Yamaha 2005 Road Star Silverado Owners Manual XV17AT(C)/AWT(C)/AMT(C)/ATT(C)ATMT(C) Owner's
2015-03-13
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OWNER’S MANUAL XV17AT(C) XV17AWT(C) XV17AMT(C) XV17ATT(C) XV17ATMT(C) YAMAHA MOTOR CO., LTD. PRINTED ON RECYCLED PAPER PRINTED IN JAPAN 2004.04-1.3×1 CR (E) LIT-11626-18-15 5VN-28199-11 U5VN11E0.book Page 1 Tuesday, April 13, 2004 5:24 PM EAU10041 U5VN11E0.book Page 1 Tuesday, April 13, 2004 5:24 PM INTRODUCTION EAU10080 Congratulations on your purchase of the Yamaha Road Star™. This model is the result of Yamaha’s vast experience in the production of fine sporting, touring, and pacesetting racing machines. It represents the high degree of craftsmanship and reliability that have made Yamaha a leader in these fields. This manual will give you an understanding of the operation, inspection, and basic maintenance of this motorcycle. If you have any questions concerning the operation or maintenance of your motorcycle, please consult a Yamaha dealer. The design and manufacture of this Yamaha motorcycle fully comply with the emissions standards for clean air applicable at the date of manufacture. Yamaha has met these standards without reducing the performance or economy of operation of the motorcycle. To maintain these high standards, it is important that you and your Yamaha dealer pay close attention to the recommended maintenance schedules and operating instructions contained within this manual. U5VN11E0.book Page 1 Tuesday, April 13, 2004 5:24 PM IMPORTANT MANUAL INFORMATION EAU10130 Particularly important information is distinguished in this manual by the following notations: The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR SAFETY IS INVOLVED! WARNING Failure to follow WARNING instructions could result in severe injury or death to the motorcycle operator, a bystander or a person inspecting or repairing the motorcycle. CAUTION: A CAUTION indicates special precautions that must be taken to avoid damage to the motorcycle. NOTE: A NOTE provides key information to make procedures easier or clearer. NOTE: ● This manual should be considered a permanent part of this motorcycle and should remain with it even if the motorcycle is subsequently sold. ● Yamaha continually seeks advancements in product design and quality. Therefore, while this manual contains the most current product information available at the time of printing, there may be minor discrepancies between your motorcycle and this manual. If you have any questions concerning this manual, please consult your Yamaha dealer. EWA10010 WARNING PLEASE READ THIS MANUAL AND THE “YOU AND YOUR MOTORCYCLE: RIDING TIPS” BOOKLET CAREFULLY AND COMPLETELY BEFORE OPERATING THIS MOTORCYCLE. DO NOT ATTEMPT TO OPERATE THIS MOTORCYCLE UNTIL YOU HAVE ATTAINED ADEQUATE KNOWLEDGE OF ITS CONTROLS AND OPERATING FEATURES U5VN11E0.book Page 2 Tuesday, April 13, 2004 5:24 PM IMPORTANT MANUAL INFORMATION AND UNTIL YOU HAVE BEEN TRAINED IN SAFE AND PROPER RIDING TECHNIQUES. REGULAR INSPECTIONS AND CAREFUL MAINTENANCE, ALONG WITH GOOD RIDING SKILLS, WILL ENSURE THAT YOU SAFELY ENJOY THE CAPABILITIES AND THE RELIABILITY OF THIS MOTORCYCLE. U5VN11E0.book Page 3 Tuesday, April 13, 2004 5:24 PM IMPORTANT MANUAL INFORMATION EAU10192 AFFIX DEALER LABEL HERE XV17AT(C)/XV17AWT(C)/XV17AMT(C)/XV17ATT(C)/ XV17ATMT(C) OWNER’S MANUAL ©2004 by Yamaha Motor Corporation, U.S.A. 1st edition, March 2004 All rights reserved. Any reprinting or unauthorized use without the written permission of Yamaha Motor Corporation, U.S.A. is expressly prohibited. Printed in Japan. P/N LIT-11626-18-15 U5VN11E0.book Page 1 Tuesday, April 13, 2004 5:24 PM TABLE OF CONTENTS SAFETY INFORMATION ..................1-1 Location of important labels ...........1-5 DESCRIPTION ..................................2-1 Left view ..........................................2-1 Right view ........................................2-3 Controls and instruments ................2-5 INSTRUMENT AND CONTROL FUNCTIONS .......................................3-1 Main switch/steering lock ................3-1 Indicator and warning lights ............3-2 Speedometer unit ...........................3-2 Self-diagnosis device .....................3-3 Fuel gauge .....................................3-3 Clock ..............................................3-4 Handlebar switches ........................3-4 Clutch lever ....................................3-5 Shift pedal ......................................3-6 Brake lever .....................................3-6 Brake pedal ....................................3-6 Fuel tank cap ..................................3-7 Fuel ................................................3-7 Fuel cock ........................................3-8 Starter (choke) knob .......................3-9 Locking the steering with a padlock ......................................3-10 Rider seat .....................................3-10 Helmet holder ...............................3-11 Windshield [XV17AT(C)/XV17ATM(C)] ........3-11 Saddlebags [XV17AT(C)] ............ 3-12 Sidecases [XV17ATM(C)] ............ 3-13 Adjusting the shock absorber assembly .................................. 3-14 Sidestand ..................................... 3-16 Ignition circuit cut-off system ....... 3-16 PRE-OPERATION CHECKS ............. 4-1 Pre-operation check list ................. 4-2 OPERATION AND IMPORTANT RIDING POINTS ................................ 5-1 Starting and warming up a cold engine ......................................... 5-1 Starting a warm engine .................. 5-2 Shifting ........................................... 5-3 Engine break-in .............................. 5-4 Parking ........................................... 5-5 PERIODIC MAINTENANCE AND MINOR REPAIR................................. 6-1 PERIODIC MAINTENANCE .......... 6-1 Owner’s tool kit .............................. 6-1 Periodic maintenance chart for the emission control system ............. 6-3 General maintenance and lubrication chart .......................... 6-4 Removing and installing the panel ........................................... 6-8 Checking the spark plugs .............. 6-8 Canister (for California only) ........ 6-10 Engine oil and oil filter cartridge ... 6-10 Transfer case oil ........................... 6-13 Cleaning the air filter element ...... 6-14 Adjusting the carburetor ............... 6-16 Adjusting the throttle cable free play ........................................... 6-16 Adjusting the valve clearance ...... 6-17 Tires (For spoke wheel model) ..... 6-17 Tires (For cast wheel models) ...... 6-19 Spoke wheels ............................... 6-21 Cast wheels .................................. 6-21 Accessories and replacement parts .......................................... 6-21 Adjusting the clutch lever free play ........................................... 6-22 Adjusting the brake lever free play ........................................... 6-23 Adjusting the rear brake light switch ........................................ 6-24 Checking the front and rear brake pads .......................................... 6-24 Checking the brake fluid level ...... 6-25 Changing the brake fluid .............. 6-26 Drive belt slack ............................. 6-26 Checking and lubricating the cables ....................................... 6-28 Checking and lubricating the throttle grip and cable ............... 6-28 Checking and lubricating the brake and shift pedals ............... 6-28 U5VN11E0.book Page 2 Tuesday, April 13, 2004 5:24 PM TABLE OF CONTENTS Checking and lubricating the brake and clutch levers .............6-29 Checking and lubricating the sidestand ...................................6-30 Checking the front fork .................6-30 Checking the steering ...................6-31 Checking the wheel bearings .......6-31 Battery ..........................................6-32 Replacing the fuses ......................6-33 Replacing the headlight bulb ........6-34 Tail/brake light ..............................6-36 Replacing a turn signal light bulb ...........................................6-36 Replacing a license plate light bulb ...........................................6-36 Supporting the motorcycle ............6-37 Troubleshooting ............................6-38 Troubleshooting chart ...................6-39 MOTORCYCLE CARE AND STORAGE ..........................................7-1 Care ................................................7-1 Storage ...........................................7-4 SPECIFICATIONS .............................8-1 CONSUMER INFORMATION.............9-1 Identification numbers ....................9-1 Reporting safety defects .................9-3 Motorcycle noise regulation ............9-4 Maintenance record ........................9-5 YAMAHA MOTOR CORPORATION, U.S.A. STREET AND ENDURO MOTORCYCLE LIMITED WARRANTY ............................... 9-7 YAMAHA EXTENDED SERVICE (Y.E.S.) ....................................... 9-9 U5VN11E0.book Page 1 Tuesday, April 13, 2004 5:24 PM SAFETY INFORMATION EAU10250 MOTORCYCLES ARE SINGLE TRACK VEHICLES. THEIR SAFE USE AND OPERATION ARE DEPENDENT UPON THE USE OF PROPER RIDING TECHNIQUES AS WELL AS THE EXPERTISE OF THE OPERATOR. EVERY OPERATOR SHOULD KNOW THE FOLLOWING REQUIREMENTS BEFORE RIDING THIS MOTORCYCLE. HE OR SHE SHOULD: ● OBTAIN THOROUGH INSTRUCTIONS FROM A COMPETENT SOURCE ON ALL ASPECTS OF MOTORCYCLE OPERATION. ● OBSERVE THE WARNINGS AND MAINTENANCE REQUIREMENTS IN THE OWNER’S MANUAL. ● OBTAIN QUALIFIED TRAINING IN SAFE AND PROPER RIDING TECHNIQUES. ● OBTAIN PROFESSIONAL TECHNICAL SERVICE AS INDICATED BY THE OWNER’S MANUAL AND/OR WHEN MADE NECESSARY BY MECHANICAL CONDITIONS. Safe riding ● Always make pre-operation checks. Careful checks may help prevent an accident. ● This motorcycle is designed to carry the operator and a passenger. ● The failure of motorists to detect and recognize motorcycles in traffic is the predominating cause of automobile/motorcycle accidents. Many accidents have been caused by an automobile driver who did not see the motorcycle. Making yourself conspicuous appears to be very effective in reducing the chance of this type of accident. Therefore: • Wear a brightly colored jacket. • Use extra caution when approaching and passing through intersections, since intersec- 1-1 ● ● tions are the most likely places for motorcycle accidents to occur. • Ride where other motorists can see you. Avoid riding in another motorist’s blind spot. Many motorcycle accidents involve inexperienced operators. In fact, many operators who have been involved in accidents do not even have a current motorcycle license. • Make sure that you are qualified and that you only lend your motorcycle to other qualified operators. • Know your skills and limits. Staying within your limits may help you to avoid an accident. • We recommend that you practice riding your motorcycle where there is no traffic until you have become thoroughly familiar with the motorcycle and all of its controls. Many motorcycle accidents have been caused by error of the motorcycle operator. A typical error made by the operator is veering 1 U5VN11E0.book Page 2 Tuesday, April 13, 2004 5:24 PM SAFETY INFORMATION 1 ● ● wide on a turn due to EXCESSIVE SPEED or undercornering (insufficient lean angle for the speed). • Always obey the speed limit and never travel faster than warranted by road and traffic conditions. • Always signal before turning or changing lanes. Make sure that other motorists can see you. The posture of the operator and passenger is important for proper control. • The operator should keep both hands on the handlebar and both feet on the operator footrests during operation to maintain control of the motorcycle. • The passenger should always hold onto the operator, seat strap, or grab bar, if equipped, with both hands and keep both feet on the passenger footrests. • Never carry a passenger unless he or she can firmly place both feet on the passenger footrests. Never ride under the influence of alcohol or other drugs. ● This motorcycle is designed for onroad use only, therefore, it is not suitable for off-road use. ● Protective apparel The majority of fatalities from motorcycle accidents are the result of head injuries. The use of a safety helmet is the single most critical factor in the prevention or reduction of head injuries. ● Always wear an approved helmet. ● Wear a face shield or goggles. Wind in your unprotected eyes could contribute to an impairment of vision which could delay seeing a hazard. ● The use of a jacket, heavy boots, trousers, gloves, etc., is effective in preventing or reducing abrasions or lacerations. ● Never wear loose-fitting clothes, otherwise they could catch on the control levers, footrests, or wheels and cause injury or an accident. ● Never touch the engine or exhaust system during or after operation. They become very hot and can 1-2 cause burns. Always wear protective clothing that covers your legs, ankles, and feet. Passengers should also observe the precautions mentioned above. Modifications Modifications made to this motorcycle not approved by Yamaha, or the removal of original equipment, may render the motorcycle unsafe for use and may cause severe personal injury. Modifications may also make your motorcycle illegal to use. Loading and accessories Adding accessories or cargo to your motorcycle can adversely affect stability and handling if the weight distribution of the motorcycle is changed. To avoid the possibility of an accident, use extreme caution when adding cargo or accessories to your motorcycle. Use extra care when riding a motorcycle that has added cargo or accessories. Here are some general guidelines to follow if loading cargo or adding accessories to your motorcycle: U5VN11E0.book Page 3 Tuesday, April 13, 2004 5:24 PM SAFETY INFORMATION Loading The total weight of the operator, passenger, accessories and cargo must not exceed the maximum load limit of XV17A 194 kg (428 lb) XV17AW 194 kg (428 lb) XV17AM 194 kg (428 lb) XV17AT 179 kg (395 lb) XV17ATM 179 kg (395 lb). When loading within this weight limit, keep the following in mind: ● Cargo and accessory weight should be kept as low and close to the motorcycle as possible. Make sure to distribute the weight as evenly as possible on both sides of the motorcycle to minimize imbalance or instability. ● Shifting weights can create a sudden imbalance. Make sure that accessories and cargo are securely attached to the motorcycle before riding. Check accessory mounts and cargo restraints frequently. ● Never attach any large or heavy items to the handlebar, front fork, or front fender. These items, including such cargo as sleeping bags, duffel bags, or tents, can create unstable handling or slow steering response. Accessories Genuine Yamaha accessories have been specifically designed for use on this motorcycle. Since Yamaha cannot test all other accessories that may be available, you must personally be responsible for the proper selection, installation and use of non-Yamaha accessories. Use extreme caution when selecting and installing any accessories. Keep the following guidelines in mind, as well as those provided under “Loading” when mounting accessories. ● Never install accessories or carry cargo that would impair the performance of your motorcycle. Carefully inspect the accessory before using it to make sure that it does not in any way reduce ground clearance or cornering clearance, 1-3 limit suspension travel, steering travel or control operation, or obscure lights or reflectors. • Accessories fitted to the handlebar or the front fork area can create instability due to improper weight distribution or aerodynamic changes. If accessories are added to the handlebar or front fork area, they must be as lightweight as possible and should be kept to a minimum. • Bulky or large accessories may seriously affect the stability of the motorcycle due to aerodynamic effects. Wind may attempt to lift the motorcycle, or the motorcycle may become unstable in cross winds. These accessories may also cause instability when passing or being passed by large vehicles. • Certain accessories can displace the operator from his or her normal riding position. This improper position limits the freedom of movement of the opera- 1 U5VN11E0.book Page 4 Tuesday, April 13, 2004 5:24 PM SAFETY INFORMATION 1 ● tor and may limit control ability, therefore, such accessories are not recommended. Use caution when adding electrical accessories. If electrical accessories exceed the capacity of the motorcycle’s electrical system, an electric failure could result, which could cause a dangerous loss of lights or engine power. Gasoline and exhaust gas ● GASOLINE IS HIGHLY FLAMMABLE: • Always turn the engine off when refueling. • Take care not to spill any gasoline on the engine or exhaust system when refueling. • Never refuel while smoking or in the vicinity of an open flame. ● Never start the engine or let it run for any length of time in a closed area. The exhaust fumes are poisonous and may cause loss of consciousness and death within a short time. Always operate your motorcycle in an area that has adequate ventilation. ● ● ● Always turn the engine off before leaving the motorcycle unattended and remove the key from the main switch. When parking the motorcycle, note the following: • The engine and exhaust system may be hot, therefore, park the motorcycle in a place where pedestrians or children are not likely to touch these hot areas. • Do not park the motorcycle on a slope or soft ground, otherwise it may fall over. • Do not park the motorcycle near a flammable source (e.g. a kerosene heater, or near an open flame), otherwise it could catch fire. When transporting the motorcycle in another vehicle, make sure that it is kept upright and that the fuel cock is turned to “ON” or “RES” (for vacuum type) / “OFF” (for manual type). If it should lean over, gasoline may leak out of the carburetor or fuel tank. If you should swallow any gasoline, inhale a lot of gasoline vapor, or allow gasoline to get into your 1-4 eyes, see your doctor immediately. If any gasoline spills on your skin or clothing, immediately wash the affected area with soap and water and change your clothes. U5VN11E0.book Page 5 Tuesday, April 13, 2004 5:24 PM SAFETY INFORMATION EAU10381 Location of important labels Please read the following important labels carefully before operating this vehicle. 1 1-5 U5VN11E0.book Page 6 Tuesday, April 13, 2004 5:24 PM SAFETY INFORMATION 1 5 1 2 6 XV17AT / XV17ATM 3 XV17AT 7 California only 4 XV17ATM 4NL-F8446-00 1-6 U5VN11E0.book Page 1 Tuesday, April 13, 2004 5:24 PM DESCRIPTION EAU32220 Left view XV17A(C)/XV17AW(C)/XV17AM(C) 2 1. 2. 3. 4. 5. 6. 7. Shift pedal (page 3-6) Starter (choke) knob (page 3-9) Fuel cock (page 3-8) Engine oil filler cap (page 6-10) Battery (page 6-32) Owner’s tool kit (page 6-1) Fuse (page 6-33) 2-1 U5VN11E0.book Page 2 Tuesday, April 13, 2004 5:24 PM DESCRIPTION XV17AT(C)/XV17ATM(C) 2 1. 2. 3. 4. 5. 6. 7. Shift pedal (page 3-6) Starter (choke) knob (page 3-9) Fuel cock (page 3-8) Engine oil filler cap (page 6-10) Battery (page 6-32) Owner’s tool kit (page 6-1) Fuse (page 6-33) 2-2 U5VN11E0.book Page 3 Tuesday, April 13, 2004 5:24 PM DESCRIPTION EAU32230 Right view XV17A(C)/XV17AW(C)/XV17AM(C) 2 1. 2. 3. 4. 5. 6. 7. 8. Muffler Passenger footrest Fuel tank (page 3-7) Fuel tank cap (page 3-7) Brake pedal (page 3-6) Rider footrest Air filter element (page 6-14) Shock absorber assembly spring preload adjusting nut (page 3-14) 2-3 U5VN11E0.book Page 4 Tuesday, April 13, 2004 5:24 PM DESCRIPTION XV17AT(C)/XV17ATM(C) 2 1. 2. 3. 4. 5. 6. 7. 8. Fuel tank (page 3-7) Fuel tank cap (page 3-7) Windshield (page 3-11) Brake pedal (page 3-6) Rider footrest Air filter element (page 6-14) Shock absorber assembly spring preload adjusting nut (page 3-14) Muffler 2-4 U5VN11E0.book Page 5 Tuesday, April 13, 2004 5:24 PM DESCRIPTION EAU32240 Controls and instruments XV17A(C)/XV17AW(C)/XV17AM(C) 2 1. 2. 3. 4. 5. 6. 7. Clutch lever (page 3-5) Left handlebar switches (page 3-4) Speedometer unit (page 3-2) Main switch/steering lock (page 3-1) Right handlebar switches (page 3-4) Throttle grip (page 6-16) Brake lever (page 3-6) 2-5 U5VN11E0.book Page 6 Tuesday, April 13, 2004 5:24 PM DESCRIPTION XV17AT(C)/XV17ATM(C) 2 1. 2. 3. 4. 5. 6. 7. Clutch lever (page 3-5) Left handlebar switches (page 3-4) Speedometer unit (page 3-2) Main switch/steering lock (page 3-1) Right handlebar switches (page 3-4) Throttle grip (page 6-16) Brake lever (page 3-6) 2-6 U5VN11E0.book Page 1 Tuesday, April 13, 2004 5:24 PM INSTRUMENT AND CONTROL FUNCTIONS EAU10460 Main switch/steering lock EAU10680 LOCK The steering is locked, and all electrical systems are off. The key can be removed. To unlock the steering To lock the steering 3 1. Push. 2. Turn. The main switch/steering lock controls the ignition and lighting systems, and is used to lock the steering. The various positions are described below. EAU10520 ON All electrical systems are supplied with power, and the headlight, meter lighting, taillight, license plate light and position lights come on, and the engine can be started. The key cannot be removed. Push the key in, and then turn it to “OFF” while still pushing it. EWA10060 WARNING 1. Push. 2. Turn. 1. Turn the handlebars all the way to the left. 2. Push the key in from the “OFF” position, and then turn it to “LOCK” while still pushing it. 3. Remove the key. EAU10660 OFF All electrical systems are off. The key can be removed. 3-1 Never turn the key to “OFF” or “LOCK” while the vehicle is moving, otherwise the electrical systems will be switched off, which may result in loss of control or an accident. Make sure that the vehicle is stopped before turning the key to “OFF” or “LOCK”. U5VN11E0.book Page 2 Tuesday, April 13, 2004 5:24 PM INSTRUMENT AND CONTROL FUNCTIONS EAU11001 Indicator and warning lights EAU11080 High beam indicator light “ ” This indicator light comes on when the high beam of the headlight is switched on. EAU11701 Speedometer unit EAU11270 Fuel level warning light “ ” This warning light comes on when the fuel level drops below approximately 3.5 L (0.92 US gal) (0.77 Imp.gal). When this occurs, turn the fuel cock lever to the “RES” position and refuel as soon as possible. 3 1. 2. 3. 4. 5. Fuel level warning light “ ” High beam indicator light “ ” Turn signal indicator light “ Neutral indicator light “ ” Engine trouble warning light “ ” EAU11500 ” EAU11020 Turn signal indicator light “ ” This indicator light flashes when the turn signal switch is pushed to the left or right. EAU11060 Neutral indicator light “ ” This indicator light comes on when the transmission is in the neutral position. Engine trouble warning light “ ” This warning light comes on or flashes when an electrical circuit monitoring the engine is defective. When this occurs, have a Yamaha dealer check the selfdiagnosis system. The electrical circuit of the warning light can be checked by turning the key to “ON”. If the warning light does not come on for a few seconds, then go off, have a Yamaha dealer check the electrical circuit. 3-2 1. 2. 3. 4. 5. Odometer/tripmeter/clock Speedometer Fuel gauge Set button Mode button The speedometer unit is equipped with a speedometer, an odometer and two tripmeters. The speedometer shows riding speed. The odometer shows the total distance traveled. The tripmeters show the distance traveled since they were last set to zero. Pushing the mode button (left) switches the display between the odometer mode “ODO” and the tripmeter modes “TRIP A” and “TRIP B” in the following order: ODO → TRIP A → TRIP B → ODO U5VN11E0.book Page 3 Tuesday, April 13, 2004 5:24 PM INSTRUMENT AND CONTROL FUNCTIONS EAU12090 Fuel gauge This model is equipped with a self-diagnosis device for various electrical circuits. If any of those circuits are defective, the engine trouble warning light will come on or flash. If this occurs, have a Yamaha dealer check the vehicle. The fuel gauge indicates the amount of fuel in the fuel tank. The needle moves towards “E” (Empty) as the fuel level decreases. When the needle reaches “E”, refuel as soon as possible. ECA11170 To reset a tripmeter, select it by pushing the mode button (left), and then hold down the set button (right) for at least one second. The tripmeters can be used to estimate the distance that can be traveled with a full tank of fuel. This information will enable you to plan future fuel stops. EAU12140 Self-diagnosis device CAUTION: To prevent engine damage, be sure to consult a Yamaha dealer as soon as possible if this occurs. NOTE: This model is not equipped with a tachometer; however, it has a built-in engine speed limiter, which prevents the engine speed from exceeding approximately 4800 r/min. 3-3 NOTE: Do not allow the fuel tank to empty itself completely. 3 U5VN11E0.book Page 4 Tuesday, April 13, 2004 5:24 PM INSTRUMENT AND CONTROL FUNCTIONS EAU12211 Clock 3 1. Clock 2. Set button 3. Mode button The digital clock shows the time regardless of the main switch position. 2. Press both the set button (right) and the mode button (left) simultaneously until the hours and minutes flash. 3. Push the left button and only the hour display will flash. 4. Push the right button to change the hours. 5. Push the left button and only the minute display will flash. 6. Push the right button to change the minutes. 7. Push the left button and both the hours and minutes will flash. 8. Push the right button for two seconds to set the clock. EAU12343 Handlebar switches Left 1. Dimmer switch “ / ” 2. Turn signal switch “ / ” 3. Horn switch “ ” Right 1. Engine stop switch “ 2. Start switch “ ” To set the clock 1. Turn the key to “ON”. 3-4 / ” U5VN11E0.book Page 5 Tuesday, April 13, 2004 5:24 PM INSTRUMENT AND CONTROL FUNCTIONS EAU12400 Dimmer switch “ / ” Set this switch to “ ” for the high beam and to “ ” for the low beam. EAU12500 Horn switch “ ” Press this switch to sound the horn. EAU12820 Clutch lever EAU12660 EAU12430 Turn signal switch “ / ” To signal a right-hand turn, push this switch to “ ”. To signal a left-hand turn, push this switch to “ ”. When released, the switch returns to the center position. Since this model is equipped with a self-canceling system, the turn signal lights will self-cancel after the vehicle has traveled both about 150 m (490 ft) and for approximately 15 seconds. However, the turn signal lights can also be canceled manually by pushing the switch in after it has returned to the center position. Engine stop switch “ / ” Set this switch to “ ” before starting the engine. Set this switch to “ ” to stop the engine in case of an emergency, such as when the vehicle overturns or when the throttle cable is stuck. EAU12710 Start switch “ ” Push this switch to crank the engine with the starter. ECA10050 CAUTION: See page 5-1 for starting instructions prior to starting the engine. NOTE: The self-canceling system only operates when the vehicle is moving, so that the turn signal lights will not self-cancel while you are stopped at an intersection. 3-5 3 1. Clutch lever The clutch lever is located at the left handlebar grip. To disengage the clutch, pull the lever toward the handlebar 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 ignition circuit cut-off system. (See page 3-16.) U5VN11E0.book Page 6 Tuesday, April 13, 2004 5:24 PM INSTRUMENT AND CONTROL FUNCTIONS EAU12880 EAU12890 EAU12941 Shift pedal Brake lever Brake pedal 1. Shift pedal 1. Brake lever 1. Brake pedal The shift pedal is located on the left side of the engine and is used in combination with the clutch lever when shifting the gears of the 5-speed constant-mesh transmission equipped on this motorcycle. The brake lever is located at the right handlebar grip. To apply the front brake, pull the lever toward the handlebar grip. The brake pedal is on the right side of the motorcycle. To apply the rear brake, press down on the brake pedal. 3 NOTE: Use your toes or heel to shift up and your toes to shift down. 3-6 U5VN11E0.book Page 7 Tuesday, April 13, 2004 5:24 PM INSTRUMENT AND CONTROL FUNCTIONS EAU13120 Fuel tank cap 2. Turn the key counterclockwise to the original position, remove it, and then close the lock cover. EAU13210 Fuel 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 is not properly installed and locked. 3 EWA10130 WARNING 1. 2. 3. 4. Fuel tank cap lock cover “ ” mark Unlock. Lock. Make sure that the fuel tank cap is properly installed before riding. 1. Fuel tank filler tube 2. Fuel level Make sure that there is sufficient fuel in the tank. Fill the fuel tank to the bottom of the filler tube as shown. 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. EWA10880 WARNING ● ● 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. 3-7 Do not overfill the fuel tank, otherwise it may overflow when the fuel warms up and expands. Avoid spilling fuel on the hot engine. U5VN11E0.book Page 8 Tuesday, April 13, 2004 5:24 PM INSTRUMENT AND CONTROL FUNCTIONS ECA10070 CAUTION: Immediately wipe off spilled fuel with a clean, dry, soft cloth, since fuel may deteriorate painted surfaces or plastic parts. EAU13300 3 Recommended fuel: UNLEADED GASOLINE ONLY Fuel tank capacity: 20.0 L (5.28 US gal) (4.40 Imp.gal) Fuel reserve amount: 3.5 L (0.92 US gal) (0.77 Imp.gal) knocking (or pinging) occurs, use a gasoline of a different brand or premium unleaded fuel. Use of unleaded fuel will extend spark plug life and reduce maintenance costs. Gasohol There are two types of gasohol: gasohol containing ethanol and that containing methanol. Gasohol containing ethanol can be used if the ethanol content does not exceed 10%. Gasohol containing methanol is not recommended by Yamaha because it can cause damage to the fuel system or vehicle performance problems. EAU13560 Fuel cock The fuel cock supplies fuel from the tank to the carburetor while filtering it also. The fuel cock has three positions: OFF ECA11400 CAUTION: 1. Pointed end positioned over “OFF” Use only unleaded gasoline. The use of leaded gasoline will cause severe damage to internal engine parts, such as the valves and piston rings, as well as to the exhaust system. With the lever in this position, fuel will not flow. Always return the lever to this position when the engine is not running. Your Yamaha engine has been designed to use regular unleaded gasoline with a pump octane number [(R+M)/2] of 86 or higher, or a research octane number of 91 or higher. If 3-8 U5VN11E0.book Page 9 Tuesday, April 13, 2004 5:24 PM INSTRUMENT AND CONTROL FUNCTIONS ON This indicates reserve. If you run out of fuel while riding, move the lever to this position. Fill the tank at the first opportunity. Be sure to set the lever back to “ON” after refueling! EAU13600 Starter (choke) knob “ ” 3 1. Pointed end positioned over “ON” Starting a cold engine requires a richer air-fuel mixture, which is supplied by the starter (choke). Move the knob in direction (a) to turn on the starter (choke). Move the knob in direction (b) to turn off the starter (choke). With the lever in this position, fuel flows to the carburetor. Normal riding is done with the lever in this position. RES 1. Pointed end positioned over “RES” 3-9 U5VN11E0.book Page 10 Tuesday, April 13, 2004 5:24 PM INSTRUMENT AND CONTROL FUNCTIONS EAU13780 Locking the steering with a padlock EAU14151 Rider seat To remove the rider seat 1. Insert the key into the main switch, and then turn it counterclockwise to “OPEN”. 3 1. Projection 2. Seat holder In addition to the main switch/steering lock, there are brackets on the right side of the steering head pipe for locking the steering with a padlock. To do so, turn the handlebar until the holes in the two brackets are aligned, and then lock the steering with a suitable padlock. 2. Remove the key from the main switch if the motorcycle will be left unattended. NOTE: Do not push inward when turning the key. 2. Pull the rider seat off. To install the rider seat 1. Insert the projection on the rear of the rider seat into the seat holder as shown, and then push the front of the seat down to lock it in place. 3-10 NOTE: Make sure that the rider seat is properly secured before riding. U5VN11E0.book Page 11 Tuesday, April 13, 2004 5:24 PM INSTRUMENT AND CONTROL FUNCTIONS EAU14320 Helmet holder To release the helmet from the helmet holder Remove the rider seat, remove the helmet from the helmet holder, and then install the seat. EAU14580 Windshield [XV17AT(C)/XV17ATM(C)] To suit the rider’s preference, the windshield angle can be adjusted and the height can be changed to one of two positions. To adjust the windshield angle 1. Loosen the bolts on each side of the windshield. 1. Helmet holder The helmet holder is located under the rider seat. To secure a helmet to the helmet holder 1. Remove the rider seat. (See page 3-10.) 2. Attach the helmet to the helmet holder, and then securely install the seat. 1. Windshield 2. Bolt EWA10160 2. Move the windshield to the desired angle. 3. Tighten the bolts to the specified torque. WARNING Never ride with a helmet attached to the helmet holder, since the helmet may hit objects, causing loss of control and possibly an accident. 3-11 3 U5VN11E0.book Page 12 Tuesday, April 13, 2004 5:24 PM INSTRUMENT AND CONTROL FUNCTIONS To change the windshield height 1. Remove the bolts on each side of the windshield. 2. Move the windshield to the other position. 3. Install the bolts and tighten them to the specified torque. 3 Tightening torque: Windshield bolt: 16 Nm (1.6 m·kgf, 12 ft·lbf) 4. Loosen the screws holding the windshield cover located above the headlight, position the cover close to the headlight without touching it, and then tighten the screws. EWA10920 EAU14613 Saddlebags [XV17AT(C)] WARNING After adjusting the windshield: ● Securely tighten the windshield bolts. ● Turn the handlebar to the left and right to make sure that the handlebar is not obstructed and that the windshield does not contact any other parts. ● Open the throttle and make sure that the throttle grip returns properly when released, otherwise an accident or injury could result. 1. Windshield cover 2. Screw 3-12 EWA11111 WARNING Improper loading or overloading can cause loss of control and possibly an accident or personal injury. See pages 1-5 and 6-17 for important loading and tire pressure information. ● Always securely close each saddlebag before riding. ● Distribute weight evenly on each side of the motorcycle. ● Do not exceed the load limit of 5 kg (11 lb) for each saddlebag. ● Do not exceed the maximum load of XV17AT(C) 179 kg (395 lb) for the vehicle. ● Do not exceed 120 km/h (80 mi/h) when riding with luggage in the sidecases, otherwise handling could be affected. Improper loading, poor tire or overall motorcycle conditions, poor road surfaces or adverse weather conditions may make it necessary to further reduce the riding speed. U5VN11E0.book Page 13 Tuesday, April 13, 2004 5:24 PM INSTRUMENT AND CONTROL FUNCTIONS To open a saddlebag Unbuckle the belts and fold up the flap. EAU35890 Sidecases [XV17ATM(C)] EWA12520 WARNING To close a saddlebag Fold the flap down and buckle both belts securely. NOTE: For saddlebag cleaning and care, see page 7-1. Improper loading or overloading can cause loss of control and possibly an accident or personal injury. See pages 1-5 and 6-17 for important loading and tire pressure information. ● Always securely close the sidecases before riding. ● Distribute weight evenly on each side of the motorcycle. ● Do not exceed the load limit of 5 kg (11 lb) for each sidecase. ● Do not exceed the maximum load of XV17ATM(C) 179 kg (395 lb) for the vehicle. ● Do not exceed 120 km/h (80 mi/h) when riding with luggage in the sidecases, otherwise handling could be affected. Improper loading, poor tire or overall motorcycle conditions, poor road surfaces or adverse weather conditions may make it necessary to further reduce the riding speed. 3-13 To open a sidecase 1. Insert the key into the lock, turn it counterclockwise, and then push it in. 3 1. Sidecase lock 2. Unlock. 2. Fold the sidecase lid up. 1. Storage compartment U5VN11E0.book Page 14 Tuesday, April 13, 2004 5:24 PM INSTRUMENT AND CONTROL FUNCTIONS To close a sidecase 1. Fold the sidecase lid down. 2. Turn the key clockwise, and then remove it. NOTE: Push the lid down so that the latch snaps into place. 3 ECA13090 CAUTION: To avoid locking the key in, never lock either sidecase and remove the key from the lock before closing the lid. EAU14811 Adjusting the shock absorber assembly load and thereby soften the suspension, turn the adjusting nut in direction (b). This shock absorber assembly is equipped with a spring preload adjusting nut. ECA10100 CAUTION: Never attempt to turn an adjusting mechanism beyond the maximum or minimum settings. Adjust the spring preload as follows. 1. Loosen the locknut. 1. Special wrench NOTE: The spring preload setting is determined by measuring distance A, shown in the illustration. The shorter distance A is, the lower the spring preload; the longer distance A is, the higher the spring preload. 1. Locknut 2. Spring preload adjusting nut 2. To increase the spring preload and thereby harden the suspension, turn the adjusting nut in direction (a). To decrease the spring pre3-14 U5VN11E0.book Page 15 Tuesday, April 13, 2004 5:24 PM INSTRUMENT AND CONTROL FUNCTIONS ECA10120 CAUTION: ● Always have a Yamaha dealer service the shock absorber. Always tighten the locknut against the adjusting nut, and then tighten the locknut to the specified torque. EWA10220 WARNING 1. Distance A Spring preload: Minimum (soft): Distance A = 42.5 mm (1.67 in) Standard: XV17A(C)/XV17AW(C)/ XV17AM(C) Distance A = 42.5 mm (1.67 in) XV17AT(C)/XV17ATM(C) Distance A = 45.5 mm (1.79 in) Maximum (hard): Distance A = 51.5 mm (2.02 in) 3. Tighten the locknut to the specified torque. Tightening torque: Locknut: 35 Nm (3.5 m·kgf, 25 ft·lbf) This shock absorber contains highly pressurized nitrogen gas. For proper handling, read and understand the following information before handling the shock absorber. The manufacturer cannot be held responsible for property damage or personal injury that may result from improper handling. ● Do not tamper with or attempt to open the gas cylinder. ● Do not subject the shock absorber to an open flame or other high heat sources, otherwise it may explode due to excessive gas pressure. ● Do not deform or damage the gas cylinder in any way, as this will result in poor damping performance. 3-15 3 U5VN11E0.book Page 16 Tuesday, April 13, 2004 5:24 PM INSTRUMENT AND CONTROL FUNCTIONS EAU15300 Sidestand The sidestand is located on the left side of the frame. Raise the sidestand or lower it with your foot while holding the vehicle upright. 3 below and have a Yamaha dealer repair it if it does not function properly. NOTE: The built-in sidestand switch is part of the ignition circuit cut-off system, which cuts the ignition in certain situations. (See further down for an explanation of the ignition circuit cut-off system.) EWA10240 WARNING The vehicle must not be ridden with the sidestand down, or if the sidestand cannot be properly moved up (or does not stay up), otherwise the sidestand could contact the ground and distract the operator, resulting in a possible loss of control. Yamaha’s ignition circuit cut-off system has been designed to assist the operator in fulfilling the responsibility of raising the sidestand before starting off. Therefore, check this system regularly as described EAU15311 Ignition circuit cut-off system The ignition circuit cut-off system (comprising the sidestand switch, clutch switch and neutral switch) has the following functions. ● It prevents starting when the transmission is in gear and the sidestand is up, but the clutch lever is not pulled. ● It prevents starting when the transmission is in gear and the clutch lever is pulled, but the sidestand is still down. ● It cuts the running engine when the transmission is in gear and the sidestand is moved down. Periodically check the operation of the ignition circuit cut-off system according to the following procedure. EWA10250 WARNING If a malfunction is noted, have a Yamaha dealer check the system before riding. 3-16 U5VN11E0.book Page 17 Tuesday, April 13, 2004 5:24 PM INSTRUMENT AND CONTROL FUNCTIONS With the engine turned off: 1. Move the sidestand down. 2. Make sure that the engine stop switch is turned on. 3. Turn the key on. 4. Shift the transmission into the neutral position. 5. Push the start switch. Does the engine start? YES NOTE: This check is most reliable if performed with a warmed-up engine. NO The neutral switch may be defective. The motorcycle should not be ridden until checked by a Yamaha dealer. NO The sidestand switch may be defective. The motorcycle should not be ridden until checked by a Yamaha dealer. NO The clutch switch may be defective. The motorcycle should not be ridden until checked by a Yamaha dealer. With the engine still running: 6. Move the sidestand up. 7. Keep the clutch lever pulled. 8. Shift the transmission into gear. 9. Move the sidestand down. Does the engine stall? YES After the engine has stalled: 10. Move the sidestand up. 11. Keep the clutch lever pulled. 12. Push the start switch. Does the engine start? YES The system is OK. The motorcycle can be ridden. 3-17 3 U5VN11E0.book Page 1 Tuesday, April 13, 2004 5:24 PM PRE-OPERATION CHECKS EAU15591 The condition of a vehicle is the owner’s responsibility. Vital components can start to deteriorate quickly and unexpectedly, even if the vehicle remains unused (for example, as a result of exposure to the elements). Any damage, fluid leakage or loss of tire air pressure could have serious consequences. Therefore, it is very important, in addition to a thorough visual inspection, to check the following points before each ride. NOTE: Pre-operation checks should be made each time the vehicle is used. Such an inspection can be accomplished in a very short time; and the added safety it assures is more than worth the time involved. 4 EWA11150 WARNING If any item in the Pre-operation check list is not working properly, have it inspected and repaired before operating the vehicle. 4-1 U5VN11E0.book Page 2 Tuesday, April 13, 2004 5:24 PM PRE-OPERATION CHECKS EAU15602 Pre-operation check list ITEM CHECKS PAGE Fuel • Check fuel level in fuel tank. • Refuel if necessary. • Check fuel line for leakage. 3-7 Engine oil • Check oil level in engine. • If necessary, add recommended oil to specified level. • Check vehicle for oil leakage. 6-10 Front brake • • • • • • • • • Check operation. If soft or spongy, have Yamaha dealer bleed hydraulic system. Check lever free play. Adjust if necessary. 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. 6-23, 6-24, 6-25 Rear brake • • • • • • • Check 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. 6-24, 6-25 Clutch • • • • Check operation. Lubricate cable if necessary. Check lever free play. Adjust if necessary. Throttle grip • Make sure that operation is smooth. • Check cable free play. • If necessary, have Yamaha dealer adjust cable free play and lubricate cable and grip housing. 4 6-22 4-2 6-16, 6-28 U5VN11E0.book Page 3 Tuesday, April 13, 2004 5:24 PM PRE-OPERATION CHECKS ITEM CHECKS PAGE Control cables • Make sure that operation is smooth. • Lubricate if necessary. Wheels and tires • • • • Brake and shift pedals • Make sure that operation is smooth. • Lubricate pedal pivoting points if necessary. 6-28 Brake and clutch levers • Make sure that operation is smooth. • Lubricate lever pivoting points if necessary. 6-29 Sidestand • Make sure that operation is smooth. • Lubricate pivot if necessary. 6-30 Chassis fasteners • Make sure that all nuts, bolts and screws are properly tightened. • Tighten if necessary. — Instruments, lights, signals and switches • Check operation. • Correct if necessary. — Sidestand switch • Check operation of ignition circuit cut-off system. • If system is defective, have Yamaha dealer check vehicle. 4 6-28 Check for damage. Check tire condition and tread depth. Check air pressure. Correct if necessary. 4-3 6-17, 6-21 3-16 U5VN11E0.book Page 1 Tuesday, April 13, 2004 5:24 PM OPERATION AND IMPORTANT RIDING POINTS EAU15950 EWA10270 WARNING ● ● ● Become thoroughly familiar with all operating controls and their functions before riding. Consult a Yamaha dealer regarding any control or function that you do not thoroughly understand. Never start the engine or operate it in a closed area for any length of time. Exhaust fumes are poisonous, and inhaling them can cause loss of consciousness and death within a short time. Always make sure that there is adequate ventilation. Before starting out, make sure that the sidestand is up. If the sidestand is not raised completely, it could contact the ground and distract the operator, resulting in a possible loss of control. EAU16390 Starting and warming up a cold engine In order for the ignition circuit cut-off system to enable starting, one of the following conditions must be met: ● The transmission is in the neutral position. ● The transmission is in gear with the clutch lever pulled and the sidestand up. EWA10290 WARNING ● ● Before starting the engine, check the function of the ignition circuit cut-off system according to the procedure described on page 3-16. Never ride with the sidestand down. 1. Turn the fuel cock lever to “ON”. 2. Turn the key to “ON” and make sure that the engine stop switch is set to “ ”. 3. Shift the transmission into the neutral position. 5-1 NOTE: When the transmission is in the neutral position, the neutral indicator light should be on, otherwise have a Yamaha dealer check the electrical circuit. 4. Turn the starter (choke) on and completely close the throttle. (See page 3-9.) 5. Start the engine by pushing the start switch. NOTE: If the engine fails to start, release the start switch, wait a few seconds, and then try again. Each starting attempt should be as short as possible to preserve the battery. Do not crank the engine more than 10 seconds on any one attempt. ECA11370 CAUTION: The engine trouble warning light should come on when the key is turned to “ON”, and then go off after a few seconds. If the engine trouble warning light comes on or flashes 5 U5VN11E0.book Page 2 Tuesday, April 13, 2004 5:24 PM OPERATION AND IMPORTANT RIDING POINTS after starting, immediately stop the engine, and have a Yamaha dealer check the self-diagnosis system. (choke) turned on, then about 2.5 minutes with the starter (choke) in the halfway position. 6. After starting the engine, move the starter (choke) back halfway. ECA11130 CAUTION: For maximum engine life, always warm the engine up before starting off. Never accelerate hard when the engine is cold! 5 7. When the engine is warm, turn the starter (choke) off. NOTE: The engine is warm when it responds normally to the throttle with the starter (choke) turned off. To avoid the possibility of excessive exhaust emissions, never leave the starter (choke) on longer than necessary. The time necessary for starter (choke) use depends upon the ambient temperature. Temperatures above 10 °C (50 °F) require about 7 seconds of starter (choke) use and temperatures below 10 °C (50 °F) require about 35 seconds with the starter 5-2 EAU16640 Starting a warm engine Follow the same procedure as for starting a cold engine with the exception that the starter (choke) is not required when the engine is warm. U5VN11E0.book Page 3 Tuesday, April 13, 2004 5:24 PM OPERATION AND IMPORTANT RIDING POINTS EAU16671 Shifting ECA10260 CAUTION: ● 1. Shift pedal 2. Neutral position Shifting gears lets you control the amount of engine power available for starting off, accelerating, climbing hills, etc. The gear positions are shown in the illustration. ● Even with the transmission in the neutral position, do not coast for long periods of time with the engine off, and do not tow the motorcycle for long distances. The transmission is properly lubricated only when the engine is running. Inadequate lubrication may damage the transmission. Always use the clutch while changing gears to avoid damaging the engine, transmission, and drive train, which are not designed to withstand the shock of forced shifting. EAU16680 NOTE: To shift the transmission into the neutral position, press the shift pedal down repeatedly until it reaches the end of its travel, and then slightly raise it. To start out and accelerate 1. Pull the clutch lever to disengage the clutch. 2. Shift the transmission into first gear. The neutral indicator light should go out. 3. Open the throttle gradually, and at the same time, release the clutch lever slowly. 5-3 4. At the recommended shift points shown in the following table, close the throttle, and at the same time, quickly pull the clutch lever in. 5. Shift the transmission into second gear. (Make sure not to shift the transmission into the neutral position.) 6. Open the throttle part way and gradually release the clutch lever. 7. Follow the same procedure when shifting to the next higher gear. NOTE: Always shift gears at the recommended shift points. EAU16700 To decelerate 1. Apply both the front and the rear brakes to slow the motorcycle. 2. Shift the transmission into first gear when the motorcycle reaches 25 km/h (16 mi/h). If the engine is about to stall or runs very roughly, pull the clutch lever in and use the brakes to stop the motorcycle. 5 U5VN11E0.book Page 4 Tuesday, April 13, 2004 5:24 PM OPERATION AND IMPORTANT RIDING POINTS 3. Shift the transmission into the neutral position when the motorcycle is almost completely stopped. The neutral indicator light should come on. EAU16720 Recommended shift points The recommended shift points during acceleration and deceleration are shown in the table below. 5 Shift up points: 1st → 2nd: 20 km/h (13 mi/h) 2nd → 3rd: 30 km/h (19 mi/h) 3rd → 4th: 40 km/h (25 mi/h) 4th → 5th: 50 km/h (31 mi/h) Shift down points: 5th → 4th: 25 km/h (16 mi/h) 4th → 3rd: 25 km/h (16 mi/h) 3rd → 2nd: 25 km/h (16 mi/h) 2nd → 1st: 25 km/h (16 mi/h) EAU16841 ECA10891 Engine break-in CAUTION: There is never a more important period in the life of your engine than the period between 0 and 1600 km (1000 mi). For this reason, you should read the following material carefully. Since the engine is brand new, do not put an excessive load on it for the first 1600 km (1000 mi). The various parts in the engine wear and polish themselves to the correct operating clearances. During this period, prolonged full-throttle operation or any condition that might result in engine overheating must be avoided. After 1000 km (600 mi) of operation, the engine oil and transfer case oil must be changed, and the oil filter cartridge or element replaced. EAU17071 0–1000 km (0–600 mi) Avoid prolonged operation above 1/3 throttle. 1000–1600 km (600–1000 mi) Avoid prolonged operation above 1/2 throttle. 5-4 1600 km (1000 mi) and beyond The vehicle can now be operated normally. ECA10270 CAUTION: If any engine trouble should occur during the engine break-in period, immediately have a Yamaha dealer check the vehicle. U5VN11E0.book Page 5 Tuesday, April 13, 2004 5:24 PM OPERATION AND IMPORTANT RIDING POINTS EAU17170 Parking When parking, stop the engine, remove the key from the main switch, and then turn the fuel cock lever to “OFF”. EWA10310 WARNING ● ● Since the engine and exhaust system can become very hot, park in a place where pedestrians or children are not likely to touch them. Do not park on a slope or on soft ground, otherwise the vehicle may overturn. 5 5-5 U5VN11E0.book Page 1 Tuesday, April 13, 2004 5:24 PM PERIODIC MAINTENANCE AND MINOR REPAIR EAU17231 EAU17301 PERIODIC MAINTENANCE Safety is an obligation of the owner. Periodic inspection, adjustment and lubrication will keep your vehicle in the safest and most efficient condition possible. The most important points of motorcycle inspection, adjustment, and lubrication are explained on the following pages. Maintenance, replacement, or repair of the emission control devices and systems may be performed by any repair establishment or individual that is certified (if applicable). 6 EWA10320 WARNING If you are not familiar with maintenance work, have a Yamaha dealer do it for you. PROPER PERIODIC MAINTENANCE OF YOUR VEHICLE IS IMPORTANT IN ORDER TO ENJOY LONG, PLEASURABLE SERVICE. ESPECIALLY IMPORTANT ARE THE MAINTENANCE SERVICES RELATED TO EMISSIONS CONTROL. THESE CONTROLS NOT ONLY FUNCTION TO ENSURE CLEANER AIR, BUT ARE ALSO VITAL TO PROPER ENGINE OPERATION AND MAXIMUM PERFORMANCE. IN THE FOLLOWING PERIODIC MAINTENANCE CHARTS, THE SERVICES RELATED TO EMISSIONS CONTROL ARE GROUPED SEPARATELY. THESE SERVICES REQUIRE SPECIALIZED DATA, KNOWLEDGE, AND EQUIPMENT. YAMAHA DEALERS ARE TRAINED AND EQUIPPED TO PERFORM THESE PARTICULAR SERVICES. 6-1 EAU17350 Owner’s tool kit 1. Owner’s tool kit The owner’s tool kit is located under the rider seat. (See page 3-10.) The service information included in this manual and the tools provided in the owner’s tool kit are intended to assist you in the performance of preventive maintenance and minor repairs. However, additional tools such as a torque wrench may be necessary to perform certain maintenance work correctly. NOTE: If you do not have the tools or experience required for a particular job, have a Yamaha dealer perform it for you. U5VN11E0.book Page 2 Tuesday, April 13, 2004 5:24 PM PERIODIC MAINTENANCE AND MINOR REPAIR EWA10340 WARNING Modifications not approved by Yamaha may cause loss of performance, excessive emissions, and render the vehicle unsafe for use. Consult a Yamaha dealer before attempting any changes. 6 6-2 U5VN11E0.book Page 3 Tuesday, April 13, 2004 5:24 PM PERIODIC MAINTENANCE AND MINOR REPAIR EAU17600 Periodic maintenance chart for the emission control system INITIAL No. 6 ITEM ROUTINE 1 * Fuel line • Check fuel hoses for cracks or damage. • Replace if necessary. 2 * Fuel filter • Replace. 3 Spark plugs • Check condition. • Adjust gap and clean. • Replace every 8000 mi (13000 km) or 12 months. 4 * Valve clearance • Check and adjust valve clearance when engine is cold. • Adjust if necessary. 5 * Crankcase breather system • Check breather hose for cracks or damage. • Replace if necessary. 6 * Idle speed • Check and adjust engine idle speed. 7 * Exhaust system • Check for leakage. • Tighten if necessary. • Replace gasket(s) if necessary. 8 * Evaporative emission control system (For California only) • Check control system for damage. • Replace if necessary. 600 mi (1000 km) or 1 month ODOMETER READINGS 4000 mi (7000 km) or 6 months √ 8000 mi 12000 mi 16000 mi 20000 mi (13000 km) (19000 km) (25000 km) (31000 km) or or or or 12 months 18 months 24 months 30 months √ √ √ √ Replace. √ Replace. √ Replace. √ Every 16000 mi (25000 km) √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ * Since these items require special tools, data and technical skills, have a Yamaha dealer perform the service. 6-3 U5VN11E0.book Page 4 Tuesday, April 13, 2004 5:24 PM PERIODIC MAINTENANCE AND MINOR REPAIR EAU32182 General maintenance and lubrication chart INITIAL No. ITEM ROUTINE 600 mi (1000 km) or 1 month ODOMETER READINGS 4000 mi (7000 km) or 6 months 8000 mi 12000 mi 16000 mi 20000 mi (13000 km) (19000 km) (25000 km) (31000 km) or or or or 12 months 18 months 24 months 30 months 1 * Air filter element • Clean with compressed air. • Replace if necessary. 2 * Clutch • Check operation. • Adjust or replace cable. 3 * Front brake 4 * Rear brake 5 * Brake hoses 6 * Wheels (For cast wheel models) • Check runout and for damage. • Replace if necessary. √ √ 7 * Wheels (For spoke wheel model) • Check runout, spoke tightness and for damage. • Tighten spokes if necessary. √ Tires • Check tread depth and for damage. • Replace if necessary. • Check air pressure. • Correct if necessary. √ 8 * √ √ √ √ √ √ √ √ √ √ √ • Check operation, fluid level, and for fluid leakage. • Replace brake pads if necessary. √ √ √ √ √ √ • Check operation, fluid level, and for fluid leakage. • Replace brake pads if necessary. √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ • Check for cracks or damage. • Replace. Every 4 years 6-4 6 U5VN11E0.book Page 5 Tuesday, April 13, 2004 5:24 PM PERIODIC MAINTENANCE AND MINOR REPAIR INITIAL No. 6 ITEM ROUTINE 600 mi (1000 km) or 1 month 9 * Wheel bearings • Check bearings for smooth operation. • Replace if necessary. 10 * Swingarm pivot bearings • Check bearing assemblies for looseness. • Moderately repack with lithiumsoap-based grease. 11 * Drive belt • Check belt tension. • Adjust if necessary. √ 12 * Steering bearings • Check bearing assemblies for looseness. • Moderately repack with lithiumsoap-based grease every 16000 mi (25000 km) or 24 months. √ 13 * Chassis fasteners 14 ODOMETER READINGS 4000 mi (7000 km) or 6 months √ 8000 mi 12000 mi 16000 mi 20000 mi (13000 km) (19000 km) (25000 km) (31000 km) or or or or 12 months 18 months 24 months 30 months √ √ √ √ √ Repack. Every 2500 mi (4000 km) √ √ √ Repack. √ • Check all chassis fitting and fasteners. • Correct if necessary. √ √ √ √ √ Brake and clutch lever pivot shafts • Apply lithium-soap-based grease (all-purpose grease) lightly. √ √ √ √ √ 15 Brake and shift pedal pivot shafts • Apply lithium-soap-based grease (all-purpose grease) lightly. √ √ √ √ √ 16 Sidestand pivot • Check operation. • Apply lithium-soap-based grease (all-purpose grease) lightly. √ √ √ √ √ 17 * Sidestand switch • Check operation and replace if necessary. √ √ √ √ √ √ 6-5 U5VN11E0.book Page 6 Tuesday, April 13, 2004 5:24 PM PERIODIC MAINTENANCE AND MINOR REPAIR INITIAL No. ITEM ROUTINE 600 mi (1000 km) or 1 month ODOMETER READINGS 4000 mi (7000 km) or 6 months 8000 mi 12000 mi 16000 mi 20000 mi (13000 km) (19000 km) (25000 km) (31000 km) or or or or 12 months 18 months 24 months 30 months 18 * Front fork • Check operation and for oil leakage. • Replace if necessary. √ √ √ √ √ 19 * Shock absorber assembly • Check operation and for oil leakage. • Replace if necessary. √ √ √ √ √ 20 * Rear suspension link pivots • Apply lithium-soap-based grease lightly. 21 Engine oil • Change (warm engine before draining). √ 22 * Engine oil filter cartridge • Replace. √ √ √ 23 * Transfer case oil • Check for leakage. • Change at initial 600 mi (1000 km) or 1 month, and thereafter every 16000 mi (25000 km) or 24 months. Change. √ Change. 24 * Control cables • Apply Yamaha chain and cable lube or engine oil SAE 10W-30 thoroughly. 25 * Throttle grip housing and cable • Check operation and free play. • Adjust the throttle cable free play if necessary. • Lubricate the throttle grip housing and cable. √ √ √ √ √ √ 6 √ √ √ √ √ √ √ √ √ √ * Since these items require special tools, data and technical skills, have a Yamaha dealer perform the service. 6-6 √ U5VN11E0.book Page 7 Tuesday, April 13, 2004 5:24 PM PERIODIC MAINTENANCE AND MINOR REPAIR NOTE: From 24000 mi (37000 km) or 36 months, repeat the maintenance intervals starting from 8000 mi (13000 km) or 12 months. EAU17630 NOTE: ● The air filter needs more frequent service if you are riding in unusually wet or dusty areas. ● Hydraulic brake service • After disassembling the brake master cylinders and calipers, always change the fluid. Regularly check the brake fluid levels and fill the reservoirs as required. • Every two years replace the internal components of the brake master cylinders and calipers, and change the brake fluid. • Replace the brake hoses every four years and if cracked or damaged. 6 6-7 U5VN11E0.book Page 8 Tuesday, April 13, 2004 5:24 PM PERIODIC MAINTENANCE AND MINOR REPAIR EAU18751 EAU19543 Removing and installing the panel Checking the spark plugs The spark plugs are important engine components, which are easy to check. Since heat and deposits will cause any spark plug to slowly erode, the spark plugs should be removed and checked in accordance with the periodic maintenance and lubrication chart. In addition, the condition of the spark plugs can reveal the condition of the engine. The panel shown needs to be removed to perform some of the maintenance jobs described in this chapter. Refer to this section each time the panel needs to be removed and installed. 1. Bolt To install the panel Place the panel in the original position, and then install the bolt. To remove a spark plug 1. Remove the spark plug cap. 6 1. Panel A EAU19151 Panel A To remove the panel Remove the bolt, and then pull the panel off as shown. 1. Spark plug cap 2. Remove the spark plug as shown, with the spark plug wrench included in the owner’s tool kit. 6-8 U5VN11E0.book Page 9 Tuesday, April 13, 2004 5:24 PM PERIODIC MAINTENANCE AND MINOR REPAIR 3. Check each spark plug for electrode erosion and excessive carbon or other deposits, and replace it if necessary. Specified spark plug: NGK/DPR7EA-9 DENSO/X22EPR-U9 1. Spark plug wrench 6 To check the spark plugs 1. Check that the porcelain insulator around the center electrode on each spark plug is a medium-tolight tan (the ideal color when the vehicle is ridden normally). 2. Check that all spark plugs installed in the engine have the same color. NOTE: If any spark plug shows a distinctly different color, the engine could be defective. Do not attempt to diagnose such problems yourself. Instead, have a Yamaha dealer check the vehicle. To install a spark plug 1. Measure the spark plug gap with a wire thickness gauge and, if necessary, adjust the gap to specification. 2. Clean the surface of the spark plug gasket and its mating surface, and then wipe off any grime from the spark plug threads. 3. Install the spark plug with the spark plug wrench, and then tighten it to the specified torque. Tightening torque: Spark plug: 17.5 Nm (1.75 m·kgf, 12.5 ft·lbf) 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 specified torque as soon as possible. 4. Install the spark plug cap. 1. Spark plug gap Spark plug gap: 0.8–0.9 mm (0.031–0.035 in) 6-9 U5VN11E0.book Page 10 Tuesday, April 13, 2004 5:24 PM PERIODIC MAINTENANCE AND MINOR REPAIR EAU19680 Canister (for California only) EAU19920 Engine oil and oil filter cartridge The engine oil level should be checked before each ride. In addition, the oil must be changed and the oil filter cartridge replaced at the intervals specified in the periodic maintenance and lubrication chart. This model is equipped with a canister to prevent the discharging of fuel vapor into the atmosphere. Before operating this vehicle, make sure to check the following: ● Check each hose connection. ● Check each hose and canister for cracks or damage. Replace if damaged. ● Make sure that the canister breather is not blocked, and if necessary, clean it. To check the engine oil level 1. Place the vehicle on a level surface and hold it in an upright position. NOTE: Make sure that the vehicle is positioned straight up when checking the oil level. A slight tilt to the side can result in a false reading. NOTE: To achieve the proper engine oil temperature for an accurate oil level reading, 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 settles, 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 the minimum and maximum level marks. 2. Remove the rider seat. (See page 3-10.) 3. Start the engine, warm it up until the engine oil has reached a normal temperature of 60 °C (140 °F), let it continue to idle for ten seconds, and then turn the engine off. 1. Engine oil filler cap 6-10 6 U5VN11E0.book Page 11 Tuesday, April 13, 2004 5:24 PM PERIODIC MAINTENANCE AND MINOR REPAIR ECA10900 CAUTION: Make sure that the oil filler cap is securely tightened, otherwise oil may seep out when the engine is running. 1. Maximum level mark 2. Minimum level mark 3. Dipstick 6 5. If the engine oil is 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 overfill the engine; the oil level rises faster starting from the half level portion on the dipstick. To change the engine oil (with or without oil filter cartridge replacement) 1. Start the engine, warm it up for several minutes, and then turn it off. 2. Place an oil pan under the oil tank to collect the used oil. 3. Remove the engine oil filler cap and drain bolt to drain the oil from the oil tank. NOTE: Skip steps 4–8 if the oil filter cartridge is not being replaced. 4. Place an oil pan under the engine to collect the used oil. 5. Remove the engine oil drain bolt to drain the oil from the crankcase. 1. Engine oil drain bolt (crankcase) 6. Remove the oil filter cartridge with an oil filter wrench. 6. Insert the dipstick into the oil filler hole, and then tighten the oil filler cap. 7. Install the rider seat. 1. Engine oil drain bolt (oil tank) 6-11 U5VN11E0.book Page 12 Tuesday, April 13, 2004 5:24 PM PERIODIC MAINTENANCE AND MINOR REPAIR Tightening torque: Oil filter cartridge: 17 Nm (1.7 m·kgf, 12 ft·lbf) 9. Install the engine oil drain bolts, and then tighten them to the specified torque. 1. Oil filter cartridge NOTE: An oil filter wrench is available at a Yamaha dealer. 7. Apply a thin coat of engine oil to the O-ring of the new oil filter cartridge. NOTE: Make sure that the O-ring is properly seated. 8. Install the new oil filter cartridge with an oil filter wrench, and then tighten it to the specified torque with a torque wrench. Tightening torque: Engine oil drain bolt: 43 Nm (4.3 m·kgf, 31 ft·lbf) 10. 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. 11. Start the engine, rev it several times, and then turn it off. 12. Remove the engine oil filler cap, and then gradually fill the oil tank with the remaining oil quantity while regularly checking the oil level on the dipstick. 6-12 Recommended engine oil: See page 8-1. Oil quantity: Without oil filter cartridge replacement: 3.70 L (3.91 US qt) (3.26 Imp.qt) With oil filter cartridge replacement: 4.10 L (4.33 US qt) (3.61 Imp.qt) ECA11620 CAUTION: ● ● In order to prevent clutch slippage (since the engine oil also lubricates the clutch), do not mix any chemical additives. Do not use oils with a diesel specification of “CD” or oils of a higher quality than specified. In addition, do not use oils labeled “ENERGY CONSERVING II” or higher. Make sure that no foreign material enters the crankcase. 13. Install the engine oil filler cap. 14. Start the engine, and then let it idle for several minutes while checking it for oil leakage. If oil is leaking, immediately turn the engine off and check for the cause. 6 U5VN11E0.book Page 13 Tuesday, April 13, 2004 5:24 PM PERIODIC MAINTENANCE AND MINOR REPAIR 15. Turn the engine off, and then check the oil level and correct it if necessary. EAU20041 Transfer case oil The transfer case oil level should be checked before each ride. In addition, the oil must be changed at the intervals specified in the periodic maintenance and lubrication chart. mended type to raise it to the correct level, and then install the oil filler cap. To check the transfer case oil level 1. Place the vehicle on a level surface and hold it in an upright position. 6 NOTE: Make sure that the vehicle is positioned straight up when checking the oil level. A slight tilt to the side can result in a false reading. 1. Transfer case oil filler cap 2. Transfer case oil level check bolt 2. Remove the oil check bolt, and then check the oil level in the transfer case. NOTE: The oil should be at the brim of the check hole. 3. If the oil is below the brim of the check hole, remove the oil filler cap, add sufficient oil of the recom6-13 1. Transfer case oil check hole 4. Install the oil check bolt, and then tighten it to the specified torque. U5VN11E0.book Page 14 Tuesday, April 13, 2004 5:24 PM PERIODIC MAINTENANCE AND MINOR REPAIR Tightening torque: Transfer case oil check bolt: 7.5 Nm (0.75 m·kgf, 5 ft·lbf) To change the transfer case oil 1. Place an oil pan under the transfer case to collect the used oil. 2. Remove the drain bolt and the check bolt to drain the oil from the transfer case. 4. Remove the oil filler cap, add the specified amount of the recommended transfer case oil, and then install and tighten the oil filler cap. Recommended transfer case oil: See page 8-1. Oil quantity: 0.40 L (0.42 US qt) (0.35 Imp.qt) EAU20652 Cleaning the air filter element The air filter element should be cleaned at the intervals specified in the periodic maintenance and lubrication chart. Clean the air filter element more frequently if you are riding in unusually wet or dusty areas. 1. Remove the air filter case bolts. ECA10870 CAUTION: Make sure that no foreign material enters the transfer case. 5. Start the engine and let it idle for several minutes while checking the transfer case for oil leakage. If oil is leaking, immediately turn the engine off and check for the cause. 6 1. Bolt 2. Air filter case 1. Transfer case oil drain bolt 2. Loosen the air filter joint clamp screw, and then slightly pull the air filter case out. 3. Install the drain bolt and the check bolt, and then tighten the drain bolt to the specified torque. Tightening torque: Transfer case oil drain bolt: 17.5 Nm (1.75 m·kgf, 13 ft·lbf) 6-14 U5VN11E0.book Page 15 Tuesday, April 13, 2004 5:24 PM PERIODIC MAINTENANCE AND MINOR REPAIR 1. Air filter joint clamp screw 3. Remove the air filter case cover by removing the screws. 4. Disconnect the hoses shown. 6 1. Screw 2. Hose 5. Remove the air filter element by removing the screws, and then disconnect the hose shown. 6. Lightly tap the air filter element to remove most of the dust and dirt, and then blow the remaining dirt out with compressed air as shown. If the air filter element is damaged, replace it. 7. Install the air filter element by inserting it into the air filter case, then installing the screws, and then connect the hose shown. 8. Install the air filter case cover by installing the screws. 9. Connect the hoses shown. 1. Screw 2. Hose 3. Air filter case cover 1. Hose 6-15 U5VN11E0.book Page 16 Tuesday, April 13, 2004 5:24 PM PERIODIC MAINTENANCE AND MINOR REPAIR 10. Install the air filter case by pushing it onto the air filter joint, and then tighten the air filter joint clamp screw. 11. Install the air filter case by installing the bolts. EAU21250 Adjusting the carburetor The carburetor is an important part of the engine and its emission control system, which requires very sophisticated adjustment. Therefore, carburetor adjustments should be left to Yamaha dealer, who has the necessary professional knowledge and experience. EAU21380 Adjusting the throttle cable free play 1. Throttle cable free play The throttle cable free play should measure 4.0–6.0 mm (0.16–0.24 in) at the throttle grip. Periodically check the throttle cable free play and, if necessary, have a Yamaha dealer adjust it. 6-16 6 U5VN11E0.book Page 17 Tuesday, April 13, 2004 5:24 PM PERIODIC MAINTENANCE AND MINOR REPAIR EAU21400 EAU32520 Adjusting the valve clearance Tires (For spoke wheel model) 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. To maximize the performance, durability, and safe operation of your motorcycle, 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. EWA10500 WARNING ● 6 ● 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 adjusted in accordance with the riding speed and with the total weight of rider, passenger, cargo, and accessories approved for this model. 6-17 Tire air pressure (measured on cold tires): 0–90 kg (0–198 lb): Front: 250 kPa (36 psi) (2.50 kgf/cm²) Rear: 250 kPa (36 psi) (2.50 kgf/cm²) 90–194 kg (198–428 lb): Front: 250 kPa (36 psi) (2.50 kgf/cm²) Rear: 280 kPa (41 psi) (2.80 kgf/cm²) Maximum load*: 194 kg (428 lb) * Total weight of rider, passenger, cargo and accessories EWA10510 WARNING Proper loading of your vehicle is important for several characteristics of your vehicle, such as handling, braking, performance and safety. Do not carry loosely packed items that can shift. Securely pack your heaviest items close to the center of the vehicle, and distribute the weight evenly from side to side. Properly adjust the suspension for your load, and check the condition and pressure of your tires. NEVER OVER- U5VN11E0.book Page 18 Tuesday, April 13, 2004 5:24 PM PERIODIC MAINTENANCE AND MINOR REPAIR LOAD YOUR VEHICLE. Make sure that the total weight of the cargo, rider, passenger, and accessories (cowling, saddlebags, etc. if approved for this model) does not exceed the maximum load of the vehicle. Operation of an overloaded vehicle could cause tire damage, an accident, or even injury. in it, or if the sidewall is cracked, contact a Yamaha dealer immediately and have the tire replaced. EWA10460 Minimum tire tread depth (front and rear): 1.0 mm (0.04 in) ● EWA10560 ● ● Always check the tires before operating the motorcycle. If a tire tread shows crosswise lines (minimum tread depth), if the tire has a nail or glass fragments WARNING WARNING Tire inspection 1. Tire sidewall 2. Tire tread depth 3. Tire wear indicator Tire information This motorcycle is equipped with spoke wheels and tube tires. ● It is dangerous to ride with a worn-out tire. When a tire tread begins to show crosswise lines, have a Yamaha dealer replace the tire immediately. The replacement of all wheeland brake-related parts, including the tires, should be left to a Yamaha dealer, who has the necessary professional knowledge and experience. It is not recommended to patch a punctured tube. If unavoidable, however, patch the tube very carefully and replace it as soon as possible with a highquality product. 6-18 ● The front and rear tires should be of the same make and design, otherwise the handling characteristics of the vehicle cannot be guaranteed. After extensive tests, only the tires listed below have been approved for this model by Yamaha Motor Co., Ltd. Front tire: Size: 130/90-16M/C 67H Manufacturer/model: BRIDGESTONE/G703M DUNLOP/D404F Rear tire: Size: 150/80B16M/C 71H Manufacturer/model: BRIDGESTONE/G702E DUNLOP/D404 6 U5VN11E0.book Page 19 Tuesday, April 13, 2004 5:24 PM PERIODIC MAINTENANCE AND MINOR REPAIR EAU21420 Tires (For cast wheel models) To ensure maximum performance, long service, and safe operation, note the following: Tire air pressure Always check and adjust the tire pressure before operating the motorcycle. EWA11010 WARNING 6 Tire inflation pressure should be checked and adjusted when the temperature of the tire equals the ambient air temperature. Tire inflation pressure must be adjusted according to total weight of cargo, rider, passenger, and accessories (windshield, saddlebags, etc. if approved for this model). Maximum load*: XV17AW 194 kg (428 lb) XV17AM 194 kg (428 lb) XV17AT 179 kg (395 lb) XV17ATM 179 kg (395 lb) Cold tires pressure: 0–90 kg (0–198 lb): Front: 250 kPa (36 psi) (2.50 kgf/cm²) Rear: 250 kPa (36 psi) (2.50 kgf/cm²) XV17AW 90–194 kg (198–428 lb) XV17AM 90–194 kg (198–428 lb) XV17AT 90–179 kg (198–395 lb) XV17ATM 90–179 kg (198–395 lb): Front: 250 kPa (36 psi) (2.50 kgf/cm²) Rear: 280 kPa (41 psi) (2.80 kgf/cm²) * Load is the total weight of cargo, rider, passenger and accessories ● ● ● ● EWA11020 WARNING ● Because loading has an enormous impact on the handling, braking, performance and safety characteristics of your motorcycle, you should keep the following precautions in mind. 6-19 NEVER OVERLOAD THE MOTORCYCLE! Operation of an overloaded motorcycle may result in tire damage, loss of control, or severe injury. Make sure that the total weight of rider, passenger, cargo, and accessories does not exceed the specified maximum load for the vehicle. Do not carry along loosely packed items, which can shift during a ride. Securely pack the heaviest items close to the center of the motorcycle and distribute the weight evenly on both sides. Adjust the suspension and tire air pressure with regard to the load. Check the tire condition and air pressure before each ride. U5VN11E0.book Page 20 Tuesday, April 13, 2004 5:24 PM PERIODIC MAINTENANCE AND MINOR REPAIR ● Tire inspection 1. Tire sidewall 2. Tire wear indicator 3. Tire tread depth Always check the tires before operating the motorcycle. If a tire tread shows crosswise line (minimum tread depth), if the tire has a nail or glass fragments in it, or if the sidewall is cracked, contact a Yamaha dealer immediately and have the tire replaced. EWA10460 WARNING ● After extensive tests, only the tires listed below have been approved for this model by Yamaha Motor Co., Ltd. Front tire: Size: 130/90-16M/C 67H Manufacturer/model: XV17AW BRIDGESTONE/G703N XV17AM BRIDGESTONE/G703N XV17AT BRIDGESTONE/G703 XV17ATM BRIDGESTONE/G703 Rear tire: Size: 150/80B16M/C 71H Manufacturer/model: XV17AW BRIDGESTONE/G702N XV17AM BRIDGESTONE/G702N XV17AT BRIDGESTONE/G702 XV17ATM BRIDGESTONE/G702 Minimum tire tread depth (front and rear): 1.0 mm (0.04 in) The front and rear tires should be of the same make and design, otherwise the handling characteristics of the vehicle cannot be guaranteed. 6-20 NOTE: These limits may be different by regulation from country to country. If so, conform to the limits specified by the regulations of your own country. EWA10580 WARNING ● ● It is dangerous to ride with a worn-out tire. When a tire tread begins to show crosswise lines, have a Yamaha dealer replace the tire immediately. The replacement of all wheeland brake-related parts, including the tires, should be left to a Yamaha dealer, who has the necessary professional knowledge and experience. 6 U5VN11E0.book Page 21 Tuesday, April 13, 2004 5:24 PM PERIODIC MAINTENANCE AND MINOR REPAIR EAU21940 6 EAU21960 Spoke wheels Cast wheels To maximize the performance, durability, and safe operation of your motorcycle, note the following points regarding the specified wheels. ● The wheel rims should be checked for cracks, bends or warpage, and the spokes for looseness or 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 handling characteristics, and a shortened tire life. ● Ride at moderate speeds after changing a tire since the tire surface must first be “broken in” for it to develop its optimal characteristics. To maximize the performance, durability, 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 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 handling characteristics, and a shortened tire life. ● Ride at moderate speeds after changing a tire since the tire surface must first be “broken in” for it to develop its optimal characteristics. 6-21 EAU22011 Accessories and replacement parts EWA10621 WARNING This vehicle is not designed to pull a trailer or to be attached to a sidecar. The accessories or replacement parts you choose for your vehicle should be designed specifically for this model, and they must be securely mounted to maintain the inherent stability of the original design. Genuine Yamaha Parts and Accessories are designed and tested to be compatible with your vehicle. Please consider Genuine Yamaha Parts and Accessories before making a purchase. Use of nonYamaha-approved accessories or replacement parts may cause loss of handling stability and riding safety. Since Yamaha cannot control the quality of accessories or parts manufactured by other companies, Yamaha cannot be held liable for U5VN11E0.book Page 22 Tuesday, April 13, 2004 5:24 PM PERIODIC MAINTENANCE AND MINOR REPAIR any consequences caused by the use of items which have not been approved by Yamaha. EAU22041 Adjusting the clutch lever free play NOTE: If the specified clutch lever free play could be obtained as described above, tighten the locknut and skip the rest of the procedure, otherwise proceed as follows. 3. Fully turn the adjusting bolt at the clutch lever in direction (a) to loosen the clutch cable. 4. Loosen the locknut at the crankcase. 1. Locknut 2. Clutch lever free play adjusting bolt 3. Clutch lever free play The clutch lever free play should measure 10.0–15.0 mm (0.39–0.59 in) as shown. Periodically check the clutch lever free play and, if necessary, adjust it as follows. 1. Loosen the locknut at the clutch lever. 2. To increase the clutch lever free play, turn the adjusting bolt in direction (a). To decrease the clutch lever free play, turn the adjusting bolt in direction (b). 6-22 6 1. Clutch lever free play adjusting nut (crankcase) 2. Locknut (crankcase) U5VN11E0.book Page 23 Tuesday, April 13, 2004 5:24 PM PERIODIC MAINTENANCE AND MINOR REPAIR 5. To increase the clutch lever free play, turn the adjusting nut in direction (a). To decrease the clutch lever free play, turn the adjusting nut in direction (b). 6. Tighten the locknut at the clutch lever and the crankcase. EAU22092 Adjusting the brake lever free play ● ● 1. Locknut 2. Brake lever free play adjusting screw 3. Brake lever free play 6 EWA10630 WARNING The brake lever free play should measure 2.0–5.0 mm (0.08–0.20 in) as shown. Periodically check the brake lever free play and, if necessary, adjust it as follows. 1. Loosen the locknut at the brake lever. 2. To increase the brake lever free play, turn the adjusting screw in direction (a). To decrease the brake lever free play, turn the adjusting screw in direction (b). 3. Tighten the locknut. 6-23 After adjusting the brake lever free play, check the free play and make sure that the brake is working properly. 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 before operating the motorcycle. Air in the hydraulic system will diminish the braking performance, which may result in loss of control and an accident. U5VN11E0.book Page 24 Tuesday, April 13, 2004 5:24 PM PERIODIC MAINTENANCE AND MINOR REPAIR Checking the front and rear brake pads point that the wear indicator almost touches the brake disc, have a Yamaha dealer replace the brake pads as a set. The front and rear brake pads must be checked for wear at the intervals specified in the periodic maintenance and lubrication chart. Rear brake pads EAU22270 Adjusting the rear brake light switch EAU22390 EAU22470 EAU22410 Front brake pads 1. Rear brake light switch 2. Rear brake light switch adjusting nut The rear brake light switch, which is activated by the brake pedal, is properly adjusted when the brake light comes on just before braking takes effect. If necessary, adjust the brake light switch as follows. Turn the adjusting 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. Brake pad wear indicator groove 1. Brake pad wear indicator Each front brake pad is provided with a wear indicator, which allows you to check the brake pad wear without having to disassemble the brake. To check the brake pad wear, check the position of the wear indicator while applying the brake. If a brake pad has worn to the 6-24 Each rear brake pad is provided with a wear indicator groove, which allows you to check the brake pad wear without having to disassemble the brake. To check the brake pad wear, check the wear indicator groove. If a brake pad has worn to the point that the wear indicator groove has almost disappeared, have a Yamaha dealer replace the brake pads as a set. 6 U5VN11E0.book Page 25 Tuesday, April 13, 2004 5:24 PM PERIODIC MAINTENANCE AND MINOR REPAIR EAU22580 Checking the brake fluid level Front brake 1. Minimum level mark Rear brake 6 Before riding, check that the brake fluid is above the minimum level mark and replenish if necessary. A low brake fluid level may indicate worn brake pads and/or brake system leakage. If the brake fluid level is low, be sure to check the brake pads for wear and the brake system for leakage. Observe these precautions: ● When checking the fluid level, make sure that the top of the brake fluid reservoir is level. ● Use only the recommended quality brake fluid, otherwise the rubber seals may deteriorate, causing leakage and poor braking performance. Recommended brake fluid: DOT 4 ● 1. Minimum level mark Refill with the same type of brake fluid. Mixing fluids may result in a harmful chemical reaction and lead to poor braking performance. Insufficient brake fluid may allow air to enter the brake system, possibly causing it to become ineffective. 6-25 ● ● ● Be careful that water does not enter the brake fluid reservoir when refilling. Water will significantly lower the boiling point of the fluid and may result in vapor lock. Brake fluid may deteriorate painted surfaces 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. However, if the brake fluid level goes down suddenly, have a Yamaha dealer check the cause. U5VN11E0.book Page 26 Tuesday, April 13, 2004 5:24 PM PERIODIC MAINTENANCE AND MINOR REPAIR EAU22730 EAU23040 Changing the brake fluid Drive belt slack Have a Yamaha dealer change the brake fluid at the intervals specified in the NOTE after the periodic maintenance and lubrication chart. In addition, have the oil seals of the master cylinders and calipers as well as the brake hoses replaced at the intervals listed below or whenever they are damaged or leaking. ● Oil seals: Replace every two years. ● Brake hoses: Replace every four years. The drive belt slack should be checked and adjusted at the intervals specified in the periodic maintenance and lubrication chart. EAU23062 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. 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 tension gauge as shown. NOTE: A belt tension gauge is available at a Yamaha dealer. NOTE: The marks near the drive belt check hole are 5 mm (0.2 in) apart. 6 1. Belt tension gauge 4. Calculate the drive belt slack by subtracting the measurement noted in step 2 from the measurement noted in step 3. Drive belt slack: 6.0–8.0 mm (0.24–0.31 in) 1. Drive belt 2. Marks 3. Drive belt slack 5. If the drive belt slack is incorrect, adjust it as follows. 6-26 U5VN11E0.book Page 27 Tuesday, April 13, 2004 5:24 PM PERIODIC MAINTENANCE AND MINOR REPAIR EAU23070 To adjust the drive belt slack 1. Loosen the rear wheel axle nut and the brake caliper bracket bolt. 3. To tighten the drive belt, turn the adjusting bolt on each side of the swingarm in direction (a). To loosen the drive belt, turn the adjusting bolt on each side of the swingarm in direction (b), and then push the rear wheel forward. NOTE: Turn each adjusting bolt the same amount for proper wheel alignment. 1. Axle nut 6 1. Drive belt slack adjusting bolt 2. Locknut 3. Wheel axle 1. Brake caliper bracket bolt 4. Tighten the locknuts. 2. Loosen the drive belt puller locknut on each side of the swingarm. 6-27 ECA10880 CAUTION: Improper drive belt slack will overload the engine. Keep the drive belt slack within the specified range. 5. Tighten the axle nut and the brake caliper bracket bolt to the specified torques. Tightening torques: Axle nut: 150 Nm (15.0 m·kgf, 108.5 ft·lbf) Brake caliper bracket bolt: 48 Nm (4.8 m·kgf, 34.7 ft·lbf) U5VN11E0.book Page 28 Tuesday, April 13, 2004 5:24 PM PERIODIC MAINTENANCE AND MINOR REPAIR EAU23090 EAU23110 Checking and lubricating the cables Checking and lubricating the throttle grip and cable The operation of all control cables and the condition of the cables should be checked before each ride, and the cables and cable ends should be lubricated if necessary. If a cable is damaged or does not move smoothly, have a Yamaha dealer check or replace it. The operation of the throttle grip should be checked before each ride. In addition, the cable should be lubricated or replaced at the intervals specified in the periodic maintenance chart. EAU23131 Checking and lubricating the brake and shift pedals Recommended lubricant: Yamaha Chain and Cable Lube or engine oil SAE 10W-30 (API SE) EWA10710 6 WARNING Damage to the outer housing of cables may result in internal rusting and cause interference with cable movement. Replace damaged cables as soon as possible to prevent unsafe conditions. The operation of the brake and shift pedals should be checked before each ride, and the pedal pivots should be lubricated if necessary. 6-28 U5VN11E0.book Page 29 Tuesday, April 13, 2004 5:24 PM PERIODIC MAINTENANCE AND MINOR REPAIR EAU23140 Recommended lubricant: Lithium-soap-based grease (all-purpose grease) Checking and lubricating the brake and clutch levers Brake lever Clutch lever 6 The operation of the brake and clutch levers should be checked before each ride, and the lever pivots should be lubricated if necessary. 6-29 Recommended lubricant: Lithium-soap-based grease (all-purpose grease) U5VN11E0.book Page 30 Tuesday, April 13, 2004 5:24 PM PERIODIC MAINTENANCE AND MINOR REPAIR EAU23200 Checking and lubricating the sidestand EAU23271 Checking the front fork The condition and operation of the front fork must be checked as follows at the intervals specified in the periodic maintenance and lubrication chart. To check the condition EWA10750 WARNING Securely support the vehicle so that there is no danger of it falling over. The operation of the sidestand should be checked before each ride, and the sidestand pivot and metal-to-metal contact surfaces should be lubricated if necessary. EWA10730 WARNING If the sidestand does not move up and down smoothly, have a Yamaha dealer check or repair it. Check the inner tubes for scratches, damage and excessive oil leakage. To check the operation 1. Place the vehicle on a level surface and hold it in an upright position. 2. While applying the front brake, push down hard on the handlebars several times to check if the front fork compresses and rebounds smoothly. Recommended lubricant: Lithium-soap-based grease (all-purpose grease) 6-30 ECA10590 CAUTION: If any damage is found or the front fork does not operate smoothly, have a Yamaha dealer check or repair it. 6 U5VN11E0.book Page 31 Tuesday, April 13, 2004 5:24 PM PERIODIC MAINTENANCE AND MINOR REPAIR EAU23280 EAU23290 Checking the steering Checking the wheel bearings Worn or loose steering bearings may cause danger. Therefore, the operation of the steering must be checked as follows at the intervals specified in the periodic maintenance and lubrication chart. 1. Place a stand under the engine to raise the front wheel off the ground. The front and rear wheel bearings must be checked at the intervals specified in the periodic maintenance and lubrication 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. EWA10750 WARNING Securely support the vehicle so that there is no danger of it falling over. 6 2. Hold the lower ends of the front fork legs and try to move them forward and backward. If any free play can be felt, have a Yamaha dealer check or repair the steering. 6-31 U5VN11E0.book Page 32 Tuesday, April 13, 2004 5:24 PM PERIODIC MAINTENANCE AND MINOR REPAIR EAU23370 EWA10760 Battery WARNING ● 1. Battery 2. Negative battery terminal 3. Positive battery terminal This model is equipped with a sealedtype (MF) battery, which does not require any maintenance. There is no need to check the electrolyte or to add distilled water. ECA10620 CAUTION: Never attempt to remove the battery cell seals, as this would permanently damage the battery. ● Electrolyte is poisonous and dangerous since it contains sulfuric acid, which causes severe burns. Avoid any contact with skin, eyes or clothing and always shield your eyes when working near batteries. In case of contact, administer the following FIRST AID. • EXTERNAL: Flush with plenty of water. • INTERNAL: Drink large quantities of water or milk and immediately call a physician. • EYES: Flush with water for 15 minutes and seek prompt medical attention. Batteries produce explosive hydrogen gas. Therefore, keep sparks, flames, cigarettes, etc., away from the battery and provide sufficient ventilation when charging it in an enclosed space. 6-32 ● KEEP THIS AND ALL BATTERIES OUT OF THE REACH OF CHILDREN. To charge the battery Have a Yamaha dealer charge the battery as soon as possible if it seems to have discharged. Keep in mind that the battery tends to discharge more quickly if the vehicle is equipped with optional electrical accessories. To store the battery 1. If the vehicle will not be used for more than one month, remove the battery, fully charge it, and then place it in a cool, dry place. 2. If the battery will be stored for more than two months, check it at least once a month and fully charge it if necessary. 3. Fully charge the battery before installation. 4. After installation, make sure that the battery leads are properly connected to the battery terminals. 6 U5VN11E0.book Page 33 Tuesday, April 13, 2004 5:24 PM PERIODIC MAINTENANCE AND MINOR REPAIR ECA10630 CAUTION: ● ● 6 Always keep the battery charged. Storing a discharged battery can cause permanent battery damage. To charge a sealed-type (MF) battery, a special (constant-voltage) battery charger is required. Using a conventional battery charger will damage the battery. If you do not have access to a sealed-type (MF) battery charger, have a Yamaha dealer charge your battery. EAU23524 Replacing the fuses 1. Bolt The main fuse and the fuse box, which contains the fuses for the individual circuits, are located behind panel A. (See page 6-8.) If a fuse is blown, replace it as follows. 1. Turn the key to “OFF” and turn off the electrical circuit in question. 2. Remove the blown fuse, and then install a new fuse of the specified amperage. 1. 2. 3. 4. 5. 6. Signaling system fuse Ignition fuse Headlight fuse Carburetor heater fuse Backup fuse (for odometer and clock) Spare fuse 1. Main fuse 2. Spare main fuse 6-33 U5VN11E0.book Page 34 Tuesday, April 13, 2004 5:24 PM PERIODIC MAINTENANCE AND MINOR REPAIR 3. Turn the key to “ON” and turn on the electrical circuit in question to check if the device operates. 4. If the fuse immediately blows again, have a Yamaha dealer check the electrical system. Specified fuses: Main fuse: 30.0 A Signaling system fuse: 10.0 A Ignition fuse: 15.0 A Headlight fuse: XV17A 15.0 A XV17AW 15.0 A XV17AM 20.0 A XV17AT 20.0 A XV17ATM 20.0 A Carburetor heater fuse: 10.0 A Backup fuse: XV17A 5.0 A XV17AW 5.0 A XV17AM 10.0 A XV17AT 10.0 A XV17ATM 10.0 A EAU23792 Replacing the headlight bulb This model is equipped with a quartz bulb headlight. If the headlight bulb burns out, replace it as follows. 1. Remove the headlight unit by removing the screws. 6 1. Screw 2. Disconnect the headlight coupler, and then remove the bulb cover. ECA10640 CAUTION: Do not use a fuse of a higher amperage rating than recommended to avoid causing extensive damage to the electrical system and possibly a fire. 6-34 U5VN11E0.book Page 35 Tuesday, April 13, 2004 5:24 PM PERIODIC MAINTENANCE AND MINOR REPAIR EWA10790 WARNING Headlight bulbs get very hot. Therefore, keep flammable products away from a lit headlight bulb, and do not touch the bulb until it has cooled down. 1. Headlight coupler 2. Headlight bulb cover 3. Unhook the headlight bulb holder, and then remove the defective bulb. 6 4. Place a new headlight bulb into position, and then secure it with the bulb holder. ECA10660 CAUTION: Do not touch the glass part of the headlight bulb to keep it free from oil, otherwise the transparency of the glass, the luminosity of the bulb, and the bulb life will be adversely affected. Thoroughly clean off any dirt and fingerprints on the headlight bulb using a cloth moistened with alcohol or thinner. 1. Headlight bulb holder 6-35 1. Do not touch the glass part of the bulb. 5. Install the headlight bulb cover, and then connect the coupler. 6. Install the headlight unit by installing the screws. 7. Have a Yamaha dealer adjust the headlight beam if necessary. U5VN11E0.book Page 36 Tuesday, April 13, 2004 5:24 PM PERIODIC MAINTENANCE AND MINOR REPAIR EAU24180 Tail/brake light This model is equipped with an LED type of tail/brake light. If the tail/brake light does not come on, have a Yamaha dealer check it. EAU24201 Replacing a turn signal light bulb 1. Remove the turn signal light lens by removing the screw. 1. Screw EAU31961 Replacing a license plate light bulb 1. Remove the license plate light unit by removing the bolts. 1. Bolt 2. Remove the defective bulb by pushing it in and turning it counterclockwise. 3. Insert a new bulb into the socket, push it in, and then turn it clockwise until it stops. 4. Install the lens by installing the screw. ECA11190 CAUTION: Do not overtighten the screw, otherwise the lens may break. 6-36 2. Remove the license plate light socket (together with the bulb) by turning it counterclockwise, and then pulling it out. 6 U5VN11E0.book Page 37 Tuesday, April 13, 2004 5:24 PM PERIODIC MAINTENANCE AND MINOR REPAIR 3. Remove the defective bulb by pulling it out. 1. Bulb 6 4. Insert a new bulb into the socket. 5. Install the socket (together with the bulb) by pushing it in, and then turn it clockwise until it stops. 6. Install the license plate light unit by installing the bolts. 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 upright. 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 under 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 motorcycle stand is not available, by placing 6-37 a jack either under each side of the frame in front of the rear wheel or under each side of the swingarm. U5VN11E0.book Page 38 Tuesday, April 13, 2004 5:24 PM PERIODIC MAINTENANCE AND MINOR REPAIR EAU25850 Troubleshooting Although Yamaha motorcycles receive a thorough inspection before shipment from the factory, trouble may occur during operation. Any problem in the fuel, compression, or ignition systems, for example, can cause poor starting and loss of power. The following troubleshooting chart represents a quick and easy procedure for checking these vital systems yourself. However, should your motorcycle require any repair, take it to a Yamaha dealer, whose skilled technicians have the necessary tools, experience, and know-how to service the motorcycle properly. Use only genuine Yamaha replacement parts. Imitation parts may look like Yamaha parts, but they are often inferior, have a shorter service life and can lead to expensive repair bills. 6 6-38 U5VN11E0.book Page 39 Tuesday, April 13, 2004 5:24 PM PERIODIC MAINTENANCE AND MINOR REPAIR EAU25891 Troubleshooting chart EWA10840 WARNING Keep away open flames and do not smoke while checking or working on the fuel system. 1. Fuel There is enough fuel. Check the compression. There is no fuel. Supply fuel. There is compression. Check the ignition. There is no compression. Have a Yamaha dealer check the vehicle. Check the fuel level in the fuel tank. The engine does not start. Check the compression. 2. Compression Operate the electric starter. 6 3. Ignition Wet Wipe off with a dry cloth and correct the spark plug gaps, or replace the spark plugs. Open the throttle halfway and operate the electric starter. Dry Have a Yamaha dealer check the vehicle. The engine does not start. Check the battery. Remove the spark plugs and check the electrodes. 4. Battery The engine turns over quickly. The battery is good. The engine turns over slowly. Check the battery lead connections, and charge the battery if necessary. Operate the electric starter. 6-39 The engine does not start. Have a Yamaha dealer check the vehicle. U5VN11E0.book Page 1 Tuesday, April 13, 2004 5:24 PM MOTORCYCLE CARE AND STORAGE ucts onto seals, gaskets, the drive belt and wheel axles. Always rinse the dirt and degreaser off with water. EAU26081 Care While the open design of a motorcycle reveals the attractiveness of the technology, it also makes it more vulnerable. Rust and corrosion can develop even if high-quality components are used. A rusty exhaust pipe may go unnoticed on a car, however, it detracts from the overall appearance of a motorcycle. Frequent and proper care does not only comply with the terms of the warranty, but it will also keep your motorcycle looking good, extend its life and optimize its performance. Before cleaning 1. Cover the muffler outlets with plastic bags after the engine has cooled down. 2. Make sure that all caps and covers as well as all electrical couplers and connectors, including the spark plug caps, are tightly installed. 3. Remove extremely stubborn dirt, like oil burnt onto the crankcase, with a degreasing agent and a brush, but never apply such prod- ● Cleaning ECA10770 CAUTION: ● ● ● Avoid using strong acidic wheel cleaners, especially on spoked wheels. If such products are used on hard-to-remove dirt, do not leave the cleaner on the affected area any longer than instructed. Also, thoroughly rinse the area off with water, immediately dry it, and then apply a corrosion protection spray. Improper cleaning can damage windshields, cowlings, panels and other plastic parts. Use only a soft, clean cloth or sponge with mild detergent and water to clean plastic. Do not use any harsh chemical products on plastic parts. Be sure to avoid using cloths or sponges which have been in contact with strong or abrasive 7-1 ● cleaning products, solvent or thinner, fuel (gasoline), rust removers or inhibitors, brake fluid, antifreeze or electrolyte. Do not use high-pressure washers or steam-jet cleaners since they cause water seepage and deterioration in the following areas: seals (of wheel and swingarm bearings, fork and brakes), electric components (couplers, connectors, instruments, switches and lights), breather hoses and vents. For motorcycles equipped with a windshield: Do not use strong cleaners or hard sponges as they will cause dulling or scratching. Some cleaning compounds for plastic may leave scratches on the windshield. Test the product on a small hidden part of the windshield to make sure that it does not leave any marks. If the windshield is scratched, use a quality plastic polishing compound after washing. 7 U5VN11E0.book Page 2 Tuesday, April 13, 2004 5:24 PM MOTORCYCLE CARE AND STORAGE After normal use Remove dirt with warm water, a mild detergent, and a soft, clean sponge, and then rinse thoroughly with clean water. Use a toothbrush or bottlebrush for hard-to-reach areas. Stubborn dirt and insects will come off more easily if the area is covered with a wet cloth for a few minutes before cleaning. 7 After riding in the rain, near the sea or on salt-sprayed roads Since sea salt or salt sprayed on roads during winter are extremely corrosive in combination with water, carry out the following steps after each ride in the rain, near the sea or on salt-sprayed roads. NOTE: Salt sprayed on roads in the winter may remain well into spring. 1. Clean the motorcycle with cold water and a mild detergent, after the engine has cooled down. ECA10790 CAUTION: Do not use warm water since it increases the corrosive action of the salt. 2. After drying the motorcycle, apply a corrosion protection spray on all metal, including chrome- and nickel-plated, surfaces to prevent corrosion. Windshield cleaning Avoid using any alkaline or strong acid cleaner, gasoline, brake fluid, or any other solvent. Clean the windshield with a cloth or sponge dampened with a neutral detergent, and after cleaning, thoroughly wash it off with water. For additional cleaning, use Yamaha Windshield Cleaner or other quality cleaner. Some cleaning compounds for plastics may leave scratches on surfaces of the windshield. Before using them, make a test by polishing an area which does not affect your visibility. 7-2 After cleaning 1. Dry the motorcycle with a chamois or an absorbing cloth. 2. Use a chrome polish to shine chrome, aluminum and stainlesssteel parts, including the exhaust system. (Even the thermally induced discoloring of stainlesssteel exhaust systems can be removed through polishing.) 3. To prevent corrosion, it is recommended to apply a corrosion protection spray on all metal, including chrome- and nickel-plated, surfaces. 4. Use spray oil as a universal cleaner to remove any remaining dirt. 5. Touch up minor paint damage caused by stones, etc. 6. Wax all painted and chrome-plated surfaces. Avoid combination cleaner waxes, many of which contain abrasives that may mar the paint or protective finish. 7. Let the motorcycle dry completely before storing or covering it. U5VN11E0.book Page 3 Tuesday, April 13, 2004 5:24 PM MOTORCYCLE CARE AND STORAGE EWA10930 WARNING ● ● Make sure that there is no oil or wax on the brakes or tires. If necessary, clean the brake discs and brake linings with a regular brake disc cleaner or acetone, and wash the tires with warm water and a mild detergent. Before operating the motorcycle test its braking performance and cornering behavior. ECA10950 CAUTION: ● ● ● ● Apply spray oil and wax sparingly and make sure to wipe off any excess. Never apply oil or wax to the drive belt. Never apply oil or wax to any rubber and plastic parts, but treat them with a suitable care product. Avoid using abrasive polishing compounds as they will wear away the paint. NOTE: Consult a Yamaha dealer for advice on what products to use. Saddlebag cleaning and care Clean the saddlebag on each side using a high-quality saddle soap. Rub the surface of the soap using a damp cloth or sponge to produce a lather, and then apply it to the surface of the saddlebags. Allow the lather to dry, and then polish the saddlebags with a soft cloth. If the saddlebags have been exposed to severe weather conditions and have become faded, or been scuffed, use a fine boot creme to return the leather to its original rich, even color. Exposure to the elements can dry out the leather over time. Therefore, an occasional application of a good quality mink oil is recommended to restore the leather and lift its water resistance. Make sure that the saddlebags are clean and dry before applying the mink oil. Using a soft cloth or a dauber, work a thin coat of mink oil into the leather 7-3 surface of the saddlebags. Wipe off any excess oil immediately and allow the saddlebags to dry for several hours. 7 U5VN11E0.book Page 4 Tuesday, April 13, 2004 5:24 PM MOTORCYCLE CARE AND STORAGE EAU26270 Storage Short-term Always store your motorcycle in a cool, dry place and, if necessary, protect it against dust with a porous cover. ECA10810 CAUTION: ● ● 7 Storing the motorcycle in a poorly ventilated room or covering it with a tarp, while it is still wet, will allow water and humidity to seep in and cause rust. To prevent corrosion, avoid damp cellars, stables (because of the presence of ammonia) and areas where strong chemicals are stored. Long-term Before storing your motorcycle for several months: 1. Follow all the instructions in the “Care” section of this chapter. 2. For motorcycles equipped with a fuel cock that has an “OFF” position: Turn the fuel cock lever to “OFF”. 3. Drain the carburetor float chambers by loosening the drain bolts; this will prevent fuel deposits from building up. Pour the drained fuel into the fuel tank. 4. Fill up the fuel tank and add fuel stabilizer (if available) to prevent the fuel tank from rusting and the fuel from deteriorating. 5. Perform the following steps to protect the cylinders, piston rings, etc. from corrosion. a. Remove the spark plug caps and spark plugs. b. Pour a teaspoonful of engine oil into each spark plug bore. c. Install the spark plug caps onto the spark plugs, and then place the spark plugs on the cylinder head so that the electrodes are grounded. (This will limit sparking during the next step.) d. Turn the engine over several times with the starter. (This will coat the cylinder walls with oil.) e. Remove the spark plug caps from the spark plugs, and then install the spark plugs and the spark plug caps. 7-4 EWA10950 WARNING To prevent damage or injury from sparking, make sure to ground the spark plug electrodes while turning the engine over. 6. Lubricate all control cables and the pivoting points of all levers and pedals as well as of the sidestand/centerstand. 7. Check and, if necessary, correct the tire air pressure, and then lift the motorcycle so that both of its wheels are off the ground. Alternatively, turn the wheels a little every month in order to prevent the tires from becoming degraded in one spot. 8. Cover the muffler outlets with plastic bags to prevent moisture from entering them. 9. Remove the battery and fully charge it. Store it in a cool, dry place and charge it once a month. Do not store the battery in an excessively cold or warm place [less than 0 °C (30 °F) or more than 30 U5VN11E0.book Page 5 Tuesday, April 13, 2004 5:24 PM MOTORCYCLE CARE AND STORAGE °C (90 °F)]. For more information on storing the battery, see page 6-32. NOTE: Make any necessary repairs before storing the motorcycle. 7 7-5 U5VN11E0.book Page 1 Tuesday, April 13, 2004 5:24 PM SPECIFICATIONS Dimensions: Overall length: 2500 mm (98.4 in) Overall width: 980 mm (38.6 in) Overall height: XV17A 1140 mm (44.9 in) XV17AW 1140 mm (44.9 in) XV17AM 1140 mm (44.9 in) XV17AT 1500 mm (59.1 in) XV17ATM 1500 mm (59.1 in) Seat height: 710 mm (28.0 in) Wheelbase: 1688 mm (66.5 in) Ground clearance: 145 mm (5.71 in) Minimum turning radius: 3200 mm (126.0 in) Weight: 8 With oil and fuel: XV17A 334.0 kg (736 lb) XV17AW 334.0 kg (736 lb) XV17AM 334.0 kg (736 lb) XV17AT 349.0 kg (769 lb) XV17ATM 349.0 kg (769 lb) Engine: Engine type: Air cooled 4-stroke, OHV Cylinder arrangement: V-type 2-cylinder Displacement: 1670.0 cm³ (101.90 cu.in) Bore × stroke: 97.0 × 113.0 mm (3.82 × 4.45 in) Compression ratio: 8.36 :1 Starting system: Electric starter Lubrication system: Dry sump Engine oil: Type: YAMALUBE 4 (20W40) or SAE20W40 Recommended engine oil grade: API service SE, SF, SG type or higher Engine oil quantity: Without oil filter cartridge replacement: 3.70 L (3.91 US qt) (3.26 Imp.qt) With oil filter cartridge replacement: 4.10 L (4.33 US qt) (3.61 Imp.qt) Transfer gear oil: Type: SAE80 API GL-4 Hypoid gear oil Quantity: 0.40 L (0.42 US qt) (0.35 Imp.qt) Air filter: Air filter element: Dry element Fuel: Recommended fuel: Unleaded gasoline only Fuel tank capacity: 20.0 L (5.28 US gal) (4.40 Imp.gal) Fuel reserve amount: 3.5 L (0.92 US gal) (0.77 Imp.gal) 8-1 Carburetor: Manufacturer: MIKUNI Type x quantity: BSR40 x 1 Spark plug(s): Manufacturer/model: NGK/DPR7EA-9 Manufacturer/model: DENSO/X22EPR-U9 Spark plug gap: 0.8–0.9 mm (0.031–0.035 in) Clutch: Clutch type: Wet, multiple-disc Transmission: Primary reduction system: Spur gear Primary reduction ratio: 72/47 (1.532) Secondary reduction system: Belt drive Secondary reduction ratio: 35/32 × 70/32 (2.393) Transmission type: Constant mesh 5-speed Operation: Left foot operation Gear ratio: 1st: 38/16 (2.375) 2nd: 30/19 (1.579) U5VN11E0.book Page 2 Tuesday, April 13, 2004 5:24 PM SPECIFICATIONS 3rd: 29/25 (1.160) 4th: 29/32 (0.906) 5th: 21/28 (0.750) Chassis: Frame type: Double cradle Caster angle: 32.00 ° Trail: 142.0 mm (5.59 in) Front tire: Type: XV17AW Tubeless XV17A With tube XV17AM Tubeless XV17AT Tubeless XV17ATM Tubeless Size: 130/90-16M/C 67H Manufacturer/model: XV17AW BRIDGESTONE/G703N XV17A BRIDGESTONE/G703M XV17AM BRIDGESTONE/G703N XV17AT BRIDGESTONE/G703 XV17ATM BRIDGESTONE/G703 Manufacturer/model: XV17A DUNLOP/D404F Rear tire: Type: XV17AW Tubeless XV17A With tube XV17AM Tubeless XV17AT Tubeless XV17ATM Tubeless Size: 150/80B16M/C 71H Manufacturer/model: XV17AW BRIDGESTONE/G702N XV17A BRIDGESTONE/G702E XV17AM BRIDGESTONE/G702N XV17AT BRIDGESTONE/G702 XV17ATM BRIDGESTONE/G702 Manufacturer/model: XV17A DUNLOP/D404 Loading: Maximum load: XV17A 194 kg (428 lb) XV17AW 194 kg (428 lb) XV17AM 194 kg (428 lb) XV17AT 179 kg (395 lb) XV17ATM 179 kg (395 lb) (Total weight of rider, passenger, cargo and accessories) Tire air pressure (measured on cold tires): Loading condition: 0–90 kg (0–198 lb) Front: 250 kPa (36 psi) (2.50 kgf/cm²) Rear: 250 kPa (36 psi) (2.50 kgf/cm²) 8-2 Loading condition: XV17A 90–194 kg (198–428 lb) XV17AW 90–194 kg (198–428 lb) XV17AM 90–194 kg (198–428 lb) XV17AT 90–179 kg (198–395 lb) XV17ATM 90–179 kg (198–395 lb) Front: 250 kPa (36 psi) (2.50 kgf/cm²) Rear: 280 kPa (41 psi) (2.80 kgf/cm²) Front wheel: Wheel type: XV17AW Cast wheel XV17A Spoke wheel XV17AM Cast wheel XV17AT Cast wheel XV17ATM Cast wheel Rim size: 16M/C x MT3.00 Rear wheel: Wheel type: XV17AW Cast wheel XV17A Spoke wheel XV17AM Cast wheel XV17AT Cast wheel XV17ATM Cast wheel Rim size: 16M/C x MT3.50 Front brake: Type: Dual disc brake Operation: Right hand operation 8 U5VN11E0.book Page 3 Tuesday, April 13, 2004 5:24 PM SPECIFICATIONS Recommended fluid: DOT 4 Rear brake: Type: Single disc brake Operation: Right foot operation Recommended fluid: DOT 4 Front suspension: Type: Telescopic fork Spring/shock absorber type: Coil spring/oil damper Wheel travel: 140.0 mm (5.51 in) Rear suspension: Type: Swingarm (link suspension) Spring/shock absorber type: Coil spring/gas-oil damper Wheel travel: 110.0 mm (4.33 in) 8 Electrical system: Ignition system: Transistorized coil ignition (digital) Charging system: A.C. magneto Battery: Headlight: Bulb type: Halogen bulb Bulb voltage, wattage x quantity: Headlight: 12 V, 60 W/55.0 W × 1 Tail/brake light: LED Front turn signal/position light: 12 V, 23 W/8.0 W × 2 Rear turn signal light: 12 V, 21.0 W × 2 Licence plate light: 12 V, 5.0 W × 1 Meter lighting: 14 V, 0.56 W x 4 Neutral indicator light: 14 V, 1.12 W High beam indicator light: 14 V, 1.12 W Turn signal indicator light: 14 V, 1.12 W Fuel level warning light: LED Engine trouble warning light: LED Fuses: Main fuse: 30.0 A Model: YTX20L-BS Voltage, capacity: 12 V, 18.0 Ah 8-3 Headlight fuse: XV17A 15.0 A XV17AW 15.0 A XV17AM 20.0 A XV17AT 20.0 A XV17ATM 20.0 A Signaling system fuse: 10.0 A Ignition fuse: 15.0 A Carburetor heater fuse: 10.0 A Backup fuse: XV17A 5.0 A XV17AW 5.0 A XV17AM 10.0 A XV17AT 10.0 A XV17ATM 10.0 A U5VN11E0.book Page 1 Tuesday, April 13, 2004 5:24 PM CONSUMER INFORMATION EAU26351 Identification numbers EAU26381 EAU26400 Key identification number Vehicle identification number 1. Key identification number 1. Vehicle identification number The key identification number is stamped into the key tag. Record this number in the space provided and use it for reference when ordering a new key. The vehicle identification number is stamped into the steering head pipe. Record this number in the space provided. Record the key identification number, vehicle identification number and model label information in the spaces provided below for assistance when ordering spare parts from a Yamaha dealer or for reference in case the vehicle is stolen. KEY IDENTIFICATION NUMBER: VEHICLE IDENTIFICATION NUMBER: MODEL LABEL INFORMATION: 9-1 NOTE: The vehicle identification number is used to identify your motorcycle and may be used to register your motorcycle with the licensing authority in your area. 9 U5VN11E0.book Page 2 Tuesday, April 13, 2004 5:24 PM CONSUMER INFORMATION EAU26470 Model label 1. Model label The model label is affixed to the frame under the rider seat. (See page 3-10.) Record the information on this label in the space provided. This information will be needed when ordering spare parts from a Yamaha dealer. 9 9-2 U5VN11E0.book Page 3 Tuesday, April 13, 2004 5:24 PM CONSUMER INFORMATION EAU26550 Reporting safety defects If you believe that your vehicle has a defect which could cause a crash or could cause injury or death, you should immediately inform the National Highway Traffic Safety Administration (NHTSA) in addition to notifying Yamaha Motor Corporation, U.S.A. If NHTSA receives similar complaints, it may open an investigation, and if it finds that a safety defect exists in a group of vehicles, it may order a recall and remedy campaign. However, NHTSA cannot become involved in individual problems between you, your dealer, or Yamaha Motor Corporation, U.S.A. To contact NHTSA, you may either call the Auto Safety Hotline toll-free at 1-800-424-9393 (or 366-0123 in Washington, D.C. area) or write to: NHTSA, U.S. Department of Transportation, Washington, D.C. 20590. You can also obtain other information about motor vehicle safety from the Hotline. 9 9-3 U5VN11E0.book Page 4 Tuesday, April 13, 2004 5:24 PM CONSUMER INFORMATION EAU26560 Motorcycle noise regulation TAMPERING WITH NOISE CONTROL SYSTEM PROHIBITED: Federal law prohibits the following acts or the causing thereof: (1) The removal or rendering inoperative by any person other than for purposes of maintenance, repair, or replacement of any device or element of design incorporated into any new vehicle for the purpose of noise control prior to its sale or delivery to the ultimate purchaser or while it is in use or (2) the use of the vehicle after such device or element of design has been removed or rendered inoperative by any person. “AMONG THOSE ACTS PRESUMED TO CONSTITUTE TAMPERING ARE THE ACTS LISTED BELOW”. These acts include tampering with the following systems; i.e., modification, removal, etc. Exhaust system • Muffler • Exhaust pipe • Silencer Intake system • Air cleaner case • Air cleaner element • Intake duct 9 9-4 U5VN11E0.book Page 5 Tuesday, April 13, 2004 5:24 PM CONSUMER INFORMATION EAU26631 Maintenance record Copies of work orders and/or receipts for parts purchased and installed on your motorcycle will be required to document that maintenance has been completed in accordance with the emissions warranty. The chart below is printed only as a reminder that maintenance work is required. It is not acceptable proof of maintenance work. Maintenance interval Date of service Servicing dealer name and address Mileage 600 mi (1000 km) or 1 month 4000 mi (7000 km) or 6 months 8000 mi (13000 km) or 12 months 12000 mi (19000 km) or 18 months 16000 mi (25000 km) or 24 months 20000 mi (31000 km) or 30 months 24000 mi (37000 km) or 36 months 28000 mi (43000 km) or 42 months 32000 mi (49000 km) or 48 months Remarks 9 9-5 U5VN11E0.book Page 6 Tuesday, April 13, 2004 5:24 PM CONSUMER INFORMATION Maintenance interval Date of service Servicing dealer name and address Mileage 36000 mi (55000 km) or 54 months 40000 mi (61000 km) or 60 months 9 9-6 Remarks U5VN11E0.book Page 7 Tuesday, April 13, 2004 5:24 PM CONSUMER INFORMATION EAU26661 YAMAHA MOTOR CORPORATION, U.S.A. STREET AND ENDURO MOTORCYCLE LIMITED WARRANTY 9 9-7 U5VN11E0.book Page 8 Tuesday, April 13, 2004 5:24 PM CONSUMER INFORMATION 9 9-8 U5VN11E0.book Page 9 Tuesday, April 13, 2004 5:24 PM CONSUMER INFORMATION EAU26750 YAMAHA EXTENDED SERVICE (Y.E.S.) Keep your Yamaha protected even after your warranty expires with genuine Yamaha Extended Service (Y.E.S.). In addition, Travel and Recreation Interruption Protection (TRIP) is included at no extra cost. TRIP gives you up to $150 reimbursement per occurrence for any reasonable expenses you incur because your Yamaha needs covered service: replacement vehicle rental, emergency towing, phone calls, even food and lodging when you are away from home. This superb coverage goes into effect when you purchase Y.E.S., so it applies to any warranty repairs as well as covered repairs during your entire Y.E.S. plan period. Y.E.S. is designed and administered by Yamaha Motor Corporation to provide maximum owner satisfaction. You get uninterrupted factory-backed coverage for extra peace of mind. Y.E.S. is flexible. You choose the plan that’s right for you: 12 months, 24 months, 36 months or, on certain models, even 48 months beyond your warranty period. Y.E.S. coverage is honored at any authorized Yamaha dealer nationwide. Y.E.S. is designed and administered by the same Yamaha people who handle your warranty – and it shows in the comprehensive coverage benefits. There are no mileage limitations. Coverage isn’t limited to “moving parts” or the “drive train” like many other plans. And Y.E.S. covers manufacturing defects just like the warranty. See the sample contract at your Yamaha dealer to see how comforting uninterrupted factorybacked protection can be. Y.E.S. coverage is transferable to a new owner if you sell or trade-in. That can make your Yamaha much more valuable! This excellent Y.E.S. plan coverage is only available to Yamaha owners like you, and only while your Yamaha is still within the Yamaha Limited Warranty period. So visit your authorized Yamaha dealer to get all the facts. He can show you how easy it is to protect your investment with Yamaha Extended Service. You don’t have to pay anything for covered repairs. There’s no deductible to pay, and repairs aren’t “pro-rated.” You don’t have any “out-of-pocket” expenses for covered repairs. 9 9-9 U5VN11E0.book Page 10 Tuesday, April 13, 2004 5:24 PM CONSUMER INFORMATION We urge you to act now. You’ll get the excellent benefits of TRIP coverage right away, and you’ll rest easy knowing you’ll have strong factory-backed protection even after your Yamaha Limited Warranty expires. A special note: If visiting your dealer isn’t convenient, contact Yamaha with your Primary ID number (your frame number). We’ll be happy to help you get the Y.E.S. coverage you need. Yamaha Service Marketing P.O. Box 6555 Cypress, CA 90630 1-(866)-YES-EXTD (1-866-937-3983) 9 9-10 U5VN11E0.book Page 1 Tuesday, April 13, 2004 5:24 PM INDEX A Fuel .........................................................3-7 Fuel cock.................................................3-8 Fuel gauge ..............................................3-3 Fuel level warning light............................3-2 Fuel tank cap...........................................3-7 Fuses, replacing....................................6-33 Accessories and replacement parts ..... 6-21 Air filter element, cleaning .................... 6-14 B Battery .................................................. 6-32 Brake and clutch levers, checking and lubricating .................................... 6-29 Brake and shift pedals, checking and lubricating ........................................... 6-28 Brake fluid, changing ............................ 6-26 Brake fluid level, checking .................... 6-25 Brake lever ............................................. 3-6 Brake lever free play, adjusting ............ 6-23 Brake pedal ............................................ 3-6 D Dimmer switch ........................................ 3-5 Drive belt slack ..................................... 6-26 E Engine break-in ...................................... 5-4 Engine oil and oil filter cartridge ........... 6-10 Engine, starting a warm.......................... 5-2 Engine stop switch.................................. 3-5 Engine trouble warning light ................... 3-2 F Rear brake light switch, adjusting ......... 6-24 Rider seat ............................................. 3-10 S Saddlebags [XV17AT(C)] ..................... 3-12 Safety defects, reporting......................... 9-3 Safety information................................... 1-1 Self-diagnosis device.............................. 3-3 Shifting.................................................... 5-3 Shift pedal............................................... 3-6 Shock absorber assembly, adjusting .... 3-14 Sidecases [XV17ATM(C)]..................... 3-13 Sidestand.............................................. 3-16 Sidestand, checking and lubricating ..... 6-30 Spark plugs, checking............................. 6-8 Specifications.......................................... 8-1 Speedometer unit ................................... 3-2 Starter (choke) knob ............................... 3-9 Starting and warming up a cold engine................................................... 5-1 Start switch ............................................. 3-5 Steering, checking ................................ 6-31 Steering, locking with a padlock ........... 3-10 Storage ................................................... 7-4 Supporting the motorcycle .................... 6-37 Handlebar switches .................................3-4 Headlight bulb, replacing.......................6-34 Helmet holder........................................3-11 High beam indicator light.........................3-2 Horn switch .............................................3-5 I Identification numbers .............................9-1 Ignition circuit cut-off system .................3-16 Indicator and warning lights ....................3-2 K Key identification number........................9-1 L Labels, location of ...................................1-5 License plate light bulb, replacing .........6-36 M Main switch/steering lock ........................3-1 Maintenance and lubrication, periodic.....6-4 Maintenance, emission control system ...6-3 Maintenance, periodic .............................6-1 Maintenance record ................................9-5 Model label..............................................9-2 N Neutral indicator light ..............................3-2 Noise regulation ......................................9-4 P Front and rear brake pads, checking.... 6-24 Front fork, checking .............................. 6-30 R H C Cables, checking and lubricating.......... 6-28 Canister (for California only)................. 6-10 Carburetor,adjusting ............................. 6-16 Care........................................................ 7-1 Clock....................................................... 3-4 Clutch lever............................................. 3-5 Clutch lever free play, adjusting ........... 6-22 Part locations .......................................... 2-1 Pre-operation check list .......................... 4-2 Panel, removing and installing ................6-8 Parking ....................................................5-5 T Tail/brake light ...................................... 6-36 Throttle cable free play, adjusting......... 6-16 Throttle grip and cable, checking and lubricating ........................................... 6-28 Tires (For cast wheel models) .............. 6-19 Tires (For spoke wheel model) ............. 6-17 U5VN11E0.book Page 2 Tuesday, April 13, 2004 5:24 PM INDEX Tool kit .................................................... 6-1 Transfer case oil ................................... 6-13 Troubleshooting .................................... 6-38 Troubleshooting chart ........................... 6-39 Turn signal indicator light ........................ 3-2 Turn signal light bulb, replacing ............ 6-36 Turn signal switch ................................... 3-5 V Valve clearance, adjusting .................... 6-17 Vehicle identification number .................. 9-1 W Warranty, extended................................. 9-9 Warranty, limited ..................................... 9-7 Wheel bearings, checking..................... 6-31 Wheels .................................................. 6-21 Windshield [XV17AT(C)/XV17ATM(C)] ................. 3-11 OWNER’S MANUAL XV17AT(C) XV17AWT(C) XV17AMT(C) XV17ATT(C) XV17ATMT(C) YAMAHA MOTOR CO., LTD. PRINTED ON RECYCLED PAPER PRINTED IN JAPAN 2004.04-1.3×1 CR (E) LIT-11626-18-15 5VN-28199-11
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