Yamaha XVS650ATT(C manual

PRINTED IN JAPAN 2004.05-2.6 × 1 CR (E) PRINTED ON RECYCLED PAPER Y AMAHA MO T OR CO . , L TD . 5FB-28199-15 LIT-11626-18-20 XVS650T(C) XVS650AT(C) XVS650ATT(C) OWNER’S MANUAL[...]

EAU10041 U5FB15E0.book Page 1 Tuesday, May 11, 2004 3:55 AM[...]

INTRODUCTION EAU10080 Cong ratul ations on you r purc hase o f the Ya maha XVS65 0(C)/ XVS65 0A( C)/XVS 650A T(C). Th is m odel is the re sult of Yama ha’s vast e xper ience in th e produ ction of fin e sp orting , tou ring, a nd pac eset ting r acing m ach ines. It repr esent s the high degre e of craf tsmanship a nd reli ability that have made [...]

IMPORTANT MANUAL INFORMATION EAU1013 0 Parti cular ly impo rtant in for mati on is disti ngui shed in th is man ual by the follo wing nota tions : NOTE: ● This ma nual sho uld be co nsid ered a pe rmanent part of this motorc ycle and should remain w ith it e ven if th e motorc ycle is subs equently so ld. ● Yamaha continually s e eks adva ncem [...]

IMPORTANT MANU AL INFORMATION AND UNTIL YOU HAVE BEEN T RAINED IN SAFE AND P ROPER RIDIN G TECHNIQUE S. REGULAR I NSPECTIONS AND CAREFUL MAINTENAN CE, ALONG WITH GOOD RIDING SKILLS, WILL ENSURE THAT YOU SAFELY ENJOY THE CAPAB ILITIES A ND THE RE LIABILITY OF THIS MOT ORCYCLE. U5FB15E0.book Page 2 Tuesday, May 11, 2004 3:55 AM[...]

IMPORTANT MANUAL INFORMATION EAU10192 XVS650 T(C)/XVS65 0A T(C)/XVS 650A TT(C) OW N E R ’ S MANU AL ©2004 by Y amaha Motor Corporation, U .S.A. 1st editi on, April 200 4 All rights reserved. Any reprinting or unauthorized use without th e written permission of Y amaha Motor Corporation, U.S.A. is expressl y prohibite d. Printed in Japan. P/N LIT[...]

TABLE OF CONTENTS SAFETY INFORMATION ............. ..... 1-1 Location of important lab els ........... 1-5 DESCRIPTION ............ ...................... 2-1 Left view ............... ...................... ..... 2-1 Right view .................. ................. ..... 2-3 Controls a nd instrumen ts ................2-5 INSTRUMENT AND CONTROL FUNC[...]

TABLE OF CONTENTS Checking the whee l bearings ..... .. 6-28 Battery ....... ...................... .............6-29 Replacing the fuses .................... ..6-30 Replaci ng the hea dlight bu lb ........6-31 Replaci ng a turn s ignal li ght bulb or the tail /brake light bul b ..........6-32 Supporting t he motorcycle ............6-33 Front wheel[...]

1-1 1 SAFETY INFORMATION EAU10251 MOT ORCYC LES A RE SI NGLE TRAC K V EHIC LE S. TH EIR SAF E USE AND OPERATION AR E DEPEN- DENT UPON THE USE OF PROPER RID ING T ECH NIQU ES A S WEL L AS THE EXPERTISE OF THE OPERA- TOR. EVERY OPERATOR SHOULD KNOW THE FOLLOWING REQUIRE- MENTS B EFORE RIDI NG THIS MOTOR CYCLE. HE OR SHE SHOULD: ● OBTAIN THOROUGH IN[...]

SAFETY INFORMATION 1-2 1 wide on a turn du e to EXCESS IVE SPEED or undercor nerin g (insu ffi- cien t lean an gle for the spee d). • Alway s obey the s peed lim it and never trav el f aster than warr ant- ed by ro ad an d traffi c con dition s. • Alway s signa l befor e turnin g or chan ging lane s. M ake su re tha t othe r motorists can see y[...]

SAFETY INFORMATION 1-3 1 Loadin g The to tal weig ht of th e operat or, pas- senger, acce ssories and ca rgo must not exce ed the ma ximum loa d limit. When lo ading with in this weight limi t, keep the f ollowing in mind: ● Cargo and a cces sory we igh t shoul d be kept as low and cl ose to the mo torcycl e as possible. Make sure t o dist ribu t[...]

SAFETY INFORMATION 1-4 1 tor an d may limi t contro l ability, therefo re, such acce ssories are not re comm ende d. ● Use ca utio n whe n addi ng el ect ri- cal accesso ries. If elect rical acces- sories e xceed t he cap acity o f the motor cycle ’ s elect rical system , an elec tric fa ilure coul d result, wh ich could cause a dang erous los [...]

SAFETY INFORMATION 1-5 1 EAU10381 Location of important labels Plea se re ad th e foll owing i mport ant l abels care fully befo re ope ratin g thi s veh icle . U5FB15E0.book Page 5 Tuesday, May 11, 2004 3:55 AM[...]

SAFETY INFORMATION 1-6 1 1 2 3 XVS650 3 XVS650A/A T 4 U5FB15E0.book Page 6 Tuesday, May 11, 2004 3:55 AM[...]

SAFETY INFORMATION 1-7 1 5 6 California onl y A1 U5FB15E0.book Page 7 Tuesday, May 11, 2004 3:55 AM[...]

DESC RIPTION 2-1 2 EAU3222 0 Left view XVS650 1. Shift pedal (page 3-4) 2. Fuel cock (page 3-7) 3. Star ter (choke) knob (page 3-8) 4. Shock absorber assembly spring preload adjusting ring (page 3-12) 5. Helmet holder (page 3-11) 6. Owner ’ s tool kit (page 6-1) 7. Storage compar tment ( page 3-11) U5FB15E0.book Page 1 Tuesday, May 11, 2004 3:55 [...]

DESCRIPTI O N 2-2 2 XVS650A/ AT 1. Shift pedal (page 3-4) 2. Fuel cock (page 3-7) 3. Star ter (choke) knob (page 3-8) 4. Shoc k absorber assembly spring pr eload adjusting ring (page 3-12) 5. Helmet holder (page 3-11) 6. Owner ’ s tool kit (page 6- 1) 7. Storage compar tment (page 3-11) U5FB15E0.book Page 2 Tuesday, May 11, 2004 3:55 AM[...]

DESC RIPTION 2-3 2 EAU3223 0 Right view XVS650 1. Engine oil filter element ( page 6-11) 2. Batter y (page 6-29) 3. Fuses (pa ge 6-30) 4. Main switch/steering lock (page 3-1) 5. Air filter ele ment (page 6-14) 6. Brake pedal (page 3-5) U5FB15E0.book Page 3 Tuesday, May 11, 2004 3:55 AM[...]

DESCRIPTI O N 2-4 2 XVS650A/ AT 1. Engine oil fi lter element (page 6-11) 2. Battery (page 6-29) 3. Fuses (page 6-30) 4. Main s witch/steer ing lock (page 3-1) 5. Air filt er element (page 6-14) 6. Brak e pedal (page 3-5) U5FB15E0.book Page 4 Tuesday, May 11, 2004 3:55 AM[...]

DESC RIPTION 2-5 2 EAU1043 0 Controls and instruments 1. Clutch le ver (page 3-4) 2. Left handlebar s witches (page 3-3) 3. Speedometer unit (page 3-2) 4. Fuel tank cap (page 3-5) 5. Right handlebar switches (page 3-3) 6. Throttle grip (page 6-16) 7. Brake le ver (page 3-5) U5FB15E0.book Page 5 Tuesday, May 11, 2004 3:55 AM[...]

INSTRUMENT AND CONTROL FUNCTIONS 3-1 3 EAU10460 Main switch/steer ing lock The main switch/st eering lo ck controls the igniti on an d ligh ting syst ems, and i s used t o lock t he st eering. The variou s posi tions ar e des cribed be low. EAU10510 ON All e lectr ical syst ems a re su pplied with power, and the hea d ligh t, met er lig ht- ing, ta[...]

INSTRUMENT A ND CONTROL FUNCTIONS 3-2 3 EAU11001 Indicator and warning lights EAU11020 Turn signal indicator l ight “” This i ndicator ligh t flas hes wh en the turn sig nal swi tch is pushed to the left or right. EAU11060 Neutral indica tor light “” This in dicato r light co mes on when t he transm ission is in the neut ral position. EAU11[...]

INSTRUMENT AND CONTROL FUNCTIONS 3-3 3 EAU12343 Handleb ar swi tches Left Right EAU12400 Dimmer switch “ / ” Set this s witch to “” for the hi gh beam an d to “” for the lo w bea m. EAU12430 Turn signal s witch “ / ” To sign al a right -hand turn, push this switch to “” . To s ign al a l eft-ha nd turn, push this sw itch to “?[...]

INSTRUMENT A ND CONTROL FUNCTIONS 3-4 3 EAU12820 Clutch lever The clu tch le ver is located at the left handle bar grip. T o dise ngag e the clutc h, pull the lever towa rd the h andl e- bar gr ip. To e ngage the cl utch, r ele ase the lev er. T he lever shoul d be pulle d rapid ly and rel eas ed slow ly fo r smoo th clutc h operat ion. The c lutch[...]

INSTRUMENT AND CONTROL FUNCTIONS 3-5 3 EAU12890 Brake le ver The brak e lever is locate d at the rig ht handle bar grip. T o appl y the front brak e, pull th e lev er towar d the ha ndle - bar gri p. EAU12941 Brake pe dal XVS650 XVS650A /AT The brake ped al is on the right si de of the moto rcycl e. To ap ply the re ar brak e, pres s down on the br[...]

INSTRUMENT A ND CONTROL FUNCTIONS 3-6 3 NOTE: The fu el tan k cap c annot b e in stal led unless the key i s in the lo ck. In ad dition, the key cannot be r emove d if the c ap is not pro perly inst alled and locke d. W ARNING EWA10130 Make su re tha t th e fuel t ank ca p is properly install ed before riding. EAU13210 Fuel Make s ure th at th ere [...]

INSTRUMENT AND CONTROL FUNCTIONS 3-7 3 knocking (or pinging) occurs, use a gasolin e of a diff erent b rand or prem i- um unl eaded fuel. Us e of unlea ded fu el will ex tend spar k plug lif e and reduc e mainte nance costs . Gasohol There are two type s of g asoho l: ga so- hol cont ainin g ethan ol and that con tain- ing met hanol . Gaso hol co n[...]

INSTRUMENT A ND CONTROL FUNCTIONS 3-8 3 ON With the fuel cock lever in thi s positi on, fuel fl ows to the carbur etors . Turn the fuel co ck lever to this po sition when star ting t he engi ne an d riding. RES This indica t es reserve. With the fuel cock lever in this position , the fuel re- serve is made avai lable. Turn the fuel cock lever to th[...]

INSTRUMENT AND CONTROL FUNCTIONS 3-9 3 EAU14180 Seats ( XVS650) Passen ger se at To rem ove the passe nger seat Rem ove the nut, a nd th en pull the p as- senge r sea t up . To instal l the passenger seat Insert the proje ction on the fron t of the passeng er sea t into the sea t hold er as shown, pla ce the s eat in the original p o- sition, and t[...]

INSTRUMENT A ND CONTROL FUNCTIONS 3-10 3 EAU14190 Seats (XVS650A /AT) Passen ger seat To re move t he pa ssenger se at Remove the bol t, and th en pull th e pas- senger seat up. To ins tall the pa sse nger seat Insert the projec tions on the fron t of the passen ger seat i nto th e hold ers as shown, place th e sea t in the or igin al po- sitio n, [...]

INSTRUMENT AND CONTROL FUNCTIONS 3-11 3 EAU14281 Helmet holder To op en th e he lmet hold er, in sert the key int o the lock, an d then turn the key as shown . To lock the helmet holder, pl ace i t in th e origi n al posit ion, and the n remove the key. W ARNING EWA10160 Never r ide with a hel met atta ched to the helm et holder, s ince the he lmet[...]

INSTRUMENT A ND CONTROL FUNCTIONS 3-12 3 EAU14860 Adjusti ng the shock ab sorbe r assem bly This shoc k abs orbe r ass embl y is equipp ed wit h a spr ing pre load adjust- ing rin g. CAUTION: ECA10100 Never a ttempt to tur n an ad justin g mechanism beyond the maximum or minimum settings. Adjus t the spring pr eload as fol lows . 1. Remove the pass[...]

INSTRUMENT AND CONTROL FUNCTIONS 3-13 3 EAU15150 Luggage strap holders There is a luggage s trap holde r on eac h passeng er footr est. EAU15300 Sidestand The side stand is located on the left side of the f ram e. Rais e the si des tand or lower it wi th your fo ot while ho lding the vehic le upri ght. NOTE: The buil t-in sidestan d switch is part [...]

INSTRUMENT A ND CONTROL FUNCTIONS 3-14 3 EAU15311 Ignition circuit cut-off system The ignit ion circu it cut-of f system (c om- prisi ng the si destan d switc h, clutch switch an d neutral swit ch) has the fol- lowing func tions . ● It pre vents start ing w hen th e tran s- missi on i s in gear a nd t he si de- stand is up, but the clu t ch lever[...]

INSTRUMENT AND CONTROL FUNCTIONS 3-15 3 With the engine turned off: 1. Mov e the sidestand down. 2. Make sure that the engine stop s witch is tur ned on. 3. T ur n the key on. 4. Shift the transmission into the neutral position. 5. Push the star t switch. Does the engine start? With the engine still running: 6. Mov e the sidestand up. 7. K eep the [...]

PRE-OPERATION CH ECKS 4-1 4 EAU15591 The con dition of a vehicl e is the owne r ’ s respo nsibilit y. Vital co mponents ca n start to deteriora te qui ckly and unexpected ly, even if th e vehi cle rema ins unused (for example , as a r esult of ex posure t o the elem ents). Any damage, fl uid leakag e or loss of tir e air p ress ure c ould ha ve s[...]

PRE-OPERATION CHE CKS 4-2 4 EAU15602 Pre-operation check list ITEM CHECKS P A GE Fuel • Check fuel le vel in fuel tank. • Refuel if necessar y . • Check fuel line for leakage. 3-6 Engine oil • Check oil le vel in engine. • If necessar y , add recommended oil to specified le vel. • Check vehicle f or oil leakage. 6-11 Fina l gea r oi l ?[...]

PRE-OPERATION CH ECKS 4-3 4 Wheels and tires • Check f or damage. • Check tire conditi on and tread depth. • Check air pressure. • Correct if necessar y . 6-17, 6-19 Brake and shift pedals • Make sure that oper ation is smooth. • Lubricate pedal piv oting points if necessar y . 6-26 Brake and clutc h lever s • Make sure that oper atio[...]

OPERATION AND IMPORTANT RIDING P OINTS 5-1 5 EAU15950 W ARNING 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 i n a closed area for an y length of tim[...]

OPERATION AND IM PORTANT RIDING POINTS 5-2 5 after starting , imm ediate ly stop the engine, and have a Yamaha dealer check the self-diagnosis system. 6. A fter starti ng th e engine , mov e the starter (c hoke) back hal fway. CAUTION: ECA11130 For maximum engine li fe, always warm the engine up before starting off. Never accelerate hard when the e[...]

OPERATION AND IMPORTANT RIDING P OINTS 5-3 5 EAU16671 Shifting XVS650 XVS650A/ AT Shifti ng gears lets you cont rol the amount of engine po wer ava ilab le for star ting of f, ac celera ting , clim bing h ills, etc. The ge ar positi ons are shown in the il- lustratio n. NOTE: To shif t the tran smission into the ne u- tral position , press the shi [...]

OPERATION AND IM PORTANT RIDING POINTS 5-4 5 NOTE: Alway s shi ft gear s at the re comm ende d shift po ints. EAU16700 To decelerate 1. Apply bo th the fr ont an d the re ar brak es to slow the moto rcycle. 2. Shift the t ransmi ssion in to fi rst gear when the motor cycle reaches 25 km/h (15.5 mi/h ). If the engine is about to st all o r run s ver[...]

OPERATION AND IMPORTANT RIDING P OINTS 5-5 5 CAUTION: ECA10331 After 1000 km (600 mi) of ope ration, the engine oil and final gear oil mus t be changed, a nd the oil filte r car- tridge or el ement repl aced. 1600 km (1000 mi) and beyond The ve hicle can now be oper ated nor- mally. CAUTION: ECA10270 If any engine trouble sh ould occur during the e[...]

PERIODI C MAINTENA NCE AND MINOR REP AIR 6-1 6 EAU17231 Safety is an obli gation of th e owne r. P e- riod ic ins pecti on, ad justmen t and lubri- cation will kee p your veh icle in t he safes t and mos t effic ien t cond itio n pos- sibl e. The m ost impo rtant p oints of motor cycle inspec tion, ad justment, a nd lubri catio n ar e expl aine d o[...]

PERIODI C MAINTENAN CE AND MINOR REPAIR 6-2 6 W ARNING EWA10340 Modifications not approved by Yamaha may cause loss of perfor- manc e, exce ssiv e emis sions, and render the vehicle unsafe for use. Consult a Yamaha dealer before at- tempting any changes. U5FB15E0.book Page 2 Tuesday, May 11, 2004 3:55 AM[...]

PERIODI C MAINTENA NCE AND MINOR REP AIR 6-3 6 EAU17600 Periodic ma intenance c hart for the e mission control system * Since th ese items re quire special too ls, data and tec hnical skills , have a Yamah a dealer pe rform the s ervice. No. ITEM R OUTINE INITIAL ODOMETER READINGS 600 mi (1000 km) or 1 month 4000 mi (7000 km) or 6 months 8000 mi (1[...]

PERIODI C MAINTENAN CE AND MINOR REPAIR 6-4 6 EAU32182 General maintenance and lubrication chart No. ITEM ROUT INE INITIAL ODOMETER READINGS 600 mi (1000 km) or 1 month 4000 mi (7000 km) or 6 month s 8000 mi (13000 km) or 12 mo nths 12000 mi (19000 km) or 18 months 16000 mi (25000 km) or 24 months 20000 mi (31000 km) or 30 months 1 * Air filter ele[...]

PERIODI C MAINTENA NCE AND MINOR REP AIR 6-5 6 9 * Swingarm piv ot bearings • Check bearing as semblies for looseness. • Moderately repack with lit hium- soap-based grease. √ Repack. 10 * Steering bearings • Check bearing as semblies for looseness. • Moderately repack with lit hium- soap-based grease ev er y 160 00 mi (25000 km ) or 24 mo[...]

PERIODI C MAINTENAN CE AND MINOR REPAIR 6-6 6 * Since th ese it ems req uire spec ial to ols, data and tech nical s kills, h ave a Yama ha dea ler per form the serv ice. NOTE: From 24 000 mi (3700 0 km) or 36 mon ths, repeat th e mai ntenanc e int ervals starti ng from 8000 mi (1300 0 km) or 12 mon ths. EAU17620 NOTE: ● The ai r fil ter ne eds m [...]

PERIODI C MAINTENA NCE AND MINOR REP AIR 6-7 6 ● Hydraul ic brake system • When di sassembling the mast er cylinde r or caliper cy linder, always replace t h e brak e fluid. Check th e brake fl uid level regularly and fill as required. • Replac e th e oil seal s o n the inner part s of the m aste r cyli nde r and cali per c ylin der ever y tw[...]

PERIODI C MAINTENAN CE AND MINOR REPAIR 6-8 6 EAU18771 Removing and installing panels The p anels s hown ne ed to be remov ed to pe rform some of th e mai nten ance jobs descri b ed in this chapter. Refer to this s ectio n each tim e a pane l need s to be r emoved a nd installe d. XVS650 XVS650A /AT EAU19192 Panel A To rem ove the pa nel Remov e th[...]

PERIODI C MAINTENA NCE AND MINOR REP AIR 6-9 6 EAU19151 Pane l B To re move the panel Remove the bo lt, an d the n pull the p an- el off as sh own. To ins tall the pa nel Place the p anel in th e origin al po siti on, and the n instal l the bo lt. EAU19543 Checki ng the spark pl ugs The spa rk plugs are importan t engine compon ents , which are ea [...]

PERIODI C MAINTENAN CE AND MINOR REPAIR 6-10 6 3. Che ck ea ch spar k plug for elec - trode e rosi on and e xces sive car- bon or other de posits, and replac e it if ne cessary. To i nstal l a s park pl ug 1. Me asure the sp ark pl ug ga p with a wire t hick ness gauge a nd, if n ec- essary, adjust th e gap to spe cifica- tion. 2. Cle an th e surf [...]

PERIODI C MAINTENA NCE AND MINOR REP AIR 6-11 6 EAU19742 Engine oil and oil filter element The en gine oil le vel s houl d be che cke d befor e each ride . In addi tion, the oil must be chan ged and th e oil filter ele- ment repl aced a t t he int erv als s pecif ied in the peri odic main tena nce an d lub ri- catio n chart. To check the e ngine oi[...]

PERIODI C MAINTENAN CE AND MINOR REPAIR 6-12 6 5. Remo ve the oil fi lter element and O-ring. 6. Inst all a new oil fi lter el ement and the O-ring. 7. Instal l the oi l filter elem ent cov ers by ins talli ng t he bo lts , and then tighten them to the speci fied torque . 8. Inst all the e ngine oil drai n bolt, and then tigh ten it t o the spe cif[...]

PERIODI C MAINTENA NCE AND MINOR REP AIR 6-13 6 ● Make sure that no foreign mate- rial en ters the cran kcase . 10. Star t the en gine, and th en let it id le for several mi nutes while checki ng it for oi l leaka ge. If o il is leak ing, im- media tely turn th e en gine off and check for the cause. 11. Turn the en gine o ff, and t hen check the [...]

PERIODI C MAINTENAN CE AND MINOR REPAIR 6-14 6 2. Rem ove the oil f iller b olt and drain bolt t o drai n the oil from th e fin al gear c ase . 3. Ins tal l the fi nal gea r oil dr ain bolt , and then tight en it to the sp ecifi ed torque . 4. Ad d the r ecomme nded final gear oil to the bri m of the filler hole. NOTE: GL4 i s a qu ality rati ng. H[...]

PERIODI C MAINTENA NCE AND MINOR REP AIR 6-15 6 4. Inser t the air f ilter elemen t into the air fi lter case as sho wn. CAUTION: ECA10480 ● Make sure th at the ai r fil ter ele- ment is p roperl y seated in the air filt er case. ● The engine should never be op- erated without the air filter ele- ment installed , otherwise the piston(s) and/or [...]

PERIODI C MAINTENAN CE AND MINOR REPAIR 6-16 6 EAU21270 Adjusting the carburetors The carbu retor s are i mpo rtant part s of the engine and emi ssion con trol sys - tem , wh ich re quir e v ery so phis tic ated adjust ment. The refor e, all c arburetor adjust ments s hould be le ft to a Y a maha deal er, who ha s the necessary profes - sion al kno[...]

PERIODI C MAINTENA NCE AND MINOR REP AIR 6-17 6 EAU32520 Tires To max imiz e the perfor man ce, dur abil- ity, an d safe operati on of your motor- cycle, no te the follo wing po ints regar ding th e specifi ed tir es. Tire air pressur e The tire air p ressure should be ch ecked and, if necessar y, adju sted befo re each ride. W ARNING EWA10500 ● [...]

PERIODI C MAINTENAN CE AND MINOR REPAIR 6-18 6 vehic le. O perati on of an ov erloa ded vehicle could c ause tire damage, a n accident, or e ven injury. Tire inspection Always che ck the tires befo re operating the moto rcycle. If a t ire trea d shows crosswise lines ( minim um trea d dept h), if the tire has a na il or gl ass frag ments in it, or [...]

PERIODI C MAINTENA NCE AND MINOR REP AIR 6-19 6 EAU21940 Spok e wheels To ma ximize th e performa nce, durabil - ity , and safe opera tion of your mot or- cycle, note the fol lowing point s rega rding th e specified wheels. ● The wh eel rim s should be checked for cracks, be nds or war page, and the spo kes for loose ness or dam- age befo re ea c[...]

PERIODI C MAINTENAN CE AND MINOR REPAIR 6-20 6 any consequences caused by the use of items which have not been approved by Yamaha. EAU22041 Adjusti ng the clutch l ever fr ee play The c lutch leve r free play s houl d mea - sure XVS6 50 10. 0 – 15.0 mm (0.39 – 0.59 in ) XVS650A 5.0 – 10.0 mm (0.20 – 0.3 9 in) XVS650A T 5.0 – 10.0 m m ( 0.[...]

PERIODI C MAINTENA NCE AND MINOR REP AIR 6-21 6 5. To increase t he clutch l e ver free play, tu rn the adjustin g nut in di rec- tion (a ). To de crease the clutch le- ver f ree pl ay, t urn the ad justi ng nut in dire ction (b). 6. Tighten the locknut at the clut ch le- ver and t he cr ankc ase. EAU22092 Adjust ing t he brak e le ver f ree play T[...]

PERIODI C MAINTENAN CE AND MINOR REPAIR 6-22 6 system . If there is air in th e hy- draulic system , have a Ya maha deal er bl eed the syste m befo re operating the motorcycle. Air in the hydraulic s ystem will dimin- ish the braking performa nce, which may result in loss of con- trol and an acc ide nt. EAU22231 Adjusting the brake pedal position a[...]

PERIODI C MAINTENA NCE AND MINOR REP AIR 6-23 6 3. Tight en the lo cknut. W ARNING EWA11230 After adjusting the brake pedal posi- tion, the brake pedal free p lay must be adju sted. Brake p edal free play The b rake peda l free pla y sho uld m ea- sure 20 .0 – 30.0 mm (0.79 – 1. 18 in ) at the b rake pedal end. Per iodic ally che ck the br ake [...]

PERIODI C MAINTENAN CE AND MINOR REPAIR 6-24 6 EAU22380 Checking the front brake pads and rear brake shoes The fro nt br ake pad s and th e rea r brake shoes must be checke d for wear at the inter vals speci fied in the peri odic ma in- ten ance and lu bri catio n char t. EAU22430 Front brake pads Each fr ont b rake pad i s prov ided w ith wear ind[...]

PERIODI C MAINTENA NCE AND MINOR REP AIR 6-25 6 ● Use o nly th e rec omm ended qual ity brake fluid, o therw ise t he rubb er seals m ay deteri orate, causi ng leak age an d poor braking per for- manc e. ● Refill with the same t ype of brake fluid. Mixing flui ds may resu lt in a harm ful che mical reac tion an d lead to po or braki ng perf orm[...]

PERIODI C MAINTENAN CE AND MINOR REPAIR 6-26 6 EAU23110 Checking and lubricating the thro ttle gri p and cab le The op eratio n of the thr ottle gr ip shou ld be check ed before each ri de. I n addi- tion , the cable s hould be lubri cated or repl aced at the i nter vals sp eci fied in the perio dic mai ntena nce chart. EAU23131 Checking and lubric[...]

PERIODI C MAINTENA NCE AND MINOR REP AIR 6-27 6 EAU23200 Checking and lubricating the sidest and The o peratio n of th e sidesta nd shou ld be ch ecked bef ore e ach r ide, and the side stand pivot a n d met a l-to -met al conta ct surface s should b e lubric ated if necessary. W ARNING EWA10730 If the sidestand does not move up and down smoothly, [...]

PERIODI C MAINTENAN CE AND MINOR REPAIR 6-28 6 EAU23280 Checking th e steer ing Worn or l oose s teeri ng be aring s may caus e danger . Ther efore, the ope ration of the steer ing must be checked as fol- lows a t the i nterv als s pecifi ed in th e pe- riod ic ma inte nance and lu bricat ion chart. 1. Pl ace a sta nd un der th e en gine to rais e [...]

PERIODI C MAINTENA NCE AND MINOR REP AIR 6-29 6 EAU23380 Battery The ba tter y is loca ted beh ind pane l B. (See pa ge 6-8.) This m odel is equipped wi th a sealed - type (M F) batte ry, wh ich d oes no t re- quire any mainte nanc e. Th ere is no need to ch eck t he ele ctrol yte or to add distil led water. CAUTION: ECA10620 Never attempt to remov[...]

PERIODI C MAINTENAN CE AND MINOR REPAIR 6-30 6 sealed-type (MF) battery charg- er, hav e a Yamaha d ealer charge your battery. EAU23524 Replaci ng the fuses The m ain fuse and the f use bo x, wh ich conta ins the fus es f or the i ndivi dual cir- cuits , are l ocated behi nd pa nel B. ( See page 6- 8.) If a fu se i s blo wn, re place it a s foll ow[...]

PERIODI C MAINTENA NCE AND MINOR REP AIR 6-31 6 CAUTION: ECA10640 Do not use a fuse of a higher amper- age rating than recommended to avoid causing extensive damage to the ele ctric al sy stem and p ossi bly a fire. 3. Turn the ke y to “ ON ” and turn on the el ect rical ci rcui t in q uest ion to chec k if th e de vice op era tes. 4. If the f [...]

PERIODI C MAINTENAN CE AND MINOR REPAIR 6-32 6 W ARNING EWA10790 Headlight bulbs get very hot. There- fore, keep fla mmable produ cts aw ay from a lit headlight bulb, and do not touch the bulb until it has cooled down. 4. Pl ace a new he adl ight bu lb i nto po - sition, a nd th en sec ure it with the bulb holde r. CAUTION: ECA10660 Do not touch th[...]

PERIODI C MAINTENA NCE AND MINOR REP AIR 6-33 6 XVS6 50A /AT 2. Remove t h e defe ctive bu lb by pushi ng it in and turn ing i t coun ter- clockwis e. 3. In sert a new bulb into th e so cket, push it in, and t hen tu rn it clock - wise unt il it stops. 4. Install the lens by i nstal ling the screws. CAUTION: ECA10680 Do not overtighten the screws, [...]

PERIODI C MAINTENAN CE AND MINOR REPAIR 6-34 6 EAU24360 Front wheel EAU24660 To remove the front wheel W ARNING EWA10820 ● It i s adv isable to have a Yamaha deal er serv ice the whe el. ● Securely support the motor- cycle so that t here is no dang er of it falli ng over. 1. Dis connect the s peedom eter c a- ble from the front whe el. 2. Lo os[...]

PERIODI C MAINTENA NCE AND MINOR REP AIR 6-35 6 5. T ighte n the wh eel a xle an d fro nt wheel axle pinch bolt t o the sp eci- fied t orques , an d then i nstall the rubber cap. 6. W hile ap plyin g the fro nt brak e, push do wn hard on the hand leba rs several t imes to check if the fron t fork co mpresse s and re bounds smoothly. 7. Co nnec t th[...]

PERIODI C MAINTENAN CE AND MINOR REPAIR 6-36 6 7. Li ft the rear wheel off th e grou nd accord ing to the proc edu re on page 6-3 3. 8. Wh ile suppor ting th e driv e shaft , pull th e rea r wheel bac k to re move the fo llowin g pa rts a s an assem - bly: wh eel, wheel axl e, final gear case, an d drive shaft . NOTE: Make sure to su ppor t the dri[...]

PERIODI C MAINTENA NCE AND MINOR REP AIR 6-37 6 EAU25850 Troubleshooting Altho ugh Yama ha moto rcycles re ceive a thor ough inspe ction befo re ship ment fro m the fact ory, tr ouble ma y occur dur - ing o peration. Any pr oblem in the f uel, compre ssion, or ignitio n systems, for exam ple, ca n cause po or sta rting and loss of po wer. The f oll[...]

PERIODI C MAINTENAN CE AND MINOR REPAIR 6-38 6 EAU25891 Troubleshooting chart W ARNING EWA10840 Keep away open flames and do not smoke while checking or wor king on the fuel system. Check the fuel level in the fuel tank. 1. Fuel There is enough fuel. There is no fuel. Check the compression. Supply fuel. The engine does not start. Check the compress[...]

MOTORCYCLE CARE A ND ST ORAGE 7-1 7 EAU26060 Care While the op en de sign of a moto rcycl e reveal s the a ttra ctivene ss of the t ech- nology , it al so makes it m ore vul n era- ble. Rust and cor rosion can d evel op even if high-q uality co mponents are used. A rusty ex haust pipe m a y go un- notic ed on a car, howe ver , it de tract s fro m t[...]

MOTORCYCLE CAR E AND STORAGE 7-2 7 After normal use Remov e dirt wi th warm wa ter, a mild det ergent , and a soft, clean s pon ge, and th en rinse th oroughly with cl ean wate r. Use a to othbr ush or bo ttlebr ush for h ard-t o-reac h areas. Stub born dirt and inse cts will com e off more e a sily if the ar ea is co vered with a w et cl oth for a[...]

MOTORCYCLE CARE A ND ST ORAGE 7-3 7 ● Avoid using abrasive polishing compounds as they will wear away the paint. NOTE: Consul t a Yama ha de aler for adv ice o n what pro ducts to use. EAU26230 Stor age Short-term Alway s stor e your mo torc ycle i n a cool, dry pl ace and, if necessar y, prot ect it agains t du st with a po rous cove r. CAUTION:[...]

MOTORCYCLE CAR E AND STORAGE 7-4 7 W ARNING EWA10950 To prevent damage or injury from sparking, make sure to g round the spark plug electrodes while turning the engine over. 6. Lu brica te al l con trol cab les and the pivoting poi nts of all levers and pedals as we ll a s of the si de- stan d/cent erst and. 7. Check an d, if necessa ry, correct th[...]

SPECI FI CAT IONS 8-1 8 Dimensions: Overa ll length: XVS650 23 40 mm (92.1 in) XVS65 0A 245 0 mm (9 6.5 in ) XVS650A T 2450 mm (9 6.5 i n) Overa ll width: XVS65 0 880 mm (34.6 in ) XVS6 50A 930 m m (3 6.6 in) XVS6 50AT 9 30 mm (3 6.6 in) Overa ll height: XVS650 10 70 mm (42.1 in) XVS65 0A 110 5 mm (4 3.5 in ) XVS650A T 1105 mm (4 3.5 i n) Seat hei [...]

SPECIFICATIONS 8-2 8 Clut ch: Clutch type: Wet, multiple-disc Transmission: Primar y reducti on sy stem: Spur gea r Prim ary re duction r atio: 68/38 (1 .789) Second ary red uction s ystem : Shaft drive Second ary red uction r atio: 19/18 × 32/1 1 (3. 071) Tran smission type : Consta nt mesh 5-spee d Oper ation: Left foot o peratio n Gear ratio: 1[...]

SPECI FI CAT IONS 8-3 8 Front: XVS6 50 200 kP a (29 psi) (2.00 k gf/cm² ) XVS6 50A 225 k Pa (3 3 psi) (2.25 kgf/cm²) XVS6 50AT 22 5 kPa (3 3 psi) (2. 25 kgf/cm²) Rear: 250 kPa (36 ps i) (2. 50 kg f/cm²) Front wheel: Whee l type: Spok e whee l Rim si ze: XVS650 19M/C x MT2.5 0 XVS650A 16M/C x MT 3.00 XVS650A T 16M/C x M T3.00 Rear wheel: Whee l [...]

CONSUMER INFORMATI ON 9-1 9 EAU26351 Identification numbers Recor d the key iden tificatio n number, vehic le ide ntifica tion number and mo d- el labe l informa tion in the s p aces pro- vided bel ow for a ssistan ce when order ing spar e par ts from a Y amaha deal er or f or re feren ce in ca se the vehi - cle is stole n. KEY IDENTIFICATION NUMBE[...]

CONSUMER INFORMA T ION 9-2 9 EAU26470 Model label The mod el label is affix ed to th e frame under the rider s eat. (Se e page 3- 9.) Record the informa tion on this labe l in the sp ace pr ovide d. Th is info rmat ion will b e ne eded wh en o rdering sp are part s from a Y amaha dealer . 1. Model label U5FB15E0.book Page 2 Tuesday, May 11, 2004 3:[...]

CONSUMER INFORMATI ON 9-3 9 EAU26550 Reporting safety defects If you be liev e that your vehi cle has a def ect whic h could cause a cr ash or could c ause inj ury or dea th, yo u sho uld im mediat ely infor m the Na tional Highw ay Traf fic Saf ety Admi nistration (NHTSA) in ad diti on to not ifyi ng Yama ha Motor Co rpora tion, U.S .A. If NH TSA [...]

CONSUMER INFORMA T ION 9-4 9 EAU26560 Motorcycle noise regulation TAMPERIN G WITH NOISE C ONTROL SY STEM PROHI BITED: Federa l law pro hibit s the fol lowin g acts or t he caus ing ther eof: (1 ) The rem oval or renderi ng in operat ive by any pers on other than f or purpo ses of m aint enan ce, rep air, or r epl acemen t of an y devi ce or el eme [...]

CONSUMER INFORMATI ON 9-5 9 EAU26631 Maintenance record Copies of work ord ers and/o r recei pts for parts purc hased and inst alled on your motor cycle will be re quired t o docu ment t hat maint enan ce ha s been compl eted i n acco rdanc e with t he emis sions warra nty. The cha rt belo w is pri nted onl y as a r eminde r that ma intenance w ork[...]

CONSUMER INFORMA T ION 9-6 9 36000 mi (55000 km) or 54 months 40000 mi (61000 km) or 60 months Maintenance interval Date of service Mile age Servicing dealer name and add ress Remarks U5FB15E0.book Page 6 Tuesday, May 11, 2004 3:55 AM[...]

CONSUMER INFORMATI ON 9-7 9 EAU26661 YAMAHA MOTOR CORPORATION, U.S.A. STREET AND ENDURO MOTORCYCLE LIMITED WARRANTY U5FB15E0.book Page 7 Tuesday, May 11, 2004 3:55 AM[...]

CONSUMER INFORMA T ION 9-8 9 U5FB15E0.book Page 8 Tuesday, May 11, 2004 3:55 AM[...]

CONSUMER INFORMATI ON 9-9 9 EAU26750 YAMAHA EXTENDED SERVICE (Y.E.S.) K eep your Y amaha protected even after y our warranty expires with gen uine Y amaha Extended Ser vice (Y .E.S.). Y .E.S. is designed and administered by Y amaha Motor Corporation to provide maximum owner satisf action. Y ou get uninterrupted factory-backed co ver age for e xtra [...]

CONSUMER INFORMA T ION 9-10 9 We urge y ou to act now . Y ou ’ ll get the excellent benefits of TRIP cov erage right aw ay , and you ’ ll rest easy knowing you ’ ll hav e strong factory-back ed protection even after y our Y amaha Limited W arranty expires. A special note: If visiting your dealer isn ’ t con venient, contact Y amaha with you[...]

INDEX A Accessories and replacement parts . .... 6-19 Air filter element, cleaning ................... . 6-14 B Batter y ....... ........ ...... ........... ........ ....... ... 6-29 Brake and clutch levers, checking and lubricating ....... ........... ... 6 -26 Brake and shift pedals, checking and lubricating ....... ........... ... 6 -26 Brake fl[...]

INDEX Troubleshooting chart ........................... 6-38 Turn sig na l in dica tor l igh t .. ...... .... .... ... .... . 3 -2 Turn signal light bulb or tail/brake light bulb, replacing ............. 6-32 Turn si gnal switch ... ........... ........ ....... .... .. 3-3 V Valve clearance, adjusting .................... 6-16 Vehicle identificatio[...]

PRINTED IN JAPAN 2004.05-2.6 × 1 CR (E) PRINTED ON RECYCLED PAPER Y AMAHA MO T OR CO . , L TD . 5FB-28199-15 LIT-11626-18-20 XVS650T(C) XVS650AT(C) XVS650ATT(C) OWNER’S MANUAL[...]