OWNER’S MANUAL XVS650S XVS650AS XVS650ATS YAMAHA MOTOR CO., LTD. PRINTED ON RECYCLED PAPER PRINTED IN JAPAN 2003.05-2.
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5FB13.book Page 1 Monday, May 12, 2003 5:20 PM INTRODUCTION EAU10080 Congratulations on your purchase of the Yamaha XVS650/XVS650A/XVS650AT. 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.
5FB13.book Page 1 Monday, May 12, 2003 5:20 PM IMPORTANT MANUAL INFORMATION EAU10130 Particularly important information is distinguished in this manual by the following notations: The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR SAFETY IS INVOLVED! WARNING Failure to follow WARNING instructions could result in severe injury or death to the motorcycle operator, a bystander or a person inspecting or repairing the motorcycle.
FB13.book Page 2 Monday, May 12, 2003 5:20 PM IMPORTANT MANUAL INFORMATION EAU10191 AFFIX DEALER LABEL HERE XVS650S/XVS650AS/XVS650ATS OWNER’S MANUAL ©2003 by Yamaha Motor Corporation, U.S.A. 1st edition, April 2003 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.
5FB13.book Page 1 Monday, May 12, 2003 5:20 PM TABLE OF CONTENTS SAFETY INFORMATION ..................1-1 Location of important labels ............1-5 DESCRIPTION ..................................2-1 Left view ..........................................2-1 Right view ........................................2-3 Controls and instruments.................2-5 INSTRUMENT AND CONTROL FUNCTIONS .......................................3-1 Main switch/steering lock ................3-1 Indicator and warning lights ...
5FB13.book Page 2 Monday, May 12, 2003 5:20 PM TABLE OF CONTENTS Checking the wheel bearings .......6-28 Battery ..........................................6-28 Replacing the fuses ......................6-29 Replacing the headlight bulb ........6-30 Replacing a turn signal light bulb or the tail/brake light bulb ..........6-32 Supporting the motorcycle ............6-32 Front wheel ...................................6-33 Rear wheel ...................................6-34 Troubleshooting .....................
5FB13.book Page 1 Monday, May 12, 2003 5:20 PM SAFETY INFORMATION EAU10250 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: ● OBTAIN THOROUGH INSTRUCTIONS FROM A COMPETENT SOURCE ON ALL ASPECTS OF MOTORCYCLE OPERATION.
5FB13.book Page 2 Monday, May 12, 2003 5:20 PM SAFETY INFORMATION ● ● wide on a turn due to EXCESSIVE SPEED or undercornering (insufficient lean angle for the speed). • Always obey the speed limit and never travel faster than warranted by road and traffic conditions. • Always signal before turning or changing lanes. Make sure that other motorists can see you. The posture of the operator and passenger is important for proper control.
5FB13.book Page 3 Monday, May 12, 2003 5:20 PM SAFETY INFORMATION 1 Loading The total weight of the operator, passenger, accessories and cargo must not exceed the maximum load limit of XVS650 180.0 kg (397 lb) XVS650A 200.0 kg (441 lb) XVS650AT 200.0 kg (441 lb). 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.
5FB13.book Page 4 Monday, May 12, 2003 5:20 PM SAFETY INFORMATION Gasoline and exhaust gas ● GASOLINE IS HIGHLY FLAMMABLE: • Always turn the engine off when refueling. • Take care not to spill any gasoline on the engine or exhaust system when refueling. • Never refuel while smoking or in the vicinity of an open flame. ● Never start the engine or let it run for any length of time in a closed area. The exhaust fumes are poisonous and may cause loss of consciousness and death within a short time.
5FB13.book Page 5 Monday, May 12, 2003 5:20 PM SAFETY INFORMATION EAU10381 Location of important labels Please read the following important labels carefully before operating this vehicle.
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5FB13.book Page 1 Monday, May 12, 2003 5:20 PM DESCRIPTION EAU32220 Left view XVS650 2 1. 2. 3. 4. 5. 6. 7.
5FB13.book Page 2 Monday, May 12, 2003 5:20 PM DESCRIPTION XVS650A/AT 2 1. 2. 3. 4. 5. 6. 7.
5FB13.book Page 3 Monday, May 12, 2003 5:20 PM DESCRIPTION EAU32230 Right view XVS650 2 1. 2. 3. 4. 5. 6.
5FB13.book Page 4 Monday, May 12, 2003 5:20 PM DESCRIPTION XVS650A/AT 2 1. 2. 3. 4. 5. 6.
5FB13.book Page 5 Monday, May 12, 2003 5:20 PM DESCRIPTION EAU10430 Controls and instruments XVS650/A/AT 2 1. 2. 3. 4. 5. 6. 7.
5FB13.book Page 1 Monday, May 12, 2003 5:20 PM INSTRUMENT AND CONTROL FUNCTIONS EAU10460 Main switch/steering lock EAU10680 LOCK The steering is locked, and all electrical systems are off. The key can be removed. To unlock the steering To lock the steering 3 1. Push. 2. Turn. The main switch/steering lock controls the ignition and lighting systems, and is used to lock the steering. The various positions are described below.
5FB13.book Page 2 Monday, May 12, 2003 5:20 PM INSTRUMENT AND CONTROL FUNCTIONS EAU11001 Indicator and warning lights EAU11080 High beam indicator light “ ” This indicator light comes on when the high beam of the headlight is switched on. EAU11630 Speedometer unit EAU11490 Engine trouble warning light “ ” This warning light comes on or flashes when an electrical circuit monitoring the engine is defective. When this occurs, have a Yamaha dealer check the selfdiagnosis system. 3 1. 2. 3. 4.
5FB13.book Page 3 Monday, May 12, 2003 5:20 PM INSTRUMENT AND CONTROL FUNCTIONS EAU12341 Handlebar switches Left EAU12400 Dimmer switch “ / ” Set this switch to “ ” for the high beam and to “ ” for the low beam. EAU12500 Horn switch “ ” Press this switch to sound the horn. EAU12660 EAU12430 Turn signal switch “ / ” To signal a right-hand turn, push this switch to “ ”. To signal a left-hand turn, push this switch to “ ”. When released, the switch returns to the center position.
5FB13.book Page 4 Monday, May 12, 2003 5:20 PM INSTRUMENT AND CONTROL FUNCTIONS EAU12820 EAU12870 Shift pedal (XVS650A/AT) EAU12880 Clutch lever Shift pedal (XVS650) 1. Clutch lever 1. Shift pedal 1. Shift pedal 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.
5FB13.book Page 5 Monday, May 12, 2003 5:20 PM INSTRUMENT AND CONTROL FUNCTIONS EAU12890 Brake lever EAU12941 Brake pedal EAU32480 Fuel tank cap XVS650 3 1. Brake lever The brake lever is located at the right handlebar grip. To apply the front brake, pull the lever toward the handlebar grip. 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. 1.
5FB13.book Page 6 Monday, May 12, 2003 5:20 PM INSTRUMENT AND CONTROL FUNCTIONS EAU13210 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. Fuel ECA10070 CAUTION: Immediately wipe off spilled fuel with a clean, dry, soft cloth, since fuel may deteriorate painted surfaces or plastic parts. EWA10130 WARNING 3 EAU13300 Make sure that the fuel tank cap is properly installed before riding. 1.
5FB13.book Page 7 Monday, May 12, 2003 5:20 PM INSTRUMENT AND CONTROL FUNCTIONS knocking (or pinging) occurs, use a gasoline of a different brand or premium unleaded fuel. Use of unleaded fuel will extend spark plug life and reduce maintenance costs. Gasohol There are two types of gasohol: gasohol containing ethanol and that containing methanol. Gasohol containing ethanol can be used if the ethanol content does not exceed 10%.
5FB13.book Page 8 Monday, May 12, 2003 5:20 PM INSTRUMENT AND CONTROL FUNCTIONS This indicates reserve. With the fuel cock lever in this position, the fuel reserve is made available. Turn the fuel cock lever to this position if you run out of fuel while riding.
5FB13.book Page 9 Monday, May 12, 2003 5:20 PM INSTRUMENT AND CONTROL FUNCTIONS EAU14190 Seats (XVS650A/AT) Passenger seat To remove the passenger seat Remove the bolt, and then pull the passenger seat up. 3 1. Bolt 2. Seat holder 3. Projection Rider seat To remove the rider seat 1. Remove the passenger seat. 2. Remove the bolts, and then pull the seat up. 1. Seat bracket 2. Projection To install the rider seat 1.
5FB13.book Page 10 Monday, May 12, 2003 5:20 PM INSTRUMENT AND CONTROL FUNCTIONS 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. EAU14280 Helmet holder 3 1. Seat holder 2. Projection 1. Helmet holder 2. Unlock. Rider seat To remove the rider seat 1. Remove the passenger seat. 2. Remove the bolt, and then pull the rider seat up. 1. Seat holder 2. Projection 2.
5FB13.book Page 11 Monday, May 12, 2003 5:20 PM INSTRUMENT AND CONTROL FUNCTIONS 2. Turn the key counterclockwise, remove it, and then close the lock cover. 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. 3 2. Pull the storage compartment cover out as shown. 1. Storage compartment cover 2. Storage compartment lock cover 3.
5FB13.book Page 12 Monday, May 12, 2003 5:20 PM INSTRUMENT AND CONTROL FUNCTIONS EAU14860 Adjusting the shock absorber assembly 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. 3 1. 2. 3. 4. 2. To increase the spring preload and thereby harden the suspension, turn the adjusting ring in direction (a).
5FB13.book Page 13 Monday, May 12, 2003 5:20 PM INSTRUMENT AND CONTROL FUNCTIONS EAU15150 Luggage strap holders 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. 1. Luggage strap holder There is a luggage strap holder on each passenger footrest. NOTE: The built-in sidestand switch is part of the ignition circuit cut-off system, which cuts the ignition in certain situations.
5FB13.book Page 14 Monday, May 12, 2003 5:20 PM INSTRUMENT AND CONTROL FUNCTIONS EAU15311 Ignition circuit cut-off system 3 The ignition circuit cut-off system (comprising the sidestand switch, clutch switch and neutral switch) has the following functions. ● It prevents starting when the transmission is in gear and the sidestand is up, but the clutch lever is not pulled. ● It prevents starting when the transmission is in gear and the clutch lever is pulled, but the sidestand is still down.
5FB13.book Page 15 Monday, May 12, 2003 5:20 PM INSTRUMENT AND CONTROL FUNCTIONS 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? YES NOTE: This check is most reliable if performed with a warmed-up engine. NO The neutral switch may be defective. The motorcycle should not be ridden until checked by a Yamaha dealer.
5FB13.book Page 1 Monday, May 12, 2003 5:20 PM 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 inspection, to check the following points before each ride.
5FB13.book Page 2 Monday, May 12, 2003 5:20 PM PRE-OPERATION CHECKS EAU15601 Pre-operation check list ITEM CHECKS PAGE Fuel • Check fuel level in fuel tank. • Refuel if necessary. • Check fuel line for leakage. 3-6 Engine oil • Check oil level in engine. • If necessary, add recommended oil to specified level. • Check vehicle for oil leakage. 6-11 Final gear oil • Check vehicle for oil leakage. 6-13 Front brake • • • • • • • • • Rear brake • Check operation. • Check pedal free play.
5FB13.book Page 3 Monday, May 12, 2003 5:20 PM PRE-OPERATION CHECKS ITEM CHECKS Wheels and tires • • • • Brake and shift pedals • Make sure that operation is smooth. • Lubricate pedal pivoting points if necessary. 6-25 Brake and clutch levers • Make sure that operation is smooth. • Lubricate lever pivoting points if necessary. 6-26 Sidestand • Make sure that operation is smooth. • Lubricate pivot if necessary.
5FB13.book Page 1 Monday, May 12, 2003 5:20 PM OPERATION AND IMPORTANT RIDING POINTS EAU15950 EWA10270 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. Exhaust fumes are poisonous, and inhaling them can cause loss of consciousness and death within a short time.
5FB13.book Page 2 Monday, May 12, 2003 5:20 PM OPERATION AND IMPORTANT RIDING POINTS after starting, immediately stop the engine, and have a Yamaha dealer check the self-diagnosis system. (choke) turned on, then about 2.5 minutes with the starter (choke) in the halfway position. 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! 5 7.
5FB13.book Page 3 Monday, May 12, 2003 5:20 PM OPERATION AND IMPORTANT RIDING POINTS EAU16671 Shifting XVS650 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 illustration. NOTE: To shift the transmission into the neutral position, press the shift pedal down repeatedly until it reaches the end of its travel, and then slightly raise it. 1. Shift pedal 2. Neutral position XVS650A/AT 1.
5FB13.book Page 4 Monday, May 12, 2003 5:20 PM OPERATION AND IMPORTANT RIDING POINTS EAU16841 NOTE: Always shift gears at the recommended shift points. EAU16700 5 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.
5FB13.book Page 5 Monday, May 12, 2003 5:20 PM OPERATION AND IMPORTANT RIDING POINTS ECA10331 EAU17170 CAUTION: Parking After 1000 km (600 mi) of operation, the engine oil and final gear oil must be changed, and the oil filter cartridge or element replaced. When parking, stop the engine, remove the key from the main switch, and then turn the fuel cock lever to “OFF”. 1600 km (1000 mi) and beyond The vehicle can now be operated normally.
5FB13.book Page 1 Monday, May 12, 2003 5:20 PM PERIODIC MAINTENANCE AND MINOR REPAIR EAU17231 EAU17300 PERIODIC MAINTENANCE 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.
5FB13.book Page 2 Monday, May 12, 2003 5:20 PM PERIODIC MAINTENANCE AND MINOR REPAIR EWA10340 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.
chapter6 Page 3 Wednesday, June 4, 2003 5:29 PM PERIODIC MAINTENANCE AND MINOR REPAIR EAU17600 Periodic maintenance chart for the emission control system INITIAL No. 6 ITEM ROUTINE 1 * Fuel line • Check fuel hose for cracks or damage. • Replace if necessary. 2 * Fuel filter • Replace. 3 Spark plugs • Check condition. • Adjust gap and clean. • Replace every 8000 mi (13000 km) or 12 months. 4 * Valve clearance • Check and adjust valve clearance when engine is cold.
5FB13.book Page 4 Monday, May 12, 2003 5:20 PM PERIODIC MAINTENANCE AND MINOR REPAIR EAU32181 General maintenance and lubrication chart INITIAL No. ITEM ROUTINE 600 mi (1000 km) or 1 month ODOMETER READINGS 4000 mi (7000 km) or 6 months 8000 mi 12000 mi 16000 mi 20000 mi (13000 km) (19000 km) (25000 km) (31000 km) or or or or 12 months 18 months 24 months 30 months 1 * Air filter element • Clean with compressed air. • Replace if necessary. 2 * Clutch • Check operation.
5FB13.book Page 5 Monday, May 12, 2003 5:20 PM PERIODIC MAINTENANCE AND MINOR REPAIR INITIAL No. ITEM ROUTINE Swingarm pivot bearings • Check bearing assemblies for looseness. • Moderately repack with lithiumsoap-based grease. 10 * Steering bearings • Check bearing assembly for looseness. • Moderately repack with lithiumsoap-based grease every 16000 mi (25000 km) or 24 months.
5FB13.book Page 6 Monday, May 12, 2003 5:20 PM PERIODIC MAINTENANCE AND MINOR REPAIR INITIAL No. ITEM ROUTINE 600 mi (1000 km) or 1 month 4000 mi (7000 km) or 6 months √ 18 Engine oil • Change (warm engine before draining). √ 19 Engine oil filter element • Replace. √ 20 Final gear oil • Check oil level and for oil leakage. • Change at initial 600 mi (1000 km) or 1 month, and thereafter every 16000 mi (25000 km) or 24 months.
5FB13.book Page 7 Monday, May 12, 2003 5:20 PM PERIODIC MAINTENANCE AND MINOR REPAIR EAU17620 NOTE: ● The air filter needs more frequent service if you are riding in unusually wet or dusty areas. ● Hydraulic brake system • When disassembling the master cylinder or caliper cylinder, always replace the brake fluid. Check the brake fluid level regularly and fill as required. • Replace the oil seals on the inner parts of the master cylinder and caliper cylinder every two years.
5FB13.book Page 8 Monday, May 12, 2003 5:20 PM PERIODIC MAINTENANCE AND MINOR REPAIR XVS650 EAU18770 Removing and installing panels XVS650 1. Panel B 1. Bolt 1. Panel A XVS650A/AT 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. To install the panel Place the panel in the original position, and then install the bolts.
5FB13.book Page 9 Monday, May 12, 2003 5:20 PM PERIODIC MAINTENANCE AND MINOR REPAIR EAU19271 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 screw. EAU19543 Checking the spark plugs The spark plugs are important engine components, which are easy to check.
5FB13.book Page 10 Monday, May 12, 2003 5:20 PM PERIODIC MAINTENANCE AND MINOR REPAIR 3. Check each spark plug for electrode erosion and excessive carbon or other deposits, and replace it if necessary. Specified spark plug: NGK/DPR7EA-9 DENSO/X22EPR-U9 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-tolight tan (the ideal color when the vehicle is ridden normally). 2.
5FB13.book Page 11 Monday, May 12, 2003 5:20 PM PERIODIC MAINTENANCE AND MINOR REPAIR EAU19740 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 vehicle on a level surface and hold it in an upright position.
5FB13.book Page 12 Monday, May 12, 2003 5:20 PM PERIODIC MAINTENANCE AND MINOR REPAIR Recommended engine oil: See page 8-1. 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) ECA11620 1. Outer oil filter element cover 2. Bolt CAUTION: 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. 8.
5FB13.book Page 13 Monday, May 12, 2003 5:20 PM PERIODIC MAINTENANCE AND MINOR REPAIR 11. Turn the engine off, and then check the oil level and correct it if necessary. EAU20020 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 vehicle. 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. 2.
5FB13.book Page 14 Monday, May 12, 2003 5:20 PM PERIODIC MAINTENANCE AND MINOR REPAIR 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·lbf) EAU20641 Cleaning the air filter element The air filter element should be cleaned at the intervals specified in the periodic maintenance and lubrication chart.
5FB13.book Page 15 Monday, May 12, 2003 5:20 PM PERIODIC MAINTENANCE AND MINOR REPAIR 4. Insert the air filter element into the air filter case as shown. EAU21270 Adjusting the carburetors 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. EAU21380 Adjusting the throttle cable free play 1.
5FB13.book Page 16 Monday, May 12, 2003 5:20 PM PERIODIC MAINTENANCE AND MINOR REPAIR EAU21400 EAU21520 Adjusting the valve clearance 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.
5FB13.book Page 17 Monday, May 12, 2003 5:20 PM PERIODIC MAINTENANCE AND MINOR REPAIR EWA10510 ● Tire inspection WARNING 6 Proper loading of your vehicle is important 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 heaviest items close to the center of the vehicle, and distribute the weight evenly from side to side.
5FB13.book Page 18 Monday, May 12, 2003 5:20 PM PERIODIC MAINTENANCE AND MINOR REPAIR EWA10560 ● ● ● EAU21940 WARNING Spoke wheels It is dangerous to ride with a worn-out tire. When a tire tread begins to show crosswise lines, have a Yamaha dealer replace the tire immediately. The replacement of all wheeland brake-related parts, including the tires, should be left to a Yamaha dealer, who has the necessary professional knowledge and experience. It is not recommended to patch a punctured tube.
5FB13.book Page 19 Monday, May 12, 2003 5:20 PM PERIODIC MAINTENANCE AND MINOR REPAIR any consequences caused by the use of items which have not been approved by Yamaha. EAU22040 Adjusting the clutch lever free play 1. Locknut 2. Clutch lever free play adjusting bolt 3. Clutch lever free play 6 The clutch lever free play should measure 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.
5FB13.book Page 20 Monday, May 12, 2003 5:20 PM PERIODIC MAINTENANCE AND MINOR REPAIR 6. To increase the clutch lever free play, turn the adjusting nut in direction (a). To decrease the clutch lever free play, turn the adjusting nut in direction (b). 7. Tighten the locknut at the clutch lever and the crankcase. EAU22091 Adjusting the brake lever free play 1. Locknut 2. Brake lever free play adjusting bolt 1. Brake lever free play The brake lever free play should measure 10.0–15.0 mm (0.39–0.
5FB13.book Page 21 Monday, May 12, 2003 5:20 PM PERIODIC MAINTENANCE AND MINOR REPAIR system. If there is air in the hydraulic system, have a Yamaha dealer bleed the system before operating the motorcycle. Air in the hydraulic system will diminish the braking performance, which may result in loss of control and an accident. 6 EAU22231 Adjusting the brake pedal position and free play XVS650 EWA10670 WARNING It is advisable to have a Yamaha dealer make these adjustments.
5FB13.book Page 22 Monday, May 12, 2003 5:20 PM PERIODIC MAINTENANCE AND MINOR REPAIR 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). EAU22270 Adjusting the rear brake light switch 1. Locknut 2. Brake pedal position adjusting bolt 3. Tighten the locknut. 1. Rear brake light switch 2.
5FB13.book Page 23 Monday, May 12, 2003 5:20 PM PERIODIC MAINTENANCE AND MINOR REPAIR Checking the front brake pads and rear brake shoes indicator grooves have almost disappeared, have a Yamaha dealer replace the brake pads as a set. 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. Rear brake shoes EAU22380 EAU32341 Checking the brake fluid level Front brake EAU22540 EAU22430 Front brake pads 1.
5FB13.book Page 24 Monday, May 12, 2003 5:20 PM PERIODIC MAINTENANCE AND MINOR REPAIR ● ● When checking the fluid level, make sure that the top of the master cylinder is level by turning the handlebars. Use only the recommended quality brake fluid, otherwise the rubber seals may deteriorate, causing leakage and poor braking performance. brake fluid level goes down suddenly, have a Yamaha dealer check the cause. Recommended brake fluid: DOT 4 ● ● ● ● Refill with the same type of brake fluid.
5FB13.book Page 25 Monday, May 12, 2003 5:20 PM PERIODIC MAINTENANCE AND MINOR REPAIR EAU23090 EAU23110 Checking and lubricating the cables Checking and lubricating the throttle grip and cable The operation of all control cables and the condition of the cables should be checked before each ride, and the cables and cable ends should be lubricated if necessary. If a cable is damaged or does not move smoothly, have a Yamaha dealer check or replace it.
5FB13.book Page 26 Monday, May 12, 2003 5:20 PM PERIODIC MAINTENANCE AND MINOR REPAIR EAU23140 Checking and lubricating the brake and clutch levers EAU23200 Checking and lubricating the sidestand Brake lever 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 maintenance and lubrication chart.
5FB13.book Page 27 Monday, May 12, 2003 5:20 PM PERIODIC MAINTENANCE AND MINOR REPAIR EAU23280 Checking the steering ECA10590 Worn or loose steering bearings may cause danger. Therefore, the operation of the steering must be checked as follows at the intervals specified in the periodic maintenance and lubrication chart. 1. Place a stand under the engine to raise the front wheel off the ground.
5FB13.book Page 28 Monday, May 12, 2003 5:20 PM PERIODIC MAINTENANCE AND MINOR REPAIR EAU23290 EAU23380 Checking the wheel bearings Battery The front and rear wheel bearings must be checked at the intervals specified in the periodic maintenance and lubrication chart. If there is play in the wheel hub or if the wheel does not turn smoothly, have a Yamaha dealer check the wheel bearings. The battery is located behind panel B. (See page 6-8.
5FB13.book Page 29 Monday, May 12, 2003 5:20 PM PERIODIC MAINTENANCE AND MINOR REPAIR 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. If the 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 installation. 4.
5FB13.book Page 30 Monday, May 12, 2003 5:20 PM PERIODIC MAINTENANCE AND MINOR REPAIR ECA10640 1. 2. 3. 4. 5. Ignition fuse Signaling system fuse Headlight fuse Carburetor heater fuse Spare fuse EAU23791 CAUTION: Replacing the headlight bulb 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. This model is equipped with a quartz bulb headlight. If the headlight bulb burns out, replace it as follows. 1.
5FB13.book Page 31 Monday, May 12, 2003 5:20 PM PERIODIC MAINTENANCE AND MINOR REPAIR EWA10790 WARNING Headlight bulbs get very hot. Therefore, keep flammable products away from a lit headlight bulb, and do not touch the bulb until it has cooled down. 1. Headlight coupler 2. Headlight bulb cover 3. Unhook the headlight bulb holder, and then remove the defective bulb. 6 4. Place a new headlight bulb into position, and then secure it with the bulb holder.
5FB13.book Page 32 Monday, May 12, 2003 5:20 PM PERIODIC MAINTENANCE AND MINOR REPAIR EAU24281 Replacing a turn signal light bulb or the tail/brake light bulb XVS650A/AT 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 upright. Check that the motorcycle is in a stable and level position before starting any maintenance.
5FB13.book Page 33 Monday, May 12, 2003 5:20 PM PERIODIC MAINTENANCE AND MINOR REPAIR 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 EWA10820 WARNING ● ● It is advisable to have a Yamaha dealer service the wheel. Securely support the motorcycle so that there is no danger of it falling over. 1. Disconnect the speedometer cable from the front wheel. 6 1. Rubber cap 2. Wheel axle 3.
5FB13.book Page 34 Monday, May 12, 2003 5:20 PM PERIODIC MAINTENANCE AND MINOR REPAIR EAU24921 To install the front wheel 1. Install the speedometer gear unit into the wheel hub so that the projections mesh with the slots. 5. Tighten the wheel axle and front wheel axle pinch bolt to the specified torques, and then install the rubber cap. EAU25140 To remove the rear wheel EWA10820 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.
5FB13.book Page 35 Monday, May 12, 2003 5:20 PM PERIODIC MAINTENANCE AND MINOR REPAIR 4. Remove the brake pedal free play adjusting nut, and then disconnect the brake rod from the brake camshaft lever. EAU25510 To install the rear wheel 1. Install the rear wheel, wheel axle, final gear case, and drive shaft by pushing the wheel forward and guiding the drive shaft into the middle gear universal joint. 1. Bolt 2. Final gear case 6 1. 2. 3. 4. 5. 6.
5FB13.book Page 36 Monday, May 12, 2003 5:20 PM PERIODIC MAINTENANCE AND MINOR REPAIR 7. Tighten the axle nut, the final gear case bolts and the brake torque rod bolt to the specified torques. Tightening torques: Axle nut: 92 Nm (9.2 m·kgf, 67 ft·lbf) Final gear case bolt: 74 Nm (7.4 m·kgf, 54 ft·lbf) Brake torque rod bolt: 20 Nm (2.0 m·kgf, 14 ft·lbf) 8. Adjust the brake pedal free play. (See page 6-21.) EWA10660 WARNING After adjusting the brake pedal free play, check the operation of the brake light.
5FB13.book Page 37 Monday, May 12, 2003 5:20 PM PERIODIC MAINTENANCE AND MINOR REPAIR EAU25891 Troubleshooting chart EWA10840 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. Check the compression.
5FB13.book Page 1 Monday, May 12, 2003 5:20 PM MOTORCYCLE CARE AND STORAGE ucts onto seals, gaskets and wheel axles. Always rinse the dirt and degreaser off with water. EAU26060 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.
5FB13.book Page 2 Monday, May 12, 2003 5:20 PM MOTORCYCLE CARE AND STORAGE 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.
5FB13.book Page 3 Monday, May 12, 2003 5:20 PM MOTORCYCLE CARE AND STORAGE ● Avoid using abrasive polishing compounds as they will wear away the paint. NOTE: Consult a Yamaha dealer for advice on what products to use. EAU32510 Storage Short-term Always store your motorcycle in a cool, dry place and, if necessary, protect it against dust with a porous cover.
5FB13.book Page 4 Monday, May 12, 2003 5:20 PM MOTORCYCLE CARE AND STORAGE EWA10950 WARNING To prevent damage or injury from sparking, make sure to ground the spark plug electrodes while turning the engine over. 7 °C (90 °F)]. For more information on storing the battery, see page 6-28. NOTE: 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 sidestand/centerstand. 7.
5FB13.book Page 1 Monday, May 12, 2003 5:20 PM 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.
5FB13.book Page 2 Monday, May 12, 2003 5:20 PM SPECIFICATIONS Primary reduction ratio: 68/38 (1.789) Secondary reduction system: Shaft drive Secondary reduction ratio: 19/18 × 32/11 (3.071) Transmission type: Constant mesh 5-speed Operation: Left foot operation Gear ratio: 1st: 38/14 (2.714) 2nd: 38/20 (1.900) 3rd: 35/24 (1.458) 4th: 28/24 (1.167) 5th: 29/30 (0.967) Chassis: 8 Frame type: Double cradle Caster angle: 35.0 ° Trail: XVS650 153.0 mm (6.02 in) XVS650A 145.0 mm (5.71 in) XVS650AT 145.0 mm (5.
5FB13.book Page 3 Monday, May 12, 2003 5:20 PM SPECIFICATIONS 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.
5FB13.book Page 1 Monday, May 12, 2003 5:20 PM CONSUMER INFORMATION EAU26351 Identification numbers EAU26380 EAU26400 Key identification number Vehicle identification number 1. Key identification number 1. Vehicle 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. The vehicle identification number is stamped into the steering head pipe. Record this number in the space provided.
5FB13.book Page 2 Monday, May 12, 2003 5:20 PM CONSUMER INFORMATION EAU26470 Model label 1. Model label The model label is affixed to the frame under the rider seat. (See page 3-8.) Record the information on this label in the space provided. This information will be needed when ordering spare parts from a Yamaha dealer.
5FB13.book Page 3 Monday, May 12, 2003 5:20 PM 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.
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5FB13.book Page 5 Monday, May 12, 2003 5:20 PM 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.
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5FB13.book Page 7 Monday, May 12, 2003 5:20 PM CONSUMER INFORMATION EAU26661 YAMAHA MOTOR CORPORATION, U.S.A.
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5FB13.book Page 9 Monday, May 12, 2003 5:20 PM CONSUMER INFORMATION EAU26750 YAMAHA EXTENDED SERVICE (Y.E.S.) Keep your Yamaha protected even after your warranty expires with genuine Yamaha Extended Service (Y.E.S.). In addition, Travel and Recreation Interruption Protection (TRIP) is included at no extra cost.
5FB13.book Page 10 Monday, May 12, 2003 5:20 PM 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. A special note: If visiting your dealer isn’t convenient, contact Yamaha with your Primary ID number (your frame number). We’ll be happy to help you get the Y.E.S. coverage you need. Yamaha Service Marketing P.O.
5FB13.book Page 1 Monday, May 12, 2003 5:20 PM INDEX A Fuel......................................................... 3-6 Fuel cock ................................................ 3-7 Fuel tank cap .......................................... 3-5 Fuses, replacing ................................... 6-29 Accessories and replacement parts...... 6-18 Air filter element, cleaning..................... 6-14 B Battery...................................................
5FB13.book Page 2 Monday, May 12, 2003 5:20 PM INDEX V Valve clearance, adjusting.................... 6-16 Vehicle identification number.................. 9-1 W Warranty, extended ................................ 9-9 Warranty, limited..................................... 9-7 Wheel bearings, checking .................... 6-28 Wheel (front) ......................................... 6-33 Wheel (rear).......................................... 6-34 Wheels..................................................
OWNER’S MANUAL XVS650S XVS650AS XVS650ATS YAMAHA MOTOR CO., LTD. PRINTED ON RECYCLED PAPER PRINTED IN JAPAN 2003.05-2.
