Yamaha 2001 V Star XVS650A Owner'S Manual Download

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PERIODIC MAINTENANCE AND MINOR REPAIR

Owner’s tool kit ....................................................6-1

Periodic maintenance and lubrication chart .........6-2

Removing and installing panels ...........................6-5

Checking the spark plugs ....................................6-7

Engine oil and oil filter element ............................6-9

Final gear oil ......................................................6-11

Cleaning the air filter element ............................6-13

Adjusting the carburetors ...................................6-14

Adjusting the engine idling speed ......................6-15

Adjusting the throttle cable free play ..................6-15

Adjusting the valve clearance ............................6-16

Tires ...................................................................6-16

Spoke wheels ....................................................6-18

Adjusting the clutch lever free play ....................6-19

Adjusting the brake lever free play .....................6-20

Adjusting the brake pedal position and

free play ...........................................................6-21

Adjusting the rear brake light switch ..................6-22

Checking the front brake pads and

rear brake shoes ..............................................6-23

Checking the brake fluid level ............................6-24

Changing the brake fluid ....................................6-25

Checking and lubricating the cables ................. 6-25

Checking and lubricating the throttle grip and

cable ............................................................... 6-25

Checking and lubricating the brake and

shift pedals ...................................................... 6-26

Checking and lubricating the brake and

clutch levers .................................................... 6-26

Checking and lubricating the sidestand ............ 6-27

Checking the front fork ...................................... 6-27

Checking the steering ....................................... 6-28

Checking the wheel bearings ............................ 6-29

Battery ............................................................... 6-29

Replacing the fuses .......................................... 6-31

Replacing the headlight bulb ............................. 6-32

Replacing a turn signal light bulb or the tail/

brake light bulb ................................................ 6-33

Supporting the motorcycle ................................ 6-34

Front wheel ....................................................... 6-35

Rear wheel ........................................................ 6-36

Troubleshooting ................................................. 6-38

Troubleshooting chart ........................................ 6-39

E_5bn.book Page 1 Monday, November 13, 2000 9:11 AM

Summary of Contents for 2001 V Star XVS650A

Page 1: ...PRINTED ON RECYCLED PAPER YAMAHA MOTOR CO LTD PRINTED IN JAPAN 2000 10 0 3 1 CR E 5BN 28199 21 XVS650 XVS650A OWNER S MANUAL ...

Page 2: ...F_5eb_Toc0 fm Page 2 Wednesday February 2 2000 2 02 PM ...

Page 3: ...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 concerning the operation or maintenance of your motorcycle please consult a Yamaha dealer E_5bn book Page 1 Monday November 13 2000 9 11 AM...

Page 4: ... 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 informat...

Page 5: ...IMPORTANT MANUAL INFORMATION EW000002 WARNING PLEASE READ THIS MANUAL CAREFULLY AND COMPLETELY BEFORE OPERATING THIS MOTORCYCLE E_5bn book Page 2 Monday November 13 2000 9 11 AM ...

Page 6: ... MANUAL 2000 by Yamaha Motor Co Ltd 1st Edition September 2000 All rights reserved Any reprinting or unauthorized use without the written permission of Yamaha Motor Co Ltd is expressly prohibited Printed in Japan E_5bn book Page 3 Monday November 13 2000 9 11 AM ...

Page 7: ...ND 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_5bn book Page 1 Monday November 13 2000 9 11 AM ...

Page 8: ...E_5bn book Page 2 Monday November 13 2000 9 11 AM ...

Page 9: ...NFORMATION 1 Safe riding 1 1 Protective apparel 1 3 Modifications 1 3 Loading and accessories 1 3 Gasoline and exhaust gas 1 5 Location of important labels 1 7 E_5bn book Page 1 Monday November 13 2000 9 11 AM ...

Page 10: ...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 motorcy...

Page 11: ...undercornering insuf ficient lean angle for the speed a Always obey the speed limit and never travel faster than warranted by road and traffic conditions b Always signal before turning or changing lanes Make sure that other motorists can see you 6 The posture of the operator and passenger is important for proper control a The operator should keep both hands on the handlebar and both feet on the op...

Page 12: ...n They become very hot and can cause burns Always wear protective clothing that covers your legs ankles and feet 6 Passengers should also observe the precautions mentioned above Modifications Modifications made to this motorcycle not approved by Yamaha or the removal of original equipment may render the motorcycle unsafe for use and may cause severe personal injury Modifications may also make your...

Page 13: ...e Yamaha accessories have been specifically designed for use on this motorcycle Since Yamaha cannot test all other accessories that may be available you must personally be responsible for the proper selection installation and use of non Yamaha accessories Use extreme caution when selecting and installing any accessories Keep the following guidelines in mind as well as those provided under Loading ...

Page 14: ...Y FLAMMABLE a Always turn the engine off when refueling b Take care not to spill any gasoline on the engine or exhaust system when refueling c Never refuel while smoking or in the vicinity of an open flame 2 Never start the engine or let it run for any length of time in a closed area The exhaust fumes are poi sonous and may cause loss of consciousness and death within a short time Always operate y...

Page 15: ...ype 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 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 E_5bn book Page 6 Monday November 13 2000 9 11 AM ...

Page 16: ...SAFETY INFORMATION 1 1 7 EAU02977 Location of important labels Please read the following important labels carefully before operating this motorcycle 1 2 E_5bn book Page 7 Monday November 13 2000 9 11 AM ...

Page 17: ...DESCRIPTION 2 Left view XVS650 2 1 Right view XVS650 2 2 Left view XVS650A 2 3 Right view XVS650A 2 4 Controls and instruments XVS650 XVS650A 2 5 E_5bn book Page 1 Monday November 13 2000 9 11 AM ...

Page 18: ...edal page 3 4 2 Fuel cock page 3 7 3 Starter choke knob page 3 9 4 Shock absorber spring preload adjusting ring page 3 14 5 Helmet holder page 3 12 6 Storage compartment page 3 13 7 Owner s tool kit page 6 1 E_5bn book Page 1 Monday November 13 2000 9 11 AM ...

Page 19: ...w XVS650 8 Engine oil filter element page 6 9 9 Battery page 6 29 10 Fuses page 6 31 11 Main switch steering lock page 3 1 12 Air filter element page 6 13 13 Brake pedal page 3 5 E_5bn book Page 2 Monday November 13 2000 9 11 AM ...

Page 20: ...page 3 5 2 Fuel cock page 3 7 3 Starter choke knob page 3 9 4 Shock absorber spring preload adjusting ring page 3 14 5 Helmet holder page 3 12 6 Storage compartment page 3 13 7 Owner s tool kit page 6 1 E_5bn book Page 3 Monday November 13 2000 9 11 AM ...

Page 21: ...w XVS650A 8 Engine oil filter element page 6 9 9 Battery page 6 29 10 Fuses page 6 31 11 Main switch steering lock page 3 1 12 Air filter element page 6 13 13 Brake pedal page 3 5 E_5bn book Page 4 Monday November 13 2000 9 11 AM ...

Page 22: ...VS650A 1 Clutch lever page 3 4 2 Left handlebar switches page 3 3 3 Speedometer unit page 3 2 4 Fuel tank cap page 3 6 5 Right handlebar switches page 3 3 6 Throttle grip page 6 15 7 Brake lever page 3 5 E_5bn book Page 5 Monday November 13 2000 9 11 AM ...

Page 23: ...0 3 4 Shift pedal XVS650A 3 5 Brake lever 3 5 Brake pedal 3 5 Fuel tank cap 3 6 Fuel 3 7 Fuel cock 3 7 Starter choke knob 3 9 Seats XVS650 3 9 Seats XVS650A 3 11 Helmet holder 3 12 Storage compartment 3 13 Adjusting the shock absorber assembly 3 14 Luggage strap holders 3 15 Sidestand 3 15 Ignition circuit cut off system 3 16 E_5bn book Page 1 Monday November 13 2000 9 11 AM ...

Page 24: ...40 LOCK The steering is locked and all electrical systems are off The key can be re moved To lock the steering 1 Turn the handlebars all the way to the left 2 Push the key in from the OFF po sition and then turn it to LOCK while still pushing it 3 Remove the key To unlock the steering Push the key in and then turn it to OFF while still pushing it EW000016 WARNING Never turn the key to OFF or LOCK ...

Page 25: ...ck the self diagnosis system NOTE _ This warning light comes on for a few seconds when the key is turned to ON but this does not indicate a malfunction _ EAU00095 Speedometer unit The speedometer unit is equipped with a speedometer an odometer and a tripmeter The speedometer shows riding speed The odometer shows the total distance traveled The tripmeter shows the distance traveled since it was las...

Page 26: ...center position EAU00119 Pass switch Press this switch to flash the headlight EAU00121 Dimmer switch Set this switch to for the high beam and to for the low beam EAU00129 Horn switch Press this switch to sound the horn EAU00143 Start switch Push this switch to crank the engine with the starter EC000005 CAUTION See page 5 1 for starting instruc tions prior to starting the engine 1 Turn signal switc...

Page 27: ...lever The lever should be pulled rapidly and released slowly for smooth clutch operation The clutch lever is equipped with a clutch switch which is part of the igni tion circuit cut off system See page 3 16 for an explanation of the ignition circuit cut off system EAU00157 Shift pedal XVS650 The shift pedal is located on the left side of the engine and is used in com bination with the clutch lever...

Page 28: ...motorcycle NOTE _ Use your toes or heel to shift up and your toes to shift down _ EAU00158 Brake lever The brake lever is located at the right handlebar grip To apply the front brake pull the lever toward the handle bar grip EAU00162 Brake pedal The brake pedal is on the right side of the motorcycle To apply the rear brake press down on the brake pedal 1 Shift pedal XVS650A 1 Brake lever 1 Brake p...

Page 29: ... key inserted in the lock and with the mark facing forward 2 Turn the key counterclockwise to the original position and then re move it 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 EW000024 WARNING Make sure that the fuel tank cap is properly installed before riding 1 Brake pedal XVS65...

Page 30: ...d surfac es or plastic parts EAU00192 EAU02969 Fuel cock The fuel cock supplies fuel from the tank to the carburetors while also filter ing it The fuel cock lever positions are ex plained as follows and shown in the illustrations OFF With the fuel cock lever in this position fuel will not flow Always turn the fuel cock lever to this position when the en gine is not running 1 Fuel tank filler tube ...

Page 31: ...es reserve With the fuel cock lever in this position the fuel re serve is made available Turn the fuel cock lever to this position if you run out of fuel while riding When this occurs refuel as soon as possible and be sure to turn the fuel cock lever back to ON 1 Arrow mark positioned over ON Normal position 1 Arrow mark positioned over RES Reserve position E_5bn book Page 8 Monday November 13 200...

Page 32: ...ff 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 In addition extended use of the starter choke will cause after burning If this occurs turn off the starter choke _ EAU01889 Seats XVS650 Passenger seat To remove the passenger seat Remove the nut and then pull the pas senger seat up 1 Starter choke knob ...

Page 33: ...ve the passenger seat 2 Remove the bolts and then pull the seat up To install the rider seat 1 Insert the projection on the front of the rider seat into the seat holder as shown place the seat in the original position and then install the bolts 2 Install the passenger seat NOTE Make sure that the seats are properly secured before riding 1 Bolt 2 2 Seat holder 3 Projection XVS650 1 Seat holder 2 Pr...

Page 34: ...seat Insert the projections on the front of the passenger seat into the holder as shown place the seat in the original position and then install the bolt Rider seat To remove the rider seat 1 Remove the passenger seat 2 Remove the bolt and then pull the rider seat up 1 Bolt XVS650A 1 Seat holder 2 2 Projection 2 XVS650A 1 Bolt XVS650A E_5bn book Page 11 Monday November 13 2000 9 11 AM ...

Page 35: ...rly secured before riding _ EAU00260 Helmet holder To open the helmet holder insert the key into the lock and then turn the key as shown To lock the helmet holder place it in the original position and then remove the key EW000030 WARNING Never ride with a helmet attached to the helmet holder since the helmet may hit objects causing loss of control and possibly an accident 1 Seat holder 2 Projectio...

Page 36: ...n turn it clockwise 2 Pull the storage compartment cov er out as shown To close the storage compartment 1 Place the storage compartment cover in its original position as shown 2 Turn the key counterclockwise re move it and then close the lock cover 1 Storage compartment cover 2 Storage compartment lock cover 3 Storage compartment lock 1 Storage compartment 2 Storage compartment cover E_5bn book Pa...

Page 37: ...d exten sion bar included in the owner s tool kit to make the adjustment CI 01E 3 Install the passenger and rider seats EAU00315 WARNING This shock absorber contains high ly pressurized nitrogen gas For proper handling read and under stand the following information be fore handling the shock absorber The manufacturer cannot be held re sponsible for property damage or personal injury that may resul...

Page 38: ...he ignition circuit cut off system EW000044 WARNING The motorcycle must not be ridden with the sidestand down or if the sidestand cannot be properly moved up or does not stay up oth erwise the sidestand could contact the ground and distract the opera tor resulting in a possible loss of control Yamaha s ignition circuit cut off system has been designed to assist the operator in fulfilling the respo...

Page 39: ...he clutch lever is not pulled It prevents starting when the trans mission is in gear and the clutch lever is pulled but the sidestand is still down It cuts the running engine when the transmission is in gear and the sidestand is moved down Periodically check the operation of the ignition circuit cut off system according to the following procedure EW000045 WARNING _ If a malfunction is noted have a...

Page 40: ...he clutch lever pulled 8 Shift the transmission into gear 9 Move the sidestand down Does the engine stall After the engine has stalled 10 Move the sidestand up 11 Keep the clutch lever pulled 12 Push the start switch Does the engine start The sidestand switch may be defective The motorcycle should not be ridden until checked by a Yamaha dealer The clutch switch may be defective The motorcycle shou...

Page 41: ...PRE OPERATION CHECKS 4 Pre operation check list 4 1 E_5bn book Page 1 Monday November 13 2000 9 11 AM ...

Page 42: ...ngine If necessary add recommended oil to specified level Check vehicle for oil leakage 6 9 6 11 Final gear oil Check vehicle for oil leakage 6 11 6 12 Front brake Check operation If soft or spongy have Yamaha dealer bleed hydraulic system Check lever free play Adjust if necessary Check fluid level in reservoir If necessary add recommended brake fluid to specified level Check hydraulic system for ...

Page 43: ...re Correct if necessary 6 16 6 18 Brake and shift pedals Make sure that operation is smooth Lubricate pedal pivoting points if necessary 6 26 Brake and clutch levers Make sure that operation is smooth Lubricate lever pivoting points if necessary 6 26 Sidestand Make sure that operation is smooth Lubricate pivot if necessary 6 27 Chassis fasteners Make sure that all nuts bolts and screws are properl...

Page 44: ...E_5bn book Page 3 Monday November 13 2000 9 11 AM ...

Page 45: ...ANT RIDING POINTS 5 Starting and warming up a cold engine 5 1 Starting a warm engine 5 2 Shifting 5 3 Tips for reducing fuel consumption 5 4 Engine break in 5 4 Parking 5 5 E_5bn book Page 1 Monday November 13 2000 9 11 AM ...

Page 46: ...ming up a cold engine In order for the ignition circuit cut off system to enable starting one of the following conditions must be met The transmission is in the neutral position The transmission is in gear with the clutch lever pulled and the sidestand up EW000054 WARNING _ Before starting the engine check the function of the igni tion circuit cut off system ac cording to the procedure described o...

Page 47: ...ary add en gine oil and then check the warning light again If the warning light does not go off after starting with suffi cient engine oil have a Yamaha deal er check the electrical circuit _ 6 After starting the engine move the starter choke knob back halfway ECA00045 CAUTION _ For maximum engine life never ac celerate hard when the engine is cold _ 7 When the engine is warm turn the starter chok...

Page 48: ...000048 CAUTION Even with the transmission in the neutral position do not coast for long periods of time with the engine off and do not tow the motorcycle for long dis tances The transmission is properly lubricated only when the engine is running Inade quate lubrication may damage the transmission Always use the clutch while changing gears to avoid dam aging the engine transmission and drive train ...

Page 49: ... 0 and 1 600 km For this rea son you should read the following ma terial carefully Since the engine is brand new do 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 that might result in engine overheating must be avoided EAU011...

Page 50: ...itch and then turn the fuel cock lever to OFF EW000058 WARNING Since the engine and exhaust system can become very hot park in a place where pedestri ans or children are not likely to touch them Do not park on a slope or on soft ground otherwise the motorcycle may overturn E_5bn book Page 5 Monday November 13 2000 9 11 AM ...

Page 51: ...ear brake light switch 6 22 Checking the front brake pads and rear brake shoes 6 23 Checking the brake fluid level 6 24 Changing the brake fluid 6 25 Checking and lubricating the cables 6 25 Checking and lubricating the throttle grip and cable 6 25 Checking and lubricating the brake and shift pedals 6 26 Checking and lubricating the brake and clutch levers 6 26 Checking and lubricating the sidesta...

Page 52: ...ith motor cycle maintenance work have a Yamaha dealer do it for you EAU01129 Owner s tool kit The owner s tool kit is located inside the storage compartment See page 3 13 for storage compartment opening procedures The service information included in this manual and the tools provided in the owner s tool kit are intended to assist you in the performance of preventive maintenance and minor repairs H...

Page 53: ...ECK 1 10 20 30 40 1 Fuel line Check fuel hoses for cracks or damage 2 Spark plugs Check condition Clean and regap Replace 3 Valves Check valve clearance Adjust 4 Air filter element Clean Replace 5 Clutch Check operation Adjust 6 Front brake Check operation fluid level and vehicle for fluid leakage See NOTE on page 6 4 Replace brake pads Whenever worn to the limit 7 Rear brake Check operation and a...

Page 54: ... nuts bolts and screws are properly tightened 15 Sidestand Check operation Lubricate 16 Sidestand switch Check operation 17 Front fork Check operation and for oil leakage 18 Rear shock absorber assembly Check operation and shock absorber for oil leakage 19 Carburetors Check starter choke operation Adjust engine idling speed and synchronization 20 Engine oil Change 21 Engine oil filter element Repl...

Page 55: ...t or dusty areas Hydraulic brake service Regularly check and if necessary correct the brake fluid level Every two years replace the internal components of the brake master cylinder and caliper and change the brake fluid Replace the brake hoses every four years and if cracked or damaged E_5bn book Page 4 Monday November 13 2000 9 11 AM ...

Page 56: ...els The panels shown above need to be removed to perform some of the main tenance jobs described in this chapter Refer to this section each time a panel needs to be removed and installed 1 Panel A XVS650 1 Panel A XVS650A 1 Panel B E_5bn book Page 5 Monday November 13 2000 9 11 AM ...

Page 57: ... and then take the panel off To install the panel Place the panel in the original position and then install the bolts EAU00491 Panel B To remove the panel Remove the bolt and then pull the pan el off as shown 1 Bolt 4 XVS650 1 Bolt 4 XVS650A 1 Bolt E_5bn book Page 6 Monday November 13 2000 9 11 AM ...

Page 58: ...d lubrication chart In addition the condition of the spark plugs can re veal the condition of the engine To remove a spark plug 1 Remove the spark plug cap 2 Remove the spark plug as shown with the spark plug wrench includ ed in the owner s tool kit To check the spark plugs 1 Check that the porcelain insulator around the center electrode on each spark plug is a medium to light tan the ideal color ...

Page 59: ... tion 2 Clean the surface of the spark plug gasket and its mating sur face and then wipe off any grime from the spark plug threads 3 Install the spark plug with the spark plug wrench and then tight en it to the specified torque NOTE If a torque wrench is not available when installing a spark plug a good estimate of the correct torque is 1 4 1 2 turn past finger tight However the spark plug should ...

Page 60: ... a few minutes until the oil set tles and then check the oil level through the check window located at the bottom left side of the crank case NOTE _ The engine oil should be between the minimum and maximum level marks _ 4 If the engine oil is below the mini mum level mark add sufficient oil of the recommended type to raise it to the correct level To change the engine oil with or without oil filter...

Page 61: ... O ring 6 Install a new oil filter element and the O ring 7 Install the oil filter element covers by installing the bolts 8 Install the engine oil drain bolt and then tighten it to the specified torque 1 Outer oil filter element cover 2 Bolt 3 Right side 1 Inner oil filter element cover 2 Bolt 5 1 Oil filter element 2 O ring Tightening torque Engine oil drain bolt 43 Nm 4 3 m kg E_5bn book Page 10...

Page 62: ...f and then check the oil level and correct it if necessary EAU03714 Final gear oil The final gear case must be checked for oil leakage before each ride If any leakage is found have a Yamaha deal er check and repair the motorcycle In addition the final gear oil level must be checked and the oil changed as follows at the intervals specified in the periodic maintenance and lubrication chart EW000066 ...

Page 63: ...se to collect the used oil 2 Remove the oil filler bolt and drain bolt to drain the oil from the final gear case 3 Install the final gear oil drain bolt and then tighten it to the specified torque 4 Add the recommended final gear oil to the brim of the filler hole NOTE _ GL4 is a quality rating Hypoid gear oils rated GL5 or GL6 may also be used _ 5 Install and tighten the filler bolt to the specif...

Page 64: ...s 1 Remove the air filter case cover by removing the screws 2 Pull the air filter element out 3 Lightly tap the air filter element to remove most of the dust and dirt and then blow the remaining dirt out with compressed air as shown If the air filter element is damaged replace it 4 Insert the air filter element into the air filter case as shown 1 Air filter case cover 2 Screw 3 1 Air filter elemen...

Page 65: ...carburetors are important parts of the engine and require very sophisti cated adjustment Therefore most car buretor adjustments should be left to a Yamaha dealer who has the neces sary professional knowledge and expe rience The adjustment described in the following section however may be serviced by the owner as part of routine maintenance EC000095 CAUTION The carburetors have been set and extensi...

Page 66: ... to the throttle 3 Check the engine idling speed and if necessary adjust it to spec ification by turning the throttle stop screw To increase the engine idling speed turn the screw in di rection a To decrease the engine idling speed turn the screw in di rection b NOTE If the specified idling speed cannot be obtained as described above have a Yamaha dealer make the adjustment EAU00635 Adjusting the ...

Page 67: ...s i e when the temperature of the tires equals the ambient temperature The tire air pressure must be adjusted in accordance with the riding speed and with the total weight of rider passenger car go and accessories approved for this model _ XVS650 CE 21E CE 07E XVS650A CE 21E CE 07E Tire air pressure measured on cold tires Load Front Rear Up to 90 kg 200 kPa 2 00 kg cm2 2 00 bar 225 kPa 2 25 kg cm2...

Page 68: ... Tire 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 sidewall is cracked con tact a Yamaha dealer immediately and have the tire replaced CE 20E NOTE _ The tire tread depth limits may differ from country to country Always comply with the local regulations _ EW000079...

Page 69: ...cle note the following points regarding the specified wheels The wheel rims should be checked for cracks bends or warpage and the spokes for looseness or dam age before each ride If any dam age is found have a Yamaha dealer replace the wheel Do not attempt even the smallest repair to the wheel A deformed or cracked wheel must be replaced The wheel should be balanced whenever either the tire or whe...

Page 70: ...lever free play could be obtained as de scribed above tighten the locknut and skip the rest of the procedure otherwise proceed as follows 4 Fully turn the adjusting bolt at the clutch lever in direction a to loos en the clutch cable 5 Loosen the locknut at the crank case 6 To increase the clutch lever free play turn the adjusting nut in di rection a To decrease the clutch lever free play turn the ...

Page 71: ... direction b 3 Tighten the locknut EW000099 WARNING After adjusting the brake lever free play check the free play and make sure that the brake is working properly A soft or spongy feeling in the brake lever can indicate the presence of air in the hydraulic system If there is air in the hy draulic system have a Yamaha dealer bleed the system before operating the motorcycle Air in the hydraulic syst...

Page 72: ... as shown Periodically check the brake pedal position and if necessary adjust it as follows 1 Loosen the locknut at the brake pedal 2 To raise the brake pedal turn the adjusting bolt in direction a To lower the brake pedal turn the ad justing bolt in direction b 3 Tighten the locknut EW000105 WARNING After adjusting the brake pedal height the brake pedal free play must be adjusted a Distance betwe...

Page 73: ...the rear brake light switch The rear brake light switch which is ac tivated by the brake pedal is properly adjusted when the brake light comes on just before braking takes effect If necessary adjust the brake light switch as follows Turn the adjusting nut while holding the rear brake light switch in place To make the brake light come on earlier turn the adjusting nut in direction a To make the bra...

Page 74: ... a brake pad has worn to the point that the wear indicators have almost disappeared have a Yamaha dealer replace the brake pads as a set EAU00727 Rear brake shoes The rear brake is provided with a wear indicator which allows you to check the brake shoe wear without having to dis assemble the brake To check the brake shoe wear check the position of the wear indicator while applying the brake If a b...

Page 75: ...quali ty brake fluid otherwise the rubber seals may deteriorate causing leakage and poor braking perfor mance Refill with the same type of brake fluid Mixing fluids may result in a harmful chemical reaction and lead to poor braking performance Be careful that water does not en ter the brake fluid reservoir when refilling Water will significantly lower the boiling point of the fluid and may result ...

Page 76: ...he outer sheath may in terfere with proper cable operation and will cause the inner cable to rust Replace a damaged cable as soon as possible to prevent unsafe conditions EAU03764 Checking and lubricating the throttle grip and cable The operation of the throttle grip and the condition of the throttle cable should be checked before each ride and the cable should be lubricated or replaced if necessa...

Page 77: ...g the brake and clutch levers The operation of the brake and clutch levers should be checked before each ride and the lever pivots should be lu bricated if necessary Recommended lubricant Throttle cable Engine oil Throttle grip housing and grip Lithium soap based grease all purpose grease Recommended lubricant Lithium soap based grease all purpose grease Recommended lubricant Lithium soap based gr...

Page 78: ...ve a Yamaha dealer check or repair it EAU02939 Checking the front fork The condition and operation of the front fork must be checked as follows at the intervals specified in the periodic main tenance and lubrication chart To check the condition EW000115 WARNING Securely support the motorcycle so that there is no danger of it falling over Check the inner tubes for scratches damage and excessive oil...

Page 79: ... EAU00794 Checking the steering Worn or loose steering bearings may cause danger Therefore the operation of the steering must be checked as fol lows at the intervals specified in the pe riodic maintenance and lubrication chart 1 Place a stand under the engine to raise the front wheel off the ground EW000115 WARNING Securely support the motorcycle so that there is no danger of it falling over 2 Hol...

Page 80: ...ld permanent ly damage the battery EW000116 WARNING Electrolyte is poisonous and dangerous since it contains sul furic acid which causes severe burns Avoid any contact with skin eyes or clothing and al ways shield your eyes when working near batteries In case of contact administer the fol lowing FIRST AID EXTERNAL Flush with plenty of water INTERNAL Drink large quan tities of water or milk and im ...

Page 81: ...e stored for more than two months check it at least once a month and fully charge it if necessary 3 Fully charge the battery before in stallation 4 After installation make sure that the battery leads are properly con nected to the battery terminals EC000102 CAUTION Always keep the battery charged Storing a discharged battery can cause permanent battery damage To charge a sealed type MF battery a s...

Page 82: ...er age rating than recommended to avoid causing extensive damage to the electrical system and possibly a fire 3 Turn the key to ON and turn on the electrical circuit in question to check if the device operates 4 If the fuse immediately blows again have a Yamaha dealer check the electrical system 1 Fuse block 2 Main fuse 3 Spare main fuse 1 Ignition fuse 2 Signaling system fuse 3 Headlight fuse 4 C...

Page 83: ...ler and then remove the headlight bulb cover 3 Unhook the headlight bulb holder and then remove the defective bulb EW000119 WARNING Headlight bulbs get very hot There fore keep flammable products away from a lit headlight bulb and do not touch the bulb until it has cooled down 4 Place a new bulb into position and then secure it with the bulb holder 1 Screw 2 1 Headlight coupler 2 Headlight bulb co...

Page 84: ... the coupler 6 Install the headlight unit by install ing the screws 7 Have a Yamaha dealer adjust the headlight beam if necessary EAU00855 Replacing a turn signal light bulb or the tail brake light bulb 1 Remove the lens by removing the screws 2 Remove the defective bulb by pushing it in and turning it counter clockwise 3 Insert a new bulb into the socket push it in and then turn it clock wise unt...

Page 85: ... for added stability To service the front wheel 1 Stabilize the rear of the motorcycle by using a motorcycle stand or if an additional motorcycle stand is not available by placing a jack un der the frame in front of the rear wheel 2 Raise the front wheel off the ground by using a motorcycle stand To service the rear wheel Raise the rear wheel off the ground by using a motorcycle stand or if a moto...

Page 86: ...TION Do not apply the brake after the wheel has been removed together with the brake disc otherwise the brake pads will be forced shut EAU03832 To install the front wheel 1 Install the speedometer gear unit into the wheel hub so that the pro jections mesh with the slots 2 Lift the wheel up between the fork legs NOTE _ Make sure that there is enough space between the brake pads before insert ing th...

Page 87: ...he motorcycle so that there is no danger of it falling over 1 Loosen the axle nut 2 Disconnect the brake torque rod from the brake shoe plate by re moving the bolt 3 Loosen the brake torque rod bolt at the swingarm 4 Remove the brake pedal free play adjusting nut and then disconnect the brake rod from the brake cam shaft lever 5 Remove panel A See page 6 6 for panel removal and installation proced...

Page 88: ... joint 2 Install the final gear case bolts and then tighten them to the spec ified torque 3 Install the brake rod onto the brake camshaft lever and then install the brake pedal free play adjusting nut onto the brake rod 4 Install the brake torque rod bolts and then tighten them to the spec ified torque 5 Install the panel 6 Lower the rear wheel so that it is on the ground 7 Tighten the axle nut to...

Page 89: ...use poor starting and loss of power The following troubleshooting chart represents a quick and easy procedure for checking these vital systems your self 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 Use only genuine Yamaha replace ment parts Imitation parts m...

Page 90: ...nition Have a Yamaha dealer check the vehicle Remove the spark plugs and check the electrodes 3 Ignition Wipe off with a dry cloth and correct the spark plug gaps or replace the spark plugs Have a Yamaha dealer check the vehicle The engine does not start Have a Yamaha dealer check the vehicle The engine does not start Check the battery Operate the electric starter 4 Battery The engine turns over q...

Page 91: ...MOTORCYCLE CARE AND STORAGE 7 Care 7 1 Storage 7 4 E_5bn book Page 1 Monday November 13 2000 9 11 AM ...

Page 92: ...ell 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 dirt and degreaser off with water Cleaning ECA00010 CAUTION Avoid using strong acidic wheel cleaners especially on ...

Page 93: ...or plastic may leave scratches on the wind shield Test the product on a small hidden part of the wind shield to make sure that it does not leave any marks If the wind shield is scratched use a quali ty plastic polishing compound after washing After normal use Remove dirt with warm water a mild detergent and a soft clean sponge and then rinse thoroughly with clean water Use a toothbrush or bottlebr...

Page 94: ...chrome and nickel plat ed 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 or covering it EWA00031 WARNING Make sure that there is no oil or wax on the brakes or tires If necessary clean the brake discs and brake linings with a regular brake ...

Page 95: ...nto the fuel tank 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 th...

Page 96: ...raded in one spot 8 Cover the muffler outlets with plas tic bags to prevent moisture from entering them 9 Remove the battery and fully charge it Store it in a cool dry place and charge it once a month Do not store the battery in an ex cessively cold or warm place less than 0 C or more than 30 C For more information on storing the battery see page 6 30 NOTE Make any necessary repairs before storing...

Page 97: ...SPECIFICATIONS 8 Specifications 8 1 Conversion table 8 6 E_5bn book Page 1 Monday November 13 2000 9 11 AM ...

Page 98: ... 1 625 mm Ground clearance 145 mm Minimum turning radius 3 400 mm Basic weight with oil and full fuel tank XVS650 233 kg XVS650A 247 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 classification AP...

Page 99: ...s Passenger car motor oils often labeled ENERGY CONSERVING II contain anti friction additives which will cause clutch and or starter clutch slippage result ing in reduced component life and poor engine performance Spark plug Manufacturer model NGK DPR7EA 9 or DENSO X22EPR U9 Gap 0 8 0 9 mm Clutch type Wet multiple disc Transmission Primary reduction system Spur gear Primary reduction ratio 1 789 S...

Page 100: ...t 200 kPa 2 00 kg cm2 2 00 bar Rear 250 kPa 2 50 kg cm2 2 50 bar Total weight of rider passenger cargo and accessories XVS650A Front Type Tube tire Size 130 90 16 67S Manufacturer model Bridgestone G703 Dunlop D404F Rear Type Tube tire Size 170 80 15 M C 77S Manufacturer model Bridgestone G702 Dunlop D404G Maximum load 200 kg Tire air pressure measured on cold tires Up to 90 kg Front 225 kPa 2 25 ...

Page 101: ...n Right foot Suspension Front Telescopic fork Rear Swingarm monocross Spring shock absorber Front Coil spring oil damper Rear Coil spring gas oil damper Wheel travel XVS650 Front 140 mm Rear 86 mm XVS650A Front 140 mm Rear 98 mm Electrical systems Ignition system Transistorized coil ignition digital Charging system Type A C magneto Standard output 14 V 20 A 5 000 r min Battery Type GT12B 4 Voltage...

Page 102: ...lighting 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 signal indicator light 12 V 1 7 W 1 Engine trouble warning light 12 V 1 7 W 1 Fuses Main fuse 30 A Ignition fuse 10 A Signaling system fuse 10 A Headlight fuse 15 A Carburetor heater fuse 15 A E_5bn book Page 5 Monday November 13 2000 9 11 AM ...

Page 103: ...etric 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 h 0 6214 mi h 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 L liter L liter 0 03527 0 06102 0 8799 0 2199 oz IMP liq cu in qt IMP liq gal IMP liq Miscellaneous kg mm kg cm2 Centigrade C 55...

Page 104: ...E_5bn book Page 7 Monday November 13 2000 9 11 AM ...

Page 105: ...ORMATION 9 Identification numbers 9 1 Key identification number 9 1 Vehicle identification number 9 1 Model label 9 2 Motorcycle noise regulation for Australia 9 2 E_5bn book Page 1 Monday November 13 2000 9 11 AM ...

Page 106: ...1E EAU01041 Key identification number The key identification number is stamped into the key tag Record this number in the space provided and use it for reference when ordering 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 y...

Page 107: ...tralia TAMPERING WITH NOISE CON TROL 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 ...

Page 108: ...dlight bulb replacing 6 32 Helmet holder 3 12 High beam indicator light 3 2 Horn switch 3 3 I Identification numbers 9 1 Idling speed adjusting 6 15 Ignition circuit cut off system 3 16 Indicator and warning lights 3 2 K Key identification number 9 1 L Labels location 1 7 Luggage strap holders 3 15 M Main switch steering lock 3 1 Model label 9 2 N Neutral indicator light 3 2 Noise regulation for A...

Page 109: ... 1 Troubleshooting 6 38 Troubleshooting chart 6 39 Turn signal indicator light 3 2 Turn signal light or tail brake light bulb replacing 6 33 Turn signal switch 3 3 V Valve clearance adjusting 6 16 Vehicle identification number 9 1 W Wheel bearings checking 6 29 Wheel front 6 35 Installing 6 35 Removing 6 35 Wheel rear 6 36 Installing 6 37 Removing 6 36 Wheels 6 18 E_5bn book Page 2 Monday November...

Page 110: ...F_5eb_Toc0 fm Page 2 Wednesday February 2 2000 2 02 PM ...

Page 111: ...F_5eb_Toc0 fm Page 2 Wednesday February 2 2000 2 02 PM ...

Page 112: ...PRINTED ON RECYCLED PAPER YAMAHA MOTOR CO LTD PRINTED IN JAPAN 2000 10 0 3 1 CR E 5BN 28199 21 XVS650 XVS650A OWNER S MANUAL ...

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