Yamaha Roadliner XV1900AV Owner'S Manual Download

Page: 66 / 86

PERIODIC MAINTENANCE AND MINOR REPAIR

6-23

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.

CAUTION:

ECA10640

Do not use a fuse of a higher amper-
age rating than recommended to
avoid causing extensive damage to
the electrical system and possibly a
fire.

3. Turn the key to “ON” and turn on

the electrical circuit in question 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 and clock)

6. ECU fuse

7. Headlight fuse
8. Parking lighting fuse

9. Spare fuse

Specified fuses:

Main fuse:

50.0 A

Headlight fuse:

20.0 A

Signaling system fuse:

10.0 A

Ignition fuse:

25.0 A

Fuel injection system fuse:

15.0 A

ECU fuse:

10.0 A

Auxiliary DC connector fuse:

3.0 A

Parking lighting fuse:

10.0 A

Backup fuse:

10.0 A

U5C520E0.book Page 23 Tuesday, April 4, 2006 10:48 AM

Summary of Contents for Roadliner XV1900AV

Page 1: ...5C5 28199 20 XV1900AV OWNER S MANUAL ...

Page 2: ...U5C520E0 book Page 2 Tuesday April 4 2006 10 48 AM ...

Page 3: ... to enjoy all advantages of your XV1900AV 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 de...

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 deat...

Page 5: ...ANUAL 2006 by Yamaha Motor Co Ltd 1st edition March 2006 All rights reserved Any reprinting or unauthorized use without the written permission of Yamaha Motor Co Ltd is expressly prohibited Printed in Japan U5C520E0 book Page 2 Tuesday April 4 2006 10 48 AM ...

Page 6: ... 2 Checking the spark plugs 6 5 Engine oil and oil filter cartridge 6 6 Transfer case oil 6 9 Air filter element 6 9 Checking the throttle cable free play 6 10 Valve clearance 6 10 Tires 6 10 Cast wheels 6 13 Clutch lever 6 13 Adjusting the rear brake light switch 6 13 Checking the front and rear brake pads 6 14 Checking the brake and clutch fluid levels 6 14 Changing the brake and clutch fluids 6...

Page 7: ...MOTORCYCLE CARE AND STORAGE 7 1 Care 7 1 Storage 7 3 SPECIFICATIONS 8 1 CONSUMER INFORMATION 9 1 Identification numbers 9 1 Motorcycle noise regulation for Australia 9 2 U5C520E0 book Page 2 Tuesday April 4 2006 10 48 AM ...

Page 8: ...nts 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 mo...

Page 9: ...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 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 e...

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 clear...

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 ...

Page 12: ...AFETY INFORMATION 1 5 1 EAU10381 Location of important labels Please read the following important labels carefully before operating this vehicle 1 2 3 4 U5C520E0 book Page 5 Tuesday April 4 2006 10 48 AM ...

Page 13: ...lea el Manual del Propietario 5RU 21568 00 Use PREMIUM unleaded gasoline with min 95 octane RON Utiliser une essence SUPER sans plomb d un indice d octane RON de min 95 Nur Super Bleifrei mit Mindestoktanzahl 95 ROZ tanken Utilizzare benzina PREMIUM super senza piombo con almeno 95 ottani RON Utilice gasolina sin plomo que tenga como mínimo 95 octanos RON 5PW 2415E 01 280 2 80 41 280 2 80 41 1D7 2...

Page 14: ...page 3 14 4 Main fuse page 6 22 5 Battery page 6 21 6 Owner s tool kit page 6 1 7 License plate light page 6 27 8 Tail brake light page 6 27 9 Engine oil drain bolt B crankcase page 6 6 10 Engine oil drain bolt A crankcase page 6 6 11 Shift pedal page 3 11 U5C520E0 book Page 1 Tuesday April 4 2006 10 48 AM ...

Page 15: ... 4 Fuse box page 6 22 5 Engine oil filler cap page 6 6 6 Fuel tank cap page 3 12 7 Front brake fluid reservoir page 6 14 8 Brake pedal page 3 12 9 Engine oil filter cartridge page 6 6 10 Engine oil drain bolt oil tank page 6 6 11 Shock absorber assembly spring preload adjusting nut page 3 16 U5C520E0 book Page 2 Tuesday April 4 2006 10 48 AM ...

Page 16: ... lever page 3 11 2 Left handlebar switches page 3 9 3 Multi function meter unit page 3 5 4 Main switch steering lock page 3 2 5 Right handlebar switches page 3 9 6 Throttle grip page 6 10 7 Brake lever page 3 11 U5C520E0 book Page 3 Tuesday April 4 2006 10 48 AM ...

Page 17: ...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 and keep the code re regis te...

Page 18: ...ghting 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 stalls EAU10660 OFF All electrical systems are off The key can be removed EAU10680 LOCK The steering is locked and all electrical systems are of...

Page 19: ...are off The key can be removed The steering must be locked before the key can be turned to CAUTION ECA11020 Do not use the parking position for an extended length of time other wise the battery may discharge EAU11003 Indicator and warning lights EAU11030 Turn signal indicator lights and The corresponding indicator light flash es when the turn signal switch is pushed to the left or right EAU11060 N...

Page 20: ...t 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 diagnosis system See page 3 5 for an explanation of the self diagnosis de vice 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...

Page 21: ... 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 NOTE Be sure to turn the key to ON before using the SELECT and RESET switches except for setting the bright ness control mode Speedometer The speedometer shows the riding speed When the key is turned to ON the speedometer needle will sweep once acros...

Page 22: ...uel as soon as possible When the key is turned to ON the fuel gauge needle will sweep once across the fuel level range and then return to the current amount in order to test the electrical circuit NOTE Do not allow the fuel tank to empty itself completely The fuel gauge does not indicate the correct fuel level for the first 5 km h 3 mi h after refueling Odometer tripmeter and clock modes Push the ...

Page 23: ...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 and then the odometer tripme ter clock display will indicate a two digit error code e g 12 13 14 This model is also equipped with a self diagnosis device for the immobilizer system If any of the immobilizer system circuits are defecti...

Page 24: ...CD item number 2 the speedometer tachometer and the fuel gauge needles item num ber 3 Select the brightness control mode as follows 1 Turn the key to OFF 2 Push and hold the SELECT switch 3 Turn the key to ON and then re lease the SELECT switch after five seconds Item number 1 is displayed 4 Adjust the multi function meter unit panel brightness level by pushing the RESET switch 5 Push the SELECT s...

Page 25: ...ushing the RESET switch 7 Push the SELECT switch The odometer tripmeter clock dis play will return to the prior mode EAU12346 Handlebar switches Left Right 1 LCD 2 Item number 3 Brightness level 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 Engine stop switch 2 Hazard switch 3 Start switch U5C...

Page 26: ...f an emergen cy such as when the vehicle overturns or when the throttle cable is stuck EAU12710 Start switch Push this switch to crank the engine with the starter CAUTION ECA10050 See page 5 1 for starting 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 malfunc...

Page 27: ... igni tion circuit cut off system See page 3 18 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 ...

Page 28: ...e 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 EWA1...

Page 29: ... 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 30: ...ter 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 Insert the key into the seat lock and then turn it counterclockwise 2 While holding the key in that posi tion lift the front of the seat up and then pull the seat off To install the rider seat 1 Insert the p...

Page 31: ... 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 attached to the helmet holder since the helmet may hit objects causing loss of con trol and possibly an accident To release the helmet f...

Page 32: ...t 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 deter mined by measuring distance A shown in the illustration The short er distance A is the higher the spring preload the longer distance A is the lower the spring preload With each complete turn of the ad justing nut distance A is changed by 2...

Page 33: ...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 EAU15281 EXUP system This model is equipped with Yamaha s EXUP EXhaust Ultimate Power valve system This system boosts engine power by means of a valve that regu lates the diameter of the exhaust pipe The EXUP system valve is constantly...

Page 34: ...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 35: ...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 36: ...15310 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 U5C520E0 book Page 20 Tuesday April 4 200...

Page 37: ...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 38: ...ied level Check hydraulic system for leakage 6 14 6 14 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 14 6 14 Clutch Check operation If soft or spongy have Yamaha dealer bleed hydraulic...

Page 39: ...ch levers Make sure that operation is smooth Lubricate lever pivoting points if necessary 6 18 Sidestand Make sure that operation is smooth Lubricate pivot if necessary 6 19 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 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 18 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 warn...

Page 41: ... the shift pedal down repeatedly until 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 A...

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 ...

Page 43: ...e 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 U5C520E0 book Page 4 Tuesday April 4 2006 10 48 AM ...

Page 44: ...re 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 14 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 wrenc...

Page 45: ...000 km ANNUAL CHECK 1 10 20 30 40 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 Check operation fluid level and vehicle for fluid leakage Replace brake pads Whenever worn to the limit 7 Rear bra...

Page 46: ...fasteners Make sure that all nuts bolts and screws are properly tightened 16 Sidestand Check operation Lubricate 17 Sidestand switch Check operation 18 Front fork Check operation and for oil leakage 19 Shock absorber assem bly Check operation and shock absorber for oil leakage 20 Rear suspension relay arm and connecting arm pivoting points Check operation Lubricate with lithium soap based grease 2...

Page 47: ...rs 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 24 Transfer case oil Check oil level Change 25 Front and rear brake switches Check operation 26 Moving parts and ca bles Lubricate 27 Throttle grip housing and cable Check operation and free play Adjust the throttle cable free play i...

Page 48: ...d 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 s...

Page 49: ...engine 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 ...

Page 50: ... and drain bolt to drain the oil from the oil tank 5 Place an oil pan under the engine to collect the used oil 6 Remove engine oil drain bolts A and B to drain the oil from the crankcase NOTE Skip steps 7 9 if the oil filter cartridge is not being replaced 7 Remove the oil filter cartridge with an oil filter wrench NOTE An oil filter wrench is available at a Yamaha dealer 8 Apply a thin coat of en...

Page 51: ...ining oil quantity while regularly checking the oil lev el on the dipstick CAUTION ECA15080 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 1 O ring 1 Oil filter cartridge 2 Torque wrench Tightening torque Oil filter cartridge 17 Nm 1 7 m kgf 12 ft lbf Tighten...

Page 52: ...nd correct it if necessary 17 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 In addi tion the transfer case oil level should be checked and the oil must be changed by a Yamaha dealer at the in tervals specified in the periodic mainte nance and lubrication...

Page 53: ...pecified in the periodic maintenance and lubrication chart EAU21780 Tires To maximize the performance durabil ity and safe operation of your motor cycle note the following points regarding the specified tires Tire air pressure The tire air pressure should be checked and if necessary adjusted before each ride WARNING EWA10500 The tire air pressure must be checked and adjusted on cold tires i e when...

Page 54: ...minimum tread depth if the tire has a nail or glass fragments in it or if the sidewall is cracked con tact a Yamaha dealer immediately and have the tire replaced 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 brak...

Page 55: ...ed tires Note the following points in order to make the most ef ficient use of these tires Use only the specified replace ment tires Other tires may run the danger of bursting at super high speeds Brand new tires can have a rela tively poor grip on certain road surfaces until they have been broken in Therefore it is ad visable before doing any high speed riding to ride conserva tively for approxim...

Page 56: ...clutch 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 d...

Page 57: ...heck 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 a...

Page 58: ...of each reservoir is level Use only the recommended quality brake fluid otherwise the rubber seals may deteriorate causing leakage and poor braking or clutch performance Refill with the same type of brake fluid Mixing fluids may result in a harmful chemical reaction and lead to poor braking or clutch per formance Be careful that water does not en ter the brake or clutch fluid reser voir when refil...

Page 59: ...fied 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 60: ...ion 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 EAU23131 Checking and lubricating the brake and...

Page 61: ...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 U5C520E0 book Page 18 Tuesday April 4 2006 10 48 AM ...

Page 62: ...ing the front fork The condition and operation of the front fork must be checked as follows at the intervals specified in the periodic main tenance and lubrication chart To check the condition WARNING EWA10750 Securely support the vehicle so that there is no danger of it falling over Check the inner tubes for scratches damage and excessive oil leakage To check the operation 1 Place the vehicle on ...

Page 63: ... 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 Yama...

Page 64: ... contact with skin eyes or clothing and al ways shield your eyes when working near batteries In case of contact administer the fol lowing FIRST AID EXTERNAL Flush with plenty of water INTERNAL Drink large quan tities of water or milk and im mediately call a physician EYES Flush with water for 15 minutes and seek prompt medical attention Batteries produce explosive hy drogen gas Therefore keep spar...

Page 65: ...y 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 b...

Page 66: ...n the electrical circuit in question 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 and clock 6 ECU fuse 7 Headlight fuse 8 Parking lighting fuse 9 Spare fuse Specified fuses Main fuse 50 0 A Headlight fuse 20 0 A Signal...

Page 67: ...ght unit 1 Remove the headlight cover by re moving 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 cover 1 Coupler 1 Screw 1 Headlight bulb holder cover U5C520E0 book Pag...

Page 68: ...erwise 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 69: ... 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 3 Connect the headlight coupler Installing the headlight unit 1 Install the headlight unit by install ing the s...

Page 70: ...nterclockwise 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 com...

Page 71: ...enterstand 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 72: ...cause 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 73: ...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 74: ...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 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 plastic...

Page 75: ...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 discoloring of stainless steel exhaust systems can be re moved through polishing 3 To prevent corrosion it is recom mended to apply a corrosion pro tection spray on all metal including chrome and nickel plat e...

Page 76: ...ycle 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 fuel from deteriorating 3 Perform the following steps to pro tect the cylinders piston rings etc from corrosion a Remove the spark plug caps and spark plugs b Pour a teaspoonful of engine oil into each ...

Page 77: ...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 Store it in a cool dry place and charge it once a month Do not store the battery in an ex cessively cold or warm place less than 0 C 30 F or more than 30 C 90 F For more information on storing the batte...

Page 78: ... qt With oil filter cartridge replacement 4 90 L 5 18 US qt 4 31 Imp qt Transfer gear oil Type SAE80 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 injector Manufacture...

Page 79: ... kgf cm Loading condition 90 210 kg 198 463 lb Front 250 kPa 36 psi 2 50 kgf cm Rear 280 kPa 41 psi 2 80 kgf cm High speed riding Front 250 kPa 36 psi 2 50 kgf cm Rear 280 kPa 41 psi 2 80 kgf cm Front wheel Wheel type Cast wheel Rim size 18M C x MT4 00 Rear wheel Wheel type Cast wheel Rim size 17M C x MT5 50 Front brake Type Dual disc brake Operation Right hand operation Recommended fluid DOT 4 Re...

Page 80: ...light 12 V 5 0 W 2 License plate light 12 V 5 0 W Meter lighting LED Neutral indicator light LED High beam indicator light LED Turn signal indicator 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 fuse 10 0 A ...

Page 81: ...ntification 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 m...

Page 82: ...STEM PROHIBITED Owners are warned that the law may prohibit a The removal or rendering inopera tive by any person other than for purposes of maintenance repair or replacement of any device or element of design incorporated into any new vehicle for the pur pose of noise control prior to its sale or delivery to the ultimate pur chaser or while it is in use and b The use of the vehicle after such dev...

Page 83: ... Immobilizer system 3 1 Immobilizer system indicator light 3 4 Indicator and warning lights 3 3 K Key identification number 9 1 L Labels location of 1 5 License plate light 6 27 M Main switch steering lock 3 2 Model label 9 2 Multi function meter unit 3 5 N Neutral indicator light 3 3 Noise regulation for Australia 9 2 P Parking 5 4 Part locations 2 1 Periodic maintenance and lubrication chart 6 2...

Page 84: ...INDEX Vehicle identification number 9 1 W Wheel bearings checking 6 21 Wheels 6 13 U5C520E0 book Page 2 Tuesday April 4 2006 10 48 AM ...

Page 85: ...U5C520E0 book Page 3 Tuesday April 4 2006 10 48 AM ...

Page 86: ...PRINTED ON RECYCLED PAPER YAMAHA MOTOR CO LTD PRINTED IN JAPAN 2006 04 0 3 1 CR E ...

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