2001 YAMAHA XVS650 clutch

OPERATION AND IMPORTANT RIDING POINTS
5-3
5
EAU00423
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 neu-
tral position, press the shift pedal down
repeatedly until it reaches the end of its
travel, and then slightly raise it. @
EC000048
CAUTION:@ l
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 dis-
tances. The transmission is
properly lubricated only when
the engine is running. Inade-
quate lubrication may damage
the transmission.
l
Always use the clutch while
changing gears to avoid dam-
aging the engine, transmission,
and drive train, which are not
designed to withstand the
shock of forced shifting.
@
1. Shift pedal
N. Neutral positionXVS650
1. Shift pedal
N. Neutral positionXVS650A
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6
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 .................................... 6-25Checking 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
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PERIODIC MAINTENANCE AND MINOR REPAIR
6-2
6
EAU03685
Periodic maintenance and lubrication chart
NOTE:_ l
The annual checks must be performed every year, except if a kilometer-based maintenance is performed instead.
l
From 50,000 km, repeat the maintenance intervals starting from 10,000 km.
l
Items marked with an asterisk should be performed by a Yamaha dealer as they require special tools, data and techni-
cal skills.
_CP-03ENO. ITEM CHECK OR MAINTENANCE JOBODOMETER READING (´1,000 km)
ANNUAL
CHECK
1 10203040
1
*Fuel line• Check fuel hoses for cracks or damage.ÖÖÖÖ Ö
2*Fuel filter• Check condition.ÖÖ
3 Spark plugs• Check condition.
• Clean and regap.ÖÖ
• Replace.ÖÖ
4*Valves• Check valve clearance.
•Adjust.ÖÖÖÖ
5 Air filter element•Clean.ÖÖ
• Replace.ÖÖ
6Clutch• Check operation.
•Adjust.ÖÖÖÖÖ
7*Front brake• Check operation, fluid level and vehicle for fluid leakage.
(See NOTE on page 6-4.)ÖÖÖÖÖ Ö
• Replace brake pads. Whenever worn to the limit
8*Rear brake• Check operation and adjust brake pedal freeplay.ÖÖÖÖÖ Ö
• Replace brake shoes. Whenever worn to the limit
9*Brake hose• Check for cracks or damage.ÖÖÖÖ Ö
• Replace. (See NOTE on page 6-4.) Every 4 years
E_5bn_Periodic.fm Page 2 Thursday, December 14, 2000 1:31 PM

PERIODIC MAINTENANCE AND MINOR REPAIR
6-11
69. Add the specified amount of the
recommended oil, and then install
and tighten the oil filler cap.
EC000072
CAUTION:_ l
In order to prevent clutch slip-
page (since the engine oil also
lubricates the clutch), do not
mix any chemical additives with
the oil or use oils of a higher
grade than “CD”. In addition, do
not use oils labeled “ENERGY
CONSERVING II” or higher.
l
Make sure that no foreign mate-
rial enters the crankcase.
_10. Start the engine, and then let it idle
for several minutes while checking
it for oil leakage. If oil is leaking,
immediately turn the engine off
and check for the cause.
11. Turn the engine off, and then
check the oil level and correct it if
necessary.
EAU02943*
Final gear oil The final gear case must be checked
for oil leakage before each ride. If any
leakage is found, have a Yamaha deal-
er check and repair the motorcycle. In
addition, the final gear oil level must be
checked and the oil changed as follows
at the intervals specified in the periodic
maintenance and lubrication chart.
EW000066
WARNING
@ l
Make sure that no foreign mate-
rial enters the final gear case.
l
Make sure that no oil gets on
the tire or wheel.
@To check the final gear oil level
1. Place the motorcycle on a level
surface and hold it in an upright
position. Recommended engine oil:
See page 8-1.
Oil quantity:
Without oil filter element
replacement:
2.6 L
With oil filter element
replacement:
2.8 L
Total amount (dry engine):
3.2 L
E_5bn.book Page 11 Wednesday, October 4, 2000 7:51 PM

PERIODIC MAINTENANCE AND MINOR REPAIR
6-19
6
EAU00685
Spoke wheels To maximize the performance, durabil-
ity, and safe operation of your motor-
cycle, note the following points
regarding the specified wheels.l
The wheel rims should be checked
for cracks, bends or warpage, and
the spokes for looseness or dam-
age before each ride. If any dam-
age is found, have a Yamaha
dealer replace the wheel. Do not
attempt even the smallest repair to
the wheel. A deformed or cracked
wheel must be replaced.
l
The wheel should be balanced
whenever either the tire or wheel
has been changed or replaced. An
unbalanced wheel can result in
poor performance, adverse han-
dling characteristics, and a short-
ened tire life.
l
Ride at moderate speeds after
changing a tire since the tire sur-
face must first be “broken in” for it
to develop its optimal characteris-
tics.
EAU00694
Adjusting the clutch lever free
play The clutch lever free play should mea-
sure 10–15 mm as shown. Periodically
check the clutch lever free play and, if
necessary, adjust it as follows.
1. Loosen the locknut at the clutch
lever.
2. To increase the clutch lever free
play, turn the adjusting bolt in di-
rection
a. To decrease the clutch
lever free play, turn the adjusting
bolt in direction
b.3. If the specified clutch lever free
play could be obtained as de-
scribed above, tighten the locknut
and skip the rest of the procedure,
otherwise proceed as follows.
4. Fully turn the adjusting bolt at the
clutch lever in direction
a to loos-
en the clutch cable.
5. Loosen the locknut at the crank-
case.
6. To increase the clutch lever free
play, turn the adjusting nut in di-
rection
a. To decrease the clutch
lever free play, turn the adjusting
nut in direction
b.1. Locknut
2. Clutch lever free play adjusting bolt
c. Clutch lever free play
1. Clutch lever free play adjusting nut
2. Locknut
E_5bn.book Page 19 Wednesday, October 4, 2000 7:51 PM

PERIODIC MAINTENANCE AND MINOR REPAIR
6-20
6 7. Tighten the locknut at the clutch
lever and the crankcase.
EAU00696
Adjusting the brake lever free
play The brake lever free play should mea-
sure 10–15 mm as shown. Periodically
check the brake lever free play and, if
necessary, adjust it as follows.1. Loosen the locknut at the brake
lever.
2. To increase the brake lever free
play, turn the adjusting bolt in di-
rection
a. To decrease the brake
lever free play, turn the adjusting
bolt in direction
b.
3. Tighten the locknut.1. Locknut
2. Brake lever free play adjusting bolt
a. Brake lever free play
E_5bn.book Page 20 Wednesday, October 4, 2000 7:51 PM

PERIODIC MAINTENANCE AND MINOR REPAIR
6-26
6
EAU03370
Checking and lubricating the
brake and shift pedals The operation of the brake and shift
pedals should be checked before each
ride, and the pedal pivots should be lu-
bricated if necessary.
EAU03164
Checking and lubricating the
brake and clutch levers The operation of the brake and clutch
levers should be checked before each
ride, and the lever pivots should be lu-
bricated if necessary. Recommended lubricant:
Throttle cable:
Engine oil
Throttle grip housing and grip:
Lithium-soap-based grease
(all-purpose grease)
Recommended lubricant:
Lithium-soap-based grease
(all-purpose grease)
Recommended lubricant:
Lithium-soap-based grease
(all-purpose grease)
E_5bn.book Page 26 Wednesday, October 4, 2000 7:51 PM

SPECIFICATIONS
8-2
8
Quantity
Without oil filter element
replacement 2.6 L
With oil filter element
replacement 2.8 L
Total amount (dry engine) 3.2 L
Final gear oil
Type Hypoid gear oil SAE 80
(API GL4) or multigrade hypoid
gear oil SAE 80W-90
Final gear case capacity 0.19 L
Air filterDry type element
Fuel
Type Regular unleaded gasoline
Fuel tank capacity 16 L
Reserve amount 3 L
Carburetor
Manufacturer MIKUNI
Model ´ quantity BDS28 ´ 2
CAUTION:Be sure to use motor oils that do not contain anti-friction
modifiers. Passenger car motor oils (often labeled
“ENERGY CONSERVING II”) contain anti-friction additives
which will cause clutch and/or starter clutch slippage, result-
ing in reduced component life and poor engine performance.
Spark plug
Manufacturer/model NGK / DPR7EA-9 or
DENSO / X22EPR-U9
Gap 0.8– 0.9 mm
Clutch typeWet, multiple-disc
Transmission
Primary reduction system Spur gear
Primary reduction ratio 1.789
Secondary reduction system Shaft drive
Secondary reduction ratio 3.070
Transmission type Constant-mesh 5-speed
Operation Left foot
Gear ratio 1st 2.714
2nd 1.900
3rd 1.458
4th 1.167
5th 0.967
Chassis
Frame type Double cradle
Caster angle 35°
Tr a i l
XVS650 153 mm
XVS650A 145 mm
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