Yamaha XV19CSY Owner'S Manual Download

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TABLE OF CONTENTS

LOCATION OF IMPORTANT
LABELS

.............................................1-1

SAFETY INFORMATION

..................2-1

DESCRIPTION

..................................3-1

Left view ..........................................3-1
Right view ........................................3-2
Controls and instruments.................3-3

INSTRUMENT AND CONTROL
FUNCTIONS

.......................................4-1

assembly ...................................4-13

EXUP system ...............................4-15
Sidestand ......................................4-15
Ignition circuit cut-off system ........4-16

Auxiliary DC connector ................. 4-18

FOR YOUR SAFETY –
PRE-OPERATION CHECKS

............. 5-1

OPERATION AND IMPORTANT
RIDING POINTS

................................. 6-1

Starting the engine ......................... 6-1
Shifting ........................................... 6-2
Engine break-in .............................. 6-3
Parking ........................................... 6-4

PERIODIC MAINTENANCE AND
ADJUSTMENT

................................... 7-1

Owner’s tool kit ............................... 7-2
Periodic maintenance chart for the

emission control system ............. 7-3

General maintenance and

lubrication chart .......................... 7-4

Checking the spark plugs  ............... 7-8
Canister (for California only)  .......... 7-9
Engine oil and oil filter cartridge  ..... 7-9
Transfer case oil ........................... 7-13
Air filter element  ........................... 7-13
Checking the throttle cable free

play ........................................... 7-13

Valve clearance ............................ 7-14
Tires ............................................. 7-14
Cast wheels .................................. 7-16
Clutch lever .................................. 7-16

Adjusting the rear brake light

switch ....................................... 7-16

Checking the front and rear brake

pads .......................................... 7-17

Checking the brake and clutch

fluid levels ................................. 7-17

Changing the brake and clutch

fluids ......................................... 7-19

Drive belt slack ............................ 7-19
Checking and lubricating the

cables ....................................... 7-20

Checking and lubricating the

throttle grip and cable ............... 7-20

Checking and lubricating the

brake and shift pedals .............. 7-20

Checking and lubricating the

brake and clutch levers ............ 7-21

Checking and lubricating the

sidestand .................................. 7-22

Lubricating the rear suspension ... 7-22
Checking the front fork ................. 7-22
Checking the steering  .................. 7-23
Checking the wheel bearings ....... 7-23
Battery ......................................... 7-24
Replacing the fuses  ..................... 7-26
Replacing the headlight bulb  ....... 7-27
Tail/brake light  ............................. 7-28
Replacing a turn signal light

bulb ........................................... 7-28

Replacing a license plate light

bulb ........................................... 7-29

U29S11E0.book Page 1 Monday, July 14, 2008 11:34 AM

Summary of Contents for XV19CSY

Page 1: ...DIC183 29S 28199 11 XV19CSY C XV19CY C OWNER S MANUAL Read this manual carefully before operating this vehicle LIT 11626 22 58...

Page 2: ...EAU10042 Read this manual carefully before operating this vehicle This manual should stay with this vehicle if it is sold U29S11E0 book Page 1 Monday July 14 2008 11 34 AM...

Page 3: ...To maintain 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 Ya...

Page 4: ...ey 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 indicat...

Page 5: ...maha Motor Corporation U S A 1st edition July 2008 All rights reserved Any reprinting or unauthorized use without the written permission of Yamaha Motor Corporation U S A is expressly prohibited Print...

Page 6: ...and lubrication chart 7 4 Checking the spark plugs 7 8 Canister for California only 7 9 Engine oil and oil filter cartridge 7 9 Transfer case oil 7 13 Air filter element 7 13 Checking the throttle ca...

Page 7: ...1 Care 8 1 Storage 8 3 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 COR...

Page 8: ...icle 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...

Page 9: ...8 2118K 00 PREMIUM UNLEADED GASOLINE ONLY 91 Min Pump Octane R M 2 BEFORE YOU OPERATE THIS VEHICLE READ THE OWNER S MANUAL AND ALL LABELS ALWAYS WEAR AN APPROVED MOTORCYCLE HELMET eye protection and p...

Page 10: ...assenger 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...

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 l...

Page 12: ...of 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 Chec...

Page 13: ...ght 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...

Page 14: ...tery page 7 24 5 Owner s tool kit page 7 2 6 Tail brake light page 7 28 7 License plate light page 7 29 8 Engine oil drain bolt B crankcase page 7 9 9 Engine oil drain bolt A crankcase page 7 9 10 Eng...

Page 15: ...page 7 26 4 Fuse box page 7 26 5 Engine oil filler cap page 7 9 6 Fuel tank cap page 4 8 7 Steering lock page 4 11 8 Brake pedal page 4 8 9 Rear brake light switch page 7 16 10 Engine oil drain bolt o...

Page 16: ...ar switches page 4 5 3 Clutch fluid reservoir page 7 17 4 Multi function meter unit page 4 2 5 Main switch page 4 1 6 Front brake fluid reservoir page 7 17 7 Right handlebar switches page 4 5 8 Thrott...

Page 17: ...tems are off The key can be removed WARNING EWA10072 Never turn the key to OFF while the vehicle is moving otherwise the electrical systems will be switched off which may result in loss of con trol or...

Page 18: ...off for 3 0 seconds If this oc curs have a Yamaha dealer check the vehicle EAU11532 Engine trouble warning light This warning light comes on or flashes if a problem is detected in the electrical circu...

Page 19: ...cuit Fuel gauge The fuel gauge indicates the amount of fuel in the fuel tank The needle moves towards E Empty as the fuel level decreases When the needle reaches E approximately 3 2 L 0 85 US gal 0 7...

Page 20: ...prior mode after refueling and traveling 5 km 3 mi To set the clock 1 Push the SELECT and reset switches together for at least three seconds 2 When the hour digits start flashing push the reset switc...

Page 21: ...y to ON and then re lease the SELECT switch after five seconds 4 Adjust the multi function meter unit panel brightness level by pushing the reset switch 5 Push the SELECT switch The odometer tripmeter...

Page 22: ...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 overturn...

Page 23: ...ll the lever toward the handle bar grip To engage the clutch release the lever The lever should be pulled rapidly and released slowly for smooth clutch operation The clutch lever is equipped with a cl...

Page 24: ...the brake pedal EAU13121 Fuel tank cap To remove the fuel tank cap Slide the lock cover open insert the key into the lock and then turn it 1 4 turn clockwise The lock will be released and the fuel ta...

Page 25: ...er refuel while smoking or while in the vi cinity of sparks open flames or other sources of ignition such as the pilot lights of water heaters and clothes dryers 2 Do not overfill the fuel tank Stop f...

Page 26: ...e ethanol con tent does not exceed 10 E10 Gas ohol containing methanol is not recommended by Yamaha because it can cause damage to the fuel system or vehicle performance problems EAU13445 Catalytic co...

Page 27: ...ndlebar all the way to the left 2 Insert the key into the steering lock located on the frame near the head pipe and then turn it 1 2 turn clockwise 3 Check that the steering is locked and then remove...

Page 28: ...n place 3 Remove the key TIP Make sure that the seat is properly se cured before riding EAU44441 Helmet holder The helmet holder is located under the rider seat A helmet holding cable is provided unde...

Page 29: ...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 EAU38404 Adjusting the shock absorber assembly This shock absorb...

Page 30: ...ut distance A is changed by 2 0 mm 0 08 in 3 Tighten the locknut to the specified torque NOTICE Always tighten the locknut against the adjust ing nut and then tighten the locknut to the specified torq...

Page 31: ...thout sufficient technical knowledge may result in poor performance of or dam age to the engine If the EXUP system cannot be heard when the main switch is turned on have a Yamaha deal er check it EAU1...

Page 32: ...It prevents starting when the trans mission 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 pull...

Page 33: ...0 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 The neutral switch may not be working correctly The...

Page 34: ...To access the auxiliary DC connec tor 1 Remove the rider seat See page 4 12 2 Unhook the battery band and then remove the battery cover 3 Turn the ECU Electronic Control Unit over to move it away from...

Page 35: ...al have the vehicle inspected by a Yamaha dealer Before using this vehicle check the following points ITEM CHECKS PAGE Fuel Check fuel level in fuel tank Refuel if necessary Check fuel line for leakag...

Page 36: ...able free play If necessary have Yamaha dealer adjust cable free play and lubricate cable and grip housing 7 13 7 20 Control cables Make sure that operation is smooth Lubricate if necessary 7 20 Wheel...

Page 37: ...gnals 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 15 ITE...

Page 38: ...vent the engine from starting even though the engine will crank when pushing the start switch EAU16244 Starting the engine In order for the ignition circuit cut off system to enable starting one of th...

Page 39: ...hown in the il lustration 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 ECA102...

Page 40: ...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...

Page 41: ...e vehicle 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 pede...

Page 42: ...nning 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 carb...

Page 43: ...he 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 main...

Page 44: ...el 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 val...

Page 45: ...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 necess...

Page 46: ...ply 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 Ap...

Page 47: ...ereafter 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 thoroughly 27 Throttle gr...

Page 48: ...ore frequently when riding in unusually wet or dusty areas Hydraulic brake and clutch systems After disassembling the brake or clutch master cylinders caliper cylinders or clutch release cylinder alwa...

Page 49: ...be operating im properly Do not attempt to diagnose such problems yourself Instead have a Yamaha dealer check the vehicle If a spark plug shows signs of electrode erosion and excessive carbon or othe...

Page 50: ...1 Place 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 12 3 Start the engine warm it up...

Page 51: ...gine is run ning To change the engine 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 12 3 Start the engine warm it up...

Page 52: ...er cartridge with an oil filter wrench and then tighten it to the specified torque with a torque wrench 11 Install the engine oil drain bolts and then tighten them to the spec ified torques 1 Oil filt...

Page 53: ...t mix any chemical additives Do not use oils with a diesel 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...

Page 54: ...periodic mainte nance and lubrication chart EAU36762 Air filter element The air filter element must be replaced at the intervals specified in the periodic maintenance and lubrication chart Have a Yama...

Page 55: ...im proper tire pressure may cause se vere injury or death from loss of control The tire air pressure must be checked and adjusted on cold tires i e when the temperature of the tires equals the ambient...

Page 56: ...uld also be left to a Yamaha dealer Tire information This motorcycle is equipped with cast wheels and tubeless tires WARNING EWA10461 The front and rear tires should be of the same make and design oth...

Page 57: ...clutch lever free play is not needed However it is necessary to check the clutch fluid level and check the hydraulic system for leakage before each ride See page 7 17 If the clutch lever free play do...

Page 58: ...ck the wear indicator grooves If a brake pad has worn to the point that the wear indicator grooves have almost disap peared have a Yamaha dealer replace the brake pads as a set EAU22500 Rear brake pad...

Page 59: ...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 bra...

Page 60: ...ied 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 th...

Page 61: ...ith cable movement Replace damaged cables as soon as possi ble to prevent unsafe conditions EWA10711 EAU23111 Checking and lubricating the throttle grip and cable The operation of the throttle grip sh...

Page 62: ...ers 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...

Page 63: ...the periodic maintenance and lubrication chart EAU23272 Checking the front fork The condition and operation of the front fork must be checked as follows at the intervals specified in the periodic main...

Page 64: ...f the ground See page 7 29 for more information WARNING To avoid injury securely support the vehicle so there is no danger of it falling over EWA10751 2 Hold the lower ends of the front fork legs and...

Page 65: ...S Flush with water for 15 minutes and seek prompt medical attention Batteries produce explosive hy drogen gas Therefore keep sparks flames cigarettes etc away from the battery and pro vide sufficient...

Page 66: ...it and then place it in a cool dry place NOTICE When removing the battery be sure the key is turned to OFF then discon nect the negative lead before disconnecting the positive lead ECA16302 2 If the...

Page 67: ...battery cover 3 Remove the blown fuse and then install a new fuse of the specified amperage WARNING Do not use a fuse of a higher amperage rating than recommended to avoid causing extensive dam age t...

Page 68: ...nsparency 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 with al coh...

Page 69: ...LED type tail brake light If the tail brake light does not come on have a Yamaha dealer check it EAU24212 Replacing a turn signal light bulb 1 Remove the turn signal lens by re moving the screws 2 Rem...

Page 70: ...t 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...

Page 71: ...l 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 pr...

Page 72: ...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 engin...

Page 73: ...ler outlets with plas tic bags 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 stal...

Page 74: ...dirt 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...

Page 75: ...ver apply oil or wax to the drive belt Never apply oil or wax to any rubber and plastic parts but treat them with a suitable care product Avoid using abrasive polishing compounds as they will wear awa...

Page 76: ...e spark plug elec trodes while turning the en gine over EWA10951 4 Lubricate all control cables and the pivoting points of all levers and pedals as well as of the side stand centerstand 5 Check and if...

Page 77: ...ilter 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 e...

Page 78: ...i Loading condition 90 204 kg 198 450 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 21M C x MT3 50 Rear wheel Wheel type Cast wheel Rim...

Page 79: ...ht 12 V 3 8 W 2 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 fu...

Page 80: ...entification 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...

Page 81: ...el is affixed to the frame under the rider seat See page 4 12 Record the information on this label in the space provided This information will be needed when ordering spare parts from a Yamaha dealer...

Page 82: ...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 Yama...

Page 83: ...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...

Page 84: ...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 4...

Page 85: ...MATION 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 U29S11E0 book Page 6 Monday July 14...

Page 86: ...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...

Page 87: ...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 c...

Page 88: ...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 incl...

Page 89: ...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 he...

Page 90: ...s location 1 1 License plate light bulb replacing 7 29 Light switch for optional lights 4 6 M Main switch 4 1 Maintenance and lubrication periodic 7 4 Maintenance emission control system 7 3 Maintenan...

Page 91: ...INDEX Vehicle identification number 10 1 W Warranty extended 10 9 Warranty limited 10 7 Wheel bearings checking 7 23 Wheels 7 16 U29S11E0 book Page 2 Monday July 14 2008 11 34 AM...

Page 92: ...A5 yoko_Blank fm Page 1 Tuesday April 8 2003 11 43 AM...

Page 93: ...A5 yoko_Blank fm Page 1 Tuesday April 8 2003 11 43 AM...

Page 94: ...PRINTED IN JAPAN 2008 07 2 3 1 CR E PRINTED ON RECYCLED PAPER YAMAHA MOTOR CO LTD DIC183...

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