2001 YAMAHA XVS650 brake

PERIODIC MAINTENANCE AND MINOR REPAIR
6-24
6
EAU03776
Checking the brake fluid level Insufficient brake fluid may allow air to
enter the brake system, possibly caus-
ing it to become ineffective.
Before riding, check that the brake fluid
is above the minimum level mark and
replenish if necessary. A low brake flu-
id level may indicate worn brake pads
and/or brake system leakage. If the
brake level is low, be sure to check the
brake pads for wear and the brake sys-
tem for leakage.Observe these precautions:
l
When checking the fluid level,
make sure that the top of the brake
fluid reservoir is level.
l
Use only the recommended quali-
ty brake fluid, otherwise the rubber
seals may deteriorate, causing
leakage and poor braking perfor-
mance.
l
Refill with the same type of brake
fluid. Mixing fluids may result in a
harmful chemical reaction and
lead to poor braking performance.
l
Be careful that water does not en-
ter the brake fluid reservoir when
refilling. Water will significantly
lower the boiling point of the fluid
and may result in vapor lock.
l
Brake fluid may deteriorate paint-
ed surfaces or plastic parts. Al-
ways clean up spilled fluid
immediately.
l
As the brake pads wear, it is nor-
mal for the brake fluid level to
gradually go down. However, if the
brake fluid level goes down sud-
denly, have a Yamaha dealer
check the cause.
1. Front brake reservoir
2. Minimum level markFront
Recommended brake fluid: DOT 4
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PERIODIC MAINTENANCE AND MINOR REPAIR
6-25
6
EAU03238
Changing the brake fluid Have a Yamaha dealer change the
brake fluid at the intervals specified in
the periodic maintenance and lubrica-
tion chart. In addition, have the oil seals
of the brake master cylinder and caliper
as well as the brake hose replaced at
the intervals listed below or whenever
they are damaged or leaking.l
Oil seals: Replace every two
years.
l
Brake hose: Replace every four
years.
EAU02962
Checking and lubricating the
cables The operation of all control cables and
the condition of the cables should be
checked before each ride, and the ca-
bles and cable ends should be lubricat-
ed if necessary. If a cable is damaged
or does not move smoothly, have a
Yamaha dealer check or replace it.
EW000112
WARNING
@ Damage to the outer sheath may in-
terfere with proper cable operation
and will cause the inner cable to
rust. Replace a damaged cable as
soon as possible to prevent unsafe
conditions. @
EAU03764
Checking and lubricating the
throttle grip and cable The operation of the throttle grip and
the condition of the throttle cable
should be checked before each ride,
and the cable should be lubricated or
replaced if necessary.NOTE:_ Since the throttle grip must be removed
to access the throttle cable end, the
throttle grip and the cable should al-
ways be lubricated at the same time. _1. Remove the throttle grip by remov-
ing the screws.
2. Hold up the throttle cable, and
then apply several drops of oil to
the cable, allowing it to trickle into
the sheaths.
3. Grease the inside of the throttle
grip housing.
4. Grease the metal-to-metal contact
surface of the throttle grip, and
then install the grip by installing
the screws. Recommended lubricant:
Engine oil
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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

PERIODIC MAINTENANCE AND MINOR REPAIR
6-28
6 To check the operation
1. Place the motorcycle on a level
surface and hold it in an upright
position.
2. While applying the front brake,
push down hard on the handle-
bars several times to check if the
front fork compresses and re-
bounds smoothly.
EC000098
CAUTION:@ If any damage is found or the front
fork does not operate smoothly,
have a Yamaha dealer check or re-
pair it. @
EAU00794
Checking the steering Worn or loose steering bearings may
cause danger. Therefore, the operation
of the steering must be checked as fol-
lows at the intervals specified in the pe-
riodic maintenance and lubrication
chart.
1. Place a stand under the engine to
raise the front wheel off the
ground.
EW000115
WARNING
@ Securely support the motorcycle so
that there is no danger of it falling
over. @
2. Hold the lower ends of the front
fork legs and try to move them for-
ward and backward. If any free
play can be felt, have a Yamaha
dealer check or repair the steer-
ing.
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PERIODIC MAINTENANCE AND MINOR REPAIR
6-33
6
EC000105
CAUTION:@ Do not touch the glass part of the
headlight bulb to keep it free from
oil, otherwise the transparency of
the glass, the luminosity of the bulb,
and the bulb life will be adversely af-
fected. Thoroughly clean off any dirt
and fingerprints on the headlight
bulb using a cloth moistened with
alcohol or thinner. @5. Install the bulb cover, and then
connect the coupler.
6. Install the headlight unit by install-
ing the screws.
7. Have a Yamaha dealer adjust the
headlight beam if necessary.
EAU00855
Replacing a turn signal light
bulb or the tail/brake light
bulb 1. Remove the lens by removing the
screws.
2. Remove the defective bulb by
pushing it in and turning it counter-
clockwise.3. Insert a new bulb into the socket,
push it in, and then turn it clock-
wise until it stops.
4. Install the lens by installing the
screws.
EC000108
CAUTION:@ Do not overtighten the screws, oth-
erwise the lens may break. @
1. Screw (´ 2)
1. Screw (´ 2)XVS650
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PERIODIC MAINTENANCE AND MINOR REPAIR
6-35
6
EAU03239
Front wheel To remove the front wheel
EW000122
WARNING
@ l
It is advisable to have a Yamaha
dealer service the wheel.
l
Securely support the motorcycle
so that there is no danger of it
falling over.
@1. Disconnect the speedometer ca-
ble from the front wheel.2. Loosen the front wheel axle pinch
bolt, then the wheel axle.
3. Lift the front wheel off the ground
according to the procedure on
page 6-34.
4. Pull the wheel axle out, and then
remove the wheel.
ECA00048
CAUTION:@ Do not apply the brake after the
wheel has been removed together
with the brake disc, otherwise the
brake pads will be forced shut. @
EAU01394
To install the front wheel
1. Install the speedometer gear unit
into the wheel hub so that the pro-
jections mesh with the slots.
2. Lift the wheel up between the fork
legs.NOTE:@ Make sure that there is enough space
between the brake pads before insert-
ing the brake disc and that the slot in
the speedometer gear unit fits over the
retainer on the fork leg. @3. Insert the wheel axle.
1. Speedometer cable
1. Wheel axle
2. Front wheel axle pinch bolt
1. Speedometer gear unit
2. Speedometer cable
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PERIODIC MAINTENANCE AND MINOR REPAIR
6-36
6 4. Lower the front wheel so that it is
on the ground.
5. Push down hard on the handlebar
several times to check for proper
fork operation.
6. Tighten the wheel axle to the
specified torque.
7. Install the front wheel axle pinch
bolt, and then tighten it to the
specified torque.
8. Connect the speedometer cable.
EAU01350
Rear wheel To remove the rear wheel
EW000122
WARNING
@ l
It is advisable to have a Yamaha
dealer service the wheel.
l
Securely support the motorcycle
so that there is no danger of it
falling over.
@1. Loosen the axle nut.
2. Disconnect the brake torque rod
from the brake shoe plate by re-
moving the bolt.
3. Loosen the brake torque rod bolt
at the swingarm.
4. Remove the brake pedal free play
adjusting nut, and then disconnect
the brake rod from the brake cam-
shaft lever.
5. Remove panel A. (See page 6-5
for panel removal and installation
procedures.) Tightening torque:
Wheel axle:
59 Nm (5.9 m·kg)
Tightening torque:
Front wheel axle pinch bolt:
20 Nm (2.0 m·kg)
1. Brake pedal free play adjusting nut
2. Brake camshaft lever
3. Brake rod
4. Bolt (shoe plate)
5. Brake torque rod
6. Bolt (swingarm)
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PERIODIC MAINTENANCE AND MINOR REPAIR
6-37
66. Remove the bolts that secure the
final gear case to the swingarm.
7. Lift the rear wheel off the ground
according to the procedure on
page 6-34.
8. While supporting the drive shaft,
pull the rear wheel back to remove
the following parts as an assem-
bly: wheel, wheel axle, final gear
case, and drive shaft.
NOTE:@ Make sure to support the drive shaft as
it is being pulled out. @
EAU01563
To install the rear wheel
1. Install the rear wheel, wheel axle,
final gear case, and drive shaft by
pushing the wheel forward and
guiding the drive shaft into the
middle gear universal joint.
2. Install the final gear case bolts,
and then tighten them to the spec-
ified torque.3. Install the brake rod onto the brake
camshaft lever, and then install
the brake pedal free play adjusting
nut onto the brake rod.
4. Install the brake torque rod bolts,
and then tighten them to the spec-
ified torque.
5. Install the panel.
6. Lower the rear wheel so that it is
on the ground.
7. Tighten the axle nut to the speci-
fied torque.
8. Adjust the brake pedal free play.
(See page 6-21 for brake pedal
free play adjustment procedures.)
1. Bolt (´ 4)
2. Final gear case
3. Axle nut
1. Middle gear universal joint
2. Drive shaft
Tightening torque:
Final gear case bolt:
90 Nm (9.0 m·kg)
Tightening torque:
Brake torque rod bolt:
20 Nm (2.0 m·kg)
Tightening torque:
Axle nut:
92 Nm (9.2 m·kg)
E_5bn.book Page 37 Wednesday, October 4, 2000 7:51 PM