Yamaha V-star XVS650S Owner'S Manual Download

Page: 61 / 98

PERIODIC MAINTENANCE AND MINOR REPAIR

6-20

6. To increase the clutch lever free

play, turn the adjusting nut in direc-
tion (a). To decrease the clutch le-
ver free play, turn the adjusting nut
in direction (b).

7. Tighten the locknut at the clutch le-

ver and the crankcase.

EAU22091

Adjusting the brake lever free
play

The brake lever free play should mea-
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 adjusting bolt in di-
rection (a). To decrease the brake
lever free play, turn the adjusting
bolt 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 the hydraulic

1. Brake lever free play

1. Locknut
2. Brake lever free play adjusting bolt

5FB13.book Page 20 Monday, May 12, 2003 5:20 PM

Summary of Contents for V-star XVS650S

Page 1: ...5FB 28199 13 LIT 11626 17 26 XVS650S XVS650AS XVS650ATS OWNER S MANUAL...

Page 2: ...EAU10041 5FB13 book Page 1 Monday May 12 2003 5 20 PM...

Page 3: ...this motorcycle If you have any questions concerning the operation or maintenance of your motorcycle please consult a Yamaha dealer The design and manufacture of this Yamaha motorcycle fully comply wi...

Page 4: ...KLET CAREFULLY AND COMPLETELY BEFORE OPERATING THIS MOTORCYCLE DO NOT ATTEMPT TO OPERATE THIS MOTOR CYCLE UNTIL YOU HAVE ATTAINED ADEQUATE KNOWLEDGE OF ITS CONTROLS AND OPERATING FEATURES AND UNTIL YO...

Page 5: ...otor Corporation U S A 1st edition April 2003 All rights reserved Any reprinting or unauthorized use without the written permission of Yamaha Motor Corporation U S A is expressly prohibited Printed in...

Page 6: ...6 1 Owner s tool kit 6 1 Periodic maintenance chart for the emission control system 6 3 General maintenance and lubrication chart 6 4 Removing and installing panels 6 8 Checking the spark plugs 6 9 En...

Page 7: ...33 Rear wheel 6 34 Troubleshooting 6 36 Troubleshooting chart 6 37 MOTORCYCLE CARE AND STORAGE 7 1 Care 7 1 Storage 7 3 SPECIFICATIONS 8 1 CONSUMER INFORMATION 9 1 Identification numbers 9 1 Reportin...

Page 8: ...dents 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...

Page 9: ...face 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 p...

Page 10: ...ind 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 b...

Page 11: ...ust 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...

Page 12: ...SAFETY INFORMATION 1 5 1 EAU10381 Location of important labels Please read the following important labels carefully before operating this vehicle 5FB13 book Page 5 Monday May 12 2003 5 20 PM...

Page 13: ...SAFETY INFORMATION 1 6 1 1 2 3 XVS650 3 XVS650A AT 4 5 5FB13 book Page 6 Monday May 12 2003 5 20 PM...

Page 14: ...page 3 4 2 Fuel cock page 3 7 3 Starter choke knob page 3 8 4 Shock absorber assembly spring preload adjusting ring page 3 12 5 Helmet holder page 3 10 6 Owner s tool kit page 6 1 7 Storage compartme...

Page 15: ...4 2 Fuel cock page 3 7 3 Starter choke knob page 3 8 4 Shock absorber assembly spring preload adjusting ring page 3 12 5 Helmet holder page 3 10 6 Owner s tool kit page 6 1 7 Storage compartment page...

Page 16: ...ight view XVS650 1 Engine oil filter element page 6 11 2 Battery page 6 28 3 Fuses page 6 29 4 Main switch steering lock page 3 1 5 Air filter element page 6 14 6 Brake pedal page 3 5 5FB13 book Page...

Page 17: ...S650A AT 1 Engine oil filter element page 6 11 2 Battery page 6 28 3 Fuses page 6 29 4 Main switch steering lock page 3 1 5 Air filter element page 6 14 6 Brake pedal page 3 5 5FB13 book Page 4 Monday...

Page 18: ...VS650 A AT 1 Clutch lever page 3 4 2 Left handlebar switches page 3 3 3 Speedometer unit page 3 2 4 Fuel tank cap page 3 5 5 Right handlebar switches page 3 3 6 Throttle grip page 6 15 7 Brake lever p...

Page 19: ...80 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 an...

Page 20: ...eck the self diagnosis system NOTE This warning light comes on for a few seconds when the key is turned to ON but this does not indicate a mal function EAU11630 Speedometer unit The speedometer unit i...

Page 21: ...ushing the switch in after it has returned to the cen ter position NOTE The self canceling system only oper ates when the vehicle is moving so that the turn signal lights will not self cancel while yo...

Page 22: ...EAU12870 Shift pedal XVS650 The shift pedal is located on the left side of the engine and is used in com bination with the clutch lever when shifting the gears of the 5 speed con stant mesh transmiss...

Page 23: ...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 i...

Page 24: ...e 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 EAU13300 CAUTION ECA11400 Use only unleaded g...

Page 25: ...l system or ve hicle performance problems 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 follo...

Page 26: ...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 a...

Page 27: ...bolts 2 Install the passenger seat NOTE Make sure that the seats are properly secured before riding EAU14190 Seats XVS650A AT Passenger seat To remove the passenger seat Remove the bolt and then pull...

Page 28: ...seat NOTE Make sure that the seats are properly secured before riding EAU14280 Helmet holder To open the helmet holder insert the key into the lock and then turn the key as shown To lock the helmet h...

Page 29: ...n turn it clockwise 2 Pull the storage compartment cov er out as shown To close the storage compartment 1 Place the storage compartment cover in its original position as shown 2 Turn the key countercl...

Page 30: ...the 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 understa...

Page 31: ...the 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 sidestan...

Page 32: ...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...

Page 33: ...fter 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 rel...

Page 34: ...sequences 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 u...

Page 35: ...necessary 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 23 Rear brake...

Page 36: ...smooth Lubricate lever pivoting points if necessary 6 26 Sidestand Make sure that operation is smooth Lubricate pivot if necessary 6 26 Chassis fasteners Make sure that all nuts bolts and screws are...

Page 37: ...ch lever 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 14 Never ri...

Page 38: ...tarter choke turned off To avoid the possi bility of excessive exhaust emissions never leave the starter choke on long er than necessary The time necessary for starter choke use depends upon the ambie...

Page 39: ...Always use the clutch while changing gears to avoid damag ing the engine transmission and drive train which are not designed to withstand the shock of forced shifting EAU16680 To start out and accele...

Page 40: ...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...

Page 41: ...ouble should occur during the engine break in period immediately have a Yamaha dealer check the vehicle EAU17170 Parking When parking stop the engine remove the key from the main switch and then turn...

Page 42: ...TED TO EMISSIONS CONTROL THESE CONTROLS NOT ONLY FUNCTION TO ENSURE CLEANER AIR BUT ARE ALSO VITAL TO PROPER EN GINE OPERATION AND MAXIMUM PERFORMANCE IN THE FOLLOW ING PERIODIC MAINTENANCE CHARTS THE...

Page 43: ...WARNING EWA10340 Modifications not approved by Yamaha may cause loss of perfor mance excessive emissions and render the vehicle unsafe for use Consult a Yamaha dealer before at tempting any changes 5...

Page 44: ...0 months 1 Fuel line Check fuel hose for cracks or damage Replace if necessary 2 Fuel filter Replace Replace 3 Spark plugs Check condition Adjust gap and clean Replace every 8000 mi 13000 km or 12 mon...

Page 45: ...Check operation Adjust or replace cable 3 Front brake Check operation fluid level and for fluid leakage Replace brake pads if necessary 4 Rear brake Check operation Adjust cable and replace brake sho...

Page 46: ...ase lightly 13 Brake and shift ped al pivot shafts Apply lithium soap based grease all purpose grease lightly 14 Sidestand pivot Check operation Apply lithium soap based grease all purpose grease ligh...

Page 47: ...e at initial 600 mi 1000 km or 1 month and thereafter every 16000 mi 25000 km or 24 months Change Change 21 Control cables Apply Yamaha chain and cable lube or engine oil 10W 30 thor oughly 22 Throttl...

Page 48: ...system When disassembling the master cylinder or caliper cylinder always replace the brake fluid Check the brake fluid level regularly and fill as required Replace the oil seals on the inner parts of...

Page 49: ...obs described in this chapter Refer to this section each time a panel needs to be removed and installed EAU19192 Panel A To remove the panel Remove the bolts and then take the panel off XVS650 To inst...

Page 50: ...nts which are easy to check Since heat and deposits will cause any spark plug to slowly erode the spark plugs should be removed and checked in accordance with the periodic mainte nance and lubrication...

Page 51: ...k plug 1 Measure the spark plug gap with a wire thickness gauge and if nec essary adjust the gap to specifica tion 2 Clean the surface of the spark plug gasket and its mating surface and then wipe off...

Page 52: ...ough the check window located at the bottom left side of the crank case NOTE The engine oil should be between the minimum and maximum level marks 4 If the engine oil is below the mini mum level mark a...

Page 53: ...tion 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 a...

Page 54: ...the 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 t...

Page 55: ...ified 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 t...

Page 56: ...alling the screws EAU21270 Adjusting the carburetors The carburetors are important parts of the engine and emission control sys tem which require very sophisticated adjustment Therefore all carburetor...

Page 57: ...res 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...

Page 58: ...ad 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 WARNING EWA10...

Page 59: ...laced The wheel should be balanced whenever either the tire or wheel has been changed or replaced An unbalanced wheel can result in poor performance adverse han dling characteristics and a short ened...

Page 60: ...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 If the specified clutch lever f...

Page 61: ...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 adjusting bolt in di rection a To decrease the brake le...

Page 62: ...be ad justed before adjusting the brake pedal free play Brake pedal position The brake pedal should be positioned approximately XVS650 82 0 mm 3 23 in XVS650A 108 0 mm 4 25 in XVS650AT 108 0 mm 4 25 i...

Page 63: ...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 b...

Page 64: ...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...

Page 65: ...r lock 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 Ho...

Page 66: ...bles as soon as possible to prevent unsafe conditions EAU23110 Checking and lubricating the throttle grip and cable The operation of the throttle grip should be checked before each ride In addi tion...

Page 67: ...Checking the front fork The condition and operation of the front fork must be checked as follows at the intervals specified in the periodic main tenance and lubrication chart To check the condition W...

Page 68: ...ng 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 S...

Page 69: ...e 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 lowin...

Page 70: ...rged 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...

Page 71: ...the electrical system EAU23791 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...

Page 72: ...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 fingerpri...

Page 73: ...ions 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 m...

Page 74: ...ver 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 accor...

Page 75: ...en install the rubber cap 6 While applying the front brake push down hard on the handlebars several times to check if the front fork compresses and rebounds smoothly 7 Connect the speedometer cable EA...

Page 76: ...ulled out EAU25510 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 universa...

Page 77: ...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 your motorcycle require any r...

Page 78: ...gnition 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 Ya...

Page 79: ...leave 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 ca...

Page 80: ...ion 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...

Page 81: ...ock 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...

Page 82: ...heels 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...

Page 83: ...19 2 48 in Compression ratio 9 00 1 Starting system Electric starter Lubrication system Wet sump Engine oil Type YAMALUBE 4 SAE10W30 or SAE20W40 Recommended engine oil grade API service SE SF SG type...

Page 84: ...XVS650 BRIDGESTONE G546 XVS650A BRIDGESTONE G702 XVS650AT BRIDGESTONE G702 Manufacturer model XVS650 DUNLOP K555 XVS650A DUNLOP D404G XVS650AT DUNLOP D404G Loading Maximum load XVS650 180 0 kg 397 lb...

Page 85: ...nition system Transistorized coil ignition digital Charging system A C magneto Battery Model GT12B 4 Voltage capacity 12 V 10 0 Ah Headlight Bulb type Halogen bulb Bulb voltage wattage x quantity Head...

Page 86: ...dentification number The key identification number is stamped into the key tag Record this number in the space provided and use it for reference when ordering a new key EAU26400 Vehicle identification...

Page 87: ...abel is affixed to the frame under the rider seat See page 3 8 Record the information on this label in the space provided This information will be needed when ordering spare parts from a Yamaha dealer...

Page 88: ...vestigation and if it finds that a safety defect exists in a group of vehicles it may order a recall and remedy campaign However NHTSA cannot become involved in individual problems between you your de...

Page 89: ...hicle for the purpose of noise control prior to its sale or delivery to the ultimate purchaser or while it is in use or 2 the use of the vehicle after such device or element of design has been removed...

Page 90: ...eminder that maintenance work is required It is not acceptable proof of maintenance work Maintenance interval Date of service Mileage Servicing dealer name and address Remarks 600 mi 1000 km or 1 mont...

Page 91: ...NFORMATION 9 6 9 36000 mi 55000 km or 54 months 40000 mi 61000 km or 60 months Maintenance interval Date of service Mileage Servicing dealer name and address Remarks 5FB13 book Page 6 Monday May 12 20...

Page 92: ...CONSUMER INFORMATION 9 7 9 EAU26661 YAMAHA MOTOR CORPORATION U S A STREET AND ENDURO MOTORCYCLE LIMITED WARRANTY 5FB13 book Page 7 Monday May 12 2003 5 20 PM...

Page 93: ...CONSUMER INFORMATION 9 8 9 5FB13 book Page 8 Monday May 12 2003 5 20 PM...

Page 94: ...red repairs There s no deductible to pay and repairs aren t pro rated You don t have any out of pocket expenses for covered repairs In addition Travel and Recreation Interruption Protection TRIP is in...

Page 95: ...cked protection even after your Yamaha Limited Warranty expires A special note If visiting your dealer isn t convenient contact Yamaha with your Primary ID number your frame number We ll be happy to h...

Page 96: ...ng lights 3 2 K Key identification number 9 1 L Labels location of 1 5 Luggage strap holders 3 13 M Main switch steering lock 3 1 Maintenance and lubrication periodic 6 4 Maintenance emission control...

Page 97: ...rance adjusting 6 16 Vehicle identification number 9 1 W Warranty extended 9 9 Warranty limited 9 7 Wheel bearings checking 6 28 Wheel front 6 33 Wheel rear 6 34 Wheels 6 18 5FB13 book Page 2 Monday M...

Page 98: ...PRINTED IN JAPAN 2003 05 2 9 2 CR E PRINTED ON RECYCLED PAPER YAMAHA MOTOR CO LTD...

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