YAMAHA XV1600AP PARTS CATALOGUE 02
XV1600AP
(5JA9)
A
2
AUSTRALIA
2A5JA–700E1
XV1600AP
PARTS CATALOGUE
E2001 by Yamaha Motor Co., Ltd.
1st Edition, Jul. 2001
All rights reserved.
Any reprinting or unauthorized use
without the written permission of
Yamaha Motor Co., Ltd.
is expressly prohibited.
A
3
FOREWORD
This Parts Catalogue is related to the parts for the model(s) in the below frame. When you are
orderingreplacementparts, please refertothis Parts Catalogueandquote both partnumbersand
part names correctly.
XV1600AP(5JA9)
1. Modifications or additions which have been made after issue of the Parts
Catalogue will be announced in the Yamaha Parts News.
It is advisable that you make necessary corrections to the Parts Catalogue
according to the Yamaha Parts News.
2. Abbreviations
The Following abbreviations are used in this Parts Catalogue.
“UR” Use specified parts number.
“UN” Use as many as needed.
“AP” Alternate Parts
“LM” Local Made (Parts need to be ordered locally)
“F#” Frame No. (Applicable machine No.)
3. Parts, which are to be supplied in an assembly, are listed with a dot(.) in
front of the part name as shown below.
EXAMPLE
CARBURETOR ASSY
.JET, PILOT
.NOZZLE, MAIN
4. Number of component for assembly
The numeral appearing to the right of each component part indicates the
quantity of parts for each assembly unit.
EXAMPLE
PART NO. DESCRIPTION Q’TY REMARKS
2F5–83310–60 FRONT FLASHER LIGHT ASSY 2
115–83311–60 .BULB (6V–18W) 1
1M1–83309–60 .REFLECTOR 1
5. Applicable colors of graphics are represented in the “REMARKS” as shown
below.
PART NO. DESCRIPTION Q’TY REMARKS
2N4–24110–00–X5 .FUEL TANK COMP. 1 MXR
3J1–24240–10 .GRAPHIC, FUEL TANK 1 FOR MXR
6. Applicable Serial No.
Engine Serial No. Frame Serial No.
7. Note that the illustrations for reference in finding parts numbers, not to be
used for assembling. When assembling, please use the applicable service
manual.
8. The asterisk (*) before a reference number indicates modification items
after the first edition.
A
4
MODEL LABEL
(1) A label called “Model Label” is affixed in the location as indicated in (3) below.
When using this parts catalogue, please be sure to cross–refer the “model code –
production code No.” in the catalogue to the “model code – production code No.
“indicated on the Model Label affixed onto the product concemed.
(2) “Model Label”Indication
ab
xxxx – xxx
c
x
(3) Model Label Affixing Location
a: Model Type Code
b: Production Code No.
c: Colouring Type
4TW1–010
A
(4) Model Code – Production Code Number of Model Listed in This Parts Catalog
Model
Code
5JA9 010 AUSTRALIA
Production
Code No.
Country
(destination)
Model
Code
Production
Code No.
(destination)
Country
(5) Colouring Information
Model
Code
5JA9
5JA9
A
5
Colouring type
code
A 0781
B 00KU DEEP SCARLET DPS
Colour
code
Colour Name
VERY DARK BLUE
METALLIC A
Abbrevi-
ation
VDBMA
ENGINE
CYLINDER HEAD B2...................................
CYLINDER B3.........................................
CRANKSHAFT. PISTON B4.............................
VALVE B5.............................................
CAMSHAFT. CHAIN B6.................................
OIL PUMP B8..........................................
INTAKE B10............................................
CARBURETOR B12.....................................
EXHAUST B14..........................................
CRANKCASE C2.......................................
CRANKCASE COVER 1 C4..............................
STARTER C7..........................................
CLUTCH C8...........................................
TRANSMISSION C10....................................
MIDDLE DRIVE GEAR C11...............................
SHIFT CAM. FORK C14..................................
SHIFT SHAFT C15......................................
CHASSIS
FRAME D2............................................
FENDER D4...........................................
SIDE COVER D5.......................................
REAR ARM. SUSPENSION D7...........................
STEERING D9.........................................
FRONT FORK D10......................................
FUEL TANK D12........................................
SEAT D14..............................................
FRONT WHEEL D15.....................................
FRONT BRAKE CALIPER E2............................
CONTENTS
REAR WHEEL E3......................................
REAR BRAKE CALIPER E5.............................
STEERING HANDLE. CABLE E6.........................
FRONT MASTER CYLINDER E7.........................
STAND. FOOTREST E9.................................
REAR MASTER CYLINDER E11..........................
GENERATOR E13.......................................
FLASHER LIGHT E14....................................
METER F2............................................
HEADLIGHT F3........................................
TAILLIGHT F4.........................................
HANDLE SWITCH. LEVER F5...........................
ELECTRICAL 1 F6.....................................
ELECTRICAL 2 F8.....................................
INDEX
NUMERICAL INDEX M1.................................
FIG. 1 CYLINDER HEAD
REF.
NO.
10 95617–08625 .BOLT, STUD 2
11 4WM–11161–00 ABSORBER 1 5
12 4WM–11162–00 ABSORBER 2 3
13 4WM–11131–00 HEAD, CYLINDER 3 1
14 4WM–11141–00 HEAD, CYLINDER 4 1
15 4WM–11182–00 GASKET, CYLINDER HEAD 2 2
PART NO. DESCRIPTION REMARKS
1 4WM–11101–00 CYLINDER HEAD ASSY 1
2 4WM–11133–10 .GUIDE, INTAKE VALVE 4
3 93440–12052 .CIRCLIP 4
4 95617–08625 .BOLT, STUD 2
5 4WM–11161–00 ABSORBER 1 5
6 4WM–11162–00 ABSORBER 2 3
7 4WM–11101–10 CYLINDER HEAD ASSY 1
8 4WM–11133–10 .GUIDE, INTAKE VALVE 4
9 93440–12052 .CIRCLIP 4
5JA9
B
16 91808–16023 PIN, DOWEL 4
17 90109–065G0 BOLT 4
18 90109–067E6 BOLT 4
19 91314–06045 BOLT 4
20 4WM–11181–00 GASKET, CYLINDER HEAD 1 2
21 4WM–11171–00 NUT, HOLDING 8
22 4WM–11175–00 WASHER, HOLDING 1 8
23 4WM–11172–00 NUT, HOLDING 4
24 4WM–11176–00 WASHER, HOLDING 4
25 90387–087A5 COLLAR 4
26 94701–00262 PLUG, SPARK (NGK DPR7EA 9) 4 UR
94701–00379 PLUG, SPARK (ND X22EPR–U9) 4 UR
2
FIG. 2 CYLINDER
REF.
NO.
10 90110–06022 BOLT, HEXAGON SOCKET HEAD 12
11 91314–06035 BOLT 4
12 91314–06050 BOLT 8
13 91314–06065 BOLT 4
14 4WM–1111M–00 COVER 1 1
15 4WM–1111N–00 COVER 2 1
PART NO. DESCRIPTION REMARKS
1 4WM–11191–00 COVER, CYLINDER HEAD 1 1
2 4GL–15371–00 BREATHER 1
3 90467–12053 CLIP 1
4 4WM–11126–00 PIPE, BREATHER 3 1
5 4WM–11166–00 PIPE, BREATHER 1 1
6 90467–13042 CLIP 1
7 4WM–11192–00 COVER, CYLINDER HEAD 2 1
8 4WM–11193–00 GASKET, HEAD COVER 1 2
9 91808–16023 PIN, DOWEL 4
5JA9
B
16 4WM–11194–00 GASKET, HEAD COVER 2 2
17 91808–16023 PIN, DOWEL 4
18 91314–06040 BOLT 10
19 90110–06023 BOLT, HEXAGON SOCKET HEAD 2
20 4WM–11311–00 CYLINDER 1 2
21 4WM–11351–00 GASKET, CYLINDER 2
22 90387–087A5 COLLAR 4
3
FIG. 3 CRANKSHAFT. PISTON
REF.
NO.
PART NO. DESCRIPTION REMARKS
1 4WM–11400–00 CRANKSHAFT ASSY 1
2 4WM–11631–00 PISTON (STD) 2
3 34L–11610–00 PISTON RING SET (STD) 2
4 4WM–11633–00 PIN, PISTON 2
5 93450–24028 CIRCLIP 4
6 4WM–11650–00 CONNECTING ROD ASSY 2
7 4WM–11654–00 .BOLT, CONNECTING ROD 2
8 4WM–11656–00 PLANE BEARING, CONNECTING ROD 4 UR BLUE
4WM–11656–10 PLANE BEARING, CONNECTING ROD 4 UR BLACK
4WM–11656–20 PLANE BEARING, CONNECTING ROD 4 UR BROWN
4WM–11656–30 PLANE BEARING, CONNECTING ROD 4 UR GREEN
4WM–11656–40 PLANE BEARING, CONNECTING ROD 4 UR YELLOW
5JA9
B
4
FIG. 4 VALVE
REF.
NO.
10 4WM–12161–00 ARM, VALVE ROCKER 2 2
11 31G–12159–02 SCREW, VALVE ADJUSTING 4
12 31G–12158–00 NUT, LOCK 4
13 4WM–12146–00 SHAFT, ROCKER 4
14 4WM–12154–00 ROD, VALVE PUSH 4
15 4WM–12153–00 LIFTER, VALVE 4
PART NO. DESCRIPTION REMARKS
1 4WM–12111–00 VALVE, INTAKE 4
2 4WM–12121–00 VALVE, EXHAUST 4
3 26H–12116–00 SEAT, VALVE SPRING 8
4 4WM–12113–00 SPRING, VALVE INNER 8
5 4WM–12114–00 SPRING, VALVE OUTER 8
6 4KM–12119–00 SEAL, VALVE STEM 8
7 26H–12117–00 RETAINER, VALVE SPRING 8
8 4G0–12118–00 COTTER, VALVE 16
9 4WM–12151–00 ARM, VALVE ROCKER 2
5JA9
B
5
FIG. 5 CAMSHAFT. CHAIN
REF.
NO.
10 4WM–11951–00 PLATE 1
11 90110–05003 BOLT, HEXAGON SOCKET HEAD 2
12 4WM–12293–00 CONNECTOR, DECOMPRESSION 1
13 4WM–12282–00 LEVER, DECOMPRESSION 1
14 90110–04255 BOLT, HEXAGON SOCKET HEAD 2
15 90201–08086 WASHER, PLATE 1
PART NO. DESCRIPTION REMARKS
1 4WM–11534–00 GEAR, BREAKER DRIVE 1
2 90282–03039 KEY, STRAIGHT 1
3 90201–100L3 WASHER, PLATE 1
4 90105–10290 BOLT, FLANGE 1
5 4WM–W1211–02 CAM SHAFT ASSY 1
6 4WM–W1153–00 DRIVEN GEAR COMP. 1
7 90282–03012 KEY, STRAIGHT 1
8 90201–140H8 WASHER, PLATE 1
9 90179–14469 NUT 1
5JA9
B
16 4WM–12298–00 ROD, DECOMPRESSION 1
17 4WM–12294–00 PIPE, DECOMPRESSION 1
18 93210–472A9 O–RING 4
19 4WM–12152–00 SUPPORT, ROCKER AR 4
20 4WM–12155–01 GUIDE, PUSH ROD 2
21 4WM–12215–00 CAP, TENSIONER CASE 1
22 4WM–12173–00 CAP, CAMSHAFT 1 1
23 4WM–12271–00 HOUSING 1
24 4WM–12272–00 HOUSING 1
25 93210–54175 O–RING 2
26 93210–54452 O–RING 2
27 93210–48364 O–RING 2
6
FIG. 5 CAMSHAFT. CHAIN
REF.
NO.
28 90110–06006 BOLT, HEXAGON SOCKET HEAD 4
PART NO. DESCRIPTION REMARKS
5JA9
B
7
FIG. 6 OIL PUMP
REF.
NO.
10 4WM–13416–00 PIPE, OIL 1 1
11 93210–16629 O–RING 1
12 91317–06020 BOLT 2
13 93210–15171 O–RING 1
14 91314–06020 BOLT 1
15 90338–06018 PLUG 1
PART NO. DESCRIPTION REMARKS
1 4WM–13300–00 OIL PUMP ASSY 1
2 91317–06080 BOLT 3
3 4WM–13412–00 HOUSING, STRAINER 1
4 4WM–13411–00 STRAINER, OIL 1
5 90110–06225 BOLT, HEXAGON SOCKET HEAD 2
6 4WM–13171–00 PIPE, DELIVERY 2 1
7 93210–09165 O–RING 2
8 93210–06667 O–RING 1
9 4WM–13360–00 DRIVEN GEAR ASSY 1
5JA9
B
16 4WM–13418–00 PIPE, OIL 2 1
17 93210–16629 O–RING 1
18 91317–06020 BOLT 2
19 93210–15171 O–RING 1
20 91314–06020 BOLT 2
21 4WM–13161–00 PIPE, DELIVERY 1 1
22 93210–13657 O–RING 1
23 91314–06020 BOLT 2
24 4WM–13573–00 BOLT 1 1
25 93210–16325 O–RING 1
26 4WM–13461–00 PLATE, ADAPTOR 1
27 3FV–13440–10 ELEMENT ASSY, OIL CLEANER 1
8
FIG. 6 OIL PUMP
REF.
NO.
28 90401–20145 BOLT, UNION 1
29 93210–23326 O–RING 2
30 90110–06222 BOLT, HEXAGON SOCKET HEAD 4
31 4WM–1357N–01 PLATE, STOPPER 1 1
32 91317–06016 BOLT 2
33 4WM–13405–00 OIL PIPE COMP. 1 1
34 90401–10175 BOLT, UNION 2
35 90430–10188 GASKET 4
36 90401–08176 BOLT, UNION 1
37 90430–08119 GASKET 2
38 4WM–13181–00 PIPE, DELIVERY 3 1
39 93210–08006 O–RING 1
40 93210–07003 O–RING 1
41 4WM–13464–00 HOSE, OIL 1 1
42 90467–10008 CLIP 2
PART NO. DESCRIPTION REMARKS
5JA9
B
9
FIG. 7 INTAKE
REF.
NO.
10 4WM–14452–00 SEAL 1
11 4WM–14453–00 JOINT, AIR CLEANER 1 1
12 4WM–1443E–00 PIPE, DRAIN 1
13 90149–06331 SCREW 1
14 97707–60540 SCREW, TAPPING 2
15 5JA–14437–00 DUCT 1
PART NO. DESCRIPTION REMARKS
1 4WM–13586–00 JOINT, CARBURETOR 1 1
2 93210–505A4 O–RING 2
3 91317–06020 BOLT 4
4 90450–58001 HOSE CLAMP ASSY 1
5 4WM–14411–00 CASE, AIR CLEANER 1 1
6 4WM–14421–00 CASE, AIR CLEANER 2 1
7 4WM–14451–00 ELEMENT, AIR CLEANER 1
8 93210–77040 .O–RING 1
9 98904–06014 SCREW, BIND 2
5JA9
B
16 4WM–14417–00 COVER 1 1
17 4WM–14413–00 STAY 1
18 97707–50525 SCREW, TAPPING 2
19 4WM–14419–00 PIPE 1
20 90450–67001 HOSE CLAMP ASSY 1
21 90110–06240 BOLT, HEXAGON SOCKET HEAD 3
22 90480–14023 GROMMET 3
23 90387–07391 COLLAR 3
24 90209–06250 WASHER 3
25 4WM–14498–00 STAY 1 1
26 90445–146K8 HOSE (L30) 1
27 90467–13083 CLIP 2
10
FIG. 7 INTAKE
REF.
NO.
28 4WM–14294–00 HOSE 1
29 90467–13083 CLIP 2
30 4WM–14295–00 PIPE, FUEL 1
31 4WM–13993–00 COVER, CONTROL RACK 1
32 98504–05012 SCREW, PAN HEAD 2
PART NO. DESCRIPTION REMARKS
5JA9
B
11
FIG. 8 CARBURETOR
REF.
NO.
10 127–14186–00 .PIN, FLOAT 1
11 4KM–14933–00 .SPRING, DIAPHRAGM 1
12 4SV–24411–00 .DIAPHRAGM 1
13 4SV–14112–00 .VALVE, THROTTLE 1 1
14 4WM–14141–02 .NOZZLE, MAIN 1
15 4SV–14107–20 .NEEDLE VALVE SET 1
PART NO. DESCRIPTION REMARKS
1 5JA–14101–02 CARBURETOR ASSY 1 1
2 239–14172–20 .PILOT JET, AIR (2.0) 1
3 5JA–1490J–00 .NEEDLE SET 1
4 4WM–14105–00 .PILOT SCREW SET 1
5 5DM–14561–00 .O–RING 1
6 4KP–14191–00 .PLUG, DRAIN 1
7 3G2–14231–00 .JET,MAIN (0.6) 1
8 620–14231–33 .JET, MAIN (#165) 1
9 98507–04008 .SCREW, PAN HEAD 3
5JA9
B
16 1FN–14565–00 .SCREW 1
17 4SV–14197–00 .PIPE 1
18 4WM–14291–00 .BRACKET 1 1
19 4WM–14565–00 .SCREW 2
20 4WM–85885–00 .THROTTLE SENSOR ASSY 1
21 3XV–14994–00 .NET, FILTER 1
22 4KM–14216–00 .SCREW 2
23 73A–14973–00 .WASHER 2
24 91492–12008 .PIN, COTTER 2
25 4WM–14264–00 .COLLAR 1
26 4WM–14327–00 .WASHER 2
27 98507–05008 .SCREW, PAN HEAD 1
12
FIG. 8 CARBURETOR
REF.
NO.
28 3FV–14147–00 .O–RING 1
29 98507–05010 .SCREW, PAN HEAD 1
30 4WM–14103–00 .THROTTLE SCREW SET 1
31 4WM–14987–00 .HOSE 1
32 98507–04010 .SCREW, PAN HEAD 4
33 4WM–14130–00 .CABLE 1
34 4WM–14504–00 .ROD SET 1
35 4WM–1490H–00 .DIAPHRAGM SET 5 1
36 1UY–14565–00 .SCREW 2
37 3LD–14958–00 .COVER, DIAPHRAGM 1
38 4WM–1410A–00 .STARTER SET 1
39 1HX–14231–20 .JET,PILOT AIR(#100) 1
40 4KM–14142–35 .JET, PILOT (# 35) 1
41 5DM–14985–00 .FLOAT 1
42 4WM–14918–00 .RING 1
PART NO. DESCRIPTION REMARKS
5JA9
B
43 3BT–83790–00 .HEATER ASSY (30W) 2
44 90201–085R5 .WASHER, PLATE 2
45 3BT–82103–00 .TERMINAL 1 1
46 5JA–81517–00 .WIRE, SUB LEAD 1
13
FIG. 9 EXHAUST
REF.
NO.
10 92904–08600 .WASHER 2
11 90179–08442 NUT 4
12 3EG–14613–00 GASKET, EXHAUST PIPE 2
13 4WM–14885–00 HOSE, BEND 5 1
14 90467–19065 CLIP 1
15 4WM–14857–00 CASE, AIR CLEANER 1
PART NO. DESCRIPTION REMARKS
1 4WM–14610–00 EXHAUST PIPE ASSY 1 1
2 97080–06008 .BOLT 1
3 92990–06600 .WASHER, PLATE 1
4 4WM–14620–00 EXHAUST PIPE ASSY 2 1
5 97080–06008 .BOLT 1
6 92990–06600 .WASHER, PLATE 1
7 5JA–14703–01 MUFFLER COMP. 1 1
8 3XW–14755–00 .GASKET, SILENCER 2
9 97024–08025 .BOLT 2
5JA9
B
16 4WM–14858–00 CAP, CASE 1
17 95607–05100 NUT, U 1
18 92907–05200 WASHER 1
19 90202–05057 WASHER, PLATE 1
20 98517–06012 SCREW, PAN HEAD 2
21 4WM–14882–00 HOSE, BEND 2 1
22 4WM–14840–00 AIR CUT VALVE ASS’Y 1
23 90462–20248 CLAMP 1
24 98507–06010 SCREW, PAN HEAD 3
25 92907–06600 WASHER, PLATE 3
26 4WM–14883–00 HOSE, BEND 3 1
27 90467–19065 CLIP 1
14
FIG. 9 EXHAUST
REF.
NO.
28 4WM–14808–00 REED VALVE ASSY 1
29 98507–06010 SCREW, PAN HEAD 3
30 92907–06600 WASHER, PLATE 3
31 4WM–14884–00 HOSE, BEND 4 1
32 4WM–14886–00 HOSE, BEND 6 1
33 90468–08104 CLIP 4
34 4WM–14871–00 PIPE 1 1
35 4WM–14872–00 PIPE 2 1
36 4WM–13542–00 HOSE, VACUUM SENSING 1 1
37 90467–08092 CLIP 2
38 4WM–14868–00 BRACKET 2 1
39 95027–06010 BOLT, FLANGE 3
40 42H–14714–10 GASKET, MUFFLER 2
PART NO. DESCRIPTION REMARKS
5JA9
B
15
FIG. 10 CRANKCASE
REF.
NO.
10 90430–05126 GASKET 1
11 90110–08004 BOLT, HEXAGON SOCKET HEAD 1
12 90430–08119 GASKET 1
13 4H7–15189–00 PLUG 1
14 93210–22382 O–RING 1
15 91314–06040 BOLT 9
PART NO. DESCRIPTION REMARKS
1 4WM–15100–00 CRANKCASE ASSY 1
2 99530–14016 .PIN, DOWEL 2
3 90110–05003 BOLT, HEXAGON SOCKET HEAD 2
4 90430–05126 GASKET 2
5 90110–08004 BOLT, HEXAGON SOCKET HEAD 1
6 90430–08119 GASKET 1
7 4WM–15123–00 PLATE, BUFFLE 1 1
8 90110–06005 BOLT, HEXAGON SOCKET HEAD 4
9 90110–05003 BOLT, HEXAGON SOCKET HEAD 1
5JA9
C
16 91314–06060 BOLT 1
17 91314–06075 BOLT 2
18 91314–06085 BOLT 2
19 91314–06105 BOLT 1
20 91314–06060 BOLT 3
21 91314–08080 BOLT 1
22 91314–08100 BOLT 2
23 95024–08012 BOLT, FLANGE 1
24 90430–08119 GASKET 1
25 92014–05010 BOLT, BUTTON HEAD 3
26 90430–05126 GASKET 3
27 4WM–15417–00 COVER, CAP 1
2
FIG. 10 CRANKCASE
REF.
NO.
28 93210–37532 O–RING 1
29 91314–06016 BOLT 2
PART NO. DESCRIPTION REMARKS
5JA9
C
3
FIG. 11 CRANKCASE COVER 1
REF.
NO.
10 91314–06035 BOLT 7
11 91314–06045 BOLT 4
12 91314–06070 BOLT 5
13 4WM–15142–00 GUIDE 1 1
14 4WM–15143–00 GUIDE 1
15 4WM–15484–00 CLAMP 2 1
PART NO. DESCRIPTION REMARKS
1 4WM–15411–00 COVER, CRANKCASE 1 1
2 93317–11287 BEARING 1
3 93102–12224 OIL SEAL 1
4 4WM–15451–00 GASKET, CRANKCASE COVER 1 1
5 90340–14117 PLUG, STRAIGHT SCREW 1
6 93210–14369 O–RING 1
7 90340–32080 PLUG, STRAIGHT SCREW 1
8 93210–32172 O–RING 1
9 99530–10114 PIN, DOWEL 2
5JA9
C
16 98507–06010 SCREW, PAN HEAD 7
17 4WM–15423–00 COVER 2 1
18 4WM–15326–00 DAMPER, ENGINE MOUNT 2 1
19 91314–06025 BOLT 1
20 91314–06035 BOLT 1
21 91314–06060 BOLT 4
22 91808–16023 PIN, DOWEL 2
23 4WM–15425–00 COVER, GENERATOR 2 1
24 4WM–15316–00 DAMPER, ENGINE MOUNT 1 1
25 90151–05001 SCREW, COUNTERSUNK 2
26 4WM–15421–00 COVER, CRANKCASE 2 1
27 4WM–15377–00 GUIDE, INLET 1
4
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