OWNER’S MANUAL XVS650R(C) XVS650AR(C) YAMAHA MOTOR CO., LTD. PRINTED ON RECYCLED PAPER PRINTED IN JAPAN 2002.03-4.
EAU03438
U5FB12.book Page 1 Tuesday, April 9, 2002 11:55 AM EAU00002 INTRODUCTION Congratulations on your purchase of the Yamaha XVS650(C)/XVS650A(C). This model is the result of Yamaha’s vast experience in the production of fine sporting, touring, and pacesetting racing machines. It represents the high degree of 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.
U5FB12.book Page 1 Tuesday, April 9, 2002 11:55 AM IMPORTANT MANUAL INFORMATION Particularly important information is distinguished in this manual by the following notations: The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR SAFETY IS INVOLVED! Failure to follow WARNING instructions could result in severe injury or death to the motorcycle operator, a bystander or a person inspecting or repairing the motorcycle.
U5FB12.book Page 2 Tuesday, April 9, 2002 11:55 AM IMPORTANT MANUAL INFORMATION EW000000 WARNING 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 MOTORCYCLE UNTIL YOU HAVE ATTAINED ADEQUATE KNOWLEDGE OF ITS CONTROLS AND OPERATING FEATURES AND UNTIL YOU HAVE BEEN TRAINED IN SAFE AND PROPER RIDING TECHNIQUES.
U5FB12.book Page 3 Tuesday, April 9, 2002 11:55 AM IMPORTANT MANUAL INFORMATION AFFIX DEALER LABEL HERE EAU04247 XVS650R(C)/XVS650AR(C) OWNER’S MANUAL ©2002 by Yamaha Motor Corporation, U.S.A. 1st edition, February 2002 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.
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U5FB12.book Page 1 Tuesday, April 9, 2002 11:55 AM SAFETY INFORMATION Safe riding .......................................................................................... 1-1 Protective apparel .............................................................................. 1-3 Modifications ...................................................................................... 1-3 Loading and accessories ................................................................... 1-3 Gasoline and exhaust gas.......
U5FB12.book Page 1 Tuesday, April 9, 2002 11:55 AM SAFETY INFORMATION EAU03633 1- 1 MOTORCYCLES ARE SINGLE TRACK VEHICLES. THEIR SAFE USE AND OPERATION ARE DEPENDENT UPON THE USE OF PROPER RIDING TECHNIQUES AS WELL AS THE EXPERTISE OF THE OPERATOR. EVERY OPERATOR SHOULD KNOW THE FOLLOWING REQUIREMENTS BEFORE RIDING THIS MOTORCYCLE. HE OR SHE SHOULD: 1. OBTAIN THOROUGH INSTRUCTIONS FROM A COMPETENT SOURCE ON ALL ASPECTS OF MOTORCYCLE OPERATION. 2.
U5FB12.book Page 2 Tuesday, April 9, 2002 11:55 AM SAFETY INFORMATION 4. Many motorcycle accidents involve inexperienced operators. In fact, many operators who have been involved in accidents do not even have a current motorcycle license. a. Make sure that you are qualified and that you only lend your motorcycle to other qualified operators. b. Know your skills and limits. Staying within your limits may help you to avoid an accident. c.
U5FB12.book Page 3 Tuesday, April 9, 2002 11:55 AM SAFETY INFORMATION Protective apparel 1 The majority of fatalities from motorcycle accidents are the result of head injuries. The use of a safety helmet is the single most critical factor in the prevention or reduction of head injuries. 1. Always wear an approved helmet. 2. Wear a face shield or goggles. Wind in your unprotected eyes could contribute to an impairment of vision which could delay seeing a hazard. 3.
U5FB12.book Page 4 Tuesday, April 9, 2002 11:55 AM SAFETY INFORMATION Loading The total weight of the operator, passenger, accessories and cargo must not exceed the maximum load limit of XVS650(C): 397 lb (180 kg)/XVS650A(C): 441 lb (200 kg). When loading within this weight limit, keep the following in mind: 1. Cargo and accessory weight should be kept as low and close to the motorcycle as possible.
U5FB12.book Page 5 Tuesday, April 9, 2002 11:55 AM SAFETY INFORMATION 1 a. Accessories fitted to the handlebar or the front fork area can create instability due to improper weight distribution or aerodynamic changes. If accessories are added to the handlebar or front fork area, they must be as lightweight as possible and should be kept to a minimum. b. Bulky or large accessories may seriously affect the stability of the motorcycle due to aerodynamic effects.
U5FB12.book Page 6 Tuesday, April 9, 2002 11:55 AM SAFETY INFORMATION a. The engine and exhaust system may be hot, therefore, park the motorcycle in a place where pedestrians or children are not likely to touch these hot areas. b. Do not park the motorcycle on a slope or soft ground, otherwise it may fall over. c. Do not park the motorcycle near a flammable source (e.g. a kerosene heater, or near an open flame), otherwise it could catch fire. 4.
U5FB12.book Page 7 Tuesday, April 9, 2002 11:55 AM SAFETY INFORMATION EAU02977 Location of important labels Please read the following important labels carefully before operating this motorcycle.
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U5FB12.book Page 1 Tuesday, April 9, 2002 11:55 AM DESCRIPTION Left view (XVS650) ............................................................................ 2-1 Right view (XVS650) .......................................................................... 2-2 Left view (XVS650A) .......................................................................... 2-3 Right view (XVS650A)........................................................................ 2-4 Controls and instruments (XVS650/XVS650A) ...........
U5FB12.book Page 1 Tuesday, April 9, 2002 11:55 AM DESCRIPTION EAU00026 2- Left view (XVS650) 2 1. Shift pedal 2. Fuel cock 3. Starter (choke) knob 4. Shock absorber assembly spring preload adjusting ring 5. Helmet holder 6. Storage compartment 7.
U5FB12.book Page 2 Tuesday, April 9, 2002 11:55 AM DESCRIPTION Right view (XVS650) 2 8. Engine oil filter element 9. Battery 10. Fuses (page 6-11) (page 6-31) (page 6-33) 11. Main switch/steering lock 12. Air filter element 13.
U5FB12.book Page 3 Tuesday, April 9, 2002 11:55 AM DESCRIPTION Left view (XVS650A) 2 1. Shift pedal 2. Fuel cock 3. Starter (choke) knob 4. Shock absorber assembly spring preload adjusting ring 5. Helmet holder 6. Storage compartment 7.
U5FB12.book Page 4 Tuesday, April 9, 2002 11:55 AM DESCRIPTION Right view (XVS650A) 2 8. Engine oil filter element 9. Battery 10. Fuses (page 6-11) (page 6-31) (page 6-33) 11. Main switch/steering lock 12. Air filter element 13.
U5FB12.book Page 5 Tuesday, April 9, 2002 11:55 AM DESCRIPTION Controls and instruments (XVS650/XVS650A) 2 1. Clutch lever 2. Left handlebar switches 3. Speedometer unit 4. Fuel tank cap 5. Right handlebar switches 6. Throttle grip 7.
U5FB12.book Page 1 Tuesday, April 9, 2002 11:55 AM INSTRUMENT AND CONTROL FUNCTIONS Main switch/steering lock .................................................................. 3-1 Indicator and warning lights ............................................................. 3-2 Speedometer unit .............................................................................. 3-2 Handlebar switches ........................................................................... 3-3 Clutch lever .......................
U5FB12.book Page 1 Tuesday, April 9, 2002 11:55 AM INSTRUMENT AND CONTROL FUNCTIONS EAU00027 3- 3 EAU00029 Main switch/steering lock The main switch/steering lock controls the ignition and lighting systems, and is used to lock the steering. The various positions are described below. EAU00032 ON All electrical systems are supplied with power, the headlight, meter lighting, taillight and front position lights come on, and the engine can be started. The key cannot be removed.
U5FB12.book Page 2 Tuesday, April 9, 2002 11:55 AM INSTRUMENT AND CONTROL FUNCTIONS EAU00061 Neutral indicator light “ ” This indicator light comes on when the transmission is in the neutral position. EAU04243* 1. 2. 3. 4. Engine trouble warning light “ ” This warning light comes on when an electrical circuit monitoring the engine is defective. When this occurs, have a Yamaha dealer check the self-diagnosis system.
U5FB12.book Page 3 Tuesday, April 9, 2002 11:55 AM INSTRUMENT AND CONTROL FUNCTIONS Since this model is equipped with a self-canceling system, the turn signal lights will self-cancel after the motorcycle 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 center position. 3 1. Dimmer switch “ / 2. Turn signal switch “ 3.
U5FB12.book Page 4 Tuesday, April 9, 2002 11:55 AM INSTRUMENT AND CONTROL FUNCTIONS XVS650 XVS650A 3 1. Clutch lever 1. Shift pedal 1. Shift pedal EAU00152 EAU00157 EAU01215 Clutch lever Shift pedal (XVS650) Shift pedal (XVS650A) The clutch lever is located at the left handlebar grip. To disengage the clutch, pull the lever toward the handlebar grip. To engage the clutch, release the lever. The lever should be pulled rapidly and released slowly for smooth clutch operation.
U5FB12.book Page 5 Tuesday, April 9, 2002 11:55 AM INSTRUMENT AND CONTROL FUNCTIONS XVS650 XVS650A 3 1. Brake lever 1. Brake pedal 1. Brake pedal EAU00158 EAU00162 Brake lever Brake pedal The brake lever is located at the right handlebar grip. To apply the front brake, pull the lever toward the handlebar grip. The brake pedal is on the right side of the motorcycle. To apply the rear brake, press down on the brake pedal.
U5FB12.book Page 6 Tuesday, April 9, 2002 11:55 AM INSTRUMENT AND CONTROL FUNCTIONS 2. Turn the key counterclockwise to the original position, remove it, and then close the lock cover. NOTE: The fuel tank cap cannot be installed unless the key is in the lock. In addition, the key cannot be removed if the cap is not properly installed and locked. _ _ EW000024 EAU03447 Fuel tank cap To remove the fuel tank cap Slide the lock cover open, insert the key into the lock, and then turn it 1/4 turn clockwise.
U5FB12.book Page 7 Tuesday, April 9, 2002 11:55 AM INSTRUMENT AND CONTROL FUNCTIONS EAU00185 CAUTION: Immediately wipe off spilled fuel with a clean, dry, soft cloth, since fuel may deteriorate painted surfaces or plastic parts. @ @ EAU04265 3 Recommended fuel: UNLEADED GASOLINE ONLY Fuel tank capacity: Total amount: 16 L (3.5 Imp gal, 4.2 US gal) Reserve amount: 3 L (0.7 Imp gal, 0.8 US gal) 1. Fuel tank filler tube 2. Fuel level EAU03753 Fuel Make sure that there is sufficient fuel in the tank.
U5FB12.book Page 8 Tuesday, April 9, 2002 11:55 AM INSTRUMENT AND CONTROL FUNCTIONS OFF: closed position ON: normal position RES: reserve position 3 1. Arrow mark positioned over “OFF” EAU02969 Fuel cock The fuel cock supplies fuel from the tank to the carburetors while also filtering it. The fuel cock lever positions are explained as follows and shown in the illustrations. 1. Arrow mark positioned over “ON” 1.
U5FB12.book Page 9 Tuesday, April 9, 2002 11:55 AM INSTRUMENT AND CONTROL FUNCTIONS ECA00038 CAUTION: Do not use the starter (choke) for more than 3 minutes as the exhaust pipe may discolor from excessive heat. In addition, extended use of the starter (choke) will cause afterburning. If this occurs, turn off the starter (choke). XVS650 _ 3 1. Starter (choke) knob “ ” _ 1.
U5FB12.book Page 10 Tuesday, April 9, 2002 11:55 AM INSTRUMENT AND CONTROL FUNCTIONS XVS650 NOTE: Make sure that the seats are properly secured before riding. XVS650 @ @ 3 1. Bolt (× 2) 2. Seat holder 3. Projection To install the passenger seat Insert the projection on the front of the passenger seat into the seat holder as shown, place the seat in the original position, and then install the nut. 1. Seat holder 2. Projection Rider seat To remove the rider seat 1. Remove the passenger seat. 2.
U5FB12.book Page 11 Tuesday, April 9, 2002 11:55 AM INSTRUMENT AND CONTROL FUNCTIONS XVS650A XVS650A XVS650A 3 1. Bolt EAU04188 Seats (XVS650A) Passenger seat To remove the passenger seat Remove the bolt, and then pull the passenger seat up. 1. Seat holder (× 2) 2. Projection (× 2) 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 position, and then install the bolt.
U5FB12.book Page 12 Tuesday, April 9, 2002 11:55 AM INSTRUMENT AND CONTROL FUNCTIONS XVS650A 3 1. Seat holder 2. Projection To install the rider seat 1. Insert the projection on the front of the rider seat into the holder as shown, place the seat in the original position, and then install the bolt. 2. Install the passenger seat. NOTE: Make sure that the seats are properly secured before riding. 1. Helmet holder 2. Unlock.
U5FB12.book Page 13 Tuesday, April 9, 2002 11:55 AM INSTRUMENT AND CONTROL FUNCTIONS 3 1. Storage compartment cover 2. Storage compartment lock cover 3. Storage compartment lock EAU01869 2. Pull the storage compartment cover out as shown. Storage compartment The storage compartment is located on the left side of the motorcycle. To open the storage compartment 1. Slide the lock cover open, insert the key into the lock, and then turn it clockwise. 3-13 1. Storage compartment 2.
U5FB12.book Page 14 Tuesday, April 9, 2002 11:55 AM INSTRUMENT AND CONTROL FUNCTIONS EAU00299 NOTE: ● Align the appropriate notch in the adjusting ring with the position indicator on the shock absorber. ● Use the special wrench and extension bar included in the owner’s tool kit to make the adjustment. Adjusting the shock absorber assembly @ This shock absorber assembly is equipped with a spring preload adjusting ring.
U5FB12.book Page 15 Tuesday, April 9, 2002 11:55 AM INSTRUMENT AND CONTROL FUNCTIONS EAU00315 WARNING This shock absorber contains highly pressurized nitrogen gas. For proper handling, read and understand the following information before handling the shock absorber. The manufacturer cannot be held responsible for property damage or personal injury that may result from improper handling. ● Do not tamper with or attempt to open the gas cylinder.
U5FB12.book Page 16 Tuesday, April 9, 2002 11:55 AM INSTRUMENT AND CONTROL FUNCTIONS EW000044 WARNING The motorcycle must not be ridden with the sidestand down, or if the sidestand 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 responsibility of raising the sidestand before starting off.
U5FB12.book Page 17 Tuesday, April 9, 2002 11:55 AM INSTRUMENT AND CONTROL FUNCTIONS CD-01E With the engine turned off: 1. Move the sidestand down. 2. Make sure that the engine stop switch is set to “ 3. Turn the key to “ON”. 4. Shift the transmission into the neutral position. 5. Push the start switch. Does the engine start? 3 YES NOTE: This check is most reliable if performed with a warmed-up engine. ”. NO The neutral switch may be defective.
U5FB12.book Page 1 Tuesday, April 9, 2002 11:55 AM PRE-OPERATION CHECKS Pre-operation check list .....................................................................
U5FB12.book Page 1 Tuesday, April 9, 2002 11:55 AM PRE-OPERATION CHECKS EAU01114 4- 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.
U5FB12.book Page 2 Tuesday, April 9, 2002 11:55 AM PRE-OPERATION CHECKS ITEM Control cables CHECKS • Make sure that operation is smooth. • Lubricate if necessary. Check for damage. Check tire condition and tread depth. Check air pressure. Correct if necessary. PAGE 6-27 Wheels and tires • • • • Brake and shift pedals • Make sure that operation is smooth. • Lubricate pedal pivoting points if necessary. 6-28 Brake and clutch levers • Make sure that operation is smooth.
U5FB12.book Page 1 Tuesday, April 9, 2002 11:55 AM OPERATION AND IMPORTANT RIDING POINTS Starting and warming up a cold engine ............................................. 5-1 Starting a warm engine ..................................................................... 5-3 Shifting .............................................................................................. 5-3 Engine break-in ................................................................................. 5-5 Parking ...................
U5FB12.book Page 1 Tuesday, April 9, 2002 11:55 AM OPERATION AND IMPORTANT RIDING POINTS EAU00372 5- @ 5 EAU00373 EAU00376 WARNING ● Become thoroughly familiar with all operating controls and their functions before riding. Consult a Yamaha dealer regarding any control or function that you do not thoroughly understand. ● Never start the engine or operate it in a closed area for any length of time.
U5FB12.book Page 2 Tuesday, April 9, 2002 11:55 AM OPERATION AND IMPORTANT RIDING POINTS ECA00101 CAUTION: The engine trouble warning light should come on when the key is turned to “ON”, and then go off after a few seconds. If the engine trouble warning light comes on or flashes after starting, immediately stop the engine, and have a Yamaha dealer check the self-diagnosis system. _ 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 “ ”. 3.
U5FB12.book Page 3 Tuesday, April 9, 2002 11:55 AM OPERATION AND IMPORTANT RIDING POINTS NOTE: The engine is warm when it responds normally to the throttle with the starter (choke) turned off. To avoid the possibility of excessive exhaust emissions, never leave the starter (choke) on longer than necessary. The time necessary for starter (choke) use depends upon the ambient temperature.
U5FB12.book Page 4 Tuesday, April 9, 2002 11:55 AM OPERATION AND IMPORTANT RIDING POINTS ● XVS650A Always use the clutch while changing gears to avoid damaging the engine, transmission, and drive train, which are not designed to withstand the shock of forced shifting. @ 1. Shift pedal N. Neutral position EC000048 @ CAUTION: ● Even with the transmission in the neutral position, do not coast for long periods of time with the engine off, and do not tow the motorcycle for long distances.
U5FB12.book Page 5 Tuesday, April 9, 2002 11:55 AM OPERATION AND IMPORTANT RIDING POINTS 5 EAU00427 EAU02974 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 neutral position when the motorcycle is almost completely stopped.
U5FB12.book Page 6 Tuesday, April 9, 2002 11:55 AM OPERATION AND IMPORTANT RIDING POINTS EAU01171* 0–1,000 km (0–600 mi) Avoid prolonged operation 1/3 throttle. EAU00457 Parking above 1,000–1,600 km (600–1,000 mi) Avoid prolonged operation above 1/2 throttle. When parking, stop the engine, remove the key from the main switch, and then turn the fuel cock lever to “OFF”.
U5FB12.book Page 1 Tuesday, April 9, 2002 11:55 AM PERIODIC MAINTENANCE AND MINOR REPAIR Periodic maintenance ..........................................6-1 Owner’s tool kit ....................................................6-1 Periodic maintenance chart for the emission control system ...................................................6-3 General maintenance and lubrication chart .........6-4 Removing and installing panels ...........................6-7 Checking the spark plugs ..........................
U5FB12.book Page 1 Tuesday, April 9, 2002 11:55 AM PERIODIC MAINTENANCE AND MINOR REPAIR EAU00462 6- EAU01790 Safety is an obligation of the owner. Periodic inspection, adjustment and lubrication will keep your vehicle in the safest and most efficient condition possible. The most important points of motorcycle inspection, adjustment, and lubrication are explained on the following pages.
U5FB12.book Page 2 Tuesday, April 9, 2002 11:55 AM PERIODIC MAINTENANCE AND MINOR REPAIR NOTE: If you do not have the tools or experience required for a particular job, have a Yamaha dealer perform it for you. _ _ EW000062 WARNING Modifications not approved by Yamaha may cause loss of performance, excessive emissions, and render the vehicle unsafe for use. Consult a Yamaha dealer before attempting any changes.
U5FB12.book Page 3 Tuesday, April 9, 2002 11:55 AM PERIODIC MAINTENANCE AND MINOR REPAIR EAU00471 Periodic maintenance chart for the emission control system INITIAL No. ROUTINE 4,000 mi (7,000 km) or 6 months 8,000 mi (13,000 km) or 12 months 12,000 mi (19,000 km) or 18 months 16,000 mi (25,000 km) or 24 months 20,000 mi (31,000 km) or 30 months √ √ √ √ √ √ Valve clearance • Check and adjust valve clearance when engine is cold. 2 Spark plugs • Check condition. • Adjust gap and clean.
U5FB12.book Page 4 Tuesday, April 9, 2002 11:55 AM PERIODIC MAINTENANCE AND MINOR REPAIR EAU00472 General maintenance and lubrication chart INITIAL No. ITEM ROUTINE ODOMETER READINGS 600 mi (1,000 km) or 1 month 4,000 mi (7,000 km) or 6 months 8,000 mi (13,000 km) or 12 months 12,000 mi (19,000 km) or 18 months 16,000 mi (25,000 km) or 24 months 20,000 mi (31,000 km) or 30 months √ √ √ √ √ 1 Engine oil • Replace (warm engine before draining). (See NOTE on page 6-6.
U5FB12.book Page 5 Tuesday, April 9, 2002 11:55 AM PERIODIC MAINTENANCE AND MINOR REPAIR INITIAL No. ITEM ROUTINE 600 mi (1,000 km) or 1 month ODOMETER READINGS 4,000 mi (7,000 km) or 6 months 8,000 mi (13,000 km) or 12 months 12,000 mi (19,000 km) or 18 months 16,000 mi (25,000 km) or 24 months 20,000 mi (31,000 km) or 30 months √ √ √ √ √ 10 * Wheel bearings • Check bearings for looseness or damage. • Replace if necessary. 11 * Swingarm • Check swing arm pivot for play.
U5FB12.book Page 6 Tuesday, April 9, 2002 11:55 AM PERIODIC MAINTENANCE AND MINOR REPAIR INITIAL No. ITEM ROUTINE 600 mi (1,000 km) or 1 month ODOMETER READINGS 4,000 mi (7,000 km) or 6 months 8,000 mi (13,000 km) or 12 months 12,000 mi (19,000 km) or 18 months 16,000 mi (25,000 km) or 24 months 20,000 mi (31,000 km) or 30 months 19 Brake and clutch lever pivot shaft • Apply chain lube lightly. #1 √ √ √ √ √ 20 Brake pedal and shift pedal shaft • Apply chain lube lightly.
U5FB12.book Page 7 Tuesday, April 9, 2002 11:55 AM PERIODIC MAINTENANCE AND MINOR REPAIR XVS650 XVS650A 1. Panel A 1. Panel A 1. Panel B EAU01122 Removing and installing panels 6 The panels shown above 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.
U5FB12.book Page 8 Tuesday, April 9, 2002 11:55 AM PERIODIC MAINTENANCE AND MINOR REPAIR XVS650 XVS650A 1. Bolt (× 4) 1. Bolt (× 4) 1. Screw EAU01573 EAU04807 Panel A To remove the panel Remove the bolts, and then take the panel off. Panel B To remove the panel Remove the screw, and then pull outward on the areas shown. To install the panel Place the panel in the original position, and then install the bolts.
U5FB12.book Page 9 Tuesday, April 9, 2002 11:55 AM PERIODIC MAINTENANCE AND MINOR REPAIR 1. Spark plug cap To install the panel Place the panel in the original position, and then install the screw. 6 1. Spark plug wrench EAU03329 Checking the spark plugs The spark plugs are important engine components, which are easy to check.
U5FB12.book Page 10 Tuesday, April 9, 2002 11:55 AM PERIODIC MAINTENANCE AND MINOR REPAIR NOTE: If any spark plug shows a distinctly different color, the engine could be defective. Do not attempt to diagnose such problems yourself. Instead, have a Yamaha dealer check the motorcycle. Tightening torque: Spark plug: 18 Nm (1.8 m·kgf, 13 ft·lbf) @ @ @ 3. Check each spark plug for electrode erosion and excessive carbon or other deposits, and replace it if necessary.
U5FB12.book Page 11 Tuesday, April 9, 2002 11:55 AM PERIODIC MAINTENANCE AND MINOR REPAIR EAU04612 Left side 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 element replaced at the intervals specified in the periodic maintenance and lubrication chart. To check the engine oil level 1. Place the motorcycle on a level surface and hold it in an upright position. 1. 2. 3. 4. 3.
U5FB12.book Page 12 Tuesday, April 9, 2002 11:55 AM PERIODIC MAINTENANCE AND MINOR REPAIR Right side 1. Engine oil drain bolt 2. Oil pan 1. Oil filter element outer cover 2. Bolt (× 3) To change the engine oil (with or without oil filter element replacement) 1. Start the engine, warm it up for several minutes, and then turn it off. 2. Place an oil pan under the engine to collect the used oil. 3. Remove the engine oil filler cap and drain bolt to drain the oil from the crankcase.
U5FB12.book Page 13 Tuesday, April 9, 2002 11:55 AM PERIODIC MAINTENANCE AND MINOR REPAIR 9. Add the specified amount of the recommended oil, and then install and tighten the oil filler cap. 1. Oil filter element 2. O-ring 6 5. Remove the oil filter element and O-ring. 6. Install a new oil filter element and the O-ring. 7. Install the oil filter element covers by installing the bolts. 8. Install the engine oil drain bolt, and then tighten it to the specified torque.
U5FB12.book Page 14 Tuesday, April 9, 2002 11:55 AM PERIODIC MAINTENANCE AND MINOR REPAIR 2. Remove the oil filler bolt, and then check the oil level in the final gear case. EAU04083 Final gear oil The final gear case must be checked for oil leakage before each ride. If any leakage is found, have a Yamaha dealer check and repair the motorcycle. In addition, the final gear oil level must be checked and the oil changed as follows at the intervals specified in the periodic maintenance and lubrication chart.
U5FB12.book Page 15 Tuesday, April 9, 2002 11:55 AM PERIODIC MAINTENANCE AND MINOR REPAIR 4. Add the recommended final gear oil to the brim of the filler hole. Recommended final gear oil: Hypoid gear oil SAE 80 (API GL4) or multi-grade hypoid gear oil SAE 80W-90 Oil quantity: 0.19 L (0.17 Imp qt, 0.20 US qt) NOTE: GL4 is a quality rating. Hypoid gear oils rated GL5 or GL6 may also be used. 1. Air filter case cover 2. Screw (× 3) 1. Air filter element _ _ 6 5. Install and tighten the oil filler bolt.
U5FB12.book Page 16 Tuesday, April 9, 2002 11:55 AM PERIODIC MAINTENANCE AND MINOR REPAIR EAU00628 Adjusting the carburetors 1. Air filter element holder 2. Projection 3. Slot 4. Insert the air filter element into the air filter case as shown. The carburetors are important parts of the engine and emission control system, which require very sophisticated adjustment. Therefore, all carburetor adjustments should be left to a Yamaha dealer, who has the necessary professional knowledge and experience. 1.
U5FB12.book Page 17 Tuesday, April 9, 2002 11:55 AM PERIODIC MAINTENANCE AND MINOR REPAIR EAU00637 Tires 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. To maximize the performance, durability, and safe operation of your motorcycle, note the following points regarding the specified tires.
U5FB12.book Page 18 Tuesday, April 9, 2002 11:55 AM PERIODIC MAINTENANCE AND MINOR REPAIR XVS650 EW000083 Tire air pressure (measured on cold tires) Load* Front @ Rear Up to 90 kg (198 lb) 200 kPa 225 kPa (2.00 kgf/cm2, (2.25 kgf/cm2, 29 psi) 33 psi) 90 kg (198 lb)– maximum 200 kPa 250 kPa (2.00 kgf/cm2, (2.
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U5FB12.book Page 20 Tuesday, April 9, 2002 11:55 AM PERIODIC MAINTENANCE AND MINOR REPAIR EAU00691 Accessories and replacement parts EW000098 ble for any consequences caused by the use of items which have not been approved by Yamaha. @ WARNING This motorcycle is not designed to pull a trailer or to be attached to a sidecar.
U5FB12.book Page 21 Tuesday, April 9, 2002 11:55 AM PERIODIC MAINTENANCE AND MINOR REPAIR 7. Tighten the locknut at the clutch lever and the crankcase. 1. Locknut 2. Clutch lever free play adjusting bolt c. Clutch lever free play 1. Clutch lever free play adjusting nut 2. Locknut EAU00694 6 Adjusting the clutch lever free play The clutch lever free play should measure 10–15 mm (0.39–0.59 in) [XVS650] or 5–10 mm (0.20–0.39 in) [XVS650A] as shown.
U5FB12.book Page 22 Tuesday, April 9, 2002 11:55 AM PERIODIC MAINTENANCE AND MINOR REPAIR EW000099 @ a. Brake lever free play EAU00696 Adjusting the brake lever free play The brake lever free play should measure 10–15 mm (0.39–0.59 in) as shown. Periodically check the brake lever free play and, if necessary, adjust it as follows. 1. Locknut 2. Brake lever free play adjusting bolt 1. Loosen the locknut at the brake lever. 2. To increase the brake lever free play, turn the adjusting bolt in direction a.
U5FB12.book Page 23 Tuesday, April 9, 2002 11:55 AM PERIODIC MAINTENANCE AND MINOR REPAIR XVS650 XVS650A a. Distance between brake pedal and footrest b. Brake pedal free play EAU00711 Adjusting the brake pedal position and free play 6 EW000104 WARNING It is advisable to have a Yamaha dealer make these adjustments. @ a. Distance between brake pedal and footrest b. Brake pedal free play 1. Locknut 2. Brake pedal position adjusting bolt 1. Loosen the locknut at the brake pedal. 2.
U5FB12.book Page 24 Tuesday, April 9, 2002 11:55 AM PERIODIC MAINTENANCE AND MINOR REPAIR 1. Brake pedal free play adjusting nut Brake pedal free play The brake pedal free play should measure 20–30 mm (0.79–1.18 in) at the brake pedal end. Periodically check the brake pedal free play and, if necessary, adjust it as follows. To increase the brake pedal free play, turn the adjusting nut at the brake rod in direction a. To decrease the brake pedal free play, turn the adjusting nut in direction b. 1.
U5FB12.book Page 25 Tuesday, April 9, 2002 11:55 AM PERIODIC MAINTENANCE AND MINOR REPAIR EAU00720 Checking the front brake pads and rear brake shoes Front Rear The front brake pads and the rear brake shoes must be checked for wear at the intervals specified in the periodic maintenance and lubrication chart. 1.
U5FB12.book Page 26 Tuesday, April 9, 2002 11:55 AM PERIODIC MAINTENANCE AND MINOR REPAIR Observe these precautions: ● When checking the fluid level, make sure that the top of the brake fluid reservoir is level. ● Use only the recommended quality brake fluid, otherwise the rubber seals may deteriorate, causing leakage and poor braking performance. 1.
U5FB12.book Page 27 Tuesday, April 9, 2002 11:55 AM PERIODIC MAINTENANCE AND MINOR REPAIR EAU03985 Changing the brake fluid 6 Have a Yamaha dealer change the brake fluid at the intervals specified in the NOTE after the periodic maintenance 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 damaged or leaking. ● Oil seals: Replace every two years.
U5FB12.book Page 28 Tuesday, April 9, 2002 11:55 AM PERIODIC MAINTENANCE AND MINOR REPAIR EAU03370 EAU03164 Checking and lubricating the brake and shift pedals Checking and lubricating the brake and clutch levers The operation of the brake and shift pedals should be checked before each ride, and the pedal pivots should be lubricated if necessary. The operation of the brake and clutch levers should be checked before each ride, and the lever pivots should be lubricated if necessary.
U5FB12.book Page 29 Tuesday, April 9, 2002 11:55 AM PERIODIC MAINTENANCE AND MINOR REPAIR EAU02939 Recommended lubricant: Lithium-soap-based grease (all-purpose grease) Checking the front fork The condition and operation of the front fork must be checked as follows at the intervals specified in the periodic maintenance and lubrication chart. To check the condition EW000115 WARNING Securely support the motorcycle so that there is no danger of it falling over.
U5FB12.book Page 30 Tuesday, April 9, 2002 11:55 AM PERIODIC MAINTENANCE AND MINOR REPAIR EAU00794 Checking the steering To check the operation 1. Place the motorcycle on a level surface and hold it in an upright position. 2. While applying the front brake, push down hard on the handlebars several times to check if the front fork compresses and rebounds smoothly. Worn or loose steering bearings may cause danger.
U5FB12.book Page 31 Tuesday, April 9, 2002 11:55 AM PERIODIC MAINTENANCE AND MINOR REPAIR EAU01144 • EXTERNAL: Flush with plenty of water. • INTERNAL: Drink large quantities of water or milk and immediately call a physician. • EYES: Flush with water for 15 minutes and seek prompt medical attention. ● Batteries produce explosive hydrogen gas. Therefore, keep sparks, flames, cigarettes, etc., away from the battery and provide sufficient ventilation when charging it in an enclosed space.
U5FB12.book Page 32 Tuesday, April 9, 2002 11:55 AM PERIODIC MAINTENANCE AND MINOR REPAIR To charge the battery Have a Yamaha dealer charge the battery as soon as possible if it seems to have discharged. Keep in mind that the battery tends to discharge more quickly if the motorcycle is equipped with optional electrical accessories. To store the battery 1. If the motorcycle will not be used for more than one month, remove the battery, fully charge it, and then place it in a cool, dry place. 2.
U5FB12.book Page 33 Tuesday, April 9, 2002 11:55 AM PERIODIC MAINTENANCE AND MINOR REPAIR EC000103 CAUTION: Do not use a fuse of a higher amperage rating than recommended to avoid causing extensive damage to the electrical system and possibly a fire. _ _ 1. Fuse box 2. Main fuse 3. Spare main fuse EAU04190* Replacing the fuses 6 The main fuse and the fuse box, which contains the fuses for the individual circuits, are located behind panel B. (See page 6-8 for panel removal and installation procedures.
U5FB12.book Page 34 Tuesday, April 9, 2002 11:55 AM PERIODIC MAINTENANCE AND MINOR REPAIR 1. Screw (× 2) EAU04189 Replacing the headlight bulb This motorcycle is equipped with a quartz bulb headlight. If the headlight bulb burns out, replace it as follows. 1. Remove the headlight unit by removing the screws. 1. Headlight coupler 2. Headlight bulb cover 1. Headlight bulb holder 3. Unhook the headlight bulb holder, and then remove the defective bulb. 2.
U5FB12.book Page 35 Tuesday, April 9, 2002 11:55 AM PERIODIC MAINTENANCE AND MINOR REPAIR EC000105 CAUTION: Do not touch the glass part of the headlight bulb to keep it free from oil, otherwise the transparency of the glass, the luminosity of the bulb, and the bulb life will be adversely affected. Thoroughly clean off any dirt and fingerprints on the headlight bulb using a cloth moistened with alcohol or thinner. XVS650 _ _ 6 5. Install the headlight bulb cover, and then connect the coupler. 6.
U5FB12.book Page 36 Tuesday, April 9, 2002 11:55 AM PERIODIC MAINTENANCE AND MINOR REPAIR EAU01579 XVS650A Supporting the motorcycle 1. Screw (× 3) 4. Install the lens by installing the screws. 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 upright. Check that the motorcycle is in a stable and level position before starting any maintenance.
U5FB12.book Page 37 Tuesday, April 9, 2002 11:55 AM PERIODIC MAINTENANCE AND MINOR REPAIR 1. Speedometer cable EAU03737 Front wheel 1. Rubber cap 2. Wheel axle 3. Front wheel axle pinch bolt EW000122 _ EAU04352 2. Loosen the front wheel axle pinch bolt. 3. Remove the rubber cap, and then loosen the wheel axle. 4. Lift the front wheel off the ground according to the procedure on page 6-36. 5. Pull the wheel axle out, and then remove the wheel. To remove the front wheel 6 1. Speedometer gear unit 2.
U5FB12.book Page 38 Tuesday, April 9, 2002 11:55 AM PERIODIC MAINTENANCE AND MINOR REPAIR 5. Tighten the wheel axle and front wheel axle pinch bolt to the specified torques, and then install the rubber cap. Tightening torques: Wheel axle: 59 Nm (5.9 m·kgf, 43 ft·lbf) Front wheel axle pinch bolt: 20 Nm (2.0 m·kgf, 14 ft·lbf) 1. Axle nut EAU01350 6. While applying the front brake, push down hard on the handlebars several times to check if the front fork compresses and rebounds smoothly. 7.
U5FB12.book Page 39 Tuesday, April 9, 2002 11:55 AM PERIODIC MAINTENANCE AND MINOR REPAIR 1. Bolt (× 4) 2. Final gear case 6. Remove the bolts that secure the final gear case to the swingarm. 7. Lift the rear wheel off the ground according to the procedure on page 6-36. 8. While supporting the drive shaft, pull the rear wheel back to remove the following parts as an assembly: wheel, wheel axle, final gear case, and drive shaft. 6 1. Middle gear universal joint 2.
U5FB12.book Page 40 Tuesday, April 9, 2002 11:55 AM PERIODIC MAINTENANCE AND MINOR REPAIR EW000103 WARNING After adjusting the brake pedal free play, check the operation of the brake light. _ _ EAU01008 Troubleshooting Although Yamaha motorcycles receive a thorough inspection before shipment from the factory, trouble may occur during operation. Any problem in the fuel, compression, or ignition systems, for example, can cause poor starting and loss of power.
U5FB12.book Page 41 Tuesday, April 9, 2002 11:55 AM PERIODIC MAINTENANCE AND MINOR REPAIR EAU01297 Troubleshooting chart EW000125 WARNING Keep away open flames and do not smoke while checking or working on the fuel system. @ @ 1. Fuel There is enough fuel. Check the compression. There is no fuel. Supply fuel. There is compression. Check the ignition. There is no compression. Have a Yamaha dealer check the vehicle. Check the fuel level in the fuel tank. The engine does not start.
U5FB12.book Page 1 Tuesday, April 9, 2002 11:55 AM MOTORCYCLE CARE AND STORAGE Care .................................................................................................. 7-1 Storage ..............................................................................................
U5FB12.book Page 1 Tuesday, April 9, 2002 11:55 AM MOTORCYCLE CARE AND STORAGE EAU03412 7- Care While the open design of a motorcycle reveals the attractiveness of the technology, it also makes it more vulnerable. Rust and corrosion can develop even if high-quality components are used. A rusty exhaust pipe may go unnoticed on a car, however, it detracts from the overall appearance of a motorcycle.
U5FB12.book Page 2 Tuesday, April 9, 2002 11:55 AM MOTORCYCLE CARE AND STORAGE ● Do not use any harsh chemical products on plastic parts. Be sure to avoid using cloths or sponges which have been in contact with strong or abrasive cleaning products, solvent or thinner, fuel (gasoline), rust removers or inhibitors, brake fluid, antifreeze or electrolyte.
U5FB12.book Page 3 Tuesday, April 9, 2002 11:55 AM MOTORCYCLE CARE AND STORAGE 7 After cleaning 1. Dry the motorcycle with a chamois or an absorbing cloth. 2. Use a chrome polish to shine chrome, aluminum and stainlesssteel parts, including the exhaust system. (Even the thermally induced discoloring of stainlesssteel exhaust systems can be removed through polishing.) 3.
U5FB12.book Page 4 Tuesday, April 9, 2002 11:55 AM MOTORCYCLE CARE AND STORAGE Storage Short-term Always store your motorcycle in a cool, dry place and, if necessary, protect it against dust with a porous cover. ECA00014 @ @ CAUTION: ● Storing the motorcycle in a poorly ventilated room or covering it with a tarp, while it is still wet, will allow water and humidity to seep in and cause rust.
U5FB12.book Page 5 Tuesday, April 9, 2002 11:55 AM MOTORCYCLE CARE AND STORAGE 7 6. Lubricate all control cables and the pivoting points of all levers and pedals as well as of the sidestand/ 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. Alternatively, turn the wheels a little every month in order to prevent the tires from becoming degraded in one spot. 8.
U5FB12.book Page 1 Tuesday, April 9, 2002 11:55 AM SPECIFICATIONS Specifications ....................................................................................
U5FB12.book Page 1 Tuesday, April 9, 2002 11:55 AM SPECIFICATIONS EAU01038 8- Specifications CS-01E Model XVS650(C)/XVS650A(C) Engine Dimensions XVS650(C) Overall length Overall width Overall height 2,340 mm (92.1 in) 880 mm (34.6 in) 1,070 mm (42.1 in) Seat height 695 mm (27.4 in) Wheelbase 1,610 mm (63.4 in) Ground clearance Minimum turning radius 140 mm (5.
U5FB12.book Page 2 Tuesday, April 9, 2002 11:55 AM SPECIFICATIONS Spark plug CAUTION: In order to prevent clutch slippage (since the engine oil also lubricates the clutch), do not mix any chemical additives. Do not use oils with a diesel specification of “CD” or oils of a higher quality than specified. In addition, do not use oils labeled “ENERGY CONSERVING II” or higher. 2.6 L (2.3 lmp qt, 2.8 US qt) With oil filter element replacement 2.8 L (2.5 lmp qt, 3.0 US qt) Total amount (dry engine) 3.
U5FB12.book Page 3 Tuesday, April 9, 2002 11:55 AM SPECIFICATIONS Tires XVS650(C) XVS650A(C) Front Front Type Type Tube tire Size 100/90-19 57S Manufacturer/model Bridgestone / L309 Size Manufacturer/model Rear Rear Type Size 170/80-15 M/C 77S Manufacturer/model 180 kg (397 lb) 200 kg (441 lb) Tire air pressure (measured on cold tires) Up to 90 kg (198 lb)* 2 Front 200 kPa (2.00 kgf/cm , 29 psi) Rear 225 kPa (2.25 kgf/cm2, 33 psi) Front 225 kPa (2.
U5FB12.book Page 4 Tuesday, April 9, 2002 11:55 AM SPECIFICATIONS Wheels XVS650(C) Suspension Front Type Spoke wheel Size 19 × MT2.50 Rear Spoke wheel Size 15 M/C × MT3.50 Telescopic fork Rear Swingarm (monocross) Spring/shock absorber 19 M/C × MT2.50 Type Front Front Coil spring / oil damper Rear Coil spring / gas-oil damper Wheel travel XVS650(C) XVS650A(C) Front Front 140 mm (5.5 in) Rear 86 mm (3.4 in) XVS650A(C) Type Spoke wheel Front 140 mm (5.5 in) Size 16 × MT3.
U5FB12.book Page 5 Tuesday, April 9, 2002 11:55 AM SPECIFICATIONS Bulb voltage, wattage × quantity Headlight 12 V, 60/55 W × 1 Tail/brake light 12 V, 8/27 W × 1 Front turn signal/ position light 12 V, 27/8 W × 2 Rear turn signal light 12 V, 27 W × 2 Meter lighting 12 V, 1.7 W × 1 Neutral indicator light 12 V, 1.7 W × 1 High beam indicator light 12 V, 1.7 W × 1 Turn signal indicator light 12 V, 1.7 W × 1 Engine trouble warning light 12 V, 1.
U5FB12.book Page 1 Tuesday, April 9, 2002 11:55 AM CONSUMER INFORMATION Identification numbers ....................................................................... 9-1 Key identification number .................................................................. 9-1 Vehicle identification number ............................................................. 9-1 Model label ........................................................................................ 9-2 Reporting safety defects .................
U5FB12.book Page 1 Tuesday, April 9, 2002 11:55 AM CONSUMER INFORMATION EAU01039 9- EAU02944 Identification numbers Record the key identification number, vehicle identification number and model label information in the spaces provided below for assistance when ordering spare parts from a Yamaha dealer or for reference in case the vehicle is stolen. 1. Key identification number 1. KEY IDENTIFICATION NUMBER: CA-02E 2.
U5FB12.book Page 2 Tuesday, April 9, 2002 11:55 AM CONSUMER INFORMATION 1. Model label EAU01804 Model label The model label is affixed to the frame under the rider seat. (See page 3-10 [XVS650] or 3-11 [XVS650A] for rider seat removal and installation procedures.) Record the information on this label in the space provided. This information will be needed when ordering spare parts from a Yamaha dealer.
U5FB12.book Page 3 Tuesday, April 9, 2002 11:55 AM CONSUMER INFORMATION EAU01051 Reporting safety defects If you believe that your vehicle has a defect which could cause a crash or could cause injury or death, you should immediately inform the National Highway Traffic Safety Administration (NHTSA) in addition to notifying Yamaha Motor Corporation, U.S.A.
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U5FB12.book Page 5 Tuesday, April 9, 2002 11:55 AM CONSUMER INFORMATION EAU01874 Maintenance record Copies of work orders and/or receipts for parts purchased and installed on your motorcycle will be required to document that maintenance has been completed in accordance with the emissions warranty. The chart below is printed only as a reminder that maintenance work is required. It is not acceptable proof of maintenance work.
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U5FB12.book Page 7 Tuesday, April 9, 2002 11:55 AM CONSUMER INFORMATION EAU02918 YAMAHA MOTOR CORPORATION, U.S.A.
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U5FB12.book Page 9 Tuesday, April 9, 2002 11:55 AM CONSUMER INFORMATION EAU01063 YAMAHA EXTENDED SERVICE (Y.E.S.
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U5FB12.book Page 1 Tuesday, April 9, 2002 11:55 AM INDEX 10- A E M Accessories and replacement parts .......6-20 Air filter element, cleaning ......................6-15 Engine break-in ....................................... 5-5 Engine oil and oil filter element .............. 6-11 Engine stop switch................................... 3-3 Engine trouble warning light .................... 3-2 Main switch/steering lock .........................3-1 Maintenance and lubrication, periodic ......
U5FB12.book Page 2 Tuesday, April 9, 2002 11:55 AM INDEX Shift pedal (XVS650) ............................... 3-4 Shift pedal (XVS650A)............................. 3-4 Shock absorber assembly, adjusting ..... 3-14 Sidestand .............................................. 3-15 Sidestand, checking and lubricating....... 6-29 Spark plugs, checking ............................. 6-9 Specifications .......................................... 8-1 Speedometer unit ....................................
OWNER’S MANUAL XVS650R(C) XVS650AR(C) YAMAHA MOTOR CO., LTD. PRINTED ON RECYCLED PAPER PRINTED IN JAPAN 2002.03-4.
