Read this manual carefully before operating this vehicle.
U29S12E0.book Page 1 Monday, June 1, 2009 1:05 PM EAU10042 Read this manual carefully before operating this vehicle. This manual should stay with this vehicle if it is sold.
U29S12E0.book Page 1 Monday, June 1, 2009 1:05 PM INTRODUCTION EAU10083 Congratulations on your purchase of the Yamaha XV19CSZ(C)/XV19CZ(C). This model is the result of Yamaha’s vast experience in the production of fine sporting, touring, and pacesetting racing machines. It represents the high degree of craftsmanship and reliability that have made Yamaha a leader in these fields. This manual will give you an understanding of the operation, inspection, and basic maintenance of this motorcycle.
U29S12E0.book Page 1 Monday, June 1, 2009 1:05 PM IMPORTANT MANUAL INFORMATION EAU10132 Particularly important information is distinguished in this manual by the following notations: This is the safety alert symbol. It is used to alert you to potential personal injury hazards. Obey all safety messages that follow this symbol to avoid possible injury or death. WARNING NOTICE TIP A WARNING indicates a hazardous situation which, if not avoided, could result in death or serious injury.
U29S12E0.book Page 2 Monday, June 1, 2009 1:05 PM IMPORTANT MANUAL INFORMATION EAU10193 XV19CSZ(C)/XV19CZ(C) OWNER’S MANUAL ©2009 by Yamaha Motor Corporation, U.S.A. 1st edition, May 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.
U29S12E0.book Page 1 Monday, June 1, 2009 1:05 PM 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 Main switch ..............................
U29S12E0.book Page 2 Monday, June 1, 2009 1:05 PM TABLE OF CONTENTS Supporting the motorcycle ............7-29 Troubleshooting ............................7-30 Troubleshooting chart ...................7-31 MOTORCYCLE CARE AND STORAGE ..........................................8-1 Matte color caution .........................8-1 Care ................................................8-1 Storage ...........................................8-3 SPECIFICATIONS .............................9-1 CONSUMER INFORMATION..
U29S12E0.book Page 1 Monday, June 1, 2009 1:05 PM LOCATION OF IMPORTANT LABELS EAU10383 1 Read and understand all of the labels on your 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.
U29S12E0.book Page 2 Monday, June 1, 2009 1:05 PM LOCATION OF IMPORTANT LABELS 1 3 California only WARNING BEFORE YOU OPERATE THIS VEHICLE, READ THE OWNER’S MANUAL AND ALL LABELS. ALWAYS WEAR AN APPROVED MOTORCYCLE HELMET, eye protection, and protectibe clothing. 1 PREMIUM UNLEADED GASOLINE ONLY 91 Min.
U29S12E0.book Page 1 Monday, June 1, 2009 1:05 PM SAFETY INFORMATION EAU10283 2 Be a Responsible Owner As the vehicle’s owner, you are responsible for the safe and proper operation of your motorcycle. Motorcycles are single-track vehicles. Their safe use and operation are dependent upon the use of proper riding techniques as well as the expertise of the operator. Every operator should know the following requirements before riding this motorcycle.
U29S12E0.book Page 2 Monday, June 1, 2009 1:05 PM SAFETY INFORMATION ● ● due to excessive speed or undercornering (insufficient lean angle for the speed). • Always obey the speed limit and never travel faster than warranted by road and traffic conditions. • Always signal before turning or changing lanes. Make sure that other motorists can see you. The posture of the operator and passenger is important for proper control.
U29S12E0.book Page 3 Monday, June 1, 2009 1:05 PM SAFETY INFORMATION ● ● 2 Do not run engine in poorly ventilated or partially enclosed areas such as barns, garages, or carports. Do not run engine outdoors where engine exhaust can be drawn into a building through openings such as windows and doors. Loading Adding accessories or cargo to your motorcycle can adversely affect stability and handling if the weight distribution of the motorcycle is changed.
U29S12E0.book Page 4 Monday, June 1, 2009 1:05 PM SAFETY INFORMATION Aftermarket Parts, Accessories, and Modifications While you may find aftermarket products similar in design and quality to genuine Yamaha accessories, recognize that some aftermarket accessories or modifications are not suitable because of potential safety hazards to you or others.
U29S12E0.book Page 1 Monday, June 1, 2009 1:05 PM DESCRIPTION EAU10410 Left view 3 1. 2. 3. 4. 5. 6. 7. 8. 9. Engine oil drain bolt A (crankcase) (page 7-9) 10.Engine oil filter cartridge (page 7-9) 11.
U29S12E0.book Page 2 Monday, June 1, 2009 1:05 PM DESCRIPTION EAU10420 Right view 1 2,3,4 5 6 7 3 10,11 1. 2. 3. 4. 5. 6. 7. 8. 9 8 9. Rear brake light switch (page 7-16) 10.Engine oil drain bolt (oil tank) (page 7-9) 11.
U29S12E0.book Page 3 Monday, June 1, 2009 1:05 PM DESCRIPTION EAU10430 Controls and instruments 3 1. 2. 3. 4. 5. 6. 7. 8. 9.
U29S12E0.book Page 1 Monday, June 1, 2009 1:05 PM INSTRUMENT AND CONTROL FUNCTIONS EAU10450 Main switch EAU45751 OFF All electrical systems are off. The key can be removed. EAU11004 Indicator and warning lights EWA10072 WARNING 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 control or an accident. 4 1. 2. 3. 4. 5. 6. The main switch controls the ignition and lighting systems.
U29S12E0.book Page 2 Monday, June 1, 2009 1:05 PM INSTRUMENT AND CONTROL FUNCTIONS EAU11080 High beam indicator light “ ” This indicator light comes on when the high beam of the headlight is switched on. EAU11365 4 Fuel level warning light “ ” This warning light comes on when the fuel level drops below approximately 3.2 L (0.85 US gal, 0.70 Imp.gal). When this occurs, refuel as soon as possible. The electrical circuit of the warning light can be checked by turning the key to “ON”.
U29S12E0.book Page 3 Monday, June 1, 2009 1:05 PM INSTRUMENT AND CONTROL FUNCTIONS ● ● ● ● ● two tripmeters (which show the distance traveled since they were last set to zero) a fuel reserve tripmeter (which shows the distance traveled on the fuel reserve) a clock a self-diagnosis device a brightness control mode TIP Be sure to turn the key to “ON” before using the “SELECT” and reset switches, except for setting the brightness control mode.
U29S12E0.book Page 4 Monday, June 1, 2009 1:05 PM INSTRUMENT AND CONTROL FUNCTIONS Odometer, tripmeters, fuel reserve tripmeter and clock F-TRIP → TRIP A → TRIP B → ODO → F-TRIP To reset a tripmeter, select it by pushing the “SELECT” switch, and then push the reset switch for at least one second. If you do not reset the fuel reserve tripmeter manually, it will reset itself automatically, and the display will return to the prior mode after refueling and traveling 5 km (3 mi). 3.
U29S12E0.book Page 5 Monday, June 1, 2009 1:05 PM INSTRUMENT AND CONTROL FUNCTIONS If the odometer/tripmeter/clock display indicates any error codes, note the code number, and then have a Yamaha dealer check the vehicle. ECA11590 NOTICE If the display indicates an error code, the vehicle should be checked as soon as possible in order to avoid engine damage. To set the brightness 1. Turn the key to “OFF”. 2. Push and hold the “SELECT” switch. 3.
U29S12E0.book Page 6 Monday, June 1, 2009 1:05 PM INSTRUMENT AND CONTROL FUNCTIONS 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 center position. Right 4 1. Engine stop switch “ / ” 2. Light switch (for optional lights) “ 3.
U29S12E0.book Page 7 Monday, June 1, 2009 1:05 PM INSTRUMENT AND CONTROL FUNCTIONS See “Multi-function meter unit” on page 4-2 for detailed information. EAU12820 EAU12870 Clutch lever Shift pedal 1. Clutch lever 1. Shift pedal The clutch lever is located at the left handlebar grip. To disengage the clutch, pull the lever toward the handlebar grip. To engage the clutch, release the lever. The lever should be pulled rapidly and released slowly for smooth clutch operation.
U29S12E0.book Page 8 Monday, June 1, 2009 1:05 PM INSTRUMENT AND CONTROL FUNCTIONS EAU12890 EAU12941 EAU13121 Brake lever Brake pedal Fuel tank cap 1. Brake lever 1. Brake pedal The brake lever is located at the right handlebar grip. To apply the front brake, pull the lever toward the handlebar grip. The brake pedal is on the right side of the motorcycle. To apply the rear brake, press down on the brake pedal. 1. 2. 3. 4. 4 Fuel tank cap lock cover “ ” mark Unlock. Lock.
U29S12E0.book Page 9 Monday, June 1, 2009 1:05 PM INSTRUMENT AND CONTROL FUNCTIONS 2. Turn the key counterclockwise to the original position, remove it, and then close the lock cover. TIP 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. EWA10131 WARNING Make sure that the fuel tank cap is properly installed before riding. Leaking fuel is a fire hazard.
U29S12E0.book Page 10 Monday, June 1, 2009 1:05 PM INSTRUMENT AND CONTROL FUNCTIONS ately. If gasoline spills on your skin, wash with soap and water. If gasoline spills on your clothing, change your clothes. EAU13381 4 Recommended fuel: PREMIUM UNLEADED GASOLINE ONLY Fuel tank capacity: 15.9 L (4.20 US gal, 3.50 Imp.gal) Fuel reserve amount (when the fuel level warning light comes on): 3.2 L (0.85 US gal, 0.70 Imp.gal) gasoline of a different brand.
U29S12E0.book Page 11 Monday, June 1, 2009 1:05 PM INSTRUMENT AND CONTROL FUNCTIONS ECA10701 NOTICE EAU44460 Steering lock To unlock the steering Use only unleaded gasoline. The use of leaded gasoline will cause unrepairable damage to the catalytic converter. 1. Unlock. 1. Steering lock 2. Lock. To lock the steering 1. Turn the handlebar 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.
U29S12E0.book Page 12 Monday, June 1, 2009 1:05 PM INSTRUMENT AND CONTROL FUNCTIONS EAU34042 EAU44441 Rider seat Helmet holder To remove the rider seat 1. Insert the key into the seat lock, and then turn it counterclockwise. 1. Projection 2. Seat holder 4 2. Push the front of the seat down to lock it in place. 3. Remove the key. 1. Seat lock 2. Unlock. 2. While holding the key in that position, lift the front of the seat up, and then pull the seat off.
U29S12E0.book Page 13 Monday, June 1, 2009 1:05 PM INSTRUMENT AND CONTROL FUNCTIONS To release the helmet from the helmet holder Remove the rider seat, remove the helmet holding cable from the helmet holder and the helmet, and then install the seat. EAU38404 Adjusting the shock absorber assembly This shock absorber assembly is equipped with a spring preload adjusting nut. ECA10101 NOTICE To avoid damaging the mechanism, do not attempt to turn beyond the maximum or minimum settings. 1.
U29S12E0.book Page 14 Monday, June 1, 2009 1:05 PM INSTRUMENT AND CONTROL FUNCTIONS 4 load and thereby soften the suspension, turn the adjusting nut in direction (b). ● To make the adjustment, use the special wrench and extension bar included in the additional tool kit, which was handed out separately at the purchase of the vehicle. ● The spring preload setting is determined by measuring distance A, shown in the illustration.
U29S12E0.book Page 15 Monday, June 1, 2009 1:05 PM INSTRUMENT AND CONTROL FUNCTIONS ● ● ● Do not subject the shock absorber assembly to an open flame or other high heat source. This may cause the unit to explode 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 assembly yourself. Take the shock absorber assembly to a Yamaha dealer for any service.
U29S12E0.book Page 16 Monday, June 1, 2009 1:05 PM INSTRUMENT AND CONTROL FUNCTIONS below and have a Yamaha dealer repair it if it does not function properly. 4 EAU44892 Ignition circuit cut-off system The ignition circuit cut-off system (comprising the sidestand switch, clutch switch and neutral switch) has the following functions. ● It prevents starting when the transmission is in gear and the sidestand is up, but the clutch lever is not pulled.
U29S12E0.book Page 17 Monday, June 1, 2009 1:05 PM INSTRUMENT AND CONTROL FUNCTIONS With the engine turned off: 1. Move the sidestand down. 2. Make sure that the engine stop switch is set to “ 3. Turn the key on. 4. Shift the transmission into the neutral position. 5. Push the start switch. Does the engine start? YES WARNING If a malfunction is noted, have a Yamaha dealer check the system before riding. ”. The neutral switch may not be working correctly.
U29S12E0.book Page 18 Monday, June 1, 2009 1:05 PM INSTRUMENT AND CONTROL FUNCTIONS EAU44585 Auxiliary DC connector 2 ECA15311 NOTICE The accessory connected to the auxiliary DC connector should not be used with the engine turned off, and the load must never exceed 36 W (3 A), otherwise the fuse may blow or the battery may discharge. 4 EWA12531 WARNING To prevent electrical shock or shortcircuiting, make sure that the cap is installed when the auxiliary DC connector is not being used.
U29S12E0.book Page 1 Monday, June 1, 2009 1:05 PM FOR YOUR SAFETY – PRE-OPERATION CHECKS EAU15596 Inspect your vehicle each time you use it to make sure the vehicle is in safe operating condition. Always follow the inspection and maintenance procedures and schedules described in the Owner’s Manual. EWA11151 WARNING Failure to inspect or maintain the vehicle properly increases the possibility of an accident or equipment damage. Do not operate the vehicle if you find any problem.
U29S12E0.book Page 2 Monday, June 1, 2009 1:05 PM FOR YOUR SAFETY – PRE-OPERATION CHECKS ITEM 5 CHECKS PAGE Rear brake • • • • • • • Check operation. If soft or spongy, have Yamaha dealer bleed hydraulic system. Check brake pads for wear. Replace if necessary. Check fluid level in reservoir. If necessary, add recommended brake fluid to specified level. Check hydraulic system for leakage. 7-16, 7-17 Clutch • • • • • Check operation. If soft or spongy, have Yamaha dealer bleed hydraulic system.
U29S12E0.book Page 3 Monday, June 1, 2009 1:05 PM FOR YOUR SAFETY – PRE-OPERATION CHECKS ITEM CHECKS Instruments, lights, signals 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.
U29S12E0.book Page 1 Monday, June 1, 2009 1:05 PM OPERATION AND IMPORTANT RIDING POINTS EAU15951 EAU47150 EAU16245 Starting the engine Read the Owner’s Manual carefully to become familiar with all controls. If there is a control or function you do not understand, ask your Yamaha dealer. EWA10271 WARNING Failure to familiarize yourself with the controls can lead to loss of control, which could cause an accident or injury.
U29S12E0.book Page 2 Monday, June 1, 2009 1:05 PM OPERATION AND IMPORTANT RIDING POINTS 2. Shift the transmission into the neutral position. (See page 6-2.) The neutral indicator light should come on. If not, ask a Yamaha dealer to check the electrical circuit. 3. Start the engine by pushing the start switch. NOTICE: For maximum engine life, never accelerate hard when the engine is cold! [ECA11041] If the engine fails to start, release the start switch, wait a few seconds, and then try again.
U29S12E0.book Page 3 Monday, June 1, 2009 1:05 PM OPERATION AND IMPORTANT RIDING POINTS 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 transmission into second gear. (Make sure not to shift the transmission into the neutral position.) 6. Open the throttle part way and gradually release the clutch lever. 7. Follow the same procedure when shifting to the next higher gear.
U29S12E0.book Page 4 Monday, June 1, 2009 1:05 PM OPERATION AND IMPORTANT RIDING POINTS 1000–1600 km (600–1000 mi) Avoid prolonged operation above 1/2 throttle. 1600 km (1000 mi) and beyond The vehicle can now be operated normally. ECA10270 EAU17213 Parking When parking, stop the engine, and then remove the key from the main switch. EWA10311 WARNING ● NOTICE If any engine trouble should occur during the engine break-in period, immediately have a Yamaha dealer check the vehicle.
U29S12E0.book Page 1 Monday, June 1, 2009 1:05 PM PERIODIC MAINTENANCE AND ADJUSTMENT EAU17232 Periodic inspection, adjustment, and lubrication will keep your vehicle in the safest and most efficient condition possible. Safety is an obligation of the vehicle owner/operator. The most important points of vehicle inspection, adjustment, and lubrication are explained on the following pages.
U29S12E0.book Page 2 Monday, June 1, 2009 1:05 PM PERIODIC MAINTENANCE AND ADJUSTMENT EAU17361 Owner’s tool kit 1. Owner’s tool kit The owner’s tool kit is located under the rider seat. (See page 4-12.) The service information included in this manual and the tools provided in the owner’s tool kit are intended to assist you in the performance of preventive maintenance and minor repairs. However, additional tools such as a torque wrench may be necessary to perform certain maintenance work correctly.
U29S12E0.book Page 3 Monday, June 1, 2009 1:05 PM PERIODIC MAINTENANCE AND ADJUSTMENT EAU17600 Periodic maintenance chart for the emission control system INITIAL No. ITEM ROUTINE 600 mi (1000 km) or 1 month ODOMETER READINGS 4000 mi (7000 km) or 6 months 8000 mi 12000 mi 16000 mi 20000 mi (13000 km) (19000 km) (25000 km) (31000 km) or or or or 12 months 18 months 24 months 30 months Fuel line • Check fuel hoses for cracks or damage. • Replace if necessary.
U29S12E0.book Page 4 Monday, June 1, 2009 1:05 PM PERIODIC MAINTENANCE AND ADJUSTMENT EAU32185 General maintenance and lubrication chart INITIAL No. ITEM ROUTINE 600 mi (1000 km) or 1 month ODOMETER READINGS 4000 mi (7000 km) or 6 months 8000 mi 12000 mi 16000 mi 20000 mi (13000 km) (19000 km) (25000 km) (31000 km) or or or or 12 months 18 months 24 months 30 months 1 * Air filter element • Replace. Every 24000 mi (37000 km) 2 * Clutch • Check operation and fluid leakage.
U29S12E0.book Page 5 Monday, June 1, 2009 1:05 PM PERIODIC MAINTENANCE AND ADJUSTMENT INITIAL No. ITEM ROUTINE 600 mi (1000 km) or 1 month Drive belt • Check belt tension. • Adjust if necessary. √ 11 * Steering bearings • Check bearing assemblies for looseness. • Moderately repack with lithiumsoap-based grease every 16000 mi (25000 km) or 24 months.
U29S12E0.book Page 6 Monday, June 1, 2009 1:05 PM PERIODIC MAINTENANCE AND ADJUSTMENT INITIAL ROUTINE 600 mi (1000 km) or 1 month ODOMETER READINGS 4000 mi (7000 km) or 6 months 8000 mi 12000 mi 16000 mi 20000 mi (13000 km) (19000 km) (25000 km) (31000 km) or or or or 12 months 18 months 24 months 30 months No. ITEM 20 * Shock absorber assembly • Check operation and for oil leakage. • Replace if necessary. 21 * Rear suspension link pivots • Apply lithium-soap-based grease lightly.
U29S12E0.book Page 7 Monday, June 1, 2009 1:05 PM PERIODIC MAINTENANCE AND ADJUSTMENT TIP From 24000 mi (37000 km) or 36 months, repeat the maintenance intervals starting from 8000 mi (13000 km) or 12 months. EAU38440 TIP ● ● Air filter • This model’s air filter is equipped with a disposable oil-coated paper element, which must not be cleaned with compressed air to avoid damaging it. • The air filter element needs to be replaced more frequently when riding in unusually wet or dusty areas.
U29S12E0.book Page 8 Monday, June 1, 2009 1:05 PM PERIODIC MAINTENANCE AND ADJUSTMENT EAU19642 Checking the spark plugs The spark plugs are important engine components, which should be checked periodically, preferably by a Yamaha dealer. Since heat and deposits will cause any spark plug to slowly erode, they should be removed and checked in accordance with the periodic maintenance and lubrication chart. In addition, the condition of the spark plugs can reveal the condition of the engine.
U29S12E0.book Page 9 Monday, June 1, 2009 1:05 PM PERIODIC MAINTENANCE AND ADJUSTMENT EAU19681 Canister (for California only) EAU38368 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 cartridge replaced at the intervals specified in the periodic maintenance and lubrication chart. 7 This model is equipped with a canister to prevent the discharging of fuel vapor into the atmosphere.
U29S12E0.book Page 10 Monday, June 1, 2009 1:05 PM PERIODIC MAINTENANCE AND ADJUSTMENT ECA10900 NOTICE Make sure that the oil filler cap is securely tightened, otherwise oil may seep out when the engine is running. 1. Maximum level mark 2. Minimum level mark 3. Engine oil dipstick 5. If the engine oil is at or below the minimum level mark, add sufficient oil of the recommended type to raise it to the correct level.
U29S12E0.book Page 11 Monday, June 1, 2009 1:05 PM PERIODIC MAINTENANCE AND ADJUSTMENT TIP Skip steps 8–10 if the oil filter cartridge is not being replaced. 8. Remove the oil filter cartridge with an oil filter wrench. 1. O-ring 1. Oil filter cartridge 2. Torque wrench TIP Make sure that the O-ring is properly seated. 1. Oil filter cartridge 2. Oil filter wrench 7 TIP An oil filter wrench is available at a Yamaha dealer. 10.
U29S12E0.book Page 12 Monday, June 1, 2009 1:05 PM PERIODIC MAINTENANCE AND ADJUSTMENT 12. Pour only 2.5 L (2.6 US qt, 2.2 Imp.qt) of the specified amount of recommended engine oil through the filler hole, insert the dipstick, and then tighten the oil filler cap. 13. Start the engine, rev it several times, and then turn it off. 14. Remove the engine oil filler cap, and then gradually fill the oil tank with the remaining oil quantity while regularly checking the oil level on the dipstick.
U29S12E0.book Page 13 Monday, June 1, 2009 1:05 PM PERIODIC MAINTENANCE AND ADJUSTMENT EAU36762 Air filter element The air filter element must be replaced at the intervals specified in the periodic maintenance and lubrication chart. Have a Yamaha dealer replace the air filter element. EAU21382 Checking the throttle cable free play 1 1. Throttle cable free play 7 The throttle cable free play should measure 4.0–6.0 mm (0.16–0.24 in) at the throttle grip.
U29S12E0.book Page 14 Monday, June 1, 2009 1:05 PM PERIODIC MAINTENANCE AND ADJUSTMENT EAU32542 Tires To maximize the performance, durability, and safe operation of your motorcycle, 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. EWA10501 WARNING Operation of this vehicle with improper tire pressure may cause severe injury or death from loss of control.
U29S12E0.book Page 15 Monday, June 1, 2009 1:05 PM PERIODIC MAINTENANCE AND ADJUSTMENT EWA10520 WARNING It is dangerous to ride with a wornout tire. When a tire tread begins to show lines, have a Yamaha dealer replace the tire immediately. Brakes, tires and related wheel parts replacement should also be left to a Yamaha dealer.
U29S12E0.book Page 16 Monday, June 1, 2009 1:05 PM PERIODIC MAINTENANCE AND ADJUSTMENT EAU22073 Clutch lever Since this model is equipped with a hydraulic clutch, adjusting the clutch lever free play is not needed. However, it is necessary to check the clutch fluid level and check the hydraulic system for leakage before each ride. (See page 7-17.
U29S12E0.book Page 17 Monday, June 1, 2009 1:05 PM PERIODIC MAINTENANCE AND ADJUSTMENT indicator grooves have almost disappeared, have a Yamaha dealer replace the brake pads as a set. EAU22500 EAU38630 Checking the brake and clutch fluid levels Clutch Front brake Rear brake pads 1. Minimum level mark 1. Minimum level mark 1. Lining thickness 7 Rear brake Insufficient brake or clutch fluid may allow air to enter the brake or clutch systems, possibly causing them to become ineffective.
U29S12E0.book Page 18 Monday, June 1, 2009 1:05 PM PERIODIC MAINTENANCE AND ADJUSTMENT 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. ● As the brake pads wear, it is normal for the brake fluid level to gradually go down.
U29S12E0.book Page 19 Monday, June 1, 2009 1:05 PM PERIODIC MAINTENANCE AND ADJUSTMENT EAU23040 Drive belt slack The drive belt slack should be checked and adjusted at the intervals specified in the periodic maintenance and lubrication 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. 3. Note the position of the drive belt with a force of 45 N (4.
U29S12E0.book Page 20 Monday, June 1, 2009 1:05 PM PERIODIC MAINTENANCE AND ADJUSTMENT EAU23111 Checking and lubricating the throttle grip and cable EAU44271 Checking and lubricating the brake and shift pedals Recommended lubricant: Lithium-soap-based grease The operation of the throttle grip should be checked before each ride. In addition, the cable should be lubricated at the intervals specified in the periodic maintenance chart.
U29S12E0.book Page 21 Monday, June 1, 2009 1:05 PM PERIODIC MAINTENANCE AND ADJUSTMENT EAU43600 Checking and lubricating the brake and clutch levers EAU23202 Recommended lubricant: Silicone grease Checking and lubricating the sidestand Brake lever The operation of the sidestand should be checked before each ride, and the sidestand pivot and metal-to-metal contact surfaces should be lubricated if necessary.
U29S12E0.book Page 22 Monday, June 1, 2009 1:05 PM PERIODIC MAINTENANCE AND ADJUSTMENT EAU23250 Lubricating the rear suspension 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 maintenance and lubrication chart. To check the condition Check the inner tubes for scratches, damage and excessive oil leakage.
U29S12E0.book Page 23 Monday, June 1, 2009 1:05 PM PERIODIC MAINTENANCE AND ADJUSTMENT EAU23283 Checking the steering 7 Worn or loose steering bearings may cause danger. Therefore, the operation of the steering must be checked as follows at the intervals specified in the periodic maintenance and lubrication chart. 1. Place a stand under the engine to raise the front wheel off the ground. (See page 7-29 for more information.
U29S12E0.book Page 24 Monday, June 1, 2009 1:05 PM PERIODIC MAINTENANCE AND ADJUSTMENT ● ● Batteries produce explosive hydrogen gas. Therefore, keep sparks, flames, cigarettes, etc., away from the battery and provide sufficient ventilation when charging it in an enclosed space. KEEP THIS AND ALL BATTERIES OUT OF THE REACH OF CHILDREN. To access the battery 1. Remove the rider seat. (See page 4-12.) 2. Unhook the battery band, and then remove the battery cover. 2 3.
U29S12E0.book Page 25 Monday, June 1, 2009 1:05 PM PERIODIC MAINTENANCE AND ADJUSTMENT battery tends to discharge more quickly if the vehicle is equipped with optional electrical accessories. ECA16520 NOTICE To charge a VRLA (Valve Regulated Lead Acid) battery, a special (constant-voltage) battery charger is required. Using a conventional battery charger will damage the battery. If you do not have access to a constant-voltage battery charger, have a Yamaha dealer charge your battery. 3.
U29S12E0.book Page 26 Monday, June 1, 2009 1:05 PM PERIODIC MAINTENANCE AND ADJUSTMENT avoid causing extensive damage to the electrical system and possibly a fire. [EWA15131] 1. 2. 3. 4. Main fuse Fuel injection system fuse Fuel injection system spare fuse Fuse box 1. 2. 3. 4. 5. 6. 7. 8. Fuse box Auxiliary DC connector fuse Signaling system fuse Ignition fuse Backup fuse (for odometer and clock) Headlight fuse Taillight fuse Spare fuse 7-26 Specified fuses: Main fuse: 50.0 A Headlight fuse: 20.
U29S12E0.book Page 27 Monday, June 1, 2009 1:05 PM PERIODIC MAINTENANCE AND ADJUSTMENT EAU23795 Replacing the headlight bulb This model is equipped with a quartz bulb headlight. If the headlight bulb burns out, replace it as follows. ECA10650 NOTICE 7 Take care not to damage the following parts: ● Headlight bulb 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 affected.
U29S12E0.book Page 28 Monday, June 1, 2009 1:05 PM PERIODIC MAINTENANCE AND ADJUSTMENT 5. Install the headlight bulb cover, and then connect the coupler. 6. Install the headlight unit by installing the screws. 7. Have a Yamaha dealer adjust the headlight beam if necessary. EAU24181 Tail/brake light This model is equipped with an LEDtype 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.
U29S12E0.book Page 29 Monday, June 1, 2009 1:05 PM PERIODIC MAINTENANCE AND ADJUSTMENT EAU24324 EAU24350 Replacing a license plate light bulb Supporting the motorcycle 1. Remove the license plate light unit by removing the nuts, washers and rubber dampers. 1. 2. 3. 4. 7 1. 2. 3. 4. Nut Washer Rubber damper License plate light unit 2. Remove the license plate light lens by removing the nuts and washers. 3. Remove the burnt-out bulb by pulling it out.
U29S12E0.book Page 30 Monday, June 1, 2009 1:05 PM PERIODIC MAINTENANCE AND ADJUSTMENT a jack 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 during operation. Any problem in the fuel, compression, or ignition systems, for example, can cause poor starting and loss of power.
U29S12E0.book Page 31 Monday, June 1, 2009 1:05 PM PERIODIC MAINTENANCE AND ADJUSTMENT EAU42601 Troubleshooting chart 1. Fuel There is enough fuel. Check the compression. There is no fuel. Supply fuel. There is compression. Check the ignition. There is no compression. Have a Yamaha dealer check the vehicle. Check the fuel level in the fuel tank. The engine does not start. Check the compression. 2. Compression Operate the electric starter. 3.
U29S12E0.book Page 1 Monday, June 1, 2009 1:05 PM MOTORCYCLE CARE AND STORAGE EAU37833 Matte color caution ucts onto seals, gaskets, the drive belt and wheel axles. Always rinse the dirt and degreaser off with water. EAU32934 Care ECA15192 NOTICE Some models are equipped with matte colored finished parts. Be sure to consult a Yamaha dealer for advice on what products to use before cleaning the vehicle.
U29S12E0.book Page 2 Monday, June 1, 2009 1:05 PM MOTORCYCLE CARE AND STORAGE ● ● 8 ● off any detergent residue using plenty of water, as it is harmful to plastic parts. Do not use any harsh chemical products on plastic parts. Be sure to avoid using cloths or sponges which have been in contact with strong or abrasive cleaning products, solvent or thinner, fuel (gasoline), rust removers or inhibitors, brake fluid, antifreeze or electrolyte.
U29S12E0.book Page 3 Monday, June 1, 2009 1:05 PM MOTORCYCLE CARE AND STORAGE 3. To prevent corrosion, it is recommended to apply a corrosion protection spray on all metal, including chrome- and nickel-plated, surfaces. 4. Use spray oil as a universal cleaner to remove any remaining dirt. 5. Touch up minor paint damage caused by stones, etc. 6. Wax all painted and chrome-plated surfaces. Avoid combination cleaner waxes, many of which contain abrasives that may mar the paint or protective finish. 7.
U29S12E0.book Page 4 Monday, June 1, 2009 1:05 PM MOTORCYCLE CARE AND STORAGE 8 3. Perform the following steps to protect 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 plugs on the cylinder head so that the electrodes are grounded. (This will limit sparking during the next step.) d.
U29S12E0.book Page 1 Monday, June 1, 2009 1:05 PM SPECIFICATIONS Dimensions: Overall length: 2572 mm (101.3 in) Overall width: 925 mm (36.4 in) Overall height: 1165 mm (45.9 in) Seat height: 695 mm (27.4 in) Wheelbase: 1799 mm (70.8 in) Ground clearance: 146 mm (5.75 in) Minimum turning radius: 3500 mm (137.
U29S12E0.book Page 2 Monday, June 1, 2009 1:05 PM SPECIFICATIONS Transmission type: Constant mesh 5-speed Operation: Left foot operation Gear ratio: 1st: 38/16 (2.375) 2nd: 33/21 (1.571) 3rd: 29/25 (1.160) 4th: 26/28 (0.929) 5th: 24/30 (0.800) Chassis: Frame type: Double cradle Caster angle: 33.20 ° Trail: 102.0 mm (4.
U29S12E0.book Page 3 Monday, June 1, 2009 1:05 PM SPECIFICATIONS Voltage, capacity: 12 V, 12.0 Ah Headlight: Bulb type: Halogen bulb Bulb voltage, wattage × quantity: Headlight: 12 V, 60 W/55 W × 1 Tail/brake light: LED Front turn signal/position light: 12 V, 23 W/8.0 W × 2 Rear turn signal light: 12 V, 21.0 W × 2 License plate light: 12 V, 3.
U29S12E0.book Page 1 Monday, June 1, 2009 1:05 PM CONSUMER INFORMATION EAU26352 Identification numbers EAU26381 EAU26400 Key identification number Vehicle identification number 1. Key identification number 1. Vehicle identification 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. The vehicle identification number is stamped into the steering head pipe.
U29S12E0.book Page 2 Monday, June 1, 2009 1:05 PM CONSUMER INFORMATION EAU26470 Model label EAU48270 Vehicle Emission Control Information label 1 1. Model label The model label 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. 1.
U29S12E0.book Page 3 Monday, June 1, 2009 1:05 PM CONSUMER INFORMATION EAU26551 Reporting safety defects If you believe that your vehicle has a defect which could cause a crash or could cause injury or death, you should immediately inform the National Highway Traffic Safety Administration (NHTSA) in addition to notifying Yamaha Motor Corporation, U.S.A.
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U29S12E0.book Page 5 Monday, June 1, 2009 1:05 PM CONSUMER INFORMATION EAU26632 Maintenance record Copies of work orders and/or receipts for parts purchased and installed on your vehicle will be required to document that maintenance has been completed in accordance with the emissions warranty. The chart below is printed only as a reminder that maintenance work is required. It is not acceptable proof of maintenance work.
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U29S12E0.book Page 7 Monday, June 1, 2009 1:05 PM CONSUMER INFORMATION EAU26663 YAMAHA MOTOR CORPORATION, U.S.A. STREET AND ENDURO MOTORCYCLE LIMITED WARRANTY Yamaha Motor Corporation, U.S.A. hereby warrants that new Yamaha motorcycles will be free from defects in material and workmanship for the period of time stated herein, subject to certain stated limitations.
U29S12E0.book Page 8 Monday, June 1, 2009 1:05 PM CONSUMER INFORMATION WARRANTY QUESTIONS AND ANSWERS CUSTOMER SERVICE Q. What costs are my responsibility during the warranty period? A. The customer’s responsibility includes all costs of normal maintenance services, non-warranty repairs, accident and collision damages, and oil, oil filters, air filters, spark plugs, and brake shoes.
U29S12E0.book Page 9 Monday, June 1, 2009 1:05 PM CONSUMER INFORMATION EAU26750 YAMAHA EXTENDED SERVICE (Y.E.S.) Keep your Yamaha protected even after your warranty expires with genuine Yamaha Extended Service (Y.E.S.). In addition, Travel and Recreation Interruption Protection (TRIP) is included at no extra cost.
U29S12E0.book Page 10 Monday, June 1, 2009 1:05 PM CONSUMER INFORMATION We urge you to act now. You’ll get the excellent benefits of TRIP coverage right away, and you’ll rest easy knowing you’ll have strong factory-backed 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.
U29S12E0.book Page 1 Monday, June 1, 2009 1:05 PM INDEX A Air filter element .................................... 7-13 Auxiliary DC connector ......................... 4-18 H B Battery................................................... 7-23 Brake and clutch fluid levels, checking ............................................. 7-17 Brake and clutch fluids, changing ......... 7-18 Brake and clutch levers, checking and lubricating ..................... 7-21 Brake and shift pedals, checking and lubricating ..
U29S12E0.book Page 2 Monday, June 1, 2009 1:05 PM INDEX Vehicle Emission Control Information label.................................................... 10-2 Vehicle identification number................ 10-1 W Warranty, extended .............................. 10-9 Warranty, limited................................... 10-7 Wheel bearings, checking .................... 7-23 Wheels..................................................
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YAMAHA MOTOR CO., LTD. PRINTED ON RECYCLED PAPER PRINTED IN JAPAN 2009.06-0.
