check engine YAMAHA XV1900A 2007 User Guide

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.
24 Engine oilChange.
Check oil level and vehicle for oil leakage.√√√√√ √
25Engine oil filter car-
tridgeReplace.√√√
26*Transfer case oilCheck oil level.√√
Change.√√√
27*Front and rear brake
switchesCheck operation.√√√√√ √
28Moving parts and ca-
blesLubricate.√√√√ √
29*Throttle grip housing
and cableCheck operation and free play.
Adjust the throttle cable free play if necessary.
Lubricate the throttle grip housing and cable.√√√√ √
30*Muffler and exhaust
pipeCheck the screw clamp for looseness.√√√√√
31*Lights, signals and
switchesCheck operation.
Adjust headlight beam.√√√√√ √ NO. ITEM CHECK OR MAINTENANCE JOBODOMETER READING (× 1000 km)
ANNUAL
CHECK
1 10203040
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PERIODIC MAINTENANCE AND MINOR REPAIR
6-6
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)
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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)
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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
6-11
6
EAU21382
Checking the throttle cable
free play The throttle cable free play should mea-
sure 4.0–6.0 mm (0.16–0.24 in) at the
throttle grip. Periodically check the
throttle cable free play and, if neces-
sary, have a Yamaha dealer adjust it.
EAU21401
Valve clearance The valve clearance changes with use,
resulting in improper air-fuel mixture
and/or engine noise. To prevent this
from occurring, the valve clearance
must be adjusted by a Yamaha dealer
at the intervals specified in the periodic
maintenance and lubrication chart.
EAU21561
Tires To maximize the performance, durabil-
ity, and safe operation of your motor-
cycle, note the following points
regarding the specified tires.
Tire air pressure
The tire air pressure should be checked
and, if necessary, adjusted before each
ride.
WARNING
EWA10500


The tire air pressure must be
checked and adjusted on cold
tires (i.e., when the temperature
of the tires equals the ambient
temperature).


The tire air pressure must be ad-
justed in accordance with the
riding speed and with the total
weight of rider, passenger, car-
go, and accessories approvedfor this model.
1. Throttle cable free playU5C4E1E0.book Page 11 Monday, November 13, 2006 1:14 PM

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
6-21
6
EAU23280
Checking the steering Worn or loose steering bearings may
cause danger. Therefore, the operation
of the steering must be checked as fol-
lows at the intervals specified in the pe-
riodic maintenance and lubrication
chart.
1. Place a stand under the engine to
raise the front wheel off the
ground.
WARNING
EWA10750
Securely support the vehicle so thatthere is no danger of it falling over.
2. Hold the lower ends of the front
fork legs and try to move them for-
ward and backward. If any free
play can be felt, have a Yamaha
dealer check or repair the steering.
EAU23290
Checking the wheel bearings The front and rear wheel bearings must
be checked at the intervals specified in
the periodic maintenance and lubrica-
tion chart. If there is play in the wheel
hub or if the wheel does not turn
smoothly, have a Yamaha dealer check
the wheel bearings.
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PERIODIC MAINTENANCE AND MINOR REPAIR
6-29
64. Insert a new bulb into the socket.
5. Install the auxiliary light socket (to-
gether with the coupler) by push-
ing it in and turning it clockwise.
6. Install the headlight unit.
EAU24350
Supporting the motorcycle Since this model is not equipped with a
centerstand, follow these precautions
when removing the front and rear
wheel or performing other maintenance
requiring the motorcycle to stand up-
right. Check that the motorcycle is in a
stable and level position before starting
any maintenance. A strong wooden
box can be placed under the engine for
added stability.
To service the front wheel
1. Stabilize the rear of the motorcycle
by using a motorcycle stand or, if
an additional motorcycle stand is
not available, by placing a jack un-
der the frame in front of the rear
wheel.
2. Raise the front wheel off the
ground by using a motorcycle
stand.
To service the rear wheel
Raise the rear wheel off the ground by
using a motorcycle stand or, if a motor-
cycle stand is not available, by placinga jack either under each side of the
frame in front of the rear wheel or under
each side of the swingarm.
1. Auxiliary light bulbU5C4E1E0.book Page 29 Monday, November 13, 2006 1:14 PM

PERIODIC MAINTENANCE AND MINOR REPAIR
6-31
6
EAU42600
Troubleshooting chart
WARNING
EWA10840
Keep away open flames and do not smoke while checking or working on the fuel system.
Check the fuel level in
the fuel tank.1. Fuel
There is enough fuel.
There is no fuel.
Check the compression.
Supply fuel.
The engine does not start.
Check the compression.
Operate the electric starter.2. Compression
There is compression.
There is no compression.
Check the ignition.
Have a Yamaha dealer
check the vehicle.
Remove the spark plugs
and check the electrodes.3. Ignition
Wipe off with a dry cloth and correct the
spark plug gaps, or replace the spark plugs.
Have a Yamaha dealer check the vehicle.
The engine does not start.
Have a Yamaha dealer
check the vehicle.
The engine does not start.
Check the battery.
Operate the electric starter.4. Battery
The engine turns over
quickly.
The engine turns over
slowly.
The battery is good.Check the battery lead connections,
and charge the battery if necessary.
DryWet
Operate the electric starter.
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