warning YAMAHA XVS650A 2002 Owner's Manual

PERIODIC MAINTENANCE AND MINOR REPAIR
6-22
6 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 ad-
justing bolt in direction
b.
3. Tighten the locknut.
EWA00044
WARNING
_ After adjusting the brake pedal posi-
tion, the brake pedal free play must
be adjusted. _
Brake pedal free play
The brake pedal free play should mea-
sure 20–30 mm at the brake pedal end.
Periodically check the brake pedal free
play and, if necessary, adjust it as fol-
lows.
To increase the brake pedal free play,
turn the adjusting nut at the brake rod
in direction
a. To decrease the brake
pedal free play, turn the adjusting nut in
direction
b.
EAU00713
Adjusting the rear brake light
switch The rear brake light switch, which is ac-
tivated by the brake pedal, is properly
adjusted when the brake light comes
on just before braking takes effect. If
necessary, adjust the brake light switch
as follows.
Turn the adjusting nut while holding the
rear brake light switch in place. To
make the brake light come on earlier,
turn the adjusting nut in direction
a. To
make the brake light come on later,
turn the adjusting nut in direction
b.
1. Locknut
2. Brake pedal position adjusting bolt
1. Brake pedal free play adjusting nut
1. Rear brake light switch
2. Rear brake light switch adjusting nut
U5SCE0.book Page 22 Thursday, June 7, 2001 11:24 AM

PERIODIC MAINTENANCE AND MINOR REPAIR
6-25
6
EAU03985
Changing the brake fluid Have a Yamaha dealer change the
brake fluid at the intervals specified in
the NOTE after the periodic mainte-
nance 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 dam-
aged or leaking.

Oil seals: Replace every two
years.


Brake hose: Replace every four
years.
EAU02962
Checking and lubricating the
cables The operation of all control cables and
the condition of the cables should be
checked before each ride, and the ca-
bles and cable ends should be lubricat-
ed if necessary. If a cable is damaged
or does not move smoothly, have a
Yamaha dealer check or replace it.
EW000112
WARNING
@ Damage to the outer sheath may in-
terfere with proper cable operation
and will cause the inner cable to
rust. Replace a damaged cable as
soon as possible to prevent unsafe
conditions. @
EAU04034
Checking and lubricating the
throttle grip and cable The operation of the throttle grip should
be checked before each ride. In addi-
tion, the cable should be lubricated or
replaced at the intervals specified in
the periodic maintenance chart.
Recommended lubricant:
Engine oil
U5SCE0.book Page 25 Thursday, June 7, 2001 11:24 AM

PERIODIC MAINTENANCE AND MINOR REPAIR
6-27
6
EAU03165
Checking and lubricating the
sidestand The operation of the sidestand should
be checked before each ride, and the
sidestand pivot and metal-to-metal
contact surfaces should be lubricated if
necessary.
EW000113
WARNING
@ If the sidestand does not move up
and down smoothly, have a Yamaha
dealer check or repair it. @
EAU02939
Checking the front fork The condition and operation of the front
fork must be checked as follows at the
intervals specified in the periodic main-
tenance and lubrication chart.
To check the condition
EW000115
WARNING
@ Securely support the motorcycle so
that there is no danger of it falling
over. @Check the inner tubes for scratches,
damage and excessive oil leakage.
Recommended lubricant:
Lithium-soap-based grease
(all-purpose grease)
U5SCE0.book Page 27 Thursday, June 7, 2001 11:24 AM

PERIODIC MAINTENANCE AND MINOR REPAIR
6-28
6 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 handle-
bars several times to check if the
front fork compresses and re-
bounds smoothly.
EC000098
CAUTION:@ If any damage is found or the front
fork does not operate smoothly,
have a Yamaha dealer check or re-
pair it. @
EAU00794
Checking the steering Worn or loose steering bearings may
cause danger. Therefore, the operation
of the steering must be checked as fol-
lows at the intervals specified in the pe-
riodic maintenance and lubrication
chart.
1. Place a stand under the engine to
raise the front wheel off the
ground.
EW000115
WARNING
@ Securely support the motorcycle so
that there is no danger of it falling
over. @
2. Hold the lower ends of the front
fork legs and try to move them for-
ward and backward. If any free
play can be felt, have a Yamaha
dealer check or repair the steer-
ing.
U5SCE0.book Page 28 Thursday, June 7, 2001 11:24 AM

PERIODIC MAINTENANCE AND MINOR REPAIR
6-29
6
EAU01144
Checking the wheel bearings The front and rear wheel bearings must
be checked at the intervals specified in
the periodic maintenance and lubrica-
tion chart. If there is play in the wheel
hub or if the wheel does not turn
smoothly, have a Yamaha dealer
check the wheel bearings.
EAU04242
Battery The battery is located behind panel B.
(See page 6-7 for panel removal and
installation procedures.)
This motorcycle is equipped with a
sealed-type (MF) battery, which does
not require any maintenance. There is
no need to check the electrolyte or to
add distilled water.
EC000101
CAUTION:_ Never attempt to remove the battery
cell seals, as this would permanent-
ly damage the battery. _
EW000116
WARNING
_

Electrolyte is poisonous and
dangerous since it contains sul-
furic acid, which causes severe
burns. Avoid any contact with
skin, eyes or clothing and al-
ways shield your eyes when
working near batteries. In case
of contact, administer the fol-
lowing FIRST AID.EXTERNAL: Flush with plenty
of water.
INTERNAL: Drink large quan-
tities of water or milk and im-
mediately call a physician.
EYES: Flush with water for
15 minutes and seek prompt
medical attention.


Batteries produce explosive hy-
drogen gas. Therefore, keep
sparks, flames, cigarettes, etc.,
away from the battery and pro-
vide sufficient ventilation when
charging it in an enclosed
space.


KEEP THIS AND ALL BATTER-
IES OUT OF THE REACH OF
CHILDREN.
_
U5SCE0.book Page 29 Thursday, June 7, 2001 11:24 AM

PERIODIC MAINTENANCE AND MINOR REPAIR
6-32
6
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 re-
moving the screws.2. Disconnect the headlight coupler,
and then remove the bulb cover.3. Unhook the headlight bulb holder,
and then remove the defective
bulb.
EW000119
WARNING
_ Headlight bulbs get very hot. There-
fore, keep flammable products away
from a lit headlight bulb, and do not
touch the bulb until it has cooled
down. _4. Place a new headlight bulb into
position, and then secure it with
the bulb holder.
1. Screw (× 2)
1. Headlight coupler
2. Headlight bulb cover
1. Headlight bulb holder
U5SCE0.book Page 32 Thursday, June 7, 2001 11:24 AM

PERIODIC MAINTENANCE AND MINOR REPAIR
6-35
6
EAU03737
Front wheel To remove the front wheel
EW000122
WARNING
_

It is advisable to have a Yamaha
dealer service the wheel.


Securely support the motor-
cycle so that there is no danger
of it falling over.
_1. Disconnect the speedometer ca-
ble from the front wheel.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.
ECA00048
CAUTION:_ Do not apply the brake after the
wheel has been removed together
with the brake disc, otherwise the
brake pads will be forced shut. _
EAU03885
To install the front wheel
1. Install the speedometer gear unit
into the wheel hub so that the pro-
jections mesh with the slots.
2. Lift the wheel up between the fork
legs.NOTE:_ Make sure that there is enough space
between the brake pads before insert-
ing the brake disc and that the slot in
the speedometer gear unit fits over the
retainer on the fork leg. _3. Insert the wheel axle.
1. Speedometer cable
1. Rubber cap
2. Wheel axle
3. Front wheel axle pinch bolt
1. Speedometer gear unit
2. Speedometer cable
U5SCE0.book Page 35 Thursday, June 7, 2001 11:24 AM

PERIODIC MAINTENANCE AND MINOR REPAIR
6-36
6 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.
7. Tighten the front wheel axle pinch
bolt to the specified torque.
8. Connect the speedometer cable.
EAU01350
Rear wheel To remove the rear wheel
EW000122
WARNING
@

It is advisable to have a Yamaha
dealer service the wheel.


Securely support the motorcycle
so that there is no danger of it
falling over.
@1. Loosen the axle nut.2. Disconnect the brake torque rod
from the brake shoe plate by re-
moving the bolt.
3. Loosen the brake torque rod bolt
at the swingarm.
4. Remove the brake pedal free play
adjusting nut, and then disconnect
the brake rod from the brake cam-
shaft lever.
5. Remove panel A. (See page 6-6
for panel removal and installation
procedures.) Tightening torque:
Wheel axle:
59 Nm (5.9 m·kgf)
Tightening torque:
Front wheel axle pinch bolt:
20 Nm (2.0 m·kgf)1. Axle nut
1. Brake pedal free play adjusting nut
2. Brake camshaft lever
3. Brake rod
4. Bolt (shoe plate)
5. Brake torque rod
6. Bolt (swingarm)
U5SCE0.book Page 36 Thursday, June 7, 2001 11:24 AM

PERIODIC MAINTENANCE AND MINOR REPAIR
6-38
6
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 dur-
ing operation. Any problem in the fuel,
compression, or ignition systems, for
example, can cause poor starting and
loss of power.
The following troubleshooting chart
represents a quick and easy procedure
for checking these vital systems your-
self. However, should your motorcycle
require any repair, take it to a Yamaha
dealer, whose skilled technicians have
the necessary tools, experience, and
know-how to service the motorcycle
properly.
Use only genuine Yamaha replace-
ment parts. Imitation parts may look
like Yamaha parts, but they are often
inferior, have a shorter service life and
can lead to expensive repair bills.
U5SCE0.book Page 38 Thursday, June 7, 2001 11:24 AM

PERIODIC MAINTENANCE AND MINOR REPAIR
6-39
6
EAU01297
Troubleshooting chart
EW000125
WARNING
@ Keep away open flames and do not smoke while checking or working on the fuel system.@
Check the fuel level in
the fuel tank.1. Fuel
There is enough fuel.
There is no fuel.
Check the compression.
Supply fuel.
The engine does not start.
Check the compression.
Operate the electric starter.2. Compression
There is compression.
There is no compression.
Check the ignition.
Have a Yamaha dealer
check the vehicle.
Remove the spark plugs
and check the electrodes.3. Ignition
Wipe off with a dry cloth and correct the
spark plug gaps, or replace the spark plugs.
Have a Yamaha dealer check the vehicle.
The engine does not start.
Have a Yamaha dealer
check the vehicle.
The engine does not start.
Check the battery.
Operate the electric starter.4. Battery
The engine turns over
quickly.
The engine turns over
slowly.
The battery is good.Check the battery lead connections,
and charge the battery if necessary.
DryWet
Open the throttle halfway and operate
the electric starter.
U5SCE0.book Page 39 Thursday, June 7, 2001 11:24 AM