Yamaha V-star Owner'S Manual Download

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PERIODIC MAINTENANCE AND MINOR REPAIR

6-35

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 6-8.)
6. Remove the bolts that secure the

final gear case to the swingarm.

7. Lift the rear wheel off the ground

according to the procedure on
page 6-32.

8. While supporting the drive shaft,

pull the rear wheel back to remove
the following parts as an assem-
bly: wheel, wheel axle, final gear
case, and drive shaft.

NOTE:

Make sure to support the drive shaft as
it is being pulled 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 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 brake torque rod bolt at

the brake shoe plate.

5. Install the panel.
6. Lower the rear wheel so that it is

on the ground.

1. Brake pedal free play adjusting nut
2. Brake camshaft lever

3. Brake rod

4. Bolt (shoe plate)
5. Brake torque rod

6. Bolt (swingarm)

1. Bolt
2. Final gear case

1. Middle gear universal joint
2. Drive shaft

5FB13.book Page 35 Monday, May 12, 2003 5:20 PM

Summary of Contents for V-star

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 with the emissions standards for clean air applicable at the date of manufacture Yamaha has met these standards without reducing the performance or economy of operation of the motorcycle To maintain th...

Page 4: ...OKLET 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 YOU HAVE BEEN TRAINED IN SAFE AND PROPER RIDING TECHNIQUES REGULAR INSPECTIONS AND CAREFUL MAINTENANCE ALONG WITH GOOD RIDING SKILLS WILL ENSURE THAT YOU SAFELY ENJOY THE CAPABILITIES AND THE RELIABILI...

Page 5: ...Motor 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 Japan P N LIT 11626 17 26 AFFIX DEALER LABEL HERE 5FB13 book Page 2 Monday May 12 2003 5 20 PM ...

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 Engine oil and oil filter element 6 11 Final gear oil 6 13 Cleaning the air filter element 6 14 Adjusting the carburetors 6 15 Adjusting the throttle cable free play 6 15 Adjusting the valve clearance ...

Page 7: ...6 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 Reporting safety defects 9 3 Motorcycle noise regulation 9 4 Maintenance record 9 5 YAMAHA MOTOR CORPORATION U S A STREET AND ENDURO MOTORCYCLE LIMITED WARRANTY 9 7 YAMAHA EXTENDED SERVICE Y E S 9 9 5FB13 bo...

Page 8: ...idents 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 motor...

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 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 en...

Page 10: ...mind as well as those provided under Load ing when mounting accessories Never install accessories or carry cargo that would impair the perfor mance of your motorcycle Care fully inspect the accessory before using it to make sure that it does not in any way reduce ground clearance or cornering clearance limit suspension travel steering travel or control operation or ob scure lights or reflectors Ac...

Page 11: ...aust 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 s...

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: ...l 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 compartment page 3 11 5FB13 book Page 1 Monday May 12 2003 5 20 PM ...

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 3 11 5FB13 book Page 2 Monday May 12 2003 5 20 PM ...

Page 16: ...Right 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 3 Monday May 12 2003 5 20 PM ...

Page 17: ...VS650A 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 May 12 2003 5 20 PM ...

Page 18: ...XVS650 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 page 3 5 5FB13 book Page 5 Monday May 12 2003 5 20 PM ...

Page 19: ...680 LOCK The steering is locked and all electrical systems are off The key can be re moved To lock the steering 1 Turn the handlebars all the way to the left 2 Push the key in from the OFF po sition and then turn it to LOCK while still pushing it 3 Remove the key To unlock the steering Push the key in and then turn it to OFF while still pushing it WARNING EWA10060 Never turn the key to OFF or LOCK...

Page 20: ...heck 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 is equipped with a speedometer an odometer and a tripmeter The speedometer shows riding speed The odometer shows the total distance traveled The tripmeter shows the distance traveled since it was last...

Page 21: ...pushing 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 you are stopped at an intersec tion EAU12500 Horn switch Press this switch to sound the horn EAU12660 Engine stop switch Set this switch to before starting the engine Set this switch to to stop the eng...

Page 22: ...4 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 transmission equipped on this motorcycle EAU12880 Shift pedal XVS650A AT 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 ...

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 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 marks on the cap and tank aligned 2 Turn the key counterclockwise to the origi...

Page 24: ...he 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 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 ...

Page 25: ...el 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 follows and shown in the il lustrations OFF With the fuel cock lever in this position fuel will not flow Always turn the fuel cock lever to this position when the en gine is not running ON With the fuel c...

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 addition extended use of the starter choke will cause after burning If this occurs turn off the starter choke EAU14180 Seats XVS650 Passenger seat To remove the passenger seat Remove the nut and then ...

Page 27: ...e 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 the pas senger seat up To install the passenger seat Insert the projections on the front of the passenger seat into the holders as shown place the seat in the original po sition and then install the...

Page 28: ...r 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 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 p...

Page 29: ...en turn it clockwise 2 Pull the storage compartment cov er out as shown To close the storage compartment 1 Place the storage compartment cover in its original position as shown 2 Turn the key counterclockwise re move it and then close the lock cover 1 Storage compartment cover 2 Storage compartment lock cover 3 Storage compartment lock 1 Storage compartment 2 Storage compartment cover 5FB13 book P...

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 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 tampe...

Page 31: ...f 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 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...

Page 32: ...t 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 WARNING EWA10250 If a malfunction is noted hav...

Page 33: ...After the engine has stalled 10 Move the sidestand up 11 Keep the clutch lever pulled 12 Push the start switch Does the engine start The 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 motorcycl...

Page 34: ...nsequences 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 no...

Page 35: ...f 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 Check operation Check pedal free play Adjust if necessary 6 21 Clutch Check operation Lubricate cable if necessary Check lever free play Adjust if necessary 6 19 Throttle grip Make sure that operatio...

Page 36: ...s 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 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 d...

Page 37: ...tch 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 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 ...

Page 38: ...starter 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 ambient temperature Tempera tures above 10 C 50 F require about 7 seconds of starter choke use and temperatures below 10 C 50 F re quire about 35 seconds with the starter choke turned on then about 2 5 mi...

Page 39: ...n 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 accelerate 1 Pull the clutch lever to disengage the clutch 2 Shift the transmission into first gear The neutral indicator light should go out 3 Open the throttle gradually and at the same time release the ...

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 put an excessive load on it for the first 1600 km 1000 mi The various parts in the engine wear and polish themselves to the correct operating clearances During this period prolonged full throt tle op...

Page 41: ...rouble 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 the fuel cock lever to OFF WARNING EWA10310 Since the engine and exhaust system can become very hot park in a place where pedestri ans or children are not likely to touch them Do not park on a slope ...

Page 42: ...ATED 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 SERVICES RELATED TO EMISSIONS CONTROL ARE GROUPED SEPARATELY THESE SERVICES REQUIRE SPECIALIZED DATA KNOWLEDGE AND EQUIP MENT YAMAHA DEALERS ARE TRAINED AND EQUIPPED TO PER FORM THESE PARTICULAR SER...

Page 43: ...6 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 5FB13 book Page 2 Monday May 12 2003 5 20 PM ...

Page 44: ...30 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 months Replace Replace 4 Valve clearance Check and adjust valve clearance when engine is cold 5 Crankcase breather system Check breather hose for cracks or damage Replace if necessary 6 Carburetor synch...

Page 45: ...h 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 shoes if necessary 5 Brake hose Check for cracks or damage Replace See NOTE Every 4 years 6 Wheels Check runout spoke tightness and for damage Tighten spokes if necessary 7 Tires Check tread depth and f...

Page 46: ...ease 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 lightly 15 Sidestand switch Check operation and replace if necessary 16 Front fork Check operation and for oil leak age Replace if necessary 17 Shock absorber as sembly Check operation and for oil leak a...

Page 47: ...ge 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 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 No ITEM ROUTINE INITIAL ODOMETER READINGS 600 mi...

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 the master cylinder and caliper cylinder every two years Replace the brake hoses every four years or if cracked or damaged 5FB13 book Page 7 Monday May 12 2003 5 20 PM ...

Page 49: ...jobs 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 install the panel Place the panel in the original position and then install the bolts XVS650A AT 1 Panel A 1 Panel A 1 Panel B 1 Bolt 1 Bolt 5FB13 book Page 8 Monday May 12 2003 5 20 PM ...

Page 50: ...ents 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 chart In addition the condition of the spark plugs can re veal the condition of the engine To remove a spark plug 1 Remove the spark plug cap 2 Remove the spark plug as shown with the spark plug wre...

Page 51: ...rk 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 any grime from the spark plug threads 3 Install the spark plug with the spark plug wrench and then tight en it to the specified torque NOTE If a torque wrench is not available when installing a spar...

Page 52: ...rough the check window located at the bottom left side of the crank case NOTE The engine oil should be between the minimum and maximum level marks 4 If the engine oil is below the mini mum level mark add sufficient oil of the recommended type to raise it to the correct level To change the engine oil with or without oil filter element replace ment 1 Start the engine warm it up for several minutes a...

Page 53: ...ation of CD or oils of a high er quality than specified In addition do not use oils labeled ENERGY CONSERVING II or higher Make sure that no foreign mate rial enters the crankcase 10 Start the engine and then let it idle for several minutes while checking it for oil leakage If oil is leaking im mediately turn the engine off and check for the cause 1 Outer oil filter element cover 2 Bolt 1 Inner oi...

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 tioned straight up when checking the oil level A slight tilt to the side can result in a false reading 2 Remove the oil filler bolt and then check the oil level in the final gear case NOTE The oil lev...

Page 55: ...cified in the periodic maintenance and lubrication chart Clean the air filter element more fre quently if you are riding in unusually wet or dusty areas 1 Remove the air filter case cover by removing the screws 2 Pull the air filter element out 3 Lightly tap the air filter element to remove most of the dust and dirt and then blow the remaining dirt out with compressed air as shown If the air filte...

Page 56: ...talling 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 adjustments should be left to a Yamaha dealer who has the necessary profes sional knowledge and experience EAU21380 Adjusting the throttle cable free play The throttle cable free play should mea sur...

Page 57: ...ires 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 Tire air pressure measured on cold tires 0 0 90 0 kg 0 198 lb Front XVS650 200 kPa 29 psi 2 00 kgf cm XVS650A 225 kPa 33 psi 2 25 kgf cm XVS650AT 225 kPa 33 p...

Page 58: ...ead 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 EWA10460 The front and rear tires should be of the same make and de sign otherwise the handling characteristics of the vehicle cannot be guaranteed After extensive tests only the tires listed below have b...

Page 59: ...placed 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 tire life Ride at moderate speeds after changing a tire since the tire sur face must first be broken in for it to develop its optimal characteris tics EAU22010 Accessories and replacement parts WARNI...

Page 60: ...h 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 free play could be obtained as de scribed above tighten the locknut and skip the rest of the procedure otherwise proceed as follows 4 Fully turn the adjusting bolt at the clutch lever in direction a t...

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 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 prope...

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 in above the top of the footrest as shown Peri odically 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...

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 before braking takes effect If necessary adjust the brake light switch as follows Turn the adjusting nut while holding the rear brake light switch in place To make the brake light come on earlier turn...

Page 64: ...ck the brake shoe wear without having to dis assemble the brake To check the brake shoe wear check the position of the wear indicator while applying the brake If a brake shoe has worn to the point that the wear indicator reaches the wear limit line have a Yamaha dealer replace the brake shoes as a set EAU32341 Checking the brake fluid level Front brake Insufficient brake fluid may allow air to ent...

Page 65: ...or 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 However if the brake fluid level goes down sud denly have a Yamaha dealer check the cause EAU22720 Changing the brake fluid Have a Yamaha dealer change the brake fluid at the intervals specified in the...

Page 66: ...a 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 the cable should be lubricated or replaced at the intervals specified in the periodic maintenance chart EAU23131 Checking and lubricating the brake and shift pedals The operation of the brake and shi...

Page 67: ...1 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 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 vehi...

Page 68: ...ing 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 Y...

Page 69: ...ce it contains sul furic acid which causes severe burns Avoid any contact with skin eyes or clothing and al ways shield your eyes when working near batteries In case of contact administer the fol lowing FIRST AID EXTERNAL Flush with plenty of water INTERNAL Drink large quan tities of water or milk and im mediately call a physician EYES Flush with water for 15 minutes and seek prompt medical attent...

Page 70: ...arged 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 sealed type MF battery charg er have a Yamaha dealer charge your battery EAU23521 Replacing the fuses The main fuse and the fuse box which contains the fuses for the in...

Page 71: ...k 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 moving the screws 2 Disconnect the headlight coupler and then remove the bulb cover 1 Ignition fuse 2 Signaling system fuse 3 Headlight fuse 4 Carburetor heater fuse 5 Spare fuse Specified fuses Mai...

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 fingerprints on the headlight bulb using a cloth moistened with al cohol or thinner 5 Install the headlight bulb cover and then connect the coupler 6 Install the headlight unit by install ing the screws 7 Hav...

Page 73: ...tions 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 of the motorcycle by using a motorcycle stand or if an additional mot...

Page 74: ...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 32 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 ...

Page 75: ...hen 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 EAU25080 Rear wheel EAU25140 To remove the rear 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 fallin...

Page 76: ...pulled 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 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 brake torqu...

Page 77: ...n 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 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 par...

Page 78: ...ignition 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...

Page 79: ...t 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 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 par...

Page 80: ...sion 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 ...

Page 81: ...cock 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 cy...

Page 82: ...wheels 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...

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 or higher Engine oil quantity Without oil filter element replacement 2 60 L 2 75 US qt 2 29 Imp qt With oil filter element replacement 2 80 L 2 96 US qt 2 46 Imp qt Final gear oil Type SAE80API GL 4 ...

Page 84: ...l 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 XVS650A 200 0 kg 441 lb XVS650AT 200 0 kg 441 lb Total weight of rider passenger cargo and accessories Tire air pressure measured on cold tires Loading condition 0 0 90 0 kg 0 198 lb Front XVS650 20...

Page 85: ...gnition 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 Headlight 12 V 60 0 W 55 0 W 1 Tail brake light 12 V 8 0 W 27 0 W 1 Front turn signal position light 12 V 27 0 W 8 0 W 2 Rear turn signal light 12 V 27 0 W 2 Meter lighting 12 V 1 7 W 1 Neutral indicator...

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

Page 87: ...label 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 1 Model label 5FB13 book Page 2 Monday May 12 2003 5 20 PM ...

Page 88: ...nvestigation 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 dealer or Yamaha Motor Corporation U S A To contact NHTSA you may either call the Auto Safety Hotline toll free at 1 800 424 9393 or 366 0123 in Washington D C area or write to NHTSA U S Department of ...

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 or rendered inoperative by any person AMONG THOSE ACTS PRESUMED TO CONSTITUTE TAMPERING ARE THE ACTS LISTED BELOW These acts include tampering with the following systems i e modification removal etc...

Page 90: ...reminder 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 month 4000 mi 7000 km or 6 months 8000 mi 13000 km or 12 months 12000 mi 19000 km or 18 months 16000 mi 25000 km or 24 months 20000 mi 31000 km or 30 months 24000 mi 37000 km or 36 months 28000 mi 43000 ...

Page 91: ...INFORMATION 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 2003 5 20 PM ...

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: ...ered 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 included at no extra cost TRIP gives you up to 150 reimbursement per occurrence for any reasonable expenses you incur because your Yamaha needs covered service replacement vehicle rental emergency towi...

Page 95: ...acked 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 help you get the Y E S coverage you need Yamaha Service Marketing P O Box 6555 Cypress CA 90630 1 866 YES EXTD 1 866 937 3983 5FB13 book Page 10 Monday May 12 2003 5 20 PM ...

Page 96: ...ing 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 system 6 3 Maintenance periodic 6 1 Maintenance record 9 5 Model label 9 2 N Neutral indicator light 3 2 Noise regulation 9 4 P Panels removing and installing 6 8 Parking 5 5 Part locations 2 1 Pre o...

Page 97: ...arance 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 May 12 2003 5 20 PM ...

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

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