brake YAMAHA XVS650A 2004 Owner's Manual
[x] Cancel search | Manufacturer: YAMAHA, Model Year: 2004, Model line: XVS650A, Model: YAMAHA XVS650A 2004Pages: 86, PDF Size: 10.9 MB
Page 68 of 86
PERIODIC MAINTENANCE AND MINOR REPAIR
6-31
6
EAU24360
Front wheel
EAU24660
To remove the front wheel
WARNING
EWA10820
It is advisable to have a Yamaha
dealer service the wheel.
Securely support the motor-
cycle so that there is no dangerof it falling over.
1. Disconnect the speedometer ca-
ble from the front wheel.
2. Loosen the front wheel axle pinch
bolt.
3. Remove the rubber cap, and then
loosen the wheel axle.4. Lift the front wheel off the ground
according to the procedure on
page 6-30.
5. Pull the wheel axle out, and then
remove the wheel.
CAUTION:
ECA11070
Do not apply the brake after the
wheel has been removed together
with the brake disc, otherwise thebrake pads will be forced shut.
EAU24921
To install the front wheel
1. Install the speedometer gear unit
into the wheel hub so that the pro-
jections mesh with the slots.
2. Lift the wheel up between the fork
legs.NOTE:Make sure that there is enough space
between the brake pads before insert-
ing the brake disc and that the slot in
the speedometer gear unit fits over theretainer on the fork leg.
3. Insert the wheel axle.
4. Lower the front wheel so that it is
on the ground.
1. Speedometer cable
1. Rubber cap
2. Wheel axle
3. Front wheel axle pinch bolt
1. Speedometer gear unit
2. Speedometer cable
3. Retainer
U5SCE1E0.book Page 31 Monday, September 8, 2003 11:32 AM
Page 69 of 86
PERIODIC MAINTENANCE AND MINOR REPAIR
6-32
6 5. Tighten the wheel axle and front
wheel axle pinch bolt to the speci-
fied torques, and then install the
rubber cap.
6. While applying the front brake,
push down hard on the handlebars
several times to check if the front
fork compresses and rebounds
smoothly.
7. Connect the speedometer cable.
EAU25080
Rear wheel
EAU25141
To remove the rear wheel
WARNING
EWA10820
It is advisable to have a Yamaha
dealer service the wheel.
Securely support the motor-
cycle so that there is no dangerof it falling over.
1. Loosen the axle nut.
2. Disconnect the brake torque rod
from the brake shoe plate by re-
moving the bolt and nut.
3. Loosen the brake torque rod nut 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 6-5.)
6. Remove the bolts that secure the
final gear case to the swingarm.
Tightening torques:
Wheel axle:
59 Nm (5.9 m·kgf, 43 ft·lbf)
Front wheel axle pinch bolt:
20 Nm (2.0 m·kgf, 14 ft·lbf)
1. Axle nut
1. Brake pedal free play adjusting nut
2. Brake camshaft lever
3. Bolt and nut (shoe plate)
4. Brake torque rod
5. Nut (swingarm)
6. Brake rod
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Page 70 of 86
PERIODIC MAINTENANCE AND MINOR REPAIR
6-33
67. Lift the rear wheel off the ground
according to the procedure on
page 6-30.
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 asit is being pulled out.
EAU25511
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 mid-
dle gear universal joint.
2. Install the final gear case bolts.
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
and nut at the brake shoe plate.
5. Install the panel.
6. Lower the rear wheel so that it is
on the ground.7. Tighten the axle nut, the final gear
case bolts and the brake torque
rod nuts to the specified torques.
8. Adjust the brake pedal free play.
(See page 6-18.)
WARNING
EWA10660
After adjusting the brake pedal free
play, check the operation of thebrake light.
1. Bolt
2. Final gear case
1. Middle gear universal joint
2. Drive shaft
Tightening torques:
Axle nut:
92 Nm (9.2 m·kgf, 67 ft·lbf)
Final gear case bolt:
74 Nm (7.4 m·kgf, 54 ft·lbf)
Brake torque rod nut:
20 Nm (2.0 m·kgf, 14 ft·lbf)
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Page 73 of 86
MOTORCYCLE CARE AND STORAGE
7-1
7
EAU26060
Care While the open design of a motorcycle
reveals the attractiveness of the tech-
nology, it also makes it more vulnera-
ble. Rust and corrosion can develop
even if high-quality components are
used. A rusty exhaust pipe may go un-
noticed on a car, however, it detracts
from the overall appearance of a motor-
cycle. Frequent and proper care does
not only comply with the terms of the
warranty, but it will also keep your
motorcycle looking good, extend its life
and optimize its performance.
Before cleaning
1. Cover the muffler outlets with plas-
tic bags after the engine has
cooled down.
2. Make sure that all caps and covers
as well as all electrical couplers
and connectors, including the
spark plug caps, are tightly in-
stalled.
3. Remove extremely stubborn dirt,
like oil burnt onto the crankcase,
with a degreasing agent and a
brush, but never apply such prod-ucts onto seals, gaskets and wheel
axles. Always rinse the dirt and de-
greaser off with water.
Cleaning
CAUTION:
ECA10770
Avoid using strong acidic wheel
cleaners, especially on spoked
wheels. If such products are
used on hard-to-remove dirt, do
not leave the cleaner on the af-
fected area any longer than in-
structed. Also, thoroughly rinse
the area off with water, immedi-
ately dry it, and then apply a cor-
rosion protection spray.
Improper cleaning can damage
windshields, cowlings, panels
and other plastic parts. Use only
a soft, clean cloth or sponge
with mild detergent and water to
clean plastic.
Do not use any harsh chemical
products on plastic parts. Be
sure to avoid using cloths or
sponges which have been in
contact with strong or abrasive
cleaning products, solvent orthinner, fuel (gasoline), rust re-
movers or inhibitors, brake flu-
id, antifreeze or electrolyte.
Do not use high-pressure wash-
ers or steam-jet cleaners since
they cause water seepage and
deterioration in the following ar-
eas: seals (of wheel and swing-
arm bearings, fork and brakes),
electric components (couplers,
connectors, instruments,
switches and lights), breather
hoses and vents.
For motorcycles equipped with
a windshield: Do not use strong
cleaners or hard sponges as
they will cause dulling or
scratching. Some cleaning com-
pounds for plastic may leave
scratches on the windshield.
Test the product on a small hid-
den part of the windshield to
make sure that it does not leave
any marks. If the windshield is
scratched, use a quality plastic
polishing compound afterwashing.
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Page 74 of 86
MOTORCYCLE CARE AND STORAGE
7-2
7After normal use
Remove dirt with warm water, a mild
detergent, and a soft, clean sponge,
and then rinse thoroughly with clean
water. Use a toothbrush or bottlebrush
for hard-to-reach areas. Stubborn dirt
and insects will come off more easily if
the area is covered with a wet cloth for
a few minutes before cleaning.
After riding in the rain, near the sea oron salt-sprayed roadsSince sea salt or salt sprayed on roads
during winter are extremely corrosive in
combination with water, carry out the
following steps after each ride in the
rain, near the sea or on salt-sprayed
roads.NOTE:Salt sprayed on roads in the winter mayremain well into spring.
1. Clean the motorcycle with cold wa-
ter and a mild detergent, after the
engine has cooled down.
CAUTION:
ECA10790
Do not use warm water since it in-
creases the corrosive action of thesalt.
2. After drying the motorcycle, apply
a corrosion protection spray on all
metal, including chrome- and nick-
el-plated, surfaces to prevent cor-
rosion.
After cleaning
1. Dry the motorcycle with a chamois
or an absorbing cloth.
2. Use a chrome polish to shine
chrome, aluminum and stainless-
steel parts, including the exhaust
system. (Even the thermally in-
duced discoloring of stainless-
steel exhaust systems can be re-
moved through polishing.)
3. To prevent corrosion, it is recom-
mended to apply a corrosion pro-
tection spray on all metal,
including chrome- and nickel-plat-
ed, surfaces.
4. Use spray oil as a universal clean-
er to remove any remaining dirt.5. Touch up minor paint damage
caused by stones, etc.
6. Wax all painted surfaces.
7. Let the motorcycle dry completely
before storing or covering it.
WARNING
EWA11130
Make sure that there is no oil or
wax on the brakes or tires.
If necessary, clean the brake
discs and brake linings with a
regular brake disc cleaner or ac-
etone, and wash the tires with
warm water and a mild deter-
gent. Before riding at higher
speeds, test the motorcycle’s
braking performance and cor-nering behavior.
CAUTION:
ECA10800
Apply spray oil and wax spar-
ingly and make sure to wipe off
any excess.
Never apply oil or wax to any
rubber and plastic parts, but
treat them with a suitable care
product.
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Page 78 of 86
SPECIFICATIONS
8-2
8
Gear ratio:
1st:
38/14 (2.714)
2nd:
38/20 (1.900)
3rd:
35/24 (1.458)
4th:
28/24 (1.167)
5th:
29/30 (0.967)Chassis:Frame type:
Double cradle
Caster angle:
35.0 °
Trail:
145.0 mm (5.71 in)Front tire:Type:
With tube
Size:
130/90-16M/C 67S
Manufacturer/model:
BRIDGESTONE/G703
Manufacturer/model:
DUNLOP/D404FRear tire:Type:
With tube
Size:
170/80-15M/C 77S
Manufacturer/model:
BRIDGESTONE/G702Manufacturer/model:
DUNLOP/D404G
Loading:Maximum load:
198 kg (437 lb)
(Total weight of rider, passenger, cargo and
accessories)Tire air pressure (measured on cold
tires):Loading condition:
0–90 kg (0–198 lb)
Front:
225 kPa (33 psi) (2.25 kgf/cm²)
Rear:
225 kPa (33 psi) (2.25 kgf/cm²)
Loading condition:
90–198 kg (198–437 lb)
Front:
225 kPa (33 psi) (2.25 kgf/cm²)
Rear:
250 kPa (36 psi) (2.50 kgf/cm²)Front wheel:Wheel type:
Spoke wheel
Rim size:
16M/C x MT3.00Rear wheel:Wheel type:
Spoke wheel
Rim size:
15M/C x MT3.50Front brake:Type:
Single disc brakeOperation:
Right hand operation
Recommended fluid:
DOT 4
Rear brake:Type:
Drum brake
Operation:
Right foot operationFront suspension:Type:
Telescopic fork
Spring/shock absorber type:
Coil spring/oil damper
Wheel travel:
140.0 mm (5.51 in)Rear suspension:Type:
Swingarm (monocross)
Spring/shock absorber type:
Coil spring/gas-oil damper
Wheel travel:
98.0 mm (3.86 in)Electrical system:Ignition system:
Transistorized coil ignition (digital)
Charging system:
A.C. magnetoBattery:Model:
GT12B-4
Voltage, capacity:
12 V, 10.0 Ah
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Page 79 of 86
SPECIFICATIONS
8-3
8
Headlight:Bulb type:
Halogen bulbBulb voltage, wattage x quantity:Headlight:
12 V, 60 W/55.0 W × 1
Tail/brake light:
12 V, 5.0/21.0 W × 1
Front turn signal light:
12 V, 21.0 W × 2
Rear turn signal light:
12 V, 21.0 W × 2
Auxiliary light:
12 V, 4.0 W × 1
Meter lighting:
12 V, 1.7 W × 1
Neutral indicator light:
12 V, 1.7 W × 1
High beam indicator light:
12 V, 1.7 W × 1
Turn signal indicator light:
12 V, 1.7 W × 1
Engine trouble warning light:
12 V, 1.7 W × 1
Immobilizer system indicator light:
LEDFuses:Main fuse:
30.0 A
Headlight fuse:
15.0 A
Signaling system fuse:
10.0 AIgnition fuse:
10.0 A
Parking lighting fuse:
10.0 A
Carburetor heater fuse:
15.0 A
Ignitor unit fuse:
5.0 A
Backup fuse:
10.0 A
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Page 82 of 86
INDEXAAir filter element, cleaning..................... 6-11
Anti-theft alarm (optional)........................ 3-5
Auxiliary light bulb, replacing ................ 6-29BBattery................................................... 6-25
Brake and clutch levers, checking and
lubricating ........................................... 6-22
Brake and shift pedals, checking and
lubricating ........................................... 6-22
Brake fluid, changing ............................ 6-21
Brake fluid level, checking .................... 6-20
Brake lever .............................................. 3-7
Brake lever free play, adjusting............. 6-17
Brake pads and shoes, checking .......... 6-19
Brake pedal ............................................. 3-8
Brake pedal position and free play,
adjusting ............................................. 6-18CCables, checking and lubricating .......... 6-21
Carburetors, adjusting........................... 6-12
Care ........................................................ 7-1
Catalytic converter ................................ 3-10
Clutch lever ............................................. 3-7
Clutch lever free play, adjusting ............ 6-16DDimmer switch ........................................ 3-6EEngine break-in ....................................... 5-4
Engine idling speed............................... 6-12
Engine oil and oil filter element ............... 6-7
Engine, starting a warm .......................... 5-2
Engine stop switch .................................. 3-6
Engine trouble warning light.................... 3-4
FFinal gear oil ......................................... 6-10
Front fork, checking .............................. 6-23
Fuel......................................................... 3-9
Fuel cock .............................................. 3-10
Fuel consumption, tips for reducing........ 5-3
Fuel tank cap .......................................... 3-8
Fuses, replacing ................................... 6-26HHandlebar switches ................................ 3-5
Hazard switch ......................................... 3-6
Headlight bulb, replacing ...................... 6-27
Helmet holder ....................................... 3-12
High beam indicator light ........................ 3-4
Horn switch ............................................. 3-6IIdentification numbers ............................ 9-1
Ignition circuit cut-off system ................ 3-15
Immobilizer system ................................. 3-1
Immobilizer system indicator light........... 3-4
Indicator and warning lights .................... 3-3KKey identification number ....................... 9-1LLuggage strap holders .......................... 3-14MMain switch/steering lock........................ 3-2
Model label ............................................. 9-2NNeutral indicator light .............................. 3-3PPanels, removing and installing .............. 6-5
Parking ................................................... 5-4
Part locations .......................................... 2-1Pass switch ............................................. 3-6
Periodic maintenance and lubrication
chart ...................................................... 6-2
Pre-operation check list........................... 4-2
RRear brake light switch, adjusting ......... 6-19SSafety information ................................... 1-1
Seats ..................................................... 3-11
Shifting .................................................... 5-2
Shift pedal ............................................... 3-7
Shock absorber assembly, adjusting .... 3-13
Sidestand .............................................. 3-15
Sidestand, checking and lubricating...... 6-23
Spark plugs, checking ............................. 6-6
Specifications .......................................... 8-1
Speedometer unit .................................... 3-5
Starter (choke) knob.............................. 3-11
Starting a cold engine ............................. 5-1
Start switch.............................................. 3-6
Steering, checking................................. 6-24
Storage.................................................... 7-3
Storage compartment............................ 3-13
Supporting the motorcycle .................... 6-30TThrottle cable free play, adjusting ......... 6-13
Throttle grip and cable, checking and
lubricating ........................................... 6-21
Tires ...................................................... 6-14
Tool kit..................................................... 6-1
Troubleshooting .................................... 6-34
Troubleshooting chart ........................... 6-35
Turn signal indicator light ........................ 3-3
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Page 83 of 86
INDEX
Turn signal light bulb or tail/brake light
bulb, replacing .................................... 6-29
Turn signal switch ................................... 3-6VValve clearance, adjusting.................... 6-13
Vehicle identification number.................. 9-1WWheel bearings, checking .................... 6-25
Wheel (front) ......................................... 6-31
Wheel (rear).......................................... 6-32
Wheels.................................................. 6-16
U5SCE1E0.book Page 2 Monday, September 8, 2003 11:32 AM