clutch YAMAHA XV1900A 2012 User Guide

PERIODIC MAINTENANCE AND ADJUSTMENT
6-7
6
EAU36771
TIP●
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 fr equently 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 ever y four years and if cracked or damaged.
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PERIODIC MAINTENANCE AND ADJUSTMENT
6-12
6
NOTICE
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-
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.
15. Install the engine oil filler cap.
16. Start the engine, and then let it idlefor several minutes while checking
it for oil leakage. If oil is leaking, im-
mediately turn the engine off and
check for the cause.
17. Turn the engine off, and then check the oil level and correct it if
necessary.
18. 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.
EAU36764
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.
U1CRE1E0.book Page 12 Monday, October 3, 2011 8:45 AM

PERIODIC MAINTENANCE AND ADJUSTMENT
6-15
6
WARNING
EWA10471
●
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 to do so.
●
Ride at moderate speeds after
changing a tire since the tire
surface must first be “broken
in” for it to develop its optimal
characteristics.
EAU21962
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, warpage or oth-
er damage before each ride. If any
damage is found, have a Yamaha
dealer replace 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.
EAU22073
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. (See page
6-17.) If the clutch lever free play does
become excessive, and shifting be-
comes rough or clutch slippage occurs,
causing poor acceleration, there may
be air in the clutch system. If there is air
in the hydraulic system, have a
Yamaha dealer bleed the system be- fore operating the motorcycle.
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PERIODIC MAINTENANCE AND ADJUSTMENT
6-17
6
EAU22392
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.
EAU43431
Front brake pads
The front brake calipers are equipped
with two sets of brake pads.
Each front brake pad is provided with a
wear indicator groove, which allows
you to check the brake pad wear with-
out having to disassemble the brake.
To check a brake pad for wear, check
its wear indicator groove. If a brake pad
has worn to the point that the wear indi- cator groove has almost disappeared,
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.
EAU38631
Checking the bra
ke and clutch
fluid levels Before riding, check that the brake and
clutch fluids are above the minimum
level marks. Check the brake and
clutch fluid levels with the tops of the
reservoirs level. Replenish the brake
and clutch fluids if necessary.
Front brake
1. Brake pad wear indicator groove
1
1
1. Lining thickness
1. Minimum level mark
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PERIODIC MAINTENANCE AND ADJUSTMENT
6-18
6Rear brake
Clutch
TIPThe rear brake fluid reservoir is located
under the rider seat. (See page 3-16.)
WARNING
EWA16000
Improper maintenance can result in
loss of braking ability or clutch oper-
ation. Observe these precautions:●
Insufficient brake or clutch fluid
may allow air to enter the brake
or clutch system, reducing
braking or clutch performance.
●
Clean the filler caps before re-
moving. Use only DOT 4 brake
fluid from a sealed container.
●
Use only the specified brake flu-
id; otherwise, the rubber seals
may deteriorate, causing leak-
age.
●
Refill with the same type of
brake fluid. Adding a brake fluid
other than DOT 4 may result in a
harmful chemical reaction.
●
Be careful that water does not
enter the brake or clutch fluid
reservoir when refilling. Water will significantly lower the boil-
ing point of the fluid and may re-
sult in vapor lock.
NOTICE
ECA17640
Brake fluid may damage painted sur-
faces or plastic parts. Always clean
up spilled fluid immediately.As the brake pads wear, it is normal for
the brake fluid level to gradually go
down. A low brake fluid level may indi-
cate worn brake pads and/or brake sys-
tem leakage; therefore, be sure to
check the brake pads for wear and the
brake system for leakage. A low clutch
fluid level may indicate clutch system
leakage; therefore, be sure to check the
clutch system for leakage. If the brake
or clutch fluid level goes down sudden-
ly, have a Yamaha dealer check the
cause before further riding.
1. Minimum level mark
1. Minimum level mark
Specified brake and clutch fluid:
DOT 4 brake fluid
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PERIODIC MAINTENANCE AND ADJUSTMENT
6-19
6
EAU22751
Changing the brake and
clutch fluids Have a Yamaha dealer change the
brake and clutch fluids at the intervals
specified in the TIP 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 slack1. Place the vehicle on the sidestand.
2. Note the current position of the drive belt using the marks near the
drive belt check hole.TIPThe marks near the drive belt check
hole are 5.0 mm (0.2 in) apart.
3. Note the position of the drive beltwith a force of 45 N (4.5 kgf, 10 lbf)
applied to the belt with a belt ten-
sion gauge as shown.TIPA belt tension gauge is available at a
Yamaha dealer.4. Calculate the drive belt slack by subtracting the measurement not-
ed in step 2 from the measurement
noted in step 3.
1. Drive belt
2. Marks2
1
1. Belt tension gauge
2. Drive belt slack
Drive belt slack: 7.5–13.0 mm (0.30–0.51 in)
6 8 10 12 14
1
2
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PERIODIC MAINTENANCE AND ADJUSTMENT
6-21
6
EAU44273
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.
Brake pedal
Shift pedal
EAU43601
Checking and lubricating the
brake and clutch levers The operation of the brake and clutch
levers should be checked before each
ride, and the lever pivots should be lu-
bricated if necessary.
Brake lever
Clutch lever
Recommended lubricant:
Lithium-soap-based grease
U1CRE1E0.book Page 21 Monday, October 3, 2011 8:45 AM

SPECIFICATIONS
8-1
8
Dimensions:Overall length:2580 mm (101.6 in)
Overall width: 1055 mm (41.5 in)
Overall height: 1105 mm (43.5 in)
Seat height:
705 mm (27.8 in)
Wheelbase: 1715 mm (67.5 in)
Ground clearance: 155 mm (6.10 in)
Minimum turning radius:
3500 mm (137.8 in)Weight:Curb weight:347 kg (765 lb)Engine:Engine type:Air cooled 4-stroke, OHV
Cylinder arrangement: V-type 2-cylinder
Displacement:
1854 cm³
Bore × stroke:
100.0 × 118.0 mm (3.94 × 4.65 in)
Compression ratio: 9.50 : 1
Starting system:
Electric starter
Lubrication system: Dry sump
Engine oil:Recommended brand:
YAMALUBE
Type: SAE 10W-30, 10W-40, 10W-50, 15W-40,
20W-40 or 20W-50
Recommended engine oil grade: API service SG type or higher, JASO
standard MA
Engine oil quantity: Without oil filter ca rtridge 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:
SAE 80 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 element
Fuel:Recommended fuel:Premium unleaded gasoline only
Fuel tank capacity: 16.0 L (4.23 US gal, 3.52 Imp.gal)
Fuel reserve amount: 3.0 L (0.79 US gal, 0.66 Imp.gal)Fuel injection:Throttle body:ID mark:
5C41 01Spark plug(s):Manufacturer/model:NGK/DPR8EA-9
Manufacturer/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 ratio:1.412 (72/51)
Final drive:
Belt
Secondary reduction ratio: 2.785 (37/30 x 70/31)
Transmission type: Constant mesh 5-speed
Operation:
Left foot operation
–20 –10 0 1020 30 40 50 C
10 30 50 70 90 110
0 130 F
SAE 10W-30
SAE 15W-40SAE 20W-40SAE 20W-50
SAE 10W-40SAE 10W-50
U1CRE1E0.book Page 1 Mond ay, October 3, 2011 8:45 AM

INDEX
AAir filter element.................................... 6-12
Anti-theft alarm (optional) ..................... 3-10
Auxiliary DC connector ......................... 3-22
Auxiliary light bulb, replacing ................ 6-30BBattery .................................................. 6-24
Brake and clutch fluid levels, checking ............................................. 6-17
Brake and clutch fluids, changing ......... 6-19
Brake and clutch levers, checking and
lubricating ........................................... 6-21
Brake and shift pedals, checking and
lubricating ........................................... 6-21
Brake lever ........................................... 3-12
Brake lever free play, checking ............ 6-16
Brake light switches .............................. 6-16
Brake pedal .......................................... 3-13CCables, checking and lubricating .......... 6-20
Care ........................................................ 7-1
Catalytic converter ................................ 3-15
Clutch lever.................................. 3-12, 6-15DDimmer switch ...................................... 3-11
Drive belt slack ..................................... 6-19EEngine break-in ...................................... 5-3
Engine oil and oil filter cartridge ............. 6-9
Engine stop switch................................ 3-11
Engine trouble warning light ................... 3-4
EXUP system ....................................... 3-19FFront and rear brake pads, checking .... 6-17 Front fork, checking............................... 6-23
Fuel ....................................................... 3-14
Fuel consumption, tips for reducing ........ 5-3
Fuel level warning light............................ 3-4
Fuel tank breather/overflow hose .......... 3-15
Fuel tank cap......................................... 3-13
Fuses, replacing .................................... 6-25
HHandlebar switches ............................... 3-10
Hazard switch........................................ 3-11
Headlight bulb, replacing....................... 6-26
Helmet holder ........................................ 3-17
High beam indicator light......................... 3-4
Horn switch ........................................... 3-11IIdentification numbers ............................. 9-1
Ignition circuit cut-off system ................. 3-20
Immobilizer system ................................. 3-1
Immobilizer system indicator light ........... 3-5
Indicator lights and warning lights ........... 3-4LLicense plate light ................................. 6-29MMain switch/steering lock ........................ 3-2
Maintenance and lubricat
ion, periodic..... 6-4
Maintenance, emission control system ... 6-3
Matte color, caution ................................. 7-1
Model label .............................................. 9-1
Multi-function meter unit .......................... 3-5NNeutral indicator light .............................. 3-4PParking .................................................... 5-4
Part locations .......................................... 2-1
RRear suspension, lubricating ................ 6-22
Rider seat ............................................. 3-16SSafety information ................................... 1-1
SELECT switch ..................................... 3-11
Shifting .................................................... 5-2
Shift pedal ............................................. 3-12
Shock absorber assembly, adjusting .... 3-18
Sidestand .............................................. 3-20
Sidestand, checking and lubricating ..... 6-22
Spark plugs, checking............................. 6-8
Specifications.......................................... 8-1
Starting the engine.................................. 5-1
Start switch ........................................... 3-11
Steering, checking ................................ 6-23
Storage ................................................... 7-3
Supporting the motorcycle .................... 6-30TTail/brake light ...................................... 6-29
Throttle grip and cable, checking and
lubricating ........................................... 6-20
Throttle grip free play, checking............ 6-13
Tires ...................................................... 6-13
Tool kit .................................................... 6-2
Transfer case oil ................................... 6-12
Troubleshooting .................................... 6-31
Troubleshooting chart ........................... 6-32
Turn signal indicator lights ...................... 3-4
Turn signal light bul b, replacing ............ 6-29
Turn signal switch ................................. 3-11VValve clearance .................................... 6-13
Vehicle identification number .................. 9-1
U1CRE1E0.book Page 1 Mond ay, October 3, 2011 8:45 AM