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Yamaha 2000 V Star XVS650AM, Owner'S Manual, Page: 71 / 105

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Yamaha 2000 V Star XVS650AM Owner'S Manual Download Page 71

PERIODIC MAINTENANCE AND MINOR REPAIR

6-21

6

EAU00720

Checking the front brake pads 
and rear brake shoes

EAU01119

Front brake
Wear indicator grooves are provided
on each brake pad. These indicators
allow checking of brake pad wear with-
out disassembling the brake. Inspect
the grooves. If they have almost disap-
peared, ask a Yamaha dealer to re-
place the pads.

EAU00727

Rear brake
Apply the brake and inspect the wear
indicator.
If the indicator reaches the wear limit
line, ask a Yamaha dealer to replace
the shoes.

EAU00731

Inspecting the brake fluid 
level

Insufficient brake fluid may let air enter
the brake system, possibly causing the
brakes to become ineffective.
Before riding, check that the brake fluid
is above the minimum level and replen-
ish when necessary.
Observe these precautions:

●

When checking the fluid level,
make sure the top of the master
cylinder is level by turning the han-
dlebars.

1. Wear indicator grooves

1. Wear limit line
2. Wear indicator

1. Minimum level mark

E_4xs_Periodic.fm  Page 21  Tuesday, November 30, 1999  2:36 PM

Summary of Contents for 2000 V Star XVS650AM

Page 1: ...4XS 28199 23 XVS650M OWNER S MANUAL XVS650AM ...

Page 2: ...ing machines It represents the high degree of craftsmanship and reliability that have made Yamaha a leader in these fields This manual will give you an understanding of the operation inspection and basic maintenance of this motorcycle If you have any questions about the operation or maintenance of your motorcycle please consult a Yamaha dealer E_4xs_Intro0 fm Page 1 Tuesday November 30 1999 2 41 P...

Page 3: ...be taken to avoid damage to the motorcycle NOTE A NOTE provides key information to make procedures easier or clearer NOTE 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 informati...

Page 4: ...IMPORTANT MANUAL INFORMATION EW000002 WARNING PLEASE READ THIS MANUAL CAREFULLY AND COMPLETELY BEFORE OPERATING THIS MOTORCYCLE E_4xs_Info0 fm Page 2 Tuesday November 30 1999 2 31 PM ...

Page 5: ...MANUAL 1999 by Yamaha Motor Co Ltd 1st Edition November 1999 All rights reserved Any reprinting or unauthorized use without the written permission of Yamaha Motor Co Ltd is expressly prohibited Printed in Japan E_4xs_Info0 fm Page 3 Tuesday November 30 1999 2 31 PM ...

Page 6: ... CONTROL FUNCTIONS 3 4 PRE OPERATION CHECKS 4 5 OPERATION AND IMPORTANT RIDING POINTS 5 6 PERIODIC MAINTENANCE AND MINOR REPAIR 6 7 MOTORCYCLE CARE AND STORAGE 7 8 SPECIFICATIONS 8 9 CONSUMER INFORMATION 9 INDEX EAU00009 E_4xs_Toc0 fm Page 1 Tuesday November 30 1999 2 31 PM ...

Page 7: ...E_4xs_Toc0 fm Page 2 Tuesday November 30 1999 2 31 PM ...

Page 8: ...MATION Safe riding 1 1 Protective apparel 1 3 Modification 1 3 Loading and accessories 1 3 Gasoline and exhaust gas 1 5 Location of the important labels 1 7 E_4xs_SafetyTOC fm Page 1 Tuesday November 30 1999 2 32 PM ...

Page 9: ... MECHANICAL CONDITIONS Safe riding 1 Always make pre operation checks Careful checks may help prevent an accident 2 This motorcycle is designed to carry the operator and a passenger 3 The failure of motorists to detect and recognize motorcycles in traffic is the predominating cause of automobile motorcycle accidents Many accidents have been caused by an automobile driver who did not see the motorc...

Page 10: ...cient lean angle for the speed a Always obey the speed limits and never travel faster than warranted by road and traffic condi tions b Always signal before turning or changing lanes Make sure other motorists see you 6 The operator s and passenger s posture are important for proper control a The operator should keep both hands on the handlebars and both feet on the operator footrests during operati...

Page 11: ...come very hot and can cause burns Always wear protective clothing that covers your legs ankles and feet 6 A passenger should also observe the above precautions Modification Modifications made to the motorcycle not approved by Yamaha or the removal of original equipment may render your motorcycle unsafe for use and may cause severe personal injury Modifications may also make your motorcycle illegal...

Page 12: ... in cluding such cargo as sleeping bags duffle bags or tents can create unstable handling or slow steering response Accessories Genuine Yamaha accessories have been specifically designed for use on this motorcycle Since Yamaha cannot test all other accessories which may be available you must personally be responsible for the proper selection installation and use of non Yamaha accessories You shoul...

Page 13: ...lity Therefore such accessories are not recommended 2 Caution must be used if adding electrical accessories If these accessories exceed the capacity of the motorcycle s electrical system an electric failure could result which could cause a dangerous loss of lights or engine power Gasoline and exhaust gas 1 GASOLINE IS HIGHLY FLAMMABLE a Always turn off the engine when refueling b Take care not to ...

Page 14: ...le could catch fire 4 When transporting the motorcycle in another vehicle be sure it is kept upright and that the fuel cock is turned to ON or RES for vacuum type OFF for manual type If it should lean over gasoline may leak out of the carburetor or fuel tank 5 If you should swallow any gasoline inhale a lot of gasoline vapor or allow gasoline to get in your eyes see your doctor immediately If any ...

Page 15: ... important labels Please read the following labels carefully before operating this motorcycle 2 1 WARNING Before you operate this vehicle read the owner s manual English 3HP 21568 00 4AA 22259 40 E_4xs_Safety fm Page 7 Tuesday November 30 1999 2 32 PM ...

Page 16: ...DESCRIPTION Left view XVS650 2 1 Right view XVS650 2 2 Left view XVS650A 2 3 Right view XVS650A 2 4 Controls Instruments XVS650 XVS650A 2 5 E_4xs_DescriptionTOC fm Page 1 Tuesday November 30 1999 2 32 PM ...

Page 17: ...al page 3 4 2 Fuel cock page 3 7 3 Starter choke page 3 8 4 Rear shock absorber spring preload adjusting ring page 3 13 5 Helmet holder page 3 11 6 Storage compartment page 3 11 7 Tool kit page 6 1 E_4xs_Description fm Page 1 Tuesday November 30 1999 2 33 PM ...

Page 18: ... Right view XVS650 8 Oil filter page 6 10 9 Battery page 6 25 10 Fuses page 6 27 11 Main switch page 3 1 12 Air filter page 6 12 13 Rear brake pedal page 3 5 E_4xs_Description fm Page 2 Tuesday November 30 1999 2 33 PM ...

Page 19: ...ge 3 4 2 Fuel cock page 3 7 3 Starter choke page 3 8 4 Rear shock absorber spring preload adjusting ring page 3 13 5 Helmet holder page 3 11 6 Storage compartment page 3 11 7 Tool kit page 6 1 E_4xs_Description fm Page 3 Tuesday November 30 1999 2 33 PM ...

Page 20: ... Right view XVS650A 8 Oil filter page 6 10 9 Battery page 6 25 10 Fuses page 6 27 11 Main switch page 3 1 12 Air filter page 6 12 13 Rear brake pedal page 3 5 E_4xs_Description fm Page 4 Tuesday November 30 1999 2 33 PM ...

Page 21: ...utch lever page 3 4 15 Left handlebar switches page 3 3 16 Speedometer page 3 2 17 Fuel tank cap page 3 5 18 Right handlebar switches page 3 3 19 Throttle grip page 6 14 20 Front brake lever page 3 5 E_4xs_Description fm Page 5 Tuesday November 30 1999 2 33 PM ...

Page 22: ...nt brake lever 3 5 Rear brake pedal 3 5 Fuel tank cap 3 5 Fuel 3 6 Fuel cock 3 7 Starter choke 3 8 Seats XVS650 3 9 Seats XVS650A 3 10 Helmet holder 3 11 Storage compartment 3 11 Rear shock absorber adjustment 3 13 Luggage strap holders 3 14 Sidestand 3 14 Sidestand clutch switch operation check 3 15 E_4xs_FunctionsTOC fm Page 1 Tuesday November 30 1999 2 33 PM ...

Page 23: ...in this position and all electrical circuits are switched off The key can be removed in this po sition To lock the steering turn the handle bars all the way to the left While push ing the key into the main switch turn it from OFF to LOCK and remove it To release the lock turn the key to OFF while pushing EW000016 WARNING Never turn the key to OFF or LOCK when the motorcycle is moving The electrica...

Page 24: ...in a monitoring circuit In such a case take the motorcycle to a Yamaha dealer to have the self diag nostic systems checked EAU00095 Speedometer The speedometer shows riding speed This speedometer is equipped with an odometer and trip odometer The trip odometer can be reset to 0 with the reset knob Use the trip odometer to estimate how far you can ride on a tank of fuel This information will enable...

Page 25: ...e passing light EAU00121 Dimmer switch Turn the switch to for the high beam and to for the low beam EAU00129 Horn switch Press the switch to sound the horn EAU00138 Engine stop switch The engine stop switch is a safety de vice for use in an emergency such as when the motorcycle overturns or if trouble occurs in the throttle system Turn the switch to to start the en gine In case of emergency turn t...

Page 26: ...he clutch lever to the handlebar to disengage the clutch and release the lever to engage the clutch The lever should be pulled rapidly and released slowly for smooth clutch oper ation Refer to the engine starting pro cedures for a description of the ignition circuit cut off system EAU00157 Shift pedal This motorcycle is equipped with a con stant mesh 5 speed transmission The shift pedal is located...

Page 27: ...pedal is on the right side of the motorcycle Press down on the brake pedal to apply the rear brake EAU00167 Fuel tank cap To open Insert the key and turn it 1 4 turn clock wise The lock will be released and the cap can be opened To close Push the tank cap into position with the key inserted To remove the key turn it counterclockwise to the original posi tion E_4xs_Functions fm Page 5 Tuesday Novem...

Page 28: ...shown in the illustra tion EW000130 WARNING Do not overfill the fuel tank Avoid spilling fuel on the hot engine Do not fill the fuel tank above the bot tom of the filler tube or it may over flow when the fuel heats up later and expands EAU00185 CAUTION Always wipe off spilled fuel immedi ately with a dry and clean soft cloth Fuel may deteriorate painted surfac es or plastic parts EAU00192 1 Filler...

Page 29: ...he engine is not running ON With the fuel cock in this position fuel flows to the carburetors Set the fuel cock to this position when starting the engine and while riding RES This indicates reserve If you run out of fuel while riding set the fuel cock to this position Fill the tank at the first oppor tunity Be sure to set the fuel cock back to ON after refueling 1 Arrow mark over OFF Closed positi...

Page 30: ...a to turn on the starter choke Move in direction b to turn off the starter choke ECA00038 CAUTION Do not use the starter choke for more than 3 minutes as the exhaust pipe may discolor from excessive heat Also longer use of the starter choke will cause afterburning If af terburning occurs turn off the starter choke 1 Starter choke E_4xs_Functions fm Page 8 Tuesday November 30 1999 2 34 PM ...

Page 31: ...Rider seat To remove 1 Remove the passenger seat 2 Remove the two bolts and pull the seat upward To install 1 Insert the projection on the front of the seat into the seat holder and install the bolts 2 Install the passenger seat NOTE Make sure that the seats are securely fitted 1 Nut XVS650 1 Bolt 2 2 Seat holder 3 Projection XVS650 1 Seat holder 2 Projection XVS650 E_4xs_Functions fm Page 9 Tuesd...

Page 32: ...up ward To install Insert the projections on the front of the seat into the holder and install the bolt Rider seat To remove 1 Remove the passenger seat 2 Remove the bolt and pull the seat upward 1 Bolt XVS650A 1 Seat holder 2 2 Projection 2 XVS650A 1 Bolt XVS650A E_4xs_Functions fm Page 10 Tuesday November 30 1999 2 34 PM ...

Page 33: ... in the lock and turn it as shown To lock the helmet holder replace the holder in its original position EW000030 WARNING Never ride with a helmet in the hel met holder The helmet may hit ob jects causing loss of control and possibly an accident EAU01869 Storage compartment The storage compartment is located on the left side of the motorcycle 1 Seat holder 2 Projection XVS650A 1 Helmet holder 1 Com...

Page 34: ...d turn it clockwise Then pull the storage compartment cover out as shown To close Place the storage compartment cover in its original position as shown Then turn the key counterclockwise and re move it Close the lock cover 1 Storage compartment E_4xs_Functions fm Page 12 Tuesday November 30 1999 2 34 PM ...

Page 35: ...315 WARNING This shock absorber contains high ly pressurized nitrogen gas Read and understand the following infor mation before handling the shock absorber The manufacturer cannot be held responsible for property damage or personal injury that may result from improper handling Do not tamper with or attempt to open the cylinder assembly Do not subject the shock ab sorber to an open flame or other h...

Page 36: ... motorcycle must not be operat ed with the sidestand in the down position If the stand is not properly retracted it could contact the ground and distract the operator re sulting in a possible loss of control Yamaha has designed into this motorcycle a lockout system to as sist the operator in fulfilling the re sponsibility of retracting the sidestand Please check carefully the operating instruction...

Page 37: ... EW000045 WARNING If improper operation is noted con sult a Yamaha dealer immediately TURN THE MAIN SWITCH TO ON AND THE ENGINE STOP SWITCH TO TRANSMISSION IS IN GEAR AND SIDESTAND IS UP PULL IN CLUTCH LEVER AND PUSH THE START SWITCH ENGINE WILL START SIDESTAND IS DOWN CLUTCH SWITCH IS OK ENGINE WILL STALL SIDESTAND SWITCH IS OK E_4xs_Functions fm Page 15 Tuesday November 30 1999 2 34 PM ...

Page 38: ...4 PRE OPERATION CHECKS Pre operation check list 4 1 E_4xs_PreopTOC fm Page 1 Tuesday November 30 1999 2 35 PM ...

Page 39: ...just if necessary 6 19 6 22 Clutch Check operation condition and free play Adjust if necessary 6 17 6 18 Throttle grip and housing Check for smooth operation Lubricate if necessary 6 14 6 23 Engine oil Check oil level Fill with oil if necessary 6 9 6 11 Final gear oil Check vehicle for leakage 6 11 6 12 Wheels and tires Check tire pressure wear damage and spoke tightness Tighten spokes if necessar...

Page 40: ...dded safety it assures is more than worth the time involved WARNING If any item in the Pre Operation Check is not working properly have it inspected and repaired before operating the motorcycle Fuel Check fuel level Fill with fuel if necessary 3 6 Lights signals and switches Check for proper operation 6 28 6 29 ITEM CHECKS PAGE E_4xs_Preop fm Page 2 Tuesday November 30 1999 2 35 PM ...

Page 41: ...E_4xs_Preop fm Page 3 Tuesday November 30 1999 2 35 PM ...

Page 42: ...RIDING POINTS Starting and warming up a cold engine 5 1 Starting a warm engine 5 4 Shifting 5 4 Tips for reducing fuel consumption 5 5 Engine break in 5 5 Parking 5 6 E_4xs_OperationTOC fm Page 1 Tuesday November 30 1999 2 35 PM ...

Page 43: ...Before starting out always be sure the sidestand is up Failure to retract the sidestand com pletely can result in a serious accident when you try to turn a corner EAU01860 Starting and warming up a cold engine NOTE This motorcycle is equipped with an ig nition circuit cut off system The engine can be started only under one of the following conditions The transmission is in neutral The sidestand is...

Page 44: ... AND SIDESTAND IS DOWN PUSH THE START SWITCH ENGINE WILL START RETRACT THE SIDESTAND AND PUT TRANSMISSION IN GEAR IF THE TRANSMISSION IS IN GEAR AND SIDESTAND IS UP PULL IN THE CLUTCH LEVER AND PUSH THE START SWITCH ENGINE WILL START MOTORCYCLE CAN BE RIDDEN MOTORCYCLE CAN BE RIDDEN E_4xs_Operation fm Page 2 Tuesday November 30 1999 2 36 PM ...

Page 45: ... start switch NOTE If the engine fails to start release the start switch wait a few seconds then try again Each attempt should be as short as possible to preserve the bat tery Do not crank the engine more than 10 seconds on any one attempt 6 After starting the engine move the starter choke to the halfway position NOTE For maximum engine life never accel erate hard with a cold engine 7 After warmin...

Page 46: ... To shift into neutral depress the shift pedal repeatedly until it reaches the end of its travel then raise the pedal slightly EC000048 CAUTION Do not coast for long periods with the engine off and do not tow the motorcycle a long dis tance Even with gears in neu tral the transmission is only properly lubricated when the engine is running Inadequate lubrication may damage the transmission Always u...

Page 47: ...ur motorcycle than the period between zero and 1 600 km For this reason we ask that you carefully read the following material Because the engine is brand new you must not put an excessive load on it for the first 1 600 km The various parts in the en gine wear and polish themselves to the correct operating clearances During this period prolonged full throttle oper ation or any condition which might...

Page 48: ...rn the fuel cock to OFF whenever stopping the engine EW000058 WARNING The exhaust system is hot Park the motorcycle in a place where pedes trians or children are not likely to touch the motorcycle Do not park the motorcycle on a slope or soft ground the motorcycle may over turn E_4xs_Operation fm Page 6 Tuesday November 30 1999 2 36 PM ...

Page 49: ...E_4xs_Operation fm Page 7 Tuesday November 30 1999 2 36 PM ...

Page 50: ... Checking the front brake pads and rear brake shoes 6 21 Inspecting the brake fluid level 6 21 Brake fluid replacement 6 22 Cable inspection and lubrication 6 22 Throttle cable and grip lubrication 6 23 Brake and shift pedal lubrication 6 23 Brake and clutch lever lubrication 6 23 Sidestand lubrication 6 24 Front fork inspection 6 24 Steering inspection 6 25 Wheel bearings 6 25 Battery 6 25 Fuse r...

Page 51: ...service this work should be done by a Yamaha dealer EAU01129 Tool kit The tool kit is located inside the storage compartment See page 3 11 for com partment opening procedures The tools provided in the owner s tool kit are to assist you in the performance of pe riodic maintenance However some other tools such as a torque wrench are also necessary to perform the mainte nance correctly The service in...

Page 52: ...eplace if necessary 5 Clutch Check operation Adjust or replace cable 6 Front brake Check operation fluid level and vehicle for fluid leakage See NOTE on page 6 4 Correct accordingly Replace brake pads if necessary 7 Rear brake Check operation Adjust brake pedal free play and replace brake shoes if necessary 8 Wheels Check balance runout spoke tightness and for damage Tighten spokes and rebalance r...

Page 53: ... and repair if necessary 15 Sidestand switch Check operation Replace if necessary 16 Front fork Check operation and for oil leakage Correct accordingly 17 Rear shock absorber assembly Check operation and shock absorber for oil leakage Replace shock absorber assembly if necessary 18 Carburetors Check engine idling speed synchronization and starter operation Adjust if necessary 19 Engine oil Check o...

Page 54: ...he brake fluid level regularly and fill as required Replace the oil seals on the inner parts of the master cylinder and caliper cylinder every two years Replace the brake hoses every four years or if cracked or damaged 21 Final gear oil Check oil level and vehicle for oil leakage Change oil at initial 1 000 km and thereafter every 24 000 km or 24 months whichever comes first NO ITEM CHECKS AND MAI...

Page 55: ...on The panels illustrated need to be re moved to perform some of the mainte nance described in this chapter Refer to this section each time a panel has to be removed or reinstalled 1 Panel A XVS650 1 Panel A XVS650A 1 Panel B E_4xs_Periodic fm Page 5 Tuesday November 30 1999 2 36 PM ...

Page 56: ...MINOR REPAIR 6 6 6 EAU01573 Panel A To remove Remove the bolts To install Place the panel in its original position and install the bolts 1 Bolt 4 XVS650 1 Bolt 4 XVS650A E_4xs_Periodic fm Page 6 Tuesday November 30 1999 2 36 PM ...

Page 57: ... the areas shown To install Place the panel in its original position and install the bolt EAU03053 Spark plugs Removal 1 Remove the spark plug caps 2 Use the spark plug wrench in the tool kit to remove the spark plugs as shown 1 Bolt 1 Spark plug cap E_4xs_Periodic fm Page 7 Tuesday November 30 1999 2 36 PM ...

Page 58: ...b lems yourself Instead take the motor cycle to a Yamaha dealer You should periodically remove and inspect the spark plugs because heat and deposits will cause any spark plug to slowly break down and erode If electrode ero sion becomes excessive or if carbon and other deposits are excessive you should replace the spark plug with the specified plug Installation 1 Measure the electrode gap with a wi...

Page 59: ...e sure the motorcycle is positioned straight up when checking the oil level A slight tilt toward the side can result in false readings 2 With the engine stopped check the oil level through the level win dow located at the lower part of the left side crankcase cover NOTE Wait a few minutes until the oil level settles before checking 3 The oil level should be between the maximum and minimum marks If...

Page 60: ...ilter and O ring 6 Reinstall the drain bolt and tighten it to the specified torque 7 Install a new oil filter and O ring 8 Install oil filter cover and cover then tighten the bolts 9 Fill the engine with oil Install the oil filler cap and tighten it 1 Engine oil filler cap 1 Cover 2 Bolt 3 Tightening torque Drain bolt 43 Nm 4 3 m kg 1 Bolt 5 2 Oil filter cover Recommended oil See page 8 1 Oil quan...

Page 61: ...el inspection 1 Place the motorcycle on a level place and hold it in an upright posi tion The engine should be cool at ambient temperature 2 Remove the oil filler bolt and check the oil level The oil level should be at the brim of the filler hole Add the recommended oil if necessary Oil replacement 1 Place an oil pan under the final gear case 2 Remove the oil filler bolt and drain bolt to drain th...

Page 62: ...ently if you are riding in un usually wet or dusty areas 1 Remove the air filter case cover by removing the screws 2 Remove the air filter 3 Tap the air filter lightly to remove most of the dust and dirt Blow out the remaining dirt with com pressed air as shown If the air fil ter is damaged replace it Final gear case capacity 0 19 L Recommended oil SAE 80 API GL 4 Hypoid gear oil If desired an SAE...

Page 63: ...AU00630 Carburetor adjustment The carburetors are important parts of the engine and require very sophisti cated adjustment Most adjustments should be left to a Yamaha dealer who has the professional knowledge and experience to do so However the idle speed may be adjusted by the owner as part of routine maintenance EC000095 CAUTION The carburetors were set at the Yamaha factory after many tests If ...

Page 64: ...e specified engine speed by adjusting the throttle stop screw Turn the screw in di rection a to increase engine speed and in direction b to de crease engine speed NOTE If the specified idle speed cannot be obtained by performing the above ad justment consult a Yamaha dealer EAU00635 Throttle cable free play inspection There should be a free play of 4 6 mm at the throttle grip If the free play is i...

Page 65: ...bient air temperature Tire infla tion pressure must be adjusted ac cording to total weight of cargo rider passenger and accessories fairing saddlebags etc if approved for this model and vehicle speed CE 32E XVS650 XVS650A Maximum load 180 kg Cold tire pressure Front Rear Up to 90 kg load 200 kPa 2 00 kgf cm2 2 00 bar 225 kPa 2 25 kgf cm2 2 25 bar 90 kg load Maximum load 200 kPa 2 00 kgf cm2 2 00 b...

Page 66: ...e inspection Always check the tires before operating the motorcycle If a tire tread shows crosswise lines minimum tread depth if the tire has a nail or glass fragments in it or if the side wall is cracked con tact a Yamaha dealer immediately and have the tire replaced CE 10E CE 10E CE 16E NOTE These limits may be different by regula tion from country to country If so con form to the limits specifi...

Page 67: ...ndition exists in a wheel consult a Yamaha dealer Do not attempt even small repairs to the wheel If a wheel is de formed or cracked it must be re placed Tires and wheels should be bal anced whenever either one is changed or replaced Failure to have a wheel balanced can result in poor performance adverse han dling characteristics and short ened tire life Ride at moderate speeds after changing a tir...

Page 68: ...se in direction a to in crease free play or in direction b to decrease free play 8 Tighten the locknut at the crank case and the clutch lever EAU00696 Front brake lever free play adjustment The free play at the front brake lever should be 10 15 mm 1 Loosen the locknut 2 Turn the adjusting bolt in direction a to increase free play or in direction b to decrease free play 3 After adjusting tighten th...

Page 69: ...ve a Yamaha dealer inspect and bleed the system if necessary EAU00711 Rear brake pedal height and free play adjustment EW000104 WARNING It is advisable to have a Yamaha dealer make this adjustment The brake pedal height should be ad justed before adjusting the brake pedal free play Pedal height The brake pedal should be positioned approximately 85 mm above the top of the footrest 1 Loosen the lock...

Page 70: ...ght switch adjustment The rear brake light switch is activated by the brake pedal and is properly ad justed when the brake light comes on just before braking takes effect To ad just the rear brake light switch hold the switch body so it does not rotate while turning the adjusting nut Turn the ad justing nut in direction a to make the brake light come on earlier Turn the adjusting nut in direction ...

Page 71: ...ndicator If the indicator reaches the wear limit line ask a Yamaha dealer to replace the shoes EAU00731 Inspecting the brake fluid level Insufficient brake fluid may let air enter the brake system possibly causing the brakes to become ineffective Before riding check that the brake fluid is above the minimum level and replen ish when necessary Observe these precautions When checking the fluid level...

Page 72: ...check the cause if the brake fluid level goes down EAU00742 Brake fluid replacement The brake fluid should be replaced only by trained Yamaha service personnel Have the Yamaha dealer replace the following components during periodic maintenance or when they are dam aged or leaking oil seals every two years brake hoses every four years EAU02962 Cable inspection and lubrication EW000112 WARNING Damag...

Page 73: ...he screws hold the end of the cable up in the air and put in several drops of lubricant With the throttle grip disassembled coat the metal surface of the grip assembly with a suitable all purpose grease EAU02984 Brake and shift pedal lubrication Lubricate the pivoting parts EAU02985 Brake and clutch lever lubrication Lubricate the pivoting parts Recommended lubricant Engine oil Recommended lubrica...

Page 74: ...the motorcycle so there is no danger of it falling over Check for scratches or damage on the inner tube and excessive oil leakage from the front fork Operation check 1 Place the motorcycle on a level place 2 Hold the motorcycle in an upright position and apply the front brake 3 Push down hard on the handle bars several times and check if the fork rebounds smoothly EC000098 CAUTION If any damage or...

Page 75: ...danger of it falling over EAU01144 Wheel bearings If there is play in the front or rear wheel hub or if the wheel does not turn smoothly have a Yamaha dealer in spect the wheel bearings EAU00800 Battery This motorcycle is equipped with a sealed type battery Therefore it is not necessary to check the electrolyte or fill the battery with distilled water If the battery seems to have dis charged consu...

Page 76: ...hen charging or using in an enclosed space Always shield your eyes when working near batteries KEEP OUT OF REACH OF CHIL DREN Battery storage When the motorcycle is not used for a month or longer remove the battery fully charge it and store it in a cool dry place EC000102 CAUTION Completely recharge the bat tery before storing Storing a discharged battery can cause permanent battery damage Use a b...

Page 77: ...ediately blows again con sult a Yamaha dealer EC000103 CAUTION Do not use fuses of higher amper age rating than those recommend ed Substitution of a fuse of improper rating can cause extensive electrical system damage and pos sibly a fire 1 Fuse block 2 Main fuse 3 Spare fuse 1 Ignition fuse 2 Signaling system fuse 3 Headlight fuse 4 Carburetor heater fuse 5 Spare fuse Specified fuses Main fuse 30...

Page 78: ...s away from a bulb while it is on as it is hot Do not touch a bulb until it cools down 4 Put a new bulb into position and secure it in place with the bulb holder EC000105 CAUTION Avoid touching the glass part of a bulb Keep it free from oil other wise the transparency of the glass life of the bulb and luminous flux will be adversely affected If oil gets on a bulb thoroughly clean it with a cloth m...

Page 79: ...ward and turn it counterclockwise 3 Place a new bulb in the socket Push the bulb inward and turn it clockwise until it engages into the socket 4 Install the lens and the screws EC000108 CAUTION Do not over tighten the screws as the lens may break 1 Screw 2 1 Screw 2 XVS650 1 Screw 3 XVS650A E_4xs_Periodic fm Page 29 Tuesday November 30 1999 2 36 PM ...

Page 80: ...box can be placed un der the engine for added stability Front wheel service To stabilize the rear of the motorcycle either use a motorcycle stand or place a motorcycle jack under the frame in front of the rear wheel to prevent it from moving from side to side Then use a motorcycle stand to elevate the front wheel off of the ground Rear wheel service Use a motorcycle stand or motorcycle jack to ele...

Page 81: ...t depress the brake lever when the disc and caliper are separated EAU01394 Front wheel installation 1 Install the speedometer gear unit into the wheel hub Make sure the wheel hub and the speedometer gear unit are installed with the pro jections meshed into the slots 2 Lift up the wheel between the front fork legs and guide the brake disc between the brake pads Make sure the slot in the speedometer...

Page 82: ...ort the motor cycle so there is no danger of it falling over 1 Loosen the axle nut Do not re move it 2 Remove the brake torque rod bolt on the brake shoe plate side 3 Loosen the brake torque rod bolt on the swingarm side 4 Remove the brake pedal free play adjusting nut and then the brake rod from the brake cam lever 5 Remove panel A See page 6 6 for removal procedures Tightening torque Wheel axle ...

Page 83: ... the fi nal gear case to the swingarm and tighten to the specified tightening torque 3 Insert the brake rod into the brake cam lever and install the brake pedal free play adjusting nut 4 Install the brake torque rod bolt and tighten both bolts to the spec ified tightening torque 5 Install panel B 6 Let the motorcycle down 7 Tighten the axle nut to the speci fied tightening torque 8 Adjust the rear...

Page 84: ... chart describes a quick easy procedure for making checks If your motorcycle requires any repair bring it to a Yamaha dealer The skilled technicians at a Yamaha dealership have the tools experience and know how to properly service your motor cycle Use only genuine Yamaha parts on your motorcycle Imitation parts may look like Yamaha parts but they are of ten inferior Consequently they have a shorte...

Page 85: ...s compression No compression Go to ignition check Ask a Yamaha dealer to inspect Remove spark plugs and check electrodes 3 Ignition Wet Dry Wipe clean with dry cloth and correct spark gap or replace spark plugs Ask a Yamaha dealer to inspect Engine doesn t start ask a Yamaha dealer to inspect Engine doesn t start go to battery check Open throttle half way and start the engine Use the electric star...

Page 86: ...7 MOTORCYCLE CARE AND STORAGE Care 7 1 Storage 7 4 E_4xs_CleaningTOC fm Page 1 Tuesday November 30 1999 2 38 PM ...

Page 87: ...tions Before cleaning 1 Cover up the muffler outlets with plastic bags 2 Make sure that all caps and covers as well as all electrical couplers and connectors including the spark plug caps are tightly in stalled 3 Remove extremely stubborn dirt like oil burnt onto the crankcase with a degreasing agent and a brush but never apply such prod ucts onto seals gaskets and wheel axles Always rinse the dir...

Page 88: ... since they cause water seepage and deterioration in the following ar eas seals of wheel bearings swingarm bearings forks and brakes electric components couplers connectors instru ments switches and lights breather hoses and vents For motorcycles equipped with a windshield Do not use strong cleaners or hard sponges as they will cause dulling or scratching Some cleaning compounds for plastic may le...

Page 89: ... nickel plated metal surfaces 4 Use spray oil as a universal clean er to remove any remaining dirt 5 Touch up minor paint damage caused by stones etc 6 Wax all painted surfaces 7 Let the motorcycle dry completely before storing it or covering it EWA00001 WARNING Make sure that there is no oil or wax on the brakes and tires If neces sary clean the brake discs and lin ings with a regular brake disc ...

Page 90: ...e fuel cock to OFF 4 Fill up the fuel tank and add fuel stabilizer if available to prevent the fuel tank from rusting and the fuel from deteriorating 5 Perform the following steps to pro tect the cylinders piston rings etc from corrosion a Remove the spark plug caps and spark plugs b Pour a teaspoonful of engine oil into each spark plug bore c Install the spark plug caps onto the spark plugs and p...

Page 91: ...er up the muffler outlets with plastic bags to prevent moisture from entering 9 Remove the battery and fully charge it Store it in a cool dry place and recharge it once a month Do not store the battery in an excessively cold or warm place less than 0 C or more than 30 C For more information see Battery storage in the chapter PERIODIC MAINTENANCE AND MINOR REPAIRS NOTE Make any necessary repairs be...

Page 92: ...8 SPECIFICATIONS Specifications 8 1 HOW TO USE THE CONVERSION TABLE 8 6 E_4xs_SpecTOC fm Page 1 Tuesday November 30 1999 2 38 PM ...

Page 93: ...25 mm Ground clearance 145 mm Minimum turning radius 3 400 mm Basic weight with oil and full fuel tank For XVS650 227 kg For XVS650A 242 kg Engine Engine type Air cooled 4 stroke SOHC Cylinder arrangement V type 2 cylinder Displacement 649 cm3 Bore stroke 81 63 mm Compression ratio 9 1 Starting system Electric starter Lubrication system Wet sump Engine oil Type Recommended engine oil classificatio...

Page 94: ... labeled Energy Conserving contain anti friction additives which will cause clutch and or starter clutch slippage resulting in reduced component life and poor engine performance Spark plug Type Manufacturer DPR7EA 9 NGK or X22EPR U9 DENSO Gap 0 8 0 9 mm Clutch type Wet multiple disc Transmission Primary reduction system Spur gear Primary reduction ratio 1 789 Secondary reduction system Shaft drive...

Page 95: ...oad maximum load Front 200 kPa 2 00 kgf cm2 2 00 bar Rear 250 kPa 2 50 kgf cm2 2 50 bar For XVS650A Type Tube Front Size 130 90 16 67S Manufacturer model Bridgestone G703 Dunlop D404F Rear Size 170 80 15 M C 77S Manufacturer model Bridgestone G702 Dunlop D404 Maximum load 201 kg Air pressure cold tire Up to 90 kg load Front 225 kPa 2 25 kgf cm2 2 25 bar Rear 225 kPa 2 25 kgf cm2 2 25 bar 90 kg loa...

Page 96: ...on Right foot operation Suspension Front Type Telescopic fork Rear Type Swingarm monocross Shock absorber Front Coil spring oil damper Rear Coil spring gas oil damper spring preload adjustable Wheel travel For XVS650 Front 140 mm Rear 86 mm For XVS650A Front 140 mm Rear 98 mm Electrical Ignition system T C I digital Charging system Type A C magneto Standard output 14 V 20 A 5 000 r min Battery Typ...

Page 97: ...t 12 V 1 7 W 1 Engine trouble indicator light 12 V 1 7 W 1 For XVS650A Headlight 12 V 60 55 W 1 Licence light 12 V 5 W 1 Tail brake light 12 V 5 21 W 1 Turn signal light 12 V 21 W 4 Meter light 12 V 1 7 W 1 Neutral indicator light 12 V 1 7 W 1 High beam indicator light 12 V 1 7 W 1 Turn indicator light 12 V 1 7 W 1 Engine trouble indicator light 12 V 1 7 W 1 Fuses Main fuse 30 A Ignition fuse 10 A...

Page 98: ...ERIAL Metric unit Multiplier Imperial unit Torque m kg m kg cm kg cm kg 7 233 86 794 0 0723 0 8679 ft lb in lb ft lb in lb Weight kg g 2 205 0 03527 lb oz Speed km hr 0 6214 mph Distance km m m cm mm 0 6214 3 281 1 094 0 3937 0 03937 mi ft yd in in Volume Capacity cc cm3 cc cm3 lt liter lt liter 0 03527 0 06102 0 8799 0 2199 oz IMP liq cu in qt IMP liq gal IMP liq Misc kg mm kg cm2 Centigrade C 55...

Page 99: ...E_4xs_Spec fm Page 7 Tuesday November 30 1999 2 39 PM ...

Page 100: ...RMATION Identification number records 9 1 Key identification number 9 1 Vehicle identification number 9 1 Model label 9 2 Noise regulation For Australia 9 2 E_4xs_ConsumerTOC fm Page 1 Tuesday November 30 1999 2 39 PM ...

Page 101: ...EAU01041 Key identification number The key identification number is stamped on the key tag Record this number in the space provided and use it for reference when obtaining a new key EAU01043 Vehicle identification number The vehicle identification number is stamped into the steering head pipe Record this number in the space pro vided NOTE The vehicle identification number is used to identify your ...

Page 102: ...SYSTEM PROHIBITED Owners are warned that the law may prohibit a The removal or rendering inopera tive by any person other than for purposes of maintenance repair or replacement of any device or element of design incorporated into any new vehicle for the pur pose of noise control prior to its sale or delivery to the ultimate pur chaser or while it is in use and b The use of the vehicle after such d...

Page 103: ...Fuel cock 3 7 Fuel tank cap 3 5 Fuse replacement 6 27 G Gasoline and exhaust gas 1 5 H Handlebar switches 3 3 Dimmer switch 3 3 Engine stop switch 3 3 Horn switch 3 3 Pass switch 3 3 Start switch 3 4 Turn signal switch 3 3 Headlight bulb replacement 6 28 Helmet holder 3 11 High beam indicator light 3 2 Horn switch 3 3 I Identification number records 9 1 Idle speed adjustment 6 14 Indicator lights ...

Page 104: ...n check 3 15 Sidestand lubrication 6 24 Spark plugs 6 7 Specifications 8 1 Speedometer 3 2 Starter choke 3 8 Starting and warming up a cold engine 5 1 Starting a warm engine 5 4 Start switch 3 4 Steering inspection 6 25 Storage 7 4 Storage compartment 3 11 Supporting the motorcycle 6 30 T Throttle cable and grip lubrication 6 23 Throttle cable free play inspection 6 14 Tips for reducing fuel consu...

Page 105: ...PRINTED IN JAPAN 99 11 0 3 1 CR E PRINTED ON RECYCLED PAPER YAMAHA MOTOR CO LTD ...

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