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
6-8
PERIODIC MAINTENANCE AND MINOR REPAIR
1
2
3
4
5
6
7
8
9
1. Spark plug wrench
Inspection
The spark plug is an important engine
component and is easy to inspect. The
condition of the spark plug can indicate
the condition of the engine. Normally,
all spark plugs from the same engine
should have the same color on the
white insulator around the center elec-
trode. The ideal color at this point is a
medium-to-light tan color for a motor-
cycle that is being ridden normally. If
one spark plug shows a distinctly dif-
ferent color, there could be something
wrong with the engine. Do not attempt
to diagnose such problems yourself.
Instead, take the motorcycle to a
Yamaha dealer. You should periodi-cally remove and inspect the spark
plugs because heat and deposits will
cause any spark plug to slowly break
down and erode. If electrode erosion
becomes excessive, or if carbon and
other deposits are excessive, you
should replace the spark plug with the
specified plug.
Specified spark plug:
DPR7EA-9 (NGK)
X22EPR-U9 (DENSO)
a. Spark plug gap
Installation
1. Measure the electrode gap with a
wire thickness gauge and, if nec-
essary, adjust the gap to specifi-
cation.
2. Clean the gasket surface. Wipe
off any grime from the threads.
3. Install the spark plug and tighten it
to the specified torque. Spark plug gap:
0.8 ~ 0.9 mm
6-35
PERIODIC MAINTENANCE AND MINOR REPAIR
1
2
3
4
56
7
8
9
EAU01297*
Troubleshooting chart
EW000125
WARNING
Never check the fuel system while smoking or in the vicinity of an open flame.
Check if there is fuel
in the fuel tank.1. Fuel
Enough fuel.
No fuel.
Go to compression check.
Supply fuel.
Engine doesn’t start, go to compression check.
Use the electric starter.2. Compression
There is compression.
No compression.
Go to ignition check.
Ask a Yamaha dealer to
inspect.
Remove spark
plugs and
check electrodes.3. Ignition
Wet.
Dry.
Wipe clean with dry cloth and correct
spark gap or replace spark plugs.
Ask a Yamaha dealer to inspect.
Engine doesn’t start, ask a Yamaha
dealer to inspect.Engine doesn’t start, go to battery
check.Open throttle half-way and start
the engine.
Use the electric starter.4. Battery
Engine turns over
quickly.
Engine turns over
slowly.
Battery good.Check connections or
recharge.
INDEX
Pass switch .............................................. 3-3
Periodic maintenance and
lubrication .............................................. 6-2
Pre-operation check list ........................... 4-1
R
Rear brake pedal ..................................... 3-6
Rear brake pedal height and free play
adjustment ........................................... 6-20
Rear shock absorber adjustment ........... 3-14
Rear wheel installation ........................... 6-33
Rear wheel removal ............................... 6-32
Right view (XVS650) ................................ 2-2
Right view (XVS650A) ............................. 2-4
S
Seats (for XVS650) .................................. 3-9
Seats (for XVS650A) .............................. 3-11
Shift pedal ................................................ 3-5
Shifting ..................................................... 5-4
Sidestand ............................................... 3-15
Sidestand lubrication .............................. 6-24
Sidestand/clutch switch operation
check ................................................... 3-16
Spark plugs .............................................. 6-7
Specifications ........................................... 8-1
Speedometer ............................................ 3-2
Start switch ............................................... 3-4
Starter (choke) “ ” ................................. 3-9
Starting a warm engine ............................ 5-4
Starting the engine ................................... 5-1
Steering inspection ................................. 6-25
Storage ..................................................... 7-4
Storage compartment ............................ 3-13
Supporting the motorcycle ..................... 6-30
T
Throttle cable and grip lubrication .......... 6-23
Throttle cable free play inspection ......... 6-15
Tips for reducing fuel consumption .......... 5-5
Tires ....................................................... 6-15
Tool kit ...................................................... 6-1
Troubleshooting ..................................... 6-34
Troubleshooting chart ............................ 6-35
Turn indicator light .................................... 3-2
Turn signal and taillight bulb
replacement ......................................... 6-29
Turn signal switch .................................... 3-3
V
Valve clearance adjustment ................... 6-15
Vehicle identification number ................... 9-1
W
Wheel bearings ...................................... 6-26
Wheels ................................................... 6-17