2001 YAMAHA XVS650A check engine

PERIODIC MAINTENANCE AND MINOR REPAIR
6-3
6
10
*Wheels• Check runout, spoke tightness and for damage.
• Tighten spokes if necessary.ÖÖÖÖ
11*Tires• Check tread depth and for damage.
• Replace if necessary.
• Check air pressure.
• Correct if necessary.ÖÖÖÖ
12*Wheel bearings• Check bearing for looseness or damage.ÖÖÖÖ
13*Swingarm• Check operation and for excessive play.ÖÖÖÖ
• Lubricate with molybdenum disulfide grease. Every 50,000 km
14*Steering bearings• Check bearing play and steering for roughness.ÖÖÖÖÖ
• Lubricate with lithium-soap-based grease. Every 20,000 km
15*Chassis fasteners• Make sure that all nuts, bolts and screws are properly tightened.ÖÖÖÖ Ö
16 Sidestand• Check operation.
• Lubricate.ÖÖÖÖ Ö
17*Sidestand switch• Check operation.ÖÖÖÖÖ Ö
18*Front fork• Check operation and for oil leakage.ÖÖÖÖ
19*Rear shock absorber
assembly• Check operation and shock absorber for oil leakage.ÖÖÖÖ
20*Carburetors• Check starter (choke) operation.
• Adjust engine idling speed and synchronization.ÖÖÖÖÖ Ö
21 Engine oil• Change.ÖÖÖÖÖ Ö
22 Engine oil filter element•Replace.ÖÖÖ
23 Final gear oil• Check oil level and vehicle for oil leakage.ÖÖ Ö
• Change.ÖÖÖ
24*Front and rear brake
switches• Check operation.ÖÖÖÖÖ Ö
25 Moving parts and cables• Lubricate.ÖÖÖÖ Ö NO. ITEM CHECK OR MAINTENANCE JOBODOMETER READING (´1,000 km)
ANNUAL
CHECK
1 10203040
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PERIODIC MAINTENANCE AND MINOR REPAIR
6-7
6
EAU03329
Checking the spark plugs The spark plugs are important engine
components, which are easy to check.
Since heat and deposits will cause any
spark plug to slowly erode, the spark
plugs should be removed and checked
in accordance with the periodic mainte-
nance and lubrication chart. In addition,
the condition of the spark plugs can re-
veal the condition of the engine.To remove a spark plug
1. Remove the spark plug cap.
2. Remove the spark plug as shown,
with the spark plug wrench includ-
ed in the owner’s tool kit.
To check the spark plugs
1. Check that the porcelain insulator
around the center electrode on
each spark plug is a medium-to-
light tan (the ideal color when the
motorcycle is ridden normally).
2. Check that all spark plugs installed
in the engine have the same color.
NOTE:@ If any spark plug shows a distinctly dif-
ferent color, the engine could be defec-
tive. Do not attempt to diagnose such
problems yourself. Instead, have a
Yamaha dealer check the motorcycle. @3. Check each spark plug for elec-
trode erosion and excessive car-
bon or other deposits, and replace
it if necessary.
1. Spark plug cap
1. Spark plug wrench
Specified spark plug:
DPR7EA-9 (NGK) or
X22EPR-U9 (DENSO)
E_5bn.book Page 7 Wednesday, October 4, 2000 7:51 PM

PERIODIC MAINTENANCE AND MINOR REPAIR
6-9
6
EAU03835
Engine oil and oil filter
element The engine oil level should be checked
before each ride. In addition, the oil
must be changed and the oil filter ele-
ment replaced at the intervals specified
in the periodic maintenance and lubri-
cation chart.
To check the engine oil level
1. Place the motorcycle on a level
surface and hold it in an upright
position.NOTE:_ Make sure that the motorcycle is posi-
tioned straight up when checking the oil
level. A slight tilt to the side can result in
a false reading. _2. Start the engine, warm it up for
several minutes, and then turn it
off.3. Wait a few minutes until the oil set-
tles, and then check the oil level
through the check window located
at the bottom-left side of the crank-
case.
NOTE:_ The engine oil should be between the
minimum and maximum level marks. _4. If the engine oil is below the mini-
mum level mark, add sufficient oil
of the recommended type to raise
it to the correct level.To change the engine oil (with or
without oil filter element replace-
ment)
1. Start the engine, warm it up for
several minutes, and then turn it
off.
2. Place an oil pan under the engine
to collect the used oil.
3. Remove the engine oil filler cap
and drain bolt to drain the oil from
the crankcase.1. Engine oil level check window
2. Maximum level mark
3. Minimum level mark
4. Engine oil filler capLeft side
1. Engine oil drain bolt
2. Oil pan
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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
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PERIODIC MAINTENANCE AND MINOR REPAIR
6-12
6
NOTE:@ l
The final gear oil level must be
checked on a cold engine.
l
Make sure that the motorcycle is
positioned straight up when
checking the oil level. A slight tilt to
the side can result in a false read-
ing.
@2. Remove the oil filler bolt, and then
check the oil level in the final gear
case.
NOTE:@ The oil level should be at the brim of
the filler hole. @3. If the oil is below the brim of the fill-
er hole, add sufficient oil of the rec-
ommended type to raise it to the
correct level.
To change the final gear oil
1. Place an oil pan under the final
gear case to collect the used oil.
2. Remove the oil filler bolt and drain
bolt to drain the oil from the final
gear case.
3. Install the final gear oil drain bolt,
and then tighten it to the specified
torque.
4. Add the recommended final gear
oil to the brim of the filler hole.
NOTE:@ GL4 is a quality rating. Hypoid gear oils
rated GL5 or GL6 may also be used. @5. Install and tighten the filler bolt to
the specified torque.
6. Check the final gear case for oil
leakage. If oil is leaking, check for
the cause.
1. Final gear oil drain bolt
2. Final gear oil filler bolt
3. Correct oil level
Tightening torque:
Final gear oil drain bolt:
23 Nm (2.3 m·kg)
Recommended final gear oil:
See page 8-2.
Oil quantity:
0.19 L
Tightening torque:
Final gear oil filler bolt:
23 Nm (2.3 m·kg)
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PERIODIC MAINTENANCE AND MINOR REPAIR
6-15
6
EAU01168
Adjusting the engine idling
speed The engine idling speed must be
checked and, if necessary, adjusted as
follows at the intervals specified in the
periodic maintenance and lubrication
chart.NOTE:@ A diagnostic tachometer is needed to
make this adjustment. @1. Attach the tachometer to the spark
plug lead.
2. Start the engine and warm it up for
several minutes at 1,000–
2,000 r/min while occasionally rev-
ving it to 4,000–5,000 r/min.NOTE:@ The engine is warm when it quickly re-
sponds to the throttle. @
3. Check the engine idling speed
and, if necessary, adjust it to spec-
ification by turning the throttle stop
screw. To increase the engine
idling speed, turn the screw in di-
rection
a. To decrease the engine
idling speed, turn the screw in di-
rection
b.NOTE:@ If the specified idling speed cannot be
obtained as described above, have a
Yamaha dealer make the adjustment. @
EAU00635
Adjusting the throttle cable
free play The throttle cable free play should
measure 4–6 mm at the throttle grip.
Periodically check the throttle cable
free play and, if necessary, have a
Yamaha dealer adjust it.
1. Throttle stop screw
Engine idling speed:
1,150–1,250 r/min
a. Throttle cable free play
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PERIODIC MAINTENANCE AND MINOR REPAIR
6-16
6
EAU00637
Adjusting the valve clearance The valve clearance changes with use,
resulting in improper air-fuel mixture
and/or engine noise. To prevent this
from occurring, the valve clearance
must be adjusted by a Yamaha dealer
at the intervals specified in the periodic
maintenance and lubrication chart.
EAU03362
Tires To maximize the performance, durabil-
ity, and safe operation of your motor-
cycle, note the following points
regarding the specified tires.
Tire air pressure
The tire air pressure should be
checked and, if necessary, adjusted
before each ride.
EW000082
WARNING
@ l
The tire air pressure must be
checked and adjusted on cold
tires (i.e., when the temperature
of the tires equals the ambient
temperature).
l
The tire air pressure must be
adjusted in accordance with the
riding speed and with the total
weight of rider, passenger, car-
go, and accessories approved
for this model.
@XVS650CE-01E
CE-07E
1. Tire sidewall
a. Tire tread depth
Tire air pressure
(measured on cold tires)
Load* Front Rear
Up to 90 kg200 kPa
(2.00 kg/cm
2,
2.00 bar)225 kPa
(2.25 kg/cm
2,
2.25 bar)
90 kg–maximum200 kPa
(2.00 kg/cm
2,
2.00 bar)250 kPa
(2.50 kg/cm
2,
2.50 bar)
Maximum load* 180 kg
* Total weight of rider, passenger, cargo and
accessories
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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
E_5bn.book Page 25 Wednesday, October 4, 2000 7:51 PM