Yamaha XV16AL User manual

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

EAS00003
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.
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!
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:

EAS00007
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
EAS00014
GENERAL INFORMATION
MOTORCYCLE IDENTIFICATION
EAS00017
VEHICLE IDENTIFICATION NUMBER
The vehicle identification number 1is
stamped into the right side of the steering
head pipe.
EAS00018
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
EAS00019
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

1 - 5
GEN
INFO
FEATURES
Hydraulic valve lifters
Since the hydraulic valve-lifting mechanism maintains a valve clearance of zero, periodic
valve clearance adjustments are unnecessary.
The advantages of this system as compared to conventional techniques include the follow-
ing: mechanical noise is reduced, the camshaft action on the valves remains unaffected by
engine speed or temperature, and the valve timing is kept stable.
1Plunger
2Oil reservoir
3Check valve spring
4Check valve
5Spring retainer
6High-pressure chamber
7Plunger spring
8Valve lifter body
9Oil supply inlet
0Push rod cup
APlunger retaining clip
BValve push rod
The hydraulic valve-lifting system functions as follows:
1. As the camshaft rotates, the valve lifter is pushed up by the passing cam lobe.
2. Since the check valve 4prevents the engine oil contained inside the high-pressure cham-
ber from escaping, the plunger 1moves up along with the valve lifter body 8and pushes
up the push rod, causing the valve to be lifted.
3. As the camshaft continues to rotate, the valve lifter moves back down to its original posi-
tion, where it remains while the cam heel passes.
When a positive valve clearance is caused by either heat expansion of the cylinder head or
engine oil leaking from the valve lifter during stage 2, the plunger, which no longer receives
pressure from the push rod, is pushed up by the plunger spring 7. As a result, the valve
clearance is zeroed and engine oil is allowed to return to the high-pressure chamber from the
reservoir 2through the check valve 4.
When, on the contrary, a negative valve clearance occurs (this is the case when the cam heel
is passing the valve lifter, but the rocker arm, pushed by the push rod, is lifting the valve), the
plunger 1continues to receive pressure from the valve push rod. As engine oil contained
inside the high-pressure chamber leaks from the gaps between the valve lifter body 8and
the plunger 1as well as between the valve lifter body 8and the check valve 4, the
plunger 1moves down and the valve clearance is zeroed.
1

GEN
INFO
1 - 6
IMPORTANT INFORMATION
EAS00020
IMPORTANT INFORMATION
PREPARATION FOR REMOVAL AND
DISASSEMBLY
1. Before removal and disassembly,
remove all dirt, mud, dust, and foreign
material.
2. Use only the proper tools and cleaning
equipment.
Refer to “SPECIAL TOOLS”.
3. When disassembling, always keep
mated parts together. This includes
gears, cylinders, pistons, and other parts
that have been “mated” through normal
wear. Mated parts must always be
reused or replaced as an assembly.
4. During disassembly, clean all of the parts
and place them in trays in the order of
disassembly. This will speed up assem-
bly and allow for the correct installation
of all parts.
5. Keep all parts away from any source of
fire.
EAS00021
REPLACEMENT PARTS
Use only genuine Yamaha parts for all
replacements. Use oil and grease recom-
mended by Yamaha for all lubrication jobs.
Other brands may be similar in function
and appearance, but inferior in quality.
EAS00022
GASKETS, OIL SEALS AND O-RINGS
1. When overhauling the engine, replace all
gaskets, seals, and O-rings. All gasket
surfaces, oil seal lips, and O-rings must
be cleaned.
2. During reassembly, properly oil all mat-
ing parts and bearings and lubricate the
oil seal lips with grease.
1

GEN
INFO
1 - 7
IMPORTANT INFORMATION
EAS00023
LOCK WASHERS/PLATES AND COTTER
PINS
After removal, replace all lock washers/
plates 1and cotter pins. After the bolt or
nut has been tightened to specification,
bend the lock washer tabs and the cotter
pin ends along a flat of the bolt or nut.
EAS00024
BEARINGS AND OIL SEALS
1. Install bearings and oil seals so that the
manufacturer’s marks or numbers are
visible. When installing oil seals, lubri-
cate the oil seal lips with a light coat of
lithium soap base grease. Oil bearings
liberally when installing, if appropriate.
1Oil seal
ACHTUNG:
CAUTION:
Do not spin bearings with compressed air
because this will damage the bearing sur-
faces.
1Bearing
EAS00025
CIRCLIPS
Before reassembly, check all circlips care-
fully and replace damaged or distorted cir-
clips. Always replace piston pin clips after
one use. When installing a circlip 1, make
sure the sharp-edged corner 2is posi-
tioned opposite the thrust 3that the circlip
receives.
4Shaft
1

GEN
INFO
1 - 8
CHECKING THE CONNECTIONS
EAS00026
CHECKING THE CONNECTIONS
Check the leads, couplers, and connectors
for stains, rust, moisture, etc.
1. Disconnect:
• lead
• coupler
• connector
2. Check:
• lead
• coupler
• connector
Moisture →Dry with an air blower.
Rust/stains →Connect and disconnect
several times.
3. Check:
• all connections
Loose connection →Connect properly.
NOTE:
If the pin 1on the terminal is flattened,
bend it up.
4. Connect:
• lead
• coupler
• connector
NOTE:
Make sure all connections are tight.
5. Check:
• continuity
(with the pocket tester)
NOTE:
• If there is no continuity, clean the termi-
nals.
• When checking the wire harness, perform
steps (1) to (3).
• As a quick remedy, use a contact revital-
izer available at most part stores.
Pocket tester
YU-03112
1

1 - 9
GEN
INFO
SPECIAL TOOLS
EAS00027
SPECIAL TOOLS
The following special tools are necessary for complete and accurate tune-up and assembly.
Use only the appropriate special tools as this will help prevent damage caused by the use of
inappropriate tools or improvised techniques. Special tools, part numbers, or both may differ
depending on the country.
When placing an order, refer to the list provided below to avoid any mistakes.
Tool No. Tool name/Function Illustration
YM-01080-A Flywheel puller
This tool is used to remove the generator
rotor.
T-handle
YM-01326
Damper rod
holder
YM-1300-1
T-handle
Damper rod holder
These tools are used to hold the cartridge
cylinder when loosening or tightening the
cartridge cylinder bolt.
YM-01312-A
Fuel level gauge
This tool is used to measure the fuel level
in the float chamber.
YM-33277-A
Timing light
This tool is used to check the ignition tim-
ing.
YM-03170
Belt tension gauge
This tool is used to measure the drive belt
slack.
Fork seal
driver weight
YM-33963
Adapter
YM-8020
Fork seal driver weight
Adapter
These tools are used to install the front
fork’s oil seal and dust seal.
YM-34487
Dynamic spark tester
This tool is used to check the ignition sys-
tem components.
YM-04019
Valve spring compressor
This tool is used to remove or install the
valve assemblies.
1

1 - 10
GEN
INFO
SPECIAL TOOLS
YM-4064-A
Valve guide remover (6 mm)
This tool is used to remove or install the
valve guides.
YM-4065-A
Valve guide installer
This tool is used to install the valve
guides.
YM-4066
Valve guide reamer
This tool is used to rebore the new valve
guides.
YM-91042
Universal clutch holder
This tool is used to hold the clutch boss
when removing or installing the clutch
boss nut.
YS-01880
Sheave holder
This tool is used to hold the generator
rotor when removing or installing the gen-
erator rotor bolt, generator shaft bolt or
pickup coil rotor bolt.
YU-01304
Piston pin puller
This tool is used to remove the piston
pins.
YU-03009
Micrometer (75 ~ 100 mm)
This tool is used to measure the piston
skirt diameter.
YU-03017
Cylinder bore gauge (50 ~ 100 mm)
This tool is used to measure the cylinder
bore.
YU-03112
Pocket tester
This tool is used to check the electrical
system.
Tool No. Tool name/Function Illustration
1

1 - 11
GEN
INFO
SPECIAL TOOLS
Compression
gauge
YU-33223
Compression
gauge adapter
YU-33223-3
Compression gauge
These tools are used to measure engine
compression.
YU-33975
Steering nut wrench
This tool is used to loosen or tighten the
steering stem ring nuts.
YU-38411
Oil filter wrench
This tool is needed to loosen or tighten
the oil filter cartridge.
YU-8036-A
Inductive tachometer
This tool is used to check engine speed.
ACC-11001-05-
01
Quick Gasket
This sealant is used to seal two mating
surfaces (e. g., crankcase mating sur-
faces).
90890-03153
Oil pressure gauge
This tool is used to measure the engine oil
pressure.
Tool No. Tool name/Function Illustration
1

SPEC
CONTENTS
SPECIFICATIONS
GENERAL SPECIFICATIONS ....................................................................... 2-1
ENGINE SPECIFICATIONS ........................................................................... 2-2
CHASSIS SPECIFICATIONS ....................................................................... 2-11
ELECTRICAL SPECIFICATIONS ................................................................. 2-15
TIGHTENING TORQUES ............................................................................ 2-18
GENERAL TIGHTENING TORQUES .................................................. 2-18
ENGINE TIGHTENING TORQUES ..................................................... 2-19
CHASSIS TIGHTENING TORQUES ................................................... 2-21
LUBRICATION POINTS AND LUBRICANT TYPES ................................... 2-23
ENGINE LUBRICATION POINTS AND LUBRICANT TYPES ............ 2-23
CHASSIS LUBRICATION POINTS AND LUBRICANT TYPES .......... 2-24
ENGINE OIL LUBRICATION CHART .......................................................... 2-25
ENGINE OIL FLOW DIAGRAMS ................................................................ 2-26
TRANSFER GEAR OIL FLOW DIAGRAMS ................................................ 2-30
CABLE ROUTING ....................................................................................... 2-32
2

GENERAL SPECIFICATIONS SPEC
2 - 1
SPECIFICATIONS
GENERAL SPECIFICATIONS
Item Standard Limit
Dimensions
Overall length 2,500 mm (98.4 in) ----
Overall width 980 mm (38.6 in) ----
Overall height 1,140 mm (44.9 in): XV16A ----
1,500 mm (59.1 in): XV16AT ----
Seat height 710 mm (28.0 in) ----
Wheelbase 1,685 mm (66.3 in) ----
Minimum ground clearance 145 mm (5.71 in) ----
Minimum turning radius 3,200 mm (126 in) ----
Weight
Wet (with oil and a full fuel tank) 332 kg (732 lb): XV16A ----
347 kg (765 lb): XV16AT ----
Dry (without oil and fuel) 307 kg (678 lb): XV16A ----
322 kg (710 lb): XV16AT ----
Maximum load (total of cargo, rider,
passenger, and accessories)
196 kg (432 lb): XV16A
181 kg (399 lb): XV16AT
----
----
2

ENGINE SPECIFICATIONS SPEC
2 - 2
ENGINE SPECIFICATIONS
Item Standard Limit
Engine
Engine type Air-cooled, 4-stroke, OHV ----
Displacement 1,602 cm3----
Cylinder arrangement V-type 2-cylinder ----
Bore ×stroke 95 ×113 mm (3.74 ×4.45 in) ----
Compression ratio 8.3:1 ----
Engine idling speed 850 ~ 950 r/min ----
Vacuum pressure at engine idling
speed
52 kPa (390 mm Hg, 15.4 in Hg) ----
Standard compression pressure
(at sea level)
1,200 kPa
(12.0 kgf/cm2, 171 psi) at 200 r/min
----
Fuel
Recommended fuel Unleaded fuel (for USA) ----
Regular unleaded gasoline (for CDN) ----
Fuel tank capacity
Total (including reserve) 20 L (17.6 Imp qt, 21.1 US qt) ----
Reserve only 3.5 L (3.08 Imp qt, 3.70 US qt) ----
Engine oil
Lubrication system Dry sump ----
Recommended oil
Yamalube 4 (20W40) or SAE 20W40 type
SE motor oil (40˚F/5˚C or above)
(Non-Friction modified)
----
Quantity
Total amount 5.0 L (4.4 Imp qt, 5.3 US qt) ----
Without oil filter cartridge
replacement
3.7 L (3.3 Imp qt, 3.9 US qt) ----
With oil filter cartridge replace-
ment
4.1 L (3.6 Imp qt, 4.3 US qt) ----
Oil pressure (hot) 60 kPa (0.6 kgf/cm2, 8.5 psi) at 900 r/min ----
Relief valve opening pressure 0.60 MPa (6.0 kgf/cm2, 85 psi) ----
Transfer gear oil
Recommended oil SAE80API “GL-4” hypoid gear oil ----
Quantity 0.4 L (0.35 Imp qt, 0.42 US qt) ----
Oil filter
Oil filter type Cartridge (paper) ----
Bypass valve opening pressure 80 ~ 120 kPa
(0.8 ~ 1.2 kgf/cm2, 11.3 ~ 17.1 psi)
----
30 40 50 60˚F
05
10 15˚C
2