OWNER’S MANUAL XV17PCS XV17PCSC YAMAHA MOTOR CO., LTD. PRINTED ON RECYCLED PAPER PRINTED IN JAPAN 2003.11-1.
U5PX12E0.
U5PX12E0.book Page 1 Saturday, November 8, 2003 8:51 AM INTRODUCTION EAU10080 Congratulations on your purchase of the Yamaha XV17PC/XV17PCC. 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.
U5PX12E0.book Page 1 Saturday, November 8, 2003 8:51 AM 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.
U5PX12E0.book Page 2 Saturday, November 8, 2003 8:51 AM 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.
U5PX12E0.book Page 3 Saturday, November 8, 2003 8:51 AM IMPORTANT MANUAL INFORMATION EAU10192 AFFIX DEALER LABEL HERE XV17PCS/XV17PCSC OWNER’S MANUAL ©2003 by Yamaha Motor Corporation, U.S.A. 1st edition, October 2003 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.
U5PX12E0.book Page 1 Saturday, November 8, 2003 8:51 AM TABLE OF CONTENTS SAFETY INFORMATION ..................1-1 Location of important labels ...........1-5 DESCRIPTION ..................................2-1 Left view ..........................................2-1 Right view ........................................2-2 Controls and instruments ................2-3 INSTRUMENT AND CONTROL FUNCTIONS .......................................3-1 Main switch/steering lock ................
U5PX12E0.book Page 2 Saturday, November 8, 2003 8:51 AM TABLE OF CONTENTS Replacing a license plate light bulb ...........................................6-36 Supporting the motorcycle ............6-37 Troubleshooting ............................6-37 Troubleshooting chart ...................6-38 MOTORCYCLE CARE AND STORAGE ..........................................7-1 Care ................................................7-1 Storage ...........................................7-3 SPECIFICATIONS .............
U5PX12E0.book Page 1 Saturday, November 8, 2003 8:51 AM SAFETY INFORMATION EAU10280 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.
U5PX12E0.book Page 2 Saturday, November 8, 2003 8:51 AM SAFETY INFORMATION 1 ● ● 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.
U5PX12E0.book Page 3 Saturday, November 8, 2003 8:51 AM SAFETY INFORMATION Loading The total weight of the operator, passenger, accessories and cargo must not exceed the maximum load limit of 185 kg (408 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.
U5PX12E0.book Page 4 Saturday, November 8, 2003 8:51 AM SAFETY INFORMATION 1 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.
U5PX12E0.book Page 5 Saturday, November 8, 2003 8:51 AM SAFETY INFORMATION EAU10381 Location of important labels Please read the following important labels carefully before operating this vehicle.
U5PX12E0.
U5PX12E0.book Page 1 Saturday, November 8, 2003 8:51 AM DESCRIPTION EAU10410 Left view 2 1. 2. 3. 4. 5. 6.
U5PX12E0.book Page 2 Saturday, November 8, 2003 8:51 AM DESCRIPTION EAU10420 Right view 2 1. 2. 3. 4. 5. 6. 7. 8. 9.
U5PX12E0.book Page 3 Saturday, November 8, 2003 8:51 AM DESCRIPTION EAU10430 Controls and instruments 2 1. 2. 3. 4. 5. 6. 7. 8.
U5PX12E0.book Page 1 Saturday, November 8, 2003 8:51 AM INSTRUMENT AND CONTROL FUNCTIONS EAU10460 Main switch/steering lock EAU10660 OFF All electrical systems are off. The key can be removed. To unlock the steering EAU10680 LOCK The steering is locked, and all electrical systems are off. The key can be removed. 3 To lock the steering The main switch/steering lock controls the ignition and lighting systems, and is used to lock the steering. The various positions are described below. 1. Push. 2.
U5PX12E0.book Page 2 Saturday, November 8, 2003 8:51 AM 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. will flash eight times, then go off for 2.5 seconds. If this occurs, have a Yamaha dealer check the vehicle. EAU11480 EAU11360 1. 2. 3. 4. 5. 6.
U5PX12E0.book Page 3 Saturday, November 8, 2003 8:51 AM INSTRUMENT AND CONTROL FUNCTIONS EAU11601 Speedometer EAU34031 Tachometer unit ● ● ● 3 ● ● 1. Speedometer The speedometer shows the riding speed. When the key is turned to “ON”, the speedometer needle will sweep once across the speed range and then return to zero in order to test the electrical circuit. 1. 2. 3. 4. 5.
U5PX12E0.book Page 4 Saturday, November 8, 2003 8:51 AM INSTRUMENT AND CONTROL FUNCTIONS 1. Tachometer red zone ECA11551 CAUTION: Do not operate the engine in the tachometer red zone. If operated in the red zone, the tachometer segments will start flashing to notify the rider.
U5PX12E0.book Page 5 Saturday, November 8, 2003 8:51 AM INSTRUMENT AND CONTROL FUNCTIONS 3 If any of those circuits are defective, the engine trouble warning light will come on and the clock display will indicate a two-digit error code (e.g., 11, 12, 13). If the clock display indicates such an error code, note the code number, and then have a Yamaha dealer check the vehicle. EAU12343 Handlebar switches Left EAU12430 Turn signal switch “ / ” To signal a right-hand turn, push this switch to “ ”.
U5PX12E0.book Page 6 Saturday, November 8, 2003 8:51 AM INSTRUMENT AND CONTROL FUNCTIONS EAU12500 Horn switch “ ” Press this switch to sound the horn. EAU12820 Clutch lever EAU12870 Shift pedal EAU12660 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.
U5PX12E0.book Page 7 Saturday, November 8, 2003 8:51 AM INSTRUMENT AND CONTROL FUNCTIONS EAU12890 EAU12941 EAU13070 Brake lever Brake pedal Fuel tank cap 1. Brake lever 1. Brake pedal 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. 1. Fuel tank cap lock cover 2. Unlock.
U5PX12E0.book Page 8 Saturday, November 8, 2003 8:51 AM INSTRUMENT AND CONTROL FUNCTIONS EAU13210 NOTE: The fuel tank cap cannot be closed unless the key is in the lock. In addition, the key cannot be removed if the cap is not properly closed and locked. Fuel ECA10070 CAUTION: Immediately wipe off spilled fuel with a clean, dry, soft cloth, since fuel may deteriorate painted surfaces or plastic parts. EWA11090 WARNING EAU13360 Make sure that the fuel tank cap is properly closed before riding. 1.
U5PX12E0.book Page 9 Saturday, November 8, 2003 8:51 AM INSTRUMENT AND CONTROL FUNCTIONS 3 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%.
U5PX12E0.book Page 10 Saturday, November 8, 2003 8:51 AM 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. EAU14720 Adjusting the front fork This front fork is equipped with spring preload adjusting bolts. EWA10180 WARNING Always adjust both fork legs equally, otherwise poor handling and loss of stability may result. Adjust the spring preload as follows. 1.
U5PX12E0.book Page 11 Saturday, November 8, 2003 8:51 AM INSTRUMENT AND CONTROL FUNCTIONS EAU34061 NOTE: Align the appropriate groove on the adjusting mechanism with the top of the front fork cap bolt. Adjusting the shock absorber assembly This shock absorber assembly is equipped with a spring preload adjusting nut and a rebound damping force adjusting knob. 2. To increase the spring preload and thereby harden the suspension, turn the adjusting nut in direction (a).
U5PX12E0.book Page 12 Saturday, November 8, 2003 8:51 AM INSTRUMENT AND CONTROL FUNCTIONS preload. With each complete turn of the adjusting nut, distance A is changed by 1.5 mm (0.06 in). ECA11240 CAUTION: Always tighten the locknut against the adjusting nut, and then tighten the locknut to the specified torque. Rebound damping force 1. Distance A Spring preload: Minimum (hard): Distance A = 163 mm (6.42 in) Standard: Distance A = 172 mm (6.77 in) Maximum (soft): Distance A = 174 mm (6.85 in) 3.
U5PX12E0.book Page 13 Saturday, November 8, 2003 8:51 AM INSTRUMENT AND CONTROL FUNCTIONS 3 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.
U5PX12E0.book Page 14 Saturday, November 8, 2003 8:51 AM INSTRUMENT AND CONTROL FUNCTIONS 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.
U5PX12E0.book Page 15 Saturday, November 8, 2003 8:51 AM 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? NOTE: This check is most reliable if performed with a warmed-up engine. 3 YES NO The neutral switch may be defective.
U5PX12E0.book Page 1 Saturday, November 8, 2003 8:51 AM 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.
U5PX12E0.book Page 2 Saturday, November 8, 2003 8:51 AM 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. 3-8 Engine oil • Check oil level in engine. • If necessary, add recommended oil to specified level. • Check vehicle for oil leakage. 6-9 Front brake • • • • • • • • • Check operation. If soft or spongy, have Yamaha dealer bleed hydraulic system. Check lever free play.
U5PX12E0.book Page 3 Saturday, November 8, 2003 8:51 AM 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. 6-27 Brake and clutch levers • Make sure that operation is smooth. • Lubricate lever pivoting points if necessary. 6-28 Sidestand • Make sure that operation is smooth.
U5PX12E0.book Page 1 Saturday, November 8, 2003 8:51 AM OPERATION AND IMPORTANT RIDING POINTS EAU15950 EWA10270 WARNING ● ● 5 ● 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.
U5PX12E0.book Page 2 Saturday, November 8, 2003 8:51 AM OPERATION AND IMPORTANT RIDING POINTS ECA11130 CAUTION: EAU16671 Shifting ECA10260 CAUTION: ● For maximum engine life, always warm the engine up before starting off. Never accelerate hard when the engine is cold! NOTE: The engine is warm when it quickly responds to the throttle. 1. Shift pedal 2. Neutral position ● Shifting gears lets you control the amount of engine power available for starting off, accelerating, climbing hills, etc.
U5PX12E0.book Page 3 Saturday, November 8, 2003 8:51 AM OPERATION AND IMPORTANT RIDING POINTS 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.
U5PX12E0.book Page 4 Saturday, November 8, 2003 8:51 AM OPERATION AND IMPORTANT RIDING POINTS ECA10891 EAU17211 CAUTION: Parking 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. When parking, stop the engine, and then remove the key from the main switch. 1600 km (1000 mi) and beyond The vehicle can now be operated normally.
U5PX12E0.book Page 1 Saturday, November 8, 2003 8:51 AM PERIODIC MAINTENANCE AND MINOR REPAIR EAU17231 EAU17300 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.
U5PX12E0.book Page 2 Saturday, November 8, 2003 8:51 AM 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.
U5PX12E0.book Page 3 Saturday, November 8, 2003 8:51 AM PERIODIC MAINTENANCE AND MINOR REPAIR EAU17600 Periodic maintenance chart for the emission control system 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 Fuel line • Check fuel hoses for cracks or damage. • Replace if necessary.
U5PX12E0.book Page 4 Saturday, November 8, 2003 8:51 AM PERIODIC MAINTENANCE AND MINOR REPAIR EAU32181 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 • Check condition and damage. • Replace if necessary. 2 * Clutch • Check operation.
U5PX12E0.book Page 5 Saturday, November 8, 2003 8:51 AM PERIODIC MAINTENANCE AND MINOR REPAIR INITIAL No. 6 ITEM ROUTINE 600 mi (1000 km) or 1 month 9 * Swingarm pivot bearings • Check bearing assemblies for looseness. • Moderately repack with lithiumsoap-based grease. 10 * Drive belt • Check belt tension. • Adjust if necessary. √ 11 * Steering bearings • Check bearing assemblies for looseness. • Moderately repack with lithiumsoap-based grease every 16000 mi (25000 km) or 24 months.
U5PX12E0.book Page 6 Saturday, November 8, 2003 8:51 AM PERIODIC MAINTENANCE AND MINOR REPAIR INITIAL 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 No. ITEM 18 * Shock absorber assembly • Check operation and for oil leakage. • Replace if necessary. 19 * Rear suspension link pivots • Apply lithium-soap-based grease lightly.
U5PX12E0.book Page 7 Saturday, November 8, 2003 8:51 AM PERIODIC MAINTENANCE AND MINOR REPAIR EAU17640 NOTE: ● Air filters • This model’s air filters are equipped with disposable oil-coated paper elements, which must not be cleaned with compressed air to avoid damaging them. • The air filter elements need to be replaced more frequently when riding in unusually wet or dusty areas. ● Hydraulic brake service • After disassembling the brake master cylinders and calipers, always change the fluid.
U5PX12E0.book Page 8 Saturday, November 8, 2003 8:51 AM PERIODIC MAINTENANCE AND MINOR REPAIR EAU19641 Checking the spark plugs The spark plugs are important engine components, which should be checked periodically, preferably by a Yamaha dealer. Since heat and deposits will cause any spark plug to slowly erode, they should be removed and checked in accordance with the periodic maintenance and lubrication chart. In addition, the condition of the spark plugs can reveal the condition of the engine.
U5PX12E0.book Page 9 Saturday, November 8, 2003 8:51 AM PERIODIC MAINTENANCE AND MINOR REPAIR EAU19680 Canister (for California only) EAU34080 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. 6 This model is equipped with a canister to prevent the discharging of fuel vapor into the atmosphere.
U5PX12E0.book Page 10 Saturday, November 8, 2003 8:51 AM 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 5. If the engine oil is at or below the minimum level mark, add sufficient oil of the recommended type to raise it to the correct level.
U5PX12E0.book Page 11 Saturday, November 8, 2003 8:51 AM PERIODIC MAINTENANCE AND MINOR REPAIR NOTE: Skip steps 7–9 if the oil filter cartridge is not being replaced. 7. Remove the oil filter cartridge with an oil filter wrench. 1. O-ring 1. Oil filter cartridge 2. Torque wrench NOTE: Make sure that the O-ring is properly seated. 6 1. Oil filter cartridge 2. Oil filter wrench NOTE: An oil filter wrench is available at a Yamaha dealer. 9.
U5PX12E0.book Page 12 Saturday, November 8, 2003 8:51 AM PERIODIC MAINTENANCE AND MINOR REPAIR 12. Start the engine, rev it several times, and then turn it off. 13. Remove the engine oil filler cap, and then gradually fill the oil tank with the remaining oil quantity while regularly checking the oil level on the dipstick. 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.
U5PX12E0.book Page 13 Saturday, November 8, 2003 8:51 AM PERIODIC MAINTENANCE AND MINOR REPAIR EAU34100 Replacing the air filter elements This model is equipped with two air filter elements, one of which is located in the air filter case, the other is located in the silencer case. The air filter elements should be replaced at the intervals specified in the periodic maintenance and lubrication chart. Replace the air filter elements more frequently if you are riding in unusually wet or dusty areas.
U5PX12E0.book Page 14 Saturday, November 8, 2003 8:51 AM PERIODIC MAINTENANCE AND MINOR REPAIR ECA11530 CAUTION: ● ● Place a towel or cloth under the fuel hose joints when disconnecting hoses A and B to prevent fuel from spilling onto the vehicle. Make sure that no foreign material enters the fuel hose joints when the hoses are disconnected. d. Remove the hoses as shown, and then remove the fuel tank by pulling it upward. 1. Foam damper 1. Air filter joint clamp screw 4.
U5PX12E0.book Page 15 Saturday, November 8, 2003 8:51 AM PERIODIC MAINTENANCE AND MINOR REPAIR b. Place the fuel tank in the original position, and then connect fuel hose B and the hoses shown. 10. Remove the clamp from the check hose, and then remove the plug to drain any accumulated water. 1. Air filter element 2. Screw 8. Install a new air filter element by inserting it into the air filter case, then installing the screws.
U5PX12E0.book Page 16 Saturday, November 8, 2003 8:51 AM PERIODIC MAINTENANCE AND MINOR REPAIR d. Connect fuel hose A. 17. Install the rider seat. 18. Install the air induction system cover by installing the bolts. EAU21380 Adjusting the throttle cable free play Silencer case air filter element To replace the air filter element 1. Remove the fuel tank. (See steps 1–3 under “Air filter case element”.) 2. Remove the silencer case air filter cover by removing the screws. 1. Silencer air filter element 4.
U5PX12E0.book Page 17 Saturday, November 8, 2003 8:51 AM PERIODIC MAINTENANCE AND MINOR REPAIR EAU21400 EAU21750 Adjusting the valve clearance Tires 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.
U5PX12E0.book Page 18 Saturday, November 8, 2003 8:51 AM PERIODIC MAINTENANCE AND MINOR REPAIR evenly from side to side. Properly adjust the suspension for your load, and check the condition and pressure of your tires. NEVER OVERLOAD 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.
U5PX12E0.book Page 19 Saturday, November 8, 2003 8:51 AM PERIODIC MAINTENANCE AND MINOR REPAIR ● ● 6 Always make sure that the valve caps are securely installed to prevent air pressure leakage. Use only the tire valves and valve cores listed below to avoid tire deflation during a high-speed ride.
U5PX12E0.book Page 20 Saturday, November 8, 2003 8:51 AM PERIODIC MAINTENANCE AND MINOR REPAIR EAU22010 Accessories and replacement parts any consequences caused by the use of items which have not been approved by Yamaha. EAU22041 Adjusting the clutch lever free play EWA10620 WARNING This motorcycle is not designed to pull a trailer or to be attached to a sidecar.
U5PX12E0.book Page 21 Saturday, November 8, 2003 8:51 AM PERIODIC MAINTENANCE AND MINOR REPAIR 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. 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.
U5PX12E0.book Page 22 Saturday, November 8, 2003 8:51 AM PERIODIC MAINTENANCE AND MINOR REPAIR EWA10630 WARNING ● ● 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.
U5PX12E0.book Page 23 Saturday, November 8, 2003 8:51 AM PERIODIC MAINTENANCE AND MINOR REPAIR indicator groove has almost disappeared, have a Yamaha dealer replace the brake pads as a set. EAU22580 Checking the brake fluid level Front brake EAU34090 Rear brake pads 1. Remove the brake caliper bolt, and then tilt the caliper forward. 1. Lining thickness 3. Install the brake caliper bolt, and then tighten it to the specified torque. 1. Minimum level mark Rear brake 6 1.
U5PX12E0.book Page 24 Saturday, November 8, 2003 8:51 AM PERIODIC MAINTENANCE AND MINOR REPAIR 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.
U5PX12E0.book Page 25 Saturday, November 8, 2003 8:51 AM PERIODIC MAINTENANCE AND MINOR REPAIR EAU23040 Drive belt slack 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. 6 3. Note the position of the drive belt with a force of 45 N (4.
U5PX12E0.book Page 26 Saturday, November 8, 2003 8:51 AM PERIODIC MAINTENANCE AND MINOR REPAIR 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: Using the alignment marks on each side of the swingarm, make sure that both belt pullers are in the same position for proper wheel alignment.
U5PX12E0.book Page 27 Saturday, November 8, 2003 8:51 AM PERIODIC MAINTENANCE AND MINOR REPAIR EAU23110 Checking and lubricating the throttle grip and cable EAU23131 Checking and lubricating the brake and shift pedals 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.
U5PX12E0.book Page 28 Saturday, November 8, 2003 8:51 AM PERIODIC MAINTENANCE AND MINOR REPAIR EAU23140 Checking and lubricating the brake and clutch levers EAU23200 Recommended lubricant: Lithium-soap-based grease (all-purpose grease) Checking and lubricating the sidestand Brake lever 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.
U5PX12E0.book Page 29 Saturday, November 8, 2003 8:51 AM PERIODIC MAINTENANCE AND MINOR REPAIR EAUM1650 Lubricating the swingarm pivots EAU23250 Lubricating the rear suspension 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.
U5PX12E0.book Page 30 Saturday, November 8, 2003 8:51 AM PERIODIC MAINTENANCE AND MINOR REPAIR EAU23280 Checking the steering ECA10590 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.
U5PX12E0.book Page 31 Saturday, November 8, 2003 8:51 AM PERIODIC MAINTENANCE AND MINOR REPAIR EAU23290 Checking the wheel bearings EAU33650 Battery 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. ● 1. Negative battery terminal 2. Battery 3.
U5PX12E0.book Page 32 Saturday, November 8, 2003 8:51 AM PERIODIC MAINTENANCE AND MINOR REPAIR battery tends to discharge more quickly if the vehicle is equipped with optional electrical accessories. If you do not have access to a sealed-type (MF) battery charger, have a Yamaha dealer charge your battery. 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.
U5PX12E0.book Page 33 Saturday, November 8, 2003 8:51 AM PERIODIC MAINTENANCE AND MINOR REPAIR 1. Main fuse 2. Spare main fuse 6. Install the battery cover, and then hook the battery band onto the holder. Specified fuses: Main fuse: 30.0 A Headlight fuse: 15.0 A Signaling system fuse: 10.0 A Ignition fuse: 10.0 A Electronic fuel injection fuse: 15.0 A ECU fuse: 10.0 A Auto-decompression fuse: 15.0 A Backup fuse: 7.5 A 6 ECA10640 CAUTION: 1. 2. 3. 4. 5. 6. 7. 8.
U5PX12E0.book Page 34 Saturday, November 8, 2003 8:51 AM PERIODIC MAINTENANCE AND MINOR REPAIR EAU23792 EWA10790 Replacing the headlight bulb WARNING 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. 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.
U5PX12E0.book Page 35 Saturday, November 8, 2003 8:51 AM PERIODIC MAINTENANCE AND MINOR REPAIR fected. Thoroughly clean off any dirt and fingerprints on the headlight bulb using a cloth moistened with alcohol or thinner. 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. EAU24180 Tail/brake light This model is equipped with an LED type of tail/brake light.
U5PX12E0.book Page 36 Saturday, November 8, 2003 8:51 AM PERIODIC MAINTENANCE AND MINOR REPAIR EAU24321 Replacing a license plate light bulb 1. Remove the license plate light unit by removing the nuts, washers and rubber dampers. 1. Turn signal light bulb 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 screws. ECA10680 CAUTION: Do not overtighten the screws, otherwise the lens may break. 1. 2. 3. 4. 1. 2. 3. 4.
U5PX12E0.book Page 37 Saturday, November 8, 2003 8:51 AM PERIODIC MAINTENANCE AND MINOR REPAIR 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.
U5PX12E0.book Page 38 Saturday, November 8, 2003 8:51 AM 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.
U5PX12E0.book Page 1 Saturday, November 8, 2003 8:51 AM MOTORCYCLE CARE AND STORAGE ucts onto seals, gaskets, the drive belt and wheel axles. Always rinse the dirt and degreaser off with water. EAU26070 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.
U5PX12E0.book Page 2 Saturday, November 8, 2003 8:51 AM 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.
U5PX12E0.book Page 3 Saturday, November 8, 2003 8:51 AM MOTORCYCLE CARE AND STORAGE ● ● ● 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. EAU26280 Storage Short-term Always store your motorcycle in a cool, dry place and, if necessary, protect it against dust with a porous cover.
U5PX12E0.book Page 4 Saturday, November 8, 2003 8:51 AM MOTORCYCLE CARE AND STORAGE 4. Lubricate all control cables and the pivoting points of all levers and pedals as well as of the sidestand/centerstand. 5. 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. 6.
U5PX12E0.book Page 1 Saturday, November 8, 2003 8:51 AM SPECIFICATIONS Dimensions: Overall length: 2385 mm (93.9 in) Overall width: 935 mm (36.8 in) Overall height: 1120 mm (44.1 in) Seat height: 730 mm (28.7 in) Wheelbase: 1665 mm (65.6 in) Ground clearance: 155 mm (6.10 in) Minimum turning radius: 3400 mm (133.9 in) Weight: With oil and fuel: 295.0 kg (650 lb) Engine: 8 Engine type: Air cooled 4-stroke, OHV Cylinder arrangement: V-type 2-cylinder Displacement: 1670.0 cm³ (101.90 cu.
U5PX12E0.book Page 2 Saturday, November 8, 2003 8:51 AM SPECIFICATIONS Caster angle: 29.25 ° Trail: 130.0 mm (5.
U5PX12E0.book Page 3 Saturday, November 8, 2003 8:51 AM SPECIFICATIONS Tail/brake light: LED Front turn signal/position light: 12 V, 23 W/8.0 W × 2 Rear turn signal light: 12 V, 23.0 W × 2 Licence plate light: 12 V, 3.8 W × 2 Meter lighting: LED Neutral indicator light: LED High beam indicator light: LED Turn signal indicator light: LED Fuel level warning light: LED Engine trouble warning light: LED Backup fuse: 7.5 A Auto-decompression fuse: 15.0 A Fuses: 8 Main fuse: 30.0 A Headlight fuse: 15.
U5PX12E0.book Page 1 Saturday, November 8, 2003 8:51 AM 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.
U5PX12E0.book Page 2 Saturday, November 8, 2003 8:51 AM CONSUMER INFORMATION EAU26470 Model label 1. Model label The model label is affixed to the frame under the rider seat. (See page 3-9.) Record the information on this label in the space provided. This information will be needed when ordering spare parts from a Yamaha dealer.
U5PX12E0.book Page 3 Saturday, November 8, 2003 8:51 AM 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.
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U5PX12E0.book Page 5 Saturday, November 8, 2003 8:51 AM 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.
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U5PX12E0.book Page 7 Saturday, November 8, 2003 8:51 AM CONSUMER INFORMATION EAU26661 YAMAHA MOTOR CORPORATION, U.S.A.
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U5PX12E0.book Page 9 Saturday, November 8, 2003 8:51 AM 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.
U5PX12E0.book Page 10 Saturday, November 8, 2003 8:51 AM 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.
U5PX12E0.book Page 1 Saturday, November 8, 2003 8:51 AM INDEX A Accessories and replacement parts ..... 6-20 Air filter elements, replacing ................. 6-13 H B Battery .................................................. 6-31 Brake and clutch levers, checking and lubricating ........................................... 6-28 Brake and shift pedals, checking and lubricating ........................................... 6-27 Brake fluid, changing ............................
U5PX12E0.book Page 2 Saturday, November 8, 2003 8:51 AM INDEX 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 ..................................................
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OWNER’S MANUAL XV17PCS XV17PCSC YAMAHA MOTOR CO., LTD. PRINTED ON RECYCLED PAPER PRINTED IN JAPAN 2003.11-1.
