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Yamaha YZF-R1 and R6 TiForce slip on exhaust system REMOVAL AND INSTALLATION MANUAL

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Filed Under (Yamaha) by admin on 09-01-2012

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1. Remove the fairing lowers. 2. 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. 3. R1 owners only -Inspect the exhaust gasket. Replace if necessary (gasket provided). 4. 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. 5. Install the TiForce end can to the S-bend tail pipe. 6. 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. 7. 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. 8. 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. 9. 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. 10. 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. 11. 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. 12. Go back and tighten all fasteners. 13. Check that all fasteners are tightened per specifications, then start the motor and check for exhaust leaks. 14. Reinstall the fairing lowers.

HARLEY DAVIDSON SOFTAIL FRONT SPOILER KITS INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 09-03-2011

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This instruction sheet references Service Manual information. A Service Manual for your model motorcycle is required for this installation and is available from a Harley-Davidson Dealer. Kit Contents See Figure 2 and Table 1. INSTALLATION 1. Position the vehicle on a motorcycle lift table. To prevent accidental vehicle start-up, which could cause death or serious injury, remove maxi-fuse before proceeding. (00251a) 2. Refer to the Service Manual and follow the instructions given to remove the Maxi® Fuse. 3. Raise the vehicle on the lift table to allow access to the lower front portion of the frame. 2008+ 2007 7 8 11 3 3 4 4 12 5 5 1 1 9 2 2 10 6 6 9 9 11 13 is02652c 8. 1. Two-pin voltage regulator connector (2007 only) Voltage regulator 2. 9. Voltage regulator attaching screws (2) Cable strap (2 for 2007, 1 for 2008 and later) 10. 3. Lower voltage regulator cover (2007 only) Voltage regulator bracket 4. 11. Bracket screw to engine crankcase (2) Oxygen sensor connector 12. 5. Crank position sensor connector (2007 only) Voltage regulator caddy 6. 13. Voltage regulator caddy cover Horn connectors (some 2008 and later models) 7. Four-pin voltage regulator connector (2007 only) Figure 1. Original Equipment Voltage Regulator  NOTE For 2007 models: The ground wire on the voltage regulator must be re-attached at the original location when re-installing the voltage regulator to ensure adequate ground. 4. For ALL models: See Figure 1. Remove and discard the voltage regulator caddy cover (6) from the regulator bracket (3) and caddy (5). For 2007 models: In addition, remove the lower voltage regulator cover (10). 5. Remove and retain the hex socket head screw (4) at the top left of the bracket For 2007 models: In addition, disconnect the ground wire. Free the cable straps (9) from the regulator bracket, beneath the regulator. 6. Remove the two hex socket head screws with washers (2) retaining the voltage regulator to the bracket. Remove and save the regulator, but discard the screws. 7. Remove and retain the screw (4) at the top right of the regulator bracket. Remove the bracket from the engine. 8. For 2008 and later models: Free the strap (9) that ties the jiffy stand wiring to the voltage regulator bracket. Unfasten the three-way jiffy stand sensor connector and the two-way crank position sensor connector [79] (12) from the T-studs on the back of the regulator bracket (3). Discard the bracket. Disconnect both plugs from the back of the voltage regulator (1). For 2007 models: Unfasten the four-way (7) and two-way (8) voltage regulator connectors from the T-studs on the back of the regulator bracket (3), and discard the bracket. Disconnect the voltage regulator (1) at both connectors. 9. For 2008 and later models: Unclip the two-way O 2 (oxygen) sensor electrical connector [138] (11) from the voltage regulator caddy (5). For 2007 models: Unfasten the two-way crank position sensor connector [79] (12) from the voltage regulator caddy (5). Remove the caddy from the vehicle frame. a. For 2007 models: Unclamp the bottom of the caddy from the engine mount spacers. b. For ALL models: Unhook the top clips from around the tabs on the front of the engine casting. Remove the original equipment (O.E.) caddy from the vehicle frame, and discard it.

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YAMAHA MOTOR CORPORATION, U.S.A. STREET & ENDURO MOTORCYCLE LIMITED WARRANTY

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Filed Under (Yamaha) by admin on 27-12-2011

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GENERALEXCLUSIONS from this warranty shall include any failures caused by: a. Competition or racing use. b. Installation of parts or accessories that are not qualitatively equivalent to genuine Yamaha parts. c. Abnormal strain, neglect, or abuse. d. Lack of proper maintenance. e. Accident or collision damage. f. Modification to original parts. g. Damage due to improper transportation. SPECIFIC EXCLUSIONS from this warranty shall include parts replaced due to normal wear or routine maintenance. THE CUSTOMER’S RESPONSIBILITY under this warranty shall be to: 1. Operate and maintain the motorcycle as specified in the appropriate Owner’s Manual. 2. Give notice to an authorized Yamaha motorcycle dealer of any and all apparent defects within ten (10) days after discovery, and make the machine available at that time for inspection and repairs at such dealer’s place of business. You may locate your nearest authorized Yamaha dealer through your local telephone directory. WARRANTY TRANSFER: To transfer any remaining warranty from the original purchaser to any subsequent purchaser, it is imperative that the machine be inspected and registered for warranty by an authorized Yamaha motorcycle dealer. In order for this warranty to remain in effect, this inspection and registration must take place within ten (10) days after transfer. Areasonable dealer imposed fee may be charged for the inspection. In no case will warranty be extended beyond the original period. EMISSIONS CONTROLSYSTEM WARRANTY Yamaha Motor Corporation, U.S.A. also warrants to the ultimate purchaser and each subsequent purchaser of each Yamaha motorcycle covered by this warranty with a displacement of 50cc or greater, that the vehicle is designed, built, and equipped so as to conform at the time of sale with all U.S. emissions standards applicable at the time of manufacture and that it is free from defects in materials and workmanship which would cause it not to meet these standards within the periods listed immediately below. Failures other than those resulting from defects in material or workmanship which arise solely as a result of owner abuse and/or lack of proper maintenance are not covered by this warranty.

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YAMAHA XVS 650AK Supplementary Service Manual

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Filed Under (Yamaha) by admin on 18-11-2010

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Dimensions: Overall length Overall width Overall height Seat height Wheelbase Minimum ground clearance Minimum turning radius 2,450 mm (96.5 in) 930 mm (36.6 in) 1,105 mm (43.5 in) 710 mm (28.0 in) 1,625 mm (64.0 in) 145 mm (57.1 in) 3,400 mm (133.9 in) Basic weight: With oil and a full fuel tank 247 kg (544.5 lb) Bulb wattage quantity: Headlight Tail/brake light Front turn signal/position light Rear turn signal light Meter light Neutral indicator light High beam indicator light Turn indicator light Engine indicator light 12 V 60 W/55 W 1 12 V 8 W/27 W 1 12 V 27 W/8 W 2 12 V 27 W 2 12 V 1.7 W 1 12 V 1.7 W 1 12 V 1.7 W 1 12 V 1.7 W 1 12 V 1.7 W 1 ENGINE Item Standard Limit Connecting rod: Oil clearance Color code (corresponding size) 0.031 0.055 mm (0.0012 0.0022 in) Blue Black Brown Green CHASSIS Item Standard Limit Front suspension: Front fork travel Fork spring free length Installed length Spring rate (K1) Stroke (K1) Optional spring Oil capacity Oil level Oil grade 140 mm (5.5 in) 332.5 mm (3.1 in) 287.4 mm (11.3 in) 3.43 N/mm (0.343 kg/mm, 19.2 lb/in) 0 140 mm (0 5.5 in) No 0.507 L (17.4 US oz) 95 mm (3.74 in) Yamaha fork oil 10 WT or equivalent 325.9 mm (12.83 in) Front brake: Type Disc outside diameter thickness Pad thickness inner Pad thickness outer Master cylinder inside diameter Caliper cylinder inside diameter Caliper cylinder inside diameter Brake fluid type Single disk 298 5 mm (11.73 0.2 in) 6.0 mm (0.24 in) 6.0 mm (0.24 in) 14.0 mm (0.55 in) 30.2 mm (1.19 in) 33.3 mm (1.31 in) DOT 4 4.5 mm (0.18 in) 0.8 mm (0.03 in) 0.8 mm (0.03 in) Brake lever & brake pedal: Brake lever free play (at pivot) Brake lever free play (at lever end) Brake pedal position Brake pedal free play Clutch lever free play (at pivot) Clutch lever free play (at lever end) 1 2 mm (0.04 0.08 in) 10 15 mm (0.39 0.59 in) 108 mm (4.25 in) 20 30 mm (0.79 1.18 in) 2 3 mm (0.08 0.12 in) 10 15 mm (0.39 0.59 in)

Yamaha XVS 650AN Supplementary Service Manual

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Filed Under (Yamaha) by admin on 15-12-2010

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MAINTENANCE SPECIFICATIONS ENGINE Item Standard Limit Connecting rod: Oil clearance Color code (corresponding size) 0.031 0.055 mm (0.0012 0.0022 in) Blue Black Brown Green CHASSIS Item Standard Limit Front suspension: Front fork travel Fork spring free length Installed length Spring rate (K1) Stroke (K1) Optional spring Oil capacity Oil level Oil grade 140 mm (5.5 in) 332.5 mm (3.1 in) 287.4 mm (11.3 in) 3.43 N/mm (0.343 kg/mm, 19.2 lb/in) 0 140 mm (0 5.5 in) No 0.507 L (17.4 US oz) 95 mm (3.74 in) Yamaha fork oil 10 WT or equivalent 325.9 mm (12.83 in) Front brake: Type Disc outside diameter thickness Pad thickness inner Pad thickness outer Master cylinder inside diameter Caliper cylinder inside diameter Caliper cylinder inside diameter Brake fluid type Single disk 298 5 mm (11.73 0.2 in) 6.0 mm (0.24 in) 6.0 mm (0.24 in) 14.0 mm (0.55 in) 30.2 mm (1.19 in) 33.3 mm (1.31 in) DOT 4 4.5 mm (0.18 in) 0.8 mm (0.03 in) 0.8 mm (0.03 in) Brake lever & brake pedal: Brake lever free play (at pivot) Brake lever free play (at lever end) Brake pedal position Brake pedal free play Clutch lever free play (at pivot) Clutch lever free play (at lever end) 1 2 mm (0.04 0.08 in) 10 15 mm (0.39 0.59 in) 108 mm (4.25 in) 20 30 mm (0.79 1.18 in) 2 3 mm (0.08 0.12 in) 10 15 mm (0.39 0.59 in) -4- MAINTENANCE SPECIFICATIONS SPEC ELECTRICAL Item Standard Limit T.C.I.: Pickup coil resistance/color T.C.I. unit model/manufacturer 182 222 Ω at 20C (68F)/Gray – Black J4T088/MITSUBISHI (U.S.A) J4T128/MITSUBISHI (CAL) Ignition coil: Model /manufacturer Minimum spark gap Primary winding resistance Secondary winding resistance F6T541/MITSUBISHI 6 mm (0.24 in) 3.6 4.8 Ω at 20C (68F) 10.7 14.5 kΩ at 20C (68F) Voltage regulator: Type Model /manufacturer No load regulated voltage Semi-conductor, short-circuit type SH650C-11/SHINDENGEN 14.1 14.9 V Rectifier: Model /manufacturer Capacity Withstand voltage SH650C-11/SHINDENGEN 18 A 200 V Electric starter system: Type Starter motor: Model /manufacturer I.D. number Output Brush overall length Commutator diameter Mica undercut Starter relay: Model /manufacturer Amperage rating Constant mesh type SM-13/MITSUBA SM-13 0.7 kW 10 mm (0.39 in) 28 mm (1.10 in) 0.7 mm (0.08 in) MS-5F-441/JIDECO 180 A 4 mm (0.16 in) 27 mm (1.06 in) Flasher relay: Type Model /manufacturer Self cancelling device Flasher frequency Wattage Semi transistor type FB257H/DENSO Yes 75 95 cycle/min 27 W 2 + 3.4 W Fuel pump relay: Model /manufacturer G8R-30Y-Q/OMRON

Yamaha V-Star 1100 Needle/ Jet Kit REMOVAL AND INSTALLATION MANUALS

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Filed Under (Honda) by admin on 27-12-2011

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To install this needle and jet kit: • Remove carburetors from the engine per Yamaha shop manual procedures. Note: Always perform internal carburetor work in a clean area. • Remove the vacuum slide from each carburetor. • Remove the OEM needle, spacer and washers, noting order of assembly. (Note; the washers are used as shims to raise the needle, each is equivalent to ½ clip position, use these to fine tune the needle) • Counting from the top to the bottom, install the new Baron needle clip on groove #4 of the replacement Baron adjustable needles. The top is the blunt end of the needle. • Reinstall the OEM spacer and washers as shown in the figure below. • Reinstall the vacuum slides along with the diaphragm spring and reattach the diaphragm covers Note: Verify that the slides maintain their full range of movement! • Drain the fuel from the float bowls and remove the bowl covers. • Remove the OEM main jets and replace them with Baron’s supplied Mikuni main jets. Install the “base setting” main jets as indicated above. NOTE: V-Star 1100 carburetion runs staggered jetting! Make sure the front cylinder’s carburetor gets the larger main jet (numerically), and the rear cylinder’s carburetor gets the smaller main jet . Important! Extra jets have been included in your kit. These will help you fine-tune the carburetors for changing conditions. These conditions include climate and weather patterns in your area as well as exhaust equipment on your motorcycle. Barons determines the jet and clip recommendations that best suit your average riding conditions based upon information supplied to us at the time of your order. Changes in weather, altitude or modifications to your exhaust system may require jets other than those supplied. • Thoroughly clean the inside of the float bowls prior to reinstalling them. 311 #1 Industrial Way – Fallbrook, CA 92028 – USA Phone: (760) 731-1200 Fax: (760) 731-1284 E-mail: tech@baronscustom.com Website: www.baronscustom.com Included in this kit: (4)Mikuni main jets #107.5, 110, 112.5, 115, (2) titanium needles, (2) clips, (8) cap-head allen screws Tools required: 3-4-5 mm allen wrenches, 10&12 mm sockets, 10mm end wrench, phillips & flat screwdrivers, pliers, drill. Revision 4.0 • Reassemble the carburetors by reversing the order of above steps. Use the new supplied cap head Allen screws in place of the OEM Phillips head screws for the float bowls. • Locate the fuel mixture screws – they will either be a screw head or a brass plug. If it is a screw head, skip to step c . If you see a brass plug with a small hole in the center, proceed as follows: a. With a 5/32″ drill bit, carefully and slowly drill through the fuel mixture plugs

Turbo+2 , Roadstar , Quantum Sport , Quantum"GL" , Entourage Owners Manual

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Filed Under (Uncategorized) by admin on 03-12-2010

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tracking Any parting within the tread, sidewall, or inner liner of the tire extending to cord material. CT A pneumatic tire with an inverted flange tire and rim system in which the rim is designed with rim flanges pointed radially inward and the tire is designed to fit on the underside of the rim in a manner that encloses the rim flanges inside the air cavity of the tire. Curb weight The weight of a motor vehicle with standard equipment including the maximum capacity of fuel, oil, and coolant, and, if so equipped, air conditioning and additional weight optional engine. Extra load tire A tire designed to operate at higher loads and at higher inflation pressures than the corresponding standard tire. Groove The space between two adjacent tread ribs. Gross AxleWeight Rating The maximum weight that any axle can support, as published on the Certification /VIN label on the front left side of the trailer. Actual weight determined by weighing each axle on a public scale, with the trailer attached to the towing vehicle. Gross Vehicle Weight Rating The maximum weight of the fully loaded trailer, as published on the Certification /VIN label. Actual weight determined by weighing trailer on a public scale, without being attached to the towing vehicle. Hitch Weight The downward force exerted on the hitch ball by the trailer coupler. Innerliner The layer(s) forming the inside surface of a tubeless tire that contains the inflating medium within the tire. Innerliner separation The parting of the innerliner from cord material in the carcass. Intended outboard sidewall The sidewall that contains a white-wall, bears white lettering or bears manufacturer, brand, and/or model name molding that is higher or deeper than the same molding on the other sidewall of the tire or the outward facing sidewall of an asymmetrical tire that has a particular side that must always face outward when mounted on a vehicle. Light truck (LT) tire A tire designated by its manufacturer as primarily intended for use on lightweight trucks or multipurpose passenger vehicles. Load rating The maximum load that a tire is rated to carry fora given inflation pressure. Maximum load rating The load rating fora tire at the maximum permissible inflation pressure for that tire. Maximum permissible inflation pressure he maximum cold inflation pressure to which a tire maybe inflated.
-9- Maximum loaded vehicle weight The sum of curb weight, accessory weight, vehicle capacity weight, and production options weight. Measuring rim The rim on which a tire is fitted for physical dimension requirements. Pin Weight The downward force applied to the 5thwheelor gooseneck ball, by the trailer kingpin or gooseneck coupler.

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1999-2010 Yamaha Roadstar 465 Series Single Shock Supplement

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Filed Under (Yamaha) by admin on 14-02-2011

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Mount the shock as you would your stock shock per your authorized shop manual (with the rebound adjustment at the bottom) noting the following: n Remove the horn located on the lower left side. Also remove the Remote Adjustable Pre-Load adjuster knob by removing the screw located in the center of the knob, then pull it straight off. n As you mount the shock, feed the Remote Adjustable Pre-Load adjuster through the opening behind where the horn was located on the left side of the bike – see figures 2 and 3. Do not loosen or attempt to rotate the line between the shock and the adjuster. n Reinstall the adjuster knob, and torque the screw to 50 in/lbs. (5.65 N-m). n Make sure the shock rebound adjustment is at the rear facing the left side of the motorcycle and the pressure valve is facing up. n Tighten shock bolts to the proper torque specifications (refer to your manual). n Mount the adjuster to the supplied mounting bracket using the supplied M6-1.0X8mm SHCS fasteners and torque them to 80-90 in/lbs (9-10 N-m). Then mount the bracket to the bike using the stock two drive-belt cover bolts – as shown in figure 4. n Using the supplied zip-ties, secure the hydraulic line away from any moving parts or heat sources. Reinstall horn. To adjust the ride height, simply turn the adjuster knob clockwise (looking at it from the back of the bike) to increase the height and counterclockwise to reduce it. See main instructions for procedure of achieving optimum ride height

YAMAHA ROADSTAR 1600/1700 POWERSHOTS EXHAUST SYSTEM INSTALLATION MANUAL

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Filed Under (Yamaha) by admin on 22-12-2010

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STOCK EXHAUST SYSTEM REMOVAL 1. Remove both frame covers. Remove the left cover first to access a bolt that holds the right side cover in place. 2. Remove right side floorboard assembly held in place by two bolts (Figure 1). 3. Remove exhaust port Allen nuts. 4. Remove Allen bolts securing rear muffler to exhaust system mounting bracket. 5. Remove complete exhaust system. Begin by lifting muffler out of mounting bracket locating hole (assistance may be required). 6. Check condition of stock exhaust gaskets. Replace if damaged or worn 7. Remove two bolts attaching stock exhaust mounting bracket to frame. 8. Remove hose clamp securing rear brake hose to exhaust mounting bracket. 9. Remove brake hose banjo bolt from rear caliper. 10. Slide hose out of loop in bracket. 11. Check condition of sealing washers on banjo bolt and replace if damaged or worn. 12. Reconnect brake hose to caliper (without bracket) and torque Banjo bolt to 25 lbs. ft. 13. Brake system must be bled or brake will not operate correctly. Refill reservoir after bleeding 1. Remove exhaust system and heat shields from protective packaging. Place exhaust on a non-abrasive surface such as a blanket or carpet. Using a non-permanent marker or tape, mark outside edge of each heat shield to show location of mounting clips that hose clamps will loop through (Figure 2). 2. Attach brake hose clamp to mounting bracket (stamped 362-P) using one 6x16mm flange bolt and nylock nut (supplied) to tab located on top of bracket (Figure 2). 3. Install mounting bracket using two 10x30mm Allen bolts and lock nuts (supplied)(Figure 3). 4. Carefully slide heat shields onto headers.

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YAMAHA ROADSTAR/ WARRIOR ADJUSTABLE REAR LOWERING KIT REMOVAL AND INSTALLATION MANUAL

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Filed Under (Yamaha) by admin on 16-01-2012

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Secure motorcycle to a bike lift and raise the motorcycle. Rear wheel should remain barely resting on the ground. 2. See diagram on page 2 for references made in parentheses, for example (#5). 3. Remove the nut from the rear suspension bolt (#5) at the bottom of the shock (#7). You may need to remove your exhaust and rear horn to access the nut and bolt. 4. Remove this suspension bolt (#5) from the non-exhaust side of the bike. You may need to raise or lower the bike to ease the tension on the bolt in order for it to come out. 5. Next remove the nut (#4) and bolt connecting the relay arm (#3) to the swingarm. From here remove the entire shock assembly and relay arm from the bike. For ease of re-installing the relay arm (Step 8) and shock be sure to take precautions that in removing the assembly, you can put it back the same way you took it off. Flipping of the relay arm can cause serious damage to the lowering kit and surrounding components. 6. Remove the two suspension arms from the relay arm(#3) and shock(#7). Compare stock arm to length of lowering arm you are about to install. Make sure the length of the lowering arm matches the link of the stock arm. To set how much you want to lower the bike, lengthen the lowering arms. Every 1/4″ longer than stock is approximately 1″ of drop. Do not lower the bike more than 2″ for safety reasons. To adjust, unscrew the large hex shaft from the threaded rods. Make sure to adjust length equally on both shafts. Be sure to tighten all jam nuts once desired lowering position is set. 7. Re-assemble the lowering arms to the top of the shock (#7) using the supplied collar, nut, and bolt. The stock collar (#6), the one in the eyelet at the top of the shock (#7), will need to be removed as it is too long. (This is because the heims are thicker than the stock arms) Do not tighten the nut, or re-install into the frame yet. 8. Re-install the relay arm (#3) to the swingarm. The large hex shafts go to the rear of the bike. This is where it

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