2004 YAMAHA XVS650A wheel

EAU26941
DECLARATION of CONFORMITY
We
Hereby declare that the product:
is in compliance with following norm(s) or documents: Type-designation:
5SL-00, 5VS-00, 5VX-00, 3HT-00, 5UX-00, 5UX-10, 5KS-00 and 5KS-10
R&TTE Directive(1999/5/EC)
EN300 330-2 v1.1.1(2001-6), EN60950(2000)
Two or Three-Wheel Motor Vehicles Directive(97/24/EC: Chapter 8, EMC)
Place of issue: Shizuoka, Japan
Date of issue: Aug. 1
st 2002 Kind of equipment: IMMOBILIZER Address: 1450-6 Mori Mori-Machi Shuchi-gun Shizuoka 437-0292 Japan Company: MORIC CO., LTD.
Kazuji Kawai
representative name and signature
U5SCE1E0.book Page 1 Monday, September 8, 2003 11:32 AM

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

TABLE OF CONTENTS
Replacing a turn signal light bulb
or the tail/brake light bulb .......... 6-29
Replacing the auxiliary light
bulb ........................................... 6-29
Supporting the motorcycle ............ 6-30
Front wheel ................................... 6-31
Rear wheel ................................... 6-32
Troubleshooting ............................ 6-34
Troubleshooting chart ................... 6-35
MOTORCYCLE CARE AND
STORAGE.......................................... 7-1
Care ................................................ 7-1
Storage ...........................................7-3
SPECIFICATIONS ............................. 8-1
CONSUMER INFORMATION............. 9-1
Identification numbers .................... 9-1
U5SCE1E0.book Page 2 Monday, September 8, 2003 11:32 AM

SAFETY INFORMATION
1-2
1 wide on a turn due to EXCESSIVE
SPEED or undercornering (insuffi-
cient lean angle for the speed).
Always obey the speed limit and
never travel faster than warrant-
ed by road and traffic conditions.
Always signal before turning or
changing lanes. Make sure that
other motorists can see you.


The posture of the operator and
passenger is important for proper
control.
The operator should keep both
hands on the handlebar and
both feet on the operator foot-
rests during operation to main-
tain control of the motorcycle.
The passenger should always
hold onto the operator, seat
strap, or grab bar, if equipped,
with both hands and keep both
feet on the passenger footrests.
Never carry a passenger unless
he or she can firmly place both
feet on the passenger footrests.


Never ride under the influence of
alcohol or other drugs.


This motorcycle is designed for on-
road use only, therefore, it is not
suitable for off-road use.
Protective apparel
The majority of fatalities from motor-
cycle accidents are the result of head
injuries. The use of a safety helmet is
the single most critical factor in the pre-
vention or reduction of head injuries.


Always wear an approved helmet.


Wear a face shield or goggles.
Wind in your unprotected eyes
could contribute to an impairment
of vision which could delay seeing
a hazard.


The use of a jacket, heavy boots,
trousers, gloves, etc., is effective in
preventing or reducing abrasions
or lacerations.


Never wear loose-fitting clothes,
otherwise they could catch on the
control levers, footrests, or wheels
and cause injury or an accident.


Never touch the engine or exhaust
system during or after operation.
They become very hot and cancause burns. Always wear protec-
tive clothing that covers your legs,
ankles, and feet.


Passengers should also observe
the precautions mentioned above.
Modifications
Modifications made to this motorcycle
not approved by Yamaha, or the re-
moval of original equipment, may ren-
der the motorcycle unsafe for use and
may cause severe personal injury.
Modifications may also make your
motorcycle illegal to use.
Loading and accessories
Adding accessories or cargo to your
motorcycle can adversely affect stabili-
ty and handling if the weight distribution
of the motorcycle is changed. To avoid
the possibility of an accident, use ex-
treme caution when adding cargo or
accessories to your motorcycle. Use
extra care when riding a motorcycle
that has added cargo or accessories.
Here are some general guidelines to
follow if loading cargo or adding acces-
sories to your motorcycle:
U5SCE1E0.book Page 2 Monday, September 8, 2003 11:32 AM

PRE-OPERATION CHECKS
4-3
4
Wheels and tiresCheck for damage.
Check tire condition and tread depth.
Check air pressure.
Correct if necessary.6-14, 6-16
Brake and shift pedalsMake sure that operation is smooth.
Lubricate pedal pivoting points if necessary.6-22
Brake and clutch leversMake sure that operation is smooth.
Lubricate lever pivoting points if necessary.6-22
SidestandMake sure that operation is smooth.
Lubricate pivot if necessary.6-23
Chassis fastenersMake sure that all nuts, bolts and screws are properly tightened.
Tighten if necessary.—
Instruments, lights, signals
and switchesCheck operation.
Correct if necessary.—
Sidestand switchCheck operation of ignition circuit cut-off system.
If system is defective, have Yamaha dealer check vehicle.3-15 ITEM CHECKS PAGE
U5SCE1E0.book Page 3 Monday, September 8, 2003 11:32 AM

PERIODIC MAINTENANCE AND MINOR REPAIR
6-3
6
9*Brake hoseCheck for cracks or damage.√√√√ √
Replace. Every 4 years
10*WheelsCheck runout, spoke tightness and for damage.
Tighten spokes if necessary.√√√√
11*TiresCheck tread depth and for damage.
Replace if necessary.
Check air pressure.
Correct if necessary.√√√√ √
12*Wheel bearingsCheck bearing for looseness or damage.√√√√
13*SwingarmCheck operation and for excessive play.√√√√
Lubricate with lithium-soap-based grease. Every 50000 km
14*Steering bearingsCheck bearing play and steering for roughness.√√√√√
Lubricate with lithium-soap-based grease. Every 20000 km
15*Chassis fastenersMake sure that all nuts, bolts and screws are properly
tightened.√√√√ √
16 SidestandCheck operation.
Lubricate.√√√√ √
17*Sidestand switchCheck operation.√√√√√ √
18*Front forkCheck operation and for oil leakage.√√√√
19*Shock absorber assem-
blyCheck operation and shock absorber for oil leakage.√√√√
20*CarburetorsCheck starter (choke) operation.
Adjust engine idling speed and synchronization.√√√√√ √
21 Engine oilChange.
Check oil level and vehicle for oil leakage.√√√√√ √ NO. ITEM CHECK OR MAINTENANCE JOBODOMETER READING (× 1000 km)
ANNUAL
CHECK
1 10203040
U5SCE1E0.book Page 3 Monday, September 8, 2003 11:32 AM

PERIODIC MAINTENANCE AND MINOR REPAIR
6-10
6
EAU20020
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 vehicle. In addi-
tion, 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.
WARNING
EWA10370


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


Make sure that no oil gets on thetire or wheel.
To check the final gear oil level
1. Place the vehicle on a level sur-
face and hold it in an upright posi-
tion.
NOTE:

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


Make sure that the vehicle is posi-
tioned straight up when checking
the oil level. A slight tilt to the sidecan result in a false reading.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 thefiller 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 oilsrated 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.
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, 17 ft·lbf)
Recommended final gear oil:
Hypoid gear oil SAE 80 (API GL4) or
multi-grade hypoid gear oil SAE
80W-90
Oil quantity:
0.19 L (0.20 US qt) (0.17 Imp.qt)
U5SCE1E0.book Page 10 Monday, September 8, 2003 11:32 AM

PERIODIC MAINTENANCE AND MINOR REPAIR
6-15
6Tire inspection
The tires must be checked before each
ride. If the center tread depth reaches
the specified limit, if the tire has a nail or
glass fragments in it, or if the sidewall is
cracked, have a Yamaha dealer re-
place the tire immediately.
NOTE:The tire tread depth limits may differ
from country to country. Always complywith the local regulations.
WARNING
EWA10570


Have a Yamaha dealer replace
excessively worn tires. Besides
being illegal, operating the
motorcycle with excessively
worn tires decreases riding sta-
bility and can lead to loss of
control.


The replacement of all wheel-
and brake-related parts, includ-
ing the tires, should be left to a
Yamaha dealer, who has the
necessary professional knowl-
edge and experience.


It is not recommended to patch
a punctured tube. If unavoid-
able, however, patch the tube
very carefully and replace it as
soon as possible with a high-quality product.
Tire information
This motorcycle is equipped with spoke
wheels and tube tires.
WARNING
EWA10460


The front and rear tires should
be of the same make and de-
sign, otherwise the handling
characteristics of the vehicle
cannot be guaranteed.


After extensive tests, only the
tires listed below have been ap-
proved for this model byYamaha Motor Co., Ltd.
1. Tire sidewall
2. Tire tread depthMinimum tire tread depth (front and
rear):
1.6 mm (0.06 in)
Front tire:
Size:
130/90-16M/C 67S
Manufacturer/model:
BRIDGESTONE/G703
DUNLOP/D404F
Rear tire:
Size:
170/80-15M/C 77S
Manufacturer/model:
BRIDGESTONE/G702
DUNLOP/D404G
U5SCE1E0.book Page 15 Monday, September 8, 2003 11:32 AM