YAMAHA XVS650A 2005 Service Manual

PERIODIC MAINTENANCE AND MINOR REPAIR
6-3
6
9*Brake hoseCheck for cracks or damage.√√√√ √
Replace. Every 4 years
10*WheelsCheck runout, spoke tightness and for damage.
Tighten spokes if necessary.√√√√
11*TiresCheck tread depth and for damage.
Replace if necessary.
Check air pressure.
Correct if necessary.√√√√ √
12*Wheel bearingsCheck bearing for looseness or damage.√√√√
13*SwingarmCheck operation and for excessive play.√√√√
Lubricate with lithium-soap-based grease. Every 50000 km
14*Steering bearingsCheck bearing play and steering for roughness.√√√√√
Lubricate with lithium-soap-based grease. Every 20000 km
15*Chassis fastenersMake sure that all nuts, bolts and screws are properly
tightened.√√√√ √
16 SidestandCheck operation.
Lubricate.√√√√ √
17*Sidestand switchCheck operation.√√√√√ √
18*Front forkCheck operation and for oil leakage.√√√√
19*Shock absorber assem-
blyCheck operation and shock absorber for oil leakage.√√√√
20*CarburetorsCheck starter (choke) operation.
Adjust engine idling speed and synchronization.√√√√√ √
21 Engine oilChange.
Check oil level and vehicle for oil leakage.√√√√√ √ NO. ITEM CHECK OR MAINTENANCE JOBODOMETER READING (× 1000 km)
ANNUAL
CHECK
1 10203040
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PERIODIC MAINTENANCE AND MINOR REPAIR
6-4
6
EAU18660
NOTE:

The air filter needs more frequent service if you are riding in unusually wet or dusty areas.


Hydraulic brake service
Regularly check and, if necessary, correct the brake fluid level.
Every two years replace the internal components of the brake master cylinder and caliper, and change the brake fluid.Replace the brake hoses every four years and if cracked or damaged.
22 Engine oil filter elementReplace.√√√
23 Final gear oilCheck oil level and vehicle for oil leakage.√√ √
Change.√√√
24*Front and rear brake
switchesCheck operation.√√√√√ √
25Moving parts and ca-
blesLubricate.√√√√ √
26*Throttle grip housing
and cableCheck operation and free play.
Adjust the throttle cable free play if necessary.
Lubricate the throttle grip housing and cable.√√√√ √
27*Muffler and exhaust
pipeCheck the screw clamp for looseness.√√√√√
28*Lights, signals and
switchesCheck operation.
Adjust headlight beam.√√√√√ √ NO. ITEM CHECK OR MAINTENANCE JOBODOMETER READING (× 1000 km)
ANNUAL
CHECK
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PERIODIC MAINTENANCE AND MINOR REPAIR
6-5
6
EAU18771
Removing and installing
panels 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.
EAU19193
Panel A
To remove the panelRemove the bolts, and then take the
panel off.To install the panel
Place the panel in the original position,
and then install the bolts.
EAU19151
Panel B
To remove the panelRemove the bolt, and then pull the pan-
el off as shown.
To install the panelPlace the panel in the original position,
and then install the bolt.
1. Panel A
1. Panel B
1. Bolt
1. Bolt
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PERIODIC MAINTENANCE AND MINOR REPAIR
6-6
6
EAU19543
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 mainte-
nance and lubrication chart. In addition,
the condition of the spark plugs can re-
veal the condition of the engine.
To remove a spark plug
1. Remove the spark plug cap.
2. Remove the spark plug as shown,
with the spark plug wrench includ-
ed in the owner’s tool kit.To check the spark plugs
1. Check that the porcelain insulator
around the center electrode on
each spark plug is a medium-to-
light tan (the ideal color when the
vehicle is ridden normally).
2. Check that all spark plugs installed
in the engine have the same color.
NOTE:If any spark plug shows a distinctly dif-
ferent color, the engine could be defec-
tive. Do not attempt to diagnose such
problems yourself. Instead, have aYamaha dealer check the vehicle.
1. Spark plug cap
1. Spark plug wrench
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PERIODIC MAINTENANCE AND MINOR REPAIR
6-7
6 3. Check each spark plug for elec-
trode erosion and excessive car-
bon or other deposits, and replace
it if necessary.
To install a spark plug
1. Measure the spark plug gap with a
wire thickness gauge and, if nec-
essary, adjust the gap to specifica-
tion.2. Clean the surface of the spark plug
gasket and its mating surface, and
then wipe off any grime from the
spark plug threads.
3. Install the spark plug with the
spark plug wrench, and then tight-
en it to the specified torque.
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 speci-fied torque as soon as possible.
4. Install the spark plug cap.
EAU19742
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 ele-
ment replaced at the intervals specified
in the periodic maintenance and lubri-
cation chart.
To check the engine oil level
1. Place the vehicle on a level sur-
face and hold it in an upright posi-
tion.NOTE:
Make sure that the vehicle is positioned
straight up when checking the oil level.
A slight tilt to the side can result in afalse reading.
2. Start the engine, warm it up for
several minutes, and then turn it
off.
3. Wait a few minutes until the oil set-
tles, and then check the oil level
through the check window located
at the bottom-left side of the crank-
case.
Specified spark plug:
NGK/DPR7EA-9
DENSO/X22EPR-U91. Spark plug gapSpark plug gap:
0.8–0.9 mm (0.031–0.035 in)
Tightening torque:
Spark plug:
17.5 Nm (1.75 m·kgf, 12.7 ft·lbf)
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PERIODIC MAINTENANCE AND MINOR REPAIR
6-8
6
NOTE:The engine oil should be between theminimum and maximum level marks.
4. If the engine oil is at or below the
minimum level mark, add sufficient
oil of the recommended type to
raise it to the correct level.
To change the engine oil (with or
without oil filter element replace-
ment)
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.
NOTE:
Skip steps 4–7 if the oil filter element isnot being replaced.
4. Remove the outer and inner oil fil-
ter element covers by removing
the bolts.
5. Remove the oil filter element and
O-ring.
1. Engine oil level check window
2. Maximum level mark
3. Minimum level mark
1. Engine oil drain bolt
1. Outer oil filter element cover
2. Bolt
1. Inner oil filter element cover
2. Bolt
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PERIODIC MAINTENANCE AND MINOR REPAIR
6-9
6 6. Install a new oil filter element and
the O-ring.
7. Install the oil filter element covers
by installing the bolts, and then
tighten them to the specified
torque.
8. Install the engine oil drain bolt, and
then tighten it to the specified
torque.
NOTE:Check the washer for damage and re-place it if necessary.9. Add the specified amount of the
recommended oil, and then install
and tighten the oil filler cap.
CAUTION:
ECA11620


In order to prevent clutch slip-
page (since the engine oil also
lubricates the clutch), do not
mix any chemical additives. Do
not use oils with a diesel speci-
fication of “CD” or oils of a high-
er quality than specified. 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, im-
mediately 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:
Oil filter element cover bolt:
10 Nm (1.0 m·kgf, 7 ft·lbf)
Tightening torque:
Engine oil drain bolt:
43 Nm (4.3 m·kgf, 31 ft·lbf)
Recommended engine oil:
See page 8-1.
Oil quantity:
Without oil filter element replace-
ment:
2.60 L (2.75 US qt) (2.29 Imp.qt)
With oil filter element replacement:
2.80 L (2.96 US qt) (2.46 Imp.qt)
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PERIODIC MAINTENANCE AND MINOR REPAIR
6-10
6
EAU20022
Final gear oil The final gear case must be checked
for oil leakage before each ride. If any
leakage is found, have a Yamaha deal-
er check and repair the vehicle. In addi-
tion, 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.
WARNING
EWA10370


Make sure that no foreign mate-
rial enters the final gear case.


Make sure that no oil gets on thetire or wheel.
To check the final gear oil level
1. Place the vehicle on a level sur-
face and hold it in an upright posi-
tion.
NOTE:

The final gear oil level must be
checked on a cold engine.


Make sure that the vehicle is posi-
tioned straight up when checking
the oil level. A slight tilt to the sidecan result in a false reading.2. Remove the oil filler bolt, and then
check the oil level in the final gear
case.
NOTE:The oil level should be at the brim of thefiller hole.
3. If the oil is below the brim of the fill-
er hole, add sufficient oil of the rec-
ommended type to raise it to the
correct level.
To change the final gear oil
1. Place an oil pan under the final
gear case to collect the used oil.2. Remove the oil filler bolt and drain
bolt to drain the oil from the final
gear case.
3. Install the final gear oil drain bolt,
and then tighten it to the specified
torque.
4. Add the recommended final gear
oil to the brim of the filler hole.
NOTE:GL4 is a quality rating. Hypoid gear oilsrated GL5 or GL6 may also be used.
5. Install the oil filler bolt, and then
tighten it to the specified torque.
1. Final gear oil drain bolt
2. Final gear oil filler bolt
3. Correct oil level
Tightening torque:
Final gear oil drain bolt:
23 Nm (2.3 m·kgf, 17 ft·lbf)
Recommended final gear oil:
SAE80 API GL-4 Hypoid gear oil
Oil quantity:
0.19 L (0.20 US qt) (0.17 Imp.qt)
Tightening torque:
Final gear oil filler bolt:
23 Nm (2.3 m·kgf, 17 ft·lbf)
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PERIODIC MAINTENANCE AND MINOR REPAIR
6-11
6 6. Check the final gear case for oil
leakage. If oil is leaking, check for
the cause.
EAU33381
Cleaning the air filter element The air filter element should be cleaned
at the intervals specified in the periodic
maintenance and lubrication chart.
Clean the air filter element more fre-
quently if you are riding in unusually
wet or dusty areas.
1. Remove the air filter case cover by
removing the bolts.
2. Pull the air filter element out.
3. Lightly tap the air filter element to
remove most of the dust and dirt,
and then blow the remaining dirt
out with compressed air as shown.
If the air filter element is damaged,
replace it.4. Insert the air filter element into the
air filter case as shown.1. Air filter case cover
2. Bolt
1. Air filter element
1. Air filter element holder
2. Projection
3. Slot
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PERIODIC MAINTENANCE AND MINOR REPAIR
6-12
6
CAUTION:
ECA10480


Make sure that the air filter ele-
ment is properly seated in the
air filter case.


The engine should never be op-
erated without the air filter ele-
ment installed, otherwise the
piston(s) and/or cylinder(s) maybecome excessively worn.
5. Install the air filter case cover by
aligning the match marks and in-
stalling the bolts.
NOTE:If dust or water collects in the air filter
check hose, remove the clamp from it,
and then remove the plug to drain thehose.
EAU21290
Adjusting the carburetors The carburetors are important parts of
the engine and require very sophisticat-
ed adjustment. Therefore, most carbu-
retor adjustments should be left to a
Yamaha dealer, who has the neces-
sary professional knowledge and expe-
rience. The adjustment described in the
following section, however, may be ser-
viced by the owner as part of routine
maintenance.CAUTION:
ECA10560
The carburetors have been set and
extensively tested at the Yamaha
factory. Changing these settings
without sufficient technical knowl-
edge may result in poor perfor-mance of or damage to the engine.
1. Match marks
1. Air filter check hose
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