Yamaha XVS650ATTC, XVS650ATC, XVS650TC User Manual

OWNER’S MANUAL

XVS650T(C)

XVS650AT(C)

XVS650ATT(C)

5FB-28199-15LIT-11626-18-20

EAU10041

INTRODUCTION

EAU10080

Congratulations on your purchase of the Yamaha XVS650(C)/XVS650A(C)/XVS650AT(C). This model is the result of
Yamaha’s vast experience in the production of fine sporting, touring, and pacesetting racing machines. It represents the high
degree of craftsmanship and reliability that have made Yamaha a leader in these fields.
This manual will give you an understanding of the operation, inspection, and basic maintenance of this motorcycle. If you
have any questions concerning the operation or maintenance of your motorcycle, please consult a Yamaha dealer.
The design and manufacture of this Yamaha motorcycle fully comply with the emissions standards for clean air applicable at
the date of manufacture. Yamaha has met these standards without reducing the performance or economy of operation of the
motorcycle. To maintain these high standards, it is important that you and your Yamaha dealer pay close attention to the
recommended maintenance schedules and operating instructions contained within this manual.

IMPORTANT MANUAL INFORMATION

Particularly important information is distinguished in this manual by the following notations:

The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR SAFETY IS
INVOLVED!

EAU10130

WARNING

Failure to follow WARNING instructions could result in severe injury or death
motorcycle operator, a bystander or a person inspecting or repairing the motor-

to the

cycle.

CAUTION:

NOTE:

A CAUTION indicates special precautions that must be taken to avoid damage to
the motorcycle.

A NOTE provides key information to make procedures easier or clearer.

NOTE:

● This manual should be considered a permanent part of this motorcycle and should remain with it even if the motorcycle

is subsequently sold.

● Yamaha continually seeks advancements in product design and quality. Therefore, while this manual contains the most

current product information available at the time of printing, there may be minor discrepancies between your motorcycle
and this manual. If you have any questions concerning this manual, please consult your Yamaha dealer.

EWA10010

WARNING

PLEASE READ THIS MANUAL AND THE “YOU AND YOUR MOTORCYCLE: RIDING TIPS” BOOKLET CAREFULLY
AND COMPLETELY BEFORE OPERATING THIS MOTORCYCLE. DO NOT ATTEMPT TO OPERATE THIS MOTOR­CYCLE UNTIL YOU HAVE ATTAINED ADEQUATE KNOWLEDGE OF ITS CONTROLS AND OPERATING FEATURES

IMPORTANT MANUAL INFORMATION

AND UNTIL YOU HAVE BEEN TRAINED IN SAFE AND PROPER RIDING TECHNIQUES. REGULAR INSPECTIONS
AND CAREFUL MAINTENANCE, ALONG WITH GOOD RIDING SKILLS, WILL ENSURE THAT YOU SAFELY ENJOY
THE CAPABILITIES AND THE RELIABILITY OF THIS MOTORCYCLE.

IMPORTANT MANUAL INFORMATION

AFFIX DEALER

LABEL HERE

XVS650T(C)/XVS650AT(C)/XVS650ATT(C)

OWNER’S MANUAL

©2004 by Yamaha Motor Corporation, U.S.A.

1st edition, April 2004

All rights reserved.

Any reprinting or unauthorized use

without the written permission of

Yamaha Motor Corporation, U.S.A.

is expressly prohibited.

Printed in Japan.

P/N LIT-11626-18-20

EAU10192

TABLE OF CONTENTS

SAFETY INFORMATION ..................1-1

Location of important labels ...........1-5

DESCRIPTION ..................................2-1

Left view ..........................................2-1

Right view........................................2-3

Controls and instruments ................2-5

INSTRUMENT AND CONTROL

FUNCTIONS.......................................3-1

Main switch/steering lock ................3-1

Indicator and warning lights ............3-2

Speedometer unit ...........................3-2

Handlebar switches ........................3-3

Clutch lever ....................................3-4

Shift pedal (XVS650) ......................3-4

Shift pedal (XVS650A/AT) ..............3-4

Brake lever .....................................3-5

Brake pedal ....................................3-5

Fuel tank cap ..................................3-5

Fuel ................................................3-6

Catalytic converter ..........................3-7

Fuel cock ........................................3-7

Starter (choke) knob .......................3-8

Seats (XVS650) ..............................3-9

Seats (XVS650A/AT) ....................3-10

Helmet holder ...............................3-11

Storage compartment ...................3-11

Adjusting the shock absorber

assembly ...................................3-12

Luggage strap holders ..................3-13

Sidestand ..................................... 3-13

Ignition circuit cut-off system ....... 3-14

PRE-OPERATION CHECKS ............. 4-1

Pre-operation check list ................. 4-2

OPERATION AND IMPORTANT

RIDING POINTS ................................ 5-1

Starting and warming up a

cold engine ................................. 5-1

Starting a warm engine .................. 5-2

Shifting ........................................... 5-3

Engine break-in .............................. 5-4

Parking ........................................... 5-5

PERIODIC MAINTENANCE AND

MINOR REPAIR................................. 6-1

PERIODIC MAINTENANCE .......... 6-1

Owner’s tool kit .............................. 6-1

Periodic maintenance chart for the

emission control system ............. 6-3

General maintenance and

lubrication chart .......................... 6-4

Removing and installing panels ..... 6-8

Checking the spark plugs .............. 6-9

Canister (for California only) ........ 6-10

Engine oil and oil filter element .... 6-11

Final gear oil ................................ 6-13

Cleaning the air filter element ...... 6-14

Adjusting the carburetors ............. 6-16

Adjusting the throttle cable

free play ....................................6-16

Adjusting the valve clearance ......6-16

Tires .............................................6-17

Spoke wheels ...............................6-19

Accessories and replacement

parts ..........................................6-19

Adjusting the clutch lever

free play ....................................6-20

Adjusting the brake lever

free play ....................................6-21

Adjusting the brake pedal position

and free play .............................6-22

Adjusting the rear brake light

switch ........................................6-23

Checking the front brake pads

and rear brake shoes ................6-24

Checking the brake fluid level ......6-24

Changing the brake fluid .............. 6-25

Checking and lubricating the

cables .......................................6-25

Checking and lubricating the

throttle grip and cable ............... 6-26

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

TABLE OF CONTENTS

Checking the wheel bearings .......6-28

Battery ..........................................6-29

Replacing the fuses ......................6-30

Replacing the headlight bulb ........6-31

Replacing a turn signal light bulb

or the tail/brake light bulb ..........6-32

Supporting the motorcycle ............6-33

Front wheel ...................................6-34

Rear wheel ...................................6-35

Troubleshooting ............................6-37

Troubleshooting chart ...................6-38

MOTORCYCLE CARE AND

STORAGE ..........................................7-1

Care ................................................7-1

Storage ...........................................7-3

SPECIFICATIONS .............................8-1

CONSUMER INFORMATION.............9-1

Identification numbers ....................9-1

Reporting safety defects .................9-3

Motorcycle noise regulation ............9-4

Maintenance record ........................9-5

YAMAHA MOTOR CORPORATION,

U.S.A. STREET AND ENDURO

MOTORCYCLE LIMITED

WARRANTY ................................9-7

YAMAHA EXTENDED SERVICE

(Y.E.S.) ........................................9-9

SAFETY INFORMATION

EAU10251

MOTORCYCLES ARE SINGLE
TRACK VEHICLES. THEIR SAFE
USE AND OPERATION ARE DEPEN­DENT UPON THE USE OF PROPER
RIDING TECHNIQUES AS WELL AS
THE EXPERTISE OF THE OPERA­TOR. EVERY OPERATOR SHOULD
KNOW THE FOLLOWING REQUIRE­MENTS BEFORE RIDING THIS
MOTORCYCLE.
HE OR SHE SHOULD:

● OBTAIN THOROUGH INSTRUC-

TIONS FROM A COMPETENT
SOURCE ON ALL ASPECTS OF
MOTORCYCLE OPERATION.

● OBSERVE THE WARNINGS

AND MAINTENANCE REQUIRE­MENTS IN THE OWNER’S MAN­UAL.

● OBTAIN QUALIFIED TRAINING

IN SAFE AND PROPER RIDING
TECHNIQUES.

● OBTAIN PROFESSIONAL TECH-

NICAL SERVICE AS INDICATED
BY THE OWNER’S MANUAL

AND/OR WHEN MADE NECES­SARY BY MECHANICAL CONDI­TIONS.

Safe riding

● Always make pre-operation

checks. Careful checks may help
prevent an accident.

● This motorcycle is designed to

carry the operator and a passen­ger.

● The failure of motorists to detect

and recognize motorcycles in traf­fic is the predominating cause of
automobile/motorcycle accidents.
Many accidents have been
caused by an automobile driver
who did not see the motorcycle.
Making yourself conspicuous ap­pears to be very effective in reduc­ing the chance of this type of
accident.

Therefore:

• Wear a brightly colored jacket.

• Use extra caution when ap-

proaching and passing through
intersections, since intersec-

1-1

tions are the most likely places
for motorcycle accidents to oc­cur.

• Ride where other motorists can
see you. Avoid riding in another
motorist’s blind spot.

● Many motorcycle accidents in-

volve inexperienced operators. In
fact, many operators who have
been involved in accidents do not
even have a current motorcycle li­cense.

• Make sure that you are qualified
and that you only lend your
motorcycle to other qualified op­erators.

• Know your skills and limits.
Staying within your limits may
help you to avoid an accident.

• We recommend that you prac­tice riding your motorcycle
where there is no traffic until you
have become thoroughly famil­iar with the motorcycle and all of
its controls.

● Many motorcycle accidents have

been caused by error of the motor­cycle operator. A typical error
made by the operator is veering

1

SAFETY INFORMATION

wide on a turn due to EXCESSIVE
SPEED or undercornering (insuffi­cient lean angle for the speed).

1

• Always obey the speed limit and
never travel faster than warrant­ed 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 foot­rests during operation to main­tain 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 motor­cycle accidents are the result of head
injuries. The use of a safety helmet is
the single most critical factor in the pre­vention 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 can

cause burns. Always wear protec­tive 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 re­moval of original equipment, may ren­der 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 stabili­ty and handling if the weight distribution
of the motorcycle is changed. To avoid
the possibility of an accident, use ex­treme 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 acces­sories to your motorcycle:

1-2

SAFETY INFORMATION

Loading
The total weight of the operator, pas­senger, accessories and cargo must
not exceed the maximum load limit.

Maximum load:

XVS650 178 kg (392 lb) (CAL)
XVS650 180 kg (397 lb) (U49)
XVS650A 198 kg (437 lb) (CAL)
XVS650A 200 kg (441 lb) (U49)
XVS650AT 198 kg (437 lb) (CAL)
XVS650AT 200 kg (441 lb) (U49)

When loading within this weight limit,
keep the following in mind:

● Cargo and accessory weight

should be kept as low and close to
the motorcycle as possible. Make
sure to distribute the weight as
evenly as possible on both sides of
the motorcycle to minimize imbal­ance or instability.

● Shifting weights can create a sud-

den imbalance. Make sure that ac­cessories and cargo are securely
attached to the motorcycle before
riding. Check accessory mounts
and cargo restraints frequently.

● Never attach any large or heavy

items to the handlebar, front fork,
or front fender. These items, in­cluding such cargo as sleeping
bags, duffel bags, or tents, can
create unstable handling or slow

steering response.
Accessories
Genuine Yamaha accessories have
been specifically designed for use on
this motorcycle. Since Yamaha cannot
test all other accessories that may be
available, you must personally be re­sponsible for the proper selection, in­stallation and use of non-Yamaha
accessories. Use extreme caution
when selecting and installing any ac­cessories.
Keep the following guidelines in mind,
as well as those provided under “Load-
ing” when mounting accessories.

● Never install accessories or carry

cargo that would impair the perfor-

mance of your motorcycle. Care-

fully inspect the accessory before

using it to make sure that it does

not in any way reduce ground

clearance or cornering clearance,

limit suspension travel, steering
travel or control operation, or ob­scure lights or reflectors.

• Accessories fitted to the handle­bar or the front fork area can
create instability due to improper
weight distribution or aerody­namic changes. If accessories
are added to the handlebar or
front fork area, they must be as
lightweight as possible and
should be kept to a minimum.

• Bulky or large accessories may
seriously affect the stability of
the motorcycle due to aerody­namic effects. Wind may at­tempt to lift the motorcycle, or
the motorcycle may become un­stable in cross winds. These ac­cessories may also cause
instability when passing or being
passed by large vehicles.

• Certain accessories can dis­place the operator from his or
her normal riding position. This
improper position limits the free­dom of movement of the opera-

1

1-3

SAFETY INFORMATION

tor and may limit control ability,
therefore, such accessories are
not recommended.

1

● Use caution when adding electri-

cal accessories. If electrical acces­sories exceed the capacity of the
motorcycle’s electrical system, an
electric failure could result, which
could cause a dangerous loss of
lights or engine power.

Gasoline and exhaust gas

● GASOLINE IS HIGHLY FLAMMA-

BLE:

• Always turn the engine off when
refueling.

• Take care not to spill any gaso­line on the engine or exhaust
system when refueling.

• Never refuel while smoking or in
the vicinity of an open flame.

● Never start the engine or let it run

for any length of time in a closed
area. The exhaust fumes are poi­sonous and may cause loss of
consciousness and death within a
short time. Always operate your
motorcycle in an area that has ad­equate ventilation.

● Always turn the engine off before

leaving the motorcycle unattended
and remove the key from the main
switch. When parking the motor­cycle, note the following:

• The engine and exhaust system
may be hot, therefore, park the
motorcycle in a place where pe­destrians or children are not like­ly to touch these hot areas.

• Do not park the motorcycle on a
slope or soft ground, otherwise it
may fall over.

• Do not park the motorcycle near
a flammable source (e.g. a kero­sene heater, or near an open
flame), otherwise it could catch
fire.

● When transporting the motorcycle

in another vehicle, make sure that
it is kept upright and that the fuel
cock is turned to “ON” or “RES” (for
vacuum type) / “OFF” (for manual
type). If it should lean over, gaso­line may leak out of the carburetor
or fuel tank.

● If you should swallow any gaso-

line, inhale a lot of gasoline vapor,
or allow gasoline to get into your

1-4

eyes, see your doctor immediately.
If any gasoline spills on your skin
or clothing, immediately wash the
affected area with soap and water
and change your clothes.

Location of important labels

Please read the following important labels carefully before operating this vehicle.

SAFETY INFORMATION

EAU10381

1

1-5

SAFETY INFORMATION

1

1

2

3 XVS650

3 XVS650A/AT

4

1-6

5

6 California only

SAFETY INFORMATION

1

A1

1-7

DESCRIPTION

Left view

XVS650

2

EAU32220

1. Shift pedal (page 3-4)

2. Fuel cock (page 3-7)

3. Starter (choke) knob (page 3-8)

4. Shock absorber assembly spring preload adjusting ring (page 3-12)

5. Helmet holder (page 3-11)

6. Owner’s tool kit (page 6-1)

7. Storage compartment (page 3-11)

2-1

XVS650A/AT

1. Shift pedal (page 3-4)

2. Fuel cock (page 3-7)

3. Starter (choke) knob (page 3-8)

4. Shock absorber assembly spring preload adjusting ring (page 3-12)

5. Helmet holder (page 3-11)

6. Owner’s tool kit (page 6-1)

7. Storage compartment (page 3-11)

DESCRIPTION

2

2-2

DESCRIPTION

Right view

XVS650

2

EAU32230

1. Engine oil filter element (page 6-11)

2. Battery (page 6-29)

3. Fuses (page 6-30)

4. Main switch/steering lock (page 3-1)

5. Air filter element (page 6-14)

6. Brake pedal (page 3-5)

2-3

XVS650A/AT

1. Engine oil filter element (page 6-11)

2. Battery (page 6-29)

3. Fuses (page 6-30)

4. Main switch/steering lock (page 3-1)

5. Air filter element (page 6-14)

6. Brake pedal (page 3-5)

DESCRIPTION

2

2-4

DESCRIPTION

Controls and instruments

2

1. Clutch lever (page 3-4)

2. Left handlebar switches (page 3-3)

3. Speedometer unit (page 3-2)

4. Fuel tank cap (page 3-5)

5. Right handlebar switches (page 3-3)

6. Throttle grip (page 6-16)

7. Brake lever (page 3-5)

EAU10430

2-5

INSTRUMENT AND CONTROL FUNCTIONS

EAU10460

Main switch/steering lock

The main switch/steering lock controls
the ignition and lighting systems, and is
used to lock the steering. The various
positions are described below.

EAU10510

ON

All electrical systems are supplied with
power, and the headlight, meter light­ing, taillight and position lights come
on, and the engine can be started. The
key cannot be removed.

EAU10660

OFF

All electrical systems are off. The key
can be removed.

LOCK

EAU10680

The steering is locked, and all electrical
systems are off. The key can be re­moved.

To lock the steering

1. Push.

2. Turn.

1. Turn the handlebars all the way to
the left.

2. Push the key in from the “OFF” po­sition, and then turn it to “LOCK”
while still pushing it.

3. Remove the key.

To unlock the steering

3

1. Push.

2. Turn.

Push the key in, and then turn it to
“OFF” while still pushing it.

EWA10060

WARNING

Never turn the key to “OFF” or
“LOCK” while the vehicle is moving,
otherwise the electrical systems will
be switched off, which may result in
loss of control or an accident. Make
sure that the vehicle is stopped be­fore turning the key to “OFF” or
“LOCK”.

3-1

INSTRUMENT AND CONTROL FUNCTIONS

Indicator and warning lights

3

1. High beam indicator light “”

2. Turn signal indicator light “”

3. Neutral indicator light “”

4. Engine trouble warning light “”

Turn signal indicator light “”

This indicator light flashes when the
turn signal switch is pushed to the left or
right.

Neutral indicator light “”

This indicator light comes on when the
transmission is in the neutral position.

EAU11001

EAU11020

EAU11060

High beam indicator light “”

EAU11080

This indicator light comes on when the
high beam of the headlight is switched
on.

EAU11500

Engine trouble warning light “”

This warning light comes on or flashes
when an electrical circuit monitoring the
engine is defective. When this occurs,
have a Yamaha dealer check the self­diagnosis system.
The electrical circuit of the warning light
can be checked by turning the key to
“ON”. If the warning light does not come
on for a few seconds, then go off, have
a Yamaha dealer check the electrical
circuit.

EAU11630

Speedometer unit

1. Tripmeter reset knob

2. Speedometer

3. Odometer

4. Tripmeter

The speedometer unit is equipped with
a speedometer, an odometer and a
tripmeter. The speedometer shows
riding speed. The odometer shows the
total distance traveled. The tripmeter
shows the distance traveled since it
was last set to zero with the reset knob.
The tripmeter can be used to estimate
the distance that can be traveled with a
full tank of fuel. This information will en­able you to plan future fuel stops.

3-2

INSTRUMENT AND CONTROL FUNCTIONS

Handlebar switches

Left

1. Dimmer switch “ / ”

2. Turn signal switch “ / ”

3. Horn switch “”

Right

1. Engine stop switch “ / ”

2. Start switch “”

EAU12343

Dimmer switch “ / ”

EAU12400

Set this switch to “” for the high
beam and to “” for the low beam.

EAU12430

Turn signal switch “ / ”

To signal a right-hand turn, push this
switch to “”. To signal a left-hand
turn, push this switch to “”. When re-
leased, the switch returns to the center
position.
Since this model is equipped with a
self-canceling system, the turn signal
lights will self-cancel after the vehicle
has traveled both about 150 m (490 ft)
and for approximately 15 seconds.
However, the turn signal lights can also
be canceled manually by pushing the
switch in after it has returned to the cen­ter position.

NOTE:

The self-canceling system only oper­ates when the vehicle is moving, so that
the turn signal lights will not self-cancel
while you are stopped at an intersec­tion.

Horn switch “”

EAU12500

Press this switch to sound the horn.

EAU12660

Engine stop switch “ / ”

Set this switch to “” before starting
the engine. Set this switch to “” to
stop the engine in case of an emergen­cy, such as when the vehicle overturns
or when the throttle cable is stuck.

EAU12710

Start switch “”

Push this switch to crank the engine
with the starter.

ECA10050

CAUTION:

See page 5-1 for starting instruc­tions prior to starting the engine.

3

3-3

INSTRUMENT AND CONTROL FUNCTIONS

Clutch lever

EAU12820

Shift pedal (XVS650)

EAU12870

3

1. Clutch lever 1. Shift pedal 1. Shift pedal

The clutch lever is located at the left
handlebar grip. To disengage the
clutch, pull the lever toward the handle­bar grip. To engage the clutch, release
the lever. The lever should be pulled
rapidly and released slowly for smooth

The shift pedal is located on the left
side of the engine and is used in com­bination with the clutch lever when
shifting the gears of the 5-speed con­stant-mesh transmission equipped on

this motorcycle.
clutch operation.
The clutch lever is equipped with a
clutch switch, which is part of the igni­tion circuit cut-off system. (See page
3-14.)

EAU12880

Shift pedal (XVS650A/AT)

The shift pedal is located on the left
side of the engine and is used in com­bination with the clutch lever when
shifting the gears of the 5-speed con­stant-mesh transmission equipped on
this motorcycle.

NOTE:

Use your toes or heel to shift up and
your toes to shift down.

3-4

INSTRUMENT AND CONTROL FUNCTIONS

EAU12890

Brake lever

1. Brake lever

The brake lever is located at the right
handlebar grip. To apply the front
brake, pull the lever toward the handle­bar grip.

EAU12941

Brake pedal

XVS650

1. Brake pedal

XVS650A/AT

1. Brake pedal

The brake pedal is on the right side of
the motorcycle. To apply the rear
brake, press down on the brake pedal.

EAU13120

Fuel tank cap

3

To remove the fuel tank cap

Slide the lock cover open, insert the key
into the lock, and then turn it 1/4 turn
clockwise. The lock will be released
and the fuel tank cap can be removed.

To install the fuel tank cap

1. Insert the fuel tank cap into the
tank opening with the key inserted
in the lock and with the “” mark
facing forward.

2. Turn the key counterclockwise to
the original position, remove it, and
then close the lock cover.

3-5

INSTRUMENT AND CONTROL FUNCTIONS

NOTE:

The fuel tank cap cannot be installed
unless the key is in the lock. In addition,
the key cannot be removed if the cap is
not properly installed and locked.

WARNING

3

Make sure that the fuel tank cap is
properly installed before riding.

EWA10130

EAU13210

Fuel

1. Fuel tank filler tube

2. Fuel level

Make sure that there is sufficient fuel in
the tank. Fill the fuel tank to the bottom
of the filler tube as shown.

EWA10880

WARNING

● Do not overfill the fuel tank, oth-

erwise it may overflow when the
fuel warms up and expands.

● Avoid spilling fuel on the hot en-

gine.

ECA10070

CAUTION:

Immediately wipe off spilled fuel
with a clean, dry, soft cloth, since
fuel may deteriorate painted surfac­es or plastic parts.

EAU13300

Recommended fuel:

UNLEADED GASOLINE ONLY

Fuel tank capacity:

16.0 L (4.23 US gal) (3.52 Imp.gal)

Fuel reserve amount:

3.0 L (0.79 US gal) (0.66 Imp.gal)

ECA11400

CAUTION:

Use only unleaded gasoline. The use
of leaded gasoline will cause severe
damage to internal engine parts,
such as the valves and piston rings,
as well as to the exhaust system.

Your Yamaha engine has been de­signed to use regular unleaded gaso­line with a pump octane number
[(R+M)/2] of 86 or higher, or a research
octane number of 91 or higher. If

3-6

INSTRUMENT AND CONTROL FUNCTIONS

knocking (or pinging) occurs, use a
gasoline of a different brand or premi­um unleaded fuel. Use of unleaded fuel
will extend spark plug life and reduce
maintenance costs.

Gasohol

There are two types of gasohol: gaso­hol containing ethanol and that contain­ing methanol. Gasohol containing
ethanol can be used if the ethanol con­tent does not exceed 10%. Gasohol
containing methanol is not recom­mended by Yamaha because it can
cause damage to the fuel system or ve­hicle performance problems.

EAU13440

Catalytic converter

This vehicle is equipped with a catalytic
converter in the muffler.

EWA10860

WARNING

The exhaust system is hot after op­eration. Make sure that the exhaust
system has cooled down before do­ing any maintenance work.

ECA10700

CAUTION:

The following precautions must be
observed to prevent a fire hazard or
other damages.

● Use only unleaded gasoline.

The use of leaded gasoline will
cause unrepairable damage to
the catalytic converter.

● Never park the vehicle near pos-

sible fire hazards such as grass
or other materials that easily
burn.

● Do not allow the engine to idle

too long.

EAU13550

Fuel cock

The fuel cock supplies fuel from the
tank to the carburetors while also filter­ing it.
The fuel cock lever positions are ex­plained as follows and shown in the il­lustrations.

3

OFF

1. Arrow mark positioned over “OFF”

With the fuel cock lever in this position,
fuel will not flow. Always turn the fuel
cock lever to this position when the en­gine is not running.

3-7

INSTRUMENT AND CONTROL FUNCTIONS

ON

3

1. Arrow mark positioned over “ON”

With the fuel cock lever in this position,
fuel flows to the carburetors. Turn the
fuel cock lever to this position when
starting the engine and riding.

RES

1. Arrow mark positioned over “RES”

This indicates reserve. With the fuel
cock lever in this position, the fuel re­serve is made available. Turn the fuel
cock lever to this position if you run out
of fuel while riding. When this occurs,
refuel as soon as possible and be sure
to turn the fuel cock lever back to “ON”!

EAU13620

Starter (choke) knob “”

1. Starter (choke) knob “”

Starting a cold engine requires a richer
air-fuel mixture, which is supplied by
the starter (choke).
Move the knob in direction (a) to turn on
the starter (choke).
Move the knob in direction (b) to turn off
the starter (choke).

ECA10990

CAUTION:

Do not use the starter (choke) for
more than 3 minutes as the exhaust
pipe may discolor from excessive
heat. In addition, extended use of
the starter (choke) will cause after­burning. If this occurs, turn off the
starter (choke).

3-8

EAU14180

Seats (XVS650)

Passenger seat

To remove the passenger seat
Remove the nut, and then pull the pas­senger seat up.

INSTRUMENT AND CONTROL FUNCTIONS

3

1. Nut

To install the passenger seat
Insert the projection on the front of the
passenger seat into the seat holder as
shown, place the seat in the original po­sition, and then install the nut.

1. Bolt

2. Seat holder

3. Projection

Rider seat

To remove the rider seat

1. Remove the passenger seat.

2. Remove the bolts, and then pull
the seat up.

3-9

1. Seat holder

2. Projection

To install the rider seat

1. Insert the projection on the front of
the rider seat into the seat holder
as shown, place the seat in the
original position, and then install
the bolts.

2. Install the passenger seat.

NOTE:

Make sure that the seats are properly
secured before riding.

INSTRUMENT AND CONTROL FUNCTIONS

Seats (XVS650A/AT)

Passenger seat

To remove the passenger seat
Remove the bolt, and then pull the pas­senger seat up.

3

1. Bolt

To install the passenger seat
Insert the projections on the front of the
passenger seat into the holders as
shown, place the seat in the original po­sition, and then install the bolt.

EAU14190

1. Seat holder

2. Projection

Rider seat

To remove the rider seat

1. Remove the passenger seat.

2. Remove the bolt, and then pull the
rider seat up.

To install the rider seat

1. Insert the projection on the front of
the rider seat into the holder as
shown, place the seat in the origi­nal position, and then install the
bolt.

1. Seat holder

2. Projection

2. Install the passenger seat.

NOTE:

Make sure that the seats are properly
secured before riding.

1. Bolt

3-10

INSTRUMENT AND CONTROL FUNCTIONS

EAU14281

Helmet holder

1. Helmet holder

2. Unlock.

To open the helmet holder, insert the
key into the lock, and then turn the key
as shown.
To lock the helmet holder, place it in the
original position, and then remove the
key.

EWA10160

WARNING

Never ride with a helmet attached to
the helmet holder, since the helmet
may hit objects, causing loss of con­trol and possibly an accident.

EAU14481

Storage compartment

The storage compartment is located on
the left side of the vehicle.

To open the storage compartment

1. Slide the lock cover open, insert
the key into the lock, and then turn
it clockwise.

1. Storage compartment cover

2. Storage compartment lock cover

3. Storage compartment lock

2. Pull the storage compartment cov­er out as shown.

3

To close the storage compartment

1. Place the storage compartment
cover in its original position as
shown.

1. Storage compartment

2. Storage compartment cover

3-11

2. Turn the key counterclockwise, re­move it, and then close the lock
cover.

INSTRUMENT AND CONTROL FUNCTIONS

Adjusting the shock absorber assembly

3

1. Position indicator

2. Spring preload adjusting ring

3. Extension bar

4. Special wrench

This shock absorber assembly is
equipped with a spring preload adjust­ing ring.

CAUTION:

Never attempt to turn an adjusting
mechanism beyond the maximum or
minimum settings.

Adjust the spring preload as follows.

1. Remove the passenger and rider
seats. (See page 3-9.)

EAU14860

ECA10100

2. To increase the spring preload and
thereby harden the suspension,
turn the adjusting ring in direction
(a). To decrease the spring pre­load and thereby soften the sus­pension, turn the adjusting ring in
direction (b).

NOTE:

● Align the appropriate notch in the

adjusting ring with the position in­dicator on the shock absorber.

● Use the special wrench and exten-

sion bar included in the owner’s
tool kit to make the adjustment.

Spring preload setting:

Minimum (soft):

1

Standard:

3

Maximum (hard):

7

3. Install the passenger and rider
seats.

EWA10220

WARNING

This shock absorber contains highly
pressurized nitrogen gas. For prop­er handling, read and understand
the following information before
handling the shock absorber. The
manufacturer cannot be held re­sponsible for property damage or
personal injury that may result from
improper handling.

● Do not tamper with or attempt to

open the gas cylinder.

● Do not subject the shock ab-

sorber to an open flame or other
high heat sources, otherwise it
may explode due to excessive
gas pressure.

● Do not deform or damage the

gas cylinder in any way, as this
will result in poor damping per­formance.

● Always have a Yamaha dealer

service the shock absorber.

3-12

INSTRUMENT AND CONTROL FUNCTIONS

EAU15150

Luggage strap holders

1. Luggage strap holder

There is a luggage strap holder on each
passenger footrest.

EAU15300

Sidestand

The sidestand is located on the left side
of the frame. Raise the sidestand or
lower it with your foot while holding the
vehicle upright.

NOTE:

The built-in sidestand switch is part of
the ignition circuit cut-off system, which
cuts the ignition in certain situations.
(See further down for an explanation of
the ignition circuit cut-off system.)

EWA10240

WARNING

The vehicle must not be ridden with
the sidestand down, or if the side­stand cannot be properly moved up
(or does not stay up), otherwise the
sidestand could contact the ground
and distract the operator, resulting
in a possible loss of control.
Yamaha’s ignition circuit cut-off
system has been designed to assist
the operator in fulfilling the respon­sibility of raising the sidestand be­fore starting off. Therefore, check
this system regularly as described

below and have a Yamaha dealer re­pair it if it does not function proper­ly.

3

3-13

INSTRUMENT AND CONTROL FUNCTIONS

EAU15311

Ignition circuit cut-off system

The ignition circuit cut-off system (com­prising the sidestand switch, clutch
switch and neutral switch) has the fol­lowing functions.

● It prevents starting when the trans-

mission is in gear and the side-

3

stand is up, but the clutch lever is
not pulled.

● It prevents starting when the trans-

mission is in gear and the clutch le­ver is pulled, but the sidestand is
still down.

● It cuts the running engine when the

transmission is in gear and the sid-

estand is moved down.
Periodically check the operation of the
ignition circuit cut-off system according
to the following procedure.

EWA10250

WARNING

If a malfunction is noted, have a
Yamaha dealer check the system be­fore riding.

3-14

INSTRUMENT AND CONTROL FUNCTIONS

With the engine turned off:

1. Move the sidestand down.

2. Make sure that the engine stop switch is turned on.

3. Turn the key on.

4. Shift the transmission into the neutral position.

5. Push the start switch.

Does the engine start?

YES NO

With the engine still running:

6. Move the sidestand up.

7. Keep the clutch lever pulled.

8. Shift the transmission into gear.

9. Move the sidestand down.

Does the engine stall?

YES NO

After the engine has stalled:

10. Move the sidestand up.

11. Keep the clutch lever pulled.

12. Push the start switch.

Does the engine start?

YES NO

The system is OK. The motorcycle can be ridden.

NOTE:

This check is most reliable if performed with
a warmed-up engine.

The neutral switch may be defective.
The motorcycle should not be ridden until
checked by a Yamaha dealer.

The sidestand switch may be defective.
The motorcycle should not be ridden until
checked by a Yamaha dealer.

The clutch switch may be defective.
The motorcycle should not be ridden until
checked by a Yamaha dealer.

3

3-15

PRE-OPERATION CHECKS

The condition of a vehicle is the owner’s responsibility. Vital components can start to deteriorate quickly and unexpectedly,
even if the vehicle remains unused (for example, as a result of exposure to the elements). Any damage, fluid leakage or loss
of tire air pressure could have serious consequences. Therefore, it is very important, in addition to a thorough visual inspec­tion, to check the following points before each ride.

NOTE:

Pre-operation checks should be made each time the vehicle is used. Such an inspection can be accomplished in a very short
time; and the added safety it assures is more than worth the time involved.

4

WARNING

If any item in the Pre-operation check list is not working properly, have it inspected and repaired before operating
the vehicle.

EAU15591

EWA11150

4-1

PRE-OPERATION CHECKS

Pre-operation check list

ITEM CHECKS PAGE

Fuel

Engine oil

Final gear oil • Check vehicle for oil leakage. 6-13

Front brake

Rear brake

Clutch

Throttle grip

Control cables

• Check fuel level in fuel tank.

• Refuel if necessary.

• Check fuel line for leakage.

• Check oil level in engine.

• If necessary, add recommended oil to specified level.

• Check vehicle for oil leakage.

• Check 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.

• Check operation.

• Check pedal free play.

• Adjust if necessary.

• Check operation.

• Lubricate cable if necessary.

• Check lever free play.

• Adjust if necessary.

• Make sure that operation is smooth.

• Check cable free play.

• If necessary, have Yamaha dealer adjust cable free play and lubricate cable and

grip housing.

• Make sure that operation is smooth.

• Lubricate if necessary.

6-11

6-21, 6-24, 6-24

6-22, 6-24

6-20

6-16, 6-26

6-25

EAU15602

3-6

4

4-2

PRE-OPERATION CHECKS

ITEM CHECKS PAGE

• Check for damage.

Wheels and tires

Brake and shift pedals

Brake and clutch levers

Sidestand

4

Chassis fasteners

Instruments, lights, signals
and switches

Sidestand switch

• Check tire condition and tread depth.

• Check air pressure.

• Correct if necessary.

• Make sure that operation is smooth.

• Lubricate pedal pivoting points if necessary.

• Make sure that operation is smooth.

• Lubricate lever pivoting points if necessary.

• Make sure that operation is smooth.

• Lubricate pivot if necessary.

• Make sure that all nuts, bolts and screws are properly tightened.

• Tighten if necessary.

• Check operation.

• Correct if necessary.

• Check operation of ignition circuit cut-off system.

• If system is defective, have Yamaha dealer check vehicle.

6-17, 6-19

6-26

6-26

6-27

—

—

3-13

4-3

OPERATION AND IMPORTANT RIDING POINTS

EAU15950

EWA10270

WARNING

● Become thoroughly familiar

with all operating controls and
their functions before riding.
Consult a Yamaha dealer re­garding any control or function
that you do not thoroughly un­derstand.

● Never start the engine or oper-

ate it in a closed area for any
length of time. Exhaust fumes
are poisonous, and inhaling
them can cause loss of con­sciousness and death within a
short time. Always make sure
that there is adequate ventila­tion.

● Before starting out, make sure

that the sidestand is up. If the
sidestand is not raised com­pletely, it could contact the
ground and distract the opera­tor, resulting in a possible loss
of control.

EAU16390

Starting and warming up a cold engine

In order for the ignition circuit cut-off
system to enable starting, one of the
following conditions must be met:

● The transmission is in the neutral

position.

● The transmission is in gear with

the clutch lever pulled and the sid­estand up.

EWA10290

WARNING

● Before starting the engine,

check the function of the igni­tion circuit cut-off system ac­cording to the procedure
described on page 3-14.

● Never ride with the sidestand

down.

1. Turn the fuel cock lever to “ON”.

2. Turn the key to “ON” and make
sure that the engine stop switch is
set to “”.

3. Shift the transmission into the neu­tral position.

NOTE:

When the transmission is in the neutral
position, the neutral indicator light
should be on, otherwise have a
Yamaha dealer check the electrical cir­cuit.

4. Turn the starter (choke) on and
completely close the throttle. (See
page 3-8.)

5. Start the engine by pushing the
start switch.

NOTE:

If the engine fails to start, release the
start switch, wait a few seconds, and
then try again. Each starting attempt
should be as short as possible to pre­serve the battery. Do not crank the en­gine more than 10 seconds on any one
attempt.

ECA11370

CAUTION:

The engine trouble warning light
should come on when the key is
turned to “ON”, and then go off after
a few seconds. If the engine trouble
warning light comes on or flashes

5

5-1

OPERATION AND IMPORTANT RIDING POINTS

after starting, immediately stop the
engine, and have a Yamaha dealer
check the self-diagnosis system.

6. After starting the engine, move the
starter (choke) back halfway.

CAUTION:

For maximum engine life, always
warm the engine up before starting
off. Never accelerate hard when the
engine is cold!

7. When the engine is warm, turn the

5

starter (choke) off.

NOTE:

The engine is warm when it responds
normally to the throttle with the starter
(choke) turned off. To avoid the possi­bility of excessive exhaust emissions,
never leave the starter (choke) on long­er than necessary. The time necessary
for starter (choke) use depends upon
the ambient temperature. Tempera­tures above 10 °C (50 °F) require about
7 seconds of starter (choke) use and
temperatures below 10 °C (50 °F) re­quire about 35 seconds with the starter

ECA11130

(choke) turned on, then about 2.5 min­utes with the starter (choke) in the half­way position.

EAU16640

Starting a warm engine

Follow the same procedure as for start­ing a cold engine with the exception
that the starter (choke) is not required
when the engine is warm.

5-2

OPERATION AND IMPORTANT RIDING POINTS

Shifting

XVS650

1. Shift pedal

2. Neutral position

XVS650A/AT

1. Shift pedal

2. Neutral position

EAU16671

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 neu­tral position, press the shift pedal down
repeatedly until it reaches the end of its
travel, and then slightly raise it.

ECA10260

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 dis­tances. The transmission is
properly lubricated only when
the engine is running. Inade­quate lubrication may damage
the transmission.

● Always use the clutch while

changing gears to avoid damag­ing the engine, transmission,

and drive train, which are not
designed to withstand the
shock of forced shifting.

EAU16680

To start out and accelerate

1. Pull the clutch lever to disengage
the clutch.

2. Shift the transmission into first
gear. The neutral indicator light
should go out.

3. Open the throttle gradually, and at
the same time, release the clutch
lever slowly.

4. At the recommended shift points
shown in the following table, close
the throttle, and at the same time,
quickly pull the clutch lever in.

5. Shift the transmission into second
gear. (Make sure not to shift the
transmission into the neutral posi­tion.)

6. Open the throttle part way and
gradually release the clutch lever.

7. Follow the same procedure when
shifting to the next higher gear.

5

5-3

OPERATION AND IMPORTANT RIDING POINTS

NOTE:

Always shift gears at the recommended
shift points.

To decelerate

1. Apply both the front and the rear
brakes to slow the motorcycle.

2. Shift the transmission into first
gear when the motorcycle reaches
25 km/h (15.5 mi/h). If the engine is
about to stall or runs very roughly,

5

pull the clutch lever in and use the
brakes to stop the motorcycle.

3. Shift the transmission into the neu­tral position when the motorcycle
is almost completely stopped. The
neutral indicator light should come
on.

Recommended shift points

The recommended shift points during
acceleration and deceleration are
shown in the table below.

EAU16700

EAU16720

Shift up points:

1st → 2nd: 16 km/h (9.9 mi/h)
2nd → 3rd: 24 km/h (14.9 mi/h)
3rd → 4th: 32 km/h (19.9 mi/h)
4th → 5th: 40 km/h (24.9 mi/h)

Shift down points:

5th → 4th: 25 km/h (15.5 mi/h)
4th → 3rd: 25 km/h (15.5 mi/h)
3rd → 2nd: 25 km/h (15.5 mi/h)
2nd → 1st: 25 km/h (15.5 mi/h)

EAU16841

Engine break-in

There is never a more important period
in the life of your engine than the period
between 0 and 1600 km (1000 mi). For
this reason, you should read the follow­ing material carefully.
Since the engine is brand new, do not
put an excessive load on it for the first
1600 km (1000 mi). The various parts in
the engine wear and polish themselves
to the correct operating clearances.
During this period, prolonged full-throt­tle operation or any condition that might
result in engine overheating must be
avoided.

EAU17041

0–1000 km (0–600 mi)

Avoid prolonged operation above 1/3
throttle.

1000–1600 km (600–1000 mi)

Avoid prolonged operation above 1/2
throttle.

5-4

OPERATION AND IMPORTANT RIDING POINTS

ECA10331

CAUTION:

After 1000 km (600 mi) of operation,
the engine oil and final gear oil must
be changed, and the oil filter car­tridge or element replaced.

1600 km (1000 mi) and beyond

The vehicle can now be operated nor­mally.

ECA10270

CAUTION:

If any engine trouble should occur
during the engine break-in period,
immediately have a Yamaha dealer
check the vehicle.

EAU17180

Parking

When parking, stop the engine, remove
the key from the main switch, and then
turn the fuel cock lever to “OFF”.

EWA10310

WARNING

● Since the engine and exhaust

system can become very hot,
park in a place where pedestri­ans or children are not likely to
touch them.

● Do not park on a slope or on soft

ground, otherwise the vehicle
may overturn.

ECA10380

CAUTION:

Never park in an area where there
are fire hazards such as grass or
other flammable materials.

5

5-5

PERIODIC MAINTENANCE AND MINOR REPAIR

Safety is an obligation of the owner. Pe­riodic inspection, adjustment and lubri­cation will keep your vehicle in the
safest and most efficient condition pos­sible. The most important points of
motorcycle inspection, adjustment, and
lubrication are explained on the follow­ing pages.

Maintenance, replacement, or repair
of the emission control devices and
systems may be performed by any
repair establishment or individual
that is certified (if applicable).

6

WARNING

If you are not familiar with mainte­nance work, have a Yamaha dealer
do it for you.

EAU17231

EWA10320

EAU17301

PERIODIC MAINTENANCE

PROPER PERIODIC MAINTENANCE
OF YOUR VEHICLE IS IMPORTANT
IN ORDER TO ENJOY LONG, PLEA­SURABLE SERVICE. ESPECIALLY
IMPORTANT ARE THE MAINTE­NANCE SERVICES RELATED TO
EMISSIONS CONTROL. THESE
CONTROLS NOT ONLY FUNCTION
TO ENSURE CLEANER AIR, BUT
ARE ALSO VITAL TO PROPER EN­GINE OPERATION AND MAXIMUM
PERFORMANCE. IN THE FOLLOW­ING PERIODIC MAINTENANCE
CHARTS, THE SERVICES RELATED
TO EMISSIONS CONTROL ARE
GROUPED SEPARATELY. THESE
SERVICES REQUIRE SPECIALIZED
DATA, KNOWLEDGE, AND EQUIP­MENT. YAMAHA DEALERS ARE
TRAINED AND EQUIPPED TO PER­FORM THESE PARTICULAR SER­VICES.

EAU17440

Owner’s tool kit

1. Owner’s tool kit

The owner’s tool kit is located inside the
storage compartment. (See page
3-11.)
The service information included in this
manual and the tools provided in the
owner’s tool kit are intended to assist
you in the performance of preventive
maintenance and minor repairs. How­ever, additional tools such as a torque
wrench may be necessary to perform
certain maintenance work correctly.

NOTE:

If you do not have the tools or experi­ence required for a particular job, have
a Yamaha dealer perform it for you.

6-1

EWA10340

WARNING

Modifications not approved by
Yamaha may cause loss of perfor­mance, excessive emissions, and
render the vehicle unsafe for use.
Consult a Yamaha dealer before at­tempting any changes.

PERIODIC MAINTENANCE AND MINOR REPAIR

6

6-2

PERIODIC MAINTENANCE AND MINOR REPAIR

Periodic maintenance chart for the emission control system

INITIAL ODOMETER READINGS

No. ITEM ROUTINE

1 * Fuel line

2 * Fuel filter • Replace. Replace.

3 Spark plugs

4 * Valve clearance

6

Crankcase breather

5 *

system

Carburetor synchro-

6 *

nization

7 * Idle speed

8 * Exhaust system

Evaporative emis-

9 *

sion control system
(For California only)

* Since these items require special tools, data and technical skills, have a Yamaha dealer perform the service.

• Check fuel hoses for cracks or
damage.

• Replace if necessary.

• Check condition.

• Adjust gap and clean.

• Replace every 8000 mi (13000

km) or 12 months.

• Check and adjust valve clearance
when engine is cold.

• Check breather hose for cracks or
damage.

• Replace if necessary.

• Adjust synchronization of carbu-

retors.

• Check and adjust engine idle
speed.

• Check for leakage.

• Tighten if necessary.

• Replace gasket(s) if necessary.

• Check control system for dam-

age.

• Replace if necessary.

600 mi

(1000 km)

or

1 month

√√√√√√

√√√√√√

6-3

4000 mi

(7000 km)

or

6 months

√√√√√

√ Replace. √ Replace. √

√√√√√

√√√√√

√√√√√

8000 mi

(13000 km)

or

12 months

12000 mi

(19000 km)

or

18 months

√√

16000 mi

(25000 km)

or

24 months

EAU17600

20000 mi

(31000 km)

or

30 months

PERIODIC MAINTENANCE AND MINOR REPAIR

General maintenance and lubrication chart

No. ITEM ROUTINE

1 * Air filter element

2 * Clutch

3 * Front brake

4 * Rear brake

5 * Brake hose

6 * Wheels

7 * Tires

8 * Wheel bearings

• Clean with compressed air.

• Replace if necessary.

• Check operation.

• Adjust or replace cable.

• Check operation, fluid level, and

for fluid leakage.

• Replace brake pads if necessary.

• Check operation.

• Adjust cable and replace brake

shoes if necessary.

• Check for cracks or damage. √√√√√

• Replace. Every 4 years

• Check runout, spoke tightness

and for damage.

• Tighten spokes if necessary.

• Check tread depth and for dam-

age.

• Replace if necessary.

• Check air pressure.

• Correct if necessary.

• Check bearings for smooth oper-

ation.

• Replace if necessary.

EAU32182

INITIAL ODOMETER READINGS

600 mi

(1000 km)

or

1 month

√√√√√√

√√√√√√

√√√√√√

4000 mi

(7000 km)

or

6 months

√√√√√

√√√√√

√√√√√

√√√√√

8000 mi

(13000 km)

or

12 months

12000 mi

(19000 km)

or

18 months

16000 mi

(25000 km)

or

24 months

20000 mi

(31000 km)

or

30 months

6

6-4

PERIODIC MAINTENANCE AND MINOR REPAIR

INITIAL ODOMETER READINGS

No. ITEM ROUTINE

Swingarm pivot

9 *

bearings

10 * Steering bearings

11 * Chassis fasteners

6

Brake and clutch le-

12

ver pivot shafts

Brake and shift ped-

13

al pivot shafts

14 Sidestand pivot

15 * Sidestand switch

16 * Front fork

Shock absorber as-

17 *

sembly

• Check bearing assemblies for
looseness.

• Moderately repack with lithium­soap-based grease.

• Check bearing assemblies for
looseness.

• Moderately repack with lithium­soap-based grease every 16000
mi (25000 km) or 24 months.

• Check all chassis fitting and fas­teners.

• Correct if necessary.

• Apply lithium-soap-based grease

(all-purpose grease) lightly.

• Apply lithium-soap-based grease
(all-purpose grease) lightly.

• Check operation.

• Apply lithium-soap-based grease

(all-purpose grease) lightly.

• Check operation and replace if
necessary.

• Check operation and for oil leak­age.

• Replace if necessary.

• Check operation and for oil leak-

age.

• Replace if necessary.

600 mi

(1000 km)

or

1 month

√√√√Repack. √

√√√√√√

6-5

4000 mi

(7000 km)

6 months

8000 mi

or

(13000 km)

or

12 months

√ Repack.

√√√√√

√√√√√

√√√√√

√√√√√

√√√√√

√√√√√

12000 mi

(19000 km)

or

18 months

16000 mi

(25000 km)

or

24 months

20000 mi

(31000 km)

or

30 months

PERIODIC MAINTENANCE AND MINOR REPAIR

INITIAL ODOMETER READINGS

No. ITEM ROUTINE

18 Engine oil

Engine oil filter ele-

19

ment

20 Final gear oil

Control and meter

21 *

cables

Throttle grip hous-

22 *

ing and cable

* Since these items require special tools, data and technical skills, have a Yamaha dealer perform the service.

• Change (warm engine before
draining).

• Replace. √√√

• Check oil level and for oil leakage.

• Change at initial 600 mi (1000

km) or 1 month, and thereafter
every 16000 mi (25000 km) or 24
months.

• Apply Yamaha chain and cable
lube or engine oil 10W-30 thor­oughly.

• Check operation and free play.

• Adjust the throttle cable free play

if necessary.

• Lubricate the throttle grip housing
and cable.

600 mi

(1000 km)

or

1 month

√√√√√√

Change. √√√Change. √

√√√√√√

NOTE:

From 24000 mi (37000 km) or 36 months, repeat the maintenance intervals starting from 8000 mi (13000 km) or 12 months.

4000 mi

(7000 km)

or

6 months

√√√√√

8000 mi

(13000 km)

or

12 months

12000 mi

(19000 km)

or

18 months

16000 mi

(25000 km)

or

24 months

20000 mi

(31000 km)

or

30 months

6

NOTE:

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

6-6

EAU17620

PERIODIC MAINTENANCE AND MINOR REPAIR

● Hydraulic brake system

• When disassembling the master cylinder or caliper cylinder, always replace the brake fluid. Check the brake fluid level
regularly and fill as required.

• Replace the oil seals on the inner parts of the master cylinder and caliper cylinder every two years.

• Replace the brake hoses every four years or if cracked or damaged.

6

6-7

PERIODIC MAINTENANCE AND MINOR REPAIR

EAU18771

Removing and installing
panels

The panels shown need to be removed
to perform some of the maintenance
jobs described in this chapter. Refer to
this section each time a panel needs to
be removed and installed.

XVS650

1. Panel A

XVS650A/AT

1. Panel A

1. Panel B

Panel A

XVS650

1. Bolt

To install the panel
Place the panel in the original position,
and then install the bolts.

6

XVS650A/AT

EAU19192

To remove the panel
Remove the bolts, and then take the
panel off.

6-8

1. Bolt

PERIODIC MAINTENANCE AND MINOR REPAIR

Panel B

To remove the panel
Remove the bolt, and then pull the pan­el off as shown.

6

1. Bolt

To install the panel
Place the panel in the original position,
and then install the bolt.

EAU19151

EAU19543

Checking the spark plugs

The spark plugs are important engine
components, which are easy to check.
Since heat and deposits will cause any
spark plug to slowly erode, the spark
plugs should be removed and checked
in accordance with the periodic mainte­nance and lubrication chart. In addition,
the condition of the spark plugs can re­veal the condition of the engine.

To remove a spark plug

1. Remove the spark plug cap.

1. Spark plug cap

2. Remove the spark plug as shown,
with the spark plug wrench includ­ed in the owner’s tool kit.

1. Spark plug wrench

To check the spark plugs

1. Check that the porcelain insulator
around the center electrode on
each spark plug is a medium-to­light tan (the ideal color when the
vehicle 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 dif­ferent color, the engine could be defec­tive. Do not attempt to diagnose such
problems yourself. Instead, have a
Yamaha dealer check the vehicle.

6-9

PERIODIC MAINTENANCE AND MINOR REPAIR

3. Check each spark plug for elec­trode erosion and excessive car­bon or other deposits, and replace
it if necessary.

Specified spark plug:

NGK/DPR7EA-9
DENSO/X22EPR-U9

To install a spark plug

1. Measure the spark plug gap with a
wire thickness gauge and, if nec­essary, adjust the gap to specifica­tion.

1. Spark plug gap

Spark plug gap:

0.8–0.9 mm (0.031–0.035 in)

2. Clean the surface of the spark plug
gasket and its mating surface, and
then wipe off any grime from the
spark plug threads.

3. Install the spark plug with the
spark plug wrench, and then tight­en it to the specified torque.

Tightening torque:

Spark plug:

17.5 Nm (1.75 m·kgf, 13 ft·lbf)

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 speci­fied torque as soon as possible.

4. Install the spark plug cap.

EAU19672

Canister (for California only)

6

This model is equipped with a canister
to prevent the discharging of fuel vapor
into the atmosphere.

● Check each hose connection.

● Check each hose and canister for

cracks or damage. Replace if dam­aged.

● Make sure the vent hose is not

blocked. Clean it if necessary.

6-10

PERIODIC MAINTENANCE AND MINOR REPAIR

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 ele­ment replaced at the intervals specified
in the periodic maintenance and lubri­cation chart.

To check the engine oil level

1. Place the vehicle on a level sur­face and hold it in an upright posi­tion.

NOTE:

6

Make sure that the vehicle is positioned
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 set­tles, and then check the oil level
through the check window located
at the bottom-left side of the crank­case.

EAU19742

NOTE:

The engine oil should be between the
minimum and maximum level marks.

1. Engine oil level check window

2. Maximum level mark

3. Minimum level mark

4. Engine oil filler cap

4. If the engine oil is at or below the
minimum level mark, add sufficient
oil of the recommended type to
raise it to the correct level.

To change the engine oil (with or
without oil filter element replace­ment)

1. Start the engine, warm it up for
several minutes, and then turn it
off.

2. Place an oil pan under the engine
to collect the used oil.

3. Remove the engine oil filler cap
and drain bolt to drain the oil from
the crankcase.

1. Engine oil filler bolt

2. Oil pan

NOTE:

Skip steps 4–7 if the oil filter element is
not being replaced.

4. Remove the outer and inner oil fil­ter element covers by removing
the bolts.

6-11

1. Outer oil filter element cover

2. Bolt

1. Inner oil filter element cover

2. Bolt

5. Remove the oil filter element and
O-ring.

PERIODIC MAINTENANCE AND MINOR REPAIR

Tightening torque:

Engine oil drain bolt:

43 Nm (4.3 m·kgf, 31 ft·lbf)

9. Add the specified amount of the
recommended oil, and then install
and tighten the oil filler cap.

Recommended engine oil:

1. Oil filter element

2. O-ring

6. Install a new oil filter element and
the O-ring.

7. Install the oil filter element covers
by installing the bolts, and then
tighten them to the specified
torque.

Tightening torque:

Oil filter element cover bolt:

10 Nm (1.0 m·kgf, 7 ft·lbf)

8. Install the engine oil drain bolt, and
then tighten it to the specified
torque.

NOTE:

Check the washer for damage and re­place it if necessary.

See page 8-1.

Oil quantity:

Without oil filter element replace­ment:

2.60 L (2.75 US qt) (2.29 Imp.qt)

With oil filter element replacement:

2.80 L (2.96 US qt) (2.46 Imp.qt)

ECA11620

CAUTION:

● In order to prevent clutch slip-

page (since the engine oil also
lubricates the clutch), do not
mix any chemical additives. Do
not use oils with a diesel speci­fication of “CD” or oils of a high­er quality than specified. In
addition, do not use oils labeled
“ENERGY CONSERVING II” or
higher.

6

6-12

PERIODIC MAINTENANCE AND MINOR REPAIR

● Make sure that no foreign mate-

rial enters the crankcase.

10. Start the engine, and then let it idle
for several minutes while checking
it for oil leakage. If oil is leaking, im­mediately turn the engine off and
check for the cause.

11. Turn the engine off, and then
check the oil level and correct it if
necessary.

6

EAU20022

Final gear oil

The final gear case must be checked
for oil leakage before each ride. If any
leakage is found, have a Yamaha deal­er check and repair the vehicle. 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.

EWA10370

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 vehicle 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 vehicle is posi-

tioned straight up when checking
the oil level. A slight tilt to the side
can 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 the
filler hole.

1. Final gear oil drain bolt

2. Final gear oil filler bolt

3. Correct oil level

3. If the oil is below the brim of the fill­er hole, add sufficient oil of the rec­ommended 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.

6-13

PERIODIC MAINTENANCE AND MINOR REPAIR

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.

Tightening torque:

Final gear oil drain bolt:

23 Nm (2.3 m·kgf, 17 ft·lbf)

4. Add the recommended final gear
oil to the brim of the filler hole.

Recommended final gear oil:

SAE80 API GL-4 Hypoid gear oil

Oil quantity:

0.19 L (0.20 US qt) (0.17 Imp.qt)

NOTE:

GL4 is a quality rating. Hypoid gear oils
rated GL5 or GL6 may also be used.

5. Install the oil filler bolt, and then
tighten it to the specified torque.

Tightening torque:

Final gear oil filler bolt:

23 Nm (2.3 m·kgf, 17 ft·lbf)

6. Check the final gear case for oil
leakage. If oil is leaking, check for
the cause.

EAU33381

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 fre­quently if you are riding in unusually
wet or dusty areas.

1. Remove the air filter case cover by
removing the bolts.

6

1. Air filter case cover

2. Bolt

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.

6-14

PERIODIC MAINTENANCE AND MINOR REPAIR

1. Air filter element

4. Insert the air filter element into the
air filter case as shown.

6

1. Air filter element holder

2. Projection

3. Slot

ECA10480

CAUTION:

● Make sure that the air filter ele-

ment is properly seated in the
air filter case.

● The engine should never be op-

erated without the air filter ele­ment installed, otherwise the
piston(s) and/or cylinder(s) may
become excessively worn.

5. Install the air filter case cover by
aligning the match marks and in­stalling the bolts.

1. Match marks

NOTE:

If dust or water collects in the air filter
check hose, remove the clamp from it,
and then remove the plug to drain the
hose.

1. Air filter check hose

6-15

PERIODIC MAINTENANCE AND MINOR REPAIR

EAU21270

Adjusting the carburetors

The carburetors are important parts of
the engine and emission control sys­tem, which require very sophisticated
adjustment. Therefore, all carburetor
adjustments should be left to a Yamaha
dealer, who has the necessary profes­sional knowledge and experience.

EAU21380

Adjusting the throttle cable free play

1. Throttle cable free play

The throttle cable free play should mea­sure 4.0–6.0 mm (0.16–0.24 in) at the
throttle grip. Periodically check the
throttle cable free play and, if neces­sary, have a Yamaha dealer adjust it.

EAU21400

Adjusting the valve clearance

The valve clearance changes with use,
resulting in improper air-fuel mixture
and/or engine noise. To prevent this
from occurring, the valve clearance
must be adjusted by a Yamaha dealer
at the intervals specified in the periodic
maintenance and lubrication chart.

6

6-16

PERIODIC MAINTENANCE AND MINOR REPAIR

Tires

To maximize the performance, durabil­ity, and safe operation of your motor­cycle, note the following points
regarding the specified tires.

Tire air pressure

The tire air pressure should be checked
and, if necessary, adjusted before each
ride.

WARNING

● The tire air pressure must be

checked and adjusted on cold

6

tires (i.e., when the temperature
of the tires equals the ambient
temperature).

● The tire air pressure must be ad-

justed in accordance with the
riding speed and with the total
weight of rider, passenger, car­go, and accessories approved
for this model.

EAU32520

EWA10500

Tire air pressure (measured on cold
tires):

0–90 kg (0–198 lb):

Front:

XVS650 200 kPa (29 psi) (2.00
kgf/cm²)
XVS650A 225 kPa (33 psi)
(2.25 kgf/cm²)
XVS650AT 225 kPa (33 psi)
(2.25 kgf/cm²)

Rear:

225 kPa (33 psi) (2.25 kgf/cm²)

XVS650 90–178 kg (198–392 lb)
(CAL)
XVS650 90–180 kg (198–397 lb)
(U49)
XVS650A 90–198 kg (198–437 lb)
(CAL)
XVS650A 90–200 kg (198–441 lb)
(U49)
XVS650AT 90–198 kg (198–437 lb)
(CAL)
XVS650AT 90–200 kg (198–441 lb)
(U49):

Front:

XVS650 200 kPa (29 psi) (2.00
kgf/cm²)
XVS650A 225 kPa (33 psi)
(2.25 kgf/cm²)
XVS650AT 225 kPa (33 psi)
(2.25 kgf/cm²)

Rear:

250 kPa (36 psi) (2.50 kgf/cm²)

6-17

Maximum load*:

XVS650 178 kg (392 lb) (CAL)
XVS650 180 kg (397 lb) (U49)
XVS650A 198 kg (437 lb) (CAL)
XVS650A 200 kg (441 lb) (U49)
XVS650AT 198 kg (437 lb) (CAL)
XVS650AT 200 kg (441 lb) (U49)

* Total weight of rider, passenger, car-

go and accessories

EWA10510

WARNING

Proper loading of your vehicle is im­portant for several characteristics of
your vehicle, such as handling,
braking, performance and safety. Do
not carry loosely packed items that
can shift. Securely pack your heavi­est items close to the center of the
vehicle, and distribute the weight
evenly from side to side. Properly
adjust the suspension for your load,
and check the condition and pres­sure of your tires. NEVER OVER­LOAD YOUR VEHICLE. Make sure
that the total weight of the cargo, rid­er, passenger, and accessories
(cowling, saddlebags, etc. if ap­proved for this model) does not ex­ceed the maximum load of the

PERIODIC MAINTENANCE AND MINOR REPAIR

vehicle. Operation of an overloaded
vehicle could cause tire damage, an
accident, or even injury.

Tire inspection

1. Tire sidewall

2. Tire wear indicator

3. Tire tread depth

Always check the tires before operating
the motorcycle. If a tire tread shows
crosswise lines (minimum tread depth),
if the tire has a nail or glass fragments
in it, or if the sidewall is cracked, con­tact a Yamaha dealer immediately and
have the tire replaced.

EWA10560

WARNING

● It is dangerous to ride with a

worn-out tire. When a tire tread
begins to show crosswise lines,
have a Yamaha dealer replace
the tire immediately.

● The replacement of all wheel-

and brake-related parts, includ­ing the tires, should be left to a
Yamaha dealer, who has the
necessary professional knowl­edge and experience.

● It is not recommended to patch

a punctured tube. If unavoid­able, however, patch the tube
very carefully and replace it as
soon as possible with a high­quality product.

Tire information

This motorcycle is equipped with spoke
wheels and tube tires.

EWA10460

WARNING

● The front and rear tires should

be of the same make and de­sign, otherwise the handling
characteristics of the vehicle
cannot be guaranteed.

● After extensive tests, only the

tires listed below have been ap­proved for this model by
Yamaha Motor Co., Ltd.

6

Minimum tire tread depth (front and
rear):

1.0 mm (0.04 in)

6-18

PERIODIC MAINTENANCE AND MINOR REPAIR

Front tire:

Size:

XVS650 100/90-19M/C 57S
XVS650A 130/90-16M/C 67S
XVS650AT 130/90-16M/C 67S

Manufacturer/model:

XVS650 BRIDGESTONE/EXE­DRA L309
XVS650A BRIDGESTONE/EXE­DRA G703
XVS650AT BRIDGESTONE/EXE­DRA G703
XVS650 DUNLOP/F24
XVS650A DUNLOP/D404F
XVS650AT DUNLOP/D404F

Rear tire:

Size:

6

170/80-15M/C 77S

Manufacturer/model:

XVS650 BRIDGESTONE/EXE­DRA G546
XVS650A BRIDGESTONE/EXE­DRA G702
XVS650AT BRIDGESTONE/EXE­DRA G702
XVS650 DUNLOP/K555
XVS650A DUNLOP/D404G
XVS650AT DUNLOP/D404G

Spoke wheels

To maximize the performance, durabil­ity, and safe operation of your motor­cycle, note the following points
regarding the specified wheels.

● The wheel rims should be checked

for cracks, bends or warpage, and
the spokes for looseness or dam­age before each ride. If any dam­age is found, have a Yamaha
dealer replace the wheel. Do not
attempt even the smallest repair to
the wheel. A deformed or cracked
wheel must be replaced.

● The wheel should be balanced

whenever either the tire or wheel
has been changed or replaced. An
unbalanced wheel can result in
poor performance, adverse han­dling characteristics, and a short­ened tire life.

● Ride at moderate speeds after

changing a tire since the tire sur­face must first be “broken in” for it
to develop its optimal characteris-

EAU21940

Accessories and replacement
parts

WARNING

This vehicle is not designed to pull a
trailer or to be attached to a sidecar.
The accessories or replacement
parts you choose for your vehicle
should be designed specifically for
this model, and they must be se­curely mounted to maintain the in­herent stability of the original
design. Genuine Yamaha Parts and
Accessories are designed and test­ed to be compatible with your vehi­cle. Please consider Genuine
Yamaha Parts and Accessories be­fore making a purchase. Use of non­Yamaha-approved accessories or
replacement parts may cause loss of
handling stability and riding safety.
Since Yamaha cannot control the
quality of accessories or parts man­ufactured by other companies,
Yamaha cannot be held liable for

EAU22011

EWA10621

tics.

6-19

PERIODIC MAINTENANCE AND MINOR REPAIR

any consequences caused by the
use of items which have not been
approved by Yamaha.

EAU22041

Adjusting the clutch lever free play

1. Locknut

2. Clutch lever free play adjusting bolt

3. Clutch lever free play

The clutch lever free play should mea­sure XVS650 10.0–15.0 mm (0.39–

0.59 in)
XVS650A 5.0–10.0 mm (0.20–0.39 in)
XVS650AT 5.0–10.0 mm (0.20–0.39
in) as shown. Periodically check the
clutch lever free play and, if necessary,
adjust it as follows.

1. Loosen the locknut at the clutch le­ver.

2. To increase the clutch lever free
play, turn the adjusting bolt in di­rection (a). To decrease the clutch
lever free play, turn the adjusting
bolt in direction (b).

NOTE:

If the specified clutch lever free play
could be obtained as described above,
tighten the locknut and skip the rest of
the procedure, otherwise proceed as
follows.

3. Fully turn the adjusting bolt at the
clutch lever in direction (a) to loos­en the clutch cable.

4. Loosen the locknut at the crank­case.

6

6-20

1. Clutch lever free play adjusting nut (crank­case)

2. Locknut

PERIODIC MAINTENANCE AND MINOR REPAIR

5. To increase the clutch lever free
play, turn the adjusting nut in direc­tion (a). To decrease the clutch le­ver free play, turn the adjusting nut
in direction (b).

6. Tighten the locknut at the clutch le­ver and the crankcase.

6

EAU22092

Adjusting the brake lever free play

1. Brake lever free play

The brake lever free play should mea­sure 10.0–15.0 mm (0.39–0.59 in) as
shown. Periodically check the brake le­ver free play and, if necessary, adjust it
as follows.

6-21

1. Locknut

2. Brake lever free play adjusting screw

1. Loosen the locknut at the brake le­ver.

2. To increase the brake lever free
play, turn the adjusting screw in di­rection (a). To decrease the brake
lever free play, turn the adjusting
screw in direction (b).

3. Tighten the locknut.

EWA10630

WARNING

● After adjusting the brake lever

free play, check the free play
and make sure that the brake is
working properly.

● A soft or spongy feeling in the

brake lever can indicate the
presence of air in the hydraulic

PERIODIC MAINTENANCE AND MINOR REPAIR

system. If there is air in the hy­draulic system, have a Yamaha
dealer bleed the system before
operating the motorcycle. Air in
the hydraulic system will dimin­ish the braking performance,
which may result in loss of con­trol and an accident.

EAU22231

Adjusting the brake pedal position and free play

XVS650

1. Distance between brake pedal and footrest

2. Brake pedal free play

XVS650A/AT

1. Distance between brake pedal and footrest

2. Brake pedal free play

EWA10670

WARNING

It is advisable to have a Yamaha
dealer make these adjustments.

NOTE:

The brake pedal position should be ad­justed before adjusting the brake pedal
free play.

Brake pedal position

The brake pedal should be positioned
approximately XVS650 102.0 mm
(4.02 in)
XVS650A 108.0 mm (4.25 in)
XVS650AT 108.0 mm (4.25 in) above
the top of the footrest as shown. Peri­odically check the brake pedal position
and, if necessary, adjust it as follows.

1. Loosen the locknut at the brake
pedal.

2. To raise the brake pedal, turn the
adjusting bolt in direction (a). To
lower the brake pedal, turn the ad­justing bolt in direction (b).

6

6-22

PERIODIC MAINTENANCE AND MINOR REPAIR

1. Locknut

2. Brake pedal position adjusting bolt

3. Tighten the locknut.

WARNING

6

After adjusting the brake pedal posi­tion, the brake pedal free play must
be adjusted.

Brake pedal free play

The brake pedal free play should mea­sure 20.0–30.0 mm (0.79–1.18 in) at
the brake pedal end. Periodically check
the brake pedal free play and, if neces­sary, adjust it as follows.

EWA11230

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).

1. Brake pedal free play adjusting nut

EAU22270

Adjusting the rear brake light
switch

1. Rear brake light switch

2. Rear brake light switch adjusting nut

The rear brake light switch, which is ac­tivated 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).

6-23

PERIODIC MAINTENANCE AND MINOR REPAIR

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 main­tenance and lubrication chart.

EAU22430

Front brake pads

1. Brake pad wear indicator groove

Each front brake pad is provided with
wear indicator grooves, which allow
you to check the brake pad wear with­out 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 disap­peared, have a Yamaha dealer replace
the brake pads as a set.

EAU22540

Rear brake shoes

1. Brake shoe wear limit line

2. Brake shoe wear indicator

The rear brake is provided with a wear
indicator, which allows you to check the
brake shoe wear without having to dis­assemble 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.

EAU32342

Checking the brake fluid level

1. Minimum level mark

Insufficient brake fluid may allow air to
enter the brake system, possibly caus­ing 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 mas­ter cylinder is level by turning the
handlebars.

6

6-24

PERIODIC MAINTENANCE AND MINOR REPAIR

● Use only the recommended quality

brake fluid, otherwise the rubber
seals may deteriorate, causing
leakage and poor braking perfor­mance.

Recommended brake fluid:

DOT 4

● 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-

6

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. Al­ways 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 sud­denly, 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 mainte­nance 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 dam­aged or leaking.

● Oil seals: Replace every two

years.

● Brake hose: Replace every four

years.

EAU23090

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 ca­bles and cable ends should be lubricat­ed if necessary. If a cable is damaged
or does not move smoothly, have a
Yamaha dealer check or replace it.

Recommended lubricant:

Yamaha Chain and Cable Lube or
engine oil SAE 10W-30 (API SE)

EWA10710

WARNING

Damage to the outer housing of ca­bles may result in internal rusting
and cause interference with cable
movement. Replace damaged ca­bles as soon as possible to prevent
unsafe conditions.

6-25

PERIODIC MAINTENANCE AND MINOR REPAIR

EAU23110

Checking and lubricating the
throttle grip and cable

The operation of the throttle grip should
be checked before each ride. In addi­tion, the cable should be lubricated or
replaced 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 lu­bricated if necessary.

Recommended lubricant:

Lithium-soap-based grease (all-pur­pose grease)

EAU23140

Checking and lubricating the
brake and clutch levers

The operation of the brake and clutch
levers should be checked before each
ride, and the lever pivots should be lu­bricated if necessary.

Recommended lubricant:

Lithium-soap-based grease (all-pur­pose grease)

6

6-26

PERIODIC MAINTENANCE AND MINOR REPAIR

Checking and lubricating the
sidestand

The operation of the sidestand should
be checked before each ride, and the
sidestand pivot and metal-to-metal

6

contact surfaces should be lubricated if
necessary.

WARNING

If the sidestand does not move up
and down smoothly, have a Yamaha
dealer check or repair it.

Recommended lubricant:

Lithium-soap-based grease (all-pur­pose grease)

EAU23200

EWA10730

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 main­tenance and lubrication chart.

To check the condition

EWA10750

WARNING

Securely support the vehicle so that
there 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 sur­face and hold it in an upright posi­tion.

2. While applying the front brake,
push down hard on the handlebars
several times to check if the front
fork compresses and rebounds
smoothly.

ECA10590

CAUTION:

If any damage is found or the front
fork does not operate smoothly,
have a Yamaha dealer check or re­pair it.

6-27

PERIODIC MAINTENANCE AND MINOR REPAIR

EAU23280

Checking the steering

Worn or loose steering bearings may
cause danger. Therefore, the operation
of the steering must be checked as fol­lows at the intervals specified in the pe­riodic maintenance and lubrication
chart.

1. Place a stand under the engine to
raise the front wheel off the
ground.

EWA10750

WARNING

Securely support the vehicle so that
there is no danger of it falling over.

2. Hold the lower ends of the front
fork legs and try to move them for­ward and backward. If any free
play can be felt, have a Yamaha
dealer check or repair the steering.

EAU23290

Checking the wheel bearings

The front and rear wheel bearings must
be checked at the intervals specified in
the periodic maintenance and lubrica­tion chart. If there is play in the wheel
hub or if the wheel does not turn
smoothly, have a Yamaha dealer check
the wheel bearings.

6

6-28

PERIODIC MAINTENANCE AND MINOR REPAIR

Battery

The battery is located behind panel B.
(See page 6-8.)
This model is equipped with a sealed­type (MF) battery, which does not re­quire any maintenance. There is no
need to check the electrolyte or to add
distilled water.

CAUTION:

Never attempt to remove the battery
cell seals, as this would permanent­ly damage the battery.

6

WARNING

● Electrolyte is poisonous and

dangerous since it contains sul­furic acid, which causes severe
burns. Avoid any contact with
skin, eyes or clothing and al­ways shield your eyes when
working near batteries. In case
of contact, administer the fol­lowing FIRST AID.

• EXTERNAL: Flush with plenty
of water.

EAU23380

ECA10620

EWA10760

• INTERNAL: Drink large quan­tities of water or milk and im­mediately call a physician.

• EYES: Flush with water for 15
minutes and seek prompt
medical attention.

● Batteries produce explosive hy-

drogen gas. Therefore, keep
sparks, flames, cigarettes, etc.,
away from the battery and pro­vide sufficient ventilation when
charging it in an enclosed
space.

● KEEP THIS AND ALL BATTER-

IES OUT OF THE REACH OF
CHILDREN.

To charge the battery

Have a Yamaha dealer charge the bat­tery as soon as possible if it seems to
have discharged. Keep in mind that the
battery tends to discharge more quickly
if the vehicle is equipped with optional
electrical accessories.

To store the battery

1. If the vehicle will not be used for
more than one month, remove the
battery, fully charge it, and then
place it in a cool, dry place.

2. If the battery will be stored for more
than two months, check it at least
once a month and fully charge it if
necessary.

3. Fully charge the battery before in­stallation.

4. After installation, make sure that
the battery leads are properly con­nected to the battery terminals.

ECA10630

CAUTION:

● Always keep the battery

charged. Storing a discharged
battery can cause permanent
battery damage.

● To charge a sealed-type (MF)

battery, a special (constant-volt­age) battery charger is required.
Using a conventional battery
charger will damage the battery.
If you do not have access to a

6-29

PERIODIC MAINTENANCE AND MINOR REPAIR

sealed-type (MF) battery charg­er, have a Yamaha dealer
charge your battery.

EAU23524

Replacing the fuses

1. Fuse box

2. Main fuse

3. Spare main fuse

The main fuse and the fuse box, which
contains the fuses for the individual cir­cuits, are located behind panel B. (See
page 6-8.)
If a fuse is blown, replace it as follows.

1. Turn the key to “OFF” and turn off
the electrical circuit in question.

2. Remove the blown fuse, and then
install a new fuse of the specified
amperage.

1. Headlight fuse

2. Signaling system fuse

3. Ignition fuse

4. Carburetor heater fuse

5. Ignitor unit fuse (for California only)

6. Spare fuse

7. Spare fuse (for California only)

6

6-30

PERIODIC MAINTENANCE AND MINOR REPAIR

Specified fuses:

Main fuse:

30.0 A

Signaling system fuse:

10.0 A

Ignition fuse:

10.0 A

Headlight fuse:

15.0 A

Carburetor heater fuse:

15.0 A

Ignitor unit fuse:

XVS650 5.0 A (CAL)
XVS650A 5.0 A (CAL)
XVS650AT 5.0 A (CAL)

CAUTION:

6

Do not use a fuse of a higher amper­age rating than recommended to
avoid causing extensive damage to
the electrical system and possibly a
fire.

3. Turn the key to “ON” and turn on
the electrical circuit in question to
check if the device operates.

4. If the fuse immediately blows
again, have a Yamaha dealer
check the electrical system.

ECA10640

EAU23792

Replacing the headlight bulb

This model is equipped with a quartz
bulb headlight. If the headlight bulb
burns out, replace it as follows.

1. Remove the headlight unit by re­moving the screws.

1. Headlight coupler

2. Headlight bulb cover

3. Unhook the headlight bulb holder,
and then remove the defective
bulb.

1. Screw

2. Disconnect the headlight coupler,
and then remove the bulb cover.

1. Headlight bulb holder

6-31

PERIODIC MAINTENANCE AND MINOR REPAIR

EWA10790

WARNING

Headlight bulbs get very hot. There­fore, keep flammable products away
from a lit headlight bulb, and do not
touch the bulb until it has cooled
down.

4. Place a new headlight bulb into po­sition, and then secure it with the
bulb holder.

ECA10660

CAUTION:

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 af­fected. Thoroughly clean off any dirt
and fingerprints on the headlight
bulb using a cloth moistened with al­cohol or thinner.

1. Do not touch the glass part of the bulb.

5. Install the headlight bulb cover,
and then connect the coupler.

6. Install the headlight unit by install­ing 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. Screw

XVS650

6

6-32

1. Screw

PERIODIC MAINTENANCE AND MINOR REPAIR

XVS650A/AT

1. Screw

2. Remove the defective bulb by
pushing it in and turning it counter­clockwise.

3. Insert a new bulb into the socket,

6

push it in, and then turn it clock­wise until it stops.

4. Install the lens by installing the
screws.

CAUTION:

Do not overtighten the screws, oth­erwise the lens may break.

ECA10680

EAU24350

Supporting the motorcycle

Since this model is not equipped with a
centerstand, follow these precautions
when removing the front and rear
wheel or performing other maintenance
requiring the motorcycle to stand up­right. Check that the motorcycle is in a
stable and level position before starting
any maintenance. A strong wooden
box can be placed under the engine for
added stability.

To service the front wheel

1. Stabilize the rear of the motorcycle
by using a motorcycle stand or, if
an additional motorcycle stand is
not available, by placing a jack un­der the frame in front of the rear
wheel.

2. Raise the front wheel off the
ground by using a motorcycle
stand.

To service the rear wheel

Raise the rear wheel off the ground by
using a motorcycle stand or, if a motor­cycle stand is not available, by placing

a jack either under each side of the
frame in front of the rear wheel or under
each side of the swingarm.

6-33

PERIODIC MAINTENANCE AND MINOR REPAIR

EAU24360

Front wheel

EAU24660

To remove the front wheel

EWA10820

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 ca­ble from the front wheel.

1. Speedometer cable

2. Loosen the front wheel axle pinch
bolt.

3. Remove the rubber cap, and then
loosen the wheel axle.

1. Rubber cap

2. Wheel axle

3. Front wheel axle pinch bolt

4. Lift the front wheel off the ground
according to the procedure on
page 6-33.

5. Pull the wheel axle out, and then
remove the wheel.

ECA11070

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.

6-34

To install the front wheel

EAU24921

1. Install the speedometer gear unit
into the wheel hub so that the pro­jections mesh with the slots.

1. Speedometer gear unit

2. Speedometer cable

3. Retainer

2. Lift the wheel up between the fork
legs.

NOTE:

Make sure that there is enough space
between the brake pads before insert­ing 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.

4. Lower the front wheel so that it is
on the ground.

6

PERIODIC MAINTENANCE AND MINOR REPAIR

5. Tighten the wheel axle and front
wheel axle pinch bolt to the speci­fied torques, and then install the
rubber cap.

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)

6. While applying the front brake,
push down hard on the handlebars
several times to check if the front
fork compresses and rebounds
smoothly.

6

7. Connect the speedometer cable.

EAU25080

Rear wheel

EAU25141

To remove the rear wheel

EWA10820

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. Loosen the axle nut.

1. Axle nut

2. Disconnect the brake torque rod
from the brake shoe plate by re­moving 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 cam­shaft lever.

1. Brake pedal free play adjusting nut

2. Brake camshaft lever

3. Brake rod

4. Bolt and nut (shoe plate)

5. Brake torque rod

6. Nut

5. Remove panel A. (See page 6-8.)

6. Remove the bolts that secure the
final gear case to the swingarm.

6-35

PERIODIC MAINTENANCE AND MINOR REPAIR

1. Bolt

2. Final gear case

7. Lift the rear wheel off the ground
according to the procedure on
page 6-33.

8. While supporting the drive shaft,
pull the rear wheel back to remove
the following parts as an assem­bly: wheel, wheel axle, final gear
case, and drive shaft.

NOTE:

Make sure to support the drive shaft as
it is being pulled out.

To install the rear wheel

EAU25511

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 mid­dle gear universal joint.

1. Middle gear universal joint

2. Drive shaft

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.

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)

8. Adjust the brake pedal free play.
(See page 6-22.)

EWA10660

WARNING

After adjusting the brake pedal free
play, check the operation of the
brake light.

6

6-36

PERIODIC MAINTENANCE AND MINOR REPAIR

EAU25850

Troubleshooting

Although Yamaha motorcycles receive
a thorough inspection before shipment
from the factory, trouble may occur dur­ing 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 your­self. However, should your motorcycle
require any repair, take it to a Yamaha
dealer, whose skilled technicians have
the necessary tools, experience, and

6

know-how to service the motorcycle
properly.
Use only genuine Yamaha replace­ment parts. Imitation parts may look like
Yamaha parts, but they are often inferi­or, have a shorter service life and can
lead to expensive repair bills.

6-37

PERIODIC MAINTENANCE AND MINOR REPAIR

Troubleshooting chart

WARNING

Keep away open flames and do not smoke while checking or working on the fuel system.

EAU25891

EWA10840

1. Fuel

Check the fuel level in
the fuel tank.

2. Compression

Operate the electric starter.

3. Ignition

Remove the spark plugs
and check the electrodes.

4. Battery

Operate the electric starter.

There is enough fuel.

There is no fuel.

There is compression.

There is no compression.

Wet

Dry

The engine turns over
quickly.

The engine turns over
slowly.

Wipe off with a dry cloth and correct the
spark plug gaps, or replace the spark plugs.

Have a Yamaha dealer check the vehicle.

Check the compression.

Supply fuel.

Check the ignition.

Have a Yamaha dealer
check the vehicle.

The battery is good.

Check the battery lead connections,
and charge the battery if necessary.

The engine does not start.
Check the compression.

6-38

6

Open the throttle halfway and operate
the electric starter.

The engine does not start.
Check the battery.

The engine does not start.
Have a Yamaha dealer
check the vehicle.

MOTORCYCLE CARE AND STORAGE

Care

While the open design of a motorcycle
reveals the attractiveness of the tech­nology, it also makes it more vulnera­ble. Rust and corrosion can develop
even if high-quality components are
used. A rusty exhaust pipe may go un­noticed on a car, however, it detracts
from the overall appearance of a motor­cycle. Frequent and proper care does
not only comply with the terms of the
warranty, but it will also keep your
motorcycle looking good, extend its life
and optimize its performance.

Before cleaning

1. Cover the muffler outlets with plas-

7

tic bags after the engine has
cooled down.

2. Make sure that all caps and covers
as well as all electrical couplers
and connectors, including the
spark plug caps, are tightly in­stalled.

3. Remove extremely stubborn dirt,
like oil burnt onto the crankcase,
with a degreasing agent and a
brush, but never apply such prod-

EAU26060

ucts onto seals, gaskets and wheel
axles. Always rinse the dirt and de­greaser off with water.

Cleaning

ECA10770

CAUTION:

● Avoid using strong acidic wheel

cleaners, especially on spoked
wheels. If such products are
used on hard-to-remove dirt, do
not leave the cleaner on the af­fected area any longer than in­structed. Also, thoroughly rinse
the area off with water, immedi­ately dry it, and then apply a cor­rosion protection spray.

● Improper cleaning can damage

windshields, cowlings, panels
and other plastic parts. Use only
a soft, clean cloth or sponge
with mild detergent and water to
clean plastic.

● Do not use any harsh chemical

products on plastic parts. Be
sure to avoid using cloths or
sponges which have been in
contact with strong or abrasive
cleaning products, solvent or

7-1

thinner, fuel (gasoline), rust re­movers or inhibitors, brake flu­id, antifreeze or electrolyte.

● Do not use high-pressure wash-

ers or steam-jet cleaners since
they cause water seepage and
deterioration in the following ar­eas: seals (of wheel and swing­arm bearings, fork and brakes),
electric components (couplers,
connectors, instruments,
switches and lights), breather
hoses and vents.

● For motorcycles equipped with

a windshield: Do not use strong
cleaners or hard sponges as
they will cause dulling or
scratching. Some cleaning com­pounds for plastic may leave
scratches on the windshield.
Test the product on a small hid­den part of the windshield to
make sure that it does not leave
any marks. If the windshield is
scratched, use a quality plastic
polishing compound after
washing.

MOTORCYCLE CARE AND STORAGE

After normal use
Remove dirt with warm water, a mild
detergent, and a soft, clean sponge,
and then rinse thoroughly with clean
water. Use a toothbrush or bottlebrush
for hard-to-reach areas. Stubborn dirt
and insects will come off more easily if
the area is covered with a wet cloth for
a few minutes before cleaning.

After riding in the rain, near the sea or
on salt-sprayed roads
Since sea salt or salt sprayed on roads
during winter are extremely corrosive in
combination with water, carry out the
following steps after each ride in the
rain, near the sea or on salt-sprayed
roads.

NOTE:

Salt sprayed on roads in the winter may
remain well into spring.

1. Clean the motorcycle with cold wa­ter and a mild detergent, after the
engine has cooled down.

ECA10790

CAUTION:

Do not use warm water since it in­creases the corrosive action of the
salt.

2. After drying the motorcycle, apply
a corrosion protection spray on all
metal, including chrome- and nick­el-plated, surfaces to prevent cor­rosion.

After cleaning

1. Dry the motorcycle with a chamois
or an absorbing cloth.

2. Use a chrome polish to shine
chrome, aluminum and stainless­steel parts, including the exhaust
system. (Even the thermally in­duced discoloring of stainless­steel exhaust systems can be re­moved through polishing.)

3. To prevent corrosion, it is recom­mended to apply a corrosion pro­tection spray on all metal,
including chrome- and nickel-plat­ed, surfaces.

4. Use spray oil as a universal clean­er to remove any remaining dirt.

5. Touch up minor paint damage
caused by stones, etc.

6. Wax all painted surfaces.

7. Let the motorcycle dry completely
before storing or covering it.

EWA11130

WARNING

● Make sure that there is no oil or

wax on the brakes or tires.

● If necessary, clean the brake

discs and brake linings with a
regular brake disc cleaner or ac­etone, and wash the tires with
warm water and a mild deter­gent. Before riding at higher
speeds, test the motorcycle’s
braking performance and cor­nering behavior.

ECA10800

CAUTION:

● Apply spray oil and wax spar-

ingly and make sure to wipe off
any excess.

● Never apply oil or wax to any

rubber and plastic parts, but
treat them with a suitable care
product.

7

7-2

MOTORCYCLE CARE AND STORAGE

● Avoid using abrasive polishing

compounds as they will wear
away the paint.

NOTE:

Consult a Yamaha dealer for advice on
what products to use.

7

EAU26230

Storage

Short-term

Always store your motorcycle in a cool,
dry place and, if necessary, protect it
against dust with a porous cover.

ECA10810

CAUTION:

● Storing the motorcycle in a

poorly ventilated room or cover­ing it with a tarp, while it is still
wet, will allow water and humid­ity to seep in and cause rust.

● To prevent corrosion, avoid

damp cellars, stables (because
of the presence of ammonia)
and areas where strong chemi­cals are stored.

Long-term

Before storing your motorcycle for sev­eral months:

1. Follow all the instructions in the
“Care” section of this chapter.

2. For motorcycles equipped with a
fuel cock that has an “OFF” posi­tion: Turn the fuel cock lever to
“OFF”.

7-3

3. Drain the carburetor float cham­bers by loosening the drain bolts;
this will prevent fuel deposits from
building up. Pour the drained fuel
into the fuel tank.

4. Fill up the fuel tank and add fuel
stabilizer (if available) to prevent
the fuel tank from rusting and the
fuel from deteriorating.

5. Perform the following steps to pro­tect the cylinders, piston rings, etc.
from corrosion.
a. Remove the spark plug caps

and spark plugs.

b. Pour a teaspoonful of engine oil

into each spark plug bore.

c. Install the spark plug caps onto

the spark plugs, and then place
the spark plugs on the cylinder
head so that the electrodes are
grounded. (This will limit spark­ing during the next step.)

d. Turn the engine over several

times with the starter. (This will
coat the cylinder walls with oil.)

e. Remove the spark plug caps

from the spark plugs, and then
install the spark plugs and the
spark plug caps.

MOTORCYCLE CARE AND STORAGE

EWA10950

WARNING

To prevent damage or injury from
sparking, make sure to ground the
spark plug electrodes while turning
the engine over.

6. Lubricate all control cables and the
pivoting points of all levers and
pedals as well as of the side­stand/centerstand.

7. Check and, if necessary, correct
the tire air pressure, and then lift
the motorcycle so that both of its
wheels are off the ground. Alterna­tively, turn the wheels a little every
month in order to prevent the tires
from becoming degraded in one
spot.

8. Cover the muffler outlets with plas­tic bags to prevent moisture from
entering them.

9. Remove the battery and fully
charge it. Store it in a cool, dry
place and charge it once a month.
Do not store the battery in an ex­cessively cold or warm place [less
than 0 °C (30 °F) or more than 30

°C (90 °F)]. For more information
on storing the battery, see page
6-29.

NOTE:

Make any necessary repairs before
storing the motorcycle.

7

7-4

SPECIFICATIONS

Dimensions:

8

Weight:

Overall length:

XVS650 2340 mm (92.1 in)
XVS650A 2450 mm (96.5 in)
XVS650AT 2450 mm (96.5 in)

Overall width:

XVS650 880 mm (34.6 in)
XVS650A 930 mm (36.6 in)
XVS650AT 930 mm (36.6 in)

Overall height:

XVS650 1070 mm (42.1 in)
XVS650A 1105 mm (43.5 in)
XVS650AT 1105 mm (43.5 in)

Seat height:

XVS650 695 mm (27.4 in)
XVS650A 710 mm (28.0 in)
XVS650AT 710 mm (28.0 in)

Wheelbase:

XVS650 1610 mm (63.4 in)
XVS650A 1625 mm (64.0 in)
XVS650AT 1625 mm (64.0 in)

Ground clearance:

140 mm (5.51 in)

Minimum turning radius:

XVS650 3100 mm (122.0 in)
XVS650A 3400 mm (133.9 in)
XVS650AT 3400 mm (133.9 in)

With oil and fuel:

XVS650 233.0 kg (514 lb) (U49)
XVS650 235.0 kg (518 lb) (CAL)
XVS650A 247.0 kg (545 lb) (U49)

XVS650A 249.0 kg (549 lb) (CAL)
XVS650AT 247.0 kg (545 lb) (U49)
XVS650AT 249.0 kg (549 lb) (CAL)

Engine:

Engine type:

Air cooled 4-stroke, SOHC

Cylinder arrangement:

V-type 2-cylinder

Displacement:

649.0 cm³ (39.60 cu.in)

Bore × stroke:

81.0 × 63.0 mm (3.19 × 2.48 in)

Compression ratio:

9.00 :1

Starting system:

Electric starter

Lubrication system:

Wet sump

Engine oil:

Type:

YAMALUBE 4, SAE10W30 or SAE20W40

0°

10° 30° 50° 70° 90°

YAMALUBE 4 (10W30)

or SAE 10W30

YAMALUBE 4 (20W40)
or SAE 20W40

–20°

–10° 0° 10° 20° 30°

Recommended engine oil grade:

API service SE, SF, SG type or higher

8-1

110°

40°

130°F

50°C

Engine oil quantity:

Without oil filter element replacement:

2.60 L (2.75 US qt) (2.29 Imp.qt)

With oil filter element replacement:

2.80 L (2.96 US qt) (2.46 Imp.qt)

Final gear oil:

Type:

SAE80 API GL-4 Hypoid gear oil

Quantity:

0.19 L (0.20 US qt) (0.17 Imp.qt)

Air filter:

Air filter element:

Dry element

Fuel:

Recommended fuel:

Unleaded gasoline only

Fuel tank capacity:

16.0 L (4.23 US gal) (3.52 Imp.gal)

Fuel reserve amount:

3.0 L (0.79 US gal) (0.66 Imp.gal)

Carburetor:

Manufacturer:

MIKUNI

Type x quantity:

BDS28 x 2

Spark plug(s):

Manufacturer/model:

NGK/DPR7EA-9

Manufacturer/model:

DENSO/X22EPR-U9

Spark plug gap:

0.8–0.9 mm (0.031–0.035 in)

SPECIFICATIONS

Clutch:

Clutch type:

Wet, multiple-disc

Transmission:

Primary reduction system:

Spur gear

Primary reduction ratio:

68/38 (1.789)

Secondary reduction system:

Shaft drive

Secondary reduction ratio:

19/18 × 32/11 (3.071)

Transmission type:

Constant mesh 5-speed

Operation:

Left foot operation

Gear ratio:

1st:

38/14 (2.714)

2nd:

38/20 (1.900)

3rd:

35/24 (1.458)

4th:

28/24 (1.167)

5th:

29/30 (0.967)

Chassis:

Frame type:

Double cradle

Caster angle:

35.00 °

Trail:

XVS650 153.0 mm (6.02 in)
XVS650A 145.0 mm (5.71 in)
XVS650AT 145.0 mm (5.71 in)

Front tire:

Type:

With tube

Size:

XVS650 100/90-19M/C 57S
XVS650A 130/90-16M/C 67S
XVS650AT 130/90-16M/C 67S

Manufacturer/model:

XVS650 BRIDGESTONE/EXEDRA L309
XVS650A BRIDGESTONE/EXEDRA
G703
XVS650AT BRIDGESTONE/EXEDRA
G703

Manufacturer/model:

XVS650 DUNLOP/F24
XVS650A DUNLOP/D404F
XVS650AT DUNLOP/D404F

Rear tire:

Type:

With tube

Size:

170/80-15M/C 77S

Manufacturer/model:

XVS650 BRIDGESTONE/EXEDRA G546
XVS650A BRIDGESTONE/EXEDRA
G702
XVS650AT BRIDGESTONE/EXEDRA
G702

Manufacturer/model:

XVS650 DUNLOP/K555
XVS650A DUNLOP/D404G
XVS650AT DUNLOP/D404G

Loading:

Maximum load:

XVS650 178 kg (392 lb) (CAL)
XVS650 180 kg (397 lb) (U49)
XVS650A 198 kg (437 lb) (CAL)
XVS650A 200 kg (441 lb) (U49)
XVS650AT 198 kg (437 lb) (CAL)
XVS650AT 200 kg (441 lb) (U49)
(Total weight of rider, passenger, cargo and
accessories)

Tire air pressure (measured on cold
tires):

Loading condition:

0–90 kg (0–198 lb)
Front:

XVS650 200 kPa (29 psi) (2.00 kgf/cm²)
XVS650A 225 kPa (33 psi) (2.25
kgf/cm²)
XVS650AT 225 kPa (33 psi) (2.25
kgf/cm²)

Rear:

225 kPa (33 psi) (2.25 kgf/cm²)

Loading condition:

XVS650 90–178 kg (198–392 lb) (CAL)
XVS650 90–180 kg (198–397 lb) (U49)
XVS650A 90–198 kg (198–437 lb) (CAL)
XVS650A 90–200 kg (198–441 lb) (U49)
XVS650AT 90–198 kg (198–437 lb) (CAL)
XVS650AT 90–200 kg (198–441 lb) (U49)

8

8-2

SPECIFICATIONS

Front wheel:

Rear wheel:

Front brake:

8

Rear brake:

Front:

XVS650 200 kPa (29 psi) (2.00 kgf/cm²)
XVS650A 225 kPa (33 psi) (2.25
kgf/cm²)
XVS650AT 225 kPa (33 psi) (2.25
kgf/cm²)

Rear:

250 kPa (36 psi) (2.50 kgf/cm²)

Wheel type:

Spoke wheel

Rim size:

XVS650 19M/C x MT2.50
XVS650A 16M/C x MT3.00
XVS650AT 16M/C x MT3.00

Wheel type:

Spoke wheel

Rim size:

15M/C x MT3.50

Type:

Single disc brake

Operation:

Right hand operation

Recommended fluid:

DOT 4

Type:

Drum brake

Operation:

Right foot operation

Front suspension:

Type:

Telescopic fork

Spring/shock absorber type:

Coil spring/oil damper

Wheel travel:

140.0 mm (5.51 in)

Rear suspension:

Type:

Swingarm (monocross)

Spring/shock absorber type:

Coil spring/gas-oil damper

Wheel travel:

XVS650 86.0 mm (3.39 in)
XVS650A 98.0 mm (3.86 in)
XVS650AT 98.0 mm (3.86 in)

Electrical system:

Ignition system:

Transistorized coil ignition (digital)

Charging system:

A.C. magneto

Battery:

Model:

GT12B-4

Voltage, capacity:

12 V, 10.0 Ah

Headlight:

Bulb type:

Halogen bulb

Bulb voltage, wattage x quantity:

Headlight:

12 V, 60 W/55.0 W × 1

Tail/brake light:

12 V, 8.0/27.0 W × 1

8-3

Front turn signal/position light:

XVS650 12 V, 27 W/8.0 W × 2
XVS650A 12 V, 23 W/8.0 W × 2
XVS650AT 12 V, 23 W/8.0 W × 2

Rear turn signal light:

XVS650 12 V, 27.0 W × 2
XVS650A 12 V, 21.0 W × 2
XVS650AT 12 V, 21.0 W × 2

Meter lighting:

12 V, 1.7 W × 1

Neutral indicator light:

12 V, 1.7 W × 1

High beam indicator light:

12 V, 1.7 W × 1

Turn signal indicator light:

12 V, 1.7 W × 1

Engine trouble warning light:

12 V, 1.7 W × 1

Fuses:

Main fuse:

30.0 A

Headlight fuse:

15.0 A

Signaling system fuse:

10.0 A

Ignition fuse:

10.0 A

Carburetor heater fuse:

15.0 A

Ignitor unit fuse:

XVS650 5.0 A (CAL)
XVS650A 5.0 A (CAL)
XVS650AT 5.0 A (CAL)

CONSUMER INFORMATION

EAU26351

Identification numbers

Record the key identification number,
vehicle identification number and mod­el label information in the spaces pro­vided below for assistance when
ordering spare parts from a Yamaha
dealer or for reference in case the vehi­cle is stolen.
KEY IDENTIFICATION NUMBER:

VEHICLE IDENTIFICATION
NUMBER:

MODEL LABEL INFORMATION:

Key identification number

1. Key identification number 1. Vehicle identification number

The key identification number is
stamped into the key tag. Record this
number in the space provided and use
it for reference when ordering a new
key.

EAU26381

Vehicle identification number

The vehicle identification number is
stamped into the steering head pipe.
Record this number in the space pro­vided.

NOTE:

The vehicle identification number is
used to identify your motorcycle and
may be used to register your motor­cycle with the licensing authority in your
area.

EAU26400

9

9-1

CONSUMER INFORMATION

Model label

1. Model label

The model label is affixed to the frame
under the rider seat. (See page 3-9.)
Record the information on this label in
the space provided. This information
will be needed when ordering spare
parts from a Yamaha dealer.

9

EAU26470

9-2

CONSUMER INFORMATION

EAU26550

Reporting safety defects

If you believe that your vehicle has a defect which could cause a crash or could cause injury or death, you should immediately
inform the National Highway Traffic Safety Administration (NHTSA) in addition to notifying Yamaha Motor Corporation,
U.S.A. If NHTSA receives similar complaints, it may open an investigation, and if it finds that a safety defect exists in a group
of vehicles, it may order a recall and remedy campaign. However, NHTSA cannot become involved in individual problems
between you, your dealer, or Yamaha Motor Corporation, U.S.A.
To contact NHTSA, you may either call the Auto Safety Hotline toll-free at 1-800-424-9393 (or 366-0123 in Washington, D.C.
area) or write to: NHTSA, U.S. Department of Transportation, Washington, D.C. 20590. You can also obtain other information
about motor vehicle safety from the Hotline.

9

9-3

CONSUMER INFORMATION

Motorcycle noise regulation

TAMPERING WITH NOISE CONTROL SYSTEM PROHIBITED:

Federal law prohibits the following acts or the causing thereof: (1) The removal or rendering inoperative by any person other
than for purposes of maintenance, repair, or replacement of any device or element of design incorporated into any new ve­hicle for the purpose of noise control prior to its sale or delivery to the ultimate purchaser or while it is in use or (2) the use of
the vehicle after such device or element of design has been removed or rendered inoperative by any person.
“AMONG THOSE ACTS PRESUMED TO CONSTITUTE TAMPERING ARE THE ACTS LISTED BELOW”.
These acts include tampering with the following systems; i.e., modification, removal, etc.

Exhaust system

• Muffler

• Exhaust pipe

• Silencer

Intake system

• Air cleaner case

• Air cleaner element

• Intake duct

9

EAU26560

9-4

CONSUMER INFORMATION

EAU26631

Maintenance record

Copies of work orders and/or receipts for parts purchased and installed on your motorcycle will be required to document that
maintenance has been completed in accordance with the emissions warranty. The chart below is printed only as a reminder
that maintenance work is required. It is not acceptable proof of maintenance work.

Maintenance

interval

600 mi

(1000 km) or

1 month
4000 mi

(7000 km) or

6 months

8000 mi

(13000 km) or

12 months

12000 mi

(19000 km) or

18 months

16000 mi

(25000 km) or

24 months

20000 mi

(31000 km) or

30 months

24000 mi

(37000 km) or

36 months

28000 mi

(43000 km) or

42 months

32000 mi

(49000 km) or

48 months

Date of
service

Mileage

Servicing dealer

name and address

Remarks

9

9-5

CONSUMER INFORMATION

Maintenance

interval

36000 mi

(55000 km) or

54 months

40000 mi

(61000 km) or

60 months

Date of
service

Mileage

Servicing dealer

name and address

Remarks

9

9-6

CONSUMER INFORMATION

YAMAHA MOTOR CORPORATION, U.S.A. STREET AND ENDURO MOTORCYCLE LIMITED
WARRANTY

EAU26661

9

9-7

CONSUMER INFORMATION

9

9-8

YAMAHA EXTENDED SERVICE (Y.E.S.)

CONSUMER INFORMATION

EAU26750

Keep your Yamaha protected even after your warranty
expires with genuine Yamaha Extended Service (Y.E.S.).

Y.E.S. is designed and administered by Yamaha Motor
Corporation to provide maximum owner satisfaction. You
get uninterrupted factory-backed coverage for extra
peace of mind.

Y.E.S. is flexible. You choose the plan that’s right for
you: 12 months, 24 months, 36 months or, on certain
models, even 48 months beyond your warranty period.

Y.E.S. is designed and administered by the same
Yamaha people who handle your warranty – and it
shows in the comprehensive coverage benefits. There
are no mileage limitations. Coverage isn’t limited to
“moving parts” or the “drive train” like many other plans.
And Y.E.S. covers manufacturing defects just like the
warranty. See the sample contract at your Yamaha
dealer to see how comforting uninterrupted factory­backed protection can be.

You don’t have to pay anything for covered repairs.
There’s no deductible to pay, and repairs aren’t
“pro-rated.” You don’t have any “out-of-pocket” expenses
for covered repairs.

In addition, Travel and Recreation Interruption Protection
(TRIP) is included at no extra cost. TRIP gives you up to
$150 reimbursement per occurrence for any reasonable
expenses you incur because your Yamaha needs
covered service: replacement vehicle rental, emergency
towing, phone calls, even food and lodging when you are
away from home. This superb coverage goes into effect
when you purchase Y.E.S., so it applies to any warranty
repairs as well as covered repairs during your entire
Y.E.S. plan period.

Y.E.S. coverage is honored at any authorized Yamaha
dealer nationwide.

Y.E.S. coverage is transferable to a new owner if you
sell or trade-in. That can make your Yamaha much more
valuable!

This excellent Y.E.S. plan coverage is only available to
Yamaha owners like you, and only while your Yamaha is still
within the Yamaha Limited Warranty period. So visit your
authorized Yamaha dealer to get all the facts. He can show
you how easy it is to protect your investment with Yamaha
Extended Service.

9

9-9

CONSUMER INFORMATION

We urge you to act now. You’ll get the excellent benefits of
TRIP coverage right away, and you’ll rest easy knowing
you’ll have strong factory-backed protection even after your
Yamaha Limited Warranty expires.

A special note:
If visiting your dealer isn’t convenient, contact Yamaha with
your Primary ID number (your frame number). We’ll be
happy to help you get the Y.E.S. coverage you need.

Yamaha Service Marketing
P.O. Box 6555
Cypress, CA 90630
1-(866)-YES-EXTD (1-866-937-3983)

9

9-10

INDEX

A

Accessories and replacement parts ..... 6-19

Air filter element, cleaning .................... 6-14

B

Battery .................................................. 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 ............................................. 3-5

Brake lever free play, adjusting ............ 6-21

Brake pads and shoes, checking.......... 6-24

Brake pedal ............................................ 3-5

Brake pedal position and free play,

adjusting............................................. 6-22

C

Cables, checking and lubricating.......... 6-25

Canister (for California only)................. 6-10

Carburetors, adjustment ....................... 6-16

Care........................................................ 7-1

Catalytic converter.................................. 3-7

Clutch lever............................................. 3-4

Clutch lever free play, adjusting ........... 6-20

D

Dimmer switch........................................ 3-3

E

Engine break-in ...................................... 5-4

Engine oil and oil filter element............. 6-11

Engine, starting a warm.......................... 5-2

Engine stop switch.................................. 3-3

Engine trouble warning light ................... 3-2

F

Final gear oil..........................................6-13

Front fork, checking...............................6-27

Fuel .........................................................3-6

Fuel cock.................................................3-7

Fuel tank cap...........................................3-5

Fuses, replacing....................................6-30

H

Handlebar switches .................................3-3

Headlight bulb, replacing.......................6-31

Helmet holder........................................3-11

High beam indicator light.........................3-2

Horn switch .............................................3-3

I

Identification numbers .............................9-1

Ignition circuit cut-off system .................3-14

Indicator and warning lights ....................3-2

K

Key identification number........................9-1

L

Labels, location of ...................................1-5

Luggage strap holders ..........................3-13

M

Main switch/steering lock ........................3-1

Maintenance and lubrication, periodic..... 6-4

Maintenance, emission control system ...6-3

Maintenance, periodic .............................6-1

Maintenance record ................................9-5

Model label..............................................9-2

N

Neutral indicator light ..............................3-2

Noise regulation ......................................9-4

P

Panels, removing and installing ..............6-8

Parking....................................................5-5

Part locations.......................................... 2-1

Pre-operation check list .......................... 4-2

R

Rear brake light switch, adjusting .........6-23

S

Safety defects, reporting......................... 9-3

Safety information................................... 1-1

Seats (XVS650) ......................................3-9

Seats (XVS650A/AT) ............................3-10

Shifting.................................................... 5-3

Shift pedal (XVS650) ..............................3-4

Shift pedal (XVS650A/AT) ......................3-4

Shock absorber assembly, adjusting .... 3-12

Sidestand..............................................3-13

Sidestand, checking and lubricating .....6-27

Spark plugs, checking.............................6-9

Specifications.......................................... 8-1

Speedometer unit ................................... 3-2

Starter (choke) knob ............................... 3-8

Starting and warming up a cold

engine................................................... 5-1

Start switch ............................................. 3-3

Steering, checking ................................ 6-28

Storage ...................................................7-3

Storage compartment ........................... 3-11

Supporting the motorcycle .................... 6-33

T

Throttle cable free play, adjusting......... 6-16

Throttle grip and cable,

checking and lubricating ..................... 6-26

Tires...................................................... 6-17

Tool kit ....................................................6-1

Troubleshooting .................................... 6-37

INDEX

Troubleshooting chart ........................... 6-38

Turn signal indicator light ........................ 3-2

Turn signal light bulb or

tail/brake light bulb, replacing ............. 6-32

Turn signal switch................................... 3-3

V

Valve clearance, adjusting .................... 6-16

Vehicle identification number.................. 9-1

W

Warranty, extended................................. 9-9

Warranty, limited.....................................9-7

Wheel bearings, checking..................... 6-28

Wheel (front) ......................................... 6-34

Wheel (rear) .......................................... 6-35

Wheels ..................................................6-19