Yamaha XV16AL User manual

SERVICEMANUAL
LIT-11616-12-56 4WM-28197-E0
XV16AL/XV16ALC
XV16ATL/XV16ATLC

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NOTICE
This manual was produced by the Yamaha Motor Company, Ltd. primarily for use by Yamaha
dealers and their qualified mechanics. It is not possible to include all the knowledge of a
mechanic in one manual. Therefore, anyone who uses this book to perform maintenance and
repairs on Yamaha vehicles should have a basic understanding of mechanics and the tech-
niques to repair these types of vehicles. Repair and maintenance work attempted by anyone
without this knowledge is likely to render the vehicle unsafe and unfit for use.
This model has been designed and manufactured to perform within certain specifications in
regard to performance and emissions. Proper service with the correct tools is necessary to
ensure that the vehicle will operate as designed. If there is any question about a service pro-
cedure, it is imperative that you contact a Yamaha dealer for any service information changes
that apply to this model. This policy is intended to provide the customer with the most satis-
faction from his vehicle and to conform with federal environmental quality objectives.
Yamaha Motor Company, Ltd. is continually striving to improve all of its models. Modifica-
tions and significant changes in specifications or procedures will be forwarded to all autho-
rized Yamaha dealers and will appear in future editions of this manual where applicable.
This Service Manual contains information regarding periodic maintenance to the emission
control system. Please read this material carefully.
NOTE:
Designs and specifications are subject to change without notice.
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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!
Failure to follow WARNING instructions could result in severe injury or
death to the motorcycle operator, a bystander or a person checking 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.
WARNING
CAUTION:
NOTE:

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HOW TO USE THIS MANUAL
This manual is intended as a handy, easy-to-read reference book for the mechanic. Compre-
hensive 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 indicate 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 sec-
tion 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.
5Numbers are given in the order of the jobs in the exploded diagram. A circled number indi-
cates a disassembly step.
6Symbols indicate parts to be lubricated or replaced.
Refer to “SYMBOLS”.
7A job instruction chart accompanies the exploded diagram, providing the order of jobs,
names of parts, notes in jobs, etc.
8Jobs requiring more information (such as special tools and technical data) are described
sequentially.

********
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 Findicate the following.
9Serviceable with engine mounted
0Filling fluid
ALubricant
BSpecial tool
CTightening torque
DWear limit, clearance
EEngine speed
FElectrical data
Symbols Gto Lin the exploded diagrams
indicate the types of lubricants and lubrica-
tion points.
GEngine oil
HGear oil
IMolybdenum disulfide oil
JWheel bearing grease
KLithium soap base grease
LMolybdenum disulfide grease
Symbols Mto Nin the exploded diagrams
indicate the following.
MApply locking agent (LOCTITE
).
NReplace the part.
12
34
56
78
90
AB
CD
EF
GHI
JKL
MN
GEN
INFO
SPEC
CHK
ADJ
CHAS
ENG
CARB
–+
ELEC TRBL
SHTG
T
R
.
.
GM
E
BLS M
LT New

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

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
1

GEN
INFO
1 - 1
MOTORCYCLE IDENTIFICATION
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GENERAL INFORMATION
MOTORCYCLE IDENTIFICATION
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VEHICLE IDENTIFICATION NUMBER
The vehicle identification number 1is
stamped into the right side of the steering
head pipe.
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MODEL CODE
The model code label 1is affixed to the
frame. This information will be needed to
order spare parts.
1

1 - 2
GEN
INFO
FEATURES
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FEATURES
Twin spark plugs
For this model, two spark plugs are incor-
porated in each cylinder.
By using two spark plugs, the combustion
time in the combustion chamber is short-
ened in an attempt to improve torque.
Speed sensor
The speed sensor is installed to the crank-
case and it detects the number of passing
gears while the vehicle is running in 5th
gear and sends the information out as an
electrical signal to the ignitor unit.
Self-diagnosis device
This model is equipped with a self-diagno-
sis device that has four functions.
The engine trouble indicator light will come
on or flash if trouble occurs in an engine
monitoring circuit.
Refer to “SELF-DIAGNOSIS” in chapter 7.
Circuit Indicator lights
Num-
ber of
flashes
Throttle
position
sensor
Engine trouble indica-
tor light 1
3
Speed
sensor
Engine trouble indica-
tor light 1
4
Solenoid Engine trouble indica-
tor light 1
6
Fuel level
meter
Fuel level indicator light
2
8
1

1 - 3
GEN
INFO
FEATURES
Auto decompression mechanism
The auto decompression mechanism occurs when the engine is started. When the engine is
started, the decompression cam and pin raise the exhaust valve lifters, push the push rods,
move the rocker arms, and lower the exhaust valves which compress the cylinder. When the
cylinder is compressed, pressure is released immediately, resulting in smoother engine start-
ing capabilities and smoother crankshaft revolutions.
1Decompression solenoid
2Decompression solenoid rod
3Decompression connector
4Decompression lever
5Decompression push rod
6Decompression cam
7Pin
8Spring
9Camshaft
1

1 - 4
GEN
INFO
FEATURES
Operation
1. When the starter switch is pushed, elec-
tricity is run to the decompression sole-
noid 1causing it to push out the
decompression solenoid rod 2.
2. When the decompression solenoid rod is
pushed out, the decompression connec-
tor 3moves the decompression levers
4in the direction indicated by the
arrows, and then the levers push the
decompression rods 5toward the cam-
shaft side.
3. The decompression cam 6is pushed in
the direction indicated by the arrow, and
then the pin 7raises the projection of
the decompression cam.
4. When the camshaft is rotated by the self-
timing motor, the exhaust valve lifters 8
are lifted by the pin just before top dead
center (TDC) and the exhaust valve push
rod 9and valve rocker arms are oper-
ated. Thus, opening the exhaust valve
becomes easy.
5. When the engine starts and reaches a
specific engine speed the decompres-
sion solenoid is turned off and the
decompression system stops operating.
1