engine YAMAHA XV1900A 2006 Owner's Manual

OPERATION AND IMPORTANT RIDING POINTS
5-1
5
EAU15950
WARNING
EWA10270


Become thoroughly familiar
with all operating controls and
their functions before riding.
Consult a Yamaha dealer re-
garding any control or function
that you do not thoroughly un-
derstand.


Never start the engine or oper-
ate it in a closed area for any
length of time. Exhaust fumes
are poisonous, and inhaling
them can cause loss of con-
sciousness and death within a
short time. Always make sure
that there is adequate ventila-
tion.


Before starting out, make sure
that the sidestand is up. If the
sidestand is not raised com-
pletely, it could contact the
ground and distract the opera-
tor, resulting in a possible lossof control.
EAU36740
Starting the engine In order for the ignition circuit cut-off
system to enable starting, one of the
following conditions must be met:

The transmission is in the neutral
position.


The transmission is in gear with
the clutch lever pulled and the sid-
estand up.WARNING
EWA10290


Before starting the engine,
check the function of the igni-
tion circuit cut-off system ac-
cording to the procedure
described on page 3-19.


Never ride with the sidestanddown.
1. Turn the key to “ON” and make
sure that the engine stop switch is
set to “”.
CAUTION:
ECA15070
The following warning lights and in-
dicator light should come on for a
few seconds, then go off.

Fuel level warning light


Engine trouble warning light


Immobilizer system indicator
light
If a warning or indicator light does
not go off, see page 3-3 for the corre-
sponding warning and indicator
light circuit check.
2. Shift the transmission into the neu-
tral position.NOTE:When the transmission is in the neutral
position, the neutral indicator light
should be on, otherwise have a
Yamaha dealer check the electrical cir-cuit.
3. Start the engine by pushing the
start switch.NOTE:If the engine fails to start, release the
start switch, wait a few seconds, and
then try again. Each starting attempt
should be as short as possible to pre-
serve the battery. Do not crank the en-
gine more than 10 seconds on any oneattempt.
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OPERATION AND IMPORTANT RIDING POINTS
5-2
5
CAUTION:
ECA11040
For maximum engine life, never ac-
celerate hard when the engine iscold!NOTE:The engine is warm when it quickly re-sponds to the throttle.
EAU16671
Shifting Shifting gears lets you control the
amount of engine power available for
starting off, accelerating, climbing hills,
etc.
The gear positions are shown in the il-
lustration.NOTE:To shift the transmission into the neu-
tral position, press the shift pedal down
repeatedly until it reaches the end of itstravel, and then slightly raise it.
CAUTION:
ECA10260


Even with the transmission in
the neutral position, do not
coast for long periods of time
with the engine off, and do not
tow the motorcycle for long dis-
tances. The transmission is
properly lubricated only when
the engine is running. Inade-
quate lubrication may damage
the transmission.


Always use the clutch while
changing gears to avoid damag-
ing the engine, transmission,
and drive train, which are not
designed to withstand theshock of forced shifting.
1. Shift pedal
2. Neutral position
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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.
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OPERATION AND IMPORTANT RIDING POINTS
5-4
5
EAU17212
Parking When parking, stop the engine, and
then remove the key from the main
switch.
WARNING
EWA10310


Since the engine and exhaust
system can become very hot,
park in a place where pedestri-
ans or children are not likely to
touch them.


Do not park on a slope or on soft
ground, otherwise the vehiclemay overturn.
CAUTION:
ECA10380
Never park in an area where there
are fire hazards such as grass orother flammable materials.U5C4E0E0.book Page 4 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
6-5
6
EAU19642
Checking the spark plugs The spark plugs are important engine
components, which should be checked
periodically, preferably by a Yamaha
dealer. Since heat and deposits will
cause any spark plug to slowly erode,
they should be removed and checked
in accordance with the periodic mainte-
nance and lubrication chart. In addition,
the condition of the spark plugs can re-
veal the condition of the engine.
The porcelain insulator around the cen-
ter electrode of each spark plug should
be a medium-to-light tan (the ideal color
when the vehicle is ridden normally),
and all spark plugs installed in the en-
gine should have the same color. If any
spark plug shows a distinctly different
color, the engine could be operating im-
properly. Do not attempt to diagnose
such problems yourself. Instead, have
a Yamaha dealer check the vehicle.
If a spark plug shows signs of electrode
erosion and excessive carbon or other
deposits, it should be replaced.Before installing a spark plug, the spark
plug gap should be measured with a
wire thickness gauge and, if necessary,
adjusted to specification.
Clean the surface of the spark plug
gasket and its mating surface, and then
wipe off any grime from the spark plug
threads.
NOTE:
If a torque wrench is not available when
installing a spark plug, a good estimate
of the correct torque is 1/4–1/2 turn
past finger tight. However, the spark
plug should be tightened to the speci-fied torque as soon as possible.
Specified spark plug:
NGK/DPR8EA-9
DENSO/X24EPR-U9
1. Spark plug gap
Spark plug gap:
0.8–0.9 mm (0.031–0.035 in)
Tightening torque:
Spark plug:
17.5 Nm (1.75 m·kgf, 12.7 ft·lbf)
U5C4E0E0.book Page 5 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
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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

PERIODIC MAINTENANCE AND MINOR REPAIR
6-9
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.
U5C4E0E0.book Page 9 Monday, March 13, 2006 10:29 AM