Yamaha XV1600AL 1999 Manuals

Manuals and User Guides for Yamaha XV1600AL 1999. We have 1 Yamaha XV1600AL 1999 manual available for free PDF download: Service Manual

Yamaha XV1600AL 1999 Service Manual

Yamaha XV1600AL 1999 Service Manual (460 pages)

Brand: Yamaha | Category: Motorcycle | Size: 39.61 MB

Table of Contents

Section 1

9
- Important Manual Information
  4
- How to Use this Manual
  5
- Table of Contents
  9
- Motorcycle Identification
  11
- Features
  12
- Important Information
  16
  - Lock Washers/Plates and Cotter Pins
    17
- Checking the Connections
  18
- Special Tools
  19
Section 2

23
- General Specifications
  25
  - Specifications Spec
    25
- Specifications
  25
- Engine Specifications
  26
- Chassis Specifications
  34
- Electrical Specifications
  41
- Conversion Table
  42
- Tightening Torques
  42
- Lubrication Points and Lubricant Types
  47
  - Engine Lubrication Points and Lubricant Types
    47
  - Chassis Lubrication Points and Lubricant Types
    48
- Engine Oil Lubrication Chart
  49
- Engine Oil Flow Diagrams
  50
- Transfer Gear Oil Flow Diagrams
  54
- Cable Routing
  56
Table of Contents

65
- Periodic Checks and Adjustments
  
  67
- Periodic Maintenance/Lubrication Intervals
  
  67
- Introduction
  
  67
- Seats and Side Covers
  
  69
- Fuel Tank
  
  70
- Air Filter Case
  
  71
- Engine
  
  72
- Chassis
  
  97
  - Adjusting the Front Brake
    97
  - Adjusting the Rear Brake
    98
  - Checking the Brake Fluid Level
    99
  - Checking the Front Brake Pads
    100
  - Checking the Rear Brake Pads
    100
  - Adjusting the Rear Brake Light Switch
    101
  - Checking the Brake Hose
    101
  - Bleeding the Hydraulic Brake System
    102
  - Adjusting the Shift Pedal
    104
  - Adjusting the Drive Belt Slack
    104
  - Checking and Adjusting the Steering Head
    106
  - Checking the Front Fork
    108
  - Adjusting the Rear Shock Absorber Assembly
    109
  - Checking the Tires
    111
  - Checking and Tightening the Spokes
    113
  - Checking and Lubricating the Cables
    114
  - Lubricating the Levers and Pedals
    115
  - Lubricating the Sidestand
    115
  - Lubricating the Rear Suspension
    115
- Electrical System
  
  116
  - Checking and Charging the Battery
    116
  - Checking the Fuses
    121
  - Replacing the Headlight Bulb
    123
  - Adjusting the Headlight Beam
    124
- Instrument Functions
  
  126
  - Indicator Lights
    126
  - Combination Meter
    126
  - Chassis Chas
    129
Table of Contents

130
- Front Wheel and Brake Discs
  138
- Front and Rear Brakes
  
  152
- Front Fork
  
  185
  - Removing the Front Fork Legs
    189
  - Disassembling the Front Fork Legs
    189
  - Checking the Front Fork Legs
    190
  - Assembling the Front Fork Legs
    191
  - Installing the Front Fork Legs
    194
- Handlebar
  
  197
  - Removing the Handlebar
    199
  - Checking the Handlebar
    199
  - Installing the Handlebar
    199
- Steering Head
  
  203
  - Removing the Lower Bracket
    205
  - Checking the Steering Head
    205
  - Installing the Steering Head
    206
- Rear Shock Absorber and Swingarm
  
  209
- Drive Belt and Drive Sprocket
  
  220
Table of Contents

226
- Rocker Arms, Push Rods and Valve Lifters
  
  240
- Camshafts
  
  257
  - Removing the Camshafts
    259
  - Checking the Camshafts
    260
  - Checking the Decompression System
    262
  - Checking the Oil Delivery Pipe
    263
  - Installing the Camshafts
    263
- Cylinder Heads
  
  267
  - Removing the Cylinder Heads
    269
  - Checking the Cylinder Heads
    269
  - Checking the Oil Delivery Pipe
    270
  - Installing the Cylinder Heads
    270
- Valves and Valve Springs
  
  272
  - Removing the Valves
    273
  - Checking the Valves and Valve Guides
    274
  - Checking the Valve Seats
    276
  - Checking the Valve Springs
    278
  - Installing the Valves
    279
- Cylinders and Pistons
  
  281
  - Removing the Cylinders and Pistons
    282
  - Checking the Cylinders and Pistons
    282
  - Checking the Piston Rings
    284
  - Checking the Piston Pins
    285
  - Installing the Pistons and Cylinders
    286
- Clutch
  
  288
  - Removing the Clutch
    293
  - Removing the Primary Drive Gear
    293
  - Checking the Friction Plates
    294
  - Checking the Clutch Plates
    294
  - Checking the Clutch Spring Plate
    295
  - Checking the Clutch Housing
    295
  - Checking the Clutch Boss
    295
  - Checking the Pressure Plate
    295
  - Checking the Pull Lever Shaft and Pull Rod
    296
  - Checking the Primary Drive
    296
  - Installing the Pickup Coil and Pull Lever Shaft
    296
  - Installing the Primary Drive Gear
    297
  - Installing the Clutch
    298
- Shift Shaft
  
  302
- Generator and Starter Clutch
  
  305
  - Removing the Generator
    308
  - Checking the Starter Clutch
    308
  - Installing the Generator
    309
- Transfer Gear Case
  
  313
  - Removing the Battery
    319
  - Removing the Middle Driven Shaft
    319
  - Checking the Middle Drive
    319
  - Checking the Oil Strainer
    320
  - Checking the Oil Pump
    320
  - Checking the Oil Pipe
    321
  - Assembling the Oil Pump
    321
  - Installing the Transfer Gear Case
    322
  - Installing the Oil Tank Cover
    325
  - Installing the Battery
    326
- Crankcase
  
  328
  - Disassembling the Crankcase
    331
  - Checking the Crankcase
    332
  - Checking the Bearing and Oil Seal
    332
  - Checking the Oil Delivery Pipe
    333
  - Checking the Engine Oil Pump Drive
    333
  - Assembling the Crankcase
    333
- Engine Oil Pump
  
  336
  - Checking the Oil Pump
    339
  - Checking the Relief Valve
    339
  - Checking the Oil Strainer
    340
  - Assembling the Oil Pump
    340
  - Installing the Oil Pump
    341
  - Installing the Oil Strainer
    341
- Crankshaft and Connecting Rods
  
  342
  - Removing the Crankshaft
    343
  - Removing the Connecting Rods
    343
  - Checking the Crankshaft and Connecting Rods
    343
  - Installing the Connecting Rods
    347
  - Installing the Crankshaft
    349
- Transmission
  
  350
Table of Contents

389
- Electrical Components
  
  391
- Arrangement of the Electrical Components and Couplers
  
  393
- Switches
  
  396
  - Checking Switch Continuity
    396
- Checking the Switches
  
  397
- Checking the Bulbs and Bulb Sockets
  
  399
  - Types of Bulbs
    399
  - Checking the Condition of the Bulbs
    399
  - Checking the Condition of the Bulb Sockets
    401
  - CHECKING the Leds
    401
- Ignition System
  
  402
  - Circuit Diagram
    402
  - Troubleshooting
    403
- Electric Starting System
  
  407
  - Circuit Diagram
    407
  - Starting Circuit Cutoff System Operation
    408
  - Troubleshooting
    409
- Starter Motor
  
  413
  - Checking the Starter Motor
    415
  - Assembling the Starter Motor
    416
  - Installing the Starter Motor
    417
- Charging System
  
  418
  - Circuit Diagram
    418
  - Troubleshooting
    419
- Lighting System
  
  421
  - Circuit Diagram
    421
  - Troubleshooting
    422
  - Checking the Lighting System
    423
- Signaling System
  
  426
  - Circuit Diagram
    426
  - Troubleshooting
    428
  - Checking the Signaling System
    429
- Fuel Pump System
  
  435
  - Circuit Diagram
    435
  - Fuel Pump Circuit Operation
    436
  - Troubleshooting
    437
  - Checking the Fuel Pump
    439
- Carburetor Heating System
  
  440
  - Circuit Diagram
    440
  - Troubleshooting
    441
- Self-Diagnosis
  
  444
Trbl Shtg

451
- Troubleshooting
  451
- Starting Problems
  
  453
  - Engine
    453
  - Fuel System
    453
  - Electrical Systems
    454
- Incorrect Engine Idling Speed
  
  454
  - Engine
    454
  - Fuel System
    454
- Faulty Gear Shifting
  
  455
  - Shifting Is Difficult
    455
  - Shift Pedal Does Not Move
    455
  - Jumps out of Gear
    455
- Faulty Clutch
  
  455
  - Clutch Slips
    455
  - Clutch Drags
    455
- Poor Medium-And-High-Speed Performance
  
  455
  - Engine
    455
  - Fuel System
    455
- Overheating
  
  456
  - Engine
    456
  - Fuel System
    456
  - Chassis
    456
  - Electrical Systems
    456
- Poor Braking Performance
  
  456
- Faulty Front Fork Legs
  
  456
  - Leaking Oil
    456
  - Malfunction
    456
- Unstable Handling
  
  457

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