Product Type:
Factory Service Repair Manual & Parts Catalogue
Manual Title:
Yamaha XV 1600 Road Star 1999-2006 Service Repair Manual
Production Years Covered:
1999, 2000, 2001, 2002, 2003, 2004, 2005, 2006
Chassis Codes:
XV1600A, XV1600AL, XV1600AT, XV1600ATL
Segment:
Cruiser Motorcycle
Target Audience:
Owners, DIY Mechanics, Professional Service Technicians
Key Competitors:
Harley-Davidson (e.g., Softail models), Honda Shadow, Kawasaki Vulcan, Suzuki Boulevard
Road Star Strengths:
Torquey V-twin engine, comfortable cruiser ergonomics, classic styling, robust build quality
Manual Value Proposition:
Provides factory-accurate information for all maintenance, repair, and parts identification tasks, enabling owners to maintain their investment effectively.
Document Type Value:
Combines essential service procedures with a parts catalog for a complete ownership resource.
Powertrain:
Engine, Transmission, Drivetrain
Chassis:
Frame, Suspension (Front & Rear), Steering, Wheels, Brakes
Electrical:
Ignition System, Lighting, Instruments, Charging System, Starting System, Wiring Diagrams
Fuel System:
Fuel Injection System (if applicable to specific sub-models), Carburetor (if applicable), Fuel Tank, Fuel Pump
Exhaust System:
Exhaust Pipes, Mufflers, Catalytic Converter (if equipped)
Bodywork:
Body Panels, Fenders, Seat, Fuel Tank, Fairings (if equipped), Trim
Controls:
Throttle, Clutch, Brakes, Shifter Linkage
Cooling System:
Air Cooling System (primarily)
Maintenance:
Scheduled Maintenance, Lubrication, Inspections, Cleaning
Repair:
Component Disassembly, Reassembly, Overhaul, Replacement
Troubleshooting:
Diagnostic Procedures, Fault Finding, Error Code Interpretation (if applicable)
Technical Data:
Torque Specifications, Clearances, Measurements, Electrical Values
Parts Information:
Parts Diagrams, Part Numbers, Assembly Breakdowns
Wiring Diagrams:
Complete and detailed electrical system wiring diagrams
Depth:
Comprehensive Factory Level - Covers routine maintenance to complete engine and transmission rebuilds. Includes detailed diagnostic procedures.
Engine Type:
Air-cooled, 4-stroke, SOHC, V-twin
Displacement:
1600 cc (1600cc / 97.6 cubic inches)
Bore X Stroke:
95.0 mm x 113.0 mm (approximate, refer to manual for exact specs)
Compression Ratio:
8.4:1 (approximate, refer to manual for exact specs)
Valvetrain:
SOHC, 4 valves per cylinder (2 intake, 2 exhaust)
Cooling Method:
Forced Air Cooling
Ignition:
Digital TCI (Transistor Controlled Ignition)
Horsepower:
Approx. 65-70 HP (at crankshaft, specific dyno results vary)
Torque:
Approx. 90-95 lb-ft (at crankshaft, specific dyno results vary)
Fuel Delivery:
Fuel Injection (likely, depending on sub-model and market; early models might have used carburetors)
Carburetor Details:
Mikuni BS40 (if applicable, refer to manual for specific models/years)
Fuel Type:
Unleaded gasoline, minimum 87 octane
Fuel Tank Capacity:
4.7 US gallons (approx. 17.8 Liters)
Length:
Approx. 96.5 inches (2450 mm)
Width:
Approx. 39.2 inches (995 mm)
Height:
Approx. 52.8 inches (1340 mm)
Wheelbase:
Approx. 66.3 inches (1685 mm)
Dry Weight:
Approx. 650 lbs (295 kg)
Wet Weight:
Approx. 692 lbs (314 kg) (with all fluids)
Gvwr:
Refer to VIN plate and manual for specific load capacities
Crash Test Ratings:
Motorcycles are not typically rated by organizations like NHTSA or IIHS.
Braking System Front:
Dual hydraulic disc brakes
Braking System Rear:
Hydraulic disc brake
Suspension Front:
Telescopic fork, 43mm inner tube diameter
Suspension Rear:
Swingarm, adjustable preload, dual shocks
Lighting:
Halogen headlight, LED tail light, turn signals
Mirrors:
Large, adjustable handlebar-mounted mirrors
Infotainment System:
Basic; typically does not feature advanced infotainment systems common in modern vehicles. Focus is on essential motorcycle controls and instrumentation.
Instrumentation:
Analog speedometer, tachometer, fuel gauge, odometer, trip meter, indicator lights.
Driver Assistance Features:
None (as expected for a motorcycle of this era).
Connectivity Features:
None.
Oil Change Interval:
Refer to manual for specific mileage/time interval (typically every 3,000-4,000 miles or annually).
Engine Oil Type:
Yamalube 4 (or equivalent JASO MA/MA2 certified motorcycle oil, SAE 10W-40 or 20W-50 depending on climate - refer to manual)
Oil Filter Part Number:
Yamaha part numbers vary by filter type (e.g., 5JX-13440-00-00 for oil filter cartridge - verify in manual)
Spark Plug Replacement:
Refer to manual for interval (e.g., 7,500-15,000 miles).
Air Filter Cleaning Replacement:
Refer to manual for interval.
Belt Drive Inspection:
Regular inspection for tension and wear is critical. Refer to manual for specific intervals and adjustment procedures.
Brake Fluid Type:
DOT 3 or DOT 4 (refer to manual for exact specification and reservoir locations).
Coolant Type:
N/A (Air-cooled engine)
Fork Oil Type:
Refer to manual for specific viscosity and grade (e.g., SAE 10W).
Common Wear Items:
Clutch plates, drive belt, tires, brake pads, fork seals.
Potential Electrical Issues:
Intermittent issues with switches, regulators, or charging systems can occur over time; manual's wiring diagrams are essential.
Engine Maintenance Considerations:
V-twin engines require regular valve adjustments and careful clutch maintenance.
Yamaha Motorcycles:
Yamaha Motor Company, founded in 1955, has a long history of producing high-quality motorcycles, known for innovation and performance across various segments.
Road Star Introduction:
The XV1600 Road Star was introduced in 1999 as Yamaha's flagship cruiser, designed to compete directly with American V-twin cruisers, emphasizing torque, comfort, and classic styling.
Key Updates:
While core platform remained similar, minor refinements and special editions (like the Limited) were introduced. Silverado models featured extensive factory customization, like fairings and saddlebags.
Manufacturing Location:
Japan (primarily for core components and assembly)
Production Period Covered By Manual:
1999-2006 (with specific model year variations noted within the manual)
Industry Recognition:
The Yamaha Road Star series was well-received by motorcycle journalists and riders for its blend of American cruiser style and Japanese reliability and engineering. Often praised for its strong torque and comfortable ride.
User Reviews:
Generally positive user reviews highlight its comfortable ride, powerful engine, and classic aesthetics.
Emissions Compliance:
Complies with relevant emissions standards for its production years; manual will contain specific details on emission control systems if present.
