torque YAMAHA XVS650A 2002 Owners Manual
[x] Cancel search | Manufacturer: YAMAHA, Model Year: 2002, Model line: XVS650A, Model: YAMAHA XVS650A 2002Pages: 108, PDF Size: 9.03 MB
Page 48 of 108
6-1
6
EAU00462
6-PERIODIC MAINTENANCE AND MINOR REPAIR
EAU00464
Safety is an obligation of the owner.
Periodic inspection, adjustment and lu-
brication will keep your vehicle in the
safest and most efficient condition pos-
sible. The most important points of in-
spection, adjustment, and lubrication
are explained on the following pages.
The intervals given in the periodic
maintenance and lubrication chart
should be simply considered as a gen-
eral guide under normal riding condi-
tions. However, DEPENDING ON THE
WEATHER, TERRAIN, GEOGRAPHI-
CAL LOCATION, AND INDIVIDUAL
USE, THE MAINTENANCE INTER-
VALS MAY NEED TO BE SHORT-
ENED.
EW000060
WARNING
@ If you are not familiar with motor-
cycle maintenance work, have a
Yamaha dealer do it for you. @
EAU01129
Owner’s tool kit The owner’s tool kit is located inside
the storage compartment. (See page
3-13 for storage compartment opening
procedures.)
The service information included in this
manual and the tools provided in the
owner’s tool kit are intended to assist
you in the performance of preventive
maintenance and minor repairs. How-
ever, additional tools such as a torque
wrench may be necessary to perform
certain maintenance work correctly.NOTE:@ If you do not have the tools or experi-
ence required for a particular job, have
a Yamaha dealer perform it for you. @
EW000063
WARNING
@ Modifications not approved by
Yamaha may cause loss of perfor-
mance and render the vehicle un-
safe for use. Consult a Yamaha
dealer before attempting any chang-
es. @
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Page 55 of 108
PERIODIC MAINTENANCE AND MINOR REPAIR
6-8
6 2. Remove the spark plug as shown,
with the spark plug wrench includ-
ed in the owner’s tool kit.
To check the spark plugs
1. Check that the porcelain insulator
around the center electrode on
each spark plug is a medium-to-
light tan (the ideal color when the
motorcycle is ridden normally).
2. Check that all spark plugs installed
in the engine have the same color.
NOTE:@ If any spark plug shows a distinctly dif-
ferent color, the engine could be defec-
tive. Do not attempt to diagnose such
problems yourself. Instead, have a
Yamaha dealer check the motorcycle. @3. Check each spark plug for elec-
trode erosion and excessive car-
bon or other deposits, and replace
it if necessary.
To install a spark plug
1. Measure the spark plug gap with a
wire thickness gauge and, if nec-
essary, adjust the gap to specifica-
tion.
2. Clean the surface of the spark
plug gasket and its mating sur-
face, and then wipe off any grime
from the spark plug threads.
3. Install the spark plug with the
spark plug wrench, and then tight-
en it to the specified torque.
1. Spark plug wrench
Specified spark plug:
DPR7EA-9 (NGK) or
X22EPR-U9 (DENSO)
a. Spark plug gapSpark plug gap:
0.8–0.9 mm
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PERIODIC MAINTENANCE AND MINOR REPAIR
6-9
6
NOTE:@ If a torque wrench is not available when
installing a spark plug, a good estimate
of the correct torque is 1/4–1/2 turn
past finger tight. However, the spark
plug should be tightened to the speci-
fied torque as soon as possible. @4. Install the spark plug cap.
EAU03835*
Engine oil and oil filter
element The engine oil level should be checked
before each ride. In addition, the oil
must be changed and the oil filter ele-
ment replaced at the intervals specified
in the periodic maintenance and lubri-
cation chart.
To check the engine oil level
1. Place the motorcycle on a level
surface and hold it in an upright
position.NOTE:_ Make sure that the motorcycle is posi-
tioned straight up when checking the oil
level. A slight tilt to the side can result in
a false reading. _2. Start the engine, warm it up for
several minutes, and then turn it
off.3. Wait a few minutes until the oil set-
tles, and then check the oil level
through the check window located
at the bottom-left side of the crank-
case.
NOTE:_ The engine oil should be between the
minimum and maximum level marks. _4. If the engine oil is below the mini-
mum level mark, add sufficient oil
of the recommended type to raise
it to the correct level. Tightening torque:
Spark plug:
18 Nm (1.8 m·kgf)1. Engine oil level check window
2. Maximum level mark
3. Minimum level mark
4. Engine oil filler capLeft side
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PERIODIC MAINTENANCE AND MINOR REPAIR
6-11
65. Remove the oil filter element and
O-ring.
6. Install a new oil filter element and
the O-ring.
7. Install the oil filter element covers
by installing the bolts.
8. Install the engine oil drain bolt, and
then tighten it to the specified
torque.9. Add the specified amount of the
recommended oil, and then install
and tighten the oil filler cap.
EC000072*
CAUTION:_
In order to prevent clutch slip-
page (since the engine oil also
lubricates the clutch), do not
mix any chemical additives with
the oil or use oils of a “CD”
grade or higher. In addition, do
not use oils labeled “ENERGY
CONSERVING II” or higher.
Make sure that no foreign mate-
rial enters the crankcase.
_10. Start the engine, and then let it idle
for several minutes while checking
it for oil leakage. If oil is leaking,
immediately turn the engine off
and check for the cause.
11. Turn the engine off, and then
check the oil level and correct it if
necessary.
1. Oil filter element
2. O-ringTightening torque:
Engine oil drain bolt:
43 Nm (4.3 m·kgf)
Recommended engine oil:
See page 8-1.
Oil quantity:
Without oil filter element
replacement:
2.6 L
With oil filter element
replacement:
2.8 L
Total amount (dry engine):
3.2 L
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Page 59 of 108
PERIODIC MAINTENANCE AND MINOR REPAIR
6-12
6
EAU04083
Final gear oil The final gear case must be checked
for oil leakage before each ride. If any
leakage is found, have a Yamaha deal-
er check and repair the motorcycle. In
addition, the final gear oil level must be
checked and the oil changed as follows
at the intervals specified in the periodic
maintenance and lubrication chart.
EW000066
WARNING
_
Make sure that no foreign mate-
rial enters the final gear case.
Make sure that no oil gets on
the tire or wheel.
_To check the final gear oil level
1. Place the motorcycle on a level
surface and hold it in an upright
position.
NOTE:_
The final gear oil level must be
checked on a cold engine.
Make sure that the motorcycle is
positioned straight up when
checking the oil level. A slight tilt to
the side can result in a false read-
ing.
_2. Remove the oil filler bolt, and then
check the oil level in the final gear
case.
NOTE:_ The oil level should be at the brim of
the filler hole. _3. If the oil is below the brim of the fill-
er hole, add sufficient oil of the rec-
ommended type to raise it to the
correct level.
To change the final gear oil
1. Place an oil pan under the final
gear case to collect the used oil.
2. Remove the oil filler bolt and drain
bolt to drain the oil from the final
gear case.
3. Install the final gear oil drain bolt,
and then tighten it to the specified
torque.
4. Add the recommended final gear
oil to the brim of the filler hole.
1. Final gear oil drain bolt
2. Final gear oil filler bolt
3. Correct oil level
Tightening torque:
Final gear oil drain bolt:
23 Nm (2.3 m·kgf)
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PERIODIC MAINTENANCE AND MINOR REPAIR
6-36
6 4. Lower the front wheel so that it is
on the ground.
5. Push down hard on the handlebar
several times to check for proper
fork operation.
6. Tighten the wheel axle to the
specified torque, and then install
the rubber cap.
7. Tighten the front wheel axle pinch
bolt to the specified torque.
8. Connect the speedometer cable.
EAU01350
Rear wheel To remove the rear wheel
EW000122
WARNING
@
It is advisable to have a Yamaha
dealer service the wheel.
Securely support the motorcycle
so that there is no danger of it
falling over.
@1. Loosen the axle nut.2. Disconnect the brake torque rod
from the brake shoe plate by re-
moving the bolt.
3. Loosen the brake torque rod bolt
at the swingarm.
4. Remove the brake pedal free play
adjusting nut, and then disconnect
the brake rod from the brake cam-
shaft lever.
5. Remove panel A. (See page 6-6
for panel removal and installation
procedures.) Tightening torque:
Wheel axle:
59 Nm (5.9 m·kgf)
Tightening torque:
Front wheel axle pinch bolt:
20 Nm (2.0 m·kgf)1. Axle nut
1. Brake pedal free play adjusting nut
2. Brake camshaft lever
3. Brake rod
4. Bolt (shoe plate)
5. Brake torque rod
6. Bolt (swingarm)
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PERIODIC MAINTENANCE AND MINOR REPAIR
6-37
66. Remove the bolts that secure the
final gear case to the swingarm.
7. Lift the rear wheel off the ground
according to the procedure on
page 6-34.
8. While supporting the drive shaft,
pull the rear wheel back to remove
the following parts as an assem-
bly: wheel, wheel axle, final gear
case, and drive shaft.
NOTE:@ Make sure to support the drive shaft as
it is being pulled out. @
EAU04191
To install the rear wheel
1. Install the rear wheel, wheel axle,
final gear case, and drive shaft by
pushing the wheel forward and
guiding the drive shaft into the
middle gear universal joint.
2. Install the final gear case bolts,
and then tighten them to the spec-
ified torque.3. Install the brake rod onto the brake
camshaft lever, and then install
the brake pedal free play adjusting
nut onto the brake rod.
4. Install the brake torque rod bolt at
the brake shoe plate, and then
tighten both bolts to the specified
torque.
5. Install the panel.
6. Lower the rear wheel so that it is
on the ground.
7. Tighten the axle nut to the speci-
fied torque.
8. Adjust the brake pedal free play.
(See page 6-21 for brake pedal
free play adjustment procedures.)
1. Bolt (× 4)
2. Final gear case
1. Middle gear universal joint
2. Drive shaft
Tightening torque:
Final gear case bolt:
74 Nm (7.4 m·kgf)
Tightening torque:
Brake torque rod bolt:
20 Nm (2.0 m·kgf)
Tightening torque:
Axle nut:
92 Nm (9.2 m·kgf)
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Page 99 of 108
SPECIFICATIONS
8-6
8
EAU03941
Conversion table CS-03EAll specification data in this manual are listed in SI and
METRIC UNITS.
Use this table to convert METRIC unit values to IMPERIAL
unit values.
Example:METRIC VALUE CONVERSION
FACTORIMPERIAL VALUE
2 mm× 0.03937 = 0.08 in
Conversion table
METRIC SYSTEM TO IMPERIAL SYSTEM
Metric unit Conversion factor Imperial unit
Torquem·kgf
m·kgf
cm·kgf
cm·kgf
× 7.233× 86.794× 0.0723× 0.8679ft·lb
in·lb
ft·lb
in·lb
Weightkg
g× 2.205× 0.03527lb
oz
Speed km/h× 0.6214 mi/h
Distancekm
m
m
cm
mm× 0.6214× 3.281× 1.094× 0.3937× 0.03937mi
ft
yd
in
in
Volume,
Capacitycc (cm
3)
cc (cm3)
L (liter)
L (liter)
× 0.03527× 0.06102× 0.8799× 0.2199oz (IMP liq.)
cu·in
qt (IMP liq.)
gal (IMP liq.)
Miscellaneouskgf/mm
kgf/cm
2
°
C
× 55.997× 14.2234× 1.8 + 32 lb/in
psi (lb/in
2)
°
F
U5SCE0.book Page 6 Thursday, June 7, 2001 11:24 AM