clutch YAMAHA XV1900A 2006 User Guide
[x] Cancel search | Manufacturer: YAMAHA, Model Year: 2006, Model line: XV1900A, Model: YAMAHA XV1900A 2006Pages: 86, PDF Size: 4.08 MB
Page 44 of 86
PERIODIC MAINTENANCE AND MINOR REPAIR
6-2
6
EAU17705
Periodic maintenance and lubrication chart NOTE:
The annual checks must be performed every year, except if a kilometer-based maintenance is performed in-
stead.
From 50000 km, repeat the maintenance intervals starting from 10000 km.
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 (× 1000 km)
ANNUAL
CHECK
1 10203040
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
8*Brake hosesCheck for cracks or damage.√√√√ √
Replace. Every 4 years
9*WheelsCheck runout and for damage.√√√√
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Page 46 of 86
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
Page 50 of 86
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
Page 55 of 86
PERIODIC MAINTENANCE AND MINOR REPAIR
6-13
6 speed riding to ride conserva-
tively for approximately 100 km
(60 mi) after installing a new tire.
The tires must be warmed up
before a high-speed run.
Always adjust the tire air pres-
sure according to the operatingconditions.
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.
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Page 57 of 86
PERIODIC MAINTENANCE AND MINOR REPAIR
6-15
6
EAU38630
Checking the brake and clutch
fluid levels Front brake
Rear brakeClutch
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 3-14.)
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.
1. Minimum level mark
1. Minimum level mark
1. Minimum level mark
Recommended brake and clutch flu-
id:
DOT 4 brake fluid
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Page 58 of 86
PERIODIC MAINTENANCE AND MINOR REPAIR
6-16
6
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.
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.1. Drive belt
2. Marks
3. Drive belt slack
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Page 60 of 86
PERIODIC MAINTENANCE AND MINOR REPAIR
6-18
6
EAU23131
Checking and lubricating the
brake and shift pedals The operation of the brake and shift
pedals should be checked before each
ride, and the pedal pivots should be lu-
bricated if necessary.
EAU23140
Checking and lubricating the
brake and clutch levers Brake lever
Clutch lever
The operation of the brake and clutch
levers should be checked before each
ride, and the lever pivots should be lu-
bricated if necessary.
Recommended lubricant:
Lithium-soap-based grease (all-pur-
pose grease)
U5C4E0E0.book Page 18 Monday, March 13, 2006 10:29 AM
Page 77 of 86
SPECIFICATIONS
8-1
8
Dimensions:Overall length:
2580 mm (101.6 in)
Overall width:
1100 mm (43.3 in)
Overall height:
1125 mm (44.3 in)
Seat height:
735 mm (28.9 in)
Wheelbase:
1715 mm (67.5 in)
Ground clearance:
155 mm (6.10 in)
Minimum turning radius:
3480 mm (137.0 in)Weight:With oil and fuel:
346.0 kg (763 lb)Engine:Engine type:
Air cooled 4-stroke, OHV
Cylinder arrangement:
V-type 2-cylinder
Displacement:
1854.0 cm³ (113.13 cu.in)
Bore × stroke:
100.0 × 118.0 mm (3.94 × 4.65 in)
Compression ratio:
9.48 :1
Starting system:
Electric starter
Lubrication system:
Dry sump
Engine oil:Type:
SAE20W40
Recommended engine oil grade:
API service SE, SF, SG type or higher
Engine oil quantity:
Without oil filter cartridge replacement:
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)Transfer gear oil:Type:
SAE80 API GL-4 Hypoid gear oil
Quantity:
0.55 L (0.58 US qt) (0.48 Imp.qt)Air filter:Air filter element:
Oil-coated paper elementFuel:Recommended fuel:
Premium unleaded gasoline only
Fuel tank capacity:
17.0 L (4.49 US gal) (3.74 Imp.gal)
Fuel reserve amount:
3.0 L (0.79 US gal) (0.66 Imp.gal)Fuel injector:Manufacturer:
NIPPON INJECTOR
Model/quantity:
INP-101/2Spark plug (s):Manufacturer/model:
NGK/DPR8EA-9Manufacturer/model:
DENSO/X24EPR-U9
Spark plug gap:
0.8–0.9 mm (0.031–0.035 in)
Clutch:Clutch type:
Wet, multiple-discTransmission:Primary reduction system:
Spur gear
Primary reduction ratio:
72/51 (1.412)
Secondary reduction system:
Belt drive
Secondary reduction ratio:
70/31 (2.258)
Transmission type:
Constant mesh 5-speed
Operation:
Left foot operation
Gear ratio:
1st:
38/16 (2.375)
2nd:
33/21 (1.571)
3rd:
29/25 (1.160)
4th:
26/28 (0.929)
5th:
24/30 (0.800)Chassis:Frame type:
Double cradle
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Page 82 of 86
INDEXAAir filter element ...................................... 6-9
Anti-theft alarm (optional)........................ 3-9
Auxiliary DC connector ......................... 3-21
Auxiliary light bulb, replacing ................ 6-28BBattery................................................... 6-21
Brake and clutch fluid levels,
checking ............................................. 6-15
Brake and clutch fluids, changing ......... 6-16
Brake and clutch levers,
checking and lubricating ..................... 6-18
Brake and shift pedals,
checking and lubricating ..................... 6-18
Brake lever ............................................ 3-11
Brake pedal ........................................... 3-12CCables, checking and lubricating .......... 6-17
Care ........................................................ 7-1
Catalytic converter ................................ 3-14
Clutch lever .................................. 3-11, 6-13DDimmer switch ...................................... 3-10
Drive belt slack...................................... 6-16EEngine break-in ....................................... 5-3
Engine oil and oil filter cartridge .............. 6-6
Engine stop switch ................................ 3-10
Engine trouble warning light.................... 3-4
EXUP system ........................................ 3-18FFront and rear brake pads, checking .... 6-14
Front fork, checking .............................. 6-20
Fuel ....................................................... 3-13Fuel consumption, tips for reducing........ 5-3
Fuel level warning light ........................... 3-4
Fuel tank breather hose........................ 3-14
Fuel tank cap ........................................ 3-12
Fuses, replacing ................................... 6-23
HHandlebar switches .............................. 3-10
Hazard switch ....................................... 3-10
Headlight bulb, replacing ...................... 6-24
Helmet holder ....................................... 3-15
High beam indicator light ........................ 3-4
Horn switch ........................................... 3-10IIdentification numbers ............................ 9-1
Ignition circuit cut-off system ................ 3-19
Immobilizer system ................................. 3-1
Immobilizer system indicator light........... 3-4
Indicator and warning lights .................... 3-3KKey identification number ....................... 9-1LLicense plate light ................................. 6-28MMain switch/steering lock........................ 3-2
Model label ............................................. 9-2
Multi-function meter unit ......................... 3-5NNeutral indicator light .............................. 3-3PParking ................................................... 5-4
Part locations .......................................... 2-1
Periodic maintenance and lubrication
chart ..................................................... 6-2
Pre-operation check list .......................... 4-2
RRear brake light switch, adjusting ......... 6-14
Rear suspension, lubricating ................. 6-19
Rider seat .............................................. 3-14SSafety information ................................... 1-1
Shifting .................................................... 5-2
Shift pedal ............................................. 3-11
Shock absorber assembly, adjusting .... 3-16
Sidestand .............................................. 3-18
Sidestand, checking and lubricating...... 6-19
Spark plugs, checking ............................. 6-5
Specifications .......................................... 8-1
Starting the engine .................................. 5-1
Start switch............................................ 3-10
Steering, checking................................. 6-20
Storage.................................................... 7-3
Supporting the motorcycle .................... 6-29TTail/brake light ....................................... 6-27
Throttle cable free play, checking ......... 6-10
Throttle grip and cable, checking
and lubricating .................................... 6-17
Tires ...................................................... 6-10
Tool kit..................................................... 6-1
Transfer case oil...................................... 6-9
Troubleshooting .................................... 6-29
Troubleshooting chart ........................... 6-30
Turn signal indicator lights ...................... 3-3
Turn signal light bulb, replacing ............ 6-27
Turn signal switch ................................. 3-10VValve clearance..................................... 6-10
Vehicle identification number .................. 9-1
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