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Yamaha 2002 V Star Silverado Owner's Manual

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1. e Apply chain lube lightly 1 Ni Ni Since these items require special tools data and technical skills have a Yamaha dealer perform the service 1 Yamaha chain and cable lube or SAE10W30 motor oil 2 Molybdenum disulfide grease 3 Lithium soap based grease all purpose grease 4 SAE80 API GL 4 hypoid gear oil NOTE Ni Ni Ni EAU03907 From 24 000 mi 37 000 km or 36 months repeat the maintenance intervals starting from 4 000 mi 7 000 km or 6 months NOTE EAU03234 The air filter needs more frequent service if you are riding in unusually wet or dusty areas Hydraulic brake service e Regularly check and if necessary correct the brake fluid level e Every two years replace the internal components of the brake master cylinder and caliper and change the brake fluid e Replace the brake hoses every four years and if cracked or damaged Engine oil type e Yamalube 4 20W 40 or engine oil SAE 20W 40 API SE for temperatures of 5 C 40 F or above e Yamalube 4 10W 30 or engine oil SAE 10W 30 API SE for temperatures of 15 C 60 F or below 6 6 PERIODIC MAINTENANCE AND MINOR REPAIR 1 Panel A 1 Panel A 1 Panel B EAU01122 Removing and installing panels The panels shown above need to be removed to perform some of the main tenance jobs described in this chapter Refer to this section each time a panel needs to be r
2. EAU00129 Horn switch bo Press this switch to sound the horn 3 3 1 Engine stop switch O R 2 Start switch EAU03890 Engine stop switch O 8 Set this switch to O before starting the engine Set this switch to to stop the engine in case of an emergen cy such as when the motorcycle over turns or when the throttle cable is stuck EAU00143 Start switch Push this switch to crank the engine with the starter EC000005 CAUTION See page 5 1 for starting instruc tions prior to starting the engine INSTRUMENT AND CONTROL FUNCTIONS 1 Clutch lever EAU00152 Clutch lever The clutch lever is located at the left handlebar grip To disengage the clutch pull the lever toward the handle bar grip To engage the clutch release the lever The lever should be pulled rapidly and released slowly for smooth clutch operation The clutch lever is equipped with a clutch switch which is part of the ignition circuit cut off system See page 3 16 for an explanation of the ignition circuit cut off system 1 Shift pedal EAU00157 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 3 4 1 Shift pedal EAU01215 Shift pedal XVS650A The shift pedal is located on the left side o
3. 6 4 Removing and installing panels cee 6 7 Checking the spark PIUQS 6 9 Canister for California only 6 11 Engine oil and oil filter element ee 6 11 Final gear oW Sen Triuir aas deena 6 14 Cleaning the air filter element eeeee 6 15 Adjusting the carburetors secese 6 16 Adjusting the throttle cable free play 6 17 Adjusting the valve clearance ssec 6 17 TIRES n recites aa ae a EEE EEA RRRA 6 17 Spoke Wheels cccceececeeeeeeeeeeeeeeeeeeeneessnaees 6 19 Accessories and replacement parts 6 20 Adjusting the clutch lever free play n e 6 21 Adjusting the brake lever free play saae 6 22 Adjusting the brake pedal position and free play ceccie eee diene 6 23 Adjusting the rear brake light switch 6 24 Checking the front brake pads and rear brake Sholes se 20ed 22 accede kaaa a aneian 6 25 Checking the brake fluid level ceee 6 26 Changing the brake fluid 0 ceeeeeeeteeeeee 6 27 Checking and lubricating the cables 6 27 Checking and lubricating the throttle Qrip and Cable csheiiesce eine ee ter veitinee 6 27 Checking and lubricating the brake and Shift Pedals eeeeceeeesecceeeeeeseeeeeeeesseeeeeeeeneees 6 28 Checking and lubricating the brake and clutch levers sssssesrisssrrirsssernrsssrnnenrerennerrnens 6 28 Checking and lubricating the sidestand 6 29 Chec
4. 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 C 30 F or more than 30 C 90 F For more informa tion on storing the battery see page 6 32 NOTE Make any necessary repairs before storing the motorcycle Specifications SPECIFICATIONS Specifications Model Dimensions XVS650 C Overall length Overall width Overall height Seat height Wheelbase Ground clearance Minimum turning radius XVS650A C Overall length Overall width Overall height Seat height Wheelbase Ground clearance Minimum turning radius Basic weight with oil and full fuel tank XVS650 C XVS650A C XVS650 C XVS650A C 2 295 mm 90 4 in 880 mm 34 6 in 1 070 mm 42 1 in 695 mm 27 4 in 1 610 mm 63 4 in 140 mm 5 5 in 3 100 mm 122 0 in 2 450 mm 96 5 in 930 mm 36 6 in 1 105 mm 43 5 in 710 mm 28 0 in 1 625 mm 64 0 in 145 mm 5 7 in 3 400 mm 133 9 in 233 kg 514 Ib 247 kg 545 Ib 8 1 Engine Engine type Cylinder arrangement Displacement Bore x stroke Compression ratio Starting system Lubrication system Engine oil Type 20 Recommended engine oil classification EAU01038 Air cooled 4 stroke SOHC V type 2 cylinder 649 cm 81 x 63 mm 3 19 x 2 48 in 9 1 Electric starter Wet sump 10 30 50 70 90 110 130 F be dl o
5. Each front brake pad is provided with wear indicator grooves which allow you to check the brake pad wear with out having to disassemble the brake To check the brake pad wear check the wear indicator grooves If a brake pad has worn to the point that the wear indicator grooves have almost disap peared have a Yamaha dealer replace the brake pads as a set 6 25 1 Brake shoe wear limit line 2 Brake shoe wear indicator EAU00727 Rear brake shoes The rear brake is provided with a wear indicator which allows you to check 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 1 Minimum level mark EAU03294 Checking the brake fluid level Insufficient brake fluid may allow air to enter the brake system possibly caus ing it to become ineffective Before riding check that the brake fluid is above the minimum level mark and replenish if necessary A low brake flu id level may indicate worn brake pads and or brake system leakage If the brake level is low be sure to check the brake pads for wear and the brake sys tem for leakage Observe these precautions When checking the fluid level make sure that the top of the brake fluid reservoir is level Use onl
6. Wheel bearings e Check bearings for looseness or damage e Replace if necessary Ni Ni Ni Ni Ni Swingarm e Check swing arm pivot for play e Correct if necessary e Moderately repack every 15 000 mi 24 000 km or 24 months 2 Steering bearings e Check bearing play and steering for smooth operation e Correct if necessary e Moderately repack every 15 000 mi 24 000 km or 24 months 3 Chassis fasteners e Check all nuts bolts and screws for tightness e Tighten if necessary Sidestand e Check operation e Lubricate pivot and contact surfaces with chain lube lightly 1 e Repair if necessary Sidestand switch e Check operation e Replace if necessary Front fork e Check operation and for oil leakage e Repair if necessary Rear shock absorber e Check operation and for oil leakage e Replace if necessary Control and meter cable e Apply chain lube thoroughly 1 6 5 PERIODIC MAINTENANCE AND MINOR REPAIR ROUTINE INITIAL ODOMETER READINGS 600 mi 1 000 km or 1 month 4 000 mi 7 000 km or 6 months 8 000 mi 13 000 km or 12 months 12 000 mi 19 000 km or 18 months 16 000 mi 25 000 km or 24 months 20 000 mi 31 000 km or 30 months Brake and clutch lever pivot shaft e Apply chain lube lightly 1 Ni Ni Ni Ni Ni Brake pedal and shift pedal shaft
7. THE CUSTOMER S RESPONSIBILITY under this war ranty shall be to 1 Operate and maintain the motorcycle as specified in the appropriate Owner s Manual and 2 Give notice to an authorized Yamaha motorcycle dealer of any and all apparent defects within ten 10 days after discovery and make the machine available at that time for inspection and repairs at such dealer s place of business WARRANTY TRANSFER To transfer the warranty from the original purchaser to any subsequent pur chaser it is imperative that the machine be inspected and registered for warranty by an authorized Yamaha motorcycle dealer In order for this warranty to remain in effect this inspection and registration must take place within ten 10 days after transfer An inspection and registration fee will be charged for this service EMISSIONS CONTROL SYSTEM WARRANTY Yamaha Motor Corporation U S A also warrants to the ultimate purchaser and each subsequent purchaser of each Yamaha motorcycle covered by this warranty with a displacement of 50cc or greater that the vehi cle is designed built and equipped so as to conform at the time of sale with all U S emissions standards applicable at the time of manufacture and that it is free from defects in materials and workmanship which would cause it not to meet these standards within the periods listed immediately below Failure other than those resulting from defects in material or workman ship which arise solely as a re
8. YAMAHA EAU03438 A WARNING The engine exhaust from this product contains chemicals known to the State of California to cause cancer birth defects or other reproductive harm YAMAHA LIT CALIF 65 01 EAU00002 INTRODUCTION Congratulations on your purchase of the Yamaha XVS650 C XVS650A C This model is the result of Yamaha s vast experience in the production of fine sporting touring and pacesetting racing machines It represents the high degree of crafts manship and reliability that have made Yamaha a leader in these fields This manual will give you an understanding of the operation inspection and basic maintenance of 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 emis sions 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 these high standards it is important that you and your Yamaha dealer pay close attention to the recommended maintenance schedules and operating instructions contained within this manual IMPORTANT MANUAL INFORMATION Particularly important information is distinguished in this manual by the following notations A The Safety Alert Symbol means ATTENTION BECOME ALERT YOUR SAFETY IS INVOLVED
9. _ a YAMALUBE 4 10W30 ior SAE 10W30 YAMALUBE 4 20W40 or SAE 20W40 40 10 20 30 40 50 C API Service SE SF SG or higher SPECIFICATIONS Spark plug CAUTION Be sure to use motor oils that do not contain anti friction Manutacturer model NGK DPR7EA 9 0r ips 3 DENSO X22EPR U9 modifiers Passenger car motor oils often labeled ENERGY CONSERVING II contain anti friction additives Gap 0 8 0 9 mm 0 03 0 04 in which will cause clutch and or starter clutch slippage result Clutch type Wet multiple disc ing in reduced component life and poor engine performance _ _qe oq m Transmission Quantity Primary reduction system Spur gear Without oil filter element Primary reduction ratio 1 789 replacement 2 6 L 2 3 Imp qt 2 8 US qt Secondary reduction system Shaft drive With oil filter element Secondary reduction ratio 3 070 replacement ooh simp abc USA Transmission type Constant mesh 5 speed Total t i 2 L 2 81 t 3 4 t otal amount dry engine 3 2 8 Imp qt 3 4 US qt Operation Left foot Final gear oil S Gear ratio ist 2 714 Type Hypoid gear oil SAE 80 API GL4 or multi grade hypoid 2nd 1 900 gear oil SAE 80W 90 3rd 1 458 Final gear case capacity 0 19 L 0 17 Imp qt 0 20 US qt 4th 1 166 Air filter Dry type element 5th 0 966 Fuel Chassis g Type UNLEADED GASOLINE ONLY Frame type Double cradle Fuel tank capacity 16 L 3 5 Imp gal 4 2 US gal Caster angle 35 Reserve amount 3 L 0
10. the brake pedal free play must free play be adjusted 6 23 N A A Ee 1 Brake pedal free play adjusting nut Brake pedal free play The brake pedal free play should mea sure 20 30 mm 0 79 1 18 in at the brake pedal end Periodically check the brake pedal free play and if necessary adjust it as follows To increase the brake pedal free play turn the adjusting nut at the brake rod in direction To decrease the brake pedal free play turn the adjusting nut in direction PERIODIC MAINTENANCE AND MINOR REPAIR 1 Rear brake light switch 2 Rear brake light switch adjusting nut EAU00713 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 the adjusting nut in direction To make the brake light come on later turn the adjusting nut in direction 6 24 PERIODIC MAINTENANCE AND MINOR REPAIR EAU00720 Checking the front brake pads and rear brake shoes The front brake pads and the rear brake shoes must be checked for wear at the intervals specified in the periodic maintenance and lubrication chart 1 Brake pad wear indicator groove x 3 EAU03938 Front brake pads
11. x 2 2 Projection x 2 Rider seat To install the passenger seat To remove the rider seat Insert the projections on the front of the 1 Remove the passenger seat passenger seat into the holders as 2 Remove the bolt and then pull the shown place the seat in the original rider seat up position and then install the bolt 3 11 1 Seat holder 2 Projection To install the rider seat 1 Insert the projection on the front of the rider seat into the holder as shown place the seat in the origi nal position and then install the bolt 2 Install the passenger seat NOTE Make sure that the seats are properly secured before riding INSTRUMENT AND CONTROL FUNCTIONS 1 Helmet holder 2 Unlock EAU00260 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 Never ride with a helmet attached to the helmet holder since the helmet may hit objects causing loss of control and possibly an accident Ew000030 3 12 INSTRUMENT AND CONTROL FUNCTIONS 1 Storage compartment cover 2 Storage compartment lock cover 3 Storage compartment lock EAU01869 Storage compartment The storage compartment is located on the left side of the motorcycle Pom 1 Storage compartment 2 Storage compartment cover To open the storage compartment 1 Slide the lo
12. A WARNING Failure to follow WARNING instructions could result in severe injury or death to the motorcycle operator a bystander or a person inspecting or repairing the motorcycle CAUTION A CAUTION indicates special precautions that must be taken to avoid damage to the motorcycle NOTE A NOTE provides key information to make procedures easier or clearer NOTE This manual should be considered a permanent part of this motorcycle and should remain with it even if the motorcycle is subsequently sold e Yamaha continually seeks advancements in product design and quality Therefore while this manual contains the most current product information available at the time of printing there may be minor discrepancies between your motorcycle and this manual If you have any questions concerning this manual please consult your Yamaha dealer IMPORTANT MANUAL INFORMATION EW000000 T PLEASE READ THIS MANUAL AND THE YOU AND YOUR MOTORCYCLE RIDING TIPS BOOKLET CAREFULLY AND COMPLETELY BEFORE OPERATING THIS MOTOR CYCLE DO NOT ATTEMPT TO OPERATE THIS MOTORCYCLE UNTIL YOU HAVE AT TAINED 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 RELI ABILITY OF THIS MOTORCYCLE IMPORTANT MANUAL INFORMATION AFFIX DEALER LABEL
13. C x MT2 50 Spoke wheel 15 M C x MT3 50 Spoke wheel 16 M C x MT3 00 Spoke wheel 15 M C x MT3 50 Single disc brake Right hand DOT 4 Drum brake Right foot Suspension Front Rear Spring shock absorber Front Rear Wheel travel XVS650 C Front Rear XVS650A C Front Rear Electrical systems Ignition system Charging system Type Standard output Battery Model Voltage capacity Headlight type SPECIFICATIONS Telescopic fork Swingarm monocross Coil spring oil damper Coil spring gas oil damper 140 mm 5 5 in 86 mm 3 4 in 140 mm 5 5 in 98 mm 3 9 in T C I digital A C magneto 14 V 20 A 5 000 r min GT12B 4 12 V 10 Ah Quartz bulb halogen SPECIFICATIONS Bulb voltage wattage x quantity Headlight 12 V 60 55 W x 1 Tail brake light 12 V 8 27 W x1 Front turn signal position light 12 V 27 8W x2 Rear turn signal light 12V 27Wx2 Meter lighting 12V 1 7Wx1 Neutral indicator light 12V 1 7Wx1 High beam indicator light 12V 1 7W x1 Turn signal indicator light 12V 1 7Wx1 Engine trouble warning light 12V 1 7Wx 1 Fuses Main fuse 30A Ignition fuse 10A Signaling system fuse 10A Headlight fuse 15A Carburetor heater fuse 15A Identification numbers Key identification number Vehicle identification number Model label Reporting safety defects Motorcycle noise regulation Maintenance record STREET AND ENDURO MOTORCYCLE LIMITED WARRANTY YAMAHA
14. Check vehicle for oil leakage Final gear oil e Check vehicle for oil leakage Front brake e Check operation e If soft or spongy have Yamaha dealer bleed hydraulic system e Check lever free play e Adjust if necessary e Check fluid level in reservoir e If necessary add recommended brake fluid to specified level e Check hydraulic system for leakage 6 22 6 25 6 26 Rear brake e Check operation e Check pedal free play e Adjust if necessary Clutch e Check operation e Lubricate cable if necessary e Check lever free play e Adjust if necessary Throttle grip e Make sure that operation is smooth e Check free play e If necessary have Yamaha dealer make adjustment or lubricate 4 1 6 17 6 27 6 28 PRE OPERATION CHECKS ITEM CHECKS e Make sure that operation is smooth e Lubricate if necessary e Check for damage e Check tire condition and tread depth e Check air pressure e Correct if necessary e Make sure that operation is smooth e Lubricate pedal pivoting points if necessary e Make sure that operation is smooth e Lubricate lever pivoting points if necessary Control cables Wheels and tires Brake and shift pedals Brake and clutch levers Sidestand Make sure that operation is smooth e Lubricate pivot if necessary e Make sure that all nuts bolts and screws are properly tightened e Tighten if necessary Instrum
15. Controls and instruments XVS650 XVS650A DESCRIPTION Left view XVS650 1 Shift pedal 2 Fuel cock 3 Starter choke knob 4 Shock absorber assembly spring preload adjusting ring page 3 4 5 Helmet holder page 3 8 6 Storage compartment page 3 9 7 Owner s tool kit page 3 14 2 1 EAU00026 page 3 12 page 3 13 page 6 1 DESCRIPTION Right view XVS650 8 Engine oil filter element page 6 11 11 Main switch steering lock page 3 1 9 Battery page 6 31 12 Air filter element page 6 15 10 Fuses page 6 33 13 Brake pedal page 3 5 2 2 DESCRIPTION Left view XVS650A 2 1 1 Shift pedal 2 Fuel cock 3 Starter choke knob 4 Shock absorber assembly spring preload adjusting ring page 3 4 5 Helmet holder page 3 8 6 Storage compartment page 3 9 7 Owner s tool kit page 3 14 2 3 page 3 12 page 3 13 page 6 1 Right view XVS650A 8 Engine oil filter element 9 Battery 10 Fuses mee RA 9 CHALA ANS s DAANAN DN 13 page 6 11 11 Main switch steering lock page 6 31 12 Air filter element page 6 33 13 Brake pedal 2 4 DESCRIPTION page 3 1 page 6 15 page 3 5 DESCRIPTION Controls and instruments XVS650 XVS650A 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 6 5 Right handlebar switches page 3 3 6 Th
16. EXTENDED SERVICE Y E S CONSUMER INFORMATION EAU02944 Identification numbers Record the key identification number vehicle identification number and mod el label information in the spaces pro vided below for assistance when ordering spare parts from a Yamaha dealer or for reference in case the vehi cle is stolen 1 KEY IDENTIFICATION NUMBER 2 VEHICLE IDENTIFICATION NUMBER Las 2 3 MODEL LABEL INFORMATION 1 Key identification number EAU01041 Key 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 9 1 EAU01039 WA 1 Vehicle identification number EAU01043 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 and may be used to register your motor cycle with the licensing authority in your area 1 Model label EAU01804 Model label The model label is affixed to the frame under the rider seat See page 3 9 XVS650 or 3 11 XVS650A for rider seat removal and installation proce dures Record the information on this label in the space provided This infor mation will be needed when ordering spare parts from a Yamaha dealer 9 2 CONSUMER INFORMATION CONSUMER INFOR
17. FUNCTIONS EAU00315 This shock absorber contains high ly pressurized nitrogen gas For proper handling read and under stand the following information be fore handling the shock absorber The manufacturer cannot be held re sponsible for property damage or personal injury that may result from improper handling e Do not tamper with or attempt to open the gas cylinder e Do not subject the shock ab sorber to an open flame or other high heat sources otherwise it may explode due to excessive gas pressure e Do not deform or damage the gas cylinder in any way as this will result in poor damping per formance e Always have a Yamaha dealer service the shock absorber 1 Luggage strap holder x 2 EAU01172 Luggage strap holders There is a luggage strap holder on each passenger footrest 3 15 EAU00330 Sidestand The sidestand is located on the left side of the frame Raise the sidestand or lower it with your foot while holding the motorcycle upright NOTE The built in sidestand switch is part of the ignition circuit cut off system which cuts the ignition in certain situations See further down for an explanation of the ignition circuit cut off system EW000044 The motorcycle must not be ridden with the sidestand down or if the sidestand cannot be properly moved up or does not stay up oth erwise the sidestand could contact the ground and distract the opera tor resulting in a possibl
18. Oil pan 2 Bolt x 3 2 Bolt x 5 To change the engine oil with or NOTE without oil filter element replace Skip steps 4 7 if the oil filter element is ment not being replaced 1 Start the engine warm it up for several minutes and then turn it off 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 4 Remove the outer and inner oil fil ter element covers by removing the bolts 6 12 PERIODIC MAINTENANCE AND MINOR REPAIR 1 Oil filter element 2 O ring 5 6 B Remove the oil filter element and O ring Install a new oil filter element and the O ring Install the oil filter element covers by installing the bolts Install the engine oil drain bolt and then tighten it to the specified torque Tightening torque Engine oil drain bolt 43 Nm 4 3 m kgf 31 ft lb 9 Add the specified amount of the Beooge72 recommended oil and then install CAUTION and tighten the oil filler cap e In order to prevent clutch slip page since the engine oil also Recommended engine oil lubricates the clutch do not See page 8 1 mix any chemical additives with Oil quantity the oil or use oils of a CD Without oil filter element grade or higher In addition do replacement not use oils labeled ENERGY 2 6 L 2 3 Imp qt 2 8 US qt CONSERVING II or higher With oil filt
19. PERIODIC MAINTENANCE AND MINOR REPAIR EC000103 CAUTION Do not use a fuse of a higher amper age rating than recommended to avoid causing extensive damage to the electrical system and possibly a fire 3 Turn the key to ON and turn on 1 Fuse box 1 Ignition fuse the electrical circuit in question to 2 Main fuse 2 Signaling system fuse check if the device abalen 3 Spare main fuse 3 Headlight fuse 4 If the fuse immediately blows NI 4 Carburetor heater fuse 5 Spare fuse x 2 again have a Yamaha dealer 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 for panel removal and instal lation procedures 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 check the electrical system Specified fuses Main fuse Headlight fuse Signaling system fuse Ignition fuse Carburetor heater fuse 6 33 PERIODIC MAINTENANCE AND MINOR REPAIR 1 Screw x 2 1 Headlight coupler 1 Headlight bulb holder ERN eye ean 3 Unhook the headlight bulb holder Replacing the headlight bulb 2 Disconnect the headlight coupler and then remove thie d fectiye This motorcycle is equipped with a and then remove the bulb cover bulb quartz bulb headlight If the hea
20. brake lever free play should mea 2 To increase the brake lever free the hydraulic system will dimin sure 10 15 mm 0 39 0 59 in as play turn the adjusting bolt in di ish the braking performance shown Periodically check the brake le rection To decrease the brake which may result in loss of con ver free play and if necessary adjust it lever free play turn the adjusting trol and an accident as follows bolt in direction 3 Tighten the locknut 6 22 PERIODIC MAINTENANCE AND MINOR REPAIR a Distance between brake pedal and footrest a Distance between brake pedal and footrest 1 Locknut b Brake pedal free play b Brake pedal free play 2 Brake pedal position adjusting bolt g Eauoo711 Brake pedal position 1 Loosen the locknut at the brake Adjusting the brake pedal The brake pedal should be positioned pedal position and free play approximately 82 mm 3 23 in XVS650 2 To raise the brake pedal turn the ewoome or 108 mm 4 25 in XVS650A above adjusting bolt in direction To the top of the footrest as shown Periodi lower the brake pedal turn the ad It is advisable to have a Yamaha cally check the brake pedal position and justing bolt in direction dealer make these adjustments if necessary adjust it as follows 3 Tighten the locknut EWA00044 NOTE A WARNING The brake pedal position should be ad After adjusting the brake pedal posi justed before adjusting the brake pedal tion
21. on the starter choke Move the knob in direction to turn off the starter choke ECA00038 CAUTION 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 3 9 1 Nut EAU01889 Seats XVS650 Passenger seat To remove the passenger seat Remove the nut and then pull the pas senger seat up 1 Bolt x 2 2 Seat holder 3 Projection To install the passenger seat Insert the projection on the front of the passenger seat into the seat holder as shown place the seat in the original position and then install the nut INSTRUMENT AND CONTROL FUNCTIONS 1 Seat holder 2 Projection 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 the rider seat into the seat holder as shown place the seat in the original position and then install the bolts 2 Install the passenger seat 3 10 NOTE Make sure that the seats are properly secured before riding INSTRUMENT AND CONTROL FUNCTIONS XVS650A EAU04188 Seats XVS650A Passenger seat To remove the passenger seat Remove the bolt and then pull the pas senger seat up 1 Bolt 1 Seat holder
22. removing the screws 2 Pull the air filter element out 6 15 1 Air filter element 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 filter element is damaged replace it PERIODIC MAINTENANCE AND MINOR REPAIR CN Z Z 1 Match marks 2 Projection 3 Slot EC000082 CAUTION Make sure that the air filter ele ment is properly seated in the air filter case The engine should never be op erated without the air filter ele ment installed otherwise the pistons and or cylinders may become excessively worn 4 Insert the air filter element into the air filter case as shown 5 Install the air filter case cover by aligning the match marks and in stalling the screws 6 16 EAU00628 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 neces sary professional knowledge and expe rience PERIODIC MAINTENANCE AND MINOR REPAIR a Throttle cable free play EAU00635 Adjusting the throttle cable free play The throttle cable free play should measure 4 6 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 EAU00
23. should be checked before each ride and the sidestand pivot and metal to metal contact surfaces should be lubricated if necessary If the sidestand does not move up and down smoothly have a Yamaha dealer check or repair it EW000113 Recommended lubricant Lithium soap based grease all purpose grease 6 29 EAU02939 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 Securely support the motorcycle so that there is no danger of it falling over EW000115 Check the inner tubes for scratches damage and excessive oil leakage To check the operation 1 Place the motorcycle on a level surface and hold it in an upright position 2 While applying the front brake push down hard on the handle bars several times to check if the front fork compresses and re bounds smoothly EC000098 CAUTION If any damage is found or the front fork does not operate smoothly have a Yamaha dealer check or re pair it PERIODIC MAINTENANCE AND MINOR REPAIR EAU00794 Checking the steering Worn or loose steering bearings may cause danger Therefore the operation of the steering 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 Securely su
24. such as names addresses model V I N frame number dates and receipts CHANGE OF ADDRESS The federal government requires each manufacturer of a motor vehicle to maintain a complete up to date list of all first purchasers against the possibility of a safety related defect and recall This list is compiled from the purchase registrations sent to Yamaha Motor Corporation U S A by the selling dealer at the time of your purchase If you should move after you have purchased your new motorcycle please advise us of your new address by sending a postcard listing your motorcycle model name V I N frame number dealer number or dealer s name as it is shown on your warranty card your name and new mailing address Mail to YAMAHA MOTOR CORPORATION U S A P O Box 6555 Cypress California 90630 Attention Warranty Department This will ensure that Yamaha Motor Corporation U S A has an up to date registration record in accordance with federal law CONSUMER INFORMATION YAMAHA EXTENDED SERVICE Y E S Keep your Yamaha protected even after your warranty expires with genuine Yamaha Extended Service Y E S e Y E S is designed and administered by Yamaha Motor Corporation to provide maximum owner satisfaction You get uninterrupted factory backed coverage for extra peace of mind e Y E S is flexible You choose the plan that s right for you 12 months 24 months or 36 months beyond your warranty period e Y E S is desi
25. the wheel according to the procedure on legs Securely support the motor page 6 36 NOTE cycle so that there is no danger 5 Pull the wheel axle out and then Make sure that there is enough space of it falling over remove the wheel e between the brake pads before insert 1 Disconnect the speedometer ca IgAUTION ing the brake disc and that the slot in ble from the front wheel the speedometer gear unit fits over the Do not apply the brake after the wheel has been removed together with the brake disc otherwise the 3 Insert the wheel axle brake pads will be forced shut 4 Lower the front wheel so that it is on the ground retainer on the fork leg 6 37 PERIODIC MAINTENANCE AND MINOR REPAIR 5 Push down hard on the handlebar several times to check for proper fork operation 6 Tighten the wheel axle to the specified torque and then install the rubber cap Tightening torque Wheel axle Pig Brake pedal free play adjusting nut Brake camshaft lever Brake rod Bolt shoe plate Brake torque rod Bolt swingarm 1 Axle nut 59 Nm 5 9 m kgf 43 ft lb EAU01350 7 Tighten the front wheel axle pinch Rear wheel bolt to the specified torque ONRAN To remove the rear wheel Tightening torque swoon 2 Disconnect the brake torque rod Front wheel axle pinch bolt PGs from the brake shoe plate by re 20 Nm 2 0 m kgf 14 ft lb itis adv
26. to store personal items near the air cleaner in take otherwise air intake will be blocked and performance will suffer Make sure not to put anything near the battery and its termi nals otherwise electrical failure and acid corrosion may result 5 1 EAU00372 EAU04219 Starting and warming up a cold engine In order for the ignition circuit cut off system to enable starting one of the following conditions must be met e The transmission is in the neutral position The transmission is in gear with the clutch lever pulled and the sidestand up e Before starting the engine check the function of the igni tion circuit cut off system ac cording to the procedure described on page 3 17 e Never ride with the sidestand down EW000054 OPERATION AND IMPORTANT RIDING POINTS 1 Turn the fuel cock lever to ON 2 Turn the key to ON and make sure that the engine stop switch is setto O 3 Shift the transmission into the neu tral position NOTE When the transmission is in the neutral position the neutral indicator light should be on otherwise have a Yamaha dealer check the electrical cir cuit 4 Turn the starter choke on and completely close the throttle See page 3 9 for starter choke opera tion 5 Start the engine by pushing the start switch NOTE If the engine fails to start release the start switch wait a few seconds and then try again Each starting attem
27. 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 set to zero with the reset knob The tripmeter 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 INSTRUMENT AND CONTROL FUNCTIONS 1 Dimmer switch 20 20 2 Turn signal switch lt a gt 3 Horn switch fo EAU00118 Handlebar switches EAU03888 Dimmer switch 0 40 Set this switch to EO for the high beam and to ZO for the low beam EAU04218 Turn signal switch lt gt To signal a right hand turn push this switch to 5 gt To signal a left hand turn push this switch to lt a When released the switch returns to the cen ter position Since this model is equipped with a self canceling system the turn signal lights will self cancel after the motor cycle has traveled both about 150 m 490 ft and for approximately 15 sec onds However the turn signal lights can also be canceled manually by pushing the switch in after it has re turned to the center position NOTE The self canceling system only oper ates when the motorcycle is moving so that the turn signal lights will not self cancel while you are stopped at an in tersection
28. 00 km or 6 months 8 000 mi 13 000 km or 12 months 12 000 mi 19 000 km or 18 months 16 000 mi 25 000 km or 24 months 20 000 mi 31 000 km or 30 months Valve clearance e Check and adjust valve clearance when engine is cold Ni Ni Ni N N N Spark plugs e Check condition e Adjust gap and clean e Replace at 8 000 mi 13 000 km or 12 months Replace Replace Crankcase ventilation system e Check ventilation hose for cracks or damage e Replace if necessary Fuel line e Check fuel hoses for cracks or damage e Replace if necessary Fuel filter e Replace Exhaust system e Check for leakage e Tighten if necessary e Replace gasket s if necessary Carburetor synchronization e Adjust synchronization of carburetors Idle speed e Check and adjust engine idle speed e Adjust cable free play Evaporative emission control system For California only e Check control system for damage e Replace if necessary 6 3 Since these items require special tools data and technical skills have a Yamaha dealer perform the service PERIODIC MAINTENANCE AND MINOR REPAIR General maintenance and lubrication chart ROUTINE INITIAL ODOMETER READINGS EAU00472 600 mi 1 000 km or 1 month 4 000 mi 7 000 km or 6 months 8 000 mi 13 000 km or 12 months 12 000 mi 19 000 k
29. 0024 3 6 INSTRUMENT AND CONTROL FUNCTIONS 1 Fuel tank filler tube 2 Fuel level EAU03753 Fuel Make sure that there is sufficient fuel in the tank Fill the fuel tank to the bottom of the filler tube as shown Do not overfill the fuel tank oth erwise it may overflow when the fuel warms up and expands Avoid spilling fuel on the hot engine Ewo000130 EAU00185 CAUTION Immediately wipe off spilled fuel with a clean dry soft cloth since fuel may deteriorate painted surfac es or plastic parts EAU04194 Recommended fuel UNLEADED GASOLINE ONLY Fuel tank capacity Total amount 16 L 3 5 Imp gal 4 2 US gal Reserve amount 3 L 0 7 Imp gal 0 8 US gal ECA00102 CAUTION Use only unleaded gasoline The use of leaded gasoline will cause se vere damage to internal engine parts such as the valves and piston rings as well as to the exhaust sys tem Your Yamaha engine has been de signed to use regular unleaded gaso line with a pump octane number R M 2 of 86 or higher or a research octane number of 91 or higher If knocking or pinging occurs use a gasoline of a different brand or premi um unleaded fuel Use of unleaded fuel will extend spark plug life and reduce maintenance costs Gasohol There are two types of gasohol gaso hol containing ethanol and that contain ing methanol Gasohol containing ethanol can be used if the ethanol con tent does not exceed 10 Gasohol conta
30. 27 1 Push 2 Turn Never turn the key to OFF or LOCK while the motorcycle is moving otherwise the electrical systems will be switched off which may result in loss of control or an accident Make sure that the motor cycle is stopped before turning the key to OFF or LOCK EW000016 1 High beam indicator light 20 2 Turn signal indicator light lt a gt 3 Neutral indicator light N 4 Engine trouble warning light us EAU03034 Indicator and warning lights EAU00063 High beam indicator light 0 This indicator light comes on when the high beam of the headlight is switched on EAU00057 Turn signal indicator light lt gt gt This indicator light flashes when the turn signal switch is pushed to the left or right INSTRUMENT AND CONTROL FUNCTIONS EAU00061 Neutral indicator light N This indicator light comes on when the transmission is in the neutral position EAU04238 Engine trouble warning light t This warning light comes on or flashes when an electrical circuit monitoring the engine is defective When this oc curs have a Yamaha dealer check 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 3 2 1 Tripmeter reset knob 2 Speedometer 3 Odometer 4 Tripmeter EAU00095 Speedometer
31. 637 Adjusting the 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 clearance must be adjusted by a Yamaha dealer at the intervals specified in the periodic maintenance and lubrication chart 6 17 EAU03360 Tires To maximize the performance durabil ity and safe operation of your motor cycle note the following points regarding the specified tires Tire air pressure The tire air pressure should be checked and if necessary adjusted before each ride e The tire air pressure must be checked and adjusted on cold tires i e when the temperature of the tires equals the ambient temperature e The tire air pressure must be adjusted in accordance with the riding speed and with the total weight of rider passenger car go and accessories approved for this model EW000082 XVS650 Tire air pressure measured on cold tires Load Front Rear Up to 90 kg 198 Ib 200 kPa 2 00 kgf cm 29 psi 225 kPa 2 25 kgf cm 33 psi 90 kg 198 Ib maximum Maximum load Total weight of rider accessories XVS650A 200 kPa 2 00 kgf cm 29 psi 250 kPa 2 50 kgf cm 36 psi 180 kg 397 Ib passenger Tire air pressure measured on cold tires cargo and Load Front Rear Up to 90 kg 198 Ib 225 kPa 2 25 kgf cm 33 psi 225 kPa 2 25 kgf cm 33 p
32. 7 Imp gal 0 8 US gal Trail Carburetor XVS650 153 mm 6 02 in Manufacturer MIKUNI XVS650A 145 mm 5 7 in Model x quantity BDS28 x 2 8 2 SPECIFICATIONS Maximum load Tire air pressure measured on cold tires Up to 90 kg 198 Ib Front Rear 90 kg 198 Ib maximum Front Rear 180 kg 397 Ib 200 kPa 2 00 kgf cm 29 psi 225 kPa 2 25 kgf cm 33 psi 200 kPa 2 00 kgf cm 29 psi 250 kPa 2 50 kgf cm 36 psi Total weight of rider passenger cargo and accessories Maximum load Tire air pressure measured on cold tires Up to 90 kg 198 Ib Front Rear 90 kg 198 Ib maximum Front Rear Tires XVS650A C XVS650 C Front Front Type Tube tire Type Tube tire Size 130 90 16 M C 67S Size 100 90 19 M C 57S Manufacturer model Bridgestone G703 Manufacturer model Bridgestone L309 Dunlop D404F Dunlop F24 Rear Rear Type Tube tire Type Tube tire Size 170 80 15 M C 77S Size 170 80 15 M C 77S Manufacturer model Bridgestone G702 Manufacturer model Bridgestone G546 Dunlop D404G Dunlop K555 200 kg 441 Ib 225 kPa 2 25 kgf cm 33 psi 225 kPa 2 25 kgf cm 33 psi 225 kPa 2 25 kgf cm 33 psi 250 kPa 2 50 kgf cm 36 psi Total weight of rider passenger cargo and accessories Wheels XVS650 C Front Type Size Rear Type Size XVS650A C Front Type Size Rear Type Size Brakes Front Type Operation Fluid Rear Type Operation Spoke wheel 19 M
33. A MOTOR CORPORATION U S A STREET AND ENDURO MOTORCYCLE LIMITED WARRANTY Yamaha Motor Corporation U S A hereby warrants each new model Yamaha motorcycle will be free from defects in material and workmanship for the period of time stated herein subject to certain stated limitations THE PERIOD OF WARRANTY for Yamaha motorcycles originally equipped with headlight stoplight and turn signals shall be one 1 year from the date of purchase with no mileage limitation MODELS EXCLUDED FROM WARRANTY include those used for non Yamaha authorized renting leas ing or other commercial purposes and TZ models DURING THE PERIOD OF WARRANTY any authorized Yamaha motorcycle dealer will free of charge repair or replace any part adjudged defective by Yamaha due to faulty workmanship or material from the factory Parts used in warranty repairs will be warranted for the balance of the product s warranty period All parts replaced under warranty become property of Yamaha Motor Corp U S A GENERAL EXCLUSIONS from this warranty shall include any failures caused by a Competition or racing use b installation of parts or accessories that are not qualitatively equivalent to genuine Yamaha parts Abnormal strain neglect or abuse Lack of proper maintenance Accident or collision damage Modification to original parts moan SPECIFIC EXCLUSIONS from this warranty shall include parts replaced due to normal wear or routine maintenance
34. HERE EAU04247 XVS650P C XVS650AP C OWNER S MANUAL 2001 by Yamaha Motor Corporation U S A 1st edition April 2001 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 15 15 1 SAFETY INFORMATION 2 DESCRIPTION 3 INSTRUMENT AND CONTROL FUNCTIONS 4 PRE OPERATION CHECKS 5 OPERATION AND IMPORTANT RIDING POINTS 6 PERIODIC MAINTENANCE AND MINOR REPAIR 7 MOTORCYCLE CARE AND STORAGE 8 SPECIFICATIONS 9 CONSUMER INFORMATION INDEX Safe riding Protective apparel Modifications Loading and accessories Gasoline and exhaust gas Location of important labels SAFETY INFORMATION _ _ _ _ __ ___ MOTORCYCLES ARE SINGLE TRACK VEHICLES THEIR SAFE USE AND OPERATION ARE DE PENDENT UPON THE USE OF PROPER RIDING TECHNIQUES AS WELL AS THE EXPERTISE OF THE OPERATOR EVERY OPERATOR SHOULD KNOW THE FOLLOWING REQUIREMENTS BE FORE RIDING THIS MOTORCYCLE HE OR SHE SHOULD 1 2 3 4 OBTAIN THOROUGH INSTRUCTIONS FROM A COMPETENT SOURCE ON ALL ASPECTS OF MOTORCYCLE OPERATION OBSERVE THE WARNINGS AND MAINTENANCE REQUIREMENTS IN THE OWNER S MANU AL OBTAIN QUALIFIED TRAINING IN SAFE AND PROPER RIDING TECHNIQUES OBTAIN PROFESSIONAL TECHNICAL SERVICE AS INDICATED BY THE OWNER S MANUAL AND OR WHEN MADE NECESSARY BY MECHANICAL CONDITIONS S
35. HESE CONTROLS NOT ONLY FUNCTION TO ENSURE CLEANER AIR BUT ARE ALSO VITAL TO PROPER ENGINE OPERATION AND MAXIMUM PERFORMANCE IN THE FOLLOWING PERIODIC MAINTE NANCE CHARTS THE SERVICES RELATED TO EMISSIONS CON TROL ARE GROUPED SEPARATE LY THESE SERVICES REQUIRE SPECIALIZED DATA KNOWLEDGE AND EQUIPMENT YAMAHA DEAL ERS ARE TRAINED AND EQUIPPED TO PERFORM THESE PARTICULAR SERVICES 6 1 EAU00462 EAU04220 Owner s tool kit The owner s tool kit is located inside the storage compartment See page 3 13 for storage compartment opening procedures The service information included in this manual and the tools provided 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 certain maintenance work correctly NOTE If you do not have the tools or experi ence required for a particular job have a Yamaha dealer perform it for you Ewo00062 a 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 PERIODIC MAINTENANCE AND MINOR REPAIR 6 2 Periodic maintenance chart for the emission control system ROUTINE INITIAL PERIODIC MAINTENANCE AND MINOR REPAIR ODOMETER READINGS EAU00471 600 mi 1 000 km or 1 month 4 000 mi 7 0
36. MATION EAU01051 Reporting safety defects If you believe that your vehicle has a defect which could cause a crash or could cause injury or death you should immedi ately inform the National Highway Traffic Safety Administration NHTSA in addition to notifying Yamaha Motor Corporation U S A If NHTSA receives similar complaints it may open an investigation 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 Transportation Washington D C 20590 You can also obtain other informa tion about motor vehicle safety from the Hotline 9 3 CONSUMER INFORMATION EAU01053 Motorcycle noise regulation TAMPERING WITH NOISE CONTROL SYSTEM PROHIBITED Federal law prohibits the following acts or the causing thereof 1 The removal or rendering inoperative by any person other than for purposes of maintenance repair or replacement of any device or element of design incorporated into any new ve 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 in
37. PERIODIC MAINTENANCE AND MINOR REPAIR EAU01297 Troubleshooting chart Keep away open flames and do not smoke while checking or working on the fuel system EW000125 1 Fuel Check the fuel level in the fuel tank There is enough fuel Check the compression The engine does not start Check the compression There is no fuel gt Supply fuel gt 2 Compression Operate the electric starter gt There is compression gt Check the ignition Have a Yamaha dealer check the vehicle There is no compression gt 3 Ignition Wipe off with a dry cloth and correct the Open the throttle halfway and operate Dry gt Have a Yamaha dealer check the vehicle Check the battery Wet spark plug gaps or replace the spark plugs the electric starter Remove the spark plugs t and check the electrodes The engine does not start 4 Battery The engine tune over Ck The battery is good quickly The engine does not start Operate the electric starter m Have a Yamaha dealer The engine turns over Check the battery lead connections check the vehicle slowly and charge the battery if necessary 6 41 Storage MOTORCYCLE CARE AND STORAGE Care While the open design of a motorcycle reveals the attractiveness of the tech
38. R REPAIR EAU01579 Supporting the motorcycle Since this model is not equipped with a centerstand follow these precautions when removing the front and rear wheel or performing other mainte nance requiring the motorcycle to stand upright Check that the motor cycle is in a stable and level position before starting any maintenance A strong wooden box can be placed un der 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 motorcycle stand is not available by placing a jack un der the frame in front of the rear wheel 2 Raise the front wheel off the ground by using a motorcycle stand 6 36 To service the rear wheel Raise the rear wheel off the ground by using a motorcycle stand or if a motor cycle stand is not available by placing a jack either under each side of the frame in front of the rear wheel or under each side of the swingarm PERIODIC MAINTENANCE AND MINOR REPAIR 1 Speedometer cable 1 Rubber cap 1 Speedometer gear unit canes 2 Axle wheel 2 Speedometer cable Front wheel 3 Front wheel axle pinch bolt e 2 Loosen the front wheel axle pinch TO install the front wheel To remove the front wheel bolt 1 Install the speedometer gear unit 6 EW000122 3 Remove the rubber cap and then into the wheel hub so that the pro A WARNING loosen the wheel axle jections mesh with the slots dealer service
39. TION Cold tire normal pressure should be set as follows Up to 90 kg 198 Ibs load THE OWNER S MANUAL AND ALL LABELS ALWAYS WEAR AN APPROVED MOTORCYCLE HELMET eye protection and protective clothing FRONT _ 225 kPa 2 25 kgf cm 33 psi REAR 225 kPa 2 25 kgf cm 33 psi 90 kg 198 Ibs maximum load FRONT 225 kPa 2 25 kgf cm 33 psi REAR 250 kPa 2 50 kgf cm 36 psi A WARNING 5BN 21668 00 This unit contains high pressure nitrogen gas Mishandling can cause explosion Read owner s manual for instructions Do not incinerate puncture or open 4 3MX 2118K AO AAA 22259 80 LOAD LIMIT 3 XVS650 1 Kg 2 Ibs 4BR 24877 A0 TIRE INFORMATION Cold tire normal pressure should be set as follows Up to 90 kg 198 Ibs load FRONT 200 kPa 2 00 kgf cm 29 psi REAR 225 kPa 2 25 kgf cm t 33 psi 90 kg 198 Ibs maximum load FRONT 200 kPa 2 00 kgf cm 29 psi REAR _ 250 kPa 2 50 kgf cm 36 psi 5SFB 21668 00 A SAFETY INFORMATION A WARNING Improper loading can cause loss of control Read owner s manual for proper loading 3JJ 28446 A0 6 California only EMISSION HOSE ROUTING CARB CARB FROM O FUEL TANK va ROLL OVER valve CANISTER TO ATMOSPHERE 5BN 21686 00 Left view XVS650 Right view XVS650 Left view XVS650A Right view XVS650A
40. afe riding 1 Always make pre operation checks Careful checks may help prevent an accident 2 This motorcycle is designed to carry the operator and a passenger 3 The failure of motorists to detect and recognize motorcycles in traffic is the predominating cause of automobile motorcycle accidents Many accidents 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 a Wear a brightly colored jacket b Use extra caution when approaching and passing through intersections since intersections are the most likely places for motorcycle accidents to occur c Ride where other motorists can see you Avoid riding in another motorist s blind spot 9 Poo A SAFETY INFORMATION Many motorcycle accidents involve inexperienced operators In fact many operators who have been involved in accidents do not even have a current motorcycle license Make sure that you are qualified and that you only lend your motorcycle to other qualified operators Know your skills and limits Staying within your limits may help you to avoid an accident We recommend that you practice riding your motorcycle where there is no traffic until you have be come thoroughly familiar with the motorcycle and all of its controls Many motorcycle accidents have been caused by error of the motorcycle operator A typical e
41. arsh chemical products on plastic parts Be sure to avoid using cloths or sponges which have been in contact with strong or abrasive cleaning products solvent or thinner fuel gasoline rust re movers or inhibitors brake flu id antifreeze or electrolyte Do not use high pressure wash ers or steam jet cleaners since they cause water seepage and deterioration in the following ar eas seals of wheel and swing arm bearings fork and brakes electric components couplers connectors instruments switch es and lights breather hoses and vents MOTORCYCLE CARE AND STORAGE e For motorcycles equipped with a windshield Do not use strong cleaners or hard sponges as they will cause dulling or scratching Some cleaning compounds for plastic may leave scratches on the wind shield Test the product on a small hidden part of the wind shield to make sure that it does not leave any marks If the wind shield is scratched use a quali ty plastic polishing compound after washing After normal use Remove 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 off more easily if the area is covered with a wet cloth for a few minutes before cleaning 7 2 After riding in the rain near the sea or on salt sprayed roads Since sea salt or salt sprayed on roads during winter are
42. ce adjusting Vehicle identification number Ww Warranty extended Warranty limited Wheel bearings checking Wheel front Installing Removing Wheel rear Installing Removing Wheels See your Authorized YAMAHA Dealer for a Genuine YAMAHA Service Manual PRINTED IN JAPAN 2001 5 3 0x1 CR
43. ces non warranty repairs accident and collision damages and oil oil filters air filters spark plugs and brake shoes What are some examples of abnormal strain neglect or abuse These terms are general and overlap each other in areas Specific examples include Running the machine out of oil sustained high rpm full throttle operating the machine with a broken or damaged part which causes another partto fail damage or failure due to improper or careless transportation and or tie down If you have any specific questions on operation or maintenance please contact your dealer for advice Does the warranty cover incidental costs such as towing or transportation due to a failure No The warranty is limited to repair of the machine itself May perform any or all of the recommended maintenance shown in the Owner s Manual instead of having the dealer do them Yes if you are a qualified mechanic and follow the procedures specified in the Owner s and Service Manual We do recommend however that items requiring special tools or equipment be done by Yamaha Motorcycle dealer Will the warranty be void or cancelled if do not operate or maintain my new motor cycle exactly as specified in the Owner s Manual No The warranty on a new motorcycle cannot be voided or cancelled However if a particular failure is caused by operation or maintenance other than as shown in the Owner s Manual that failure may not be covered un
44. ck cover open insert the key into the lock and then turn 1 it clockwise To close the storage compartment 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 2 Pull the storage compartment cov er out as shown 3 13 EAU00299 Adjusting the shock absorber assembly This shock absorber assembly is equipped with a spring preload adjust ing ring EC000015 CAUTION Never attempt to turn an adjusting mechanism beyond the maximum or minimum settings INSTRUMENT AND CONTROL FUNCTIONS 1 Position indicator 2 Spring preload adjusting ring 3 Extension bar 4 Special wrench Adjust the spring preload as follows 1 Remove the passenger and rider seats See page 3 9 XVS650 or 3 11 XVS650A for removal and installation procedures 2 To increase the spring preload and thereby harden the suspen sion turn the adjusting ring in di rection To decrease the spring preload and thereby soften the suspension turn the adjusting ring in direction 3 14 NOTE Align the appropriate notch in the adjusting ring with the position in dicator on the shock absorber Use the special wrench and exten sion bar included in the owners tool kit to make the adjustment Setting Minimum soft 1 Standard 3 Maximum hard 7 3 Install the passenger and rider seats INSTRUMENT AND CONTROL
45. d be obtained as de scribed above tighten the locknut play and skip the rest of the procedure The clutch lever free play should mea otherwise proceed as follows Sare eae mm seer ee 4 Fully turn the adjusting bolt at the or 5 10 mm 0 0 0 39 in XVS650A clutch lever in direction to loos as shown Periodically check the clutch en the clutch cable lever free play and if necessary adjust it 5 Loosen the locknut at the crank EAU00694 Adjusting the clutch lever free as follows dase 1 Loosen the locknut at the clutch le 6 To increase the clutch lever free ver play turn the adjusting nut in di rection To decrease the clutch lever free play turn the adjusting nut in direction 2 To increase the clutch lever free play turn the adjusting bolt in di rection To decrease the clutch lever free play turn the adjusting bolt in direction 6 21 PERIODIC MAINTENANCE AND MINOR REPAIR EW000099 e After adjusting the brake lever free play check the free play and make sure that the brake is working properly e A soft or spongy feeling in the brake lever can indicate the presence of air in the hydraulic system If there is air in the hy a Brake lever free play 1 Locknut ee 2 Brake lever free play adjusting bolt f draulic system have a Yamaha Adjusting the brake lever free 1 Loosen the locknut at the brake le dealer bleed the system before play VEI operating the motorcycle Air in The
46. der warranty What responsibility does my dealer have under this warranty Each Yamaha Motorcycle dealer is expected to 1 Completely set up every new machine before sale 2 Explain the operation maintenance and warranty requirements to your satis faction at the time of sale and upon your request at any later date 3 Each Yamaha Motorcycle dealer is held responsible for his setup service and warranty repair work Is the warranty transferable to second owners Yes The remainder of the existing warranty can be transferred upon request The unit has to be inspected and re registered by an authorized Yamaha Motorcycle dealer for the policy to remain effective 9 8 CONSUMER INFORMATION CUSTOMER SERVICE If your machine requires warranty service you must take it to any authorized Yamaha Motorcycle dealer within the continental United States Be sure to bring your warranty registration card or other valid proof of the original date of purchase If a question or problem arises regarding warranty first con tact the owner of the dealership Since all warranty matters are handled at the dealer level this person is in the best position to help you If you are still not satisfied and require additional assistance please write YAMAHA MOTOR CORPORATION U S A CUSTOMER RELATIONS DEPARTMENT P O Box 6555 Cypress California 90630 When contacting Yamaha Motor Corporation U S A don t forget to include any important information
47. dlight EW000119 bulb burns out replace it as follows 1 Remove the headlight unit by re Headlight bulbs get very hot There moving the screws fore keep flammable products away from a lit headlight bulb and do not touch the bulb until it has cooled down 4 Place a new headlight bulb into position and then secure it with the bulb holder 6 34 PERIODIC MAINTENANCE AND MINOR REPAIR EC000105 CAUTION Do not touch the glass 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 and fingerprints on the headlight bulb using a cloth moistened with Sew 2 LSU se alcohol or thinner A AA 3 Insert a new bulb into the socket Replacing a turn signal light push it in and then turn it clock 5 Install the headlight bulb cover bulb or the tail brake light wise until it stops and then connect the coupler bulb 1 Remove the lens by removing the screws 2 Remove the defective bulb by pushing it in and turning it counter clockwise 6 6 Install the headlight unit by install ing the screws 7 Have a Yamaha dealer adjust the headlight beam if necessary 6 35 1 Screw x 3 4 Install the lens by installing the screws EC000108 CAUTION Do not overtighten the screws oth erwise the lens may break PERIODIC MAINTENANCE AND MINO
48. e loss of control Yamaha s ignition circuit cut off system has been designed to assist the operator in fulfilling the responsibility of raising the side stand before starting off Therefore check this system regularly as de scribed below and have a Yamaha dealer repair it if it does not function properly INSTRUMENT AND CONTROL FUNCTIONS EAU03720 Ignition circuit cut off system The ignition circuit cut off system com prising the sidestand switch clutch switch and neutral switch has the fol lowing functions It prevents starting when the trans mission is in gear and the side stand is up but the clutch lever is not pulled It prevents starting when the trans mission is in gear and the clutch lever is pulled but the sidestand is still down It cuts the running engine when the transmission is in gear and the sidestand is moved down Periodically check the operation of the ignition circuit cut off system according to the following procedure If a malfunction is noted have a Yamaha dealer check the system before riding EW000045 3 16 INSTRUMENT AND CONTROL FUNCTIONS With the engine turned off NOTE 1 Move the sidestand down This check is most reliable if performed with 2 Make sure that the engine stop switch is set to O a warmed up engine 3 Turn the key to ON 4 Shift the transmission into the neutral position 5 Push the start switch Does the engine start The
49. e starter choke is not required when the engine is warm 1 Shift pedal N Neutral position EAU00423 Shifting Shifting gears lets you control the amount of engine power available for starting off accelerating climbing hills etc The gear positions are shown in the il lustration NOTE To shift the transmission into the neu tral position press the shift pedal down repeatedly until it reaches the end of its travel and then slightly raise it 1 Shift pedal N Neutral position EC000048 CAUTION Even with the transmission in the neutral position do not coast for long periods of time with the engine off and do not tow the motorcycle for long dis tances The transmission is properly lubricated only when the engine is running Inade quate lubrication may damage the transmission Always use the clutch while changing gears to avoid dam aging the engine transmission and drive train which are not designed to withstand the shock of forced shifting 5 4 OPERATION AND IMPORTANT RIDING POINTS EAU02988 To start out and accelerate 1 2 NOTE Pull the clutch lever to disengage the clutch Shift the transmission into first gear The neutral indicator light should go out Open the throttle gradually and at the same time release the clutch lever slowly At the recommended shift points shown in the table on page 5 5 close the throttle and at the same time quickly pul
50. els Manufacturer Size Bridgestone 100 90 19 M C 57S Dunlop REAR XVS650 Manufacturer 100 90 19 M C 57S Size Bridgestone 170 80 15M C 77S Dunlop 170 80 15M C 77S FRONT XVS650A Manufacturer Size Bridgestone 130 90 16 M C 67S Dunlop REAR XVS650A Manufacturer 130 90 16 M C 67S Size Bridgestone 170 80 15M C 77S Dunlop Minimum tire tread depth 1 0 mm 0 04 in front and rear 170 80 15M C 77S worn out tire When a tire tread begins to show crosswise lines have a Yamaha dealer replace the tire immediately The replacement of all wheel and 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 however patch the tube very carefully and replace it as soon as possible with a high quality product 6 19 ity and safe operation of your motor cycle note the following points regarding the specified wheels The wheel rims should be checked for cracks bends or warpage and the spokes for looseness or dam age before each ride If any dam age is found have a Yamaha dealer replace the wheel Do not attempt even the smallest repair to the wheel A deformed or cracked wheel must be replaced The wheel should be balanced whenever either the tire or wheel has been changed
51. emoved and installed 6 7 1 Bolt x 4 EAU01573 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 PERIODIC MAINTENANCE AND MINOR REPAIR 1 Bolt x 4 6 8 1 Bolt EAU00491 Panel B To remove the panel Remove the bolt and then pull the pan el off as shown PERIODIC MAINTENANCE AND MINOR REPAIR 1 Spark plug cap 1 Spark plug wrench To install the panel Checki h ipl FAVORS 2 Remove the spark plug as shown Place the panel in the original position ecking the spark plugs with the spark plug wrench includ and then install the bolt The spark plugs are important engine ed in the owner s tool kit components which are easy to check Since heat and deposits will cause any T check the spark plugs spark plug to slowly erode the spark 4 Check that the porcelain insulator plugs should be removed and checked around the center electrode on in accordance with the periodic mainte each spark plug is a medium to nance and lubrication chart In addition light tan the ideal color when the the condition of the spark plugs can re motorcycle is ridden normally veal the condition of the engine 2 Check that all spark plugs installed in the engine have the same color To remove a spark plug 1 Remove the spark plug cap 6 9 NOTE If an
52. ents lights signals e Check operation and switches e Correct if necessary Chassis fasteners e Check operation of ignition circuit cut off system Sidestand switch e If system is defective have Yamaha dealer check vehicle NOTE Pre operation checks should be made each time the motorcycle 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 If any item in the Pre operation check list is not working properly have it inspected and repaired before operating the motorcycle EWA00033 4 2 Starting and warming up a cold engine Starting a warm engine Shifting Engine break in Parking EAU00373 e Become thoroughly familiar with all operating controls and their functions before riding Consult a Yamaha dealer re garding any control or function that you do not thoroughly un derstand Never start the engine or oper ate it in a closed area for any length of time Exhaust fumes are poisonous and inhaling them can cause loss of con sciousness and death within a short time Always make sure that there is adequate ventila tion Before starting out make sure that the sidestand is up If the sidestand is not raised com pletely it could contact the ground and distract the opera tor resulting in a possible loss of control OPERATION AND IMPORTANT RIDING POINTS EAU00376 CAUTION Make sure not
53. er element e Make sure that no foreign mate replacement rial enters the crankcase 2 8 L 2 5 Imp qt 3 0 US at 10 Start the engine and then let it idle Total amount dry engine for several minutes while checking 3 2 L 2 8 Imp qt 3 4 US qt it for oil leakage If oil is leaking immediately turn the engine off and check for the cause 11 Turn the engine off and then check the oil level and correct it if necessary 6 13 EAU04083 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 motorcycle In addition the final gear oil level must be checked and the oil changed as follows at the intervals specified in the periodic maintenance and lubrication chart EW000066 WARNING e Make sure that no foreign mate rial enters the final gear case e Make sure that no oil gets on the tire or wheel PERIODIC MAINTENANCE AND MINOR REPAIR 1 Final gear oil drain bolt 2 Final gear oil filler bolt 3 Correct oil level To check the final gear oil level 1 Place the motorcycle on a level surface and hold it in an upright position NOTE The final gear oil level must be checked on a cold engine Make sure that the motorcycle is positioned straight up when checking the oil level A slight tilt to the side can result in a false read ing 6 14 2 Remove the oil filler bolt and then check the oil
54. ers gloves etc is effective in preventing or reducing abra sions 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 engine or exhaust system during or after operation They become very hot and can cause burns Always wear protective clothing that covers your legs ankles and feet Passengers should also observe the precautions mentioned above Modifications Modifications made to this motorcycle not approved by Yamaha or the removal of original equipment may render the motorcycle unsafe for use and may cause severe personal injury Modifications may also make your motorcycle illegal to use Loading and accessories Adding accessories or cargo to your motorcycle can adversely affect stability and handling if the weight distribution of the motorcycle is changed 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 are some general guidelines to follow if loading cargo or adding ac cessories to your motorcycle A SAFETY INFORMATION Loading The total weight of the operator passenger accessories and cargo must not exceed the maximum load limit of XVS650 C 397 Ib 180 kg XVS650A C 441 Ib 200 kg When loading within this weight limit keep the following in mind 1 Carg
55. extremely corrosive in combination with water carry out the following steps after each ride in the rain near the sea or on salt sprayed roads NOTE Salt sprayed on roads in the winter may remain well into spring 1 Clean the motorcycle with cold water and a mild detergent after the engine has cooled down ECA00012 CAUTION Do not use warm water since it in creases the corrosive action of the salt 2 After drying the motorcycle apply a corrosion protection spray on all metal including chrome and nick el plated surfaces to prevent cor rosion MOTORCYCLE CARE AND STORAGE After cleaning Dry the motorcycle with a chamois 7 WIZGINING 1 2 or an absorbing cloth 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 TO prevent corrosion it is recom mended to apply a corrosion pro tection spray on all metal including chrome and nickel plat ed surfaces Use spray oil as a universal clean er to remove any remaining dirt Touch up minor paint damage caused by stones etc Wax all painted surfaces Let the motorcycle dry completely before storing or covering it EWA00031 Make sure that there is no oil or wax on the brakes or tires If necessary clean the brake discs and brake lining
56. f 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 NOTE Use your toes or heel to shift up and your toes to shift down INSTRUMENT AND CONTROL FUNCTIONS ae amp 1 Brake lever EAU00158 Brake lever The brake lever is located at the right handlebar grip To apply the front brake pull the lever toward the handle bar grip 1 Brake pedal EAU00162 Brake pedal The brake pedal is on the right side of the motorcycle To apply the rear brake press down on the brake pedal 3 5 F e TE N T eS be tf 1 Brake pedal EAU03447 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 re leased and the fuel tank cap can be re moved 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 INSTRUMENT AND CONTROL FUNCTIONS 2 Turn the key counterclockwise to the original position remove it and then close the lock cover NOTE The fuel tank cap cannot be installed unless the key is in the lock In addition the key cannot be removed if the cap is not properly installed and locked Make sure that the fuel tank cap is properly installed before riding EW00
57. gned and administered by the same Yamaha people who handle your warranty and it shows in the comprehensive coverage benefits There are no mileage limitations Coverage isn t limited to moving parts or the drive train like many other plans And Y E S covers manufacturing defects just like the warranty See the sample contract at your Yamaha dealer to see how comforting uninterrupted factory backed protection can be e You don t have to pay anything for covered 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 e 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 towing phone calls even food and lodging when you are away from home This superb coverage goes into effect when you purchase Y E S so it applies to any warranty repairs as well as covered repairs during your entire Y E S plan period e Y E S coverage is honored at any authorized Yamaha dealer nationwide e Y E S coverage is transferable to a new owner if you sell or trade in That can make your Yamaha much more valuable This excellent Y E S plan coverage is only available to Yamaha owners like you and only while your Yamaha is still withi
58. he engine wear and polish them selves to the correct operating clear ances During this period prolonged full throttle operation or any condition that might result in engine overheating must be avoided EAU01171 0 600 mi 0 1 000 km Avoid prolonged operation above 1 3 throttle 600 1 000 mi 1 000 1 600 km Avoid prolonged operation above 1 2 throttle EC000056 CAUTION After 600 mi 1 000 km of operation the engine oil and final gear oil must be changed and the oil filter ele ment replaced 1 000 mi 1 600 km and beyond The vehicle can now be operated normally EC000049 CAUTION If any engine trouble should occur during the engine break in period immediately have a Yamaha dealer check the vehicle OPERATION AND IMPORTANT RIDING POINTS EAU00457 Parking When parking stop the engine re move the key from the main switch and then turn the fuel cock lever to OFF 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 e Do not park on a slope or on soft ground otherwise the motorcycle may overturn EW000058 5 6 PERIODIC MAINTENANCE AND MINOR REPAIR Periodic maintenance ceeeeeeeeeeeteeeeeeeeeaes 6 1 Owner s tool kit eceeeeseeeeeeeeeeeneeeeeseeseneeeesenees 6 1 Periodic maintenance chart for the emission control SYSTEM oo eee ao 6 3 General maintenance and lubrication chart
59. ining methanol is not recom mended by Yamaha because it can cause damage to the fuel system or ve hicle performance problems OFF closed position e 1 Arrow mark positioned over OFF EAU02969 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 INSTRUMENT AND CONTROL FUNCTIONS ON normal position 1 Arrow mark positioned over ON ON With the fuel cock lever in this position fuel flows to the carburetors Turn the fuel cock lever to this position when starting the engine and riding 3 8 RES reserve position Z A 5 1 Arrow mark positioned over RES RES This indicates reserve With the fuel cock lever in this position the fuel re serve is made available Turn the fuel cock lever to this position if you run out of fuel while riding When this occurs refuel as soon as possible and be sure to turn the fuel cock lever back to ON INSTRUMENT AND CONTROL FUNCTIONS 1 Starter choke knob N EAU03031 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 to turn
60. isable to have a Yamaha moving the bolt dealer service the wheel 3 Loosen the brake torque rod bolt 8 Connect the speedometer cable Securely support the motor at the swingarm cycle so that there is no danger 4 Remove the brake pedal free play of it falling over adjusting nut and then disconnect 1 Loosen the axle nut the brake rod from the brake cam shaft lever 5 Remove panel A See page 6 8 for panel removal and installation procedures 6 38 PERIODIC MAINTENANCE AND MINOR REPAIR 1 Bolt x 4 2 Final gear case 6 7 NOTE Remove the bolts that secure the final gear case to the swingarm Lift the rear wheel off the ground according to the procedure on page 6 36 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 Make sure to support the drive shaft as it is being pulled out 2 Drive shaft EAU04191 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 middle gear universal joint Install the final gear case bolts and then tighten them to the spec ified torque Tightening torque Final gear case bolt 74 Nm 7 4 m kgf 54 ft lb 6 39 Install the brake rod onto the brake camshaft lever and then install the brake pedal free p
61. king the front fork sses 6 29 Checking the steering ssssseeriresserirrssserrreene 6 30 Checking the wheel bearings ceeeeee 6 31 Battery 2 device aa ieee e E 6 31 Replacing the fuses eee 6 33 Replacing the headlight bulb 6 34 Replacing a turn signal light bulb or the tail brake light DUI erore 6 35 Supporting the motorcycle c cceeeceeeeee 6 36 FVOMt wheal arire niia e tht vassnastaease eens 6 37 Rear wheel ceeeccceeeeesseeeeeeesseneeeeeeseeneeeeeseaes 6 38 Troubleshooting eeeeeeeeeeereereereeerenreern 6 40 Troubleshooting chart seese 6 41 PERIODIC MAINTENANCE AND MINOR REPAIR EAU01790 Safety is an obligation of the owner Periodic inspection adjustment and lu brication will keep your vehicle in the safest and most efficient condition pos sible The most important points of motorcycle inspection adjustment and lubrication are explained on the follow ing pages Maintenance replacement or repair of the emission control devices and systems may be performed by any repair establishment or individual that is certified if applicable Ewo00060 A WARNING If you are not familiar with motor cycle maintenance work have a Yamaha dealer do it for you EAU00467 PERIODIC MAINTENANCE PROPER PERIODIC MAINTENANCE OF YOUR MOTORCYCLE IS IMPOR TANT IN ORDER TO ENJOY LONG PLEASURABLE SERVICE ESPE CIALLY IMPORTANT ARE THE MAINTENANCE SERVICES RELAT ED TO EMISSIONS CONTROL T
62. l the clutch lever in Shift the transmission into second gear Make sure not to shift the transmission into the neutral posi tion Open the throttle part way and gradually release the clutch lever Follow the same procedure when shifting to the next higher gear Always shift gears at the recommend ed shift points OPERATION AND IMPORTANT RIDING POINTS EAU00427 To decelerate 1 Apply both the front and the rear brakes to slow the motorcycle 2 Shift the transmission into first gear when the motorcycle reaches 15 5 mi h 25 km h If the engine is about to stall or runs very rough ly pull the clutch lever in and use the brakes to stop the motorcycle 3 Shift the transmission into the neu tral position when the motorcycle is almost completely stopped The neutral indicator light should come on EAU02974 Recommended shift points The recommended shift points during acceleration and deceleration are shown in the table below Deceleration shift point km h mi h 25 15 5 Acceleration shift point km h mi h 16 9 9 24 14 9 32 19 9 40 24 9 EAU01128 Engine break in There is never a more important period in the life of your engine than the period between 0 and 1 000 mi 1 600 km For this reason you should read the following material carefully Since the engine is brand new do not put an excessive load on it for the first 1 000 mi 1 600 km The various parts in t
63. lay adjusting nut onto the brake rod Install the brake torque rod bolt at the brake shoe plate and then tighten both bolts to the specified torque Tightening torque Brake torque rod bolt 20 Nm 2 0 m kgf 14 ft lb Install the panel Lower the rear wheel so that it is on the ground Tighten the axle nut to the speci fied torque Tightening torque Axle nut 92 Nm 9 2 m kgf 67 ft lb 8 Adjust the brake pedal free play See page 6 23 for brake pedal free play adjustment procedures EW000103 After adjusting the brake pedal free play check the operation of the brake light PERIODIC MAINTENANCE AND MINOR REPAIR EAU01008 Troubleshooting Although Yamaha motorcycles receive a thorough inspection before shipment from the factory trouble may occur dur ing operation Any 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 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 parts may look like Yamaha parts but they are often inferior have a shorter service life and can lead to expensive repair bills 6 40
64. level in the final gear case NOTE The oil level should be at the brim of the filler hole 3 Ifthe 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 To change the final gear oil 1 Place an oil pan under the final gear case to collect the used oil 2 Remove the oil filler bolt and drain bolt to drain the oil from the final gear case 3 Install the final gear oil drain bolt and then tighten it to the specified torque Tightening torque Final gear oil drain bolt 23 Nm 2 3 m kgf 17 ft lb PERIODIC MAINTENANCE AND MINOR REPAIR 4 Add the recommended final gear oil to the brim of the filler hole Recommended final gear oil Hypoid gear oil SAE 80 API GL4 or multi grade hypoid gear oil SAE 80W 90 Oil quantity 0 19 L 0 17 Imp qt 0 20 US qt NOTE GL4 is a quality rating Hypoid gear oils rated GL5 or GL6 may also be used 5 Install and tighten the oil filler bolt 6 Check the final gear case for oil leakage If oil is leaking check for the cause 1 Air filter case cover 2 Screw x 3 EAU00586 Cleaning the air filter element The air filter element should 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 air filter case cover by
65. m or 18 months 16 000 mi 25 000 km or 24 months 20 000 mi 31 000 km or 30 months Engine oil e Replace warm engine before draining See NOTE on page 8 1 Ni Ni Ni Ni Ni Ni Engine oil filter element e Replace at initial 600 mi 1 000 km or 1 month and thereafter every 8 000 mi 13 000 km or 12 months Air filter element e Clean or replace if necessary Clutch e Check operation e Adjust or replace cable Front brake e Check operation fluid level and for fluid leakage See NOTE on page 6 6 e Correct accordingly e Replace brake pads if necessary Rear brake e Check operation e Adjust cable and replace brake shoes if necessary Final gear oil e Check oil level and for oil leakage e Replace at initial 600 mi 1 000 km or 1 month and thereafter every 15 000 mi 24 000 km or 24 months 4 Replace Replace e Check balance runout spoke tightness and for damage e Tighten spokes and rebalance or replace if necessary e Check tire tread wear and for damage e Replace if necessary ROUTINE INITIAL PERIODIC MAINTENANCE AND MINOR REPAIR ODOMETER READINGS 600 mi 1 000 km or 1 month 4 000 mi 7 000 km or 6 months 8 000 mi 13 000 km or 12 months 12 000 mi 19 000 km or 18 months 16 000 mi 25 000 km or 24 months 20 000 mi 31 000 km or 30 months
66. n the Yamaha Limited Warranty period So visit your authorized Yamaha dealer to get all the facts He can show you how easy it is to protect your investment with Yamaha Extended Service EAU01063 We urge you to act now You ll get the excellent benefits of TRIP coverage right away and you ll rest easy knowing you ll have strong factory backed protection even after your Yamaha Limited Warranty expires You can also save money Y E S costs less within the first 90 days after you buy your Yamaha See your dealer today 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 9 10 CONSUMER INFORMATION Y YAMAHA EXTENDED SERVICE A Accessories and replacement parts Air filter element cleaning Brake and clutch levers checking and lubricating Brake and shift pedals checking and lubricating Brake fluid changing Brake fluid level checking Brake lever Brake lever free play adjusting Brake light switch rear adjusting Brake pads and shoes checking Brake pedal Brake pedal position and free play adjusting c Clutch lever Clutch lever free play adjusting D Dimmer switch E Engine break in Engine oil and oil filter element Engine stop switch Engine trouble warning light F Final gear oil Front fork checki
67. neutral switch may be defective The motorcycle should not be ridden until checked by a Yamaha dealer With the engine still running 6 Move the sidestand up 7 Keep the clutch lever pulled 8 Shift the transmission into gear 9 Move the sidestand down Does the engine stall The sidestand switch may be defective The motorcycle should not be ridden until checked by a Yamaha dealer 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 clutch switch may be defective The motorcycle should not be ridden until checked by a Yamaha dealer The system is OK The motorcycle can be ridden 3 17 Pre operation check list PRE OPERATION CHECKS The condition of a vehicle is the owner s responsibility Vital components can start to deteriorate quickly and unexpectedly even if the vehicle remains unused for example as a result of exposure to the elements Any damage fluid leakage or loss of tire air pressure could have serious consequences Therefore it is very important in addition to a thorough visual inspec tion to check the following points before each ride Pre operation check list CHECKS EAU01114 EAU03439 e Check fuel level in fuel tank e Refuel if necessary e Check fuel line for leakage Engine oil e Check oil level in engine e If necessary add recommended oil to specified level e
68. ng Fuel tank cap Fuses replacing H Handlebar switches Headlight bulb replacing Helmet holder High beam indicator light Horn switch l Identification numbers Ignition circuit cut off system Indicator and warning lights K Key identification number L Labels location Luggage strap holders M Main switch steering lock Maintenance and lubrication periodic Maintenance emission control system Maintenance periodic Maintenance record Model label N Neutral indicator light Noise regulation P Panels removing and installing Parking Part locations Pre operation check list S Safety defects reporting Safety information Seats XVS650 Passenger seat Rider seat Seats XVS650A Passenger seat Rider seat Shifting Decelerating Shift points Starting out and accelerating Shift pedal XVS650 Shift pedal XVS650A Shock absorber assembly adjusting Sidestand Sidestand checking and lubricating Spark plugs checking Specifications Speedometer unit Starter choke knob Starting and warming up a cold engine 5 1 Starting a warm engine Start switch Steering checking Storage Storage compartment Supporting the motorcycle T Throttle cable free play adjusting Throttle grip and cable checking and Troubleshooting Troubleshooting chart Turn signal indicator light Turn signal light or tail brake light bulb replacing Turn signal switch Vv Valve clearan
69. nology it also makes it more vulnera ble Rust and corrosion can develop even if high quality components are used A rusty exhaust pipe may go un noticed on a car however it detracts from the overall appearance of a motorcycle Frequent and proper care does not only comply with the terms of the warranty but it will also keep your motorcycle looking good extend its life and optimize its performance Before cleaning 1 Cover the muffler outlets with plas tic bags after the engine has cooled down Make sure that all caps and covers as well as all electrical couplers and connectors including the spark plug caps are tightly in stalled Remove extremely stubborn dirt like oil burnt onto the crankcase with a degreasing agent and a brush but never apply such prod ucts onto seals gaskets and wheel axles Always rinse the dirt and degreaser off with water 7 1 EAU03412 Cleaning ECA00010 CAUTION e Avoid using strong acidic wheel cleaners especially on spoked wheels If such products are used on hard to remove dirt do not 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 corrosion protection spray e 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 h
70. o and accessory weight should be kept as low and close to the motorcycle as possible Make sure to distribute the weight as evenly as possible on both sides of the motorcycle to minimize im balance or instability 2 Shifting weights can create a sudden imbalance Make sure that accessories and cargo are secure ly attached to the motorcycle before riding Check accessory mounts and cargo restraints frequent ly 3 Never attach any large or heavy items to the handlebar front fork or front fender These items in cluding such cargo as sleeping bags duffel bags or tents can create unstable handling or slow steering response Accessories Genuine Yamaha accessories have been specifically designed for use on this motorcycle Since Yamaha cannot test all other accessories that may be available you must personally be responsible for the proper selection installation and use of non Yamaha accessories Use extreme caution when select ing and installing any accessories Keep the following guidelines in mind as well as those provided under Loading when mounting acces sories 1 Never install accessories or carry cargo that would impair the performance of your motorcycle Carefully 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 opera tion or obscure lights or reflectors A SAFETY INFORMATION a Acce
71. operative 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 Muffler Exhaust system Exhaust pipe Silencer Air cleaner case Intake system Air cleaner element Intake duct 9 4 CONSUMER INFORMATION EAU01874 Maintenance record Copies of work orders and or receipts for parts purchased and installed on your motorcycle will be required to document that maintenance has been completed in accordance with the emissions warranty The chart below is printed only as a reminder that maintenance work is required It is not acceptable proof of maintenance work Maintenance Date of 7 Servicing dealer Mileage i f Remarks interval service 600 mi 1 000 km or 1 month name and address 4 000 mi 7 000 km or 6 months 8 000 mi 13 000 km or 12 months 12 000 mi 19 000 km or 18 months 16 000 mi 25 000 km or 24 months 20 000 mi 31 000 km or 30 months 24 000 mi 37 000 km or 36 months 9 5 CONSUMER INFORMATION Maintenance Date of P Servicing dealer Mileage f Remarks interval service 28 000 mi 43 000 km or 42 months name and address 32 000 mi 49 000 km or 48 months 36 000 mi 55 000 km or 54 months 40 000 mi 61 000 km or 60 months 9 6 CONSUMER INFORMATION YAMAH
72. or replaced An unbalanced wheel can result in poor performance adverse han dling characteristics and a short ened tire life e 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 EAU00691 Accessories and replacement parts This motorcycle is not designed to pull a trailer or to be attached to a sidecar The accessories or replace ment parts you choose for your motorcycle should be designed spe cifically for this model and they must be securely mounted to main tain the inherent stability of the orig inal design Genuine Yamaha Parts and Accessories are designed and tested to be compatible with your motorcycle Please consider Genu ine Yamaha Parts and Accessories before making a purchase Use of non Yamaha approved accessories or replacement parts may cause loss of handling stability and riding safety Since Yamaha cannot con trol the quality of accessories or parts manufactured by other com panies Yamaha cannot be held lia EW000098 PERIODIC MAINTENANCE AND MINOR REPAIR ble for any consequences caused by the use of items which have not been approved by Yamaha 6 20 a I e 7 Tighten the locknut at the clutch lever and the crankcase 1 Locknut 1 ore evo iee play o nut 2 Clutch lever free play adjusting bolt 2 Locknut c Clutch lever free play 3 If the specified clutch lever free play coul
73. pport the motorcycle so that there is no danger of it falling over EW000115 6 30 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 dealer check or repair the steer ing PERIODIC MAINTENANCE AND MINOR REPAIR EAU01144 Checking the wheel bearings The front and rear wheel bearings must be checked at the intervals specified in the periodic maintenance and lubrica tion chart If there is play in the wheel hub or if the wheel does not turn smoothly have a Yamaha dealer check the wheel bearings EAU04242 Battery The battery is located behind panel B See page 6 8 for panel removal and installation procedures This motorcycle is equipped with a sealed type MF battery which does not require any maintenance There is no need to check the electrolyte or to add distilled water EC000101 CAUTION Never attempt to remove the battery cell seals as this would permanent ly damage the battery Electrolyte is poisonous and dangerous since 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 EW000116 6 31 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 fo
74. pt should be as short as possible to pre serve the battery Do not crank the en gine more than 10 seconds on any one attempt 5 2 ECA00101 CAUTION The engine trouble warning light should come on when the key is turned to ON and then go off after a few seconds If the engine trouble warning light comes on or flashes after starting immediately stop the engine and have a Yamaha dealer check the self diagnosis system 6 After starting the engine move the starter choke knob back halfway ECA00055 CAUTION For maximum engine life always warm the engine up before starting off Never accelerate hard when the engine is cold 7 When the engine is warm turn the starter choke off OPERATION AND IMPORTANT RIDING POINTS NOTE The engine is warm when it responds normally to the throttle with the 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 min utes with the starter choke in the half way position EAU01258 Starting a warm engine Follow the same procedure as for start ing a cold engine with the exception that th
75. r 15 minutes and seek prompt medical attention Batteries produce explosive hy drogen gas Therefore keep 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 To charge the battery Have a Yamaha dealer charge the bat tery as soon as possible if it seems to have discharged Keep in mind that the battery tends to discharge more quickly if the motorcycle is equipped with op tional electrical accessories To store the battery 1 If the motorcycle will not be used for more than one month remove the battery fully charge it and then place it in a cool dry place If the battery will be stored for more than two months check it at least once a month and fully charge it if necessary Fully charge the battery before in stallation After installation make sure that the battery leads are properly con nected to the battery terminals PERIODIC MAINTENANCE AND MINOR REPAIR EC000102 CAUTION Always keep the battery charged Storing a discharged battery can cause permanent battery damage To charge a sealed type MF battery a special constant voltage battery charger is re quired Using a conventional battery charger will damage the battery If you do not have ac cess to a sealed type MF bat tery charger have a Yamaha dealer charge your battery 6 32
76. 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 check or replace it Recommended lubricant Yamaha Chain and Cable Lube or engine oil SAE 10W 30 API SE Damage to the outer housing of ca bles may result in internal rusting and cause interference with cable movement Replace damaged ca bles as soon as possible to prevent unsafe conditions EW000111 6 27 EAU04034 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 PERIODIC MAINTENANCE AND MINOR REPAIR EAU03370 Checking and lubricating the brake 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 Recommended lubricant Lithium soap based grease all purpose grease EAU03164 Checking and lubricating the brake and clutch levers The operation of the brake and clutch levers should be checked before each ride and the lever pivots should be lu bricated if necessary Recommended lubricant Lithium soap based grease all purpose grease 6 28 PERIODIC MAINTENANCE AND MINOR REPAIR EAU03165 Checking and lubricating the sidestand The operation of the sidestand
77. rottle grip page 6 17 7 Brake lever page 3 5 2 5 Main switch steering lock Indicator and warning lights Speedometer unit Handlebar switches Clutch lever Shift pedal XVS650 Shift pedal XVS650A Brake lever Brake pedal Fuel tank cap Fuel cock Starter choke knob Seats XVS650 Seats XVS650A Helmet holder Storage compartment Adjusting the shock absorber assembly Luggage strap holders Sidestand Ignition circuit cut off system INSTRUMENT AND CONTROL FUNCTIONS EAU00029 Main switch steering lock The main switch steering lock controls the ignition and lighting systems and is used to lock the steering The various positions are described below ON All electrical systems are supplied with power the headlight meter lighting taillight and front position lights come on and the engine can be started The key cannot be removed OFF All electrical systems are off The key can be removed EAU00032 EAU00038 OF LOCK push OFF push T LOCK EAU00040 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 3 1 EAU000
78. rror made by the operator is veering wide on a turn due to EXCESSIVE SPEED or undercornering in sufficient lean angle for the speed Always obey the speed limit and never travel faster than warranted by road and traffic conditions Always signal before turning or changing lanes Make sure that other motorists can see you The posture of the operator and passenger is important for proper control The operator should keep both hands on the handlebar and both feet on the operator footrests dur ing operation to maintain control of the motorcycle The passenger should always hold onto the operator seat strap or grab bar if equipped with both hands and keep both feet on the passenger footrests Never carry a passenger unless he or she can firmly place both feet on the passenger footrests Never ride under the influence of alcohol or other drugs This motorcycle is designed for on road use only therefore it is not suitable for off road use A SAFETY INFORMATION Protective apparel The majority of fatalities from motorcycle accidents are the result of head injuries The use of a safety helmet is the single most critical factor in the prevention or reduction of head injuries 1 2 3 4 5 6 Always wear an approved helmet Wear a 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 trous
79. s with a regular brake disc cleaner or ac etone and wash the tires with warm water and a mild deter gent Before riding at higher speeds test the motorcycle s braking performance and cor nering behavior ECA00013 CAUTION NOTE Consult a Yamaha dealer for advice on what products to use Apply spray oil and wax spar ingly and make sure to wipe off any excess Never apply oil or wax 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 Storage Short term Always store your motorcycle in a cool dry place and if necessary protect it against dust with a porous cover ECA00014 CAUTION e Storing the motorcycle in a poorly ventilated room or cover ing it with a tarp while it is still wet will allow water and humid ity to seep in and cause rust e To prevent corrosion avoid damp cellars stables because of the presence of ammonia and areas where strong chemi cals are stored MOTORCYCLE CARE AND STORAGE Long term Before storing your motorcycle for several months 1 Follow all the instructions in the Care section of this chapter 2 For motorcycles equipped with a fuel cock that has an OFF posi tion Turn the fuel cock lever to OFF Drain the carburetor float cham bers by loosening the drain bolts this will prevent fuel deposits from building up Po
80. si 90 kg 198 Ib maximum Maximum load Total weight of rider accessories 225 kPa 2 25 kgf cm 33 psi 250 kPa 2 50 kgf cm 36 psi 200 kg 441 Ib passenger cargo and PERIODIC MAINTENANCE AND MINOR REPAIR EW000083 Proper loading of your motorcycle is important for several characteris tics of your motorcycle such as handling braking performance and safety Do not carry loosely packed items that can shift Securely pack your heaviest items close to the center of the motorcycle and dis tribute the weight evenly from side to side Properly adjust the suspen sion for your load and check the condition and pressure of your tires NEVER OVERLOAD YOUR MOTOR CYCLE Make sure the total weight of the cargo rider passenger and accessories cowling saddlebags etc if approved for this model does not exceed the maximum load of the motorcycle Operation of an over loaded motorcycle could cause tire damage an accident or even injury 6 18 A 5 1 Tire sidewall 2 Tire wear indicator a Tire tread depth Tire inspection Always check the tires before operating the motorcycle If a tire tread 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 PERIODIC MAINTENANCE AND MINOR REPAIR FRONT XVS650 EAU00680 EAU00685 Spoke whe
81. ss and death within a short time Always operate your motorcycle in an area that has adequate ventilation Always turn the engine off before leaving the motorcycle unattended and remove the key from the main switch When parking the motorcycle note the following A SAFETY INFORMATION The engine and exhaust system may be hot therefore park the motorcycle in a place where pedes trians or children are not likely 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 kerosene heater or near an open flame otherwise it could catch fire When transporting the motorcycle in another vehicle make sure that it is kept upright and that the fuel cock is turned to ON or RES for vacuum type OFF for manual type If it should lean over gasoline may leak out of the carburetor or fuel tank If you should swallow any gasoline inhale a lot of gasoline vapor or allow gasoline to get into your eyes see your doctor immediately If any gasoline spills on your skin or clothing immediately wash the affected area with soap and water and change your clothes A SAFETY INFORMATION E EAU02977 Location of important labels Please read the following important labels carefully before operating this motorcycle A SAFETY INFORMATION 1 3 XVS650A BEFORE YOU OPERATE THIS VEHICLE READ TIRE INFORMA
82. ssories fitted to the handlebar or the front fork area can create instability due to improper weight distribution or aerodynamic changes If accessories are added to the handlebar or front fork area they must be as lightweight as possible and should be kept to a minimum Bulky or large accessories may seriously affect the stability of the motorcycle due to aerodynamic effects Wind may attempt to lift the motorcycle or the motorcycle may become unstable in cross winds These accessories may also cause instability when passing or being passed by large vehi cles Certain accessories can displace the operator from his or her normal riding position This improper position limits the freedom of movement of the operator and may limit control ability therefore such accessories are not recommended Use caution when adding electrical accessories If electrical accessories exceed the capacity of the motorcycle s electrical system an electric failure could result which could cause a dangerous loss of lights or engine power Gasoline and exhaust gas _ a b c 2 GASOLINE IS HIGHLY FLAMMABLE Always turn the engine off when refueling Take care not to spill any gasoline on the engine or exhaust system when refueling Never refuel while smoking or in the vicinity of an open flame Never start the engine or let it run for any length of time in a closed area The exhaust fumes are poi sonous and may cause loss of consciousne
83. sult of owner abuse and or lack of proper maintenance are not covered by this warranty 9 7 ENGINE DISPLACEMENT 50cc to 169cc PERIOD 12 000 km 7 465 miles or five years whichever occurs first 170cc to 279cc 18 000 km 11 185 miles or five years whichever occurs first 280cc or over 30 000 km 18 641 miles or five years whichever occurs first YAMAHA MOTOR CORPORATION U S A MAKES NO OTHER WARRANTY OF ANY KIND EXPRESSED OR IMPLIED ALL IMPLIED WARRANTIES OF MER CHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE WHICH EXCEED THE OBLIGATIONS AND TIME LIMITS STATED IN THIS WARRANTY ARE HEREBY DISCLAIMED BY YAMAHA MOTOR COR PORATION U S A AND EXCLUDED FROM THIS WARRANTY SOME STATES DO NOT ALLOW LIMITATIONS ON HOW LONG AN IMPLIED WARRANTY LASTS SO THE ABOVE LIMITATION MAY NOT APPLY TO YOU ALSO EXCLUDED FROM THIS WARRANTY ARE ANY IN CIDENTAL OR CONSEQUENTIAL DAMAGES INCLUD ING LOSS OF USE SOME STATES DO NOT ALLOW THE EXCLUSION OR LIMITATION OF INCIDENTAL OR CONSEQUENTIAL DAMAGES SO THE ABOVE EXCLUSION MAY NOT APPLY TO YOU THIS WARRANTY GIVES YOU SPECIFIC LEGAL RIGHTS AND YOU MAY ALSO HAVE OTHER RIGHTS WHICH VARY FROM STATE TO STATE YAMAHA MOTOR CORPORATION U S A P O Box 6555 Cypress California 90630 EAU02918 p r Oo P P WARRANTY QUESTIONS AND ANSWERS What costs are my responsibility during the warranty period The customer s responsibility includes all costs of normal maintenance servi
84. the atmosphere Check each hose connection Check each hose and canister for cracks or damage Replace if damaged Make sure the vent hose is not blocked Clean it if necessary EAU03835 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 intervals specified in the periodic maintenance and lubri cation chart To check the engine oil level 1 Place the motorcycle on a level surface and hold it in an upright position NOTE Make sure that the motorcycle is posi tioned straight up when checking the oil level A slight tilt to the side can result in a false reading 2 Start the engine warm it up for several minutes and then turn it off 6 11 1 Engine oil level check window 2 Maximum level mark 3 Minimum level mark 4 Engine oil filler cap 3 Wait a few minutes until the oil set tles and then check the oil level through 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 aa EERO IC MAINTENANCE AND MINOR REPAIR 1 Engine oil drain bolt 1 Oil filter element outer cover 1 Oil filter element inner cover 2
85. ur the drained fuel into the fuel tank Fill up the fuel tank and add fuel stabilizer if available to prevent the fuel tank from rusting and the fuel from deteriorating Perform the following steps to pro tect the cylinders piston rings etc from corrosion 7 4 a b Remove the spark plug caps and spark plugs Pour a teaspoonful of engine oil into each spark plug bore Install the spark plug caps onto the spark plugs and then place the spark plugs on the cylinder head so that the electrodes are ground ed This will limit sparking during the next step Turn the engine over several times with the starter This will coat the cylinder walls with oil Remove the spark plug caps from the spark plugs and then install the spark plugs and the spark plug caps EWA00003 To prevent damage or injury from sparking make sure to ground the spark plug electrodes while turning the engine over MOTORCYCLE CARE AND STORAGE 6 Lubricate all control cables and the pivoting points of all levers and pedals as well as of the sidestand centerstand Check and if necessary correct the tire air pressure and then lift the motorcycle so that both of its 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 Cover the muffler outlets with plas tic bags to prevent moisture from entering them
86. y spark plug shows a distinctly dif ferent color the engine could be defec tive Do not attempt to diagnose such problems yourself Instead have a Yamaha dealer check the motorcycle 3 Check each spark plug for elec trode erosion and excessive car bon or other deposits and replace it if necessary Specified spark plug DPR7EA 9 NGk or X22EPR U9 DENSO PERIODIC MAINTENANCE AND MINOR REPAIR a Spark plug gap To install a spark plug 1 Measure the spark plug gap with a wire thickness gauge and if nec essary adjust the gap to specifica tion Spark plug gap 0 8 0 9 mm 0 03 0 04 in 2 Clean the surface of the spark plug gasket and its mating sur face 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 6 10 Tightening torque Spark plug 18 Nm 1 8 m kgf 13 ft lb NOTE If a torque wrench is not 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 4 Install the spark plug cap PERIODIC MAINTENANCE AND MINOR REPAIR Messe gt To fuel tank gt To carburetor ye Vent hose EAU01796 Canister for California only This model is equipped with a canister to prevent the discharging of fuel vapor into
87. y the recommended quali ty brake fluid otherwise the rubber seals may deteriorate causing leakage and poor braking perfor mance Recommended brake fluid DOT 4 e Refill with the same type of brake fluid Mixing fluids may result in a harmful chemical reaction and lead to poor braking performance Be careful that water does not en ter the brake fluid reservoir when refilling Water will significantly lower the boiling point of the fluid and may result in vapor lock Brake fluid may deteriorate paint ed surfaces or plastic parts Al ways clean up spilled fluid immediately 6 26 PERIODIC MAINTENANCE AND MINOR REPAIR e As the brake pads wear it is nor mal for the brake fluid level to gradually go down However if the brake fluid level goes down sud denly have a Yamaha dealer check the cause PERIODIC MAINTENANCE AND MINOR REPAIR EAU03985 Changing the brake fluid Have a Yamaha dealer change the 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 hose replaced at the intervals listed below or whenever they are dam aged or leaking Oil seals Replace every two years Brake hose Replace every four years EAU03297 Checking and lubricating the cables The operation of all control cables and the condition of the cables should be checked before each

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