Yamaha 2007 V Star XVS650W Owner'S Manual Download Page 62 | Manualshive

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PERIODIC MAINTENANCE AND MINOR REPAIR

6-20

6

3. Tighten the locknut.

WARNING

EWA11230

After adjusting the brake pedal posi-
tion, the brake pedal free play must
be adjusted.

Brake pedal free play

The brake pedal free play should mea-
sure 20.0–30.0 mm (0.79–1.18 in) at
the brake pedal end. Periodically check
the brake pedal free play and, if neces-
sary, adjust it as follows.

To increase the brake pedal free play,
turn the adjusting nut at the brake rod in
direction (a). To decrease the brake
pedal free play, turn the adjusting nut in
direction (b).

EAU22270

Adjusting 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 brake light come on later, turn
the adjusting nut in direction (b).

1. Locknut
2. Brake pedal position adjusting bolt

1. Brake pedal free play adjusting nut

1. Brake light switch

2. Rear brake light switch adjusting nut

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Summary of Contents for 2007 V Star XVS650W

Page 1: ...3B7 28199 21 XVS650W XVS650AW OWNER S MANUAL ...

Page 2: ...U3B721E0 book Page 2 Wednesday March 15 2006 11 31 AM ...

Page 3: ...o enjoy all advantages of your XVS650W XVS650AW The own er s manual does not only instruct you in how to operate inspect and maintain your motorcycle but also in how to safeguard yourself and others from trouble and injury In addition the many tips given in this manual will help keep your motorcycle in the best possible condition If you have any further questions do not hesitate to contact your Ya...

Page 4: ...f you have any questions concerning this manual please consult your Yamaha dealer WARNING EWA10030 PLEASE READ THIS MANUAL CAREFULLY AND COMPLETELY BEFORE OPERATING THIS MOTORCYCLE Product and specifications are subject to change without notice The Safety Alert Symbol means ATTENTION BECOME ALERT YOUR SAFETY IS INVOLVED Failure to follow WARNING instructions could result in severe injury or death ...

Page 5: ...S MANUAL 2006 by Yamaha Motor Co Ltd 1st edition March 2006 All rights reserved Any reprinting or unauthorized use without the written permission of Yamaha Motor Co Ltd is expressly prohibited Printed in Japan U3B721E0 book Page 2 Wednesday March 15 2006 11 31 AM ...

Page 6: ...g fuel consumption 5 4 Engine break in 5 4 Parking 5 5 PERIODIC MAINTENANCE AND MINOR REPAIR 6 1 Owner s tool kit 6 1 Periodic maintenance and lubrication chart 6 2 Removing and installing panels 6 5 Checking the spark plugs 6 6 Engine oil and oil filter element 6 7 Final gear oil 6 10 Cleaning the air filter element 6 11 Adjusting the carburetors 6 13 Adjusting the engine idling speed 6 13 Checki...

Page 7: ...e light bulb 6 30 Replacing the auxiliary light bulb XVS650AW 6 31 Supporting the motorcycle 6 32 Front wheel 6 32 Rear wheel 6 34 Troubleshooting 6 35 Troubleshooting chart 6 36 MOTORCYCLE CARE AND STORAGE 7 1 Care 7 1 Storage 7 3 SPECIFICATIONS 8 1 CONSUMER INFORMATION 9 1 Identification numbers 9 1 Motorcycle noise regulation for Australia 9 2 U3B721E0 book Page 2 Wednesday March 15 2006 11 31 ...

Page 8: ...ts have been caused by an automobile driver who did not see the motorcycle Making yourself conspicuous appears to be very effective in reducing the chance of this type of accident Therefore Wear a brightly colored jacket Use extra caution when ap proaching and passing through intersections since intersec tions are the most likely places for motorcycle accidents to oc cur Ride where other motorists...

Page 9: ...e shield or goggles Wind in your unprotected eyes could contribute to an impairment of vision which could delay seeing a hazard The use of a jacket heavy boots trousers gloves etc is effective in preventing or reducing abrasions or lacerations Never wear loose fitting clothes otherwise they could catch on the control levers footrests or wheels and cause injury or an accident Never touch the engine...

Page 10: ...on when selecting and installing any ac cessories Keep the following guidelines in mind as well as those provided under Load ing when mounting accessories Never install accessories or carry cargo that would impair the perfor mance of your motorcycle Care fully inspect the accessory before using it to make sure that it does not in any way reduce ground clearance or cornering clearance limit suspens...

Page 11: ...ff before leaving the motorcycle unattended and remove the key from the main switch When parking the motor cycle note the following The engine and exhaust system may be hot therefore park the motorcycle in a place where pe destrians or children are not like ly to touch these hot areas Do not park the motorcycle on a slope or soft ground otherwise it may fall over Do not park the motorcycle near a ...

Page 12: ...SAFETY INFORMATION 1 5 1 EAU10381 Location of important labels Please read the following important labels carefully before operating this vehicle U3B721E0 book Page 5 Wednesday March 15 2006 11 31 AM ...

Page 13: ...SAFETY INFORMATION 1 6 1 3 XVS650W 3 XVS650AW 5FB 21668 01 U3B721E0 book Page 6 Wednesday March 15 2006 11 31 AM ...

Page 14: ...7 2 Fuel cock page 3 10 3 Starter choke knob page 3 11 4 Shock absorber assembly spring preload adjusting ring page 3 15 5 Helmet holder page 3 14 6 Storage compartment page 3 14 7 Owner s tool kit page 6 1 U3B721E0 book Page 1 Wednesday March 15 2006 11 31 AM ...

Page 15: ...ight view 1 Engine oil filter element page 6 7 2 Battery page 6 27 3 Fuses page 6 28 4 Main switch steering lock page 3 2 5 Air filter element page 6 11 6 Brake pedal page 3 8 U3B721E0 book Page 2 Wednesday March 15 2006 11 31 AM ...

Page 16: ...s 1 Clutch lever page 3 7 2 Left handlebar switches page 3 5 3 Speedometer unit page 3 5 4 Fuel tank cap page 3 8 5 Right handlebar switches page 3 5 6 Throttle grip page 6 14 7 Brake lever page 3 8 U3B721E0 book Page 3 Wednesday March 15 2006 11 31 AM ...

Page 17: ...Y IF IT IS LOST If the code re reg istering key is lost registering new codes in the standard keys is impossible The standard keys can still be used to start the vehicle however if code re registering is required i e if a new standard key is made or all keys are lost the entire immobi lizer system must be replaced Therefore it is highly recom mended to use either standard key and keep the code re ...

Page 18: ...istering key red bow keep it in a safe place and only use it for code re registering EAU10480 ON XVS650W All electrical systems are supplied with power and the headlight meter lighting and taillight come on and the engine can be started The key cannot be re moved EAU33590 ON XVS650AW All electrical circuits are supplied with power the meter lighting taillight and auxiliary light come on and the en...

Page 19: ...s moving otherwise the electrical systems will be switched off which may result in loss of control or an accident Make sure that the vehicle is stopped be fore turning the key to OFF or LOCK EAU33001 Parking XVS650AW The steering is locked and the taillight and auxiliary light are on The hazard lights and turn signal lights can be turned on but all other electrical sys tems are off The key can be ...

Page 20: ... come on for a few seconds then go off have a Yamaha dealer check the electrical cir cuit When the key is turned to OFF and 30 seconds have passed the indicator light will start flashing indicating the im mobilizer system is enabled After 24 hours have passed the indicator light will stop flashing however the immobi lizer system is still enabled NOTE This model is also equipped with a self diagnos...

Page 21: ... 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 last set to zero with the reset knob The tripmeter can be used to estimate the distance that can be traveled with a full tank of fuel This information will en able you to plan future fue...

Page 22: ... to stop the engine in case of an emergen cy such as when the vehicle overturns or when the throttle cable is stuck EAU12710 Start switch Push this switch to crank the engine with the starter CAUTION ECA10050 See page 5 1 for starting instruc tions prior to starting the engine EAU12733 Hazard switch XVS650AW With the key in the ON or posi tion use this switch to turn on the haz ard lights simultan...

Page 23: ...U12870 Shift pedal XVS650W The shift pedal is located on the left side of the engine and is used in com bination with the clutch lever when shifting the gears of the 5 speed con stant mesh transmission equipped on this motorcycle EAU12880 Shift pedal XVS650AW The shift pedal is located on the left side of the engine and is used in com bination with the clutch lever when shifting the gears of the 5...

Page 24: ...n the brake pedal EAU13120 Fuel tank cap To remove the fuel tank cap Slide the lock cover open insert the key into the lock and then turn it 1 4 turn clockwise The lock will be released and the fuel tank cap can be removed To install the fuel tank cap 1 Insert the fuel tank cap into the tank opening with the key inserted in the lock and with the mark facing forward 1 Brake lever 1 Brake pedal 1 Br...

Page 25: ...nd expands Avoid spilling fuel on the hot en gine CAUTION ECA10070 Immediately wipe off spilled fuel with a clean dry soft cloth since fuel may deteriorate painted surfac es or plastic parts EAU13330 CAUTION ECA11400 Use only unleaded gasoline The use of leaded gasoline will cause severe damage to internal engine parts such as the valves and piston rings as well as to the exhaust system Your Yamah...

Page 26: ...s follows and shown in the il lustrations 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 ON With the fuel cock lever in this position fuel flows to the carburetors Turn the fuel cock lever to this position when starting the engine and riding RES 1 Arrow mark positioned over OFF 1 Arrow mark positione...

Page 27: ... to turn off the starter choke CAUTION ECA10990 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 EAU14184 Seats XVS650W Passenger seat To remove the passenger seat Remove the nut and washer and then pull the passenger seat up To i...

Page 28: ...ger seat NOTE Make sure that the seats are properly secured before riding EAU14191 Seats XVS650AW Passenger seat To remove the passenger seat Remove the nut and washer and then pull the passenger seat up To install the passenger seat 1 Insert the projections on the front of the passenger seat into the holders as shown and place the seat in the original position 2 Install the washer and nut and the...

Page 29: ...tion on the front of the rider seat into the holder as shown place the seat in the origi nal position and then install the bolt 2 Install the passenger seat NOTE Make sure that the seats are properly secured before riding Tightening torque Passenger seat nut 13 Nm 1 3 m kgf 9 4 ft lbf 1 Seat holder 2 Projection 1 Bolt 1 Seat holder 2 Projection U3B721E0 book Page 13 Wednesday March 15 2006 11 31 A...

Page 30: ...torage compartment is located on the left side of the vehicle To open the storage compartment 1 Slide the lock cover open insert the key into the lock and then 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...

Page 31: ... owner s tool kit to make the adjustment 3 Install the passenger and rider seats WARNING EWA10220 This shock absorber contains highly pressurized nitrogen gas For prop er handling read and understand the following information before handling the shock absorber The manufacturer cannot be held re sponsible for property damage or personal injury that may result from improper handling Do not tamper wi...

Page 32: ...e ignition circuit cut off system WARNING EWA10240 The vehicle must not be ridden with the sidestand down or if the side stand cannot be properly moved up or does not stay up otherwise the sidestand could contact the ground and distract the operator resulting in a possible loss of control Yamaha s ignition circuit cut off system has been designed to assist the operator in fulfilling the respon sib...

Page 33: ...e clutch lever is not pulled It prevents starting when the trans mission is in gear and the clutch le ver is pulled but the sidestand is still down It cuts the running engine when the transmission is in gear and the sid estand is moved down Periodically check the operation of the ignition circuit cut off system according to the following procedure WARNING EWA10250 If a malfunction is noted have a ...

Page 34: ... 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 system is OK The motorcycle can be ridden This check is most reliable if performed with a warmed up engine The neutral switch may be defective The motorcycle should not be ridden until checked by a Yamaha dealer The sidestand switch may be defective The motorcycle sho...

Page 35: ...uences Therefore it is very important in addition to a thorough visual inspec tion to check the following points before each ride NOTE Pre operation checks should be made each time the vehicle is used Such an inspection can be accomplished in a very short time and the added safety it assures is more than worth the time involved WARNING EWA11150 If any item in the Pre operation check list is not wo...

Page 36: ...Check brake pads for wear Replace if necessary Check fluid level in reservoir If necessary add recommended brake fluid to specified level Check hydraulic system for leakage 6 18 6 21 6 21 Rear brake Check operation Check pedal free play Adjust if necessary 6 19 6 21 Clutch Check operation Lubricate cable if necessary Check lever free play Adjust if necessary 6 17 Throttle grip Make sure that opera...

Page 37: ...oth Lubricate lever pivoting points if necessary 6 24 Sidestand Make sure that operation is smooth Lubricate pivot if necessary 6 25 Chassis fasteners Make sure that all nuts bolts and screws are properly tightened Tighten if necessary Instruments lights signals and switches Check operation Correct if necessary Sidestand switch Check operation of ignition circuit cut off system If system is defect...

Page 38: ...pulled and the sid estand up WARNING EWA10290 Before starting the engine check the function of the igni tion circuit cut off system ac cording to the procedure described on page 3 17 Never ride with the sidestand down 1 Turn the fuel cock lever to ON 2 Turn the key to ON and make sure that the engine stop switch is set to 3 Shift the transmission into the neu tral position NOTE When the transmissi...

Page 39: ...he elec trical circuit If the indicator light flashes after starting have a Yamaha dealer check the self diagnosis system 6 After starting the engine move the starter choke back halfway CAUTION ECA11130 For maximum engine life always warm the engine up before starting off Never accelerate hard when the engine is cold 7 When the engine is warm turn the starter choke off NOTE The engine is warm when...

Page 40: ...ly raise it CAUTION ECA10260 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 damag ing the engine transmission an...

Page 41: ...uld read the follow ing material carefully Since the engine is brand new do not put an excessive load on it for the first 1600 km 1000 mi The various parts in the engine wear and polish themselves to the correct operating clearances During this period prolonged full throt tle operation or any condition that might result in engine overheating must be avoided EAU17041 0 1000 km 0 600 mi Avoid prolon...

Page 42: ...tch and then turn the fuel cock lever to OFF WARNING EWA10310 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 vehicle may overturn U3B721E0 book Page 5 Wednesday March 15 2006 11 31 AM ...

Page 43: ... familiar with mainte nance work have a Yamaha dealer do it for you EAU17450 Owner s tool kit The owner s tool kit is located inside the storage compartment See page 3 14 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 How ever additional tools such as a torque w...

Page 44: ... NO ITEM CHECK OR MAINTENANCE JOB ODOMETER READING 1000 km ANNUAL CHECK 1 10 20 30 40 1 Fuel line Check fuel hoses for cracks or damage 2 Fuel filter Check condition 3 Spark plugs Check condition Clean and regap Replace 4 Valves Check valve clearance Adjust 5 Air filter element Clean Replace 6 Clutch Check operation Adjust 7 Front brake Check operation fluid level and vehicle for fluid leakage Rep...

Page 45: ... bearing play and steering for roughness Lubricate with lithium soap based grease Every 20000 km 15 Chassis fasteners Make sure that all nuts bolts and screws are properly tightened 16 Sidestand Check operation Lubricate 17 Sidestand switch Check operation 18 Front fork Check operation and for oil leakage 19 Shock absorber assem bly Check operation and shock absorber for oil leakage 20 Carburetors...

Page 46: ...2 Engine oil filter element Replace 23 Final gear oil Check oil level and vehicle for oil leakage Change 24 Front and rear brake switches Check operation 25 Moving parts and ca bles Lubricate 26 Throttle grip housing and cable Check operation and free play Adjust the throttle cable free play if necessary Lubricate the throttle grip housing and cable 27 Muffler and exhaust pipe Check the screw clam...

Page 47: ...apter Refer to this section each time a panel needs to be removed and installed XVS650W XVS650AW EAU19193 Panel A To remove the panel Remove the bolts and then take the panel off XVS650W XVS650AW To install the panel Place the panel in the original position and then install the bolts 1 Panel A 1 Panel A 1 Panel B 1 Bolt 1 Bolt U3B721E0 book Page 5 Wednesday March 15 2006 11 31 AM ...

Page 48: ... 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 when the vehicle is ridden normally 2 Check that all spark...

Page 49: ...he spark plug cap EAU19742 Engine oil and oil filter ele ment The engine oil level should be checked before each ride In addition the oil must be changed and the oil filter ele ment replaced at the intervals specified in the periodic maintenance and lubri cation chart To check the engine oil level 1 Place the vehicle on a level sur face and hold it in an upright posi tion NOTE Make sure that the v...

Page 50: ...ral minutes and then turn it off 2 Place an oil pan under the engine to collect the used oil 3 Remove the engine oil filler cap and drain bolt to drain the oil from the crankcase NOTE Skip steps 4 7 if the oil filter element is not being replaced 4 Remove the outer and inner oil fil ter element covers by removing the bolts 1 Engine oil level check window 2 Maximum level mark 3 Minimum level mark 4...

Page 51: ... use oils with a diesel speci fication of CD or oils of a high er quality than specified In addition do not use oils labeled ENERGY CONSERVING II or higher Make sure that no foreign mate rial enters the crankcase 10 Start the engine and then let it idle for several minutes while checking it for oil leakage If oil is leaking im mediately turn the engine off and check for the cause 1 Inner oil filte...

Page 52: ... final gear oil level 1 Place the vehicle on a level sur face and hold it in an upright posi tion NOTE The final gear oil level must be checked on a cold engine Make sure that the vehicle is posi tioned straight up when checking the oil level A slight tilt to the side can result in a false reading 2 Remove the oil filler bolt and then check the oil level in the final gear case NOTE The oil level s...

Page 53: ... be cleaned at the intervals specified in the periodic maintenance and lubrication chart Clean the air filter element more fre quently if you are riding in unusually wet or dusty areas 1 Remove the air filter case cover by removing the bolts 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 compresse...

Page 54: ...r ele ment installed otherwise the piston s and or cylinder s may become excessively worn 5 Install the air filter case cover by aligning the match marks and in stalling the bolts NOTE If dust or water collects in the air filter check hose remove the clamp from it and then remove the plug to drain the hose 1 Air filter element 1 Air filter element holder 2 Projection 3 Slot 1 Match marks 1 Air fil...

Page 55: ...ine idling speed The engine idling speed must be checked and if necessary adjusted as follows at the intervals specified in the periodic maintenance and lubrication chart The engine should be warm before making this adjustment NOTE The engine is warm when it quickly responds to the throttle A diagnostic tachometer is needed to make this adjustment 1 Attach the tachometer to the spark plug lead 2 C...

Page 56: ...cified in the periodic maintenance and lubrication chart EAU32771 Tires To maximize the performance durabil ity and safe operation of your motor cycle note the following points regarding the specified tires Tire air pressure The tire air pressure should be checked and if necessary adjusted before each ride WARNING EWA10500 The tire air pressure must be checked and adjusted on cold tires i e when t...

Page 57: ...ire damage an accident or even injury 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 Tire air pressure measured on cold tires 0 90 kg 0 198 lb Front XVS650AW 225 kPa 33 psi 2 2...

Page 58: ...t as soon as possible with a high quality product Tire information This motorcycle is equipped with spoke wheels and tube tires WARNING EWA10460 The front and rear tires should be of the same make and de sign otherwise the handling characteristics of the vehicle cannot be guaranteed After extensive tests only the tires listed below have been ap proved for this model by Yamaha Motor Co Ltd Front ti...

Page 59: ... it to develop its optimal characteris tics EAU22041 Adjusting the clutch lever free play The clutch lever free play should mea sure XVS650AW 5 0 10 0 mm 0 20 0 39 in XVS650W 10 0 15 0 mm 0 39 0 59 in as shown Periodically check the clutch lever free play and if necessary adjust it as follows 1 Loosen the locknut at the clutch le ver 2 To increase the clutch lever free play turn the adjusting bolt...

Page 60: ...r free play and if necessary adjust it as follows 1 Loosen the locknut at the brake le ver 2 To increase the brake lever free play turn the adjusting screw in di rection a To decrease the brake lever free play turn the adjusting screw in direction b 3 Tighten the locknut WARNING EWA10630 After adjusting the brake lever free play check the free play and make sure that the brake is working properly ...

Page 61: ... should be ad justed before adjusting the brake pedal free play Brake pedal position The brake pedal should be positioned approximately XVS650AW 108 0 mm 4 25 in XVS650W 82 0 mm 3 23 in above the top of the footrest as shown Periodical ly 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 i...

Page 62: ...djusting nut in direction b EAU22270 Adjusting 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 t...

Page 63: ...k 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 brake shoe has worn to the point that the wear indicator reaches the wear limit line have a Yamaha dealer replace the brake shoes as a set EAU32343 Checking the front brake fluid level Insufficient brake fluid may allow air to enter the ...

Page 64: ...ock Brake fluid may deteriorate paint ed surfaces or plastic parts Al ways clean up spilled fluid immediately As the brake pads wear it is nor mal for the brake fluid level to grad ually go down However if the brake fluid level goes down sud denly have a Yamaha dealer check the cause EAU22720 Changing the brake fluid Have a Yamaha dealer change the brake fluid at the intervals specified in the NOT...

Page 65: ...n and will cause the inner cable to rust Replace a damaged cable as soon as possible to prevent unsafe conditions EAU23111 Checking and lubricating the throttle grip and cable The operation of the throttle grip should be checked before each ride In addi tion the cable should be lubricated at the intervals specified in the periodic maintenance chart EAU23131 Checking and lubricating the brake and s...

Page 66: ...ver 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 Lithium soap based grease all pur pose grease Recommended lubricant Lithium soap based grease all pur pose grease U3B721E0 book Page 24 Wednesday March 15 2006 11 31 AM ...

Page 67: ...dic main tenance and lubrication chart To check the condition WARNING EWA10750 Securely support the vehicle so that there is no danger of it falling over Check the inner tubes for scratches damage and excessive oil leakage To check the operation 1 Place the vehicle on a level sur face and hold it in an upright posi tion 2 While applying the front brake push down hard on the handlebars several time...

Page 68: ...support the vehicle so that there is no danger of it falling over 2 Hold the lower ends of the front fork legs and try to move them for ward and backward If any free play can be felt have a Yamaha dealer check or repair the steering EAU23290 Checking the wheel bearings The front and rear wheel bearings must be checked at the intervals specified in the periodic maintenance and lubrica tion chart If...

Page 69: ... call a physician EYES Flush with water for 15 minutes and seek prompt medical attention Batteries produce explosive hy drogen gas Therefore keep sparks flames cigarettes etc away from the battery and pro vide sufficient ventilation when charging it in an enclosed space KEEP THIS AND ALL BATTER IES OUT OF THE REACH OF CHILDREN To store the battery 1 If the model will not be used for more than one ...

Page 70: ...nd panel B See page 6 5 If a fuse is blown replace it as follows 1 Turn the key to OFF and turn off the electrical circuit in question 2 Remove the blown fuse and then install a new fuse of the specified amperage 1 Fuse box 2 Main fuse 3 Spare main fuse 1 Headlight fuse 2 Signaling system fuse 3 Ignition fuse 4 Carburetor heater fuse 5 Parking lighting fuse for XVS650AW only 6 Backup fuse for odom...

Page 71: ...s equipped with a quartz bulb headlight If the headlight bulb burns out replace it as follows 1 Remove the headlight unit by re moving the screws 2 Disconnect the headlight coupler and then remove the bulb cover 3 Remove the headlight bulb holder by turning it counterclockwise and then remove the defective bulb Specified fuses Main fuse 30 0 A Signaling system fuse 10 0 A Ignition fuse 10 0 A Head...

Page 72: ...the glass the luminosity of the bulb and the bulb life will be adversely af fected Thoroughly clean off any dirt and fingerprints on the headlight bulb using a cloth moistened with al cohol or thinner 5 Install the headlight bulb cover and then connect the coupler 6 Install the headlight unit by install ing the screws 7 Have a Yamaha dealer adjust the headlight beam if necessary EAU24281 Replacing...

Page 73: ... light bulb burns out re place it as follows 1 Remove the headlight unit by re moving the screws 2 Remove the socket together with the bulb by pushing it in and turn ing it counterclockwise 3 Remove the defective bulb by pushing it in and turning it counter clockwise 4 Insert a new bulb into the socket push it in and then turn it clock wise until it stops 5 Install the socket together with the bul...

Page 74: ...e 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 motor cycle stand is not available by placing a jack either under each side of the frame in front of the rear wheel or under each side of the swingarm EAU24360 Front wheel...

Page 75: ...s before insert ing the brake disc and that the slot in the speedometer gear unit fits over the retainer on the fork leg 3 Insert the wheel axle 4 Lower the front wheel so that it is on the ground 5 Tighten the wheel axle to the spec ified torque 6 Tighten the front wheel axle pinch bolt to the specified torque 7 While applying the front brake push down hard on the handlebars several times to chec...

Page 76: ...nnect the brake rod from the brake cam shaft lever 5 Remove panel A See page 6 5 6 Remove the bolts that secure the final gear case to the swingarm 7 Lift the rear wheel off the ground according to the procedure on page 6 32 8 While supporting the drive shaft pull the rear wheel back to remove the following parts as an assem bly wheel wheel axle final gear case and drive shaft NOTE Make sure to su...

Page 77: ...ht EAU25850 Troubleshooting Although Yamaha motorcycles receive a thorough inspection before shipment from the factory trouble may occur dur ing operation Any problem in the fuel compression or ignition systems for example can cause 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 you...

Page 78: ...tion 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 qui...

Page 79: ...ave the cleaner on the af fected area any longer than in structed Also thoroughly rinse the area off with water immedi ately dry it and then apply a cor rosion protection spray Improper cleaning can damage windshields cowlings panels and other plastic parts Use only a soft clean cloth or sponge with mild detergent and water to clean plastic Do not use any harsh chemical products on plastic parts B...

Page 80: ... After cleaning 1 Dry the motorcycle with a chamois or an absorbing cloth 2 Use a chrome polish to shine chrome aluminum and stainless steel parts including the exhaust system Even the thermally in duced discoloring of stainless steel exhaust systems can be re moved through polishing 3 To prevent corrosion it is recom mended to apply a corrosion pro tection spray on all metal including chrome and ...

Page 81: ... that has an OFF posi tion Turn the fuel cock lever to OFF 3 Drain the carburetor float cham bers by loosening the drain bolts this will prevent fuel deposits from building up Pour the drained fuel into 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 cylind...

Page 82: ...ls are off the ground Alterna tively turn the wheels a little every month in order to prevent the tires from becoming degraded 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 3...

Page 83: ...r SAE20W50 Recommended engine oil grade API service SE SF SG type or higher Engine oil quantity Without oil filter element replacement 2 60 L 2 75 US qt 2 29 Imp qt With oil filter element replacement 2 80 L 2 96 US qt 2 46 Imp qt Final gear oil Type SAE80 API GL 4 Hypoid gear oil Quantity 0 19 L 0 20 US qt 0 17 Imp qt Air filter Air filter element Dry element Fuel Recommended fuel Unleaded gasoli...

Page 84: ...W DUNLOP D404G XVS650W DUNLOP K555 Loading Maximum load XVS650AW 200 kg 441 lb XVS650W 180 kg 397 lb Total weight of rider passenger cargo and accessories Tire air pressure measured on cold tires Loading condition 0 90 kg 0 198 lb Front XVS650AW 225 kPa 33 psi 2 25 kgf cm XVS650W 200 kPa 29 psi 2 00 kgf cm Rear 225 kPa 33 psi 2 25 kgf cm Loading condition XVS650AW 90 200 kg 198 441 lb XVS650W 90 1...

Page 85: ... voltage wattage quantity Headlight 12 V 60 W 55 0 W 1 Tail brake light 12 V 5 0 W 21 0 W 1 Front turn signal light 12 V 21 0 W 2 Rear turn signal light 12 V 21 0 W 2 Auxiliary light XVS650AW 12 V 4 0 W 1 Meter 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 Immobili...

Page 86: ...NFORMATION EAU26381 Key identification number XVS650W XVS650AW 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 EAU26400 Vehicle identification number The vehicle identification number is stamped into the steering head pipe Record this number in the space pro vided 1 Key identification number 1 Key i...

Page 87: ...26570 Motorcycle noise regulation for Australia 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 ultim...

Page 88: ...or light 3 4 Horn switch 3 6 I Identification numbers 9 1 Ignition circuit cut off system 3 17 Immobilizer system indicator light XVS650AW 3 4 Immobilizer system XVS650AW 3 1 Indicator and warning lights 3 4 K Key identification number 9 1 L Labels location of 1 5 Luggage strap holders 3 16 M Main switch steering lock XVS650AW 3 2 Main switch steering lock XVS650W 3 2 Model label 9 2 N Neutral ind...

Page 89: ...ing chart 6 36 Turn signal indicator light 3 4 Turn signal light bulb or tail brake light bulb replacing 6 30 Turn signal switch 3 6 V Valve clearance 6 14 Vehicle identification number 9 1 W Wheel bearings checking 6 26 Wheel front 6 32 Wheel rear 6 34 Wheels 6 17 U3B721E0 book Page 2 Wednesday March 15 2006 11 31 AM ...

Page 90: ...A5 yoko_Blank fm Page 1 Tuesday April 8 2003 11 43 AM ...

Page 91: ...A5 yoko_Blank fm Page 1 Tuesday April 8 2003 11 43 AM ...

Page 92: ...PRINTED ON RECYCLED PAPER YAMAHA MOTOR CO LTD PRINTED IN JAPAN 2006 03 0 3 1 CR E ...

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