2006 YAMAHA XV1900A check engine

TABLE OF CONTENTSSAFETY INFORMATION ..................1-1
DESCRIPTION ..................................2-1
Left view ..........................................2-1
Right view ........................................2-2
Controls and instruments.................2-3
INSTRUMENT AND CONTROL
FUNCTIONS.......................................3-1
Immobilizer system .........................3-1
Main switch/steering lock ................3-2
Indicator and warning lights ............3-3
Multi-function meter unit .................3-5
Anti-theft alarm (optional) ...............3-9
Handlebar switches ......................3-10
Clutch lever ...................................3-11
Shift pedal .....................................3-11
Brake lever ...................................3-11
Brake pedal ..................................3-12
Fuel tank cap ................................3-12
Fuel ...............................................3-13
Fuel tank breather hose ................3-14
Catalytic converter ........................3-14
Rider seat .....................................3-14
Helmet holder ...............................3-15
Adjusting the shock absorber
assembly ...................................3-16
EXUP system ...............................3-18
Sidestand ......................................3-18
Ignition circuit cut-off system ........3-19
Auxiliary DC connector .................3-21PRE-OPERATION CHECKS............. 4-1
Pre-operation check list .................. 4-2
OPERATION AND IMPORTANT
RIDING POINTS................................. 5-1
Starting the engine ......................... 5-1
Shifting ........................................... 5-2
Tips for reducing fuel
consumption ............................... 5-3
Engine break-in .............................. 5-3
Parking ........................................... 5-4
PERIODIC MAINTENANCE AND
MINOR REPAIR................................. 6-1
Owner’s tool kit ............................... 6-1
Periodic maintenance and
lubrication chart .......................... 6-2
Checking the spark plugs ............... 6-5
Engine oil and oil filter cartridge ..... 6-6
Transfer case oil ............................. 6-9
Air filter element ............................. 6-9
Checking the throttle cable
free play .................................... 6-10
Valve clearance ............................ 6-10
Tires ............................................. 6-10
Cast wheels .................................. 6-13
Clutch lever .................................. 6-13
Adjusting the rear brake light
switch ........................................ 6-14
Checking the front and rear
brake pads ................................ 6-14Checking the brake and clutch
fluid levels ................................. 6-15
Changing the brake and clutch
fluids ......................................... 6-16
Drive belt slack ............................ 6-16
Checking and lubricating the
cables ....................................... 6-17
Checking and lubricating the
throttle grip and cable ............... 6-17
Checking and lubricating the
brake and shift pedals .............. 6-18
Checking and lubricating the
brake and clutch levers ............ 6-18
Checking and lubricating the
sidestand .................................. 6-19
Lubricating the rear suspension ... 6-19
Checking the front fork ................. 6-20
Checking the steering .................. 6-20
Checking the wheel bearings ....... 6-21
Battery ......................................... 6-21
Replacing the fuses ..................... 6-23
Replacing a headlight bulb .......... 6-24
Tail/brake light ............................. 6-27
Replacing a turn signal light
bulb ........................................... 6-27
License plate light ........................ 6-28
Replacing an auxiliary light
bulb ........................................... 6-28
Supporting the motorcycle ........... 6-29
Troubleshooting ........................... 6-29
Troubleshooting chart .................. 6-30U5C4E0E0.book Page 1 Monday, March 13, 2006 10:29 AM

INSTRUMENT AND CONTROL FUNCTIONS
3-4
3
EAU11080
High beam indicator light “”
This indicator light comes on when the
high beam of the headlight is switched
on.
EAU11361
Fuel level warning light “”
This warning light comes on when the
fuel level drops below approximately
3.0 L (0.79 US gal) (0.66 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”.
If the warning light does not come on
for a few seconds, and then go off,
have a Yamaha dealer check the elec-
trical circuit.NOTE:This model is also equipped with a self-
diagnosis device for the fuel level de-
tection circuit. If the fuel level detection
circuit is defective, the following cycle
will be repeated until the malfunction is
corrected: The fuel level warning lightwill flash eight times, and then go off for
3.0 seconds. If this occurs, have a
Yamaha dealer check the vehicle.
EAU11530
Engine trouble warning light “”
This warning light comes on or flashes
when an electrical circuit monitoring the
engine is defective. When this occurs,
have a Yamaha dealer check the self-
diagnosis system. (See page 3-5 for an
explanation of the self-diagnosis de-
vice.)
The electrical circuit of the warning light
can be checked by turning the key to
“ON”. If the warning light does not come
on for a few seconds, then go off, have
a Yamaha dealer check the electrical
circuit.
EAU38620
Immobilizer system indicator light
The electrical circuit of the indicator
light can be checked by turning the key
to “ON”.
If the indicator light does not come on
for a few seconds, then go off, have a
Yamaha dealer check the electrical cir-
cuit.When the key is turned to “OFF” and 30
seconds have passed, the indicator
light will start flashing indicating the im-
mobilizer system is enabled. After 24
hours have passed, the indicator light
will stop flashing, however the immobi-
lizer system is still enabled.
This model is also equipped with a self-
diagnosis device for the immobilizer
system. (See page 3-5 for an explana-
tion of the self-diagnosis device.)
U5C4E0E0.book Page 4 Monday, March 13, 2006 10:29 AM

INSTRUMENT AND CONTROL FUNCTIONS
3-8
3
NOTE:Make sure there are no other immobi-
lizer keys close to the main switch, and
do not keep more than one immobilizer
key on the same key ring! Immobilizer
system keys may cause signal interfer-
ence, which may prevent the enginefrom starting.
2. If the engine starts, turn it off and
try starting the engine with the
standard keys.
3. If one or both of the standard keys
do not start the engine, take the
vehicle, the code re-registering
key and both standard keys to a
Yamaha dealer and have the stan-
dard keys re-registered.
If the odometer/tripmeter/clock display
indicates any error codes, note the
code number, and then have a Yamaha
dealer check the vehicle.CAUTION:
ECA11590
If the display indicates an error
code, the vehicle should be checked
as soon as possible in order to avoidengine damage.Brightness control mode
The brightness can be adjusted for the
following:


the multi-function meter unit panel
(item number “1”)


the LCD (item number “2”)


the speedometer, tachometer, and
the fuel gauge needles (item num-
ber “3”)
Select the brightness control mode as
follows.
1. Turn the key to “OFF”.
2. Push and hold the “SELECT”
switch.3. Turn the key to “ON”, and then re-
lease the “SELECT” switch after
five seconds.
Item number “1” is displayed.
4. Adjust the multi-function meter unit
panel brightness level by pushing
the “RESET” switch.
5. Push the “SELECT” switch to se-
lect the LCD.
Item number “2” is displayed.
Adjust the LCD brightness level by
pushing the “RESET” switch.
1. Multi-function meter unit panel
2. LCD
3. Speedometer needle
4. Tachometer needle
5. Fuel gauge needle
1. Multi-function meter unit panel
2. Item number
3. Brightness level
U5C4E0E0.book Page 8 Monday, March 13, 2006 10:29 AM

INSTRUMENT AND CONTROL FUNCTIONS
3-14
3
EAU13410
Fuel tank breather hose Before operating the motorcycle:

Check the fuel tank breather hose
connection.


Check the fuel tank breather hose
for cracks or damage, and replace
it if damaged.


Make sure that the end of the fuel
tank breather hose is not blocked,
and clean it if necessary.
EAU13431
Catalytic converter This model is equipped with a catalytic
converter in the exhaust system.
WARNING
EWA10860
The exhaust system is hot after op-
eration. Make sure that the exhaust
system has cooled down before do-ing any maintenance work.CAUTION:
ECA10700
The following precautions must be
observed to prevent a fire hazard or
other damages.

Use only unleaded gasoline.
The use of leaded gasoline will
cause unrepairable damage to
the catalytic converter.


Never park the vehicle near pos-
sible fire hazards such as grass
or other materials that easily
burn.


Do not allow the engine to idletoo long.
EAU34042
Rider seat To remove the rider seat
1. Insert the key into the seat lock,
and then turn it counterclockwise.
2. While holding the key in that posi-
tion, lift the front of the seat up, and
then pull the seat off.
To install the rider seat
1. Insert the projection on the rear of
the seat into the seat holder as
shown.
1. Fuel tank breather hose
1. Seat lock
2. Unlock.
U5C4E0E0.book Page 14 Monday, March 13, 2006 10:29 AM

INSTRUMENT AND CONTROL FUNCTIONS
3-18
3
EAU15281
EXUP system This model is equipped with Yamaha’s
EXUP (EXhaust Ultimate Power valve)
system. This system boosts engine
power by means of a valve that regu-
lates the diameter of the exhaust pipe.
The EXUP system valve is constantly
adjusted in accordance with the engine
speed by a computer-controlled servo-
motor.CAUTION:
ECA10191


The EXUP system has been set
and extensively tested at the
Yamaha factory. Changing
these settings without 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.
EAU15301
Sidestand The sidestand is located on the left side
of the frame. Raise the sidestand or
lower it with your foot while holding the
vehicle upright.NOTE:The built-in sidestand switch is part of
the ignition circuit cut-off system, which
cuts the ignition in certain situations.
(See further down for an explanation ofthe ignition circuit cut-off system.)
WARNING
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 starting off. Therefore, check
this system regularly as describedbelow and have a Yamaha dealer re-
pair it if it does not function proper-
ly.
U5C4E0E0.book Page 18 Monday, March 13, 2006 10:29 AM

INSTRUMENT AND CONTROL FUNCTIONS
3-19
3
EAU15311
Ignition circuit cut-off system The ignition circuit cut-off system (com-
prising the sidestand switch, clutch
switch and neutral switch) has the fol-
lowing functions.

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 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 a
Yamaha dealer check the system be-fore riding.
U5C4E0E0.book Page 19 Monday, March 13, 2006 10:29 AM

INSTRUMENT AND CONTROL FUNCTIONS
3-20
3
With the engine turned off:
1. Move the sidestand down.
2. Make sure that the engine stop switch is turned on.
3. Turn the key on.
4. Shift the transmission into the neutral position.
5. Push the start switch.
Does the engine start?
With the engine still running:
6. Move the sidestand up.
7. Keep the clutch lever pulled.
8. Shift the transmission into gear.
9. Move the sidestand down.
Does the engine stall?
After 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 should not be ridden until
checked by a Yamaha dealer.
The clutch switch may be defective.
The motorcycle should not be ridden until
checked by a Yamaha dealer.
YES NO YES NO YES NONOTE:
U5C4E0E0.book Page 20 Monday, March 13, 2006 10:29 AM

PRE-OPERATION CHECKS
4-2
4
EAU15603
Pre-operation check list
ITEM CHECKS PAGE
FuelCheck fuel level in fuel tank.
Refuel if necessary.
Check fuel line for leakage.3-13
Engine oilCheck oil level in oil tank.
If necessary, add recommended oil to specified level.
Check vehicle for oil leakage.6-6
Transfer case oilCheck vehicle for oil leakage. 6-9
Front brakeCheck 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.6-14, 6-15
Rear brakeCheck 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.6-14, 6-15
ClutchCheck operation.
If soft or spongy, have Yamaha dealer bleed hydraulic system.
Check fluid level in reservoir.
If necessary, add recommended fluid to specified level.
Check hydraulic system for leakage.6-13, 6-15
Throttle gripMake sure that operation is smooth.
Check cable free play.
If necessary, have Yamaha dealer adjust cable free play and lubricate cable and
grip housing.6-10, 6-17
U5C4E0E0.book Page 2 Monday, March 13, 2006 10:29 AM