Yamaha Star XV19CTMC Owner'S Manual Download | Manualshive

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PERIODIC MAINTENANCE AND MINOR REPAIR

6-19

6

●

As the brake pads wear, it is nor-
mal for the brake fluid level to grad-
ually go down. However, if the
brake fluid level goes down sud-
denly, have a Yamaha dealer
check the cause.

EAU22750

Changing the brake and
clutch fluids

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

●

Oil seals: Replace every two
years.

●

Brake and clutch hoses: Replace
every four years.

EAU23040

Drive belt slack

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

EAU38410

To check the drive belt slack

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

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

NOTE:

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

1. Drive belt
2. Marks

3. Drive belt slack

U2C512E0.book Page 19 Tuesday, July 10, 2007 5:18 PM

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Summary of Contents for Star XV19CTMC

Page 1: ...2C5 28199 12 XV19CTSX C XV19CTMX C OWNER S MANUAL LIT 11626 21 50 ...

Page 2: ...EAU10041 U2C512E0 book Page 1 Tuesday July 10 2007 5 18 PM ...

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

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

Page 5: ...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 Product and specifications are subject to change without notice U2C512E0 book Page 2 Tuesday July 10 2007 5 18 PM ...

Page 6: ...r Corporation U S A 1st edition June 2007 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 21 50 AFFIX DEALER LABEL HERE U2C512E0 book Page 3 Tuesday July 10 2007 5 18 PM ...

Page 7: ...tenance chart for the emission control system 6 3 General maintenance and lubrication chart 6 4 Checking the spark plugs 6 8 Canister for California only 6 9 Engine oil and oil filter cartridge 6 9 Transfer case oil 6 12 Air filter element 6 13 Checking the throttle cable free play 6 13 Valve clearance 6 13 Tires 6 14 Cast wheels 6 15 Accessories and replacement parts 6 16 Clutch lever 6 16 Adjust...

Page 8: ...AND STORAGE 7 1 Matte color caution 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 ENDURO MOTORCYCLE LIMITED WARRANTY 9 7 YAMAHA EXTENDED SERVICE Y E S 9 9 U2C512E0 book Page 2 Tuesday July 10 2007 5 18 PM ...

Page 9: ...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 10: ...hield 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 ...

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 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 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 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 13: ...SAFETY INFORMATION 1 5 1 EAU10381 Location of important labels Please read the following important labels carefully before operating this vehicle U2C512E0 book Page 5 Tuesday July 10 2007 5 18 PM ...

Page 14: ...SAFETY INFORMATION 1 6 1 U2C512E0 book Page 6 Tuesday July 10 2007 5 18 PM ...

Page 15: ...in fuse page 6 26 6 Battery page 6 24 7 Owner s tool kit page 6 1 8 Passenger backrest page 3 13 9 Sidebag page 3 17 10 License plate light page 6 31 11 Tail brake light page 6 30 12 Engine oil drain bolt B crankcase page 6 9 13 Engine oil drain bolt A crankcase page 6 9 14 Shift pedal page 3 9 U2C512E0 book Page 1 Tuesday July 10 2007 5 18 PM ...

Page 16: ... 4 Fuse box page 6 26 5 Engine oil filler cap page 6 9 6 Fuel tank cap page 3 10 7 Front brake fluid reservoir page 6 18 8 Brake pedal page 3 10 9 Engine oil filter cartridge page 6 9 10 Engine oil drain bolt oil tank page 6 9 11 Shock absorber assembly spring preload adjusting nut page 3 19 U2C512E0 book Page 2 Tuesday July 10 2007 5 18 PM ...

Page 17: ...h lever page 3 9 2 Left handlebar switches page 3 7 3 Multi function meter unit page 3 3 4 Main switch steering lock page 3 1 5 Right handlebar switches page 3 7 6 Throttle grip page 6 13 7 Brake lever page 3 9 U2C512E0 book Page 3 Tuesday July 10 2007 5 18 PM ...

Page 18: ...and position 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 off The key can be re moved To lock the s...

Page 19: ...s on when the high beam of the headlight is switched on EAU11361 Fuel level warning light This warning light comes on when the fuel level drops below approximately 3 0 L 0 79 US gal 0 66 Imp gal When this occurs refuel as soon as possible 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 and then go off have ...

Page 20: ...ing any setting changes to the multi function meter unit The multi function meter unit is equipped with the following a speedometer which shows the riding speed a tachometer which shows the en gine speed a fuel gauge an odometer which shows the to tal distance traveled two tripmeters which show the distance traveled since they were last set to zero a fuel reserve tripmeter which shows the distance...

Page 21: ...to monitor the engine speed and keep it within the ideal power range When the key is turned to ON the ta chometer needle will sweep once across the r min range and then return to zero r min in order to test the electri cal circuit CAUTION ECA10031 Do not operate the engine in the ta chometer red zone Red zone 5000 r min and above 1 SELECT switch 1 Reset switch 1 Speedometer 1 Tachometer 2 Tachomet...

Page 22: ...een the odometer mode ODO the tripmeter modes TRIP 1 and TRIP 2 and the clock mode in the following order ODO TRIP 1 TRIP 2 Clock ODO If the fuel level warning light comes on see page 3 2 the odometer display will automatically change to the fuel re serve tripmeter mode F TRIP and start counting the distance traveled from that point In that case push the SELECT switch to switch the display between...

Page 23: ...es any error codes note the code number and then have a Yamaha dealer check the vehicle CAUTION ECA11590 If the display indicates an error code the vehicle should be checked as soon as possible in order to avoid engine damage Brightness control mode The brightness can be adjusted for the following the multi function meter unit panel item number 1 the LCD item number 2 the speedometer tachometer an...

Page 24: ... the speedometer tachometer and the fuel gauge needles by pushing the reset switch 7 Push the SELECT switch The odometer tripmeter clock dis play will return to the prior mode EAU12347 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 switch 2 Turn signal switch 3 Horn switch 1...

Page 25: ...AU12500 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 EAU38331 Light switch for optional lights This model can be equipped with op tional lights available at a Yamaha dealer Push this switch...

Page 26: ...e igni tion circuit cut off system See page 3 21 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 27: ...he 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 EWA...

Page 28: ...en de signed to use premium unleaded gaso line with a pump octane number R M 2 of 91 or higher or a research octane number of 95 or higher If knocking or pinging occurs use a gasoline of a different brand Use of un leaded fuel will 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 ...

Page 29: ...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 30: ...by pulling it to the rear 5 Close the sidebag lids To install the backrest 1 Open the sidebag lids See page 3 17 2 Fit the slot on each backrest brack et left and right side into the groove of its holder CAUTION ECA15371 Be careful not to scratch the fender when fitting the slot into the groove 3 Push the rear of the backrest down smoothly but forcefully to lock it in place and make sure that the ...

Page 31: ...s EAU38341 Helmet holder The helmet holder is located under the rider seat A helmet holding cable is provided beside the owner s tool kit to secure a helmet to the helmet holder To secure a helmet to the helmet holder 1 Remove the rider seat See page 3 12 2 Pass the helmet holding cable through the buckle on the helmet strap as shown and then hook the cable loop over the helmet holder 1 Holder 2 L...

Page 32: ...holder since the helmet may hit objects causing loss of con trol and possibly an accident To release the helmet from the hel met holder Remove the rider seat remove the hel met holding cable from the helmet hold er and the helmet and then install the seat EAU39140 Windshield To remove the windshield 1 Insert the key into the windshield lock turn it clockwise and then re move the key 2 Remove the w...

Page 33: ...ot in each windshield bracket left and right side into its holder WARNING EWA14300 Make sure that the throttle cables are not pinched 2 Push the windshield backward un til it snaps into place 3 Insert the key into the windshield lock turn it counterclockwise until it stops to lock the fastener and then remove the key WARNING EWA14270 Make sure that the fastener is locked in place as shown 1 Slot 2...

Page 34: ...otorcycle conditions poor road surfaces or adverse weath er conditions may make it nec essary to further reduce the riding speed CAUTION ECA15380 To avoid locking the key in never lock either sidebag and remove the key from the lock before closing the lid To open a sidebag lid 1 Insert the key into the sidebag lock and then turn the key coun terclockwise 2 Push the key in and then fold the sidebag...

Page 35: ...g lid WARNING EWA14311 Make sure that all the fasteners in both sidebags are turned complete ly clockwise before riding NOTE Water can be harmful to untreated leather Use Yamaha Saddle Soap or another quality brand according to the manufacturer s directions to clean the leather on the sidebags Polish the dry leather with a soft cloth and then treat with Yamaha Mink Oil or another high quality leat...

Page 36: ...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 37: ... 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 constantl...

Page 38: ...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 EAU15312 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 39: ...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 40: ...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 U2C512E0 book Page 23 Tuesday July 10 200...

Page 41: ...equences Therefore it is very important in addition to a thorough visual inspec tion to check the following points before each ride NOTE Pre operation checks should be made each time the vehicle is used Such an inspection can be accomplished in a very short time and the added safety it assures is more than worth the time involved WARNING EWA11150 If any item in the Pre operation check list is not ...

Page 42: ...fied level Check hydraulic system for leakage 6 17 6 18 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 17 6 18 Clutch Check operation If soft or spongy have Yamaha dealer bleed hydrauli...

Page 43: ...ch levers Make sure that operation is smooth Lubricate lever pivoting points if necessary 6 21 Sidestand Make sure that operation is smooth Lubricate pivot if necessary 6 22 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 44: ... 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 described on page 3 21 Never ride with the sidestand down 1 Turn the key to ON and make sure that the engine stop switch is set to CAUTION ECA11560 The fuel level warning light and en gine trouble warning l...

Page 45: ...ission in the neutral position do not coast for long periods of time with the engine off and do not tow the motorcycle for long dis tances The transmission is properly lubricated only when the engine is running Inade quate lubrication may damage the transmission Always use the clutch while changing gears to avoid damag ing the engine transmission and drive train which are not designed to withstand...

Page 46: ...icator 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 more important period in the life of your engine than the period between 0 and 1600 km 1000 mi For this reason you should read the follow ing material carefully Since the engine is brand new do not put...

Page 47: ...c 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 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 o...

Page 48: ...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 49: ...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 U2C512E0 book Page 2 Tuesday July 10 2007 5 18 PM ...

Page 50: ...fuel hoses for cracks 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 when engine is cold Adjust if necessary Every 16000 mi 25000 km 4 Crankcase breather system Check breather hose for cracks or damage Replace if necessary 5 Fuel injection Adjust synchro...

Page 51: ... Check operation and fluid leak age Correct if necessary 3 Front brake Check operation fluid level and for fluid leakage Replace brake pads if necessary 4 Rear brake Check operation fluid level and for fluid leakage Replace brake pads if necessary 5 Brake hoses Check for cracks or damage Replace Every 4 years 6 Wheels Check runout and for damage Replace if necessary 7 Tires Check tread depth and f...

Page 52: ...ivot shaft Apply silicone grease lightly 14 Brake pedal pivot shaft Apply lithium soap based grease lightly 15 Clutch lever pivot shaft Apply silicone grease lightly 16 Shift pedal pivot shaft Apply lithium soap based grease lightly 17 Sidestand pivot Check operation Apply lithium soap based grease lightly 18 Sidestand switch Check operation and replace if necessary No ITEM ROUTINE INITIAL ODOMETE...

Page 53: ... month and thereafter every 16000 mi 25000 km or 24 months Change Change 25 Front and rear brake switches Check operation 26 Control cables Apply Yamaha chain and cable lube or engine oil SAE 10W 30 thoroughly 27 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 No ITEM ROUTINE INITIAL ODOME...

Page 54: ...stems After disassembling the brake or clutch master cylinders caliper cylinders or clutch release cylinder always change the fluid Regularly check the brake and clutch fluid levels and fill the reservoirs as required Replace the oil seals on the inner parts of the brake or clutch master cylinders caliper cylinders and clutch release cylinder every two years Replace the brake and clutch hoses ever...

Page 55: ...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 56: ...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 See page 3 12 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 ...

Page 57: ... 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 12 2 Start the engine warm it up for several minutes and then turn it off 3 Place an oil pan under the oil tank to collect the used oil 4 Remove the engine oil filler cap and drain bolt to drain the oil from the oil tank 5 Place an oil pan unde...

Page 58: ...er 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 spec ified torques 1 Oil filter cartridge 2 Oil filter wrench 1 O ring 1 Oil filter cartridge 2 Torque wrench Tightening torque Oil filter cartridge 17 Nm 1 7 m kgf 12 ft lbf Tightening torques Engine oil drain bolt A crankcase 4...

Page 59: ... labeled ENERGY CONSERVING II or higher Make sure that no foreign mate rial enters the oil tank 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 mediately turn the engine off and check for the cause 16 Turn the engine off and then check the oil level and correct it if necessary 17 Install the ri...

Page 60: ...y should mea sure 4 0 6 0 mm 0 16 0 24 in at the throttle grip Periodically check the throttle cable free play and if neces sary have a Yamaha dealer adjust it EAU21401 Valve clearance The valve clearance changes with use resulting in improper air fuel mixture and or engine noise To prevent this from occurring the valve clearance must be adjusted by a Yamaha dealer at the intervals specified in th...

Page 61: ...tems close to the center of the vehicle and distribute the weight evenly from side to side Properly adjust the suspension for your load and check the condition and pres sure of your tires NEVER OVER LOAD YOUR VEHICLE Make sure that the total weight of the cargo rid er passenger and accessories cowling saddlebags etc if ap proved for this model does not ex ceed the maximum load of the vehicle Opera...

Page 62: ...ce durabil ity and safe operation of your vehicle note the following points regarding the specified wheels The wheel rims should be checked for cracks bends or warpage be fore each ride If any damage is found have a Yamaha 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...

Page 63: ...e 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 consequences caused by the use of items which have not been approved by Yamaha EAU22072 Clutch lever Since this model is equipped with a hy draulic clutch adjusting the clutch lever free play is not needed However it is...

Page 64: ...als spec ified in the periodic maintenance and lubrication chart EAU22430 Front brake pads Each front brake pad is provided with wear indicator grooves which allow you to check the brake pad wear with out having to disassemble the brake To check the brake pad wear check the wear indicator grooves If a brake pad has worn to the point that the wear indicator grooves have almost disap peared have a Y...

Page 65: ...or wear Observe these precautions When checking the brake and clutch fluid levels make sure that the top of each reservoir is level Use only the recommended quality brake fluid otherwise the rubber seals may deteriorate causing leakage and poor braking or clutch performance Refill with the same type of brake fluid Mixing fluids may result in a harmful chemical reaction and lead to poor braking or ...

Page 66: ...ali pers as well as the brake and clutch hoses replaced at the intervals listed below or whenever they are damaged or leaking Oil seals Replace every two years Brake and clutch hoses Replace every four years EAU23040 Drive belt slack The drive belt slack should be checked and adjusted at the intervals specified in the periodic maintenance and lubri cation chart EAU38410 To check the drive belt sla...

Page 67: ...e ca bles and cable ends should be lubricat ed if necessary If a cable is damaged or does not move smoothly have a Yamaha dealer check or replace it WARNING EWA10710 Damage to the outer housing of ca bles may result in internal rusting and cause interference with cable movement Replace damaged ca bles as soon as possible to prevent unsafe conditions EAU23111 Checking and lubricating the throttle g...

Page 68: ...ride and the pedal pivots should be lu bricated if necessary EAU43600 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 U2C512E0 book Page 21 Tuesday July 10 2007 5 18 PM ...

Page 69: ...A10730 If the sidestand does not move up and down smoothly have a Yamaha dealer check or repair it EAU23250 Lubricating the rear suspen sion The pivoting points of the rear suspen sion must be lubricated at the intervals specified in the periodic maintenance and lubrication chart Recommended lubricant Silicone grease Recommended lubricant Lithium soap based grease Recommended lubricant Lithium soa...

Page 70: ...to check if the front fork compresses and rebounds smoothly CAUTION ECA10590 If any damage is found or the front fork does not operate smoothly have a Yamaha dealer check or re pair it EAU23280 Checking the steering Worn or loose steering bearings may cause danger Therefore the operation of the steering must be checked as fol lows at the intervals specified in the pe riodic maintenance and lubrica...

Page 71: ... the wheel bearings EAU33650 Battery This model is equipped with a sealed type MF battery which does not re quire any maintenance There is no need to check the electrolyte or to add distilled water WARNING EWA10760 Electrolyte is poisonous and dangerous since it contains sul furic acid which causes severe burns Avoid any contact with skin eyes or clothing and al ways shield your eyes when 1 Negati...

Page 72: ...ore quickly if the vehicle is equipped with optional electrical accessories To store the battery 1 If the vehicle will not be used for more than one month remove the battery fully charge it and then place it in a cool dry place 2 If the battery will be stored for more than two months check it at least once a month and fully charge it if necessary 3 Fully charge the battery before in stallation 4 A...

Page 73: ...ge 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 1 Main fuse 2 Fuel injection system fuse 3 Fuel injection system spare fuse 4 Fuse box 1 Fuse box 2 Auxiliary DC connector fuse 3 Signaling system fuse 4 Ignition fuse 5 Backup fuse for odometer and clock 6 ECU Electronic Control Unit fuse 7 Headlight ...

Page 74: ... bulbs If the high beam or the low beam bulb burns out replace it as follows Removing the headlight unit 1 Remove the windshield See page 3 15 2 Remove the headlight body cover by removing the bolts 3 Disconnect the coupler shown 4 Remove the headlight unit by re moving the screws 1 Low beam headlight bulb 2 High beam headlight bulb 1 Bolt 2 Headlight body cover 1 Coupler U2C512E0 book Page 27 Tue...

Page 75: ...t with the bulb holder CAUTION ECA10650 Take care not to damage the follow ing parts Headlight bulb Do not touch the glass part of the headlight bulb to keep it free from oil otherwise 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 ...

Page 76: ... ECA10650 Take care not to damage the follow ing parts Headlight bulb Do not touch the glass part of the headlight bulb to keep it free from oil otherwise 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 ...

Page 77: ...D type of tail brake light If the tail brake light does not come on have a Yamaha dealer check it EAU38380 Replacing a turn signal light bulb 1 Remove the turn signal light lens by removing the screw and then turning the lens counterclockwise 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 unti...

Page 78: ...fore 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 by using a motorcycle stand To service the rear wh...

Page 79: ...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 80: ...on Check the ignition Have a Yamaha dealer check the vehicle Remove the spark plugs and check the electrodes 3 Ignition Wipe off with a dry cloth and correct the spark plug gaps or replace the spark plugs Have a Yamaha dealer check the vehicle The engine does not start Have a Yamaha dealer check the vehicle The engine does not start Check the battery Operate the electric starter 4 Battery The engi...

Page 81: ...r the muffler outlet with a plastic bag after the engine has cooled down 2 Make sure that all caps and covers as well as all electrical couplers and connectors including the spark plug caps are tightly in stalled 3 Remove extremely stubborn dirt like oil burnt onto the crankcase with a degreasing agent and a brush but never apply such prod ucts onto seals gaskets the drive belt and wheel axles Alw...

Page 82: ...ater Use a toothbrush or bottlebrush for hard to reach areas Stubborn dirt and insects will come off more easily if the area is covered with a wet cloth for a few minutes before cleaning After riding in the rain near the sea or on salt sprayed roads Since sea salt or salt sprayed on roads during winter are extremely corrosive in combination with water carry out the following steps after each ride ...

Page 83: ...and plastic parts but treat them with a suitable care product Avoid using abrasive polishing compounds as they will wear away the paint NOTE Consult a Yamaha dealer for advice on what products to use Special care is needed for cleaning the windshield and sidebags on this model Be sure to follow the instruc tions below Cleaning the windshield Avoid using any alkaline or strong acid cleaner gasoline...

Page 84: ...t 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 the spark plugs and then install the spark plugs and the spark plug caps WARNING EWA10950 To prevent damage or injury from sparking make sure to ground the spark plug electrodes while turning ...

Page 85: ...ridge 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 injection Throttle body Manufacturer MIKUNI ...

Page 86: ...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 Rear brake Type Single disc brake Operation Right foot operation Recommended fluid DOT 4 Front suspension Type Telescopic fork Spring shock absorber type Coil spring oil damper Wheel travel 130 0 mm 5 12...

Page 87: ...cator light LED Turn signal indicator light LED Fuel level warning light LED Engine trouble warning light LED Fuses Main fuse 50 0 A Headlight fuse 20 0 A Taillight fuse 10 0 A Signaling system fuse 10 0 A Ignition fuse 25 0 A ECU Electronic Control Unit fuse 10 0 A Fuel injection system fuse 15 0 A Auxiliary DC connector fuse 3 0 A Backup fuse 10 0 A U2C512E0 book Page 3 Tuesday July 10 2007 5 18...

Page 88: ...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 89: ...el is affixed to the frame under the rider seat See page 3 12 Record the information on this label in the space provided This information will be needed when ordering spare parts from a Yamaha dealer 1 Model label U2C512E0 book Page 2 Tuesday July 10 2007 5 18 PM ...

Page 90: ...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 call the Vehicle Safety Hotline toll free at 1 888 327 4236 TTY 1 800 424 9153 go to http www safercar gov or write to Administrator NHTSA 400 Seven...

Page 91: ...icle for the purpose of noise control prior to its sale or delivery to the ultimate purchaser or while it is in use or 2 the use of the vehicle after such device or element of design has been removed or rendered inoperative by any person AMONG THOSE ACTS PRESUMED TO CONSTITUTE TAMPERING ARE THE ACTS LISTED BELOW These acts include tampering with the following systems i e modification removal etc E...

Page 92: ...nder 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 o...

Page 93: ...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 U2C512E0 book Page 6 Tuesday July 10 2007 5 18 PM ...

Page 94: ...r warranty by an authorized Yamaha motorcycle dealer In order for this warranty to remain in effect this inspection and registration must take place within ten 10 days after transfer An inspection and registration fee will be charged for this service EMISSION CONTROL SYSTEM WARRANTY Yamaha Motor Corporation U S A also warrants to the ultimate purchaser and each subsequent purchaser of each Yamaha ...

Page 95: ...y later date Each Yamaha motorcycle dealer is held responsible for his setup service and warranty repair work Is the warranty transferable to second owners Yes The remainder of the existing warranty can be transferred upon request The unit has to be inspected and re registered by an authorized Yamaha motorcycle dealer for the policy to remain effective CUSTOMER SERVICE If your machine requires war...

Page 96: ...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 97: ...ked 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 U2C512E0 book Page 10 Tuesday July 10 2007 5 18 PM ...

Page 98: ...ey identification number 9 1 L Labels location of 1 5 License plate light 6 31 Light switch for optional lights 3 8 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 Matte color caution 7 1 Model label 9 2 Multi function meter unit 3 3 N Neutral indicator light 3 2 Noise regulation 9 4 P ...

Page 99: ...g 6 30 Turn signal switch 3 8 V Valve clearance 6 13 Vehicle identification number 9 1 W Warranty extended 9 9 Warranty limited 9 7 Wheel bearings checking 6 24 Wheels 6 15 Windshield 3 15 U2C512E0 book Page 2 Tuesday July 10 2007 5 18 PM ...

Page 100: ...A5 yoko_Blank fm Page 1 Tuesday April 8 2003 11 43 AM ...

Page 101: ...A5 yoko_Blank fm Page 1 Tuesday April 8 2003 11 43 AM ...

Page 102: ...PRINTED IN JAPAN 2007 07 0 7 1 CR E PRINTED ON RECYCLED PAPER YAMAHA MOTOR CO LTD ...

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