2002 YAMAHA XVS650A light

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:@

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.


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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OPERATION AND IMPORTANT RIDING POINTS
5-4
5
EAU02941
Recommended shift points
(for Switzerland only) The recommended shift points during
acceleration are shown in the table be-
low.CF-01ENOTE:_ When shifting down two gears at a
time, reduce the speed accordingly
(e.g., down to 35 km/h when shifting
from 4th to 2nd gear). _
EAU00424
Tips for reducing fuel
consumption Fuel consumption depends largely on
your riding style. Consider the following
tips to reduce fuel consumption:

Thoroughly warm up the engine.


Turn the starter (choke) off as
soon as possible.


Shift up swiftly, and avoid high en-
gine speeds during acceleration.


Do not rev the engine while shift-
ing down, and avoid high engine
speeds with no load on the engine.


Turn the engine off instead of let-
ting it idle for an extended length
of time (e.g., in traffic jams, at traf-
fic lights or at railroad crossings).
Shift point
(km/h)
1st→2nd
2nd→3rd
3rd→4th
4th→5th23
36
50
60
U5SCE0.book Page 4 Thursday, June 7, 2001 11:24 AM

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 ...................................................... 6-12
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
U5SCE0.book Page 1 Thursday, June 7, 2001 11:24 AM

PERIODIC MAINTENANCE AND MINOR REPAIR
6-4
6
EAU03541
NOTE:@

The air filter needs more frequent service if you are riding in unusually wet or dusty areas.


Hydraulic brake service
Regularly check and, if necessary, correct the brake fluid level.
Every two years replace the internal components of the brake master cylinder and caliper, and change the brake fluid.
Replace the brake hoses every four years and if cracked or damaged.
@25 Moving parts and cablesLubricate.√√√√ √
26
*Lights, signals and
switchesCheck operation.
Adjust headlight beam.√√√√√ √ NO. ITEM CHECK OR MAINTENANCE JOBODOMETER READING (×1,000 km)
ANNUAL
CHECK
1 10203040
U5SCE0.book Page 4 Thursday, June 7, 2001 11:24 AM

PERIODIC MAINTENANCE AND MINOR REPAIR
6-8
6 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.
To install a spark plug
1. Measure the spark plug gap with a
wire thickness gauge and, if nec-
essary, adjust the gap to specifica-
tion.
2. Clean the surface of the spark
plug gasket and its mating sur-
face, and then wipe off any grime
from the spark plug threads.
3. Install the spark plug with the
spark plug wrench, and then tight-
en it to the specified torque.
1. Spark plug wrench
Specified spark plug:
DPR7EA-9 (NGK) or
X22EPR-U9 (DENSO)
a. Spark plug gapSpark plug gap:
0.8–0.9 mm
U5SCE0.book Page 8 Thursday, June 7, 2001 11:24 AM

PERIODIC MAINTENANCE AND MINOR REPAIR
6-9
6
NOTE:@ If a torque wrench is not available when
installing a spark plug, a good estimate
of the correct torque is 1/4–1/2 turn
past finger tight. However, the spark
plug should be tightened to the speci-
fied torque as soon as possible. @4. Install the spark plug cap.
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. Tightening torque:
Spark plug:
18 Nm (1.8 m·kgf)1. Engine oil level check window
2. Maximum level mark
3. Minimum level mark
4. Engine oil filler capLeft side
U5SCE0.book Page 9 Thursday, June 7, 2001 11:24 AM

PERIODIC MAINTENANCE AND MINOR REPAIR
6-12
6
EAU04083
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
_

Make sure that no foreign mate-
rial enters the final gear case.


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.
NOTE:_

The final gear oil level must be
checked on a cold engine.


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.
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·kgf)
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PERIODIC MAINTENANCE AND MINOR REPAIR
6-13
6
NOTE:_ GL4 is a quality rating. Hypoid gear oils
rated GL5 or GL6 may also be used. _5. Install and tighten the oil filler bolt.
6. Check the final gear case for oil
leakage. If oil is leaking, check for
the cause.
EAU00586*
Cleaning the air filter element The air filter element should be cleaned
at the intervals specified in the periodic
maintenance and lubrication chart.
Clean the air filter element more fre-
quently if you are riding in unusually
wet or dusty areas.
1. Remove the air filter case cover by
removing the screws.
2. Pull the air filter element out.3. Lightly tap the air filter element to
remove most of the dust and dirt,
and then blow the remaining dirt
out with compressed air as shown.
If the air filter element is damaged,
replace it. Recommended final gear oil:
Hypoid gear oil SAE 80 (API GL4)
or multi-grade hypoid gear oil
SAE 80W-90
Oil quantity:
0.19 L1. Air filter case cover
2. Screw (× 3)
1. Air filter element
U5SCE0.book Page 13 Thursday, June 7, 2001 11:24 AM