oil YAMAHA XVS650A 2001 Owners Manual

2-2
DESCRIPTION
1
2
2
4
5
6
7
8
9

Right view (XVS650)
8. Oil filter (page 6-10)
9. Battery (page 6-26)
10. Fuses (page 6-27)
11. Main switch (page 3-1)
12. Air filter (page 6-12)
13. Rear brake pedal (page 3-6)

2-4
DESCRIPTION
1
2
2
4
5
6
7
8
9

Right view (XVS650A)
8. Oil filter (page 6-10)
9. Battery (page 6-26)
10. Fuses (page 6-27)
11. Main switch (page 3-1)
12. Air filter (page 6-12)
13. Rear brake pedal (page 3-6)

4-1
PRE-OPERATION CHECKS
1
2
34
5
6
7
8
9
Owners are personally responsible for their vehicle’s condition. Your motorcycle’s vital functions can start to deteriorate
quickly and unexpectedly, even if it remains unused (for instance, if it is exposed to the elements). Any damage, fluid leak or
loss of tire pressure could have serious consequences. Therefore, it is very important that, in addition to a thorough visual in-
spection, you check the following points before each ride.
EAU00340
PRE-OPERATION CHECK LIST
ITEM CHECKS PAGE
Front brake
• Check operation, free play, fluid level and vehicle for fluid leakage.
• Fill with DOT 4 brake fluid if necessary.6-19 ~ 6-22
Rear brake
• Check operation, condition and free play.
• Adjust if necessary.6-20 ~ 6-22
Clutch
• Check operation, condition and free play.
• Adjust if necessary.6-18
Throttle grip and housing
• Check for smooth operation.
• Lubricate if necessary.6-15, 6-23
Engine oil
• Check oil level.
• Fill with oil if necessary.6-9 ~ 6-11
Final gear oil
• Check vehicle for leakage. 6-11 ~ 6-12
Wheels and tires
• Check tire pressure, wear, damage and spoke tightness.
• Tighten spokes if necessary.6-15 ~ 6-17
Control and meter cable
• Check for smooth operation.
• Lubricate if necessary.6-23
Brake and shift pedal shafts
• Check for smooth operation.
• Lubricate if necessary.6-23
Brake and clutch lever pivots
• Check for smooth operation.
• Lubricate if necessary.6-24
Sidestand pivot
• Check for smooth operation.
• Lubricate if necessary.6-24

EAU01114

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.

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

6-3
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)

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

If a torque wrench is not available
when you are installing a spark plug, a
good estimate of the correct torque is
1/4 to 1/2 turn past finger tight. Have
the spark plug tightened to the speci-
fied torque as soon as possible.Tightening torque:
Spark plug:
20 Nm (2.0 m·kg)
1. Maximum level mark
2. Minimum level mark
EAU01326*
Engine oil
Oil level inspection
1. Place the motorcycle on a level
place and hold it in an upright po-
sition. Warm up the engine for
several minutes.
NOTE:

Be sure the motorcycle is positioned
straight up when checking the oil level.
A slight tilt toward the side can result in
false readings.
1. Engine oil drain bolt
2. With the engine stopped, check
the oil level through the level win-
dow located at the lower part of
the left side crankcase cover.
NOTE:

Wait a few minutes until the oil level
settles before checking.
3. The oil level should be between
the maximum and minimum
marks. If the level is low, fill the
engine with sufficient oil to the
specified level.

6-10
PERIODIC MAINTENANCE AND MINOR REPAIR
1
2
3
4
5
6
7
8
9

1. Engine oil filler cap
Engine oil and oil filter element re-
placement
1. Warm up the engine for a few
minutes.
2. Stop the engine. Place an oil pan
under the engine and remove the
oil filler cap.
3. Remove the drain bolt and drain
the oil.
1. Cover
2. Bolt (
´
3)
4. Remove the cover and the oil filter
cover by removing the bolts.
5. Remove the oil filter and O-ring.
6. Reinstall the drain bolt and tighten
it to the specified torque.
7. Install a new oil filter and O-ring.Tightening torque:
Drain bolt:
43 Nm (4.3 m·kg)
1. Bolt (
´
5)
2. Oil filter cover
8. Install oil filter cover and cover,
then tighten the bolts.
9. Fill the engine with oil. Install the
oil filler cap and tighten it.
Recommended oil:
See page 8-1.
Oil quantity:
Total amount:
3.2 L
Periodic oil change:
2.6 L
With oil filter replacement:
2.8 L

6-11
PERIODIC MAINTENANCE AND MINOR REPAIR
1
2
3
4
5
6
7
8
9

1. O-ring
2. Oil filter element
EC000066
CAUTION:

l
Do not put in any chemical ad-
ditives. Engine oil also lubri-
cates the clutch and additives
could cause clutch slippage.
l
Be sure no foreign material en-
ters the crankcase.
10. Start the engine and warm it up
for a few minutes. While warming
up, check for oil leakage. If oil
leakage is found, stop the engine
immediately and check for the
cause.
1. Final gear oil drain bolt
2. Final gear oil filler bolt
3. Proper level
EAU02943*
Final gear oil
EW000066
WARNING

Do not let foreign material enter the
final gear case. Be sure oil does not
get on the tire or wheel.
Oil level inspection
1. Place the motorcycle on a level
place and hold it in an upright po-
sition. The engine should be cool
at ambient temperature.2. Remove the oil filler bolt and
check the oil level. The oil level
should be at the brim of the filler
hole. Add the recommended oil if
necessary.
Oil replacement
1. Place an oil pan under the final
gear case.
2. Remove the oil filler bolt and drain
bolt to drain the oil.
3. Install and tighten the drain bolt to
the specified torque.
4. Fill the gear case to the brim of the
filler hole with the recommended
oil. Tightening torque:
Drain bolt:
23 Nm (2.3 m·kg)