Read this manual carefully before operating this vehicle.
U1BF10E0.book Page 1 Friday, April 17, 2009 10:46 AM EAU10042 Read this manual carefully before operating this vehicle. This manual should stay with this vehicle if it is sold.
U1BF10E0.book Page 1 Friday, April 17, 2009 10:46 AM INTRODUCTION EAU10083 Congratulations on your purchase of the Yamaha XVS65Z(C)/XVS65AZ(C)/XVS65ATZ(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.
U1BF10E0.book Page 1 Friday, April 17, 2009 10:46 AM IMPORTANT MANUAL INFORMATION EAU10132 Particularly important information is distinguished in this manual by the following notations: This is the safety alert symbol. It is used to alert you to potential personal injury hazards. Obey all safety messages that follow this symbol to avoid possible injury or death. WARNING NOTICE TIP A WARNING indicates a hazardous situation which, if not avoided, could result in death or serious injury.
U1BF10E0.book Page 2 Friday, April 17, 2009 10:46 AM IMPORTANT MANUAL INFORMATION EAU10193 XVS65Z(C)/XVS65AZ(C)/XVS65ATZ(C) OWNER’S MANUAL ©2009 by Yamaha Motor Corporation, U.S.A. 1st edition, March 2009 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.
U1BF10E0.book Page 1 Friday, April 17, 2009 10:46 AM TABLE OF CONTENTS LOCATION OF IMPORTANT LABELS .............................................1-1 SAFETY INFORMATION ..................2-1 DESCRIPTION ..................................3-1 Left view ..........................................3-1 Right view ........................................3-2 Controls and instruments.................3-3 INSTRUMENT AND CONTROL FUNCTIONS .......................................4-1 Main switch/steering lock .............
U1BF10E0.book Page 2 Friday, April 17, 2009 10:46 AM TABLE OF CONTENTS Lubricating the swingarm pivots ...7-28 Checking the front fork .................7-29 Checking the steering ...................7-29 Checking the wheel bearings .......7-30 Battery ..........................................7-30 Replacing the fuses ......................7-31 Replacing the headlight bulb ........7-32 Replacing a turn signal light bulb or the tail/brake light bulb ..........7-34 Supporting the motorcycle ............
U1BF10E0.book Page 1 Friday, April 17, 2009 10:46 AM LOCATION OF IMPORTANT LABELS EAU10383 1 Read and understand all of the labels on your vehicle. They contain important information for safe and proper operation of your vehicle. Never remove any labels from your vehicle. If a label becomes difficult to read or comes off, a replacement label is available from your Yamaha dealer.
U1BF10E0.book Page 2 Friday, April 17, 2009 10:46 AM LOCATION OF IMPORTANT LABELS 1 3 XVS65AZ/XVS65ATZ TIRE INFORMATION Cold tire normal pressure should be set as follows. • Up to 90 kg (198 lbs) load FRONT : 225 kPa, (2.25 kgf/cm²), 33 psi REAR : 225 kPa, (2.25 kgf/cm²), 33 psi • 90kg (198 lbs) ~ maximum load FRONT : 225 kPa, (2.25 kgf/cm²), 33 psi REAR : 250 kPa, (2.50 kgf/cm²), 36 psi 2 1BF-21668-00 4 3 XVS65Z TIRE INFORMATION Cold tire normal pressure should be set as follows.
U1BF10E0.book Page 3 Friday, April 17, 2009 10:46 AM LOCATION OF IMPORTANT LABELS 5 1 A1 6 California only EMISSION HOSE ROUTING CARB.
U1BF10E0.book Page 1 Friday, April 17, 2009 10:46 AM SAFETY INFORMATION EAU10283 Be a Responsible Owner As the vehicle’s owner, you are responsible for the safe and proper operation of your motorcycle. 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.
U1BF10E0.book Page 2 Friday, April 17, 2009 10:46 AM SAFETY INFORMATION 2 ● ● 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.
U1BF10E0.book Page 3 Friday, April 17, 2009 10:46 AM SAFETY INFORMATION ● ● Do not run engine in poorly ventilated or partially enclosed areas such as barns, garages, or carports. Do not run engine outdoors where engine exhaust can be drawn into a building through openings such as windows and doors. Loading Adding accessories or cargo to your motorcycle can adversely affect stability and handling if the weight distribution of the motorcycle is changed.
U1BF10E0.book Page 4 Friday, April 17, 2009 10:46 AM SAFETY INFORMATION 2 Many companies with no connection to Yamaha manufacture parts and accessories or offer other modifications for Yamaha vehicles. Yamaha is not in a position to test the products that these aftermarket companies produce. Therefore, Yamaha can neither endorse nor recommend the use of accessories not sold by Yamaha or modifications not specifically recommended by Yamaha, even if sold and installed by a Yamaha dealer.
U1BF10E0.book Page 1 Friday, April 17, 2009 10:46 AM DESCRIPTION EAU10410 Left view 3 1. 2. 3. 4. 5. 6. 7.
U1BF10E0.book Page 2 Friday, April 17, 2009 10:46 AM DESCRIPTION EAU10420 Right view 3 1. 2. 3. 4. 5. 6.
U1BF10E0.book Page 3 Friday, April 17, 2009 10:46 AM DESCRIPTION EAU10430 Controls and instruments 3 1. 2. 3. 4. 5. 6. 7.
U1BF10E0.book Page 1 Friday, April 17, 2009 10:46 AM INSTRUMENT AND CONTROL FUNCTIONS EAU10460 Main switch/steering lock EAU10661 OFF All electrical systems are off. The key can be removed. To lock the steering EWA10061 WARNING 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.
U1BF10E0.book Page 2 Friday, April 17, 2009 10:46 AM INSTRUMENT AND CONTROL FUNCTIONS To unlock the steering EAU11004 Indicator and warning lights EAU11080 High beam indicator light “ ” This indicator light comes on when the high beam of the headlight is switched on. EAU11505 1. Push. 2. Turn. Push the key in, and then turn it to “OFF” while still pushing it. 1. 2. 3. 4.
U1BF10E0.book Page 3 Friday, April 17, 2009 10:46 AM INSTRUMENT AND CONTROL FUNCTIONS EAU11630 Speedometer unit EAU12092 Self-diagnosis device EAU12348 Handlebar switches This model is equipped with a self-diagnosis device for various electrical circuits. If a problem is detected in any of those circuits, the engine trouble warning light will come on or flash. If this occurs, have a Yamaha dealer check the vehicle. Left ECA11170 4 1. 2. 3. 4.
U1BF10E0.book Page 4 Friday, April 17, 2009 10:46 AM INSTRUMENT AND CONTROL FUNCTIONS 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. EAU12820 Clutch lever 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.
U1BF10E0.book Page 5 Friday, April 17, 2009 10:46 AM INSTRUMENT AND CONTROL FUNCTIONS EAU12870 Shift pedal (XVS65Z) EAU12880 Shift pedal (XVS65AZ/XVS65ATZ) EAU12890 Brake lever 4 1. Shift pedal 2. Neutral position The shift pedal is located on the left side of the engine and is used in combination with the clutch lever when shifting the gears of the 5-speed constant-mesh transmission equipped on this motorcycle. 1. Brake lever 1. Shift pedal 2.
U1BF10E0.book Page 6 Friday, April 17, 2009 10:46 AM INSTRUMENT AND CONTROL FUNCTIONS EAU12941 Brake pedal EAU13121 Fuel tank cap XVS65Z 2. Turn the key counterclockwise to the original position, remove it, and then close the lock cover. TIP 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. EWA10131 WARNING 1. Brake pedal XVS65AZ/XVS65ATZ 1. 2. 3. 4. Fuel tank cap lock cover “ ” mark Unlock.
U1BF10E0.book Page 7 Friday, April 17, 2009 10:46 AM INSTRUMENT AND CONTROL FUNCTIONS ately. If gasoline spills on your skin, wash with soap and water. If gasoline spills on your clothing, change your clothes. EAU13221 Fuel Make sure there is sufficient gasoline in the tank. EWA10881 WARNING 4 Gasoline and gasoline vapors are extremely flammable. To avoid fires and explosions and to reduce the risk of injury when refueling, follow these instructions. 1.
U1BF10E0.book Page 8 Friday, April 17, 2009 10:46 AM INSTRUMENT AND CONTROL FUNCTIONS um 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% (E10). Gasohol containing methanol is not recommended by Yamaha because it can cause damage to the fuel system or vehicle performance problems.
U1BF10E0.book Page 9 Friday, April 17, 2009 10:46 AM INSTRUMENT AND CONTROL FUNCTIONS EAU13550 Fuel cock 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. When this occurs, refuel as soon as possible and be sure to turn the fuel cock lever back to “ON”! ON The fuel cock supplies fuel from the tank to the carburetors while also filtering it.
U1BF10E0.book Page 10 Friday, April 17, 2009 10:46 AM INSTRUMENT AND CONTROL FUNCTIONS EAU13620 Starter (choke) knob “ ” EAU14184 Seats (XVS65Z) Passenger seat Tightening torque: Passenger seat nut: 13 Nm (1.3 m·kgf, 9.4 ft·lbf) To remove the passenger seat Remove the nut and washer, and then pull the passenger seat up. 4 1. Starter (choke) knob “ ” Starting a cold engine requires a richer air-fuel mixture, which is supplied by the starter (choke).
U1BF10E0.book Page 11 Friday, April 17, 2009 10:46 AM INSTRUMENT AND CONTROL FUNCTIONS 2. Install the passenger seat holder by installing its bolts. 3. Install the passenger seat. TIP Make sure that the seats are properly secured before riding. 4 EAU14192 Seats (XVS65AZ/XVS65ATZ) Passenger seat To remove the passenger seat Remove the nut and washer, and then pull the passenger seat up. 1. Bolt 2. Passenger seat holder To install the rider seat 1.
U1BF10E0.book Page 12 Friday, April 17, 2009 10:46 AM INSTRUMENT AND CONTROL FUNCTIONS 2. Install the passenger seat. Tightening torque: Passenger seat nut: 13 Nm (1.3 m·kgf, 9.4 ft·lbf) TIP Make sure that the seats are properly secured before riding. 1. Bolt 1. Passenger seat holder 2. Projection Rider seat 4 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.
U1BF10E0.book Page 13 Friday, April 17, 2009 10:46 AM INSTRUMENT AND CONTROL FUNCTIONS EAU14481 EAU14282 Helmet holder 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. 4 To close the storage compartment 1. Place the storage compartment cover in its original position as shown. 1. Helmet holder 2. Unlock.
U1BF10E0.book Page 14 Friday, April 17, 2009 10:46 AM INSTRUMENT AND CONTROL FUNCTIONS EAU14863 Adjusting the shock absorber assembly 1. 2. 3. 4. Position indicator Spring preload adjusting ring Extension bar Special wrench This shock absorber assembly is equipped with a spring preload adjusting ring. ECA10101 NOTICE To avoid damaging the mechanism, do not attempt to turn beyond the maximum or minimum settings. 2.
U1BF10E0.book Page 15 Friday, April 17, 2009 10:46 AM INSTRUMENT AND CONTROL FUNCTIONS EAU15151 Luggage strap holders EAU15303 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. 4 1. Luggage strap holder There is a luggage strap holder on each passenger footrest. TIP The built-in sidestand switch is part of the ignition circuit cut-off system, which cuts the ignition in certain situations.
U1BF10E0.book Page 16 Friday, April 17, 2009 10:46 AM INSTRUMENT AND CONTROL FUNCTIONS EAU15314 Ignition circuit cut-off system 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.
U1BF10E0.book Page 17 Friday, April 17, 2009 10:46 AM INSTRUMENT AND CONTROL FUNCTIONS 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 on. 4. Shift the transmission into the neutral position. 5. Push the start switch. Does the engine start? YES 4 WARNING If a malfunction is noted, have a Yamaha dealer check the system before riding. ”. NO The neutral switch may not be working correctly.
U1BF10E0.book Page 1 Friday, April 17, 2009 10:46 AM FOR YOUR SAFETY – PRE-OPERATION CHECKS EAU15596 Inspect your vehicle each time you use it to make sure the vehicle is in safe operating condition. Always follow the inspection and maintenance procedures and schedules described in the Owner’s Manual. EWA11151 WARNING Failure to inspect or maintain the vehicle properly increases the possibility of an accident or equipment damage. Do not operate the vehicle if you find any problem.
U1BF10E0.book Page 2 Friday, April 17, 2009 10:46 AM FOR YOUR SAFETY – PRE-OPERATION CHECKS ITEM CHECKS Clutch • • • • Throttle grip • 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. Control cables • Make sure that operation is smooth. • Lubricate if necessary. Wheels and tires • • • • Brake and shift pedals • Make sure that operation is smooth.
U1BF10E0.book Page 1 Friday, April 17, 2009 10:46 AM OPERATION AND IMPORTANT RIDING POINTS EAU15951 Read the Owner’s Manual carefully to become familiar with all controls. If there is a control or function you do not understand, ask your Yamaha dealer. EWA10271 WARNING Failure to familiarize yourself with the controls can lead to loss of control, which could cause an accident or injury.
U1BF10E0.book Page 2 Friday, April 17, 2009 10:46 AM OPERATION AND IMPORTANT RIDING POINTS (choke) turned on, then about 2.5 minutes with the starter (choke) in the halfway position. EAU16640 Starting a warm engine Follow the same procedure as for starting a cold engine with the exception that the starter (choke) is not required when the engine is warm. EAU16671 Shifting XVS65Z 1. Shift pedal 2. Neutral position XVS65AZ/XVS65ATZ 6 1. Shift pedal 2.
U1BF10E0.book Page 3 Friday, April 17, 2009 10:46 AM 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 illustration. TIP 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.
U1BF10E0.book Page 4 Friday, April 17, 2009 10:46 AM OPERATION AND IMPORTANT RIDING POINTS EAU16841 Shift up points: 1st → 2nd: 16 km/h (10 mi/h) 2nd → 3rd: 24 km/h (15 mi/h) 3rd → 4th: 32 km/h (20 mi/h) 4th → 5th: 40 km/h (25 mi/h) Shift down points: 5th → 4th: 25 km/h (16 mi/h) 4th → 3rd: 25 km/h (16 mi/h) 3rd → 2nd: 25 km/h (16 mi/h) 2nd → 1st: 25 km/h (16 mi/h) 6 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).
U1BF10E0.book Page 5 Friday, April 17, 2009 10:46 AM OPERATION AND IMPORTANT RIDING POINTS EAU17181 Parking When parking, stop the engine, remove the key from the main switch, and then turn the fuel cock lever to “OFF”. EWA10311 WARNING ● ● ● Since the engine and exhaust system can become very hot, park in a place where pedestrians or children are not likely to touch them and be burned.
U1BF10E0.book Page 1 Friday, April 17, 2009 10:46 AM PERIODIC MAINTENANCE AND ADJUSTMENT EAU17232 Periodic inspection, adjustment, and lubrication will keep your vehicle in the safest and most efficient condition possible. Safety is an obligation of the vehicle owner/operator. The most important points of vehicle inspection, adjustment, and lubrication are explained on the following pages.
U1BF10E0.book Page 2 Friday, April 17, 2009 10:46 AM PERIODIC MAINTENANCE AND ADJUSTMENT EAU17451 Owner’s tool kit 1. Owner’s tool kit The owner’s tool kit is located inside the storage compartment. (See page 4-13.) 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.
U1BF10E0.book Page 3 Friday, April 17, 2009 10:46 AM PERIODIC MAINTENANCE AND ADJUSTMENT EAU17600 Periodic maintenance chart for the emission control system INITIAL No. 7 ITEM ROUTINE 1 * Fuel line • Check fuel hoses 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.
U1BF10E0.book Page 4 Friday, April 17, 2009 10:46 AM PERIODIC MAINTENANCE AND ADJUSTMENT EAU32185 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.
U1BF10E0.book Page 5 Friday, April 17, 2009 10:46 AM PERIODIC MAINTENANCE AND ADJUSTMENT INITIAL No. ROUTINE Swingarm pivot bearings • Check bearing assemblies for looseness. • Moderately repack with lithiumsoap-based grease. 10 * Steering bearings • Check bearing assemblies for looseness. • Moderately repack with lithiumsoap-based grease every 16000 mi (25000 km) or 24 months.
U1BF10E0.book Page 6 Friday, April 17, 2009 10:46 AM PERIODIC MAINTENANCE AND ADJUSTMENT 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 18 * Front fork • Check operation and for oil leakage. • Replace if necessary. √ √ √ √ √ 19 * Shock absorber assembly • Check operation and for oil leakage.
U1BF10E0.book Page 7 Friday, April 17, 2009 10:46 AM PERIODIC MAINTENANCE AND ADJUSTMENT TIP From 24000 mi (37000 km) or 36 months, repeat the maintenance intervals starting from 8000 mi (13000 km) or 12 months. EAU17620 TIP ● ● 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.
U1BF10E0.book Page 8 Friday, April 17, 2009 10:46 AM PERIODIC MAINTENANCE AND ADJUSTMENT EAU18771 Removing and installing panels XVS65AZ/XVS65ATZ XVS65Z 1. Panel A 1. Bolt XVS65Z/XVS65AZ/XVS65ATZ XVS65AZ/XVS65ATZ 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. XVS65Z 7 1. Panel A 1. Panel B 1.
U1BF10E0.book Page 9 Friday, April 17, 2009 10:46 AM PERIODIC MAINTENANCE AND ADJUSTMENT EAU19151 Panel B To remove the panel Remove the bolt, and then pull the panel off as shown. EAU19544 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 maintenance and lubrication chart.
U1BF10E0.book Page 10 Friday, April 17, 2009 10:46 AM PERIODIC MAINTENANCE AND ADJUSTMENT 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 To install a spark plug 1. Measure the spark plug gap with a wire thickness gauge and, if necessary, adjust the gap to specification. 2.
U1BF10E0.book Page 11 Friday, April 17, 2009 10:46 AM PERIODIC MAINTENANCE AND ADJUSTMENT 3. Remove the engine oil filler cap and drain bolt to drain the oil from the crankcase. EAU19744 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. 7 To check the engine oil level 1.
U1BF10E0.book Page 12 Friday, April 17, 2009 10:46 AM PERIODIC MAINTENANCE AND ADJUSTMENT Tightening torque: Engine oil drain bolt: 43 Nm (4.3 m·kgf, 31 ft·lbf) 9. Refill with the specified amount of the recommended oil, and then install and tighten the oil filler cap. 1. Outer oil filter element cover 2. Bolt 1. Oil filter element 2. O-ring 6. Install a new oil filter element and the O-ring. 7.
U1BF10E0.book Page 13 Friday, April 17, 2009 10:46 AM PERIODIC MAINTENANCE AND ADJUSTMENT ● er quality than specified. In addition, do not use oils labeled “ENERGY CONSERVING II” or higher. Make sure that no foreign material enters the crankcase. 10. Start the engine, and then let it idle for several minutes while checking it for oil leakage. If oil is leaking, immediately turn the engine off and check for the cause. 11. Turn the engine off, and then check the oil level and correct it if necessary.
U1BF10E0.book Page 14 Friday, April 17, 2009 10:46 AM PERIODIC MAINTENANCE AND ADJUSTMENT Tightening torque: Final gear oil filler bolt: 23 Nm (2.3 m·kgf, 17 ft·lbf) To change the final gear oil 1. Place an oil pan under the final gear case to collect the used oil. 2. Remove the oil filler bolt and drain bolt to drain the oil from the final gear case. 3. Install the final gear oil drain bolt, and then tighten it to the specified torque. 5.
U1BF10E0.book Page 15 Friday, April 17, 2009 10:46 AM PERIODIC MAINTENANCE AND ADJUSTMENT TIP If dust or water collects in the air filter check hose, remove the clamp from it, and then remove the plug to drain the hose. 1. Air filter element 7 4. Insert the air filter element into the air filter case as shown. NOTICE: Make sure that the air filter element is properly seated in the air filter case.
U1BF10E0.book Page 16 Friday, April 17, 2009 10:46 AM PERIODIC MAINTENANCE AND ADJUSTMENT EAU21271 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.
U1BF10E0.book Page 17 Friday, April 17, 2009 10:46 AM PERIODIC MAINTENANCE AND ADJUSTMENT EAU21401 EAU32521 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.
U1BF10E0.book Page 18 Friday, April 17, 2009 10:46 AM PERIODIC MAINTENANCE AND ADJUSTMENT EWA10511 Tire air pressure (measured on cold tires): XVS65AZ 0–90 kg (0–198 lb): Front: 225 kPa (2.25 kgf/cm², 33 psi) Rear: 225 kPa (2.25 kgf/cm², 33 psi) 90–200 kg (198–441 lb): Front: 225 kPa (2.25 kgf/cm², 33 psi) Rear: 250 kPa (2.50 kgf/cm², 36 psi) XVS65AZC 0–90 kg (0–198 lb): Front: 225 kPa (2.25 kgf/cm², 33 psi) Rear: 225 kPa (2.25 kgf/cm², 33 psi) 90–198 kg (198–437 lb): Front: 225 kPa (2.
U1BF10E0.book Page 19 Friday, April 17, 2009 10:46 AM PERIODIC MAINTENANCE AND ADJUSTMENT EWA10461 Minimum tire tread depth (front and rear): 1.0 mm (0.04 in) EWA10560 WARNING ● ● 7 ● 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.
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U1BF10E0.book Page 21 Friday, April 17, 2009 10:46 AM PERIODIC MAINTENANCE AND ADJUSTMENT 7 The clutch lever free play should measure XVS65ATZ 5.0–10.0 mm (0.20–0.39 in) XVS65ATZC 5.0–10.0 mm (0.20–0.39 in) XVS65AZ 5.0–10.0 mm (0.20–0.39 in) XVS65AZC 5.0–10.0 mm (0.20–0.39 in) XVS65Z 10.0–15.0 mm (0.39–0.59 in) XVS65ZC 10.0–15.0 mm (0.39–0.59 in) as shown. Periodically check the clutch lever free play and, if necessary, adjust it as follows. 1. Slide the rubber cover back at the clutch lever. 2.
U1BF10E0.book Page 22 Friday, April 17, 2009 10:46 AM PERIODIC MAINTENANCE AND ADJUSTMENT ● EAU22093 Adjusting the brake lever free play 1. Locknut 2. Brake lever free play adjusting screw 1. Brake lever free play The brake lever free play should measure 10.0–15.0 mm (0.39–0.59 in) as shown. Periodically check the brake lever free play and, if necessary, adjust it as follows. 1. Loosen the locknut at the brake lever. 2.
U1BF10E0.book Page 23 Friday, April 17, 2009 10:46 AM PERIODIC MAINTENANCE AND ADJUSTMENT EAU22231 Adjusting the brake pedal position and free play XVS65Z EWA10670 WARNING It is advisable to have a Yamaha dealer make these adjustments. TIP The brake pedal position should be adjusted before adjusting the brake pedal free play. 1. Distance between brake pedal and footrest 2. Brake pedal free play XVS65AZ/XVS65ATZ 7 1. Distance between brake pedal and footrest 2.
U1BF10E0.book Page 24 Friday, April 17, 2009 10:46 AM PERIODIC MAINTENANCE AND ADJUSTMENT 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).
U1BF10E0.book Page 25 Friday, April 17, 2009 10:46 AM PERIODIC MAINTENANCE AND ADJUSTMENT indicator grooves have almost disappeared, have a Yamaha dealer replace the brake pads as a set. EAU32344 Checking the brake fluid level ● EAU22540 Rear brake shoes Use only the recommended quality brake fluid, otherwise the rubber seals may deteriorate, causing leakage and poor braking performance. Recommended brake fluid: DOT 4 ● 1. Minimum level mark 1. Brake shoe wear limit line 2.
U1BF10E0.book Page 26 Friday, April 17, 2009 10:46 AM PERIODIC MAINTENANCE AND ADJUSTMENT EAU22721 Changing the brake fluid Have a Yamaha dealer change the brake fluid at the intervals specified in the TIP 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.
U1BF10E0.book Page 27 Friday, April 17, 2009 10:46 AM PERIODIC MAINTENANCE AND ADJUSTMENT EAU44271 Checking and lubricating the brake and shift pedals EAU23142 Recommended lubricant: Lithium-soap-based grease Checking and lubricating the brake and clutch levers Brake lever Clutch lever 7 The operation of the brake and shift pedals should be checked before each ride, and the pedal pivots should be lubricated if necessary.
U1BF10E0.book Page 28 Friday, April 17, 2009 10:46 AM PERIODIC MAINTENANCE AND ADJUSTMENT EAU23202 Recommended lubricants: Brake lever: Silicone grease Clutch lever: Lithium-soap-based grease Checking and lubricating the sidestand EAUM1650 Lubricating the swingarm pivots The swingarm pivots must be lubricated at the intervals specified in the periodic maintenance and lubrication chart.
U1BF10E0.book Page 29 Friday, April 17, 2009 10:46 AM PERIODIC MAINTENANCE AND ADJUSTMENT EAU23272 EAU23283 Checking the front fork Checking the steering The condition and operation of the front fork must be checked as follows at the intervals specified in the periodic maintenance and lubrication chart. 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.
U1BF10E0.book Page 30 Friday, April 17, 2009 10:46 AM PERIODIC MAINTENANCE AND ADJUSTMENT EAU23290 Checking the wheel bearings EAU23385 EWA10760 Battery WARNING 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. ● 1. Positive battery lead (red) 2.
U1BF10E0.book Page 31 Friday, April 17, 2009 10:46 AM PERIODIC MAINTENANCE AND ADJUSTMENT ● KEEP THIS AND ALL BATTERIES OUT OF THE REACH OF CHILDREN. 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 vehicle is equipped with optional electrical accessories.
U1BF10E0.book Page 32 Friday, April 17, 2009 10:46 AM PERIODIC MAINTENANCE AND ADJUSTMENT avoid causing extensive damage to the electrical system and possibly a fire. [EWA15131] 1. 2. 3. 4. 5. 6. Headlight fuse Signaling system fuse Ignition fuse Carburetor heater fuse Ignitor unit fuse Spare fuse EAU23795 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: 5.0 A 3.
U1BF10E0.book Page 33 Friday, April 17, 2009 10:46 AM PERIODIC MAINTENANCE AND ADJUSTMENT 5. Install the headlight bulb cover, and then connect the coupler. 6. Install the headlight unit by installing the screws. 7. Have a Yamaha dealer adjust the headlight beam if necessary. 1. Do not touch the glass part of the bulb. 1. Remove the headlight unit by removing the screws. 1. Headlight coupler 2. Headlight bulb cover 3. Unhook the headlight bulb holder, and then remove the burnt-out bulb. 7 1.
U1BF10E0.book Page 34 Friday, April 17, 2009 10:46 AM PERIODIC MAINTENANCE AND ADJUSTMENT EAU24283 Replacing a turn signal light bulb or the tail/brake light bulb XVS65AZ/XVS65ATZ 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.
U1BF10E0.book Page 35 Friday, April 17, 2009 10:46 AM PERIODIC MAINTENANCE AND ADJUSTMENT 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 EAU24601 To remove the front wheel EWA10821 WARNING To avoid injury, securely support the vehicle so there is no danger of it falling over. 1. Disconnect the speedometer cable from the front wheel. 7 1. Speedometer cable 2. Loosen the front wheel axle pinch bolt, then the wheel axle.
U1BF10E0.book Page 36 Friday, April 17, 2009 10:46 AM PERIODIC MAINTENANCE AND ADJUSTMENT 2. Lift the wheel up between the fork legs. TIP Make sure that there is enough space between the brake pads before inserting the brake disc and that the slot in the speedometer gear unit fits over the retainer on the fork leg. EAU25080 Tightening torque: Wheel axle: 59 Nm (5.9 m·kgf, 43 ft·lbf) 6. Tighten the front wheel axle pinch bolt to the specified torque.
U1BF10E0.book Page 37 Friday, April 17, 2009 10:46 AM PERIODIC MAINTENANCE AND ADJUSTMENT 4. Remove the brake pedal free play adjusting nut, and then disconnect the brake rod from the brake camshaft lever. EAU25512 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 7 1. 2. 3. 4. 5. 6.
U1BF10E0.book Page 38 Friday, April 17, 2009 10:46 AM PERIODIC MAINTENANCE AND ADJUSTMENT 6. Lower the rear wheel so that it is on the ground, and then put the sidestand down. 7. Tighten the axle nut, the final gear case bolts and the brake torque rod nuts to the specified torques. Tightening torques: Axle nut: 92 Nm (9.2 m·kgf, 66 ft·lbf) Final gear case bolt: 74 Nm (7.4 m·kgf, 53 ft·lbf) Brake torque rod nut: 20 Nm (2.0 m·kgf, 14 ft·lbf) 8. Adjust the brake pedal free play. (See page 7-23.
U1BF10E0.book Page 39 Friday, April 17, 2009 10:46 AM PERIODIC MAINTENANCE AND ADJUSTMENT EAU25892 Troubleshooting chart 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. 2. Compression Operate the electric starter. 3.
U1BF10E0.book Page 1 Friday, April 17, 2009 10:46 AM MOTORCYCLE CARE AND STORAGE EAU37833 Matte color caution ucts onto seals, gaskets and wheel axles. Always rinse the dirt and degreaser off with water. EAU26063 Care ECA15192 NOTICE Some models are equipped with matte colored finished parts. Be sure to consult a Yamaha dealer for advice on what products to use before cleaning the vehicle.
U1BF10E0.book Page 2 Friday, April 17, 2009 10:46 AM MOTORCYCLE CARE AND STORAGE ● ● 8 ● off any detergent residue using plenty of water, as it is harmful to plastic parts. 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.
U1BF10E0.book Page 3 Friday, April 17, 2009 10:46 AM MOTORCYCLE CARE AND STORAGE 3. To prevent corrosion, it is recommended to apply a corrosion protection spray on all metal, including chrome- and nickel-plated, surfaces. 4. Use spray oil as a universal cleaner to remove any remaining dirt. 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.
U1BF10E0.book Page 4 Friday, April 17, 2009 10:46 AM MOTORCYCLE CARE AND STORAGE 8 3. Drain the carburetor float chambers by loosening the drain bolts; this will prevent fuel deposits from building up. Pour the drained fuel into the fuel tank. 4. Fill up the fuel tank and add fuel stabilizer (if available) to prevent the fuel tank from rusting and the fuel from deteriorating. 5. Perform the following steps to protect the cylinders, piston rings, etc. from corrosion. a.
U1BF10E0.book Page 1 Friday, April 17, 2009 10:46 AM SPECIFICATIONS Dimensions: Overall length: XVS65ATZ 2450 mm (96.5 in) XVS65ATZC 2450 mm (96.5 in) XVS65AZ 2450 mm (96.5 in) XVS65AZC 2450 mm (96.5 in) XVS65Z 2340 mm (92.1 in) XVS65ZC 2340 mm (92.1 in) Overall width: XVS65ATZ 930 mm (36.6 in) XVS65ATZC 930 mm (36.6 in) XVS65AZ 930 mm (36.6 in) XVS65AZC 930 mm (36.6 in) XVS65Z 880 mm (34.6 in) XVS65ZC 880 mm (34.6 in) Overall height: XVS65ATZ 1110 mm (43.7 in) XVS65ATZC 1110 mm (43.
U1BF10E0.book Page 2 Friday, April 17, 2009 10:46 AM SPECIFICATIONS 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: Type × 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.
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U1BF10E0.book Page 4 Friday, April 17, 2009 10:46 AM SPECIFICATIONS Spring/shock absorber type: Coil spring/gas-oil damper Wheel travel: XVS65ATZ 98.0 mm (3.86 in) XVS65ATZC 98.0 mm (3.86 in) XVS65AZ 98.0 mm (3.86 in) XVS65AZC 98.0 mm (3.86 in) XVS65Z 86.0 mm (3.39 in) XVS65ZC 86.0 mm (3.39 in) Electrical system: Ignition system: TCI (digital) Charging system: AC magneto Battery: Model: GT12B-4 Voltage, capacity: 12 V, 10.0 Ah Headlight: Bulb type: Halogen bulb Neutral indicator light: 12 V, 1.
U1BF10E0.book Page 1 Friday, April 17, 2009 10:46 AM CONSUMER INFORMATION EAU26352 Identification numbers EAU26381 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.
U1BF10E0.book Page 2 Friday, April 17, 2009 10:46 AM CONSUMER INFORMATION EAU26470 Model label 1. Model label The model label is affixed to the frame under the rider seat. (See page 4-10.) Record the information on this label in the space provided. This information will be needed when ordering spare parts from a Yamaha dealer. EAU48060 Vehicle Emission Control Information label 1 1.
U1BF10E0.book Page 3 Friday, April 17, 2009 10:46 AM CONSUMER INFORMATION EAU26551 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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U1BF10E0.book Page 5 Friday, April 17, 2009 10:46 AM CONSUMER INFORMATION EAU26632 Maintenance record Copies of work orders and/or receipts for parts purchased and installed on your vehicle 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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U1BF10E0.book Page 7 Friday, April 17, 2009 10:46 AM CONSUMER INFORMATION EAU26663 YAMAHA MOTOR CORPORATION, U.S.A. STREET AND ENDURO MOTORCYCLE LIMITED WARRANTY Yamaha Motor Corporation, U.S.A. hereby warrants that new Yamaha motorcycles will be free from defects in material and workmanship for the period of time stated herein, subject to certain stated limitations.
U1BF10E0.book Page 8 Friday, April 17, 2009 10:46 AM CONSUMER INFORMATION WARRANTY QUESTIONS AND ANSWERS CUSTOMER SERVICE Q. What costs are my responsibility during the warranty period? A. The customer’s responsibility includes all costs of normal maintenance services, non-warranty repairs, accident and collision damages, and oil, oil filters, air filters, spark plugs, and brake shoes.
U1BF10E0.book Page 9 Friday, April 17, 2009 10:46 AM 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.
U1BF10E0.book Page 10 Friday, April 17, 2009 10:46 AM 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.
U1BF10E0.book Page 1 Friday, April 17, 2009 10:46 AM INDEX A F Air filter element, cleaning .................... 7-14 Final gear oil..........................................7-13 Front fork, checking...............................7-29 Fuel .........................................................4-7 Fuel cock.................................................4-9 Fuel tank cap...........................................4-6 Fuses, replacing....................................7-31 B Battery .................
U1BF10E0.book Page 2 Friday, April 17, 2009 10:46 AM INDEX Troubleshooting .................................... 7-38 Troubleshooting chart ........................... 7-39 Turn signal indicator light ........................ 4-2 Turn signal light bulb or tail/brake light bulb, replacing .................................... 7-34 Turn signal switch ................................... 4-4 V Valve clearance .................................... 7-17 Vehicle Emission Control Information label ..................
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YAMAHA MOTOR CO., LTD. PRINTED ON RECYCLED PAPER PRINTED IN JAPAN 2009.05-1.
