brake YAMAHA XVS650A 2004 User Guide

PERIODIC MAINTENANCE AND MINOR REPAIR
6-4
6
EAU18660
NOTE:

The air filter needs more frequent service if you are riding in unusually wet or dusty areas.


Hydraulic brake service
Regularly check and, if necessary, correct the brake fluid level.
Every two years replace the internal components of the brake master cylinder and caliper, and change the brake fluid.Replace the brake hoses every four years and if cracked or damaged.
22 Engine oil filter elementReplace.√√√
23 Final gear oilCheck oil level and vehicle for oil leakage.√√ √
Change.√√√
24*Front and rear brake
switchesCheck operation.√√√√√ √
25Moving parts and ca-
blesLubricate.√√√√ √
26*Throttle grip housing
and cableCheck operation and free play.
Adjust the throttle cable free play if necessary.
Lubricate the throttle grip housing and cable.√√√√ √
27*Muffler and exhaust
pipeCheck the screw clamp for looseness.√√√√√
28*Lights, signals and
switchesCheck operation.
Adjust headlight beam.√√√√√ √ NO. ITEM CHECK OR MAINTENANCE JOBODOMETER READING (× 1000 km)
ANNUAL
CHECK
1 10203040
U5SCE1E0.book Page 4 Monday, September 8, 2003 11:32 AM

PERIODIC MAINTENANCE AND MINOR REPAIR
6-15
6Tire inspection
The tires must be checked before each
ride. If the center tread depth reaches
the specified limit, if the tire has a nail or
glass fragments in it, or if the sidewall is
cracked, have a Yamaha dealer re-
place the tire immediately.
NOTE:The tire tread depth limits may differ
from country to country. Always complywith the local regulations.
WARNING
EWA10570


Have a Yamaha dealer replace
excessively worn tires. Besides
being illegal, operating the
motorcycle with excessively
worn tires decreases riding sta-
bility and can lead to loss of
control.


The replacement of all wheel-
and brake-related parts, includ-
ing the tires, should be left to a
Yamaha dealer, who has the
necessary professional knowl-
edge and experience.


It is not recommended to patch
a punctured tube. If unavoid-
able, however, patch the tube
very carefully and replace it as
soon as possible with a high-quality product.
Tire information
This motorcycle is equipped with spoke
wheels and tube tires.
WARNING
EWA10460


The front and rear tires should
be of the same make and de-
sign, otherwise the handling
characteristics of the vehicle
cannot be guaranteed.


After extensive tests, only the
tires listed below have been ap-
proved for this model byYamaha Motor Co., Ltd.
1. Tire sidewall
2. Tire tread depthMinimum tire tread depth (front and
rear):
1.6 mm (0.06 in)
Front tire:
Size:
130/90-16M/C 67S
Manufacturer/model:
BRIDGESTONE/G703
DUNLOP/D404F
Rear tire:
Size:
170/80-15M/C 77S
Manufacturer/model:
BRIDGESTONE/G702
DUNLOP/D404G
U5SCE1E0.book Page 15 Monday, September 8, 2003 11:32 AM

PERIODIC MAINTENANCE AND MINOR REPAIR
6-17
67. Tighten the locknut at the clutch le-
ver and the crankcase.
EAU22092
Adjusting the brake lever free
play The brake lever free play should mea-
sure 10.0–15.0 mm (0.39–0.59 in) as
shown. Periodically check the brake le-
ver free play and, if necessary, adjust it
as follows.1. Loosen the locknut at the brake le-
ver.
2. To increase the brake lever free
play, turn the adjusting screw in di-
rection (a). To decrease the brake
lever free play, turn the adjusting
screw in direction (b).
3. Tighten the locknut.
WARNING
EWA10630


After adjusting the brake lever
free play, check the free play
and make sure that the brake is
working properly.


A soft or spongy feeling in the
brake lever can indicate the
presence of air in the hydraulic
1. Brake lever free play
1. Locknut
2. Brake lever free play adjusting screw
U5SCE1E0.book Page 17 Monday, September 8, 2003 11:32 AM

PERIODIC MAINTENANCE AND MINOR REPAIR
6-18
6 system. If there is air in the hy-
draulic system, have a Yamaha
dealer bleed the system before
operating the motorcycle. Air in
the hydraulic system will dimin-
ish the braking performance,
which may result in loss of con-
trol and an accident.
EAU22231
Adjusting the brake pedal
position and free play
WARNING
EWA10670
It is advisable to have a Yamahadealer make these adjustments.NOTE:The brake pedal position should be ad-
justed before adjusting the brake pedalfree play.
Brake pedal position
The brake pedal should be positioned
approximately 108.0 mm (4.25 in)
above the top of the footrest as shown.Periodically check the brake pedal po-
sition and, if necessary, adjust it as fol-
lows.
1. Loosen the locknut at the brake
pedal.
2. To raise the brake pedal, turn the
adjusting bolt in direction (a). To
lower the brake pedal, turn the ad-
justing bolt in direction (b).
3. Tighten the locknut.
WARNING
EWA11230
After adjusting the brake pedal posi-
tion, the brake pedal free play mustbe adjusted.
1. Distance between brake pedal and footrest
2. Brake pedal free play
1. Locknut
2. Brake pedal position adjusting bolt
U5SCE1E0.book Page 18 Monday, September 8, 2003 11:32 AM

PERIODIC MAINTENANCE AND MINOR REPAIR
6-19
6Brake pedal free play
The brake pedal free play should mea-
sure 20.0–30.0 mm (0.79–1.18 in) at
the brake pedal end. Periodically check
the brake pedal free play and, if neces-
sary, adjust it as follows.
To increase the brake pedal free play,
turn the adjusting nut at the brake rod in
direction (a). To decrease the brake
pedal free play, turn the adjusting nut in
direction (b).
EAU22270
Adjusting the rear brake light
switch The rear brake light switch, which is ac-
tivated by the brake pedal, is properly
adjusted when the brake light comes
on just before braking takes effect. If
necessary, adjust the brake light switch
as follows.
Turn the adjusting nut while holding the
rear brake light switch in place. To
make the brake light come on earlier,
turn the adjusting nut in direction (a). To
make the brake light come on later, turn
the adjusting nut in direction (b).
EAU22380
Checking the front brake pads
and rear brake shoes The front brake pads and the rear brake
shoes must be checked for wear at the
intervals specified in the periodic main-
tenance and lubrication chart.
EAU22430
Front brake pads
Each front brake pad is provided with
wear indicator grooves, which allow
you to check the brake pad wear with-
out having to disassemble the brake.
To check the brake pad wear, check
the wear indicator grooves. If a brake
pad has worn to the point that the wear
1. Brake pedal free play adjusting nut
1. Brake light switch
2. Rear brake light switch adjusting nut
1. Brake pad wear indicator groove
U5SCE1E0.book Page 19 Monday, September 8, 2003 11:32 AM

PERIODIC MAINTENANCE AND MINOR REPAIR
6-20
6 indicator grooves have almost disap-
peared, have a Yamaha dealer replace
the brake pads as a set.
EAU22540
Rear brake shoes
The rear brake is provided with a wear
indicator, which allows you to check the
brake shoe wear without having to dis-
assemble the brake. To check the
brake shoe wear, check the position of
the wear indicator while applying the
brake. If a brake shoe has worn to the
point that the wear indicator reaches
the wear limit line, have a Yamaha
dealer replace the brake shoes as a
set.
EAU22580
Checking the brake fluid level Insufficient brake fluid may allow air to
enter the brake system, possibly caus-
ing it to become ineffective.
Before riding, check that the brake fluid
is above the minimum level mark and
replenish if necessary. A low brake fluid
level may indicate worn brake pads
and/or brake system leakage. If the
brake fluid level is low, be sure to check
the brake pads for wear and the brake
system for leakage.
Observe these precautions:

When checking the fluid level,
make sure that the top of the brake
fluid reservoir is level.


Use only the recommended quality
brake fluid, otherwise the rubber
seals may deteriorate, causing
leakage and poor braking perfor-
mance.


Refill with the same type of brake
fluid. Mixing fluids may result in a
harmful chemical reaction and
lead to poor braking performance.


Be careful that water does not en-
ter the brake fluid reservoir when
refilling. Water will significantly
lower the boiling point of the fluid
and may result in vapor lock.


Brake fluid may deteriorate paint-
ed surfaces or plastic parts. Al-
ways clean up spilled fluid
immediately.


As the brake pads wear, it is nor-
mal for the brake fluid level to grad-
ually go down. However, if the
brake fluid level goes down sud-
denly, have a Yamaha dealer
check the cause.
1. Brake shoe wear limit line
2. Brake shoe wear indicator
1. Minimum level mark
Recommended brake fluid:
DOT 4
U5SCE1E0.book Page 20 Monday, September 8, 2003 11:32 AM

PERIODIC MAINTENANCE AND MINOR REPAIR
6-21
6
EAU22720
Changing the brake fluid Have a Yamaha dealer change the
brake fluid at the intervals specified in
the NOTE after the periodic mainte-
nance and lubrication chart. In addition,
have the oil seals of the brake master
cylinder and caliper as well as the
brake hose replaced at the intervals
listed below or whenever they are dam-
aged or leaking.

Oil seals: Replace every two
years.


Brake hose: Replace every four
years.
EAU23100
Checking and lubricating the
cables The operation of all control cables and
the condition of the cables should be
checked before each ride, and the ca-
bles and cable ends should be lubricat-
ed if necessary. If a cable is damaged
or does not move smoothly, have a
Yamaha dealer check or replace it.
WARNING
EWA10720
Damage to the outer sheath may in-
terfere with proper cable operation
and will cause the inner cable to
rust. Replace a damaged cable as
soon as possible to prevent unsafeconditions.
EAU23110
Checking and lubricating the
throttle grip and cable The operation of the throttle grip should
be checked before each ride. In addi-
tion, the cable should be lubricated or
replaced at the intervals specified in the
periodic maintenance chart.
Recommended lubricant:
Engine oil
U5SCE1E0.book Page 21 Monday, September 8, 2003 11:32 AM

PERIODIC MAINTENANCE AND MINOR REPAIR
6-22
6
EAU23131
Checking and lubricating the
brake and shift pedals The operation of the brake and shift
pedals should be checked before each
ride, and the pedal pivots should be lu-
bricated if necessary.
EAU23140
Checking and lubricating the
brake and clutch levers Brake lever
Clutch lever
The operation of the brake and clutch
levers should be checked before each
ride, and the lever pivots should be lu-
bricated if necessary.
Recommended lubricant:
Lithium-soap-based grease (all-pur-
pose grease)
U5SCE1E0.book Page 22 Monday, September 8, 2003 11:32 AM

PERIODIC MAINTENANCE AND MINOR REPAIR
6-23
6
EAU23200
Checking and lubricating the
sidestand The operation of the sidestand should
be checked before each ride, and the
sidestand pivot and metal-to-metal
contact surfaces should be lubricated if
necessary.
WARNING
EWA10730
If the sidestand does not move up
and down smoothly, have a Yamahadealer check or repair it.
EAU23271
Checking the front fork The condition and operation of the front
fork must be checked as follows at the
intervals specified in the periodic main-
tenance and lubrication chart.
To check the condition
WARNING
EWA10750
Securely support the vehicle so thatthere is no danger of it falling over.
Check the inner tubes for scratches,
damage and excessive oil leakage.
To check the operation
1. Place the vehicle on a level sur-
face and hold it in an upright posi-
tion.
2. While applying the front brake,
push down hard on the handlebars
several times to check if the front
fork compresses and rebounds
smoothly.
Recommended lubricant:
Lithium-soap-based grease (all-pur-
pose grease)
Recommended lubricant:
Lithium-soap-based grease (all-pur-
pose grease)
U5SCE1E0.book Page 23 Monday, September 8, 2003 11:32 AM

PERIODIC MAINTENANCE AND MINOR REPAIR
6-29
6
EAU24281
Replacing a turn signal light
bulb or the tail/brake light bulb 1. Remove the lens by removing the
screws.2. Remove the defective bulb by
pushing it in and turning it counter-
clockwise.
3. Insert a new bulb into the socket,
push it in, and then turn it clock-
wise until it stops.
4. Install the lens by installing the
screws.
CAUTION:
ECA10680
Do not overtighten the screws, oth-erwise the lens may break.
EAU33411
Replacing the auxiliary light
bulb If the auxiliary light bulb burns out, re-
place it as follows.
1. Remove the headlight unit by re-
moving the screws.
2. Remove the socket (together with
the bulb) by pushing it in and turn-
ing it counterclockwise.
1. Screw
1. Screw
1. Screw
U5SCE1E0.book Page 29 Monday, September 8, 2003 11:32 AM