2007 YAMAHA XV1900A checking oil

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 ............3-4
Multi-function meter unit .................3-5
Anti-theft alarm (optional) .............3-10
Handlebar switches ......................3-10
Clutch lever ...................................3-12
Shift pedal .....................................3-12
Brake lever ...................................3-12
Brake pedal ..................................3-13
Fuel tank cap ................................3-13
Fuel ...............................................3-14
Fuel tank breather hose ................3-15
Catalytic converter ........................3-15
Rider seat .....................................3-15
Helmet holder ...............................3-16
Adjusting the shock absorber
assembly ...................................3-17
EXUP system ...............................3-19
Sidestand ......................................3-19
Ignition circuit cut-off system ........3-20
Auxiliary DC connector .................3-22PRE-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 ............... 6-6
Engine oil and oil filter cartridge ..... 6-7
Transfer case oil ........................... 6-10
Air filter element ........................... 6-10
Checking the throttle cable
free play .................................... 6-11
Valve clearance ............................ 6-11
Tires ............................................. 6-11
Cast wheels .................................. 6-13
Clutch lever .................................. 6-14
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 ............................ 6-17
Checking and lubricating the
cables ....................................... 6-17
Checking and lubricating the
throttle grip and cable ............... 6-18
Checking and lubricating the
brake and shift pedals .............. 6-18
Checking and lubricating the
brake and clutch levers ............ 6-19
Checking and lubricating the
sidestand .................................. 6-19
Lubricating the rear suspension ... 6-20
Checking the front fork ................. 6-20
Checking the steering .................. 6-21
Checking the wheel bearings ....... 6-21
Battery ......................................... 6-22
Replacing the fuses ..................... 6-23
Replacing a headlight bulb .......... 6-24
Tail/brake light ............................. 6-27
Replacing a turn signal light
bulb ........................................... 6-28
License plate light ........................ 6-28
Replacing an auxiliary light
bulb ........................................... 6-28
Supporting the motorcycle ........... 6-29
Troubleshooting ........................... 6-30
Troubleshooting chart .................. 6-31U5C4E1E0.book Page 1 Monday, November 13, 2006 1:14 PM

PERIODIC MAINTENANCE AND MINOR REPAIR
6-7
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
3-15.)
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
6-9
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)
U5C4E1E0.book Page 9 Monday, November 13, 2006 1:14 PM

PERIODIC MAINTENANCE AND MINOR REPAIR
6-10
6 er quality than specified. In
addition, do not use oils labeled
“ENERGY CONSERVING II” or
higher.


Make sure that no foreign mate-rial enters the oil tank.
14. Install the engine oil filler cap.
15. Start the engine, and then let it idle
for several minutes while checking
it for oil leakage. If oil is leaking, im-
mediately turn the engine off and
check for the cause.
16. Turn the engine off, and then
check the oil level and correct it if
necessary.
17. Install the rider seat.
EAU20051
Transfer case oil The transfer case must be checked for
oil leakage before each ride. If any
leakage is found, have a Yamaha deal-
er check and repair the vehicle. In addi-
tion, the transfer case oil level should
be checked and the oil must be
changed by a Yamaha dealer at the in-
tervals specified in the 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 Yamaha dealer replace the air
filter element.
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PERIODIC MAINTENANCE AND MINOR REPAIR
6-16
6 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.


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.
Recommended brake and clutch flu-
id:
DOT 4 brake fluid
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PERIODIC MAINTENANCE AND MINOR REPAIR
6-17
6
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.3. Note the position of the drive belt
with a force of 45 N (4.5 kgf, 10 lbf)
applied to the belt with a belt ten-
sion gauge as shown.
NOTE:A belt tension gauge is available at aYamaha dealer.
4. Calculate the drive belt slack by
subtracting the measurement not-
ed in step 2 from the measurement
noted in step 3.
5. If the drive belt slack is incorrect,
have a Yamaha dealer adjust it.
EAU23100
Checking and lubricating the
cables The operation of all control cables and
the condition of the cables should be
checked before each ride, and the ca-
bles and cable ends should be lubricat-
ed if necessary. If a cable is damaged
or does not move smoothly, have a
Yamaha dealer check or replace it.
WARNING
EWA10720
Damage to the outer sheath may in-
terfere with proper cable operation
and will cause the inner cable to
rust. Replace a damaged cable as
soon as possible to prevent unsafeconditions.
1. Drive belt
2. Marks
3. Drive belt slack
1. Belt tension gaugeDrive belt slack:
7.5–13.0 mm (0.30–0.51 in)
Recommended lubricant:
Engine oil
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PERIODIC MAINTENANCE AND MINOR REPAIR
6-20
6
EAU23250
Lubricating the rear suspen-
sion The pivoting points of the rear suspen-
sion must be lubricated at the intervals
specified in the periodic maintenance
and lubrication chart.
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.
Recommended lubricant:
Lithium-soap-based grease
U5C4E1E0.book Page 20 Monday, November 13, 2006 1:14 PM

INDEXAAir filter element .................................... 6-10
Anti-theft alarm (optional)...................... 3-10
Auxiliary DC connector ......................... 3-22
Auxiliary light bulb, replacing ................ 6-28BBattery................................................... 6-22
Brake and clutch fluid levels,
checking ............................................. 6-15
Brake and clutch fluids, changing ......... 6-16
Brake and clutch levers, checking
and lubricating .................................... 6-19
Brake and shift pedals, checking
and lubricating .................................... 6-18
Brake lever ............................................ 3-12
Brake pedal ........................................... 3-13CCables, checking and lubricating .......... 6-17
Care ........................................................ 7-1
Catalytic converter ................................ 3-15
Clutch lever .................................. 3-12, 6-14DDimmer switch ...................................... 3-11
Drive belt slack...................................... 6-17EEngine break-in ....................................... 5-3
Engine oil and oil filter cartridge .............. 6-7
Engine stop switch ................................ 3-11
Engine trouble warning light.................... 3-4
EXUP system ........................................ 3-19FFront and rear brake pads, checking .... 6-14
Front fork, checking .............................. 6-20
Fuel ....................................................... 3-14Fuel consumption, tips for reducing........ 5-3
Fuel level warning light ........................... 3-4
Fuel tank breather hose........................ 3-15
Fuel tank cap ........................................ 3-13
Fuses, replacing ................................... 6-23
HHandlebar switches .............................. 3-10
Hazard switch ....................................... 3-11
Headlight bulb, replacing ...................... 6-24
Helmet holder ....................................... 3-16
High beam indicator light ........................ 3-4
Horn switch ........................................... 3-11IIdentification numbers ............................ 9-1
Ignition circuit cut-off system ................ 3-20
Immobilizer system ................................. 3-1
Immobilizer system indicator light........... 3-4
Indicator and warning lights .................... 3-4KKey identification number ....................... 9-1LLicense plate light ................................. 6-28MMain switch/steering lock........................ 3-2
Matte color, caution ................................ 7-1
Model label ............................................. 9-2
Multi-function meter unit ......................... 3-5NNeutral indicator light .............................. 3-4PParking ................................................... 5-4
Part locations .......................................... 2-1
Periodic maintenance and lubrication
chart ..................................................... 6-2Pre-operation check list........................... 4-2
RRear brake light switch, adjusting ......... 6-14
Rear suspension, lubricating ................. 6-20
Rider seat .............................................. 3-15SSafety information ................................... 1-1
Shifting .................................................... 5-2
Shift pedal ............................................. 3-12
Shock absorber assembly, adjusting .... 3-17
Sidestand .............................................. 3-19
Sidestand, checking and lubricating...... 6-19
Spark plugs, checking ............................. 6-6
Specifications .......................................... 8-1
Starting the engine .................................. 5-1
Start switch............................................ 3-11
Steering, checking................................. 6-21
Storage.................................................... 7-3
Supporting the motorcycle .................... 6-29TTail/brake light ....................................... 6-27
Throttle cable free play, checking ......... 6-11
Throttle grip and cable, checking
and lubricating .................................... 6-18
Tires ...................................................... 6-11
Tool kit..................................................... 6-1
Transfer case oil.................................... 6-10
Troubleshooting .................................... 6-30
Troubleshooting chart ........................... 6-31
Turn signal indicator lights ...................... 3-4
Turn signal light bulb, replacing ............ 6-28
Turn signal switch ................................. 3-11VValve clearance..................................... 6-11
U5C4E1E0.book Page 1 Monday, November 13, 2006 1:14 PM