Read this manual carefully before operating this vehicle.
U1BF11E0.book Page 1 Tuesday, April 13, 2010 9:28 AM EAU10042 Read this manual carefully before operating this vehicle. This manual should stay with this vehicle if it is sold.
U1BF11E0.book Page 1 Tuesday, April 13, 2010 9:28 AM INTRODUCTION EAU10083 Congratulations on your purchase of the Yamaha XVS65A(C). This model is the result of Yamaha’s vast experience in the production of fine sporting, touring, and pacesetting racing machines. It represents the high degree of craftsmanship and reliability that have made Yamaha a leader in these fields. This manual will give you an understanding of the operation, inspection, and basic maintenance of this motorcycle.
U1BF11E0.book Page 1 Tuesday, April 13, 2010 9:28 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.
U1BF11E0.book Page 2 Tuesday, April 13, 2010 9:28 AM IMPORTANT MANUAL INFORMATION EAU10193 XVS65A(C) OWNER’S MANUAL ©2010 by Yamaha Motor Corporation, U.S.A. 1st edition, April 2010 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.
U1BF11E0.book Page 1 Tuesday, April 13, 2010 9:28 AM TABLE OF CONTENTS LOCATION OF IMPORTANT LABELS .............................................1-1 Luggage strap holders ................. 4-13 Sidestand ..................................... 4-13 Ignition circuit cut-off system ........ 4-14 SAFETY INFORMATION ..................2-1 DESCRIPTION ..................................3-1 Left view ..........................................3-1 Right view ........................................
U1BF11E0.book Page 2 Tuesday, April 13, 2010 9:28 AM TABLE OF CONTENTS Checking the steering ...................7-28 Checking the wheel bearings .......7-28 Battery ..........................................7-29 Replacing the fuses ......................7-30 Replacing the headlight bulb ........7-31 Replacing a turn signal light bulb or the tail/brake light bulb ..........7-32 Supporting the motorcycle ............7-33 Front wheel ...................................7-34 Rear wheel .........................
U1BF11E0.book Page 1 Tuesday, April 13, 2010 9:28 AM LOCATION OF IMPORTANT LABELS EAU10384 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.
U1BF11E0.book Page 2 Tuesday, April 13, 2010 9:28 AM LOCATION OF IMPORTANT LABELS 1 4 1 2 5 A1 3 6 California only TIRE INFORMATION EMISSION HOSE ROUTING Cold tire normal pressure should be set as follows. CARB. CARB. FROM FUEL TANK • Up to 90 kg (198 lbs) load FRONT : 200 kPa, (2.00 kgf/cm²), 29 psi REAR : 225 kPa, (2.25 kgf/cm²), 33 psi • 90kg (198 lbs) ~ maximum load FRONT : 200 kPa, (2.00 kgf/cm²), 29 psi REAR : 250 kPa, (2.
U1BF11E0.book Page 1 Tuesday, April 13, 2010 9:28 AM SAFETY INFORMATION EAU10287 2 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.
U1BF11E0.book Page 2 Tuesday, April 13, 2010 9:28 AM SAFETY INFORMATION ● ● 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.
U1BF11E0.book Page 3 Tuesday, April 13, 2010 9:28 AM SAFETY INFORMATION ● ● 2 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.
U1BF11E0.book Page 4 Tuesday, April 13, 2010 9:28 AM SAFETY INFORMATION modifications not specifically recommended by Yamaha, even if sold and installed by a Yamaha dealer. Aftermarket Parts, Accessories, and Modifications While you may find aftermarket products similar in design and quality to genuine Yamaha accessories, recognize that some aftermarket accessories or modifications are not suitable because of potential safety hazards to you or others.
U1BF11E0.book Page 5 Tuesday, April 13, 2010 9:28 AM SAFETY INFORMATION ● ● 2 ● ● ● Check that the fuel cock (if equipped) is in the “OFF” position and that there are no fuel leaks. Point the front wheel straight ahead on the trailer or in the truck bed, and choke it in a rail to prevent movement. Shift the transmission in gear (for models with a manual transmission).
U1BF11E0.book Page 1 Tuesday, April 13, 2010 9:28 AM DESCRIPTION EAU10410 Left view 3 5 4 3 2 6,7 1 1. 2. 3. 4. 5. 6. 7.
U1BF11E0.book Page 2 Tuesday, April 13, 2010 9:28 AM DESCRIPTION EAU10420 Right view 3 4 1. 2. 3. 4. 5. 6.
U1BF11E0.book Page 3 Tuesday, April 13, 2010 9:28 AM DESCRIPTION EAU10430 Controls and instruments 3 1. 2. 3. 4. 5. 6. 7.
U1BF11E0.book Page 1 Tuesday, April 13, 2010 9:28 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.
U1BF11E0.book Page 2 Tuesday, April 13, 2010 9:28 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.
U1BF11E0.book Page 3 Tuesday, April 13, 2010 9:28 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.
U1BF11E0.book Page 4 Tuesday, April 13, 2010 9:28 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.
U1BF11E0.book Page 5 Tuesday, April 13, 2010 9:28 AM INSTRUMENT AND CONTROL FUNCTIONS EAU12871 EAU12890 EAU12941 Shift pedal Brake lever Brake pedal 1. Shift pedal 2. Neutral position 1. Brake lever 1. 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.
U1BF11E0.book Page 6 Tuesday, April 13, 2010 9:28 AM INSTRUMENT AND CONTROL FUNCTIONS EAU13121 Fuel tank cap 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. 2. 3. 4. Fuel tank cap lock cover “ ” mark Unlock. Lock.
U1BF11E0.book Page 7 Tuesday, April 13, 2010 9:28 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. EAU13313 4 1. Fuel tank filler tube 2. Maximum fuel level 3. Wipe up any spilled fuel immediately. NOTICE: Immediately wipe off spilled fuel with a clean, dry, soft cloth, since fuel may deteriorate painted surfaces or plastic parts. [ECA10071] 4. Be sure to securely close the fuel tank cap.
U1BF11E0.book Page 8 Tuesday, April 13, 2010 9:28 AM INSTRUMENT AND CONTROL FUNCTIONS EAU13445 ECA10701 EAU13550 Catalytic converters NOTICE Fuel cock This vehicle is equipped with catalytic converters in the exhaust system. Use only unleaded gasoline. The use of leaded gasoline will cause unrepairable damage to the catalytic converter. The fuel cock supplies fuel from the tank to the carburetors while also filtering it.
U1BF11E0.book Page 9 Tuesday, April 13, 2010 9:28 AM INSTRUMENT AND CONTROL FUNCTIONS ON 4 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”! EAU13620 Starter (choke) knob “ ” 1. Arrow mark positioned over “ON” 1.
U1BF11E0.book Page 10 Tuesday, April 13, 2010 9:28 AM INSTRUMENT AND CONTROL FUNCTIONS EAU14184 Seats 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. 1. Bolt 2. Passenger seat holder 1. Passenger seat holder 2. Projection Rider seat 1. Nut 2. Washer To install the passenger seat 1.
U1BF11E0.book Page 11 Tuesday, April 13, 2010 9:28 AM INSTRUMENT AND CONTROL FUNCTIONS 2. Install the passenger seat holder by installing its bolts. 3. Install the passenger seat. EAU14481 EAU14282 Helmet holder Storage compartment The storage compartment is located on the left side of the vehicle. TIP Make sure that the seats are properly secured before riding. To open the storage compartment 1. Slide the lock cover open, insert the key into the lock, and then turn it clockwise. 4 1.
U1BF11E0.book Page 12 Tuesday, April 13, 2010 9:28 AM INSTRUMENT AND CONTROL FUNCTIONS ● EAU14865 Adjusting the shock absorber assembly This shock absorber assembly is equipped with a spring preload adjusting ring. Use the special wrench and extension bar included in the owner’s tool kit to make the adjustment. ECA10101 NOTICE To close the storage compartment 1. Place the storage compartment cover in its original position as shown. 1. Storage compartment 2.
U1BF11E0.book Page 13 Tuesday, April 13, 2010 9:28 AM INSTRUMENT AND CONTROL FUNCTIONS EWA10221 WARNING 4 This shock absorber assembly contains highly pressurized nitrogen gas. Read and understand the following information before handling the shock absorber assembly. ● Do not tamper with or attempt to open the cylinder assembly. ● Do not subject the shock absorber assembly to an open flame or other high heat source. This may cause the unit to explode due to excessive gas pressure.
U1BF11E0.book Page 14 Tuesday, April 13, 2010 9:28 AM INSTRUMENT AND CONTROL FUNCTIONS this system regularly and have a Yamaha dealer repair it if it does not function properly. 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.
U1BF11E0.book Page 15 Tuesday, April 13, 2010 9:28 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.
U1BF11E0.book Page 1 Tuesday, April 13, 2010 9:28 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.
U1BF11E0.book Page 2 Tuesday, April 13, 2010 9:28 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.
U1BF11E0.book Page 1 Tuesday, April 13, 2010 9:28 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.
U1BF11E0.book Page 2 Tuesday, April 13, 2010 9:28 AM OPERATION AND IMPORTANT RIDING POINTS ECA11042 EAU16640 NOTICE Starting a warm engine For maximum engine life, never accelerate hard when the engine is cold! 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 1. Shift pedal 2.
U1BF11E0.book Page 3 Tuesday, April 13, 2010 9:28 AM OPERATION AND IMPORTANT RIDING POINTS ECA10260 NOTICE ● ● Even with the transmission in the neutral position, do not coast for long periods of time with the engine off, and do not tow the motorcycle for long distances. The transmission is properly lubricated only when the engine is running. Inadequate lubrication may damage the transmission.
U1BF11E0.book Page 4 Tuesday, April 13, 2010 9:28 AM OPERATION AND IMPORTANT RIDING POINTS EAU16841 Engine break-in 6 There is never a more important period in the life of your engine than the period between 0 and 1600 km (1000 mi). For this reason, you should read the following material carefully. Since the engine is brand new, do not put an excessive load on it for the first 1600 km (1000 mi). The various parts in the engine wear and polish themselves to the correct operating clearances.
U1BF11E0.book Page 1 Tuesday, April 13, 2010 9:28 AM PERIODIC MAINTENANCE AND ADJUSTMENT EAU17243 EWA15121 EAU17302 WARNING 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.
U1BF11E0.book Page 2 Tuesday, April 13, 2010 9:28 AM PERIODIC MAINTENANCE AND ADJUSTMENT EAU17451 Owner’s tool kit 1. Owner’s tool kit 7 The owner’s tool kit is located inside the storage compartment. (See page 4-11.) The service information included in this manual and the tools provided in the owner’s tool kit are intended to assist you in the performance of preventive maintenance and minor repairs.
U1BF11E0.book Page 3 Tuesday, April 13, 2010 9:28 AM PERIODIC MAINTENANCE AND ADJUSTMENT EAU48490 TIP ● ● From 24000 mi (37000 km) or 36 months, repeat the maintenance intervals starting from 8000 mi (13000 km) or 12 months. Items marked with an asterisk require special tools, data and technical skills, have a Yamaha dealer perform the service. EAU17601 Periodic maintenance chart for the emission control system INITIAL No. ITEM ROUTINE 1 * Fuel line • Check fuel hoses for cracks or damage.
U1BF11E0.book Page 4 Tuesday, April 13, 2010 9:28 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 7 * Idle speed • Check and adjust engine idle speed. √ √ √ √ √ 8 * Exhaust system • Check for leakage. • Tighten if necessary. • Replace gasket(s) if necessary.
U1BF11E0.book Page 5 Tuesday, April 13, 2010 9:28 AM PERIODIC MAINTENANCE AND ADJUSTMENT EAU32186 General maintenance and lubrication chart INITIAL No. ITEM ROUTINE 1 * Air filter element • Clean with compressed air. • Replace if necessary. 2 * Clutch • Check operation. • Adjust or replace cable. 3 * Front brake 4 * Rear brake 5 * Brake hose 6 * Wheels • Check runout, spoke tightness and for damage. • Tighten spokes if necessary.
U1BF11E0.book Page 6 Tuesday, April 13, 2010 9:28 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.
U1BF11E0.book Page 7 Tuesday, April 13, 2010 9:28 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.
U1BF11E0.book Page 8 Tuesday, April 13, 2010 9:28 AM PERIODIC MAINTENANCE AND ADJUSTMENT 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. • Replace the oil seals on the inner parts of the master cylinder and caliper cylinder every two years.
U1BF11E0.book Page 9 Tuesday, April 13, 2010 9:28 AM PERIODIC MAINTENANCE AND ADJUSTMENT Removing and installing panels To install the panel Place the panel in the original position, and then install the bolts. 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. Panel B EAU18771 EAU19151 To remove the panel Remove the bolt, and then pull the panel off as shown. 1.
U1BF11E0.book Page 10 Tuesday, April 13, 2010 9:28 AM PERIODIC MAINTENANCE AND ADJUSTMENT EAU19545 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. In addition, the condition of the spark plugs can reveal the condition of the engine. To remove a spark plug 1.
U1BF11E0.book Page 11 Tuesday, April 13, 2010 9:28 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 4. Measure the spark plug gap with a wire thickness gauge and, if necessary, adjust the gap to specification. To install a spark plug 1.
U1BF11E0.book Page 12 Tuesday, April 13, 2010 9:28 AM PERIODIC MAINTENANCE AND ADJUSTMENT 3. Remove the engine oil filler cap, the engine oil drain bolt and its gasket to drain the oil from the crankcase. EAU19745 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.
U1BF11E0.book Page 13 Tuesday, April 13, 2010 9:28 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. TIP Make sure that the O-ring is properly seated. 1. Inner oil filter element cover 2. Bolt 5.
U1BF11E0.book Page 14 Tuesday, April 13, 2010 9:28 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.
U1BF11E0.book Page 15 Tuesday, April 13, 2010 9:28 AM PERIODIC MAINTENANCE AND ADJUSTMENT EAU33383 Tightening torque: Final gear oil filler bolt: 23 Nm (2.3 m·kgf, 17 ft·lbf) Tightening torque: Final gear oil drain 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 final gear oil filler bolt, the final gear oil drain bolt and their gasket to drain the oil from the final gear case. 4.
U1BF11E0.book Page 16 Tuesday, April 13, 2010 9:28 AM PERIODIC MAINTENANCE AND ADJUSTMENT 1 2 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. The engine should never be operated without the air filter element installed, otherwise the piston(s) and/or cylinder(s) may become excessively worn.
U1BF11E0.book Page 17 Tuesday, April 13, 2010 9:28 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.
U1BF11E0.book Page 18 Tuesday, April 13, 2010 9:28 AM PERIODIC MAINTENANCE AND ADJUSTMENT EAU21401 EAU32524 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.
U1BF11E0.book Page 19 Tuesday, April 13, 2010 9:28 AM PERIODIC MAINTENANCE AND ADJUSTMENT Tire inspection EWA10562 WARNING ● ● 1. Tire sidewall 2. Tire wear indicator 3. Tire tread depth Always check the tires before operating the motorcycle. If a tire tread shows crosswise lines (minimum tread depth), if the tire has a nail or glass fragments in it, or if the sidewall is cracked, contact a Yamaha dealer immediately and have the tire replaced. Minimum tire tread depth (front and rear): 1.0 mm (0.
U1BF11E0.book Page 20 Tuesday, April 13, 2010 9:28 AM PERIODIC MAINTENANCE AND ADJUSTMENT EAU21942 Spoke wheels EWA10610 WARNING EAU22043 Adjusting the clutch lever free play The wheels on this model are not designed for use with tubeless tires. Do not attempt to use tubeless tires on this model. 7 To maximize the performance, durability, and safe operation of your motorcycle, note the following points regarding the specified wheels.
U1BF11E0.book Page 21 Tuesday, April 13, 2010 9:28 AM PERIODIC MAINTENANCE AND ADJUSTMENT 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 crankcase. 8. Tighten the locknut at the clutch lever and then slide the rubber cover to its original position. EAU22093 Adjusting the brake lever free play 1. Locknut 2. Brake lever free play adjusting screw 1.
U1BF11E0.book Page 22 Tuesday, April 13, 2010 9:28 AM PERIODIC MAINTENANCE AND ADJUSTMENT ● 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. Air in the hydraulic system will diminish the braking performance, which may result in loss of control and an accident.
U1BF11E0.book Page 23 Tuesday, April 13, 2010 9:28 AM PERIODIC MAINTENANCE AND ADJUSTMENT EWA11230 WARNING EAU22273 Brake light switches After adjusting the brake pedal position, the brake pedal free play must be adjusted. Brake pedal free play The brake pedal free play should measure 20.0–30.0 mm (0.79–1.18 in) at the brake pedal end. Periodically check the brake pedal free play and, if necessary, adjust it as follows.
U1BF11E0.book Page 24 Tuesday, April 13, 2010 9:28 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.
U1BF11E0.book Page 25 Tuesday, April 13, 2010 9:28 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.
U1BF11E0.book Page 26 Tuesday, April 13, 2010 9:28 AM PERIODIC MAINTENANCE AND ADJUSTMENT EAU44272 Checking and lubricating the brake and shift pedals EAU23142 Checking and lubricating the brake and clutch levers Brake lever The operation of the brake and shift pedals should be checked before each ride, and the pedal pivots should be lubricated if necessary.
U1BF11E0.book Page 27 Tuesday, April 13, 2010 9:28 AM PERIODIC MAINTENANCE AND ADJUSTMENT EAU23202 Checking and lubricating the sidestand EAUM1651 Lubricating the swingarm pivots The swingarm pivots must be lubricated by a Yamaha dealer at the intervals specified in the periodic maintenance and lubrication chart.
U1BF11E0.book Page 28 Tuesday, April 13, 2010 9:28 AM PERIODIC MAINTENANCE AND ADJUSTMENT EAU23283 Checking the steering ECA10590 NOTICE If any damage is found or the front fork does not operate smoothly, have a Yamaha dealer check or repair it. 7 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.
U1BF11E0.book Page 29 Tuesday, April 13, 2010 9:28 AM PERIODIC MAINTENANCE AND ADJUSTMENT EAU23387 EWA10760 Battery WARNING ● 1. Positive battery lead (red) 2. Negative battery lead (black) The battery is located behind panel B. (See page 7-9.) This model is equipped with a VRLA (Valve Regulated Lead Acid) battery. There is no need to check the electrolyte or to add distilled water. However, the battery lead connections need to be checked and, if necessary, tightened.
U1BF11E0.book Page 30 Tuesday, April 13, 2010 9:28 AM PERIODIC MAINTENANCE AND ADJUSTMENT nect the negative lead before disconnecting the positive lead. avoid causing extensive damage to the electrical system and possibly a fire. [EWA15131] EAU23526 Replacing the fuses [ECA16302] 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.
U1BF11E0.book Page 31 Tuesday, April 13, 2010 9:28 AM PERIODIC MAINTENANCE AND ADJUSTMENT 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. Turn the key to “ON” and turn on the electrical circuit in question to check if the device operates. 4. If the fuse immediately blows again, have a Yamaha dealer check the electrical system.
U1BF11E0.book Page 32 Tuesday, April 13, 2010 9:28 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. EAU24283 Replacing a turn signal light bulb or the tail/brake light bulb 1. Remove the lens by removing the screws. 1. Headlight coupler 2. Headlight bulb cover 3.
U1BF11E0.book Page 33 Tuesday, April 13, 2010 9:28 AM PERIODIC MAINTENANCE AND ADJUSTMENT 2. Remove the burnt-out bulb by pushing it in and turning it counterclockwise. 3. Insert a new bulb into the socket, push it in, and then turn it clockwise until it stops. 4. Install the lens by installing the screws. NOTICE: Do not overtighten the screws, otherwise the lens may break.
U1BF11E0.book Page 34 Tuesday, April 13, 2010 9:28 AM PERIODIC MAINTENANCE AND ADJUSTMENT 2. Lift the wheel up between the fork legs. EAU24360 Front wheel 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. 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.
U1BF11E0.book Page 35 Tuesday, April 13, 2010 9:28 AM PERIODIC MAINTENANCE AND ADJUSTMENT 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. Tightening torque: Front wheel axle pinch bolt: 20 Nm (2.0 m·kgf, 14 ft·lbf) 7. While applying the front brake, push down hard on the handlebars several times to check if the front fork compresses and rebounds smoothly. 8. Connect the speedometer cable.
U1BF11E0.book Page 36 Tuesday, April 13, 2010 9:28 AM PERIODIC MAINTENANCE AND ADJUSTMENT 1 1. Bolt 2. Final gear case 7 7. Lift the rear wheel off the ground according to the procedure on page 7-33. 8. While supporting the drive shaft, pull the rear wheel back to remove the following parts as an assembly: wheel, wheel axle, final gear case, and drive shaft. 1. Drive shaft 1. Middle gear universal joint 2. Drive shaft TIP Make sure to support the drive shaft as it is being pulled out.
U1BF11E0.book Page 37 Tuesday, April 13, 2010 9:28 AM PERIODIC MAINTENANCE AND ADJUSTMENT EAU25851 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 nut: 20 Nm (2.0 m·kgf, 14 ft·lbf) Troubleshooting 8. Adjust the brake pedal free play. (See page 7-22.) EWA10660 WARNING After adjusting the brake pedal free play, check the operation of the brake light.
U1BF11E0.book Page 38 Tuesday, April 13, 2010 9:28 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.
U1BF11E0.book Page 1 Tuesday, April 13, 2010 9:28 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.
U1BF11E0.book Page 2 Tuesday, April 13, 2010 9:28 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.
U1BF11E0.book Page 3 Tuesday, April 13, 2010 9:28 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.
U1BF11E0.book Page 4 Tuesday, April 13, 2010 9:28 AM MOTORCYCLE CARE AND STORAGE 8 2. For motorcycles equipped with a fuel cock that has an “OFF” position: Turn the fuel cock lever to “OFF”. 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.
U1BF11E0.book Page 1 Tuesday, April 13, 2010 9:28 AM SPECIFICATIONS Dimensions: Overall length: 2340 mm (92.1 in) Overall width: 880 mm (34.6 in) Overall height: 1075 mm (42.3 in) Seat height: 695 mm (27.4 in) Wheelbase: 1610 mm (63.4 in) Ground clearance: 140 mm (5.51 in) Minimum turning radius: 3100 mm (122.
U1BF11E0.book Page 2 Tuesday, April 13, 2010 9:28 AM SPECIFICATIONS 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: Frame type: Double cradle Caster angle: 35.00 ° Trail: 153.0 mm (6.
U1BF11E0.book Page 3 Tuesday, April 13, 2010 9:28 AM SPECIFICATIONS Voltage, capacity: 12 V, 10.0 Ah Headlight: Bulb type: Halogen bulb Carburetor heater fuse: 15.0 A Ignitor unit fuse: 5.0 A Bulb voltage, wattage × quantity: Headlight: 12 V, 60 W/55 W × 1 Tail/brake light: 12 V, 8.0 W/27.0 W × 1 Front turn signal/position light: 12 V, 23 W/8.0 W × 2 Rear turn signal light: 12 V, 21.0 W × 2 Meter lighting: 12 V, 1.7 W × 1 Neutral indicator light: 12 V, 1.7 W × 1 High beam indicator light: 12 V, 1.
U1BF11E0.book Page 1 Tuesday, April 13, 2010 9:28 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.
U1BF11E0.book Page 2 Tuesday, April 13, 2010 9:28 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. EAU48061 Vehicle Emission Control Information label 1 1.
U1BF11E0.book Page 3 Tuesday, April 13, 2010 9:28 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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U1BF11E0.book Page 5 Tuesday, April 13, 2010 9:28 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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U1BF11E0.book Page 7 Tuesday, April 13, 2010 9:28 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.
U1BF11E0.book Page 8 Tuesday, April 13, 2010 9:28 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.
U1BF11E0.book Page 9 Tuesday, April 13, 2010 9:28 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.
U1BF11E0.book Page 10 Tuesday, April 13, 2010 9:28 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.
U1BF11E0.book Page 1 Tuesday, April 13, 2010 9:28 AM INDEX A F Air filter element, cleaning..................... 7-15 Final gear oil ......................................... 7-14 Front fork, checking .............................. 7-27 Fuel......................................................... 4-6 Fuel cock ................................................ 4-8 Fuel tank cap .......................................... 4-6 Fuses, replacing ................................... 7-30 B Battery.............
U1BF11E0.book Page 2 Tuesday, April 13, 2010 9:28 AM INDEX Turn signal switch................................... 4-4 V Valve clearance .................................... 7-18 Vehicle Emission Control Information label.................................................... 10-2 Vehicle identification number................ 10-1 W Warranty, extended .............................. 10-9 Warranty, limited................................... 10-7 Wheel bearings, checking .................... 7-28 Wheel (front) .
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YAMAHA MOTOR CO., LTD. PRINTED ON RECYCLED PAPER PRINTED IN JAPAN 2010.04-0.
