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Yamaha ROAD STAN XV17AC, Owner'S Manual, Page: 74 / 105

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Yamaha ROAD STAN XV17AC Owner'S Manual Download Page 74

PERIODIC MAINTENANCE AND MINOR REPAIR

6-29

6

EAU23140

Checking and lubricating the 
brake and clutch levers 

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 (all-pur-
pose grease)

Recommended lubricant:

Lithium-soap-based grease (all-pur-
pose grease)

U5VN11E0.book  Page 29  Tuesday, April 13, 2004  5:24 PM

Summary of Contents for ROAD STAN XV17AC

Page 1: ...5VN 28199 11 LIT 11626 18 15 XV17AT C XV17AWT C XV17AMT C XV17ATT C XV17ATMT C OWNER S MANUAL ...

Page 2: ...EAU10041 U5VN11E0 book Page 1 Tuesday April 13 2004 5 24 PM ...

Page 3: ...rcycle 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 high s...

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 WA...

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 U5VN11E0 book Page 2 Tuesday April 13 2004 5 24 PM ...

Page 6: ...y Yamaha Motor Corporation U S A 1st edition March 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 15 AFFIX DEALER LABEL HERE U5VN11E0 book Page 3 Tuesday April 13 2004 5 24 PM ...

Page 7: ...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 the panel 6 8 Checking the spark plugs 6 8 Canister for California only 6 10 Engine oil and oil filter cartridge 6 10 Transfer case oil 6 13 Cleaning the air filter ...

Page 8: ...n signal light bulb 6 36 Replacing a license plate light bulb 6 36 Supporting the motorcycle 6 37 Troubleshooting 6 38 Troubleshooting chart 6 39 MOTORCYCLE CARE AND STORAGE 7 1 Care 7 1 Storage 7 4 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 STREET AND ENDU...

Page 9: ...ts 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 motoris...

Page 10: ...ce 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 engin...

Page 11: ...he proper selection in stallation and use of non Yamaha accessories 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 tha...

Page 12: ...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 fall over Do not park the motorcycle near a...

Page 13: ...SAFETY INFORMATION 1 5 1 EAU10381 Location of important labels Please read the following important labels carefully before operating this vehicle U5VN11E0 book Page 5 Tuesday April 13 2004 5 24 PM ...

Page 14: ...SAFETY INFORMATION 1 6 1 XV17ATM 1 5 2 3 6 4 7 XV17AT XV17ATM California only XV17AT 4NL F8446 00 U5VN11E0 book Page 6 Tuesday April 13 2004 5 24 PM ...

Page 15: ... C XV17AW C XV17AM C 1 Shift pedal page 3 6 2 Starter choke knob page 3 9 3 Fuel cock page 3 8 4 Engine oil filler cap page 6 10 5 Battery page 6 32 6 Owner s tool kit page 6 1 7 Fuse page 6 33 U5VN11E0 book Page 1 Tuesday April 13 2004 5 24 PM ...

Page 16: ...17ATM C 1 Shift pedal page 3 6 2 Starter choke knob page 3 9 3 Fuel cock page 3 8 4 Engine oil filler cap page 6 10 5 Battery page 6 32 6 Owner s tool kit page 6 1 7 Fuse page 6 33 U5VN11E0 book Page 2 Tuesday April 13 2004 5 24 PM ...

Page 17: ... 1 Passenger footrest 2 Fuel tank page 3 7 3 Fuel tank cap page 3 7 4 Brake pedal page 3 6 5 Rider footrest 6 Air filter element page 6 14 7 Shock absorber assembly spring preload adjusting nut page 3 14 8 Muffler U5VN11E0 book Page 3 Tuesday April 13 2004 5 24 PM ...

Page 18: ...age 3 7 2 Fuel tank cap page 3 7 3 Windshield page 3 11 4 Brake pedal page 3 6 5 Rider footrest 6 Air filter element page 6 14 7 Shock absorber assembly spring preload adjusting nut page 3 14 8 Muffler U5VN11E0 book Page 4 Tuesday April 13 2004 5 24 PM ...

Page 19: ... XV17AM C 1 Clutch lever page 3 5 2 Left handlebar switches page 3 4 3 Speedometer unit page 3 2 4 Main switch steering lock page 3 1 5 Right handlebar switches page 3 4 6 Throttle grip page 6 16 7 Brake lever page 3 6 U5VN11E0 book Page 5 Tuesday April 13 2004 5 24 PM ...

Page 20: ...ever page 3 5 2 Left handlebar switches page 3 4 3 Speedometer unit page 3 2 4 Main switch steering lock page 3 1 5 Right handlebar switches page 3 4 6 Throttle grip page 6 16 7 Brake lever page 3 6 U5VN11E0 book Page 6 Tuesday April 13 2004 5 24 PM ...

Page 21: ...ed EAU10680 LOCK The steering 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 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 in and then turn it to OFF while still pushing it WARNING EWA10060 Never turn the key to OFF...

Page 22: ...is defective When this occurs have a Yamaha dealer check the self diagnosis 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 EAU11701 Speedometer unit The speedometer unit is equipped with a speedometer an odometer and two tripmeters The sp...

Page 23: ...0 r min EAU12090 Self diagnosis device This model is equipped with a self diag nosis device for various electrical cir cuits If any of those circuits are defective the engine trouble warning light will come on or flash If this occurs have a Yamaha dealer check the vehicle CAUTION ECA11170 To prevent engine damage be sure to consult a Yamaha dealer as soon as possible if this occurs EAU12140 Fuel g...

Page 24: ... hour display will flash 4 Push the right button to change the hours 5 Push the left button and only the minute display will flash 6 Push the right button to change the minutes 7 Push the left button and both the hours and minutes will flash 8 Push the right button for two sec onds to set the clock EAU12343 Handlebar switches Left Right 1 Clock 2 Set button 3 Mode button 1 Dimmer switch 2 Turn sig...

Page 25: ...ot self cancel while you are stopped at an intersec 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 CA...

Page 26: ...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 U5...

Page 27: ...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 EWA10...

Page 28: ... extend spark plug life and reduce maintenance 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 EAU13560 Fuel cock The fuel co...

Page 29: ... Fill the tank at the first oppor tunity Be sure to set the lever back to ON after refueling 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 end positioned over ON 1 Pointed end positioned over RE...

Page 30: ...seat To remove the rider seat 1 Insert the key into the main switch and then turn it counterclockwise to OPEN NOTE Do not push inward when turning the key 2 Pull the rider seat off To install the rider seat 1 Insert the projection on the rear of the rider seat into the seat holder as shown and then push the front of the seat down to lock it in place 2 Remove the key from the main switch if the mot...

Page 31: ... con trol and possibly an accident To release the helmet from the hel met holder Remove the rider seat remove the hel met from the helmet holder and then install the seat EAU14580 Windshield XV17AT C XV17ATM C To suit the rider s preference the wind shield angle can be adjusted and the height can be changed to one of two positions To adjust the windshield angle 1 Loosen the bolts on each side of t...

Page 32: ...ise an accident or injury could result EAU14613 Saddlebags XV17AT C WARNING EWA11111 Improper loading or overloading can cause loss of control and possibly an accident or personal injury See pages 1 5 and 6 17 for important loading and tire pressure informa tion Always securely close each saddlebag before riding Distribute weight evenly on each side of the motorcycle Do not exceed the load limit o...

Page 33: ...ng Distribute weight evenly on each side of the motorcycle Do not exceed the load limit of 5 kg 11 lb for each sidecase Do not exceed the maximum load of XV17ATM C 179 kg 395 lb for the vehicle Do not exceed 120 km h 80 mi h when riding with luggage in the sidecases otherwise han dling could be affected Improp er loading poor tire or overall motorcycle conditions poor road surfaces or adverse weat...

Page 34: ...er attempt to turn an adjusting mechanism beyond the maximum or minimum settings Adjust the spring preload as follows 1 Loosen the 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 The spring preload setting is deter mined by m...

Page 35: ...t 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 have a Yamaha dealer service the shock absorber 1 Distance A Spring preload Mi...

Page 36: ...g the respon sibility of raising the sidestand be fore starting off Therefore check this system regularly as described below and have a Yamaha dealer re pair it if it does not function proper ly EAU15311 Ignition circuit cut off system The ignition circuit cut off system com prising the sidestand switch clutch switch and neutral switch has the fol lowing functions It prevents starting when the tra...

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: ...quences 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 w...

Page 39: ... necessary add recommended brake fluid to specified level Check hydraulic system for leakage 6 23 6 24 6 25 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 24 6 25 Clutch Check operation...

Page 40: ...ch 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 30 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 c...

Page 41: ... lever pulled 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 16 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 tra...

Page 42: ...rter choke turned off To avoid the possi bility of excessive exhaust emissions never leave the starter choke on long er than necessary The time necessary for starter choke use depends upon the ambient temperature Tempera tures above 10 C 50 F require about 7 seconds of starter choke use and temperatures below 10 C 50 F re quire about 35 seconds with the starter choke turned on then about 2 5 min u...

Page 43: ...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 44: ...es During this period prolonged full throt tle operation or any condition that might result in engine overheating must be avoided EAU17071 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 ECA10891 After 1000 km 600 mi of operation the engine oil and transfer case oil must be changed and the oil filter cart...

Page 45: ...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 U5VN11E0 book Page 5 Tuesday April 13 2004 5 24 PM ...

Page 46: ...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 47: ...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 U5VN11E0 book Page 2 Tuesday April 13 2004 5 24 PM ...

Page 48: ...ks or damage Replace if 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 Adjust if necessary Every 16000 mi 25000 km 5 Crankcase breather system Check breather hose for cracks or damage Replace if necessary 6 Idle speed Check a...

Page 49: ...ust or replace cable 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 For cast wheel models Check runout and for damage Replace if necessary 7 Wheels For spoke wheel model Check runout s...

Page 50: ...ers Check all chassis fitting and fas teners Correct if necessary 14 Brake and clutch le ver pivot shafts Apply lithium soap based grease all purpose grease lightly 15 Brake and shift ped al pivot shafts Apply lithium soap based grease all purpose grease lightly 16 Sidestand pivot Check operation Apply lithium soap based grease all purpose grease lightly 17 Sidestand switch Check operation and rep...

Page 51: ...e 23 Transfer case oil Check for leakage Change at initial 600 mi 1000 km or 1 month and thereafter every 16000 mi 25000 km or 24 months Change Change 24 Control cables Apply Yamaha chain and cable lube or engine oil SAE 10W 30 thoroughly 25 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 52: ...sually wet or dusty areas Hydraulic brake service After disassembling the brake master cylinders and calipers always change the fluid Regularly check the brake fluid levels and fill the reservoirs as required Every two years replace the internal components of the brake master cylinders and calipers and change the brake fluid Replace the brake hoses every four years and if cracked or damaged U5VN11...

Page 53: ... then install the bolt EAU19543 Checking the spark plugs The spark plugs are important engine components which are easy to check Since heat and deposits will cause any spark plug to slowly erode the spark plugs should be removed and checked in accordance with the periodic mainte nance and lubrication chart In addition the condition of the spark plugs can re veal the condition of the engine To remo...

Page 54: ...g 1 Measure the spark plug gap with a wire thickness gauge and if nec essary adjust the gap to specifica tion 2 Clean the surface of the spark plug gasket and its mating surface and then wipe off any grime from the spark plug threads 3 Install the spark plug with the spark plug wrench and then tight en it to the specified torque NOTE If a torque wrench is not available when installing a spark plug...

Page 55: ...d hold it in an upright posi tion NOTE Make sure that the vehicle is positioned straight up when checking the oil level A slight tilt to the side can result in a false reading 2 Remove the rider seat See page 3 10 3 Start the engine warm it up until the engine oil has reached a nor mal temperature of 60 C 140 F let it continue to idle for ten sec onds and then turn the engine off NOTE To achieve t...

Page 56: ...e is run ning To change the engine oil with or without oil filter cartridge replace ment 1 Start the engine warm it up for several minutes and then turn it off 2 Place an oil pan under the oil tank to collect the used oil 3 Remove the engine oil filler cap and drain bolt to drain the oil from the oil tank NOTE Skip steps 4 8 if the oil filter cartridge is not being replaced 4 Place an oil pan unde...

Page 57: ...ly checking the oil lev el on the dipstick CAUTION ECA11620 In order to prevent clutch slip page since the engine oil also lubricates the clutch do not mix any chemical additives Do not use oils with a diesel 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 13...

Page 58: ...e vehicle is positioned straight up when checking the oil level A slight tilt to the side can result in a false reading 2 Remove the oil check bolt and then check the oil level in the trans fer case NOTE The oil should be at the brim of the check hole 3 If the oil is below the brim of the check hole remove the oil filler cap add sufficient oil of the recom mended type to raise it to the cor rect l...

Page 59: ...sfer case for oil leakage If oil is leaking immediately turn the en gine off and check for the cause EAU20652 Cleaning the air filter element The air filter element should be cleaned at the intervals specified in the periodic maintenance and lubrication chart Clean the air filter element more fre quently if you are riding in unusually wet or dusty areas 1 Remove the air filter case bolts 2 Loosen ...

Page 60: ...and dirt and then blow the remaining dirt out with compressed air as shown If the air filter element is damaged replace it 7 Install the air filter element by in serting it into the air filter case then installing the screws and then connect the hose shown 8 Install the air filter case cover by in stalling the screws 9 Connect the hoses shown 1 Air filter joint clamp screw 1 Screw 2 Hose 3 Air fil...

Page 61: ...ts emission control sys tem which requires very sophisticated adjustment Therefore carburetor ad justments should be left to Yamaha dealer who has the necessary profes sional knowledge and experience EAU21380 Adjusting the throttle cable 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 s...

Page 62: ...t temperature The tire air pressure must be ad justed in accordance with the riding speed and with the total weight of rider passenger car go and accessories approved for this model WARNING EWA10510 Proper loading of your vehicle is im portant for several characteristics of your vehicle such as handling braking performance and safety Do not carry loosely packed items that can shift Securely pack y...

Page 63: ...l wheel and brake related parts includ ing the tires should be left to a Yamaha dealer who has the necessary professional knowl edge and experience It is not recommended to patch a punctured tube If unavoid able however patch the tube very carefully and replace it as soon as possible with a high quality product Tire information This motorcycle is equipped with spoke wheels and tube tires WARNING E...

Page 64: ...rcycle 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 heaviest items close to the center of the motorcycle and distribute the weight evenly on both sides Adjust the...

Page 65: ... form to the limits specified by the regulations of your own country WARNING EWA10580 It is dangerous to ride with a worn out tire When a tire tread begins to show crosswise lines have a Yamaha dealer replace the tire immediately The replacement of all wheel and brake related parts includ ing the tires should be left to a Yamaha dealer who has the necessary professional knowl edge and experience 1...

Page 66: ...amaha dealer re place 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 or replaced An unbalanced wheel can result in poor performance adverse han dling characteristics and a short ened tire life Ride at moderate speeds after changing a tire since the tire sur f...

Page 67: ...lay turn the adjusting bolt in di rection a To decrease the clutch lever free play turn the adjusting bolt in direction b NOTE If the specified clutch lever free play could be obtained as described above tighten the locknut and skip the rest of the procedure otherwise proceed as follows 3 Fully turn the adjusting bolt at the clutch lever in direction a to loos en the clutch cable 4 Loosen the lock...

Page 68: ...r 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 brake is working properly A soft or spongy feeling in the brake lever can indicate the presence of air in the hydraulic system If there is air in...

Page 69: ...Each front brake pad is provided with a wear indicator which allows you to check the brake pad wear without hav ing to disassemble the brake To check the brake pad wear check the position of the wear indicator while applying the brake If a brake pad has worn to the point that the wear indicator almost touches the brake disc have a Yamaha dealer replace the brake pads as a set EAU22470 Rear brake p...

Page 70: ...he recommended quality brake fluid otherwise the rubber seals may deteriorate causing leakage and poor braking perfor mance Refill with the same type of brake fluid Mixing fluids may result in a harmful chemical reaction and lead to poor braking performance Be careful that water does not en ter the brake fluid reservoir when refilling Water will significantly lower the boiling point of the fluid a...

Page 71: ...ntenance and lubri cation chart EAU23062 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 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 N...

Page 72: ...ion b and then push the rear wheel forward NOTE Turn each adjusting bolt the same amount for proper wheel alignment 4 Tighten the locknuts CAUTION ECA10880 Improper drive belt slack will over load the engine Keep the drive belt slack within the specified range 5 Tighten the axle nut and the brake caliper bracket bolt to the specified torques 1 Axle nut 1 Brake caliper bracket bolt 1 Drive belt sla...

Page 73: ...able movement Replace damaged ca bles as soon as possible to prevent unsafe conditions EAU23110 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 or replaced at the intervals specified in the periodic maintenance chart EAU23131 Checking and lubricating the brake and shift pedals The...

Page 74: ...ever 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 all pur pose grease Recommended lubricant Lithium soap based grease all pur pose grease U5VN11E0 book Page 29 Tuesday April 13 2004 5 24 PM ...

Page 75: ...odic 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 level sur face and hold it in an upright posi tion 2 While applying the front brake push down hard on the handlebars several tim...

Page 76: ...y 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 Yamaha dealer check or repair the steering EAU23290 Checking the wheel bearings The front and rear wheel bearings must be checked at the intervals specified in the periodic maintenance and lubrica tion chart ...

Page 77: ...oduce explosive hy drogen gas Therefore keep sparks flames cigarettes etc away from the battery and pro vide sufficient ventilation when charging it in an enclosed space KEEP THIS AND ALL BATTER IES OUT OF THE REACH OF CHILDREN To charge the battery Have a Yamaha dealer charge the bat tery as soon as possible if it seems to have discharged Keep in mind that the battery tends to discharge more quic...

Page 78: ...ealer charge your battery EAU23524 Replacing the fuses The main fuse and the fuse box which contains the fuses for the individual cir cuits are located behind panel A See page 6 8 If a fuse is blown replace it as follows 1 Turn the key to OFF and turn off the electrical circuit in question 2 Remove the blown fuse and then install a new fuse of the specified amperage 1 Bolt 1 Signaling system fuse ...

Page 79: ...23792 Replacing 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 Specified fuses Main fuse 30 0 A Signaling system fuse 10 0 A Ignition fuse 15 0 A Headlight fuse XV17A 15 0 A XV17AW 15 0 A XV17AM 20 0 A XV...

Page 80: ...e headlight bulb to keep it free from oil otherwise the transparency 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...

Page 81: ...ng 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 installing the screw CAUTION ECA11190 Do not overtighten the screw other wise the lens may break EAU31961 Replacing a license plate light bulb 1 Remove the license plate light unit by removing the bolts 2 Remove the license plate light socket tog...

Page 82: ...e 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 front wheel off the ground b...

Page 83: ...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 may look like Yamaha parts but they are often infer...

Page 84: ...ition 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 turns over qu...

Page 85: ...do not leave the cleaner on the af fected area any longer than in structed Also thoroughly rinse the area off with water immedi ately dry it and then apply a cor rosion protection spray Improper cleaning can damage windshields cowlings panels and other plastic parts Use only a soft clean cloth or sponge with mild detergent and water to clean plastic Do not use any harsh chemical products on plasti...

Page 86: ...rong acid cleaner gasoline brake fluid or any other solvent Clean the windshield with a cloth or sponge dampened with a neutral detergent and after cleaning thoroughly wash it off with water For additional cleaning use Yamaha Wind shield Cleaner or other quality cleaner Some cleaning compounds for plastics may leave scratches on surfaces of the windshield Before using them make a test by polishing...

Page 87: ...ean the saddlebag on each side us ing a high quality saddle soap Rub the surface of the soap using a damp cloth or sponge to produce a lather and then apply it to the surface of the saddle bags Allow the lather to dry and then polish the saddlebags with a soft cloth If the saddlebags have been exposed to severe weather conditions and have become faded or been scuffed use a fine boot creme to retur...

Page 88: ...caps and spark plugs b Pour a teaspoonful of engine oil into each spark plug bore c Install the spark plug caps onto the spark plugs and then place the spark plugs on the cylinder head so that the electrodes are grounded This will limit spark ing during the next step d Turn the engine over several times with the starter This will coat the cylinder walls with oil e Remove the spark plug caps from t...

Page 89: ...CYCLE CARE AND STORAGE 7 5 7 C 90 F For more information on storing the battery see page 6 32 NOTE Make any necessary repairs before storing the motorcycle U5VN11E0 book Page 5 Tuesday April 13 2004 5 24 PM ...

Page 90: ...ice SE SF SG type or higher Engine oil quantity Without oil filter cartridge replacement 3 70 L 3 91 US qt 3 26 Imp qt With oil filter cartridge replacement 4 10 L 4 33 US qt 3 61 Imp qt Transfer gear oil Type SAE80 API GL 4 Hypoid gear oil Quantity 0 40 L 0 42 US qt 0 35 Imp qt Air filter Air filter element Dry element Fuel Recommended fuel Unleaded gasoline only Fuel tank capacity 20 0 L 5 28 US...

Page 91: ...404 Loading Maximum load XV17A 194 kg 428 lb XV17AW 194 kg 428 lb XV17AM 194 kg 428 lb XV17AT 179 kg 395 lb XV17ATM 179 kg 395 lb Total weight of rider passenger cargo and accessories Tire air pressure measured on cold tires Loading condition 0 90 kg 0 198 lb Front 250 kPa 36 psi 2 50 kgf cm Rear 250 kPa 36 psi 2 50 kgf cm Loading condition XV17A 90 194 kg 198 428 lb XV17AW 90 194 kg 198 428 lb XV...

Page 92: ...lb type Halogen bulb Bulb voltage wattage x quantity Headlight 12 V 60 W 55 0 W 1 Tail brake light LED Front turn signal position light 12 V 23 W 8 0 W 2 Rear turn signal light 12 V 21 0 W 2 Licence plate light 12 V 5 0 W 1 Meter lighting 14 V 0 56 W x 4 Neutral indicator light 14 V 1 12 W High beam indicator light 14 V 1 12 W Turn signal indicator light 14 V 1 12 W Fuel level warning light LED En...

Page 93: ...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 94: ...l is affixed to the frame under the rider seat See page 3 10 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 U5VN11E0 book Page 2 Tuesday April 13 2004 5 24 PM ...

Page 95: ...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 96: ...cle 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 Ex...

Page 97: ...inder 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 98: ...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 U5VN11E0 book Page 6 Tuesday April 13 2004 5 24 PM ...

Page 99: ...CONSUMER INFORMATION 9 7 9 EAU26661 YAMAHA MOTOR CORPORATION U S A STREET AND ENDURO MOTORCYCLE LIMITED WARRANTY U5VN11E0 book Page 7 Tuesday April 13 2004 5 24 PM ...

Page 100: ...CONSUMER INFORMATION 9 8 9 U5VN11E0 book Page 8 Tuesday April 13 2004 5 24 PM ...

Page 101: ...d repairs There s no deductible to pay and repairs aren t pro rated You don t have any out of pocket expenses for covered repairs In addition Travel and Recreation Interruption Protection TRIP is included at no extra cost TRIP gives you up to 150 reimbursement per occurrence for any reasonable expenses you incur because your Yamaha needs covered service replacement vehicle rental emergency towing ...

Page 102: ...ed protection even after your Yamaha Limited Warranty expires A special note If visiting your dealer isn t convenient contact Yamaha with your Primary ID number your frame number We ll be happy to help you get the Y E S coverage you need Yamaha Service Marketing P O Box 6555 Cypress CA 90630 1 866 YES EXTD 1 866 937 3983 U5VN11E0 book Page 10 Tuesday April 13 2004 5 24 PM ...

Page 103: ... Indicator and warning lights 3 2 K Key identification number 9 1 L Labels location of 1 5 License plate light bulb replacing 6 36 M Main switch steering lock 3 1 Maintenance and lubrication periodic 6 4 Maintenance emission control system 6 3 Maintenance periodic 6 1 Maintenance record 9 5 Model label 9 2 N Neutral indicator light 3 2 Noise regulation 9 4 P Panel removing and installing 6 8 Parki...

Page 104: ...r light 3 2 Turn signal light bulb replacing 6 36 Turn signal switch 3 5 V Valve clearance adjusting 6 17 Vehicle identification number 9 1 W Warranty extended 9 9 Warranty limited 9 7 Wheel bearings checking 6 31 Wheels 6 21 Windshield XV17AT C XV17ATM C 3 11 U5VN11E0 book Page 2 Tuesday April 13 2004 5 24 PM ...

Page 105: ...PRINTED IN JAPAN 2004 04 1 3 1 CR E PRINTED ON RECYCLED PAPER YAMAHA MOTOR CO LTD ...

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