maintenance YAMAHA XVS650A 2001 Owners Manual

EAA30002
TABLE OF CONTENTS
1 GIVE SAFETY THE RIGHT OF WAY
1
2 DESCRIPTION
2
3 INSTRUMENT AND CONTROL FUNCTIONS
3
4 PRE-OPERATION CHECKS
4
5 OPERATION AND IMPORTANT RIDING POINTS
5
6 PERIODIC MAINTENANCE AND MINOR REPAIR
6
7 MOTORCYCLE CARE AND STORAGE
7
8 SPECIFICATIONS
8
9 CONSUMER INFORMATION
9
INDEX
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1-1
GIVE SAFETY THE RIGHT OF WAY
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Motorcycles are fascinating vehicles, which can give you an unsurpassed feeling of power and freedom.
However, they also impose certain limits, which you must accept; even the best motorcycle does not ig-
nore the laws of physics.
Regular care and maintenance are essential for preserving your motorcycle’s value and operating condi-
tion. Moreover, what is true for the motorcycle is also true for the rider: good performance depends on be-
ing in good shape. Riding under the influence of medication, drugs and alcohol is, of course, out of the
question. Motorcycle riders – more than car drivers – must always be at their mental and physical best.
Under the influence of even small amounts of alcohol, there is a tendency to take dangerous risks.
Protective clothing is as essential for the motorcycle rider as seat belts are for car drivers and passengers.
Always wear a complete motorcycle suit (whether made of leather or tear-resistant synthetic materials
with protectors), sturdy boots, motorcycle gloves and a properly fitting helmet. Optimum protective wear,
however, should not encourage carelessness. Though full-coverage helmets and suits, in particular, cre-
ate an illusion of total safety and protection, motorcyclists will always be vulnerable. Riders who lack criti-
cal self-control run the risk of going too fast and are apt to take chances. This is even more dangerous in
wet weather. The good motorcyclist rides safely, predictably and defensively – avoiding all dangers, in-
cluding those caused by others.
Enjoy your ride!
GIVE SAFETY THE RIGHT OF WAY
GIVE SAFETY THE RIGHT OF WAY
EAU00021

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
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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
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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
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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
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*

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)

6-5
PERIODIC MAINTENANCE AND MINOR REPAIR
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XVS650

1. Panel A
EAU01122
Panel removal and
installation
The panels illustrated need to be re-
moved to perform some of the mainte-
nance described in this chapter. Refer
to this section each time a panel has to
be removed or reinstalled.
XVS650A

1. Panel A
1. Panel B

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XVS650

1. Bolt (
´
4)
EAU01573
Panel A
To remove
Remove the bolts.
To install
Place the panel in its original position
and install the bolts.
XVS650A

1. Bolt (
´
4)

6-7
PERIODIC MAINTENANCE AND MINOR REPAIR
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1. Bolt
EAU00491
Panel B
To remove
Remove the bolt and pull outward on
the areas shown.
To install
Place the panel in its original position
and install the bolt.
1. Spark plug cap
EAU01485
Spark plugs
Removal
1. Remove the spark plug cap.
2. Use the spark plug wrench in the
tool kit to remove the spark plug
as shown.