Yamaha Vstar XVS650T 2004 Owner'S Manual Download

Page: 73 / 101

PERIODIC MAINTENANCE AND MINOR REPAIR

6-30

sealed-type (MF) battery charg-
er, have a Yamaha dealer
charge your battery.

EAU23524

Replacing the fuses

The main fuse and the fuse box, which
contains the fuses for the individual cir-
cuits, are located behind panel B. (See
page 6-8.)
If a fuse is blown, replace it as follows.

1. Turn the key to “OFF” and turn off

the electrical circuit in question.

2. Remove the blown fuse, and then

install a new fuse of the specified
amperage.

1. Fuse box

2. Main fuse

3. Spare main fuse

1. Headlight fuse
2. Signaling system fuse

3. Ignition fuse

4. Carburetor heater fuse
5. Ignitor unit fuse (for California only)

6. Spare fuse

7. Spare fuse (for California only)

chapter6 Page 30 Wednesday, May 12, 2004 5:08 AM

Summary of Contents for Vstar XVS650T 2004

Page 1: ...PRINTED IN JAPAN 2004 05 2 6 1 CR E PRINTED ON RECYCLED PAPER YAMAHA MOTOR CO LTD 5FB 28199 15 LIT 11626 18 20 XVS650T C XVS650AT C XVS650ATT C OWNER S MANUAL...

Page 2: ...EAU10041 U5FB15E0 book Page 1 Tuesday May 11 2004 3 55 AM...

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 w...

Page 4: ...consult your Yamaha dealer WARNING EWA10010 PLEASE READ THIS MANUAL AND THE YOU AND YOUR MOTORCYCLE RIDING TIPS BOOKLET CAREFULLY AND COMPLETELY BEFORE OPERATING THIS MOTORCYCLE DO NOT ATTEMPT TO OPER...

Page 5: ...AINED 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 RELIABILITY OF THIS MOTO...

Page 6: ...Motor Corporation U S A 1st edition April 2004 All rights reserved Any reprinting or unauthorized use without the written permission of Yamaha Motor Corporation U S A is expressly prohibited Printed i...

Page 7: ...er 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 Canister...

Page 8: ...4 Rear wheel 6 35 Troubleshooting 6 37 Troubleshooting chart 6 38 MOTORCYCLE CARE AND STORAGE 7 1 Care 7 1 Storage 7 3 SPECIFICATIONS 8 1 CONSUMER INFORMATION 9 1 Identification numbers 9 1 Reporting...

Page 9: ...ts have been caused by an automobile driver who did not see the motorcycle Making yourself conspicuous ap pears to be very effective in reduc ing the chance of this type of accident Therefore Wear a b...

Page 10: ...ce 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 pre...

Page 11: ...the following guidelines in mind as well as those provided under Load ing when mounting accessories Never install accessories or carry cargo that would impair the perfor mance of your motorcycle Care...

Page 12: ...off before leaving the motorcycle unattended and remove the key from the main switch When parking the motor cycle note the following The engine and exhaust system may be hot therefore park the motorcy...

Page 13: ...SAFETY INFORMATION 1 5 1 EAU10381 Location of important labels Please read the following important labels carefully before operating this vehicle U5FB15E0 book Page 5 Tuesday May 11 2004 3 55 AM...

Page 14: ...SAFETY INFORMATION 1 6 1 1 2 3 XVS650 3 XVS650A AT 4 U5FB15E0 book Page 6 Tuesday May 11 2004 3 55 AM...

Page 15: ...SAFETY INFORMATION 1 7 1 5 6 California only A1 U5FB15E0 book Page 7 Tuesday May 11 2004 3 55 AM...

Page 16: ...age 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 11 6 Owner s tool kit page 6 1 7 Storage compartment...

Page 17: ...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 11 6 Owner s tool kit page 6 1 7 Storage compartment page 3...

Page 18: ...ht view XVS650 1 Engine oil filter element page 6 11 2 Battery page 6 29 3 Fuses page 6 30 4 Main switch steering lock page 3 1 5 Air filter element page 6 14 6 Brake pedal page 3 5 U5FB15E0 book Page...

Page 19: ...50A AT 1 Engine oil filter element page 6 11 2 Battery page 6 29 3 Fuses page 6 30 4 Main switch steering lock page 3 1 5 Air filter element page 6 14 6 Brake pedal page 3 5 U5FB15E0 book Page 4 Tuesd...

Page 20: ...ts 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 16 7 Brake lever page 3 5...

Page 21: ...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...

Page 22: ...al circuit of the warning light can be checked by turning the key to ON If the warning light does not come on for a few seconds then go off have a Yamaha dealer check the electrical circuit EAU11630 S...

Page 23: ...hing 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...

Page 24: ...AU12870 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 transmissio...

Page 25: ...3120 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...

Page 26: ...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 gas...

Page 27: ...eration Make sure that the exhaust system has cooled down before do ing any maintenance work CAUTION ECA10700 The following precautions must be observed to prevent a fire hazard or other damages Use...

Page 28: ...e fuel cock lever back to ON EAU13620 Starter choke knob Starting a cold engine requires a richer air fuel mixture which is supplied by the starter choke Move the knob in direction a to turn on the st...

Page 29: ...nd then install the nut Rider seat To remove the rider seat 1 Remove the passenger seat 2 Remove the bolts and then pull the seat up To install the rider seat 1 Insert the projection on the front of t...

Page 30: ...then install the bolt Rider seat To remove the rider seat 1 Remove the passenger seat 2 Remove the bolt and then pull the rider seat up To install the rider seat 1 Insert the projection on the front...

Page 31: ...storage compartment is located on the left side of the vehicle To open the storage compartment 1 Slide the lock cover open insert the key into the lock and then turn it clockwise 2 Pull the storage co...

Page 32: ...e 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...

Page 33: ...he 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...

Page 34: ...he 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...

Page 35: ...er 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 relia...

Page 36: ...quences 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 use...

Page 37: ...y 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 21 6 24 6 24 Rear brake...

Page 38: ...mooth Lubricate lever pivoting points if necessary 6 26 Sidestand Make sure that operation is smooth Lubricate pivot if necessary 6 27 Chassis fasteners Make sure that all nuts bolts and screws are pr...

Page 39: ...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...

Page 40: ...rter 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...

Page 41: ...lways 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 accelera...

Page 42: ...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 pu...

Page 43: ...diately have a Yamaha dealer check the vehicle EAU17180 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 eng...

Page 44: ...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 SER...

Page 45: ...ARNING 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 U5F...

Page 46: ...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 val...

Page 47: ...ch 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 s...

Page 48: ...se 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 light...

Page 49: ...r oil Check oil level and for oil leakage Change at initial 600 mi 1000 km or 1 month and thereafter every 16000 mi 25000 km or 24 months Change Change 21 Control and meter cables Apply Yamaha chain a...

Page 50: ...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...

Page 51: ...apter Refer to this section each time a panel needs to be removed and installed XVS650 XVS650A AT EAU19192 Panel A To remove the panel Remove the bolts and then take the panel off XVS650 To install th...

Page 52: ...he 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 wrench includ ed in the owner s tool kit...

Page 53: ...t available when installing a spark plug a good estimate of the correct torque is 1 4 1 2 turn past finger tight However the spark plug should be tightened to the speci fied torque as soon as possible...

Page 54: ...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 at or below the minimum level mark...

Page 55: ...p page since the engine oil also lubricates the clutch do not mix any chemical additives Do not use oils with a diesel speci fication of CD or oils of a high er quality than specified In addition do n...

Page 56: ...e that no foreign mate rial enters the final gear case Make sure that no oil gets on the tire or wheel To check the final gear oil level 1 Place the vehicle on a level sur face and hold it in an uprig...

Page 57: ...ld be cleaned at the intervals specified in the periodic maintenance and lubrication chart Clean the air filter element more fre quently if you are riding in unusually wet or dusty areas 1 Remove the...

Page 58: ...er ele ment installed otherwise the piston s and or cylinder s may become excessively worn 5 Install the air filter case cover by aligning the match marks and in stalling the bolts NOTE If dust or wat...

Page 59: ...free play The throttle cable free play should mea sure 4 0 6 0 mm 0 16 0 24 in at the throttle grip Periodically check the throttle cable free play and if neces sary have a Yamaha dealer adjust it EAU...

Page 60: ...side to side Properly adjust the suspension for your load and check the condition and pres sure of your tires NEVER OVER LOAD YOUR VEHICLE Make sure that the total weight of the cargo rid er passenge...

Page 61: ...brake related parts includ ing the tires should be left to a Yamaha dealer who has the necessary professional knowl edge and experience It is not recommended to patch a punctured tube If unavoid able...

Page 62: ...ar The accessories or replacement parts you choose for your vehicle should be designed specifically for this model and they must be se curely mounted to maintain the in herent stability of the origina...

Page 63: ...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 NOTE If the specified clutch lever fr...

Page 64: ...er free play and if necessary adjust it as follows 1 Loosen the locknut at the brake le ver 2 To increase the brake lever free play turn the adjusting screw in di rection a To decrease the brake lever...

Page 65: ...ad justed before adjusting the brake pedal free play Brake pedal position The brake pedal should be positioned approximately XVS650 102 0 mm 4 02 in XVS650A 108 0 mm 4 25 in XVS650AT 108 0 mm 4 25 in...

Page 66: ...justing 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 bef...

Page 67: ...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...

Page 68: ...e brake fluid at the intervals specified in the NOTE after the periodic mainte nance and lubrication chart In addition have the oil seals of the brake master cylinder and caliper as well as the brake...

Page 69: ...and shift pedals The operation of the brake and shift pedals should be checked before each ride and the pedal pivots should be lu bricated if necessary EAU23140 Checking and lubricating the brake and...

Page 70: ...odic 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 an...

Page 71: ...y support the vehicle so that there is no danger of it falling over 2 Hold the lower ends of the front fork legs and try to move them for ward and backward If any free play can be felt have a Yamaha d...

Page 72: ...attery and pro vide sufficient ventilation when charging it in an enclosed space KEEP THIS AND ALL BATTER IES OUT OF THE REACH OF CHILDREN To charge the battery Have a Yamaha dealer charge the bat ter...

Page 73: ...See page 6 8 If a fuse is blown replace it as follows 1 Turn the key to OFF and turn off the electrical circuit in question 2 Remove the blown fuse and then install a new fuse of the specified ampera...

Page 74: ...ulb 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...

Page 75: ...f 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 thinn...

Page 76: ...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 whee...

Page 77: ...70 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...

Page 78: ...ere is no danger of it falling over 1 Loosen the axle nut 2 Disconnect the brake torque rod from the brake shoe plate by re moving the bolt and nut 3 Loosen the brake torque rod nut at the swingarm 4...

Page 79: ...stall 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 Inst...

Page 80: ...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 techni...

Page 81: ...ition 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 Yama...

Page 82: ...eave 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...

Page 83: ...n 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 d...

Page 84: ...k 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 i...

Page 85: ...els 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 mo...

Page 86: ...linder Displacement 649 0 cm 39 60 cu in Bore stroke 81 0 63 0 mm 3 19 2 48 in Compression ratio 9 00 1 Starting system Electric starter Lubrication system Wet sump Engine oil Type YAMALUBE 4 SAE10W30...

Page 87: ...OP D404F XVS650AT DUNLOP D404F Rear tire Type With tube Size 170 80 15M C 77S Manufacturer model XVS650 BRIDGESTONE EXEDRA G546 XVS650A BRIDGESTONE EXEDRA G702 XVS650AT BRIDGESTONE EXEDRA G702 Manufac...

Page 88: ...m 3 86 in XVS650AT 98 0 mm 3 86 in Electrical system Ignition system Transistorized coil ignition digital Charging system A C magneto Battery Model GT12B 4 Voltage capacity 12 V 10 0 Ah Headlight Bulb...

Page 89: ...ntification 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 n...

Page 90: ...el is affixed to the frame under the rider seat See page 3 9 Record the information on this label in the space provided This information will be needed when ordering spare parts from a Yamaha dealer 1...

Page 91: ...stigation 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 deal...

Page 92: ...cle 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 o...

Page 93: ...inder 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...

Page 94: ...ORMATION 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 U5FB15E0 book Page 6 Tuesday May 11...

Page 95: ...CONSUMER INFORMATION 9 7 9 EAU26661 YAMAHA MOTOR CORPORATION U S A STREET AND ENDURO MOTORCYCLE LIMITED WARRANTY U5FB15E0 book Page 7 Tuesday May 11 2004 3 55 AM...

Page 96: ...CONSUMER INFORMATION 9 8 9 U5FB15E0 book Page 8 Tuesday May 11 2004 3 55 AM...

Page 97: ...d 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 incl...

Page 98: ...ed 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 hel...

Page 99: ...n numbers 9 1 Ignition circuit cut off system 3 14 Indicator and warning 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...

Page 100: ...il brake light bulb replacing 6 32 Turn signal switch 3 3 V Valve clearance adjusting 6 16 Vehicle identification number 9 1 W Warranty extended 9 9 Warranty limited 9 7 Wheel bearings checking 6 28 W...

Page 101: ...PRINTED IN JAPAN 2004 05 2 6 1 CR E PRINTED ON RECYCLED PAPER YAMAHA MOTOR CO LTD 5FB 28199 15 LIT 11626 18 20 XVS650T C XVS650AT C XVS650ATT C OWNER S MANUAL...

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