2006 YAMAHA XVS650A brake

PERIODIC MAINTENANCE AND MINOR REPAIR
6-21
6


When checking the fluid level,
make sure that the top of the mas-
ter cylinder is level by turning the
handlebars.


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 master cylinder when refill-
ing. 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 thebrake fluid level goes down sud-
denly, have a Yamaha dealer
check the cause.
EAU22720
Changing the brake fluid Have a Yamaha dealer change the
brake fluid at the intervals specified in
the NOTE after the periodic mainte-
nance and lubrication 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 dam-
aged or leaking.

Oil seals: Replace every two
years.


Brake hose: Replace every four
years.
Recommended brake fluid:
DOT 4
U4C5E0E0.book Page 21 Friday, August 5, 2005 1:08 PM

PERIODIC MAINTENANCE AND MINOR REPAIR
6-22
6
EAU23100
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.
WARNING
EWA10720
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 unsafeconditions.
EAU23111
Checking and lubricating the
throttle grip and cable The operation of the throttle grip should
be checked before each ride. In addi-
tion, the cable should be lubricated at
the intervals specified in the periodic
maintenance chart.
EAU23131
Checking and lubricating the
brake and shift pedals The operation of the brake and shift
pedals should be checked before each
ride, and the pedal pivots should be lu-
bricated if necessary.
Recommended lubricant:
Engine oil
U4C5E0E0.book Page 22 Friday, August 5, 2005 1:08 PM

PERIODIC MAINTENANCE AND MINOR REPAIR
6-23
6
EAU23140
Checking and lubricating the
brake and clutch levers Brake lever
Clutch lever
The operation of the brake and clutch
levers should be checked before each
ride, and the lever pivots should be lu-
bricated if necessary.
Recommended lubricant:
Lithium-soap-based grease (all-pur-
pose grease)
Recommended lubricant:
Lithium-soap-based grease (all-pur-
pose grease)
U4C5E0E0.book Page 23 Friday, August 5, 2005 1:08 PM

PERIODIC MAINTENANCE AND MINOR REPAIR
6-24
6
EAU23200
Checking and lubricating the
sidestand The operation of the sidestand should
be checked before each ride, and the
sidestand pivot and metal-to-metal
contact surfaces should be lubricated if
necessary.
WARNING
EWA10730
If the sidestand does not move up
and down smoothly, have a Yamahadealer check or repair it.
EAU23271
Checking the front fork The condition and operation of the front
fork must be checked as follows at the
intervals specified in the periodic main-
tenance and lubrication chart.
To check the condition
WARNING
EWA10750
Securely support the vehicle so thatthere is no danger of it falling over.
Check the inner tubes for scratches,
damage and excessive oil leakage.
To check the operation
1. Place the vehicle on a level sur-
face and hold it in an upright posi-
tion.
2. While applying the front brake,
push down hard on the handlebars
several times to check if the front
fork compresses and rebounds
smoothly.
CAUTION:
ECA10590
If any damage is found or the front
fork does not operate smoothly,
have a Yamaha dealer check or re-pair it.
Recommended lubricant:
Lithium-soap-based grease (all-pur-
pose grease)
U4C5E0E0.book Page 24 Friday, August 5, 2005 1:08 PM

PERIODIC MAINTENANCE AND MINOR REPAIR
6-29
6
WARNING
EWA10790
Headlight bulbs get very hot. There-
fore, keep flammable products away
from a lit headlight bulb, and do not
touch the bulb until it has cooleddown.
4. Place a new headlight bulb into po-
sition, and then secure it with the
bulb holder.CAUTION:
ECA10660
Do not touch the glass part of the
headlight bulb to keep it free from
oil, otherwise the transparency of
the glass, the luminosity of the bulb,
and the bulb life will be adversely af-
fected. Thoroughly clean off any dirt
and fingerprints on the headlight
bulb using a cloth moistened with al-cohol or thinner.5. Install the headlight bulb cover,
and then connect the coupler.
6. Install the headlight unit by install-
ing the screws.
7. Have a Yamaha dealer adjust the
headlight beam if necessary.
EAU24281
Replacing a turn signal light
bulb or the tail/brake light bulb 1. Remove the lens by removing the
screws.
1. Do not touch the glass part of the bulb.
1. Screw
1. Screw
U4C5E0E0.book Page 29 Friday, August 5, 2005 1:08 PM

PERIODIC MAINTENANCE AND MINOR REPAIR
6-32
64. Lift the front wheel off the ground
according to the procedure on
page 6-31.
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.5. Tighten the wheel axle and front
wheel axle pinch bolt to the speci-
fied torques, and then install the
rubber cap.
6. While applying the front brake,
push down hard on the handlebars
several times to check if the front
fork compresses and rebounds
smoothly.
7. Connect the speedometer cable.
1. Rubber cap
2. Wheel axle
3. Front wheel axle pinch bolt
1. Speedometer gear unit
2. Speedometer cable
3. Retainer
Tightening torques:
Wheel axle:
59 Nm (5.9 m·kgf, 43 ft·lbf)
Front wheel axle pinch bolt:
20 Nm (2.0 m·kgf, 14 ft·lbf)
U4C5E0E0.book Page 32 Friday, August 5, 2005 1:08 PM

PERIODIC MAINTENANCE AND MINOR REPAIR
6-33
6
EAU25080
Rear wheel
EAU25141
To remove the rear 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. Loosen the axle nut.
2. Disconnect the brake torque rod
from the brake shoe plate by re-
moving the bolt and nut.
3. Loosen the brake torque rod nut at
the swingarm.4. Remove the brake pedal free play
adjusting nut, and then disconnect
the brake rod from the brake cam-
shaft lever.
5. Remove panel A. (See page 6-5.)
6. Remove the bolts that secure the
final gear case to the swingarm.7. Lift the rear wheel off the ground
according to the procedure on
page 6-31.
8. While supporting the drive shaft,
pull the rear wheel back to remove
the following parts as an assem-
bly: wheel, wheel axle, final gear
case, and drive shaft.
NOTE:Make sure to support the drive shaft asit is being pulled out.
1. Axle nut
1. Brake pedal free play adjusting nut
2. Brake camshaft lever
3. Bolt and nut (shoe plate)
4. Brake torque rod
5. Bolt and nut (swingarm)
6. Brake rod
1. Bolt
2. Final gear case
U4C5E0E0.book Page 33 Friday, August 5, 2005 1:08 PM

PERIODIC MAINTENANCE AND MINOR REPAIR
6-34
6
EAU25511
To install the rear wheel
1. Install the rear wheel, wheel axle,
final gear case, and drive shaft by
pushing the wheel forward and
guiding the drive shaft into the mid-
dle gear universal joint.
2. Install the final gear case bolts.
3. Install the brake rod onto the brake
camshaft lever, and then install the
brake pedal free play adjusting nut
onto the brake rod.
4. Install the brake torque rod bolt
and nut at the brake shoe plate.
5. Install the panel.
6. Lower the rear wheel so that it is
on the ground.7. Tighten the axle nut, the final gear
case bolts and the brake torque
rod nuts to the specified torques.
8. Adjust the brake pedal free play.
(See page 6-18.)
WARNING
EWA10660
After adjusting the brake pedal free
play, check the operation of thebrake light.
EAU25850
Troubleshooting Although Yamaha motorcycles receive
a thorough inspection before shipment
from the factory, trouble may occur dur-
ing operation. Any problem in the fuel,
compression, or ignition systems, for
example, can cause poor starting and
loss of power.
The following troubleshooting chart
represents a quick and easy procedure
for checking these vital systems your-
self. However, should your motorcycle
require any repair, take it to a Yamaha
dealer, whose skilled technicians have
the necessary tools, experience, and
know-how to service the motorcycle
properly.
Use only genuine Yamaha replace-
ment parts. Imitation parts may look like
Yamaha parts, but they are often inferi-
or, have a shorter service life and can
lead to expensive repair bills.
1. Middle gear universal joint
2. Drive shaft
Tightening torques:
Axle nut:
92 Nm (9.2 m·kgf, 67 ft·lbf)
Final gear case bolt:
74 Nm (7.4 m·kgf, 54 ft·lbf)
Brake torque rod nut:
20 Nm (2.0 m·kgf, 14 ft·lbf)
U4C5E0E0.book Page 34 Friday, August 5, 2005 1:08 PM