Yamaha midnightstar XV1900A Owner'S Manual Download | Manualshive

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PERIODIC MAINTENANCE AND MINOR REPAIR

6-17

6

EAU22750

Changing the brake and
clutch fluids

Have a Yamaha dealer change the
brake and clutch fluids at the intervals
specified in the NOTE after the periodic
maintenance and lubrication chart. In
addition, have the oil seals of the brake
and clutch master cylinders and cali-
pers as well as the brake and clutch
hoses replaced at the intervals listed
below or whenever they are damaged
or leaking.

●

Oil seals: Replace every two
years.

●

Brake and clutch hoses: Replace
every four years.

EAU23040

Drive belt slack

The drive belt slack should be checked
and adjusted at the intervals specified
in the periodic maintenance and lubri-
cation chart.

EAU38410

To check the drive belt slack

1. Place the vehicle on the sidestand.
2. Note the current position of the

drive belt using the marks near the
drive belt check hole.

NOTE:

The marks near the drive belt check
hole are 5.0 mm (0.2 in) apart.

3. Note the position of the drive belt

with a force of 45 N (4.5 kgf, 10 lbf)
applied to the belt with a belt ten-
sion gauge as shown.

NOTE:

A belt tension gauge is available at a
Yamaha dealer.

4. Calculate the drive belt slack by

subtracting the measurement not-
ed in step 2 from the measurement
noted in step 3.

5. If the drive belt slack is incorrect,

have a Yamaha dealer adjust it.

1. Drive belt
2. Marks

3. Drive belt slack

1. Belt tension gauge

Drive belt slack:

7.5–13.0 mm (0.30–0.51 in)

U5C4E2E0.book Page 17 Friday, September 7, 2007 4:17 PM

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Summary of Contents for midnightstar XV1900A

Page 1: ...5C4 28199 E2 XV1900A OWNER S MANUAL ...

Page 2: ...integrate type designation 9 Jun 2005 Date of issue 1 Aug 2002 Place of issue Shizuoka Japan R TTE Directive 1999 5 EC EN300 330 2 v1 1 1 2001 6 EN60950 1 2001 Two or Three Wheel Motor Vehicles Directive 97 24 EC Chapter 8 EMC is in compliance with following norm s or documents Kind of equipment IMMOBILIZER Type designation 5SL 00 Hereby declare that the product Company YAMAHA MOTOR ELECTRONICS CO...

Page 3: ...to enjoy all advantages of your XV1900A The owner s manual does not only instruct you in how to operate inspect and maintain your motorcycle but also in how to safeguard yourself and others from trouble and injury In addition the many tips given in this manual will help keep your motorcycle in the best possible condition If you have any further questions do not hesitate to contact your Yamaha deal...

Page 4: ...If you have any questions concerning this manual please consult your Yamaha dealer WARNING EWA10030 PLEASE READ THIS MANUAL CAREFULLY AND COMPLETELY BEFORE OPERATING THIS MOTORCYCLE Product and specifications are subject to change without notice The Safety Alert Symbol means ATTENTION BECOME ALERT YOUR SAFETY IS INVOLVED Failure to follow WARNING instructions could result in severe injury or death...

Page 5: ...UAL 2007 by Yamaha Motor Co Ltd 1st edition August 2007 All rights reserved Any reprinting or unauthorized use without the written permission of Yamaha Motor Co Ltd is expressly prohibited Printed in Japan U5C4E2E0 book Page 2 Friday September 7 2007 4 17 PM ...

Page 6: ...tion chart 6 2 Checking the spark plugs 6 6 Engine oil and oil filter cartridge 6 7 Transfer case oil 6 10 Air filter element 6 11 Checking the throttle cable free play 6 11 Valve clearance 6 11 Tires 6 12 Cast wheels 6 14 Clutch lever 6 14 Adjusting the rear brake light switch 6 14 Checking the front and rear brake pads 6 15 Checking the brake and clutch fluid levels 6 15 Changing the brake and c...

Page 7: ... CONTENTS MOTORCYCLE CARE AND STORAGE 7 1 Matte color caution 7 1 Care 7 1 Storage 7 3 SPECIFICATIONS 8 1 CONSUMER INFORMATION 9 1 Identification numbers 9 1 U5C4E2E0 book Page 2 Friday September 7 2007 4 17 PM ...

Page 8: ...ts have been caused by an automobile driver who did not see the motorcycle Making yourself conspicuous appears to be very effective in reducing the chance of this type of accident Therefore Wear a brightly colored jacket Use extra caution when you are approaching and passing through intersections since in tersections are the most likely places for motorcycle accidents to occur Ride where other mot...

Page 9: ...eld or goggles Wind in your unprotected eyes could contribute to an impairment of vision that 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 engine or ex...

Page 10: ...Use extreme caution when selecting and installing any ac cessories Keep the following guidelines in mind as well as those provided under 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 cleara...

Page 11: ...equate ventilation Always turn the engine off before leaving the motorcycle unattended and remove the key from the main switch When parking the motor cycle note the following The engine and exhaust 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 f...

Page 12: ...age 3 15 4 Main fuse page 6 23 5 Battery page 6 22 6 Owner s tool kit page 6 1 7 License plate light page 6 28 8 Tail brake light page 6 28 9 Engine oil drain bolt B crankcase page 6 7 10 Engine oil drain bolt A crankcase page 6 7 11 Shift pedal page 3 12 U5C4E2E0 book Page 1 Friday September 7 2007 4 17 PM ...

Page 13: ...3 5 Engine oil filler cap page 6 7 6 Fuel tank cap page 3 13 7 Front brake fluid reservoir page 6 15 8 Brake pedal page 3 13 9 Rear brake light switch page 6 14 10 Engine oil filter cartridge page 6 7 11 Engine oil drain bolt oil tank page 6 7 12 Shock absorber assembly spring preload adjusting nut page 3 17 U5C4E2E0 book Page 2 Friday September 7 2007 4 17 PM ...

Page 14: ...ever page 3 12 2 Left handlebar switches page 3 10 3 Multi function meter unit page 3 5 4 Main switch steering lock page 3 2 5 Right handlebar switches page 3 10 6 Throttle grip page 6 11 7 Brake lever page 3 12 U5C4E2E0 book Page 3 Friday September 7 2007 4 17 PM ...

Page 15: ...R DEALER IMMEDIATELY IF IT IS LOST If the code re reg istering key is lost registering new codes in the standard keys is impossible The standard keys can still be used to start the vehicle however if code re registering is required i e if a new standard key is made or all keys are lost the entire immobi lizer system must be replaced Therefore it is highly recom mended to use either standard key an...

Page 16: ...d bow keep it in a safe place and only use it for code re registering EAU36870 ON All electrical circuits are supplied with power the meter lighting taillight li cense plate light and auxiliary lights come on and the engine can be start ed The key cannot be removed NOTE The headlight comes on automatically when the engine is started and stays on until the key is turned to OFF even if the engine st...

Page 17: ...ched off which may result in loss of control or an accident Make sure that the vehicle is stopped be fore turning the key to OFF or LOCK EAU10941 Parking The steering is locked and the taillight license plate light and auxiliary lights are on The hazard lights and turn sig nal lights can be turned on but all other electrical systems are off The key can be removed The steering must be locked before...

Page 18: ...owing cycle will be repeated until the malfunction is corrected The fuel level warning light will flash eight times and then go off for 3 0 seconds If this occurs have a Yamaha dealer check the vehicle EAU11530 Engine trouble warning light This warning light comes on or flashes when an electrical circuit monitoring the engine is defective When this occurs have a Yamaha dealer check the self diagno...

Page 19: ...s equipped with the following a speedometer which shows the riding speed a tachometer which shows the en gine speed a fuel gauge an odometer which shows the to tal distance traveled two tripmeters which show the distance traveled since they were last set to zero a fuel reserve tripmeter which shows the distance traveled on the fuel reserve a clock a self diagnosis device a brightness control mode ...

Page 20: ... monitor the engine speed and keep it within the ideal power range When the key is turned to ON the ta chometer needle will sweep once across the r min range and then return to zero r min in order to test the electri cal circuit CAUTION ECA10031 Do not operate the engine in the ta chometer red zone Red zone 5000 r min and above 1 SELECT switch 1 Reset switch 1 Speedometer 1 Tachometer 2 Tachometer...

Page 21: ...en the odometer mode ODO the tripmeter modes TRIP 1 and TRIP 2 and the clock mode in the following order ODO TRIP 1 TRIP 2 Clock ODO If the fuel level warning light comes on see page 3 4 the odometer display will automatically change to the fuel re serve tripmeter mode F TRIP and start counting the distance traveled from that point In that case push the SELECT switch to switch the display between ...

Page 22: ...ash and then the display will indicate a two digit error code NOTE If the display indicates error code 52 this could be caused by transponder in terference If this error code appears try the following 1 Use the code re registering key to start the engine NOTE Make sure there are no other immobi lizer keys close to the main switch and do not keep more than one immobilizer key on the same key ring I...

Page 23: ...on meter unit panel brightness level by pushing the reset switch 5 Push the SELECT switch to se lect the LCD Item number 2 is displayed Adjust the LCD brightness level by pushing the reset switch 6 Push the SELECT switch to se lect the speedometer tachometer and the fuel gauge needles Item number 3 is displayed Adjust the brightness level of the speedometer tachometer and the fuel gauge needles by...

Page 24: ... model can be equipped with an optional anti theft alarm by a Yamaha dealer Contact a Yamaha dealer for more information EAU12347 Handlebar switches Left 1 Speedometer needle 2 Tachometer needle 3 Fuel gauge needle 4 Item number 5 Brightness level 1 Dimmer Pass switch 2 Turn signal switch 3 Horn switch 1 SELECT switch U5C4E2E0 book Page 10 Friday September 7 2007 4 17 PM ...

Page 25: ...e with the starter CAUTION ECA10050 See page 5 1 for starting instruc tions prior to starting the engine EAU41700 The engine trouble warning light will come on when the key is turned to ON and the start switch is pushed but this does not indicate a malfunction EAU12733 Hazard switch With the key in the ON or posi tion use this switch to turn on the haz ard lights simultaneous flashing of all turn ...

Page 26: ...igni tion circuit cut off system See page 3 20 EAU12880 Shift pedal The shift pedal is located on the left side of the engine and is used in com bination with the clutch lever when shifting the gears of the 5 speed con stant mesh transmission equipped on 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 h...

Page 27: ... fuel tank cap 1 Insert the fuel tank cap into the tank opening with the key inserted in the lock and with the mark facing forward 2 Turn the key counterclockwise to the original position remove it and then close 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 EWA10...

Page 28: ...gasoline The use of leaded gasoline will cause severe damage to internal engine parts such as the valves and piston rings as well as to the exhaust system Your Yamaha engine has been de signed to use premium unleaded gaso line with a research octane number of 95 or higher If knocking or pinging oc curs use a gasoline of a different brand Use of unleaded fuel will extend spark plug life and reduce ...

Page 29: ...N ECA10700 The following precautions must be observed to prevent a fire hazard or other damages Use only unleaded gasoline The use of leaded gasoline will cause unrepairable damage to the catalytic converter Never park the vehicle near pos sible fire hazards such as grass or other materials that easily burn Do not allow the engine to idle too long EAU34042 Rider seat To remove the rider seat 1 Ins...

Page 30: ...rough the buckle on the helmet strap as shown and then hook the cable loop over the helmet holder 3 Place the helmet on the left side of the vehicle and then install the rid er seat CAUTION ECA15330 Be sure to place the helmet on the left side of the vehicle Some hel mets may contact the muffler when placed on the right side because of their size or shape WARNING EWA10160 Never ride with a helmet ...

Page 31: ...locknut 2 To increase the spring preload and thereby harden the suspension turn the adjusting nut in direction a To decrease the spring pre load and thereby soften the sus pension turn the adjusting nut in direction b NOTE To make the adjustment use the special wrench included in the ad ditional tool kit which was handed out separately at the purchase of the vehicle The spring preload setting is d...

Page 32: ...nnot be held re sponsible for property damage or personal injury that may result from improper handling Do not tamper with or attempt to open the gas cylinder Do not subject the shock ab sorber to an open flame or other high heat sources otherwise it may explode due to excessive gas pressure Do not deform or damage the gas cylinder in any way as this will result in poor damping per formance Always...

Page 33: ...d on the left side of the frame Raise the sidestand or lower it with your foot while holding the vehicle upright NOTE The built in sidestand switch 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 si...

Page 34: ...e 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 EWA10250 If a malfunction is noted have a ...

Page 35: ...and down Does the engine stall After 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 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 should not be ridden until check...

Page 36: ...5310 The accessory connected to the auxiliary DC connector should not be used with the engine turned off and the load must never exceed 36 W 3 A otherwise the battery may discharge WARNING EWA12531 To prevent electrical shock or short circuiting make sure that the cap is installed when the auxiliary DC con nector is not being used 1 Auxiliary DC connector U5C4E2E0 book Page 22 Friday September 7 2...

Page 37: ...uences 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 wo...

Page 38: ...ed level Check hydraulic system for leakage 6 15 6 15 Rear brake Check operation If soft or spongy have Yamaha dealer bleed hydraulic system 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 15 6 15 Clutch Check operation If soft or spongy have Yamaha dealer bleed hydraulic ...

Page 39: ...h levers Make sure that operation is smooth Lubricate lever pivoting points if necessary 6 19 Sidestand Make sure that operation is smooth Lubricate pivot if necessary 6 20 Chassis fasteners Make sure that all nuts bolts and screws are properly tightened Tighten if necessary Instruments lights signals and switches Check operation Correct if necessary Sidestand switch Check operation of ignition ci...

Page 40: ...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 20 Never ride with the sidestand down 1 Turn the key to ON and make sure that the engine stop switch is set to CAUTION ECA15070 The following warning lights and in dicator light should come on for a few seconds then go off Fuel level warni...

Page 41: ...ntil it reaches the end of its travel and then slightly raise it CAUTION ECA10260 Even with the transmission in the neutral position do not coast for long periods of time with the engine off and do not tow the motorcycle for long dis tances The transmission is properly lubricated only when the engine is running Inade quate lubrication may damage the transmission Always use the clutch while changin...

Page 42: ...the engine is brand new do not put an excessive load on it for the first 1600 km 1000 mi The various parts in the engine wear and polish themselves to the correct operating clearances During this period prolonged full throt tle operation or any condition that might result in engine overheating must be avoided EAU17111 0 1000 km 0 600 mi Avoid prolonged operation above 2500 r min 1000 1600 km 600 1...

Page 43: ... 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 CAUTION ECA10380 Never park in an area where there are fire hazards such as grass or other flammable materials U5C4E2E0 book Page 4 Friday September 7 2007 4 17 PM ...

Page 44: ...e not familiar with mainte nance work have a Yamaha dealer do it for you EAU17360 Owner s tool kit The owner s tool kit is located under the rider seat See page 3 15 The service information included in this manual and the tools provided in the owner s tool kit are intended to assist you in the performance of preventive maintenance and minor repairs How ever additional tools such as a torque wrench...

Page 45: ...EM CHECK OR MAINTENANCE JOB ODOMETER READING ANNUAL CHECK 1000 km 600 mi 10000 km 6000 mi 20000 km 12000 mi 30000 km 18000 mi 40000 km 24000 mi 1 Fuel line Check fuel hoses for cracks or damage 2 Spark plugs Check condition Clean and regap Replace 3 Valves Check valve clearance Adjust 4 Air filter element Replace 5 Clutch Check operation fluid level and vehicle for fluid leakage 6 Front brake Chec...

Page 46: ...aligned Every 4000 km 2500 mi 14 Steering bearings Check bearing play and steering for roughness Lubricate with lithium soap based grease Every 50000 km 30000 mi 15 Chassis fasteners Make sure that all nuts bolts and screws are properly tightened 16 Brake lever pivot shaft Lubricate with silicone grease 17 Brake pedal pivot shaft Lubricate with lithium soap based grease 18 Clutch lever pivot shaft...

Page 47: ...g arm pivoting points Check operation Lubricate with lithium soap based grease 25 Fuel injection sys tem Adjust synchronization 26 Engine oil Change Check oil level and vehicle for oil leakage 27 Engine oil filter car tridge Replace 28 Transfer case oil Check oil level Change 29 Front and rear brake switches Check operation 30 Moving parts and cables Lubricate NO ITEM CHECK OR MAINTENANCE JOB ODOM...

Page 48: ...ake master cylinders and calipers as well as clutch master and release cylinders and change the brake and clutch fluids Replace the brake and clutch hoses every four years and if cracked or damaged 31 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 32 Muffler and exhaust pipe Check the scr...

Page 49: ... be operating im properly Do not attempt to diagnose such problems yourself Instead have a Yamaha dealer check the vehicle If a spark plug shows signs of electrode erosion and excessive carbon or other deposits it should be replaced Before installing a spark plug the spark plug gap should be measured with a wire thickness gauge and if necessary adjusted to specification Clean the surface of the sp...

Page 50: ...ngine oil tem perature for an accurate oil level read ing the engine must have first completely cooled down and then warmed up again for several minutes to normal operating temperature 4 Wait a few minutes until the oil set tles remove the oil filler cap wipe the dipstick clean insert it back into the oil filler hole without screwing it in and then remove it again to check the oil level NOTE The e...

Page 51: ...gine oil filler cap and drain bolt to drain the oil from the oil tank 6 Place an oil pan under the engine to collect the used oil 7 Remove engine oil drain bolts A and B to drain the oil from the crankcase NOTE Skip steps 8 10 if the oil filter cartridge is not being replaced 8 Remove the oil filter cartridge with an oil filter wrench NOTE An oil filter wrench is available at a Yamaha dealer 9 App...

Page 52: ... and then gradually fill the oil tank with the remaining oil quantity while regularly checking the oil lev el on the dipstick NOTE Be sure to wipe off spilled oil on any parts after the engine and exhaust sys tem have cooled down 1 O ring 1 Oil filter cartridge 2 Torque wrench Tightening torque Oil filter cartridge 17 Nm 1 7 m kgf 12 ft lbf Tightening torques Engine oil drain bolt A crankcase 43 N...

Page 53: ...everal minutes while checking it for oil leakage If oil is leaking im mediately turn the engine off and check for the cause 17 Turn the engine off and then check the oil level and correct it if necessary 18 Install the rider seat EAU20051 Transfer case oil The transfer case must be checked for oil leakage before each ride If any leakage is found have a Yamaha deal er check and repair the vehicle I...

Page 54: ...ould 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 EAU21401 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 by a Yamaha dealer at the intervals specified in the pe...

Page 55: ...ld keep the following precautions in mind NEVER OVERLOAD THE MOTORCYCLE Operation of an overloaded motorcycle may re sult in tire damage loss of con trol or severe injury Make sure that the total weight of rider passenger cargo and accesso ries does not exceed the speci fied maximum load for the vehicle Do not carry along loosely packed items which can shift during a ride Securely pack the heavies...

Page 56: ...istics of the vehicle cannot be guaranteed After extensive tests only the tires listed below have been ap proved for this model by Yamaha Motor Co Ltd WARNING EWA10470 Have a Yamaha dealer replace excessively worn tires Besides being illegal operating the vehi cle with excessively worn tires decreases riding stability and can lead to loss of control The replacement of all wheel and brake related p...

Page 57: ...lutch adjusting the clutch lever free play is not needed However it is necessary to check the clutch fluid level and check the hydraulic system for leakage before each ride If the clutch lever free play does become excessive and shifting becomes rough or clutch slippage occurs causing poor acceler ation there may be air in the clutch sys tem If there is air in the hydraulic system have a Yamaha de...

Page 58: ...eck 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 EAU22500 Rear brake pads Check each rear brake pad for damage and measure the lining thickness If a brake pad is damaged or if the lining thickness is less than 0 8 mm 0 03 in have a Yamaha dealer replace the brake pads as...

Page 59: ...f 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 voir when refill...

Page 60: ...ied in the periodic maintenance and lubri cation chart EAU38410 To check the drive belt slack 1 Place the vehicle on the sidestand 2 Note the current position of the drive belt using the marks near the drive belt check hole NOTE The marks near the drive belt check hole are 5 0 mm 0 2 in apart 3 Note the position of the drive belt with a force of 45 N 4 5 kgf 10 lbf applied to the belt with a belt ...

Page 61: ...on and will cause the inner cable to rust Replace a damaged cable as soon as possible to prevent unsafe conditions EAU23111 Checking and lubricating the throttle grip and cable The operation of the throttle grip should be checked before each ride In addi tion the cable should be lubricated at the intervals specified in the periodic maintenance chart EAU44271 Checking and lubricating the brake and ...

Page 62: ...ers Brake lever Clutch lever The operation of the brake and clutch levers should be checked before each ride and the lever pivots should be lu bricated if necessary Recommended lubricant Lithium soap based grease Recommended lubricant Silicone grease U5C4E2E0 book Page 19 Friday September 7 2007 4 17 PM ...

Page 63: ...271 Checking 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 ve...

Page 64: ...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 Yamah...

Page 65: ...ontact 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 mediately call a physician EYES Flush with water for 15 minutes and seek prompt medical attention Batteries produce explosive hy drogen gas Therefore keep sparks...

Page 66: ... 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 Using a conventional battery charger will damage the battery If you do not have access to a sealed type MF battery charg er have a Yamaha dealer charge your ba...

Page 67: ...n to check if the device operates 4 If the fuse immediately blows again have a Yamaha dealer check the electrical system 1 Fuse box 2 Auxiliary DC connector fuse 3 Signaling system fuse 4 Ignition fuse 5 Backup fuse for odometer clock and immo bilizer system 6 ECU Electronic Control Unit fuse 7 Headlight fuse 8 Parking lighting fuse 9 Spare fuse Specified fuses Main fuse 50 0 A Headlight fuse 20 0...

Page 68: ...nit 1 Remove the headlight body cover by removing the bolts 2 Disconnect the coupler shown 3 Remove the headlight unit by re moving the screws To replace the high beam headlight bulb 1 Remove the headlight bulb holder cover by turning it counterclock wise 1 Low beam headlight bulb 2 High beam headlight bulb 1 Bolt 2 Headlight body cover 1 Coupler 1 Screw 1 Headlight bulb holder cover U5C4E2E0 book...

Page 69: ...rwise the transpar ency of the glass the luminosity of the bulb and the bulb life will be adversely affected Thor oughly clean off any dirt and fin gerprints on the headlight bulb using a cloth moistened with al cohol or thinner Headlight lens Do not affix any type of tinted film or stickers to the headlight lens Do not use a headlight bulb of a wattage higher than specified 5 Connect the coupler ...

Page 70: ...sely affected Thor oughly clean off any dirt and fin gerprints on the headlight bulb using a cloth moistened with al cohol or thinner Headlight lens Do not affix any type of tinted film or stickers to the headlight lens Do not use a headlight bulb of a wattage higher than specified 3 Connect the headlight coupler Installing the headlight unit 1 Install the headlight unit by install ing the screws ...

Page 71: ...erclockwise 2 Remove the defective bulb by pushing it in and turning it counter clockwise 3 Insert a new bulb into the socket push it in and then turn it clock wise until it stops 4 Install the lens by turning it clock wise and then installing the screw CAUTION ECA11190 Do not overtighten the screw other wise the lens may break EAU24330 License plate light If the license plate light does not come ...

Page 72: ...nterstand follow these precautions when removing the front and rear wheel or performing other maintenance requiring the motorcycle to stand 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 ...

Page 73: ...ause poor starting and loss of power The following troubleshooting chart represents a quick and easy procedure 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 ...

Page 74: ... 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 The engine...

Page 75: ... the muffler outlet with a plastic bag after the engine has cooled down 2 Make sure that all caps and covers as well as all electrical couplers and connectors including the spark plug caps are tightly in stalled 3 Remove extremely stubborn dirt like oil burnt onto the crankcase with a degreasing agent and a brush but never apply such prod ucts onto seals gaskets the drive belt and wheel axles Alwa...

Page 76: ...ter Use a toothbrush or bottlebrush for hard to reach areas Stubborn dirt and insects will come off more easily if the area is covered with a wet cloth for a few minutes before cleaning After riding in the rain near the sea or on salt sprayed roads Since sea salt or salt sprayed on roads during winter are extremely corrosive in combination with water carry out the following steps after each ride i...

Page 77: ... wax spar ingly and make sure to wipe off any excess Never apply oil or wax to the drive belt Never apply oil or wax to any rubber and plastic parts but treat them with a suitable care product Avoid using abrasive polishing compounds as they will wear away the paint NOTE Consult a Yamaha dealer for advice on what products to use EAU26280 Storage Short term Always store your motorcycle in a cool dr...

Page 78: ...o ground the spark plug electrodes while turning the engine over 4 Lubricate all control cables and the pivoting points of all levers and pedals as well as of the side stand centerstand 5 Check and if necessary correct the tire air pressure and then lift the motorcycle so that both of its wheels are off the ground Alterna tively turn the wheels a little every month in order to prevent the tires fr...

Page 79: ...cement 4 90 L 5 18 US qt 4 31 Imp qt Transfer gear oil Type SAE 80 API GL 4 Hypoid gear oil Quantity 0 55 L 0 58 US qt 0 48 Imp qt Air filter Air filter element Oil coated paper element Fuel Recommended fuel Premium unleaded gasoline only Fuel tank capacity 17 0 L 4 49 US gal 3 74 Imp gal Fuel reserve amount 3 0 L 0 79 US gal 0 66 Imp gal Fuel injection Throttle body Manufacturer MIKUNI Type quant...

Page 80: ...el type Cast wheel Rim size 17M C x MT5 50 Front brake Type Dual disc brake Operation Right hand operation Recommended fluid DOT 4 Rear brake Type Single disc brake Operation Right foot operation Recommended fluid DOT 4 Front suspension Type Telescopic fork Spring shock absorber type Coil spring oil damper Wheel travel 130 0 mm 5 12 in Rear suspension Type Swingarm link suspension Spring shock abs...

Page 81: ...r light LED Fuel level warning light LED Engine trouble warning light LED Immobilizer system indicator light LED Fuses Main fuse 50 0 A Headlight fuse 20 0 A Signaling system fuse 10 0 A Ignition fuse 25 0 A Parking lighting fuse 10 0 A ECU Electronic Control Unit fuse 10 0 A Fuel injection system fuse 15 0 A Auxiliary DC connector fuse 3 0 A Backup fuse 10 0 A U5C4E2E0 book Page 3 Friday Septembe...

Page 82: ...tification 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 may be used to register your mo...

Page 83: ... is affixed to the frame under the rider seat See page 3 15 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 U5C4E2E0 book Page 2 Friday September 7 2007 4 17 PM ...

Page 84: ...numbers 9 1 Ignition circuit cut off system 3 20 Immobilizer system 3 1 Immobilizer system indicator light 3 4 Indicator and warning lights 3 4 K Key identification number 9 1 L License plate light 6 28 M Main switch steering lock 3 2 Matte color caution 7 1 Model label 9 2 Multi function meter unit 3 5 N Neutral indicator light 3 4 P Parking 5 4 Part locations 2 1 Periodic maintenance and lubrica...

Page 85: ...INDEX V Valve clearance 6 11 Vehicle identification number 9 1 W Wheel bearings checking 6 22 Wheels 6 14 U5C4E2E0 book Page 2 Friday September 7 2007 4 17 PM ...

Page 86: ...A5 yoko_Blank fm Page 1 Tuesday April 8 2003 11 43 AM ...

Page 87: ...A5 yoko_Blank fm Page 1 Tuesday April 8 2003 11 43 AM ...

Page 88: ...PRINTED ON RECYCLED PAPER YAMAHA MOTOR CO LTD PRINTED IN JAPAN 2007 09 0 3 1 CR E ...

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