Yamaha XV16AL Manuals

Manuals and User Guides for Yamaha XV16AL. We have 1 Yamaha XV16AL manual available for free PDF download: Service Manual

Yamaha XV16AL Service Manual (449 pages)

Brand: Yamaha | Category: Motorcycle | Size: 13.31 MB

Gen Info

6
- How to Use this Manual
  3
- Table of Contents
  6
- General Information
  
  7
- Motorcycle Identification
  
  7
  - Vehicle Identification Number
    7
  - Model Code
    7
- Features
  
  8
- Important Information
  
  12
  - Preparation for Removal and Disassembly
    12
  - Replacement Parts
    12
  - Gaskets, Oil Seals and O-Rings
    12
  - Lock Washers/Plates and Cotter Pins
    13
  - Bearings and Oil Seals
    13
  - Circlips
    13
- Checking the Connections
  
  14
- Special Tools
  
  15
Table of Contents

18
- General Specifications
  19
- Specifications
  19
- Engine Specifications
  20
- Chassis Specifications
  29
- Electrical Specifications
  33
- Tightening Torques
  36
- Lubrication Points and Lubricant Types
  41
  - Engine Lubrication Points and Lubricant Types
    41
  - Chassis Lubrication Points and Lubricant Types
    42
- Engine Oil Lubrication Chart
  43
- Engine Oil Flow Diagrams
  44
- Transfer Gear Oil Flow Diagrams
  48
- Cable Routing
  50
Table of Contents

56
- General Maintenance and Lubrication Chart
  
  58
- Periodic Checks and Adjustments
  
  58
- Periodic Maintenance/Lubrication Intervals
  
  58
- Introduction
  
  58
- Seats and Side Covers
  
  60
- Xv16At Accessory Parts
  
  61
- Fuel Tank
  
  63
- Air Filter Case
  
  64
- Engine
  
  65
- Chassis
  
  89
  - Adjusting the Front Brake
    89
  - Adjusting the Rear Brake
    90
  - Checking the Brake Fluid Level
    91
  - Checking the Front Brake Pads
    92
  - Checking the Rear Brake Pads
    92
  - Adjusting the Rear Brake Light Switch
    93
  - Checking the Brake Hose
    93
  - Bleeding the Hydraulic Brake System
    94
  - Adjusting the Shift Pedal
    96
  - Adjusting the Drive Belt Slack
    96
  - Checking and Adjusting the Steering Head
    98
  - Checking the Front Fork
    100
  - Adjusting the Rear Shock Absorber Assembly
    101
  - Checking the Tires
    102
  - Checking and Tightening the Spokes
    105
  - Checking and Lubricating the Cables
    106
  - Lubricating the Levers and Pedals
    107
  - Lubricating the Sidestand
    107
  - Lubricating the Rear Suspension
    107
- Electrical System
  
  108
  - Checking and Charging the Battery
    108
  - Checking the Fuses
    113
  - Replacing the Headlight Bulb
    115
  - Adjusting the Headlight Beam
    116
- Instrument Functions
  
  118
  - Indicator Lights
    118
  - Combination Meter
    118
Front Wheel and Brake Discs/Rear Wheel, Brake Disc and Rear Wheel Pulley

120
- Front Wheel and Brake Discs
  
  123
  - Removing the Front Wheel
    125
  - Disassembling the Front Wheel
    125
  - Checking the Front Wheel
    126
  - Checking the Brake Discs
    128
  - Assembling the Front Wheel
    129
  - Installing the Front Wheel
    129
  - Adjusting the Front Wheel Static Balance
    131
- Rear Wheel, Brake Disc and Rear Wheel Pulley
  
  133
  - Removing the Rear Wheel
    138
  - Checking the Rear Wheel
    138
  - Checking the Rear Wheel Drive Hub
    139
  - Checking and Replacing the Rear Wheel Pulley
    139
  - Assembling the Rear Wheel
    140
  - Installing the Rear Wheel
    140
  - Adjusting the Rear Wheel Static Balance
    143
- Front and Rear Brakes
  
  144
- Front Fork
  
  177
  - Removing the Front Fork Legs
    181
  - Disassembling the Front Fork Legs
    181
  - Checking the Front Fork Legs
    182
  - Assembling the Front Fork Legs
    183
  - Installing the Front Fork Legs
    186
- Handlebar
  
  189
  - Removing the Handlebar
    191
  - Checking the Handlebar
    191
  - Installing the Handlebar
    191
- Steering Head
  
  195
  - Removing the Lower Bracket
    197
  - Checking the Steering Head
    197
  - Installing the Steering Head
    198
- Rear Shock Absorber and Swingarm
  
  201
- Drive Belt and Drive Pulley
  
  212
Table of Contents

217
- Rocker Arms, Push Rods and Valve Lifters
  
  231
- Camshafts
  
  248
  - Removing the Camshafts
    250
  - Checking the Camshafts
    251
  - Checking the Decompression System
    253
  - Checking the Oil Delivery Pipe
    254
  - Installing the Camshafts
    254
- Cylinder Heads
  
  258
  - Removing the Cylinder Heads
    260
  - Checking the Cylinder Heads
    260
  - Checking the Oil Delivery Pipe
    261
  - Installing the Cylinder Heads
    261
- Valves and Valve Springs
  
  263
  - Removing the Valves
    264
  - Checking the Valves and Valve Guides
    265
  - Checking the Valve Seats
    267
  - Checking the Valve Springs
    269
  - Installing the Valves
    270
- Cylinders and Pistons
  
  272
  - Removing the Cylinders and Pistons
    273
  - Checking the Cylinders and Pistons
    273
  - Checking the Piston Rings
    275
  - Checking the Piston Pins
    276
  - Installing the Pistons and Cylinders
    277
- Clutch
  
  279
  - Removing the Clutch
    284
  - Removing the Primary Drive Gear
    284
  - Checking the Friction Plates
    285
  - Checking the Clutch Plates
    285
  - Checking the Clutch Spring Plate
    286
  - Checking the Clutch Housing
    286
  - Checking the Clutch Boss
    286
  - Checking the Pressure Plate
    286
  - Checking the Pull Lever Shaft and Pull Rod
    287
  - Checking the Primary Drive
    287
  - Installing the Pickup Coil and Pull Lever Shaft
    287
  - Installing the Primary Drive Gear
    288
  - Installing the Clutch
    289
- Shift Shaft
  
  293
- Generator and Starter Clutch
  
  296
  - Removing the Generator
    299
  - Checking the Starter Clutch
    299
  - Installing the Generator
    300
- Transfer Gear Case
  
  304
  - Removing the Battery
    310
  - Removing the Middle Driven Shaft
    310
  - Checking the Middle Drive
    310
  - Checking the Oil Strainer
    311
  - Checking the Oil Pump
    311
  - Checking the Oil Pipe
    312
  - Assembling the Oil Pump
    312
  - Installing the Transfer Gear Case
    313
  - Installing the Oil Tank Cover
    316
  - Installing the Battery
    317
- Crankcase
  
  323
  - Checking the Crankcase
    323
  - Checking the Bearings and Oil Seal
    323
  - Checking the Oil Delivery Pipe
    324
  - Checking the Engine Oil Pump Drive
    324
  - Assembling the Crankcase
    324
- Engine Oil Pump
  
  327
  - Checking the Oil Pump
    330
  - Checking the Relief Valve
    330
  - Checking the Oil Strainer
    331
  - Assembling the Oil Pump
    331
  - Installing the Oil Pump
    332
  - Installing the Oil Strainer
    332
- Crankshaft and Connecting Rods
  
  333
  - Removing the Crankshaft
    334
  - Removing the Connecting Rods
    334
  - Checking the Crankshaft and Connecting Rods
    334
  - Installing the Connecting Rods
    338
  - Installing the Crankshaft
    340
- Transmission
  
  343
Carburetor/Air Induction System

347
- Carburetor
  
  350
  - Checking the Carburetor
    354
  - Checking the Carburetor Joint
    356
  - Installing the Carburetor Joint
    360
  - Installing the Carburetor
    360
  - Measuring and Adjusting the Fuel Level
    362
  - Checking and Adjusting the Throttle Position Sensor
    363
  - Checking the Fuel Pump
    367
  - Checking the Fuel Cock
    367
  - Checking the Fuel Cock Operation
    368
- Air Induction System
  
  369
  - Air Injection
    369
  - Air Cutoff Valve
    369
Carb Air Induction System

378
- Electrical Components
  
  380
- Arrangement of the Electrical Components and Couplers
  
  381
- Switches
  
  385
  - Checking Switch Continuity
    385
- Checking the Switches
  
  386
- Checking the Bulbs and Bulb Sockets
  
  388
  - Types of Bulbs
    388
  - Checking the Condition of the Bulbs
    388
  - Checking the Condition of the Bulb Sockets
    390
  - CHECKING the Leds
    390
- Ignition System
  
  391
  - Circuit Diagram
    391
  - Troubleshooting
    392
- Electric Starting System
  
  396
  - Circuit Diagram
    396
  - Starting Circuit Cutoff System Operation
    397
  - Troubleshooting
    398
- Starter Motor
  
  398
  - Checking the Starter Motor
    404
  - Assembling the Starter Motor
    405
  - Installing the Starter Motor
    406
- Charging System
  
  407
  - Circuit Diagram
    407
  - Troubleshooting
    408
- Lighting System
  
  410
  - Circuit Diagram
    410
  - Troubleshooting
    411
  - Checking the Lighting System
    412
- Signaling System
  
  415
  - Circuit Diagram
    415
  - Troubleshooting
    417
  - Checking the Signaling System
    418
- Fuel Pump System
  
  424
  - Circuit Diagram
    424
  - Fuel Pump Circuit Operation
    425
  - Troubleshooting
    426
  - Checking the Fuel Pump
    428
- Carburetor Heating System
  
  429
  - Circuit Diagram
    429
  - Troubleshooting
    430
- Self-Diagnosis
  
  434
  - Troubleshooting
    440
    
    Incorrect Engine Idling Speed
    443
    
    Faulty Gear Shifting
    444
    
    Unstable Handling
    446

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Yamaha XV16AL Manuals

Yamaha XV16AL Service Manual (449 pages)

Table of Contents

Gen Info

General Information

Motorcycle Identification

Features

Important Information

Checking the Connections

Special Tools

Table of Contents

Table of Contents

General Maintenance and Lubrication Chart

Periodic Checks and Adjustments

Periodic Maintenance/Lubrication Intervals

Introduction

Seats and Side Covers

Xv16At Accessory Parts

Fuel Tank

Air Filter Case

Engine

Chassis

Electrical System

Instrument Functions

Front Wheel and Brake Discs/Rear Wheel, Brake Disc and Rear Wheel Pulley

Front Wheel and Brake Discs

Rear Wheel, Brake Disc and Rear Wheel Pulley

Front and Rear Brakes

Front Fork

Handlebar

Steering Head

Rear Shock Absorber and Swingarm

Drive Belt and Drive Pulley

Table of Contents

Rocker Arms, Push Rods and Valve Lifters

Camshafts

Cylinder Heads

Valves and Valve Springs

Cylinders and Pistons

Clutch

Shift Shaft

Generator and Starter Clutch

Transfer Gear Case

Crankcase

Engine Oil Pump

Crankshaft and Connecting Rods

Transmission

Carburetor/Air Induction System

Carburetor

Air Induction System

Carb Air Induction System

Electrical Components

Arrangement of the Electrical Components and Couplers

Switches

Checking the Switches

Checking the Bulbs and Bulb Sockets

Ignition System

Electric Starting System

Starter Motor

Charging System

Lighting System

Signaling System

Fuel Pump System

Carburetor Heating System

Self-Diagnosis

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