Yamaha XSR 2016 Manuals

Manuals and User Guides for Yamaha XSR 2016. We have 1 Yamaha XSR 2016 manual available for free PDF download: Service Manual

Yamaha XSR 2016 Service Manual

Yamaha XSR 2016 Service Manual (552 pages)

Brand: Yamaha | Category: Motorcycle | Size: 25.3 MB

Table of Contents

Table of Contents

7
- General Information
  9
  - Identification
    10
    
    Vehicle Identification Number
    10
    
    Model Label
    10
  - Features
    11
    
    YCC-T (Yamaha Chip Controlled Throttle)
    11
    
    OUTLINE of the TCS (Traction Control System)
    13
    
    Instrument Functions
    17
  - Important Information
    22
    
    Preparation for Removal and Disassembly
    22
    
    Replacement Parts
    22
    
    Gaskets, Oil Seals and O-Rings
    22
    
    Lock Washers/Plates and Cotter Pins
    22
    
    Bearings and Oil Seals
    23
    
    Circlips
    23
    
    Rubber Parts
    23
  - Basic Service Information
    24
    
    Quick Fasteners
    24
    
    Electrical System
    25
  - Special Tools
    29
Specifications

37
- General Specifications
  38
- Engine Specifications
  39
- Chassis Specifications
  44
- Electrical Specifications
  47
- Tightening Torques
  49
- Lubrication Points and Lubricant Types
  52
  - Engine
    52
  - Chassis
    53
- Lubrication System Chart and Diagrams
  56
  - Engine Oil Lubrication Chart
    56
  - Lubrication Diagrams
    58
- Cooling System Diagrams
  68
- Cable Routing
  72
Periodic Checks and Adjustments

107
- General Maintenance and Lubrication Chart
  109
- Introduction
  109
- Periodic Maintenance
  109
- Periodic Maintenance Chart for the Emission Control System
  109
- Checking the Fuel Line
  112
- Checking the Spark Plugs
  112
- Adjusting the Valve Clearance
  113
- Checking the Engine Idling Speed
  116
- Synchronizing the Throttle Bodies
  116
- Adjusting the Exhaust Gas Volume
  118
- Checking the Air Induction System
  118
- Checking the Canister
  118
- Checking the Cylinder Head Breather Hose
  118
- Checking the Throttle Body Joints
  118
- Adjusting the Clutch Lever Free Play
  119
- Replacing the Air Filter Element
  119
- Checking the Brake Fluid Level
  120
- Checking the Brake Operation
  120
- Adjusting the Front Disc Brake
  121
- Adjusting the Rear Disc Brake
  121
- Checking the Front Brake Pads
  121
- Bleeding the Hydraulic Brake System (Abs)
  122
- Checking the Front Brake Hoses
  122
- Checking the Rear Brake Hose
  122
- Checking the Rear Brake Pads
  122
- Checking the Wheels
  123
- Checking the Tires
  124
- Checking the Swingarm Operation
  125
- Checking the Wheel Bearings
  125
- Drive Chain Slack
  125
- Lubricating the Swingarm Pivot
  125
- Checking and Adjusting the Steering Head
  126
- Lubricating the Drive Chain
  126
- Checking the Chassis Fasteners
  127
- Lubricating the Brake Lever
  127
- Lubricating the Clutch Lever
  127
- Lubricating the Steering Head
  127
- Adjusting the Shift Pedal
  128
- Checking the Front Fork
  128
- Checking the Sidestand
  128
- Checking the Sidestand Switch
  128
- Lubricating the Pedal
  128
- Lubricating the Sidestand
  128
- Adjusting the Front Fork Legs
  129
- Adjusting the Rear Shock Absorber Assembly
  130
- Checking the Rear Shock Absorber Assembly
  130
- Changing the Engine Oil
  131
- Checking the Connecting Arm and Relay Arm
  131
- Checking the Engine Oil Level
  131
- Measuring the Engine Oil Pressure
  132
- Checking the Coolant Level
  133
- Changing the Coolant
  134
- Checking the Cooling System
  134
- Adjusting the Rear Brake Light Switch
  136
- Checking and Lubricating the Cables
  136
- Checking the Front Brake Light Switch
  136
- Checking the Throttle Grip
  136
- Checking and Charging the Battery
  137
- Checking the Fuses
  137
- Replacing the Headlight Bulb
  137
- Adjusting the Headlight Beam
  138
- Replacing the License Plate Light Bulb
  139
Chassis

141
- General Chassis (1)
  152
  - Installing the Fuel Tank Covers
    152
- Front Wheel
  153
  - Removing the Front Wheel
    155
  - Disassembling the Front Wheel
    155
  - Checking the Front Wheel
    155
  - Assembling the Front Wheel
    156
  - Maintenance of the Front Wheel Sensor and Sensor Rotor
    157
  - Adjusting the Front Wheel Static Balance
    158
  - Installing the Front Wheel (Front Brake Discs)
    159
  - Rear Wheel
    161
  - Removing the Rear Wheel
    164
  - Disassembling the Rear Wheel
    164
  - Checking the Rear Wheel
    165
  - Checking the Rear Wheel Drive Hub
    165
  - Checking and Replacing the Rear Wheel Sprocket
    165
  - Assembling the Rear Wheel
    165
  - Maintenance of the Rear Wheel Sensor and Sensor Rotor
    166
  - Adjusting the Rear Wheel Static Balance
    166
  - Installing the Rear Wheel (Rear Brake Disc)
    166
- Front Brake
  169
- Introduction
  174
- Rear Brake
  182
  - Introduction
    188
  - Checking the Rear Brake Disc
    188
  - Replacing the Rear Brake Pads
    188
  - Removing the Rear Brake Caliper
    189
  - Disassembling the Rear Brake Caliper
    190
  - Checking the Rear Brake Caliper
    190
  - Assembling the Rear Brake Caliper
    191
  - Installing the Rear Brake Caliper
    191
  - Removing the Rear Brake Master Cylinder
    192
  - Checking the Rear Brake Master Cylinder
    192
  - Assembling the Rear Brake Master Cylinder
    193
  - Installing the Rear Brake Master Cylinder
    193
- Abs (Anti-Lock Brake System)
  194
  - Abs Components Chart
    196
  - Removing the Hydraulic Unit Assembly
    197
  - Checking the Hydraulic Unit Assembly
    197
  - Installing the Hydraulic Unit Assembly
    197
  - Hydraulic Unit Operation Tests
    199
  - Checking the Abs Warning Light
    202
- Handlebar
  203
  - Removing the Handlebar
    205
  - Checking the Handlebar
    205
  - Installing the Handlebar
    205
- Front Fork
  208
  - Removing the Front Fork Legs
    211
  - Disassembling the Front Fork Legs
    211
  - Checking the Front Fork Legs
    212
  - Assembling the Front Fork Legs
    213
  - Installing the Front Fork Legs
    218
- Steering Head
  219
  - Removing the Lower Bracket
    221
  - Checking the Steering Head
    221
  - Installing the Steering Head
    222
- Rear Shock Absorber Assembly
  223
- Swingarm
  227
  - Removing the Swingarm
    228
  - Checking the Swingarm
    228
  - Installing the Swingarm
    229
- Chain Drive
  230
  - Removing the Drive Chain
    231
Engine

235
- Engine Inspection
  238
- Measure the Compression Pressure
  238
- Engine Removal
  240
  - Removing the Engine
    244
  - Installing the Engine
    244
- Camshafts
  246
  - Removing the Camshafts
    248
  - Checking the Camshafts
    249
  - Checking the Timing Chain and Camshaft Sprocket
    250
  - Checking the Timing Chain Guides
    250
  - Checking the Timing Chain Tensioner
    250
  - Installing the Camshafts
    251
- Cylinder Head
  256
- Valves and Valve Springs
  260
  - Removing the Valves
    260
  - Checking the Valves and Valve Guides
    260
  - Checking the Valve Seats
    262
  - Checking the Valve Springs
    263
  - Checking the Valve Lifters
    264
  - Installing the Valves
    264
- Generator and Starter Clutch
  266
  - Removing the Generator
    268
  - Removing the Starter Clutch
    268
  - Checking the Starter Clutch
    268
  - Installing the Starter Clutch
    269
  - Installing the Generator
    269
- Electric Starter
  273
  - Checking the Starter Motor
    273
  - Assembling the Starter Motor
    274
  - Installing the Starter Motor
    274
- Clutch
  275
  - Removing the Clutch
    279
  - Checking the Friction Plates
    280
  - Checking the Clutch Plates
    280
  - Checking the Clutch Springs
    281
  - Checking the Clutch Housing
    281
  - Checking the Clutch Boss
    282
  - Checking the Pressure Plate
    282
  - Checking the Primary Drive Gear
    282
  - Checking the Primary Driven Gear
    282
  - Checking the Pull Lever Shaft and Pull Rod
    282
  - Installing the Clutch
    283
- Shift Shaft
  287
  - Checking the Shift Shaft
    287
  - Checking the Stopper Lever
    287
  - Installing the Shift Shaft
    287
- Oil Pump
  288
  - Checking the Sprocket and Chain
    290
  - Checking the Oil Pump
    290
  - Checking the Relief Valve
    290
  - Assembling the Oil Pump
    291
  - Installing the Oil Pump
    291
- Oil Pan
  292
  - Removing the Oil Pan
    293
  - Checking the Oil Strainer
    293
  - Installing the Oil Pan
    293
- Crankcase
  294
  - Disassembling the Crankcase
    295
  - Checking the Crankcase
    295
  - Assembling the Crankcase
    295
- Connecting Rods and Pistons
  298
  - Removing the Connecting Rods and Pistons
    299
  - Checking the Cylinder and Piston
    299
  - Checking the Piston Rings
    300
  - Checking the Piston Pin
    301
  - Checking the Connecting Rods
    302
  - Installing the Connecting Rod and Piston
    304
- Crankshaft and Balancer Shaft
  308
  - Removing the Crankshaft and Balancer Shaft
    309
  - Checking the Oil Nozzles
    309
  - Checking the Crankshaft
    309
  - Checking the Balancer Shaft
    311
  - Installing the Crankshaft
    312
  - Installing the Balancer Assembly
    313
- Transmission
  314
  - Removing the Transmission
    318
  - Checking the Shift Forks
    318
Cooling System

323
- Radiator
  324
  - Checking the Radiator
    325
  - Installing the Radiator
    325
- Oil Cooler
  327
  - Checking the Oil Cooler
    328
  - Installing the Oil Cooler
    328
- Thermostat
  329
  - Checking the Thermostat
    330
  - Installing the Thermostat Assembly
    330
- Water Pump
  331
  - Disassembling the Water Pump
    333
  - Checking the Water Pump
    333
  - Assembling the Water Pump
    333
Fuel System

335
- Fuel Tank
  336
- Removing the Fuel Tank
  339
  - Removing the Fuel Pump
    339
  - Checking the Fuel Pump Body
    339
  - Checking the Fuel Pump Operation
    339
  - Installing the Fuel Pump
    340
  - Installing the Fuel Tank
    340
- Throttle Bodies
  341
- Checking the Injectors (before Removing)
  344
  - Removing the Fuel Hose (Fuel Rail Side)
    344
  - Removing the Injectors
    344
  - Checking the Injectors
    344
  - Checking and Cleaning the Throttle Bodies
    344
  - Replacing the Throttle Bodies
    346
  - Installing the Injectors
    346
  - Checking the Injector Pressure
    346
  - Checking the Fuel Pressure
    347
  - Installing the Fuel Hose (Fuel Rail Side)
    348
  - Adjusting the Throttle Position Sensor
    348
  - Adjusting the Accelerator Position Sensor
    349
- Air Induction System
  350
  - Checking the Air Induction System
    353
  - Installing the Air Induction System
    353
Electrical System

355
- Ignition System
  358
  - Circuit Diagram
    358
  - Engine Stopping Due to Sidestand Operation
    360
  - Troubleshooting
    361
- Electric Starting System
  364
  - Circuit Diagram
    364
  - Starting Circuit Cut-Off System Operation
    366
  - Troubleshooting
    368
- Charging System
  370
  - Circuit Diagram
    370
  - Troubleshooting
    372
- Lighting System
  374
  - Circuit Diagram
    374
  - Troubleshooting
    376
- Signaling System
  378
  - Circuit Diagram
    378
  - Troubleshooting
    380
- Cooling System
  386
  - Circuit Diagram
    386
- Troubleshooting
  388
  - Fuel Injection System
    390
    
    Circuit Diagram
    390
    
    Ecu Self-Diagnostic Function
    392
    
    Troubleshooting Method
    392
    
    Yamaha Diagnostic Tool
    393
    
    Troubleshooting Details (Fault Code)
    394
Troubleshooting

527
- General Information
  528
- Incorrect Engine Idling Speed
  528
- Starting Failures
  528
- Troubleshooting
  528
- Faulty Clutch
  529
- Faulty Gear Shifting
  529
- Jumps out of Gear
  529
- Overheating
  529
- Poor Medium-And-High-Speed Performance
  529
- Shift Pedal Does Not Move
  529
- Faulty Front Fork Legs
  530
- Faulty Lighting or Signaling System
  530
- Overcooling
  530
- Poor Braking Performance
  530
- Unstable Handling
  530
- Troubleshooting at the Abs Warning Light
  531
- Self-Diagnostic Function and Diagnostic Code Table
  532
- Self-Diagnostic Function Table
  532
- Communication Error with the Meter
  540
- Diagnostic Code: Sensor Operation Table
  540
- Diagnostic Code: Actuator Operation Table
  543

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