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XV16AL
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
Table of Contents
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
General Tightening Torques
36
Engine Tightening Torques
37
Chassis Tightening Torques
39
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
Adjusting the Valve Clearance
65
Adjusting the Engine Idling Speed
69
Adjusting the Throttle Cable Free Play
70
Checking the Spark Plugs
71
Checking the Ignition Timing
73
Measuring the Compression Pressure
75
Checking the Engine Oil Level
77
Changing the Engine Oil
79
Measuring the Engine Oil Pressure
82
Checking the Transfer Gear Oil Level
83
Changing the Transfer Gear Oil
84
Adjusting the Clutch Cable Free Play
85
Cleaning the Air Filter Element
86
Checking the Carburetor Joint
87
Checking the Fuel Hoses and Fuel Filter
87
Checking the Cylinder Head Breather Hose and Transfer Gear Case Breather Hose
88
Checking the Exhaust System
88
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
Replacing the Front Brake Pads
146
Replacing the Rear Brake Pads
149
Disassembling the Front Brake Master Cylinder
153
Disassembling the Rear Brake Master Cylinder
157
Checking the Front and Rear Brake Master Cylinders
158
Assembling and Installing the Front Brake Master Cylinder
159
Assembling and Installing the Rear Brake Master Cylinder
162
Disassembling the Front Brake Calipers
169
Disassembling the Rear Brake Caliper
169
Checking the Front and Rear Brake Calipers
170
Assembling and Installing the Front Brake Calipers
171
Assembling and Installing the Rear Brake Caliper
174
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
Handling the Rear Shock Absorber
205
Disposing of a Rear Shock Absorber and Gas Cylinder
205
Removing the Rear Shock Absorber and Swingarm
205
Checking the Rear Shock Absorber
206
Checking the Replay Arm and Connecting Arm
207
Checking the Swingarm
207
Installing the Rear Shock Absorber and Swingarm
208
Drive Belt and Drive Pulley
212
Removing the Drive Belt and Drive Pulley
212
Checking the Drive Belt
213
Installing the Drive Belt and Drive Pulley
214
Table of Contents
217
Rocker Arms, Push Rods and Valve Lifters
231
Removing the Rocker Arms, Push Rods and Valve Lifters
237
Checking the Rocker Arms and Rocker Arm Shafts
237
Checking the Rocker Arm Bases
239
Checking the Push Rods
239
Checking the Valve Lifters and Valve Lifter Cases
239
Bleeding the Valve Lifter
240
Checking the Push Rod Covers
242
Installing the Valve Lifters and Push Rod Covers
242
Installing the Rocker Arms and Push Rods
243
Installing the Cylinder Head Covers
245
Installing the Camshaft Sprocket Cover and Engine Left Side Cover
246
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
Checking the Shift Shaft
294
Checking the Stopper Lever
294
Installing the Stopper Lever and Shift Shaft
294
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
Checking the Shift Forks
344
Checking the Shift Drum Assembly
344
Checking the Transmission
345
Installing the Transmission, Shift Drum Assembly and Shift Forks
345
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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