service YAMAHA XVS650A 2001 Owners Manual

3-14
INSTRUMENT AND CONTROL FUNCTIONS
1
23
4
5
6
7
8
9
1. Position indicator
2. Adjusting ring
3. Extension bar
4. Special wrench
EAU00299*
Rear shock absorber adjust-
mentThis shock absorber is equipped with a
spring preload adjuster. Adjust spring
preload as follows:
1. Remove the passenger seat and
rider seat. (See page 3-9 for re-
moval procedures.)2. Use the special wrench and the
extension bar in the owner’s tool
kit to turn the adjusting ring. Turn
the adjusting ring in direction a
to increase spring preload and in
direction b to decrease spring
preload. Make sure that the ap-
propriate notch in the adjusting
ring is aligned with the position in-
dicator on the rear shock absorb-
er.
COPY CI-15ECI-15E3. Install the seats.
SoftStan-
dardHard
Adjusting
position12 3 4567
EAU00315
WARNING
This shock absorber contains high-
ly pressurized nitrogen gas. Read
and understand the following infor-
mation before handling the shock
absorber. The manufacturer cannot
be held responsible for property
damage or personal injury that may
result from improper handling.l
Do not tamper with or attempt
to open the cylinder assembly.
l
Do not subject the shock ab-
sorber to an open flame or oth-
er high heat source. This may
cause the unit to explode due
to excessive gas pressure.
l
Do not deform or damage the
cylinder in any way. Cylinder
damage will result in poor
damping performance.
l
Take your shock absorber to aYamaha dealer for any service.

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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.

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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)

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PERIODIC MAINTENANCE AND MINOR REPAIR
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a. Free play
EAU00635
Throttle cable free play
inspectionThere should be a free play of 4 ~
6 mm at the throttle grip. If the free play
is incorrect, ask a Yamaha dealer to
make this adjustment.
EAU00637
Valve clearance adjustmentThe correct valve clearance changes
with use, resulting in improper fuel/air
supply or engine noise. To prevent
this, the valve clearance must be ad-
justed regularly. This adjustment how-
ever, should be left to a professional
Yamaha service technician.
a. Tread depth
1. Side wall
EAU00647*
TiresTo ensure maximum performance,
long service, and safe operation, note
the following:
Tire air pressure
Always check and adjust the tire pres-
sure before operating the motorcycle.

6-17
PERIODIC MAINTENANCE AND MINOR REPAIR
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9Tire inspection
Always check the tires before operat-
ing the motorcycle. If center tread
depth reaches the limit as shown, if the
tire has a nail or glass fragments in it,
or if the side wall is cracked, contact a
Yamaha dealer immediately and have
the tire replaced.
COPY CE-10ECE-10E
CE-10EFRONT (XVS650)
Manufacturer Size Type
Bridgestone 100/90-19 57S L309
Dunlop 100/90-19 57S F24
REAR (XVS650)
Manufacturer Size Type
Bridgestone 170/80-15M/C 77S G546
Dunlop 170/80-15M/C 77S K555
FRONT (XVS650A)
Manufacturer Size Type
Bridgestone 130/90-16 67S G703
Dunlop 130/90-16 67S D404F
REAR (XVS650A)
Manufacturer Size Type
Bridgestone 170/80-15M/C 77S G702
Dunlop 170/80-15M/C 77S D404
CE-26ECE-26ENOTE:These limits may be different by regu-
lation from country to country. If so,
conform to the limits specified by theregulations of your own country.
EAU00681
WARNING
l
Operating the motorcycle with
excessively worn tires de-
crease riding stability and can
lead to loss of control. Have ex-
cessively worn tires replaced
by a Yamaha dealer immediate-
ly. Brakes, tires, and related
wheel parts replacement
should be left to a Yamaha Ser-
vice Technician.
l
Patching a punctured tube is
not recommended. If it is abso-
lutely necessary to do so, use
great care and replace the tube
as soon as possible with agood quality replacement.
Minimum tire tread depth
(front and rear)1.6 mm
EAU00685
WheelsTo ensure maximum performance,
long service, and safe operation, note
the following:l
Always inspect the wheels before
a ride. Check for cracks, bends or
warpage of the wheel. Be sure
the spokes are tight and undam-
aged. If any abnormal condition
exists in a wheel, consult a
Yamaha dealer. Do not attempt
even small repairs to the wheel. If
a wheel is deformed or cracked, it
must be replaced.
l
Tires and wheels should be bal-
anced whenever either one is
changed or replaced. Failure to
have a wheel balanced can result
in poor performance, adverse
handling characteristics, and
shortened tire life.
l
Ride at moderate speeds after
changing a tire since the tire sur-
face must first be broken in for it to
develop its optimal characteristics.

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PERIODIC MAINTENANCE AND MINOR REPAIR
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1. Minimum level mark
EAU00731
Inspecting the brake fluid
levelInsufficient brake fluid may let air enter
the brake system, possibly causing the
brakes to become ineffective.
Before riding, check that the brake flu-
id is above the minimum level and re-
plenish when necessary. Observe
these precautions:l
When checking the fluid level,
make sure the top of the master
cylinder is level by turning the
handlebars.
l
Use only the designated quality
brake fluid. Otherwise, the rubber
seals may deteriorate, causing
leakage and poor brake perfor-
mance.
l
Refill with the same type of brake
fluid. Mixing fluids may result in a
harmful chemical reaction and
lead to poor brake performance.
l
Be careful that water does not en-
ter the master cylinder when refill-
ing. Water will significantly lower
the boiling point of the fluid and
may result in vapor lock.
l
Brake fluid may deteriorate paint-
ed surfaces or plastic parts. Al-
ways clean up spilled fluid
immediately.
l
Have a Yamaha dealer check the
cause if the brake fluid level goes
down. Recommended brake fluid: DOT 4
EAU00742
Brake fluid replacementThe brake fluid should be replaced
only by trained Yamaha service per-
sonnel. Have the Yamaha dealer re-
place the following components during
periodic maintenance or when they are
damaged or leaking:l
oil seals (every two years)
l
brake hoses (every four years)

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PERIODIC MAINTENANCE AND MINOR REPAIR
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XVS650A1. Screw (´ 3)
EC000108
CAUTION:
Do not over-tighten the screws asthe lens may break.
EAU01579
Supporting the motorcycleSince the Yamaha XVS650/XVS650A
has no centerstand, follow these pre-
cautions when removing the front and
rear wheel or performing other mainte-
nance requiring the motorcycle to
stand upright. Check that the motor-
cycle is in a stable and level position
before starting any maintenance. A
strong wooden box can be placed un-
der the engine for added stability.
Front wheel service
To stabilize the rear of the motorcycle,
either use a motorcycle stand or place
a motorcycle jack under the frame in
front of the rear wheel to prevent it
from moving from side to side. Then
use a motorcycle stand to elevate the
front wheel off of the ground.
Rear wheel service
Use a motorcycle stand or motorcycle
jack to elevate the motorcycle so the
rear wheel is off the ground. Alterna-
tively, two jacks can be placed under
the frame or swingarm.

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PERIODIC MAINTENANCE AND MINOR REPAIR
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1. Speedometer cable
EAU00894
Front wheel removal
EW000122
WARNING
l
It is advisable to have a
Yamaha dealer service the
wheel.
l
Securely support the motor-
cycle so there is no danger of itfalling over.
1. Remove the speedometer cable
from the front wheel side.
1. Axle
2. Pinch bolt2. Loosen the pinch bolt and wheel
axle.
3. Elevate the front wheel by placing
a suitable stand under the en-
gine.
4. Remove the wheel axle and the
front wheel.NOTE:Do not depress the brake lever whenthe disc and caliper are separated.
1. Speedometer gear unit housing
EAU01394
Front wheel installation1. Install the speedometer gear unit
into the wheel hub. Make sure the
wheel hub and the speedometer
gear unit are installed with the
projections meshed into the slots.
2. Lift up the wheel between the
front fork legs and guide the brake
disc between the brake pads.
Make sure the slot in the speed-
ometer gear unit fits over the stop-
per on the front fork outer tube.
3. Install the wheel axle and let the
motorcycle down.

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PERIODIC MAINTENANCE AND MINOR REPAIR
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9 4. Push down hard on the handle-
bars several times to check for
proper fork operation.
5. Tighten the wheel axle to the
specified torque.
6. Install the pinch bolt and tighten it
to the specified torque.
7. Install the speedometer cable.Tightening torque:
Wheel axle:
59 Nm (5.9 m·kg)
Pinch bolt:
20 Nm (2.0 m·kg)
1. Adjusting nut
2. Brake rod
3. Brake torque rod bolt (´ 2)
4. Brake torque rod
EAU01350*
Rear wheel removal
EW000122
WARNING
l
It is advisable to have a
Yamaha dealer service the
wheel.
l
Securely support the motor-
cycle so there is no danger of itfalling over.1. Loosen the axle nut. Do not re-
move it.
2. Remove the brake torque rod bolt
on the brake shoe plate side.
3. Loosen the brake torque rod bolt
on the swingarm side.
4. Remove the brake pedal free play
adjusting nut and then the brake
rod from the brake cam lever.
5. Remove panel A. (See page 6-5
for removal procedures.)

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EAU01008
TroubleshootingAlthough Yamaha motorcycles receive
a rigid inspection before shipment from
the factory, trouble may occur during
operation.
Any problem in the fuel, compression,
or ignition systems can cause poor
starting and loss of power. The trou-
bleshooting chart describes a quick,
easy procedure for making checks.
If your motorcycle requires any repair,
bring it to a Yamaha dealer. The skilled
technicians at a Yamaha dealership
have the tools, experience, and know-
how to properly service your motor-
cycle. Use only genuine Yamaha parts
on your motorcycle. Imitation parts
may look like Yamaha parts, but they
are often inferior. Consequently, they
have a shorter service life and can
lead to expensive repair bills.