Yamaha DragStar XVS650A Owner'S Manual Download

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PERIODIC MAINTENANCE AND MINOR REPAIR

6-31

EAU24360

Front wheel

EAU24660

To remove the front wheel

WARNING

EWA10820

●

It is advisable to have a Yamaha
dealer service the wheel.

●

Securely support the motor-
cycle so that there is no danger
of it falling over.

1. Disconnect the speedometer ca-

ble from the front wheel.

2. Loosen the front wheel axle pinch

bolt.

3. Remove the rubber cap, and then

loosen the wheel axle.

4. Lift the front wheel off the ground

according to the procedure on
page 6-30.

5. Pull the wheel axle out, and then

remove the wheel.

CAUTION:

ECA11070

Do not apply the brake after the
wheel has been removed together
with the brake disc, otherwise the
brake pads will be forced shut.

EAU24921

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 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.

1. Speedometer cable

1. Rubber cap
2. Wheel axle

3. Front wheel axle pinch bolt

1. Speedometer gear unit
2. Speedometer cable

3. Retainer

U5SCE1E0.book Page 31 Monday, September 8, 2003 11:32 AM

Summary of Contents for DragStar XVS650A

Page 1: ...5SC 28199 E1 XVS650A OWNER S MANUAL ...

Page 2: ...TE Directive 1999 5 EC EN300 330 2 v1 1 1 2001 6 EN60950 2000 Two or Three Wheel Motor Vehicles Directive 97 24 EC Chapter 8 EMC Place of issue Shizuoka Japan Date of issue Aug 1st 2002 Kind of equipment IMMOBILIZER Address 1450 6 Mori Mori Machi Shuchi gun Shizuoka 437 0292 Japan Company MORIC CO LTD Kazuji Kawai representative name and signature U5SCE1E0 book Page 1 Monday September 8 2003 11 32...

Page 3: ...to enjoy all advantages of your XVS650A The owner 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 Yamaha deal...

Page 4: ...our motorcycle and this manual If 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 The Safety Alert Symbol means ATTENTION BECOME ALERT YOUR SAFETY IS INVOLVED Failure to follow WARNING instructions could result in severe injury or death to the motorcycle operator a bys...

Page 5: ...UAL 2003 by Yamaha Motor Co Ltd 1st edition August 2003 All rights reserved Any reprinting or unauthorized use without the written permission of Yamaha Motor Co Ltd is expressly prohibited Printed in Japan U5SCE1E0 book Page 2 Monday September 8 2003 11 32 AM ...

Page 6: ...c 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 12 Adjusting the engine idling speed 6 12 Adjusting the throttle cable free play 6 13 Adjusting the valve clearance 6 13 Tires 6 14 Spoke wheels 6 16 Adjusting the clutch le...

Page 7: ...ary light bulb 6 29 Supporting the motorcycle 6 30 Front wheel 6 31 Rear wheel 6 32 Troubleshooting 6 34 Troubleshooting chart 6 35 MOTORCYCLE CARE AND STORAGE 7 1 Care 7 1 Storage 7 3 SPECIFICATIONS 8 1 CONSUMER INFORMATION 9 1 Identification numbers 9 1 U5SCE1E0 book Page 2 Monday September 8 2003 11 32 AM ...

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: ...er 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 suspension travel steering travel or control operation or ob scure lights or reflectors Accessories fitted to the handle bar...

Page 11: ... 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 flammable source e g a kero sene heater or near an open flame otherwise it could catch fire When transporting the motorcycle in another vehicle make sure ...

Page 12: ...7 2 Fuel cock page 3 10 3 Starter choke knob page 3 11 4 Shock absorber assembly spring preload adjusting ring page 3 13 5 Helmet holder page 3 12 6 Storage compartment page 3 13 7 Owner s tool kit page 6 1 U5SCE1E0 book Page 1 Monday September 8 2003 11 32 AM ...

Page 13: ...ight view 1 Engine oil filter element page 6 7 2 Battery page 6 25 3 Fuses page 6 26 4 Main switch steering lock page 3 2 5 Air filter element page 6 11 6 Brake pedal page 3 8 U5SCE1E0 book Page 2 Monday September 8 2003 11 32 AM ...

Page 14: ...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 13 7 Brake lever page 3 7 U5SCE1E0 book Page 3 Monday September 8 2003 11 32 AM ...

Page 15: ... 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 regi...

Page 16: ... meter lighting taillight and auxiliary light come on and the engine can be started The key cannot be re moved NOTE The headlight comes on automatically when the engine is started and stays on until the key is turned to OFF even if the engine stalls EAU10660 OFF All electrical systems are off The key can be removed EAU10680 LOCK The steering is locked and all electrical systems are off The key can...

Page 17: ... all other electrical systems are off The key can be removed The steering must be locked before the key can be turned to CAUTION ECA11020 Do not use the parking position for an extended length of time other wise the battery may discharge EAU11001 Indicator and warning lights EAU11020 Turn signal indicator light This indicator light flashes when the turn signal switch is pushed to the left or right...

Page 18: ...ed the indicator light will stop flashing however the immobi lizer system is still enabled NOTE This model is also equipped with a self diagnosis device for the immobilizer system If the immobilizer system is de fective the indicator light will start flash ing a pattern when the key is turned to ON When this occurs have a Yamaha dealer check the self diagno sis system However if the indicator ligh...

Page 19: ...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 fuel stops EAU12330 Anti theft alarm optional This model can be equipped with an optional anti theft alarm by a Yamaha dealer Contact a Yamaha dealer for more information EAU12342 Handlebar switches Left 1 Tripmeter reset knob 2 Speedometer 3 Odometer 4 Trip...

Page 20: ...et this switch to 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 EAU12731 Hazard switch With the key in the ON or posi tion use this switch to turn on the haz ard light s...

Page 21: ...igni tion circuit cut off system See page 3 15 EAU12880 Shift pedal 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 NOTE 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 h...

Page 22: ... 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 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 WARNING EWA10130 Make...

Page 23: ...nleaded 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 Yamaha engine has been de signed to use regular unleaded gaso line with a research octane number of 91 or higher If knocking or pinging oc curs use a gasoline of a different brand or premium unleaded fuel Use of un leaded fuel will ...

Page 24: ...rds such as grass or other materials that easily burn Do not allow the engine to idle too long EAU13550 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 il lustrations OFF With the fuel cock lever in this position fuel will not flow Always turn the fuel cock lever to this positio...

Page 25: ...starter choke Move the knob in direction b 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 EAU14190 Seats Passenger seat To remove the passenger seat Remove the bolt and then pull th...

Page 26: ...t NOTE Make sure that the seats are properly secured before riding EAU14281 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 WARNING EWA10160 Never ride with a helmet attached to the helmet holder since the helmet may hit objects causing loss of con trol and possib...

Page 27: ...se re move it and then close the lock cover EAU14860 Adjusting the shock absorber assembly This shock absorber assembly is equipped with a spring preload adjust ing ring CAUTION ECA10100 Never attempt to turn an adjusting mechanism beyond the maximum or minimum settings Adjust the spring preload as follows 1 Remove the passenger and rider seats See page 3 11 1 Storage compartment cover 2 Storage c...

Page 28: ...andling 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 with or attempt to open the gas cylinder Do not subject the shock ab sorber to an open flame or other high heat sources otherwise it may explode due to excessive gas pressure...

Page 29: ...the respon sibility of raising the sidestand be fore starting off Therefore check this system regularly as described below and have a Yamaha dealer re pair it if it does not function proper ly EAU15311 Ignition circuit cut off system The ignition circuit cut off system com prising the sidestand switch clutch switch and neutral switch has the fol lowing functions It prevents starting when the trans...

Page 30: ... 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 31: ...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 32: ...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 17 6 19 6 20 Rear brake Check operation Check pedal free play Adjust if necessary 6 18 6 19 Clutch Check operation Lubricate cable if necessary Check lever free play Adjust if necessary 6 16 Throttle grip Make sure that opera...

Page 33: ...oth Lubricate lever pivoting points if necessary 6 22 Sidestand Make sure that operation is smooth Lubricate pivot if necessary 6 23 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 34: ...lled 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 15 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 transmission...

Page 35: ...arter choke turned off EAU16640 Starting a warm engine Follow the same procedure as for start ing a cold engine with the exception that the starter choke is not required when the engine is warm EAU16671 Shifting Shifting gears lets you control the amount of engine power available for starting off accelerating climbing hills etc The gear positions are shown in the il lustration NOTE To shift the tr...

Page 36: ...n the table be low NOTE When shifting down two gears at a time reduce the speed accordingly e g down to 35 km h 22 mi h when shifting from 4th to 2nd gear EAU16800 Tips for reducing fuel consumption Fuel consumption depends largely on your riding style Consider the following tips to reduce fuel consumption Turn the starter choke off as soon as possible Shift up swiftly and avoid high en gine speed...

Page 37: ... above 1 2 throttle CAUTION ECA10331 After 1000 km 600 mi of operation the engine oil and final gear oil must be changed and the oil filter car tridge or element replaced 1600 km 1000 mi and beyond The vehicle can now be operated nor mally CAUTION ECA10270 If any engine trouble should occur during the engine break in period immediately have a Yamaha dealer check the vehicle EAU17180 Parking When p...

Page 38: ... 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 13 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 39: ... 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 40: ... 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 41: ...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 42: ...d installed EAU19192 Panel A To remove the panel Remove the bolts and then take the panel off To install the panel Place the panel in the original position and then install the bolts EAU19151 Panel B To remove the panel Remove the bolt and then pull the pan el off as shown To install the panel Place the panel in the original position and then install the bolt 1 Panel A 1 Panel B 1 Bolt 1 Bolt U5SC...

Page 43: ...he 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 plugs installed in the engine have the same color NOTE If any spark plug shows ...

Page 44: ...e spark plug cap EAU19741 Engine oil and oil filter element 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 veh...

Page 45: ...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 5 Remove the oil filter element and O ring 1 Engine oil level check window 2 Maximum level mark 3 Minimu...

Page 46: ... 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 Turn the engine off and then check the oil level and co...

Page 47: ...l gear case NOTE 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 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 filler bolt and drain bolt to drain the oil from the final gear case 3 Install the fi...

Page 48: ...low 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 CAUTION ECA10480 Make sure that the air filter ele ment is properly seated in the air filter case The engine should never be op erated without the air filter ele ment installed otherwise the piston s and or cylinder s may become e...

Page 49: ...ese settings without sufficient technical knowl edge may result in poor perfor mance of or damage to the engine EAU21340 Adjusting the engine 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 qui...

Page 50: ... the throttle cable free play and if neces sary have a Yamaha dealer adjust it EAU21400 Adjusting the valve clearance The valve clearance changes with use resulting in improper air fuel mixture and or engine noise To prevent this from occurring the valve clearance must be adjusted by a Yamaha dealer at the intervals specified in the periodic maintenance and lubrication chart 1 Throttle stop screw ...

Page 51: ...d keep the following precautions in mind NEVER OVERLOAD THE MOTORCYCLE Operation of an overloaded motorcycle may re sult in tire damage loss of con trol or severe injury Make sure that the total weight of rider passenger cargo and accesso ries does not exceed the speci fied maximum load for the vehicle Do not carry along loosely packed items which can shift during a ride Securely pack the heaviest...

Page 52: ... a Yamaha dealer who has the necessary professional knowl edge and experience 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 EWA10460 The front and rear tires should be of the same make and de sig...

Page 53: ...usting the clutch lever free play The clutch lever free play should mea sure 5 0 10 0 mm 0 20 0 39 in as shown Periodically check the clutch le ver 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 in di rection a To decrease the clutch lever free play turn the adjusting bolt in direction b 3 I...

Page 54: ...rake 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 A soft or spongy feeling in the brake lever can indicate the presence of air in...

Page 55: ...ke pedal free play Brake pedal position The brake pedal should be positioned approximately 108 0 mm 4 25 in above the top of the footrest as shown Periodically check the brake pedal po sition and if necessary adjust it as fol lows 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 ...

Page 56: ... 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 EAU22380 Checking the front brake pads and rear brake shoes The front brake pads and the rear brake shoes must be checked for wear at the intervals specified in the periodic main tenance and lub...

Page 57: ...id level is low be sure to check the brake pads for wear and the brake system for leakage Observe these precautions When checking the fluid level make sure that the top of the brake fluid reservoir is level Use only the recommended quality 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 ...

Page 58: ...he condition of the cables should be checked before each ride and the ca bles and cable ends should be lubricat ed if necessary If a cable is damaged or does not move smoothly have a Yamaha dealer check or replace it WARNING EWA10720 Damage to the 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 un...

Page 59: ... pedal pivots should be lu bricated if necessary EAU23140 Checking and lubricating the brake and clutch levers Brake lever Clutch lever 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 U5SCE1E0 book Page 22 Monday September 8 2003 11 32 AM ...

Page 60: ...rvals specified in the periodic 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...

Page 61: ...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 WARNING EWA10750 Securely 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 Yamah...

Page 62: ...ep in mind that the battery tends to discharge more quickly if the vehicle is equipped with optional electrical accessories WARNING EWA10760 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 EXTE...

Page 63: ...n 4 After installation make sure that the battery leads are properly con nected to the battery terminals CAUTION ECA10630 Always keep the battery charged Storing a discharged battery can cause permanent battery damage To charge a sealed type MF battery a special constant volt age battery charger is required Using a conventional battery charger will damage the battery If you do not have access to a...

Page 64: ...the device operates 4 If the fuse immediately blows again have a Yamaha dealer check the electrical system EAU23780 Replacing the headlight bulb This model is 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 1 Parking lighting fuse 2 Headl...

Page 65: ...ass part of the headlight bulb to keep it free from oil otherwise the transparency of 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 s...

Page 66: ... then turn it clock wise until it stops 4 Install the lens by installing the screws CAUTION ECA10680 Do not overtighten the screws oth erwise the lens may break EAU33411 Replacing the auxiliary light bulb If the auxiliary 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 counte...

Page 67: ...nd 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 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 fro...

Page 68: ...0 Do not apply the brake after the wheel has been removed together with the brake disc otherwise the brake pads will be forced shut EAU24921 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 the bra...

Page 69: ... 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 and nut 3 Loosen the brake torque rod nut 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 5 6 Remove the bolts that secure the final gear case to the swinga...

Page 70: ...tall 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 bolt and nut at the brake shoe plate 5 Install the panel 6 Lower the rear wheel so that it is on the ground 7 Tighten the axle nut the final gear case bolts and the brake torque rod nuts to the specified torques 8 Adjust the brake pedal free pl...

Page 71: ...oubleshooting 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 may look like Yamaha parts but they are often inferi ...

Page 72: ...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 73: ...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 74: ... 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 75: ... 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 76: ...s 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 30...

Page 77: ...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 Regular unleaded gasoline only Fuel tank capacity 16 0 L 4 23 US gal 3 52 Imp gal Fuel reserve amount 3 0 L 0 79 US gal 0 66 Imp gal Carburetor Manufacturer MIKUNI Type x...

Page 78: ... psi 2 25 kgf cm Loading condition 90 198 kg 198 437 lb Front 225 kPa 33 psi 2 25 kgf cm Rear 250 kPa 36 psi 2 50 kgf cm Front wheel Wheel type Spoke wheel Rim size 16M C x MT3 00 Rear wheel Wheel type Spoke wheel Rim size 15M C x MT3 50 Front brake Type Single disc brake Operation Right hand operation Recommended fluid DOT 4 Rear brake Type Drum brake Operation Right foot operation Front suspensi...

Page 79: ...ting 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 LED Fuses Main fuse 30 0 A Headlight fuse 15 0 A Signaling system fuse 10 0 A Ignition fuse 10 0 A Parking lighting fuse 10 0 A Carburetor heater fuse 15 0 A Ignitor unit fuse 5 0 A Backup...

Page 80: ...ification 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 NOTE The vehicle identification number is used to identify your motorcycle and may be used to register your mot...

Page 81: ... is affixed to the frame under the rider seat See page 3 11 Record the information on this label in the space provided This information will be needed when ordering spare parts from a Yamaha dealer 1 Model label U5SCE1E0 book Page 2 Monday September 8 2003 11 32 AM ...

Page 82: ...27 Helmet holder 3 12 High beam indicator light 3 4 Horn switch 3 6 I Identification numbers 9 1 Ignition circuit cut off system 3 15 Immobilizer system 3 1 Immobilizer system indicator light 3 4 Indicator and warning lights 3 3 K Key identification number 9 1 L Luggage strap holders 3 14 M Main switch steering lock 3 2 Model label 9 2 N Neutral indicator light 3 3 P Panels removing and installing...

Page 83: ...light bulb replacing 6 29 Turn signal switch 3 6 V Valve clearance adjusting 6 13 Vehicle identification number 9 1 W Wheel bearings checking 6 25 Wheel front 6 31 Wheel rear 6 32 Wheels 6 16 U5SCE1E0 book Page 2 Monday September 8 2003 11 32 AM ...

Page 84: ...A5 yoko_Blank fm Page 1 Tuesday April 8 2003 11 43 AM ...

Page 85: ...A5 yoko_Blank fm Page 1 Tuesday April 8 2003 11 43 AM ...

Page 86: ...PRINTED ON RECYCLED PAPER YAMAHA MOTOR CO LTD PRINTED IN JAPAN 2003 09 0 3 1 CR E ...

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