YAMAHA XV1900A 2012 Workshop Manual

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
6-8
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.
TIPIf 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-U91. Spark plug gapSpark plug gap:0.8–0.9 mm (0.031–0.035 in)
Tightening torque:
Spark plug: 18 Nm (1.8 m·kgf, 13 ft·lbf)
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PERIODIC MAINTENANCE AND ADJUSTMENT
6-9
6
EAU3836A
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 level1. Place the vehicle on a level sur- face and hold it in an upright posi-
tion. A slight tilt to the side can
result in a false reading.
2. Remove the rider seat. (See page 3-16.)
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.TIPTo 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 to
normal operating temperature.
4. Wait a few minutes until the oil set-
tles, remove the oil filler cap, wipe
the engine oil dipstick clean, insert
it back into the oil filler hole (with-
out screwing it in), and then re-
move it again to check the oil level.TIPThe engine oil should be between the
minimum and maximum level marks.
5. If the engine oil is at or below theminimum level mark, add sufficient
oil of the recommended type to
raise it to the correct level.TIPWhen adding oil, be careful not to over-
fill the engine oil tank; the oil level rises
faster starting from the half level portion
on 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. Engine oil dipstick
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PERIODIC MAINTENANCE AND ADJUSTMENT
6-10
6
NOTICE
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. Place the vehicle on a level sur- face.
2. Remove the rider seat. (See page 3-16.)
3. Start the engine, warm it up for several minutes, and then turn it
off.
4. Place an oil pan under the oil tank to collect the used oil.
5. Remove the engine oil filler cap, the engine oil drain bolt and its
gasket to drain the oil from the oil
tank. 6. Place an oil pan under the engine
to collect the used oil.
7. Remove engine oil drain bolts A and B, and their gasket to drain the
oil from the crankcase.
TIPSkip steps 8–10 if the oil filter cartridge
is not being replaced.8. Remove the oil filter cartridge withan oil filter wrench.TIPAn oil filter wrench is available at a
Yamaha dealer.9. Apply a thin coat of clean engine oil to the O-ring of the new oil filter
cartridge.
1. Engine oil drain bolt (oil tank)
2. Gasket
1. Engine oil drain bolt A (crankcase)
2. Engine oil drain bolt B (crankcase)
3. Gasket
12
1
2
3
1. Oil filter cartridge
2. Oil filter wrench
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PERIODIC MAINTENANCE AND ADJUSTMENT
6-11
6
TIPMake sure that the O-ring is properly
seated.10. Install the new oil filter cartridgewith an oil filter wrench, and then
tighten it to the specified torque
with a torque wrench. 11. Install the engine oil drain bolts
and their new gasket, and then
tighten the bolts to the specified
torques. 12. 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 ti ghten the oil fill-
er cap.
13. Start the engine, rev it several times, and then turn it off.
14. 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.
TIPBe sure to wipe off spilled oil on any
parts after the engine and exhaust sys-
tem have cooled down.
1. O-ring
1. Oil filter cartridge
2. Torque wrench
Tightening torque:Oil filter cartridge:17 Nm (1.7 m·kgf, 12 ft·lbf)
Tightening torques: Engine oil drain bolt A (crankcase):32 Nm (3.2 m·kgf, 23 ft·lbf)
Engine oil drain bolt B (crankcase): 32 Nm (3.2 m·kgf, 23 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 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.
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PERIODIC MAINTENANCE AND ADJUSTMENT
6-13
6
EAU21384
Checking the throttle grip free
play The throttle grip free play should mea-
sure 4.0–6.0 mm (0.16–0.24 in) at the
inner edge of the throttle grip. Periodi-
cally check the throttle grip free play
and, if necessary, have a Yamaha deal-
er 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.
EAU21565
Tires To maximize the performance, durabil-
ity, and safe operation of your motorcy-
cle, 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
EWA10503
Operation of this vehicle with im-
proper tire pressure may cause se-
vere injury or death from loss of
control.●
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 approved
for this model.
1. Throttle grip free play
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PERIODIC MAINTENANCE AND ADJUSTMENT
6-14
6
WARNING
EWA10511
Never overload your vehicle. Opera-
tion of an overloaded vehicle could
cause an accident.
Tire inspection
The tires must be checked before each
ride. If the center tread depth reaches
the specified limit, if the tire has a nail or
glass fragments in it, or if the sidewall is
cracked, have a Yamaha dealer re-
place the tire immediately.TIPThe tire tread depth limits may differ
from country to country. Always comply
with the local regulations.
Tire information
This motorcycle is equipped with tube-
less tires, tire air valves and cast
wheels.
WARNING
EWA10461
The front and rear tires should be of
the same make and design, other-
wise the handling characteristics of
the vehicle may be different, which
could lead to an accident.After extensive tests, only the tires list-
ed below have been approved for this
model by Yamaha Motor Co., Ltd.
Tire air pressure (measured on cold
tires): 0–90 kg (0–198 lb):Front:
250 kPa (2.50 kgf/cm², 36 psi)
Rear: 280 kPa (2.80 kgf/cm², 41 psi)
90–203 kg (198–448 lb): Front:250 kPa (2.50 kgf/cm², 36 psi)
Rear: 280 kPa (2.80 kgf/cm², 41 psi)
Maximum load*:
203 kg (448 lb)
* Total weight of rider, passenger, car- go and accessories
1. Tire sidewall
2. Tire tread depthMinimum tire tread depth (front and
rear):
1.6 mm (0.06 in)
Front tire:Size:
130/70R18M/C 63H
Manufacturer/model: DUNLOP/D251F
Rear tire: Size: 190/60R17M/C 78H
Manufacturer/model: DUNLOP/D251
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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
6-16
6
EAU37913
Checking the brake lever free
play There should be no free play at the
brake lever end. If there is free play,
have a Yamaha dealer inspect the
brake system.
WARNING
EWA14211
A soft or spongy feeling in the brake
lever can indicate the presence of air
in the hydraulic system. If there is air
in the hydraulic system, have a
Yamaha dealer bleed the system be- fore operating the vehicle. Air in the
hydraulic system will diminish the braking performance, which may re-
sult in loss of control and an acci-
dent.
EAU22273
Brake light switches The brake light, which is activated by
the brake pedal and brake lever, should
come on just before braking takes ef-
fect. If necessary, adjust the rear brake
light switch as follows, but the front
brake light switch should be adjusted
by a Yamaha dealer.
Turn the rear brake light switch adjust-
ing nut while holding the rear brake light
switch in place. To make the brake light
come on earlier, turn the adjusting nut
in direction (a). To make the brake light
come on later, turn the adjusting nut in
direction (b).
1. No brake lever free play
1
1. Rear brake light switch
2. Rear brake light switch adjusting nut
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