2004 YAMAHA XVS650A brake pads

TABLE OF CONTENTSSAFETY INFORMATION ..................1-1
DESCRIPTION ..................................2-1
Left view ..........................................2-1
Right view ........................................2-2
Controls and instruments.................2-3
INSTRUMENT AND CONTROL
FUNCTIONS.......................................3-1
Immobilizer system .........................3-1
Main switch/steering lock ................3-2
Indicator and warning lights ............3-3
Speedometer unit ...........................3-5
Anti-theft alarm (optional) ...............3-5
Handlebar switches ........................3-5
Clutch lever .....................................3-7
Shift pedal .......................................3-7
Brake lever .....................................3-7
Brake pedal ....................................3-8
Fuel tank cap ..................................3-8
Fuel .................................................3-9
Catalytic converter ........................3-10
Fuel cock ......................................3-10
Starter (choke) knob ......................3-11
Seats ............................................3-11
Helmet holder ...............................3-12
Storage compartment ...................3-13
Adjusting the shock absorber
assembly ...................................3-13
Luggage strap holders ..................3-14
Sidestand ......................................3-15Ignition circuit cut-off system ........ 3-15
PRE-OPERATION CHECKS............. 4-1
Pre-operation check list .................. 4-2
OPERATION AND IMPORTANT
RIDING POINTS................................. 5-1
Starting a cold engine .................... 5-1
Starting a warm engine .................. 5-2
Shifting ........................................... 5-2
Tips for reducing fuel
consumption ............................... 5-3
Engine break-in .............................. 5-4
Parking ........................................... 5-4
PERIODIC MAINTENANCE AND
MINOR REPAIR................................. 6-1
Owner’s tool kit ............................... 6-1
Periodic maintenance and
lubrication chart .......................... 6-2
Removing and installing panels ..... 6-5
Checking the spark plugs ............... 6-6
Engine oil and oil filter element ...... 6-7
Final gear oil ................................. 6-10
Cleaning the air filter element ...... 6-11
Adjusting the carburetors ............. 6-12
Adjusting the engine idling
speed ........................................ 6-12
Adjusting the throttle cable free
play ........................................... 6-13
Adjusting the valve clearance ...... 6-13Tires ............................................. 6-14
Spoke wheels .............................. 6-16
Adjusting the clutch lever free
play ........................................... 6-16
Adjusting the brake lever free
play ........................................... 6-17
Adjusting the brake pedal position
and free play ............................. 6-18
Adjusting the rear brake light
switch ....................................... 6-19
Checking the front brake pads
and rear brake shoes ............... 6-19
Checking the brake fluid level ...... 6-20
Changing the brake fluid .............. 6-21
Checking and lubricating the
cables ....................................... 6-21
Checking and lubricating the
throttle grip and cable ............... 6-21
Checking and lubricating the
brake and shift pedals .............. 6-22
Checking and lubricating the
brake and clutch levers ............ 6-22
Checking and lubricating the
sidestand .................................. 6-23
Checking the front fork ................. 6-23
Checking the steering .................. 6-24
Checking the wheel bearings ....... 6-25
Battery ......................................... 6-25
Replacing the fuses ..................... 6-26
Replacing the headlight bulb ....... 6-27U5SCE1E0.book Page 1 Monday, September 8, 2003 11:32 AM

PRE-OPERATION CHECKS
4-2
4
EAU15602
Pre-operation check list
ITEM CHECKS PAGE
FuelCheck fuel level in fuel tank.
Refuel if necessary.
Check fuel line for leakage.3-9
Engine oilCheck oil level in engine.
If necessary, add recommended oil to specified level.
Check vehicle for oil leakage.6-7
Final gear oilCheck vehicle for oil leakage. 6-10
Front brakeCheck operation.
If soft or spongy, have Yamaha dealer bleed hydraulic system.
Check lever free play.
Adjust if necessary.
Check brake pads for wear.
Replace if necessary.
Check fluid level in reservoir.
If necessary, add recommended brake fluid to specified level.
Check hydraulic system for leakage.6-17, 6-19, 6-20
Rear brakeCheck operation.
Check pedal free play.
Adjust if necessary.6-18, 6-19
ClutchCheck operation.
Lubricate cable if necessary.
Check lever free play.
Adjust if necessary.6-16
Throttle gripMake sure that operation is smooth.
Check cable free play.
If necessary, have Yamaha dealer adjust cable free play and lubricate cable and
grip housing.6-13, 6-21
Control cablesMake sure that operation is smooth.
Lubricate if necessary.6-21
U5SCE1E0.book Page 2 Monday, September 8, 2003 11:32 AM

PERIODIC MAINTENANCE AND MINOR REPAIR
6-2
6
EAU17702
Periodic maintenance and lubrication chart NOTE:

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


From 50000 km, repeat the maintenance intervals starting from 10000 km.


Items marked with an asterisk should be performed by a Yamaha dealer as they require special tools, data and technicalskills.
NO. ITEM CHECK OR MAINTENANCE JOBODOMETER READING (× 1000 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.√√√√√ √
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
U5SCE1E0.book Page 2 Monday, September 8, 2003 11:32 AM

PERIODIC MAINTENANCE AND MINOR REPAIR
6-19
6Brake pedal free play
The brake pedal free play should mea-
sure 20.0–30.0 mm (0.79–1.18 in) at
the brake pedal end. Periodically check
the brake pedal free play and, if neces-
sary, adjust it as follows.
To increase the brake pedal free play,
turn the adjusting nut at the brake rod in
direction (a). To decrease the brake
pedal free play, turn the adjusting nut in
direction (b).
EAU22270
Adjusting the rear brake light
switch The rear brake light switch, which is ac-
tivated by the brake pedal, is properly
adjusted when the brake light comes
on just before braking takes effect. If
necessary, adjust the brake light switch
as follows.
Turn the adjusting nut while holding the
rear brake light switch in place. To
make the brake light come on earlier,
turn the adjusting nut in direction (a). To
make the brake light come on later, turn
the adjusting nut in direction (b).
EAU22380
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 main-
tenance and lubrication chart.
EAU22430
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
1. Brake pedal free play adjusting nut
1. Brake light switch
2. Rear brake light switch adjusting nut
1. Brake pad wear indicator groove
U5SCE1E0.book Page 19 Monday, September 8, 2003 11:32 AM

PERIODIC MAINTENANCE AND MINOR REPAIR
6-20
6 indicator grooves have almost disap-
peared, have a Yamaha dealer replace
the brake pads as a set.
EAU22540
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.
EAU22580
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 fluid
level may indicate worn brake pads
and/or brake system leakage. If the
brake fluid level is low, be sure to check
the brake pads for wear and the brake
system 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 quality
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 grad-
ually go down. However, if the
brake fluid level goes down sud-
denly, have a Yamaha dealer
check the cause.
1. Brake shoe wear limit line
2. Brake shoe wear indicator
1. Minimum level mark
Recommended brake fluid:
DOT 4
U5SCE1E0.book Page 20 Monday, September 8, 2003 11:32 AM

PERIODIC MAINTENANCE AND MINOR REPAIR
6-31
6
EAU24360
Front wheel
EAU24660
To remove the front wheel
WARNING
EWA10820


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


Securely support the motor-
cycle so that there is no dangerof 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 6-30.
5. Pull the wheel axle out, and then
remove the wheel.
CAUTION:
ECA11070
Do not apply the brake after the
wheel has been removed together
with the brake disc, otherwise thebrake pads will be forced shut.
EAU24921
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 theretainer on the fork leg.
3. Insert the wheel axle.
4. Lower the front wheel so that it is
on the ground.
1. Speedometer cable
1. Rubber cap
2. Wheel axle
3. Front wheel axle pinch bolt
1. Speedometer gear unit
2. Speedometer cable
3. Retainer
U5SCE1E0.book Page 31 Monday, September 8, 2003 11:32 AM

INDEXAAir filter element, cleaning..................... 6-11
Anti-theft alarm (optional)........................ 3-5
Auxiliary light bulb, replacing ................ 6-29BBattery................................................... 6-25
Brake and clutch levers, checking and
lubricating ........................................... 6-22
Brake and shift pedals, checking and
lubricating ........................................... 6-22
Brake fluid, changing ............................ 6-21
Brake fluid level, checking .................... 6-20
Brake lever .............................................. 3-7
Brake lever free play, adjusting............. 6-17
Brake pads and shoes, checking .......... 6-19
Brake pedal ............................................. 3-8
Brake pedal position and free play,
adjusting ............................................. 6-18CCables, checking and lubricating .......... 6-21
Carburetors, adjusting........................... 6-12
Care ........................................................ 7-1
Catalytic converter ................................ 3-10
Clutch lever ............................................. 3-7
Clutch lever free play, adjusting ............ 6-16DDimmer switch ........................................ 3-6EEngine break-in ....................................... 5-4
Engine idling speed............................... 6-12
Engine oil and oil filter element ............... 6-7
Engine, starting a warm .......................... 5-2
Engine stop switch .................................. 3-6
Engine trouble warning light.................... 3-4
FFinal gear oil ......................................... 6-10
Front fork, checking .............................. 6-23
Fuel......................................................... 3-9
Fuel cock .............................................. 3-10
Fuel consumption, tips for reducing........ 5-3
Fuel tank cap .......................................... 3-8
Fuses, replacing ................................... 6-26HHandlebar switches ................................ 3-5
Hazard switch ......................................... 3-6
Headlight bulb, replacing ...................... 6-27
Helmet holder ....................................... 3-12
High beam indicator light ........................ 3-4
Horn switch ............................................. 3-6IIdentification numbers ............................ 9-1
Ignition circuit cut-off system ................ 3-15
Immobilizer system ................................. 3-1
Immobilizer system indicator light........... 3-4
Indicator and warning lights .................... 3-3KKey identification number ....................... 9-1LLuggage strap holders .......................... 3-14MMain switch/steering lock........................ 3-2
Model label ............................................. 9-2NNeutral indicator light .............................. 3-3PPanels, removing and installing .............. 6-5
Parking ................................................... 5-4
Part locations .......................................... 2-1Pass switch ............................................. 3-6
Periodic maintenance and lubrication
chart ...................................................... 6-2
Pre-operation check list........................... 4-2
RRear brake light switch, adjusting ......... 6-19SSafety information ................................... 1-1
Seats ..................................................... 3-11
Shifting .................................................... 5-2
Shift pedal ............................................... 3-7
Shock absorber assembly, adjusting .... 3-13
Sidestand .............................................. 3-15
Sidestand, checking and lubricating...... 6-23
Spark plugs, checking ............................. 6-6
Specifications .......................................... 8-1
Speedometer unit .................................... 3-5
Starter (choke) knob.............................. 3-11
Starting a cold engine ............................. 5-1
Start switch.............................................. 3-6
Steering, checking................................. 6-24
Storage.................................................... 7-3
Storage compartment............................ 3-13
Supporting the motorcycle .................... 6-30TThrottle cable free play, adjusting ......... 6-13
Throttle grip and cable, checking and
lubricating ........................................... 6-21
Tires ...................................................... 6-14
Tool kit..................................................... 6-1
Troubleshooting .................................... 6-34
Troubleshooting chart ........................... 6-35
Turn signal indicator light ........................ 3-3
U5SCE1E0.book Page 1 Monday, September 8, 2003 11:32 AM