2008 YAMAHA XV1900A brake

PERIODIC MAINTENANCE AND MINOR REPAIR
6-2
6
EAU1770A
Periodic maintenance and lubrication chart NOTE:

The annual checks must be performed every year, except if a kilometer-based maintenance, or for the UK, a
mileage-based maintenance, is performed instead.


From 50000 km (30000 mi), repeat the maintenance intervals starting from 10000 km (6000 mi).


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
ANNUAL
CHECK 1000 km
(600 mi)10000 km
(6000 mi)20000 km
(12000 mi)30000 km
(18000 mi)40000 km
(24000 mi)
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
U5C4E2E0.book Page 2 Friday, September 7, 2007 4:17 PM

PERIODIC MAINTENANCE AND MINOR REPAIR
6-3
6
8*Brake hosesCheck for cracks or damage.√√√√√
Replace. Every 4 years
9*WheelsCheck runout and for damage.√√√√
10*TiresCheck tread depth and for dam-
age.
Replace if necessary.
Check air pressure.
Correct if necessary.√√√√√
11*Wheel bearingsCheck bearing for looseness or
damage.√√√√
12*SwingarmCheck operation and for exces-
sive play.√√√√
13*Drive beltCheck belt tension.
Make sure that the rear wheel is
properly aligned.Every 4000 km (2500 mi)
14*Steering bearingsCheck bearing play and steering
for roughness.√√√√√
Lubricate with lithium-soap-based
grease.Every 50000 km (30000 mi)
15*Chassis fastenersMake sure that all nuts, bolts and
screws are properly tightened.√√√√√
16Brake lever pivot
shaftLubricate with silicone grease.√√√√√
17Brake pedal pivot
shaftLubricate with lithium-soap-based
grease.√√√√√
18Clutch lever pivot
shaftLubricate with silicone grease.√√√√√ NO. ITEM CHECK OR MAINTENANCE JOBODOMETER READING
ANNUAL
CHECK 1000 km
(600 mi)10000 km
(6000 mi)20000 km
(12000 mi)30000 km
(18000 mi)40000 km
(24000 mi)
U5C4E2E0.book Page 3 Friday, September 7, 2007 4:17 PM

PERIODIC MAINTENANCE AND MINOR REPAIR
6-4
6
19Shift pedal pivot
shaftLubricate with lithium-soap-based
grease.√√√√√
20 SidestandCheck operation.
Lubricate.√√√√√
21*Sidestand switchCheck operation.√√√√√√
22*Front forkCheck operation and for oil leak-
age.√√√√
23*Shock absorber as-
semblyCheck operation and shock ab-
sorber for oil leakage.√√√√
24*Rear suspension re-
lay arm and con-
necting arm
pivoting pointsCheck operation.√√√√
Lubricate with lithium-soap-based
grease.√√
25*Fuel injection sys-
temAdjust synchronization.√√√√√
26 Engine oilChange.
Check oil level and vehicle for oil
leakage.√√√√√√
27Engine oil filter car-
tridgeReplace.√√√
28*Transfer case oilCheck oil level.√√
Change.√√√
29*Front and rear brake
switchesCheck operation.√√√√√√
30Moving parts and
cablesLubricate.√√√√√ NO. ITEM CHECK OR MAINTENANCE JOBODOMETER READING
ANNUAL
CHECK 1000 km
(600 mi)10000 km
(6000 mi)20000 km
(12000 mi)30000 km
(18000 mi)40000 km
(24000 mi)
U5C4E2E0.book Page 4 Friday, September 7, 2007 4:17 PM

PERIODIC MAINTENANCE AND MINOR REPAIR
6-5
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.
31*Throttle grip hous-
ing and cableCheck operation and free play.
Adjust the throttle cable free play
if necessary.
Lubricate the throttle grip housing
and cable.√√√√√
32*Muffler and exhaust
pipeCheck the screw clamp for loose-
ness.√√√√√
33*Lights, signals and
switchesCheck operation.
Adjust headlight beam.√√√√√√ NO. ITEM CHECK OR MAINTENANCE JOBODOMETER READING
ANNUAL
CHECK 1000 km
(600 mi)10000 km
(6000 mi)20000 km
(12000 mi)30000 km
(18000 mi)40000 km
(24000 mi)U5C4E2E0.book Page 5 Friday, September 7, 2007 4:17 PM

PERIODIC MAINTENANCE AND MINOR REPAIR
6-13
6Tire inspection
The tires must be checked before each
ride. If the center tread depth reaches
the specified limit, if the tire has a nail or
glass fragments in it, or if the sidewall is
cracked, have a Yamaha dealer re-
place the tire immediately.
NOTE:The tire tread depth limits may differ
from country to country. Always complywith the local regulations.Tire information
This motorcycle is equipped with cast
wheels and tubeless tires.
WARNING
EWA10460


The front and rear tires should
be of the same make and de-
sign, otherwise the handling
characteristics of the vehicle
cannot be guaranteed.


After extensive tests, only the
tires listed below have been ap-
proved for this model byYamaha Motor Co., Ltd.
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.
1. Tire sidewall
2. Tire tread depthMinimum tire tread depth (front and
rear):
1.6 mm (0.06 in)
Front tire:
Size:
130/70R18M/C 63H
Manufacturer/model:
DUNLOP/D251F
Rear tire:
Size:
190/60R17M/C 78H
Manufacturer/model:
DUNLOP/D251
U5C4E2E0.book Page 13 Friday, September 7, 2007 4:17 PM

PERIODIC MAINTENANCE AND MINOR REPAIR
6-14
6
EAU21960
Cast wheels To maximize the performance, durabil-
ity, and safe operation of your vehicle,
note the following points regarding the
specified wheels.

The wheel rims should be checked
for cracks, bends or warpage be-
fore each ride. If any damage is
found, have a Yamaha dealer re-
place the wheel. Do not attempt
even the smallest repair to the
wheel. A deformed or cracked
wheel must be replaced.


The wheel should be balanced
whenever either the tire or wheel
has been changed or replaced. An
unbalanced wheel can result in
poor performance, adverse han-
dling characteristics, and a short-
ened tire life.


Ride at moderate speeds after
changing a tire since the tire sur-
face must first be “broken in” for it
to develop its optimal characteris-
tics.
EAU22072
Clutch lever Since this model is equipped with a hy-
draulic 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. If the clutch
lever free play does become excessive,
and shifting becomes rough or clutch
slippage occurs, causing poor acceler-
ation, there may be air in the clutch sys-
tem. If there is air in the hydraulic
system, have a Yamaha dealer bleed
the system before operating the motor-
cycle.
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).1. Rear brake light switch
2. Rear brake light switch adjusting nut
U5C4E2E0.book Page 14 Friday, September 7, 2007 4:17 PM

PERIODIC MAINTENANCE AND MINOR REPAIR
6-15
6
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.
EAU38630
Checking the brake and clutch
fluid levels Front brake
Rear brake
1. Brake pad wear indicator groove
1. Lining thickness
1. Minimum level mark
1. Minimum level mark
U5C4E2E0.book Page 15 Friday, September 7, 2007 4:17 PM

PERIODIC MAINTENANCE AND MINOR REPAIR
6-16
6 Clutch
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 3-15.)
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.


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.
1. Minimum level mark
Recommended brake and clutch flu-
id:
DOT 4 brake fluid
U5C4E2E0.book Page 16 Friday, September 7, 2007 4:17 PM