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Yamaha 1999 V Star Custom Owner's Manual

1. 5 SS m X y SEN SSS _ o X SSeS ONERE SE S SSS 52 SERRE EE SESS S SRS a SE IQ 3 x X 5 SS D S NC CIE E SES SSS CLEANING AND STORAGE EAUO1010 EAUO1330 A CLEANING Frequent thorough cleaning of your motorcycle will not only enhance its appearance but will improve its gener al performance and extend the useful life of many components ECA00002 CAUTION e improper cleaning can damage the cowlings panels and other plastic parts Use only a soft clean cloth or sponge with mild detergent and water to clean plastic e Do not use any harsh 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 T Before cleaning the motorcycle a Block off the end of the exhaust pipes to prevent water entry a plastic bag and strong rubber band may be used Make sure the spark plugs and all filler caps are properly installed If the engine case is excessively greasy apply degreaser with a paint brush Do not apply de greaser to wheel axles Rinse the dirt and degreaser off with a garden hose Use only enough pressure to do the job 7 1
2. lt LO 0 gt 5 0 gt a E 5 o e 5 aa Ss O O v 0 0 gt V gt zx 8 6 2292 DED LO o 0 gt gt gt gt d NN SS EAU00026 DESCRIPTION Left view XVS650 2 1 1 Shift pedal page 3 5 5 Helmet holder page 3 11 2 Fuel cock page 3 8 6 Storage compartment page 3 12 3 Starter choke page 3 9 7 Tool kit page 6 1 4 Rear shock absorber spring preload adjusting ring 2 1 DESCRIPTION Right view XVS650 11 12 13 8 Oil filter page 6 13 11 Main switch page 3 1 9 Battery page 6 29 12 Air filter page 6 15 10 Fuses page 6 30 13 Rear brake pedal page 3 6 2 2 DESCRIPTION Left view XVS650A 1 Shift pedal page 3 5 5 Helmet holder page 3 11 2 Fuel cock page 3 8 6 Storage compartment page 3 12 3 Starter choke page 3 9 7 Tool kit page 6 1 4 Rear shock absorber spring preload adjusting ring 2 3 DESCRIPTION Right view XVS650A 10 9 8 8 Oil filter page 6 13 11 Main switch page 3 1 9 Battery page 6 29 12 Air filter page 6 15 10 Fuses page 6 30 13 Rear brake pedal page 3 6 2 4 DESCRIPTION Controls Instruments XVS650 XVS650A 14 15 16 17 18 19 20 14 Clutch lever page 3 5 15 Left handlebar s
3. 6 24 Inspecting the brake fluid level 6 25 Troubleshooting aienea 6 37 Front wheel installation 6 35 Rear wheel installation Front wheel 6 34 Rear wheel removal Turn signal and taillight bulb replacement 6 32 Supporting the motorcycle 6 33 Fuse 6 30 Headlight bulb replacement 6 31 Wheel 26 DANGLY Aout sc ccm Front fork inspection 1 6 07 Sidestand lubrication 6 27 Steer Brake and clutch lever lubrication 6 27 Cable inspection and lubrication 6 26 Throttle cable and grip lubrication 6 26 Brake and shift pedal lubrication 6 26 Brake fluid 6 25 o 79 a o D 9 cn Checking the front brake pads and Troubleshoot enne OG ission
4. eio OWNERS MANI JAL xv LIT 11626 12 30 D dd 5BN 28199 z INTRODUCTION EAU00002 Congratulations on your purchase of the Yamaha XVS650 C XVS650A C This mod el 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 craftsmanship and reliability that have made Yamaha 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 about the operation or main tenance 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 motorcycle s performance or economy of opera tion To maintain these high standards it is important that you and your dealer pay close attention to the recommended maintenance schedules and operating instructions contained within this manual IMPORTANT MANUAL INFORMATION EAU00003 Particularly important information is distinguished in this manual by the following notations Q The Safety Alert Symbol means ATTENTION BECOME ALERT YOUR SAFETY IS INVOLVED Failure to follow WARNING instructions could result in severe injury or death t
5. performance Transmission Primary reduction system Spur gear Primary reduction ratio 1 789 Quantity Secondary reduction system Shaft drive Periodic oil change 2 6 L 2 3 Imp qt 2 8 US qt Secondary reduction ratio 3 070 With oil filter replacement 2 81 2 5 Imp at 3 0 US qt Transmission type Constant mesh 5 speed Total amount 3 2 L 2 8 Imp qt 3 4 US qt Operation Left foot operation Final gear oil Gear ratio 1st 2 714 Oil 3rd 1 458 Final gear case capacity 0 19 L 0 17 Imp at 0 20 US qt 4t 1 167 Air filter Dry type element 5th 0 967 Fuel Chassis Type Unleaded fuel For XVS650 C Fuel tank capacity 161 3 5 Imp gal 4 2 US gal Frame type Double cradle Reserve amount 3 L 0 7 Imp gal 0 8 US gal Caster angle 35 Carburetor Trail 153 mm 6 02 in Type x quantity BDS28 x2 Manufacturer MIKUNI 8 2 SPECIFICATIONS For XVS650A C For XVS650A C Frame type Double cradle Type Tube Caster angle 35 Size Trail 145 mm 5 7 in Front 130 90 16 67 Tires Rear 170 80 15 778 For 9650 Manufacturer model Type june Front Bridgestone G703 Size Dunlop D404F ront 1009019579 Rear Bridgestone G702 Rear 170 80 15 M C 77 Dunlop D404 Manufacturer model Maximum load 200 kg 441 ib Front Bridgestone L309 Air pressure cold tire pr Up to 90 kg 198 Ib load Rear Bridgestone 1946 Front 225 kPa 2 25 kgf cm 33 psi re Rear 225 kPa 2 25 kgf cm 33 psi Maximum load 180 kg 397 Ib 90 kg 198 Ib
6. 000111 CAUTION Excessive hose pressure may cause water seepage and deteriora tion of wheel bearings front fork brakes transmission seals and electrical parts Many expensive repair bills have re sulted from improper high pressure detergent applications such as those available in coin operated car washers 4 After riding on salted roads wash the motorcycle with cold water im mediately Do not use warm wa ter as it increases the chemical reaction of the salt 5 Once the majority of the dirt has been hosed off wash all surfaces with warm water and mild deter gent type soap An old toothbrush or bottle brush is handy for hard to get at places 6 Rinse the motorcycle off immedi ately with clean water and dry all surfaces with chamois clean towel or soft absorbent cloth Clean the seat with a vinyl uphol stery cleaner to keep the cover pliable and glossy Automotive type wax may be ap plied to all painted and chrome plated surfaces Avoid combina tion cleaner waxes Many contain abrasives which may mar the paint or protective finish When finished start the engine and let it idle for several minutes CLEANING AND STORAGE EAU01026 B STORAGE Long term storage 60 days or more of your motorcycle will require some preventive procedures to guard against deterioration After thoroughly cleaning the motorcycle prepare for storage as follows 1 Fillthe fuel tank with fuel and add fuel stabiliz
7. TRANSMISSION IS IN GEAR AND sult a Yamaha dealer immediately SIDESTAND IS UP PULL IN CLUTCH LEVER AND PUSH THE START SWITCH ENGINE WILL START CLUTCH SWITCH IS OK 3 15 72 lt VIKING H gt gt H i 555252250225 PRE OPERATION Owners are personally responsible for their vehicle s condition Your motorcycle s vital functions can start to deteriorate quickly and unexpectedly even if it remains unused for instance if it is exposed to the elements Any damage fluid leak or loss of tire pressure could have serious consequences Therefore it is very important that in addition to a thorough visual in spection you check the following points before each ride PRE OPERATION CHECK LIST LETT Hnecessay nn Sates Sm Final gear of Final gear oil Check vehicle for leakage 6 14 6 15 Check tire pressure wear damage and spoke tightness Pores Wheels and tires Tighten spokes if necessary 6 17 6 19 6 28 6 33 EAU00340 meter cable Lubricate if necessary 4 1 PRE OPERATION ITEM CHECKS Make sure that all nuts bolts and screws are properly tightened Chassis fasteners Tighten if neces
8. control system 6 2 General maintenance and lubrication chart 6 4 tenance chart for em tenance Ic main IC main ING Front brake lever free play adjustment 6 21 Clutch lever free play adjustment 6 21 Rear brake pedal height and free play Valve clearance adjustment 6 17 Carburetor adjustment Throttle cable free play inspection 6 Frid ge ane sed Air filter Canister for California 6 12 Spalk PIMOS ordei eda Eng Panel removal and installation 6 8 Panel A Panel 6 9 Period Accessories or replacement parts 6 20 S NNNM SEN S 2 ASS SSeS 2 S NS 5 SEN SSE SS SSS 5 SSS SESS SSS NE KE amp SSS SSS SS x PERIODIC MAINTENANCE AND MINOR REPAIR EAU00462 EAUO0463 Periodic inspection adjustment and lubrication will keep your motorcycle in the safest and most efficient condition possible Safety is an obligation of the motorcycle owner The most important points of motorcycle inspection ad
9. sary ask a Yamaha dealer to make that adjustment 1 Screw x 2 EAU00855 Turn signal and taillight bulb replacement 1 Remove the screws and the lense 2 Push the bulb inward and turn it counterclockwise 3 Place a new bulb in the socket Push the bulb inward and turn it clockwise until it engages into the socket 4 Install the lense and the screws 000108 CAUTION Do not over tighten the screws as the lense may break 6 32 1 Screw PERIODIC MAINTENANCE AND MINOR REPAIR x 2 PERIODIC MAINTENANCE AND MINOR REPAIR XVS650A LA LE aT N t 1 Screw x 3 EAU00862 Supporting the motorcycle Since the Yamaha XVS650 XVS650A has no centerstand follow these pre cautions when removing the front and rear wheel or performing other mainte nance requiring the motorcycle to stand upright Front wheel service To stabilize the rear of the motorcycle either use a motorcycle stand or place a motorcycle jack under the frame in front of the rear wheel to prevent it from moving from side to side Then use a motorcycle stand to elevate the front wheel off of the ground Rear wheel service Use a motorcycle stand or motorcycle jack to elevate the motorcycle so the rear wheel is off the ground Alterna tively two jacks can be placed under the frame or swingarm 6 33 Check that the motorcycle is in a stable and level position before starting a
10. Install the bolts that secure the fi nal gear case to the swingarm and tighten to the specified tight ening torque Specified torque Final gear case bolts 90 Nm 9 0 m kg 65 ft lb 6 36 3 Insert the brake rod into the brake cam lever and install the brake pedal free play adjusting nut Install the brake torque rod bolt and tighten both bolts to the spec tightening torque Specified torque Brake torque rod bolts 20 Nm 2 0 m kg 14 ft lb Install panel A Let the motorcycle down Tighten the axle nut to the speci fied tightening torque Specified torque 8 Axle nut 92 Nm 9 2 m kg 67 ft lb Adjust the rear brake pedal free play See page 6 23 PERIODIC MAINTENANCE AND MINOR REPAIR EAUO1008 Troubleshooting Although Yamaha motorcycles receive a rigid inspection before shipment from the factory trouble may occur during operation Any problem in the fuel compression or ignition systems can cause poor starting and loss of power The trou bleshooting chart describes a quick easy procedure for making checks If your motorcycle requires any repair bring it to a Yamaha dealer The skilled technicians at a Yamaha dealership have the tools experience and know how to properly service your motor cycle Use only genuine Yamaha parts on your motorcycle Imitation parts may look like Yamaha parts but they are often inferior Consequently they have a
11. Yamaha dealer replace the tire immediately Brakes tires and related wheel parts replace ment should also be left to Yamaha dealer Patching punctured tube 1 not recommended If it is abso lutely necessary to do so use great care and replace the tube as soon as possible with a good quality replacement 6 19 EAU00685 Wheels To ensure maximum performance long service and safe operation note the following Always inspect the wheels before a ride Check for cracks bends or warpage of the wheel Be sure the spokes are tight and undam aged any abnormal condition exists in a wheel consult a Yamaha dealer Do not attempt even small repairs to the wheel If a wheel is deformed or cracked it must be replaced e Tires and wheels should be bal anced whenever either one is changed or replaced Failure to have a wheel balanced can result in poor performance adverse handling characteristics shortened 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 characteristics PERIODIC MAINTENANCE AND MINOR REPAIR EAUO0691 Accessories or replacement parts This motorcycle is not designed to pull a trailer or to be attached to a sidecar The accessories or re placement parts you choose for your motorcycle should be de signed specifically for it and they must be securely mounted to main tain the inherent
12. cause if the brake fluid level goes down EAU00742 Brake fluid replacement The brake fluid should be replaced only by trained Yamaha service per sonnel Have the Yamaha dealer re place the following components during periodic maintenance or when they are damaged or leaking oil seals every two years brake hoses every four years PERIODIC MAINTENANCE AND MINOR REPAIR 001541 Cable inspection and lubrication Damage to the outer housing of ca bles may allow internal rusting and cause interference with cable movement Replace damaged ca bles as soon as possible to prevent unsafe conditions 000111 Lubricate the cables and cable ends If a cable does not operate smoothly ask a Yamaha dealer to replace it Recommended lubricant Yamaha Chain and Cable Lube or SAE 10W30 motor oil EAU00773 Throttle cable and grip lubrication The throttle twist grip assembly should be greased at the time that the cable is lubricated since the grip must be re moved to get at the end of the throttle cable After removing the screws hold the end of the cable up in the air and put in several drops of lubricant With the throttle grip disassembled coat the metal surface of the grip assembly with a suitable all purpose grease 6 26 EAUO0775 Brake and shift pedal lubrication Lubricate the pivoting parts Hecommended lubricant Yamaha Chain and Cable Lube or SAE 10W30 motor
13. 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 SPECIFIC EXCLUSIONS from this warranty shall include parts replaced due to normal wear or routine maintenance 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 registrat
14. 1 Panel 1 Panel 1 Panel 122 Panel removal and installation The panels illustrated need to be re moved to perform some of the mainte nance described in this chapter Refer to this section each time a panel has to be removed or reinstalled 6 8 PERIODIC MAINTENANCE AND MINOR REPAIR 5650 1 Bolt x 4 EAUO1573 Panel A To remove Remove the bolts To install Place the panel in its original position and install the bolts 6 9 1 Bolt EAU00491 Panel B To remove Remove the bolt and pull outward on the areas shown PERIODIC MAINTENANCE AND MINOR REPAIR 1 Spark plug cap To install Place the panel in its original position plugs and install the bolt EAUO1485 Removal 1 Remove the spark plug cap 2 Use the spark plug wrench in the tool kit to remove the spark plug as shown 6 10 1 Spark plug wrench Inspection The spark plug is an important engine component and is easy to inspect The condition of the spark plug can indicate the condition of the engine Normally all spark plugs from the same engine should have the same color on the white insulator around the center elec trode The ideal color at this point is a medium to light tan color for a motor cycle that is being ridden normally f one spark plug shows a distinctly dif ferent color there coul
15. 1st Edition July 1998 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 12 30 2 ______ INSTRUMENT AND CONTROL FUNCTIONS 5 OPERATION AND IMPORTANT RIDING POINTS 6 PERIODIC MAINTENANCE AND MINOR REPAIR 4 PRE OPERATION CHECKS 7 CLEANING AND STORAGE 9 CONSUMER INFORMATION 2 lt 2 gt ke Lu lt 42 2 DESCRIPTION 3 8 SPECIFICATIONS S 53555 X FE 2222225 SECS SSS ESS a c USO N 5 S ES SEES GR S SSN 5535552 SSE 5 7 1 1 1 22 22 22222 Loading and accessor Gasoline and exhaust 685 000466000 Location of the important labels Safe r Modificat SAFETY INFORMATION TWO WHEELED MOTORCYCLES ARE SINGLE TRACK VEHICLES THEIR SAFE USE AND OPERA TION ARE DEPENDENT UPON THE USE OF PROPER RIDING TECHNIQUES AS WELL AS THE EX PERTISE OF THE OPERATOR EVERY OPERATOR SHOULD KNOW THE FOLLOWING REQUIREMENTS BEFORE RIDING HE OR SHE SHOULD Dm 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 MANUAL OBTAIN QUALIFIED TRAINING IN SAFE AND P
16. il back to ON after refueling lustrations OFF With the fuel cock in this position fuel will not flow Always set the fuel cock to this position when the engine is not running 3 8 INSTRUMENT AND CONTROL 1 Starter choke IN EAUO1462 Starter choke N Starting a cold engine requires a richer air fuel mixture A separate starter cir cuit supplies this mixture Move in direction 8 to turn on the starter choke Move in direction to turn off the starter choke 00016 CAUTION Do not use the starter choke for more than 3 minutes as the exhaust pipe may discolor from excessive heat 1 Nut EAU00256 Seats for XVS650 To remove the passenger seat re move the nut and pull the seat upward 3 9 1 Bolt x 2 2 Seat holder 3 Projection To reinstall the passenger seat insert the projection on the front of the seat into the seat holder and install the nut To remove the rider seat remove the passenger seat Then remove the two bolts and pull the seat upward 1 Seat holder 2 Projection To reinstall the rider seat insert the projection on the front of the seat into the seat holder and install the bolts Then reinstall the passenger seat NOTE Make sure that the seat is securely fit ted INSTRUMENT AND CONTROL FUNCTIONS 1 Bolt XVS650A 01130 Seats
17. load Air pressure cold tire Maximum load Up to 90 kg 198 ib load Front 225 kPa 2 25 kgf cm 33 psi Front 200 kPa 2 00 kgf cm 29 psi Rear 250 kPa 2 50 kgf cm 36 psi Rear 225 kPa 2 25 kgf cm 33 psi Load is total weight of cargo rider passenger and accessories 90 kg 198 Ib load Maximum load Front 200 kPa 2 00 kgf cm 29 psi Rear 250 kPa 2 50 kgf cm 36 psi 8 3 Wheels For XVS650 C Type Front Rear Size Front Rear For XVS650A C Type Front Rear Size Front Rear Brakes Front Type Operation Fluid Rear Type Operation Spoke Spoke 19 x MT2 50 15M C x MT3 50 Spoke Spoke 16 x MT3 00 15M C x MT3 50 Single disc brake Right hand operation DOT 4 Drum brake Right foot operation Suspension Front Type Rear Type Shock absorber Front Rear Wheel travel For XVS650 C Front Rear For XVS650A C Front Rear Electrical systems Ignition system Charging system Type Standard output Battery Type Voltage capacity Headlight type SPECIFICATIONS Telescopic fork Swingarm 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 1 digital A C magneto 14 V 20A 5 000 rpm GT12B 4 12 10 AH Quartz bulb halogen SPECIFICATIONS Buib voltage wattage x quantity Headlight 12V 60W 55Wx 1 Tail brake light 12V 8W 27W Front turn signal position light 12V 27W 8Wx2 Rear
18. oil PERIODIC MAINTENANCE AND MINOR REPAIR 5 pes D Rs E S Brake and clutch lever lubrication Lubricate the pivoting parts 4 EAU00777 Recommended lubricant Yamaha Chain and Cable Lube or SAE 10W30 motor oil EAUO1542 Sidestand lubrication Lubricate the sidestand pivoting point and metal to metal contact surfaces Check that the sidestand moves up and down smoothly Recommended lubricant Yamaha Chain and Cable Lube or SAE 10W30 motor oil EW000113 If the sidestand does not move smoothly consult a Yamaha dealer 6 27 EAU00793 Front fork inspection Securely support the motorcycle so there is no danger of it falling over EW000115 Visual check Check for scratches or damage on the inner tube and excessive oil leakage from the front fork Operation check Place the motorcycle on level place 1 Hold the motorcycle in an upright position and apply the front brake PERIODIC MAINTENANGE AND MINOR REPAIR 2 Push down hard on the handle bars several times and check if the fork rebounds smoothly EC000098 CAUTION If any damage or unsmooth move ment is found with the front fork consulit a Yamaha dealer EAU00794 Steering inspection Periodically inspect the condition of the steering Worn out or loose steer ing bearings may be dangerous Place a stand under the engine
19. stamped on the key tag Record this number in the space provided and use it for reference when obtaining new key 9 1 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 motorcy cle with the licensing authority in your state CONSUMER INFORMATION 1 Model label EAUO1050 Model label The model label is affixed to the frame under the seat See page 3 9 for seat removal procedures Record the infor mation on this label in the space pro vided This information will be needed to order spare parts from your Yamaha dealer 9 2 CONSUMER INFORMATION EAUO1051 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 CORP U S A If NHTSA receives similar complaints it may open an investigation and if it finds that a safety defect exists in 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 CORP U S A To contact NHTSA you may either ca
20. the right handlebar Pull it toward the han dlebar to apply the front brake INSTRUMENT AND CONTROL FUNCTIONS EAU00162 Rear brake pedal The rear brake pedal is on the right side of the motorcycle Press down on the brake pedal to apply the rear brake EAUO0167 Fuel tank cap To open Insert the key and turn it 1 4 turn clock wise The lock will be released and the cap can be opened To close Push the tank cap into position with the key inserted To remove the key turn it counterclockwise to the original posi tion NOTE e 2222 This tank cap cannot be closed unless the key is in the lock The key cannot be removed if the cap is not locked properly EW000023 Be sure the cap is properly installed and locked in place before riding the motorcycle INSTRUMENT AND CONTROL FUNCTIONS 1 Filler tube 2 Fuel level 001183 Fuel Make sure there is sufficient fuel in the tank Fill the fuel tank to the bottom of the filler tube as shown in the illustra tion Do not overfill the fuel tank Avoid spilling fuel on the hot engine Do not fill the fuel tank above the bot tom of the filler tube or it may over flow when the fuel heats up later and expands EW000130 EAUO0185 Always wipe off spilled fuel immedi ately with a dry and clean soft cloth Fuel may deteriorate painted sur faces or plastic parts EAU00189 Recommended fuel UNLEADED FUEL Fuel tank cap
21. 0 C 50 F require about 7 sec onds of starter use Cold ambient temperatures below 10 C 50 F require about 35 seconds with the starter turned on then about 2 5 minutes with the starter in the halfway position e For maximum engine life always warm up the engine before start ing off Never accelerate hard with a cold engine OPERATION AND IMPORTANT RIDING POINTS EAUO1258 Starting a warm engine The starter choke is not required when the engine is warm 000046 See the break in section prior to operating the motorcycle for the first time EAUO0423 Shifting The transmission lets you contro the amount of power you have available at a given speed for starting accelerat ing climbing hills etc The use of the shift pedal is shown in the illustration To shift into neutral depress the shift pedal repeatedly until it reaches the end of its travel then raise the pedal slightly 5 4 EC000048 e Do not coast for long periods with the engine off and do not tow the motorcycle a long dis tance Even with gears in neu tral the transmission is only properly lubricated when the engine is running Inadequate lubrication may damage the transmission Always use the clutch when changing gears The engine transmission and driveline are not designed to withstand the shock of forced shifting and can be damaged by shifting without using the clutch OPERATION AND IMPOR
22. FF All electrical circuits are switched off The key can be removed in this posi tion Lock Release OFF Push OFF 97 LOCK LOCK push EAU00040 1 Push LOCK 2 Turn The steering is locked in this position and all electrical circuits are switched off The key can be removed in this po sition To lock the steering turn the handlebars all the way to the left While pushing the key into the main switch turn it from OFF to LOCK and remove it To release the lock turn the key to OFF while pushing 3 1 EW000016 Never turn the key to or LOCK when the motorcycle is moving The electrical circuits will be switched off which may result in loss of control or an accident Be sure the motorcycle is stopped be fore turning the key to OFF or LOCK INSTRUMENT AND CONTROL FUNCTIONS 2 Turn indicator light lt gt Neutral indicator light N 4 Engine trouble indicator light C EAU00056 Indicator lights EAU00063 1 High beam indicator light 20 This indicator comes on when the headlight high beam is used EAU00057 2 Turn indicator light lt gt This indicator flashes when the turn switch is moved to the left or right EAUOO0061 3 Neutral indicator light This indicator comes on when the transmission is in neutral EAU00091 4 Engine trouble indicator light 66 HK 39 This i
23. 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 CONSUMER INFORMATION Y YAMAHA EXTENDED SERVICE Accessories or replacement parts Brake and clutch lever lubrication Brake and shift pedal lubrication Brake fluid replacement Brake light switch adjustment Cable inspection and lubrication Canister for California only Carburetor adjustment Checking the front brake pads and rear brake shoes Clutch lever Clutch lever free play adjustment Controls Instruments XVS650 XVS650A D Dimmer switch E Engine break in Engine oil Engine stop switch Engine trouble indicator light F Final gear oil Front brake lever Front brake lever free play adjustment Front fork inspection Front wheel installation Front wheel removal Fuel cock Fuel tank cap Fuse replacement G Gasoline and exhaust gas General maintenance and lubrication H Handlebar switches Dimmer switch Engine stop switch Horn switch Start switch Turn signal switch Headlight bulb replacement Helmet holder High beam indicator light Horn switch Identification numbers record Indicator lights Engine trouble indicator light High beam indicator light Neutral indicator light Turn indicator light Inspecting the brake fluid level K Key identification number L Left view XVS650 Left view XVS650A Loading and acc
24. IS UP PUSH START SWITCH PULL IN CLUTCH LEVER AND PUSH START ENGINE WILL START SWITCH ENGINE WILL START RETRACT SIDESTAND AND PUT TRANSMISSION IN GEAR MOTORCYCLE CAN BE RIDDEN MOTORCYCLE CAN BE RIDDEN 5 2 OPERATION AND IMPORTANT RIDING POINTS 1 Turn the fuel cock to ON 2 Turn the main switch to ON and the engine stop switch to 3 Shift transmission into neutral NOTE When the transmission is neutral the neutral indicator light should be on If the light does not come on ask Yamaha dealer to inspect it 4 Turn on the starter choke and completely close the throttle grip 5 Start the engine by pushing the start switch NOTE y y If the engine fails to start release the start switch wait a few seconds then try again Each attempt should be as short as possible to preserve the bat tery Do not crank the engine more than 10 seconds on any one attempt 6 After starting the engine turn off the starter choke The starter operation periods differ with the ambient temperature so refer to the following notes NOTE e The engine is warm when it re sponds normally to the throttle with the starter turned off To avoid the possibility of excessive exhaust emissions never leave the starter circuit on longer than necessary The length of time the starter is needed depends upon the ambient temperature Warm ambient temperatures above 1
25. M 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 6555 Cypress California 90630 EAUO01061 gt gt gt gt P WARRANTY QUESTIONS AND ANSWERS What costs are my responsibility during the warranty period The customer s responsibility includes all costs of normal maintenance services 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 part to 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 cos
26. MATION 1 3 XVS650A TIRE INFORMATION BEFORE YOU OPERATE THIS VEHICLE READ THE OWNER S MANUAL AND ALL LABELS Cold tire normat pressure should be set as ALWAYS WEAR AN APPROVED MOTORCYCLE follows HELMET eye protection and protective clothing Up to 90 kg 198 Ibs load mmm 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 SBN 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 LOAD LIMIT 4 22259 00 1 Kg 2 165 4BR 24877 A0 3 XVS650 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 33 psi 90 kg 198 lbs maximum load FRONT 200 kPa 2 00 kgf cm 29 psi REAR 250 kPa 2 50 kgf cm 36 psi 5FB 21668 00 1 8 N SAFETY INFORMATION A WARNING Improper loading can cause loss of control Read owner s manuali for proper loading 3JJ 28446 A0 6 California only EMISSION HOSE ROUTING CARB CARB FROM FUEL TANK 2 ROLL OVER VALVE Hn CANISTER TO ATMOSPHERE 5BN 21686 00 1 9 1 2 2 2 3 2 4 2 5
27. 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 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 Y E S is designed 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 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 repair
28. OUTINE 600 mi 4 400 8 200 mi 12 000 mi 15 800 mi 19 600 mi or or or 1month 7 months 13 months 19 months 25 months 31 months Rear shock Check operation and for oil leakage absorber Replace if necessary Control and meter Brake Clutch lever Brake pedal and 3 Since these items require special tools data and technical skills they should be serviced by a Yamaha dealer o 1 Yamaha chain and cable lube or SAE10W30 motor oil 2 Molybdenum disulfide grease 3 Lithium soap base grease 4 5 80 API GL 4 hypoid gear oil EAUO0476 NOTE E m er For odometer readings or time periods higher than 31 000 km 19 600 mi or 31 months repeat the same maintenance as listed in the chart from the 7 000 km 4 400 mi or 7 month interval 6 6 PERIODIC MAINTENANCE AND MINOR REPAIR EAU01450 NOTE e The air filter needs more frequent service if you are riding in unusually wet or dusty areas e Hydraulic brake system When disassembling the master cylinder or caliper cylinder always replace the brake fluid Check the brake fluid level regularly and fill as required Replace the oil seals on the inner parts of the master cylinder and caliper cylinder every two years Replace the brake hoses every four years or if cracked or damaged 6 7 PERIODIC MAINTENANCE AND MINOR REPAIR XV5650 XVS650A E VG
29. ROPER RIDING TECHNIQUES OBTAIN PROFESSIONAL TECHNICAL SERVICE AS INDICATED BY THE OWNER S MANUAL AND OR WHEN MADE NECESSARY BY MECHANICAL CONDITIONS Safe riding 1 2 3 Always make pre operation checks Careful checks may help prevent an accident This motorcycle is designed to carry the operator and a passenger The failure of motorists to detect and recognize motorcycles in traffic is the predominating cause of au tomobile 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 you approach and pass through intersections since intersections are the most likely places for motorcycle accidents c Ride where other motorists can see you Avoid riding in another motorist s blind spot SAFETY INFORMATION Many accidents involve inexperienced operators In fact many operators who have been involved in accidents do not even have a current motorcycle license a Make sure you are qualified Also only lend your motorcycle to experienced operators b Know your skills and limits Staying within your limits may help you to avoid an accident that you practice riding your motorcycle where there is no traffic until you have be come thoroughly familiar with your
30. TANT RIDING POINTS EAUO1205 To start out and accelerate 1 2 Pull the clutch lever to disengage the clutch Shift into first gear The neutral in dicator light should go out Open the throttle gradually and at the same time release the clutch lever slowly At the recommended shift point in the table on page 5 5 close the throttle and at the same time quickly pull in the clutch lever Shift into second gear Be care ful not to shift into neutral 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 recom mended shift points EAU00427 To decelerate 1 Apply both the front and the rear brakes at the same time to slow the motorcycle When the motorcycle reaches 25 km h 15 5 mi h shift into first gear Any time the engine 15 about to stall or runs very roughly pull in the clutch and use the brakes to stop When the motorcycle is almost completely stopped shift into neutral The neutral indicator light should come on 5 5 EAU00429 Recommended shift point Acceleration Deceleration shift point shift point km h mi h km h mi h ist gt 2nd 2nd gt 3rd 3rd gt 4th 4th gt 5th 25 15 5 25 15 5 25 15 5 OPERATION AND IMPORTANT RIDING POINTS EAU01128 Engine break in There is never a more important period in the life of your moto
31. XVS650A To remove the passenger seat re move the bolt and pull the seat up ward 3 10 1 Seat holder 2 Projection x 2 To install the passenger seat insert the projections on the front of the seat into the holder and install the bolt INSTRUMENT AND CONTROL FUNCTIONS XVS650A 1 Bolt To remove the rider seat remove the passenger seat Then remove the bolt and pull the seat upward 2 Projection To install the rider seat insert the pro jection on the front of the seat into the holder and install the bolt Then install the passenger seat NOTE Make sure that the seat is securely fit ted EAU00260 Helmet holder To open the helmet holder insert the key in the lock and turn it as shown To lock the helmet holder replace the holder in its original position Never ride with helmet in the hel met holder The helmet may hit ob jects causing loss of control and possibly an accident EW000030 INSTRUMENT AND CONTROL FUNCTIONS L nt 1 Compartment cover 1 Storage compartment 2 Lock Eauow77 remove the compartment cover in install the compartment cover Storage compartment sert the key the lock and turn it place it in the original position as The storage compartment is located clockwise Then pull the cover out as shown Then turn the key counter on the left side of the motorcycle shown clockwise a
32. acity Total 16 L 3 5 Imp gal 4 2 US gal Reserve 3 L 0 7 Imp gal 0 8 US gal 3 7 Your Yamaha engine has been de signed to use regular unleaded gaso line with a pump octane number 2 of 86 or higher or research octane number of 91 or higher If knocking or pinging occurs use a dif ferent brand of gasoline or premium unleaded fuel Unleaded fuel will give you longer spark plug life and reduced maintenance cost If unleaded gaso line is not available then leaded regu lar gasoline can be used Gasohol There are two types of gasohol gaso hol containing ethanol and that con taining methanol Gasohol containing ethanol can be used if ethanol content does not exceed 1096 Gasohol con taining methanol is not recommended by Yamaha because it can cause fuel system damage or vehicle perform ance problems INSTRUMENT AND CONTROL FUNCTIONS 1 Arrow mark 1 Arrow mark 1 Arrow mark EAU00205 Fuel cock ON RES The fuel cock supplies fuel from the With the fuel cock in this position fuel This indicates reserve If you run out of tank to the carburetors while filtering it flows to the carburetors Set the fuel fuel while riding set the fuel cock to also cock to this position when starting the this position Fill the tank at the first op The fuel cock has three positions engine and while riding portunity Be sure to set the fuel cock which should be set as shown in the
33. any length of time in a closed area The exhaust fumes are poi sonous and may cause loss of consciousness and death within a short time Always operate your mo torcycle in an area that has adequate ventilation 3 Always turn off the engine before leaving the motorcycle unattended and remove the ignition key When parking the motorcycle note the following SAFETY INFORMATION a The engine and exhaust system may be hot Park the motorcycle in a place where pedestrians or children are not likely to touch these hot areas b Do not park the motorcycle on a slope or soft ground the motorcycle may fall over Do not park the motorcycle near flammable source e g kerosene heater or near open flame The motorcycle could catch fire 4 When transporting the motorcycle in another vehicle be sure 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 5 f you should swallow any gasoline inhale a lot of gasoline vapor or allow gasoline to get in your eyes see your doctor immediately any gasoline spills on your skin or clothing immediately wash it off with soap and water and change your clothes N SAFETY INFORMATION EAU00025 Location of the important labels Please read the following labels carefully before operating this motorcycle 1 7 SAFETY INFOR
34. ary information for completing some of your own pre ventive maintenance and minor re pairs NOTE If you do not have necessary tools re quired during a service operation take your motorcycle to a Yamaha dealer for service PERIODIC MAINTENANCE AND MINOR REPAIR EW000062 Modifications to this motorcycle not approved by Yamaha may cause loss of performance excessive emissions and render it unsafe for use Consult a Yamaha dealer be fore attempting any changes 6 2 PERIODIC MAINTENANCE AND MINOR REPAIR EAUO0471 PERIODIC MAINTENANCE CHART FOR EMISSION CONTROL SYSTEM INITIAL ODOMETER READINGS 1 000 km 7 000 km 13 000 km 19 000 km 25 000 km 31 000 km ITEM ROUTINE 600 mi 4 400 mi 8 200 mi 12 000 mi 15 800 mi 19 600 mi Or or 1 month 7 months Check and adjust valve clearance Valv 29081059 when engine is cold Check condition Adjust gap and clean Spark plugs Replace at 13 000 km 8 200 mi or Replace Replace 13 months and thereafter every 12 000 km 7 600 mi or 12 months Crankcase Check ventilation hose for cracks or ventilation damage system Replace if necessary Fuel line Check fuel hose for cracks or damage Replace if necessary B E Check for Exhaust system Retighten if necessary Replace gasket s if necessary Carburetor synchronization Adjust synchronization of carburetors Check and adju
35. 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 Motorcycie 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 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 reg strations sent to Yamaha Motor Corporation U S A by the selling deater 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
36. bling the brake Inspect the grooves If they have almost disap peared ask a Yamaha dealer to re place the pads 6 24 1 Wear limit line 2 Wear indicator EAU00727 Rear brake Apply the brake and inspect the wear indicator If the indicator reaches the wear limit line ask Yamaha dealer to replace the shoes PERIODIC MAINTENANCE AND MINOR REPAIR GE 1 Minimum level mark EAU00731 Inspecting the brake fluid level Insufficient brake fluid may let air enter the brake system possibly causing the brakes to become ineffective Before riding check that the brake flu id is above the minimum level and re plenish when necessary Observe these precautions e When checking the fluid level make sure the top of the master cylinder is level by turning the handlebars e Use only the designated quality brake fluid Otherwise the rubber seals may deteriorate causing leakage and poor brake perform ance 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 brake performance e Becareful that water does not en ter the master cylinder when refill ing Water will significantly lower the boiling point of the fluid and may result in vapor lock e Brake fluid may deteriorate paint ed surfaces or plastic parts Al ways clean up spilled fluid immediately e Have a Yamaha dealer check the
37. cle 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 MOTORCYCLE Make sure the total weight of the cargo rider passen ger and accessories fairing sad dlebags etc if approved for this model does not exceed the maxi mum load of the motorcycle Opera tion of an overloaded motorcycle could cause tire damage an acci dent or even injury 6 18 1 Side wall 2 Wear indicator a Tread depth 2 Tire inspection Always check the tires before erating the motorcycle tire tread shows crosswise lines min imum tread depth if the tire has a nail or glass fragments in it or if the side wall is cracked contact a Yamaha dealer immediately and have the tire replaced PERIODIC MAINTENANCE AND MINOR REPAIR FRONT XVS650 100 90 19 57S L309 REAR XVS650 FRONT XVS650A 130 90 16 678 G703 130 90 16 675 D404F REAR XVS650A Bridgestone 170 80 15M C 778 G702 170 80 15M C 778 D404 Minimum tire tread depth front and rear 1 0 mm 0 04 in EAU00680 e It is dangerous to ride with a worn out tire When a tire tread begins to show lines have
38. ction 8 to in crease free play or in direction b to decrease free play 8 Tighten the locknut at the crank case and the clutch lever 6 21 a Free play 000696 Front brake lever free play adjustment The free play at the front brake lever should be 10 15 0 39 0 59 in PERIODIC MAINTENANCE AND MINOR REPAIR EW000099 WARNING e Check brake lever free play 1 Locknut 2 Adjusting bolt 1 2 Loosen the locknut Turn the adjusting bolt in direction to increase free play or in di rection to decrease free play After adjusting tighten the lock nut Be sure the brake is working properly A soft or spongy feeling in the brake lever can indicate the presence of air in the brake system This air must be re moved by bleeding the brake system before the motorcycle is operated Air in the system will cause greatly diminished braking capability and can re sult in loss of control and an accident Have a Yamaha deal er inspect and bleed the system if necessary 6 22 PERIODIC MAINTENANCE AND MINOR REPAIR p gt Ka AP L7 EA j c Pedal height d Free play EAUOO711 Rear brake pedal height and free play adjustment is advisable to have a Yamaha dealer make this adjustment The brake pedal height should be ad justed before adjusting the brake pedal free play EW000104 Pedal height The brak
39. d be something wrong with the engine Do not attempt to diagnose such problems yourself Instead take the motorcycle to a Yamaha dealer You should periodi PERIODIC MAINTENANCE AND MINOR REPAIR cally remove and inspect the spark plugs because heat and deposits will cause any spark plug to slowly break down and erode If electrode erosion becomes excessive or if carbon and other deposits are excessive you should replace the spark plug with the specified plug Specified spark plug 7 9 or X22EPR U9 DENSO Spark plug Installation 1 Measure the electrode gap with wire thickness gauge and if nec essary adjust the gap to specifi cation Spark plug gap 0 8 0 9 mm 0 03 0 04 in 2 Clean the gasket surface Wipe off any grime from the threads 3 Install the spark plug and tighten it to the specified torque Tightening torque Spark plug 20 Nm 2 0 m kg 14 ft lb NOTE If torque wrench is not available when you are installing a spark plug a good estimate of the correct torque 1 1 4 to 1 2 turn past finger tight Have the spark plug tightened to the speci fied torque as soon as possible PERIODIC MAINTENANCE AND MINOR REPAIR gt To fuel tank To carburetor Vent hose 000498 Canister for California only This model is equipped with canister to prevent the discharging of fu
40. e pedal should be positioned approximately 85 mm 3 35 in above the top of the footrest 1 Locknut 2 Adjusting bolt 1 Loosen the locknut 2 Turn the adjusting bolt in direction 8 to raise pedal height or in di rection to lower pedal height 3 Tighten the locknut After adjusting the pedal height ad just brake pedal free play EW000105 6 23 1 Adjusting nut Free play The brake pedal free play should be adjusted to 20 30 mm 0 79 1 18 in at the brake pedal end Turn the adjusting nut on the brake rod in di rection 8 to increase free play or in di rection to decrease free play PERIODIC MAINTENANCE AND MINOR REPAIR 1 Brake light switch 2 Adjusting nut 000713 Brake light switch adjustment The rear brake light switch is activated by the brake pedal and is properly ad justed when the brake light comes on just before braking takes effect To ad just the rear brake light switch hold the switch body so it does not rotate while turning the adjusting nut Turn the ad justing nut in direction 8 to make the brake light come on earlier Turn the adjusting nut in direction b to make the brake light come on later EAUO0720 Checking the front brake pads and rear brake shoes 1 Wear indicator grooves EAUO1119 Front brake Wear indicator grooves are provided on each brake pad These indicators allow checking of brake pad wear with out disassem
41. e pinch bolt and tighten it to the specified torque Tightening torque Wheel axle 59 Nm 5 9 m kg 43 ft Ib 7 Pinch bolt 20 Nm 2 0 m kg 14 ft lb Install the speedometer cable 6 35 pedal free play adjusting nut Brake rod Brake torque rod bolt Brake torque rod EAU01350 Rear wheel removal e itis advisable to have a Yamaha EW000122 dealer service the wheel Securely support the motor cycle so there is no danger of it falling over Loosen the axle nut Do not re move it Remove the brake torque rod bolt on the brake shoe plate side Loosen the brake torque rod bolt on the swingarm side Bolt x 4 2 Final gear case 3 Axle nut 4 Remove the brake pedal free play adjusting nut and then the brake rod from the brake cam le ver Remove panel A See page 6 9 for removal procedures Remove the bolts that secure the final gear case to the swingarm Elevate the rear wheel off of the ground Pull the wheel backward while supporting the drive shaft to re move the wheel axle final gear case and drive shaft as an as sembly PERIODIC MAINTENANCE AND MINOR REPAIR 1 Middle drive shaft joint 2 Drive shaft 001563 Rear wheel installation 1 install the rear wheel axle final gear case and drive shaft as an assembly by pushing the wheel forward and guiding the drive shaft into the middle drive shaft U joint
42. ection 1 Place the motorcycle on a level place and hold it in an upright po sition The engine should be cool at ambient temperature 2 Remove the oil filler bolt and check the oil level The oil level should be at the brim of the filler hole Add the recommended oil if necessary Oil replacement 1 Place an oil pan under the final gear case 2 Remove the oil filler bolt and drain plug to drain the oil 3 Reinstall and tighten the drain plug to the specified torque Tightening torque Drain plug 23 Nm 2 3 m kg 17 ft lb 4 Fill the gear case to the brim of the filler hole with the recom mended oil PERIODIC MAINTENANCE AND MINOR REPAIR Final gear case capacity 0 19 L 0 17 Imp qt 0 20 US qt Recommended oil SAE 80 GL 4 Hypoid gear oil If desired an SAE 80W90 hypoid gear oil may be used for all conditions NOTE GL 4 is a quality and additive rating Hypoid gear oils rated GL 5 or GL 6 may also be used 5 Reinstall and tighten the filler bolt to the specified torque Tightening torque Oil filler bolt 23 Nm 2 3 m kg 17 ft lb 6 After replacing the final gear oil be sure to check for oil leakage 1 Case cover 2 Screw 3 EAU00586 Air filter The air filter should be cleaned at the specified intervals t should be cleaned more frequently if you are riding in unusually wet or dusty areas 1 Remove the air filter case cover by re
43. el vapor into the atmosphere Before using this motorcycle be sure to Check each hose connection Check each hose and canister for cracks or damage Replace if damaged Make sure the vent hose 1 not blocked Clean it if necessary 1 Maximum level mark 2 Minimum level mark EAUO1326 Engine oil Oil level inspection 1 Place the motorcycle on a level place and hold it in an upright po sition Warm up the engine for several minutes NOTE Be sure the motorcycle is positioned straight up when checking the oil level A slight tilt toward the side can result in false readings 5 D ft AVE NN WORD 1 1 Engine oil drain plug 2 With the engine stopped check the oil level through the level win dow located at the lower part of the left side crankcase cover NOTE Wait few minutes until the oil level settles before checking 3 The oil level should be between the maximum and minimum marks If the level is low fill the engine with sufficient oil to the specified level PERIODIC MAINTENANCE AND MINOR REPAIR 1 Cover 2 Bolt x 3 Engine oil and oil filter element re placement 1 Warm up the engine for few minutes 2 Stop the engine Place an oil pan under the engine and remove the oil filler cap 3 Remove the drain plug and drain the oil 4 Remove the cover and the o
44. er if available 2 Remove the spark plugs pour about one tablespoon of engine oil in each spark plug hole and re install the spark plugs Turn the engine over several times ground spark plug leads to coat the cylinder walls with oil When using the starter motor to crank the engine remove the spark plug wires and ground them to pre vent sparking EWO000127 3 Lubricate all control cables 7 2 4 Block up the frame to raise both wheels off the ground 5 Tiea plastic bag over the exhaust pipe outlets to prevent moisture from entering 6 If storing in a humid or salt air at mosphere coat all exposed metal surfaces with a light film of oil Do not apply oil to any rubber parts or the seat cover 7 Remove the battery and fully charge it Store it in a cool dry place and completely recharge it once a month Do not store the battery in an excessively warm or cold place less than 0 30 F or more than 30 C 90 F See page 6 29 for battery storage pre cautions NOTE ss Make any necessary repairs before storing the motorcycle 8 Specificat RNN SKRE SPECIFICATIONS EAU01038 Specifications Model Dimensions For XVS650 C Overall length Overall width Overall height Seat height Wheelbase Ground clearance Minimum turning radius For XVS650A C Overall length Overall width Overall height Seat height Wheelbase Ground clearance Minimum turn
45. es of higher amper age rating than those recommend ed Substitution of a fuse of improper rating can cause exten sive electrical system damage and possibly a fire 6 30 PERIODIC MAINTENANCE AND MINOR REPAIR Specified fuses Main fuse Ignition fuse Signaling system fuse Headlight fuse Carburetor heater fuse PERIODIC MAINTENANCE AND MINOR REPAIR 1 Screw x 2 EAU00832 Headlight bulb replacement This motorcycle is equipped with quartz bulb headlight If the headlight bulb burns out replace the bulb as fol lows 1 Remove the screws holding the headlight assembly v 1 Connector 2 Bulb cover 2 Remove the headlight connector and the bulb cover 6 31 1 Bulb holder 3 Unhook the bulb holder and re move the defective bulb Keep flammable products and your hands away from a bulb while it is on as it is hot Do not touch a bulb until it cools down EW000119 4 Put a new bulb into position and secure it in place with the bulb holder CAUTION Avoid touching the glass part of a bulb Keep it free from oil other wise the transparency of the glass life of the bulb and luminous flux will be adversely affected If oil gets on a bulb thoroughly clean it with a cloth moistened with alcohol or lac quer thinner 5 Install the bulb cover and the headlight connector the head light beam adjustment is neces
46. essories Location of the important labels Luggage strap holders M Main switch Steering lock Maintenance record Model label Modification Motorcycle noise regulation N Panel B Panel removal and installation Parking Periodic maintenance Periodic maintenance chart for emission control system Pre operation check list Protective apparel R Rear brake pedal Rear brake pedal height and free play adjustment Rear shock absorber adjustment Rear wheel installation Rear wheel removal Recommended shift point Reporting safety defects Right view XVS650 Right view XVS650A S Sidestand clutch switch operation check Spark plugs Specifications Speedometer Start switch Starter choke NJ Starting a warm engine Starting and warming up a cold engine Steering inspection Storage compartment Street and enduro motorcycle limited warranty Supporting the motorcycle 1 Throttle cable and grip lubrication Throttle cable free play inspection Troubleshooting Troubleshooting chart Turn indicator light Turn signal and taillight bulb replacement Turn signal switch
47. il fil ter cover by removing the bolts NW 2 EN Moor 555255 1 VA INT y en A 1 Engine oi filler cap 1 Bolt x 5 5 Remove the oil filter and O ring 6 Reinstall the drain plug and tight en it to the specified torque Tightening torque Drain plug 43 Nm 4 3 m kg 31 10 7 Install a new oil filter and O ring 8 Install oil filter cover and cover then tighten the bolts 9 Fill the engine with oil Install the oil filler cap and tighten it 6 13 2 Oil filter cover Recommended oil See page 8 1 Oil quantity Total amount 3 2 L 2 8 Imp at 3 4 US qt Periodic oil change 2 6 L 2 3 Imp qt 2 8 US at With oil filter replacement 2 8 L 2 5 Imp at 3 0 US at PERIODIC MAINTENANCE AND MINOR REPAIR 1 O ring 2 Oil filter element EC000066 CAUTION e Do not put in any chemical ad ditives Engine oil also lubri cates the clutch and additives could cause clutch slippage e Be sure no foreign material en ters the crankcase 10 Start the engine and warm it up for a few minutes While warming up check for oil leakage If oil leakage is found stop the engine immediately and check for the cause 1 Final gear oil drain plug 2 Final gear oil filler bolt 3 Proper level EAU00542 Final gear oil Do not let foreign material enter the final gear case Be sure oil does not get on the tire or wheel 000066 level insp
48. ing radius Basic weight with oil and full fuel tank For XVS650 C For XVS650A C XVS650 CY XVS650A C Engine Engine type Cylinder arrangement 2 295 mm 90 4 in 880 mm 34 6 in 1 065 mm 41 9 in 695 mm 27 4 in 1 610 mm 63 4 in 140 mm 5 5 in 3 100 mm 122 0 in Displacement Bore x stroke Compression ratio Starting system Lubrication system Engine oil Type 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 Recommended engine oil classification 227 kg 500 Ib 243 kg 535 Ib 8 1 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 ie T E pipaa 1 YAMALUBE 4 10W30 or SAE 10W30 t 1 a oa o YAMALUBE 4 20W40 or SAE 20W40 1 1 1 1 1 1 0 1 t 1 1 1 1 t 1 t 1 1 1 20 10 0 10 20 30 40 50 C Service SE SF SG type or higher SPECIFICATIONS Spark plug Be sure to use motor oils that do not contain anti fric Type Manufacturer DPR7EA 9 NGK or tion modifiers Passenger car motor oils often labeled X22EPR U9 DENSO Energy Conserving contain anti friction additives Gap 0 8 0 9 mm 0 03 0 04 in which will cause clutch and or starter clutch slippage Clutch t Wet muitiple disc resulting in reduced component life and poor engine
49. intenance work is required It is not acceptable proof of maintenance work MAINTENANCE DATE OF SERVICING DEALER INTERVAL SERVICE AND ADDRESS REMARKS 1 000km 600 mi or 1 mo 7 000km 4 400 7 mos 13 000km 8 200mi or 15 800mi or 25 mos 31 000km 19 600mi or 31 mos 13 mos 9 5 19 000km 12 000 mi or 19 mos 25 000km CONSUMER INFORMATION MAINTENANCE DATE OF SERVICING DEALER INTERVAL SERVICE Munere NAME AND ADDRESS MEAS 37 000km 23 400 37 mos 43 000km 27 200mi or 43 mos 49 000 km 31 000mi or 49 mos 55 000km 34 800 mi or 55 mos 61 000km 38 600 mi or 61 mos 9 6 YAMAHA MOTOR CORPORATION U S A CONSUMER INFORMATION 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
50. ion 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 result 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 30 000 km 18 641 miles or five years whichever occurs first 280cc or over 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 FRO
51. justment and lubrication are explained in the following pages Maintenance replacement or re pair of the emission control devices and systems may be performed by any repair establishment or individ ual using any part which is certified if applicable If you are not familiar with motorcy cle service this work should be done by a Yamaha dealer EW000060 EAU00467 PERIODIC MAINTENANCE PROPER PERIODIG 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 THESE CONTHOLS NOT ONLY FUNCTION TO ENSURE CLEANER AIR BUT ARE ALSO VITAL TO PROPER ENGINE OPERATION AND MAXIMUM PERFORMANCE IN THE FOLLOWING TABLES OF PERIODIC MAINTENANCE THE SERVICES RELATED TO EMISSIONS CON TROL ARE GROUPED SEPARATE LY THESE SERVICES REQUIRE SPECIALIZED DATA KNOWL EDGE AND EQUIPMENT YAMAHA DEALERS TRAINED AND EQUIPPED TO PERFORM THESE PARTICULAR SERVICES 6 1 EAUO1129 Tool kit The tool kit is located inside of the stor age compartment See page 3 12 for compartment opening procedures The tools provided in the owner s tool kit are to assist you in the performance of periodic maintenance However some other tools such as torque wrench are also necessary to perform the maintenance correctly The service information included in this manual is intended to provide you the owner with the necess
52. ll 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 inoperative by any person AMONG THOSE ACTS PRESUMED TO CONSTITUTE TAMPERING ARE THE ACTS LISTED BELOW These acts include tampering with the following systems i e modification removal etc Muffler Exhaust system Exhaust pipe Silencer Air cleaner case Intake system Air cleaner element Intake duct 9 4 CONSUMER INFORMATION EAUO1059 MAINTENANCE RECORD Copies of work orders and or receipts for parts you purchase and install will be required to document that maintenance has been completed in accordance with the emission warranty The chart below is printed only as a reminder to you that the ma
53. months 4 Check balance runout spoke tightness and for damage Tighten spokes and rebalance or replace if necessary PERIODIC MAINTENANCE AND MINOR REPAIR INITIAL ODOMETER READINGS 1 000 km 7 000 km j 19 000 km 25 000 km 31 000 km ITEM ROUTINE 600 mi 4 400 mi 8 200 mi 12 000 mi 15 800 mi 19 600 mi or or 1 month 7 months 13 months 19 months 25 months 31 months Check tire tread wear and for damage Tires Replace if necessary Check bearings for looseness or damage Replace if necessary Check swing arm pivot for play Correct if necessary Moderately repack every 24 000 km 15 200 mi or 24 months 2 Check bearing play and steering for smooth operation Correct if necessary Moderately repack every 24 000 km 15 200 mi or 24 months 3 Check all nuts bolts and screws for Chassis fasteners tightness Tighten if necessary Check operation Lubricate pivot and contact surfaces with chain lube lightly 1 Repair if necessary Sidestand switch operation Replace if 50 3 13 Repair if necessary 6 5 Steering bearings A Sidestand PERIODIC MAINTENANCE AND MINOR REPAIR ODOMETER READINGS EUN 000 km 7 000 km 13 000 km 19 000 km 25 000 km 31 000 km ITEM R
54. motorcycle and all of its controls Many motorcycle accidents have been caused by motorcycle operator errors A typical error made by the operator is veering wide on a turn due to EXCESSIVE SPEED or undercornering insufficient lean angle for the speed a Always obey the speed limits and never travel faster than warranted by road and traffic conditions b Always signal before turning or changing lanes Make sure other motorists see you The operator s and passenger s posture are important for proper control a The operator should keep both hands on the handlebars and both feet on the operator footrests during operation to maintain control of the motorcycle b The passenger should always hold on to the operator or the seat strap or grab bar if the motorcycle is so equipped with both hands and keep both feet on the passenger footrests c 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 drugs This motorcycle is designed for on road use only It is not suitable for off road use 1 2 N SAFETY INFORMATION Protective apparel The majority of fatalities from motorcycle accidents are the result of head injuries The use of a safety hel met is the single most critical factor in the prevention or reduction of head injuries 1 Always wear an approved helmet 2 Wear a face shield or goggles Wind on your unprotected eyes could contrib
55. moving the screws 2 Remove the air filter 6 15 Tap the air filter lightly to remove most of the dust and dirt Blow out the remaining dirt with com pressed air as shown If the air fil ter is damaged replace it PERIODIC MAINTENANCE AND MINOR REPAIR EAU00628 Carburetor adjustment QI 7 SS 1 Be 7 The carburetors are important parts of We fo NW Re engine and emission control sys AD tem Adjusting should be left to LE S x Yamaha dealer with the professional I knowledge specialized data and Lae IQ gt gt equipment to do so properly 3 amp ND 1 Holder 1 Match marks 5 Align the match marks and install the air filter case cover 4 Install the air filter on the air filter case as shown CAUTION e Make sure the air filter is prop erly seated in the air filter case e The engine should never be run without the air filter installed Excessive piston and or cylin der wear may result EC000082 6 16 PERIODIC MAINTENANCE AND MINOR REPAIR a Free play EAU00635 Throttle cable free play inspection There should be free play of 4 6 mm 0 16 0 24 in at the throttle grip If the free play is incorrect ask a Yamaha dealer to make this adjust ment EAU00637 Valve clearance adjustment The correct valve clearance changes with use resulting i
56. n improper fuel air supply or engine noise To prevent this the valve clearance must be ad justed regularly This adjustment how ever should be left to a professional Yamaha service technician EAU00645 Tires To ensure maximum performance long service and safe operation note the following Tire air pressure Always check and adjust the tire pres sure before operating the motorcycle EW000082 WARNING Tire inflation pressure should be checked and adjusted when the temperature of the tire equals the ambient air temperature Tire infla tion pressure must be adjusted ac cording to total weight of cargo rider passenger and accessories fairing saddlebags etc if ap proved for this model and vehicle speed PERIODIC MAINTENANCE AND MINOR REPAIR XVS650 GET E 200 kPa 225 kPa s 90 kg 198 10 00 kgt em 2 25 29 psi 33 psi 200 kPa 250 kPa 2 00 kgf cm 2 50 kgf cm 29 psi 36 psi Load is the total weight of cargo rider passenger and accessories XVS650A org AT 225 kPa 225 kPa Up to 90 kg 198 Ib 2 26 kgtlom 2 25 33 psi 33 psi 90 kg 198 Ib load Maximum load 225 kPa 250 kPa 2 25 kgf cm 2 50 kgf cm 33 psi 36 psi Load is the total weight of cargo rider passenger and accessories EW000083 Proper loading of your motorcycle is important for several characteris tics of your motorcy
57. n travel steering travel or control operation or obscure lights or reflectors 1 4 N SAFETY INFORMATION a Accessories 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 b 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 being passed by or passing large vehi cle C 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 2 Caution must be used if adding electrical accessories If these 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 1 GASOLINE IS HIGHLY FLAMMABLE a Always turn off the engine when refueling b Take care not to spill any gasoline on the engine or exhaust system when refueling c Never refuel while smoking or in the vicinity of an open flame 2 Never start the engine or let it run for
58. nd remove it 3 12 INSTRUMENT AND CONTROL FUNCTIONS 1 Position indicator 2 Adjusting ring 3 Extension bar 4 Special wrench EAU00299 Rear shock absorber adjustment This shock absorber is equipped with spring preload adjuster Adjust spring preload as follows 1 Remove the passenger seat and rider seat See page 3 9 3 11 for removal procedures 2 Use the special wrench and the extension bar in the owner s tool kit to turn the adjusting ring Turn the adjusting ring in direction to increase spring preload and in direction to decrease spring preload Make sure that the ap propriate notch in the adjusting ring is aligned with the position in dicator on the rear shock absorb er Stan Soft dard Hard position 3 Reinstall the seats 3 13 EAU00315 This shock absorber contains high ly pressurized nitrogen gas Read and understand the following infor mation before handling the shock absorber The manufacturer cannot be held responsible for property damage or personal injury that may result from improper handling e Do not tamper with or attempt to open the cylinder assembly e Do not subject the shock ab sorber to an open flame or oth er high heat source This may cause the unit to explode due to excessive gas pressure e Do not deform or damage the cylinder in any way Cylinder damage will result in poor damping performance e Take your shock absorber
59. ndicator light will come on or flash if trouble occurs in monitoring circuit In such case take the motorcycle to a Yamaha dealer to have the self diag nostic systems checked 3 2 1 Reset knob 2 Speedometer 3 Odometer 4 Trip odometer EAU00095 Speedometer The speedometer shows riding speed This speedometer is equipped with an odometer and trip odometer The trip odometer can be reset to 0 with the reset knob Use the trip odometer to estimate how far you can ride on tank of fuel This information will en able you to plan fuel stops in the fu ture INSTRUMENT AND CONTROL FUNCTIONS 3 3 EAUOO118 Handlebar switches EAU00121 1 Dimmer switch Turn the switch to for the high beam and to Z0 for the low beam EAU00124 2 Turn signal switch lt This model is equipped with self can celling turn signals To signal a right hand turn push the switch to the right To signal a left hand turn push the switch to the left Once the switch is re leased it will return to the center posi tion To cancel the signal push the switch in after it has returned to the center position If the switch is not can celled by hand it will self cancel after the motorcycle has travelled at least 150 meters and 15 seconds have passed self cancelling mecha nism only operates when the motorcy cle is moving Therefore the signal will not self cancel while you are stop
60. ny maintenance A strong wooden box can be placed under the engine for added stability INGES NSG 1 Speedometer cable EAU00894 Front wheel removal e it is advisable to have a 000122 Yamaha dealer service the wheel e Securely support the motor 1 cycle so there is no danger of it falling over Remove the speedometer cable from the front wheel side PERIODIC MAINTENANCE AND MINOR REPAIR 1 Axle 2 Pinch bolt 2 Loosen the pinch bolt and wheel 3 Elevate the front wheel by placing a suitable stand under the en gine 4 Remove the wheel axle and the front wheel NOTE Do not depress the brake lever when the disc and caliper are separated 6 34 PERIODIC MAINTENANCE AND MINOR REPAIR 1 Speedometer gear unit housing EAUO1394 Front wheel installation 1 Install the speedometer gear unit into the wheel hub Make sure the wheel hub and the speedometer gear unit are installed with the projections meshed into the slots Lift up the wheel between the front fork legs and guide the brake disc between the brake pads Make sure the slot in the speedometer gear unit fits over the stopper on the front fork outer tube Install the wheel axle and let the motorcycle down 4 Push down hard on the handle bars several times to check for proper fork operation Tighten the wheel axle to the specified torque Install th
61. o the motorcycle operator bystander or person inspecting or repairing the motorcycle 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 CAUTION NOTE E fe eL e 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 there is any question con cerning this manual please consult your Yamaha dealer IMPORTANT MANUAL INFORMATION EW000000 PLEASE READ THIS MANUAL AND THE YOU AND YOUR MOTORCYCLE RIDING TIPS BOOKLET CAREFULLY AND COMPLETELY BEFORE OPERATING THIS MOTORCYCLE DO NOT TO OPERATE THIS MOTORCYCLE UNTIL YOU HAVE ATTAINED SATISFAC TORY 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 RELIABILITY OF THIS MOTORCYCLE LABEL HERE EAUC1399 XVS650L CY XVS650AL C OWNER S MANUAL O 1998 by Yamaha Motor Corporation U S A
62. ped at an intersection EAU00129 3 Horn switch bo Press the switch to sound the horn INSTRUMENT AND CONTROL FUNCTIONS EAU001 38 1 Engine stop switch The engine stop switch is safety de vice for use in an emergency Such as when the motorcycle overturns or if trouble occurs in the throttle system Turn the switch to to start the en gine In case of emergency turn the switch to 64 to stop the engine EAU00143 2 Start switch The starter motor cranks the engine when pushing the start switch EC000005 CAUTION See starting instructions prior to starting the engine INSTRUMENT AND CONTROL FUNCTIONS FAU00152 Clutch lever The clutch lever is located on the left handlebar and the ignition circuit cut off system is incorporated in the clutch lever holder Pull the clutch lever to the handlebar to disengage the clutch and release the lever to engage the clutch The lever should be pulled rapidly and released slowly for smooth clutch op eration Refer to the engine starting procedures for description of the ig nition circuit cut off system 1 Shift pedal EAUO0157 Shift pedal This motorcycle is equipped with a constant mesh 5 speed transmission The shift pedal is located on the left side of the engine and is used in com bination with the clutch when shifting 3 5 EAU00158 Front brake lever The front brake lever is located on
63. rcycle than the period between zero and 1 600 km 1 000 mi For this reason we ask that you carefully read the following materi al Because the engine is brand new you must not put an excessive load on it for the first 1 600 km 1 000 mi The various parts in the engine wear and polish themselves to the correct oper ating clearances During this period prolonged full throttle operation or any condition which might result in exces sive heating of the engine must be avoided EAUO1171 0 1 000 km 0 600 mi Avoid operation above 1 3 throttle 1 000 1 600 km 600 1 000 mi Avoid cruising speeds in excess of 1 2 throttle EC000056 CAUTION After 1 000 km 600 mi of operation be sure to replace the engine oil oil filter and final gear oil 1 600 km 1 000 mi and beyond Proceed with normal riding EC000049 If any engine trouble should occur during the break in period consult a Yamaha dealer immediately 5 6 EAU00457 Parking When parking the motorcycle stop the engine and remove the ignition key Turn the fuel cock to OFF whenever stopping the engine The exhaust system is hot Park the motorcycle in a place where pedes trians or children are not likely to touch the motorcycle Do not park the motorcycle on a slope or soft ground the motorcycle may over turn EW000058 38 6 36 6 28 hart ii ing c ing inspec rear brake 5
64. rstand Never start your engine or let it run for any length of time in a closed area The exhaust fumes are poisonous and can cause loss of consciousness and death within a short time Always operate your motorcy cle in an area with adequate ventilation e Before starting out always be sure the sidestand is up Fail ure to retract the sidestand completely can result in a seri ous accident when you try to turn a corner EAUO0376 CAUTION e Be careful where you store per sonal items on the motorcycle Avoid blocking the air cleaner intake or performance will suf fer e Be careful not to put anything near the battery and its termi nals Electrical failure and acid corrosion may result 5 1 EAUO1131 Starting and warming up a cold engine NOTE This motorcycle is equipped with an ig nition circuit cut off system The engine can be started only under the following conditions e he transmission is in neutral e The sidestand is up the transmis sion is in gear and the clutch is disengaged The motorcycle must not be ridden when the sidestand is down Before going through the following steps check the function of the sid estand switch and clutch switch Refer to page 3 15 EW000054 OPERATION AND IMPORTANT RIDING POINTS TURN THE MAIN SWITCH TO AND THE ENGINE STOP SWITCH TO IF TRANSMISSION 1 IN NEUTRAL AND IF TRANSMISSION IS IN GEAR AND SIDESTAND IS DOWN SIDESTAND
65. s 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 within 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 001063 We 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
66. s 180 kg XVS650A 441 Ibs 200 kg When loading within these weight limits keep the following in mind 1 Cargo and accessory weight should be kept as low and close to the motorcycle as possible Be sure to distribute the weight as evenly as possible on both sides of the machine to minimize imbalance or in stability 2 Shifting weights can create a sudden imbalance Make sure that accessories and cargo are securely attached to the motorcycle before riding Recheck accessory mounts and cargo restraints frequently 3 Never attach any large or heavy items to the handlebars front forks or front fender These items in cluding such cargo as sleeping bags duffle bags or tents can create unstable handling or slow steer ing response Accessories Genuine Yamaha accessories have been specifically designed for use on this motorcycle Since Yamaha cannot test all other accessories which may be available you must personally be responsible for the prop er selection installation and use of non Yamaha accessories You should use extreme caution when se lecting and installing any accessories Keep in mind these guidelines for mounting accessories in addition to those provided under LOADING 1 Never install accessories or carry cargo that would impair the performance of your motorcycle Care fully inspect the accessory before using it to make sure it does not in any way reduce ground clearance ot cornering clearance limit suspensio
67. sary Check fuel level Lights signals and switches Check for proper operation 6 31 6 33 NOTE ini mun TT a ae Pre operation checks should be made each time the motorcycle is used Such an inspection can be thoroughly accom plished in a very short time and the added safety it assures is more than worth the time involved e If any item in the PRE OPERATION CHECK is not working properly have it inspected and repaired before op erating the motorcycle e The engine exhaust system will be very hot after the engine has been run Be careful not to touch them or to allow any clothing item to contact them during inspection or repair 4 2 4 4 5 5 5 6 7 5 5 5 5 5 5 5 ine ing a Warm FE In Recommended shift po Engine break To start out and accelerate 2 decelerale were or EE E ode bee v lee RR Park c 9 Q 5 D E E 79 a O 4 Start Shi ISSN ONANI 444 ARNE LESS 55 RG SSS us MOOR NR RN _ 553222 S 5 HUI SSSA SRSA SARS SSE N ENE AANI RINA SSSR SSS OPERATION AND IMPORTANT RIDING POINTS EAU00372 EAU00373 e Before riding this motorcycle become thoroughly familiar with all operating controls and their functions Consult a Yamaha dealer regarding any control or function that you do not thoroughly unde
68. shorter service life and can lead to expensive repair bills 6 37 PERIODIC MAINTENANCE AND REPAIR EAUO1297 Troubleshooting chart WARNING Never check the fuel system while smoking or in the vicinity of an open flame Enough fuel Go to compression check There is compression No compression 3 Ignition Wipe clean with dry cloth and correct Open throttle half way and start spark or replace spark plugs the engine EW000125 1 Fuel Check if there is fuel in the fuel tank Engine doesn t start go to compression check 2 Compression Go to ignition check Use the electric starter Ask a Yamaha dealer to inspect Remove spark plugs and check electrodes Engine doesn t start go to battery Ask a Yamaha dealer to inspect check Engine turns over quickly Engine turns over slowly 4 Battery Battery good Engine doesn t start ask a Yamaha Use the electric starter dealer to inspect Check connections or recharge 6 38 1 3 7 222 22220 0999949 HKN AAK 9009990000071 HE KKK 3444999097 LOMAS 9000399994081 ENES sen ES EEE Tac tei aene 502220002
69. st engine idle speed Idle speed Adjust cable free play Evaporative emission control Check control system for damage system For Replace if necessary California only Since these items require special tools data and technical skills they should be serviced by a Yamaha dealer 6 3 PERIODIC MAINTENANCE AND MINOR REPAIR EAU00472 GENERAL MAINTENANCE AND LUBRICATION CHART INITIAL ELLE 000 km ODOMETER READINGS 7 000 km 13 000 km 19 000 km 25 000 km 31 000 km 4 400 mi 8 200 mi 12 000 mi 15 800 mi 19 mi or ITEM ROUTINE 7 months 13 months 19 months 25 months 31 monie Replace warm engine before draining See NOTE on page 8 1 Replace at initial 1 000 km 600 mi or 1 month and thereafter every 12 000 km 7 600 mi or 12 months Clean or replace if necessary Check operation Adjust or replace cable Check operation fluid level and for EN fluid leakage See NOTE on page 6 7 Correct accordingly Replace brake pads if necessary Check operation Rear brake Adjust cable and replace brake shoes if necessary Final gear oil KJ RE TI TITT B E Check oil level and for oil leakage Replace at initial 1 000 km 600 mi or 1 month and thereafter every 24 000 km 15 200 mi or 24
70. stability of the original design Genuine Yamaha Parts and Accessories are de signed and tested to be compatible with your motorcycle Please con sider Genuine Yamaha Parts and Accessories before making an ac cessory purchase Use of non Yamaha approved parts or acces sories may cause loss of handling stability and riding safety Since Yamaha cannot control the quality of parts or accessories manufac tured by other companies Yamaha EW000098 cannot be held liable for any conse quences caused by the use of items which have not been approved by Yamaha PERIODIC MAINTENANCE AND MINOR REPAIR E te Wa S KOS ay N t Locknut 2 Adjusting bolt c Free play EAUO0694 Clutch lever free play adjustment The clutch lever free play should be adjusted to 10 15 mm 0 39 0 59 in 1 Loosen the locknut at the clutch lever 2 Turn the adjusting boit at the clutch lever in direction 8 to in crease free play or in direction b to decrease free play 3 Tighten the locknut at the clutch lever 1 Adjusting nut 2 Locknut If the specified free play cannot be ob tained proceed with the following steps 4 Loosen the locknut at the clutch lever 5 the adjusting bolt at the clutch lever in direction 8 to loos en the cable 6 Loosen the locknut at the crank case side 7 Tum the adjusting nut at the crankcase in dire
71. ter for 15 minutes and get prompt medi cal attention Batteries produce explosive gases Keep sparks flame cigarettes etc away Ventilate when charging or using in an enclosed space Always shield your eyes when working near batteries KEEP OUT OF REACH OF CHIL DREN Battery storage When the motorcycle is not used for a month or longer remove the battery fully charge it and store it in a cool dry place EC000102 CAUTION O Z OZO OOOO e Completely recharge the bat tery before storing Storing a discharged battery can cause permanent battery damage Use a battery charger designed for a sealed type MF battery Using a conventional battery charger will cause battery dam age you do not have sealed type battery charger contact your Yamaha dealer e Always make sure the connec tions are correct when reinstall ing the battery 1 Fuse block 2 Main fuse 3 Spare fuse EAU00825 Fuse replacement The fuses are located behind panel B See page 6 8 for panel removal pro cedures If a fuse is blown turn off the main switch and the switch of the circuit in question Instail a new fuse of proper amperage Turn on the switches and see if the electrical device operates If the fuse immediately blows again con sult a Yamaha dealer 1 Ignition fuse 2 Signaling system fuse 3 Headlight fuse 4 Carburetor heater fuse 5 Spare fuse EC000103 CAUTION Do not use fus
72. to a Yamaha dealer for any service 1 Luggage strap holder 2 EAUO1172 Luggage strap holders There is a luggage strap holder locat ed at each passenger footrest INSTRUMENT AND CONTROL FUNCTIONS EAUO0330 Sidestand This model is equipped with an ignition circuit cut off system The motorcycle must not be ridden when the sidestand is down The sidestand is located on the left side of the frame Refer to page 5 1 for an explanation of this sys tem This motorcycle must not be operat ed with the sidestand in the down position If the stand is not properly retracted it could contact the ground and distract the operator re sulting in a possible loss of control Yamaha has designed into this mo torcycle a lockout system to assist the operator in fulfilling the respon sibility of retracting the sidestand Please check carefully the operating instructions listed below and if there is any indication of a malfunction return the motorcycle to a Yamaha dealer immediately for repair EW000044 3 14 INSTRUMENT AND CONTROL FUNCTIONS 000331 Sidestand ciutch switch SIDESTAND IS DOWN operation check ENGINE WILL STALL SIDESTAND SWITCH IS OK Check the operation of the sidestand switch and clutch switch against the in formation below TURN THE MAIN SWITCH TO ON DEE ENGINE STOP SWITCH EW000045 If improper operation is noted
73. to raise the front wheel off the ground Hold the lower end of the front forks and try to move them forward and backward If any free play can be felt ask a Yamaha dealer to inspect and adjust the steering Inspection is easier if the front wheel is removed Securely support the motorcycle so there is no danger of it falling over EW000115 6 28 EAUO1144 Wheel bearings If there is play in the front or rear wheel hub or if the wheel does not turn smoothly have a Yamaha dealer in spect the wheel bearings PERIODIC MAINTENANCE AND MINOR REPAIR EAU00800 Battery This motorcycle is equipped with sealed type battery Therefore it is not necessary to check the electrolyte or fill the battery with distilled water e If the battery seems to have dis charged consult Yamaha deal er e motorcycle is equipped with optional electrical accessories the battery tends to discharge more quickly so be sure to re charge it periodically EC000101 GAUTION Never try to remove the sealing caps of the battery cells The bat tery will be damaged EW000116 Battery electrolyte is poisonous and dangerous causing severe burns etc It contains sulfuric acid Avoid contact with skin eyes or clothing ANTIDOTE e EXTERNAL Flush with water e INTERNAL Drink large quanti ties of water or milk Follow with milk of magnesia beaten egg or vegetable oil Call a physician immediately e EYES Flush with wa
74. ts such as towing or transportation due to a failure No The warranty is limited to repair of the machine itseif Mayl 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 I do not operate or maintain my new motor gt gt 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 under 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
75. turn signal light 12V 27W x2 Meter light 12V 1 7W x 1 Neutral indicator light 12V 1 7W x1 High beam indicator light 12V 1 7W x1 Turn indicator light 12V 1 7W x 1 Engine trouble indicator light 12V 1 7W x 1 Fuses Main fuse 30A Ignition fuse 10A Signaling system fuse 10A Headlight fuse 15A Carburetor heater fuse 15A dentification numbers 2 9 1 ey identification ehicle identification number EEE eporting Safety Defects otorcycle Noise Regulation vod aintenance SE treet and enduro motorcycle limited warranty amaha extended CONSUMER INFORMATION EAUO1039 EAU01040 Identification numbers record Record the key identification number vehicle identification number and mod el label information in the spaces pro vided for assistance when ordering spare parts from a Yamaha dealer or for reference in case the vehicle is sto len 1 KEY IDENTIFICATION NUMBER _ 2 VEHICLE IDENTIFICATION NUMBER 3 MODEL LABEL INFORMATION 1 Key identification number EAUO1041 Key identification number The key identification number is
76. ute to an impairment of vi sion which could delay seeing a hazard 3 The use of heavy boots jacket trousers gloves etc is effective in preventing or reducing abrasions or lacerations 4 Never wear loose fitting clothing It could catch on the control levers footrests or wheels and cause in jury or accident 5 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 6 A passenger should also observe the above precautions Modification Modifications made to the motorcycle not approved by Yamaha or the removal of original equipment may render your 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 machine is changed To avoid the possibility of an accident extreme caution should be used if adding cargo or accessories to your motorcycle Use extra care if riding a motorcycle which has added cargo or accessories Here are some general guidelines to follow if loading cargo or adding acces sories to your motorcycle 1 3 SAFETY INFORMATION Loading The total weight of the operator passenger accessories and cargo must not exceed the maximum load limit of XV8650 C 397 Ib
77. witches page 3 3 16 Speedometer page 3 2 17 Fuel tank cap page 3 6 18 Right handlebar switches page 3 4 19 Throttle grip 20 Front brake lever page 3 5 2 5 6 6 7 8 9 9 10 11 12 13 14 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 1 eee ee ee eee eee eee eee ey heck AHO MOM HM ION Sidestand clutch switch operat Rear shock absorber adjustment Luggage strap holders RT n OE Canine Storage compartment Seats for XVS6BDA vasen Helmsbhold6l s ee choke EEE EE Seats flor VISS ae Ee se Fe PUGH TARK Cap mp gt Q 2 LL 9 E 0 v o0 gt 2 A G 5 IO FR HKN 2 INSTRUMENT AND CONTROL FUNCTIONS EAUO0027 EAU00029 Main switch Steering lock The main switch controls the ignition and lighting systems Its operation is described below EAU00032 ON All electrical circuits are switched on and the headlight meter light taillight and front position lights come on The engine can be started The key cannot be removed in this position EAU00038 O

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