brake YAMAHA XVS650 2002 Owners Manual

DESCRIPTION
2-2
2
Right view (XVS650)8. Engine oil filter element (page 6-9)
9. Battery (page 6-29)
10. Fuses (page 6-31)
11. Main switch/steering lock (page 3-1)
12. Air filter element (page 6-13)
13. Brake pedal (page 3-6)
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DESCRIPTION
2-4
2
Right view (XVS650A)8. Engine oil filter element (page 6-9)
9. Battery (page 6-29)
10. Fuses (page 6-31)
11. Main switch/steering lock (page 3-1)
12. Air filter element (page 6-13)
13. Brake pedal (page 3-6)
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DESCRIPTION
2-5
2
Controls and instruments (XVS650/XVS650A)1. Clutch lever (page 3-5)
2. Left handlebar switches (page 3-3)
3. Speedometer unit (page 3-3)
4. Fuel tank cap (page 3-7)
5. Right handlebar switches (page 3-4)
6. Throttle grip (page 6-15)
7. Brake lever (page 3-6)
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INSTRUMENT AND CONTROL FUNCTIONS
3
Main switch/steering lock .................................................................. 3-1
Indicator and warning lights ............................................................. 3-2
Speedometer unit .............................................................................. 3-3
Anti-theft alarm (optional) .................................................................. 3-3
Handlebar switches ........................................................................... 3-3
Clutch lever ....................................................................................... 3-5
Shift pedal (XVS650).......................................................................... 3-5
Shift pedal (XVS650A) ....................................................................... 3-5
Brake lever ........................................................................................ 3-6
Brake pedal ....................................................................................... 3-6
Fuel tank cap ..................................................................................... 3-7
Fuel ................................................................................................... 3-7
Fuel cock ........................................................................................... 3-9
Starter (choke) knob......................................................................... 3-10
Seats (XVS650) ............................................................................... 3-11
Seats (XVS650A) ............................................................................. 3-12
Helmet holder .................................................................................. 3-13
Storage compartment ..................................................................... 3-13
Adjusting the shock absorber assembly .......................................... 3-15
Luggage strap holders .................................................................... 3-16
Sidestand ........................................................................................ 3-17
Ignition circuit cut-off system ........................................................... 3-17
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INSTRUMENT AND CONTROL FUNCTIONS
3-6
3
EAU00158
Brake lever The brake lever is located at the right
handlebar grip. To apply the front
brake, pull the lever toward the handle-
bar grip.
EAU00162
Brake pedal The brake pedal is on the right side of
the motorcycle. To apply the rear
brake, press down on the brake pedal.
1. Brake lever
1. Brake pedalXVS650
1. Brake pedalXVS650A
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4-1
4
EAU01114
4-PRE-OPERATION CHECKSThe condition of a vehicle is the owner’s responsibility. Vital components can start to deteriorate quickly and unexpectedly,
even if the vehicle remains unused (for example, as a result of exposure to the elements). Any damage, fluid leakage or loss
of tire air pressure could have serious consequences. Therefore, it is very important, in addition to a thorough visual inspec-
tion, to check the following points before each ride.
EAU03439
Pre-operation check list
ITEM CHECKS PAGE
FuelCheck fuel level in fuel tank.
Refuel if necessary.
Check fuel line for leakage.3-7–3-8
Engine oilCheck oil level in engine.
If necessary, add recommended oil to specified level.
Check vehicle for oil leakage.6-9–6-11
Final gear oilCheck vehicle for oil leakage. 6-12–6-13
Front brakeCheck operation.
If soft or spongy, have Yamaha dealer bleed hydraulic system.
Check lever free play.
Adjust if necessary.
Check fluid level in reservoir.
If necessary, add recommended brake fluid to specified level.
Check hydraulic system for leakage.6-20–6-21, 6-23–6-25
Rear brakeCheck operation.
Check pedal free play.
Adjust if necessary.6-21–6-25
ClutchCheck operation.
Lubricate cable if necessary.
Check lever free play.
Adjust if necessary.6-19–6-20
Throttle gripMake sure that operation is smooth.
Check free play.
If necessary, have Yamaha dealer make adjustment or lubricate.6-15, 6-25
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PRE-OPERATION CHECKS
4-2
4
NOTE:@ Pre-operation checks should be made each time the motorcycle is used. Such an inspection can be accomplished in a very
short time; and the added safety it assures is more than worth the time involved. @
EWA00033
WARNING
@ If any item in the Pre-operation check list is not working properly, have it inspected and repaired before operating
the motorcycle. @Control cablesMake sure that operation is smooth.
Lubricate if necessary.6-25
Wheels and tiresCheck for damage.
Check tire condition and tread depth.
Check air pressure.
Correct if necessary.6-16–6-19
Brake and shift pedalsMake sure that operation is smooth.
Lubricate pedal pivoting points if necessary.6-26
Brake and clutch leversMake sure that operation is smooth.
Lubricate lever pivoting points if necessary.6-26
SidestandMake sure that operation is smooth.
Lubricate pivot if necessary.6-27
Chassis fastenersMake sure that all nuts, bolts and screws are properly tightened.
Tighten if necessary.—
Instruments, lights, signals
and switchesCheck operation.
Correct if necessary.—
Sidestand switchCheck operation of ignition circuit cut-off system.
If system is defective, have Yamaha dealer check vehicle.3-17 ITEM CHECKS PAGE
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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 ...................................................... 6-12
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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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
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PERIODIC MAINTENANCE AND MINOR REPAIR
6-3
6
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 50,000 km
14*Steering bearingsCheck bearing play and steering for roughness.√√√√√
Lubricate with lithium-soap-based grease. Every 20,000 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
assemblyCheck 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.√√√√√ √
22 Engine oil filter elementReplace.√√√
23 Final gear oilCheck oil level and vehicle for oil leakage.√√ √
Change.√√√
24*Front and rear brake
switchesCheck operation.√√√√√ √ NO. ITEM CHECK OR MAINTENANCE JOBODOMETER READING (×1,000 km)
ANNUAL
CHECK
1 10203040
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