Yamaha XV16 Road Star 1999-2003 Motorcycle Repair Manual

ELECTRIC STARTING SYSTEM ELEC – + EB803404 EB802412 6.Starter relay 8.Engine stop switch • Disconnect the starter relay from the • Check the engine stop switch for conti- coupler. nuity. Refer to “CHECKING THE SWITCHES”. • Connect the pocket tester (Ω × 1) and battery (12 V) to the starter relay termi- • Is the engine stop switch OK? nals as shown. YES NO Battery positive terminal → red/white 1 Battery negative terminal → blue 2 Replace the right handlebar switch. Tester positive probe → red 3 Tester negative probe → black 4 EB802413 9.Neutral switch • Check the neutral switch for continuity. Refer to “CHECKING THE SWITCHES”. • Is the neutral switch OK? YES NO • Does the starter relay have continuity Replace the neutral between red and black? switch. YES NO EB802414 Replace the starter 10.Sidestand switch relay. • Check the sidestand switch for continu- ity. Refer to “CHECKING THE SWITCHES”. EB802411 • Is the sidestand switch OK? 7.Main switch YES NO • Check the main switch for continuity. Refer to “CHECKING THE SWITCHES”. Replace the side- stand switch. 7 • Is the main switch OK? YES NO Replace the main switch. 7 - 21

ELECTRIC STARTING SYSTEM ELEC – + 11.Diode EB803406 • Remove the diode from the coupler. 13.Start switch • Connect the pocket tester (Ω × 1) to the • Check the start switch for continuity. diode terminals as shown. Refer to “CHECKING THE SWITCHES”. • Check the diode for continuity as fol- • Is the start switch OK? lows. YES NO Tester positive probe → blue/white 1 Continu- Replace the right handlebar switch. Tester negative probe → ity FAS00754 blue/yellow 2 14.Wiring Tester positive probe → blue/yellow 2 No conti- • Check the entire starting system’s wir- ing. Tester negative probe → nuity Refer to “CIRCUIT DIAGRAM”. blue/white 1 • Is the starting system’s wiring properly connected and without defects? YES NO NOTE: Properly connect When you switch the tester’s positive or repair the start- and negative probes, the readings in the ing system’s wir- above chart will be reversed. ing. • Are the tester readings correct? 15.Decompression solenoid (thermistor) 7 YES NO • Check the decompression solenoid for Replace the diode. continuity. Refer to “SELF-DIAGNOSIS”. EB803405 • Is the decompression solenoid OK? 12.Clutch switch • Check the clutch switch for continuity. YES NO Refer to “CHECKING THE SWITCHES”. Replace the ignitor Replace the decom- • Is the clutch switch OK? unit. pression solenoid. YES NO Replace the clutch switch. 7 - 22

STARTER MOTOR ELEC – + EB803500 STARTER MOTOR Order Job/Part Q’ty Remarks Remove the parts in the order listed. Removing the starter motor 1 1 Starter motor lead 1 2 Starter motor assembly For installation, reverse the removal procedure. 7 7 - 23

STARTER MOTOR ELEC – + EB803501 Order Job/Part Q’ty Remarks 7 Disassembling the starter motor Remove the parts in the order listed. 1 Circlip 2 Starter motor 1 3 Starter motor rear cover 1 4 Lock washer 1 5 Oil seal 1 6 Bearing 1 7 Washer set 1 8 Starter motor front cover 1 9 Washer set 1 0 O-ring 1 A Armature assembly 2 B Brush seat (along with the brushes) 1 C Brush holder (along with the brushes) 1 D Starter motor yoke 1 1 For assembly, reverse the disassembly procedure 7 - 24

STARTER MOTOR ELEC – + EB803511 CHECKING THE STARTER MOTOR 1. Check: • commutator Dirt → Clean with 600 grit sandpaper. 2. Measure: • commutator diameter a Out of specification → Replace the starter motor. Minimum commutator diameter 27 mm (1.06 in) 3. Measure: • mica undercut a Out of specification → Scrape the mica to the proper measurement with a hacksaw blade which has been grounded to fit the commutator. Mica undercut 0.7 mm (0.03 in) NOTE: The mica must be undercut to ensure proper operation of the commutator. 4. Measure: • armature assembly resistances (commu- tator and insulation) Out of specification → Replace the starter motor. 7 wwwwwwwwwwwwwwwwwwwwwwwwwwww a. Measure the armature assembly resis- tances with the pocket tester. Pocket tester YU-03112 Armature assembly Commutator resistance 1 0.025 ~ 0.035 Ω at 20 ˚C (68 ˚F) Insulation resistance 2 Above 1 MΩ at 20 ˚C (68 ˚F) b. If any resistance is out of specification, replace the starter motor. vvvvvvvvvvvvvvvvvvvvvvvvvvvv 7 - 25

STARTER MOTOR ELEC – + 5. Measure: • brush length a Out of specification → Replace the brushes as a set. Minimum brush length 5 mm (0.20 in) 6. Measure: • brush spring force Out of specification → Replace the brush springs as a set. Brush spring force 7.65 ~ 10.01 N (765 ~ 1,001 gf, 27.0 ~ 35.3 oz) 7. Check: • gear teeth Damage/wear → Replace the gear. 8. Check: • bearing • oil seal Damage/wear → Replace the defective part(s). EB803701 ASSEMBLING THE STARTER MOTOR 1. Install: • starter motor yoke 1 • bush holder 2 7 2. Install: • brush seat 1 NOTE: Align the tab a on the brush seat with the slot b in the starter motor rear cover. 7 - 26

STARTER MOTOR ELEC – + 3. Install: • armature assembly 4. Install: • bearing • oil seal • lock washer 1 5. Install: • O-rings 1 New • starter motor rear cover 2 • starter motor front cover 3 • bolts T. R. T. R. T. R. 7 Nm (0.7 m · kg, 5.1 ft · lb) NOTE: Align the match marks a on the starter motor yoke with the match marks b on the front and rear covers. 6. Install: • starter motor gear 1 • circlip 2 7 INSTALLING THE STARTER MOTOR 1. Install: • starter motor 1 7 Nm (0.7 m · kg, 5.1 ft · lb) 2. Connect: • starter lead 2 5 Nm (0.5 m · kg, 3.6 ft · lb) 7 - 27

CHARGING SYSTEM ELEC – + EB804000 CHARGING SYSTEM CIRCUIT DIAGRAM B R (BLACK) WW W W W R 8 R/G 1W W2 R W W RR B WW WW W W R R 5 RR R/W L 3 R Br/L R R L/Y L/B L ON 4 6 OFF (BLACK) R/W B B Br/L L/B Br/L R B B L/Y L/B L/Y BB 7 (BLACK) B B 7 1 Generator 2 Rectifier/regulator 4 Battery 5 Main fuse 7 - 28

CHARGING SYSTEM ELEC – + EB804010 EB802401 TROUBLESHOOTING 2.Battery The battery is not being charged. • Check the condition of the battery. Refer to “CHECKING AND CHARGING Check: THE BATTERY” in chapter 3. 1. main fuse 2. battery Open-circuit voltage 3. charging voltage 12.8 V or more at 20 ˚C (68 ˚F) 4. stator coil assembly resistance 5. wiring • Is the battery OK? (of the entire charging system) YES NO NOTE: • Clean the battery • Before troubleshooting, remove the fol- terminals. lowing part(s): • Recharge or 1) rider seat replace the battery. 2) left side cover • Troubleshoot with the following special tool(s). Inductive tachometer EB804400 YU-8036-A 3.Charging voltage Pocket tester YU-03112 • Connect the inductive tachometer to the spark plug lead of cylinder #1. • Connect the pocket tester (DC 20V) to the battery as shown. Tester positive probe → battery positive terminal Tester negative probe → battery negative terminal EB802400 1.Main fuse • Check the main fuse for continuity. Refer to “CHECKING THE FUSES” in chapter 3. 7 • Is the main fuse OK? YES NO Replace the fuse. • Start the engine and let it run at approxi- mately 1,000 r/min. • Measure the charging voltage. Charging voltage 14 V at 1,000 r/min 7 - 29

CHARGING SYSTEM ELEC – + NOTE: EB804404 Make sure that the battery is fully charged. 5.Wiring • Is the charging voltage within specifica- • Check the wiring connections of the tion? entire charging system. Refer to “CIRCUIT DIAGRAM”. NO YES • Is the charging system’s wiring properly The charging circuit connected and without defects? is OK. YES NO EB804401 Replace the recti- Properly connect 4.Stator coil assembly resistances fier/regulator. or repair the charg- ing system’s wir- • Disconnect the generator coupler from ing. the wire harness. • Connect the pocket tester (Ω × 1) to the stator coil assembly coupler as shown. Tester positive probe → white 1 Tester negative probe → white 2 Tester positive probe → white 1 Tester negative probe → white 3 • Measure the stator coil assembly resis- 7 tances. Stator coil resistance 0.45 ~ 0.55 Ω at 20 ˚C (68 ˚F) • Is the stator coil assembly OK? YES NO Replace the stator coil assembly. 7 - 30

7 3 Main switch EB805000 4 Battery 7 - 31 5 Main fuse LIGHTING SYSTEM O High beam indicator light P Meter light CIRCUIT DIAGRAM V Dimmer switch Z Front turn signal/position light \\ Headlight c Tail/brake light h Headlight fuse LIGHTING SYSTEM ELEC – +

LIGHTING SYSTEM ELEC – + EB805010 EB802401 TROUBLESHOOTING 2.Battery • Check the condition of the battery. Any of the following fail to light: head- light, high beam indicator light, taillight, Refer to “CHECKING AND CHARGING position light or meter light. THE BATTERY” in chapter 3. Check: Open-circuit voltage 1. main, and headlight fuses 12.8 V or more at 20 ˚C (68 ˚F) 2. battery 3. main switch • Is the battery OK? 4. dimmer switch 5. wiring YES NO (of the entire charging system) • Clean the battery terminals. NOTE: • Before troubleshooting, remove the fol- • Recharge or replace the battery. lowing part(s): 1) rider seat EB802411 2) fuel tank 3) left side cover 3.Main switch 4) headlight lens unit • Check the main switch for continuity. • Troubleshoot with the following special Refer to “CHECKING THE SWITCHES”. tool(s). • Is the main switch OK? Pocket tester YU-03112 YES NO EB802400 Replace the main 7 switch. 1.Main and headlight fuses EB805401 • Check the main and headlight fuses for continuity. 4.Dimmer switch Refer to “CHECKING THE FUSES” in chapter 3. • Check the dimmer switch for continuity. Refer to “CHECKING THE SWITCHES”. • Are the main and headlight fuses OK? • Is the dimmer switch OK? YES NO Replace the fuse(s). YES NO Replace the left han- dlebar switch. 7 - 32

EB805404 LIGHTING SYSTEM ELEC – + 5.Wiring EB805410 • Check the entire lighting system’s wir- CHECKING THE LIGHTING SYSTEM ing. 1. The headlight and the high beam indica- Refer to “CIRCUIT DIAGRAM”. tor light fail to come on. • Is the lighting system’s wiring properly connected and without defects? 1.Headlight bulb and socket YES NO • Check the headlight bulb and socket for continuity. Check the condition Properly connect Refer to “CHECKING THE BULBS AND of each of the light- or repair the light- BULB SOCKETS”. ing system’s cir- ing system’s wir- cuits. ing. • Is the headlight bulb and socket OK? Refer to “CHECK- ING THE LIGHTING YES NO SYSTEM”. Replace the head- light bulb, socket or both. 2.High beam indicator light bulb and socket • Check the high beam indicator light bulb and socket for continuity. Refer to “CHECKING THE BULBS AND BULB SOCKETS”. • Is the high beam indicator light bulb and socket OK? YES NO Replace the high beam indicator light bulb, socket or both. 7 3.Voltage • Connect the pocket tester (DC 20 V) to the headlight coupler and the meter assembly couplers as shown. Å When the dimmer switch is set to “ ” ı When the dimmer switch is set to “ ” Headlight coupler 7 - 33

Headlight LIGHTING SYSTEM ELEC – + Tester positive probe → yellow 1 or green 2 EB805411 Tester negative probe → black 3 2. A meter light fails to come on. High beam indicator light Tester positive probe → yellow 4 1.Meter light bulb and socket Tester negative probe → black 5 • Check the meter light bulb and socket Meter assembly coupler (wire harness for continuity. Refer to “CHECKING THE BULBS AND side) BULB SOCKETS”. • Are the meter light bulb and socket OK? YES NO Replace the meter light bulb, socket or both. • Set the main switch to “ON”. 2.Voltage • Set the dimmer switch to “ ” or • Connect the pocket tester (20 V) to the “ ”. meter assembly coupler (wire harness • Measure the voltage (12 V) of yellow side) as shown. (green) 2 on the headlight coupler and Tester positive probe → blue 1 yellow 4 on the meter assembly cou- Tester negative probe → black 2 pler. • Is the voltage within specification? • Set the main switch to “ON”. 7 • Measure the voltage (12 V) of blue 1 on YES NO the meter assembly coupler (wire har- The wiring circuit ness side). from the main • Is the voltage within specification? switch to the head- light coupler and YES NO meter assembly couplers are faulty and must be repaired. This circuit is OK. The wiring circuit from the main switch to the meter assembly coupler is faulty and must be repaired. 7 - 34

EB805412 LIGHTING SYSTEM ELEC – + 3. A tail/brake light fails to come on. 4. The front turn signal/position light fails to come on. 1.Tail/brake light bulb and socket 1.Front turn signal/position light bulb and • Check the tail/brake light bulb and socket socket for continuity. Refer to “CHECKING THE BULBS AND • Check the front turn signal/position light BULB SOCKETS”. bulb and socket for continuity. Refer to “CHECKING THE BULBS AND • Are the tail/brake light bulb and socket BULB SOCKETS”. OK? • Are the front turn signal/position light YES NO bulb and socket OK? Replace the tail/ YES NO brake light bulb, socket or both. Replace the front turn signal/position light 2.Voltage bulb, socket or both. • Connect the pocket tester (DC 20 V) to 2.Voltage the tail/brake light connectors (wire har- ness side) as shown. • Connect the pocket tester (DC 20 V) to the front turn signal/position light con- Tester positive probe → blue 1 nectors (wire harness side) as shown. Tester negative probe → black 2 Tester positive probe → blue 1 Tester negative probe → black 2 • Set the main switch to “ON”. 7 • Measure the voltage (12 V) of blue 1 on • Set the main switch to “ON”. the tail/brake light coupler (wire harness • Measure the voltage (12 V) of blue 1 on side). the front turn signal/position light con- • Is the voltage within specification? nectors (wire harness side). YES NO • Is the voltage within specification? This circuit is OK. The wiring circuit YES NO from the main This circuit is OK. switch to the tail/ The wiring circuit brake light coupler from the main is faulty and must switch to the front be repaired. turn signal/posi- tion light connec- tors is faulty and must be repaired. 7 - 35

SIGNALING SYSTEM ELEC – + EB806000 SIGNALING SYSTEM CIRCUIT DIAGRAM 7 7 - 37

SIGNALING SYSTEM ELEC – + 3 Main switch 4 Battery 5 Main fuse 8 Backup fuse B Ignitor unit G Neutral switch J Engine trouble indicator light K Turn signal indicator light L Neutral indicator light M Speedometer assembly (speedometer, combination meter and fuel level meter) N Fuel level indicator light Q Fuel sender R Turn signal relay S Horn W Horn switch X Turn signal switch Z Front turn signal/position light [ Rear turn signal light _ Front brake light switch c Tail/brake light d Rear brake light switch j Signaling system fuse 7 7 - 38

SIGNALING SYSTEM ELEC – + EB806010 EB802401 TROUBLESHOOTING 2.Battery • Check the condition of the battery. • Any of the following fail to light: turn signal light, brake light or an indicator Refer to “CHECKING THE BATTERY” in light. chapter 3. • The horn fails to sound. Open-circuit voltage 12.8 V or more at 20 ˚C (68 ˚F) Check: 1. main, signaling system and backup fuses • Is the battery OK? 2. battery 3. main switch YES NO 4. wiring • Clean the battery (of the entire signaling system) terminals. NOTE: • Recharge or • Before troubleshooting, remove the fol- replace the battery. lowing part(s): EB802411 1) rider seat 2) fuel tank 3.Main switch 3) side covers • Check the main switch for continuity. 4) headlight lens unit • Troubleshoot with the following special Refer to “CHECKING THE SWITCHES”. • Is the main switch OK? tool(s). YES NO Pocket tester YU-03112 EB802400 Replace the main switch. 1.Main, signaling system and backup fuses EB806400 • Check the main, signaling system and 4.Wiring backup fuses for continuity. • Check the entire signaling system’s wir- Refer to “CHECKING AND CHARGING ing. THE FUSES” in chapter 3. Refer to “CIRCUIT DIAGRAM”. 7 • Are the main, signaling system and • Is the signaling system’s wiring properly backup fuses OK? connected and without defects? YES NO YES NO Replace the fuse(s). Check the condition Properly connect of each of the sig- or repair the signal- naling system’s cir- ing system’s wir- cuits. ing. Refer to “CHECK- ING THE SIGNAL- ING SYSTEM”. 7 - 39

SIGNALING SYSTEM ELEC – + EB806410 3.Horn CHECKING THE SIGNALING SYSTEM • Disconnect the horn coupler at the horn. 1.The horn fails to sound. • Connect a jumper lead 1 to the brown 1.Horn switch terminal in the horn coupler and the • Check the horn switch for continuity. horn terminal. • Connect a jumper lead 2 to the horn ter- Refer to “CHECKING THE SWITCHES”. minal and ground the jumper lead. • Is the horn switch OK? • Set the main switch to “ON”. • Push the horn switch. YES NO • Does the horn sound? Replace the left han- dlebar switch. 2.Voltage • Connect the pocket tester (DC 20 V) to the horn coupler as shown. Tester positive probe → brown 1 Tester negative probe → ground NO YES The horn is OK. • Set the main switch to “ON”. 4.Voltage • Push the horn switch. • Measure the voltage (12 V) of brown on • Connect the pocket tester (DC 20 V) to the horn coupler as shown. the horn coupler. • Is the voltage within specification? Tester positive probe → pink 1 Tester negative probe → ground YES NO 7 The wiring circuit • Set the main switch to “ON”. from the main • Measure the voltage (12 V) of pink 1 on switch to the horn connector is faulty the horn coupler. and must be • Is the voltage within specification? repaired. YES NO Repair or replace Replace the horn. the horn. 7 - 40

SIGNALING SYSTEM ELEC – + EB806411 • Set the main switch to “ON”. • Pull in the brake lever or push down on 2. A tail/brake light fails to come on. the brake pedal. 1.Tail/brake light bulb and socket • Measure the voltage (12 V) of yellow at • Check the tail/brake light bulb and socket the tail/brake light coupler (wire harness for continuity. side). Refer to “CHECKING THE BULBS AND • Is the voltage within specification? BULB SOCKETS”. YES NO • Are the tail/brake light bulb and socket OK? YES NO This circuit is OK. The wiring circuit from the main Replace the tail/ switch to the tail/ brake light bulb, brake light coupler socket or both. is faulty and must be repaired. 2.Brake light switches EB806413 • Check the brake light switches for conti- 3. A turn signal light, turn signal indicator nuity. light or both fail to blink. Refer to “CHECKING THE SWITCHES”. • Is the brake light switch OK? 1.Turn signal light bulb and socket YES NO • Check the turn signal light bulb and socket for continuity. Replace the brake Refer to “CHECKING THE BULBS AND light switch. BULB SOCKETS”. • Are the turn signal light bulb and socket OK? 3.Voltage YES NO • Connect the pocket tester (DC 20 V) to Replace the turn the tail/brake light coupler (wire harness signal light bulb, side) as shown. socket or both. 7 Tester positive probe → yellow 1 2.Turn signal indicator light bulb and socket Tester negative probe → black 2 • Check the turn signal indicator light bulb and socket for continuity. Refer to “CHECKING THE BULBS AND BULB SOCKETS”. • Is the turn signal indicator light bulb and socket OK? YES NO 7 - 41 Replace the turn sig- nal indicator light bulb, socket or both.

SIGNALING SYSTEM ELEC – + 3.Turn signal switch • Check the turn signal switch for continu- ity. Refer to “CHECKING THE SWITCHES”. • Is the turn signal switch OK? YES NO Replace the left han- • Set the main switch to “ON”. dlebar switch. • Set the turn signal switch to “ ” or “ ”. • Measure the voltage (12 V) of brown/ 4.Voltage white at the turn signal relay coupler. • Connect the pocket tester (DC 20 V) to • Is the voltage within specification? the turn signal relay coupler as shown. YES NO Tester positive probe → brown 1 Tester negative probe → ground The turn signal relay is faulty and must be replaced. • Set the main switch to “ON”. 6.Voltage 7 • Measure the voltage (12 V) of brown 1 • Connect the pocket tester (DC 20 V) to at the turn signal relay coupler. the turn signal light connectors (wire • Is the voltage within specification? harness side) or the meter assembly coupler as shown. YES NO Å Turn signal light The wiring circuit ı Turn signal indicator light from the main switch to the turn Left turn signal light signal relay coupler Tester positive probe → chocolate 1 is faulty and must Tester negative probe → ground be repaired. Right turn signal light 5.Voltage Tester positive probe → dark green 2 Tester negative probe → ground • Connect the pocket tester (DC 20 V) to the turn signal relay coupler as shown. Å Tester positive probe → brown/white 1 Tester negative probe → ground 7 - 42

SIGNALING SYSTEM ELEC – + ı 2.Neutral switch • Check the neutral switch for continuity. Refer to “CHECKING THE SWITCHES”. • Is the neutral switch OK? YES NO • Set the main switch to “ON”. Replace the neutral • Set the turn signal switch to “ ” or switch. “ ”. 3.Voltage • Measure the voltage (12 V) of chocolate 1 • Connect the pocket tester (DC 20 V) to or dark green 2 at the turn signal light con- the meter assembly coupler as shown. nectors (wire harness side) or the meter assembly coupler. Tester positive probe → brown 1 • Is the voltage within specification? Tester negative probe → sky blue 2 YES NO This circuit is OK. The wiring circuit from the turn signal switch to the turn • Set the main switch to “ON”. signal light connec- • Measure the voltage (12 V) of brown 1 tor or the meter assembly coupler and sky blue 2 at the meter assembly are faulty and must coupler. be repaired. • Is the voltage within specification? EB806414 YES NO 4. The neutral indicator light fails to come on. 1.Neutral indicator light bulb and socket 7 • Check the neutral indicator light bulb This circuit is OK. The wiring circuit and socket for continuity. from the main Refer to “CHECKING THE BULBS AND switch to the meter BULB SOCKETS”. assembly coupler is • Are the neutral indicator light bulb and faulty and must be socket OK? repaired. YES NO Replace the neutral indicator light bulb, socket or both. 7 - 43

SIGNALING SYSTEM ELEC – + EB806417 3.Voltage 5. The fuel level indicator light, fuel level • Connect the pocket tester (DC 20 V) to meter or both fail to come on. the meter assembly coupler (wire har- ness side) as shown. 1.Fuel level indicator light LED Tester positive probe → brown 1 • Check the LED of the fuel level indicator Tester negative probe → black 2 light. Refer to “CHECKING THE BULBS AND BULB SOCKETS”. • Is the fuel level indicator light LED OK? YES NO Replace the meter assembly. 2.Fuel sender • Set the main switch to “ON”. • Measure the voltage (12 V). • Disconnect the fuel sender coupler from • Is the voltage within specification? the wire harness. YES NO • Drain the fuel from the fuel tank and remove the fuel sender from the fuel Replace the meter The wiring circuit tank. assembly. from the main switch to the meter • Connect the pocket tester (Ω × 10) to the assembly coupler is fuel sender coupler. faulty and must be repaired. Tester positive probe → green 1 Tester negative probe → black/blue 2 • Measure the fuel sender resistance. 6. An engine trouble indicator light fails to 7 come on. Fuel sender resistance Full position of the float Å 1.Engine trouble indicator LED 11 ~ 13 Ω at 20 ˚C (68 ˚F) • Check the LED of the engine indicator Empty position of the float ı 140 ~ 143 Ω at 20 ˚C (68 ˚F) light. Refer to “CHECKING THE BULBS AND • Is the fuel sender OK? BULB SOCKETS”. YES NO YES NO Replace the meter assembly. Replace the fuel sender. 7 - 44

SIGNALING SYSTEM ELEC – + EAS00843 2.Wire harness • Check the wire harness for continuity. Refer to “CIRCUIT DIAGRAM”. • Is the wire harness OK? YES NO Replace the ignitor Repair or replace unit. the wire harness. 7 7 - 45

EB808000 FUEL PUMP SYSTEM CIRCUIT DIAGRAM 73 Main switch FUEL PUMP SYSTEM ELEC – + 4 Battery 7 - 465 Main fuse 9 Relay unit 0 Fuel pump B Ignitor unit a Engine stop switch i Ignition fuse

FUEL PUMP SYSTEM ELEC – + EB808010 FUEL PUMP CIRCUIT OPERATION The ignitor unit includes the control unit for the fuel pump. 1 Battery 2 Main fuse 3 Main switch 4 Ignition fuse 5 Engine stop switch 6 Ignitor unit 7 Fuel pump relay 8 Fuel pump 7 FWD 7 - 47

FUEL PUMP SYSTEM ELEC – + EB808020 EAS00739 TROUBLESHOOTING 2.Battery • Check the condition of the battery. The fuel pump fails to operate. Refer to “CHECKING AND CHARGING Check: THE BATTERY” in chapter 3. 1. main and ignition fuses 2. battery Minimum open circuit voltage 3. main switch 12.8 V or more at 20 ˚C (68 ˚F) 4. engine stop switch 5. relay unit (fuel pump relay) • Is the battery OK? 6. fuel pump 7. wiring YES NO (the entire fuel pump system) • Clean the battery terminals. NOTE: • Before troubleshooting, remove the fol- • Recharge or replace the battery. lowing part(s): 1) rider seat EAS00749 2) fuel tank 3) side covers 3.Main switch 4) headlight lens unit • Check the main switch for continuity. • Troubleshoot with the following special Refer to “CHECKING THE SWITCHES”. tool(s). • Is the main switch OK? Pocket tester YES NO YU-03112 EAS00738 Replace the main 7 switch. 1.Main and ignition fuses • Check the main and ignition fuses for EAS00750 continuity. 4.Engine stop switch Refer to “CHECKING THE FUSES” in • Check the engine stop switch for conti- chapter 3. • Are the main and ignition fuses OK? nuity. Refer to “CHECKING THE SWITCHES”. YES NO • Is the engine stop switch OK? Replace the fuse(s). YES NO Replace the right handlebar switch. 7 - 48

FUEL PUMP SYSTEM ELEC – + 5.Relay unit (fuel pump relay) • Measure the fuel pump resistance. • Disconnect the relay unit from the cou- Fuel pump resistance pler. 1.6 ~ 2.2 Ω at 20 ˚C (68 ˚F) • Connect the pocket tester (Ω × 1) and • Is the fuel pump OK? battery (12 V) to the relay unit terminals as shown. YES NO Battery positive terminal → red/black 1 Battery negative terminal → blue/red 2 Replace the fuel Tester positive probe → red/black 1 pump. Tester negative probe → blue/black 3 EAS00754 • Does the fuel pump relay have continu- ity between red/black and blue/black? 7.Wiring YES NO • Check the entire fuel pump system’s wir- Replace the relay ing. unit. Refer to “CIRCUIT DIAGRAM”. • Is the fuel pump system’s wiring prop- erly connected and without defects? YES NO Replace the ignitor Properly connect unit. or repair the fuel pump system’s wir- ing. EB808400 6.Fuel pump resistance • Disconnect the fuel pump coupler from the wire harness. • Connect the pocket tester (Ω × 1) to the 7 fuel pump coupler (fuel pump side) as shown. Tester positive probe → black/blue 1 Tester negative probe → black 2 7 - 49

FUEL PUMP SYSTEM ELEC – + EB808410 CHECKING THE FUEL PUMP WAWRNARINNGING Gasoline is extremely flammable and under certain circumstances there can be a dan- ger of an explosion or fire. Be extremely careful and note the following points: • Stop the engine before refuelling. • Do not smoke and keep away from open flames, sparks or any other source of fire. • If you do accidentally spill gasoline, wipe it up immediately with dry rags. • If gasoline touches the engine when it is hot, a fire may occur. Therefore, make sure that the engine is completely cool before performing the following test. 1.Check: 7 • fuel pump operation wwwwwwwwwwwwwwwwwwwwwwwwwwww a. Fill the fuel tank. b. Put the end of the fuel hose into an open container. c. Turn the fuel cock to “ON” or “RES”. d. Connect the battery (12 V) to the fuel pump coupler as shown. Battery positive lead → black/blue 1 Battery negative lead → black 2 e. If fuel flows out of the fuel hose, the fuel pump is OK. If fuel does not flow, replace the fuel pump. vvvvvvvvvvvvvvvvvvvvvvvvvvvv 7 - 50

CARBURETOR HEATING SYSTEM ELEC – + EAS00820 CARBURETOR HEATING SYSTEM CIRCUIT DIAGRAM 3 Main switch 4 Battery 5 Main fuse e Carburetor heater f Thermo switch g Carburetor heater fuse 7 7 - 51

CARBURETOR HEATING SYSTEM ELEC – + EAS00821 EAS00739 TROUBLESHOOTING 2.Battery • Check the condition of the battery. The carburetor heating system fails to operate. Refer to “CHECKING AND CHARGING THE BATTERY” in chapter 3. Check: 1. Main and carburetor heater fuses Minimum open circuit voltage 2. Battery 12.8 V or more at 20 ˚C (68 ˚F) 3. Main switch 4. Thermo switch • Is the battery OK? 5. Carburetor heater 6. Wiring YES NO (of the entire carburetor heating system) • Clean the battery terminals. NOTE: • Before troubleshooting, remove the fol- • Recharge or replace the battery. lowing part(s). 1) rider seat EAS00749 2) fuel tank 3) carburetor 3.Main switch 4) left side cover • Check the main switch for continuity. • Troubleshoot with the following special Refer to “CHECKING THE SWITCHES”. tool(s). • Is the main switch OK? Pocket tester YES NO YU-03112 EAS00738 Replace the main 7 switch. 1.Main and carburetor heater fuses EAS00823 • Check the main and carburetor heater fuses for continuity. 4.Thermo switch Refer to “CHECKING THE FUSES” in chapter 3. • Remove the thermo switch from the plastic bracket. • Are the main and carburetor heater fuses OK? • Connect the pocket tester to the thermo switch coupler as shown. YES NO Tester positive lead → black 1 Replace the fuse(s). Tester negative lead → black 2 • Immerse the thermo switch in a con- tainer filled with water 3. • Place a thermometer 4 in the water. • Slowly heat the water, than let it cool to the specified temperature as indicated in the table. • Check the thermo switch for continuity at the temperatures indicated in the table. 7 - 52

CARBURETOR HEATING SYSTEM ELEC – + WAWRNARINNGING • Handle the thermo switch with special care. • Never subject the thermo switch to strong shocks. If the thermo switch is dropped, replace it. • Does the thermo switch operate prop- erly? YES NO Replace the thermo switch. 5.Carburetor heater • Remove the carburetor heater from the carburetor. • Connect the pocket tester to the carbure- tor heater as shown. Tester positive probe → carburetor heater terminal 1 Tester negative probe → carburetor heater body 2 Å The thermo switch circuit is open. ı The thermo switch circuit is closed. Test step Water temperature Continu- ity 71 Less than 23 ± 3 ˚C YES (73.4 ± 5.4 ˚F) • Measure carburetor heater resistance. 2 More than 23 ± 3 ˚C NO Carburetor heater resistance (73.4 ± 5.4 ˚F) 12 V 30 W: 6 ~ 10 Ω at 20˚C (68˚F) 3 More than 12 ± 4 ˚C NO • Is the carburetor heater OK? (53.6 ± 7.2 ˚F) 4 Less than 12 ± 4 ˚C YES YES NO (53.6 ± 7.2 ˚F) Test steps 1 & 2: Heating phase Replace the carbu- Test steps 3 & 4: Cooling phase retor heater. 7 - 53

CARBURETOR HEATING SYSTEM ELEC – + EAS00754 6.Wiring • Check the entire carburetor heating sys- tem’s wiring. Refer to “CIRCUIT DIAGRAM”. • Is the carburetor heating system’s wir- ing properly connected and without defects? YES NO This circuit is OK. Properly connect or repair the carbu- retor heating sys- tem’s wiring. 7 7 - 54

SELF-DIAGNOSIS ELEC – + EB812000 SELF-DIAGNOSIS The XV16AL/XV16ALC/XV16ATL/XV16ATLC features a self-diagnosing system for the follow- ing circuit(s): • throttle position sensor • speed sensor • decompression solenoid • fuel level meter If any of these circuits is defective, the respective condition code will be displayed by the engine trouble indicator light or fuel level indicator light when the main switch is set to “ON” (irrespective of whether the engine is running or not). Condition code Indica- Circuit Defect(s) System response When When tor light engine is engine is stopped running Throttle posi- • Disconnected • The ignitor unit stays set to the Blinks in Lights up tion sensor • Short-circuit wide-open throttle ignition tim- patterns • Locked ing. The motorcycle can be rid- of 3 den. • The engine trouble indicator light displays the condition code. Speed sensor • Abnormal pulse • The engine speed limiter sets in Blinks in Lights up • Disconnected approximately 4,400 rpm. patterns • Short-circuit • The engine trouble indicator of 4 light displays the condition code. Decompres- • Disconnected • The decompression solenoid Blinks in Lights up sion solenoid • Short-circuit does not move. patterns • Over heated • The starter motor does not oper- of 6 solenoid ate. • Disconnected • The engine trouble indicator thermistor in light displays the condition code. solenoid • Short-circuited thermistor in solenoid 7 Fuel level • Disconnected • The fuel level meter displays the Blinks in Blinks in meter • Short-circuit empty position. patterns patterns • The fuel level indicator light dis- of 8 of 8 plays the condition code. NOTE: When the main switch is turned on, the engine trouble indicator light in the meter assembly normally comes on for 1.4 seconds and then goes off. However, if there is a malfunction, the corresponding indicator light then begins flashing when the engine is stopped or comes on when the engine is running. 7 - 55

SELF-DIAGNOSIS ELEC – + Display order on the engine trouble indicator light and fuel level indicator light 1 Engine trouble indicator light 2 Fuel level indicator light 1 Indicator lights check...............................1.4 seconds 2 Light off ....................................................3 seconds 3 Condition code.........................................First fault code (3 = throttle position sensor) 4 Condition code.........................................Next fault code (4 = speed sensor) 5 Light on ....................................................0.5 second 6 Light off ....................................................0.5 second Å Light on ı Light off Ç Main switch is turned on Î Repetition 7 7 - 56

EB812010 SELF-DIAGNOSIS ELEC – + TROUBLESHOOTING EAS00843 The engine trouble indicator light or the 1.Wire harness fuel level indicator light starts to blink, • Check the wire harness for continuity. display the self-diagnosis sequence. Refer to “CIRCUIT DIAGRAM”. Check: • Is the wire harness OK? 1. throttle position sensor 2. speed sensor YES NO 3. decompression solenoid 4. fuel level meter Repair or replace the wire harness. NOTE: • Before troubleshooting, remove the fol- EB812401 lowing part(s): 2.Throttle position sensor 1) rider seat • Check the throttle position sensor for 2) fuel tank 3) left side cover continuity. • Troubleshoot with the following special Refer to “CHECKING AND ADJUSTING THE THROTTLE POSITION SENSOR” in tool(s). chapter 6. • Is the throttle position sensor OK? Pocket tester YU-03112 YES NO EB812020 Replace the ignitor Replace the throt- 1. Throttle position sensor unit. tle position sensor. CIRCUIT DIAGRAM 7 A Throttle position sensor B Ignitor unit 7 - 57

SELF-DIAGNOSIS ELEC – + 2. Speed sensor CIRCUIT DIAGRAM B Ignitor unit 7 H Speed sensor EAS00843 1.Wire harness • Check the wire harness for continuity. Refer to “CIRCUIT DIAGRAM”. • Is the wire harness OK? YES NO Replace the speed sensor. BAD Replace the ignitor Repair or replace unit. the wire harness. 7 - 58

SELF-DIAGNOSIS ELEC – + 3. Decompression solenoid CIRCUIT DIAGRAM B Ignitor unit E Decompression solenoid EAS00843 1.Wire harness • Check the wire harness for continuity. Refer to “CIRCUIT DIAGRAM”. • Is the wire harness OK? YES NO • Measure the decompression solenoid Repair or replace resistance. the wire harness. Decompression solenoid resis- tance (thermistor) 7 2.Decompression solenoid (thermistor) 68.75 ~ 78.75 Ω at 25 ˚C (77 ˚F) • Disconnect the decompression solenoid NOTE: couplers from the wire harness. The resistance value for the thermistor • Connect the pocket tester (Ω × 10) to the changes when the temperature changes; decompression solenoid coupler as shown. therefore, measure the decompression Tester positive probe → green 1 solenoid resistance at the specified tem- Tester negative probe → green 2 perature. • Connect the pocket tester (Ω × 1) to the decompression solenoid coupler as shown. Tester positive probe → black 3 Tester negative probe → black 4 Decompression solenoid resistance 1.2 Ω at 20 ˚C (68 ˚F) 7 - 59

• Check the decompression solenoid for SELF-DIAGNOSIS ELEC – + continuity. EB812403 • Is the decompression solenoid OK? 1.Fuel level indicator light LED YES NO • Check the LED of the fuel level indicator Replace the ignitor Replace the decom- light. Refer to “CHECKING THE LEDs”. unit. pression solenoid. • Is the fuel level indicator light LED OK? EB812040 YES NO 4. Fuel level meter Repair the meter CIRCUIT DIAGRAM assembly. 2.Fuel sender • Disconnect the fuel sender coupler from the wire harness. • Drain the fuel from the fuel tank and remove the fuel sender from the fuel tank. • Connect the pocket tester (Ω × 10) to the fuel sender coupler. Tester positive probe → green 1 Tester negative probe → black/blue 2 M Speedometer assembly (fuel level meter) • Measure the fuel sender resistance. N Fuel level indicator light Q Fuel sender Fuel sender resistance Full position of the float Å 11 ~ 13 Ω at 20 ˚C (68 ˚F) 7 Empty position of the float ı 140 ~ 143 Ω at 20 ˚C (68 ˚F) • Is the fuel sender OK? YES NO Replace the fuel sender. 7 - 60

SELF-DIAGNOSIS ELEC – + EAS00843 3.Wire harness • Check the wire harness for continuity. Refer to “CIRCUIT DIAGRAM”. • Is the wire harness OK? YES NO Replace the meter Replace or replace assembly. the wire harness. 7 7 - 61

TRBL SHTG CONTENTS TROUBLESHOOTING STARTING PROBLEMS ................................................................................ 8-1 ENGINE ................................................................................................. 8-1 FUEL SYSTEM ...................................................................................... 8-1 ELECTRICAL SYSTEMS ....................................................................... 8-2 INCORRECT ENGINE IDLING SPEED .......................................................... 8-2 ENGINE ................................................................................................. 8-2 FUEL SYSTEM ...................................................................................... 8-2 ELECTRICAL SYSTEMS ....................................................................... 8-2 POOR MEDIUM-AND-HIGH-SPEED PERFORMANCE ................................ 8-3 ENGINE ................................................................................................. 8-3 FUEL SYSTEM ...................................................................................... 8-3 FAULTY GEAR SHIFTING ............................................................................ 8-3 SHIFTING IS DIFFICULT ....................................................................... 8-3 SHIFT PEDAL DOES NOT MOVE ......................................................... 8-3 JUMPS OUT OF GEAR ......................................................................... 8-3 FAULTY CLUTCH ......................................................................................... 8-3 CLUTCH SLIPS ...................................................................................... 8-3 CLUTCH DRAGS ................................................................................... 8-3 OVERHEATING ............................................................................................. 8-4 ENGINE ................................................................................................. 8-4 FUEL SYSTEM ...................................................................................... 8-4 CHASSIS ............................................................................................... 8-4 ELECTRICAL SYSTEMS ....................................................................... 8-4 POOR BRAKING PERFORMANCE................................................................ 8-4 FAULTY FRONT FORK LEGS........................................................................ 8-4 LEAKING OIL ........................................................................................ 8-4 8 MALFUNCTION .................................................................................... 8-4 UNSTABLE HANDLING ............................................................................... 8-5

TRBL SHTG FAULTY LIGHTING OR SIGNALING SYSTEM ........................................... 8-5 HEADLIGHT DOES NOT LIGHT ........................................................... 8-5 HEADLIGHT BULB BURNT OUT ......................................................... 8-5 TAIL/BRAKE LIGHT DOES NOT LIGHT ............................................... 8-5 TAIL/BRAKE LIGHT BULB BURNT OUT .............................................. 8-5 TURN SIGNAL DOES NOT LIGHT ....................................................... 8-5 TURN SIGNAL BLINKS SLOWLY ........................................................ 8-5 TURN SIGNAL REMAINS LIT .............................................................. 8-5 TURN SIGNAL BLINKS QUICKLY ....................................................... 8-5 HORN DOES NOT SOUND .................................................................. 8-5 8

EAS00844 TRBL STARTING PROBLEMS SHTG TROUBLESHOOTING NOTE: The following guide for troubleshooting does not cover all the possible causes of trouble. It should be helpful, however, as a guide to basic troubleshooting. Refer to the relative proce- dure in this manual for checks, adjustments, and replacement of parts. STARTING PROBLEMS FUEL SYSTEM Fuel tank (See page 3-6) ENGINE Cylinders and cylinder heads (See page • Empty fuel tank 5-39 to 5-43 and 5-53 to 5-59) • Clogged fuel filter • Clogged fuel strainer • Loose spark plug • Clogged fuel tank breather hose • Loose cylinder head or cylinder • Clogged rollover valve • Damaged cylinder head gasket • Clogged rollover valve hose • Damaged cylinder gasket • Deteriorated or contaminated fuel • Worn or damaged cylinder Fuel pump (See page 7-46 to 7-50) • Incorrect valve clearance • Faulty fuel pump • Incorrectly sealed valve • Faulty fuel pump relay • Incorrect valve-to-valve-seat contact Fuel cock (See page 6-19 to 6-20) • Incorrect valve timing • Clogged or damaged fuel hose • Faulty valve spring Carburetor (See page 6-1 to 6-20) • Seized valve • Deteriorated or contaminated fuel Pistons and piston rings (See page 5-53 to • Clogged pilot jet 5-59) • Clogged pilot air passage • Incorrectly installed piston ring • Sucked-in air • Damaged, worn, or fatigued piston ring • Damaged float • Seized piston ring • Worn needle valve • Seized or damaged piston • Incorrectly installed needle valve seat Air filter (See page 3-7 and 3-29) • Incorrect fuel level • Incorrectly installed air filter • Incorrectly installed pilot jet • Clogged air filter element • Clogged starter jet Crankcase and crankshaft (See page 5-100 • Faulty starter plunger to 5-107 and 5-114 to 5-121) • Incorrectly adjusted starter cable • Incorrectly assembled crankcase • Seized crankshaft 8 8-1

STARTING PROBLEMS/ TRBL INCORRECT ENGINE IDLING SPEED SHTG ELECTRICAL SYSTEMS Ignition system (See page 7-12 to 7-16) Battery (See page 3-51 to 3-56) • Faulty ignitor unit • Faulty pickup coil • Faulty battery • Discharged battery Switches and wiring (See page 7-7 to 7-8) Fuses (See page 3-56 to 3-58) • Faulty main switch • Blown, damaged, or incorrect fuse • Faulty engine stop switch • Incorrectly installed fuse • Broken or shorted wiring Spark plugs (See page 3-14 to 3-15) • Faulty neutral switch • Incorrect spark plug gap • Faulty start switch • Incorrect spark plug heat range • Faulty sidestand switch • Fouled spark plug • Faulty clutch switch • Worn or damaged electrode • Incorrectly grounded circuit • Worn or damaged insulator • Loose connections • Faulty spark plug cap Ignition coils (See page 7-14 to 7-15) Starting system (See page 7-17 to 7-27) • Damaged ignition coil • Faulty starter motor • Broken or shorted primary or secondary • Faulty starter relay • Faulty starting circuit cutoff relay coils • Faulty starter clutch • Faulty spark plug lead EAS00846 ELECTRICAL SYSTEMS 8 Battery (See page 3-51 to 3-56) INCORRECT ENGINE IDLING SPEED • Incorrectly charged battery ENGINE • Faulty battery Cylinders and cylinder heads (See page Spark plugs (See page 3-14 to 3-15) 5-39 to 5-43 and 5-53 to 5-59) • Incorrect spark plug gap • Incorrect spark plug heat range • Incorrect valve clearance • Fouled spark plug • Damaged valve train components • Worn or damaged electrode Air filter (See page 3-7 and 3-29) • Worn or damaged insulator • Clogged air filter element • Faulty spark plug cap FUEL SYSTEM Ignition coils (See page 7-14 to 7-15) Carburetor (See page 6-1 to 6-20) • Broken or shorted primary or secondary • Faulty starter plunger • Loose or clogged pilot jet coils • Loose or clogged pilot air jet • Faulty spark plug lead • Damaged or loose carburetor joint • Damaged ignition coil • Incorrectly adjusted engine idling speed Ignition system (See page 7-12 to 7-16) • Faulty ignitor unit (throttle stop screw) • Faulty pickup coil • Incorrect throttle cable free play • Flooded carburetor • Faulty air induction system 8-2

POOR MEDIUM-AND-HIGH-SPEED PERFORMANCE/ TRBL FAULTY GEAR SHIFTING/FAULTY CLUTCH SHTG EAS00848 POOR MEDIUM-AND-HIGH-SPEED PERFORMANCE Refer to “STARTING PROBLEMS”. FUEL SYSTEM ENGINE Carburetor (See page 6-1 to 6-20) Air filter (See page 3-7 and 3-29) • Faulty diaphragm • Clogged air filter element • Incorrect fuel level • Loose or clogged main jet Fuel pump (See page 7-46 to 7-50) • Faulty fuel pump EAS00850 JUMPS OUT OF GEAR Shift shaft (See page 5-74 to 5-76) FAULTY GEAR SHIFTING • Incorrect shift pedal position SHIFTING IS DIFFICULT • Incorrectly returned stopper lever Refer to “CLUTCH DRAGS”. Shift forks (See page 5-122 to 5-127) SHIFT PEDAL DOES NOT MOVE • Worn shift fork Shift shaft (See page 5-74 to 5-76) Shift drum (See page 5-122 to 5-127) • Incorrect axial play • Incorrectly adjusted shift rod • Worn shift drum groove • Bent shift shaft Transmission (See page 5-122 to 5-127) Shift drum and shift forks (See page 5-122 • Worn gear dog to 5-127) • Foreign object in a shift drum groove • Seized shift fork • Bent shift fork guide bar Transmission (See page 5-122 to 5-127) • Seized transmission gear • Foreign object between transmission gears • Incorrectly assembled transmission EAS00851 CLUTCH DRAGS Clutch (See page 5-60 to 5-73) FAULTY CLUTCH • Unevenly tensioned clutch springs CLUTCH SLIPS • Warped pressure plate Clutch (See page 5-60 to 5-73) • Bent clutch plate • Swollen friction plate • Incorrectly assembled clutch • Bent clutch push rod • Incorrectly adjusted clutch cable • Damaged clutch boss • Loose or fatigued clutch spring • Burnt primary driven gear bushing • Worn friction plate • Match marks not aligned Engine oil (See page 3-20 to 3-21) 8 • Worn clutch plate • Incorrect oil level Engine oil (See page 3-20 to 3-21) • Incorrect oil viscosity (high) • Incorrect oil level • Deteriorated oil • Incorrect oil viscosity (low) • Deteriorated oil 8-3

OVERHEATING/POOR BRAKING PERFORMANCE/ TRBL FAULTY FRONT FORK LEGS SHTG EAS00855 OVERHEATING ENGINE CHASSIS Cylinder heads and pistons (See page 5-53 Brakes (See page 3-34 to 3-38 and 4-22 to to 5-59) 4-54) • Heavy carbon buildup • Dragging brake Engine oil (See page 3-20 to 3-21) ELECTRICAL SYSTEMS Spark plugs (See page 3-14 to 3-15) • Incorrect oil level • Incorrect oil viscosity • Incorrect spark plug gap • Inferior oil quality • Incorrect spark plug heat range FUEL SYSTEM Ignition system (See page 7-12 to 7-16) Carburetor (See page 6-1 to 6-20) • Faulty ignitor unit • Incorrect main jet setting • Incorrect fuel level • Damaged or loose carburetor joint Air filter (See page 3-7 and 3-29) • Clogged air filter element EAS00857 POOR BRAKING PERFORMANCE (See page 3-34 to 3-38 and 4-22 to 4-54) • Worn brake pad • Worn brake disc • Air in hydraulic brake system • Leaking brake fluid • Faulty brake caliper seal • Loose union bolt • Damaged brake hose • Oil or grease on the brake disc • Oil or grease on the brake pad • Incorrect brake fluid level EAS00860 FAULTY FRONT FORK LEGS (See page 3-43 to 3-44 and 4-55 to 4-66) LEAKING OIL MALFUNCTION 8 • Bent, damaged, or rusty inner tube • Bent or damaged inner tube • Damaged outer tube • Bent or damaged outer tube • Incorrectly installed oil seal • Damaged fork spring • Damaged oil seal lip • Worn or damaged outer tube bushing • Incorrect oil level (high) • Bent or damaged cartridge • Loose damper rod assembly bolt • Incorrect oil viscosity • Damaged cartridge cylinder bolt copper • Incorrect oil level washer • Damaged cap bolt O-ring 8-4

UNSTABLE HANDLING/FAULTY LIGHTING OR TRBL SIGNALING SYSTEM SHTG EAS00864 UNSTABLE HANDLING Handlebar (See page 4-67 to 4-72) Rear shock absorber assembly • Bent or incorrectly installed handlebar (See page 4-79 to 4-89) Steering head components (See page 3-41 • Faulty rear shock absorber spring to 3-43 and 4-73 to 4-78) • Leaking oil or gas Tires (See page 3-45 to 3-48) • Incorrectly installed upper bracket • Uneven tire pressures (front and rear) • Incorrectly installed lower bracket • Incorrect tire pressure • Uneven tire wear (incorrectly tightened ring nut) Wheels (See page 3-48 to 3-49 and • Bent steering stem 4-1 to 4-21) • Damaged ball bearing or bearing race • Incorrect wheel balance Front fork legs (See page 3-43 to 3-44 and • Deformed cast wheel 4-55 to 4-66) • Damaged wheel bearing • Uneven oil levels (both front fork legs) • Bent or loose wheel axle • Unevenly tensioned fork spring (both • Excessive wheel runout Frame front fork legs) • Bent frame • Damaged fork spring • Damaged steering head pipe • Bent or damaged inner tube • Incorrectly installed bearing race • Bent or damaged outer tube Swingarm (See page 4-79 to 4-89) • Worn bearing or bushing • Bent or damaged swingarm EAS00866 FAULTY LIGHTING OR SIGNALING SYSTEM (See page 7-31 to 7-45) HEADLIGHT DOES NOT LIGHT TURN SIGNAL DOES NOT LIGHT • Wrong headlight bulb • Faulty turn signal switch • Too many electrical accessories • Faulty turn signal relay • Hard charging • Burnt-out turn signal bulb • Incorrect connection • Incorrect connection • Incorrectly grounded circuit • Damaged or faulty wire harness • Poor contacts (main or dimmer switch) • Incorrectly grounded circuit • Burnt-out headlight bulb • Faulty battery HEADLIGHT BULB BURNT OUT • Blown, damaged, or incorrect fuse • Wrong headlight bulb TURN SIGNAL BLINKS SLOWLY • Faulty battery • Faulty turn signal relay • Faulty rectifier/regulator • Faulty main switch • Faulty turn signal switch • Incorrectly grounded circuit • Incorrect turn signal bulb • Faulty main switch TURN SIGNAL REMAINS LIT • Faulty dimmer switch • Faulty turn signal relay 8 • Headlight bulb life expired • Burnt-out turn signal bulb TAIL/BRAKE LIGHT DOES NOT LIGHT TURN SIGNAL BLINKS QUICKLY • Wrong tail/brake light bulb • Incorrect turn signal bulb • Too many electrical accessories • Faulty turn signal relay • Incorrect connection • Burnt-out turn signal bulb • Burnt-out tail/brake light bulb HORN DOES NOT SOUND TAIL/BRAKE LIGHT BULB BURNT OUT • Incorrectly adjusted horn • Damaged or faulty horn • Wrong tail/brake light bulb • Faulty main switch • Faulty battery • Faulty horn switch • Incorrectly adjusted rear brake light • Faulty battery switch • Blown, damaged, or incorrect fuse • Tail/brake light bulb life expired 8 - 5 • Faulty wire harness

XV16AL/XV16ALC/XV16ATL/XV16ATLC WIRING DIAGRAM (For USA and CDN) COLOR CODE P............ pink Br/B ....... brown/black L/W........ blue/wh B ........... black R............ red Br/L ....... brown/blue L/Y ......... blue/yel Br .......... brown Sb ......... sky blue Br/W ...... brown/white R/B......... red/blac Ch ......... chocolate W .......... white Br/Y ....... brown/yellow R/G ........ red/gree Dg ......... dark green Y............ yellow G/B ........ green/black R/W ....... red/whi G ........... green B/L......... black/blue G/R ........ green/red R/Y......... red/yell Gy ......... gray B/R ........ black/red G/Y ........ green/yellow Y/B......... yellow/b L............ blue B/W ....... black/white L/B ......... blue/black Y/R......... yellow/r Lg.......... light green B/Y ........ black/yellow L/R ......... blue/red O ........... orange

hite 1 Generator llow 2 Rectifier/regulator ck 3 Main switch en 4 Battery ite 5 Main fuse low 6 Starter relay black 7 Starter motor red 8 Backup fuse 9 Relay unit 0 Fuel pump A Throttle position sensor B Ignitor unit C Ignition coil D Spark plug E Decompression solenoid F Pickup coil G Neutral switch H Speed sensor I Meter assembly J Engine trouble indicator light K Turn signal indicator light L Neutral indicator light M Speedometer assembly (speedometer, combination meter and fuel level meter) N Fuel level indicator light O High beam indicator light P Meter light Q Fuel sender R Turn signal relay S Horn T Solenoid U Left handlebar switch V Dimmer switch W Horn switch X Turn signal switch Y Clutch switch Z Front turn signal/position light [ Rear turn signal light \\ Headlight ] Right handlebar switch ^ Front brake light switch a Engine stop switch b Start switch c Tail/brake light d Rear brake light switch e Carburetor heater f Thermo switch g Carburetor heater fuse h Headlight fuse i Ignition fuse j Signaling system fuse k Sidestand switch l Diode

YAMAHA MOTOR CO., LTD. 2500 SHINGAI IWATA SHIZUOKA JAPAN PRINTED IN U.S.A.