Yamaha 2010 V Star XVS650AZ Owner'S Manual Download | Manualshive

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PERIODIC MAINTENANCE AND ADJUSTMENT

7-20

7

●

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 system will dimin-
ish the braking performance,
which may result in loss of con-
trol and an accident.

EAU22231

Adjusting the brake pedal po-
sition and free play

XVS650Z

XVS650AZ

WARNING

EWA10670

It is advisable to have a Yamaha
dealer make these adjustments.

TIP

The brake pedal position should be ad-
justed before adjusting the brake pedal
free play.

Brake pedal position

The brake pedal should be positioned
approximately XVS650AZ 108.0 mm
(4.25 in)
XVS650Z 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 in direction (a). To
lower the brake pedal, turn the ad-
justing bolt in direction (b).

1. Distance between brake pedal and footrest
2. Brake pedal free play

1. Distance between brake pedal and footrest

2. Brake pedal free play

U1BF20E0.book Page 20 Thursday, April 9, 2009 9:10 AM

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Summary of Contents for 2010 V Star XVS650AZ

Page 1: ...DIC183 XVS650Z XVS650AZ OWNER S MANUAL Read this manual carefully before operating this vehicle 1BF 28199 20 ...

Page 2: ...EAU46090 Read this manual carefully before operating this vehicle This manual should stay with this vehicle if it is sold U1BF20E0 book Page 1 Thursday April 9 2009 9 10 AM ...

Page 3: ...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 Yamaha dealer The Yamaha team wishes you many safe and pleasant rides So remember to put safety first Yamaha continually seeks advancements in product design and quality Therefore while this manual contains the mos...

Page 4: ...ey all safety messages that follow this symbol to avoid possible injury or death A WARNING indicates a hazardous situation which if not avoided could result in death or serious injury A NOTICE indicates special precautions that must be taken to avoid damage to the vehicle or other property A TIP provides key information to make procedures easier or clearer WARNING NOTICE TIP U1BF20E0 book Page 1 T...

Page 5: ... S MANUAL 2009 by Yamaha Motor Co Ltd 1st edition April 2009 All rights reserved Any reprinting or unauthorized use without the written permission of Yamaha Motor Co Ltd is expressly prohibited Printed in Japan U1BF20E0 book Page 2 Thursday April 9 2009 9 10 AM ...

Page 6: ...a warm engine 6 2 Shifting 6 2 Tips for reducing fuel consumption 6 3 Engine break in 6 3 Parking 6 4 PERIODIC MAINTENANCE AND ADJUSTMENT 7 1 Owner s tool kit 7 1 Periodic maintenance chart for the emission control system 7 2 General maintenance and lubrication chart 7 3 Removing and installing panels 7 7 Checking the spark plugs 7 8 Engine oil and oil filter element 7 9 Final gear oil 7 12 Cleani...

Page 7: ... headlight bulb 7 30 Replacing a turn signal light bulb or the tail brake light bulb 7 31 Replacing the auxiliary light bulb XVS650AZ 7 32 Supporting the motorcycle 7 32 Front wheel 7 33 Rear wheel 7 34 Troubleshooting 7 36 Troubleshooting chart 7 37 MOTORCYCLE CARE AND STORAGE 8 1 Matte color caution 8 1 Care 8 1 Storage 8 3 SPECIFICATIONS 9 1 CONSUMER INFORMATION 10 1 Identification numbers 10 1...

Page 8: ...cle They contain important information for safe and proper operation of your vehicle Never remove any labels from your vehicle If a label becomes difficult to read or comes off a replacement label is available from your Yamaha dealer 1 2 3 4 1 2 U1BF20E0 book Page 1 Thursday April 9 2009 9 10 AM ...

Page 9: ... kPa 2 50 kgf cm 36 psi 3B6 21668 00 TIRE INFORMATION Cold tire normal pressure should be set as follows Up to 90 kg 198 lbs load FRONT REAR 225 kPa 2 25 kgf cm 33 psi 225 kPa 2 25 kgf cm 33 psi 90kg 198 lbs maximum load FRONT REAR 225 kPa 2 25 kgf cm 33 psi 250 kPa 2 50 kgf cm 36 psi 1BF 21668 00 4 STATIONARY NOISE TEST INFORMATION TESTED 86 dB A AT 3250 r min SILENCINGSYSTEM YAMAHA IDENTIFICATIO...

Page 10: ...assenger The failure of motorists to detect and recognize motorcycles in traf fic is the predominating cause of automobile motorcycle accidents Many accidents 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 ...

Page 11: ...d contribute to an impairment of vision that 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 Always wear protective clothing that covers your legs ankles and feet The eng...

Page 12: ... evenly as possi ble on both sides of the motorcycle to minimize imbalance or instabili ty Shifting weights can create a sud den imbalance Make sure that ac cessories and cargo are securely attached to the motorcycle before riding Check accessory mounts and cargo restraints frequently Properly adjust the suspension for your load suspension ad justable models only and check the condition and pres s...

Page 13: ...ork area can create instability due to improper weight distribution or aerody namic changes If accessories are added to the handlebar or front fork area they must be as lightweight as possible and should be kept to a minimum Bulky or large accessories may seriously affect the stability of the motorcycle due to aerody namic effects Wind may at tempt to lift the motorcycle or the motorcycle may beco...

Page 14: ... 8 2 Fuel cock page 4 11 3 Starter choke knob page 4 12 4 Shock absorber assembly spring preload adjusting ring page 4 16 5 Helmet holder page 4 15 6 Storage compartment page 4 15 7 Owner s tool kit page 7 1 U1BF20E0 book Page 1 Thursday April 9 2009 9 10 AM ...

Page 15: ... Right view 1 Engine oil filter element page 7 9 2 Battery page 7 27 3 Fuses page 7 29 4 Main switch steering lock page 4 2 5 Air filter element page 7 13 6 Brake pedal page 4 9 U1BF20E0 book Page 2 Thursday April 9 2009 9 10 AM ...

Page 16: ...ts 1 Clutch lever page 4 7 2 Left handlebar switches page 4 6 3 Speedometer unit page 4 5 4 Fuel tank cap page 4 9 5 Right handlebar switches page 4 6 6 Throttle grip page 7 15 7 Brake lever page 4 8 U1BF20E0 book Page 3 Thursday April 9 2009 9 10 AM ...

Page 17: ...DEALER IMMEDIATELY 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 ...

Page 18: ...o lock the steering The various positions are described below EAU10471 Main switch steering lock XVS650AZ The main switch steering lock controls the ignition and lighting systems and is used to lock the steering TIP Be sure to use the standard key black bow for regular use of the vehicle To minimize the risk of losing the code re registering key red bow keep it in a safe place and only use it for ...

Page 19: ...061 Never turn the key to OFF or LOCK while the vehicle is moving Otherwise the electrical systems will be switched off which may result in loss of control or an accident EAU10681 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 ...

Page 20: ...n EAU11505 Engine trouble warning light This warning light comes on or flashes if a problem is detected in the electrical circuit monitoring the engine If this oc curs have a Yamaha dealer check the self diagnosis system See page 4 6 for an explanation of the self diagnosis device The electrical circuit of the warning light can be checked by turning the key to ON The warning light should come on f...

Page 21: ... flashes two times repeatedly this error could be caused by signal in terference If this occurs try the follow ing 1 Use the code re registering key to start the engine TIP Make sure there are no other immobi lizer keys close to the main switch and do not keep more than one immobilizer key on the same key ring Immobilizer system keys may cause signal interfer ence which may prevent the engine from...

Page 22: ...ossible if this occurs EAU12348 Handlebar switches Left Right XVS650Z Right XVS650AZ EAU12350 Pass switch Press this switch to flash the headlight EAU12400 Dimmer switch Set this switch to for the high beam and to for the low beam EAU12460 Turn signal switch To signal a right hand turn push this switch to To signal a left hand turn push this switch to When re leased the switch returns to the cente...

Page 23: ... use this switch to turn on the haz ard lights simultaneous flashing of all turn signal lights The hazard lights are used in case of an emergency or to warn other drivers when your vehicle is stopped where it might be a traffic hazard NOTICE ECA10061 Do not use the hazard lights for an extended length of time with the en gine not running otherwise the bat tery may discharge EAU12820 Clutch lever T...

Page 24: ...ocated 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 TIP Use your toes or heel to shift up and your toes to shift down EAU12890 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 1 Shift ...

Page 25: ...ap 1 Insert the fuel tank cap into the tank opening with the key inserted in the lock and with the mark facing forward 2 Turn the key counterclockwise to the original position remove it and then close the lock cover TIP 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 WARNING EWA10131 Make sure...

Page 26: ...sure to securely close the fuel tank cap WARNING EWA15151 Gasoline is poisonous and can cause injury or death Handle gaso line with care Never siphon gaso line by mouth If you should swallow some gasoline or inhale a lot of gas oline vapor or get some gasoline in your eyes see your doctor immedi ately If gasoline spills on your skin wash with soap and water If gaso line spills on your clothing cha...

Page 27: ...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 This indicates 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 ...

Page 28: ...ke EAU14184 Seats XVS650Z 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 projection on the front of the passenger seat into the seat holder as shown and place the seat in the original position 2 Install the washer and nut and then tighten the nut to the specified torque Rider seat To remove the ri...

Page 29: ...properly secured before riding EAU14192 Seats XVS650AZ 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 then tighten the nut to the specified torque 1...

Page 30: ...n 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 TIP 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 Passenger seat holder 2 Projection 1 Bolt 1 Seat holder 2 Projection U1BF20E0 book Page 14 Thursday April 9 2009 9 1...

Page 31: ...storage 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 loc...

Page 32: ...d in the owner s tool kit to make the adjustment 3 Install the passenger and rider seats WARNING EWA10221 This shock absorber assembly con tains highly pressurized nitrogen gas Read and understand the fol lowing information before handling the shock absorber assembly Do not tamper with or attempt to open the cylinder assembly Do not subject the shock ab sorber assembly to an open flame or other hi...

Page 33: ... 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 sibi...

Page 34: ...nd is up but the 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 TIP This check is most reliable if ...

Page 35: ... 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 The neutral switch may not be working correctly The motorcycle should not be ridden until checked by a Yamaha dealer The sidestand switch may not be working correctly The motorcycle should not be ridden until checked by a Yamaha dealer The clutch switc...

Page 36: ...g this vehicle check the following points ITEM CHECKS PAGE Fuel Check fuel level in fuel tank Refuel if necessary Check fuel line for leakage 4 10 Engine oil Check oil level in engine If necessary add recommended oil to specified level Check vehicle for oil leakage 7 9 Final gear oil Check vehicle for oil leakage 7 12 Front brake Check operation If soft or spongy have Yamaha dealer bleed hydraulic...

Page 37: ...ssary 7 16 7 18 Brake and shift pedals Make sure that operation is smooth Lubricate pedal pivoting points if necessary 7 24 Brake and clutch levers Make sure that operation is smooth Lubricate lever pivoting points if necessary 7 25 Sidestand Make sure that operation is smooth Lubricate pivot if necessary 7 25 Chassis fasteners Make sure that all nuts bolts and screws are properly tightened Tighte...

Page 38: ...sure that the engine stop switch is set to 3 Shift the transmission into the neu tral position See page 6 2 The neutral indicator light should come on If not ask a Yamaha dealer to check the electrical circuit 4 Turn the starter choke on and completely close the throttle See page 4 12 5 Start the engine by pushing the start switch If the engine fails to start release the start switch wait a few se...

Page 39: ...smission into the neu tral position press the shift pedal down repeatedly until it reaches the end of its travel and then slightly raise it NOTICE 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 l...

Page 40: ...t railroad crossings EAU16841 Engine break in There is never a more important period in the life of your engine than the period between 0 and 1600 km 1000 mi For this reason you should 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 operati...

Page 41: ...171 Parking When parking stop the engine remove the key from the main switch and then turn the fuel cock lever to OFF WARNING EWA10311 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 and be burned Do not park on a slope or on soft ground otherwise the vehicle may overturn increasing the risk of a fuel leak and fire...

Page 42: ...th vehicle ser vice have a Yamaha dealer perform service WARNING EWA15121 Turn off the engine when performing maintenance unless otherwise specified A running engine has moving parts that can catch on body parts or clothing and electrical parts that can cause shocks or fires Running the engine while ser vicing can lead to eye injury burns fire or carbon monoxide poisoning possibly leading to death...

Page 43: ...ical skills EAU46910 Periodic maintenance chart for the emission control system NO ITEM CHECK OR MAINTENANCE JOB ODOMETER READING ANNUAL CHECK 1000 km 600 mi 10000 km 6000 mi 20000 km 12000 mi 30000 km 18000 mi 40000 km 24000 mi 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...

Page 44: ...hicle for fluid leakage Adjust brake lever free play Replace brake pads Whenever worn to the limit 4 Rear brake Check operation and adjust brake pedal free play Replace brake shoes Whenever worn to the limit 5 Brake hose Check for cracks or damage Replace Every 4 years 6 Wheels Check runout spoke tightness and for damage Tighten spokes if necessary 7 Tires Check tread depth and for dam age Replace...

Page 45: ...cone grease 13 Brake pedal pivot shaft Lubricate with lithium soap based grease 14 Clutch lever pivot shaft Lubricate with lithium soap based grease 15 Shift pedal pivot shaft Lubricate with lithium soap based grease 16 Sidestand Check operation Lubricate 17 Sidestand switch Check operation 18 Front fork Check operation and for oil leak age 19 Shock absorber as sembly Check operation and shock ab ...

Page 46: ... Engine oil filter ele ment Replace 22 Final gear oil Check oil level and vehicle for oil leakage Change 23 Front and rear brake switches Check operation 24 Moving parts and cables Lubricate 25 Throttle grip hous ing and cable Check operation and free play Adjust the throttle cable free play if necessary Lubricate the throttle grip housing and cable 26 Lights signals and switches Check operation A...

Page 47: ...PERIODIC MAINTENANCE AND ADJUSTMENT 7 6 7 Replace the brake hoses every four years and if cracked or damaged U1BF20E0 book Page 6 Thursday April 9 2009 9 10 AM ...

Page 48: ...fer to this section each time a panel needs to be removed and installed XVS650Z XVS650AZ XVS650Z XVS650AZ EAU19193 Panel A To remove the panel Remove the bolts and then take the panel off XVS650Z XVS650AZ 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 U1BF20E0 book Page 7 Thursday April 9 2009 9 10 AM ...

Page 49: ...k 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 spar...

Page 50: ...all the spark plug cap EAU19744 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 A slight tilt to the...

Page 51: ...ct the used oil 3 Remove the engine oil filler cap and drain bolt to drain the oil from the crankcase TIP 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 5 Remove the oil filter element and O ring 1 Engine oil level check window 2 Maximum level mark 3 Minimum level mark 4 Engine oil filler cap 1 Engine oil...

Page 52: ...itives Do not 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 11 T...

Page 53: ...the final gear case TIP The oil level should be at the brim of the filler hole 3 If the oil is below the brim of the fill er hole add sufficient oil of the rec ommended type to raise it to the correct level 4 Install the oil filler bolt and then tighten it to the specified torque To change the final gear oil 1 Place an oil pan under the final gear case to collect the used oil 2 Remove the oil fill...

Page 54: ...ving 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 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 NOTICE Make sure that the air filter ele ment is properly seated in the air filter case The engine...

Page 55: ...e most carbu retor 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 ser viced by the owner as part of routine maintenance NOTICE ECA10560 The carburetors have been set and extensively tested at the Yamaha factory Changing these settings without sufficient technical knowl edge...

Page 56: ... 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 en gine idling speed turn the screw in direction b TIP If the specified idling speed cannot be obtained as described above have a Yamaha dealer make the adjustment EAU21382 Checking the throttle cable free play The throttle cable free p...

Page 57: ... The tire air pressure must be checked and adjusted on cold tires i e when the temperature of the tires equals the ambient temperature The tire air pressure must be ad justed in accordance with the riding speed and with the total weight of rider passenger car go and accessories approved for this model WARNING EWA10511 Never overload your vehicle Opera tion of an overloaded vehicle could cause an a...

Page 58: ...nce It is not recommended to patch a punctured tube If unavoid able however patch the tube very carefully and replace it as soon as possible with a high quality product Tire information This motorcycle is equipped with spoke wheels and tube tires WARNING EWA10461 The front and rear tires should be of the same make and design other wise the handling characteristics of the vehicle may be different w...

Page 59: ...t to develop its optimal characteris tics EAU22043 Adjusting the clutch lever free play The clutch lever free play should mea sure XVS650AZ 5 0 10 0 mm 0 20 0 39 in XVS650Z 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 Slide the rubber cover back at the clutch lever 2 Loosen the locknut 3 To increase the clutch lever free p...

Page 60: ...a sure 10 0 15 0 mm 0 39 0 59 in as shown Periodically check the brake le ver 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 brake lever free play adjusting screw in direction a To decrease the brake lever free play turn the adjusting screw in direc tion b 3 Tighten the locknut WARNING EWA10630 After adjusti...

Page 61: ... these adjustments TIP The brake pedal position should be ad justed before adjusting the brake pedal free play Brake pedal position The brake pedal should be positioned approximately XVS650AZ 108 0 mm 4 25 in XVS650Z 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 ...

Page 62: ...he adjusting nut in direction b EAU22272 Adjusting the rear brake light switch The rear brake light which is activated by the brake pedal should come on just before braking takes effect If neces sary adjust the rear brake light switch as follows Turn the rear brake light switch adjust ing nut while holding the rear brake light switch in place To make the brake light come on earlier turn the adjust...

Page 63: ...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 EAU32344 Checking the brake fluid level Insufficient brake fluid may allow air to enter the brake system possibly caus ing it to become ineffective Bef...

Page 64: ... a Yamaha dealer change the brake fluid at the intervals specified in the TIP after the periodic maintenance and lubrication chart In addition have the oil seals of the brake master cylin der and caliper as well as the brake hose replaced at the intervals listed be low or whenever they are damaged or leaking Oil seals Replace every two years Brake hose Replace every four years EAU23101 Checking an...

Page 65: ... the cable should be lubricated at the intervals specified in the periodic maintenance chart EAU44271 Checking and lubricating the brake and shift pedals The operation of the brake and shift pedals should be checked before each ride and the pedal pivots should be lu bricated if necessary Recommended lubricant Lithium soap based grease U1BF20E0 book Page 24 Thursday April 9 2009 9 10 AM ...

Page 66: ...d should be checked before each ride and the sidestand pivot and metal to metal contact surfaces should be lubricated if necessary WARNING EWA10731 If the sidestand does not move up and down smoothly have a Yamaha dealer check or repair it Otherwise the sidestand could contact the ground and distract the operator re sulting in a possible loss of control Recommended lubricants Brake lever Silicone ...

Page 67: ...nner 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 WARNING To avoid injury securely support the vehicle so there is no danger of it falling over EWA10751 2 While applying the front brake push down hard on the handlebars several times to check if the front fork compresses and rebounds smoothly ...

Page 68: ...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 there is play in the wheel hub or if the wheel does not turn smoothly have a Yamaha dealer check the wheel bearings EAU23385 Battery The battery is located behind panel B See page 7 7 This model is equip...

Page 69: ...ge more quickly if the vehicle is equipped with optional electrical accessories NOTICE ECA16520 To charge a VRLA Valve Regulated Lead Acid battery a special con stant voltage battery charger is re quired Using a conventional battery charger will damage the battery If you do not have access to a con stant voltage battery charger have a Yamaha dealer charge your battery To store the battery 1 If the...

Page 70: ...cal system and possibly a fire EWA15131 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 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 XVS650AZ 6 Backup fuse for...

Page 71: ...rt and fin gerprints on the headlight bulb using a cloth moistened with al cohol or thinner Headlight lens Do not affix any type of tinted film or stickers to the headlight lens Do not use a headlight bulb of a wattage higher than specified 1 Remove the headlight unit by re moving the screws 2 Disconnect the headlight coupler and then remove the bulb cover 3 Unhook the headlight bulb holder and th...

Page 72: ...ight bulb or the tail brake light bulb 1 Remove the lens by removing the screws XVS650Z XVS650AZ 2 Remove the burnt out 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 until it stops 4 Install the lens by installing the screws NOTICE Do not over tighten the screws otherwise the lens may break ECA10681 1 Screw 1 Screw...

Page 73: ...ince this model is not equipped with a centerstand follow these precautions when removing the front and rear wheel or performing other maintenance requiring the motorcycle to stand up right Check that the motorcycle is in a stable and level position before starting any maintenance A strong wooden box can be placed under the engine for added stability To service the front wheel 1 Stabilize the rear...

Page 74: ... front wheel axle pinch bolt then the wheel axle 3 Lift the front wheel off the ground according to the procedure on page 7 32 4 Pull the wheel axle out and then remove the wheel NOTICE Do not apply the brake after the wheel has been removed to gether with the brake disc oth erwise the brake pads will be forced shut ECA11071 EAU24933 To install the front wheel 1 Install the speedometer gear unit i...

Page 75: ...front brake push down hard on the handlebars several times to check if the front fork compresses and rebounds smoothly 8 Connect the speedometer cable EAU25080 Rear wheel EAU25142 To remove the rear wheel WARNING EWA10821 To avoid injury securely support the vehicle so 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 movi...

Page 76: ...is being pulled out EAU25512 To install the rear wheel 1 Install the rear wheel wheel axle final gear case and drive shaft by pushing the wheel forward and guiding the drive shaft into the mid dle gear universal joint 2 Install the final gear case bolts 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 br...

Page 77: ...nd 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 may look like Yamaha parts but they are often inferi or have a shorter service life and can l...

Page 78: ... 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 quickly The engine turns over slowly The battery is g...

Page 79: ... the muffler outlets with plas tic bags after the engine has cooled down 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 d...

Page 80: ...dirt with warm water a mild detergent and a soft clean sponge and then rinse thoroughly with clean water Use a toothbrush or bottlebrush for hard to reach areas Stubborn dirt and insects will come off more easily if the area is covered with a wet cloth for a few minutes before cleaning After riding in the rain near the sea or on salt sprayed roads Since sea salt or salt sprayed on roads during win...

Page 81: ...rubber and plastic parts but treat them with a suitable care product Avoid using abrasive polishing compounds as they will wear away the paint TIP Consult a Yamaha dealer for ad vice on what products to use Washing rainy weather or humid climates can cause the headlight lens to fog Turning the headlight on for a short period of time will help remove the moisture from the lens EAU26231 Storage Shor...

Page 82: ...ury from sparking make sure to ground the spark plug electrodes while turning the engine over EWA10951 e Remove the spark plug caps from the spark plugs and then install the spark plugs and the spark plug caps 6 Lubricate all control cables and the pivoting points of all levers and pedals as well as of the side stand centerstand 7 Check and if necessary correct the tire air pressure and then lift ...

Page 83: ...Recommended engine oil grade API service SG type or higher JASO standard MA 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 SAE 80 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 gasol...

Page 84: ...ories Tire air pressure measured on cold tires Loading condition 0 90 kg 0 198 lb Front XVS650AZ 225 kPa 2 25 kgf cm 33 psi XVS650Z 200 kPa 2 00 kgf cm 29 psi Rear 225 kPa 2 25 kgf cm 33 psi Loading condition XVS650AZ 90 200 kg 198 441 lb XVS650Z 90 180 kg 198 397 lb Front XVS650AZ 225 kPa 2 25 kgf cm 33 psi XVS650Z 200 kPa 2 00 kgf cm 29 psi Rear 250 kPa 2 50 kgf cm 36 psi Front wheel Wheel type ...

Page 85: ... Front turn signal light 12 V 21 0 W 2 Rear turn signal light 12 V 21 0 W 2 Auxiliary light XVS650AZ 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 Immobilizer system indicator light XVS650AZ LED Fuses Main fuse 30 0 A Headlight fuse 15 0 A Signal...

Page 86: ... INFORMATION EAU26381 Key identification number XVS650Z XVS650AZ 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...

Page 87: ...AU26570 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 ult...

Page 88: ...ght 4 4 Horn switch 4 7 I Identification numbers 10 1 Ignition circuit cut off system 4 18 Immobilizer system indicator light XVS650AZ 4 5 Immobilizer system XVS650AZ 4 1 Indicator and warning lights 4 4 K Key identification number 10 1 L Labels location 1 1 Luggage strap holders 4 17 M Main switch steering lock XVS650AZ 4 2 Main switch steering lock XVS650Z 4 2 Maintenance and lubrication periodi...

Page 89: ... 7 1 Troubleshooting 7 36 Troubleshooting chart 7 37 Turn signal indicator light 4 4 Turn signal light bulb or tail brake light bulb replacing 7 31 Turn signal switch 4 6 V Valve clearance 7 16 Vehicle identification number 10 1 W Wheel bearings checking 7 27 Wheel front 7 33 Wheel rear 7 34 Wheels 7 18 U1BF20E0 book Page 2 Thursday April 9 2009 9 10 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 2009 05 0 4 1 CR E DIC183 ...

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