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Yamaha Road Star Warrior 2006, Owner'S Manual

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Yamaha Road Star Warrior 2006 Owner'S Manual Download Page 46

PERIODIC MAINTENANCE AND MINOR REPAIR

6-7

6

NOTE:

From 24000 mi (37000 km) or 36 months, repeat the maintenance intervals starting from 8000 mi (13000 km) or 12 months.

EAU17640

NOTE:

●

Air filters

• This model’s air filters are equipped with disposable oil-coated paper elements, which must not be cleaned with com-

pressed air to avoid damaging them.

• The air filter elements need to be replaced more frequently when riding in unusually 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.

U5PX15E0.book  Page 7  Tuesday, May 16, 2006  10:10 AM

Summary of Contents for Road Star Warrior 2006

Page 1: ...5PX 28199 15 XV17PCW C XV17PCMW C OWNER S MANUAL LIT 11626 20 22...

Page 2: ...EAU10041 U5PX15E0 book Page 1 Tuesday May 16 2006 10 10 AM...

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 t...

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 OPER...

Page 5: ...ECHNIQUES REGULAR INSPECTIONS AND CAREFUL MAINTENANCE ALONG WITH GOOD RIDING SKILLS WILL ENSURE THAT YOU SAFELY ENJOY THE CAPABILITIES AND THE RELIABILITY OF THIS MOTORCYCLE Product and specifications...

Page 6: ...Corporation U S A 1st edition April 2006 All rights reserved Any reprinting or unauthorized use without the written permission of Yamaha Motor Corporation U S A is expressly prohibited Printed in Japa...

Page 7: ...plugs 6 8 Canister for California only 6 9 Engine oil and oil filter cartridge 6 9 Transfer case oil 6 12 Replacing the air filter elements 6 13 Checking the throttle cable free play 6 16 Valve cleara...

Page 8: ...ND STORAGE 7 1 Care 7 1 Storage 7 3 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 MO...

Page 9: ...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 bri...

Page 10: ...ield 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 preventin...

Page 11: ...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...

Page 12: ...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 sy...

Page 13: ...SAFETY INFORMATION 1 5 1 EAU10381 Location of important labels Please read the following important labels carefully before operating this vehicle U5PX15E0 book Page 5 Tuesday May 16 2006 10 10 AM...

Page 14: ...SAFETY INFORMATION 1 6 1 2 4 California only 1 3 5 California only U5PX15E0 book Page 6 Tuesday May 16 2006 10 10 AM...

Page 15: ...0 Left view 1 Engine oil drain bolt crankcase page 6 9 2 Shift pedal page 3 6 3 Fuel tank cap page 3 7 4 Helmet holder page 3 10 5 Fuses page 6 32 6 Owner s tool kit page 6 1 U5PX15E0 book Page 1 Tues...

Page 16: ...ge 6 13 5 Front fork spring preload adjusting bolt page 3 10 6 Engine oil filter cartridge page 6 9 7 Brake pedal page 3 7 8 Engine oil drain bolt oil tank page 6 9 9 Shock absorber assembly spring pr...

Page 17: ...page 3 6 2 Left handlebar switches page 3 5 3 Speedometer page 3 3 4 Tachometer unit page 3 3 5 Main switch steering lock page 3 1 6 Right handlebar switches page 3 5 7 Throttle grip page 6 16 8 Brak...

Page 18: ...AU10660 OFF All electrical systems are off The key can be removed 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 handle...

Page 19: ...he elec trical circuit NOTE This model is also equipped with a self diagnosis device for the fuel level de tection circuit If the fuel level detection circuit is defective the following cycle will be...

Page 20: ...electrical circuit The tachometer unit is equipped with the following an odometer which shows the to tal distance traveled two tripmeters which show the distance traveled since they were last set to...

Page 21: ...d If you do not reset the fuel reserve tripmeter manually it will reset itself automatically and the display will return to the prior mode after refueling and 90 seconds have passed Meter lighting con...

Page 22: ...Turn signal switch To signal a right hand turn push this switch to To signal a left hand turn push this switch to When re leased the switch returns to the center position Since this model is equipped...

Page 23: ...the start switch is pushed but this does not indicate a malfunction EAU12820 Clutch lever The clutch lever is located at the left handlebar grip To disengage the clutch pull the lever toward the handl...

Page 24: ...070 Fuel tank cap To open the fuel tank cap Open the fuel tank cap lock cover in sert the key into the lock and then turn it 1 4 turn clockwise The lock will be re leased and the fuel tank cap can be...

Page 25: ...70 Immediately wipe off spilled fuel with a clean dry soft cloth since fuel may deteriorate painted surfac es or plastic parts EAU13360 CAUTION ECA11400 Use only unleaded gasoline The use of leaded ga...

Page 26: ...amaha because it can cause damage to the fuel system or ve hicle performance problems EAU34042 Rider seat To remove the rider seat 1 Insert the key into the seat lock and then turn it counterclockwise...

Page 27: ...the rider seat remove the hel met from the helmet holder and then install the seat EAU14720 Adjusting the front fork This front fork is equipped with spring preload adjusting bolts WARNING EWA10180 A...

Page 28: ...load 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 Use the speci...

Page 29: ...n production the actual number of clicks always represents the entire ad justing range To obtain a precise ad justment it would be advisable to check the number of clicks of the damping force adjustin...

Page 30: ...e 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...

Page 31: ...he 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...

Page 32: ...r 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 reliab...

Page 33: ...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 use...

Page 34: ...er 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 le...

Page 35: ...t operation is smooth Lubricate pedal pivoting points if necessary 6 27 Brake and clutch levers Make sure that operation is smooth Lubricate lever pivoting points if necessary 6 28 Sidestand Make sure...

Page 36: ...is in gear with the clutch 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 describ...

Page 37: ...ON 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...

Page 38: ...cator light should come on EAU16720 Recommended shift points The recommended shift points during acceleration and deceleration are shown in the table below EAU16841 Engine break in There is never a mo...

Page 39: ...cur during the engine break in period immediately have a Yamaha dealer check the vehi cle EAU17212 Parking When parking stop the engine and then remove the key from the main switch WARNING EWA10310 S...

Page 40: ...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 TH...

Page 41: ...RNING 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 U5PX...

Page 42: ...acks or damage Replace if necessary 2 Spark plugs Check condition Adjust gap and clean Replace every 8000 mi 13000 km or 12 months Replace Replace 3 Valve clearance Check and adjust valve clearance wh...

Page 43: ...Clutch Check operation Adjust 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 le...

Page 44: ...and clutch le ver pivot shafts Apply lithium soap based grease all purpose grease lightly 14 Brake and shift ped al pivot shafts Apply lithium soap based grease all purpose grease lightly 15 Sidestan...

Page 45: ...ter every 16000 mi 25000 km or 24 months Change Change 23 Front and rear brake switches Check operation 24 Control cables Apply Yamaha chain and cable lube or engine oil SAE 10W 30 thoroughly 25 Throt...

Page 46: ...ng them The air filter elements need to be replaced more frequently when riding in unusually wet or dusty areas Hydraulic brake service After disassembling the brake master cylinders and calipers alwa...

Page 47: ...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 othe...

Page 48: ...nd 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...

Page 49: ...y tightened otherwise oil may seep out when the engine is run ning To change the engine oil with or without oil filter cartridge replace ment 1 Remove the rider seat See page 3 9 2 Start the engine wa...

Page 50: ...ted 9 Install the new oil filter cartridge with an oil filter wrench and then tighten it to the specified torque with a torque wrench 10 Install the engine oil drain bolts and then tighten them to the...

Page 51: ...no foreign mate rial enters the crankcase 14 Install the engine oil filler cap 15 Start the engine and then let it idle for several minutes while checking it for oil leakage If oil is leaking im medi...

Page 52: ...cation chart Replace the air filter elements more frequently if you are riding in un usually wet or dusty areas Air filter case element To replace the air filter element 1 Remove the rider seat See pa...

Page 53: ...nect ed d Remove the hoses as shown and then remove the fuel tank by pulling it upward e Remove the foam damper 4 Remove the air filter case bolts 5 Loosen the air filter case joint clamp bolt and the...

Page 54: ...ter case cover by in stalling the screws 14 Install the air filter case by pushing it onto the air filter case joint and then tightening the clamp bolt 15 Install the air filter case by install ing th...

Page 55: ...r ele ment 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...

Page 56: ...ambient 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 EWA1...

Page 57: ...ced 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 br...

Page 58: ...e operating conditions EAU21960 Cast wheels To maximize the performance durabil ity and safe operation of your vehicle note the following points regarding the specified wheels The wheel rims should be...

Page 59: ...ment parts may cause loss of handling stability and riding safety Since Yamaha cannot control the quality of accessories or parts man ufactured by other companies Yamaha cannot be held liable for any...

Page 60: ...in direction b 6 Tighten the locknut at the clutch le ver and the crankcase EAU22092 Adjusting the brake lever free play The brake lever free play should mea sure 2 0 5 0 mm 0 08 0 20 in as shown Per...

Page 61: ...ect If necessary adjust the brake light switch as follows Turn the adjusting nut while holding the rear brake light switch in place To make the brake light come on earlier turn the adjusting nut in di...

Page 62: ...f the lining thickness is less than 0 8 mm 0 03 in have a Yamaha dealer replace the brake pads as a set 3 Install the brake caliper bolt and then tighten it to the specified torque EAU22580 Checking t...

Page 63: ...water does not en ter the brake fluid reservoir when refilling Water will significantly lower the boiling point of the fluid and may result in vapor lock Brake fluid may deteriorate paint ed surfaces...

Page 64: ...belt with a force of 45 N 4 6 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 subtracti...

Page 65: ...AU23091 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...

Page 66: ...e should be lubricated 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 c...

Page 67: ...and lubricating the sidestand The operation of the sidestand should be checked before each ride and the sidestand pivot and metal to metal contact surfaces should be lubricated if necessary WARNING EW...

Page 68: ...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...

Page 69: ...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 Sec...

Page 70: ...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 l...

Page 71: ...arged 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 wi...

Page 72: ...r check the electrical system 6 Install the battery cover and then hook the battery band onto the holder 1 Main fuse 2 Spare main fuse 1 Headlight fuse 2 Signaling system fuse 3 Ignition fuse 4 Fuel i...

Page 73: ...ep flammable products away from a lit headlight bulb and do not touch the bulb until it has cooled down 4 Place a new headlight bulb into po sition and then secure it with the bulb holder CAUTION ECA1...

Page 74: ...4180 Tail brake light This model is equipped with an LED type of tail brake light If the tail brake light does not come on have a Yamaha dealer check it EAU24210 Replacing a turn signal light bulb 1 R...

Page 75: ...ing the nuts washers and rubber dampers 2 Remove the license plate light lens by removing the nuts and washers 3 Remove the defective bulb by pull ing it out 4 Insert a new bulb into the socket 5 Inst...

Page 76: ...ng a motorcycle stand or if a motor cycle stand is not available by placing a jack either under each side of the frame in front of the rear wheel or under each side of the swingarm EAU25850 Troublesho...

Page 77: ...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 Yama...

Page 78: ...o 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 cleani...

Page 79: ...ng 1 Dry the motorcycle with a chamois or an absorbing cloth 2 Use a chrome polish to shine chrome aluminum and stainless steel parts including the exhaust system Even the thermally in duced discolori...

Page 80: ...cle for sev eral months 1 Follow all the instructions in the Care section of this chapter 2 Fill up the fuel tank and add fuel stabilizer if available to prevent the fuel tank from rusting and the fue...

Page 81: ...ry month in order to prevent the tires from becoming degraded in one spot 6 Cover the muffler outlet with a plastic bag to prevent moisture from entering it 7 Remove the battery and fully charge it St...

Page 82: ...ent 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 Oil coated paper element Fuel Recommended f...

Page 83: ...si 2 50 kgf cm Rear 250 kPa 36 psi 2 50 kgf cm Front wheel Wheel type Cast wheel Rim size 18M C x MT3 50 Rear wheel Wheel type Cast wheel Rim size 17M C x MT6 00 Front brake Type Dual disc brake Opera...

Page 84: ...indicator light LED High beam indicator light LED Turn signal indicator light LED Fuel level warning light LED Engine trouble warning light LED Fuses Main fuse 30 0 A Headlight fuse 15 0 A Signaling...

Page 85: ...tification 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 nu...

Page 86: ...l is affixed to the frame under the rider seat See page 3 9 Record the information on this label in the space provided This information will be needed when ordering spare parts from a Yamaha dealer 1...

Page 87: ...tigation 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 deale...

Page 88: ...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 o...

Page 89: ...der 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 40...

Page 90: ...RMATION 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 U5PX15E0 book Page 6 Tuesday May 16 2...

Page 91: ...CONSUMER INFORMATION 9 7 9 EAU26662 YAMAHA MOTOR CORPORATION U S A STREET AND ENDURO MOTORCYCLE LIMITED WARRANTY U5PX15E0 book Page 7 Tuesday May 16 2006 10 10 AM...

Page 92: ...CONSUMER INFORMATION 9 8 9 U5PX15E0 book Page 8 Tuesday May 16 2006 10 10 AM...

Page 93: ...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 inclu...

Page 94: ...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 hel...

Page 95: ...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...

Page 96: ...INDEX V Valve clearance 6 17 Vehicle identification number 9 1 W Warranty extended 9 9 Warranty limited 9 7 Wheel bearings checking 6 31 Wheels 6 19 U5PX15E0 book Page 2 Tuesday May 16 2006 10 10 AM...

Page 97: ...PRINTED IN JAPAN 2006 05 0 6 1 CR E PRINTED ON RECYCLED PAPER YAMAHA MOTOR CO LTD...

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