2000 YAMAHA XVS650 brake

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PERIODIC MAINTENANCE AND MINOR REPAIR
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EAU00473
PERIODIC MAINTENANCE AND LUBRICATION
NO. ITEM CHECKS AND MAINTENANCE JOBSInitial
(1,000 km)EVERY
6,000 km
or
6 months
(whichever
comes first)12,000 km
or
12 months
(whichever
comes first)
1
*
Fuel line
• Check fuel hoses for cracks or damage.
• Replace if necessary.
ÖÖ
2 Spark plugs
• Check condition.
• Clean, regap or replace if necessary.
ÖÖÖ
3

*
Valves
• Check valve clearance.
• Adjust if necessary.
ÖÖÖ
4 Air filter
• Clean or replace if necessary.
ÖÖ
5 Clutch
• Check operation.
• Adjust or replace cable.
ÖÖÖ
6

*
Front brake
• Check operation, fluid level and vehicle for fluid leakage.
(See NOTE on page 6-4.)
• Correct accordingly.
• Replace brake pads if necessary.
ÖÖÖ
7
*
Rear brake
• Check operation.
• Adjust brake pedal and replace brake shoes if necessary.
ÖÖÖ
8
*
Wheels
• Check balance, runout, spoke tightness and for damage.
• Tighten spokes and rebalance, replace if necessary.
ÖÖ
9
*
Tires
• Check tread depth and for damage.
• Replace if necessary.
• Check air pressure.
• Correct if necessary.
ÖÖ
10
*
Wheel bearings
• Check bearing for looseness or damage.
• Replace if necessary.
ÖÖ

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*

Since these items require special tools, data and technical skills, they should be serviced by a Yamaha dealer.
EAU02970
NOTE:

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The air filter needs more frequent service if you are riding in unusually wet or dusty areas.
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Hydraulic brake system
• When disassembling the master cylinder or caliper, always replace the brake fluid. Check the brake fluid level regularly
and fill as required.
• Replace the oil seals on the inner parts of the master cylinder and caliper every two years.
• Replace the brake hoses every four years or if cracked or damaged.
20 Engine oil filter element
• Replace.
ÖÖ
21
Final gear oil
• Check oil level and vehicle for oil leakage.
• Change oil at initial 1,000 km and thereafter every 24,000 km or
24 months (whichever comes first).
ÖÖÖ
NO. ITEM CHECKS AND MAINTENANCE JOBSInitial
(1,000 km)EVERY
6,000 km
or
6 months
(whichever
comes first)12,000 km
or
12 months
(whichever
comes first)

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9Tire inspection
Always check the tires before operat-
ing the motorcycle. If center tread
depth reaches the limit as shown, if the
tire has a nail or glass fragments in it,
or if the side wall is cracked, contact a
Yamaha dealer immediately and have
the tire replaced.
COPY CE-10ECE-10E
CE-10EFRONT (XVS650)
Manufacturer Size Type
Bridgestone 100/90-19 57S L309
Dunlop 100/90-19 57S F24
REAR (XVS650)
Manufacturer Size Type
Bridgestone 170/80-15M/C 77S G546
Dunlop 170/80-15M/C 77S K555
FRONT (XVS650A)
Manufacturer Size Type
Bridgestone 130/90-16 67S G703
Dunlop 130/90-16 67S D404F
REAR (XVS650A)
Manufacturer Size Type
Bridgestone 170/80-15M/C 77S G702
Dunlop 170/80-15M/C 77S D404
CE-26ECE-26ENOTE:These limits may be different by regu-
lation from country to country. If so,
conform to the limits specified by theregulations of your own country.
EAU00681
WARNING
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Operating the motorcycle with
excessively worn tires de-
crease riding stability and can
lead to loss of control. Have ex-
cessively worn tires replaced
by a Yamaha dealer immediate-
ly. Brakes, tires, and related
wheel parts replacement
should be left to a Yamaha Ser-
vice Technician.
l
Patching a punctured tube is
not recommended. If it is abso-
lutely necessary to do so, use
great care and replace the tube
as soon as possible with agood quality replacement.
Minimum tire tread depth
(front and rear)1.6 mm
EAU00685
WheelsTo ensure maximum performance,
long service, and safe operation, note
the following:l
Always inspect the wheels before
a ride. Check for cracks, bends or
warpage of the wheel. Be sure
the spokes are tight and undam-
aged. If any abnormal condition
exists in a wheel, consult a
Yamaha dealer. Do not attempt
even small repairs to the wheel. If
a wheel is deformed or cracked, it
must be replaced.
l
Tires and wheels should be bal-
anced whenever either one is
changed or replaced. Failure to
have a wheel balanced can result
in poor performance, adverse
handling characteristics, and
shortened tire life.
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Ride at moderate speeds after
changing a tire since the tire sur-
face must first be broken in for it to
develop its optimal characteristics.

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1. Locknut
2. Adjusting bolt
EAU00696
Front brake lever free play
adjustmentThe free play at the front brake lever
should be 10 ~ 15 mm.
1. Loosen the locknut.
2. Turn the adjusting bolt in direction
a to increase free play or in di-
rection b to decrease free play.
3. After adjusting, tighten the lock-
nut.
a. Free play
EW000099
WARNING
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Check the brake lever free play.
Be sure the brake is working
properly.
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A soft or spongy feeling in the
brake lever can indicate the
presence of air in the brake
system. This air must be re-
moved by bleeding the brake
system before the motorcycle
is operated. Air in the system
will cause greatly diminished
braking capability and can re-
sult in loss of control and anaccident. Have a Yamaha dealer
inspect and bleed the system if
necessary.

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a. Pedal height
b. Free play
EAU00711
Rear brake pedal height and
free play adjustment
EW000104
WARNING
It is advisable to have a Yamahadealer make this adjustment.
The brake pedal height should be ad-
justed before adjusting the brake pedal
free play.
Pedal height
The brake pedal should be positioned
approximately 85 mm above the top of
the footrest.
1. Locknut
2. Adjusting bolta. Loosen the locknut.
b. Turn the adjusting bolt in direction
a to raise pedal height or in di-
rection b to lower pedal height.
c. Tighten the locknut.
1. Adjusting nut
EW000105
WARNING
After adjusting the pedal height ad-just brake pedal free play.
Free play
The brake pedal free play should be
adjusted to 20 ~ 30 mm at the brake
pedal end. Turn the adjusting nut on
the brake rod in direction a to in-
crease free play or in direction b to
decrease free play.

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1. Brake light switch
2. Adjusting nut
EAU00713
Brake light switch adjustmentThe rear brake light switch is activated
by the brake pedal and is properly ad-
justed when the brake light comes on
just before braking takes effect. To ad-
just the rear brake light switch, hold the
switch body so it does not rotate while
turning the adjusting nut. Turn the ad-
justing nut in direction a to make the
brake light come on earlier. Turn the
adjusting nut in direction b to make
the brake light come on later.
1. Wear indicator grooves
EAU00720
Checking the front brake
pads and rear brake shoes
EAU01119
Front brake
Wear indicator grooves are provided
on each brake pad. These indicators
allow checking of brake pad wear with-
out disassembling the brake. Inspect
the grooves. If they have almost disap-
peared, ask a Yamaha dealer to re-
place the pads.
1. Wear limit line
2. Wear indicator
EAU00727
Rear brake
Apply the brake and inspect the wear
indicator.
If the indicator reaches the wear limit
line, ask a Yamaha dealer to replace
the shoes.

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1. Minimum level mark
EAU00731
Inspecting the brake fluid
levelInsufficient brake fluid may let air enter
the brake system, possibly causing the
brakes to become ineffective.
Before riding, check that the brake flu-
id is above the minimum level and re-
plenish when necessary. Observe
these precautions:l
When checking the fluid level,
make sure the top of the master
cylinder is level by turning the
handlebars.
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Use only the designated quality
brake fluid. Otherwise, the rubber
seals may deteriorate, causing
leakage and poor brake perfor-
mance.
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Refill with the same type of brake
fluid. Mixing fluids may result in a
harmful chemical reaction and
lead to poor brake performance.
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Be careful that water does not en-
ter the master cylinder when refill-
ing. Water will significantly lower
the boiling point of the fluid and
may result in vapor lock.
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Brake fluid may deteriorate paint-
ed surfaces or plastic parts. Al-
ways clean up spilled fluid
immediately.
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Have a Yamaha dealer check the
cause if the brake fluid level goes
down. Recommended brake fluid: DOT 4
EAU00742
Brake fluid replacementThe brake fluid should be replaced
only by trained Yamaha service per-
sonnel. Have the Yamaha dealer re-
place the following components during
periodic maintenance or when they are
damaged or leaking:l
oil seals (every two years)
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brake hoses (every four years)

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EAU02962
Cable inspection and
lubrication
EW000112
WARNING
Damage to the outer housing of ca-
bles may lead to internal rusting
and interfere with the cable move-
ment. Replace damaged cables as
soon as possible to prevent unsafeconditions.
Lubricate the cables and cable ends. If
a cable does not operate smoothly,
ask a Yamaha dealer to replace it.
Recommended lubricant:
Engine oil
EAU00773
Throttle cable and grip lubri-
cationThe throttle twist grip assembly should
be greased at the time that the cable is
lubricated, since the grip must be re-
moved to get at the end of the throttle
cable. After removing the screws, hold
the end of the cable up in the air and
put in several drops of lubricant. With
the throttle grip disassembled, coat the
metal surface of the grip assembly with
a suitable all-purpose grease.
EAU02984
Brake and shift pedal
lubricationLubricate the pivoting parts.
Recommended lubricant:
Engine oil