Yamaha Venture XVZ13TFC Owner'S Manual Download | Manualshive

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PERIODIC MAINTENANCE AND MINOR REPAIR

7-24

7

EAU22092

Adjusting the brake lever free
play

The brake lever free play should mea-
sure 2.0–5.0 mm (0.08–0.20 in) as
shown. Periodically check the brake le-
ver free play and, if necessary, adjust it
as follows.

1. Loosen the locknut at the brake le-

ver.

2. To increase the brake lever free

play, turn the adjusting screw in di-
rection (a). To decrease the brake
lever free play, turn the adjusting
screw in direction (b).

3. Tighten the locknut.

WARNING

EWA10630

●

After adjusting the brake lever
free play, check the free play
and make sure that the brake is
working properly.

●

A soft or spongy feeling in the
brake lever can indicate the
presence of air in the hydraulic
system. If there is air in the hy-
draulic system, have a Yamaha
dealer bleed the system before
operating the motorcycle. Air in
the hydraulic system will dimin-
ish the braking performance,
which may result in loss of con-
trol and an accident.

EAU22280

Adjusting the rear brake light
switch

The rear brake light switch, which is ac-
tivated by the brake pedal, is properly
adjusted when the brake light comes
on just before braking takes effect.
Since the brake light switch is a compo-
nent of the cruise control system, it
must be adjusted by a Yamaha dealer,
who has the necessary professional
knowledge and experience.

1. Locknut

2. Brake lever free play adjusting screw
3. Brake lever free play

U4XY16E0.book Page 24 Friday, June 4, 2004 10:06 AM

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Summary of Contents for Venture XVZ13TFC

Page 1: ...4XY 28199 16 LIT 11626 18 37 XVZ13TFT C XVZ13TFMT C OWNER S MANUAL ...

Page 2: ...EAU10041 U4XY16E0 book Page 1 Friday June 4 2004 10 06 AM ...

Page 3: ... motorcycle If you have any questions concerning the operation or maintenance of your motorcycle please consult a Yamaha dealer The design and manufacture of this Yamaha motorcycle fully comply with 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 h...

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: ...RAINED IN SAFE AND PROPER RIDING TECHNIQUES REGULAR INSPECTIONS AND CAREFUL MAINTENANCE ALONG WITH GOOD RIDING SKILLS WILL ENSURE THAT YOU SAFELY ENJOY THE CAPABILITIES AND THE RELIABILITY OF THIS MOTORCYCLE U4XY16E0 book Page 2 Friday June 4 2004 10 06 AM ...

Page 6: ...or Corporation U S A 1st edition May 2004 All rights reserved Any reprinting or unauthorized use without the written permission of Yamaha Motor Corporation U S A is expressly prohibited Printed in Japan P N LIT 11626 18 37 AFFIX DEALER LABEL HERE U4XY16E0 book Page 3 Friday June 4 2004 10 06 AM ...

Page 7: ...11 Optional CD changer operation 4 15 CB radio operation 4 16 Auxiliary audio source operation 4 20 PRE OPERATION CHECKS 5 1 Pre operation check list 5 2 OPERATION AND IMPORTANT RIDING POINTS 6 1 Starting and warming up a cold engine 6 1 Starting a warm engine 6 2 Shifting 6 3 Engine break in 6 4 Parking 6 5 PERIODIC MAINTENANCE AND MINOR REPAIR 7 1 PERIODIC MAINTENANCE 7 1 Owner s tool kit 7 1 Pe...

Page 8: ... steering 7 30 Checking the wheel bearings 7 30 Battery 7 31 Replacing the fuses 7 32 Replacing the headlight bulb 7 34 Replacing a turn signal light bulb or the tail brake light bulb 7 35 Supporting the motorcycle 7 35 Troubleshooting 7 36 Troubleshooting charts 7 37 MOTORCYCLE CARE AND STORAGE 8 1 Cleaning 8 1 Storage 8 2 SPECIFICATIONS 9 1 CONSUMER INFORMATION 10 1 Identification numbers 10 1 R...

Page 9: ...nts have been caused by an automobile driver who did not see the motorcycle Making yourself conspicuous ap pears to be very effective in reduc ing the chance of this type of accident Therefore Wear a brightly colored jacket Use extra caution when ap proaching and passing through intersections since intersec tions are the most likely places for motorcycle accidents to oc cur Ride where other motori...

Page 10: ...ace shield or goggles Wind in your unprotected eyes could contribute to an impairment of vision which could delay seeing a hazard The use of a jacket heavy boots trousers gloves etc is effective in preventing or reducing abrasions or lacerations Never wear loose fitting clothes otherwise they could catch on the control levers footrests or wheels and cause injury or an accident Never touch the engi...

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: ... off before leaving the motorcycle unattended and remove the key from the main switch When parking the motor cycle note the following The engine and exhaust system may be hot therefore park the motorcycle in a place where pe destrians or children are not like ly to touch these hot areas Do not park the motorcycle on a slope or soft ground otherwise it may fall over Do not park the motorcycle near ...

Page 13: ...SAFETY INFORMATION 1 5 1 EAU10381 Location of important labels Please read the following important labels carefully before operating this vehicle U4XY16E0 book Page 5 Friday June 4 2004 10 06 AM ...

Page 14: ...ION 1 6 1 1 5 3 2 CAUTION Cleaning with alkaline or acid cleaner gasoline or solvent will damage windshield Use neutral detergent 5JW 00 5JW 2835Y 00 4 CALIFORNIA ONLY U4XY16E0 book Page 6 Friday June 4 2004 10 06 AM ...

Page 15: ...3 12 3 Fuel tank cap page 3 10 4 Fuel cock page 3 11 5 Battery page 7 31 6 Coolant reservoir page 7 16 7 Fuse box 2 page 7 32 8 Sidecase page 3 14 9 Helmet holder page 3 14 10 Tail brake light page 7 35 11 Rear turn signal light page 7 35 U4XY16E0 book Page 1 Friday June 4 2004 10 06 AM ...

Page 16: ...at page 3 13 6 Shock absorber assembly air valve page 3 17 7 Rider seat page 3 13 8 Fuel tank page 3 10 9 Front fork air valve page 3 16 10 Headlight page 7 34 11 Front turn signal position lights page 7 35 12 Fuse box 1 page 7 32 13 Brake pedal page 3 9 14 Rider footrest 15 Passenger footrest U4XY16E0 book Page 2 Friday June 4 2004 10 06 AM ...

Page 17: ...B radio control unit page 4 3 3 Left handlebar switches page 3 7 4 Rider headset jack page 4 2 5 Speedometer unit page 3 4 6 Main switch steering lock page 3 1 7 Right handlebar switches page 3 7 8 Throttle grip page 7 20 9 Brake lever page 3 9 U4XY16E0 book Page 3 Friday June 4 2004 10 06 AM ...

Page 18: ...0 LOCK The steering is locked and all electrical systems are off The key can be re moved To lock the steering 1 Turn the handlebars all the way to the left 2 Push the key in from the OFF po sition and then turn it to LOCK while still pushing it 3 Remove the key To unlock the steering Push the key in and then turn it to OFF while still pushing it WARNING EWA10060 Never turn the key to OFF or LOCK w...

Page 19: ...e corresponding indicator light flash es when the turn signal switch is pushed to the left or right EAU11060 Neutral indicator light This indicator light comes on when the transmission is in the neutral position 1 Left turn signal indicator light 2 High beam indicator light 3 Oil level warning light 4 Overdrive indicator light O D 5 Engine trouble warning light 6 Fuel level warning light 1 Cruise ...

Page 20: ...n the fuel cock le ver to the RES position and refuel as soon as possible EAU11380 Cruise control indicator lights See page 3 5 for an explanation of these indicator lights EAU11410 Coolant temperature warning light This warning light comes on when the engine overheats When this occurs stop the engine immediately and allow the engine to cool The electrical circuit of the warning light can be check...

Page 21: ...and odometer modes in the following order TRIP F TRIP 1 TRIP 2 ODO TRIP F To reset a tripmeter select it by push ing the SELECT button and then push the RESET button If you do not reset the fuel reserve tripmeter manual ly it will reset itself automatically and the display will return to TRIP 1 after refueling and traveling 5 km 3 mi NOTE After resetting the fuel reserve tripme ter the display wil...

Page 22: ... this occurs have a Yamaha dealer check the electrical cir cuit EAU11840 Cruise control system This model is equipped with a cruise control system designed to maintain a set traveling speed Activating and setting the cruise control system The cruise control system can only be activated when riding in 4th or 5th gear at speeds between 50 km h 30 mi h and 130 km h 80 mi h To activate and set the cru...

Page 23: ...ng the clutch will automatically deactivate the cruise control system Push the CANCEL switch to manually deactivate cruise control NOTE When the cruise control system is deactivated the RES resume indicator light will come on Traveling speed decreases as soon as the cruise control system is deactivated unless the throttle grip is turned Push the RES ACC side of the cruise control switch to reactiv...

Page 24: ...he turn signal lights will self cancel after the vehicle has traveled both about 150 m 490 ft and for approximately 15 seconds However the turn signal lights can also be canceled manually by pushing the switch in after it has returned to the cen ter position NOTE 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 st...

Page 25: ...ts are used in case of an emergency or to warn other drivers when your vehicle is stopped where it might be a traffic hazard CAUTION ECA10060 Do not use the hazard light for an ex tended length of time otherwise the battery may discharge EAU12780 Cruise control switches See page 3 5 for an explanation of the cruise control system EAU12820 Clutch lever The clutch lever is located at the left handle...

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

Page 27: ...n 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 EWA10130 Make sure that the fuel tank cap is properly installed before riding EAU13210 Fuel Make sure that there is sufficient fuel in the tank Fill the fuel tank to the bottom of the filler tube as shown WARNI...

Page 28: ...aintenance costs Gasohol There are two types of gasohol gaso hol containing ethanol and that contain ing methanol Gasohol containing ethanol can be used if the ethanol con tent does not exceed 10 Gasohol containing methanol is not recom mended by Yamaha because it can cause damage to the fuel system or ve hicle performance problems EAU13550 Fuel cock The fuel cock supplies fuel from the tank to th...

Page 29: ...o this position if you run out of fuel while riding When this occurs refuel as soon as possible and be sure to turn the fuel cock lever back to ON EAU13600 Starter choke knob Starting a cold engine requires a richer air fuel mixture which is supplied by the starter choke Move the knob in direction a to turn on the starter choke Move the knob in direction b to turn off the starter choke 1 Pointed e...

Page 30: ...rackets are aligned and then lock the steering with a suitable pad lock EAU14240 Rider seat To remove the rider seat Remove the nuts and then pull the rid er seat up To install the rider seat Insert the projection on the rear of the rider seat into the seat holder as shown place the seat in the original po sition and then tighten the nuts NOTE Make sure that the rider seat is properly secured befo...

Page 31: ...possibly an accident or personal injury See pages 1 5 and 7 20 for important loading and tire pressure informa tion Always securely close the side cases and travel trunk before riding Distribute weight evenly on each side of the motorcycle Do not exceed the load limit of 9 kg 20 lb for each sidecase and the travel trunk Do not exceed the maximum load of 190 kg 419 lb for the ve hicle Do not exceed...

Page 32: ...clockwise and then remove it NOTE Push both sides of the lid down so that both latches snap into place Travel trunk To open the travel trunk 1 Insert the key into the lock turn it counterclockwise and then push it in 2 Fold the travel trunk lid up and then release it so that it will rest in place as shown 1 Sidecase lock 2 Unlock 1 Storage compartment 2 Storage pouch 1 Travel trunk lock 2 Unlock 1...

Page 33: ...either sidecase or the travel trunk and remove the key from the lock before closing the lid EAU14651 Adjusting the front fork This front fork is equipped with air valves for adjusting the spring rate WARNING EWA10180 Always adjust both fork legs equal ly otherwise poor handling and loss of stability may result Adjust the spring rate as follows 1 Place the vehicle on the sidestand NOTE When checkin...

Page 34: ...ng the spring rate CAUTION ECA10100 Never attempt to turn an adjusting mechanism beyond the maximum or minimum settings Adjust the spring rate as follows 1 Place the vehicle on the sidestand NOTE When checking and adjusting the air pressure there should be no weight on the vehicle 2 Remove the air valve cap 3 Check the air pressure with the air pressure gauge included in the owner s tool kit 4 To ...

Page 35: ...G EWA10240 The vehicle must not be ridden with the sidestand down or if the side stand cannot be properly moved up or does not stay up otherwise the sidestand could contact the ground and distract the operator resulting in a possible loss of control Yamaha s ignition circuit cut off system has been designed to assist the operator in fulfilling the respon sibility of raising the sidestand be fore s...

Page 36: ...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 WARNING EWA10250 If a malfunction is noted have ...

Page 37: ...ter 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 ...

Page 38: ...1030 The accessories connected to the auxiliary DC jack and terminals should not be used with the engine turned off and their combined load must never exceed 5 A or 60 W oth erwise the battery may discharge WARNING EWA11050 To prevent electrical shock or short circuiting make sure that the caps are installed when the auxiliary DC jack and terminals are not being used 1 Auxiliary DC jack 1 Auxiliar...

Page 39: ...ront speaker 3 Rider headset jack 4 Cassette deck lid 5 Main switch steering lock 6 Eject button 7 Cassette deck compartment 8 Auxiliary audio input jack 9 Rear speaker 10 Passenger volume control knob 11 Passenger TALK button 12 Passenger headset jack U4XY16E0 book Page 1 Friday June 4 2004 10 06 AM ...

Page 40: ...is good prac tice to cover them with a plastic bag when washing the motor cycle When cleaning the control unit display use a neutral detergent Never use strong abrasive cleaning products fuel gaso line thinner etc EAU15450 Headsets optional For CB Citizens Band radio transmis sion a headset is necessary however CB reception is possible without a headset For intercom use two head sets are necessary...

Page 41: ...direction Tuning in a radio station automati cally Selecting a CD in the optional CD changer Audio system button AUDIO This button is used to perform the fol lowing operations Short push less than one second Turning on the audio system Changing the audio source in the following sequence Long push one second or more Turning off the audio system Selection button SELECT This button is used to perform...

Page 42: ...rning on off the audio system To turn the power on 1 Make sure that the key is in the ACC or ON position 2 Push the AUDIO button once for less than one second To turn the power off Push the AUDIO button once for one second or more Output BASS TREB FAD Auto volume Intercom volume Radio SP HS Treble frequency Fade 1 2 IC AV 1 2 This mode does not appear in the display when the headsets are selected ...

Page 43: ...hat the key is in the ACC or ON position 2 Push the CB button once for less than one second The current CB channel appears in the display To turn the power off Push the CB button once for one sec ond or more The CB indicator light will go off Adjusting the CB reception volume Turn the control knob until the desired CB reception volume is displayed e g Vo 10 The CB reception volume can be set betwe...

Page 44: ... 2 While the selected mode is dis played for about five seconds re peatedly push either side of the up down switch for less than one second until the desired setting is displayed Selecting the output speakers or headsets 1 Repeatedly push the SELECT button for less than one second until either SP speakers or HS and headsets appears in the display 2 Push either side of the up down switch for less t...

Page 45: ...dly push either side of the up down switch for less than one second until the desired level is displayed The treble level can be set between 6 and 6 Adjusting the fade level balance be tween front and rear speakers 1 Make sure that the speakers are selected as the output source See the Selecting the output section 2 Repeatedly push the SELECT button for less than one second until FAD appears at th...

Page 46: ...ompensates for external noise 1 Repeatedly push the SELECT button for less than one second until the auto volume e g AV 3 appears in the display 2 Repeatedly push either side of the up down switch for less than one second until the desired volume is displayed The auto volume can be set between 0 and 5 Turning on off the CB roger beep 1 Repeatedly push the SELECT button for less than one second unt...

Page 47: ...allow the inside of the cassette deck to get wet If this happens keep the cassette deck lid open and dry out the deck in the shade To clean the tape head use a de magnetizing cleaning cas sette but be sure to turn the vol ume all the way down to avoid speaker damage Playing a cassette tape 1 Make sure that the audio system is turned on See page 4 3 2 Insert a cassette tape into the cas sette compa...

Page 48: ...OTE The maximum number of songs that can be skipped in either direc tion is 9 To stop skipping songs push the up down switch in the opposite di rection that songs are being skipped Skipping a blank When there is a long blank portion of tape on the cassette BLS appears in the display and the cassette deck auto matically fast forwards the tape to the next song Changing the tape play direction While ...

Page 49: ... NOTE The Dolby noise reduction system has been manufactured under li cense from Dolby Laboratories Li censing Corporation Dolby and the double D symbol are registered trademarks of Dolby Laboratories Licensing Corpora tion Ejecting the cassette tape Push the eject button to eject the tape from the cassette deck EJCT appears in the display and then CASS starts flashing EAU15532 Radio operation 1 E...

Page 50: ... and one AM band Since all three FM bands cover the whole FM frequency range any one of them can be selected for tuning in an FM station These three FM bands are useful for categorizing FM preset stations Repeatedly push the AUDIO button for less than one second until the desired frequency band appears in the display Tuning in a radio station automati cally 1 Select a frequency band See the Select...

Page 51: ...eps for AM Tuning in a preset radio station 1 Select a frequency band See the Selecting a frequency band sec tion 2 Repeatedly push either side of the up down switch for less than one second until the desired preset station number is displayed NOTE To be able to tune in a preset radio sta tion you must have previously pro grammed at least one See the following sections Programing preset radio stat...

Page 52: ...o tune in a station automati cally 4 Repeatedly push either side of the up down switch for less than one second until the desired preset number 1 through 6 is dis played 5 Push the SELECT button once for less than one second to store the radio station selected in step 3 under the preset number selected in step 4 6 Repeat this procedure to preset other radio stations Programing preset radio station...

Page 53: ... ty An optional six disc CD changer can be mounted in the travel trunk Ask a Yamaha dealer to install the genuine Clarion CDC635 model Playing a CD 1 Insert up to six CDs into the CD changer Follow the manufactur er s directions 2 Push the AUDIO button until as well as the CD number and track number e g 6 3 ap pear in the display The CD starts playing NOTE 6 3 indicates track no 3 on CD no 6 Selec...

Page 54: ...enough level to be aware of traf fic conditions and ensure safe ty Never ride the motorcycle with the CB antenna folded down NOTE The antenna can be folded down after lifting the sleeve This CB radio will operate on any of the 40 frequencies designated as Citizens band channels by the Federal Commu nications Commission F C C This model features a frequency synthesiz ing circuit with PHASE LOCK LOO...

Page 55: ...in no lessening of the operating privileges or responsibilities of CB users An opera tor of a CB radio station is still required to comply with the Communications Act and with the rules of CB Radio Service CB radio functions The CB radio is capable of the following functions which are further explained in the following sections Selecting a CB channel for trans mitting or receiving Adjusting the sq...

Page 56: ...ears in the dis play For maximum reception sensitivity the squelch level should be set by turning the control knob fully counterclockwise and then slowly turning it clockwise un til the background noise has been suffi ciently reduced In order for an incoming CB signal to be heard it must be stronger than the noise received Turning the control further clockwise will increase the threshold level tha...

Page 57: ... requirements applicable to equipment operating in the Citizens Radio Service it is not to be used for any other purpose Channel Channel Frequency in MHz Channel Channel Frequency in MHz 1 26 965 21 27 215 2 26 975 22 27 225 3 36 985 23 27 235 4 27 005 24 27 245 5 27 015 25 27 255 6 27 025 26 27 265 7 27 035 27 27 275 8 27 055 28 27 285 9 27 065 29 27 295 10 27 075 30 27 305 11 27 085 31 27 315 12...

Page 58: ...eration Auxiliary audio equipment can be con nected to and played through the au dio system 1 Insert the output plug of the auxil iary equipment into the jack locat ed at the right of the cassette deck 2 Repeatedly push the AUDIO but ton for less than one second until AUX appears in the display The auxiliary equipment can now be played through the audio system 1 Talk switch 1 Passenger TALK button...

Page 59: ...AUDIO SYSTEM AND CB RADIO 4 21 4 U4XY16E0 book Page 21 Friday June 4 2004 10 06 AM ...

Page 60: ...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 61: ...em for leakage 7 16 Front brake Check operation If soft or spongy have Yamaha dealer bleed hydraulic system Check lever free play Adjust if necessary Check brake pads for wear Replace if necessary Check fluid level in reservoir If necessary add recommended brake fluid to specified level Check hydraulic system for leakage 7 24 7 25 7 25 Rear brake Check operation If soft or spongy have Yamaha deale...

Page 62: ...ition and tread depth Check air pressure Correct if necessary 7 20 7 22 Brake and shift pedals Make sure that operation is smooth Lubricate pedal pivoting points if necessary 7 28 Brake and clutch levers Make sure that operation is smooth Lubricate lever pivoting points if necessary 7 28 Sidestand Make sure that operation is smooth Lubricate pivot if necessary 7 29 Chassis fasteners Make sure that...

Page 63: ...ssion 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 19 Never ride with the sidestand down 1 Turn the fuel cock lever to ON 2 Turn the key to ON and make sure that the engine stop switch is set to CAUTION ECA10220 If the fuel level wa...

Page 64: ...arm turn the starter choke off NOTE The engine is warm when it responds normally to the throttle with the starter choke turned off To avoid the possi bility of excessive exhaust emissions never leave the starter choke on long er than necessary The time necessary for starter choke use depends upon the ambient temperature Tempera tures above 10 C 50 F require about 7 seconds of starter choke use and...

Page 65: ...EAU16680 To start out and accelerate 1 Pull the clutch lever to disengage the clutch 2 Shift the transmission into first gear The neutral indicator light should go out 3 Open the throttle gradually and at the same time release the clutch lever slowly 4 At the recommended shift points shown in the following table close the throttle and at the same time quickly pull the clutch lever in 5 Shift the t...

Page 66: ...nces During this period prolonged full throt tle operation or any condition that might result in engine overheating must be avoided EAU17041 0 1000 km 0 600 mi Avoid prolonged operation above 1 3 throttle 1000 1600 km 600 1000 mi Avoid prolonged operation above 1 2 throttle CAUTION ECA10331 After 1000 km 600 mi of operation the engine oil and final gear oil must be changed and the oil filter car t...

Page 67: ...switch and then turn the fuel cock lever to OFF WARNING EWA10310 Since the engine and exhaust system can become very hot park in a place where pedestri ans or children are not likely to touch them Do not park on a slope or on soft ground otherwise the vehicle may overturn U4XY16E0 book Page 5 Friday June 4 2004 10 06 AM ...

Page 68: ...ED 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 V...

Page 69: ...WARNING 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 U4XY16E0 book Page 2 Friday June 4 2004 10 06 AM ...

Page 70: ...necessary 2 Fuel filter Replace Replace 3 Spark plugs Check condition Adjust gap and clean Replace every 8000 mi 13000 km or 12 months Replace Replace 4 Valve clearance Check and adjust valve clearance when engine is cold Every 26600 mi 42000 km 5 Crankcase breather system Check breather hose for cracks or damage Replace if necessary 6 Carburetor synchro nization Adjust synchronization of carbu re...

Page 71: ...heck 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 for...

Page 72: ...ase lightly 13 Brake and shift ped al pivot shafts Apply lithium soap based grease all purpose grease lightly 14 Sidestand pivot Check operation Apply lithium soap based grease all purpose grease lightly 15 Sidestand switch Check operation and replace if necessary 16 Front fork Check operation and for oil leak age Replace if necessary 17 Shock absorber as sembly Check operation and for oil leak ag...

Page 73: ...r oil Check oil level and for oil leakage Change at initial 600 mi 1000 km or 1 month and thereafter every 16000 mi 25000 km or 24 months Change Change 23 Control cables Apply Yamaha chain and cable lube or engine oil SAE 10W 30 thoroughly 24 Throttle grip hous ing and cable Check operation and free play Adjust the throttle cable free play if necessary Lubricate the throttle grip housing and cable...

Page 74: ...utch 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 brake and clutch hos...

Page 75: ... to be re moved and installed EAU35841 Cowling A To remove the cowling 1 Remove the bolts 2 Remove the quick fastener screw by turning it 1 4 turn counterclock wise and then take the cowling off To install the cowling Place the cowling in the original posi tion and then install the quick fastener screw and the bolts 1 Cowling A 2 Panel A 1 Cowling B 2 Panel B 3 Panel C 1 Cowling A 2 Bolt 3 Quick f...

Page 76: ...s shown To install the cowling 1 Place the cowling in the original position and then install the bolts NOTE Make sure that the projection fits into the grommet 2 Install cowling A EAU35860 Panels A and B To remove one of the panels Remove the bolt and then pull the pan el off as shown 1 Grommet 2 Projection 3 Cowling A 1 Cowling B 2 Bolt 1 Bolt 1 Panel A 2 Bolt U4XY16E0 book Page 9 Friday June 4 2...

Page 77: ...e panel 1 Remove the left passenger foot rest by removing the bolts 2 Remove the screw and then pull the panel off as shown To install the panel 1 Place the panel in the original posi tion and then install the screw 2 Install the passenger footrest by installing the bolts 1 Panel B 2 Bolt 1 Panel C 2 Screw 3 Bolt U4XY16E0 book Page 10 Friday June 4 2004 10 06 AM ...

Page 78: ...round the center electrode on each spark plug is a medium to light tan the ideal color when the vehicle is ridden normally 2 Check that all spark plugs installed in the engine have the same color NOTE If any spark plug shows a distinctly dif ferent color the engine could be defec tive Do not attempt to diagnose such problems yourself Instead have a Yamaha dealer check the vehicle 3 Check each spar...

Page 79: ...acks or damage Replace if dam aged Make sure the vent hose is not blocked Clean it if necessary EAU19902 Engine oil and oil filter cartridge The engine oil level should be checked before each ride In addition the oil must be changed and the oil filter car tridge replaced at the intervals speci fied in the periodic maintenance and lubrication chart To check the engine oil level 1 Place the vehicle ...

Page 80: ...ce an oil pan under the engine to collect the used oil 3 Remove the engine oil filler cap and drain bolt to drain the oil from the crankcase NOTE Skip steps 4 6 if the oil filter cartridge is not being replaced 4 Remove the oil filter cartridge with an oil filter wrench NOTE An oil filter wrench is available at a Yamaha dealer 5 Apply a thin coat of engine oil to the O ring of the new oil filter c...

Page 81: ...el speci fication of CD or oils of a high er quality than specified In addition do not use oils labeled ENERGY CONSERVING II or higher Make sure that no foreign mate rial enters the crankcase 9 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 1 O ring 1 Torque wrench 2 Oil filter w...

Page 82: ...EWA10370 Make sure that no foreign mate rial enters the final gear case Make sure that no oil gets on the tire or wheel To check the final gear oil level 1 Place the vehicle on a level sur face and hold it in an upright posi tion NOTE The final gear oil level must be checked on a cold engine Make sure that the vehicle is posi tioned straight up when checking the oil level A slight tilt to the side...

Page 83: ...ied in the periodic maintenance and lubrication chart EAU20211 To check the coolant level 1 Place the vehicle on a level sur face and hold it in an upright posi tion 2 Remove panel A See page 7 8 NOTE The coolant level must be checked on a cold engine since the level varies with engine temperature Make sure that the vehicle is posi tioned straight up when checking the coolant level A slight tilt t...

Page 84: ...ed and the cool ing system will not be protected against frost and corrosion If water has been added to the coolant have a Yamaha dealer check the antifreeze content of the coolant as soon as possible otherwise the effectiveness of the coolant will be reduced WARNING EWA10380 Never attempt to remove the radiator cap when the engine is hot 5 Install the panel NOTE The radiator fan is automatically ...

Page 85: ...nt 2 Remove the air filter case by re moving the bolts 3 Loosen the air filter joint clamp screw and then pull the air filter off 4 Remove the air filter case cover by removing the screws 5 Remove the air filter element by removing the screws 6 Lightly tap the air filter element to remove most of the dust and dirt and then blow the remaining dirt out with compressed air as shown If the air filter ...

Page 86: ...r case cover by in stalling the screws 9 Install the air filter by pushing it onto the air filter joint then tighten ing the air filter joint clamp screw 10 Install the air filter case by install ing the bolts 11 Install the cowlings NOTE Make sure that the carburetor air vent hose is routed as shown EAU21270 Adjusting the carburetors The carburetors are important parts of the engine and emission ...

Page 87: ...ervals specified in the periodic maintenance and lubrication chart EAU32541 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 ...

Page 88: ...ad 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 EWA10520 It is dangerous to ride with a worn out tire When a tire tread begins to show lines have a Yamaha dealer replace the tire immediately Brakes tires and related wheel parts re placement should also be left to a Yamaha dealer Tire info...

Page 89: ...hould be balanced whenever either the tire or wheel has been changed or replaced An unbalanced wheel can result in poor performance adverse han dling characteristics and a short ened tire life Ride at moderate speeds after changing a tire since the tire sur face must first be broken in for it to develop its optimal characteris tics After repairing or replacing the rear tire tighten the valve stem ...

Page 90: ...g 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 EAU22071 Clutch lever free play Since this model is equipped with a hy draulic clutch adjusting the clutch lever free play is not needed However it is necess...

Page 91: ...ngy feeling in the brake lever can indicate the presence of air in the hydraulic system If there is air in the hy draulic system have a Yamaha dealer bleed the system before operating the motorcycle Air in the hydraulic system will dimin ish the braking performance which may result in loss of con trol and an accident EAU22280 Adjusting the rear brake light switch The rear brake light switch which ...

Page 92: ...r indicator grooves have almost disap peared have a Yamaha dealer replace the brake pads as a set EAU22470 Rear brake pads Each rear brake pad is provided with a wear indicator groove which allows you to check the brake pad wear with out having to disassemble the brake To check the brake pad wear check the wear indicator groove If a brake pad has worn to the point that the wear indicator groove ha...

Page 93: ...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 refilling Water will significantly lower the ...

Page 94: ... and the condition of the cables should be checked before each ride and the 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 ...

Page 95: ...d be lu bricated if necessary EAU23140 Checking and lubricating the brake and clutch levers 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 U4XY16E0 book Page 28 Friday June 4 ...

Page 96: ...iodic main tenance and lubrication chart To check the condition WARNING EWA10750 Securely support the vehicle so that there is no danger of it falling over Check the inner tubes for scratches damage and excessive oil leakage To check the operation 1 Place the vehicle on a level sur face and hold it in an upright posi tion 2 While applying the front brake push down hard on the handlebars several ti...

Page 97: ...ly support the vehicle so that there is no danger of it falling over 2 Hold the lower ends of the front fork legs and try to move them for ward and backward If any free play can be felt have a Yamaha dealer check or repair the steering EAU23290 Checking the wheel bearings The front and rear wheel bearings must be checked at the intervals specified in the periodic maintenance and lubrica tion chart...

Page 98: ...roduce explosive hy drogen gas Therefore keep sparks flames cigarettes etc away from the battery and pro vide sufficient ventilation when charging it in an enclosed space KEEP THIS AND ALL BATTER IES OUT OF THE REACH OF CHILDREN To charge the battery Have a Yamaha dealer charge the bat tery as soon as possible if it seems to have discharged Keep in mind that the battery tends to discharge more qui...

Page 99: ...tery If you do not have access to a sealed type MF battery charg er have a Yamaha dealer charge your battery EAU23662 Replacing the fuses The main fuse is located behind panel C See page 7 8 Fuse box 1 is located behind cowling A See page 7 8 Fuse box 2 is located behind panel B See page 7 8 1 Main fuse 2 Spare main fuse 1 Cruise control fuse 2 Carburetor heater fuse 3 Auxiliary DC terminal fuse 4...

Page 100: ...trical 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 Backup fuse for odometer and clock 2 Radiator fan fuse 3 Headlight fuse 4 Signaling system fuse 5 Ignition fuse 6 Spare fuse Specified fuses Fuse box 1 Cruse control fuse 10 0 A Carburetor heater fuse 10 0 A Auxiliary DC terminal fuse 5 0 A Auxiliary D...

Page 101: ...bulb until it has cooled down 3 Place a new bulb into position and then secure it with the bulb holder CAUTION ECA10660 Do not touch the glass part of the headlight bulb to keep it free from oil otherwise the transparency of the glass the luminosity of the bulb and the bulb life will be adversely af fected Thoroughly clean off any dirt and fingerprints on the headlight bulb using a cloth moistened...

Page 102: ...hen 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 stand or if an additional motorcycle...

Page 103: ...n cause poor starting and loss of power The following troubleshooting charts represent quick and easy procedures 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 part...

Page 104: ...ompression 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 ...

Page 105: ...e hissing sound has stopped press down on the cap while turning it counterclockwise and then remove the cap NOTE If coolant is not available tap water can be temporarily used instead provided that it is changed to the recommended coolant as soon as possible Wait until the engine has cooled Check the coolant level in the reservoir and radiator The coolant level is OK The coolant level is low Check ...

Page 106: ... the wheel axles Cleaning the motorcycle 1 Rinse any dirt and degreaser off with a garden hose using only enough pressure to do the job CAUTION ECA10940 Do not use high pressure wash ers since excessive high pres sure may cause water seepage and deterioration of wheel bear ings the front fork brakes transmission seals audio sys tem speakers saddlebags travel trunk and electrical parts Many expensi...

Page 107: ...ilizer 1 fluid oz per gallon or 7 5 ml per li ter Operate the engine for several minutes to insure the newly condi tioned fuel enters the entire fuel system and carburetors NOTE Use of Yamaha Fuel Conditioner and Stabilizer eliminates the need to drain the fuel system If necessary have a Yamaha dealer drain the fuel system 2 Remove the spark plugs and pour about one tablespoon of SAE 10W 30 or SAE...

Page 108: ...e seat cover 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 battery see page 7 31 NOTE If necessary make repairs before stor ing the motorcycle U4XY16E0 book Page 3 Friday June 4 2004 10 06 AM ...

Page 109: ...6 Imp qt Final gear oil Type SAE80 API GL 4 Hypoid gear oil Quantity 0 20 L 0 21 US qt 0 18 Imp qt Cooling system Coolant reservoir capacity up to the maximum level mark 0 84 L 0 89 US qt 0 74 Imp qt Radiator capacity including all routes 3 50 L 3 70 US qt 3 08 Imp qt Air filter Air filter element Dry element Fuel Recommended fuel Unleaded gasoline only Fuel tank capacity 22 5 L 5 94 US gal 4 95 I...

Page 110: ...g 0 198 lb Front 250 kPa 36 psi 2 50 kgf cm Rear 250 kPa 36 psi 2 50 kgf cm Loading condition 90 190 kg 198 419 lb 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 16M C x MT3 50 Rear wheel Wheel type Cast wheel Rim size 15M C x MT4 00 Front brake Type Dual disc brake Operation Right hand operation Recommended fluid DOT 4 Rear brake Type S...

Page 111: ...rature warning light 12 V 1 7 W 1 Engine trouble warning light 12 V 1 7 W 1 Overdrive indicator light 12 V 1 7 W 1 Cruise control SET indicator light 12 V 1 7 W 1 Cruise control RES indicator light 12 V 1 7 W 1 Cruise control ON indicator light 12 V 1 7 W 1 Audio system amplifier Speaker output 14 W 4 Headset output 1 W 2 Auto volume range 5 steps Speaker impedance 4 Ω Headset impedance 8 16 Ω Fus...

Page 112: ...dentification 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 an...

Page 113: ...bel is affixed to the frame under the rider seat See page 3 13 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 U4XY16E0 book Page 2 Friday June 4 2004 10 06 AM ...

Page 114: ...vestigation and if it finds that a safety defect exists in a group of vehicles it may order a recall and remedy campaign However NHTSA cannot become involved in individual problems between you your dealer or Yamaha Motor Corporation U S A To contact NHTSA you may either call the Auto Safety Hotline toll free at 1 800 424 9393 or 366 0123 in Washington D C area or write to NHTSA U S Department of T...

Page 115: ...hicle 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 ...

Page 116: ...minder that maintenance work is required It is not acceptable proof of maintenance work Maintenance interval Date of service Mileage Servicing dealer name and address Remarks 600 mi 1000 km or 1 month 4000 mi 7000 km or 6 months 8000 mi 13000 km or 12 months 12000 mi 19000 km or 18 months 16000 mi 25000 km or 24 months 20000 mi 31000 km or 30 months 24000 mi 37000 km or 36 months 28000 mi 43000 km...

Page 117: ...ORMATION 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 U4XY16E0 book Page 6 Friday June 4 2004 10 06 AM ...

Page 118: ...CONSUMER INFORMATION 10 7 10 EAU26702 YAMAHA MOTOR CORPORARION U S A ROYAL STAR VENTURE LIMITED WARRANTY U4XY16E0 book Page 7 Friday June 4 2004 10 06 AM ...

Page 119: ...CONSUMER INFORMATION 10 8 10 U4XY16E0 book Page 8 Friday June 4 2004 10 06 AM ...

Page 120: ...CONSUMER INFORMATION 10 9 10 U4XY16E0 book Page 9 Friday June 4 2004 10 06 AM ...

Page 121: ...p switch 3 8 Engine trouble warning light 3 3 F Final gear oil 7 15 Front and rear brake pads checking 7 25 Front fork adjusting 3 16 Front fork checking 7 29 Fuel 3 10 Fuel cock 3 11 Fuel level warning light 3 3 Fuel tank cap 3 10 Fuses replacing 7 32 H Handlebar switches 3 7 Hazard switch 3 8 Headlight bulb replacing 7 34 Headsets 4 2 Helmet holders 3 14 High beam indicator light 3 3 Horn switch...

Page 122: ...he motorcycle 7 35 T TALK switch 3 7 Throttle cable free play adjusting 7 20 Throttle grip and cable checking and lubricating 7 27 Tires 7 20 Tool kit 7 1 Troubleshooting 7 36 Troubleshooting charts 7 37 Turn signal indicator lights 3 2 Turn signal light bulb or tail brake light bulb replacing 7 35 Turn signal switch 3 7 V Valve clearance adjusting 7 20 Vehicle identification number 10 1 W Warrant...

Page 123: ...PRINTED IN JAPAN 2004 06 0 6 1 CR E PRINTED ON RECYCLED PAPER YAMAHA MOTOR CO LTD ...

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