![Yamaha XV16ALC (1998) [275/449] Cylinders and pistons](/img/pdf.png)
Yamaha XV16ALC (1998) [275/449] Cylinders and pistons
![Yamaha XV16ATL (1998) [275/449] Cylinders and pistons](/views2/1121376/page275/bg113.png)
5 - 55
ENG
CYLINDERS AND PISTONS
2. Measure:
• piston-to-cylinder clearance
▼ ▼ ▼ ▼ ▼ ▼ ▼ ▼ ▼ ▼ ▼ ▼ ▼ ▼ ▼ ▼ ▼ ▼ ▼ ▼ ▼ ▼ ▼ ▼ ▼ ▼ ▼ ▼
a. Measure cylinder bore “C” with the cyl-
inder bore gauge.
NOTE:
Measure cylinder bore “C” by taking side-
to-side and front-to-back measurements of
the cylinder. Then, find the average of the
measurements.
b. If out of specification, replace the cylin-
der, and the piston and piston rings as a
set.
c. Measure piston skirt diameter “P” with
the micrometer.
a 5 mm (0.20 in) from the bottom edge of the
piston
d. If out of specification, replace the piston
and piston rings as a set.
e. Calculate the piston-to-cylinder clear-
ance with the following formula.
Cylinder bore gauge
YU-03017
Cylinder bore “C”
95.000 ~ 95.010 mm
(3.7402 ~ 3.7406 in)
Maximum taper “T” 0.05 mm (0.0016 in)
Out of round “R” 0.05 mm (0.0016 in)
“C” = maximum of D
1 ~ D6
“T” = maximum of D1 or D2 – maximum of
D
5 or D6
“R” = maximum of D1, D3 or D5
– minimum of D2, D4 or D6
Micrometer
YU-03009
Piston size “P”
Standard
94.960 ~ 94.975 mm
(3.7386 ~ 3.7392 in)
Piston-to-cylinder clearance =
Cylinder bore “C” –
Piston skirt diameter “P”
5
Содержание
- Caution 3
- Important manual information 3
- Notice 3
- Warning 3
- How to use this manual 4
- Chk adj 5
- Elec trbl shtg 5
- Gen info 5
- Symbols 5
- Carburetion 6
- Chassis 6
- Electrical system 6
- Engine 6
- General information 6
- Periodic checks and adjustments 6
- Specifications 6
- Table of contents 6
- Troubleshooting 6
- Contents general information 7
- Gen info 7
- Gen info 8
- General information 8
- Motorcycle identification 8
- Features 9
- Gen info 9
- Auto decompression mechanism the auto decompression mechanism occurs when the engine is started when the engine is started the decompression cam and pin raise the exhaust valve lifters push the push rods move the rocker arms and lower the exhaust valves which compress the cylinder when the cylinder is compressed pressure is released immediately resulting in smoother engine start ing capabilities and smoother crankshaft revolutions 10
- Features 10
- Gen info 10
- Features 11
- Gen info 11
- Features 12
- Gen info 12
- Gen info 13
- Important information 13
- Caution 14
- Gen info 14
- Important information 14
- Checking the connections 15
- Gen info 15
- Gen info 16
- Special tools 16
- Gen info 17
- Special tools 17
- Gen info 18
- Special tools 18
- Contents specifications 19
- General specification 20
- General specifications 20
- Specifications 20
- Engine specification 21
- Engine specifications 21
- Engine specification 22
- Engine specification 23
- Engine specification 24
- Engine specification 25
- Engine specification 26
- Engine specification 27
- Engine specification 28
- Engine specification 29
- Chassis specification 30
- Chassis specifications 30
- Chassis specification 31
- Chassis specification 32
- Chassis specification 33
- Electrical specification 34
- Electrical specifications 34
- Electrical specification 35
- Electrical specification 36
- Tightening torques 37
- Tightening torques 38
- Tightening torques 39
- Tightening torques 40
- Tightening torques 41
- Lubrication points and lubricant types 42
- Lubrication points and lubricant types 43
- Engine oil flow diagrams 45
- Engine oil flow diagrams 46
- Engine oil flow diagrams 47
- Engine oil flow diagrams 48
- Transfer gear oil flow diagrams 49
- Transfer gear oil flow diagrams 50
- Cable routing 51
- Cable routing 52
- Cable routing 53
- Cable routing 54
- Cable routing 55
- Cable routing 56
- Evaporative emission control system california only 56
- Chk adj 57
- Contents periodic checks and adjustments 57
- Chk adj 58
- Chk adj 59
- General maintenance and lubrication chart 59
- Introduction 59
- Periodic checks and adjustments 59
- Periodic maintenance lubrication intervals 59
- Chk adj 60
- General maintenance and lubrication chart 60
- Note the air filter element needs more frequent service if you are riding in unusually wet or dry areas 1 hydraulic brake system replace the brake fluid after disassembling the master cylinder or caliper cylinder check the brake fluid level and add fluid as required replace the master cylinder and caliper cylinder oil seals every two years replace the brake hoses every four years or if cracked or damaged 60
- Chk adj 61
- Seats and side covers 61
- Chk adj 62
- Xv16at accessory parts 62
- Chk adj 63
- Xv16at accessory parts 63
- Chk adj 64
- Fuel tank 64
- Air filter case 65
- Chk adj 65
- Adjusting the valve clearance 66
- Chk adj 66
- Engine 66
- Adjusting the valve clearance 67
- Chk adj 67
- Adjusting the valve clearance 68
- Caution 68
- Chk adj 68
- Adjusting the valve clearance 69
- Chk adj 69
- Adjusting the engine idling speed 70
- Chk adj 70
- Adjusting the engine idling speed adjusting the throttle cable free play 71
- Chk adj 71
- Adjusting the throttle cable free play checking the spark plugs 72
- Chk adj 72
- Warning warning 72
- Caution 73
- Checking the spark plugs 73
- Chk adj 73
- Checking the ignition timing 74
- Chk adj 74
- Checking the ignition timing 75
- Chk adj 75
- Caution 76
- Checking the ignition timing measuring the compression pressure 76
- Chk adj 76
- Chk adj 77
- Measuring the compression pressure 77
- Warning warning 77
- Chk adj 78
- Measuring the compression pressure checking the engine oil level 78
- Caution 79
- Checking the engine oil level 79
- Chk adj 79
- Caution 80
- Changing the engine oil 80
- Chk adj 80
- Caution 81
- Changing the engine oil 81
- Chk adj 81
- Changing the engine oil 82
- Chk adj 82
- Caution 83
- Chk adj 83
- Measuring the engine oil pressure 83
- Warning warning 83
- Chk adj 84
- Measuring the engine oil pressure checking the transfer gear oil level 84
- Caution 85
- Checking the transfer gear oil level changing the transfer gear oil 85
- Chk adj 85
- Adjusting the clutch cable free play 86
- Chk adj 86
- Caution 87
- Chk adj 87
- Cleaning the air filter element 87
- Checking the carburetor joint checking the fuel hoses and fuel filter 88
- Chk adj 88
- Caution 89
- Chk adj 89
- Adjusting the front brake 90
- Caution 90
- Chassis 90
- Chk adj 90
- Warning warning 90
- Adjusting the rear brake 91
- Caution 91
- Chk adj 91
- Warning warning 91
- Caution 92
- Checking the brake fluid level 92
- Chk adj 92
- Warning warning 92
- Chk adj 93
- Adjusting the rear brake light switch checking the brake hose 94
- Chk adj 94
- Bleeding the hydraulic brake system 95
- Chk adj 95
- Warning warning 95
- Bleeding the hydraulic brake system 96
- Chk adj 96
- Warning warning 96
- Adjusting the shift pedal adjusting the drive belt slack 97
- Caution 97
- Chk adj 97
- Adjusting the drive belt slack 98
- Chk adj 98
- Warning warning 98
- Adjusting the drive belt slack checking and adjusting the steering head 99
- Chk adj 99
- Warning warning 99
- Checking and adjusting the steering head 100
- Chk adj 100
- Warning warning 100
- Checking and adjusting the steering head checking the front fork 101
- Chk adj 101
- Warning warning 101
- Caution 102
- Checking the front fork adjusting the rear shock absorber assembly 102
- Chk adj 102
- Warning warning 102
- Adjusting the rear shock absorber assembly checking the tires 103
- Caution 103
- Chk adj 103
- Warning warning 103
- Checking the tires 104
- Chk adj 104
- Warning warning 104
- Checking the tires 105
- Chk adj 105
- Checking the tires checking and tightening the spokes 106
- Chk adj 106
- Warning warning 106
- Checking and tightening the spokes checking and lubricating the cables 107
- Chk adj 107
- Warning warning 107
- Chk adj 108
- Lubricating the levers and pedals lubricating the sidestand lubricating the rear suspension 108
- Caution 109
- Checking and charging the battery 109
- Chk adj 109
- Electrical system 109
- Warning warning 109
- Caution 110
- Checking and charging the battery 110
- Chk adj 110
- Caution 111
- Checking and charging the battery 111
- Chk adj 111
- Warning warning 111
- Caution 114
- Checking and charging the battery checking the fuses 114
- Chk adj 114
- Checking the fuses 115
- Chk adj 115
- Warning warning 115
- Checking the fuses replacing the headlight bulb 116
- Chk adj 116
- Warning warning 116
- Caution 117
- Chk adj 117
- Replacing the headlight bulb adjusting the headlight beam 117
- Adjusting the headlight beam 118
- Chk adj 118
- Chk adj 119
- Instrument functions 119
- Chk adj 120
- Instrument functions 120
- Contents chassis 121
- Chassis 124
- Front wheel and brake discs 124
- Front wheel and brake discs 125
- Front wheel and brake discs 126
- Warning warning 126
- Front wheel and brake discs 127
- Warning warning 127
- Caution 128
- Front wheel and brake discs 128
- Front wheel and brake discs 129
- Caution 130
- Front wheel and brake discs 130
- Caution 131
- Front wheel and brake discs 131
- Warning warning 131
- Front wheel and brake discs 132
- Front wheel and brake discs 133
- Rear wheel brake disc and rear wheel pulley 134
- Rear wheel brake disc and rear wheel pulley 135
- Rear wheel brake disc and rear wheel pulley 136
- Rear wheel brake disc and rear wheel pulley 137
- Rear wheel brake disc and rear wheel pulley 138
- Rear wheel brake disc and rear wheel pulley 139
- Warning warning 139
- Rear wheel brake disc and rear wheel pulley 140
- Rear wheel brake disc and rear wheel pulley 141
- Rear wheel brake disc and rear wheel pulley 142
- Rear wheel brake disc and rear wheel pulley 143
- Rear wheel brake disc and rear wheel pulley 144
- Front and rear brakes 145
- Front and rear brakes 146
- Caution 147
- Front and rear brakes 147
- Front and rear brakes 148
- Caution 149
- Front and rear brakes 149
- Front and rear brakes 150
- Front and rear brakes 151
- Front and rear brakes 152
- Front and rear brakes 153
- Front and rear brakes 154
- Front and rear brakes 155
- Front and rear brakes 156
- Front and rear brakes 157
- Front and rear brakes 158
- Front and rear brakes 159
- Front and rear brakes 160
- Warning warning 160
- Front and rear brakes 161
- Warning warning 161
- Caution 162
- Front and rear brakes 162
- Warning warning 162
- Front and rear brakes 163
- Warning warning 163
- Caution 164
- Front and rear brakes 164
- Warning warning 164
- Front and rear brakes 165
- Front and rear brakes 166
- Front and rear brakes 167
- Front and rear brakes 168
- Front and rear brakes 169
- Front and rear brakes 170
- Warning warning 170
- Front and rear brakes 171
- Warning warning 171
- Front and rear brakes 172
- Warning warning 172
- Front and rear brakes 173
- Caution 174
- Front and rear brakes 174
- Warning warning 174
- Front and rear brakes 175
- Warning warning 175
- Caution 176
- Front and rear brakes 176
- Warning warning 176
- Caution 177
- Front and rear brakes 177
- Warning warning 177
- Front fork 178
- Front fork 179
- Front fork 180
- Front fork 181
- Caution 182
- Front fork 182
- Warning warning 182
- Caution 183
- Front fork 183
- Warning warning 183
- Front fork 184
- Warning warning 184
- Caution 185
- Front fork 185
- Caution 186
- Front fork 186
- Front fork 187
- Front fork 188
- Warning warning 188
- Front fork 189
- Handlebar 190
- Handlebar 191
- Caution 192
- Handlebar 192
- Warning warning 192
- Handlebar 193
- Handlebar 194
- Warning warning 194
- Handlebar 195
- Steering head 196
- Steering head 197
- Steering head 198
- Warning warning 198
- Caution 199
- Steering head 199
- Steering head 200
- Steering head 201
- Rear shock absorber and swingarm 202
- Rear shock absorber and swingarm 203
- Rear shock absorber and swingarm 204
- Rear shock absorber and swingarm 205
- Rear shock absorber and swingarm 206
- Warning warning 206
- Rear shock absorber and swingarm 207
- Rear shock absorber and swingarm 208
- Warning warning 208
- Rear shock absorber and swingarm 209
- Rear shock absorber and swingarm 210
- Rear shock absorber and swingarm 211
- Rear shock absorber and swingarm 212
- Drive belt and drive pulley 213
- Caution 214
- Drive belt and drive pulley 214
- Caution 215
- Drive belt and drive pulley 215
- Drive belt and drive pulley 216
- Contents engine 217
- Engine 221
- Engine 222
- Engine 223
- Engine 224
- Engine 225
- Engine 226
- Engine 227
- Engine 228
- Engine 229
- Engine 230
- Engine 231
- Rocker arms push rods and valve lifters 232
- Rocker arms push rods and valve lifters 233
- Rocker arms push rods and valve lifters 234
- Rocker arms push rods and valve lifters 235
- Rocker arms push rods and valve lifters 236
- Rocker arms push rods and valve lifters 237
- Caution 238
- Rocker arms push rods and valve lifters 238
- Rocker arms push rods and valve lifters 239
- Rocker arms push rods and valve lifters 240
- Rocker arms push rods and valve lifters 241
- Caution 242
- Rocker arms push rods and valve lifters 242
- Warning warning 242
- Rocker arms push rods and valve lifters 243
- Rocker arms push rods and valve lifters 244
- Rocker arms push rods and valve lifters 245
- Rocker arms push rods and valve lifters 246
- Rocker arms push rods and valve lifters 247
- Rocker arms push rods and valve lifters 248
- Camshafts 249
- Camshafts 250
- Camshafts 251
- Camshafts 252
- Camshafts 253
- Camshafts 254
- Camshafts 255
- Camshafts 256
- Camshafts 257
- Camshafts 258
- Cylinder heads 259
- Cylinder heads 260
- Cylinder heads 261
- Cylinder heads 262
- Cylinder heads 263
- Valves and valve springs 264
- Valves and valve springs 265
- Valves and valve springs 266
- Valves and valve springs 267
- Valves and valve springs 268
- Caution 269
- Valves and valve springs 269
- Valves and valve springs 270
- Valves and valve springs 271
- Caution 272
- Valves and valve springs 272
- Cylinders and pistons 273
- Caution 274
- Cylinders and pistons 274
- Cylinders and pistons 275
- Cylinders and pistons 276
- Cylinders and pistons 277
- Cylinders and pistons 278
- Cylinders and pistons 279
- Clutch 280
- Clutch 281
- Clutch 282
- Clutch 283
- Clutch 284
- Clutch 285
- Clutch 286
- Clutch 287
- Clutch 288
- Caution 289
- Clutch 289
- Clutch 290
- Clutch 291
- Clutch 292
- Clutch 293
- Shift shaft 294
- Shift shaft 295
- Shift shaft 296
- Generator and starter clutch 297
- Generator and starter clutch 298
- Generator and starter clutch 299
- Generator and starter clutch 300
- Generator and starter clutch 301
- Generator and starter clutch 302
- Generator and starter clutch 303
- Generator and starter clutch 304
- Transfer gear case 305
- Transfer gear case 306
- Transfer gear case 307
- Transfer gear case 308
- Transfer gear case 309
- Transfer gear case 310
- Transfer gear case 311
- Warning warning 311
- Transfer gear case 312
- Transfer gear case 313
- Transfer gear case 314
- Transfer gear case 315
- Transfer gear case 316
- Transfer gear case 317
- Transfer gear case 318
- Caution 319
- Transfer gear case 319
- Crankcase 320
- Crankcase 321
- Crankcase 322
- Crankcase 323
- Caution 324
- Crankcase 324
- Crankcase 325
- Crankcase 326
- Crankcase 327
- Engine oil pump 328
- Engine oil pump 329
- Engine oil pump 330
- Engine oil pump 331
- Engine oil pump 332
- Engine oil pump 333
- Crankshaft and connecting rods 334
- Crankshaft and connecting rods 335
- Caution 336
- Crankshaft and connecting rods 336
- Caution 337
- Crankshaft and connecting rods 337
- Crankshaft and connecting rods 338
- Crankshaft and connecting rods 339
- Caution 340
- Crankshaft and connecting rods 340
- Crankshaft and connecting rods 341
- Transmission 342
- Transmission 343
- Transmission 344
- Transmission 345
- Warning warning 345
- Transmission 346
- Transmission 347
- Contents carburetor 348
- Carburetor 350
- Carburetor 351
- Carburetor 352
- Carburetor 353
- Carburetor 354
- Carburetor 355
- Carburetor 356
- Carburetor 357
- Caution 357
- Carburetor 358
- Carburetor 359
- Carburetor 360
- Carburetor 361
- Carburetor 362
- Carburetor 363
- Carburetor 364
- Carburetor 365
- Carburetor 366
- Carburetor 367
- Carburetor 368
- Carburetor 369
- Air induction system 370
- Air induction system 371
- Air induction system 372
- Air induction system 373
- Air induction system 374
- Air induction system 375
- Air induction system 376
- Air induction system 377
- Air induction system 378
- Contents electrical system 379
- Electrical components 381
- Electrical system 381
- Arrangement of the electrical components and couplers 382
- Arrangement of the electrical components and couplers 383
- Arrangement of the electrical components and couplers 384
- Arrangement of the electrical components and couplers 385
- Caution 386
- Switches 386
- Checking the switches 387
- Checking the switches 388
- Checking the bulbs and bulb sockets 389
- Caution 390
- Checking the bulbs and bulb sockets 390
- Warning warning 390
- Checking the bulbs and bulb sockets 391
- Warning warning 391
- Circuit diagram 392
- Ignition system 392
- Ignition system 393
- Ignition system 394
- Ignition system 395
- Ignition system 396
- Circuit diagram 397
- Electric starting system 397
- Electric starting system 398
- Starting circuit cutoff system operation if the engine stop switch is set to and the main switch is set to on both switches are closed the starter motor can only operate if at least one of the following conditions is met 398
- The starting circuit cutoff relay prevents the starter motor from operating when neither of these conditions has been met in this instance the starting circuit cutoff relay is open so current cannot reach the starter motor when at least one of the above con ditions has been met the starting circuit cut off relay is closed and the engine can be started by pressing the start switch 398
- The transmission is in neutral the neu tral switch is closed the clutch lever is pulled to the handle bar the clutch switch is closed and the sidestand is up the sidestand switch is closed 398
- When the sidestand is up and the clutch lever is pulled to the handlebar 398
- When the transmission is in neutral 398
- Electric starting system 399
- Warning warning 399
- Electric starting system 400
- Electric starting system 401
- Electric starting system 402
- Starter motor 403
- Starter motor 404
- Starter motor 405
- Starter motor 406
- Starter motor 407
- Charging system 408
- Charging system 409
- Charging system 410
- Circuit diagram 411
- Lighting system 411
- Lighting system 412
- Lighting system 413
- Lighting system 414
- Lighting system 415
- Circuit diagram 416
- Signaling system 416
- Signaling system 417
- Signaling system 418
- Signaling system 419
- Signaling system 420
- Signaling system 421
- Signaling system 422
- Signaling system 423
- Signaling system 424
- Circuit diagram 425
- Fuel pump system 425
- Fuel pump system 426
- Fuel pump system 427
- Fuel pump system 428
- Fuel pump system 429
- Warning warning 429
- Carburetor heating system 430
- Circuit diagram 430
- Carburetor heating system 431
- Carburetor heating system 432
- Warning warning 432
- Carburetor heating system 433
- Note when the main switch is turned on the engine trouble indicator light and fuel level indicator light in the meter assembly normally come on for 1 seconds and then go 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 434
- Self diagnosis 434
- 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 434
- Display order on the engine trouble indicator light and fuel level indicator light 435
- Self diagnosis 435
- Self diagnosis 436
- Self diagnosis 437
- Self diagnosis 438
- Self diagnosis 439
- Self diagnosis 440
- Contents troubleshooting 441
- Trbl shtg 441
- Trbl shtg 442
- Starting problems 443
- Trbl shtg 443
- Troubleshooting 443
- Incorrect engine idling speed 444
- Starting problems incorrect engine idling speed 444
- Trbl shtg 444
- Faulty clutch 445
- Faulty gear shifting 445
- Poor medium and high speed performance 445
- Poor medium and high speed performance faulty gear shifting faulty clutch 445
- Trbl shtg 445
- Faulty front fork legs see page 3 43 to 3 44 and 4 55 to 4 66 446
- Overheating 446
- Overheating poor braking performance faulty front fork legs 446
- Poor braking performance see page 3 34 to 3 38 and 4 22 to 4 54 446
- Trbl shtg 446
- Faulty lighting or signaling system see page 7 31 to 7 45 447
- Trbl shtg 447
- Unstable handling 447
- Unstable handling faulty lighting or signaling system 447
- Xv16al xv16alc xv16atl xv16atlc wiring diagram for usa and cdn 448
- Shingai iwata shizuoka japan 449
- Yamaha motor co ltd 449
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