Yamaha Wild Star XV1600A(L) 1999 Service Manual (P/N 5JA1-AE1)

This Yamaha factory service manual covers the 1999 XV1600A and XV1600AL Wild Star. It is the first edition, dated December 1998, P/N 5JA1-AE1.

PDF Search, Bookmarks, and Wiring Detail

Finding procedures and wiring details: The main chapter text is searchable, and bookmarks open all eight chapters and both full wiring diagrams. The diagram headings are searchable, while the small connector markings and wire-color codes are best read by zooming in. The two return bookmarks point to separate files.

The download is one printable English-language PDF with 468 pages, including the original cover and two blank pages.

V-Twin Overhaul, Chassis Service, and Electrical Diagnosis

The selected procedures below are part of the manual’s coverage. It also includes a periodic maintenance and lubrication schedule and headlight beam adjustment.

• Engine repair: Step-by-step engine removal and installation, with overhaul procedures for the cylinder heads, valves, pistons, crankcase, oil pumps, crankshaft, and connecting rods.

• Drivetrain work: Clutch and primary-drive inspection, shift-shaft service, generator rotor and starter-clutch removal, transfer gear case repair, transmission disassembly, and drive belt and sprocket installation.

• Chassis service: Wheel and brake disc inspection, static wheel balancing, brake master cylinder and caliper overhaul, hydraulic brake bleeding, front fork rebuild, steering head service, and rear shock and swingarm removal.

• Fuel and air induction: Mikuni BSR40 carburetor teardown, fuel-level measurement, throttle position sensor adjustment, fuel pump and fuel cock testing, and air induction system inspection.

• Electrical troubleshooting: Ignition and starter circuit diagnosis, starter motor repair, charging-system tests, and fault isolation for lighting, signaling, fuel pump control, and carburetor heating.

• Drawings and schematics: Exploded views with job-order charts, engine and transfer gear oil flow diagrams, cable routing drawings, electrical component and coupler location views, and full EUR and AUS wiring diagrams.

Yamaha wrote this manual primarily for its dealers and qualified mechanics and assumes a working knowledge of motorcycle maintenance and repair.

Valve Lifters, Lubrication, and Crankcase Work

The air-cooled OHV V-twin uses twin spark plugs, automatic decompression, and dry-sump lubrication. The oil-pressure-operated lifters normally take up all valve clearance. Yamaha describes how to check and manually correct clearance on maladjusted or worn valve pairs, and how to bleed and install the lifters.

Internal engine work includes camshaft and gear alignment, decompression mechanism inspection, valve seat service, piston ring checks, and big-end bearing clearance measurement and selection. The crankcase illustrations show the shift drum segment position for separating and joining the case halves, where misaligned teeth can contact and damage the case.

Clutch, Transfer Gears, and Transmission

Clutch inspection covers the friction and steel plates, spring plate, clutch boss, housing, pressure plate, and pull rod. The drivetrain sections also cover the shift stopper lever, middle driven shaft, transfer oil pump, transmission main and drive axles, shift drum, and shift forks.

Carburetor and Market-Specific Wiring

Fuel-level and throttle position sensor adjustments are documented for the single-carburetor setup. The XV1600A self-diagnosis section explains how indicator-light patterns identify faults in the throttle position sensor, speed sensor, decompression solenoid, and fuel-level meter.

Use the XV1600A diagram for EUR or the XV1600AL diagram for AUS to match the market wiring. The circuit diagrams and coupler views let you follow a fault from the circuit under test to the connector on the motorcycle, including when tracing the starter cutoff circuit.

Factory Specifications, Tools, and Repair Cautions

Factory data include component torque tables, oil pressure checks, fuel pump test specifications, fluid capacities, wear limits, clearances, battery charging guidance, and electrical resistance and output values. Yamaha lists the flywheel puller (90890-01080), damper rod holder (90890-01294), belt tension gauge (90890-03170), clutch holding tool (90890-04086), and oil pressure gauge (90890-03153).

Solvent can swell or distort hydraulic brake piston seals and lead to leaks. Before wheel, fork, brake, or engine work, support the motorcycle securely on a suitable stand or lift and follow Yamaha’s precautions for fuel, brake fluid, the maintenance-free battery, hot engine parts, and the gas-charged rear shock.

Compression and Fork Oil Specification Preview

The standard cylinder compression is 1,200 kPa at sea level and 200 r/min. The compression test also specifies a maximum difference of 100 kPa between cylinders.

For a front fork rebuild, Yamaha specifies 554 cm³ of oil per leg and an oil level of 110 mm below the top of the inner tube, measured with the tube fully compressed and the spring removed.