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Yamaha 2005 Royal Star XVZ13CTT, Owner'S Manual

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Yamaha 2005 Royal Star XVZ13CTT Owner'S Manual Download Page 64

PERIODIC MAINTENANCE AND MINOR REPAIR

6-18

6

The coolant must be changed at the in-
tervals specified in the periodic mainte-
nance and lubrication chart. Have a
Yamaha dealer change the coolant.

EAU35191

Cleaning the air filter elements 

The air filter elements should be
cleaned at the intervals specified in the
periodic maintenance and lubrication
chart. Clean the air filter elements more
frequently if you are riding in unusually
wet or dusty areas.

1. Remove cowlings A and B. (See

page 6-8.)

NOTE:

Continue as follows for each air filter el-
ement.

2. Remove the air filter case by re-

moving the bolts.

3. Loosen the air filter joint clamp

screw, and then pull the air filter
off.

4. Remove the air filter case cover by

removing the screws.

5. Remove the air filter element by

removing the screws.

1. Air filter case
2. Bolt

1. Air filter joint clamp screw

1. Screw

U1D610E0.book  Page 18  Monday, March 15, 2004  4:00 PM

Summary of Contents for 2005 Royal Star XVZ13CTT

Page 1: ...PRINTED IN JAPAN 2004 03 0 8 1 CR E PRINTED ON RECYCLED PAPER YAMAHA MOTOR CO LTD 1D6 28199 10 LIT 11626 18 02 XVZ13CTT C OWNER S MANUAL ...

Page 2: ...EAU10041 U1D610E0 book Page 1 Monday March 15 2004 4 00 PM ...

Page 3: ...motorcycle If you have any questions concerning the operation or maintenance of your motorcycle please consult a Yamaha dealer The design and manufacture of this Yamaha motorcycle fully comply with the emissions standards for clean air applicable at the date of manufacture Yamaha has met these standards without reducing the performance or economy of operation of the motorcycle To maintain these hi...

Page 4: ... consult your Yamaha dealer WARNING EWA10010 PLEASE READ THIS MANUAL AND THE YOU AND YOUR MOTORCYCLE RIDING TIPS BOOKLET CAREFULLY AND COMPLETELY BEFORE OPERATING THIS MOTORCYCLE DO NOT ATTEMPT TO OPERATE THIS MOTOR CYCLE UNTIL YOU HAVE ATTAINED ADEQUATE KNOWLEDGE OF ITS CONTROLS AND OPERATING FEATURES The Safety Alert Symbol means ATTENTION BECOME ALERT YOUR SAFETY IS INVOLVED Failure to follow W...

Page 5: ...AINED IN SAFE AND PROPER RIDING TECHNIQUES REGULAR INSPECTIONS AND CAREFUL MAINTENANCE ALONG WITH GOOD RIDING SKILLS WILL ENSURE THAT YOU SAFELY ENJOY THE CAPABILITIES AND THE RELIABILITY OF THIS MOTORCYCLE U1D610E0 book Page 2 Monday March 15 2004 4 00 PM ...

Page 6: ...ation U S A 1st edition February 2004 All rights reserved Any reprinting or unauthorized use without the written permission of Yamaha Motor Corporation U S A is expressly prohibited Printed in Japan P N LIT 11626 18 02 AFFIX DEALER LABEL HERE U1D610E0 book Page 3 Monday March 15 2004 4 00 PM ...

Page 7: ...in 5 4 Parking 5 5 PERIODIC MAINTENANCE AND MINOR REPAIR 6 1 PERIODIC MAINTENANCE 6 1 Owner s tool kit 6 1 Periodic maintenance chart for the emission control system 6 3 General maintenance and lubrication chart 6 4 Removing and installing cowlings and panels 6 8 Checking the spark plugs 6 11 Canister for California only 6 12 Engine oil and oil filter cartridge 6 12 Final gear oil 6 15 Coolant 6 1...

Page 8: ...t bulb or the tail brake light bulb 6 35 Supporting the motorcycle 6 36 Troubleshooting 6 37 Troubleshooting charts 6 38 MOTORCYCLE CARE AND STORAGE 7 1 Cleaning 7 1 Storage 7 2 SPECIFICATIONS 8 1 CONSUMER INFORMATION 9 1 Identification numbers 9 1 Reporting safety defects 9 3 Motorcycle noise regulation 9 4 Maintenance record 9 5 YAMAHA MOTOR CORPORATION U S A ROYAL STAR SERIES LIMITED WARRANTY 9...

Page 9: ...nts have been caused by an automobile driver who did not see the motorcycle Making yourself conspicuous ap pears to be very effective in reduc ing the chance of this type of accident Therefore Wear a brightly colored jacket Use extra caution when ap proaching and passing through intersections since intersec tions are the most likely places for motorcycle accidents to oc cur Ride where other motori...

Page 10: ...ace shield or goggles Wind in your unprotected eyes could contribute to an impairment of vision which could delay seeing a hazard The use of a jacket heavy boots trousers gloves etc is effective in preventing or reducing abrasions or lacerations Never wear loose fitting clothes otherwise they could catch on the control levers footrests or wheels and cause injury or an accident Never touch the engi...

Page 11: ...nder Load ing when mounting accessories Never install accessories or carry cargo that would impair the perfor mance of your motorcycle Care fully inspect the accessory before using it to make sure that it does not in any way reduce ground clearance or cornering clearance limit suspension travel steering travel or control operation or ob scure lights or reflectors Accessories fitted to the handle b...

Page 12: ...st system may be hot therefore park the motorcycle in a place where pe destrians or children are not like ly to touch these hot areas Do not park the motorcycle on a slope or soft ground otherwise it may fall over Do not park the motorcycle near a flammable source e g a kero sene heater or near an open flame otherwise it could catch fire When transporting the motorcycle in another vehicle make sur...

Page 13: ...SAFETY INFORMATION 1 5 1 EAU10381 Location of important labels Please read the following important labels carefully before operating this vehicle U1D610E0 book Page 5 Monday March 15 2004 4 00 PM ...

Page 14: ...ION 1 6 1 1 5 CALIFORNIA ONLY 3 2 CAUTION Cleaning with alkaline or acid cleaner gasoline or solvent will damage windshield Use neutral detergent 5JW 00 5JW 2835Y 00 4 U1D610E0 book Page 6 Monday March 15 2004 4 00 PM ...

Page 15: ...3 11 3 Fuel cock page 3 10 4 Fuel tank cap page 3 9 5 Battery page 6 31 6 Coolant reservoir page 6 16 7 Fuse box 2 page 6 32 8 Helmet holder page 3 14 9 Sidecase page 3 16 10 Tail brake light page 6 35 11 Rear turn signal light page 6 35 U1D610E0 book Page 1 Monday March 15 2004 4 00 PM ...

Page 16: ...bsorber assembly air valve page 3 17 6 Rider seat page 3 12 7 Fuel tank page 3 9 8 Front fork air valve page 3 17 9 Windshield page 3 15 10 Headlight page 6 34 11 Front turn signal position lights page 6 35 12 Fuse box 1 page 6 32 13 Brake pedal page 3 8 14 Rider footrest 15 Passenger footrest U1D610E0 book Page 2 Monday March 15 2004 4 00 PM ...

Page 17: ...Clutch lever page 3 7 2 Left handlebar switches page 3 6 3 Speedometer unit page 3 3 4 Main switch steering lock page 3 1 5 Right handlebar switches page 3 6 6 Throttle grip page 6 20 7 Brake lever page 3 8 U1D610E0 book Page 3 Monday March 15 2004 4 00 PM ...

Page 18: ...ering is locked and all electrical systems are off The key can be re moved To lock the steering 1 Turn the handlebars all the way to the left or right 2 Push the key in from the OFF po sition and then turn it to LOCK while still pushing it 3 Remove the key To unlock the steering Push the key into the main switch and then turn it to OFF while still pushing it WARNING EWA10060 Never turn the key to ...

Page 19: ...20 Oil level warning light This warning light comes on when the engine oil level is low The electrical circuit of the warning light can be checked by turning the key to ON If the warning light does not come on for a few seconds then go off have a Yamaha dealer check the electrical cir cuit NOTE Even if the oil level is sufficient the warning light may flicker when riding on a slope or during sudde...

Page 20: ...ight comes on when an electrical circuit monitoring the engine is defective When this occurs have a Yamaha dealer check the self diagno sis system The electrical circuit of the warning light can be checked by turning the key to ON If the warning light does not come on for a few seconds then go off have a Yamaha dealer check the electrical circuit EAU35151 Speedometer unit The speedometer unit is e...

Page 21: ...T button for at least two seconds To change the display back to the odometer and tripmeter modes push the SELECT button To set the clock 1 Push both the SELECT and RE SET buttons for at least two sec onds 2 When the hour digits start flashing push the RESET button to set the hours 3 Push the SELECT button and the minute digits will start flashing 4 Push the RESET button to set the minutes 5 Push t...

Page 22: ...ired traveling speed as follows Press the RES ACC re sume accelerate side of the cruise control switch to increase the set speed or the SET DEC side to decrease the speed NOTE Pressing the cruise control switch once will change the speed in increments of 1 6 km h 1 mi h Holding the cruise control switch down will increase or de crease the speed continuously until the switch is released The traveli...

Page 23: ...eed will return to the previously set speed Once the cruise control system is reactivated the SET indicator light will come on Push the CRUISE switch to the OFF position to completely cancel the cruise control system The ON indicator light will go off until the cruise control system is activated again NOTE Even if the CRUISE switch is in the ON position turning the main switch to OFF when the vehi...

Page 24: ...ersec tion EAU12500 Horn switch Press this switch to sound the horn EAU12660 Engine stop switch Set this switch to before starting the engine Set this switch to to stop the engine in case of an emergen cy such as when the vehicle overturns or when the throttle cable is stuck EAU12710 Start switch Push this switch to crank the engine with the starter CAUTION ECA10050 See page 5 1 for starting instr...

Page 25: ... this motorcycle NOTE Use your toes or heel to shift up and your toes to shift down EAU12890 Brake lever The brake lever is located at the right handlebar grip To apply the front brake pull the lever toward the handle bar grip EAU12941 Brake pedal The brake pedal is on the right side of the motorcycle To apply the rear brake press down on the brake pedal 1 Shift pedal 1 Brake lever 1 Brake pedal U...

Page 26: ...ose the lock cover NOTE The fuel tank cap cannot be installed unless the key is in the lock In addition the key cannot be removed if the cap is not properly installed and locked WARNING EWA10130 Make sure that the fuel tank cap is properly installed before riding EAU13210 Fuel Make sure that there is sufficient fuel in the tank Fill the fuel tank to the bottom of the filler tube as shown WARNING E...

Page 27: ...aintenance costs Gasohol There are two types of gasohol gaso hol containing ethanol and that contain ing methanol Gasohol containing ethanol can be used if the ethanol con tent does not exceed 10 Gasohol containing methanol is not recom mended by Yamaha because it can cause damage to the fuel system or ve hicle performance problems EAU13550 Fuel cock The fuel cock supplies fuel from the tank to th...

Page 28: ... this position if you run out of fuel while riding When this occurs refuel as soon as possible and be sure to turn the fuel cock lever back to ON EAU13600 Starter choke knob Starting a cold engine requires a richer air fuel mixture which is supplied by the starter choke Move the knob in direction a to turn on the starter choke Move the knob in direction b to turn off the starter choke 1 Pointed en...

Page 29: ...ckets are aligned and then lock the steering with a suitable pad lock EAU35170 Rider seat To remove the rider seat Remove the bolts and then pull the rid er seat up To install the rider seat Insert the projection on the rear of the rider seat into the seat holder as shown place the seat in the original po sition and then tighten the bolts NOTE Make sure that the rider seat is properly secured befo...

Page 30: ... move it by pulling it to the rear as shown To install the backrest Place the backrest in the original posi tion then pull it backward until it stops and the levers snap locking it into place WARNING EWA12561 A loose backrest could cause an ac cident After installing the backrest check that both levers are fully locked into place 1 Backrest lever 1 Locked position U1D610E0 book Page 13 Monday Marc...

Page 31: ...p and then hook the cable loops over the helmet holder 4 Place the helmet holder in the orig inal position and then remove the key WARNING EWA11040 Never ride with a helmet attached to a helmet holder since the helmet may hit objects causing loss of con trol and possibly an accident To release the helmet from the hel met holder 1 Open the helmet holder remove the helmet holding cable from the helm...

Page 32: ...ce the windshield in the original position as shown 2 Push the lever on each side of the windshield backward onto its fas tener to lock it into place WARNING EWA12541 A loose windshield could cause an accident Be sure the slot in each lever is securely fitted onto its fastener Be sure to pull both levers fully backward to lock the windshield into place 1 Windshield lever U1D610E0 book Page 15 Mond...

Page 33: ...ge in the sidecases otherwise han dling could be affected Improp er loading poor tire or overall motorcycle conditions poor road surfaces or adverse weath er conditions may make it nec essary to further reduce the riding speed To open a sidecase 1 Insert the key into the lock turn it counterclockwise and then push it in 2 Fold the sidecase lid up To close a sidecase 1 Fold the sidecase lid down 2 ...

Page 34: ...se the spring rate and thereby soften the suspen sion decrease the air pressure by pushing each valve stem down CAUTION ECA10090 Never exceed the maximum air pres sure otherwise the front fork oil seals may become damaged 5 Securely install the air valve caps EAU14800 Adjusting the shock absorber assembly This shock absorber assembly is equipped with an air valve for adjusting the spring rate CAUT...

Page 35: ...is part of the ignition circuit cut off system which cuts the ignition in certain situations See further down for an explanation of the ignition circuit cut off system WARNING EWA10240 The vehicle must not be ridden with the sidestand down or if the side stand cannot be properly moved up or does not stay up otherwise the sidestand could contact the ground and distract the operator resulting in a p...

Page 36: ... in gear and the side stand is up but the clutch lever is not pulled It prevents starting when the trans mission is in gear and the clutch le ver is pulled but the sidestand is still down It cuts the running engine when the transmission is in gear and the sid estand is moved down Periodically check the operation of the ignition circuit cut off system according to the following procedure WARNING EW...

Page 37: ...er the engine has stalled 10 Move the sidestand up 11 Keep the clutch lever pulled 12 Push the start switch Does the engine start The system is OK The motorcycle can be ridden This check is most reliable if performed with a warmed up engine The neutral switch may be defective The motorcycle should not be ridden until checked by a Yamaha dealer The sidestand switch may be defective The motorcycle s...

Page 38: ... The accessories connected to the auxiliary DC terminals should not be used with the engine turned off and the combined load must never ex ceed 5 A or 60 W otherwise the bat tery may discharge WARNING EWA12530 To prevent electrical shock or short circuiting make sure that the caps are installed when the auxiliary DC terminals are not being used 1 Auxiliary DC terminal U1D610E0 book Page 21 Monday ...

Page 39: ...equences Therefore it is very important in addition to a thorough visual inspec tion to check the following points before each ride NOTE Pre operation checks should be made each time the vehicle is used Such an inspection can be accomplished in a very short time and the added safety it assures is more than worth the time involved WARNING EWA11150 If any item in the Pre operation check list is not ...

Page 40: ...m for leakage 6 16 Front brake Check operation If soft or spongy have Yamaha dealer bleed hydraulic system Check lever free play Adjust if necessary Check brake pads for wear Replace if necessary Check fluid level in reservoir If necessary add recommended brake fluid to specified level Check hydraulic system for leakage 6 24 6 25 6 26 Rear brake Check operation If soft or spongy have Yamaha dealer...

Page 41: ...tion and tread depth Check air pressure Correct if necessary 6 21 6 22 Brake and shift pedals Make sure that operation is smooth Lubricate pedal pivoting points if necessary 6 28 Brake and clutch levers Make sure that operation is smooth Lubricate lever pivoting points if necessary 6 29 Sidestand Make sure that operation is smooth Lubricate pivot if necessary 6 29 Chassis fasteners Make sure that ...

Page 42: ...led and the sid estand up WARNING EWA10290 Before starting the engine check the function of the igni tion circuit cut off system ac cording to the procedure described on page 3 19 Never ride with the sidestand down 1 Turn the fuel cock lever to ON 2 Turn the key to ON and make sure that the engine stop switch is set to 3 Shift the transmission into the neu tral position NOTE When the transmission ...

Page 43: ...130 For maximum engine life always warm the engine up before starting off Never accelerate hard when the engine is cold 7 When the engine is warm turn the starter choke off NOTE The engine is warm when it responds normally to the throttle with the starter choke turned off To avoid the possi bility of excessive exhaust emissions never leave the starter choke on long er than necessary The time neces...

Page 44: ...AU16680 To start out and accelerate 1 Pull the clutch lever to disengage the clutch 2 Shift the transmission into first gear The neutral indicator light should go out 3 Open the throttle gradually and at the same time release the clutch lever slowly 4 At the recommended shift points shown in the following table close the throttle and at the same time quickly pull the clutch lever in 5 Shift the tr...

Page 45: ...nces During this period prolonged full throt tle operation or any condition that might result in engine overheating must be avoided EAU17041 0 1000 km 0 600 mi Avoid prolonged operation above 1 3 throttle 1000 1600 km 600 1000 mi Avoid prolonged operation above 1 2 throttle CAUTION ECA10331 After 1000 km 600 mi of operation the engine oil and final gear oil must be changed and the oil filter car t...

Page 46: ...witch and then turn the fuel cock lever to OFF WARNING EWA10310 Since the engine and exhaust system can become very hot park in a place where pedestri ans or children are not likely to touch them Do not park on a slope or on soft ground otherwise the vehicle may overturn U1D610E0 book Page 5 Monday March 15 2004 4 00 PM ...

Page 47: ...ATED TO EMISSIONS CONTROL THESE CONTROLS NOT ONLY FUNCTION TO ENSURE CLEANER AIR BUT ARE ALSO VITAL TO PROPER EN GINE OPERATION AND MAXIMUM PERFORMANCE IN THE FOLLOW ING PERIODIC MAINTENANCE CHARTS THE SERVICES RELATED TO EMISSIONS CONTROL ARE GROUPED SEPARATELY THESE SERVICES REQUIRE SPECIALIZED DATA KNOWLEDGE AND EQUIP MENT YAMAHA DEALERS ARE TRAINED AND EQUIPPED TO PER FORM THESE PARTICULAR SER...

Page 48: ...ARNING EWA10340 Modifications not approved by Yamaha may cause loss of perfor mance excessive emissions and render the vehicle unsafe for use Consult a Yamaha dealer before at tempting any changes U1D610E0 book Page 2 Monday March 15 2004 4 00 PM ...

Page 49: ...necessary 2 Fuel filter Replace Replace 3 Spark plugs Check condition Adjust gap and clean Replace every 8000 mi 13000 km or 12 months Replace Replace 4 Valve clearance Check and adjust valve clearance when engine is cold Every 26600 mi 42000 km 5 Crankcase breather system Check breather hose for cracks or damage Replace if necessary 6 Carburetor synchro nization Adjust synchronization of carbu re...

Page 50: ...heck operation and fluid leak age Correct if necessary 3 Front brake Check operation fluid level and for fluid leakage Replace brake pads if necessary 4 Rear brake Check operation fluid level and for fluid leakage Replace brake pads if necessary 5 Brake hoses Check for cracks or damage Replace Every 4 years 6 Wheels Check runout and for damage Replace if necessary 7 Tires Check tread depth and for...

Page 51: ...se lightly 13 Brake and shift ped al pivot shafts Apply lithium soap based grease all purpose grease lightly 14 Sidestand pivot Check operation Apply lithium soap based grease all purpose grease lightly 15 Sidestand switch Check operation and replace if necessary 16 Front fork Check operation and for oil leak age Replace if necessary 17 Shock absorber as sembly Check operation and for oil leak age...

Page 52: ...r oil Check oil level and for oil leakage Change at initial 600 mi 1000 km or 1 month and thereafter every 16000 mi 25000 km or 24 months Change Change 23 Control cables Apply Yamaha chain and cable lube or engine oil SAE 10W 30 thoroughly 24 Throttle grip hous ing and cable Check operation and free play Adjust the throttle cable free play if necessary Lubricate the throttle grip housing and cable...

Page 53: ...tch systems After disassembling the brake or clutch master cylinders caliper cylinders or clutch release cylinder always change the fluid Regularly check the brake and clutch fluid levels and fill the reservoirs as required Replace the oil seals on the inner parts of the brake or clutch master cylinders caliper cylinders and clutch release cylinder every two years Replace the brake and clutch hose...

Page 54: ... to be re moved and installed EAU35841 Cowling A To remove the cowling 1 Remove the bolts 2 Remove the quick fastener screw by turning it 1 4 turn counterclock wise and then take the cowling off To install the cowling Place the cowling in the original posi tion and then install the quick fastener screw and the bolts 1 Cowling A 2 Panel A 1 Cowling B 2 Panel B 3 Panel C 1 Cowling A 2 Bolt 3 Quick f...

Page 55: ...s shown To install the cowling 1 Place the cowling in the original position and then install the bolts NOTE Make sure that the projection fits into the grommet 2 Install cowling A EAU35860 Panels A and B To remove one of the panels Remove the bolt and then pull the pan el off as shown 1 Grommet 2 Projection 3 Cowling A 1 Cowling B 2 Bolt 1 Bolt 1 Panel A 2 Bolt U1D610E0 book Page 9 Monday March 15...

Page 56: ... panel 1 Remove the left passenger foot rest by removing the bolts 2 Remove the screw and then pull the panel off as shown To install the panel 1 Place the panel in the original posi tion and then install the screw 2 Install the passenger footrest by installing the bolts 1 Panel B 2 Bolt 1 Panel C 2 Screw 3 Bolt U1D610E0 book Page 10 Monday March 15 2004 4 00 PM ...

Page 57: ...round the center electrode on each spark plug is a medium to light tan the ideal color when the vehicle is ridden normally 2 Check that all spark plugs installed in the engine have the same color NOTE If any spark plug shows a distinctly dif ferent color the engine could be defec tive Do not attempt to diagnose such problems yourself Instead have a Yamaha dealer check the vehicle 3 Check each spar...

Page 58: ...acks or damage Replace if dam aged Make sure the vent hose is not blocked Clean it if necessary EAU19902 Engine oil and oil filter cartridge The engine oil level should be checked before each ride In addition the oil must be changed and the oil filter car tridge replaced at the intervals speci fied in the periodic maintenance and lubrication chart To check the engine oil level 1 Place the vehicle ...

Page 59: ...e an oil pan under the engine to collect the used oil 3 Remove the engine oil filler cap and drain bolt to drain the oil from the crankcase NOTE Skip steps 4 6 if the oil filter cartridge is not being replaced 4 Remove the oil filter cartridge with an oil filter wrench NOTE An oil filter wrench is available at a Yamaha dealer 5 Apply a thin coat of engine oil to the O ring of the new oil filter ca...

Page 60: ...l speci fication of CD or oils of a high er quality than specified In addition do not use oils labeled ENERGY CONSERVING II or higher Make sure that no foreign mate rial enters the crankcase 9 Start the engine and then let it idle for several minutes while checking it for oil leakage If oil is leaking im mediately turn the engine off and check for the cause 1 O ring 1 Torque wrench 2 Oil filter wr...

Page 61: ...WA10370 Make sure that no foreign mate rial enters the final gear case Make sure that no oil gets on the tire or wheel To check the final gear oil level 1 Place the vehicle on a level sur face and hold it in an upright posi tion NOTE The final gear oil level must be checked on a cold engine Make sure that the vehicle is posi tioned straight up when checking the oil level A slight tilt to the side ...

Page 62: ...ed in the periodic maintenance and lubrication chart EAU20211 To check the coolant level 1 Place the vehicle on a level sur face and hold it in an upright posi tion 2 Remove panel A See page 6 8 NOTE The coolant level must be checked on a cold engine since the level varies with engine temperature Make sure that the vehicle is posi tioned straight up when checking the coolant level A slight tilt to...

Page 63: ... frost and corrosion If water has been added to the coolant have a Yamaha dealer check the antifreeze content of the coolant as soon as possible otherwise the effectiveness of the coolant will be reduced WARNING EWA10380 Never attempt to remove the radiator cap when the engine is hot 5 Install the panel NOTE The radiator fan is automatically switched on or off according to the coolant temperature ...

Page 64: ...chart Clean the air filter elements more frequently if you are riding in unusually wet or dusty areas 1 Remove cowlings A and B See page 6 8 NOTE Continue as follows for each air filter el ement 2 Remove the air filter case by re moving the bolts 3 Loosen the air filter joint clamp screw and then pull the air filter off 4 Remove the air filter case cover by removing the screws 5 Remove the air fil...

Page 65: ...is properly seated in the air filter case The engine should never be op erated without the air filter ele ment installed otherwise the piston s and or cylinder s may become excessively worn 8 Install the air filter case cover by in stalling the screws 9 Install the air filter by pushing it onto the air filter joint then tighten ing the air filter joint clamp screw 10 Install the air filter case by...

Page 66: ... free play The throttle cable free play should mea sure 4 0 6 0 mm 0 16 0 24 in at the throttle grip Periodically check the throttle cable free play and if neces sary have a Yamaha dealer adjust it EAU21400 Adjusting the valve clearance The valve clearance changes with use resulting in improper air fuel mixture and or engine noise To prevent this from occurring the valve clearance must be adjusted...

Page 67: ...tems close to the center of the vehicle and distribute the weight evenly from side to side Properly adjust the suspension for your load and check the condition and pres sure of your tires NEVER OVER LOAD YOUR VEHICLE Make sure that the total weight of the cargo rid er passenger and accessories cowling saddlebags etc if ap proved for this model does not ex ceed the maximum load of the vehicle Opera...

Page 68: ...your motor cycle note the following points regarding the specified wheels The wheel rims should be checked for cracks bends warpage or damage before each ride If any damage is found have a Yamaha dealer replace the wheel Do not attempt even the smallest repair to the wheel A deformed or cracked wheel must be replaced The wheel should be balanced whenever either the tire or wheel has been changed o...

Page 69: ...s are designed and tested to be compatible with your motorcycle Please consider Genu ine Yamaha Parts and Accessories before making a purchase Use of non Yamaha approved accessories or replacement parts may cause loss of handling stability and riding safety Since Yamaha cannot control the quality of accessories or parts manufactured by other companies Yamaha cannot be held liable for any consequen...

Page 70: ...cally check the brake le ver free play and if necessary adjust it as follows 1 Loosen the locknut at the brake le ver 2 To increase the brake lever free play turn the adjusting screw in di rection a To decrease the brake lever free play turn the adjusting screw in direction b 3 Tighten the locknut WARNING EWA10630 After adjusting the brake lever free play check the free play and make sure that the...

Page 71: ...rake pad is provided with wear indicator grooves which allow you to check the brake pad wear with out having to disassemble the brake To check the brake pad wear check the wear indicator grooves If a brake pad has worn to the point that the wear indicator grooves have almost disap peared have a Yamaha dealer replace the brake pads as a set EAU22470 Rear brake pads Each rear brake pad is provided w...

Page 72: ... that the top of each reservoir is level Use only the recommended quality brake fluid otherwise the rubber seals may deteriorate causing leakage and poor braking or clutch performance Refill with the same type of brake fluid Mixing fluids may result in a harmful chemical reaction and lead to poor braking or clutch per formance Be careful that water does not en ter the brake or clutch fluid reser v...

Page 73: ...il seals Replace every two years Brake and clutch hoses Replace every four years EAU23090 Checking and lubricating the cables The operation of all control cables and the condition of the cables should be checked before each ride and the ca bles and cable ends should be lubricat ed if necessary If a cable is damaged or does not move smoothly have a Yamaha dealer check or replace it WARNING EWA10710...

Page 74: ...uld be lubricated or replaced at the intervals specified in the periodic maintenance chart EAU23131 Checking and lubricating the brake and shift pedals The operation of the brake and shift pedals should be checked before each ride and the pedal pivots should be lu bricated if necessary Recommended lubricant Lithium soap based grease all pur pose grease U1D610E0 book Page 28 Monday March 15 2004 4 ...

Page 75: ...g the front fork The condition and operation of the front fork must be checked as follows at the intervals specified in the periodic main tenance and lubrication chart To check the condition WARNING EWA10750 Securely support the vehicle so that there is no danger of it falling over Check the inner tubes for scratches damage and excessive oil leakage To check the operation 1 Place the vehicle on a ...

Page 76: ...g must be checked as fol lows at the intervals specified in the pe riodic maintenance and lubrication chart 1 Place a stand under the engine to raise the front wheel off the ground WARNING EWA10750 Securely support the vehicle so that there is no danger of it falling over 2 Hold the lower ends of the front fork legs and try to move them for ward and backward If any free play can be felt have a Yam...

Page 77: ...manent ly damage the battery WARNING EWA10760 Electrolyte is poisonous and dangerous since it contains sul furic acid which causes severe burns Avoid any contact with skin eyes or clothing and al ways shield your eyes when working near batteries In case of contact administer the fol lowing FIRST AID EXTERNAL Flush with plenty of water INTERNAL Drink large quan tities of water or milk and im mediat...

Page 78: ... a month and fully charge it if necessary 3 Fully charge the battery before in stallation 4 After installation make sure that the battery leads are properly con nected to the battery terminals CAUTION ECA10630 Always keep the battery charged Storing a discharged battery can cause permanent battery damage To charge a sealed type MF battery a special constant volt age battery charger is required Usi...

Page 79: ...tensive damage to the electrical system and possibly a fire 1 Cruise control fuse 2 Carburetor heater fuse 3 Auxiliary DC terminal fuse 4 Spare fuse 1 Backup fuse for odometer and clock 2 Radiator fan fuse 3 Headlight fuse 4 Signaling system fuse 5 Ignition fuse 6 Spare fuse Specified fuses Fuse box 1 Cruse control fuse 10 0 A Carburetor heater fuse 15 0 A Auxiliary DC terminal fuse 5 0 A Fuse box...

Page 80: ...lacing the headlight bulb This model is equipped with a quartz bulb headlight If the headlight bulb burns out replace it as follows 1 Remove the headlight unit by re moving the screws 2 Disconnect the headlight coupler and then remove the bulb cover 3 Unhook the headlight bulb holder and then remove the defective bulb 1 Screw 1 Headlight coupler 2 Headlight bulb cover 1 Headlight bulb holder U1D61...

Page 81: ...cy of the glass the luminosity of the bulb and the bulb life will be adversely af fected Thoroughly clean off any dirt and fingerprints on the headlight bulb using a cloth moistened with al cohol or thinner 5 Install the headlight bulb cover and then connect the coupler 6 Install the headlight unit by install ing the screws 7 Have a Yamaha dealer adjust the headlight beam if necessary EAU24281 Rep...

Page 82: ...d up right Check that the motorcycle is in a stable and level position before starting any maintenance A strong wooden box can be placed under the engine for added stability To service the front wheel 1 Stabilize the rear of the motorcycle by using a motorcycle stand or if an additional motorcycle stand is not available by placing a jack un der the frame in front of the rear wheel 2 Raise the fron...

Page 83: ... troubleshooting charts represent quick and easy procedures for checking these vital systems your self However should your motorcycle require any repair take it to a Yamaha dealer whose skilled technicians have the necessary tools experience and know how to service the motorcycle properly Use only genuine Yamaha replace ment parts Imitation parts may look like Yamaha parts but they are often infer...

Page 84: ...ompression Check the ignition Have a Yamaha dealer check the vehicle Remove the spark plugs and check the electrodes 3 Ignition Wipe off with a dry cloth and correct the spark plug gaps or replace the spark plugs Have a Yamaha dealer check the vehicle The engine does not start Have a Yamaha dealer check the vehicle The engine does not start Check the battery Operate the electric starter 4 Battery ...

Page 85: ... hissing sound has stopped press down on the cap while turning it counterclockwise and then remove the cap NOTE If coolant is not available tap water can be temporarily used instead provided that it is changed to the recommended coolant as soon as possible Wait until the engine has cooled Check the coolant level in the reservoir and radiator The coolant level is OK The coolant level is low Check t...

Page 86: ...the wheel axles Cleaning the motorcycle 1 Rinse any dirt and degreaser off with a garden hose using only enough pressure to do the job CAUTION ECA10940 Do not use high pressure wash ers since excessive high pres sure may cause water seepage and deterioration of wheel bear ings the front fork brakes transmission seals audio sys tem speakers saddlebags travel trunk and electrical parts Many expensiv...

Page 87: ...ilizer 1 fluid oz per gallon or 7 5 ml per li ter Operate the engine for several minutes to insure the newly condi tioned fuel enters the entire fuel system and carburetors NOTE Use of Yamaha Fuel Conditioner and Stabilizer eliminates the need to drain the fuel system If necessary have a Yamaha dealer drain the fuel system 2 Remove the spark plugs and pour about one tablespoon of SAE 10W 30 or SAE...

Page 88: ...e seat cover 7 Remove the battery and fully charge it Store it in a cool dry place and charge it once a month Do not store the battery in an excessively cold or warm place less than 0 C 30 F or more than 30 C 90 F For more information on storing the battery see page 6 31 NOTE If necessary make repairs before stor ing the motorcycle U1D610E0 book Page 3 Monday March 15 2004 4 00 PM ...

Page 89: ... Imp qt Final gear oil Type SAE80 API GL 4 Hypoid gear oil Quantity 0 20 L 0 21 US qt 0 18 Imp qt Cooling system Coolant reservoir capacity up to the maximum level mark 0 35 L 0 37 US qt 0 31 Imp qt Radiator capacity including all routes 3 50 L 3 70 US qt 3 08 Imp qt Air filter Air filter element Dry element Fuel Recommended fuel Unleaded gasoline only Fuel tank capacity 20 0 L 5 28 US gal 4 40 Im...

Page 90: ...6 psi 2 50 kgf cm Loading condition 90 201 kg 198 443 lb Front 250 kPa 36 psi 2 50 kgf cm Rear 280 kPa 41 psi 2 80 kgf cm Front wheel Wheel type Cast wheel Rim size 16M C x MT3 50 Rear wheel Wheel type Cast wheel Rim size 15M C x MT4 00 Front brake Type Dual disc brake Operation Right hand operation Recommended fluid DOT 4 Rear brake Type Single disc brake Operation Right foot operation Recommende...

Page 91: ...cator light LED Oil level warning light LED Turn signal indicator light LED Coolant temperature warning light LED Engine trouble warning light LED Overdrive indicator light LED Cruise control SET indicator light LED Cruise control ON indicator light LED Fuses Main fuse 30 0 A Headlight fuse 15 0 A Signaling system fuse 15 0 A Ignition fuse 10 0 A Radiator fan fuse 10 0 A Carburetor heater fuse 15 ...

Page 92: ...ntification number The key identification number is stamped into the key tag Record this number in the space provided and use it for reference when ordering a new key EAU26400 Vehicle identification number The vehicle identification number is stamped into the steering head pipe Record this number in the space pro vided NOTE The vehicle identification number is used to identify your motorcycle and ...

Page 93: ...el is affixed to the frame under the rider seat See page 3 12 Record the information on this label in the space provided This information will be needed when ordering spare parts from a Yamaha dealer 1 Model label U1D610E0 book Page 2 Monday March 15 2004 4 00 PM ...

Page 94: ...stigation and if it finds that a safety defect exists in a group of vehicles it may order a recall and remedy campaign However NHTSA cannot become involved in individual problems between you your dealer or Yamaha Motor Corporation U S A To contact NHTSA you may either call the Auto Safety Hotline toll free at 1 800 424 9393 or 366 0123 in Washington D C area or write to NHTSA U S Department of Tra...

Page 95: ...icle for the purpose of noise control prior to its sale or delivery to the ultimate purchaser or while it is in use or 2 the use of the vehicle after such device or element of design has been removed or rendered inoperative by any person AMONG THOSE ACTS PRESUMED TO CONSTITUTE TAMPERING ARE THE ACTS LISTED BELOW These acts include tampering with the following systems i e modification removal etc E...

Page 96: ...minder that maintenance work is required It is not acceptable proof of maintenance work Maintenance interval Date of service Mileage Servicing dealer name and address Remarks 600 mi 1000 km or 1 month 4000 mi 7000 km or 6 months 8000 mi 13000 km or 12 months 12000 mi 19000 km or 18 months 16000 mi 25000 km or 24 months 20000 mi 31000 km or 30 months 24000 mi 37000 km or 36 months 28000 mi 43000 km...

Page 97: ...ORMATION 9 6 9 36000 mi 55000 km or 54 months 40000 mi 61000 km or 60 months Maintenance interval Date of service Mileage Servicing dealer name and address Remarks U1D610E0 book Page 6 Monday March 15 2004 4 00 PM ...

Page 98: ...dealer of any and all apparent de fects within ten 10 days after discovery and make the ma chine available at that time for inspection and repairs at such dealer s place of business WARRANTY TRANSFER To transfer the warranty from the original purchaser to any subsequent purchaser it is imperative that the machine be in spected and registered for warranty by an authorized Yamaha motorcycle dealer I...

Page 99: ...te In addition each Yamaha motorcycle dealer is held responsible for his setup service and warranty repair work Is the warranty transferable to second owners Yes The remainder of the existing warranty can be transferred upon request The unit has to be inspected and re registered by an authorized Yamaha motorcycle dealer for the warranty coverage to remain effective CUSTOMER SERVICE If your machine...

Page 100: ...3 9 Fuel cock 3 10 Fuel tank cap 3 9 Fuses replacing 6 32 H Handlebar switches 3 6 Headlight bulb replacing 6 34 Helmet holder 3 14 High beam indicator light 3 2 Horn switch 3 7 I Identification numbers 9 1 Ignition circuit cut off system 3 19 Indicator and warning lights 3 2 K Key identification number 9 1 L Labels location of 1 5 M Main switch steering lock 3 1 Maintenance and lubrication period...

Page 101: ...6 1 Troubleshooting 6 37 Troubleshooting charts 6 38 Turn signal indicator light 3 2 Turn signal light bulb or tail brake light bulb replacing 6 35 Turn signal switch 3 7 V Valve clearance adjusting 6 20 Vehicle identification number 9 1 W Warranty limited 9 7 Wheel bearings checking 6 31 Wheels 6 22 Windshield 3 15 U1D610E0 book Page 2 Monday March 15 2004 4 00 PM ...

Page 102: ...PRINTED IN JAPAN 2004 03 0 8 1 CR E PRINTED ON RECYCLED PAPER YAMAHA MOTOR CO LTD 1D6 28199 10 LIT 11626 18 02 XVZ13CTT C OWNER S MANUAL ...

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