Yamaha XV1600A1999 User manual

EB000000
XV1600A (L)
SERVICE MANUAL
1998 by Yamaha Motor Co., Ltd.
First Edition, December 1998
All rights reserved. Any reproduction or
unauthorized use without the written
permission of Yamaha Motor Co., Ltd.
is expressly prohibited.

NOTE:
CAUTION:
EAS00002 NOTICE
This manual was produced by the Yamaha Motor Company, Ltd. primarily for use by Yamaha dealers
andtheirqualifiedmechanics.Itisnotpossibletoincludealltheknowledgeofamechanicinonemanu-
al. Therefore, anyone who uses this book to perform maintenance and repairs on Yamaha vehicles
shouldhaveabasicunderstandingofmechanicsandthetechniquestorepairthesetypesofvehicles.
Repair and maintenance work attempted by anyone without this knowledge is likely to render the ve-
hicle unsafe and unfit for use.
Yamaha Motor Company,Ltd.iscontinuallystrivingtoimproveallofitsmodels.Modifications and sig-
nificant changes in specifications or procedures will be forwarded to all authorized Yamaha dealers
and will appear in future editions of this manual where applicable.
Designs and specifications are subject to change without notice.
EAS00004
IMPORTANT MANUAL INFORMATION
Particularly important information is distinguished in this manual by the following.
The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR
SAFETY IS INVOLVED!
FailuretofollowWARNINGinstructionscouldresultinsevere injuryordeathto
themotorcycleoperator,abystanderorapersonchecking or repairing the mo-
torcycle.
ACAUTIONindicatesspecialprecautionsthatmustbetaken to avoid damage
to the motorcycle.
NOTE: A NOTE provides key information to make procedures easier or clearer.

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EAS00007 HOW TO USE THIS MANUAL
This manual is intended as a handy, easy-to-read reference book for the mechanic. Comprehensive
explanations of all installation, removal, disassembly, assembly, repair and check procedures are laid
out with the individual steps in sequential order.
1The manual is divided into chapters. An abbreviation and symbol in the upper right corner of each page indi-
cate the current chapter.
Refer to “SYMBOLS”.
2Each chapter is divided into sections. The current section title is shown at the top of each page, except in
Chapter 3 (“PERIODIC CHECKS AND ADJUSTMENTS”), where the sub-section title(-s) appears.
3Sub-section titles appear in smaller print than the section title.
4To help identify parts and clarify procedure steps, there are exploded diagrams at the start of each removal
and disassembly section.
5Numbersaregivenintheorderofthejobsintheexplodeddiagram.Acirclednumberindicatesadisassembly
step.
6Symbols indicate parts to be lubricated or replaced.
Refer to “SYMBOLS”.
7Ajob instruction chartaccompanies the explodeddiagram, providingthe order ofjobs, names ofparts, notes
in jobs, etc.
8Jobs requiring more information (such as special tools and technical data) are described sequentially.

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5
7
9
2
4
8
6
23 24
2220
18 1917
1615
1413
11 12
10
GEN
INFO SPEC
ENG CARB
ELEC
CHK
ADJ
TRBL
SHTG
CHAS
********
SYMBOLS
The following symbols are not relevant to every
vehicle.
Symbols 1to 8indicate the subject of each
chapter.
1General information
2Specifications
3Periodic checks and adjustments
4Chassis
5Engine
6Carburetor
7Electrical system
8Troubleshooting
Symbols 9to 16 indicate the following.
9Serviceable with engine mounted
10 Filling fluid
11 Lubricant
12 Special tool
13 Tightening torque
14 Wear limit, clearance
15 Engine speed
16 Electrical data
Symbols 17 to 22 intheexplodeddiagramsindi-
cate the types of lubricants and lubrication
points.
17 Engine oil
18 Gear oil
19 Molybdenum disulfide oil
20 Wheel bearing grease
21 Lithium soap base grease
22 Molybdenum disulfide grease
Symbols 23 to 24 intheexplodeddiagramsindi-
cate the following.
23 Apply locking agent (LOCTITE)
24 Replace the part

GENERAL INFORMATION
SPECIFICATIONS
PERIODIC CHECKS AND
ADJUSTMENTS
ENGINE
CARBURETION
CHASSIS
ELECTRICAL SYSTEM
TROUBLESHOOTING
GEN
INFO 1
SPEC 2
3
ENG 5
CARB 6
CHAS 4
ELEC 7
TRBL
SHTG 8
CHK
ADJ
******** TABLE OF CONTENTS

E
GEN
INFO
CONTENTS
GENERAL INFORMATION
MOTORCYCLE IDENTIFICATION 1-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
VEHICLE IDENTIFICATION NUMBER 1-1. . . . . . . . . . . . . . . . . . . . . . . . .
MODEL CODE 1-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FEATURES 1-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
IMPORTANT INFORMATION 1-6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PREPARATION FOR REMOVAL AND DISASSEMBLY 1-6. . . . . . . . . .
REPLACEMENT PARTS 1-6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
GASKETS, OIL SEALS AND O-RINGS 1-6. . . . . . . . . . . . . . . . . . . . . . . .
LOCK WASHERS/PLATES AND COTTER PINS 1-7. . . . . . . . . . . . . . . .
BEARINGS AND OIL SEALS 1-7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CIRCLIPS 1-7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE CONNECTIONS 1-8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SPECIAL TOOLS 1-9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

E
GEN
INFO