SERVICE MANUAL

XVS95Y(C)

XVS95CTY(C)

5S7-28197-10

LIT-11616-22-60

2009

EAS20050

XVS95Y(C)/XVS95CTY(C)

SERVICE MANUAL

©2008 by Yamaha Motor Corporation, U.S.A.

First edition, October 2008

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-11616-22-60

EAS20071

NOTICE

This manual was produced by the Yamaha Motor Company, Ltd. primarily for use by Yamaha deal-

ers 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. 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 his vehicle and to conform

to federal environmental quality objectives.

Yamaha Motor Company, Ltd. is continually striving to improve all of its models. Modifications and

significant changes in specifications or procedures will be forwarded to all authorized Yamaha deal-

ers and will appear in future editions of this manual where applicable.

TIP

• 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.

EAS20081

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 per-

sonal 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

damage to the vehicle or other property.

A TIP provides key information to make procedures easier or clearer.

WARNUNG

EAS20090

HOW TO USE THIS MANUAL

This manual is intended as a handy, easy-to-read reference book for the mechanic. Comprehensive

explanations of all installation, removal, disassembly, assembly, repair and check procedures are

laid out with the individual steps in sequential order.

• The manual is divided into chapters and each chapter is divided into sections. The current section

title “1” is shown at the top of each page.

• Sub-section titles “2” appear in smaller print than the section title.

• To help identify parts and clarify procedure steps, there are exploded diagrams “3” at the start of

each removal and disassembly section.

• Numbers “4” are given in the order of the jobs in the exploded diagram. A number indicates a dis-

assembly step.

• Symbols “5” indicate parts to be lubricated or replaced.

Refer to “SYMBOLS”.

• A job instruction chart “6” accompanies the exploded diagram, providing the order of jobs, names

of parts, notes in jobs, etc.

• Jobs “7” requiring more information (such as special tools and technical data) are described

sequentially.

EAS20100

SYMBOLS

The following symbols are used in this manual for easier understanding.

TIP

The following symbols are not relevant to every vehicle.

SYMBOL

DEFINITION

SYMBOL

DEFINITION

Serviceable with engine

mounted

Gear oil

Filling fluid

Molybdenum disulfide oil

Lubricant

Brake fluid

Special tool

Wheel bearing grease

Tightening torque

Lithium-soap-based grease

Wear limit, clearance

Molybdenum disulfide grease

Engine speed

Silicone grease

Electrical data

Apply locking agent (LOC-

TITE®).

Engine oil

Replace the part with a new

one.

1

2

3

4

5

6

7

8

EAS20110 TABLE OF CONTENTS

GENERAL INFORMATION

SPECIFICATIONS

PERIODIC CHECKS AND ADJUSTMENTS

CHASSIS

ENGINE

FUEL SYSTEM

ELECTRICAL SYSTEM

TROUBLESHOOTING

1

GENERAL INFORMATION

IDENTIFICATION..........................................................................................1-1

VEHICLE IDENTIFICATION NUMBER...................................................1-1

MODEL LABEL.......................................................................................1-1

FEATURES ...................................................................................................1-2

OUTLINE OF THE FI SYSTEM ..............................................................1-2

FI SYSTEM.............................................................................................1-3

INSTRUMENT FUNCTIONS ..................................................................1-4

IMPORTANT INFORMATION .......................................................................1-6

PREPARATION FOR REMOVAL AND DISASSEMBLY..........................1-6

REPLACEMENT PARTS.........................................................................1-6

GASKETS, OIL SEALS AND O-RINGS..................................................1-6

LOCK WASHERS/PLATES AND COTTER PINS ...................................1-6

BEARINGS AND OIL SEALS .................................................................1-7

CIRCLIPS ...............................................................................................1-7

CHECKING THE CONNECTIONS ...............................................................1-8

SPECIAL TOOLS..........................................................................................1-9

IDENTIFICATION

1-1

EAS20130

IDENTIFICATION

EAS20140

VEHICLE IDENTIFICATION NUMBER

The vehicle identification number “1” is

stamped into the right side of the steering

head pipe.

EAS20150

MODEL LABEL

The model label “1” is affixed to the frame. This

information will be needed to order spare

parts.

2

3

1

1

FEATURES

1-2

EAS20170

FEATURES

EAS5S71022

OUTLINE OF THE FI SYSTEM

The main function of a fuel supply system is to provide fuel to the combustion chamber at the opti-

mum air-fuel ratio in accordance with the engine operating conditions and the atmospheric tempera-

ture. In the conventional carburetor system, the air-fuel ratio of the mixture that is supplied to the

combustion chamber is created by the volume of the intake air and the fuel that is metered by the jet

used in the respective carburetor.

Despite the same volume of intake air, the fuel volume requirement varies by the engine operating

conditions, such as acceleration, deceleration, or operating under a heavy load. Carburetors that

meter the fuel through the use of jets have been provided with various auxiliary devices, so that an

optimum air-fuel ratio can be achieved to accommodate the constant changes in the operating con-

ditions of the engine.

As the requirements for the engine to deliver more performance and cleaner exhaust gases

increase, it becomes necessary to control the air-fuel ratio in a more precise and finely tuned man-

ner. To accommodate this need, this model has adopted an electronically controlled fuel injection

(FI) system, in place of the conventional carburetor system. This system can achieve an optimum

air-fuel ratio required by the engine at all times by using a microprocessor that regulates the fuel

injection volume according to the engine operating conditions detected by various sensors.

The adoption of the FI system has resulted in a highly precise fuel supply, improved engine

response, better fuel economy, and reduced exhaust emissions.

1. Air temperature sensor

2. Intake air pressure sensor

3. Engine trouble warning light

4. Fuel pump

5. Front cylinder injector

6. Rear cylinder injector

7. Throttle position sensor

8. Spark plug

9. Speed sensor

10.Relay unit (fuel pump relay)

11.ECU (engine control unit)

12.O2 sensor

13.Lean angle sensor

14.ISC (idle speed control) unit

15.Crankshaft position sensor

16.Rear cylinder ignition coil

17.Front cylinder ignition coil

18.Engine temperature sensor

FEATURES

1-3

EAS5S71020

FI SYSTEM

The fuel pump delivers fuel to the fuel injector via the fuel filter. The pressure regulator maintains the

fuel pressure that is applied to the fuel injector at only 392 kPa (3.92 kg/cm², 56.9 psi). Accordingly,

when the energizing signal from the ECU energizes the fuel injector, the fuel passage opens, caus-

ing the fuel to be injected into the intake manifold only during the time the passage remains open.

Therefore, the longer the length of time the fuel injector is energized (injection duration), the greater

the volume of fuel that is supplied. Conversely, the shorter the length of time the fuel injector is ener-

gized (injection duration), the lesser the volume of fuel that is supplied.

The injection duration and the injection timing are controlled by the ECU. Signals that are input from

the throttle position sensor, crankshaft position sensor, intake air pressure sensor, air temperature

sensor, engine temperature sensor, lean angle sensor, speed sensor and O2 sensor enable the

ECU to determine the injection duration. The injection timing is determined through the signals from

the crankshaft position sensor. As a result, the volume of fuel that is required by the engine can be

supplied at all times in accordance with the driving conditions.

Illustration is for reference only.

15

A

1

2

3

C

12

13

14

B

9

11

4

8

7

6

5

Front

Rear

10

16

1. Fuel pump

2. Fuel injector

3. Ignition coil

4. ECU (engine control unit)

5. Air temperature sensor

6. Lean angle sensor

7. ISC (idle speed control) unit

8. Throttle position sensor

9. O2 sensor

10.Engine temperature sensor

11.Catalytic converter

12.Crankshaft position sensor

13.Intake air pressure sensor

14.Throttle body

15.Air filter case

16.Speed sensor

A. Fuel system

B. Air system

C. Control system

FEATURES

1-4

EAS5S71021

INSTRUMENT FUNCTIONS

Multi-function meter unit

WARNING

EWA5S71001

Be sure to stop the vehicle before making

any setting changes to the multi-function

meter unit.

The multi-function meter unit is equipped with

the following:

• a speedometer (which shows the riding

speed)

• an odometer (which shows the total distance

traveled)

• two tripmeters (which show the distance trav-

eled since they were last set to zero)

• a fuel reserve tripmeter (which shows the

distance traveled on the fuel reserve)

• a clock

• a self-diagnosis device

• a brightness control mode

TIP

Be sure to turn the key to “ON” before using

the “SELECT” switch and “RESET” switch,

except for setting the brightness control mode.

Speedometer

The speedometer shows the riding speed.

When the key is turned to “ON”, the speedom-

eter needle will sweep once across the speed

range and then return to zero in order to test

the electrical circuit.

Clock

To set the clock:

1. Push the “SELECT” switch and the

“RESET” switch together for at least three

seconds.

2. When the hour digits start flashing, push

the “RESET” switch to set the hours.

3. Push the “SELECT” switch, and the minute

digits will start flashing.

4. Push the “RESET” switch to set the min-

utes.

5. Push the “SELECT” switch and then

release it to start the clock.

1. Speedometer

2. Odometer/tripmeter/fuel reserve tripmeter/

clock

1. “SELECT” switch

2. “RESET” switch

1

2

1

2

1. Speedometer

1. Clock

1

1

FEATURES

1-5

Odometer, tripmeter, and fuel reserve trip-

meter modes

Push the “SELECT” switch to change the dis-

play between the odometer mode “ODO”, the

tripmeter modes “TRIP A” and “TRIP B” in the

following order:

ODO → TRIP A → TRIP B → ODO

If the fuel level warning light comes on, the

odometer display will automatically change to

the fuel reserve tripmeter mode “TRIP F” and

start counting the distance traveled from that

point. In that case, push the “SELECT” switch

to change the display between the various trip-

meter and odometer modes in the following

order:

TRIP F → TRIP A → TRIP B → ODO → TRIP

F

To reset a tripmeter, select it by pushing the

“SELECT” switch, and then push the “RESET”

switch for at least one second. If you do not

reset the fuel reserve tripmeter manually, it will

reset itself automatically, and the display will

return to the prior mode after refueling and

traveling 5 km (3 mi).

Self-diagnosis device

This model is equipped with a self-diagnosis

device for various electrical circuits.

If any of those circuits are defective, the engine

trouble warning light will come on, and then the

odometer/tripmeter/clock display will indicate a

two-digit error code (e.g., 12, 13, 14).

If the odometer/tripmeter/clock display indi-

cates any error codes, note the code number,

and then check the vehicle. Refer to “FUEL

INJECTION SYSTEM” on page 7-27.

ECA5S71001

If the display indicates an error code, the

vehicle should be checked as soon as pos-

sible in order to avoid engine damage.

Brightness control mode

This function allows you to adjust the bright-

ness of the multi-function meter unit panel to

suit the outside lighting conditions.

To set the brightness:

1. Turn the key to “OFF”.

2. Push and hold the “SELECT” switch.

3. Turn the key to “ON”, and then release the

“SELECT” switch after five seconds.

4. Adjust the multi-function meter unit panel

brightness level by pushing the “SELECT”

switch.

5. Push the “RESET” switch.

The odometer/tripmeter/clock display will

return to the prior mode.

1. Odometer/tripmeter/fuel reserve tripmeter

1. Error code display

1

1

1. Brightness level

1

IMPORTANT INFORMATION

1-6

EAS20180

IMPORTANT INFORMATION

EAS20190

PREPARATION FOR REMOVAL AND DISAS-

SEMBLY

1. Before removal and disassembly, remove

all dirt, mud, dust and foreign material.

2. Use only the proper tools and cleaning

equipment.

Refer to “SPECIAL TOOLS” on page 1-9.

3. When disassembling, always keep mated

parts together. This includes gears, cylin-

ders, 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 dis-

assembly. This will speed up assembly and

allow for the correct installation of all parts.

5. Keep all parts away from any source of fire.

EAS20200

REPLACEMENT PARTS

Use only genuine Yamaha parts for all replace-

ments. Use oil and grease recommended by

Yamaha for all lubrication jobs. Other brands

may be similar in function and appearance, but

inferior in quality.

EAS20210

GASKETS, OIL SEALS AND O-RINGS

1. When overhauling the engine, replace all

gaskets, seals and O-rings. All gasket sur-

faces, 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.

EAS20220

LOCK WASHERS/PLATES AND COTTER

PINS

After removal, replace all lock washers/plates

“1” 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.

1. Oil

2. Lip

3. Spring

4. Grease