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Yamaha XVS650T(C) Motorcycle User Manual

1. 1 Fuel m There is enough fuel Check the compression Check the fuel level in the fuel tank a ned rach e engine does not start There is no fuel Supply fuel Check the compression 2 Compression There is compression t Check the ignition Operate the electric starter i Have a Yamaha dealer There is no compression gt check the Vehicle 3 Ignition Wet Wipe off with a dry cloth and correct the Open the throttle halfway and operate spark plug gaps or replace the spark plugs the electric starter Remove the spark plugs 1 and check the electrodes P The engine does not start gt Dry Have a Yamaha dealer check the vehicle Check the battery 4 Battery aero e engine MMS OVer L g The battery is good quickly The engine does not start Operate the electric starter gt Have a Yamaha dealer The engine turns over Check the battery lead connections check the vehicle slowly and charge the battery if necessary 6 38 MOTORCYCLE CARE AND STORAGE EAU26060 Care While the open design of a motorcycle reveals the attractiveness of the tech nology it also makes it more vulnera ble Rust and corrosion can develop even if high quality components are used A rusty exhaust pipe may go un noticed on a car however it detracts from the overall appearance of a motor cycle Frequent and proper care does not only comply with the t
2. iu emrvrmrvvvsvvrrreereeseneee 6 35 Wheels unnuvvvvvvvervrrrrrvnnvrnrvrervrnvrrersrsee 6 19 See your Authorized YAMAHA Dealer for a Genuine YAMAHA Service Manual PRINTED IN JAPAN 2004 05 2 6x1 CR E
3. 2 Locknut PERIODIC MAINTENANCE AND MINOR REPAIR 5 To increase the clutch lever free dur ats apc play turn the adjusting nut in direc Adjusting the brake lever free tion a To decrease the clutch le Play ver free play turn the adjusting nut in direction b 1 6 Tighten the locknut at the clutch le ver and the crankcase 1 Locknut 2 Brake lever free play adjusting screw 1 Loosen the locknut at the brake le 1 Brake lever free play ver The brake lever free play should mea 2 To increase the brake lever free sure 10 0 15 0 mm 0 39 0 59 in as play turn the adjusting screw in di shown Periodically check the brake le rection a To decrease the brake ver free play and if necessary adjust it lever free play turn the adjusting as follows screw in direction b 3 Tighten the locknut e After adjusting the brake lever free play check the free play and make sure that the brake is working properly e A soft or spongy feeling in the brake lever can indicate the presence of air in the hydraulic EWA10630 6 21 system If there is air in the hy draulic system have a Yamaha dealer bleed the system before operating the motorcycle Air in the hydraulic system will dimin ish the braking performance which may result in loss of con trol and an accident PERIODIC MAINTENANCE AND MINOR REPAIR 22231 Adjusting the brake pedal position and free play XVS650 1 Distance between brak
4. API service SE SF SG type or higher 8 1 Engine oil quantity Without oil filter element replacement 2 60 L 2 75 US qt 2 29 Imp qt With oil filter element replacement 2 80 L 2 96 US qt 2 46 Imp qt Final gear oil Type SAE80 API GL 4 Hypoid gear oil Quantity 0 19 L 0 20 US qt 0 17 Imp qt Air filter Air filter element Dry element Fuel Recommended fuel Unleaded gasoline only Fuel tank capacity 16 0 L 4 23 US gal 3 52 Imp gal Fuel reserve amount 3 0 L 0 79 US gal 0 66 Imp gal Carburetor Manufacturer MIKUNI Type x quantity BDS28 x 2 Spark plug s Manufacturer model NGK DPR7EA 9 Manufacturer model DENSO X22EPR U9 Spark plug gap 0 8 0 9 mm 0 031 0 035 in Clutch Clutch type Wet multiple disc Transmission Primary reduction system Spur gear Primary reduction ratio 68 38 1 789 Secondary reduction system Shaft drive Secondary reduction ratio 19 18 x 32 11 3 071 Transmission type Constant mesh 5 speed Operation Left foot operation Gear ratio ist 38 14 2 714 2nd 38 20 1 900 ard 35 24 1 458 4th 28 24 1 167 5th 29 30 0 967 Chassis Frame type Double cradle Caster angle 35 00 Trail XVS650 153 0 mm 6 02 in XVS650A 145 0 mm 5 71 in XVS650AT 145 0 mm 5 71 in Front tire Type With tube Size XVS650 100 90 19M C 57S XVS650A 130 90 16M C 67S XVS650AT 130 90 16M C 67S Manufacturer model XVS650 BRIDGESTONE EXEDRA L309
5. EAU24921 To install the front wheel 1 Install the speedometer gear unit into the wheel hub so that the pro jections mesh with the slots S AE fea a 4 _ i j ra ra 1 Speedometer gear unit 2 Speedometer cable 3 Retainer 2 Lift the wheel up between the fork legs NOTE Make sure that there is enough space between the brake pads before insert ing the brake disc and that the slot in the speedometer gear unit fits over the retainer on the fork leg 3 Insert the wheel axle 4 Lower the front wheel so that it is on the ground PERIODIC MAINTENANCE AND MINOR REPAIR 5 Tighten the wheel axle and front EAU2S080 4 Remove the brake pedal free play wheel axle pinch bolt to the speci Rear wheel adjusting nut and then disconnect fied torques and then install the EN the brake rod from the brake cam rubber cap To remove the rear wheel shaft lever EWA10820 Tightening torques 2 Scones m kgf 43 ft Ibf Itis advisable to have a Yamaha p l Front wheel axle pinch bolt dealer service the wheel ale 20 Nm 2 0 m kgf 14 ft Ibf Securely support the motor cycle so that there is no danger 6 While applying the front brake of it falling over push down hard on the handlebars several times to check if the front fork compresses and rebounds smoothly 7 Connect the speedometer cable 1 Loosen the axle nut Brake pedal free play adjusting nut Brake camshaft lever Brake rod
6. Front XVS650 200 kPa 29 psi 2 00 kgf cm XVS650A 225 kPa 33 psi 2 25 kgf cm XVS650AT 225 kPa 33 psi 2 25 kgf cm Rear 250 kPa 36 psi 2 50 kgf cm 6 17 XVS650 180 kg 397 Ib U49 XVS650A 198 kg 437 Ib CAL XVS650A 200 kg 441 Ib U49 XVS650AT 198 kg 437 Ib CAL XVS650AT 200 kg 441 Ib U49 Total weight of rider passenger car go and accessories EWA10510 Proper loading of your vehicle is im portant for several characteristics of your vehicle such as handling braking performance and safety Do not carry loosely packed items that can shift Securely pack your heavi est items close to the center of the vehicle and distribute the weight evenly from side to side Properly adjust the suspension for your load and check the condition and pres sure of your tires NEVER OVER LOAD YOUR VEHICLE Make sure that the total weight of the cargo rid er passenger and accessories cowling saddlebags etc if ap proved for this model does not ex ceed the maximum load of the PERIODIC MAINTENANCE AND MINOR REPAIR vehicle Operation of an overloaded ee Oe AE vehicle could cause tire damage an A WARNING A WARNING accident or even injury It is dangerous to ride with a e The front and rear tires should Tire inspection 1 Tire sidewall 2 Tire wear indicator 3 Tire tread depth Always check the tires before operating the motorcycle If a tire tread shows crosswis
7. and spark plugs b Pour a teaspoonful of engine oil into each spark plug bore c Install the spark plug caps onto the spark plugs and then place the spark plugs on the cylinder head so that the electrodes are grounded This will limit spark ing during the next step d Turn the engine over several times with the starter This will coat the cylinder walls with oil e Remove the spark plug caps from the spark plugs and then install the spark plugs and the spark plug caps MOTORCYCLE CARE AND STORAGE EA 080 C 90 F For more information WARNING Ge Se on storing the battery see page To prevent damage or injury from 6 29 sparking make sure to ground the NOTE spark plug electrodes while turning A the engine over Make any necessary repairs before storing the motorcycle 6 Lubricate all control cables and the pivoting points of all levers and pedals as well as of the side stand centerstand 7 Check and if necessary correct the tire air pressure and then lift the motorcycle so that both of its wheels are off the ground Alterna tively turn the wheels a little every month in order to prevent the tires from becoming degraded in one spot 8 Cover the muffler outlets with plas tic bags to prevent moisture from entering them 9 Remove the battery and fully charge it Store it in a cool dry place and charge it once a month Do not store the battery in an ex cessively cold or warm place
8. each new model Yamaha motorcycle will be free from defects in material and workmanship for the period of time stated herein subject to certain stated limitations THE PERIOD OF WARRANTY for Yamaha motorcycles originally equipped with headlight stoplight and turn signals shall be one 1 year from the date of purchase with no mileage limitation MODELS EXCLUDED FROM WARRANTY include those used for non Yamaha authorized renting leas ing or other commercial purposes and TZ models DURING THE PERIOD OF WARRANTY any authorized Yamaha motorcycle dealer will free of charge repair or replace any part adjudged defective by Yamaha due to faulty workmanship or material from the factory Parts used in warranty repairs will be warranted for the balance of the product s warranty period All parts replaced under warranty become property of Yamaha Motor Corp U S A GENERAL EXCLUSIONS from this warranty shall include any failures caused by a Competition or racing use b Installation of parts or accessories that are not qualitatively equivalent to genuine Yamaha parts Abnormal strain neglect or abuse Lack of proper maintenance Accident or collision damage Modification to original parts 020 SPECIFIC EXCLUSIONS from this warranty shall include parts replaced due to normal wear or routine maintenance CONSUMER INFORMATION THE CUSTOMER S RESPONSIBILITY under this war ranty shall be to 1 Operate and maintain the motorc
9. 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 costs such as towing or transportation due to May perform any or all of the recommended maintenance shown in the Owner s 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 Will the warranty be void or cancelled if do not operate or maintain my new motor CUSTOMER SERVICE If your machine requires warranty service you must take it to any authorized Yamaha Motorcycle dealer within the continental United States Be sure to bring your warranty registration card or other valid proof of the original date of purchase If a question or problem arises regarding warranty first con tact the owner of the dealership Since all warranty matters are handled at the dealer level this person is in the best position to help you If you are still not satisfied and require additional assistance please write YAMAHA MOTOR CORPORATION U S A CUSTOMER RELATIONS DEPARTMENT P O Box 6555 Cypress California 90630 When contacting Yamaha Motor Corporation U S A don t forget to include any important inf
10. 1 Place the vehicle on a level sur face and hold it in an upright posi tion NOTE Make sure that the vehicle is positioned straight up when checking the oil level A slight tilt to the side can result in a false reading 2 Start the engine warm it up for several minutes and then turn it off 3 Wait a few minutes until the oil set tles and then check the oil level through the check window located at the bottom left side of the crank case NOTE The engine oil should be between the minimum and maximum level marks 1 Engine oil level check window 2 Maximum level mark 3 Minimum level mark 4 Engine oil filler cap 4 If the engine oil is at or below the minimum level mark add sufficient oil of the recommended type to raise it to the correct level To change the engine oil with or without oil filter element replace ment 1 Start the engine warm it up for several minutes and then turn it off 6 11 2 Place an oil pan under the engine to collect the used oil 3 Remove the engine oil filler cap and drain bolt to drain the oil from the crankcase 1 Engine oil filler bolt 2 Oil pan NOTE Skip steps 4 7 if the oil filter element is not being replaced 4 Remove the outer and inner oil fil ter element covers by removing the bolts 2 Bolt 1 Inner oil filter element cover 2 Bolt 5 Remove the oil filter element and O ring PERIODIC MAINTENANCE AND M
11. XVS650A BRIDGESTONE EXEDRA G703 XVS650AT BRIDGESTONE EXEDRA G703 Manufacturer model XVS650 DUNLOP F24 XVS650A DUNLOP D404F XVS650AT DUNLOP D404F Rear tire Type With tube Size 170 80 15M C 77S Manufacturer model XVS650 BRIDGESTONE EXEDRA G546 XVS650A BRIDGESTONE EXEDRA G702 XVS650AT BRIDGESTONE EXEDRA G702 SPECIFICATIONS Manufacturer model XVS650 DUNLOP K555 XVS650A DUNLOP D404G XVS650AT DUNLOP D404G Loading Maximum load XVS650 178 kg 392 Ib CAL XVS650 180 kg 397 Ib U49 XVS650A 198 kg 437 Ib CAL XVS650A 200 kg 441 Ib U49 XVS650AT 198 kg 437 Ib CAL XVS650AT 200 kg 441 Ib U49 Total weight of rider passenger cargo and accessories Tire air pressure measured on cold tires Loading condition 0 90 kg 0 198 Ib Front XVS650 200 kPa 29 psi 2 00 kgf cm XVS650A 225 kPa 33 psi 2 25 kgf cm XVS650AT 225 kPa 33 psi 2 25 kgf cm Rear 225 kPa 33 psi 2 25 kgf cm Loading condition XVS650 90 178 kg 198 392 Ib CAL XVS650 90 180 kg 198 397 Ib U49 XVS650A 90 198 kg 198 437 Ib CAL XVS650A 90 200 kg 198 441 Ib U49 XVS650AT 90 198 kg 198 437 Ib CAL XVS650AT 90 200 kg 198 441 Ib U49 SPECIFICATIONS Front XVS650 200 kPa 29 psi 2 00 kgf cm XVS650A 225 kPa 33 psi 2 25 kgf cm XVS650AT 225 kPa 33 psi 2 25 kgf cm Rear 250 kPa 36 psi 2 50 kgf cm Front wheel Wheel type Spoke wheel Rim size XVS650 19M C x
12. condition Securely support the vehicle so that there is no danger of it falling over EWA10750 Check the inner tubes for scratches damage and excessive oil leakage To check the operation 1 Place the vehicle on a level sur face and hold it in an upright posi tion 2 While applying the front brake push down hard on the handlebars several times to check if the front fork compresses and rebounds smoothly 6 27 ECA10590 CAUTION If any damage is found or the front fork does not operate smoothly have a Yamaha dealer check or re pair it EAU23280 Checking the steering Worn or loose steering bearings may cause danger Therefore the operation of the steering must be checked as fol lows at the intervals specified in the pe riodic maintenance and lubrication chart 1 Place a stand under the engine to raise the front wheel off the ground Securely support the vehicle so that there is no danger of it falling over EWA10750 2 Hold the lower ends of the front fork legs and try to move them for ward and backward If any free play can be felt have a Yamaha dealer check or repair the steering PERIODIC MAINTENANCE AND MINOR REPAIR 6 28 EAU23290 Checking the wheel bearings The front and rear wheel bearings must be checked at the intervals specified in the periodic maintenance and lubrica tion chart If there is play in the wheel hub or if the wheel does not turn smoothly have a Yamaha deal
13. ers or steam jet cleaners since they cause water seepage and deterioration in the following ar eas seals of wheel and swing arm bearings fork and brakes electric components couplers connectors instruments switches and lights breather hoses and vents For motorcycles equipped with a windshield Do not use strong cleaners or hard sponges as they will cause dulling or scratching Some cleaning com pounds for plastic may leave scratches on the windshield Test the product on a small hid den part of the windshield to make sure that it does not leave any marks If the windshield is scratched use a quality plastic polishing compound _ after washing After normal use Remove dirt with warm water a mild detergent and a soft clean sponge and then rinse thoroughly with clean water Use a toothbrush or bottlebrush for hard to reach areas Stubborn dirt and insects will come off more easily if the area is covered with a wet cloth for a few minutes before cleaning After riding in the rain near the sea or on salt sprayed roads Since sea salt or salt sprayed on roads during winter are extremely corrosive in combination with water carry out the following steps after each ride in the rain near the sea or on salt sprayed roads NOTE Salt sprayed on roads in the winter may remain well into spring 1 Clean the motorcycle with cold wa ter and a mild detergent after the engine has cooled down MOTORCY
14. gt 2nd 16 km h 9 9 mi h 2nd gt 3rd 24 km h 14 9 mi h ard gt 4th 32 km h 19 9 mi h 4th gt 5th 40 km h 24 9 mi h Shift down points 5th gt 4th 25 km h 15 5 mi h 4th gt 3rd 25 km h 15 5 mi h 3rd gt 2nd 25 km h 15 5 mi h 2nd gt 1st 25 km h 15 5 mi h 5 4 EAU16841 Engine break in There is never a more important period in the life of your engine than the period between 0 and 1600 km 1000 mi For this reason you should read the follow ing material carefully Since the engine is brand new do not put an excessive load on it for the first 1600 km 1000 mi The various parts in the engine wear and polish themselves to the correct operating clearances During this period prolonged full throt tle operation or any condition that might result in engine overheating must be avoided EAU17041 0 1000 km 0 600 mi Avoid prolonged operation above 1 3 throttle 1000 1600 km 600 1000 mi Avoid prolonged operation above 1 2 throttle ECA10331 CAUTION After 1000 km 600 mi of operation the engine oil and final gear oil must be changed and the oil filter car tridge or element replaced 1600 km 1000 mi and beyond The vehicle can now be operated nor mally ECA10270 CAUTION If any engine trouble should occur during the engine break in period immediately have a Yamaha dealer check the vehicle OPERATION AND IMPORTANT RIDING POINTS EAU17180 Parking When parking stop th
15. less than 0 C 30 F or more than 30 7 4 SPECIFICATIONS Dimensions Overall length XVS650 2340 mm 92 1 in XVS650A 2450 mm 96 5 in XVS650AT 2450 mm 96 5 in Overall width XVS650 880 mm 34 6 in XVS650A 930 mm 36 6 in XVS650AT 930 mm 36 6 in Overall height XVS650 1070 mm 42 1 in XVS650A 1105 mm 43 5 in XVS650AT 1105 mm 43 5 in Seat height XVS650 695 mm 27 4 in XVS650A 710 mm 28 0 in XVS650AT 710 mm 28 0 in Wheelbase XVS650 1610 mm 63 4 in XVS650A 1625 mm 64 0 in XVS650AT 1625 mm 64 0 in Ground clearance 140 mm 5 51 in Minimum turning radius XVS650 3100 mm 122 0 in XVS650A 3400 mm 133 9 in XVS650AT 3400 mm 133 9 in Weight With oil and fuel XVS650 233 0 kg 514 Ib U49 XVS650 235 0 kg 518 Ib CAL XVS650A 247 0 kg 545 Ib U49 XVS650A 249 0 kg 549 Ib CAL XVS650AT 247 0 kg 545 Ib U49 XVS650AT 249 0 kg 549 Ib CAL Engine Engine type Air cooled 4 stroke SOHC Cylinder arrangement V type 2 cylinder Displacement 649 0 cm 39 60 cu in Bore x stroke 81 0 x 63 0 mm 3 19 x 2 48 in Compression ratio 9 00 1 Starting system Electric starter Lubrication system Wet sump Engine oil Type YAMALUBE 4 SAE10W30 or SAE20W40 10 30 50 70 90 107130 TT YAMALUBE 4 10W30 or SAE 10W30 RT _ gt YAMALUBE 4 20W40 or SAE 20W40 EE ESN I o 1 1 1 20 10 0 10 20 30 40 50 C Recommended engine oil grade
16. machine itself Manual instead of having the dealer do them gt Pk oe or equipment be done by Yamaha Motorcycle dealer o cycle exactly as specified in the Owner s Manual A 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 Q What responsibility does my dealer have under this warranty A 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 Q Is the warranty transferable to second owners A Yes The remainder of the existing warranty can be transferred upon request The unit has to be inspected and re registered by an authorized Yamaha Motorcycle dealer for the policy to remain effective 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 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
17. pivot shafts Apply lithium soap based grease all purpose grease lightly Sidestand pivot e Check operation Apply lithium soap based grease all purpose grease lightly Sidestand switch e Check operation and replace if necessary Front fork e Check operation and for oil leak age Replace if necessary Shock absorber as sembly e Check operation and for oil leak age Replace if necessary Be xxrry _ EE MAINTENANCE AND MINOR RERAIR ROUTINE INITIAL ODOMETER READINGS 600 mi 1000 km or 1 month 4000 mi 7000 km or 6 months 8000 mi 13000 km or 12 months 12000 mi 19000 km or 18 months 16000 mi 25000 km or 24 months 20000 mi 31000 km or 30 months Engine oil Change warm engine before draining Ni Ni Ni Ni Ni Ni Engine oil filter ele ment e Replace V Final gear oil Check oil level and for oil leakage e Change at initial 600 mi 1000 km or 1 month and thereafter every 16000 mi 25000 km or 24 months Control and meter cables Apply Yamaha chain and cable lube or engine oil 10W 30 thor oughly Throttle grip hous ing and cable Since these items require special tools data and technical skills have a Yamaha dealer perform the service NOTE Check operation and free play Adjust the throttle cable free play if nece
18. seat 1 Remove the passenger seat 2 Remove the bolts and then pull the seat up 1 Nut To install the passenger seat Insert the projection on the front of the passenger seat into the seat holder as shown place the seat in the original po sition and then install the nut 3 9 1 Seat holder 2 Projection To install the rider seat 1 Insert the projection on the front of the rider seat into the seat holder as shown place the seat in the original position and then install the bolts 2 Install the passenger seat NOTE Make sure that the seats are properly secured before riding INSTRUMENT AND CONTROL FUNCTIONS EAU14190 Seats XVS650A AT Passenger seat To remove the passenger seat Remove the bolt and then pull the pas senger seat up 1 Bolt To install the passenger seat Insert the projections on the front of the passenger seat into the holders as shown place the seat in the original po sition and then install the bolt 1 Seat holder 2 Projection Rider seat To remove the rider seat 1 Remove the passenger seat 2 Remove the bolt and then pull the rider seat up 3 10 To install the rider seat 1 Insert the projection on the front of the rider seat into the holder as shown place the seat in the origi nal position and then install the bolt 1 Seat holder 2 Projection 2 Install the passenger seat NOTE Make sure
19. winds These ac cessories may also cause instability when passing or being passed by large vehicles Certain accessories can dis place the operator from his or her normal riding position This improper position limits the free dom of movement of the opera tor and may limit control ability therefore such accessories are not recommended e Use caution when adding electri cal accessories If electrical acces sories 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 GASOLINE IS HIGHLY FLAMMA BLE Always turn the engine off when refueling Take care not to spill any gaso line on the engine or exhaust system when refueling Never refuel while smoking or in the vicinity of an open flame Never start the engine or let it run for any length of time in a closed area The exhaust fumes are poi sonous and may cause loss of consciousness and death within a short time Always operate your motorcycle in an area that has ad equate ventilation A SAFETY INFORMATION Always turn the engine off before leaving the motorcycle unattended and remove the key from the main switch When parking the motor cycle note the following The engine and exhaust system may be hot therefore park the motorcycle in a place where pe destrians or children are not like ly to touch these hot areas Do n
20. 50A BRIDGESTONE EXE DRA G702 XVS650AT BRIDGESTONE EXE DRA G702 XVS650 DUNLOP K555 XVS650A DUNLOP D404G XVS650AT DUNLOP D404G EAU21940 Spoke wheels To maximize the performance durabil ity and safe operation of your motor cycle note the following points regarding the specified wheels The wheel rims should be checked for cracks bends or warpage and the spokes for looseness or dam age before each ride If any dam age is found have a Yamaha dealer replace the wheel Do not attempt even the smallest repair to the wheel A deformed or cracked wheel must be replaced The wheel should be balanced whenever either the tire or wheel has been changed or replaced An unbalanced wheel can result in poor performance adverse han dling characteristics and a short ened tire life Ride at moderate speeds after changing a tire since the tire sur face must first be broken in for it to develop its optimal characteris tics 6 19 EAU22011 Accessories and replacement parts This vehicle is not designed to pull a trailer or to be attached to a sidecar The accessories or replacement parts you choose for your vehicle should be designed specifically for this model and they must be se curely mounted to maintain the in herent stability of the original design Genuine Yamaha Parts and Accessories are designed and test ed to be compatible with your vehi cle Please consider Genuine Yamaha Parts and Accessories b
21. 9 To store the battery 1 If the vehicle will not be used for more than one month remove the battery fully charge it and then place it in a cool dry place 2 Ifthe battery will be stored for more than two months check it at least once a month and fully charge it if necessary 3 Fully charge the battery before in stallation 4 After installation make sure that the battery leads are properly con nected to the battery terminals ECA10630 CAUTION e Always keep the battery charged Storing a discharged battery can cause permanent battery damage To charge a sealed type MF battery a special constant volt age battery charger is required Using a conventional battery charger will damage the battery If you do not have access to a PERIODIC MAINTENANCE AND MINOR REPAIR sealed type MF battery charg Replacing the fuses Eaua er have a Yamaha dealer charge your battery N Headlight fuse 1 2 Signaling system fuse 1 Fuse box 3 Ignition fuse 2 Main fuse 4 Carburetor heater fuse 3 Spare main fuse 5 Ignitor unit fuse for California only The main fuse and the fuse box which Kar Pa EE contains the fuses for the individual cir ak aat cuits are located behind panel B See page 6 8 If a fuse is blown replace it as follows 1 Turn the key to OFF and turn off the electrical circuit in question 2 Remove the blown fuse and then install a new fuse of the specifie
22. A WARNING This unit contains high pressure nitrogen gas Mishandling can cause explosion Read owner s manual for instructions 4 Do not incinerate puncture or open 4AA 22259 80 LOAD LIMIT 3 XVS650 1 Kg 2 Ibs 4BR 24877 A0 TIRE INFORMATION Cold tire normal pressure should be set as follows amp 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 Ibs maximum load FRONT 200 kPa 2 00 kgf cm 29 psi REAR _ 250 kPa 2 50 kgf cm 36 psi 5FB 21668 00 1 6 A SAFETY INFORMATION WARNING 1 Improper loading can cause loss of control Read owner s manual for proper loading 3JJ 28446 A1 6 California only EMISSION HOSE ROUTING CARB CARB FUEL TANK ROLL OVER VALVE CANISTER TO ATMOSPHERE 5BN 21686 00 DESCRIPTION Left view XVS650 OarWN Shift pedal page 3 4 Fuel cock page 3 7 Starter choke knob page 3 8 Shock absorber assembly spring preload adjusting ring page 3 12 Helmet holder page 3 11 Owner s tool kit page 6 1 7 Storage compartment page 3 11 EAU32220 DESCRIPTION XVS650A AT C 3 a N A CA ZAA In 2 ta oe N KR i VIG Q INC VA AV SKP 1 BJ Gee S 1 Shift pedal page 3 4 2 Fuel cock page 3 7 3 Starter choke knob page 3 8 4 Shock absorber assembly spring preload adjusting
23. AU23140 Checking and lubricating the Checking and lubricating the Checking and lubricating the throttle grip and cable brake and shift pedals brake and clutch levers The operation of the throttle grip should be checked before each ride In addi tion the cable should be lubricated or replaced at the intervals specified in the periodic maintenance chart The operation of the brake and shift The operation of the brake and clutch pedals should be checked before each levers should be checked before each ride and the pedal pivots should be lu ride and the lever pivots should be lu bricated if necessary bricated if necessary Recommended lubricant Recommended lubricant Lithium soap based grease all pur Lithium soap based grease all pur pose grease pose grease 6 26 PERIODIC MAINTENANCE AND MINOR REPAIR EAU23200 Checking and lubricating the sidestand D A The operation of the sidestand should be checked before each ride and the sidestand pivot and metal to metal contact surfaces should be lubricated if necessary If the sidestand does not move up and down smoothly have a Yamaha dealer check or repair it EWA10730 Recommended lubricant Lithium soap based grease all pur pose grease EAU23271 Checking the front fork The condition and operation of the front fork must be checked as follows at the intervals specified in the periodic main tenance and lubrication chart To check the
24. Bolt and nut shoe plate Brake torque rod Nut DNAN 5 Remove panel A See page 6 8 6 Remove the bolts that secure the final gear case to the swingarm 1 Axle nut 2 Disconnect the brake torque rod from the brake shoe plate by re moving the bolt and nut 3 Loosen the brake torque rod nut at the swingarm 6 35 PERIODIC MAINTENANCE AND MINOR REPAIR PAUSEN 7 Tighten the axle nut the final gear case bolts and the brake torque rod nuts to the specified torques aT To install the rear wheel 1 Install the rear wheel wheel axle Th r final gear case and drive shaft by pushing the wheel forward and Pr E Tightening torques guiding the drive shaft into the mid Axle nut dle gear universal joint 92 Nm 9 2 m kgf 67 ft lbf Final gear case bolt 74 Nm 7 4 m kgf 54 ft Ibf Brake torque rod nut 20 Nm 2 0 m kgf 14 ft Ibf 1 Bolt Re case 8 Adjust the brake pedal free play See page 6 22 7 Lift the rear wheel off the ground according to the procedure on page 6 33 EWA10660 8 While supporting the drive shaft Ei i After adjusting the brake pedal free 6 pull the rear wheel back to remove 1 Middle gear universal joint play check the operation of the the following parts as an assem 2 Drive shaft brake light bly wheel wheel axle final gear case and drive shaft 2 Install the final gear case bolts 3 Install the brake rod onto the brake N
25. CLE CARE AND STORAGE ECA10790 CAUTION Do not use warm water since it in creases the corrosive action of the salt 2 After drying the motorcycle apply a corrosion protection spray on all metal including chrome and nick el plated surfaces to prevent cor rosion After cleaning 1 Dry the motorcycle with a chamois or an absorbing cloth 2 Use a chrome polish to shine chrome aluminum and stainless steel parts including the exhaust system Even the thermally in duced discoloring of stainless steel exhaust systems can be re moved through polishing 3 To prevent corrosion it is recom mended to apply a corrosion pro tection spray on all metal including chrome and nickel plat ed surfaces 4 Use spray oil as a universal clean er to remove any remaining dirt 7 2 5 Touch up minor paint damage caused by stones etc 6 Wax all painted surfaces 7 Let the motorcycle dry completely before storing or covering it EWA11130 A WARNING Make sure that there is no oil or wax on the brakes or tires e If necessary clean the brake discs and brake linings with a regular brake disc cleaner or ac etone and wash the tires with warm water and a mild deter gent Before riding at higher speeds test the motorcycle s braking performance and cor nering behavior ECA10800 CAUTION _ _ __ e Apply spray oil and wax spar ingly and make sure to wipe off any excess e Never apply oi
26. GVAMAHA gt IS stcrz AE ri rn EAU10041 A WARNING The engine exhaust from this product contains chemicals known to the State of California to cause cancer birth defects or other reproductive harm YAMAHA LIT CALIF 65 01 INTRODUCTION EAU10080 Congratulations on your purchase of the Yamaha XVS650 C XVS650A C XVS650AT C This model is the result of Yamaha s vast experience in the production of fine sporting touring and pacesetting racing machines It represents the high degree of craftsmanship and reliability that have made Yamaha a leader in these fields This manual will give you an understanding of the operation inspection and basic maintenance of this motorcycle If you have any questions concerning the operation or maintenance of your motorcycle please consult a Yamaha dealer The design and manufacture of this Yamaha motorcycle fully comply with the emissions standards for clean air applicable at the date of manufacture Yamaha has met these standards without reducing the performance or economy of operation of the motorcycle To maintain these high standards it is important that you and your Yamaha dealer pay close attention to the recommended maintenance schedules and operating instructions contained within this manual IMPORTANT MANUAL INFORMATION EAU10130 Particularly important information is distinguished in this manual by the following notations The Safety Alert Symbol means ATTE
27. INOR REPAIR x hah JE i i k 1 Faj z a tl ta T j er 1 RAV VAR y 1 Oil filter element 2 O ring 6 Install a new oil filter element and the O ring 7 Install the oil filter element covers by installing the bolts and then tighten them to the specified torque Tightening torque Oil filter element cover bolt 10 Nm 1 0 m kgf 7 ft lbf 8 Installthe engine oil drain bolt and then tighten it to the specified torque NOTE Check the washer for damage and re place it if necessary 6 12 Tightening torque Engine oil drain bolt 43 Nm 4 3 m kgf 31 ft Ibf 9 Add the specified amount of the recommended oil and then install and tighten the oil filler cap Recommended engine oil See page 8 1 Oil quantity Without oil filter element replace ment 2 60 L 2 75 US qt 2 29 Imp qt With oil filter element replacement 2 80 L 2 96 US qt 2 46 Imp qt ECA11620 CAUTION e In order to prevent clutch slip page since the engine oil also lubricates the clutch do not mix any chemical additives Do not use oils with a diesel speci fication of CD or oils of a high er quality than specified In addition do not use oils labeled ENERGY CONSERVING II or higher PERIODIC MAINTENANCE AND MINOR REPAIR Make sure that no foreign mate 10 Start the engine and then let it idle 11 rial enters the crankcase for several minutes w
28. If necessary add recommended brake fluid to specified level Check hydraulic system for leakage 6 21 6 24 6 24 Rear brake Check operation Check pedal free play Adjust if necessary 6 22 6 24 Clutch Check operation Lubricate cable if necessary Check lever free play Adjust if necessary 6 20 Throttle grip e Make sure that operation is smooth Check cable free play If necessary have Yamaha dealer adjust cable free play and lubricate cable and grip housing 6 16 6 26 Control cables Make sure that operation is smooth Lubricate if necessary 4 2 6 25 PRE OPERATION CHECKS CHECKS Wheels and tires Check for damage e Check tire condition and tread depth Check air pressure Correct if necessary Brake and shift pedals e Make sure that operation is smooth Lubricate pedal pivoting points if necessary Brake and clutch levers e Make sure that operation is smooth Lubricate lever pivoting points if necessary Sidestand Make sure that operation is smooth Lubricate pivot if necessary Chassis fasteners Make sure that all nuts bolts and screws are properly tightened Tighten if necessary Instruments lights signals and switches Check operation Correct if necessary Sidestand switch Check operation of ignition circuit cut off system e If system is defective have Yam
29. MT2 50 XVS650A 16M C x MT3 00 XVS650AT 16M C x MT3 00 Rear wheel Wheel type Spoke wheel Rim size 15M C x MT3 50 Front brake Type Single disc brake Operation Right hand operation Recommended fluid DOT 4 Rear brake Type Drum brake Operation Right foot operation Front suspension Type Telescopic fork Spring shock absorber type Coil spring oil damper Wheel travel 140 0 mm 5 51 in Rear suspension Type Swingarm monocross Spring shock absorber type Coil spring gas oil damper Wheel travel XVS650 86 0 mm 3 39 in XVS650A 98 0 mm 3 86 in XVS650AT 98 0 mm 3 86 in Electrical system Ignition system Transistorized coil ignition digital Charging system A C magneto Battery Model GT12B 4 Voltage capacity 12 V 10 0 Ah Headlight Bulb type Halogen bulb Bulb voltage wattage x quantity Headlight 12 V 60 W 55 0 W x 1 Tail brake light 12 V 8 0 27 0 W x 1 8 3 Front turn signal position light XVS650 12 V 27 W 8 0 W x 2 XVS650A 12 V 23 W 8 0W x 2 XVS650AT 12 V 23 W 8 0W x 2 Rear turn signal light XVS650 12 V 27 0W x2 XVS650A 12 V 21 0W x2 XVS650AT 12 V 21 0W x2 Meter lighting 12V 1 7Wx1 Neutral indicator light 12V 1 7Wx1 High beam indicator light 12V 1 7Wx1 Turn signal indicator light 12V 1 7Wx1 Engine trouble warning light 12V 1 7Wx1 Fuses Main fuse 30 0 A Headlight fuse 15 0A Signaling system fuse 10 0 A Ignition fuse 10 0 A Carb
30. NTION BECOME ALERT YOUR SAFETY IS A INVOLVED Failure to follow WARNING instructions could result in severe injury or death to the A WARNING motorcycle operator a bystander or a person inspecting or repairing the motor cycle 7 A CAUTION indicates special precautions that must be taken to avoid damage to CAUTION the motorcycle NOTE A NOTE provides key information to make procedures easier or clearer NOTE This manual should be considered a permanent part of this motorcycle and should remain with it even if the motorcycle is subsequently sold amp Yamaha continually seeks advancements in product design and quality Therefore while this manual contains the most current product information available at the time of printing there may be minor discrepancies between your motorcycle and this manual If you have any questions concerning this manual please consult your Yamaha dealer PLEASE READ THIS MANUAL AND THE YOU AND YOUR MOTORCYCLE RIDING TIPS BOOKLET CAREFULLY AND COMPLETELY BEFORE OPERATING THIS MOTORCYCLE DO NOT ATTEMPT TO OPERATE THIS MOTOR CYCLE UNTIL YOU HAVE ATTAINED ADEQUATE KNOWLEDGE OF ITS CONTROLS AND OPERATING FEATURES EWA10010 IMPORTANT MANUAL INFORMATION 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 IM
31. ODIC MAINTENANCE CHARTS THE SERVICES RELATED TO EMISSIONS CONTROL ARE GROUPED SEPARATELY THESE SERVICES REQUIRE SPECIALIZED DATA KNOWLEDGE AND EQUIP MENT YAMAHA DEALERS ARE TRAINED AND EQUIPPED TO PER FORM THESE PARTICULAR SER VICES 6 1 EAU17440 Owner s tool kit 1 Owner s tool kit The owner s tool kit is located inside the storage compartment See page 3 11 The service information included in this manual and the tools provided in the owner s tool kit are intended to assist you in the performance of preventive maintenance and minor repairs How ever additional tools such as a torque wrench may be necessary to perform certain maintenance work correctly NOTE If you do not have the tools or experi ence required for a particular job have a Yamaha dealer perform it for you EWA10340 Modifications not approved by Yamaha may cause loss of perfor mance excessive emissions and render the vehicle unsafe for use Consult a Yamaha dealer before at tempting any changes PERIODIC MAINTENANCE AND MINOR REPAIR 6 2 ROUTINE INITIAL Periodic maintenance chart for the emission control system PERIODIC MAINTENANCE AND MINOR REPAIR ODOMETER READINGS EAU17600 600 mi 1 month 4000 mi 6 months 8000 mi 13000 km or 12 months 12000 mi 19000 km or 18 months 16000 mi 25000 km or 24 months 20000 mi 31000 km or 30 months Fuel line e Check fue
32. OR CORPORATION U S A STREET AND ENDURO MOTORCYCLE LIMITED WARRANTY ENGINE DISPLACEMENT 50cc to 169cc PERIOD 12 000 km 7 465 miles or five years whichever occurs first 170cc to 279cc 18 000 km 11 185 miles or five years whichever occurs first 280cc or over 30 000 km 18 641 miles or five years whichever occurs first YAMAHA MOTOR CORPORATION U S A MAKES NO OTHER WARRANTY OF ANY KIND EXPRESSED OR IMPLIED ALL IMPLIED WARRANTIES OF MER CHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE WHICH EXCEED THE OBLIGATIONS AND TIME LIMITS STATED IN THIS WARRANTY ARE HEREBY DISCLAIMED BY YAMAHA MOTOR COR PORATION U S A AND EXCLUDED FROM THIS WARRANTY SOME STATES DO NOT ALLOW LIMITATIONS ON HOW LONG AN IMPLIED WARRANTY LASTS SO THE ABOVE LIMITATION MAY NOT APPLY TO YOU ALSO EXCLUDED FROM THIS WARRANTY ARE ANY IN CIDENTAL OR CONSEQUENTIAL DAMAGES INCLUD ING LOSS OF USE SOME STATES DO NOT ALLOW THE EXCLUSION OR LIMITATION OF INCIDENTAL OR CONSEQUENTIAL DAMAGES SO THE ABOVE EXCLUSION MAY NOT APPLY TO YOU THIS WARRANTY GIVES YOU SPECIFIC LEGAL RIGHTS AND YOU MAY ALSO HAVE OTHER RIGHTS WHICH VARY FROM STATE TO STATE YAMAHA MOTOR CORPORATION U S A P O Box 6555 Cypress California 90630 EAU26661 CONSUMER INFORMATION WARRANTY QUESTIONS AND ANSWERS What costs are my responsibility during the warranty period PP plugs and brake shoes pe a failure No The warranty is limited to repair of the
33. OTE camshaft lever and then install the Make sure to support the drive shaft as brake pedal free play adjusting nut it is being pulled out onto the brake rod 4 Install the brake torque rod bolt and nut at the brake shoe plate 5 Install the panel 6 Lower the rear wheel so that it is on the ground 6 36 PERIODIC MAINTENANCE AND MINOR REPAIR EAU25850 Troubleshooting Although Yamaha motorcycles receive a thorough inspection before shipment from the factory trouble may occur dur ing operation Any problem in the fuel compression or ignition systems for example can cause poor starting and loss of power The following troubleshooting chart represents a quick and easy procedure for checking these vital systems your self However should your motorcycle require any repair take it to a Yamaha dealer whose skilled technicians have the necessary tools experience and know how to service the motorcycle properly Use only genuine Yamaha replace ment parts Imitation parts may look like Yamaha parts but they are often inferi or have a shorter service life and can lead to expensive repair bills 6 37 PERIODIC MAINTENANCE AND MINOR REPAIR EAU25891 Troubleshooting chart Keep away open flames and do not smoke while checking or working on the fuel system EWA10840
34. PORTANT MANUAL INFORMATION EAU10192 LABEL HERE B AFFIX DEALER _ XVS650T C XVS650AT C XVS650ATT C OWNER S MANUAL 2004 by Yamaha Motor Corporation U S A 1st edition April 2004 All rights reserved Any reprinting or unauthorized use without the written permission of Yamaha Motor Corporation U S A is expressly prohibited Printed in Japan P N LIT 11626 18 20 SAFETY INFORMATION 1 1 Location of important labels 1 5 DESCRIPTION o ae 2 1 Left view corpons goca piniet 2 1 Right view eerie 2 3 Controls and instruments 2 5 INSTRUMENT AND CONTROL FUNCTIONS 3 1 Main switch steering lock 45 3 1 Indicator and warning lights 3 2 Speedometer unit 0 0 eee 3 2 Handlebar switches ssec 3 3 Clutch lever mmmrnernrnonrrrrronvrnnnnnnnr 3 4 Shift pedal XVS650 eee 3 4 Shift pedal XVS650A AT 3 4 Brake lever nsien 3 5 Brake pedal eeseeeeseeeesenreeesees 3 5 Fuel tank cap ceee 3 5 a EEE EAT 3 6 Catalytic converter rrrrvrnnnrnnenrnr 3 7 Fue COCK ienaa 3 7 Starter choke knob c eee 3 8 Seats XVS650 rrrnnnnrnnnrnnennnenrenrn 3 9 Seats XVS650A AT ranrnnnrnrnre 3 10 Helmet holder ccce 3 11 Storage compartment rrrnrnrnrnnn 3 11 Adjusting the shock absorber assembly rerrnnvnnnnnvvnnnnnvnnsvnnnn 3 12 Luggage strap holders 3 13 Sidestand rnnrorvrnnnrn
35. When the transmission is in the neutral position the neutral indicator light should be on otherwise have a Yamaha dealer check the electrical cir cuit 4 Turn the starter choke on and completely close the throttle See page 3 8 5 Start the engine by pushing the start switch NOTE If the engine fails to start release the start switch wait a few seconds and then try again Each starting attempt should be as short as possible to pre serve the battery Do not crank the en gine more than 10 seconds on any one attempt ECA11370 CAUTION The engine trouble warning light should come on when the key is turned to ON and then go off after a few seconds If the engine trouble warning light comes on or flashes OPERATION AND IMPORTANT RIDING POINTS after starting immediately stop the engine and have a Yamaha dealer check the self diagnosis system 6 After starting the engine move the starter choke back halfway ECA11130 CAUTION For maximum engine life always warm the engine up before starting off Never accelerate hard when the engine is cold 7 When the engine is warm turn the starter choke off NOTE The engine is warm when it responds normally to the throttle with the starter choke turned off To avoid the possi bility of excessive exhaust emissions never leave the starter choke on long er than necessary The time necessary for starter choke use depends upo
36. aged replace it PERIODIC MAINTENANCE AND MINOR REPAIR ECA10480 CAUTION NOTE e Make sure that the air filter ele that the air filter ele If dust or water collects in the air filter F check hose remove the clamp from it ment is properly seated in the apa and then remove the plug to drain the air filter case The engine should never be op hasa erated without the air filter ele ment installed otherwise the piston s and or cylinder s may become excessively worn 1 Air filter element 5 Install the air filter case cover by aligning the match marks and in stalling the bolts 7 RN 1 Match marks 4 Insert the air filter element into the air filter case as shown 1 Air filter check hose L V 2 Projection 3 Slot 6 15 PERIODIC MAINTENANCE AND MINOR REPAIR EAU21270 Adjusting the carburetors The carburetors are important parts of the engine and emission control sys tem which require very sophisticated adjustment Therefore all carburetor adjustments should be left to a Yamaha dealer who has the necessary profes sional knowledge and experience EAU21380 Adjusting the throttle cable free play 1 Throttle cable free play The throttle cable free play should mea sure 4 0 6 0 mm 0 16 0 24 in at the throttle grip Periodically check the throttle cable free play and if neces sary have a Yamaha dealer adjust it 6 16 EAU21400 Adjusting
37. aha dealer check vehicle 4 3 EAU15950 EWA10270 e Become thoroughly familiar with all operating controls and their functions before riding Consult a Yamaha dealer re garding any control or function that you do not thoroughly un derstand amp Never start the engine or oper ate it in a closed area for any length of time Exhaust fumes are poisonous and inhaling them can cause loss of con sciousness and death within a short time Always make sure that there is adequate ventila tion e Before starting out make sure that the sidestand is up If the sidestand is not raised com pletely it could contact the ground and distract the opera tor resulting in a possible loss of control OPERATION AND IMPORTANT RIDING POINTS EAU16390 Starting and warming up a cold engine In order for the ignition circuit cut off system to enable starting one of the following conditions must be met e The transmission is in the neutral position e The transmission is in gear with the clutch lever pulled and the sid estand up e Before starting the engine check the function of the igni tion circuit cut off system ac cording to the procedure described on page 3 14 e Never ride with the sidestand down EWA10290 1 Turn the fuel cock lever to ON 2 Turn the key to ON and make sure that the engine stop switch is set to O 3 Shift the transmission into the neu tral position 5 1 NOTE
38. al injury Modifications may also make your motorcycle illegal to use Loading and accessories Adding accessories or cargo to your motorcycle can adversely affect stabili ty and handling if the weight distribution of the motorcycle is changed To avoid the possibility of an accident use ex treme caution when adding cargo or accessories to your motorcycle Use extra care when riding a motorcycle that has added cargo or accessories Here are some general guidelines to follow if loading cargo or adding acces sories to your motorcycle Loading The total weight of the operator pas senger accessories and cargo must not exceed the maximum load limit Maximum load XVS650 178 kg 392 Ib CAL XVS650 180 kg 397 Ib U49 XVS650A 198 kg 437 Ib CAL XVS650A 200 kg 441 Ib U49 XVS650AT 198 kg 437 Ib CAL XVS650AT 200 kg 441 Ib U49 When loading within this weight limit keep the following in mind Cargo and accessory weight should be kept as low and close to the motorcycle as possible Make sure to distribute the weight as evenly as possible on both sides of the motorcycle to minimize imbal ance or instability Shifting weights can create a sud den imbalance Make sure that ac cessories and cargo are securely attached to the motorcycle before riding Check accessory mounts and cargo restraints frequently A SAFETY INFORMATION amp Never attach any large or heavy items to the handlebar front f
39. are parts from a Yamaha dealer 9 2 CONSUMER INFORMATION EAU26550 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 immediately inform the National Highway Traffic Safety Administration NHTSA in addition to notifying Yamaha Motor Corporation U S A If NHTSA receives similar complaints it may open an investigation and if it finds that a safety defect exists in a group of vehicles it may order a recall and remedy campaign However NHTSA cannot become involved in individual problems between you your dealer or Yamaha Motor Corporation U S A To contact NHTSA you may either call the Auto Safety Hotline toll free at 1 800 424 9393 or 366 0123 in Washington D C area or write to NHTSA U S Department of Transportation Washington D C 20590 You can also obtain other information about motor vehicle safety from the Hotline 9 3 CONSUMER INFORMATION EAU26560 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 el
40. by a Yamaha dealer PRE OPERATION CHECKS EAU15591 The condition of a vehicle is the owner s responsibility Vital components can start to deteriorate quickly and unexpectedly even if the vehicle remains unused for example as a result of exposure to the elements Any damage fluid leakage or loss of tire air pressure could have serious consequences Therefore it is very important in addition to a thorough visual inspec tion to check the following points before each ride NOTE Pre operation checks should be made each time the vehicle is used Such an inspection can be accomplished in a very short time and the added safety it assures is more than worth the time involved If any item in the Pre operation check list is not working properly have it inspected and repaired before operating the vehicle EWA11150 4 1 PRE OPERATION CHECKS Pre operation check list CHECKS EAU15602 Fuel e Check fuel level in fuel tank Refuel if necessary Check fuel line for leakage Engine oil Check oil level in engine If necessary add recommended oil to specified level Check vehicle for oil leakage Final gear oil Check vehicle for oil leakage Front brake Check operation If soft or spongy have Yamaha dealer bleed hydraulic system Check lever free play Adjust if necessary Check brake pads for wear Replace if necessary Check fluid level in reservoir
41. cing forward 2 Turn the key counterclockwise to the original position remove it and then close the lock cover INSTRUMENT AND CONTROL FUNCTIONS NOTE The fuel tank cap cannot be installed unless the key is in the lock In addition the key cannot be removed if the cap is not properly installed and locked Make sure that the fuel tank cap is properly installed before riding EWA10130 EAU13210 Fuel 1 Fuel tank filler tube 2 Fuel level Make sure that there is sufficient fuel in the tank Fill the fuel tank to the bottom of the filler tube as shown amp Do not overfill the fuel tank oth erwise it may overflow when the fuel warms up and expands e Avoid spilling fuel on the hot en gine EWA10880 ECA10070 CAUTION Immediately wipe off spilled fuel with a clean dry soft cloth since fuel may deteriorate painted surfac es or plastic parts EAU13300 Recommended fuel UNLEADED GASOLINE ONLY Fuel tank capacity 16 0 L 4 23 US gal 3 52 Imp gal Fuel reserve amount 3 0 L 0 79 US gal 0 66 Imp gal ECA11400 CAUTION Use only unleaded gasoline The use of leaded gasoline will cause severe damage to internal engine parts such as the valves and piston rings as well as to the exhaust system Your Yamaha engine has been de signed to use regular unleaded gaso line with a pump octane number R M 2 of 86 or higher or a research octane number of 91 or higher If knocki
42. d amperage 6 30 PERIODIC MAINTENANCE AND MINOR REPAIR Specified fuses Main fuse 30 0 A Signaling system fuse 10 0 A Ignition fuse 10 0 A Headlight fuse 15 0 A Carburetor heater fuse 15 0 A Ignitor unit fuse XVS650 5 0 A CAL XVS650A 5 0 A CAL XVS650AT 5 0 A CAL ECA10640 CAUTION Do not use a fuse of a higher amper age rating than recommended to avoid causing extensive damage to the electrical system and possibly a fire 3 Turn the key to ON and turn on the electrical circuit in question to check if the device operates 4 lf the fuse immediately blows again have a Yamaha dealer check the electrical system 1 Screw 2 Disconnect the headlight coupler EAU23792 Replacing the headlight bulb This model is equipped with a quartz bulb headlight If the headlight bulb burns out replace it as follows 1 Remove the headlight unit by re moving the screws 1 Headlight coupler 2 Headlight bulb cover 3 Unhook the headlight bulb holder and then remove the defective bulb and then remove the bulb cover 1 Headlight bulb holder 6 31 EWA10790 Headlight bulbs get very hot There fore keep flammable products away from a lit headlight bulb and do not touch the bulb until it has cooled down 4 Place a new headlight bulb into po sition and then secure it with the bulb holder ECA10660 CAUTION Do not touch the glass part of the headlight bulb
43. e fore making a purchase Use of non Yamaha approved accessories or replacement parts may cause loss of handling stability and riding safety Since Yamaha cannot control the quality of accessories or parts man ufactured by other companies Yamaha cannot be held liable for EWA10621 PERIODIC MAINTENANCE AND MINOR REPAIR EAU22041 Adjusting the clutch lever free play 2 To increase the clutch lever free play turn the adjusting bolt in di rection a To decrease the clutch any consequences caused by the use of items which have not been approved by Yamaha 1 Locknut 2 Clutch lever free play adjusting bolt 3 Clutch lever free play The clutch lever free play should mea sure XVS650 10 0 15 0 mm 0 39 0 59 in XVS650A 5 0 10 0 mm 0 20 0 39 in XVS650AT 5 0 10 0 mm 0 20 0 39 in as shown Periodically check the clutch lever free play and if necessary adjust it as follows 1 Loosen the locknut at the clutch le ver 6 20 lever free play turn the adjusting bolt in direction b NOTE If the specified clutch lever free play could be obtained as described above tighten the locknut and skip the rest of the procedure otherwise proceed as follows 3 Fully turn the adjusting bolt at the clutch lever in direction a to loos en the clutch cable 4 Loosen the locknut at the crank om w LET BY vr gt x NG RAS z 1 Clutch lever free play adjusting nut en case
44. e engine remove the key from the main switch and then turn the fuel cock lever to OFF Since the engine and exhaust system can become very hot park in a place where pedestri ans or children are not likely to touch them e Do not park ona slope or on soft ground otherwise the vehicle may overturn EWA10310 ECA10380 CAUTION Never park in an area where there are fire hazards such as grass or other flammable materials 5 5 PERIODIC MAINTENANCE AND MINOR REPAIR EAU17231 Safety is an obligation of the owner Pe riodic inspection adjustment and lubri cation will keep your vehicle in the safest and most efficient condition pos sible The most important points of motorcycle inspection adjustment and lubrication are explained on the follow ing pages Maintenance replacement or repair of the emission control devices and systems may be performed by any repair establishment or individual that is certified if applicable EWA10320 A WARNING If you are not familiar with mainte nance work have a Yamaha dealer do it for you EAU17301 PERIODIC MAINTENANCE PROPER PERIODIC MAINTENANCE OF YOUR VEHICLE IS IMPORTANT IN ORDER TO ENJOY LONG PLEA SURABLE SERVICE ESPECIALLY IMPORTANT ARE THE MAINTE NANCE SERVICES RELATED TO EMISSIONS CONTROL THESE CONTROLS NOT ONLY FUNCTION TO ENSURE CLEANER AIR BUT ARE ALSO VITAL TO PROPER EN GINE OPERATION AND MAXIMUM PERFORMANCE IN THE FOLLOW ING PERI
45. e final gear case to collect the used oil 2 Remove the oil filler bolt and drain bolt to drain the oil from the final gear case 3 Install the final gear oil drain bolt and then tighten it to the specified torque Tightening torque Final gear oil drain bolt 23 Nm 2 3 m kgf 17 ft Ibf 4 Add the recommended final gear oil to the brim of the filler hole Recommended final gear oil SAE80 API GL 4 Hypoid gear oil Oil quantity 0 19 L 0 20 US qt 0 17 Imp qt NOTE GL4 is a quality rating Hypoid gear oils rated GL5 or GL6 may also be used 5 Install the oil filler bolt and then tighten it to the specified torque Tightening torque Final gear oil filler bolt 23 Nm 2 3 m kgf 17 ft Ibf 6 Check the final gear case for oil leakage If oil is leaking check for the cause 6 14 PERIODIC MAINTENANCE AND MINOR REPAIR EAU33381 Cleaning the air filter element The air filter element should be cleaned at the intervals specified in the periodic maintenance and lubrication chart Clean the air filter element more fre quently if you are riding in unusually wet or dusty areas 1 Remove the air filter case cover by removing the bolts 1 Air filter case cover 2 Bolt 2 Pullthe air filter element out 3 Lightly tap the air filter element to remove most of the dust and dirt and then blow the remaining dirt out with compressed air as shown If the air filter element is dam
46. e lines minimum tread depth worn out tire When a tire tread begins to show crosswise lines have a Yamaha dealer replace the tire immediately The replacement of all wheel and brake related parts includ ing the tires should be left to a Yamaha dealer who has the necessary professional knowl edge and experience It is not recommended to patch a punctured tube If unavoid able however patch the tube very carefully and replace it as soon as possible with a high quality product be of the same make and de sign otherwise the handling characteristics of the vehicle cannot be guaranteed After extensive tests only the tires listed below have been ap proved for this model by Yamaha Motor Co Lid Tire information This motorcycle is equipped with spoke wheels and tube tires if the tire has a nail or glass fragments in it or if the sidewall is cracked con tact a Yamaha dealer immediately and have the tire replaced Minimum tire tread depth front and rear 1 0 mm 0 04 in 6 18 PERIODIC MAINTENANCE AND MINOR REPAIR Front tire Size XVS650 100 90 19M C 57S XVS650A 130 90 16M C 67S XVS650AT 130 90 16M C 67S Manufacturer model XVS650 BRIDGESTONE EXE DRA L309 XVS650A BRIDGESTONE EXE DRA G703 XVS650AT BRIDGESTONE EXE DRA G703 XVS650 DUNLOP F24 XVS650A DUNLOP D404F XVS650AT DUNLOP D404F Rear tire Size 170 80 15M C 77S Manufacturer model XVS650 BRIDGESTONE EXE DRA G546 XVS6
47. e pedal and footrest 2 Brake pedal free play XVS650A AT 1 Distance between brake pedal and footrest 2 Brake pedal free play 6 22 EWA10670 It is advisable to have a Yamaha dealer make these adjustments NOTE The brake pedal position should be ad justed before adjusting the brake pedal free play Brake pedal position The brake pedal should be positioned approximately XVS650 102 0 mm 4 02 in XVS650A 108 0 mm 4 25 in XVS650AT 108 0 mm 4 25 in above the top of the footrest as shown Peri odically check the brake pedal position and if necessary adjust it as follows 1 Loosen the locknut at the brake pedal 2 To raise the brake pedal turn the adjusting bolt in direction a To lower the brake pedal turn the ad justing bolt in direction b PERIODIC MAINTENANCE AND MINOR REPAIR 1 Locknut 2 Brake pedal position adjusting bolt 3 Tighten the locknut After adjusting the brake pedal posi tion the brake pedal free play must be adjusted EWA11230 Brake pedal free play The brake pedal free play should mea sure 20 0 30 0 mm 0 79 1 18 in at the brake pedal end Periodically check the brake pedal free play and if neces sary adjust it as follows To increase the brake pedal free play turn the adjusting nut at the brake rod in direction a To decrease the brake pedal free play turn the adjusting nut in direction b In al 1 Brake pedal free play adj
48. els removing and installing 6 8 Parkingu vuvvinassvakdh rs dabesteettears Part locations Pre operation check list eee 4 2 R Rear brake light switch adjusting 6 23 S Safety defects reporting ee 9 3 Safety information eee 1 1 Seats XVS650 es Seats XVS650A AT s Shifti gann a na tT Shift pedal XVS650 Shift pedal XVS650A AT Shock absorber assembly adjusting 3 12 Sidestand ussmunvvarvvenvvrennvenrvrvsvveerveenn 3 13 Sidestand checking and lubricating 6 27 Spark plugs Checking e eee eee 6 9 Specifications Speedometer unit 5 Starter choke knob uu eee eee 3 8 Starting and warming up a cold ET ea gt EE E EE 5 1 Start switChusnuamauwmnsrunnsuiauiniren 3 3 Steering Checking eee 6 28 Storage iiie business 7 3 Storage compartment ee 3 11 Supporting the motorcycle 6 33 T Throttle cable free play adjusting 6 16 Throttle grip and cable INDEX Troubleshooting chart ee 6 38 Turn signal indicator light 3 2 Turn signal light bulb or tail brake light bulb replacing 6 32 Turn signal switch sessen 3 3 V Valve clearance adjusting 0 6 16 Vehicle identification number 0 9 1 Ww Warranty extended 9 9 Warranty limited s 9 7 Wheel bearings checking 6 28 Wheel front 0 0 ee eseeeseeesseesseesseeeesees 6 34 Wheel rear
49. ement 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 Exhaust system e Muffler e Exhaust pipe e Silencer Intake system Air cleaner case Air cleaner element e Intake duct 9 4 CONSUMER INFORMATION EAU26631 Maintenance record Copies of work orders and or receipts for parts purchased and installed on your motorcycle will be required to document that maintenance has been completed in accordance with the emissions warranty The chart below is printed only as a reminder that maintenance work is required It is not acceptable proof of maintenance work Maintenance Date of Mileage Servicing dealer Remarks interval service name and address 600 mi 1000 km or 1 month 4000 mi 7000 km or 6 months 8000 mi 13000 km or 12 months 12000 mi 19000 km or 18 months 16000 mi 25000 km or 24 months 20000 mi 31000 km or 30 months 24000 mi 37000 km or 36 months 28000 mi 43000 km or 42 months 32000 mi 49000 km or 48 months CONSUMER INFORMATION Maintenance interval Mileage Servicing dealer name and address Remarks 36000 mi 55000 km or 54 months 40000 mi 61000 km or 60 months 9 6 Yamaha Motor Corporation U S A hereby warrants
50. er check the wheel bearings D FA warning PERIODIC MAINTENANCE AND MINOR REPAIR EAU23380 Battery The battery is located behind panel B See page 6 8 This model is equipped with a sealed type MF battery which does not re quire any maintenance There is no need to check the electrolyte or to add distilled water ECA10620 CAUTION Never attempt to remove the battery cell seals as this would permanent ly damage the battery EWA10760 e Electrolyte is poisonous and dangerous since it contains sul furic acid which causes severe burns Avoid any contact with skin eyes or clothing and al ways shield your eyes when working near batteries In case of contact administer the fol lowing FIRST AID e EXTERNAL Flush with plenty of water e INTERNAL Drink large quan tities of water or milk and im mediately call a physician e EYES Flush with water for 15 minutes and seek prompt medical attention e Batteries produce explosive hy drogen gas Therefore keep sparks flames cigarettes etc away from the battery and pro vide sufficient ventilation when charging it in an enclosed space e KEEP THIS AND ALL BATTER IES OUT OF THE REACH OF CHILDREN To charge the battery Have a Yamaha dealer charge the bat tery as soon as possible if it seems to have discharged Keep in mind that the battery tends to discharge more quickly if the vehicle is equipped with optional electrical accessories 6 2
51. erms of the warranty but it will also keep your motorcycle looking good extend its life and optimize its performance Before cleaning 1 Cover the muffler outlets with plas tic bags after the engine has cooled down 2 Make sure that all caps and covers as well as all electrical couplers and connectors including the spark plug caps are tightly in stalled 3 Remove extremely stubborn dirt like oil burnt onto the crankcase with a degreasing agent and a brush but never apply such prod ucts onto seals gaskets and wheel axles Always rinse the dirt and de greaser off with water Cleaning ECA10770 CAUTION e Avoid using strong acidic wheel cleaners especially on spoked wheels If such products are used on hard to remove dirt do not leave the cleaner on the af fected area any longer than in structed Also thoroughly rinse the area off with water immedi ately dry it and then apply a cor rosion protection spray Improper cleaning can damage windshields cowlings panels and other plastic parts Use only a soft clean cloth or sponge with mild detergent and water to clean plastic 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 7 1 thinner fuel gasoline rust re movers or inhibitors brake flu id antifreeze or electrolyte Do not use high pressure wash
52. ff The key can be re moved To lock the steering 1 Push 2 Turn 1 Turn the handlebars all the way to the left 2 Push the key in from the OFF po sition and then turn it to LOCK while still pushing it 3 Remove the key 3 1 To unlock the steering 1 Push 2 Turn Push the key in and then turn it to OFF while still pushing it Never turn the key to OFF or LOCK while the vehicle is moving otherwise the electrical systems will be switched off which may result in loss of control or an accident Make sure that the vehicle is stopped be fore turning the key to OFF or LOCK EWA10060 INSTRUMENT AND CONTROL FUNCTIONS EAU11001 Indicator and warning lights D 1 High beam indicator light 20 2 Turn signal indicator light lt a p gt 3 Neutral indicator light N 4 Engine trouble warning light ws EAU11020 Turn signal indicator light lt gt This indicator light flashes when the turn signal switch is pushed to the left or right EAU11060 Neutral indicator light N This indicator light comes on when the transmission is in the neutral position EAU11080 High beam indicator light o This indicator light comes on when the high beam of the headlight is switched on EAU11500 Engine trouble warning light 5 This warning light comes on or f
53. flexible You choose the plan that s right for you 12 months 24 months 36 months or on certain models even 48 months beyond your warranty period e 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 repairs 9 9 150 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 owner
54. he it if necessary spark plug threads 777 gt To fuel tank 3 Install the spark plug with the gt To carburetor Specified spark plug spark plug wrench and then tight NGK DPR7EA 9 en it to the specified torque DENSO X22EPR U9 Tightening torque To install a spark plug Spark plug 1 Measure the spark plug gap with a 17 5 Nm 1 75 m kgf 13 ft lbf wire thickness gauge and if nec Canister essary adjust the gap to specifica NOTE tion If a torque wrench is not available when installing a spark plug a good estimate SFE of the correct torque is 1 4 1 2 turn Vent hose past finger tight However the spark plug should be tightened to the speci fied torque as soon as possible This model is equipped with a canister to prevent the discharging of fuel vapor 1 4 Install the spark plug cap into the atmosphere Check each hose connection Check each hose and canister for cracks or damage Replace if dam 1 Spark plug gap aged Sparel Make sure the vent hose is not park plug gap me 0 8 0 9 mm 0 031 0 035 in blocked Clean it if necessary 6 10 PERIODIC MAINTENANCE AND MINOR REPAIR EAU19742 Engine oil and oil filter element The engine oil level should be checked before each ride In addition the oil must be changed and the oil filter ele ment replaced at the intervals specified in the periodic maintenance and lubri cation chart To check the engine oil level
55. he 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 As the brake pads wear it is nor mal for the brake fluid level to grad ually go down However if the brake fluid level goes down sud denly have a Yamaha dealer check the cause EAU22720 Changing the brake fluid Have a Yamaha dealer change the brake fluid at the intervals specified in the NOTE after the periodic mainte nance and lubrication chart In addition have the oil seals of the brake master cylinder and caliper as well as the brake hose replaced at the intervals listed below or whenever they are dam aged or leaking Oil seals Replace every two years e Brake hose Replace every four years 6 25 EAU23090 Checking and lubricating the cables The operation of all control cables and the condition of the cables should be checked before each ride and the ca bles and cable ends should be lubricat ed if necessary If a cable is damaged or does not move smoothly have a Yamaha dealer check or replace it Recommended lubricant Yamaha Chain and Cable Lube or engine oil SAE 10W 30 API SE EWA10710 Damage to the outer housing of ca bles may result in internal rusting and cause interference with cable movement Replace damaged ca bles as soon as possible to prevent unsafe conditions PERIODIC MAINTENANCE AND MINOR REPAIR EAU23110 EAU23131 E
56. hile checking it for oil leakage If oil is leaking im mediately turn the engine off and check for the cause Turn the engine off and then check the oil level and correct it if necessary EAU20022 Final gear oil The final gear case must be checked for oil leakage before each ride If any leakage is found have a Yamaha deal er check and repair the vehicle In addi tion the final gear oil level must be checked and the oil changed as follows at the intervals specified in the periodic maintenance and lubrication chart EWA10370 A WARNING Make sure that no foreign mate rial enters the final gear case Make sure that no oil gets on the tire or wheel To check the final gear oil level 1 Place the vehicle on a level sur face and hold it in an upright posi tion NOTE e The final gear oil level must be checked on a cold engine Make sure that the vehicle is posi tioned straight up when checking the oil level A slight tilt to the side can result in a false reading 6 13 2 Remove the oil filler bolt and then check the oil level in the final gear case NOTE The oil level should be at the brim of the filler hole 1 Final gear oil drain bolt 2 Final gear oil filler bolt 3 Correct oil level 3 If the oil is below the brim of the fill er hole add sufficient oil of the rec ommended type to raise it to the correct level To change the final gear oil 1 Place an oil pan under th
57. iia 1 Luggage strap holder There is a luggage strap holder on each passenger footrest INSTRUMENT AND CONTROL FUNCTIONS EAU15300 Sidestand The sidestand is located on the left side of the frame Raise the sidestand or lower it with your foot while holding the vehicle upright NOTE The built in sidestand switch is part of the ignition circuit cut off system which cuts the ignition in certain situations See further down for an explanation of the ignition circuit cut off system The vehicle must not be ridden with the sidestand down or if the side stand cannot be properly moved up or does not stay up otherwise the sidestand could contact the ground and distract the operator resulting in a possible loss of control Yamaha s ignition circuit cut off system has been designed to assist the operator in fulfilling the respon sibility of raising the sidestand be fore starting off Therefore check this system regularly as described EWA10240 3 13 below and have a Yamaha dealer re pair it if it does not function proper ly INSTRUMENT AND CONTROL FUNCTIONS EAU15311 Ignition circuit cut off system The ignition circuit cut off system com prising the sidestand switch clutch switch and neutral switch has the fol lowing functions It prevents starting when the trans mission is in gear and the side stand is up but the clutch lever is not pulled It prevents starting when the trans mis
58. ion fuel will not flow Always turn the fuel cock lever to this position when the en gine is not running INSTRUMENT AND CONTROL FUNCTIONS ON This indicates reserve With the fuel UR iden cock lever in this position the fuel re Starter choke knob serve is made available Turn the fuel cock lever to this position if you run out of fuel while riding When this occurs refuel as soon as possible and be sure to turn the fuel cock lever back to ON 1 Arrow mark positioned over ON 1 Starter choke knob jx With the fuel cock lever in this position fuel flows to the carburetors Turn the fuel cock lever to this position when starting the engine and riding Starting a cold engine requires a richer air fuel mixture which is supplied by the starter choke Move the knob in direction a to turn on RES the starter choke Move the knob in direction b to turn off the starter choke ECA10990 CAUTION Do not use the starter choke for more than 3 minutes as the exhaust pipe may discolor from excessive heat In addition extended use of the starter choke will cause after burning If this occurs turn off the starter choke 3 8 INSTRUMENT AND CONTROL FUNCTIONS EAU14180 Seats XVS650 Passenger seat To remove the passenger seat Remove the nut and then pull the pas senger seat up 1 Bolt 2 Seat holder 3 Projection Rider seat To remove the rider
59. ism beyond the maximum or minimum settings Adjust the spring preload as follows 1 Remove the passenger and rider seats See page 3 9 2 To increase the spring preload and thereby harden the suspension turn the adjusting ring in direction a To decrease the spring pre load and thereby soften the sus pension turn the adjusting ring in direction b NOTE e Align the appropriate notch in the adjusting ring with the position in dicator on the shock absorber amp Use the special wrench and exten sion bar included in the owners tool kit to make the adjustment Spring preload setting Minimum soft 1 Standard 3 Maximum hard 7 3 Install the passenger and rider seats 3 12 EWA10220 This shock absorber contains highly pressurized nitrogen gas For prop er handling read and understand the following information before handling the shock absorber The manufacturer cannot be held re sponsible for property damage or personal injury that may result from improper handling e Do not tamper with or attempt to open the gas cylinder e Do not subject the shock ab sorber to an open flame or other high heat sources otherwise it may explode due to excessive gas pressure e Do not deform or damage the gas cylinder in any way as this will result in poor damping per formance e Always have a Yamaha dealer service the shock absorber EAU15150 Luggage strap holders P
60. ith both hands and keep both feet on the passenger footrests Never carry a passenger unless he or she can firmly place both feet on the passenger footrests e Never ride under the influence of alcohol or other drugs This motorcycle is designed for on road use only therefore it is not suitable for off road use Protective apparel The majority of fatalities from motor cycle accidents are the result of head injuries The use of a safety helmet is the single most critical factor in the pre vention or reduction of head injuries amp Always wear an approved helmet e Wear a face shield or goggles Wind in your unprotected eyes could contribute to an impairment of vision which could delay seeing a hazard The use of a jacket heavy boots trousers gloves etc is effective in preventing or reducing abrasions or lacerations amp Never wear loose fitting clothes otherwise they could catch on the control levers footrests or wheels and cause injury or an accident Never touch the engine or exhaust system during or after operation They become very hot and can 1 2 cause burns Always wear protec tive clothing that covers your legs ankles and feet e Passengers should also observe the precautions mentioned above Modifications Modifications made to this motorcycle not approved by Yamaha or the re moval of original equipment may ren der the motorcycle unsafe for use and may cause severe person
61. l hoses for cracks or damage e Replace if necessary Fuel filter Replace Replace Spark plugs e Check condition e Adjust gap and clean Replace every 8000 mi 13000 km or 12 months Replace Replace Valve clearance e Check and adjust valve clearance when engine is cold Crankcase breather system Check breather hose for cracks or damage Replace if necessary Carburetor synchro nization e Adjust synchronization of carbu retors Idle speed e Check and adjust engine idle speed Exhaust system e Check for leakage Tighten if necessary Replace gasket s if necessary Evaporative emis sion control system For California only e Check control system for dam age Replace if necessary 6 3 Since these items require special tools data and technical skills have a Yamaha dealer perform the service General maintenance and lubrication chart PERIODIC MAINTENANCE AND MINOR REPAIR ROUTINE INITIAL ODOMETER READINGS EAU32182 600 mi 1 month 4000 mi 6 months 8000 mi 13000 km or 12 months 12000 mi 19000 km or 18 months 16000 mi 25000 km or 24 months 20000 mi 31000 km or 30 months Air filter element Clean with compressed air Replace if necessary Ni Ni Ni Ni Clutch e Check operation Adjust or replace cable Ni Ni Front b
62. l or wax to any rubber and plastic parts but treat them with a suitable care product MOTORCYCLE CARE AND STORAGE e Avoid using abrasive polishing compounds as they will wear away the paint EAU26230 Storage Short term NOTE Consult a Yamaha dealer for advice on what products to use Always store your motorcycle in a cool dry place and if necessary protect it against dust with a porous cover ECA10810 CAUTION e Storing the motorcycle in a poorly ventilated room or cover ing it with a tarp while it is still wet will allow water and humid ity to seep in and cause rust To prevent corrosion avoid damp cellars stables because of the presence of ammonia and areas where strong chemi cals are stored Long term Before storing your motorcycle for sev eral months 1 2 Follow all the instructions in the Care section of this chapter For motorcycles equipped with a fuel cock that has an OFF posi tion Turn the fuel cock lever to OFP 7 3 3 Drain the carburetor float cham bers by loosening the drain bolts this will prevent fuel deposits from building up Pour the drained fuel into the fuel tank Fill up the fuel tank and add fuel stabilizer if available to prevent the fuel tank from rusting and the fuel from deteriorating Perform the following steps to pro tect the cylinders piston rings etc from corrosion a Remove the spark plug caps
63. lashes when an electrical circuit monitoring the engine is defective When this occurs have a Yamaha dealer check the self diagnosis system The electrical circuit of the warning light can be checked by turning the key to ON If the warning light does not come on for a few seconds then go off have a Yamaha dealer check the electrical circuit 3 2 EAU11630 Speedometer unit 3 K 1 Tripmeter reset knob 2 Speedometer 3 Odometer 4 Tripmeter The speedometer unit is equipped with a speedometer an odometer and a tripmeter The speedometer shows riding speed The odometer shows the total distance traveled The tripmeter shows the distance traveled since it was last set to zero with the reset knob The tripmeter can be used to estimate the distance that can be traveled with a full tank of fuel This information will en able you to plan future fuel stops Handlebar switches Left EAU12343 1 Dimmer switch 20 20 2 Turn signal switch lt gt 3 Horn switch pe Right 1 Engine stop switch O R 2 Start switch INSTRUMENT AND CONTROL FUNCTIONS EAU12400 Dimmer switch 0 20 Set this switch to o for the high beam and to zo for the low beam EAU12430 Turn signal switch lt gt To signal a right hand turn push this switch to gt To signal a left hand turn push this switch to lt When re leased the switch re
64. n the ambient temperature Tempera tures above 10 C 50 F require about 7 seconds of starter choke use and temperatures below 10 C 50 F re quire about 35 seconds with the starter choke turned on then about 2 5 min utes with the starter choke in the half way position 5 2 EAU16640 Starting a warm engine Follow the same procedure as for start ing a cold engine with the exception that the starter choke is not required when the engine is warm EAU16671 Shifting XVS650 1 Shift pedal 2 Neutral position XVS650A AT 1 Shift pedal 2 Neutral position OPERATION AND IMPORTANT RIDING POINTS Shifting gears lets you control the amount of engine power available for starting off accelerating climbing hills etc The gear positions are shown in the il lustration NOTE To shift the transmission into the neu tral position press the shift pedal down repeatedly until it reaches the end of its travel and then slightly raise it ECA10260 CAUTION e Even with the transmission in the neutral position do not coast for long periods of time with the engine off and do not tow the motorcycle for long dis tances The transmission is properly lubricated only when the engine is running Inade quate lubrication may damage the transmission e Always use the clutch while changing gears to avoid damag ing the engine transmission 5 3 and drive train which are
65. ndicator which allows you to check the brake shoe wear without having to dis assemble the brake To check the brake shoe wear check the position of the wear indicator while applying the brake If a brake shoe has worn to the point that the wear indicator reaches the wear limit line have a Yamaha dealer replace the brake shoes as a set 6 24 Checking the brake fluid level 1 Minimum level mark Insufficient brake fluid may allow air to enter the brake system possibly caus ing it to become ineffective Before riding check that the brake fluid is above the minimum level mark and replenish if necessary A low brake fluid level may indicate worn brake pads and or brake system leakage If the brake fluid level is low be sure to check the brake pads for wear and the brake system for leakage Observe these precautions When checking the fluid level make sure that the top of the mas ter cylinder is level by turning the handlebars PERIODIC MAINTENANCE AND MINOR REPAIR Use only the recommended quality brake fluid otherwise the rubber seals may deteriorate causing leakage and poor braking perfor mance Recommended brake fluid DOT 4 e Refill with the same type of brake fluid Mixing fluids may result in a harmful chemical reaction and lead to poor braking performance e Be careful that water does not en ter the master cylinder when refill ing Water will significantly lower the boiling point of t
66. ng or pinging occurs use a gasoline of a different brand or premi um unleaded fuel Use of unleaded fuel will extend spark plug life and reduce maintenance costs Gasohol There are two types of gasohol gaso hol containing ethanol and that contain ing methanol Gasohol containing ethanol can be used if the ethanol con tent does not exceed 10 Gasohol containing methanol is not recom mended by Yamaha because it can cause damage to the fuel system or ve hicle performance problems INSTRUMENT AND CONTROL FUNCTIONS EAU13440 Catalytic converter This vehicle is equipped with a catalytic converter in the muffler The exhaust system is hot after op eration Make sure that the exhaust system has cooled down before do ing any maintenance work EWA10860 ECA10700 CAUTION The following precautions must be observed to prevent a fire hazard or other damages e Use only unleaded gasoline The use of leaded gasoline will cause unrepairable damage to the catalytic converter e Never park the vehicle near pos sible fire hazards such as grass or other materials that easily burn Do not allow the engine to idle too long 3 7 EAU13550 Fuel cock The fuel cock supplies fuel from the tank to the carburetors while also filter ing it The fuel cock lever positions are ex plained as follows and shown in the il lustrations 1 Arrow mark positioned over OFF With the fuel cock lever in this posit
67. ng wooden box can be placed under the engine for added stability To service the front wheel 1 Stabilize the rear of the motorcycle by using a motorcycle stand or if an additional motorcycle stand is not available by placing a jack un der the frame in front of the rear wheel 2 Raise the front wheel off the ground by using a motorcycle stand To service the rear wheel Raise the rear wheel off the ground by using a motorcycle stand or if a motor cycle stand is not available by placing 6 33 a jack either under each side of the frame in front of the rear wheel or under each side of the swingarm EAU24360 Front wheel EAU24660 To remove the front wheel Itis advisable to have a Yamaha dealer service the wheel e Securely support the motor cycle so that there is no danger of it falling over EWA10820 1 Disconnect the speedometer ca ble from the front wheel 1 Speedometer cable 2 Loosen the front wheel axle pinch bolt 3 Remove the rubber cap and then loosen the wheel axle PERIODIC MAINTENANCE AND MINOR REPAIR by 1 Rubber cap 2 Wheel axle 3 Front wheel axle pinch bolt 4 Lift the front wheel off the ground according to the procedure on page 6 33 5 Pull the wheel axle out and then remove the wheel ECA11070 CAUTION Do not apply the brake after the wheel has been removed together with the brake disc otherwise the brake pads will be forced shut 6 34
68. ni tion circuit cut off system See page 3 14 EAU12870 Shift pedal XVS650 1 Shift pedal The shift pedal is located on the left side of the engine and is used in com bination with the clutch lever when shifting the gears of the 5 speed con stant mesh transmission equipped on this motorcycle 3 4 AU12880 Shift pedal XVS650A AT 1 Shift pedal The shift pedal is located on the left side of the engine and is used in com bination with the clutch lever when shifting the gears of the 5 speed con stant mesh transmission equipped on this motorcycle NOTE Use your toes or heel to shift up and your toes to shift down EAU12890 Brake lever 1 Brake lever The brake lever is located at the right handlebar grip To apply the front brake pull the lever toward the handle bar grip INSTRUMENT AND CONTROL FUNCTIONS EAU12941 Brake pedal XVS650 1 Brake pedal XVS650A AT 1 Brake pedal The brake pedal is on the right side of the motorcycle To apply the rear brake press down on the brake pedal 3 5 EAU13120 Fuel tank cap To remove the fuel tank cap Slide the lock cover open insert the key into the lock and then turn it 1 4 turn clockwise The lock will be released and the fuel tank cap can be removed To install the fuel tank cap 1 Insert the fuel tank cap into the tank opening with the key inserted in the lock and with the A mark fa
69. not designed to withstand the shock of forced shifting EAU16680 To start out and accelerate 1 Pull the clutch lever to disengage the clutch 2 Shift the transmission into first gear The neutral indicator light should go out 3 Open the throttle gradually and at the same time release the clutch lever slowly 4 At the recommended shift points shown in the following table close the throttle and at the same time quickly pull the clutch lever in 5 Shift the transmission into second gear Make sure not to shift the transmission into the neutral posi tion 6 Open the throttle part way and gradually release the clutch lever 7 Follow the same procedure when shifting to the next higher gear OPERATION AND IMPORTANT RIDING POINTS NOTE Always shift gears at the recommended shift points EAU16700 To decelerate 1 Apply both the front and the rear brakes to slow the motorcycle 2 Shift the transmission into first gear when the motorcycle reaches 25 km h 15 5 mi h If the engine is about to stall or runs very roughly pull the clutch lever in and use the brakes to stop the motorcycle 3 Shift the transmission into the neu tral position when the motorcycle is almost completely stopped The neutral indicator light should come on EAU16720 Recommended shift points The recommended shift points during acceleration and deceleration are shown in the table below Shift up points 1st
70. onrrrsnrnnvrnnsnne 3 13 Ignition circuit cut off system 3 14 PRE OPERATION CHECKS 4 1 Pre operation check list 4 4 2 OPERATION AND IMPORTANT RIDING POINTS 0 eee 5 1 Starting and warming up a cold engine murrnnrnvrvrrnrnnrrnerennn 5 1 Starting a warm engine ssrnnrnrnn 5 2 SAING AEAT 5 3 Engine break in urervnrrvnnrvrennenrn 5 4 Parking wiih elt 5 5 PERIODIC MAINTENANCE AND MINOR REPAIR 6 1 PERIODIC MAINTENANCE 6 1 Owner s tool kit aseeseen 6 1 Periodic maintenance chart for the emission control system 6 3 General maintenance and lubrication Chart neee 6 4 Removing and installing panels 6 8 Checking the spark plugs 6 9 Canister for California only 6 10 Engine oil and oil filter element 6 11 Final gear Oil leee 6 13 Cleaning the air filter element 6 14 Adjusting the carburetors 6 16 TABLE OF CONTENTS Adjusting the throttle cable free play mmrnrnrvrrnnvnonvavnennnrenrnne 6 16 Adjusting the valve clearance 6 16 TGS anna aid 6 17 Spoke wheels rrnrnrrnnnrnnnrnnrnnvennn 6 19 Accessories and replacement pars sager 6 19 Adjusting the clutch lever free play Laagamasesesekte 6 20 Adjusting the brake lever free play mmrnnnrvrnnnvvenrnvnerensennnnn 6 21 Adjusting the brake pedal position and free play eccriene 6 22 Adjusting the rear brake light SWITCH aire k
71. ork or front fender These items in cluding such cargo as sleeping bags duffel bags or tents can create unstable handling or slow steering response Accessories Genuine Yamaha accessories have been specifically designed for use on this motorcycle Since Yamaha cannot test all other accessories that may be available you must personally be re sponsible for the proper selection in stallation and use of non Yamaha accessories Use extreme caution when selecting and installing any ac cessories Keep the following guidelines in mind as well as those provided under Load ing when mounting accessories e Never install accessories or carry cargo that would impair the perfor mance of your motorcycle Care fully inspect the accessory before using it to make sure that it does not in any way reduce ground clearance or cornering clearance 1 3 limit suspension travel steering travel or control operation or ob scure lights or reflectors Accessories fitted to the handle bar or the front fork area can create instability due to improper weight distribution or aerody namic changes If accessories are added to the handlebar or front fork area they must be as lightweight as possible and should be kept to a minimum Bulky or large accessories may seriously affect the stability of the motorcycle due to aerody namic effects Wind may at tempt to lift the motorcycle or the motorcycle may become un stable in cross
72. ormation such as names addresses model V I N frame number dates and receipts CHANGE OF ADDRESS The federal government requires each manufacturer of a motor vehicle to maintain a complete up to date list of all first purchasers against the possibility of a safety related defect and recall This list is compiled from the purchase registrations sent to Yamaha Motor Corporation U S A by the selling dealer at the time of your purchase If you should move after you have purchased your new motorcycle please advise us of your new address by sending a postcard listing your motorcycle model name V I N frame number dealer number or dealer s name as it is shown on your warranty card your name and new mailing address Mail to YAMAHA MOTOR CORPORATION U S A P O Box 6555 Cypress California 90630 Attention Warranty Department This will ensure that Yamaha Motor Corporation U S A has an up to date registration record in accordance with federal law CONSUMER INFORMATION EAU26750 YAMAHA EXTENDED SERVICE Y E S Keep your Yamaha protected even after your warranty e In addition Travel and Recreation Interruption Protection expires with genuine Yamaha Extended Service Y E S TRIP is included at no extra cost TRIP gives you up to e Y E S is designed and administered by Yamaha Motor Corporation to provide maximum owner satisfaction You get uninterrupted factory backed coverage for extra peace of mind e Y E S is
73. ot park the motorcycle on a slope or soft ground otherwise it may fall over Do not park the motorcycle near a flammable source e g a kero sene heater or near an open flame otherwise it could catch fire When transporting the motorcycle in another vehicle make sure that it is kept upright and that the fuel cock is turned to ON or RES for vacuum type OFF for manual type If it should lean over gaso line may leak out of the carburetor or fuel tank If you should swallow any gaso line inhale a lot of gasoline vapor or allow gasoline to get into your 1 4 eyes see your doctor immediately If any gasoline spills on your skin or clothing immediately wash the affected area with soap and water and change your clothes A SAFETY INFORMATION EAU10381 Location of important labels Please read the following important labels carefully before operating this vehicle A SAFETY INFORMATION 1 3 XVS650A AT A WARNING TIRE INFORMATION BEFORE YOU OPERATE THIS VEHICLE READ THE OWNER S MANUAL AND ALL LABELS Cold tire normal pressure should be set as ALWAYS WEAR AN APPROVED MOTORCYCLE follows HELMET eye protection and protective clothing Up to 90 kg 198 Ibs load 5GK2115K00 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 5BN 21668 00
74. rake Check operation fluid level and for fluid leakage Replace brake pads if necessary Rear brake Check operation Adjust cable and replace brake shoes if necessary Ni Brake hose e Check for cracks or damage NI Ni e Replace Every 4 years e Check runout spoke tightness and for damage Tighten spokes if necessary Ni Ni e Check tread depth and for dam age e Replace if necessary e Check air pressure e Correct if necessary Wheel bearings e Check bearings for smooth oper ation e Replace if necessary ROUTINE INITIAL PERIODIC MAINTENANCE AND MINOR REPAIR ODOMETER READINGS 600 mi 1000 km or 1 month 4000 mi 7000 km or 6 months 8000 mi 13000 km or 12 months 12000 mi 19000 km or 18 months 16000 mi 25000 km or 24 months 20000 mi 31000 km or 30 months Swingarm pivot bearings Check bearing assemblies for looseness e Moderately repack with lithium soap based grease Repack Steering bearings Check bearing assemblies for looseness e Moderately repack with lithium soap based grease every 16000 mi 25000 km or 24 months Chassis fasteners e Check all chassis fitting and fas teners e Correct if necessary Brake and clutch le ver pivot shafts Apply lithium soap based grease all purpose grease lightly Brake and shift ped al
75. ring page 3 12 5 Helmet holder page 3 11 6 Owner s tool kit page 6 1 7 Storage compartment page 3 11 2 2 DESCRIPTION EAU32230 Right view XVS650 Engine oil filter element page 6 11 Battery page 6 29 Fuses page 6 30 Main switch steering lock page 3 1 Air filter element page 6 14 Brake pedal page 3 5 dAAROND 2 3 XVS650A AT OooaRWND Engine oil filter element page 6 11 Battery page 6 29 Fuses page 6 30 Main switch steering lock page 3 1 Air filter element page 6 14 Brake pedal page 3 5 2 4 DESCRIPTION DESCRIPTION EAU10430 Controls and instruments 1 Clutch lever page 3 4 2 Left handlebar switches page 3 3 3 Speedometer unit page 3 2 4 Fuel tank cap page 3 5 5 Right handlebar switches page 3 3 6 Throttle grip page 6 16 7 Brake lever page 3 5 2 5 EAU10460 The main switch steering lock controls the ignition and lighting systems and is used to lock the steering The various positions are described below EAU10510 ON All electrical systems are supplied with power and the headlight meter light ing taillight and position lights come on and the engine can be started The key cannot be removed EAU10660 OFF All electrical systems are off The key can be removed INSTRUMENT AND CONTROL FUNCTIONS EAU10680 LOCK The steering is locked and all electrical systems are o
76. rins ni 6 23 Checking the front brake pads and rear brake shoes 6 24 Checking the brake fluid level 6 24 Changing the brake fluid 6 25 Checking and lubricating the CADIS EE 6 25 Checking and lubricating the throttle grip and cable 6 26 Checking and lubricating the brake and shift pedals 6 26 Checking and lubricating the brake and clutch levers 6 26 Checking and lubricating the sidestand nsien 6 27 Checking the front fork 6 27 Checking the steering 6 28 TABLE OF CONTENTS Checking the wheel bearings 6 28 Battery ceric ed eset 6 29 Replacing the fuses e 6 30 Replacing the headlight bulb 6 31 Replacing a turn signal light bulb or the tail brake light bulb 6 32 Supporting the motorcycle 6 33 Front wheel 00 eee eeeeeeeseeeeeeeeeeees 6 34 Rear wheel 0 escceeeeeeeeeeeereees 6 35 Troubleshooting sece 6 37 Troubleshooting chart s es 6 38 MOTORCYCLE CARE AND STORAGE 2h inn 7 1 Calena adle 7 1 Storage sunni anit 7 3 SPECIFICATIONS rrrrnrronvrnnnrrenrne 8 1 CONSUMER INFORMATION 9 1 Identification numbers ee 9 1 Reporting safety defects 9 3 Motorcycle noise regulation 9 4 Maintenance record eee 9 5 YAMAHA MOTOR CORPORATION U S A STREET AND ENDURO MOTORCYCLE LIMITED WARRANTY sssses
77. s 6 22 Cc Cables checking and lubricating 6 25 Canister for California only 6 10 Carburetors adjustment 6 16 Care Catalytic converter Clutch lever eee eee eeeeeees s Clutch lever free play adjusting 6 20 D Dimmer switch ooo eee cece eee eee 3 3 E Engine break in ou cece ceeeeeeeeneeeeeee Engine oil and oil filter element Engine starting a warm Engine stop SWitCN eee eee Engine trouble warning light Fuoloa Fuel cock Fuel tank cap serusnvranvrrnnvnnnvrervrenvvrnrnvene 3 5 Fuses replacing cece eee eeee eee 6 30 H Handlebar switches eee eee eee Headlight bulb replacing Helmet holder sonononennnenvennnnernvevnnenr High beam indicator light Horn switch nc ceccivcssceecvecsoretcavtesceseretctesees I Identification numbers ssassn Ignition circuit cut off system Indicator and warning lights 00 K Key identification number 9 1 L Labels location Of rrrrrnrnnnnnvvrvrnrnnrnnnnnr 1 5 Luggage strap holders ee 3 13 M Main switch steering lock 3 1 Maintenance and lubrication periodic 6 4 Maintenance emission control system 6 3 Maintenance periodic 6 1 Maintenance record 9 5 Model label musrnnvvvnrvvenvvrnnnvnnnvrnnnrnnnnrne 9 2 N Neutral indicator light 0 ee 3 2 Noise regulation eee rere 9 4 P Pan
78. s 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 CONSUMER INFORMATION We urge you to act now You ll get the excellent benefits of TRIP coverage right away and you ll rest easy knowing you ll have strong factory backed protection even after your Yamaha Limited Warranty expires special note If visiting your dealer isn t convenient contact Yamaha with your Primary ID number your frame number We ll be YAMAHA EXTENDED SERVICE happy to help you get the Y E S coverage you need Yamaha Service Marketing P O Box 6555 Cypress CA 90630 1 866 YES EXTD 1 866 937 3983 9 10 A Accessories and replacement parts 6 19 Air filter element cleaning 0 6 14 B Battery seressvoenvavnvnnnnenvernsenenssrnesnnavenne 6 29 Brake and clutch levers checking and lubricating 00 6 26 Brake and shift pedals checking and lubricating 000 6 26 Brake fluid changing c e eee 6 25 Brake fluid level checking 20 6 24 Brake lever oc eee eeeeeeeeeeees we 3 5 Brake lever free play adjusting 6 21 Brake pads and shoes checking 6 24 Brake pedal cece eee eeeeeeeee 3 5 Brake pedal position and free play adjusting 0 eee cece eects eeeeeeeaee
79. sion is in gear and the clutch le ver is pulled but the sidestand is still down Itcuts the running engine when the transmission is in gear and the sid estand is moved down Periodically check the operation of the ignition circuit cut off system according to the following procedure If a malfunction is noted have a Yamaha dealer check the system be fore riding EWA10250 3 14 With the engine turned off 1 Move the sidestand down 2 Make sure that the engine stop switch is turned on 3 Turn the key on 4 Shift the transmission into the neutral position 5 Push the start switch Does the engine start With the engine still running 6 Move the sidestand up 7 Keep the clutch lever pulled 8 Shift the transmission into gear 9 Move the sidestand down Does the engine stall INSTRUMENT AND CONTROL FUNCTIONS NOTE This check is most reliable if performed with a warmed up engine After the engine has stalled 10 Move the sidestand up 11 Keep the clutch lever pulled 12 Push the start switch Does the engine start The system is OK The motorcycle can be ridden 3 15 The neutral switch may be defective The motorcycle should not be ridden until checked by a Yamaha dealer The sidestand switch may be defective The motorcycle should not be ridden until checked by a Yamaha dealer The clutch switch may be defective The motorcycle should not be ridden until checked
80. ssary Lubricate the throttle grip housing and cable From 24000 mi 37000 km or 36 months repeat the maintenance intervals starting from 8000 mi 13000 km or 12 months NOTE EAU17620 The air filter needs more frequent service if you are riding in unusually wet or dusty areas 6 6 PERIODIC MAINTENANCE AND MINOR REPAIR Hydraulic brake system e When disassembling the master cylinder or caliper cylinder always replace the brake fluid Check the brake fluid level regularly and fill as required e Replace the oil seals on the inner parts of the master cylinder and caliper cylinder every two years e Replace the brake hoses every four years or if cracked or damaged 6 7 EAU18771 Removing and installing panels The panels shown need to be removed to perform some of the maintenance jobs described in this chapter Refer to this section each time a panel needs to be removed and installed XVS650 1 Panel A PERIODIC MAINTENANCE AND MINOR REPAIR XVS650A AT 1 Panel B Panel A To remove the panel Remove the bolts and then take the panel off 6 8 XVS650 ee 1 Bolt To install the panel Place the panel in the original position and then install the bolts XVS650A AT PERIODIC MAINTENANCE AND MINOR REPAIR EAU19151 Panel B To remove the panel Remove the bolt and then pull the pan el off as shown 1 Bol
81. sssssesesssssseeeseee 9 7 YAMAHA EXTENDED SERVICE VEST 9 9 A SAFETY INFORMATION EAU10251 MOTORCYCLES ARE SINGLE TRACK VEHICLES THEIR SAFE USE AND OPERATION ARE DEPEN DENT UPON THE USE OF PROPER RIDING TECHNIQUES AS WELL AS THE EXPERTISE OF THE OPERA TOR EVERY OPERATOR SHOULD KNOW THE FOLLOWING REQUIRE MENTS BEFORE RIDING THIS MOTORCYCLE HE OR SHE SHOULD OBTAIN THOROUGH INSTRUC TIONS FROM A COMPETENT SOURCE ON ALL ASPECTS OF MOTORCYCLE OPERATION e OBSERVE THE WARNINGS AND MAINTENANCE REQUIRE MENTS IN THE OWNER S MAN UAL e OBTAIN QUALIFIED TRAINING IN SAFE AND PROPER RIDING TECHNIQUES OBTAIN PROFESSIONAL TECH NICAL SERVICE AS INDICATED BY THE OWNER S MANUAL AND OR WHEN MADE NECES SARY BY MECHANICAL CONDI TIONS Safe riding Always make pre operation checks Careful checks may help prevent an accident This motorcycle is designed to carry the operator and a passen ger The failure of motorists to detect and recognize motorcycles in traf fic is the predominating cause of automobile motorcycle accidents Many accidents have been caused by an automobile driver who did not see the motorcycle Making yourself conspicuous ap pears to be very effective in reduc ing the chance of this type of accident Therefore e Wear a brightly colored jacket e Use extra caution when ap proaching and passing through intersections since intersec tions are the most likely places for mo
82. t To install the panel Place the panel in the original position and then install the bolt EAU19543 Checking the spark plugs The spark plugs are important engine components which are easy to check Since heat and deposits will cause any spark plug to slowly erode the spark plugs should be removed and checked in accordance with the periodic mainte nance and lubrication chart In addition the condition of the spark plugs can re veal the condition of the engine To remove a spark plug 1 Remove the spark plug cap 1 Spark plug cap 2 Remove the spark plug as shown with the spark plug wrench includ ed in the owner s tool kit 6 9 1 Spark plug wrench To check the spark plugs 1 Check that the porcelain insulator around the center electrode on each spark plug is a medium to light tan the ideal color when the vehicle is ridden normally 2 Check that all spark plugs installed in the engine have the same color NOTE If any spark plug shows a distinctly dif ferent color the engine could be defec tive Do not attempt to diagnose such problems yourself Instead have a Yamaha dealer check the vehicle PERIODIC MAINTENANCE AND MINOR REPAIR 3 Check each spark plug for elec 2 Clean the surface of the spark plug s EAU19672 trode erosion and excessive car gasket and its mating surface and Canister for California only bon or other deposits and replace then wipe off any grime from t
83. that the seats are properly secured before riding EAU14281 Helmet holder 1 Helmet holder 2 Unlock To open the helmet holder insert the key into the lock and then turn the key as shown To lock the helmet holder place it in the original position and then remove the key Never ride with a helmet attached to the helmet holder since the helmet may hit objects causing loss of con trol and possibly an accident EWA10160 INSTRUMENT AND CONTROL FUNCTIONS EAU14481 Storage compartment The storage compartment is located on the left side of the vehicle To open the storage compartment 1 Slide the lock cover open insert the key into the lock and then turn it clockwise 1 Storage compartment cover 2 Storage compartment lock cover 3 Storage compartment lock 2 Pullthe storage compartment cov er out as shown 3 11 To close the storage compartment 1 Place the storage compartment cover in its original position as shown 1 Storage compartment 2 Storage compartment cover 2 Turn the key counterclockwise re move it and then close the lock cover INSTRUMENT AND CONTROL FUNCTIONS EAU14860 Adjusting the shock absorber assembly 1 Position indicator 2 Spring preload adjusting ring 3 Extension bar 4 Special wrench This shock absorber assembly is equipped with a spring preload adjust ing ring ECA10100 CAUTION Never attempt to turn an adjusting mechan
84. the valve clearance The valve clearance changes with use resulting in improper air fuel mixture and or engine noise To prevent this from occurring the valve clearance must be adjusted by a Yamaha dealer at the intervals specified in the periodic maintenance and lubrication chart PERIODIC MAINTENANCE AND MINOR REPAIR EAU32520 5 Maximum load XVS650 178 kg 392 Ib CAL Tire air pressure measured on cold Tires tires To maximize the performance durabil ity and safe operation of your motor cycle note the following points regarding the specified tires Tire air pressure The tire air pressure should be checked and if necessary adjusted before each ride The tire air pressure must be checked and adjusted on cold tires i e when the temperature of the tires equals the ambient temperature e The tire air pressure must be ad justed in accordance with the riding speed and with the total weight of rider passenger car go and accessories approved for this model EWA10500 0 90 kg 0 198 Ib Front XVS650 200 kPa 29 psi 2 00 kgf cm XVS650A 225 kPa 33 psi 2 25 kgf cm XVS650AT 225 kPa 33 psi 2 25 kgf cm Rear 225 kPa 33 psi 2 25 kgf cm XVS650 90 178 kg 198 392 Ib CAL XVS650 90 180 kg 198 397 Ib U49 XVS650A 90 198 kg 198 437 Ib CAL XVS650A 90 200 kg 198 441 Ib U49 XVS650AT 90 198 kg 198 437 Ib CAL XVS650AT 90 200 kg 198 441 Ib U49
85. to keep it free from oil otherwise the transparency of the glass the luminosity of the bulb and the bulb life will be adversely af fected Thoroughly clean off any dirt and fingerprints on the headlight bulb using a cloth moistened with al cohol or thinner PERIODIC MAINTENANCE AND MINOR REPAIR 1 Do not touch the glass part of the bulb 5 6 Install the headlight bulb cover and then connect the coupler Install the headlight unit by install ing the screws Have a Yamaha dealer adjust the headlight beam if necessary 6 32 EAU24281 Replacing a turn signal light bulb or the tail brake light bulb 1 Remove the lens by removing the screws 1 Screw XVS650 1 Screw a PERIODIC MAINTENANCE AND MINOR REPAIR XVS650A AT 1 Screw 2 Remove the defective bulb by pushing it in and turning it counter clockwise Insert a new bulb into the socket push it in and then turn it clock wise until it stops 4 Install the lens by installing the screws ECA10680 CAUTION Do not overtighten the screws oth erwise the lens may break EAU24350 Supporting the motorcycle Since this model is not equipped with a centerstand follow these precautions when removing the front and rear wheel or performing other maintenance requiring the motorcycle to stand up right Check that the motorcycle is in a stable and level position before starting any maintenance A stro
86. torcycle accidents to oc cur Ride where other motorists can see you Avoid riding in another motorist s blind spot Many motorcycle accidents in volve inexperienced operators In fact many operators who have been involved in accidents do not even have a current motorcycle li cense e Make sure that you are qualified and that you only lend your motorcycle to other qualified op erators Know your skills and limits Staying within your limits may help you to avoid an accident We recommend that you prac tice riding your motorcycle where there is no traffic until you have become thoroughly famil iar with the motorcycle and all of its controls Many motorcycle accidents have been caused by error of the motor cycle operator A typical error made by the operator is veering A SAFETY INFORMATION wide on a turn due to EXCESSIVE SPEED or undercornering insuffi cient lean angle for the speed Always obey the speed limit and never travel faster than warrant ed by road and traffic conditions Always signal before turning or changing lanes Make sure that other motorists can see you The posture of the operator and passenger is important for proper control The operator should keep both hands on the handlebar and both feet on the operator foot rests during operation to main tain control of the motorcycle The passenger should always hold onto the operator seat strap or grab bar if equipped w
87. turns to the center position Since this model is equipped with a self canceling system the turn signal lights will self cancel after the vehicle has traveled both about 150 m 490 ft and for approximately 15 seconds However the turn signal lights can also be canceled manually by pushing the switch in after it has returned to the cen ter position NOTE The self canceling system only oper ates when the vehicle is moving so that the turn signal lights will not self cancel while you are stopped at an intersec tion 3 3 EAU12500 Horn switch gt Press this switch to sound the horn EAU12660 Engine stop switch 2 3 Set this switch to CQ before starting the engine Set this switch to sq to stop the engine in case of an emergen cy such as when the vehicle overturns or when the throttle cable is stuck EAU12710 Start switch Push this switch to crank the engine with the starter ECA10050 CAUTION See page 5 1 for starting instruc tions prior to starting the engine INSTRUMENT AND CONTROL FUNCTIONS EAU12820 Clutch lever 1 Clutch lever The clutch lever is located at the left handlebar grip To disengage the clutch pull the lever toward the handle bar grip To engage the clutch release the lever The lever should be pulled rapidly and released slowly for smooth clutch operation The clutch lever is equipped with a clutch switch which is part of the ig
88. uretor heater fuse 15 0 A Ignitor unit fuse XVS650 5 0 A CAL XVS650A 5 0 A CAL XVS650AT 5 0 A CAL EAU26351 Identification numbers Record the key identification number vehicle identification number and mod el label information in the spaces pro vided below for assistance when ordering spare parts from a Yamaha dealer or for reference in case the vehi cle is stolen KEY IDENTIFICATION NUMBER ee VEHICLE IDENTIFICATION NUMBER mm MODEL LABEL INFORMATION CONSUMER INFORMATION EAU26381 Key identification number 1 Key identification number The key identification number is stamped into the key tag Record this number in the space provided and use it for reference when ordering a new key 9 1 EAU26400 Vehicle identification number LA a Ti Jos AN W 1 PAN 4 AANE 1 Vehicle ideiitiication number ct i Fan Y A wie Z The vehicle identification number is stamped into the steering head pipe Record this number in the space pro vided NOTE The vehicle identification number is used to identify your motorcycle and may be used to register your motor cycle with the licensing authority in your area CONSUMER INFORMATION EAU26470 Model label 1 Model label The model label is affixed to the frame under the rider seat See page 3 9 Record the information on this label in the space provided This information will be needed when ordering sp
89. usting nut 6 23 EAU22270 Adjusting the rear brake light switch II F F SN 1 Rear brake light switch 2 Rear brake light switch adjusting nut The rear brake light switch which is ac tivated by the brake pedal is properly adjusted when the brake light comes on just before braking takes effect If necessary adjust the brake light switch as follows Turn the adjusting nut while holding the rear brake light switch in place To make the brake light come on earlier turn the adjusting nut in direction a To make the brake light come on later turn the adjusting nut in direction b PERIODIC MAINTENANCE AND MINOR REPAIR EAU22380 Checking the front brake pads and rear brake shoes The front brake pads and the rear brake shoes must be checked for wear at the intervals specified in the periodic main tenance and lubrication chart EAU22430 Front brake pads Hs 1 Brake pad wear indicator groove Each front brake pad is provided with wear indicator grooves which allow you to check the brake pad wear with out having to disassemble the brake To check the brake pad wear check the wear indicator grooves If a brake pad has worn to the point that the wear indicator grooves have almost disap peared have a Yamaha dealer replace the brake pads as a set EAU22540 Rear brake shoes i y 1 Brake shoe wear limit line 2 Brake shoe wear indicator The rear brake is provided with a wear i
90. ycle as specified in the appropriate Owner s Manual and 2 Give notice to an authorized Yamaha motorcycle dealer of any and all apparent defects within ten 10 days after discovery and make the machine available at that time for inspection and repairs at such dealer s place of business WARRANTY TRANSFER To transfer the warranty from the original purchaser to any subsequent pur chaser it is imperative that the machine be inspected and registered for warranty by an authorized Yamaha motorcycle dealer In order for this warranty to remain in effect this inspection and registration must take place within ten 10 days after transfer An inspection and registration fee will be charged for this service EMISSIONS CONTROL SYSTEM WARRANTY Yamaha Motor Corporation U S A also warrants to the ultimate purchaser and each subsequent purchaser of each Yamaha motorcycle covered by this warranty with a displacement of 50cc or greater that the vehi cle is designed built and equipped so as to conform at the time of sale with all U S emissions standards applicable at the time of manufacture and that it is free from defects in materials and workmanship which would cause it not to meet these standards within the periods listed immediately below Failure other than those resulting from defects in material or workman ship which arise solely as a result of owner abuse and or lack of proper maintenance are not covered by this warranty YAMAHA MOT

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