2002 YAMAHA XVS650A brake pads

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
6-2
6
EAU03685
Periodic maintenance and lubrication chart
NOTE:_

The annual checks must be performed every year, except if a kilometer-based maintenance is performed instead.


From 50,000 km, repeat the maintenance intervals starting from 10,000 km.


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 lineCheck fuel hoses for cracks or damage.√√√√ √
2*Fuel filterCheck condition.√√
3 Spark plugsCheck condition.
Clean and regap.√√
Replace.√√
4*ValvesCheck valve clearance.
Adjust.√√√√
5 Air filter elementClean.√√
Replace.√√
6ClutchCheck operation.
Adjust.√√√√√
7*Front brakeCheck operation, fluid level and vehicle for fluid leakage.
(See NOTE on page 6-4.)√√ √ √ √ √
Replace brake pads. Whenever worn to the limit
8*Rear brakeCheck operation and adjust brake pedal free play.√√√√√ √
Replace brake shoes. Whenever worn to the limit
9*Brake hoseCheck for cracks or damage.√√√√ √
Replace. (See NOTE on page 6-4.) Every 4 years
U5SCE0.book Page 2 Thursday, June 7, 2001 11:24 AM

PERIODIC MAINTENANCE AND MINOR REPAIR
6-23
6
EAU00720
Checking the front brake pads
and rear brake shoes The front brake pads and the rear
brake shoes must be checked for wear
at the intervals specified in the periodic
maintenance and lubrication chart.
EAU03938
Front brake pads
Each front brake pad is provided with
wear indicator grooves, which allow
you to check the brake pad wear with-
out having to disassemble the brake.
To check the brake pad wear, check
the wear indicator grooves. If a brake
pad has worn to the point that the wear
indicator grooves have almost disap-
peared, have a Yamaha dealer replace
the brake pads as a set.
EAU00727
Rear brake shoes
The rear brake is provided with a wear
indicator, which allows you to check the
brake shoe wear without having to dis-
assemble the brake. To check the
brake shoe wear, check the position of
the wear indicator while applying the
brake. If a brake shoe has worn to the
point that the wear indicator reaches
the wear limit line, have a Yamaha
dealer replace the brake shoes as a
set.
1. Brake pad wear indicator groove (× 3)Front
1. Brake shoe wear limit line
2. Brake shoe wear indicatorRear
U5SCE0.book Page 23 Thursday, June 7, 2001 11:24 AM

PERIODIC MAINTENANCE AND MINOR REPAIR
6-24
6
EAU03294
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:


When checking the fluid level,
make sure that the top of the brake
fluid reservoir is level.


Use only the recommended quali-
ty brake fluid, otherwise the rubber
seals may deteriorate, causing
leakage and poor braking perfor-
mance.


Refill with the same type of brake
fluid. Mixing fluids may result in a
harmful chemical reaction and
lead to poor braking performance.


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.


Brake fluid may deteriorate paint-
ed surfaces or plastic parts. Al-
ways clean up spilled fluid
immediately.


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. Minimum level markFront
Recommended brake fluid: DOT 4
U5SCE0.book Page 24 Thursday, June 7, 2001 11:24 AM

PERIODIC MAINTENANCE AND MINOR REPAIR
6-35
6
EAU03737
Front wheel To remove the front wheel
EW000122
WARNING
_

It is advisable to have a Yamaha
dealer service the wheel.


Securely support the motor-
cycle 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.
3. Remove the rubber cap, and then
loosen the wheel axle.
4. Lift the front wheel off the ground
according to the procedure on
page 6-34.
5. 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. _
EAU03885
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. Rubber cap
2. Wheel axle
3. Front wheel axle pinch bolt
1. Speedometer gear unit
2. Speedometer cable
U5SCE0.book Page 35 Thursday, June 7, 2001 11:24 AM

10-INDEXAAir filter element, cleaning ...................... 6-13
Anti-theft alarm ........................................3-3BBattery ................................................... 6-29
Brake and clutch levers, checking
and lubricating ..................................... 6-26
Brake and shift pedals, checking
and lubricating ..................................... 6-26
Brake fluid, changing ............................. 6-25
Brake fluid level, checking...................... 6-24
Brake lever...............................................3-6
Brake lever free play, adjusting .............. 6-20
Brake light switch (rear), adjusting ......... 6-22
Brake pads and shoes, checking ........... 6-23
Brake pedal..............................................3-6
Brake pedal position and free play,
adjusting .............................................. 6-21CCables, checking and lubricating............ 6-25
Carburetors, adjusting............................ 6-14
Care.........................................................7-1
Clutch lever ..............................................3-5
Clutch lever free play, adjusting ............. 6-19
Conversion table ......................................8-6DDimmer switch .........................................3-4EEngine break-in........................................5-5
Engine oil and oil filter element.................6-9
Engine stop switch ...................................3-4
Engine trouble warning light .................... 3-2FFinal gear oil .......................................... 6-12
Front fork, checking ............................... 6-27
Fuel ......................................................... 3-7
Fuel cock ................................................. 3-9
Fuel consumption, tips for reducing ......... 5-4
Fuel tank cap ........................................... 3-7
Fuses, replacing .................................... 6-31HHandlebar switches ................................. 3-3
Headlight bulb, replacing ....................... 6-32
Helmet holder ........................................ 3-13
High beam indicator light ......................... 3-2
Horn switch ............................................. 3-4IIdentification numbers ............................. 9-1
Idling speed, adjusting ........................... 6-15
Ignition circuit cut-off system.................. 3-17
Indicator and warning lights ..................... 3-2KKey identification number ........................ 9-1LLight switch.............................................. 3-4
Luggage strap holders ........................... 3-16MMain switch/steering lock ......................... 3-1
Model label .............................................. 9-2
NNeutral indicator light ...............................3-2PPanels, removing and installing ................6-5
Parking.....................................................5-5
Part locations ...........................................2-1
Pass switch ..............................................3-4
Periodic maintenance and
lubrication chart .....................................6-2
Pre-operation check list ............................4-1SSafety information ....................................1-1
Seats (XVS650) .....................................3-11
Passenger seat.................................3-11
Rider seat .........................................3-11
Seats (XVS650A) ...................................3-12
Passenger seat.................................3-12
Rider seat .........................................3-12
Shifting .....................................................5-3
Shift pedal (XVS650)................................3-5
Shift pedal (XVS650A) .............................3-5
Shift points (for Switzerland only) .............5-4
Shock absorber assembly, adjusting ......3-15
Sidestand ...............................................3-17
Sidestand, checking and lubricating .......6-27
Spark plugs, checking ..............................6-7
Specifications ...........................................8-1
Speedometer unit.....................................3-3
Starter (choke) knob...............................3-10
Starting a warm engine ............................5-2
Starting the engine ...................................5-1
Start switch ..............................................3-4
U5SCE0.book Page 1 Thursday, June 7, 2001 11:24 AM