2000 YAMAHA XVS650 clutch

5-5
OPERATION AND IMPORTANT RIDING POINTS
1
2
3
4
5
6
7
8
9

EAU00424
Tips for reducing fuel con-
sumption
Your motorcycle’s fuel consumption
depends to a large extent on your
riding style. The following tips can help
reduce fuel consumption:
l
Warm up the engine before
riding.
l
Turn off the starter (choke) as
soon as possible.
l
Shift up swiftly and avoid high en-
gine speeds during acceleration.
l
Do not double-clutch or rev the
engine while shifting down and
avoid high engine speeds with no
load on the engine.
l
Turn off the engine instead of let-
ting it idle for an extended length
of time, i.e. in traffic jams, at traffic
lights or railroad crossings.
EAU01128
Engine break-in
There is never a more important period
in the life of your motorcycle than the
period between zero and 1,600 km.
For this reason we ask that you care-
fully read the following material. Be-
cause the engine is brand new, you
must not put an excessive load on it for
the first 1,600 km. The various parts in
the engine wear and polish them-
selves to the correct operating clear-
ances. During this period, prolonged
full throttle operation, or any condition
which might result in excessive heat-
ing of the engine, must be avoided.
EAU01171
0 ~ 1,000 km
Avoid operation above 1/3 throttle.
1,000 ~ 1,600 km
Avoid cruising speeds in excess of
1/2 throttle.

EC000056
CAUTION:
After 1,000 km of operation, be sure
to replace the engine oil, oil filter

and final gear oil.
1,600 km and beyond
Proceed with normal riding.
EC000049
CAUTION:
If any engine trouble should occur
during the break-in period, consult

a Yamaha dealer immediately.

Tool kit ................................................................ 6-1
Periodic maintenance and lubrication ................ 6-2
Panel removal and installation............................ 6-5
Panel A ............................................................... 6-6
Panel B ............................................................... 6-7
Spark plugs ........................................................ 6-7
Engine oil............................................................ 6-9
Final gear oil ..................................................... 6-11
Air filter ............................................................. 6-12
Carburetor adjustment...................................... 6-13
Idle speed adjustment ...................................... 6-14
Throttle cable free play inspection .................... 6-15
Valve clearance adjustment.............................. 6-15
Tires ................................................................. 6-15
Wheels ............................................................. 6-17
Clutch lever free play adjustment ..................... 6-18
Front brake lever free play
adjustment ...................................................... 6-19
Rear brake pedal height and free play
adjustment ...................................................... 6-20
Brake light switch adjustment ........................... 6-21
Checking the front brake pads and
rear brake shoes ............................................ 6-21
Inspecting the brake fluid level.......................... 6-22
Brake fluid replacement .................................... 6-22
Cable inspection and lubrication ....................... 6-23
Throttle cable and grip lubrication..................... 6-23
Brake and shift pedal lubrication....................... 6-23
Brake and clutch lever lubrication ..................... 6-24
Sidestand lubrication ........................................ 6-24
Front fork inspection ......................................... 6-25
Steering inspection ........................................... 6-25
Wheel bearings ................................................. 6-26
Battery .............................................................. 6-26
Fuse replacement ............................................. 6-27
Headlight bulb replacement .............................. 6-28
Turn signal and taillight bulb replacement......... 6-29
Supporting the motorcycle ................................ 6-30
Front wheel removal ......................................... 6-31
Front wheel installation ..................................... 6-31
Rear wheel removal .......................................... 6-32
Rear wheel installation...................................... 6-33
Troubleshooting ................................................ 6-34
Troubleshooting chart ....................................... 6-35

PERIODIC MAINTENANCE AND MINOR REPAIR
6

6-2
PERIODIC MAINTENANCE AND MINOR REPAIR
1
2
3
4
5
6
7
8
9

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

6-11
PERIODIC MAINTENANCE AND MINOR REPAIR
1
2
3
4
5
6
7
8
9

1. O-ring
2. Oil filter element
EC000066
CAUTION:

l
Do not put in any chemical ad-
ditives. Engine oil also lubri-
cates the clutch and additives
could cause clutch slippage.
l
Be sure no foreign material en-
ters the crankcase.
10. Start the engine and warm it up
for a few minutes. While warming
up, check for oil leakage. If oil
leakage is found, stop the engine
immediately and check for the
cause.
1. Final gear oil drain bolt
2. Final gear oil filler bolt
3. Proper level
EAU02943*
Final gear oil
EW000066
WARNING

Do not let foreign material enter the
final gear case. Be sure oil does not
get on the tire or wheel.
Oil level inspection
1. Place the motorcycle on a level
place and hold it in an upright po-
sition. The engine should be cool
at ambient temperature.2. Remove the oil filler bolt and
check the oil level. The oil level
should be at the brim of the filler
hole. Add the recommended oil if
necessary.
Oil replacement
1. Place an oil pan under the final
gear case.
2. Remove the oil filler bolt and drain
bolt to drain the oil.
3. Install and tighten the drain bolt to
the specified torque.
4. Fill the gear case to the brim of the
filler hole with the recommended
oil. Tightening torque:
Drain bolt:
23 Nm (2.3 m·kg)

6-18
PERIODIC MAINTENANCE AND MINOR REPAIR
1
2
3
4
56
7
8
9
1. Locknut
2. Adjusting bolt
c. Free play
EAU00694
Clutch lever free play
adjustmentThe clutch lever free play should be
adjusted to 10 ~ 15 mm.
1. Loosen the locknut at the clutch
lever.
2. Turn the adjusting bolt at the
clutch lever in direction a to in-
crease free play or in direction b
to decrease free play.
3. Tighten the locknut at the clutch
lever.
1. Adjusting nut
2. LocknutIf the specified free play cannot be ob-
tained, proceed with the following
steps.
4. Loosen the locknut at the clutch
lever.
5. Turn the adjusting bolt at the
clutch lever in direction a to loos-
en the cable.
6. Loosen the locknut at the crank-
case side.
7. Turn the adjusting nut at the
crankcase in direction a to in-
crease free play or in direction b
to decrease free play.
8. Tighten the locknut at the crank-
case and the clutch lever.

6-24
PERIODIC MAINTENANCE AND MINOR REPAIR
1
2
3
4
56
7
8
9
EAU02985
Brake and clutch lever
lubricationLubricate the pivoting parts.
Recommended lubricant:
Engine oil
EAU02986
Sidestand lubricationLubricate the sidestand pivoting point
and metal-to-metal contact surfaces.
Check that the sidestand moves up
and down smoothly.
EW000113
WARNING
If the sidestand does not movesmoothly, consult a Yamaha dealer.Recommended lubricant:
Engine oil

8-2
SPECIFICATIONS
1
2
3
4
5
6
7
8
9

Quantity
Periodic oil change 2.6 L
With oil filter replacement 2.8 L
Total amount 3.2 L
Final gear oil
Type SAE80API “GL-4” Hypoid Gear
Oil
Quantity 0.19 L
Air filter
Dry type element
Fuel
Type Regular unleaded gasoline
Fuel tank capacity 16 L
Reserve amount 3 L
Carburetor
Type
´
quantity BDS28
´
2
Manufacturer MIKUNI
CAUTION:Be sure to use motor oils that do not contain anti-fric-
tion modifiers. Passenger car motor oils (often labeled
“Energy Conserving”) contain anti-friction additives
which will cause clutch and/or starter clutch slippage,
resulting in reduced component life and poor engineperformance.
Spark plug
Type/Manufacturer DPR7EA-9 / NGK
X22EPR-U9 / DENSO
Gap 0.8 ~ 0.9 mm
Clutch type
Wet, multiple-disc
Transmission
Primary reduction system Spur gear
Primary reduction ratio 1.789
Secondary reduction system Shaft drive
Secondary reduction ratio 3.071
Transmission type Constant mesh 5-speed
Operation Left foot operation
Gear ratio 1st 2.714
2nd 1.900
3rd 1.458
4th 1.166
5th 0.966
Chassis
XVS650
Frame type Double cradle
Caster angle 35˚
Trail 153 mm

INDEX
A
Air filter ....................................................6-12
Antitheft alarm (optional) ..........................3-3
B
Battery ....................................................6-26
Brake and clutch lever lubrication ..........6-24
Brake and shift pedal lubrication ............6-23
Brake fluid replacement ..........................6-22
Brake light switch adjustment .................6-21
C
Cable inspection and lubrication ............6-23
Carburetor adjustment ............................6-13
Care ..........................................................7-1
Checking the front brake pads and
rear brake shoes ..................................6-21
Clutch lever ...............................................3-5
Clutch lever free play adjustment ...........6-18
Controls/Instruments
(XVS650/XVS650A) ..............................2-5
D
Dimmer switch ..........................................3-3
E
Engine break-in ........................................5-5
Engine oil ..................................................6-9
Engine stop switch ...................................3-4
Engine trouble indicator light ....................3-2
F
Final gear oil ...........................................6-11
Front brake lever ......................................3-5
Front brake lever free play
adjustment ...........................................6-19
Front fork inspection ...............................6-25
Front wheel installation ...........................6-31
Front wheel removal ...............................6-31
Fuel ...........................................................3-7
Fuel cock ..................................................3-8
Fuel tank breather hose ...........................3-7
Fuel tank cap ............................................3-6
Fuse replacement ...................................6-27
G
Give safety the right of way ......................1-1
H
Handlebar switches ..................................3-3
Dimmer switch ....................................3-3
Engine stop switch ..............................3-4
Horn switch .........................................3-3
Lights switch .......................................3-4
Pass switch .........................................3-3
Start switch .........................................3-4
Turn signal switch ...............................3-3
Headlight bulb replacement ...................6-28
Helmet holder .........................................3-12
High beam indicator light ..........................3-2
Horn switch ...............................................3-3
I
Identification number records ...................9-1
Idle speed adjustment ............................6-14
Indicator lights ..........................................3-2
Engine trouble indicator light ..............3-2
High beam indicator light ....................3-2
Neutral indicator light ..........................3-2
Turn indicator light ..............................3-2
Inspecting the brake fluid level ...............6-22
K
Key identification number .........................9-1
L
Left view (XVS650) ...................................2-1
Left view (XVS650A) ................................2-3
Lights switch .............................................3-4
Luggage strap holders ............................3-15
M
Main switch/Steering lock .........................3-1
Model label ...............................................9-2
N
Neutral indicator light ................................3-2
P
Panel A .....................................................6-6
Panel B .....................................................6-7
Panel removal and installation .................6-5
Parking ......................................................5-6