2006 YAMAHA XV1900A oil filter

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

DESCRIPTION
2-2
2
EAU10420
Right view1. Helmet holder (page 3-15)
2. Fuel injection system fuse (page 6-23)
3. Rear brake fluid reservoir (page 6-15)
4. Fuse box (page 6-23)
5. Engine oil filler cap (page 6-6)
6. Fuel tank cap (page 3-12)
7. Front brake fluid reservoir (page 6-15)
8. Brake pedal (page 3-12)9. Engine oil filter cartridge (page 6-6)
10.Engine oil drain bolt (oil tank) (page 6-6)
11.Shock absorber assembly spring preload adjusting nut (page 3-16)
U5C4E0E0.book Page 2 Monday, March 13, 2006 10:29 AM

OPERATION AND IMPORTANT RIDING POINTS
5-3
5
EAU16810
Tips for reducing fuel con-
sumption Fuel consumption depends largely on
your riding style. Consider the following
tips to reduce fuel consumption:

Shift up swiftly, and avoid high en-
gine speeds during acceleration.


Do not rev the engine while shifting
down, and avoid high engine
speeds with no load on the engine.


Turn the engine off instead of let-
ting it idle for an extended length of
time (e.g., in traffic jams, at traffic
lights or at railroad crossings).
EAU16841
Engine break-in There is never a more important period
in the life of your engine than the period
between 0 and 1600 km (1000 mi). For
this reason, you should read the follow-
ing material carefully.
Since the engine is brand new, do not
put an excessive load on it for the first
1600 km (1000 mi). The various parts in
the engine wear and polish themselves
to the correct operating clearances.
During this period, prolonged full-throt-
tle operation or any condition that might
result in engine overheating must be
avoided.
EAU17111
0–1000 km (0–600 mi)
Avoid prolonged operation above 2500
r/min.
1000–1600 km (600–1000 mi)
Avoid prolonged operation above 3000
r/min.
CAUTION:
ECA10891
After 1000 km (600 mi) of operation,
the engine oil and transfer case oil
must be changed, and the oil filtercartridge or element replaced.
1600 km (1000 mi) and beyond
The vehicle can now be operated nor-
mally.CAUTION:
ECA10310


Keep the engine speed out of
the tachometer red zone.


If any engine trouble should oc-
cur during the engine break-in
period, immediately have a
Yamaha dealer check the vehi-cle.
U5C4E0E0.book Page 3 Monday, March 13, 2006 10:29 AM

PERIODIC MAINTENANCE AND MINOR REPAIR
6-3
6
10*TiresCheck tread depth and for damage.
Replace if necessary.
Check air pressure.
Correct if necessary.√√√√ √
11*Wheel bearingsCheck bearing for looseness or damage.√√√√
12*SwingarmCheck operation and for excessive play.√√√√
13*Drive beltCheck belt tension.
Make sure that the rear wheel is properly aligned.Every 4000 km
14*Steering bearingsCheck bearing play and steering for roughness.√√√√√
Lubricate with lithium-soap-based grease. Every 50000 km
15*Chassis fastenersMake sure that all nuts, bolts and screws are properly
tightened.√√√√ √
16 SidestandCheck operation.
Lubricate.√√√√ √
17*Sidestand switchCheck operation.√√√√√ √
18*Front forkCheck operation and for oil leakage.√√√√
19*Shock absorber assem-
blyCheck operation and shock absorber for oil leakage.√√√√
20*Rear suspension relay
arm and connecting
arm pivoting pointsCheck operation.√√√√
Lubricate with lithium-soap-based grease.√√
21*Fuel injection systemAdjust synchronization.√√√√ √
22 Engine oilChange.
Check oil level and vehicle for oil leakage.√√√√√ √
23Engine oil filter car-
tridgeReplace.√√√ NO. ITEM CHECK OR MAINTENANCE JOBODOMETER READING (× 1000 km)
ANNUAL
CHECK
1 10203040
U5C4E0E0.book Page 3 Monday, March 13, 2006 10:29 AM

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

PERIODIC MAINTENANCE AND MINOR REPAIR
6-6
6
EAU38361
Engine oil and oil filter car-
tridge 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 on a level sur-
face and hold it in an upright posi-
tion.NOTE:
Make sure that the vehicle is positioned
straight up when checking the oil level.
A slight tilt to the side can result in afalse reading.
2. Remove the rider seat. (See page
3-14.)
3. Start the engine, warm it up until
the engine oil has reached a nor-
mal temperature of 60 °C (140 °F),
let it continue to idle for ten sec-
onds, and then turn the engine off.
NOTE:To achieve the proper engine oil tem-
perature for an accurate oil level read-
ing, the engine must have first
completely cooled down, and then
warmed up again for several minutes tonormal operating temperature.
4. Wait a few minutes until the oil set-
tles, remove the oil filler cap, wipe
the dipstick clean, insert it back
into the oil filler hole (without
screwing it in), and then remove it
again to check the oil level.NOTE:The engine oil should be between theminimum and maximum level marks.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.
NOTE:When adding oil, be careful not to over-
fill the engine oil tank; the oil level rises
faster starting from the half level portionon the dipstick.
6. Insert the dipstick into the oil filler
hole, and then tighten the oil filler
cap.
7. Install the rider seat.
1. Engine oil filler cap
1. Maximum level mark
2. Minimum level mark
3. Dipstick
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PERIODIC MAINTENANCE AND MINOR REPAIR
6-7
6
CAUTION:
ECA10900
Make sure that the oil filler cap is se-
curely tightened, otherwise oil may
seep out when the engine is run-ning.
To change the engine oil (with or
without oil filter cartridge replace-
ment)
1. Remove the rider seat. (See page
3-14.)
2. Start the engine, warm it up for
several minutes, and then turn it
off.
3. Place an oil pan under the oil tank
to collect the used oil.
4. Remove the engine oil filler cap
and drain bolt to drain the oil from
the oil tank.5. Place an oil pan under the engine
to collect the used oil.
6. Remove engine oil drain bolts A
and B to drain the oil from the
crankcase.
NOTE:Skip steps 7–9 if the oil filter cartridge isnot being replaced.
7. Remove the oil filter cartridge with
an oil filter wrench.NOTE:An oil filter wrench is available at aYamaha dealer.
8. Apply a thin coat of engine oil to
the O-ring of the new oil filter car-
tridge.
1. Engine oil drain bolt (oil tank)
1. Engine oil drain bolt A (crankcase)
2. Engine oil drain bolt B (crankcase)
1. Oil filter cartridge
2. Oil filter wrench
U5C4E0E0.book Page 7 Monday, March 13, 2006 10:29 AM

PERIODIC MAINTENANCE AND MINOR REPAIR
6-8
6
NOTE:
Make sure that the O-ring is properlyseated.
9. Install the new oil filter cartridge
with an oil filter wrench, and then
tighten it to the specified torque
with a torque wrench.10. Install the engine oil drain bolts,
and then tighten them to the spec-
ified torque.11. 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.
12. Start the engine, rev it several
times, and then turn it off.
13. Remove the engine oil filler cap,
and then gradually fill the oil tank
with the remaining oil quantity
while regularly checking the oil lev-
el on the dipstick.
CAUTION:
ECA15080


In order to prevent clutch slip-
page (since the engine oil also
lubricates the clutch), do not
mix any chemical additives. Do
not use oils with a diesel speci-
fication of “CD” or oils of a high-
1. O-ring
1. Oil filter cartridge
2. Torque wrenchTightening torque:
Oil filter cartridge:
17 Nm (1.7 m·kgf, 12 ft·lbf)
Tightening torques:
Engine oil drain bolt A (crankcase):
43 Nm (4.3 m·kgf, 31 ft·lbf)
Engine oil drain bolt B (crankcase):
43 Nm (4.3 m·kgf, 31 ft·lbf)
Engine oil drain bolt (oil tank):
43 Nm (4.3 m·kgf, 31 ft·lbf)
Recommended engine oil:
See page 8-1.
Oil quantity:
Without oil filter cartridge replace-
ment:
4.10 L (4.33 US qt) (3.61 Imp.qt)
With oil filter cartridge replacement:
4.90 L (5.18 US qt) (4.31 Imp.qt)
U5C4E0E0.book Page 8 Monday, March 13, 2006 10:29 AM