checking oil YAMAHA XVS650A 2004 Owners Manual

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

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
6-9
66. Install a new oil filter element and
the O-ring.
7. Install the oil filter element covers
by installing the bolts, and then
tighten them to the specified
torque.
8. Install the engine oil drain bolt, and
then tighten it to the specified
torque.
NOTE:Check the washer for damage and re-place it if necessary.9. Add the specified amount of the
recommended oil, and then install
and tighten the oil filler cap.
CAUTION:
ECA11620


In order to prevent clutch slip-
page (since the engine oil also
lubricates the clutch), do not
mix any chemical additives. Do
not use oils with a diesel speci-
fication of “CD” or oils of a high-
er quality than specified. 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, im-
mediately 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:
Oil filter element cover bolt:
10 Nm (1.0 m·kgf, 7 ft·lbf)
Tightening torque:
Engine oil drain bolt:
43 Nm (4.3 m·kgf, 31 ft·lbf)
Recommended engine oil:
See page 8-1.
Oil quantity:
Without oil filter element replace-
ment:
2.60 L (2.75 US qt) (2.29 Imp.qt)
With oil filter element replacement:
2.80 L (2.96 US qt) (2.46 Imp.qt)
U5SCE1E0.book Page 9 Monday, September 8, 2003 11:32 AM

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
6-20
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
6-23
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

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
U5SCE1E0.book Page 1 Monday, September 8, 2003 11:32 AM