YAMAHA XVS650 2001 Service Manual

OPERATION AND IMPORTANT RIDING POINTS
5-2
5 5. Start the engine by pushing the
start switch.
NOTE:@ If the engine fails to start, release the
start switch, wait a few seconds, and
then try again. Each starting attempt
should be as short as possible to pre-
serve the battery. Do not crank the en-
gine more than 10 seconds on any one
attempt. @
ECA00059
CAUTION:@ If the oil level warning light flickers
or remains on after starting, immedi-
ately stop the engine, and then
check the engine oil level and thevehicle for oil leakage. If necessary,
add engine oil, and then check the
warning light again. If the warning
light does not go off after starting
with sufficient engine oil, have a
Yamaha dealer check the electrical
circuit.
@6. After starting the engine, move the
starter (choke) knob back halfway.
ECA00055
CAUTION:@ For maximum engine life, always
warm the engine up before starting
off. Never accelerate hard when the
engine is cold! @7. When the engine is warm, turn the
starter (choke) off.NOTE:@ The engine is warm when it responds
normally to the throttle with the starter
(choke) turned off. @
EAU01258
Starting a warm engine Follow the same procedure as for start-
ing a cold engine with the exception
that the starter (choke) is not required
when the engine is warm.
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OPERATION AND IMPORTANT RIDING POINTS
5-3
5
EAU00423
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.NOTE:@ To shift the transmission into the neu-
tral position, press the shift pedal down
repeatedly until it reaches the end of its
travel, and then slightly raise it. @
EC000048
CAUTION:@ l
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 dis-
tances. The transmission is
properly lubricated only when
the engine is running. Inade-
quate lubrication may damage
the transmission.
l
Always use the clutch while
changing gears to avoid dam-
aging the engine, transmission,
and drive train, which are not
designed to withstand the
shock of forced shifting.
@
1. Shift pedal
N. Neutral positionXVS650
1. Shift pedal
N. Neutral positionXVS650A
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OPERATION AND IMPORTANT RIDING POINTS
5-4
5
EAU00424
Tips for reducing fuel
consumption Fuel consumption depends largely on
your riding style. Consider the following
tips to reduce fuel consumption:l
Thoroughly warm up the engine.
l
Turn the starter (choke) off as
soon as possible.
l
Shift up swiftly, and avoid high en-
gine speeds during acceleration.
l
Do not rev the engine while shift-
ing down, and avoid high engine
speeds with no load on the engine.
l
Turn the engine off instead of let-
ting it idle for an extended length
of time (e.g., in traffic jams, at traf-
fic lights or at railroad crossings).
EAU01128
Engine break-in There is never a more important period
in the life of your engine than the period
between 0 and 1,600 km. For this rea-
son, you should read the following ma-
terial 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 en-
gine wear and polish themselves to the
correct operating clearances. During
this period, prolonged full-throttle oper-
ation or any condition that might result
in engine overheating must be avoided.
EAU01171*
0–1,000 km
Avoid prolonged operation above
1/3 throttle.
1,000–1,600 km
Avoid prolonged operation above
1/2 throttle.
EC000056*
CAUTION:@ After 1,000 km of operation, the en-
gine oil and final gear oil must be
changed, and the oil filter element
replaced. @1,600 km and beyond
The vehicle can now be operated
normally.
EC000049
CAUTION:@ If any engine trouble should occur
during the engine break-in period,
immediately have a Yamaha dealer
check the vehicle. @
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OPERATION AND IMPORTANT RIDING POINTS
5-5
5
EAU00457
Parking When parking, stop the engine, re-
move the key from the main switch,
and then turn the fuel cock lever to
“OFF”.
EW000058
WARNING
@ l
Since the engine and exhaust
system can become very hot,
park in a place where pedestri-
ans or children are not likely to
touch them.
l
Do not park on a slope or on
soft ground, otherwise the
motorcycle may overturn.
@E_5bn.book Page 5 Wednesday, October 4, 2000 7:51 PM

6
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 ...................................................... 6-11
Cleaning the air filter element ............................ 6-13
Adjusting the carburetors ................................... 6-14
Adjusting the engine idling speed ...................... 6-15
Adjusting the throttle cable free play .................. 6-15
Adjusting the valve clearance ............................ 6-16
Tires ................................................................... 6-16
Spoke wheels .................................................... 6-19
Adjusting the clutch lever free play .................... 6-19
Adjusting the brake lever free play ..................... 6-20
Adjusting the brake pedal position and
free play ........................................................... 6-21
Adjusting the rear brake light switch .................. 6-22
Checking the front brake pads and
rear brake shoes .............................................. 6-23
Checking the brake fluid level ............................ 6-24
Changing the brake fluid .................................... 6-25Checking and lubricating the cables ................. 6-25
Checking and lubricating the throttle grip and
cable ............................................................... 6-25
Checking and lubricating the brake and
shift pedals ...................................................... 6-26
Checking and lubricating the brake and
clutch levers .................................................... 6-26
Checking and lubricating the sidestand ............ 6-27
Checking the front fork ...................................... 6-27
Checking the steering ....................................... 6-28
Checking the wheel bearings ............................ 6-29
Battery ............................................................... 6-29
Replacing the fuses .......................................... 6-31
Replacing the headlight bulb ............................. 6-32
Replacing a turn signal light bulb or the tail/
brake light bulb ................................................ 6-33
Supporting the motorcycle ................................ 6-34
Front wheel ....................................................... 6-35
Rear wheel ........................................................ 6-36
Troubleshooting ................................................. 6-38
Troubleshooting chart ........................................ 6-39
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6-1
6
EAU00462
6-PERIODIC MAINTENANCE AND MINOR REPAIR
EAU00464
Safety is an obligation of the owner.
Periodic inspection, adjustment and lu-
brication will keep your vehicle in the
safest and most efficient condition pos-
sible. The most important points of in-
spection, adjustment, and lubrication
are explained on the following pages.
The intervals given in the periodic
maintenance and lubrication chart
should be simply considered as a gen-
eral guide under normal riding condi-
tions. However, DEPENDING ON THE
WEATHER, TERRAIN, GEOGRAPHI-
CAL LOCATION, AND INDIVIDUAL
USE, THE MAINTENANCE INTER-
VALS MAY NEED TO BE SHORT-
ENED.
EW000060
WARNING
@ If you are not familiar with motor-
cycle maintenance work, have a
Yamaha dealer do it for you. @
EAU01129
Owner’s tool kit The owner’s tool kit is located inside
the storage compartment. (See page
3-13 for storage compartment opening
procedures.)
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. How-
ever, additional tools such as a torque
wrench may be necessary to perform
certain maintenance work correctly.NOTE:@ If you do not have the tools or experi-
ence required for a particular job, have
a Yamaha dealer perform it for you. @
EW000063
WARNING
@ Modifications not approved by
Yamaha may cause loss of perfor-
mance and render the vehicle un-
safe for use. Consult a Yamaha
dealer before attempting any chang-
es. @
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PERIODIC MAINTENANCE AND MINOR REPAIR
6-2
6
EAU03685
Periodic maintenance and lubrication chart
NOTE:_ l
The annual checks must be performed every year, except if a kilometer-based maintenance is performed instead.
l
From 50,000 km, repeat the maintenance intervals starting from 10,000 km.
l
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 line• Check fuel hoses for cracks or damage.ÖÖÖÖ Ö
2*Fuel filter• Check condition.ÖÖ
3 Spark plugs• Check condition.
• Clean and regap.ÖÖ
• Replace.ÖÖ
4*Valves• Check valve clearance.
•Adjust.ÖÖÖÖ
5 Air filter element•Clean.ÖÖ
• Replace.ÖÖ
6Clutch• Check operation.
•Adjust.ÖÖÖÖÖ
7*Front brake• Check operation, fluid level and vehicle for fluid leakage.
(See NOTE on page 6-4.)ÖÖÖÖÖ Ö
• Replace brake pads. Whenever worn to the limit
8*Rear brake• Check operation and adjust brake pedal freeplay.ÖÖÖÖÖ Ö
• Replace brake shoes. Whenever worn to the limit
9*Brake hose• Check for cracks or damage.ÖÖÖÖ Ö
• Replace. (See NOTE on page 6-4.) Every 4 years
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PERIODIC MAINTENANCE AND MINOR REPAIR
6-3
6
10
*Wheels• Check runout, spoke tightness and for damage.
• Tighten spokes if necessary.ÖÖÖÖ
11*Tires• Check tread depth and for damage.
• Replace if necessary.
• Check air pressure.
• Correct if necessary.ÖÖÖÖ
12*Wheel bearings• Check bearing for looseness or damage.ÖÖÖÖ
13*Swingarm• Check operation and for excessive play.ÖÖÖÖ
• Lubricate with molybdenum disulfide grease. Every 50,000 km
14*Steering bearings• Check bearing play and steering for roughness.ÖÖÖÖÖ
• Lubricate with lithium-soap-based grease. Every 20,000 km
15*Chassis fasteners• Make sure that all nuts, bolts and screws are properly tightened.ÖÖÖÖ Ö
16 Sidestand• Check operation.
• Lubricate.ÖÖÖÖ Ö
17*Sidestand switch• Check operation.ÖÖÖÖÖ Ö
18*Front fork• Check operation and for oil leakage.ÖÖÖÖ
19*Rear shock absorber
assembly• Check operation and shock absorber for oil leakage.ÖÖÖÖ
20*Carburetors• Check starter (choke) operation.
• Adjust engine idling speed and synchronization.ÖÖÖÖÖ Ö
21 Engine oil• Change.ÖÖÖÖÖ Ö
22 Engine oil filter element•Replace.ÖÖÖ
23 Final gear oil• Check oil level and vehicle for oil leakage.ÖÖ Ö
• Change.ÖÖÖ
24*Front and rear brake
switches• Check operation.ÖÖÖÖÖ Ö
25 Moving parts and cables• Lubricate.ÖÖÖÖ Ö NO. ITEM CHECK OR MAINTENANCE JOBODOMETER READING (´1,000 km)
ANNUAL
CHECK
1 10203040
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PERIODIC MAINTENANCE AND MINOR REPAIR
6-4
6
EAU03541
NOTE:@l
The air filter needs more frequent service if you are riding in unusually wet or dusty areas.
l
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.
@26
*Lights, signals and
switches• Check operation.
• Adjust headlight beam.ÖÖÖÖÖ Ö NO. ITEM CHECK OR MAINTENANCE JOBODOMETER READING (´1,000 km)
ANNUAL
CHECK
1 10203040
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PERIODIC MAINTENANCE AND MINOR REPAIR
6-5
6
EAU01122
Removing and installing
panels The panels shown above need to be
removed to perform some of the main-
tenance jobs described in this chapter.
Refer to this section each time a panel
needs to be removed and installed.
EAU01573
Panel A
To remove the panelRemove the bolts, and then take the
panel off.
To install the panelPlace the panel in the original position,
and then install the bolts.
1. Panel A
1. Panel B
1. Bolt (´ 4)
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