuit.

@

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:

4. Turn the starter (choke) on and
completely close the throttle. (See
page 3-11 for starter (choke) oper­ation.)

5. Start the engine by pushing the
start switch.

NOTE:

@

If the engine fails to start, release the
start switch, wait a few seconds, and
then try again. Each starting attempt
should be as short as possible to pre­serve the battery. Do not crank the en­gine more than 10 seconds on any one
attempt.

@

6. After starting the engine, move the
starter (choke) knob back halfway.

@

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. The time necessary
for starter (choke) use depends upon
the ambient temperature. Tempera­tures above 50°F (10°C) require about
7seconds of starter (choke) use and
temperatures below 50°F (10°C) re­quire about 35 seconds with the starter
(choke) turned on, then about

2.5 minutes with the starter (choke) in
the halfway position.

@

5

5-2

OPERATION AND IMPORTANT RIDING POINTS

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.

5

EAU01258

EAU00423

Shifting

Shifting gears lets you control the
amount of engine power available for
starting off, accelerating, climbing hills,
etc.
The gear positions are shown in the il­lustration.

NOTE:

@

To shift the transmission into the neu­tral position, press the shift pedal down
repeatedly until it reaches the end of its
travel, and then slightly raise it.

@

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 dis­tances. The transmission is
properly lubricated only when
the engine is running. Inade­quate lubrication may damage
the transmission.
Always use the clutch while

●

changing gears to avoid dam­aging the engine, transmission,
and drive train, which are not
designed to withstand the
shock of forced shifting.

@

EC000048

5-3

OPERATION AND IMPORTANT RIDING POINTS

EAU02988*

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. (Make sure not to shift the
transmission into the neutral posi­tion.)

6. Open the throttle part way and
gradually release the clutch lever.

7. Follow the same procedure when
shifting to the next higher gear.

NOTE:

@

Always shift gears at the recommend­ed 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. Shift the transmission into the neu­tral position when the motorcycle
is almost completely stopped. The
neutral indicator light should come
on.

EAU02974

Recommended shift points

The recommended shift points during
acceleration and deceleration are
shown in the table below.

CF-04E

1st → 2nd
2nd → 3rd
3rd → 4th
4th → 5th

Acceleration

shift point

mi/h (km/h)

13 (20)
19 (30)
25 (40)
31 (50)

Deceleration

shift point

mi/h (km/h)

16 (25)
16 (25)
16 (25)
16 (25)

5

5-4

OPERATION AND IMPORTANT RIDING POINTS

Engine break-in

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). The various parts
in the engine wear and polish them­selves to the correct operating clear-

5

ances. During this period, prolonged
full-throttle operation or any condition
that might result in engine overheating
must be avoided.

EAU01128

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 filter
cartridge replaced.

@

1,000 mi (1,600 km) and beyond

The vehicle can now be operated
normally.

EC000049

CAUTION:

@

If any engine trouble should occur
during the engine break-in period,
immediately have a Yamaha dealer
check the vehicle.

@

5-5

EAU00457

Parking

When parking, stop the engine, re­move the key from the main switch,
and then turn the fuel cock lever to
“OFF”.

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.

@

EW000058

OPERATION AND IMPORTANT RIDING POINTS

5

5-6

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) ................................6-9

Engine oil and oil filter cartridge ..........................6-9

Transfer case oil .................................................6-13

Cleaning the air filter element ........................... .6-15

Adjusting the carburetor .....................................6-17

Adjusting the throttle cable free play ..................6-17

Adjusting the valve clearance ............................6-17

Tires....................................................................6-18

Spoke wheels ...................... ... .... ... ... ... .... ... .......6-20

Accessories and replacement parts ..................6-20

Adjusting the clutch lever 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 lubricating the brake and

clutch levers .................................................... 6-29

Checking and lubricating the sidestand ............ 6-29

Checking the front fork ...................................... 6-30

Checking the steering ....................................... 6-31

Checking the wheel bearings ............................ 6-31

Battery ............... ... ... ... ....................................... 6-32

Replacing the fuses .......................................... 6-33

Replacing the headlight bulb ............................. 6-35

Replacing a turn signal light bulb or

the tail/brake light bulb .................................... 6-37

Supporting the motorcycle ................................ 6-37

Troubleshooting ................. ................................ 6-38

Troubleshooting chart ........ ... ... .... ... ... ... ... .... ... ... 6-39

6

6-

PERIODIC MAINTENANCE AND MINOR REPAIR

EAU00462

Safety is an obligation of the owner.
Periodic inspection, adjustment and lu­brication will keep your vehicle in the
safest and most efficient condition pos­sible. The most important points of
motorcycle inspection, adjustment, and
lubrication are explained on the follow­ing pages.

Maintenance, replacement, or repair
of the emission control devices and
systems may be performed by any
repair establishment or individual
that is certified (if applicable).

6

WARNING

@

If you are not familiar with motor­cycle maintenance work, have a
Yamaha dealer do it for you.

@

EAU01790

EW000060

TROL ARE GROUPED SEPARATE­LY. THESE SERVICES REQUIRE
SPECIALIZED DATA, KNOWLEDGE,
AND EQUIPMENT. YAMAHA DEAL­ERS ARE TRAINED AND EQUIPPED
TO PERFORM THESE PARTICULAR
SERVICES.

EAU00467

PERIODIC MAINTENANCE

PROPER PERIODIC MAINTENANCE
OF YOUR MOTORCYCLE IS IMPOR­TANT IN ORDER TO ENJOY LONG,
PLEASURABLE SERVICE. ESPE­CIALLY IMPORTANT ARE THE
MAINTENANCE SERVICES RELAT­ED TO EMISSIONS CONTROL.
THESE CONTROLS NOT ONLY
FUNCTION TO ENSURE CLEANER
AIR, BUT ARE ALSO VITAL TO
PROPER ENGINE OPERATION AND
MAXIMUM PERFORMANCE. IN THE
FOLLOWING PERIODIC MAINTE­NANCE CHARTS, THE SERVICES
RELATED TO EMISSIONS CON-

6-1

1. Owner’s tool kit

EAU03644

Owner’s tool kit

The owner’s tool kit is located under
the rider seat. (See page 3-11 for rider
seat removal and installation proce­dures.)
The service information included in this
manual and the tools provided in the
owner’s tool kit are intended to assist
you in the performance of preventive
maintenance and minor repairs. How­ever, additional tools such as a torque
wrench may be necessary to perform
certain maintenance work correctly.

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.

_

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.

_

EW000062

6

6-2

PERIODIC MAINTENANCE AND MINOR REPAIR

Periodic maintenance chart for the emission control system

EAU00471

No. ITEM ROUTINE

•Check valve clearance when engine is
cold.

•Adjust if necessary.

•Check condition.

•Adjust gap and clean.

•Replace at 8,000 mi (13,000 km) or
12 months and thereafter every
8,000mi (13,000 km) or 12 months.

•Check ventilation hose for cracks or
damage.

•Replace if necessary.

•Check fuel hose for cracks or damage.

•Replace if necessary.

•Replace initial 20, 000 mi ( 31,000 km) or
30 months and thereafter every 20,000 mi
(31,000 km) or 30 months.

•Check for leakage.

•Retighten if necessary.

•Replace gasket(s) if necessary.

•Check and adjust engine idle speed.

•Adjust cable free play.

•Check control system for damage.

•Replace if necessary.

6

Valve clearance

1

*

2Spark plug

Crankcase

3

*

ventilation system

4*Fuel line

5*Fuel filter

6

Exhaust system

*

7*Idle speed

Evaporative
Emission control

8

*

system (For
California only)

INITIAL ODOMETER READINGS

600 mi

(1,000 km)

or

1 month

√ √√√√√

4,000 mi

(7,000 km)

or

6 months

√

√√√√√

√√√√√

√√√√√

*Since these items require special t ools, dat a a nd t ech nica l skills, have a Y amah a de aler pe rform the se rvice.

8,000 mi

(13,000 km)

or

12 months

Every 16,000 mi (25,000 km)

Replace

12,000 mi

(19,000 km)

or

18 months

√

√√

16,000 mi

(25,000 km)

or

24 months

Replace

20,000 mi

(31,000 km)

or

30 months

√

Replace

6-3

PERIODIC MAINTENANCE AND MINOR REPAIR

General maintenance and lubrication chart

INITIAL ODOMETER READINGS

No. ITEM ROUTINE TYPE

1Engine oil
2*Oil filter

Air filter
(See NOTE on

3

*

page 6-6.)

4*Front brake

5*Rear brake

6*Clutch

7*Transfer case oil

Control cable

8

*

Rear arm pivot

9

*

bearing

•Replace See page 8-1.

•Replace

•Clean with compressed
air.

•Replace if necessary.

•Check operation and fluid
leakage. (See NOTE page
6-6.)

• Correct if necessary.

•Check operation and fluid
leakage. (See NOTE page
6-6.)

• Correct if necessary.

•Check operation and free
play.

• Correct if necessary.

•Check vehicle for leakage.

•Replace every 16,000 mi
(25,000 km) or 24 months.

•Apply chain lube
thoroughly.

•Check bearing assembly
for looseness.

•Moderately repack every
16,000 mi (25,000 km) or
24 months.

SAE 80 API “GL-4”
hypoid gear oil

Yamaha chain and
cable lube or
SAE 10W30 motor oil

Medium weight wheel
bearing grease

-

-

-

-

-

600 mi

(1,000 km)

or

1 month

√√√√√√

√√√

√√√√

√√√√

√√√√√√

Replace Check Replace

√√√√√√

*Since these items require special too ls, data and techn ical skills, have a Yamaha dealer perform the service.

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

Replace

brake fluid

Replace

brake fluid

Repack

EAU00472

20,000 mi

(31,000 km)

or

30 months

√

√

6

6-4

PERIODIC MAINTENANCE AND MINOR REPAIR

INITIAL ODOMETER READINGS

No. ITEM ROUTINE TYPE

Brake/

10

11

12*Sidestand pivot

13*Sidestand switch

14*Front fork

6

15

*

16*Wheel bearings

17

*

18*Drive belt

Clutch lever
pivot shaft

Brake pedal
and shift
pedal shaft

Steering
bearings

Rear suspen­sion link pivots

•Apply chain lube lightly.

•Lubricate

•Apply chain lube lightly.

•Check operation and
lubricate.

•Apply chain lube lightly.

•Check and clean or
replace if necessary.

•Check operation and for
leakage.

• Check bearing assembly
for looseness.

•Moderately repack every
16,000 mi (25,000 km) or
24 months.

• Check bearings for
smooth rotation.

•Apply grease lightly.

• Check for belt tension

•Adjust if necessary

Yamaha chain and
cable lube or
SAE 10W30 motor oil

Yamaha chain and
cable lube or
SAE 10W30 motor oil

Yamaha chain and
cable lube or
SAE 10W30 motor oil

-

-

Lithium soap base
grease

-

Molybdenum disulfide
grease

-

600 mi

(1,000 km)

or

1 month

√√√√√√

√

*Since these items require special t ools, dat a a nd t ech nica l skills, have a Y amah a de aler pe rform the se rvice.

4,000 mi

(7,000 km)

or

6 months

√ √√√√

√ √√√√

√ √√√√

√ √√√√

√√√

√ √√√√

8,000 mi

(13,000 km)

or

12 months

12,000 mi

(19,000 km)

18 months

Every 2,500 mi (4,000 km)

16,000 mi

or

(25,000 km)

or

24 months

Repack

20,000 mi

(31,000 km)

or

30 months

√

√

6-5

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.

_

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.

• 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 cracked or damaged.

@

EAU03057

6

6-6

PERIODIC MAINTENANCE AND MINOR REPAIR

1. Panel A 1. Bolt

EAU01777

Removing and installing the
panel

The panel shown above needs to be

6

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.

Panel A

To remove the panel
Remove the bolt, and then pull the pan­el off as shown.

EAU00491

To install the panel
Place the panel in the original position,
and then install the bolt.

6-7

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.

The porcelain insulator around the cen­ter electrode of each spark plug should
be a medium-to-light tan (the ideal col­or when the motorcycle is ridden nor­mally), and all spark plugs installed in
the engine should have the same color.
If any spark plug shows a distinctly dif­ferent color, the engine could be defec­tive. 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.

Specified spark plug:

DPR7EA-9/NGK or
X22EPR-U9/DENSO

Before installing a spark plug, the spark
plug gap should be measured with a
wire thickness gauge and, if necessary,
adjusted to specification.

Clean the surface of the spark plug
gasket and its mating surface, and then
wipe off any grime from the spark plug
threads.

Tightening torque:

Spark plug:

12.5 ft·lbf (1.75 m·kgf, 17.5 Nm)

NOTE:

@

If a torque wrench is not available when
installing a spark plug, a good estimate
of the correct torque is 1/4–1/2 turn
past finger tight. However, the spark
plug should be tightened to the speci­fied torque as soon as possible.

@

6

Spark plug gap:

0.03–0.04 in (0.8–0.9 mm)

6-8

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

Canister (for California only)

This model is equipped with a canister
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 nec­essary, clean it.

EAU00499

1. Engine oil filler cap

EAU04628

Engine oil and oil filter
cartridge

The engine oil level should be checked
before each ride. In addition, the oil
must be changed and the oil filter car­tridge replaced at the intervals speci­fied in the periodic maintenance and
lubrication chart.

To check the engine oil level

1. Place the motorcycle on a level
surface and hold it in an upright
position.

6-9

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 rider seat. (See page
3-11 for rider seat removal and in­stallation procedures.)

3. Start the engine, warm it up until
the engine oil has reached a nor­mal temperature of 140 °F (60 °C),
let it continue to idle for ten sec­onds, and then turn the engine off.

NOTE:

_

To achieve the proper engine oil tem­perature for an accurate oil level read­ing, the engine must have first
completely cooled down, and then
warmed up again for several minutes to
normal operating temperature.

_

1. Maximum level mark

2. Minimum level mark

3. Dipstick

4. Wait a few minutes until the oil set­tles, 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 mini­mum level mark, add sufficient oil
of the recommended type to raise
it to the correct level.

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.

_

6. Insert the dipstick into the oil filler
hole, and then tighten the oil filler
cap.

7. Install the rider seat.

ECA00027

CAUTION:

_

Make sure that the oil filler cap is se­curely tightened, otherwise oil may
seep out when the engine is run­ning.

_

6

6-10

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) 1. Engine oil drain bolt (crankcase)

To change the engine oil (with or
without oil filter cartridge replace­ment)

1. Start the engine, warm it up for

6

several minutes, and then turn it
off.

2. Place an oil pan under the oil tank
to collect the used oil.

3. Remove the engine oil filler cap
and drain bolt to drain the oil from
the oil tank.

NOTE:

_

Skip steps 4–8 if the oil filter cartridge is
not being replaced.

_

4. Place an oil pan under the engine
to collect the used oil.

6-11

7. Apply a thin coat of engine oil to
the O-ring of the new oil filter car­tridge.

NOTE:

_

Make sure that the O-ring is properly
seated.

_

8. Install the new oil filter cartridge
with an oil filter wrench, and then
tighten it to the specified torque
with a torque wrench.

Tightening torque:

Oil filter cartridge:

12 ft·lbf (1.7 m·kgf, 17 Nm)

PERIODIC MAINTENANCE AND MINOR REPAIR

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)

10. Pour only 2.6 US qt (2.2 Imp qt,

2.5 L) of the specified amount of
recommended engine oil through
the filler hole, insert the dipstick,
and then tighten the oil filler cap.

11. Start the engine, rev it several
times, and then turn it off.

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.

Recommended engine oil:

See page 8-1.

Oil quantity:

Without oil filter cartridge
replacement:

3.9 US qt (3.3 Imp qt, 3.7 L)
With oil filter cartridge
replacement:

4.3 US qt (3.6 Imp qt, 4.1 L)
Total amount (dry engine):

5.3 US qt (4.4 Imp qt, 5.0 L)

ECA00133

CAUTION:

_

In order to prevent clutch slip-

●

page (since the engine oil also
lubricates the clutch), do not
mix any chemical additives. Do
not use oils with a diesel speci­fication 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 the engine off
and check for the cause.

15. Turn the engine off, and then
check the oil level and correct it if
necessary.

6

6-12

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

Transfer case oil

The transfer case oil level should be
checked before each ride. In addition,

6

the oil must be changed at the intervals
specified in the periodic maintenance
and lubrication chart.

To check the transfer case oil level

1. Place the motorcycle on a level
surface and hold it in an upright
position.

EAU04251

NOTE:

_

The oil should be at 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 rec­ommended 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.

Tightening torque:

Transfer case oil check bolt:

5 ft·lbf (0.75 m·kgf, 7.5 Nm)

1. Transfer case oil drain bolt

To change the transfer case oil

1. Place an oil pan under the transfer
case to collect the used oil.

2. Remove the drain bolt and the
check bolt to drain the oil from the
transfer case.

3. Install the drain bolt and the check
bolt, and then tighten the drain bolt
to the specified torque.

Tightening torque:

Transfer case oil drain bolt:

13 ft·lbf (1.75 m·kgf, 17.5 Nm)

6-13

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.

Recommended transfer case oil:

See page 8-2.

Oil quantity:

0.42 US qt (0.35 Imp qt, 0.4 L)

ECA00024

CAUTION:

_

Make sure that no foreign material
enters the transfer case.

_

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.

6

6-14

PERIODIC MAINTENANCE AND MINOR REPAIR

1. Bolt (× 4)

2. Air filter case

Cleaning the air filter element

The air filter element should be cleaned
at the intervals specified in the periodic

6

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.

EAU03707

1. Air filter joint clamp screw 1. Screw (× 2)

2. Loosen the air filter joint clamp
screw, and then slightly pull the air
filter case out.

2. Hose (× 2)

3. Air filter case cover

3. Remove the air filter case cover by
removing the screws.

4. Disconnect the hoses shown.

6-15

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.

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. Install the air filter case cover by
installing the screws.

6-16

1. Hose (× 2)

9. Connect the hoses shown.

10. Install the air filter case by pushing
it onto the air filter joint, and then
tighten the air filter joint clamp
screw.

11. Install the air filter case by install­ing the bolts.

6

PERIODIC MAINTENANCE AND MINOR REPAIR

Adjusting the carburetor

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.

6

EAU01752

EAU00637

Adjusting the valve clearance

The valve clearance changes with use,
resulting in improper air-fuel mixture
and/or engine noise. To prevent this
from occurring, the valve clearance
must be adjusted by a Yamaha dealer
at the intervals specified in the periodic
maintenance and lubrication chart.

a. Throttle cable free play

EAU00635

Adjusting 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 neces­sary, have a Yamaha dealer adjust it.

6-17

PERIODIC MAINTENANCE AND MINOR REPAIR

EAU01846

Tires

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.

WARNING

_

Tire inflation pressure should be
checked and adjusted when the
temperature of the tire equals the
ambient air temperature. Tire infla­tion pressure must be adjusted ac­cording to total weight of cargo,

EWA00011

rider, passenger, and accessories
(windshield, saddlebags, etc. if ap­proved for this model).

_

CE-05E

Load* Front Rear

Up to 198 lb (90 kg)

198 lb (90 kg)–
maximum

CE-16E

Maximum load*

*Total weight of rider, passenger, cargo and

accessories

WARNING

_

Tire air pressure

(measured on cold tires)

36 psi
(2.50 kgf/cm
250 kPa)

36 psi
(2.50 kgf/cm
250 kPa)

XV16A(C)/XV16ALE(C)/
XV16AS(C): 432 lb (196 kg)
XV16AT(C)/XV16ATLE(C):
399 lb (181 kg)

2

,

2

,

36 psi
(2.50 kgf/cm2,
250 kPa)

41 psi
(2.80 kgf/cm2,
280 kPa)

EWA00012

Proper loading of your motorcycle
is important for several characteris­tics of your motorcycle, such as
handling, braking, performance 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 the suspen­sion for your load, and check the
condition and pressure of your tires.
NEVER OVERLOAD YOUR MOTOR­CYCLE. Make sure the total weight
of the cargo, rider, passenger, and
accessories (windshield, saddle­bags, etc. if approved for this model)
does not exceed the maximum load
of the motorcycle. Operation of an
overloaded motorcycle could cause
tire damage, an accident, or even in­jury.

_

6

6-18

PERIODIC MAINTENANCE AND MINOR REPAIR

1. Tire sidewall

2. Tire wear indicator
a. Tire tread depth

Tire inspection

Always check the tires before operating
the motorcycle. If a tire tread shows

6

crosswise line (minimum tread depth),
if the tire has a nail or glass fragments
in it, or if the side wall is cracked, con­tact a Yamaha dealer immediately and
have the tire replaced.

WARNING

_

After extensive tests, the tires men­tioned below have been approved
by Yamaha Motor Co., Ltd. for this
model. No guarantee for handling
characteristics can be given if tire

EW000078

combinations other than what is ap­proved are used on this motorcycle.
The front and rear tires should be of
the same manufacture and design.

_

CE-10E

FRONT

Manufacturer Size Model

Dunlop

Bridgestone

REAR

Manufacturer Size Model

Dunlop

Bridgestone

CE-23E

Minimum tire tread depth
(front and rear)

NOTE:

_

130/90-16 67H

130/90-16 M/C 67H

130/90-16 67H

130/90-16 M/C 67H

150/80B-16 71H

150/80B-16 M/C 71H

150/80B-16 71H

150/80B-16 M/C 71H

0.04 in (1.0 mm)

D404FL

G703F

D404

G702

These limits may be different by regula­tion from country to country. If so, con­form to the limits specified by the
regulations of your own country.

_

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, includ­ing the tires, should be left to a

Yamaha dealer, who has the

necessary professional knowl­edge and experience.
It is not recommended to patch

●

a punctured tube. If unavoid­able, however, patch the tube
very carefully and replace it as
soon as possible with a high­quality product.

_

EAU00680

6-19

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.
The wheel should be balanced

●

whenever either the tire or wheel
has been changed or replaced. An
unbalanced wheel can result in
poor performance, adverse han­dling characteristics, and a short­ened tire life.
Ride at moderate speeds after

●

changing a tire since the tire sur­face 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 replace­ment parts you choose for your
motorcycle should be designed spe­cifically for this model, and they
must be securely mounted to main­tain the inherent stability of the orig­inal design. Genuine Yamaha Parts
and Accessories are designed and
tested to be compatible with your
motorcycle. Please consider Genu­ine Yamaha Parts and Accessories
before making a purchase. Use of
non-Yamaha-approved accessories
or replacement parts may cause
loss of handling stability and riding
safety. Since Yamaha cannot con­trol the quality of accessories or
parts manufactured by other com­panies, Yamaha cannot be held lia­ble for any consequences caused

6-20

by the use of items which have not
been approved by Yamaha.

@

6

PERIODIC MAINTENANCE AND MINOR REPAIR

1. Locknut

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

Adjusting the clutch lever free
play

6

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. To decrease the clutch
lever free play, turn the adjusting
bolt in direction b.

EAU00694

1. Clutch lever free play adjusting nut

2. Locknut

3. If the specified clutch lever free
play could be obtained as de­scribed 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 loos­en the clutch cable.

5. Loosen the locknut at the
crankcase.

6. To increase the clutch lever free
play, turn the adjusting nut in di­rectiona. 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.

6-21

1. Locknut

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

EAU00696

Adjusting the brake lever free
play

The brake lever free play should mea­sure 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 di­rection a. To decrease the brake
lever free play, turn the adjusting
bolt in direction b.

PERIODIC MAINTENANCE AND MINOR REPAIR

3. Tighten the locknut.

WARNING

@

After adjusting the brake lever

●

free play, check the free play
and make sure that the brake is
working properly.
A soft or spongy feeling in the

●

brake lever can indicate the
presence of air in the hydraulic
system. If there is air in the 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.

@

EW000099

a. Distance between brake pedal and footrest

EAU01746

Adjusting the brake pedal
position

The top of the brake pedal should be po­sitioned approximately 3.9 in (100 mm)
above the top of the footrest as shown.
Periodically check the brake pedal posi­tion 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 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.

@

6

6-22

PERIODIC MAINTENANCE AND MINOR REPAIR

1. Rear brake light switch

2. Rear brake light switch adjusting nut

Adjusting the rear brake light
switch

The rear brake light switch, which is ac-

6

tivated by the brake pedal, is properly
adjusted when the brake light comes
on just before braking takes effect. If
necessary, adjust the brake light switch
as follows.
Turn the adjusting nut while holding the
rear brake light switch in place. To
make the brake light come on earlier,
turn the adjusting nut in direction a. To
make the brake light come on later,
turn the adjusting nut in direction b.

EAU00713

EAU00721

Checking the front and rear
brake pads

The front and rear brake pads must be
checked for wear at the intervals spec­ified in the periodic maintenance and
lubrication chart.

Front

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.
To check the brake pad wear, check
the wear indicator grooves. If a brake
pad has worn to the point that the wear
indicator grooves have almost disap­peared, have a Yamaha dealer replace
the brake pads as a set.

6-23

PERIODIC MAINTENANCE AND MINOR REPAIR

Rear

1. Brake pad wear indicator groove

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.

Front

1. Minimum level mark

EAU03294

Checking the brake fluid level

Insufficient brake fluid may allow air to
enter the brake system, possibly caus­ing it to become ineffective.
Before riding, check that the brake fluid
is above the minimum level mark and
replenish if necessary. A low brake flu­id level may indicate worn brake pads
and/or brake system leakage. If the
brake level is low, be sure to check the
brake pads for wear and the brake sys­tem for leakage.

Rear

1. Minimum level mark

Observe these precautions:

When checking the fluid level,

●

make sure that the top of the brake
fluid reservoir is level.
Use only the recommended quali-

●

ty brake fluid, otherwise the rubber
seals may deteriorate, causing
leakage and poor braking perfor­mance.

Recommended brake fluid: DOT 4

Refill with the same type of brake

●

fluid. Mixing fluids may result in a
harmful chemical reaction and
lead to poor braking performance.

6

6-24

PERIODIC MAINTENANCE AND MINOR REPAIR

Be careful that water does not en-

●

ter 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 paint-

●

ed surfaces or plastic parts. Al­ways clean up spilled fluid
immediately.
As the brake pads wear, it is nor-

●

mal for the brake fluid level to
gradually go down. However, if the
brake fluid level goes down sud­denly, have a Yamaha dealer

6

check the cause.

Changing the brake fluid

Have a Yamaha dealer change the
brake fluid at the intervals specified in
the NOTE after the periodic mainte­nance and lubrication chart. In addition,
have the oil seals of the master cylin­ders 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.

EAU03976

1. Drive belt

2. Marks
a. Drive belt slack

EAU04452

Drive belt slack

The drive belt slack should be checked
and adjusted at the intervals specified
in the periodic maintenance and lubri­cation chart.

To check the drive belt slack

1. Place the motorcycle on a level

surface and hold it in an upright
position.

2. Note the current position of the

drive belt using the marks near the
drive belt check hole.

6-25

NOTE:

_

The marks near the drive belt check
hole are 0.2 in (5 mm) apart.

_

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.

NOTE:

_

A belt tension gauge is available at a
Yamaha dealer.

_

4. Calculate the drive belt slack by
subtracting the measurement not­ed in step 2 from the measure­ment noted in step 3.

Drive belt slack:

0.3–0.5 in (7.5–13 mm)

5. If the drive belt slack is incorrect,
adjust it as follows.

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

6-26

PERIODIC MAINTENANCE AND MINOR REPAIR

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

6

adjusting bolt on each side of the
swingarm in direction a. To loos­en the drive belt, turn the adjusting
bolt on each side of the swingarm
in direction b, and then push the
rear wheel forward.

NOTE:

@

Turn each adjusting bolt the same
amount for proper wheel alignment.

@

4. Tighten the locknuts.

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.

Tightening torques:

Axle nut:

108.5 ft·lbf (15 m·kgf, 150 Nm)

Brake caliper bracket bolt:

34.7 ft·lbf (4.8 m·kgf, 48 Nm)

EAU04034

Checking and lubricating the
throttle grip and cable

The operation of the throttle grip should
be checked before each ride. In addi­tion, the cable should be lubricated or
replaced at the intervals specified in
the periodic maintenance chart.

6-27

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.

Recommended lubricant:

Lithium-soap-based grease
(all-purpose grease)

PERIODIC MAINTENANCE AND MINOR REPAIR

6

6-28

PERIODIC MAINTENANCE AND MINOR REPAIR

Checking and lubricating the
brake and clutch levers

The operation of the brake and clutch

6

levers should be checked before each
ride, and the lever pivots should be lu­bricated if necessary.

Recommended lubricant:

Lithium-soap-based grease
(all-purpose grease)

EAU03164

6-29

EAU03165

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.

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)

EW000113

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.

PERIODIC MAINTENANCE AND MINOR REPAIR

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. 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 handle­bars several times to check if the
front fork compresses and re­bounds smoothly.

EC000098

CAUTION:

@

If any damage is found or the front
fork does not operate smoothly,
have a Yamaha dealer check or re­pair it.

@

6-30

6

PERIODIC MAINTENANCE AND MINOR REPAIR

Checking the steering

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.

WARNING

@

Securely support the motorcycle so
that there is no danger of it falling

6

over.

@

EAU00794

EW000115

EAU01144

Checking the wheel bearings

The front and rear wheel bearings must
be checked at the intervals specified in
the periodic maintenance and lubrica­tion chart. If there is play in the wheel
hub or if the wheel does not turn
smoothly, have a Yamaha dealer
check the wheel bearings.

2. Hold the lower ends of the front
fork legs and try to move them for­ward and backward. If any free
play can be felt, have a Yamaha
dealer check or repair the steering.

6-31

PERIODIC MAINTENANCE AND MINOR REPAIR

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.

CAUTION:

@

Never attempt to remove the battery
cell seals, as this would permanent­ly damage the battery.

@

EC000101

WARNING

@

Electrolyte is poisonous and

●

dangerous since it contains sul­furic acid, which causes severe
burns. Avoid any contact with
skin, eyes or clothing and al­ways shield your eyes when
working near batteries. In case
of contact, administer the fol­lowing FIRST AID.

• EXTERNAL: Flush with plenty
of water.

•INTERNAL: Drink large quan­tities of water or milk and im­mediately call a physician.

• EYES: Flush with water for
15 minutes and seek prompt
medical attention.

Batteries produce explosive hy-

●

drogen gas. Therefore, keep
sparks, flames, cigarettes, etc.,
away from the battery and pro­vide sufficient ventilation when
charging it in an enclosed space.
KEEP THIS AND ALL BATTER-

●

IES OUT OF THE REACH OF
CHILDREN.

@

6-32

EW000116

To charge the battery

Have a Yamaha dealer charge the bat­tery as soon as possible if it seems to
have discharged. Keep in mind that the
battery tends to discharge more quickly
if the motorcycle is equipped with op­tional electrical accessories.

To store the battery

1. If the motorcycle will not be used
for more than one month, remove
the battery, fully charge it, and
then place it in a cool, dry place.

2. If the battery will be stored for
more than two months, check it at
least once a month and fully
charge it if necessary.

3. Fully charge the battery before in­stallation.

4. After installation, make sure that
the battery leads are properly con­nected to the battery terminals.

6

PERIODIC MAINTENANCE AND MINOR REPAIR

EC000102

CAUTION:

@

Always keep the battery

●

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

6

dealer charge your battery.

@

1. Bolt 1. Signaling system fuse

Replacing the fuses

The main fuse and the fuse box, which
contains the fuses for the individual cir­cuits, are located behind panel A. (See
page 6-7 for panel removal and instal­lation procedures.)

EAU04190*

2. Ignition fuse

3. Headlight fuse

4. Carburetor heater fuse

5. Odometer fuse

6. Spare fuse (× 3)

If a fuse is blown, replace it as follows.

1. Turn the key to “OFF” and turn off
the electrical circuit in question.

2. Remove the blown fuse, and then
install a new fuse of the specified
amperage.

6-33

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

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.

_

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.

6

6-34

PERIODIC MAINTENANCE AND MINOR REPAIR

1. Screw (× 2) 1. Headlight coupler

EAU04189

Replacing the headlight bulb

2. Headlight bulb cover

2. Disconnect the headlight coupler,

This motorcycle is equipped with a
quartz bulb headlight. If the headlight
bulb burns out, replace it as follows.

6

1. Remove the headlight unit by re­moving the screws.

and then remove the bulb cover.

6-35

1. Headlight bulb holder

3. Unhook the headlight bulb holder,
and then remove the defective
bulb.

1. Do not touch this area.

EW000119

WARNING

_

Headlight bulbs get very hot. There­fore, keep flammable products away
from a lit headlight bulb, and do not
touch the bulb until it has cooled
down.

_

4. Place a new headlight bulb into
position, and then secure it with
the bulb holder.

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.

_

5. Install the headlight bulb cover,
and then connect the coupler.

6. Install the headlight unit by install­ing the screws.

7. Have a Yamaha dealer adjust the
headlight beam if necessary.

6

6-36

PERIODIC MAINTENANCE AND MINOR REPAIR

1. Screw (× 2) 1. Screw (× 3)

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.

EAU00855

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.

CAUTION:

@

Do not overtighten the screws, oth­erwise the lens may break.

@

EC000108

EAU01579

Supporting the motorcycle

Since this model is not equipped with a
centerstand, follow these precautions
when removing the front and rear
wheel or performing other mainte­nance requiring the motorcycle to
stand upright. Check that the motor­cycle is in a stable and level position
before starting any maintenance. A
strong wooden box can be placed un­der the engine for added stability.

To service the front wheel

1. Stabilize the rear of the motorcycle
by using a motorcycle stand or, if
an additional motorcycle stand is
not available, by placing a jack un­der the frame in front of the rear
wheel.

2. Raise the front wheel off the
ground by using a motorcycle
stand.

6-37

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. 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 your­self. However, should your motorcycle
require any repair, take it to a Yamaha
dealer, whose skilled technicians have
the necessary tools, experience, and
know-how to service the motorcycle
properly.
Use only genuine Yamaha replace­ment parts. Imitation parts may look
like Yamaha parts, but they are often
inferior, have a shorter service life and
can lead to expensive repair bills.

6

6-38

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

Check the fuel level in

There is enough fuel.

the fuel tank.

There is no fuel.

Check the compression.

Supply fuel.

The engine does not start.
Check the compression.

2. Compression

There is compression.

Operate the electric starter.

6

3. Ignition

Remove the spark plugs
and check the electrodes.

4. Battery

Operate the electric starter.

There is no compression.

Wet

Dry

The engine turns over
quickly.

The engine turns over
slowly.

Wipe off with a dry cloth and correct the
spark plug gaps, or replace the spark plugs.

Have a Yamaha dealer check the vehicle.

Check the ignition.

Have a Yamaha dealer
check the vehicle.

The battery is good.

Check the battery lead connections,
and charge the battery if necessary.

6-39

Open the throttle halfway and operate
the electric starter.

The engine does not start.
Check the battery.

The engine does not start.
Have a Yamaha dealer
check the vehicle.

MOTORCYCLE CARE AND STORAGE

Care .................................................................................................. 7-1

Storage ...................................... .................... ................... ................. 7-5

7

7-

MOTORCYCLE CARE AND STORAGE

EAU03708

Care

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

7

used. A rusty exhaust pipe may go un­noticed on a car, however, it detracts
from the overall appearance of a
motorcycle. Frequent and proper care
does not only comply with the terms of
the warranty, but it will also keep your
motorcycle looking good, extend its life
and optimize its performance.

Before cleaning

1. Cover the muffler outlets with plas­tic bags after the engine has
cooled down.

2. Make sure that all caps and covers
as well as all electrical couplers
and connectors, including the
spark plug caps, are tightly in­stalled.

3. Remove extremely stubborn dirt,
like oil burnt onto the crankcase,
with a degreasing agent and a
brush, but never apply such prod­ucts 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-remove dirt, do
not leave the cleaner on the af­fected area any longer than in­structed. Also, thoroughly rinse
the area off with water, immedi­ately dry it, and then apply a
corrosion protection spray.

● Improper cleaning can damage

windshields, cowlings, panels
and other plastic parts. Use
only a soft, clean cloth or
sponge with mild detergent and
water to clean plastic.

● Do not use any harsh chemical

products on plastic parts. Be
sure to avoid using cloths or
sponges which have been in
contact with strong or abrasive
cleaning products, solvent or

7-1

MOTORCYCLE CARE AND STORAGE

thinner, fuel (gasoline), rust re­movers or inhibitors, brake flu­id, antifreeze or electrolyte.
Do not use high-pressure wash-

●

ers 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.
For motorcycles equipped with

●

a windshield: Do not use strong
cleaners or hard sponges as
they will cause dulling or
scratching. Some cleaning
compounds for plastic may
leave scratches on the wind­shield. Test the product on a
small hidden part of the wind­shield to make sure that it does
not leave any marks. If the wind-

shield is scratched, use a quali­ty plastic polishing compound
after washing.

_

After normal use
Remove dirt with warm water, a mild
detergent, and a soft, clean sponge,
and then rinse thoroughly with clean
water. Use a toothbrush or bottlebrush
for hard-to-reach areas. Stubborn dirt
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 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 roads in the winter may
remain well into spring.

_

7-2

1. Clean the motorcycle with cold
water and a mild detergent, after
the engine has cooled down.

ECA00012

CAUTION:

_

Do not use warm water since it in­creases the corrosive action of the
salt.

_

2. After drying the motorcycle, apply
a corrosion protection spray on all
metal, including chrome- and nick­el-plated, surfaces to prevent cor­rosion.

Windshield cleaning
(for XV16AT(C)/XV16ATLE(C) only)
Avoid using any alkaline or strong acid
cleaner, gasoline, brake fluid, or any
other solvent. Clean the windshield
with a cloth or sponge dampened with
a neutral detergent, and after cleaning,
thoroughly wash it off with water. For
additional cleaning, use Yamaha Wind­shield Cleaner or other quality cleaner.
Some cleaning compounds for plastics
may leave scratches on surfaces of the

7

MOTORCYCLE CARE AND STORAGE

windshield. Before using them, make a
test by polishing an area which does
not affect your visibility.

After cleaning

1. Dry the motorcycle with a chamois
or an absorbing cloth.

2. Use a chrome polish to shine
chrome, aluminum and stainless­steel parts, including the exhaust
system. (Even the thermally in­duced discoloring of stainless­steel exhaust systems can be re­moved through polishing.)

3. To prevent corrosion, it is recom­mended to apply a corrosion pro-

7

tection spray on all metal,
including chrome- and nickel-plat­ed, surfaces.

4. Use spray oil as a universal clean­er to remove any remaining dirt.

5. Touch up minor paint damage
caused by stones, etc.

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.

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 ac­etone, and wash the tires with
warm water and a mild deter­gent.
Before operating the motor-

●

cycle test its braking perfor­mance and cornering behavior.

_

ECA00033

CAUTION:

_

Apply spray oil and wax spar-

●

ingly and make sure to wipe off
any excess.
Never apply oil or wax to the

●

drive belt.
Never apply oil or wax to any

●

rubber and plastic parts, but
treat them with a suitable care
product.
Avoid using abrasive polishing

●

compounds as they will wear
away the paint.

_

NOTE:

_

Consult a Yamaha dealer for advice on
what products to use.

_

7-3