2018 Yamaha STAR VENTURE Service & Repair Manual

STARVENTURE

eAs20000 IMPORTANT ThismanualwasproducedbytheYamahaMotorCompany,Ltd.primarilyforusebyYamahadealers andtheirqualifiedmechanics.Itisnotpossibletoincludealltheknowledgeofamechanicinonemanual.Therefore,anyonewhousesthisbooktoperformmaintenanceandrepairsonYamahavehicles shouldhaveabasicunderstandingofmechanicsandthetechniquestorepairthesetypesofvehicles. Pleasereferto“BASICINFORMATION”(separatevolume,YOA-28197-10*)forbasicinstructionsthat mustbeobservedduringservicing.Repairandmaintenanceworkattemptedbyanyonewithoutthis knowledgeislikelytorenderthevehicleunsafeandunfitforuse. Thismodelhasbeendesignedandmanufacturedtoperformwithincertainspecificationsinregardto performanceandemissions.Properservicewiththecorrecttoolsisnecessarytoensurethatthevehiclewilloperateasdesigned.Ifthereisanyquestionaboutaserviceprocedure,itisimperativethatyou contactaYamahadealerforanyserviceinformationchangesthatapplytothismodel.Thispolicyis intendedtoprovidethecustomerwiththemostsatisfactionfromtheirvehicleandtoconformtofederal environmentalqualityobjectives. YamahaMotorCompany,Ltd.iscontinuallystrivingtoimproveallofitsmodels.Modificationsandsig- nificantchangesinspecificationsorprocedureswillbeforwardedtoallauthorizedYamahadealersand willappearinfutureeditionsofthismanualwhereapplicable. TIP *Ifthecontentsofthemanualarerevised,thelastdigitofthemanualnumberwillbeincreasedby one. ¢ThisServiceManualcontainsinformationregardingperiodicmaintenancetotheemissioncontrolsystem.Pleasereadthismaterialcarefully. ¢Designsandspecificationsaresubjecttochangewithoutnotice. AS20001 IMPORTANTMANUALINFORMATION Particularlyimportantinformationisdistinguishedinthismanualbythefollowingnotations. Thisisthesafetyalertsymbol.Itisusedtoalertyoutopotentialpersonalinju- aryhazards.Obeyallsafetymessagesthatfollowthissymboltoavoidpossible injuryordeath. AWARNINGindicatesahazardoussituationwhich,ifnotavoided,couldresult AWARNINGindeathorseriousinjury. ANOTICEindicatesspecialprecautionsthatmustbetakentoavoiddamageto NOTICEthevehicleorotherproperty. TIPATIPprovideskeyinformationtomakeprocedureseasierorclearer. eas20002 XV19FJ SERVICEMANUAL ©2017byYamahaMotorCorporation,U.S.A. Firstedition,October2017 Allrightsreserved. Anyreproductionorunauthorizeduse withoutthewrittenpermissionof YamahaMotorCorporation,U.S.A. isexpresslyprohibited. PrintedinU.S.A. P/NLIT-11616-31-04

@YAMAHA SERVICEMANUAL BASICINFORMATION LIT-11616-MC-BOYOA-28197-10

IMPORTANT ThismanualwasproducedbytheYamahaMotorCompany,Ltd.primarilyforusebyYamahadealers andtheirqualifiedmechanics. Thismanualcontainsonlybasicinstructionsthatmustbeobservedduringservicing.Refertotheapplicableservicemanualfordetailedinformationonchecking,adjustment,andreplacement. TIP. Designsandspecificationsaresubjecttochangewithoutnotice. IMPORTANTMANUALINFORMATION Particularlyimportantinformationisdistinguishedinthismanualbythefollowingnotations. Thisisthesafetyalertsymbol.Itisusedtoalertyoutopotentialpersonal ainjuryhazards.Obeyallsafetymessagesthatfollowthissymboltoavoid possibleinjuryordeath. AWARNINGindicatesahazardoussituationwhich,ifnotavoided,could resultindeathorseriousinjury. ANOTICEindicatesspecialprecautionsthatmustbetakentoavoid NOTICEdamagetothevehicleorotherproperty. TIPATIPprovideskeyinformationtomakeprocedureseasierorclearer. BASICINFORMATION SERVICEMANUAL ©2017byYamahaMotorCorporation,U.S.A. Firstedition,January2017 Allrightsreserved. Anyreproductionorunauthorizeduse withoutthewrittenpermissionof YamahaMotorCorporation,U.S.A. isexpresslyprohibited. PrintedinU.S.A. P/NLIT-11616-MC-BO

SYMBOLS Thefollowingsymbolsareusedinthismanualforeasierunderstanding. TIP. Thefollowingsymbolsarenotrelevanttoeveryvehicle. Electricaldata Applylockingagent(LOCTITE®). Engineoil Replacethepartwithanewone. Molybdenumdisulfideoil SYMBOLDEFINITIONSYMBOLDEFINITION otsServiceablewithenginemounted4Gearoil NPFillingfluidABrakefluid em|(Lubricanta=Siliconefluid fo) VeeSpecialtool=@BD4|Wheelbearinggrease wsTighteningtorque—=@isD4|Lithium-soap-basedgrease oxWearlimit,clearanceasMolybdenumdisulfidegrease tyEnginespeed=@sBq|Siliconegrease ral 1 © i (a)

IMPORTANTINFORMATION PREPARATIONFORREMOVALANDDISASSEMBL REPLACEMENTPARTS... GASKETS,OILSEALSANDO-RINGS LOCKWASHERS/PLATESANDCOTTERPINS BEARINGSANDOILSEALS CIRCLIPS........ RUBBERPARTS. VNNBoooe BASICSERVICEINFORMATION QUICKFASTENERS... ELECTRICALSYSTEM GENERALTIGHTENINGTORQUESPECIFICATIONS ADJUSTINGTHEWHEELSTATICBALANCE CHECKINGTHESWITCHES...... CHECKINGTHEBULBSANDBULBSOCKETS CHECKINGANDCHARGINGTHEBATTERY... TROUBLESHOOTING...seeneeeee: GENERALINFORMATION. TROUBLESHOOTINGOFENGINE(faultcodenotdetected) TROUBLESHOOTINGOFCLUTCH TROUBLESHOOTINGOFTRANSMISSION... TROUBLESHOOTINGOFCOOLINGSYSTEM TROUBLESHOOTINGOFBRAKE...........-+. TROUBLESHOOTINGATABSWARNINGLIGHT. TROUBLESHOOTINGOFSUSPENSION.......... TROUBLESHOOTINGOFSTEERING/HANDLING.. TROUBLESHOOTINGOFCHARGINGSYSTEM.. TROUBLESHOOTINGOFLIGHTINGSYSTEM. TROUBLESHOOTINGOFSIGNALINGSYSTEM...

IMPORTANTINFORMATION IMPORTANTINFORMATION PREPARATIONFORREMOVALAND DISASSEMBLY 1.Beforeremovalanddisassembly,removeall dirt,mud,dustandforeignmaterial. 2.Useonlythepropertoolsandcleaningequip- ment. Referto“SPECIALTOOLS’intheapplicable servicemanual. 3.Whendisassembling,alwayskeepmated partstogether.Thisincludesgears,cylinders, pistonsandotherpartsthathavebeen“mated”throughnormalwear.Matedpartsmust alwaysbereusedorreplacedasanassembly. 4.Duringdisassembly,cleanallofthepartsand placethemintraysintheorderofdisassembly.Thiswillspeedupassemblyandallowfor thecorrectinstallationofallparts. 5.Keepallpartsawayfromanysourceoffire. REPLACEMENTPARTS UseonlygenuineYamahapartsforallreplace- ments.UseoilandgreaserecommendedbyYa- mahaforalllubricationjobs.Otherbrandsmay besimilarinfunctionandappearance,butinferi- orinquality. GASKETS,OILSEALSANDO-RINGS 1.Whenoverhaulingtheengine,replaceall gaskets,sealsandO-rings.Allgasketsurfac- es,oilseallipsandO-ringsmustbecleaned. 2.Duringreassembly,properlyoilallmating partsandbearingsandlubricatetheoilseal lipswithgrease. Oil Lip Spring Grease RONs LOCKWASHERS/PLATESANDCOTTER PINS Afterremoval,replacealllockwashers/plates “4”andcotterpins.Afterthebolt ornuthasbeen tightenedtospecification,bendthelocktabs alongaflatoftheboltornut.

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2018 Yamaha STAR VENTURE Service & Repair Manual

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