YAMAHA XVS650A 2001 Service Manual

5-3
OPERATION AND IMPORTANT RIDING POINTS
1
2
3
4
5
6
7
8
9

1. Turn the fuel cock to “ON”.
2. Turn the main switch to “ON” and
the engine stop switch to “ ”.
3. Shift transmission into neutral.
NOTE:

When the transmission is in neutral,
the neutral indicator light should be on.
If the light does not come on, ask a
Yamaha dealer to inspect it.
4. Turn on the starter (choke) and
completely close the throttle grip.
5. Start the engine by pushing the
start switch.
NOTE:

If the engine fails to start, release the
start switch, wait a few seconds, then
try again. Each attempt should be as
short as possible to preserve the bat-
tery. Do not crank the engine more
than 10 seconds on any one attempt.
6. After starting the engine, move
the starter (choke) to the halfway
position.
NOTE:

For maximum engine life, never accel-
erate hard with a cold engine!7. After warming up the engine, turn
off the starter (choke) completely.
NOTE:

The engine is warm when it responds
normally to the throttle with the starter
(choke) turned off.

5-4
OPERATION AND IMPORTANT RIDING POINTS
1
2
3
4
5
6
7
8
9

EAU01258
Starting a warm engine
The starter (choke) is not required
when the engine is warm.
EC000046
CAUTION:
See the “Engine break-in” section
prior to operating the motorcycle

for the first time.
EAU00423
Shifting
The transmission lets you control the
amount of power you have available at
a given speed for starting, accelerat-
ing, climbing hills, etc. The use of the
shift pedal is shown in the illustration.
To shift into neutral, depress the shift
pedal repeatedly until it reaches the
end of its travel, then raise the pedal
slightly.
EC000048
CAUTION:

l
Do not coast for long periods
with the engine off, and do not
tow the motorcycle a long dis-
tance. Even with gears in neu-
tral, the transmission is only
properly lubricated when the
engine is running. Inadequate
lubrication may damage the
transmission.
l
Always use the clutch when
changing gears. The engine,
transmission, and driveline are
not designed to withstand the
shock of forced shifting and
can be damaged by shifting
without using the clutch.

5-5
OPERATION AND IMPORTANT RIDING POINTS
1
2
3
4
5
6
7
8
9

EAU00424
Tips for reducing fuel con-
sumption
Your motorcycle’s fuel consumption
depends to a large extent on your
riding style. The following tips can help
reduce fuel consumption:
l
Warm up the engine before
riding.
l
Turn off the starter (choke) as
soon as possible.
l
Shift up swiftly and avoid high en-
gine speeds during acceleration.
l
Do not double-clutch or rev the
engine while shifting down and
avoid high engine speeds with no
load on the engine.
l
Turn off the engine instead of let-
ting it idle for an extended length
of time, i.e. in traffic jams, at traffic
lights or railroad crossings.
EAU01128
Engine break-in
There is never a more important period
in the life of your motorcycle than the
period between zero and 1,600 km.
For this reason we ask that you care-
fully read the following material. Be-
cause the engine is brand new, you
must not put an excessive load on it for
the first 1,600 km. The various parts in
the engine wear and polish them-
selves to the correct operating clear-
ances. During this period, prolonged
full throttle operation, or any condition
which might result in excessive heat-
ing of the engine, must be avoided.
EAU01171
0 ~ 1,000 km
Avoid operation above 1/3 throttle.
1,000 ~ 1,600 km
Avoid cruising speeds in excess of
1/2 throttle.

EC000056
CAUTION:
After 1,000 km of operation, be sure
to replace the engine oil, oil filter

and final gear oil.
1,600 km and beyond
Proceed with normal riding.
EC000049
CAUTION:
If any engine trouble should occur
during the break-in period, consult

a Yamaha dealer immediately.

5-6
OPERATION AND IMPORTANT RIDING POINTS
1
2
3
4
5
6
7
8
9

EAU00457
Parking
When parking the motorcycle, stop the
engine and remove the ignition key.
Turn the fuel cock to “OFF” whenever
stopping the engine.
EW000058
WARNING

The exhaust system is hot. Park the
motorcycle in a place where pedes-
trians or children are not likely to
touch the motorcycle. Do not park
the motorcycle on a slope or soft
ground; the motorcycle may over-
turn.

1
2
3
4
5
6
7
8
9

Tool kit ................................................................ 6-1
Periodic maintenance and lubrication ................ 6-2
Panel removal and installation............................ 6-5
Panel A ............................................................... 6-6
Panel B ............................................................... 6-7
Spark plugs ........................................................ 6-7
Engine oil............................................................ 6-9
Final gear oil ..................................................... 6-11
Air filter ............................................................. 6-12
Carburetor adjustment...................................... 6-13
Idle speed adjustment ...................................... 6-14
Throttle cable free play inspection .................... 6-15
Valve clearance adjustment.............................. 6-15
Tires ................................................................. 6-15
Wheels ............................................................. 6-17
Clutch lever free play adjustment ..................... 6-18
Front brake lever free play
adjustment ...................................................... 6-19
Rear brake pedal height and free play
adjustment ...................................................... 6-20
Brake light switch adjustment ........................... 6-21
Checking the front brake pads and
rear brake shoes ............................................ 6-21
Inspecting the brake fluid level.......................... 6-22
Brake fluid replacement .................................... 6-22
Cable inspection and lubrication ....................... 6-23
Throttle cable and grip lubrication..................... 6-23
Brake and shift pedal lubrication....................... 6-23
Brake and clutch lever lubrication ..................... 6-24
Sidestand lubrication ........................................ 6-24
Front fork inspection ......................................... 6-25
Steering inspection ........................................... 6-25
Wheel bearings ................................................. 6-26
Battery .............................................................. 6-26
Fuse replacement ............................................. 6-27
Headlight bulb replacement .............................. 6-28
Turn signal and taillight bulb replacement......... 6-29
Supporting the motorcycle ................................ 6-30
Front wheel removal ......................................... 6-31
Front wheel installation ..................................... 6-31
Rear wheel removal .......................................... 6-32
Rear wheel installation...................................... 6-33
Troubleshooting ................................................ 6-34
Troubleshooting chart ....................................... 6-35

PERIODIC MAINTENANCE AND MINOR REPAIR
6

6-1
PERIODIC MAINTENANCE AND MINOR REPAIR
1
2
3
4
56
7
8
9
EAU00462
EAU00464
Periodic inspection, adjustment and lu-
brication will keep your motorcycle in
the safest and most efficient condition
possible. Safety is an obligation of the
motorcycle owner. The maintenance
and lubrication schedule chart should
be considered strictly as a guide to
general maintenance and lubrication
intervals. YOU MUST TAKE INTO
CONSIDERATION THAT WEATH-
ER, TERRAIN, GEOGRAPHICAL LO-
CATIONS, AND A VARIETY OF
INDIVIDUAL USES ALL TEND TO
DEMAND THAT EACH OWNER AL-
TER THIS TIME SCHEDULE TO
SHORTER INTERVALS TO MATCH
THE ENVIRONMENT. The most im-
portant points of motorcycle inspec-
tion, adjustment, and lubrication are
explained in the following pages.
EW000060
WARNING

If you are not familiar with motor-
cycle service, this work should be
done by a Yamaha dealer.
EAU01129
Tool kit
The tool kit is located inside of the stor-
age compartment. (See page 3-11 for
compartment opening procedures.)
The tools provided in the owner’s tool
kit are to assist you in the performance
of periodic maintenance. However,
some other tools such as a torque
wrench are also necessary to perform
the maintenance correctly.
The service information included in
this manual is intended to provide you,
the owner, with the necessary informa-
tion for completing some of your own
preventive maintenance and minor re-
pairs.
NOTE:

If you do not have necessary tools re-
quired during a service operation, take
your motorcycle to a Yamaha dealer
for service.
EW000062
WARNING

Modifications to this motorcycle not
approved by Yamaha may cause
loss of performance, excessive
emissions, and render it unsafe for
use. Consult a Yamaha dealer be-
fore attempting any changes.

6-2
PERIODIC MAINTENANCE AND MINOR REPAIR
1
2
3
4
5
6
7
8
9

EAU00473
PERIODIC MAINTENANCE AND LUBRICATION
NO. ITEM CHECKS AND MAINTENANCE JOBSInitial
(1,000 km)EVERY
6,000 km
or
6 months
(whichever
comes first)12,000 km
or
12 months
(whichever
comes first)
1
*
Fuel line
• Check fuel hoses for cracks or damage.
• Replace if necessary.
ÖÖ
2 Spark plugs
• Check condition.
• Clean, regap or replace if necessary.
ÖÖÖ
3

*
Valves
• Check valve clearance.
• Adjust if necessary.
ÖÖÖ
4 Air filter
• Clean or replace if necessary.
ÖÖ
5 Clutch
• Check operation.
• Adjust or replace cable.
ÖÖÖ
6

*
Front brake
• Check operation, fluid level and vehicle for fluid leakage.
(See NOTE on page 6-4.)
• Correct accordingly.
• Replace brake pads if necessary.
ÖÖÖ
7
*
Rear brake
• Check operation.
• Adjust brake pedal and replace brake shoes if necessary.
ÖÖÖ
8
*
Wheels
• Check balance, runout, spoke tightness and for damage.
• Tighten spokes and rebalance, replace if necessary.
ÖÖ
9
*
Tires
• Check tread depth and for damage.
• Replace if necessary.
• Check air pressure.
• Correct if necessary.
ÖÖ
10
*
Wheel bearings
• Check bearing for looseness or damage.
• Replace if necessary.
ÖÖ

6-3
PERIODIC MAINTENANCE AND MINOR REPAIR
1
2
3
4
5
6
7
8
9

11
*
Swingarm
• Check swingarm pivoting point for play.
• Correct if necessary.
• Lubricate with molybdenum disulfide grease every 24,000 km or
24 months (whichever comes first).
ÖÖ
12
*
Steering bearings
• Check bearing play and steering for roughness.
• Correct accordingly.
• Lubricate with lithium soap base grease every 24,000 km or
24 months (whichever comes first).
ÖÖ
13
*
Chassis fasteners
• Make sure that all nuts, bolts and screws are properly tightened.
• Tighten if necessary.
ÖÖ
14 Sidestand
• Check operation.
• Lubricate and repair if necessary.
ÖÖ
15

*
Sidestand switch
• Check operation.
• Replace if necessary.
ÖÖÖ
16
*
Front fork
• Check operation and for oil leakage.
• Correct accordingly.
ÖÖ
17
*
Rear shock absorber
assembly
• Check operation and shock absorber for oil leakage.
• Replace shock absorber assembly if necessary.
ÖÖ
18
*
Carburetors
• Check engine idling speed, synchronization and starter operation.
• Adjust if necessary.
ÖÖÖ
19 Engine oil
• Check oil level and vehicle for oil leakage.
• Correct if necessary.
• Change. (Warm engine before draining.)
ÖÖÖ
NO. ITEM CHECKS AND MAINTENANCE JOBSInitial
(1,000 km)EVERY
6,000 km
or
6 months
(whichever
comes first)12,000 km
or
12 months
(whichever
comes first)

6-4
PERIODIC MAINTENANCE AND MINOR REPAIR
1
2
3
4
5
6
7
8
9
*

Since these items require special tools, data and technical skills, they should be serviced by a Yamaha dealer.
EAU02970
NOTE:

l
The air filter needs more frequent service if you are riding in unusually wet or dusty areas.
l
Hydraulic brake system
• When disassembling the master cylinder or caliper, always replace the brake fluid. Check the brake fluid level regularly
and fill as required.
• Replace the oil seals on the inner parts of the master cylinder and caliper every two years.
• Replace the brake hoses every four years or if cracked or damaged.
20 Engine oil filter element
• Replace.
ÖÖ
21
Final gear oil
• Check oil level and vehicle for oil leakage.
• Change oil at initial 1,000 km and thereafter every 24,000 km or
24 months (whichever comes first).
ÖÖÖ
NO. ITEM CHECKS AND MAINTENANCE JOBSInitial
(1,000 km)EVERY
6,000 km
or
6 months
(whichever
comes first)12,000 km
or
12 months
(whichever
comes first)