Segment:
Cruiser Motorcycle
Target Audience:
Owners and technicians seeking detailed repair and maintenance information.
Competitors:
Harley-Davidson Heritage Softail, Honda Shadow, Kawasaki Vulcan.
Key Selling Points:
Torque-rich V-twin engine, classic styling, extensive aftermarket support.
Manual Features:
Comprehensive troubleshooting guides, clear step-by-step instructions, and detailed diagrams.
Engine:
Complete engine disassembly, assembly, tuning, and troubleshooting.
Transmission:
Gearbox inspection, repair, clutch service, and maintenance.
Electrical System:
Wiring diagrams, component testing, ignition system, charging system, lighting, and accessories.
Fuel System:
Carburetor adjustment and overhaul, fuel pump, fuel lines, and tank service.
Suspension:
Front fork service, rear shock absorber replacement and adjustment.
Brakes:
Brake caliper service, master cylinder, brake fluid replacement, and bleeding procedures.
Chassis And Frame:
Frame inspection, steering head bearing service, and swingarm maintenance.
Bodywork:
Panel removal and installation, trim, seating, and accessory mounting.
Troubleshooting:
Diagnostic procedures for common and uncommon issues.
Type:
Factory Service Manual (FSM)
Format:
Digital PDF (Downloadable)
Engine Management:
Detailed information on ignition timing, carburetor synchronization, and fuel delivery.
Cooling System:
While air-cooled, covers any related components and heat dissipation principles.
Lubrication System:
Oil pump operation, oil filter replacement, and oil capacity specifications.
Exhaust System:
Exhaust pipe and muffler inspection, repair, and replacement guidelines.
Drivetrain:
Final drive maintenance, driveshaft inspection, and universal joint service.
Wheels And Tires:
Tire pressure, wheel bearing service, and spoke tensioning.
Controls:
Throttle, clutch, and brake lever adjustments and cable replacement.
Lighting And Indicators:
Headlight, taillight, turn signals, and brake light bulb replacement and circuit testing.
Instrumentation:
Speedometer, tachometer, and indicator light diagnostics.
Preventive Maintenance:
Scheduled maintenance checks, fluid changes, filter replacements, and lubrication points.
Diagnostic Procedures:
Step-by-step guides for identifying and resolving performance issues and electrical faults.
Component Overhaul:
Detailed instructions for rebuilding carburetors, brake calipers, and other key components.
Torque Specifications:
Essential torque values for critical fasteners throughout the motorcycle.
Adjustment Procedures:
Valve clearance adjustment, clutch lever free play, and throttle cable free play.
Wiring Diagrams:
Comprehensive, color-coded wiring schematics for easy troubleshooting.
Depth:
Comprehensive from basic owner maintenance to full engine and transmission rebuilds.
Diagnostic Tools:
Mentions necessary tools and techniques for accurate diagnostics.
Parts Identification:
Illustrations and descriptions for component identification.
Engine Type:
Air-cooled, V-twin, SOHC, 4-stroke
Displacement:
1600 cc (98 cubic inches)
Bore X Stroke:
97.0 mm x 109.6 mm
Valve Configuration:
SOHC, 4 valves per cylinder
Horsepower:
Approx. 65 HP @ 4,000 RPM (factory estimate)
Torque:
Approx. 94 lb-ft @ 2,500 RPM (factory estimate)
Carburetion:
Dual Mikuni BSR40 carburetors
Fuel Capacity:
4.0 US gal (15 L)
Fuel Type:
Unleaded gasoline, 87 octane or higher
Oil Capacity With Filter:
4.0 US qt (3.8 L)
Oil Type:
Yamalube 4 (or equivalent) SAE 20W-40 API SE, SF, SG type motor oil
Oil Filter Part Number:
Yamaha 5JX-13440-00-00
Overall Length:
98.6 in (2505 mm)
Overall Width:
36.0 in (915 mm)
Overall Height:
54.5 in (1385 mm)
Wheelbase:
67.1 in (1705 mm)
Dry Weight:
672 lbs (305 kg)
Wet Weight:
Approx. 714 lbs (324 kg) (with fluids)
Gvwr:
Not specified, typical for cruisers is around 900-1000 lbs
Front Suspension Travel:
5.5 in (140 mm)
Rear Suspension Travel:
4.3 in (110 mm)
Front Tire Size:
130/90-16 M/C 67H
Rear Tire Size:
150/80-16 M/C 71H
Front Brake Type:
Dual hydraulic disc
Rear Brake Type:
Hydraulic disc
Wheel Type:
Cast aluminum alloy (standard), spoke (Silverado/Midnight)
Wheel Size:
16 inch front and rear
Bolt Pattern:
Not applicable for cast wheels, specific hub for spoke wheels.
Crash Test Results:
N/A (Motorcycle specific safety focus is on rider protection and handling)
Braking System:
Powerful dual front disc and single rear disc brakes for effective stopping power.
Lighting:
Halogen headlight for enhanced visibility, integrated turn signals.
Frame Construction:
Robust steel frame designed for stability and rider confidence.
Ergonomics:
Comfortable riding position designed to reduce fatigue on long rides.
Infotainment System:
N/A (Focus on core motorcycle mechanics, no integrated infotainment)
Driver Assistance Features:
N/A (Focus on core motorcycle mechanics, no electronic rider aids)
Connectivity Features:
N/A (Focus on core motorcycle mechanics, no electronic connectivity)
First Service:
1000 km (600 miles) or 6 months, whichever comes first.
Subsequent Services:
Every 6000 km (3750 miles) or 12 months thereafter.
Valve Clearance Check:
Every 12,000 km (7,500 miles)
Clutch Adjustment:
As needed, check free play every 3000 km (1875 miles)
Engine Oil Change Interval:
Every 6000 km (3750 miles) or 12 months
Brake Fluid Change Interval:
Every 2 years
Carburetor Sync:
Carburetors can drift out of sync, leading to rough idle or poor performance; manual provides sync procedure.
Fuel Line Perishing:
Older fuel lines may degrade; manual details inspection and replacement of fuel lines.
Starter Clutch Wear:
Some models may experience starter clutch wear; manual covers diagnostic steps and replacement.
Rear Shock Leaks:
Rear shock absorbers may develop leaks over time; manual covers replacement and service.
Belt Drive Tension:
Proper belt tension is crucial; manual provides specifications and adjustment procedures.
Yamaha Motorcycle Division:
Yamaha Motor Company, established in 1955, known for innovation and performance across various vehicle types.
Road Star Lineage:
Introduced in 1999 as a competitor to American V-twin cruisers, emphasizing classic styling and large displacement.
Xv1600 Development:
Designed with a focus on torque, comfort, and a substantial road presence, featuring belt drive for reduced maintenance.
Trim Level Introduction:
Silverado introduced with touring amenities like windshields and saddlebags; Midnight offered with blacked-out styling.
Manufacturing Location:
Japan
Production Years:
1999-2003 (covered by this manual), continued with XV1700 Road Star Warrior and later models.
Model Awards:
While specific awards for the 1999-2003 models are not widely documented, the Road Star line was generally well-received for its styling, comfort, and performance in the cruiser segment.
Industry Reviews:
Praised for its large displacement V-twin engine, smooth power delivery, and comfortable ride for long-distance touring.
Manual Certification:
This manual is designed to meet professional service standards and provide accurate, reliable repair information.
