check engine light YAMAHA XVS650A 2004 Owners Manual
[x] Cancel search | Manufacturer: YAMAHA, Model Year: 2004, Model line: XVS650A, Model: YAMAHA XVS650A 2004Pages: 86, PDF Size: 10.9 MB
Page 6 of 86
TABLE OF CONTENTSSAFETY INFORMATION ..................1-1
DESCRIPTION ..................................2-1
Left view ..........................................2-1
Right view ........................................2-2
Controls and instruments.................2-3
INSTRUMENT AND CONTROL
FUNCTIONS.......................................3-1
Immobilizer system .........................3-1
Main switch/steering lock ................3-2
Indicator and warning lights ............3-3
Speedometer unit ...........................3-5
Anti-theft alarm (optional) ...............3-5
Handlebar switches ........................3-5
Clutch lever .....................................3-7
Shift pedal .......................................3-7
Brake lever .....................................3-7
Brake pedal ....................................3-8
Fuel tank cap ..................................3-8
Fuel .................................................3-9
Catalytic converter ........................3-10
Fuel cock ......................................3-10
Starter (choke) knob ......................3-11
Seats ............................................3-11
Helmet holder ...............................3-12
Storage compartment ...................3-13
Adjusting the shock absorber
assembly ...................................3-13
Luggage strap holders ..................3-14
Sidestand ......................................3-15Ignition circuit cut-off system ........ 3-15
PRE-OPERATION CHECKS............. 4-1
Pre-operation check list .................. 4-2
OPERATION AND IMPORTANT
RIDING POINTS................................. 5-1
Starting a cold engine .................... 5-1
Starting a warm engine .................. 5-2
Shifting ........................................... 5-2
Tips for reducing fuel
consumption ............................... 5-3
Engine break-in .............................. 5-4
Parking ........................................... 5-4
PERIODIC MAINTENANCE AND
MINOR REPAIR................................. 6-1
Owner’s tool kit ............................... 6-1
Periodic maintenance and
lubrication chart .......................... 6-2
Removing and installing panels ..... 6-5
Checking the spark plugs ............... 6-6
Engine oil and oil filter element ...... 6-7
Final gear oil ................................. 6-10
Cleaning the air filter element ...... 6-11
Adjusting the carburetors ............. 6-12
Adjusting the engine idling
speed ........................................ 6-12
Adjusting the throttle cable free
play ........................................... 6-13
Adjusting the valve clearance ...... 6-13Tires ............................................. 6-14
Spoke wheels .............................. 6-16
Adjusting the clutch lever free
play ........................................... 6-16
Adjusting the brake lever free
play ........................................... 6-17
Adjusting the brake pedal position
and free play ............................. 6-18
Adjusting the rear brake light
switch ....................................... 6-19
Checking the front brake pads
and rear brake shoes ............... 6-19
Checking the brake fluid level ...... 6-20
Changing the brake fluid .............. 6-21
Checking and lubricating the
cables ....................................... 6-21
Checking and lubricating the
throttle grip and cable ............... 6-21
Checking and lubricating the
brake and shift pedals .............. 6-22
Checking and lubricating the
brake and clutch levers ............ 6-22
Checking and lubricating the
sidestand .................................. 6-23
Checking the front fork ................. 6-23
Checking the steering .................. 6-24
Checking the wheel bearings ....... 6-25
Battery ......................................... 6-25
Replacing the fuses ..................... 6-26
Replacing the headlight bulb ....... 6-27U5SCE1E0.book Page 1 Monday, September 8, 2003 11:32 AM
Page 10 of 86
SAFETY INFORMATION
1-3
1Loading
The total weight of the operator, pas-
senger, accessories and cargo must
not exceed the maximum load limit of
198 kg (437 lb). When loading within
this weight limit, keep the following in
mind:
Cargo and accessory weight
should be kept as low and close to
the motorcycle as possible. Make
sure to distribute the weight as
evenly as possible on both sides of
the motorcycle to minimize imbal-
ance or instability.
Shifting weights can create a sud-
den imbalance. Make sure that ac-
cessories and cargo are securely
attached to the motorcycle before
riding. Check accessory mounts
and cargo restraints frequently.
Never attach any large or heavy
items to the handlebar, front fork,
or front fender. These items, in-
cluding such cargo as sleeping
bags, duffel bags, or tents, can
create unstable handling or slow
steering response.Accessories
Genuine Yamaha accessories have
been specifically designed for use on
this motorcycle. Since Yamaha cannot
test all other accessories that may be
available, you must personally be re-
sponsible for the proper selection, in-
stallation and use of non-Yamaha
accessories. Use extreme caution
when selecting and installing any ac-
cessories.
Keep the following guidelines in mind,
as well as those provided under “Load-
ing” when mounting accessories.
Never install accessories or carry
cargo that would impair the perfor-
mance of your motorcycle. Care-
fully inspect the accessory before
using it to make sure that it does
not in any way reduce ground
clearance or cornering clearance,
limit suspension travel, steering
travel or control operation, or ob-
scure lights or reflectors.
Accessories fitted to the handle-
bar or the front fork area can
create instability due to improper
weight distribution or aerody-
namic changes. If accessoriesare added to the handlebar or
front fork area, they must be as
lightweight as possible and
should be kept to a minimum.
Bulky or large accessories may
seriously affect the stability of
the motorcycle due to aerody-
namic effects. Wind may at-
tempt to lift the motorcycle, or
the motorcycle may become un-
stable in cross winds. These ac-
cessories may also cause
instability when passing or being
passed by large vehicles.
Certain accessories can dis-
place the operator from his or
her normal riding position. This
improper position limits the free-
dom of movement of the opera-
tor and may limit control ability,
therefore, such accessories are
not recommended.
Use caution when adding electri-
cal accessories. If electrical acces-
sories exceed the capacity of the
motorcycle’s electrical system, an
electric failure could result, which
could cause a dangerous loss of
lights or engine power.
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Page 18 of 86
INSTRUMENT AND CONTROL FUNCTIONS
3-4
3
EAU11080
High beam indicator light “”
This indicator light comes on when the
high beam of the headlight is switched
on.
EAU11500
Engine trouble warning light “”
This warning light comes on or flashes
when an electrical circuit monitoring the
engine is defective. When this occurs,
have a Yamaha dealer check the self-
diagnosis system.
The electrical circuit of the warning light
can be checked by turning the key to
“ON”. If the warning light does not come
on for a few seconds, then go off, have
a Yamaha dealer check the electrical
circuit.
EAU27020
Immobilizer system indicator light
“”
The electrical circuit of the indicator
light can be checked by turning the key
to “ON”.
If the indicator light does not come on
for a few seconds, then go off, have a
Yamaha dealer check the electrical cir-
cuit.When the key is turned to “OFF” and 30
seconds have passed, the indicator
light will start flashing indicating the im-
mobilizer system is enabled. After 24
hours have passed, the indicator light
will stop flashing, however the immobi-
lizer system is still enabled.
NOTE:This model is also equipped with a self-
diagnosis device for the immobilizer
system. If the immobilizer system is de-
fective, the indicator light will start flash-
ing a pattern when the key is turned to
“ON”. When this occurs, have a
Yamaha dealer check the self-diagno-
sis system. However, if the indicator
light slowly flashes five times, and then
quickly flashes two times repeatedly,
this error could be caused by signal in-
terference. If this occurs, try the follow-ing.
1. Use the code re-registering key to
start the engine.NOTE:Make sure there are no other immobi-
lizer keys close to the main switch, and
do not keep more than one immobilizerkey on the same key ring! Immobilizer
system keys may cause signal interfer-
ence, which may prevent the engine
from starting.
2. If the engine starts, turn it off, and
try starting the engine with the
standard keys.
3. If one or both of the standard keys
do not start the engine, take the
vehicle, the code re-registering
key and both standard keys to a
Yamaha dealer and have the stan-
dard keys re-registered.
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OPERATION AND IMPORTANT RIDING POINTS
5-1
5
EAU15950
WARNING
EWA10270
Become thoroughly familiar
with all operating controls and
their functions before riding.
Consult a Yamaha dealer re-
garding any control or function
that you do not thoroughly un-
derstand.
Never start the engine or oper-
ate it in a closed area for any
length of time. Exhaust fumes
are poisonous, and inhaling
them can cause loss of con-
sciousness and death within a
short time. Always make sure
that there is adequate ventila-
tion.
Before starting out, make sure
that the sidestand is up. If the
sidestand is not raised com-
pletely, it could contact the
ground and distract the opera-
tor, resulting in a possible lossof control.
EAU16400
Starting a cold engine In order for the ignition circuit cut-off
system to enable starting, one of the
following conditions must be met:
The transmission is in the neutral
position.
The transmission is in gear with
the clutch lever pulled and the sid-
estand up.WARNING
EWA10290
Before starting the engine,
check the function of the igni-
tion circuit cut-off system ac-
cording to the procedure
described on page 3-15.
Never ride with the sidestanddown.
1. Turn the fuel cock lever to “ON”.
2. Turn the key to “ON” and make
sure that the engine stop switch is
set to “”.
3. Shift the transmission into the neu-
tral position.
NOTE:When the transmission is in the neutral
position, the neutral indicator light
should be on, otherwise have a
Yamaha dealer check the electrical cir-cuit.
4. Turn the starter (choke) on and
completely close the throttle. (See
page 3-11.)
5. Start the engine by pushing the
start switch.NOTE:If the engine fails to start, release the
start switch, wait a few seconds, and
then try again. Each starting attempt
should be as short as possible to pre-
serve the battery. Do not crank the en-
gine more than 10 seconds on any oneattempt.CAUTION:
ECA11370
The engine trouble warning light
should come on when the key is
turned to “ON”, and then go off after
a few seconds. If the engine trouble
warning light comes on or flashes
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OPERATION AND IMPORTANT RIDING POINTS
5-2
5 after starting, immediately stop the
engine, and have a Yamaha dealer
check the self-diagnosis system.
6. After starting the engine, move the
starter (choke) back halfway.CAUTION:
ECA11040
For maximum engine life, never ac-
celerate hard when the engine iscold!
7. When the engine is warm, turn the
starter (choke) off.NOTE:The engine is warm when it responds
normally to the throttle with the starter(choke) turned off.
EAU16640
Starting a warm engine Follow the same procedure as for start-
ing a cold engine with the exception
that the starter (choke) is not required
when the engine is warm.
EAU16671
Shifting Shifting gears lets you control the
amount of engine power available for
starting off, accelerating, climbing hills,
etc.
The gear positions are shown in the il-
lustration.NOTE:To shift the transmission into the neu-
tral position, press the shift pedal down
repeatedly until it reaches the end of itstravel, and then slightly raise it.1. Shift pedal
2. Neutral position
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Page 41 of 86
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
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PERIODIC MAINTENANCE AND MINOR REPAIR
6-6
6
EAU19543
Checking the spark plugs The spark plugs are important engine
components, which are easy to check.
Since heat and deposits will cause any
spark plug to slowly erode, the spark
plugs should be removed and checked
in accordance with the periodic mainte-
nance and lubrication chart. In addition,
the condition of the spark plugs can re-
veal the condition of the engine.
To remove a spark plug
1. Remove the spark plug cap.
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
vehicle 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 aYamaha dealer check the vehicle.
1. Spark plug cap
1. Spark plug wrench
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PERIODIC MAINTENANCE AND MINOR REPAIR
6-7
63. 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 surface, 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.
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.
EAU19741
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 vehicle on a level sur-
face and hold it in an upright posi-
tion.NOTE:
Make sure that the vehicle is positioned
straight up when checking the oil level.
A slight tilt to the side can result in afalse 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.
Specified spark plug:
NGK/DPR7EA-9
DENSO/X22EPR-U91. Spark plug gapSpark plug gap:
0.8–0.9 mm (0.031–0.035 in)
Tightening torque:
Spark plug:
17.5 Nm (1.75 m·kgf, 12.7 ft·lbf)
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PERIODIC MAINTENANCE AND MINOR REPAIR
6-10
6
EAU20020
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 vehicle. In addi-
tion, 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.
WARNING
EWA10370
Make sure that no foreign mate-
rial enters the final gear case.
Make sure that no oil gets on thetire or wheel.
To check the final gear oil level
1. Place the vehicle on a level sur-
face and hold it in an upright posi-
tion.
NOTE:
The final gear oil level must be
checked on a cold engine.
Make sure that the vehicle is posi-
tioned straight up when checking
the oil level. A slight tilt to the sidecan result in a false reading.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 thefiller 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.
NOTE:GL4 is a quality rating. Hypoid gear oilsrated GL5 or GL6 may also be used.
5. Install and tighten the oil filler bolt.
6. Check the final gear case for oil
leakage. If oil is leaking, check for
the cause.
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, 17 ft·lbf)
Recommended final gear oil:
Hypoid gear oil SAE 80 (API GL4) or
multi-grade hypoid gear oil SAE
80W-90
Oil quantity:
0.19 L (0.20 US qt) (0.17 Imp.qt)
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PERIODIC MAINTENANCE AND MINOR REPAIR
6-30
6 3. Remove the defective bulb by
pushing it in and turning it counter-
clockwise.
4. Insert a new bulb into the socket,
push it in, and then turn it clock-
wise until it stops.
5. Install the socket (together with the
bulb) by pushing it in and turning it
clockwise until it stops.
6. Install the headlight unit by install-
ing the screws.
EAU24350
Supporting the motorcycle Since this model is not equipped with a
centerstand, follow these precautions
when removing the front and rear
wheel or performing other maintenance
requiring the motorcycle to stand up-
right. Check that the motorcycle is in a
stable and level position before starting
any maintenance. A strong wooden
box can be placed under the engine for
added stability.
To service the front wheel
1. Stabilize the rear of the motorcycle
by using a motorcycle stand or, if
an additional motorcycle stand is
not available, by placing a jack un-
der the frame in front of the rear
wheel.
2. Raise the front wheel off the
ground by using a motorcycle
stand.
To service the rear wheel
Raise the rear wheel off the ground by
using a motorcycle stand or, if a motor-
cycle stand is not available, by placinga jack either under each side of the
frame in front of the rear wheel or under
each side of the swingarm.
1. Auxiliary light bulb socket
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