Yamaha Star XV19CTSZ 2009 Page 68 Owner'S Manual Download | Manualshive

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PERIODIC MAINTENANCE AND ADJUSTMENT

7-20

7

●

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.

EAU22751

Changing the brake and
clutch fluids

Have a Yamaha dealer change the
brake and clutch fluids at the intervals
specified in the TIP 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.

TIP

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

2

1

3

U2C514E0.book Page 20 Tuesday, September 8, 2009 10:12 AM

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Summary of Contents for Star XV19CTSZ 2009

Page 1: ...DIC183 2C5 28199 14 XV19CTSZ C OWNER S MANUAL Read this manual carefully before operating this vehicle LIT 11626 23 34 ...

Page 2: ...EAU10042 Read this manual carefully before operating this vehicle This manual should stay with this vehicle if it is sold U2C514E0 book Page 1 Tuesday September 8 2009 10 12 AM ...

Page 3: ...tain these high standards it is important that you and your Yamaha dealer pay close attention to the recommended maintenance schedules and operating instructions contained within this manual Yamaha continually seeks advancements in product design and quality Therefore while this manual contains the most cur rent product information available at the time of printing there may be minor discrepancies...

Page 4: ... all safety messages that follow this symbol to avoid possible injury or death A WARNING indicates a hazardous situation which if not avoided could result in death or serious injury A NOTICE indicates special precautions that must be taken to avoid damage to the vehicle or other property A TIP provides key information to make procedures easier or clearer WARNING NOTICE TIP U2C514E0 book Page 1 Tue...

Page 5: ...or Corporation U S A 1st edition September 2009 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 23 34 U2C514E0 book Page 2 Tuesday September 8 2009 10 12 AM ...

Page 6: ...2 Periodic maintenance chart for the emission control system 7 3 General maintenance and lubrication chart 7 5 Checking the spark plugs 7 9 Canister for California only 7 10 Engine oil and oil filter cartridge 7 10 Transfer case oil 7 13 Air filter element 7 14 Checking the throttle cable free play 7 14 Valve clearance 7 14 Tires 7 15 Cast wheels 7 16 Clutch lever 7 17 Checking the brake lever fre...

Page 7: ...CARE AND STORAGE 8 1 Matte color caution 8 1 Care 8 1 Storage 8 4 SPECIFICATIONS 9 1 CONSUMER INFORMATION 10 1 Identification numbers 10 1 Reporting safety defects 10 3 Motorcycle noise regulation 10 4 Maintenance record 10 5 YAMAHA MOTOR CORPORATION U S A STREET AND ENDURO MOTORCYCLE LIMITED WARRANTY 10 7 YAMAHA EXTENDED SERVICE Y E S 10 9 U2C514E0 book Page 2 Tuesday September 8 2009 10 12 AM ...

Page 8: ...vehicle They contain important information for safe and proper operation of your vehicle Never remove any labels from your vehicle If a label becomes difficult to read or comes off a replacement label is available from your Yamaha dealer U2C514E0 book Page 1 Tuesday September 8 2009 10 12 AM ...

Page 9: ...15K 00 TIRE INFORMATION Cold tire normal pressure should be set as follows Up to 90 kg 198 lbs load FRONT REAR 250 kPa 2 50 kgf cm 36 psi 280 kPa 2 80 kgf cm 41 psi 90kg 198 lbs maximum load FRONT REAR 250 kPa 2 50 kgf cm 36 psi 280 kPa 2 80 kgf cm 41 psi 1D7 21668 00 1 2 3 4 7 6 5 California only U2C514E0 book Page 2 Tuesday September 8 2009 10 12 AM ...

Page 10: ...senger The failure of motorists to detect and recognize motorcycles in traf fic is the predominating cause of automobile motorcycle accidents Many accidents 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 yo...

Page 11: ...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 Always wear protective clothing that covers your legs ankles and feet The engin...

Page 12: ...f the motorcycle to minimize imbalance or instabili ty Shifting weights can create a sud den imbalance Make sure that ac cessories and cargo are securely attached to the motorcycle before riding Check accessory mounts and cargo restraints frequently Properly adjust the suspension for your load suspension ad justable models only and check the condition and pres sure of your tires Never attach any l...

Page 13: ...ht distribution or aerody namic changes If accessories are added to the handlebar or front fork area they must be as lightweight as possible and should be kept to a minimum Bulky or large accessories may seriously affect the stability of the motorcycle due to aerody namic effects Wind may at tempt to lift the motorcycle or the motorcycle may become un stable in cross winds These ac cessories may a...

Page 14: ... fuse page 7 26 6 Battery page 7 25 7 Owner s tool kit page 7 2 8 Passenger backrest page 4 14 9 Sidebag page 4 18 10 License plate light page 7 30 11 Tail brake light page 7 30 12 Engine oil drain bolt B crankcase page 7 10 13 Engine oil drain bolt A crankcase page 7 10 14 Shift pedal page 4 10 U2C514E0 book Page 1 Tuesday September 8 2009 10 12 AM ...

Page 15: ...5 Engine oil filler cap page 7 10 6 Fuel tank cap page 4 11 7 Front brake fluid reservoir page 7 19 8 Brake pedal page 4 10 9 Rear brake light switch page 7 18 10 Engine oil filter cartridge page 7 10 11 Engine oil drain bolt oil tank page 7 10 12 Shock absorber assembly spring preload adjusting nut page 4 20 U2C514E0 book Page 2 Tuesday September 8 2009 10 12 AM ...

Page 16: ...ever page 4 9 2 Left handlebar switches page 4 8 3 Multi function meter unit page 4 3 4 Main switch steering lock page 4 1 5 Right handlebar switches page 4 8 6 Throttle grip page 7 14 7 Brake lever page 4 10 U2C514E0 book Page 3 Tuesday September 8 2009 10 12 AM ...

Page 17: ...eadlight comes on automatically when the engine is started and stays on until the key is turned to OFF even if the engine stalls EAU10661 OFF All electrical systems are off The key can be removed WARNING EWA10061 Never turn the key to OFF or LOCK while the vehicle is moving Otherwise the electrical systems will be switched off which may result in loss of control or an accident EAU10683 LOCK The st...

Page 18: ...ccurs refuel as soon as possible The electrical circuit of the warning light can be checked by turning the key to ON The warning light should come on for a few seconds and then go off If the warning light does not come on initially when the key is turned to ON or if the warning light remains on have a Yamaha dealer check the electrical circuit TIP This model is also equipped with a self diagnosis ...

Page 19: ... EWA12422 Be sure to stop the vehicle before making any setting changes to the multi function meter unit Changing settings while riding can distract the operator and increase the risk of an accident The multi function meter unit is equipped with the following a speedometer a tachometer a fuel gauge an odometer two tripmeters which show the distance traveled since they were last set to zero a fuel ...

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

Page 21: ...he 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 4 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 the ...

Page 22: ...is detected in any of those circuits the engine trouble warning light will come on or flash and the odome ter tripmeter clock display will indicate an error code If the odometer tripmeter clock display indicates any error codes note the code number and then have a Yamaha dealer check the vehicle NOTICE ECA11590 If the display indicates an error code the vehicle should be checked as soon as possibl...

Page 23: ...ber 2 is displayed Adjust the LCD brightness level by pushing the reset switch 6 Push the SELECT switch to se lect the speedometer tachometer and the fuel gauge needles Item number 3 is displayed Adjust the brightness level of the speedometer tachometer and the fuel gauge needles by pushing the reset switch 7 Push the SELECT switch The odometer tripmeter clock dis play will return to the prior mod...

Page 24: ...he switch in after it has returned to the cen ter position TIP The self canceling system only oper ates when the vehicle is moving so that the turn signal lights will not self cancel while you are stopped at an intersec tion EAU12500 Horn switch Press this switch to sound the horn EAU12660 Engine stop switch Set this switch to before starting the engine Set this switch to to stop the engine in cas...

Page 25: ... this does not indicate a malfunction EAU44602 SELECT switch This switch is used to perform selec tions in the odometer and tripmeters to set the clock and to set the brightness control mode of the multi function meter unit See Multi function meter unit on page 4 3 for detailed information EAU12820 Clutch lever The clutch lever is located at the left handlebar grip To disengage the clutch pull the...

Page 26: ...ycle TIP Use your toes or heel to shift up and your toes to shift down EAU12890 Brake lever The brake lever is located at the right handlebar grip To apply the front brake pull the lever toward the handle bar grip EAU12941 Brake pedal The brake pedal is on the right side of the motorcycle To apply the rear brake press down on the brake pedal 1 Shift pedal 2 Neutral position 1 Brake lever 1 Brake p...

Page 27: ...tank cap is properly installed before riding Leaking fuel is a fire hazard EAU13212 Fuel Make sure there is sufficient gasoline in the tank WARNING EWA10881 Gasoline and gasoline vapors are extremely flammable To avoid fires and explosions and to reduce the risk of injury when refueling follow these instructions 1 Before refueling turn off the en gine and be sure that no one is sit ting on the veh...

Page 28: ...he 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 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 ...

Page 29: ...haust system WARNING EWA10862 The exhaust system is hot after op eration To prevent a fire hazard or burns Do not park the vehicle near possible fire hazards such as grass or other materials that easily burn Park the vehicle in a place where pedestrians or children are not likely to touch the hot exhaust system Make sure that the exhaust sys tem has cooled down before do ing any maintenance work D...

Page 30: ...at into the seat holder as shown 2 Push the front of the seat down to lock it in place 3 Remove the key TIP Make sure that the seat is properly se cured before riding EAU39155 Passenger backrest To remove the backrest 1 Open the sidebag lids See page 4 18 2 Insert the key into the passenger backrest lock turn it counterclock wise and then remove the key 3 Pull the lever on each side of the backres...

Page 31: ...ting the slot into the groove ECA15372 3 Push the rear of the backrest down smoothly but forcefully to lock it in place and make sure that the lever hook on each side is securely fit over its holder WARNING Both lever hooks must be securely fitted over their holder If the backrest is loose a passenger might lose balance and fall EWA14283 4 Insert the key into the passenger backrest lock turn it cl...

Page 32: ...e vehicle and then install the rid er seat WARNING Never ride with a helmet attached to the helmet holder since the helmet may hit objects causing loss of control and possibly an acci dent EWA10161 NOTICE Be sure to place the helmet on the left side of the vehicle Some helmets may contact the muffler when placed on the right side be cause of their size or shape ECA15331 To release the helmet from ...

Page 33: ...fall off the sidestand EWA14321 NOTICE ECA15350 Securely hold the windshield to pre vent it from falling when removing To install the windshield 1 Fit the slot in each windshield bracket left and right side into its holder WARNING Make sure that the throttle cables are not pinched EWA14301 2 Push the windshield backward un til it snaps into place 3 Insert the key into the windshield lock turn it c...

Page 34: ...not exceed the maximum load of 186 kg 410 lb for the ve hicle Do not exceed 120 km h 80 mi h when riding with luggage in the sidebags otherwise han dling could be affected Improp er loading poor tire or overall motorcycle conditions poor road surfaces or adverse weath er conditions may make it nec essary to further reduce the riding speed NOTICE ECA15380 To avoid locking the key in never lock eith...

Page 35: ...pward TIP The fasteners will come loose after the sidebags are removed Be sure not to lose the fasteners To install a sidebag 1 Open the sidebag lid 2 Place the sidebag on the bracket and then align all holes in the side bag with the holes in the holders on the bracket 3 Insert the fasteners through the holes in the sidebag into their hold ers and then turn them clockwise until they stop 1 Fastene...

Page 36: ...ttempt to turn beyond the maximum or minimum settings Adjust the spring preload as follows 1 Loosen the locknut 2 To increase the spring preload and thereby harden the suspension turn the adjusting nut in direction a To decrease the spring pre load and thereby soften the sus pension turn the adjusting nut in direction b To make the adjustment use the special wrench and exten sion bar included in t...

Page 37: ...the shock ab sorber assembly to an open flame or other high heat source This may cause the unit to ex plode due to excessive gas pressure Do not deform or damage the cylinder in any way Cylinder damage will result in poor damping performance Do not dispose of a damaged or worn out shock absorber as sembly yourself Take the shock absorber assembly to a Yamaha dealer for any service 1 Special wrench...

Page 38: ...cated on the left side of the frame Raise the sidestand or lower it with your foot while holding the vehicle upright TIP The built in sidestand switch is part of the ignition circuit cut off system which cuts the ignition in certain situations See page 4 23 for an explanation of the ignition circuit cut off system WARNING EWA10240 The vehicle must not be ridden with the sidestand down or if the si...

Page 39: ...sion is in gear and the side stand is up but the clutch lever is not pulled It prevents starting when the trans mission is in gear and the clutch le ver is pulled but the sidestand is still down It cuts the running engine when the transmission is in gear and the sid estand is moved down Periodically check the operation of the ignition circuit cut off system according to the following procedure U2C...

Page 40: ...ove the sidestand up 11 Keep the clutch lever pulled 12 Push the start switch Does the engine start The system is OK The motorcycle can be ridden The neutral switch may not be working correctly The motorcycle should not be ridden until checked by a Yamaha dealer The sidestand switch may not be working correctly The motorcycle should not be ridden until checked by a Yamaha dealer The clutch switch ...

Page 41: ...se the fuse may blow or 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 A 12 V accessory connected to the auxiliary DC connector under the rider seat can be used when the key is in the ON position 1 Auxiliary DC connector 2 Auxiliary DC connector cap U2C514E0 book Page ...

Page 42: ...ing this vehicle check the following points ITEM CHECKS PAGE Fuel Check fuel level in fuel tank Refuel if necessary Check fuel line for leakage Check the fuel tank breather overflow hose for obstructions cracks or damage and check the hose connection 4 11 4 13 Engine oil Check oil level in oil tank If necessary add recommended oil to specified level Check vehicle for oil leakage 7 10 Transfer case...

Page 43: ...ble free play If necessary have Yamaha dealer adjust cable free play and lubricate cable and grip housing 7 14 7 21 Control cables Make sure that operation is smooth Lubricate if necessary 7 21 Wheels and tires Check for damage Check tire condition and tread depth Check air pressure Correct if necessary 7 15 7 16 Brake and shift pedals Make sure that operation is smooth Lubricate pedal pivoting po...

Page 44: ...nals and switches Check operation Correct if necessary Sidestand switch Check operation of ignition circuit cut off system If system is not working correctly have Yamaha dealer check vehicle 4 22 ITEM CHECKS PAGE U2C514E0 book Page 3 Tuesday September 8 2009 10 12 AM ...

Page 45: ...ps automatically if left idling for 20 minutes In this case the multi function meter unit indi cates error code 70 but this is not a malfunction Push the start switch to clear the error code and to restart the engine EAU16246 Starting the engine In order for the ignition circuit cut off system to enable starting one of the following conditions must be met The transmission is in the neutral positio...

Page 46: ...n TIP To shift the transmission into the neu tral position press the shift pedal down repeatedly until it reaches the end of its travel and then slightly raise it NOTICE 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 i...

Page 47: ...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 an excessive load on it for...

Page 48: ...a Yamaha dealer check the vehi cle EAU17213 Parking When parking stop the engine and then remove the key from the main switch WARNING EWA10311 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 and be burned Do not park on a slope or on soft ground otherwise the vehicle may overturn increasing the risk of a fuel leak ...

Page 49: ...ning engine has moving parts that can catch on body parts or clothing and electrical parts that can cause shocks or fires Running the engine while ser vicing can lead to eye injury burns fire or carbon monoxide poisoning possibly leading to death See page 2 1 for more in formation about carbon monox ide EAU17302 Emission controls not only function to ensure cleaner air but are also vital to proper...

Page 50: ...e owner s tool kit are intended to assist you in the performance of preventive maintenance and minor repairs How ever additional tools such as a torque wrench may be necessary to perform certain maintenance work correctly TIP If you do not have the tools or experi ence required for a particular job have a Yamaha dealer perform it for you 1 Owner s tool kit U2C514E0 book Page 2 Tuesday September 8 ...

Page 51: ... 12 months 12000 mi 19000 km or 18 months 16000 mi 25000 km or 24 months 20000 mi 31000 km or 30 months 1 Fuel line Check 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...

Page 52: ...l system for dam age Replace if necessary No ITEM ROUTINE INITIAL ODOMETER READINGS 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 U2C514E0 book Page 4 Tuesday September 8 2009 10 12 AM ...

Page 53: ... 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 for dam age Replace if necessary Check air pres...

Page 54: ...ed 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 19 Front fork Check operation and for oil leak age Replace if necessary No ITEM ROUTINE INITIAL ODOMETER READINGS 600 mi ...

Page 55: ...ange 25 Front and rear brake switches Check operation 26 Control cables Apply Yamaha chain and cable lube or engine oil 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 28 Lights signals and switches Check operation Adjust headlight beam No ITEM ROUTINE INITIAL ODOMETER READIN...

Page 56: ...ydraulic brake and clutch systems 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...

Page 57: ...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 58: ... the vehicle on a level sur face and hold it in an upright posi tion A slight tilt to the side can result in a false reading 2 Remove the rider seat See page 4 14 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 TIP To achieve the proper engine oil tem perature for an accurate oi...

Page 59: ...oil with or without oil filter cartridge replace ment 1 Place the vehicle on a level sur face 2 Remove the rider seat See page 4 14 3 Start the engine warm it up for several minutes and then turn it off 4 Place an oil pan under the oil tank to collect the used oil 5 Remove the engine oil filler cap the engine oil drain bolt and its gasket to drain the oil from the oil tank 6 Place an oil pan under...

Page 60: ...ith an oil filter wrench and then tighten it to the specified torque with a torque wrench 11 Install the engine oil drain bolts and their new gasket and then tighten the bolts to the specified 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 ...

Page 61: ...eled ENERGY CONSERVING II or higher Make sure that no foreign mate rial enters the oil tank 15 Install the engine oil filler cap 16 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 17 Turn the engine off and then check the oil level and correct it if necessary 18 Install the rider ...

Page 62: ...d mea sure 4 0 6 0 mm 0 16 0 24 in at the throttle grip Periodically check the throttle cable free play and if neces sary have a Yamaha dealer adjust it EAU21401 Valve clearance The valve clearance changes with use resulting in improper air fuel mixture and or engine noise To prevent this from occurring the valve clearance must be adjusted by a Yamaha dealer at the intervals specified in the perio...

Page 63: ... model WARNING EWA10511 Never overload your vehicle Opera tion of an overloaded vehicle could cause an accident Tire inspection Always check the tires before operating the motorcycle If a tire tread shows crosswise line 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 Tire air pressure ...

Page 64: ... 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 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 ...

Page 65: ...n the hydraulic system have a Yamaha dealer bleed the system be fore operating the motorcycle EAU37913 Checking the brake lever free play There should be no free play at the brake lever end If there is free play have a Yamaha dealer inspect the brake system WARNING EWA14211 A soft or spongy feeling in the brake lever can indicate the presence of air in the hydraulic system If there is air in the h...

Page 66: ...r wear at the intervals 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 d...

Page 67: ...ear 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 clut...

Page 68: ...s 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 Pl...

Page 69: ... 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 Damage to the outer housing of cables may result in in ternal rusting and cause interfer ence with cable movement Replace damaged cables as soon as possi ble to prevent unsafe conditions EWA10711 EAU23112 Checking and lubricating the throttle grip and ...

Page 70: ...re each 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 U2C514E0 book Page 22 Tuesday September 8 2009 10 12 AM ...

Page 71: ...a dealer check or repair it Otherwise the sidestand could contact the ground and distract the operator re sulting in a possible loss of control EAU23251 Lubricating the rear suspen sion The pivoting points of the rear suspen sion must be lubricated by a Yamaha dealer at the intervals specified in the periodic maintenance and lubrication chart Recommended lubricant Silicone grease Recommended lubri...

Page 72: ...t fork compresses and rebounds smoothly NOTICE ECA10590 If any damage is found or the front fork does not operate smoothly have a Yamaha dealer check or re pair it EAU23283 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 lubrication chart 1 Place a ...

Page 73: ... clothing and al ways shield your eyes when working near batteries In case of contact administer the fol lowing FIRST AID EXTERNAL Flush with plenty of water INTERNAL Drink large quan tities of water or milk and im mediately call a physician EYES Flush with water for 15 minutes and seek prompt medical attention Batteries produce explosive hy drogen gas Therefore keep sparks flames cigarettes etc a...

Page 74: ...gative lead before disconnecting the positive lead ECA16302 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 After installation make sure that the battery leads are properly con nected to the battery terminals NOTICE ECA16530 Always keep the battery charged Storing a discharged...

Page 75: ...th two quartz bulbs If the high beam or the low beam bulb burns out replace it as follows NOTICE 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 1 Fuse box 2 Auxiliary DC connector fuse ...

Page 76: ...d Removing the headlight unit 1 Remove the windshield See page 4 17 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 To replace the high beam headlight bulb 1 Remove the headlight bulb holder cover by turning it counterclock wise 1 Do not touch the glass part of the bulb 1 Do not touch the glass part of the b...

Page 77: ...upler and then remove the burnt out bulb by turning it counterclock wise 2 Install a new bulb by turning it clockwise 3 Connect the headlight coupler Installing the headlight unit 1 Install the headlight unit by install ing the screws 2 Connect the coupler to the head light body cover 3 Install the headlight body cover by installing the bolts 4 Install the windshield 5 Have a Yamaha dealer adjust ...

Page 78: ...rclockwise 2 Remove the burnt out 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 NOTICE Do not overtighten the screw otherwise the lens may break ECA11191 EAU24330 License plate light If the license plate light does not come on ...

Page 79: ...k either under each side of the frame in front of the rear wheel or under each side of the swingarm EAU25851 Troubleshooting Although Yamaha motorcycles receive a thorough inspection before shipment from the factory trouble may occur dur ing operation Any problem in the fuel compression or ignition systems for example can cause poor starting and loss of power The following troubleshooting chart re...

Page 80: ...ODIC MAINTENANCE AND ADJUSTMENT 7 32 7 heaters or furnaces Gasoline or gasoline vapors can ignite or ex plode causing severe injury or property damage U2C514E0 book Page 32 Tuesday September 8 2009 10 12 AM ...

Page 81: ...ehicle 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 quickly The engine turns over slowly The...

Page 82: ...ler 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 Always rinse ...

Page 83: ...rt with warm water a mild detergent and a soft clean sponge and then rinse thoroughly with clean water 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 winte...

Page 84: ... parts but treat them with a suitable care product Avoid using abrasive polishing compounds as they will wear away the paint TIP Consult a Yamaha dealer for ad vice on what products to use Washing rainy weather or humid climates can cause the headlight lens to fog Turning the headlight on for a short period of time will help remove the moisture from the lens Special care is needed for cleaning the...

Page 85: ...ll 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 spark plug bore c Install the spark plug caps onto the spark plugs and then place the spark plu...

Page 86: ...y 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 batter...

Page 87: ... oil filter cartridge replacement 4 90 L 5 18 US qt 4 31 Imp qt Transfer gear oil Type SAE 80 API GL 4 Hypoid gear oil Quantity 0 55 L 0 58 US qt 0 48 Imp qt Air filter Air filter element Oil coated paper element Fuel Recommended fuel Premium unleaded gasoline only Fuel tank capacity 17 0 L 4 49 US gal 3 74 Imp gal Fuel reserve amount 3 0 L 0 79 US gal 0 66 Imp gal Fuel injection Throttle body ID ...

Page 88: ...nt 250 kPa 2 50 kgf cm 36 psi Rear 280 kPa 2 80 kgf cm 41 psi Loading condition 90 186 kg 198 410 lb Front 250 kPa 2 50 kgf cm 36 psi Rear 280 kPa 2 80 kgf cm 41 psi 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 Rear brake Type Single disc bra...

Page 89: ...ight 12 V 21 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 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 fuse 10 0 A Fuel injection system fuse 15 0 A Auxiliary DC...

Page 90: ...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 number The vehicle identification number is stamped into the steering head pipe Record this number in the space pro vided TIP The vehicle identification number is used to identify your motorcycle and ma...

Page 91: ...dering spare parts from a Yamaha dealer EAU48270 Vehicle Emission Control Informa tion label The Vehicle Emission Control Informa tion label is affixed at the location in the illustration This label shows specifica tions related to exhaust emissions as required by federal law state law and Environment Canada 1 Model label 1 Vehicle Emission Control Information label 1 U2C514E0 book Page 2 Tuesday ...

Page 92: ...nd 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 Sevent...

Page 93: ...le 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 Exh...

Page 94: ...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 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 or...

Page 95: ...ATION 10 6 10 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 U2C514E0 book Page 6 Tuesday September 8 2009 10 12 AM ...

Page 96: ...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 mo...

Page 97: ...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 warra...

Page 98: ... 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 p...

Page 99: ...d 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 U2C514E0 book Page 10 Tuesday September 8 2009 10 12 AM ...

Page 100: ...ystem 4 23 Indicator and warning lights 4 2 K Key identification number 10 1 L Labels location 1 1 License plate light 7 30 Light switch for optional lights 4 8 M Main switch steering lock 4 1 Maintenance and lubrication periodic 7 5 Maintenance emission control system 7 3 Maintenance record 10 5 Matte color caution 8 1 Model label 10 2 Multi function meter unit 4 3 N Neutral indicator light 4 2 N...

Page 101: ... 7 14 Vehicle Emission Control Information label 10 2 Vehicle identification number 10 1 W Warranty extended 10 9 Warranty limited 10 7 Wheel bearings checking 7 25 Wheels 7 16 Windshield 4 17 U2C514E0 book Page 2 Tuesday September 8 2009 10 12 AM ...

Page 102: ...A5 yoko_Blank fm Page 1 Tuesday April 8 2003 11 43 AM ...

Page 103: ...A5 yoko_Blank fm Page 1 Tuesday April 8 2003 11 43 AM ...

Page 104: ...PRINTED IN JAPAN 2009 09 0 3 1 CR E PRINTED ON RECYCLED PAPER YAMAHA MOTOR CO LTD DIC183 ...

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