clutch YAMAHA XVS650A 2002 User Guide

PERIODIC MAINTENANCE AND MINOR REPAIR
6-2
6
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 techni-
cal skills.
_CP-03ENO. ITEM CHECK OR MAINTENANCE JOBODOMETER READING (×1,000 km)
ANNUAL
CHECK
1 10203040
1
*Fuel lineCheck fuel hoses for cracks or damage.√√√√ √
2*Fuel filterCheck condition.√√
3 Spark plugsCheck condition.
Clean and regap.√√
Replace.√√
4*ValvesCheck valve clearance.
Adjust.√√√√
5 Air filter elementClean.√√
Replace.√√
6ClutchCheck operation.
Adjust.√√√√√
7*Front brakeCheck operation, fluid level and vehicle for fluid leakage.
(See NOTE on page 6-4.)√√ √ √ √ √
Replace brake pads. Whenever worn to the limit
8*Rear brakeCheck operation and adjust brake pedal free play.√√√√√ √
Replace brake shoes. Whenever worn to the limit
9*Brake hoseCheck for cracks or damage.√√√√ √
Replace. (See NOTE on page 6-4.) Every 4 years
U5SCE0.book Page 2 Thursday, June 7, 2001 11:24 AM

PERIODIC MAINTENANCE AND MINOR REPAIR
6-11
65. 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.9. Add the specified amount of the
recommended oil, and then install
and tighten the oil filler cap.
EC000072*
CAUTION:_

In order to prevent clutch slip-
page (since the engine oil also
lubricates the clutch), do not
mix any chemical additives with
the oil or use oils of a “CD”
grade or higher. In addition, do
not use oils labeled “ENERGY
CONSERVING II” or higher.


Make sure that no foreign mate-
rial 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.
1. Oil filter element
2. O-ringTightening torque:
Engine oil drain bolt:
43 Nm (4.3 m·kgf)
Recommended engine oil:
See page 8-1.
Oil quantity:
Without oil filter element
replacement:
2.6 L
With oil filter element
replacement:
2.8 L
Total amount (dry engine):
3.2 L
U5SCE0.book Page 11 Thursday, June 7, 2001 11:24 AM

PERIODIC MAINTENANCE AND MINOR REPAIR
6-19
6
EAU00681
WARNING
@

Have a Yamaha dealer replace
excessively worn tires. Besides
being illegal, operating the
motorcycle with excessively
worn tires decreases riding sta-
bility and can lead to loss of
control.


The replacement of all wheel-
and brake-related parts, includ-
ing the tires, should be left to a
Yamaha dealer, who has the
necessary professional knowl-
edge and experience.


It is not recommended to patch
a punctured tube. If unavoid-
able, however, patch the tube
very carefully and replace it as
soon as possible with a high-
quality product.
@
EAU00685
Spoke wheels To maximize the performance, durabil-
ity, and safe operation of your motor-
cycle, note the following points
regarding the specified wheels.

The wheel rims should be checked
for cracks, bends or warpage, and
the spokes for looseness or dam-
age before each ride. If any dam-
age is found, have a Yamaha
dealer replace the wheel. Do not
attempt even the smallest repair to
the wheel. A deformed or cracked
wheel must be replaced.


The wheel should be balanced
whenever either the tire or wheel
has been changed or replaced. An
unbalanced wheel can result in
poor performance, adverse han-
dling characteristics, and a short-
ened tire life.


Ride at moderate speeds after
changing a tire since the tire sur-
face must first be “broken in” for it
to develop its optimal characteris-
tics.
EAU00694*
Adjusting the clutch lever free
play The clutch lever free play should mea-
sure 10–15 mm (XVS650) or 5–10 mm
(XVS650A) as shown. Periodically
check the clutch lever free play and, if
necessary, adjust it as follows.
1. Loosen the locknut at the clutch
lever.
2. To increase the clutch lever free
play, turn the adjusting bolt in di-
rection
a. To decrease the clutch
lever free play, turn the adjusting
bolt in direction
b.1. Locknut
2. Clutch lever free play adjusting bolt
c. Clutch lever free play
U5SCE0.book Page 19 Thursday, June 7, 2001 11:24 AM

PERIODIC MAINTENANCE AND MINOR REPAIR
6-20
6 3. If the specified clutch lever free
play could be obtained as de-
scribed 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 loos-
en the clutch cable.
5. Loosen the locknut at the crank-
case.
6. To increase the clutch lever free
play, turn the adjusting nut in di-
rection
a. To decrease the clutch
lever free play, turn the adjusting
nut in direction
b.
7. Tighten the locknut at the clutch
lever and the crankcase.
EAU00696
Adjusting the brake lever free
play The brake lever free play should mea-
sure 10–15 mm 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. To increase the brake lever free
play, turn the adjusting bolt in di-
rection
a. To decrease the brake
lever free play, turn the adjusting
bolt in direction
b.
3. Tighten the locknut.
1. Clutch lever free play adjusting nut
2. Locknut
a. Brake lever free play
1. Locknut
2. Brake lever free play adjusting bolt
U5SCE0.book Page 20 Thursday, June 7, 2001 11:24 AM

PERIODIC MAINTENANCE AND MINOR REPAIR
6-26
6
EAU03370
Checking and lubricating the
brake and shift pedals The operation of the brake and shift
pedals should be checked before each
ride, and the pedal pivots should be lu-
bricated if necessary.
EAU03164
Checking and lubricating the
brake and clutch levers The operation of the brake and clutch
levers should be checked before each
ride, and the lever pivots should be lu-
bricated if necessary.
Recommended lubricant:
Lithium-soap-based grease
(all-purpose grease) Recommended lubricant:
Lithium-soap-based grease
(all-purpose grease)
U5SCE0.book Page 26 Thursday, June 7, 2001 11:24 AM

SPECIFICATIONS
8-2
8
Quantity
Without oil filter element
replacement 2.6 L
With oil filter element
replacement 2.8 L
Total amount (dry engine) 3.2 L
Final gear oil
Type Hypoid gear oil SAE 80
(API GL4) or multi-grade hypoid
gear oil SAE 80W-90
Final gear case capacity 0.19 L
Air filterDry type element
Fuel
Type REGULAR UNLEADED
GASOLINE ONLY
Fuel tank capacity 16 L
Reserve amount 3 L
Carburetor
Manufacturer MIKUNI
Model × quantity BDS28 × 2
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, result-
ing in reduced component life and poor engine performance.
Spark plug
Manufacturer/model NGK / DPR7EA-9 or
DENSO / X22EPR-U9
Gap 0.8–0.9 mm
Clutch typeWet, multiple-disc
Transmission
Primary reduction system Spur gear
Primary reduction ratio 1.789
Secondary reduction system Shaft drive
Secondary reduction ratio 3.071
Transmission type Constant-mesh 5-speed
Operation Left foot
Gear ratio 1st 2.714
2nd 1.900
3rd 1.458
4th 1.167
5th 0.967
Chassis
Frame type Double cradle
Caster angle 35°
Tr a i l
XVS650 153 mm
XVS650A 145 mm
U5SCE0.book Page 2 Thursday, June 7, 2001 11:24 AM

10-INDEXAAir filter element, cleaning ...................... 6-13
Anti-theft alarm ........................................3-3BBattery ................................................... 6-29
Brake and clutch levers, checking
and lubricating ..................................... 6-26
Brake and shift pedals, checking
and lubricating ..................................... 6-26
Brake fluid, changing ............................. 6-25
Brake fluid level, checking...................... 6-24
Brake lever...............................................3-6
Brake lever free play, adjusting .............. 6-20
Brake light switch (rear), adjusting ......... 6-22
Brake pads and shoes, checking ........... 6-23
Brake pedal..............................................3-6
Brake pedal position and free play,
adjusting .............................................. 6-21CCables, checking and lubricating............ 6-25
Carburetors, adjusting............................ 6-14
Care.........................................................7-1
Clutch lever ..............................................3-5
Clutch lever free play, adjusting ............. 6-19
Conversion table ......................................8-6DDimmer switch .........................................3-4EEngine break-in........................................5-5
Engine oil and oil filter element.................6-9
Engine stop switch ...................................3-4
Engine trouble warning light .................... 3-2FFinal gear oil .......................................... 6-12
Front fork, checking ............................... 6-27
Fuel ......................................................... 3-7
Fuel cock ................................................. 3-9
Fuel consumption, tips for reducing ......... 5-4
Fuel tank cap ........................................... 3-7
Fuses, replacing .................................... 6-31HHandlebar switches ................................. 3-3
Headlight bulb, replacing ....................... 6-32
Helmet holder ........................................ 3-13
High beam indicator light ......................... 3-2
Horn switch ............................................. 3-4IIdentification numbers ............................. 9-1
Idling speed, adjusting ........................... 6-15
Ignition circuit cut-off system.................. 3-17
Indicator and warning lights ..................... 3-2KKey identification number ........................ 9-1LLight switch.............................................. 3-4
Luggage strap holders ........................... 3-16MMain switch/steering lock ......................... 3-1
Model label .............................................. 9-2
NNeutral indicator light ...............................3-2PPanels, removing and installing ................6-5
Parking.....................................................5-5
Part locations ...........................................2-1
Pass switch ..............................................3-4
Periodic maintenance and
lubrication chart .....................................6-2
Pre-operation check list ............................4-1SSafety information ....................................1-1
Seats (XVS650) .....................................3-11
Passenger seat.................................3-11
Rider seat .........................................3-11
Seats (XVS650A) ...................................3-12
Passenger seat.................................3-12
Rider seat .........................................3-12
Shifting .....................................................5-3
Shift pedal (XVS650)................................3-5
Shift pedal (XVS650A) .............................3-5
Shift points (for Switzerland only) .............5-4
Shock absorber assembly, adjusting ......3-15
Sidestand ...............................................3-17
Sidestand, checking and lubricating .......6-27
Spark plugs, checking ..............................6-7
Specifications ...........................................8-1
Speedometer unit.....................................3-3
Starter (choke) knob...............................3-10
Starting a warm engine ............................5-2
Starting the engine ...................................5-1
Start switch ..............................................3-4
U5SCE0.book Page 1 Thursday, June 7, 2001 11:24 AM