Download Software 2009 Yamaha Stratoliner Manual

. OWNER’S MANUAL XV19CTSW(C) XV19CTW(C) XV19CTMW(C) LIT-11626-20-41 2C5-28199-11. 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.

Click here download for free. 2009 YAMAHA RAIDER STRATOLINER SERVICE REPAIR MANUAL PDF includes the procedures for maintenance, disassembling, reassembling. 2009 Yamaha Stratoliner Service Manual Yamaha stratoliner xv19ctsc owner's manual pdf download, view and download yamaha stratoliner xv19ctsc owner's manual online.

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. IMPORTANT MANUAL INFORMATION AND UNTIL YOU HAVE BEEN TRAINED IN SAFE AND PROPER RIDING TECHNIQUES.


Any reprinting or unauthorized use without the written permission of Yamaha Motor Corporation, U.S.A. Is expressly prohibited. TABLE OF CONTENTS SAFETY INFORMATION.1-1 Auxiliary DC connector.3-23 Accessories and replacement Location of important labels.1-5 parts. 6-16 PRE-OPERATION CHECKS. 4-1 Clutch lever.6-16 DESCRIPTION.2-1 Pre-operation check list.4-2 Adjusting the rear brake light Left view.2-1 switch. Matte color caution.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. SAFETY INFORMATION EAU10281 AND/OR WHEN MADE NECES-. Ride where other motorists can SARY BY MECHANICAL CONDI- see you. Avoid riding in another MOTORCYCLES SINGLE TIONS. Motorist’s blind spot. TRACK VEHICLES. THEIR SAFE USE Many accidents involve inexperi- AND OPERATION ARE DEPENDENT Safe riding enced operators.

Modifications made to this motorcycle other motorists can see you. The single most critical factor in the pre- not approved by Yamaha, or the re- The posture of the operator and vention or reduction of head injuries. Moval of original equipment, may ren- passenger is important for proper Always wear an approved helmet. Maximum load: been specifically designed for use on create instability due to improper 186 kg (410 lb) this motorcycle.

Since Yamaha cannot weight distribution or aerody- test all other accessories that may be namic changes. If accessories When loading within this weight limit. SAFETY INFORMATION tor and may limit control ability, Always turn the engine off before or clothing, immediately wash the therefore, such accessories are leaving the motorcycle unattended affected area with soap and water not recommended.

And remove the key from the main and change your clothes. SAFETY INFORMATION EAU10381 Location of important labels Please read the following important labels carefully before operating this vehicle. SAFETY INFORMATION. DESCRIPTION EAU10410 Left view 1. Headlight (page 6-27) 9. Sidebag (page 3-17) 2. Windshield (page 3-15) 10.License plate light (page 6-31) 3.

Clutch fluid reservoir (page 6-18) 11.Tail/brake light (page 6-30) 4. Seat lock (page 3-12) 12.Engine oil drain bolt B (crankcase) (page 6-9) 5. DESCRIPTION EAU10420 Right view 1. Helmet holder (page 3-14) 9.

Engine oil filter cartridge (page 6-9) 2. Fuel injection system fuse (page 6-26) 10.Engine oil drain bolt (oil tank) (page 6-9) 3. Rear brake fluid reservoir (page 6-18) 11.Shock absorber assembly spring preload adjusting nut (page 3-19) 4. DESCRIPTION EAU10430 Controls and instruments 1.

Clutch lever (page 3-9) 2. Left handlebar switches (page 3-7) 3. Multi-function meter unit (page 3-3) 4. Main switch/steering lock (page 3-1) 5. Right handlebar switches (page 3-7) 6. Throttle grip (page 6-13) 7.

Brake lever (page 3-9). INSTRUMENT AND CONTROL FUNCTIONS EAU38390 EAU10540 To lock the steering Main switch/steering lock All electrical circuits are supplied with The main switch/steering lock is locat- power, and the meter lighting, taillight, ed under the main switch/steering lock license plate light and position lights cover.

Fuel level warning light “ ” for a few seconds, and then go off, Never turn the key to “OFF” or have a Yamaha dealer check the elec- EAU11030 “LOCK” while the vehicle is moving, trical circuit. Turn signal indicator lights “. When this occurs, a clock a self-diagnosis device have a Yamaha dealer check the self- a brightness control mode diagnosis system.

(See page 3-3 for an explanation of the self-diagnosis de- 1. Speedometer NOTE: vice.). INSTRUMENT AND CONTROL FUNCTIONS Speedometer Tachometer 1. “SELECT” switch 1.

Speedometer 1. Tachometer 2. Tachometer red zone The speedometer shows the riding The electric tachometer allows the rider speed. To monitor the engine speed and keep it When the key is turned to “ON”, the within the ideal power range. INSTRUMENT AND CONTROL FUNCTIONS Fuel gauge The fuel gauge does not indicate start counting the distance traveled the correct fuel level for the first 5 from that point.

In that case, push the km/h (3 mi/h) after refueling. “SELECT” switch to switch the display between the various tripmeter, odome- ter, and clock modes in the following or- Odometer, tripmeter, and.

Push the “SELECT” switch to indicates any error codes, note the (item number “1”) change the display to the clock code number, and then have a Yamaha the LCD (item number “2”) mode. Dealer check the vehicle. The speedometer, tachometer, and 2. INSTRUMENT AND CONTROL FUNCTIONS 4. Adjust the multi-function meter unit EAU12347 Handlebar switches panel brightness level by pushing the “RESET” switch. Push the “SELECT” switch to se- lect the LCD. Item number “2” is displayed.

Adjust the LCD brightness level by pushing the “RESET”. This model can be equipped with op- has traveled both about 150 m (490 ft) tional lights available at a Yamaha and for approximately 15 seconds.

However, the turn signal lights can also. INSTRUMENT AND CONTROL FUNCTIONS EAU12820 EAU12880 EAU12890 Clutch lever Shift pedal Brake lever 1. Clutch lever 1.

Shift pedal 1. Brake lever The clutch lever is located at the left The shift pedal is located on the left The brake lever is located at the right handlebar grip.

INSTRUMENT AND CONTROL FUNCTIONS EAU12941 EAU13120 2. Turn the key counterclockwise to Brake pedal Fuel tank cap the original position, remove it, and then close the lock cover.

NOTE: The fuel tank cap cannot be installed unless the key is in the lock. In addition, the key cannot be removed if the cap is not properly installed and locked.

Fuel tank filler tube ONLY 2. Fuel level mended by Yamaha because it can Fuel tank capacity: cause damage to the fuel system or ve- 17.0 L (4.49 US gal) (3.74 Imp.gal) Make sure that there is sufficient fuel in hicle performance problems. INSTRUMENT AND CONTROL FUNCTIONS EAU13431 EAU34042 Catalytic converter Rider seat This model is equipped with a catalytic converter in the exhaust system. To remove the rider seat 1. Insert the key into the seat lock, EWA10860 WARNING and then turn it counterclockwise. The exhaust system is hot after op- eration.

INSTRUMENT AND CONTROL FUNCTIONS EAU39154 To install the backrest Passenger backrest 1. Open the sidebag lids.

(See page 3-17.) To remove the backrest 2. Fit the slot on each backrest brack- 1. Open the sidebag lids. (See page et (left and right side) into the 3-17.) groove of its holder. INSTRUMENT AND CONTROL FUNCTIONS 4. Insert the key into the passenger EAU38341 Helmet holder backrest lock, turn it clockwise, and then remove the key. Close the sidebag lids.

Helmet holder 2. Helmet holding cable The helmet holder is located under the rider seat.

INSTRUMENT AND CONTROL FUNCTIONS To release the helmet from the hel- EAU39140 Windshield met holder Remove the rider seat, remove the hel- To remove the windshield met holding cable from the helmet hold- 1. Insert the key into the windshield er and the helmet, and then install the lock, turn it clockwise and then re- seat. INSTRUMENT AND CONTROL FUNCTIONS EWA14300 3. Insert the key into the windshield WARNING lock, turn it counterclockwise until Make sure that the throttle cables it stops to lock the fastener, and then remove the key.

Are not pinched. EWA14270 WARNING Make sure that the fastener is locked in place as shown. INSTRUMENT AND CONTROL FUNCTIONS EAU39132 ECA15380 Sidebags CAUTION: EWA14340 To avoid locking the key in, never WARNING lock either sidebag and remove the Improper loading or overloading can key from the lock before closing the cause loss of control and possibly lid. Polish the dry To install a sidebag leather with a soft cloth, and then treat 1.

Open the sidebag lid. With Yamaha Mink Oil or another high- 2. Place the sidebag on the bracket, 1. Fastener quality leather protectant for increased and then align all holes in the side- water resistance. INSTRUMENT AND CONTROL FUNCTIONS EAU38401 load and thereby soften the sus- With each complete turn of the ad- Adjusting the shock absorber pension, turn the adjusting nut in justing nut, distance A is changed assembly direction (b).


By 2.0 mm (0.08 in). This shock absorber assembly is equipped with a spring preload adjust- ing nut. Always have a Yamaha dealer EAU15281 EXUP system CAUTION: service the shock absorber. This model is equipped with Yamaha’s Always tighten the locknut against EXUP (EXhaust Ultimate Power valve) the adjusting nut, and then tighten system. This system boosts engine the locknut to the specified torque. INSTRUMENT AND CONTROL FUNCTIONS EAU15301 below and have a Yamaha dealer re- EAU15311 Sidestand Ignition circuit cut-off system pair it if it does not function proper- The sidestand is located on the left side The ignition circuit cut-off system (com- of the frame. Push the start switch.

Does the engine start? The neutral 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. Keep the clutch lever pulled.

INSTRUMENT AND CONTROL FUNCTIONS EAU38350 EWA12531 Auxiliary DC connector WARNING To prevent electrical shock or short- circuiting, make sure that the cap is installed when the auxiliary DC con- nector is not being used. Auxiliary DC connector A 12-V accessory connected to the auxiliary DC connector under the rider seat can be used when the key is in the “ON”. 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. If necessary, add recommended fluid to specified level.

Check hydraulic system for leakage. Make sure that operation is smooth. Check cable free play.

Throttle grip 6-13, 6-20. If necessary, have Yamaha dealer adjust cable free play and lubricate cable and grip housing. Chassis fasteners —. Tighten if necessary. Instruments, lights, signals. Check operation.

— and switches. Correct if necessary. Check operation of ignition circuit cut-off system. Sidestand switch 3-21. If system is defective, have Yamaha dealer check vehicle. EWA10290 Yamaha dealer check the electrical cir- WARNING Never start the engine or oper- cuit.

Ate it in a closed area for any Before. OPERATION AND IMPORTANT RIDING POINTS ECA11130 EAU16671 ECA10260 Shifting CAUTION: CAUTION: For maximum engine life, always Even with the transmission in warm the engine up before starting the neutral position, do not off. Never accelerate hard when the coast for long periods of time engine is cold! With the engine off, and do not tow the motorcycle for long dis. OPERATION AND IMPORTANT RIDING POINTS 4. At the recommended shift points 3.

Shift the transmission into the neu- EAU16841 Engine break-in shown in the following table, close tral position when the motorcycle There is never a more important period the throttle, and at the same time, is almost completely stopped. If any engine trouble should oc- may overturn. Cur during the engine break-in ECA10380 period, immediately have a CAUTION: Yamaha dealer check the vehi- Never park in an area where there cle.

Are fire hazards such as grass or other flammable materials. TRAINED AND EQUIPPED TO PER- certain maintenance work correctly. FORM THESE PARTICULAR SER- VICES. NOTE: If you do not have the tools or experi- ence required for a particular job, have a Yamaha dealer perform it for you. PERIODIC MAINTENANCE AND MINOR REPAIR EWA10340 WARNING Modifications approved Yamaha may cause loss of perfor- mance, excessive emissions, and render the vehicle unsafe for use. Consult a Yamaha dealer before at- tempting any changes.

Replace gasket(s) if necessary. Evaporative emis-.

Check control system for dam- √ √ sion control system age. (For California only). Replace if necessary. Since these items require special tools, data and technical skills, have a Yamaha dealer perform the service. PERIODIC MAINTENANCE AND MINOR REPAIR EAU32183 General maintenance and lubrication chart INITIAL ODOMETER READINGS 600 mi 4000 mi 8000 mi 12000 mi 16000 mi 20000 mi ITEM ROUTINE (1000 km) (7000 km) (13000 km) (19000 km) (25000 km) (31000 km) 1 month 6 months 12 months. PERIODIC MAINTENANCE AND MINOR REPAIR INITIAL ODOMETER READINGS 600 mi 4000 mi 8000 mi 12000 mi 16000 mi 20000 mi ITEM ROUTINE (1000 km) (7000 km) (13000 km) (19000 km) (25000 km) (31000 km) 1 month 6 months 12 months 18 months 24 months 30 months.

Lubricate the throttle grip housing and cable. Lights, signals and. Check operation.

√ √ √ √ √ √ 26. switches.

Adjust headlight beam. Since these items require special tools, data and technical skills, have a Yamaha dealer perform the service. 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. EAU38440 NOTE: Air filter. This model’s air filter is equipped with a disposable oil-coated paper element, which must not be cleaned with com- pressed air to avoid damaging it. Do not attempt to diagnose 0.8–0.9 mm (0.031–0.035 in) such problems yourself. Instead, have a Yamaha dealer check the vehicle.

Clean the surface of the spark plug If a spark plug shows signs of electrode gasket and its mating surface, and then. PERIODIC MAINTENANCE AND MINOR REPAIR EAU19681 EAU38361 Canister (for California only) Engine oil and oil filter car- NOTE: To achieve the proper engine oil tem- tridge perature for an accurate oil level read- The engine oil level should be checked ing, the engine must have first before each ride. PERIODIC MAINTENANCE AND MINOR REPAIR ECA10900 CAUTION: Make sure that the oil filler cap is se- curely tightened, otherwise oil may seep out when the engine is run- ning. To change the engine oil (with or without oil filter cartridge replace- 1. NOTE: An oil filter wrench is available at a Tightening torques: Yamaha dealer. Engine oil drain bolt A (crankcase): 43 Nm (4.3 mkgf, 31 ftlbf) 8.

Apply a thin coat of engine oil to Engine oil drain bolt B (crankcase): the O-ring of the new oil filter car- 43 Nm (4.3 mkgf, 31 ftlbf). 13. Remove the engine oil filler cap, 15.

Start the engine, and then let it idle changed by a Yamaha dealer at the in- and then gradually fill the oil tank for several minutes while checking. To prevent this Have a Yamaha dealer replace the air from occurring, the valve clearance filter element. Must be adjusted by a Yamaha dealer at the intervals specified in the periodic maintenance and lubrication chart. PERIODIC MAINTENANCE AND MINOR REPAIR EAU32541 LOAD YOUR VEHICLE.

Make sure Tire air pressure (measured on cold Tires that the total weight of the cargo, rid- tires): To maximize the performance, durabil- er, passenger, and accessories 0–90 kg (0–198 lb): ity, and safe operation of your motor- Front: (cowling, saddlebags, etc. PERIODIC MAINTENANCE AND MINOR REPAIR in it, or if the sidewall is cracked, con- After extensive tests, only the EAU21960 Cast wheels tact a Yamaha dealer immediately and tires listed below have been ap- To maximize the performance, durabil- have the tire replaced. If there is air in the hydraulic herent stability of the original system, have a Yamaha dealer bleed design. Genuine Yamaha Parts and the system before operating the motor- Accessories are designed and test- cycle.

Ed to be compatible with your vehi- cle. EAU22270 EAU22390 indicator grooves have almost disap- Adjusting the rear brake light Checking the front and rear peared, have a Yamaha dealer replace switch brake pads the brake pads as a set. The front and rear brake pads must be.

PERIODIC MAINTENANCE AND MINOR REPAIR EAU38630 Clutch Observe these precautions: Checking the brake and clutch When checking the brake and fluid levels clutch fluid levels, make sure that the top of each reservoir is level. Front brake Use only the recommended quality brake fluid, otherwise the rubber seals may deteriorate, causing leakage and poor braking or clutch. The drive belt slack should be checked ually go down.

However, if the and adjusted at the intervals specified Have a Yamaha dealer change the brake fluid level goes down sud- in the periodic maintenance and lubri- brake and clutch fluids at the intervals denly, have a Yamaha dealer cation chart. Yamaha dealer. Ed if necessary. If a cable is damaged maintenance chart. Or does not move smoothly, have a Yamaha dealer check or replace it. Recommended lubricant: Yamaha Chain and Cable Lube or engine oil SAE 10W-30 EWA10710.

PERIODIC MAINTENANCE AND MINOR REPAIR EAU23131 EAU23140 Recommended lubricant: Checking and lubricating the Checking and lubricating the Lithium-soap-based grease (all-pur- brake and shift pedals brake and clutch levers pose grease) Brake lever Clutch lever The operation of the brake and shift pedals should be checked before each The operation of the brake and clutch ride, and the pedal pivots should be lu. Recommended lubricant: EWA10730 WARNING Lithium-soap-based grease If the sidestand does not move up and down smoothly, have a Yamaha dealer check or repair it. Recommended lubricant: Lithium-soap-based grease (all-pur- pose grease) 6-22.

Securely support the vehicle so that fork does not operate smoothly, damage and excessive oil leakage. There is no danger of it falling over. Have a Yamaha dealer check or re- pair it. To check the operation 2. Hold the lower ends of the front 1. If there is play in the wheel hub or if the wheel does not turn smoothly, have a Yamaha dealer check the wheel bearings. Negative battery terminal 2.

Positive battery terminal 3. Storing a discharged battery can cause permanent To charge the battery battery damage. Have a Yamaha dealer charge the bat- To charge a sealed-type (MF) tery as soon as possible if it seems to battery, a special (constant-volt- have discharged. Keep in mind that the age) battery charger is required.

PERIODIC MAINTENANCE AND MINOR REPAIR EAU38372 Specified fuses: Replacing the fuses Main fuse: The main fuse, the fuel injection system 50.0 A fuse, and the fuse box, which contains Headlight fuse: the fuses for the individual circuits, are 20.0 A Signaling system fuse: located under the rider seat. PERIODIC MAINTENANCE AND MINOR REPAIR 4. If the fuse immediately blows EAU39121 Replacing a headlight bulb again, have a Yamaha dealer check the electrical system. Main switch/steering lock cover 1. Low beam headlight bulb 3. Disconnect the coupler shown. PERIODIC MAINTENANCE AND MINOR REPAIR 2.

Disconnect the headlight coupler, ECA10650 CAUTION: and then unhook the headlight bulb holder. Take care not to damage the follow- ing parts: Headlight bulb Do not touch the glass part of the headlight bulb to keep it free from oil, otherwise the transpar- ency of the glass, the luminosity of the bulb, and the bulb life will. PERIODIC MAINTENANCE AND MINOR REPAIR Headlight bulb Do not touch the glass part of the headlight bulb to keep it free from oil, otherwise the transpar- ency of the glass, the luminosity of the bulb, and the bulb life will be adversely affected. Install the main switch/steering lock cover by installing the bolts.

Install the windshield. Have a Yamaha dealer adjust the headlight beam if necessary. Remove the defective bulb by pushing it in and turning it counter- clockwise. If the license plate light does not come Since this model is not equipped with a each side of the swingarm. On, have a Yamaha dealer check the centerstand, follow these precautions electrical circuit or replace the bulb.

When removing the front and rear. 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.

Remove the spark plugs and check the electrodes. The engine does not start. Have a Yamaha dealer check the vehicle. Check the battery. Battery The engine turns over The battery is good. Rust and corrosion can develop matte colored finished parts. Be Cleaning even if high-quality components are sure to consult a Yamaha dealer for ECA10770 advice on what products to use be- used.

A rusty exhaust pipe may go un- CAUTION: fore cleaning the vehicle. MOTORCYCLE CARE AND STORAGE cleaning products, solvent or After normal use ECA10790 CAUTION: thinner, fuel (gasoline), rust re- Remove dirt with warm water, a mild movers or inhibitors, brake flu- detergent, and a soft, clean sponge, Do not use warm water since it in- id, antifreeze or electrolyte. EWA11130 WARNING NOTE: leather on the sidebags. Polish the dry Consult a Yamaha dealer for advice on Make sure that there is no oil or leather with a soft cloth, and then treat what products to use. Wax on the brakes or tires. MOTORCYCLE CARE AND STORAGE EAU26280 3.

Perform the following steps to pro- 4. Lubricate all control cables and the Storage tect the cylinders, piston rings, etc.

Pivoting points of all levers and from corrosion. Pedals as well as of the side- Short-term a. SPECIFICATIONS Dimensions: Engine oil: Manufacturer/model: DENSO/X24EPR-U9 Overall length: Type: Spark plug gap: 2580 mm (101.6 in) YAMALUBE 4 (20W40) or SAE20W40 0.8–0.9 mm (0.031–0.035 in) Overall width: Recommended engine oil grade: Clutch: 1100 mm (43.3 in) API service SG type or higher, JASO Overall height: standard MA Clutch type. SPECIFICATIONS Caster angle: Rear: Front suspension: 31.30 ° 280 kPa (41 psi) (2.80 kgf/cm²) Type: Trail: Loading condition: Telescopic fork 152.0 mm (5.98 in) 90–186 kg (198–410 lb) Spring/shock absorber type: Front tire: Front: Coil spring/oil damper 250 kPa (36 psi) (2.50 kgf/cm²) Type: Wheel travel: Rear. SPECIFICATIONS Front turn signal/position light: Auxiliary DC connector fuse: 12 V, 23 W/8.0 W × 2 3.0 A Rear turn signal light: Backup fuse: 12 V, 21.0 W × 2 10.0 A License plate light: 12 V, 5.0 W Meter lighting: Neutral indicator light: High beam indicator light: Turn signal indicator light. Record the key identification number, vehicle identification number and mod- el label information in the spaces pro- vided below for assistance when ordering spare parts from a Yamaha dealer or for reference in case the vehi- cle is stolen. KEY IDENTIFICATION NUMBER: 1.

Model label The model label is affixed to the frame under the rider seat. (See page 3-12.) Record the information on this label in the space provided. This information will be needed when ordering spare parts from a Yamaha dealer.

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. 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 ve- hicle 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. CONSUMER INFORMATION EAU26632 Maintenance record Copies of work orders and/or receipts for parts purchased and installed on your vehicle 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.

CONSUMER INFORMATION Maintenance Date of Servicing dealer Mileage Remarks interval service name and address 36000 mi (55000 km) or 54 months 40000 mi (61000 km) or 60 months. CONSUMER INFORMATION EAU26663 YAMAHA MOTOR CORPORATION, U.S.A. STREET AND ENDURO MOTORCYCLE LIMITED WARRANTY Yamaha Motor Corporation, U.S.A. Hereby warrants that CUSTOMER’S RESPONSIBILITY under this Engine new Yamaha motorcycles will be free from defects in warranty shall be to: Displacement Period. CUSTOMER SERVICE What costs are my responsibility during the warranty period? If your machine requires warranty service, you must take it to any authorized Yamaha The customer’s responsibility includes all costs of normal maintenance services, motorcycle dealer within the continental United States. Be sure to bring your warranty non-warranty repairs, accident and collision damages, and oil, oil filters, air filters, registration card or other valid proof of the original date of purchase.

This excellent Y.E.S. Plan coverage is only available to dealer to see how comforting uninterrupted factory- Yamaha owners like you, and only while your Yamaha is still backed protection can be. Within the Yamaha Limited Warranty period. So visit your authorized Yamaha dealer to get all the facts. 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. INDEX Fuel level warning light.3-2 Part locations.

2-1 Fuel tank cap.3-10 Passenger backrest.3-13 Accessories and replacement parts.6-16 Fuses, replacing.6-26 Pre-operation check list.4-2 Air filter element.6-13 Auxiliary DC connector.3-23 Handlebar switches. INDEX Turn signal light bulb, replacing. 6-30 Turn signal switch.3-8 Valve clearance.6-13 Vehicle identification number.9-1 Warranty, extended. 9-9 Warranty, limited.9-7 Wheel bearings, checking.6-24 Wheels.6-15 Windshield.3-15. YAMAHA MOTOR CO., LTD. PRINTED ON RECYCLED PAPER PRINTED IN JAPAN 2006.07-0.6×1 CR.

Remove the fairing lowers. For R1 owners, please remove the existing exhaust system from the EXUP valve rearward (EXUP valve is retained) and set aside. Save the stock exhaust clamp for reuse. For R6 owners, please disconnect the stock S-bend from the rear of the collector and set aside. Save the stock exhaust clamp for reuse (new clamp provided). Save the stock end can mounting bolt for reuse as well. R1 owners only -Inspect the exhaust gasket.

Replace if necessary (gasket provided). For R1 owners -Install the S-Bend to the rear of the EXUP valve, make sure the system fits flush. Reuse the stock exhaust clamp to connect the S-bend to the valve. For R6 owners -Install the TiForce S-bend to the rear of the stock head pipes and collector.

Make sure the system fits flush and snug. Reuse the stock exhaust clamp or the provided clamp and loosely attach for now. Install the TiForce end can to the S-bend tail pipe. Loosely attach the two rubber bands, stainless steel bands (K), and stay to the end can using the supplied 6mm hardware (H) and the hanger / stay arm (G). See figure 1 for the assembly procedure. R1 owners -Place the bands approximately 180mm from the edge of the end can.

See figure 2. R6 owners -Place the bands approximately 195mm from the edge of the end can. See figure 2. R1 owners -Using the stock provided mounting point on the passenger footpeg, use the M10x45mm bolt and hardware to mount the end can loosely, allowing for some adjustment.

Carefully align the two stainless bands so that theyare parallel to each other, and spaced properly on the can. Tighten the 6mm hardware (H). Make sure that the rubber pads fully cover the bands (K).

USE CAUTION WHEN TIGHTENING THE 6MM HARDWARE AND THE TWO BANDS SO AS NOT TO CRUSH OR DISTORT THE SLEEVE OF THE CAN. Using some brake and contact cleaner on a clean rag, carefully wipe down the entire TiForce exhaust system to remove any residual oils, anti seize, fingerprints and dirt prior to starting the motor. FAILURE TO CLEAN THE TUBING AND CAN MAY RESULT IN PERMANENT STAINING OF THE SYSTEM WHEN HEATED.

Attach the supplied springs to secure the end can to the S-bend pipe using a spring installation tool if available. Make sure the exhaust system is free and clear of the bike. If necessary, adjust for proper clearance. Go back and tighten all fasteners. Check that all fasteners are tightened per specifications, then start the motor and check for exhaust leaks. Reinstall the fairing lowers.

The author of this manual has the conviction that the only way in which a meaningful and easy to follow text can be written is first to do the work himself, under conditions similar to those found in the average household. As a result, the hands seen in the photographs are those of the author. Even the machines are not new: examples that have covered a consider- able mileage were selected so that the conditions encountered would be typical of those found by the average owner. Unless specially mentioned, and therefore considered essential, Honda service tools have not been used. There is invariably some alternative means of slackening or removing some vital component when service tools are not available and isk of damage has to be avoided at all costs. Each of the six Chapters is divided into numbered Sections. Within the Sections are numbered paragraphs.

In consequence, cross reference throughout this manual is both straightforward and logical. When a reference is made ‘See Section 5.12′ it means Section 5, paragraph 12 in the same Chapter. If another Chapter were meant, the text would read ‘See Chapter 2, Section 5.12′. All photographs are captioned with a Section/paragraph number to which they refer and are always relevant to the Chapter text adjacent. Figure numbers (usually line illustrations) appear in numerical order, within a given Chapter. 1.1 therefore refers o the first figure in Chapter 1.

Left-hand and right-hand descriptions of the machines and their component parts refer to the right and left of a given machine when the rider is seated normally. Motorcycle manufacturers continually make changes to specifications and recommendations, and these, when notified,mare incorporated into our manuals at the earliest opportunity. We take great pride in the accuracy of information given in this manual, but motorcycle manufacturers make alterations and design changes during the production run of a particular n motorcycle of which they do not inform us. No liability can be ccepted by the authors or publishers for loss, damage or injury caused by any errors in, or omissions from, the information give Incoming search terms:.

The LegUp® system has many components. Pleased be sure you have them all before starting your installation. COMPONENTS: 1) Control Switch Box 2) Linear Actuator 3) On-board Computer Module 4) Proximity Sensor 5) Leg Support Stand 6) Leg/Wheel System 7) Hardware Bag 8) Actuator Bracket If you believe you are missing any parts, please contact Chopper Design at 407-834-5007, and we will rectify the situation. Figure 1 6 PREPARE FOR INSTALLATION Place the motorcycle on an acceptable bike lift. You will need to keep the bike on its wheels for most of the installation, and jack the rear wheel off the lift for some portion of the installation. Make SURE the motorcycle is secure on the lift!

Remove the seat, saddlebags and side covers, they are not needed until the very end of the installation. We are now ready to begin! 7 INSTALL LEG SUPPORT STAND LegUp has developed a new, stronger attachment system which holds the Leg system to the bike! You will need to remove the two Exhaust Bolts from the exhaust bracket in order to install the support stand. These Bolts are replaced with two from the kit. Remove the Black button-head bolt from the left side of the bike, directly below the left foot peg.

This bolt will be replaced. If inserted into the stand, the long stainless steel shaft with the small bolts in the end should have one of the bolts removed, and be slid out of the pipe in the stand.

Just set this aside for now. The first step is to install the right upright described above, outside the exhaust bracket and frame. The spacer goes to the inside against the exhaust bracket then the 90 degree bracket outside with two bolts supplied.

Get the bolt holes to line up, and install the bolts (with a bit of blue Locktite on the bolts) loosely. The other, longer 90 degree bracket (the one with the rounded relief on it) is hung from the left side of the bike next where you removed the button-head bolt earlier. Again, some Locktite and keep the bolt loose for now!

Cover the right frame tube in front of the exhaust with duct tape or any suitable material to protect frame during exhaust removal. Remove the three capscrews holding the muffl er assembly to the support bar, loosen the muffl er clamp and carefully remove the muffl er from the motorcycle.

Remove and save the two 12mm bolts from the right side fl oorboard assembly (Figure 1) and carefully lower the fl oorboard out of the way. NOTE: Support the fl oorboard with a block of wood or other appropriate material, do not let it “hang” by the brake switch wire. Remove the chrome cover over the power valve pulley.

Using a 10mm wrench, remove both cables attached to the power valve pulley (Figure 2). Remove and save the 5mm capscrew on the rear side cover to gain access to the O2 sensor harness plug and unplug O2 sensor from harness (Figure 3).

Remove the 4 nuts holding the exhaust system and carefully remove the exhaust system from the motorcycle (may require assistance). NOTE: It may be necessary to loosen the heatshield clamps to access the nuts on the front cylinder. Trace the power valve cables to the drive motor (just under the rear fender on the right side).

Remove the power valve cables and mounting clips from the motorcycle. Using a 22mm wrench, carefully remove the O2 sensor from stock exhaust system and save for reuse with the new system. Remove the plastic cover over the clutch banjo bolt (Figure 4). Check the stock exhaust gaskets to be sure they are in good shape.

If you have any doubts as to their condition, replace them. Remove right side Foot peg assembly or Floorboard. (Whichever is applicable to your model.) 2.

Remove bolts that are holding muffler at rear mounting bracket. Remove Cables from exhaust valve.

Remove O2 Sensor from pipe. Remove the two nuts that secure the rear exhaust header pipe to the rear cylinder head. Remove the two nuts that secure the front exhaust header pipe to the front cylinder head. Remove complete pipe assembly. Hard-Krome Exhaust System Installation NOTE: Take care when fitting this Hard-Krome aftermarket exhaust system on your motorcycle.

It has been designed to replace a STOCK exhaust system on a motorcycle with its engine, frame and other components in their STOCK design, configuration and location. WARNING: Re-check and re-tighten ALL fasteners and supports after 50 miles, then re-check and tighten as necessary on a periodic basis to ensure proper operation and performance. NOTE: All fasteners should be loose during initial installation to ensure proper fit and location of the new exhaust system.

Install new exhaust gaskets. Install mounting bracket using Bolts with flat & lock washers. (See Illustration) 3. Install O2 Sensor onto front pipe and install front pipe onto front cylinder, taking care to not scratch chrome surfaces on pipe, engine or motorcycle. Install the two nuts to secure the flange that holds the exhaust header pipe to the front cylinder head — DO NOT TIGHTEN NUTS! Install 3/8-16 Square nut into each slotted bracket of front pipe and start the 3/8-16×3/4″ Bolt with flat & lock washer through backside of mounting bracket. — DO NOT TIGHTEN BOLTS!

Carefully install rear pipe onto rear cylinder. Install the two nuts to secure the flange that holds the exhaust header pipe to the rear cylinder head — (Remove chrome plastic valve cover to access top nut) — DO NOT TIGHTEN NUTS! Install 3/8-16 Square nut into each slotted bracket of rear pipe and start the 3/8-16×3/4″ Bolt with flat & lock washer through backside of mounting bracket. — DO NOT TIGHTEN BOLTS! Tighten the two bolts that secure the rear exhaust header pipe flange. Tighten the two bolts that secure the front exhaust header pipe flange. Tighten front pipe bolts at mounting bracket.

Tighten rear pipe bolts at mounting bracket. Reinstall foot peg assembly or floorboard. If applicable to your model install foot peg relocating brackets and foot pegs as shown in illustration. Always make a pre-ride inspection before you start the engine. You may prevent an accident or equipment damage. 2 Many accidents involve inexperienced riders. Most countries require a special riding test or license.

Make sure you are qualified before you ride. NEVER lend your motorcycle to an inexperienced rider.

3 Many car/motorcycle accidents happen because the car driver does not “ see the motorcyclist. Make yourself conspicuous to help avoid the accident that is not your fault:. Wear bright or reflective clothing. Don’t drive in another motorist’s “blind spot” 4 Obey all national, and local laws and regulations Excessive speed is a factor in many accidents. Obey the speed limits am NEVER travel faster than conditions warrant.

Signal before you make a turn or lane change. Your size and manoeuvrability can surprise other motorists.5 Don’t let other motorists surprise you. Use extra caution at intersections, parking entrances and exits and driveways. 6 Keep both hands on the handlebars and both feet on the footrests while riding. A passenger should hold onto the motorcycle or the rider with both hands, and keep both feet on the passenger footrests. PROTECTIVE APPAREL 1 Most motorcycle accidents fatalities are due to head impact. ALWAYS wear a helmet.

You should also wear a face shield or goggles; boots, gloves, and protective clothing. A passenger needs the same protection.

The exhaust system becomes very hot during operation, and it remains hot after operation. Never touch any part of the hot exhaust system. Wear clothing that fully covers your legs. 3 Do not wear loose clothing which could catch on the control levers, footrests, or wheels. Removing Your Old Filter and Beauty Cover In order to install the new Remote Oil Filter Kit, you’ll need to remove the stock Yamaha “beauty cover” and the old filter and filter cover. Remove the engine parts necessary to access the stock filter as outlined in the V-Star owner’s manual.

The parts should come off in this order: 1. Muffler assembly 2. Front exhaust pipe 3. Rear brake reservoir cover bolt and brake cover (the reservoir should not be removed, it can remain in place and be moved aside as needed) 4.

Right floorboard (this can be simply loosened, by loosening the two bolts underneath) With the above parts removed, you can remove the Allen bolts holding the beauty cover and filter cap from your engine. There are five Allen bolts holding the beauty cover (so named, because most of the cover just covers the chromed side of the engine There are five bolts holding the cover. Ignore the three on the “Yamaha” cap in the middle – these just hold the Yamaha cap to the beauty cover itself. One bolt is hidd – in this picture – just be the Yamaha ca en low p. The bottommost bolt on the beauty cover will likely leak some oil when you remove it – it holds on the inner oil filter cover. Once you remove the beauty cover, you can remove the oil filter cover, and the oil filter Keep these two “O” rings, you’ll need them for the remote kit Old oil filter.

Toss it away; you’ll never need one again! Throw away the old filter, and carefully remove the orange and black “O” rings from the filter cover (see picture above). These two “O” rings will go on the new engine cap in the same order as on the old filter cover. “O” ring for bottom bolt.

When the beauty cover and filter cover are removed, be sure not to lose the tiny “O” ring that the bottom bolt goes through. Preparing the Remote Oil Filter Kit Remove the orange and black “O” rings from the stock filter cover plate, and place them on the Remote Oil Filter Kit engine cap – black on the inside, orange on the outside – just like on the stock filter cover. GASOLINE IS HIGHLY FLAMMA- BLE: 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. If the motorcycle should lean over, gasoline may leak out of the fuel tank. If you should swallow any gasoline, inhale a lot of gasoline vapor, or allow gasoline to get into your 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 Incoming search terms:. REMOVAL Prepare for Service 1. Position motorcycle on a suitable lift. NOTE If vehicle is equipped with Harley-Davidson Smart Security System, see owner’s manual for instructions to disarm the system. To prevent accidental vehicle start-up, which could cause death or serious injury, disconnect negative (-) battery cable before proceeding. Disconnect battery cables, negative (-) battery cable first.

Remove seat according to the instructions in the service manual. Refer to service manual to remove left saddlebag and side cover. When servicing the fuel system, do not smoke or allow open flame or sparks in the vicinity.

Gasoline is extremely flammable and highly explosive, which could result in death or serious injury. Remove fuel tank according to the instructions in the service manual.

Remove Engine Components 1. Remove existing air cleaner assembly. Discard backplate but save remaining parts. Refer to AIR CLEANER REMOVAL in service manual. Remove existing exhaust system.

Refer to EXHAUST SYSTEM REMOVAL in service manual. Remove engine from chassis following the instructions in the service manual. Disassemble engine top end and bottom end. Refer to appropriate ENGINE sections in service manual. Remove existing clutch diaphragm spring. Refer to CLUTCH REMOVAL in service manual. The procedures in this instruction sheet should be performed by one experienced in precision measuring techniques.

Failure to meet tolerances called for in this instruction sheet can result in engine damage. (00511b) -J04793 1 2 is03517 1. O-ring counterbore 2. Spigot bore Figure 1. Spigot Bore and O-Ring Counterbore Dimensions Table 1.

Spigot Bore and O-Ring Counterbore Dimensions Depth Bore Description 1.625 +/- 0.010 in. (41.3 +/- 0.25 mm) 4.205 +/- 0.010 in. (107 +/- 0.25 mm) Spigot Bore 0.085 +/- 0.003 in.

(2.16 +/- 0.08 mm) 4.415 +/- 0.002 in. (112 +/- 0.05 mm) O-Ring Counter- bore is03456 Figure 2.

Cylinder Wall MACHINE CRANKCASE Crankcase Boring Preparation NOTE During final assembly of the engine, Harley-Davidson recommends replacing the OE cylinder studs with Screamin’ Eagle High Tensile Studs (16505-01). Remove cylinder studs from the engine crankcase. Mask off all bearings and oil holes to prevent debris and contaminants from entering those areas. Inspect and clean engine case mating surfaces. See Figure 6. Reassemble engine case with OE screws, except the top center screw between the cylinders, and tighten to specifications listed in service manual. NOTE To prevent damage to crankcase boring tool, it is important to replace the top center screw with a modified top center screw (1093).

This screw is included in the Crankcase Boring Tool Kit (94419-06) and can be purchased separately from a Harley- Davidson dealer. Install modified top center screw (1093) between the cylinders and tighten to 50-90 in-lbs (5.6-10.2 Nm). See Figure 1 and Table 1. Machine crankcase cylinder spigot bore and O-ring counterbore to the dimensions shown. Modify Crankcase Incoming search terms:.

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Cover the throttle bodies to prevent anything from dropping into the engine. Remove the front seat and disconnect the battery.

(Refer to Service Manual, Page 8-8) 2. Lift up the fuel tank. (Refer to Service Manual, Page 5-3) 3. Remove the air cleaner box.

(Refer to Service Manual, Page 5-14) 4. Remove and replace the ISC valve. (Refer to Service Manual, Page 5-25) NOTE: Since the ECM is also being replaced there is no need to perform the ISC valve preset operation. Install the air cleaner box in reverse order of removal. (Refer to Service Manual, Page 5-14) 6. Lower the fuel tank.

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(Refer to Service Manual, Page 5-3) 7. Remove the upper seat rail plate. Disconnect and remove the ECM. (Figure 1) @ ISC Valve Mounting Screw Torque: 2.1± ±0.6 N.m (1.5± ±0.4 lb-ft)!

Carefully insert the ISC valve straight into the throttle body hole to prevent damaging the o-ring. Turn the ISC valve slightly to confirm that the o-ring has not twisted. Using the new screw provided in the replacement parts kit, make sure the screw is completely seated on the plate after the screw has been tightened to the specified torque.

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Remove and replace the ISC valve. (Refer to Service Manual, Page 5-25) NOTE: Since the ECM is also being replaced there is no need to perform the ISC valve preset operation.! Cover the throttle bodies to prevent anything from dropping into the engine. Remove the front seat and disconnect the battery.

(Refer to Service Manual, Page 8-8) 2. Lift up the fuel tank. (Refer to Service Manual, Page 5-3) 3. Remove the air cleaner box.

(Refer to Service Manual, Page 5-14) REPLACEMENT PROCEDURE: 8. Install the new ECM in reverse order of removal. Apply thread lock to the upper plate mounting bolts when reinstalling the upper seat rail plate. Incoming search terms:.