User manual YAMAHA XVS650-2001

OWNER'S MANUAL XVS650 XVS650A 5BN-28199-E1 EAU03338 INTRODUCTION Welcome to the Yamaha world of motorcycling! As the owner of an XVS650/XVS650A, you are benefiting from Yamaha's vast experience and newest technology regarding the design and manufacture of high-quality products, which have earned Yamaha a reputation for dependability. Please take the time to read this manual thoroughly, so as to enjoy all advantages of your XVS650's. The owner's manual does not only instruct you in how to operate, inspect and maintain your motorcycle, but also in how to safeguard yourself and others from trouble and injury. In addition, the many tips given in this manual will help keep your motorcycle in the best possible condition. If you have any further questions, do not hesitate to contact your Yamaha dealer. The Yamaha team wishes you many safe and pleasant rides. So, remember to put safety first! IMPORTANT MANUAL INFORMATION Particularly important information is distinguished in this manual by the following notations: The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR SAFETY IS INVOLVED! WARNING Failure to follow WARNING instructions could result in severe injury or death to the motorcycle operator, a bystander, or a person inspecting or repairing the motorcycle. A CAUTION indicates special precautions that must be taken to avoid damage to the motorcycle. A NOTE provides key information to make procedures easier or clearer. EAU00005 CAUTION: NOTE: NOTE: q This manual should be considered a permanent part of this motorcycle and should remain with it even if the motorcycle is subsequently sold. q Yamaha continually seeks advancements in product design and quality. Therefore, while this manual contains the most current product information available at the time of printing, there may be minor discrepancies between your motorcycle and this manual. If you have any questions concerning this manual, please consult your Yamaha dealer. @ @ IMPORTANT MANUAL INFORMATION EW000002 WARNING PLEASE READ THIS MANUAL CAREFULLY AND COMPLETELY BEFORE OPERATING THIS MOTORCYCLE. @ @ IMPORTANT MANUAL INFORMATION EAU03337 XVS650/XVS650A OWNER'S MANUAL © 2000 by Yamaha Motor Co., Ltd. 1st Edition, August 2000 All rights reserved. Any reprinting or unauthorized use without the written permission of Yamaha Motor Co., Ltd. is expressly prohibited. Printed in Japan. EAU00009 TABLE OF CONTENTS 1 GIVE SAFETY THE RIGHT OF WAY 2 DESCRIPTION 3 INSTRUMENT AND CONTROL FUNCTIONS 4 PRE-OPERATION CHECKS 5 OPERATION AND IMPORTANT RIDING POINTS 6 PERIODIC MAINTENANCE AND MINOR REPAIR 7 MOTORCYCLE CARE AND STORAGE 8 SPECIFICATIONS 9 CONSUMER INFORMATION INDEX 1 2 3 4 5 6 7 8 9 GIVE SAFETY THE RIGHT OF WAY GIVE SAFETY THE RIGHT OF WAY ................................................ 1-1 1 1- GIVE SAFETY THE RIGHT OF WAY EAU00021 Motorcycles are fascinating vehicles, which can give you an unsurpassed feeling of power and freedom. However, they also impose certain limits, which you must accept; even the best motorcycle does not ignore the laws of physics. 1 Regular care and maintenance are essential for preserving value and operating condition of your motorcycle. Moreover, what is true for the motorcycle is also true for the rider: good performance depends on being in good shape. Riding under the influence of medication, drugs and alcohol is, of course, out of the question. Motorcycle riders--more than car drivers--must always be at their mental and physical best. Under the influence of even small amounts of alcohol, there is a tendency to take dangerous risks. Protective clothing is as essential for the motorcycle rider as seat belts are for car drivers and passengers. Always wear a complete motorcycle suit (whether made of leather or tear-resistant synthetic materials with protectors), sturdy boots, motorcycle gloves and a properly fitting helmet. Optimum protective wear, however, should not encourage carelessness. Although full-coverage helmets and suits, in particular, create an illusion of total safety and protection, motorcyclists will always be vulnerable. Riders who lack critical self-control run the risk of going too fast and are apt to take chances. This is even more dangerous in wet weather. The good motorcyclist rides safely, predictably and defensively--avoiding all dangers, including those caused by others. Enjoy your ride! 1-1 DESCRIPTION Left view (XVS650) ............................................................................ 2-1 Right view (XVS650) .......................................................................... 2-2 Left view (XVS650A) .......................................................................... 2-3 Right view (XVS650A)........................................................................ 2-4 Controls and instruments (XVS650/XVS650A) .................................. 2-5 2 2- DESCRIPTION EAU00026 Left view (XVS650) 2 1. Shift pedal 2. Fuel cock 3. Starter (choke) knob 4. Shock absorber spring preload adjusting ring (page 3-5) (page 3-8) (page 3-9) (page 3-14) 2-1 5. Helmet holder 6. Storage compartment 7. Owner's tool kit (page 3-12) (page 3-13) (page 6-1) DESCRIPTION Right view (XVS650) 2 8. Engine oil filter element 9. Battery 10. Fuses 11. Main switch/steering lock 12. Air filter element 13. Brake pedal (page 6-9) (page 6-29) (page 6-31) (page 3-1) (page 6-13) (page 3-6) 2-2 DESCRIPTION Left view (XVS650A) 2 1. Shift pedal 2. Fuel cock 3. Starter (choke) knob 4. Shock absorber spring preload adjusting ring (page 3-5) (page 3-8) (page 3-9) (page 3-14) 2-3 5. Helmet holder 6. Storage compartment 7. Owner's tool kit (page 3-12) (page 3-13) (page 6-1) DESCRIPTION Right view (XVS650A) 2 8. Engine oil filter element 9. Battery 10. Fuses 11. Main switch/steering lock 12. Air filter element 13. Brake pedal (page 6-9) (page 6-29) (page 6-31) (page 3-1) (page 6-13) (page 3-6) 2-4 DESCRIPTION Controls and instruments (XVS650/XVS650A) 2 1. Clutch lever 2. Left handlebar switches 3. Speedometer unit 4. Fuel tank cap 5. Right handlebar switches 6. Throttle grip 7. Brake lever (page 3-5) (page 3-3) (page 3-3) (page 3-7) (page 3-4) (page 6-15) (page 3-6) 2-5 INSTRUMENT AND CONTROL FUNCTIONS Main switch/steering lock .................................................................. 3-1 Indicator and warning lights ............................................................. 3-2 Speedometer unit .............................................................................. 3-3 Anti-theft alarm (optional) .................................................................. 3-3 Handlebar switches ........................................................................... 3-3 Clutch lever ....................................................................................... 3-5 Shift pedal (XVS650).......................................................................... 3-5 Shift pedal (XVS650A) ....................................................................... 3-5 Brake lever ........................................................................................ 3-6 Brake pedal ....................................................................................... 3-6 Fuel tank cap ..................................................................................... 3-7 Fuel ................................................................................................... 3-7 Fuel cock ........................................................................................... 3-8 Starter (choke) knob .......................................................................... 3-9 Seats (XVS650) ............................................................................... 3-10 Seats (XVS650A) ............................................................................. 3-11 Helmet holder .................................................................................. 3-12 Storage compartment ..................................................................... 3-13 Adjusting the shock absorber assembly .......................................... 3-14 Luggage strap holders .................................................................... 3-15 Sidestand ........................................................................................ 3-15 Ignition circuit cut-off system ........................................................... 3-16 3 3- INSTRUMENT AND CONTROL FUNCTIONS EAU00027 3 1. Push. 2. Turn. EW000016 EAU00029 EAU00040 Main switch/steering lock The main switch/steering lock controls the ignition and lighting systems, and is used to lock the steering. The various positions are described below. EAU00036 LOCK The steering is locked, and all electrical systems are off. The key can be removed. To lock the steering 1. Turn the handlebars all the way to the left. 2. Push the key in from the "OFF" position, and then turn it to "LOCK" while still pushing it. 3. Remove the key. To unlock the steering Push the key in, and then turn it to "OFF" while still pushing it. 3-1 ON All electrical systems are supplied with power, and the engine can be started. The key cannot be removed. EAU00038 WARNING Never turn the key to "OFF" or "LOCK" while the motorcycle is moving, otherwise the electrical systems will be switched off, which may result in loss of control or an accident. Make sure that the motorcycle is stopped before turning the key to "OFF" or "LOCK". @ @ OFF All electrical systems are off. The key can be removed. INSTRUMENT AND CONTROL FUNCTIONS EAU00044 EAU00063 (Parking) The steering is locked, and the taillight is on, but all other electrical systems are off. The key can be removed. The steering must be locked before the key can be turned to " ". ECA00043 High beam indicator light " " This indicator light comes on when the high beam of the headlight is switched on. EAU03182 CAUTION: Do not use the parking position for an extended length of time, otherwise the battery may discharge. @ @ 1. 2. 3. 4. High beam indicator light " " Turn signal indicator light " " Neutral indicator light " " Engine trouble warning light " " EAU03034 Engine trouble warning light " " This warning light comes on or flashes when an electrical circuit monitoring the engine is defective. When this occurs, have the Yamaha dealer check the self-diagnosis system. NOTE: This warning light comes on for a few seconds when the key is turned to "ON", but this does not indicate a malfunction. @ @ 3 Indicator and warning lights EAU00057 Turn signal indicator light " " This indicator light flashes when the turn signal switch is pushed to the left or right. EAU00061 Neutral indicator light " " This indicator light comes on when the transmission is in the neutral position. 3-2 INSTRUMENT AND CONTROL FUNCTIONS EAU00109 Anti-theft alarm (optional) This motorcycle can be equipped with an optional anti-theft alarm by a Yamaha dealer. Contact a Yamaha dealer for more information. 3 1. 2. 3. 4. Tripmeter reset knob Speedometer Odometer Tripmeter EAU00095 1. 2. 3. 4. Turn signal switch Pass switch " " Dimmer switch Horn switch " " EAU00118 Speedometer unit The speedometer unit is equipped with a speedometer, an odometer and a tripmeter. The speedometer shows riding speed. The odometer shows the total distance traveled. The tripmeter shows the distance traveled since it was last set to zero with the reset knob. The tripmeter can be used to estimate the distance that can be traveled with a full tank of fuel. This information will enable you to plan future fuel stops. Handlebar switches EAU00127 Turn signal switch To signal a right-hand turn, push this switch to " ". To signal a left-hand turn, push this switch to " ". When released, the switch returns to the center position. To cancel the turn signal lights, push the switch in after it has returned to the center position. 3-3 INSTRUMENT AND CONTROL FUNCTIONS EAU00119 EAU00138 Pass switch " " Press this switch to flash the headlight. EAU00121 Dimmer switch Set this switch to " " for the high beam and to " " for the low beam. EAU00129 Engine stop switch Set this switch to " " to stop the engine in case of an emergency, such as when the motorcycle overturns or when the throttle cable is stuck. EAU00134 Horn switch " " Press this switch to sound the horn. 1. Start switch " " 2. Engine stop switch 3. Light switch EAU00143 Light switch Set this switch to " " to turn on the auxiliary light, meter lighting and taillight. Set the switch to " " to turn on the headlight also. 3 Start switch " " Push this switch to crank the engine with the starter. EC000005 CAUTION: See page 5-1 for starting instructions prior to starting the engine. @ @ 3-4 INSTRUMENT AND CONTROL FUNCTIONS XVS650 XVS650A 3 1. Clutch lever EAU00152 1. Shift pedal EAU00157 1. Shift pedal EAU01215 Clutch lever The clutch lever is located at the left handlebar grip. To disengage the clutch, pull the lever toward the handlebar grip. To engage the clutch, release the lever. The lever should be pulled rapidly and released slowly for smooth clutch operation. The clutch lever is equipped with a clutch switch, which is part of the ignition circuit cut-off system. (See page 3-16 for an explanation of the ignition circuit cut-off system.) Shift pedal (XVS650) The shift pedal is located on the left side of the engine and is used in combination with the clutch lever when shifting the gears of the 5-speed constant-mesh transmission equipped on this motorcycle. Shift pedal (XVS650A) The shift pedal is located on the left side of the engine and is used in combination with the clutch lever when shifting the gears of the 5-speed constant-mesh transmission equipped on this motorcycle. NOTE: Use your toes or heel to shift up and your toes to shift down. _ _ 3-5 INSTRUMENT AND CONTROL FUNCTIONS XVS650 XVS650A 3 1. Brake lever EAU00158 1. Brake pedal EAU00162 1. Brake pedal Brake lever The brake lever is located at the right handlebar grip. To apply the front brake, pull the lever toward the handlebar grip. Brake pedal The brake pedal is on the right side of the motorcycle. To apply the rear brake, press down on the brake pedal. 3-6 INSTRUMENT AND CONTROL FUNCTIONS NOTE: The fuel tank cap cannot be installed unless the key is in the lock. In addition, the key cannot be removed if the cap is not properly installed and locked. @ @ EW000024 3 1. " "mark 2. Unlock. EAU00169 WARNING Make sure that the fuel tank cap is properly installed before riding. @ @ 1. Fuel tank filler tube 2. Fuel level EAU01183 Fuel tank cap To remove the fuel tank cap Insert the key into the lock and turn it 1/4 turn clockwise. The lock will be released and the fuel tank cap can be removed. To install the fuel tank cap 1. Insert the fuel tank cap into the tank opening with the key inserted in the lock and with the " " mark facing forward. 2. Turn the key counterclockwise to the original position, and then remove it. 3-7 Fuel Make sure that there is sufficient fuel in the tank. Fill the fuel tank to the bottom of the filler tube as shown in the illustration. EW000130 @ WARNING Do not overfill the fuel tank, otherwise it may overflow when the fuel warms up and expands. q Avoid spilling fuel on the hot engine. q @ INSTRUMENT AND CONTROL FUNCTIONS EAU00185 CAUTION: Immediately wipe off spilled fuel with a clean, dry, soft cloth, since fuel may deteriorate painted surfaces or plastic parts. @ @ Off position Normal position EAU00191 3 1. Arrow mark positioned over "OFF" EAU02969 Recommended fuel: Regular unleaded gasoline with a research octane number of 91 or higher Fuel tank capacity: Total amount: 16 L Reserve amount: 3L NOTE: If knocking (or pinging) occurs, use gasoline of a different brand or with a higher octane grade. @ @ 1. Arrow mark positioned over "ON" Fuel cock The fuel cock supplies fuel from the tank to the carburetors while also filtering it. The fuel cock lever positions are explained as follows and shown in the illustrations. OFF With the fuel cock lever in this position, fuel will not flow. Always turn the fuel cock lever to this position when the engine is not running. ON With the fuel cock lever in this position, fuel flows to the carburetors. Turn the fuel cock lever to this position when starting the engine and riding. 3-8 INSTRUMENT AND CONTROL FUNCTIONS Reserve position ECA00038 3 1. Arrow mark positioned over "RES" 1. Starter (choke) knob " " EAU03031 CAUTION: Do not use the starter (choke) for more than 3 minutes as the exhaust pipe may discolor from excessive heat. In addition, extended use of the starter (choke) will cause afterburning. If this occurs, turn off the starter (choke). _ _ RES This indicates reserve. With the fuel cock lever in this position, the fuel reserve is made available. Turn the fuel cock lever to this position if you run out of fuel while riding. When this occurs, refuel as soon as possible and be sure to turn the fuel cock lever back to "ON"! Starter (choke) knob Starting a cold engine requires a richer air-fuel mixture, which is supplied by the starter (choke). Move the knob in direction a to turn on the starter (choke). Move the knob in direction b to turn off the starter (choke). 3-9 INSTRUMENT AND CONTROL FUNCTIONS XVS650 XVS650 XVS650 3 1. Nut EAU01889 Seats (XVS650) Passenger seat To remove the passenger seat Remove the nut, and then pull the passenger seat up. 1. Bolt (× 2) 2. Seat holder 3. Projection 1. Seat holder 2. Projection To install the passenger seat Insert the projection on the front of the passenger seat into the seat holder as shown, place the seat in the original position, and then install the nut. Rider seat To remove the rider seat 1. Remove the passenger seat. 2. Remove the bolts, and then pull the seat up. To install the rider seat 1. Insert the projection on the front of the rider seat into the seat holder as shown, place the seat in the original position, and then install the bolts. 2. Install the passenger seat. NOTE: Make sure that the seats are properly secured before riding. @ @ 3-10 INSTRUMENT AND CONTROL FUNCTIONS XVS650A XVS650A XVS650A 3 1. Bolt EAU01888 1. Seat holder (× 2) 2. Projection (× 2) 1. Bolt Seats (XVS650A) Passenger seat To remove the passenger seat Remove the bolt, and then pull the passenger seat up. To install the passenger seat Insert the projections on the front of the passenger seat into the holder as shown, place the seat in the original position, and then install the bolt. Rider seat To remove the rider seat 1. Remove the passenger seat. 2. Remove the bolt, and then pull the rider seat up. 3-11 INSTRUMENT AND CONTROL FUNCTIONS XVS650A 3 1. Seat holder 2. Projection 1. Helmet holder 2. Unlock. EAU00260 To install the rider seat 1. Insert the projection on the front of the rider seat into the holder as shown, place the seat in the original position, and then install the bolt. 2. Install the passenger seat. NOTE: Make sure that the seats are properly secured before riding. _ _ Helmet holder To open the helmet holder, insert the key into the lock, and then turn the key as shown. To lock the helmet holder, place it in the original position, and then remove the key. EW000030 WARNING Never ride with a helmet attached to the helmet holder, since the helmet may hit objects, causing loss of control and possibly an accident. @ @ 3-12 INSTRUMENT AND CONTROL FUNCTIONS 3 1. Storage compartment cover 2. Storage compartment lock cover 3. Storage compartment lock EAU01869 Storage compartment The storage compartment is located on the left side of the motorcycle. To open the storage compartment 1. Slide the lock cover open, insert the key into the lock, and then turn it clockwise. 2. Pull the storage compartment cover out as shown. 1. Storage compartment 2. Storage compartment cover To close the storage compartment 1. Place the storage compartment cover in its original position as shown. 2. Turn the key counterclockwise, remove it, and then close the lock cover. 3-13 INSTRUMENT AND CONTROL FUNCTIONS EC000015 CI-01E CAUTION: Never attempt to turn an adjusting mechanism beyond the maximum or minimum settings. @ @ Minimum (soft) Setting 1 2 Standard 3 4 Maximum (hard) 5 6 7 3. Install the passenger and rider seats. 1. 2. 3. 4. Position indicator Spring preload adjusting ring Extension bar Special wrench EAU00299 Adjusting the shock absorber assembly This shock absorber assembly is equipped with a spring preload adjusting ring. Adjust the spring preload as follows. 1. Remove the passenger and rider seats. (See page 3-10 [XVS650] or 3-11 [XVS650A] for removal and installation procedures.) 2. To increase the spring preload and thereby harden the suspension, turn the adjusting ring in direction a. To decrease the spring preload and thereby soften the suspension, turn the adjusting ring in direction b. NOTE: q Align the appropriate notch in the adjusting ring with the position indicator on the shock absorber. q Use the special wrench and extension bar included in the owner's tool kit to make the adjustment. @ @ 3 3-14 INSTRUMENT AND CONTROL FUNCTIONS EAU00315 EAU00330 3 WARNING This shock absorber contains highly pressurized nitrogen gas. For proper handling, read and understand the following information before handling the shock absorber. The manufacturer cannot be held responsible for property damage or personal injury that may result from improper handling. q Do not tamper with or attempt to open the gas cylinder. q Do not subject the shock absorber to an open flame or other high heat sources, otherwise it may explode due to excessive gas pressure. q Do not deform or damage the gas cylinder in any way, as this will result in poor damping performance. q Always have a Yamaha dealer service the shock absorber. @ @ Sidestand The sidestand is located on the left side of the frame. Raise the sidestand or lower it with your foot while holding the motorcycle upright. NOTE: The built-in sidestand switch is part of the ignition circuit cut-off system, which cuts the ignition in certain situations. (See further down for an explanation of the ignition circuit cut-off system.) @ @ 1. Luggage strap holder (× 2) EAU01172 Luggage strap holders There is a luggage strap holder on each passenger footrest. 3-15 INSTRUMENT AND CONTROL FUNCTIONS EW000044 EAU03720 WARNING The motorcycle must not be ridden with the sidestand down, or if the sidestand cannot be properly moved up (or does not stay up), otherwise the sidestand could contact the ground and distract the operator, resulting in a possible loss of control. Yamaha's ignition circuit cut-off system has been designed to assist the operator in fulfilling the responsibility of raising the sidestand before starting off. Therefore, check this system regularly as described below and have a Yamaha dealer repair it if it does not function properly. @ @ Ignition circuit cut-off system The ignition circuit cut-off system (comprising the sidestand switch, clutch switch and neutral switch) has the following functions. q It prevents starting when the transmission is in gear and the sidestand is up, but the clutch lever is not pulled. q It prevents starting when the transmission is in gear and the clutch lever is pulled, but the sidestand is still down. q It cuts the running engine when the transmission is in gear and the sidestand is moved down. Periodically check the operation of the ignition circuit cut-off system according to the following procedure. EW000045 3 WARNING If a malfunction is noted, have a Yamaha dealer check the system before riding. _ _ 3-16 INSTRUMENT AND CONTROL FUNCTIONS CD-01E With the engine turned off: 1. Move the sidestand down. 2. Make sure that the engine stop switch is set to " 3. Turn the key to "ON". 4. Shift the transmission into the neutral position. 5. Push the start switch. Does the engine start? ". NOTE: This check is most reliable if performed with a warmed-up engine. 3 YES With the engine still running: 6. Move the sidestand up. 7. Keep the clutch lever pulled. 8. Shift the transmission into gear. 9. Move the sidestand down. Does the engine stall? NO The neutral switch may be defective. The motorcycle should not be ridden until checked by a Yamaha dealer. YES After the engine has stalled: 10. Move the sidestand up. 11. Keep the clutch lever pulled. 12. Push the start switch. Does the engine start? NO The sidestand switch may be defective. The motorcycle should not be ridden until checked by a Yamaha dealer. YES NO The clutch switch may be defective. The motorcycle should not be ridden until checked by a Yamaha dealer. The system is OK. The motorcycle can be ridden. 3-17 PRE-OPERATION CHECKS Pre-operation check list ..................................................................... 4-1 4 4- PRE-OPERATION CHECKS EAU01114 The condition of a vehicle is the owner's responsibility. Vital components can start to deteriorate quickly and unexpectedly, even if the vehicle remains unused (for example, as a result of exposure to the elements). Any damage, fluid leakage or loss of tire air pressure could have serious consequences. Therefore, it is very important, in addition to a thorough visual inspection, to check the following points before each ride. EAU03439 Pre-operation check list ITEM Fuel · Check fuel level in fuel tank. · Refuel if necessary. · Check fuel line for leakage. · Check oil level in engine. · If necessary, add recommended oil to specified level. · Check vehicle for oil leakage. · Check vehicle for oil leakage. · · · · · · · Check operation. If soft or spongy, have Yamaha dealer bleed hydraulic system. Check lever free play. Adjust if necessary. Check fluid level in reservoir. If necessary, add recommended brake fluid to specified level. Check hydraulic system for leakage. CHECKS PAGE 3-7­3-8 4 Engine oil Final gear oil 6-9­6-11 6-11­6-12 Front brake 6-20­6-21, 6-23­6-25 Rear brake · Check operation. · Check pedal free play. · Adjust if necessary. · · · · · · · · Check operation. Lubricate cable if necessary. Check lever free play. Adjust if necessary. Make sure that operation is smooth. Lubricate throttle grip, housing and cables if necessary. Check free play. If necessary, have Yamaha dealer make adjustment. 4-1 6-21­6-25 Clutch 6-19­6-20 Throttle grip 6-15, 6-25 PRE-OPERATION CHECKS ITEM Control cables CHECKS · Make sure that operation is smooth. · Lubricate if necessary. · · · · Check for damage. Check tire condition and tread depth. Check air pressure. Correct if necessary. PAGE 6-25 Wheels and tires 6-16­6-19 Brake and shift pedals Brake and clutch levers Sidestand Chassis fasteners Instruments, lights, signals and switches Sidestand switch · Make sure that operation is smooth. · Lubricate pedal pivoting points if necessary. · Make sure that operation is smooth. · Lubricate lever pivoting points if necessary. · Make sure that operation is smooth. · Lubricate pivot if necessary. · Make sure that all nuts, bolts and screws are properly tightened. · Tighten if necessary. · Check operation. · Correct if necessary. · Check operation of ignition circuit cut-off system. · If system is defective, have Yamaha dealer check vehicle. 6-26 6-26 6-27 -- -- 3-15­3-16 4 NOTE: Pre-operation checks should be made each time the motorcycle is used. Such an inspection can be accomplished in a very short time; and the added safety it assures is more than worth the time involved. @ @ EWA00033 WARNING If any item in the Pre-operation check list is not working properly, have it inspected and repaired before operating the motorcycle. @ @ 4-2 OPERATION AND IMPORTANT RIDING POINTS Starting the engine ............................................................................ 5-1 Starting a warm engine ..................................................................... 5-2 Shifting .............................................................................................. 5-3 Tips for reducing fuel consumption ................................................... 5-4 Engine break-in ................................................................................. 5-4 Parking .............................................................................................. 5-5 5 5- OPERATION AND IMPORTANT RIDING POINTS EAU00373 EAU03461* EAU00372 @ 5 WARNING Become thoroughly familiar with all operating controls and their functions before riding. Consult a Yamaha dealer regarding any control or function that you do not thoroughly understand. q Never start the engine or operate it in a closed area for any length of time. Exhaust fumes are poisonous, and inhaling them can cause loss of consciousness and death within a short time. Always make sure that there is adequate ventilation. q Before starting out, make sure that the sidestand is up. If the sidestand is not raised completely, it could contact the ground and distract the operator, resulting in a possible loss of control. q Starting the engine In order for the ignition circuit cut-off system to enable starting, one of the following conditions must be met: q The transmission is in the neutral position. q The transmission is in gear with the clutch lever pulled and the sidestand up. EW000054 @ WARNING q Before starting the engine, check the function of the ignition circuit cut-off system according to the procedure described on page 3-17. q Never ride with the sidestand down. 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 neutral 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 circuit. @ @ @ @ 4. Turn the starter (choke) on and completely close the throttle. (See page 3-9 for starter (choke) operation.) 5-1 OPERATION AND IMPORTANT RIDING POINTS vehicle for oil leakage. If necessary, add engine oil, and then check the warning light again. If the warning light does not go off after starting with sufficient engine oil, have a Yamaha dealer check the electrical circuit. @ EAU01258 Starting a warm engine Follow the same procedure as for starting a cold engine with the exception that the starter (choke) is not required when the engine is warm. 6. After starting the engine, move the starter (choke) knob back halfway. ECA00055 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 preserve the battery. Do not crank the engine more than 10 seconds on any one attempt. @ @ CAUTION: For maximum engine life, always warm the engine up before starting off. Never accelerate hard when the engine is cold! @ @ 5 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. @ @ ECA00059 CAUTION: If the oil level warning light flickers or remains on after starting, immediately stop the engine, and then check the engine oil level and the @ 5-2 OPERATION AND IMPORTANT RIDING POINTS XVS650 XVS650A q Always use the clutch while changing gears to avoid damaging the engine, transmission, and drive train, which are not designed to withstand the shock of forced shifting. @ 1. Shift pedal N. Neutral position EAU00423 1. Shift pedal N. Neutral position EC000048 5 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 illustration. NOTE: To shift the transmission into the neutral position, press the shift pedal down repeatedly until it reaches the end of its travel, and then slightly raise it. @ @ @ CAUTION: q Even with the transmission in the neutral position, do not coast for long periods of time with the engine off, and do not tow the motorcycle for long distances. The transmission is properly lubricated only when the engine is running. Inadequate lubrication may damage the transmission. 5-3 OPERATION AND IMPORTANT RIDING POINTS EAU00424 EAU01128 EAU01171* Tips for reducing fuel consumption Fuel consumption depends largely on your riding style. Consider the following tips to reduce fuel consumption: q Thoroughly warm up the engine. q Turn the starter (choke) off as soon as possible. q Shift up swiftly, and avoid high engine speeds during acceleration. q Do not rev the engine while shifting down, and avoid high engine speeds with no load on the engine. q Turn the engine off instead of letting it idle for an extended length of time (e.g., in traffic jams, at traffic lights or at railroad crossings). Engine break-in There is never a more important period in the life of your engine than the period between 0 and 1,600 km. For this reason, you should read the following material carefully. Since the engine is brand new, do not put an excessive load on it for the first 1,600 km. The various parts in the engine wear and polish themselves to the correct operating clearances. During this period, prolonged full-throttle operation or any condition that might result in engine overheating must be avoided. 0­1,000 km Avoid prolonged 1/3 throttle. 1,000­1,600 km Avoid prolonged 1/2 throttle. operation above operation above EC000056* CAUTION: After 1,000 km of operation, the engine oil and final gear oil must be changed, and the oil filter element replaced. @ @ 5 1,600 km and beyond The vehicle can now be operated normally. EC000049 CAUTION: If any engine trouble should occur during the engine break-in period, immediately have a Yamaha dealer check the vehicle. @ @ 5-4 OPERATION AND IMPORTANT RIDING POINTS EAU00457 Parking When parking, stop the engine, remove the key from the main switch, and then turn the fuel cock lever to "OFF". EW000058 @ 5 WARNING q Since the engine and exhaust system can become very hot, park in a place where pedestrians or children are not likely to touch them. q Do not park on a slope or on soft ground, otherwise the motorcycle may overturn. @ 5-5 PERIODIC MAINTENANCE AND MINOR REPAIR Owner's tool kit ....................................................6-1 Periodic maintenance and lubrication chart .........6-2 Removing and installing panels ...........................6-5 Checking the spark plugs ....................................6-7 Engine oil and oil filter element ............................6-9 Final gear oil ......................................................6-11 Cleaning the air filter element ............................6-13 Adjusting the carburetors ...................................6-14 Adjusting the engine idling speed ......................6-15 Adjusting the throttle cable free play ..................6-15 Adjusting the valve clearance ............................6-16 Tires ...................................................................6-16 Spoke wheels ....................................................6-19 Adjusting the clutch lever free play ....................6-19 Adjusting the brake lever free play .....................6-20 Adjusting the brake pedal position and free play ...........................................................6-21 Adjusting the rear brake light switch ..................6-22 Checking the front brake pads and rear brake shoes ..............................................6-23 Checking the brake fluid level ............................6-24 Changing the brake fluid ....................................6-25 Checking and lubricating the cables ................. 6-25 Checking and lubricating the throttle grip and cable ............................................................... 6-25 Checking and lubricating the brake and shift pedals ...................................................... 6-26 Checking and lubricating the brake and clutch levers .................................................... 6-26 Checking and lubricating the sidestand ............ 6-27 Checking the front fork ...................................... 6-27 Checking the steering ....................................... 6-28 Checking the wheel bearings ............................ 6-29 Battery ............................................................... 6-29 Replacing the fuses .......................................... 6-31 Replacing the headlight bulb ............................. 6-32 Replacing a turn signal light bulb or the tail/ brake light bulb ................................................ 6-33 Supporting the motorcycle ................................ 6-34 Front wheel ....................................................... 6-35 Rear wheel ........................................................ 6-36 Troubleshooting ................................................. 6-38 Troubleshooting chart ........................................ 6-39 6 6- PERIODIC MAINTENANCE AND MINOR REPAIR EAU00464 EAU01129 EAU00462 EW000063 6 Safety is an obligation of the owner. Periodic inspection, adjustment and lubrication will keep your vehicle in the safest and most efficient condition possible. The most important points of inspection, adjustment, and lubrication are explained on the following pages. The intervals given in the periodic maintenance and lubrication chart should be simply considered as a general guide under normal riding conditions. However, DEPENDING ON THE WEATHER, TERRAIN, GEOGRAPHICAL LOCATION, AND INDIVIDUAL USE, THE MAINTENANCE INTERVALS MAY NEED TO BE SHORTENED. EW000060 Owner's tool kit The owner's tool kit is located inside the storage compartment. (See page 3-13 for storage compartment opening procedures.) The service information included in this manual and the tools provided in the owner's tool kit are intended to assist you in the performance of preventive maintenance and minor repairs. However, additional tools such as a torque wrench may be necessary to perform certain maintenance work correctly. NOTE: If you do not have the tools or experience required for a particular job, have a Yamaha dealer perform it for you. @ @ WARNING Modifications not approved by Yamaha may cause loss of performance and render the vehicle unsafe for use. Consult a Yamaha dealer before attempting any changes. @ @ WARNING If you are not familiar with motorcycle maintenance work, have a Yamaha dealer do it for you. @ @ 6-1 PERIODIC MAINTENANCE AND MINOR REPAIR EAU03685 Periodic maintenance and lubrication chart NOTE: q The annual checks must be performed every year, except if a kilometer-based maintenance is performed instead. q From 50,000 km, repeat the maintenance intervals starting from 10,000 km. q Items marked with an asterisk should be performed by a Yamaha dealer as they require special tools, data and technical skills. _ _ CP-03E NO. 1 2 3 4 5 6 7 ITEM CHECK OR MAINTENANCE JOB · Check fuel hoses for cracks or damage. · Check condition. · Check condition. · Clean and regap. · Replace. · Check valve clearance. · Adjust. · Clean. · Replace. · Check operation. · Adjust. · Check operation, fluid level and vehicle for fluid leakage. (See NOTE on page 6-4.) · Replace brake pads. · Check operation and adjust brake pedal freeplay. · Replace brake shoes. · Check for cracks or damage. · Replace. (See NOTE on page 6-4.) 6-2 ODOMETER READING (×1,000 km) 1 10 20 30 40 ANNUAL CHECK * Fuel line * Fuel filter Spark plugs