brake YAMAHA XV1900A 2008 Owners Manual

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 ........................... 6-11
Checking the throttle cable free
play ........................................... 6-11
Valve clearance ............................ 6-11
Tires ............................................. 6-12
Cast wheels .................................. 6-14
Clutch lever .................................. 6-14
Adjusting the rear brake light
switch ........................................ 6-14
Checking the front and rear brake
pads .......................................... 6-15Checking the brake and clutch
fluid levels ................................. 6-15
Changing the brake and clutch
fluids ......................................... 6-17
Drive belt slack ............................ 6-17
Checking and lubricating
the cables ................................. 6-18
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 ............................ 6-20
Lubricating the rear suspension ... 6-20
Checking the front fork ................. 6-20
Checking the steering .................. 6-21
Checking the wheel bearings ....... 6-22
Battery ......................................... 6-22
Replacing the fuses ..................... 6-23
Replacing a headlight bulb .......... 6-25
Tail/brake light ............................. 6-28
Replacing a turn signal
light bulb ................................... 6-28
License plate light ........................ 6-28
Replacing an auxiliary light
bulb ........................................... 6-29
Supporting the motorcycle ........... 6-29
Troubleshooting ........................... 6-30
Troubleshooting chart .................. 6-31U5C4E2E0.book Page 1 Friday, September 7, 2007 4:17 PM

DESCRIPTION
2-1
2
EAU10410
Left view1. Headlight (page 6-25)
2. Clutch fluid reservoir (page 6-15)
3. Seat lock (page 3-15)
4. Main fuse (page 6-23)
5. Battery (page 6-22)
6. Owner’s tool kit (page 6-1)
7. License plate light (page 6-28)
8. Tail/brake light (page 6-28)9. Engine oil drain bolt B (crankcase) (page 6-7)
10.Engine oil drain bolt A (crankcase) (page 6-7)
11.Shift pedal (page 3-12)U5C4E2E0.book Page 1 Friday, September 7, 2007 4:17 PM

DESCRIPTION
2-2
2
EAU10420
Right view1. Helmet holder (page 3-16)
2. Fuel injection system fuse (page 6-23)
3. Rear brake fluid reservoir (page 6-15)
4. Fuse box (page 6-23)
5. Engine oil filler cap (page 6-7)
6. Fuel tank cap (page 3-13)
7. Front brake fluid reservoir (page 6-15)
8. Brake pedal (page 3-13)9. Rear brake light switch (page 6-14)
10.Engine oil filter cartridge (page 6-7)
11.Engine oil drain bolt (oil tank) (page 6-7)
12.Shock absorber assembly spring preload adjusting nut (page 3-17)
U5C4E2E0.book Page 2 Friday, September 7, 2007 4:17 PM

DESCRIPTION
2-3
2
EAU10430
Controls and instruments1. Clutch lever (page 3-12)
2. Left handlebar switches (page 3-10)
3. Multi-function meter unit (page 3-5)
4. Main switch/steering lock (page 3-2)
5. Right handlebar switches (page 3-10)
6. Throttle grip (page 6-11)
7. Brake lever (page 3-12)U5C4E2E0.book Page 3 Friday, September 7, 2007 4:17 PM

INSTRUMENT AND CONTROL FUNCTIONS
3-12
3
EAU12820
Clutch lever The clutch lever is located at the left
handlebar grip. To disengage the
clutch, pull the lever toward the handle-
bar grip. To engage the clutch, release
the lever. The lever should be pulled
rapidly and released slowly for smooth
clutch operation.
The clutch lever is equipped with a
clutch switch, which is part of the igni-
tion circuit cut-off system. (See page
3-20.)
EAU12880
Shift pedal The shift pedal is located on the left
side of the engine and is used in com-
bination with the clutch lever when
shifting the gears of the 5-speed con-
stant-mesh transmission equipped on
this motorcycle.NOTE:Use your toes or heel to shift up andyour toes to shift down.
EAU12890
Brake lever The brake lever is located at the right
handlebar grip. To apply the front
brake, pull the lever toward the handle-
bar grip.
1. Clutch lever
1. Shift pedal
1. Brake lever
U5C4E2E0.book Page 12 Friday, September 7, 2007 4:17 PM

INSTRUMENT AND CONTROL FUNCTIONS
3-13
3
EAU12941
Brake pedal The brake pedal is on the right side of
the motorcycle. To apply the rear
brake, press down on the brake pedal.
EAU13120
Fuel tank cap To remove the fuel tank cap
Slide the lock cover open, insert the key
into the lock, and then turn it 1/4 turn
clockwise. The lock will be released
and the fuel tank cap can be removed.
To install the fuel tank cap
1. Insert the fuel tank cap into the
tank opening with the key inserted
in the lock and with the“” mark
facing forward.2. Turn the key counterclockwise to
the original position, remove it, and
then close the lock cover.
NOTE:The fuel tank cap cannot be installed
unless the key is in the lock. In addition,
the key cannot be removed if the cap isnot properly installed and locked.
WARNING
EWA10130
Make sure that the fuel tank cap isproperly installed before riding.
1. Brake pedal
1. Fuel tank cap lock cover
2.“” mark
3. Unlock.
4. Lock.
U5C4E2E0.book Page 13 Friday, September 7, 2007 4:17 PM

PRE-OPERATION CHECKS
4-2
4
EAU15605
Pre-operation check list
ITEM CHECKS PAGE
FuelCheck fuel level in fuel tank.
Refuel if necessary.
Check fuel line for leakage.3-14
Engine oilCheck oil level in oil tank.
If necessary, add recommended oil to specified level.
Check vehicle for oil leakage.6-7
Transfer case oilCheck vehicle for oil leakage. 6-10
Front brakeCheck operation.
If soft or spongy, have Yamaha dealer bleed hydraulic system.
Check brake pads for wear.
Replace if necessary.
Check fluid level in reservoir.
If necessary, add recommended brake fluid to specified level.
Check hydraulic system for leakage.6-15, 6-15
Rear brakeCheck operation.
If soft or spongy, have Yamaha dealer bleed hydraulic system.
Check brake pads for wear.
Replace if necessary.
Check fluid level in reservoir.
If necessary, add recommended brake fluid to specified level.
Check hydraulic system for leakage.6-15, 6-15
ClutchCheck operation.
If soft or spongy, have Yamaha dealer bleed hydraulic system.
Check fluid level in reservoir.
If necessary, add recommended fluid to specified level.
Check hydraulic system for leakage.6-14, 6-15
Throttle gripMake sure that operation is smooth.
Check cable free play.
If necessary, have Yamaha dealer adjust cable free play and lubricate cable and
grip housing.6-11, 6-18
U5C4E2E0.book Page 2 Friday, September 7, 2007 4:17 PM

PRE-OPERATION CHECKS
4-3
4
Control cablesMake sure that operation is smooth.
Lubricate if necessary.6-18
Wheels and tiresCheck for damage.
Check tire condition and tread depth.
Check air pressure.
Correct if necessary.6-12, 6-14
Brake and shift pedalsMake sure that operation is smooth.
Lubricate pedal pivoting points if necessary.6-18
Brake and clutch leversMake sure that operation is smooth.
Lubricate lever pivoting points if necessary.6-19
SidestandMake sure that operation is smooth.
Lubricate pivot if necessary.6-20
Chassis fastenersMake sure that all nuts, bolts and screws are properly tightened.
Tighten if necessary.—
Instruments, lights, signals
and switchesCheck operation.
Correct if necessary.—
Sidestand switchCheck operation of ignition circuit cut-off system.
If system is defective, have Yamaha dealer check vehicle.3-19 ITEM CHECKS PAGE
U5C4E2E0.book Page 3 Friday, September 7, 2007 4:17 PM

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