OWNER’S MANUAL YAMAHA MOTOR CO., LTD. PRINTED ON RECYCLED PAPER PRINTED IN JAPAN 2001 · 5 - 0.
Shiro.
U5SCE0.book Page 1 Thursday, June 7, 2001 11:24 AM INTRODUCTION EAU03338 Welcome to the Yamaha world of motorcycling! As the owner of an XVS650/XVS650A, you are benefiting from Yamaha’s vast experience and newest technology regarding the design and manufacture of high-quality products, which have earned Yamaha a reputation for dependability. Please take the time to read this manual thoroughly, so as to enjoy all advantages of your XVS650/XVS650A.
U5SCE0.book Page 1 Thursday, June 7, 2001 11:24 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.
U5SCE0.book Page 2 Thursday, June 7, 2001 11:24 AM IMPORTANT MANUAL INFORMATION EW000002 WARNING PLEASE READ THIS MANUAL CAREFULLY AND COMPLETELY BEFORE OPERATING THIS MOTORCYCLE.
U5SCE0.book Page 3 Thursday, June 7, 2001 11:24 AM IMPORTANT MANUAL INFORMATION EAU04229 XVS650/XVS650A OWNER’S MANUAL © 2001 by Yamaha Motor Co., Ltd. 1st edition, April 2001 All rights reserved. Any reprinting or unauthorized use without the written permission of Yamaha Motor Co., Ltd. is expressly prohibited. Printed in Japan.
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U5SCE0.book Page 1 Thursday, June 7, 2001 11:24 AM GIVE SAFETY THE RIGHT OF WAY GIVE SAFETY THE RIGHT OF WAY ................................................
U5SCE0.book Page 1 Thursday, June 7, 2001 11:24 AM GIVE SAFETY THE RIGHT OF WAY EAU00021 1- Motorcycles are fascinating vehicles, which can give you an unsurpassed feeling of power and freedom. However, they also impose certain limits, which you must accept; even the best motorcycle does not ignore the laws of physics. 1 Regular care and maintenance are essential for preserving value and operating condition of your motorcycle.
U5SCE0.book Page 1 Thursday, June 7, 2001 11:24 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) ...........
U5SCE0.book Page 1 Thursday, June 7, 2001 11:24 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.
U5SCE0.book Page 2 Thursday, June 7, 2001 11:24 AM DESCRIPTION Right view (XVS650) 2 8. Engine oil filter element 9. Battery 10. Fuses 11. Main switch/steering lock 12. Air filter element 13.
U5SCE0.book Page 3 Thursday, June 7, 2001 11:24 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.
U5SCE0.book Page 4 Thursday, June 7, 2001 11:24 AM DESCRIPTION Right view (XVS650A) 2 8. Engine oil filter element 9. Battery 10. Fuses 11. Main switch/steering lock 12. Air filter element 13.
U5SCE0.book Page 5 Thursday, June 7, 2001 11:24 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.
U5SCE0.book Page 1 Thursday, June 7, 2001 11:24 AM INSTRUMENT AND CONTROL FUNCTIONS Main switch/steering lock .................................................................. 3-1 Indicator and warning lights ............................................................. 3-2 Speedometer unit .............................................................................. 3-3 Anti-theft alarm (optional) .................................................................. 3-3 Handlebar switches .................
U5SCE0.book Page 1 Thursday, June 7, 2001 11:24 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. EAU00036 ON All electrical systems are supplied with power, and the engine can be started. The key cannot be removed. EAU00040 LOCK The steering is locked, and all electrical systems are off. The key can be removed.
U5SCE0.book Page 2 Thursday, June 7, 2001 11:24 AM INSTRUMENT AND CONTROL FUNCTIONS EAU00048 EAU00061 (Parking) The steering is locked, and the taillight and auxiliary light are on, but all other electrical systems are off. The key can be removed. The steering must be locked before the key can be turned to “ ”. Neutral indicator light “ ” This indicator light comes on when the transmission is in the neutral position.
U5SCE0.book Page 3 Thursday, June 7, 2001 11:24 AM INSTRUMENT AND CONTROL FUNCTIONS EAU00109 Anti-theft alarm (optional) This motorcycle can be equipped with an optional anti-theft alarm by a Yamaha dealer. Contact a Yamaha dealer for more information. 3 1. 2. 3. 4. Tripmeter reset knob Speedometer Odometer Tripmeter 1. 2. 3. 4.
U5SCE0.book Page 4 Thursday, June 7, 2001 11:24 AM INSTRUMENT AND CONTROL FUNCTIONS EAU00119 EAU03890 Pass switch “ ” Press this switch to flash the headlight. Engine stop switch “ / ” Set this switch to “ ” before starting the engine. Set this switch to “ ” to stop the engine in case of an emergency, such as when the motorcycle overturns or when the throttle cable is stuck. EAU03888 Dimmer switch “ / ” Set this switch to “ ” for the high beam and to “ ” for the low beam.
U5SCE0.book Page 5 Thursday, June 7, 2001 11:24 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.
U5SCE0.book Page 6 Thursday, June 7, 2001 11:24 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.
U5SCE0.book Page 7 Thursday, June 7, 2001 11:24 AM INSTRUMENT AND CONTROL FUNCTIONS NOTE: The fuel tank cap cannot be installed unless the key is in the lock. In addition, the key cannot be removed if the cap is not properly installed and locked. @ @ EW000024 WARNING Make sure that the fuel tank cap is properly installed before riding. @ 3 1. “ ” mark 2. Unlock. @ 1. Fuel tank filler tube 2. Fuel level EAU00169 EAU03753 Fuel tank cap Fuel Make sure that there is sufficient fuel in the tank.
U5SCE0.book Page 8 Thursday, June 7, 2001 11:24 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. @ @ EAU04202 Your Yamaha engine has been designed to use regular unleaded gasoline with a research octane number of 91 or higher. If knocking (or pinging) occurs, use a gasoline of a different brand or premium unleaded fuel.
U5SCE0.book Page 9 Thursday, June 7, 2001 11:24 AM INSTRUMENT AND CONTROL FUNCTIONS ON: normal position OFF: closed 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.
U5SCE0.book Page 10 Thursday, June 7, 2001 11:24 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). _ 1. Starter (choke) knob “ ” _ EAU03031 Starter (choke) knob “ ” Starting a cold engine requires a richer air-fuel mixture, which is supplied by the starter (choke).
U5SCE0.book Page 11 Thursday, June 7, 2001 11:24 AM INSTRUMENT AND CONTROL FUNCTIONS XVS650 XVS650 XVS650 1. Bolt (× 2) 2. Seat holder 3. Projection 1. Seat holder 2. Projection 3 1. Nut EAU01889 Seats (XVS650) Passenger seat To remove the passenger seat Remove the nut, and then pull the passenger seat up. 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.
U5SCE0.book Page 12 Thursday, June 7, 2001 11:24 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.
U5SCE0.book Page 13 Thursday, June 7, 2001 11:24 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.
U5SCE0.book Page 14 Thursday, June 7, 2001 11:24 AM INSTRUMENT AND CONTROL FUNCTIONS 3 To open the storage compartment 1. Slide the lock cover open, insert the key into the lock, and then turn it clockwise. 2. Pull the storage compartment cover out as shown. 1. Storage compartment 2. Storage compartment cover To close the storage compartment 1. Place the storage compartment cover in its original position as shown. 2. Turn the key counterclockwise, remove it, and then close the lock cover.
U5SCE0.book Page 15 Thursday, June 7, 2001 11:24 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.
U5SCE0.book Page 16 Thursday, June 7, 2001 11:24 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.
U5SCE0.book Page 17 Thursday, June 7, 2001 11:24 AM INSTRUMENT AND CONTROL FUNCTIONS EAU00330 Sidestand The sidestand is located on the left side of the frame. Raise the sidestand or lower it with your foot while holding the motorcycle upright. NOTE: The built-in sidestand switch is part of the ignition circuit cut-off system, which cuts the ignition in certain situations. (See further down for an explanation of the ignition circuit cut-off system.
U5SCE0.book Page 18 Thursday, June 7, 2001 11:24 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? YES NOTE: This check is most reliable if performed with a warmed-up engine. ”. NO The neutral switch may be defective.
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U5SCE0.book Page 1 Thursday, June 7, 2001 11:24 AM PRE-OPERATION CHECKS Pre-operation check list .....................................................................
U5SCE0.book Page 1 Thursday, June 7, 2001 11:24 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.
U5SCE0.book Page 2 Thursday, June 7, 2001 11:24 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 6-25 Wheels and tires • • • • Brake and shift pedals • Make sure that operation is smooth. • Lubricate pedal pivoting points if necessary. 6-26 Brake and clutch levers • Make sure that operation is smooth.
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U5SCE0.book Page 1 Thursday, June 7, 2001 11:24 AM OPERATION AND IMPORTANT RIDING POINTS Starting the engine ............................................................................ 5-1 Starting a warm engine ..................................................................... 5-2 Shifting .............................................................................................. 5-3 Recommended shift points (for Switzerland only) .............................
U5SCE0.book Page 1 Thursday, June 7, 2001 11:24 AM OPERATION AND IMPORTANT RIDING POINTS EAU00372 5- EAU00373 @ 5 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.
U5SCE0.book Page 2 Thursday, June 7, 2001 11:24 AM OPERATION AND IMPORTANT RIDING POINTS warning light comes on or flashes after starting, immediately stop the engine, and have a Yamaha dealer check the self-diagnosis system. _ 6. After starting the engine, move the starter (choke) knob back halfway. EAU01258 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.
U5SCE0.book Page 3 Thursday, June 7, 2001 11:24 AM OPERATION AND IMPORTANT RIDING POINTS XVS650 ● XVS650A @ 1. Shift pedal N. Neutral position 1. Shift pedal N. Neutral position EAU00423 5 EC000048 Shifting 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.
U5SCE0.book Page 4 Thursday, June 7, 2001 11:24 AM OPERATION AND IMPORTANT RIDING POINTS EAU02941 EAU00424 Recommended shift points (for Switzerland only) Tips for reducing fuel consumption The recommended shift points during acceleration are shown in the table below. Fuel consumption depends largely on your riding style. Consider the following tips to reduce fuel consumption: ● Thoroughly warm up the engine. ● Turn the starter (choke) off as soon as possible.
U5SCE0.book Page 5 Thursday, June 7, 2001 11:24 AM OPERATION AND IMPORTANT RIDING POINTS EAU01128 Engine break-in 5 There is never a more important period in the life of your engine than the period between 0 and 1,600 km. For this reason, you should read the following material carefully. Since the engine is brand new, do not put an excessive load on it for the first 1,600 km. The various parts in the engine wear and polish themselves to the correct operating clearances.
U5SCE0.book Page 1 Thursday, June 7, 2001 11:24 AM PERIODIC MAINTENANCE AND MINOR REPAIR Owner’s tool kit ....................................................6-1 Periodic maintenance and lubrication chart .........6-2 Removing and installing panels ...........................6-5 Checking the spark plugs ....................................6-7 Engine oil and oil filter element ............................6-9 Final gear oil ......................................................
U5SCE0.book Page 1 Thursday, June 7, 2001 11:24 AM PERIODIC MAINTENANCE AND MINOR REPAIR EAU00462 6- EAU00464 6 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 inspection, adjustment, and lubrication are explained on the following pages.
U5SCE0.book Page 2 Thursday, June 7, 2001 11:24 AM PERIODIC MAINTENANCE AND MINOR REPAIR EAU03685 Periodic maintenance and lubrication chart NOTE: ● The annual checks must be performed every year, except if a kilometer-based maintenance is performed instead. ● From 50,000 km, repeat the maintenance intervals starting from 10,000 km. ● Items marked with an asterisk should be performed by a Yamaha dealer as they require special tools, data and technical skills. _ _ CP-03E NO.
U5SCE0.book Page 3 Thursday, June 7, 2001 11:24 AM PERIODIC MAINTENANCE AND MINOR REPAIR NO. CHECK OR MAINTENANCE JOB ODOMETER READING (× 1,000 km) 1 10 20 30 40 * Wheels • Check runout, spoke tightness and for damage. • Tighten spokes if necessary. √ √ √ √ 11 * Tires • Check tread depth and for damage. • Replace if necessary. • Check air pressure. • Correct if necessary. √ √ √ √ 12 * Wheel bearings • Check bearing for looseness or damage.
U5SCE0.book Page 4 Thursday, June 7, 2001 11:24 AM PERIODIC MAINTENANCE AND MINOR REPAIR NO. 25 26 ITEM CHECK OR MAINTENANCE JOB ODOMETER READING (× 1,000 km) 1 Moving parts and cables • Lubricate. Lights, signals and * switches • Check operation. • Adjust headlight beam. √ 10 20 30 40 ANNUAL CHECK √ √ √ √ √ √ √ √ √ √ EAU03541 NOTE: ● The air filter needs more frequent service if you are riding in unusually wet or dusty areas.
U5SCE0.book Page 5 Thursday, June 7, 2001 11:24 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.
U5SCE0.book Page 6 Thursday, June 7, 2001 11:24 AM PERIODIC MAINTENANCE AND MINOR REPAIR XVS650 XVS650A 1. Bolt (× 4) 1. Bolt (× 4) EAU01573 Panel A To remove the panel Remove the bolts, and then take the panel off. 6 To install the panel Place the panel in the original position, and then install the bolts.
U5SCE0.book Page 7 Thursday, June 7, 2001 11:24 AM PERIODIC MAINTENANCE AND MINOR REPAIR 1. Bolt 1. Spark plug cap EAU00491 6 Panel B To remove the panel Remove the bolt, and then pull the panel off as shown. To install the panel Place the panel in the original position, and then install the bolt. EAU03329 Checking the spark plugs The spark plugs are important engine components, which are easy to check.
U5SCE0.book Page 8 Thursday, June 7, 2001 11:24 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. @ @ 1. Spark plug wrench 2. Remove the spark plug as shown, with the spark plug wrench included in the owner’s tool kit. To check the spark plugs 1.
U5SCE0.book Page 9 Thursday, June 7, 2001 11:24 AM PERIODIC MAINTENANCE AND MINOR REPAIR EAU03835* Tightening torque: Spark plug: 18 Nm (1.8 m·kgf) NOTE: If a torque wrench is not available when installing a spark plug, a good estimate of the correct torque is 1/4–1/2 turn past finger tight. However, the spark plug should be tightened to the specified torque as soon as possible. @ @ 4. Install the spark plug cap.
U5SCE0.book Page 10 Thursday, June 7, 2001 11:24 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.
U5SCE0.book Page 11 Thursday, June 7, 2001 11:24 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.
U5SCE0.book Page 12 Thursday, June 7, 2001 11:24 AM PERIODIC MAINTENANCE AND MINOR REPAIR EAU04083 NOTE: The oil level should be at the brim of the filler hole. 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.
U5SCE0.book Page 13 Thursday, June 7, 2001 11:24 AM PERIODIC MAINTENANCE AND MINOR REPAIR 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 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. 6. Check the final gear case for oil leakage. If oil is leaking, check for the cause.
U5SCE0.book Page 14 Thursday, June 7, 2001 11:24 AM PERIODIC MAINTENANCE AND MINOR REPAIR EAU00630 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. 1. Match marks EC000082* @ CAUTION: ● Make sure that the air filter element is properly seated in the air filter case.
U5SCE0.book Page 15 Thursday, June 7, 2001 11:24 AM PERIODIC MAINTENANCE AND MINOR REPAIR EAU01168 Adjusting the engine idling speed The engine idling speed must be checked and, if necessary, adjusted as follows at the intervals specified in the periodic maintenance and lubrication chart. NOTE: A diagnostic tachometer is needed to make this adjustment. @ 1. Throttle stop screw 3. Check the engine idling speed and, if necessary, adjust it to specification by turning the throttle stop screw.
U5SCE0.book Page 16 Thursday, June 7, 2001 11:24 AM PERIODIC MAINTENANCE AND MINOR REPAIR EAU00637 EW000082 Adjusting the valve clearance @ The valve clearance changes with use, resulting in improper air-fuel mixture and/or engine noise. To prevent this from occurring, the valve clearance must be adjusted by a Yamaha dealer at the intervals specified in the periodic maintenance and lubrication chart. 1. Tire sidewall a.
U5SCE0.book Page 17 Thursday, June 7, 2001 11:24 AM PERIODIC MAINTENANCE AND MINOR REPAIR XVS650A CE-01E Tire air pressure (measured on cold tires) Load* Front Rear Up to 90 kg 225 kPa 225 kPa (2.25 kgf/cm2, (2.25 kgf/cm2, 2.25 bar) 2.25 bar) 90 kg–maximum 225 kPa 250 kPa (2.25 kgf/cm2, (2.50 kgf/cm2, 2.25 bar) 2.
U5SCE0.book Page 18 Thursday, June 7, 2001 11:24 AM PERIODIC MAINTENANCE AND MINOR REPAIR @ EW000079 EW000078 WARNING ● Have a Yamaha dealer replace excessively worn tires. Besides being illegal, operating the motorcycle with excessively worn tires decreases riding stability and can lead to loss of control. ● 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.
U5SCE0.book Page 19 Thursday, June 7, 2001 11:24 AM PERIODIC MAINTENANCE AND MINOR REPAIR EAU00681 @ 6 @ WARNING ● Have a Yamaha dealer replace excessively worn tires. Besides being illegal, operating the motorcycle with excessively worn tires decreases riding stability and can lead to loss of control. ● 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.
U5SCE0.book Page 20 Thursday, June 7, 2001 11:24 AM PERIODIC MAINTENANCE AND MINOR REPAIR 1. Clutch lever free play adjusting nut 2. Locknut 3. If the specified clutch lever free play could be obtained as described above, tighten the locknut and skip the rest of the procedure, otherwise proceed as follows. 4. Fully turn the adjusting bolt at the clutch lever in direction a to loosen the clutch cable. 5. Loosen the locknut at the crankcase. 6.
U5SCE0.book Page 21 Thursday, June 7, 2001 11:24 AM PERIODIC MAINTENANCE AND MINOR REPAIR EW000099 @ 6 @ WARNING ● After adjusting the brake lever free play, check the free play and make sure that the brake is working properly. ● A soft or spongy feeling in the brake lever can indicate the presence of air in the hydraulic system. If there is air in the hydraulic system, have a Yamaha dealer bleed the system before operating the motorcycle.
U5SCE0.book Page 22 Thursday, June 7, 2001 11:24 AM PERIODIC MAINTENANCE AND MINOR REPAIR 1. Locknut 2. Brake pedal position adjusting bolt 1. Brake pedal free play adjusting nut 1. Loosen the locknut at the brake pedal. 2. To raise the brake pedal, turn the adjusting bolt in direction a. To lower the brake pedal, turn the adjusting bolt in direction b. 3. Tighten the locknut. EWA00044 WARNING After adjusting the brake pedal position, the brake pedal free play must be adjusted.
U5SCE0.book Page 23 Thursday, June 7, 2001 11:24 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.
U5SCE0.book Page 24 Thursday, June 7, 2001 11:24 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. Front 1.
U5SCE0.book Page 25 Thursday, June 7, 2001 11:24 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.
U5SCE0.book Page 26 Thursday, June 7, 2001 11:24 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.
U5SCE0.book Page 27 Thursday, June 7, 2001 11:24 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.
U5SCE0.book Page 28 Thursday, June 7, 2001 11:24 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.
U5SCE0.book Page 29 Thursday, June 7, 2001 11:24 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.
U5SCE0.book Page 30 Thursday, June 7, 2001 11:24 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.
U5SCE0.book Page 31 Thursday, June 7, 2001 11:24 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 6-7 for panel removal and installation procedures.
U5SCE0.book Page 32 Thursday, June 7, 2001 11:24 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.
U5SCE0.book Page 33 Thursday, June 7, 2001 11:24 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.
U5SCE0.book Page 34 Thursday, June 7, 2001 11:24 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.
U5SCE0.book Page 35 Thursday, June 7, 2001 11:24 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 _ EAU03885 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 6-34. 5. Pull the wheel axle out, and then remove the wheel. To remove the front wheel 6 1. Speedometer gear unit 2.
U5SCE0.book Page 36 Thursday, June 7, 2001 11:24 AM PERIODIC MAINTENANCE AND MINOR REPAIR 4. Lower the front wheel so that it is on the ground. 5. Push down hard on the handlebar several times to check for proper fork operation. 6. Tighten the wheel axle to the specified torque, and then install the rubber cap. Tightening torque: Wheel axle: 59 Nm (5.9 m·kgf) 7. Tighten the front wheel axle pinch bolt to the specified torque. 1.
U5SCE0.book Page 37 Thursday, June 7, 2001 11:24 AM PERIODIC MAINTENANCE AND MINOR REPAIR 3. Install the brake rod onto the brake camshaft lever, and then install the brake pedal free play adjusting nut onto the brake rod. 4. Install the brake torque rod bolt at the brake shoe plate, and then tighten both bolts to the specified torque. 1. Bolt (× 4) 2. Final gear case 6. Remove the bolts that secure the final gear case to the swingarm. 7.
U5SCE0.book Page 38 Thursday, June 7, 2001 11:24 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.
U5SCE0.book Page 39 Thursday, June 7, 2001 11:24 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.
U5SCE0.book Page 1 Thursday, June 7, 2001 11:24 AM MOTORCYCLE CARE AND STORAGE Care .................................................................................................. 7-1 Storage ..............................................................................................
U5SCE0.book Page 1 Thursday, June 7, 2001 11:24 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.
U5SCE0.book Page 2 Thursday, June 7, 2001 11:24 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.
U5SCE0.book Page 3 Thursday, June 7, 2001 11:24 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. 1.
U5SCE0.book Page 4 Thursday, June 7, 2001 11:24 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.
U5SCE0.book Page 5 Thursday, June 7, 2001 11:24 AM MOTORCYCLE CARE AND STORAGE 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. Cover the muffler outlets with plastic bags to prevent moisture from entering them. 9. Remove the battery and fully charge it.
U5SCE0.book Page 1 Thursday, June 7, 2001 11:24 AM SPECIFICATIONS Specifications .................................................................................... 8-1 Conversion table ...............................................................................
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U5SCE0.book Page 2 Thursday, June 7, 2001 11:24 AM SPECIFICATIONS Spark plug CAUTION: Be sure to use motor oils that do not contain anti-friction modifiers. Passenger car motor oils (often labeled “ENERGY CONSERVING II”) contain anti-friction additives which will cause clutch and/or starter clutch slippage, resulting in reduced component life and poor engine performance. 2.6 L With oil filter element replacement 2.8 L Total amount (dry engine) 3.2 L 0.8–0.
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U5SCE0.book Page 4 Thursday, June 7, 2001 11:24 AM SPECIFICATIONS Wheels Suspension XVS650 Front Telescopic fork Front Rear Swingarm (monocross) Type Spoke wheel Size 19 × MT 2.50 Spring/shock absorber 19 M/C × MT 2.50 Rear Front Coil spring / oil damper Rear Coil spring / gas-oil damper Wheel travel Type Spoke wheel Size 15 M/C × MT 3.50 XVS650 XVS650A Front Front 140 mm Rear 86 mm XVS650A Type Spoke wheel Front 140 mm Size 16 × MT 3.00 Rear 98 mm 16 M/C × MT 3.
U5SCE0.book Page 5 Thursday, June 7, 2001 11:24 AM SPECIFICATIONS Bulb voltage, wattage × quantity Headlight 12 V, 60/55 W × 1 Auxiliary light 12 V, 4 W × 1 Tail/brake light 12 V, 5/21 W × 1 Turn signal light 12 V, 21 W × 4 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.
U5SCE0.book Page 6 Thursday, June 7, 2001 11:24 AM SPECIFICATIONS EAU03941 Conversion table CS-03E Conversion table All specification data in this manual are listed in SI and METRIC UNITS. METRIC SYSTEM TO IMPERIAL SYSTEM Metric unit Use this table to convert METRIC unit values to IMPERIAL unit values. Example: METRIC VALUE 2 mm CONVERSION FACTOR × 0.03937 Torque ft·lb in·lb ft·lb in·lb Weight kg g × 2.205 × 0.03527 lb oz Speed km/h × 0.6214 mi/h Distance km m m cm mm × 0.6214 × 3.
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U5SCE0.book Page 1 Thursday, June 7, 2001 11:24 AM CONSUMER INFORMATION Identification numbers ....................................................................... 9-1 Key identification number .................................................................. 9-1 Vehicle identification number ............................................................. 9-1 Model label ........................................................................................
U5SCE0.book Page 1 Thursday, June 7, 2001 11:24 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.
U5SCE0.book Page 2 Thursday, June 7, 2001 11:24 AM CONSUMER INFORMATION 1. Model label EAU01804 Model label The model label is affixed to the frame under the rider seat. (See page 3-11 [XVS650] or 3-12 [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.
U5SCE0.book Page 1 Thursday, June 7, 2001 11:24 AM INDEX 10- A Engine trouble warning light .................... 3-2 N Air filter element, cleaning ......................6-13 Anti-theft alarm ........................................3-3 F Neutral indicator light ...............................3-2 Final gear oil.......................................... 6-12 Front fork, checking ............................... 6-27 Fuel ......................................................... 3-7 Fuel cock..........
U5SCE0.book Page 2 Thursday, June 7, 2001 11:24 AM INDEX Steering, checking ................................. 6-28 Storage.................................................... 7-4 Storage compartment ............................ 3-13 Supporting the motorcycle ..................... 6-34 T Throttle cable free play, adjusting .......... 6-15 Throttle grip and cable, checking and lubricating..................................... 6-25 Tires ...................................................... 6-16 Tool kit....
Shiro.
Shiro.
OWNER’S MANUAL YAMAHA MOTOR CO., LTD. PRINTED ON RECYCLED PAPER PRINTED IN JAPAN 2001 · 5 - 0.
