2006 YAMAHA XV1900A brake
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PERIODIC MAINTENANCE AND MINOR REPAIR
6-2
6
EAU17705
Periodic maintenance and lubrication chart NOTE:
The annual checks must be performed every year, except if a kilometer-based maintenance is performed in-
stead.
From 50000 km, repeat the maintenance intervals starting from 10000 km.
Items marked with an asterisk should be performed by a Yamaha dealer as they require special tools, data and technicalskills.
NO. ITEM CHECK OR MAINTENANCE JOBODOMETER READING (× 1000 km)
ANNUAL
CHECK
1 10203040
1*Fuel lineCheck fuel hoses for cracks or damage.√√√√ √
2*Spark plugsCheck condition.
Clean and regap.√√
Replace.√√
3*ValvesCheck valve clearance.
Adjust.√√
4*Air filter elementReplace.√
5*ClutchCheck operation, fluid level and vehicle for fluid leakage.√√√√√
6*Front brakeCheck operation, fluid level and vehicle for fluid leakage.√√√√√ √
Replace brake pads. Whenever worn to the limit
7*Rear brakeCheck operation, fluid level and vehicle for fluid leakage.√√√√√ √
Replace brake pads. Whenever worn to the limit
8*Brake hosesCheck for cracks or damage.√√√√ √
Replace. Every 4 years
9*WheelsCheck runout and for damage.√√√√
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Page 46 of 86
PERIODIC MAINTENANCE AND MINOR REPAIR
6-4
6
EAU36771
NOTE:
Air filter
This model’s air filter is equipped with a disposable oil-coated paper element, which must not be cleaned with com-
pressed air to avoid damaging it.
The air filter element needs to be replaced more frequently when riding in unusually wet or dusty areas.
Hydraulic brake and clutch service
Regularly check and, if necessary, correct the brake fluid and clutch fluid levels.
Every two years replace the internal components of the brake master cylinders and calipers as well as clutch master
and release cylinders, and change the brake and clutch fluids.Replace the brake and clutch hoses every four years and if cracked or damaged.
24*Transfer case oilCheck oil level.√√
Change.√√√
25*Front and rear brake
switchesCheck operation.√√√√√ √
26Moving parts and ca-
blesLubricate.√√√√ √
27*Throttle grip housing
and cableCheck operation and free play.
Adjust the throttle cable free play if necessary.
Lubricate the throttle grip housing and cable.√√√√ √
28*Muffler and exhaust
pipeCheck the screw clamp for looseness.√√√√√
29*Lights, signals and
switchesCheck operation.
Adjust headlight beam.√√√√√ √ NO. ITEM CHECK OR MAINTENANCE JOBODOMETER READING (× 1000 km)
ANNUAL
CHECK
1 10203040U5C4E0E0.book Page 4 Monday, March 13, 2006 10:29 AM
Page 54 of 86
PERIODIC MAINTENANCE AND MINOR REPAIR
6-12
6
WARNING
EWA10470
Have a Yamaha dealer replace
excessively worn tires. Besides
being illegal, operating the vehi-
cle with excessively worn tires
decreases riding stability and
can lead to loss of control.
The replacement of all wheel
and brake related parts, includ-
ing the tires, should be left to a
Yamaha dealer, who has the
necessary professional knowl-edge and experience.
Tire informationThis motorcycle is equipped with cast
wheels and tubeless tires with valves.
WARNING
EWA10480
The front and rear tires should
be of the same make and de-
sign, otherwise the handling
characteristics of the motor-
cycle cannot be guaranteed.
After extensive tests, only the
tires listed below have been ap-
proved for this model by
Yamaha Motor Co., Ltd.
Always make sure that the valve
caps are securely installed to
prevent air pressure leakage.
Use only the tire valves and
valve cores listed below to
avoid tire deflation during ahigh-speed ride.
WARNING
EWA10600
This motorcycle is fitted with super-
high-speed tires. Note the following
points in order to make the most ef-
ficient use of these tires.
Use only the specified replace-
ment tires. Other tires may run
the danger of bursting at super
high speeds.
Brand-new tires can have a rela-
tively poor grip on certain road
surfaces until they have been
“broken in”. Therefore, it is ad-
visable before doing any high-
1. Tire air valve
2. Tire air valve core
3. Tire air valve cap with seal
Front tire:
Size:
130/70R18M/C 63H
Manufacturer/model:
DUNLOP/D251F
Rear tire:
Size:
190/60R17M/C 78H
Manufacturer/model:
DUNLOP/D251
FRONT and REAR:
Tire air valve:
TR412
Va l ve c o r e :
#9100 (original)
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Page 56 of 86
PERIODIC MAINTENANCE AND MINOR REPAIR
6-14
6
EAU22270
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. If
necessary, adjust the brake light switch
as follows.
Turn the adjusting nut while holding the
rear brake light switch in place. To
make the brake light come on earlier,
turn the adjusting nut in direction (a). To
make the brake light come on later, turn
the adjusting nut in direction (b).
EAU22390
Checking the front and rear
brake pads The front and rear brake pads must be
checked for wear at the intervals spec-
ified in the periodic maintenance and
lubrication chart.
EAU22430
Front brake pads
Each front brake pad is provided with
wear indicator grooves, which allow
you to check the brake pad wear with-
out having to disassemble the brake.
To check the brake pad wear, check
the wear indicator grooves. If a brake
pad has worn to the point that the wearindicator grooves have almost disap-
peared, have a Yamaha dealer replace
the brake pads as a set.
EAU22500
Rear brake pads
Check each rear brake pad for damage
and measure the lining thickness. If a
brake pad is damaged or if the lining
thickness is less than 0.8 mm (0.03 in),
have a Yamaha dealer replace the
brake pads as a set.
1. Rear brake light switch
2. Rear brake light switch adjusting nut
1. Brake pad wear indicator groove
1. Lining thickness
U5C4E0E0.book Page 14 Monday, March 13, 2006 10:29 AM
Page 57 of 86
PERIODIC MAINTENANCE AND MINOR REPAIR
6-15
6
EAU38630
Checking the brake and clutch
fluid levels Front brake
Rear brakeClutch
Insufficient brake or clutch fluid may al-
low air to enter the brake or clutch sys-
tems, possibly causing them to become
ineffective.
NOTE:The rear brake fluid reservoir is locatedunder the rider seat. (See page 3-14.)
Before riding, check that the brake and
clutch fluids are above the minimum
level marks and replenish if necessary.
A low brake or clutch fluid level may in-
dicate brake or clutch system leakage
and/or worn brake pads. If the brake or
clutch levels are low, be sure to check
the brake or clutch systems for leakage
and the brake pads for wear.Observe these precautions:
When checking the brake and
clutch fluid levels, make sure that
the top of each reservoir is level.
Use only the recommended quality
brake fluid, otherwise the rubber
seals may deteriorate, causing
leakage and poor braking or clutch
performance.
Refill with the same type of brake
fluid. Mixing fluids may result in a
harmful chemical reaction and
lead to poor braking or 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 boiling point
of the fluid and may result in vapor
lock.
Brake fluid may deteriorate paint-
ed surfaces or plastic parts. Al-
ways clean up spilled fluid
immediately.
1. Minimum level mark
1. Minimum level mark
1. Minimum level mark
Recommended brake and clutch flu-
id:
DOT 4 brake fluid
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Page 58 of 86
PERIODIC MAINTENANCE AND MINOR REPAIR
6-16
6
As the brake pads wear, it is nor-
mal for the brake fluid level to grad-
ually go down. However, if the
brake fluid level goes down sud-
denly, have a Yamaha dealer
check the cause.
EAU22750
Changing the brake and
clutch fluids Have a Yamaha dealer change the
brake and clutch fluids at the intervals
specified in the NOTE after the periodic
maintenance and lubrication chart. In
addition, have the oil seals of the brake
and clutch master cylinders and cali-
pers as well as the brake and clutch
hoses replaced at the intervals listed
below or whenever they are damaged
or leaking.
Oil seals: Replace every two
years.
Brake and clutch hoses: Replace
every four years.
EAU23040
Drive belt slack The drive belt slack should be checked
and adjusted at the intervals specified
in the periodic maintenance and lubri-
cation chart.
EAU38410
To check the drive belt slack
1. Place the vehicle on the sidestand.
2. Note the current position of the
drive belt using the marks near the
drive belt check hole.NOTE:The marks near the drive belt checkhole are 5.0 mm (0.2 in) apart.1. Drive belt
2. Marks
3. Drive belt slack
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Page 60 of 86
PERIODIC MAINTENANCE AND MINOR REPAIR
6-18
6
EAU23131
Checking and lubricating the
brake and shift pedals The operation of the brake and shift
pedals should be checked before each
ride, and the pedal pivots should be lu-
bricated if necessary.
EAU23140
Checking and lubricating the
brake and clutch levers Brake lever
Clutch lever
The operation of the brake and clutch
levers should be checked before each
ride, and the lever pivots should be lu-
bricated if necessary.
Recommended lubricant:
Lithium-soap-based grease (all-pur-
pose grease)
U5C4E0E0.book Page 18 Monday, March 13, 2006 10:29 AM
Page 62 of 86
PERIODIC MAINTENANCE AND MINOR REPAIR
6-20
6
EAU23271
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-
tenance and lubrication chart.
To check the condition
WARNING
EWA10750
Securely support the vehicle so thatthere 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 times to check if the front
fork compresses and rebounds
smoothly.
CAUTION:
ECA10590
If any damage is found or the front
fork does not operate smoothly,
have a Yamaha dealer check or re-pair it.
EAU23280
Checking the steering Worn or loose steering bearings may
cause danger. Therefore, the operation
of the steering must be checked as fol-
lows at the intervals specified in the pe-
riodic maintenance and lubrication
chart.
1. Place a stand under the engine to
raise the front wheel off the
ground.
WARNING
EWA10750
Securely support the vehicle so thatthere 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.
U5C4E0E0.book Page 20 Monday, March 13, 2006 10:29 AM