Yamaha XVS650A Owner'S Manual Download Page 55

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PERIODIC MAINTENANCE AND MINOR REPAIR

6-18

system. If there is air in the hy-
draulic system, have a Yamaha
dealer bleed the system before
operating the motorcycle. Air in
the hydraulic system will dimin-
ish the braking performance,
which may result in loss of con-
trol and an accident.

EAU22231

Adjusting the brake pedal
position and free play

WARNING

EWA10670

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

NOTE:

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

Brake pedal position

The brake pedal should be positioned
approximately 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 (b).

3. Tighten the locknut.

WARNING

EWA11230

After adjusting the brake pedal posi-
tion, the brake pedal free play must
be adjusted.

1. Distance between brake pedal and footrest

2. Brake pedal free play

1. Locknut
2. Brake pedal position adjusting bolt

U5SCE1E0.book Page 18 Monday, September 8, 2003 11:32 AM

Summary of Contents for XVS650A

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

Page 2: ...E 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 equipme...

Page 3: ...o 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 troubl...

Page 4: ...ur 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...

Page 5: ...AL 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 J...

Page 6: ...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 Ad...

Page 7: ...ry 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...

Page 8: ...s 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 brig...

Page 9: ...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 preve...

Page 10: ...r 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 i...

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...

Page 12: ...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 pag...

Page 13: ...ght 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 Mond...

Page 14: ...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 U5...

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 r...

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 th...

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...

Page 18: ...d 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 sy...

Page 19: ...ripmeter 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 ca...

Page 20: ...t 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...

Page 21: ...gni 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 o...

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 a...

Page 23: ...leaded 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...

Page 24: ...ds 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 T...

Page 25: ...tarter 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 ad...

Page 26: ...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...

Page 27: ...e 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...

Page 28: ...ndling 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 imprope...

Page 29: ...he 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...

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...

Page 31: ...ences 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...

Page 32: ...heck 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 Ch...

Page 33: ...th 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 prope...

Page 34: ...led 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...

Page 35: ...rter 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 EAU1667...

Page 36: ...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 Fu...

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...

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 includ...

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...

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...

Page 41: ...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 Thrott...

Page 42: ...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 T...

Page 43: ...e 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...

Page 44: ...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 inter...

Page 45: ...ff 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 no...

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...

Page 47: ...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 T...

Page 48: ...ow 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...

Page 49: ...se 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...

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...

Page 51: ...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...

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 soo...

Page 53: ...sting 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 Loo...

Page 54: ...ake 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...

Page 55: ...e 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 ne...

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 directi...

Page 57: ...d 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...

Page 58: ...e 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 chec...

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 be...

Page 60: ...vals 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 tub...

Page 61: ...ust 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 Secur...

Page 62: ...p 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...

Page 63: ...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 permanen...

Page 64: ...he 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 t...

Page 65: ...ss 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 an...

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 b...

Page 67: ...d 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...

Page 68: ...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 un...

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...

Page 70: ...all 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 Instal...

Page 71: ...ubleshooting 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 technicia...

Page 72: ...ion 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...

Page 73: ...ve 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 da...

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 duc...

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 int...

Page 76: ...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 moist...

Page 77: ...9 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 e...

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...

Page 79: ...ing 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 indic...

Page 80: ...fication 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...

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 M...

Page 82: ...7 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 Indic...

Page 83: ...ight 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...

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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