Yamaha XVS650H 2016 Owner'S Manual Download Page 49

Page: 49 / 96

Perio

ic maintenance an

justment

7-7

• Every two years replace the internal components of the brake master cylinder and caliper, and change the brake

fluid.

• Replace the brake hoses every four years and if cracked or damaged.

U1BF27E0.book Page 7 Tuesday, May 17, 2016 8:35 AM

Summary of Contents for XVS650H 2016

Page 1: ...DIC183 XVS650H XVS650AH OWNER S MANUAL Read this manual carefully before operating this vehicle 1BF 28199 27 English E...

Page 2: ...EAU46091 Read this manual carefully before operating this vehicle This manual should stay with this vehicle if it is sold U1BF27E0 book Page 1 Tuesday May 17 2016 8 35 AM...

Page 3: ...and injury In addition the many tips given in this manual will help keep your motorcycle in the best possible condition If you have any further questions do not hesitate to contact your Yamaha dealer...

Page 4: ...ntial personal injury hazards Obey all safety messages that follow this symbol to avoid possible injury or death A WARNING indicates a hazardous situation which if not avoided could result in death or...

Page 5: ...S MANUAL 2016 by Yamaha Motor Co Ltd 1st edition April 2016 All rights reserved Any reprinting or unauthorized use without the written permission of Yamaha Motor Co Ltd is expressly prohibited Printe...

Page 6: ...kit 7 2 Periodic maintenance chart for the emission control system 7 3 General maintenance and lubrication chart 7 4 Removing and installing panels 7 8 Checking the spark plugs 7 9 Engine oil and oil...

Page 7: ...ail light bulb 7 34 Supporting the motorcycle 7 34 Front wheel 7 35 Rear wheel 7 36 Troubleshooting 7 38 Troubleshooting chart 7 40 Motorcycle care and storage 8 1 Matte color caution 8 1 Care 8 1 Sto...

Page 8: ...hicle They contain important information for safe and proper operation of your vehicle Never remove any labels from your vehicle If a label becomes difficult to read or comes off a replacement label i...

Page 9: ...bs maximum load FRONT REAR 200 kPa 2 00 kgf cm 29 psi 250 kPa 2 50 kgf cm 36 psi 3B6 21668 00 TIRE INFORMATION Cold tire normal pressure should be set as follows Up to 90 kg 198 lbs load FRONT REAR 22...

Page 10: ...ou Safe Riding Perform the pre operation checks each time you use the vehicle to make sure it is in safe operating condition Failure to inspect or maintain the vehi cle properly increases the possibil...

Page 11: ...o main tain control of the motorcycle The passenger should always hold onto the operator the seat strap or grab bar if equipped with both hands and keep both feet on the passenger footrests Never carr...

Page 12: ...d To avoid the possibility of an accident use extreme caution when adding cargo or accessories to your motorcycle Use extra care when riding a motorcycle that has added cargo or accessories Here along...

Page 13: ...change any of the vehicle s design or operation characteristics can put you and others at greater risk of serious injury or death You are responsible for injuries related to changes in the vehicle Kee...

Page 14: ...nstruc tions before transporting the motorcy cle in another vehicle Remove all loose items from the motorcycle Check that the fuel cock if equipped is in the OFF position and that there are no fuel le...

Page 15: ...8 2 Fuel cock page 4 11 3 Starter choke knob page 4 12 4 Shock absorber assembly spring preload adjusting ring page 4 16 5 Helmet holder page 4 15 6 Storage compartment page 4 15 7 Owner s tool kit p...

Page 16: ...6 7 5 1 Engine oil filter element page 7 11 2 Battery page 7 30 3 Fuses page 7 31 4 Fuel tank cap page 4 9 5 Main switch steering lock page 4 2 6 Air filter element page 7 15 7 Brake pedal page 4 9 U1...

Page 17: ...struments 1 2 3 4 5 6 1 Clutch lever page 4 7 2 Left handlebar switches page 4 6 3 Speedometer unit page 4 5 4 Right handlebar switches page 4 6 5 Throttle grip page 7 17 6 Brake lever page 4 8 U1BF27...

Page 18: ...EALER IMMEDIATELY IF 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 cod...

Page 19: ...ard key black bow for regular use of the vehicle To minimize the risk of losing the code re registering key red bow keep it in a safe place and only use it for code re registering EAU61860 ON XVS650H...

Page 20: ...ey can be re moved To lock the steering 1 Turn the handlebars all the way to the left 2 With the key in the OFF position push the key in and turn it to LOCK 3 Remove the key TIP If the steering will n...

Page 21: ...t This warning light comes on or flashes if a problem is detected in the electrical circuit monitoring the engine If this oc curs have a Yamaha dealer check the self diagnosis system See page 4 6 for...

Page 22: ...mes and then quickly flashes two times repeat edly this error could be caused by signal interference If this occurs try the following 1 Make sure there are no other im mobilizer keys close to the main...

Page 23: ...nsult a Yamaha dealer as soon as possible if this occurs EAU1234K Handlebar switches Left Right XVS650H Right XVS650AH EAU12352 Pass switch Press this switch to flash the headlight TIP When the dimmer...

Page 24: ...ing the en gine EAU12735 Hazard switch XVS650AH With the key in the ON or posi tion use this switch to turn on the haz ard lights simultaneous flashing of all turn signal lights The hazard lights are...

Page 25: ...5 speed con stant mesh transmission equipped on this motorcycle TIP For XVS650AH Use your toes or heel to shift up and your toes to shift down EAU12892 Brake lever The brake lever is located on the ri...

Page 26: ...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 remove it and...

Page 27: ...d surfaces or plastic parts ECA10072 4 Be sure to securely close the fuel tank cap WARNING EWA15152 Gasoline is poisonous and can cau se injury or death Handle gasoline with care Never siphon gasoline...

Page 28: ...nce problems EAU13551 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 lustra...

Page 29: ...tarter choke Move the knob in direction b to turn off the starter choke NOTICE ECA10991 Do not use the starter choke for more than 3 minutes as the exhaust pipe may discolor from excessive heat In add...

Page 30: ...seat into the seat holder as shown and then place the seat in the original position 2 Install the seat holder by installing its bolts 3 Install the passenger seat TIP Make sure that the seats are pro...

Page 31: ...at 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 of the rider seat into the seat holder as shown place th...

Page 32: ...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 c...

Page 33: ...owner s tool kit to make the adjustment 3 Install the passenger and rider seats WARNING EWA10222 This shock absorber assembly con tains highly pressurized nitrogen gas Read and understand the fol low...

Page 34: ...xplanation of the ignition circuit cut off system WARNING EWA10242 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...

Page 35: ...is up but the clutch le ver is not pulled It prevents starting when the transmission is in gear and the clutch lever is pulled but the side stand is still down It cuts the running engine when the tra...

Page 36: ...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 The neutral switch may not be working correctly The...

Page 37: ...g this vehicle check the following points ITEM CHECKS PAGE Fuel Check fuel level in fuel tank Refuel if necessary Check fuel line for leakage 4 10 Engine oil Check oil level in engine If necessary add...

Page 38: ...if necessary 7 18 7 20 Brake and shift pedals Make sure that operation is smooth Lubricate pedal pivoting points if necessary 7 26 Brake and clutch levers Make sure that operation is smooth Lubricate...

Page 39: ...d make sure that the engine stop switch is set to 3 Shift the transmission into the neutral position The neutral indi cator light should come on If not ask a Yamaha dealer to check the electrical circ...

Page 40: ...smission into the neu tral position press the shift pedal down repeatedly until it reaches the end of its travel and then slightly raise it NOTICE ECA10261 Even with the transmission in the neutral po...

Page 41: ...at railroad crossings EAU16842 Engine break in There is never 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 fol...

Page 42: ...72 Parking When parking stop the engine re move the key from the main switch and then turn the fuel cock lever to OFF WARNING EWA10312 Since the engine and exhaust system can become very hot park in a...

Page 43: ...performing maintenance unless otherwise specified A running engine has moving parts that can catch on body parts or clothing and electrical parts that can cause shocks or fires Running the engine whil...

Page 44: ...d in the owner s tool kit are intended to assist you in the performance of preventive maintenance and minor repairs How ever additional tools such as a torque wrench may be necessary to perform certai...

Page 45: ...cal skills EAU46912 Periodic maintenance chart for the emission control system NO ITEM CHECK OR MAINTENANCE JOB ODOMETER READING ANNUAL CHECK 1000 km 600 mi 10000 km 6000 mi 20000 km 12000 mi 30000 km...

Page 46: ...fluid leakage Adjust brake lever free play Replace brake pads Whenever worn to the limit 4 Rear brake Check operation and adjust brake pedal free play Replace brake shoes Whenever worn to the limit 5...

Page 47: ...htened 13 Brake lever pivot shaft Lubricate with silicone grease 14 Brake pedal pivot shaft Lubricate with lithium soap based grease 15 Clutch lever pivot shaft Lubricate with lithium soap based greas...

Page 48: ...22 Engine oil filter ele ment 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 cables Lubricate 26 Thro...

Page 49: ...7 7 Every two years replace the internal components of the brake master cylinder and caliper and change the brake fluid Replace the brake hoses every four years and if cracked or damaged U1BF27E0 boo...

Page 50: ...of the maintenance jobs described in this chapter Refer to this section each time a panel needs to be removed and installed XVS650H XVS650AH XVS650H XVS650AH EAU56011 Panel A To remove the panel Remo...

Page 51: ...plugs are important engine components 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 pe...

Page 52: ...spark plug gap with a wire thickness gauge and if nec essary adjust the gap to specifi cation To install a spark plug 1 Clean the surface of the spark plug gasket and its mating surfa ce and then wipe...

Page 53: ...through the engine oil level check window located at the bottom left side of the crankcase TIP The engine oil should be between the minimum and maximum level marks 4 If the engine oil is at or below t...

Page 54: ...lling the bolts and then tighten them to the specified torque 8 Install the engine oil drain bolt and its new gasket and then tighten the bolt to the specified torque 9 Refill with the specified amoun...

Page 55: ...rrect it if necessary EAU20028 Final gear oil The final gear case must be checked for oil leakage before each ride If any leakage is found have a Yamaha deal er check and repair the vehicle In ad diti...

Page 56: ...ll the final gear oil drain bolt and its new gasket and then tight en the bolt to the specified torque 4 Refill with the recommended final gear oil to the brim of the filler hole 5 Check the oil fille...

Page 57: ...and then blow 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 NOTICE Make sure tha...

Page 58: ...se settings without sufficient technical knowl edge may result in poor perfor mance of or damage to the engine EAU21341 Adjusting the engine idling speed The engine idling speed must be checked and if...

Page 59: ...ssary have a Yamaha dealer adjust it EAU21402 Valve clearance The valve clearance changes with use resulting in improper air fuel mixture and or engine noise To prevent this from occurring the valve c...

Page 60: ...the total weight of rider passenger car go and accessories approved for this model WARNING EWA10512 Never overload your vehicle Opera tion of an overloaded vehicle could cause an accident Tire inspec...

Page 61: ...it to develop its optimal characteristics Tire information This model is equipped with tube tires Tires age even if they have not been used or have only been used occasion ally Cracking of the tread a...

Page 62: ...g characteristics and a short ened tire life EAU22047 Adjusting the clutch lever free play Measure the clutch lever free play as shown Periodically check the clutch lever free play and if necessary ad...

Page 63: ...y as shown Periodically check the brake lever free play and if necessary adjust it as fol lows 1 Loosen the locknut at the brake le ver 2 To increase the brake lever free play turn the brake lever fre...

Page 64: ...is advisable to have a Yamaha dealer make these adjustments Periodically check the brake pedal height and free play and if necessary adjust them as follows TIP The brake pedal height should be ad jus...

Page 65: ...turn the adjusting nut in direction b EAU22274 Brake light switches The brake light which is activated by the brake pedal and brake lever should come on just before braking takes effect If necessary a...

Page 66: ...ke is provided with a wear indicator which allows you to check the brake shoe wear without having to disassemble the brake To check the brake shoe wear check the position of the wear indicator while a...

Page 67: ...es or plastic parts Always clean up spilled fluid immediately As the brake pads wear it is normal for the brake fluid level to gradually go down A low brake fluid level may indi cate worn brake pads a...

Page 68: ...lace damaged cables as soon as possible to prevent unsafe condi tions EWA10712 EAU49921 Checking and lubricating the throttle grip and cable The operation of the throttle grip should be checked before...

Page 69: ...the brake and clutch levers should be checked before each ride and the lever pivots should be lu bricated if necessary Brake lever Clutch lever Recommended lubricant Lithium soap based grease Recomme...

Page 70: ...on chart EAU57910 Checking the front fork The condition and operation of the front fork must be checked as follows at the intervals specified in the periodic maintenance and lubrication chart To check...

Page 71: ...round See page 7 34 WARNING To avoid injury se curely support the vehicle so there is no danger of it falling over EWA10752 2 Hold the lower ends of the front fork legs and try to move them for ward a...

Page 72: ...eep sparks flames cigarettes etc away from the battery and pro vide sufficient ventilation when charging it in an enclosed space KEEP THIS AND ALL BATTER IES OUT OF THE REACH OF CHILDREN NOTICE ECA106...

Page 73: ...charged battery can cause permanent battery damage EAU2352A 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...

Page 74: ...y 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 1 Remove the headlight...

Page 75: ...it as follows 1 Remove the headlight unit by re moving the screws 2 Remove the socket together with the bulb by pushing it in and turn ing it counterclockwise 3 Remove the burnt out bulb by pushing it...

Page 76: ...when removing the front and rear wheel or performing other mainte nance requiring the motorcycle to stand upright Check that the motorcy cle is in a stable and level position be fore starting any main...

Page 77: ...h bolt then the wheel axle 3 Lift the front wheel off the ground according to the procedure in the previous section Supporting the motorcycle 4 Pull the wheel axle out and then remove the wheel NOTICE...

Page 78: ...hard on the handle bars several times to check if the front fork compresses and re bounds smoothly 8 Connect the speedometer cable EAU25081 Rear wheel EAU56630 To remove the rear wheel WARNING EWA1082...

Page 79: ...ack to remove the following parts as an assem bly wheel wheel axle final gear case and drive shaft TIP Make sure to support the drive shaft as it is being pulled out To install the rear wheel 1 Instal...

Page 80: ...problem in the fuel compression or ignition systems for example can cause poor starting and loss of power The following troubleshooting chart represents a quick and easy procedure for checking these v...

Page 81: ...iodic maintenance and adjustment 7 39 7 heaters or furnaces Gasoline or gasoline vapors can ignite or ex plode causing severe injury or prop erty damage U1BF27E0 book Page 39 Tuesday May 17 2016 8 35...

Page 82: ...e 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 eng...

Page 83: ...the muffler outlets with plastic bags after the engine has cooled down 2 Make sure that all caps and cov ers as well as all electrical cou plers and connectors including the spark plug caps are tightl...

Page 84: ...dirt with warm water a mild detergent and a soft clean sponge and then rinse thoroughly with clean water Use a toothbrush or bottlebrush for hard to reach areas Stubborn dirt and insects will come of...

Page 85: ...x to any rubber and plastic parts but treat them with a suitable care product Avoid using abrasive polishing compounds as they will wear away the paint TIP Consult a Yamaha dealer for ad vice on what...

Page 86: ...er walls with oil WARNING To prevent dam age or injury from sparking make sure to ground the spark plug electrodes while turning the engine over EWA10952 e Remove the spark plug caps from the spark pl...

Page 87: ...Engine oil Recommended brand YAMALUBE SAE viscosity grades 10W 40 20W 40 Recommended engine oil grade API service SG type or higher JASO standard MA Engine oil quantity Oil change 2 60 L 2 75 US qt 2...

Page 88: ...0 kPa 2 00 kgf cm 29 psi XVS650H 225 kPa 2 25 kgf cm 33 psi XVS650AH Rear 225 kPa 2 25 kgf cm 33 psi 90 kg 198 lb load maximum load Front 200 kPa 2 00 kgf cm 29 psi XVS650H 225 kPa 2 25 kgf cm 33 psi...

Page 89: ...2 Auxiliary light 4 0 W 1 XVS650AH Meter lighting 1 7 W 1 Neutral indicator light 1 7 W 1 High beam indicator light 1 7 W 1 Turn signal indicator light 1 7 W 1 Engine trouble warning light 1 7 W 1 Im...

Page 90: ...ERIAL NUMBER MODEL LABEL INFORMATION EAU26401 Vehicle identification number The vehicle identification number is stamped into the steering head pipe Record this number in the space pro vided TIP The v...

Page 91: ...EM PROHIBITED Owners are warned that the law may prohibit a The removal or rendering inopera tive by any person other than for purposes of maintenance repair or replacement of any device or element of...

Page 92: ...beam indicator light 4 4 Horn switch 4 7 I Identification numbers 10 1 Ignition circuit cut off system 4 18 Immobilizer system 4 1 Immobilizer system indicator light 4 5 Indicator lights and warning...

Page 93: ...light bulb or brake tail light bulb replacing 7 34 Turn signal switch 4 7 V Valve clearance 7 17 Vehicle identification number 10 1 W Wheel bearings checking 7 29 Wheel front 7 35 Wheel rear 7 36 Whe...

Page 94: ...A5 yoko_Blank fm Page 1 Thursday December 8 2011 2 18 PM...

Page 95: ...A5 yoko_Blank fm Page 1 Thursday December 8 2011 2 18 PM...

Page 96: ...DIC183 PRINTED ON RECYCLED PAPER PRINTED IN JAPAN 2016 06 0 3 1 CR E...

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