OWNER’S MANUAL

XVS650M

XVS650AM
4XS-28199-23
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EAU00000
INTRODUCTION

Congratulations on your purchase of the Yamaha XVS650/XVS650A. 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 about the operation or
maintenance of your motorcycle, please consult a Yamaha dealer.
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IMPORTANT MANUAL INFORMATION EAU00005

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

The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR SAFETY IS IN-
VOLVED!

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

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

NOTE: 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 there is any
question concerning this manual, please consult your Yamaha dealer.
@
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IMPORTANT MANUAL INFORMATION

EW000002

@
WARNING
PLEASE READ THIS MANUAL CAREFULLY AND COMPLETELY BEFORE OPERATING
THIS MOTORCYCLE.
@
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IMPORTANT MANUAL INFORMATION

EAU00008

XVS650M/XVS650AM
OWNER’S MANUAL
© 1999 by Yamaha Motor Co., Ltd.
1st Edition, November 1999
All rights reserved. Any reprinting or
unauthorized use without the written
permission of Yamaha Motor Co., Ltd.
is expressly prohibited.
Printed in Japan.
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EAU00009
TABLE OF CONTENTS

1 SAFETY INFORMATION 1

2 DESCRIPTION 2

3 INSTRUMENT AND CONTROL FUNCTIONS 3

4 PRE-OPERATION CHECKS 4

5 OPERATION AND IMPORTANT RIDING POINTS 5

6 PERIODIC MAINTENANCE AND MINOR REPAIR 6

7 MOTORCYCLE CARE AND STORAGE 7

8 SPECIFICATIONS 8

9 CONSUMER INFORMATION 9

INDEX
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E_4xs_SafetyTOC.fm Page 1 Tuesday, November 30, 1999 2:32 PM

SAFETY INFORMATION

Safe riding .......................................................................................... 1-1

Protective apparel .............................................................................. 1-3
1
Modification ........................................................................................ 1-3
Loading and accessories ................................................................... 1-3
Gasoline and exhaust gas.................................................................. 1-5
Location of the important labels ......................................................... 1-7
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SAFETY INFORMATION
1-
EAU01771

TWO-WHEELED 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
1 FOLLOWING REQUIREMENTS BEFORE RIDING.
HE OR SHE SHOULD:
1. OBTAIN THOROUGH INSTRUCTIONS FROM A COMPETENT SOURCE ON ALL ASPECTS OF
MOTORCYCLE OPERATION.
2. OBSERVE THE WARNINGS AND MAINTENANCE REQUIREMENTS IN THE OWNER’S MANU-
AL.
3. OBTAIN QUALIFIED TRAINING IN SAFE AND PROPER RIDING TECHNIQUES.
4. OBTAIN PROFESSIONAL TECHNICAL SERVICE AS INDICATED BY THE OWNER’S MANUAL
AND/OR WHEN MADE NECESSARY BY MECHANICAL CONDITIONS.

Safe riding
1. Always make pre-operation checks. Careful checks may help prevent an accident.
2. This motorcycle is designed to carry the operator and a passenger.
3. 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:
a. Wear a brightly colored jacket.
b. Use extra caution when you approach and pass through intersections, since intersections are the
most likely places for motorcycle accidents.
c. Ride where other motorists can see you. Avoid riding in another motorist’s “blind spot”.

1-1
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SAFETY INFORMATION
4. Many accidents involve inexperienced operators. In fact, many operators who have been involved in
accidents do not even have a current motorcycle license.
a. Make sure you are qualified. Also, only lend your motorcycle to experienced operators.
b. Know your skills and limits. Staying within your limits may help you to avoid an accident. 1
c. We recommend that you practice riding your motorcycle where there is no traffic until you have
become thoroughly familiar with your motorcycle and all of its controls.
5. Many motorcycle accidents have been caused by motorcycle operator errors. A typical error made by
the operator is veering wide on a turn due to EXCESSIVE SPEED or undercornering (insufficient lean
angle for the speed).
a. Always obey the speed limits and never travel faster than warranted by road and traffic condi-
tions.
b. Always signal before turning or changing lanes. Make sure other motorists see you.
6. The operator’s and passenger’s posture are important for proper control.
a. The operator should keep both hands on the handlebars and both feet on the operator footrests
during operation to maintain control of the motorcycle.
b. The passenger should always hold on to the operator, or the seat strap or grab bar if the motor-
cycle is so equipped, with both hands and keep both feet on the passenger footrests.
c. Never carry a passenger unless he or she can firmly place both feet on the passenger footrests.
7. Never ride under the influence of alcohol or drugs.
8. This motorcycle is designed for on-road use only. It is not suitable for off-road use.

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SAFETY INFORMATION
Protective apparel
The majority of fatalities from motorcycle accidents are the result of head injuries. The use of a safety
1 helmet is the single most critical factor in the prevention or reduction of head injuries.
1. Always wear an approved helmet.
2. Wear a face shield or goggles. Wind on your unprotected eyes could contribute to an impairment of
vision which could delay seeing a hazard.
3. The use of heavy boots, jacket, trousers, gloves, etc. is effective in preventing or reducing abrasions
or lacerations.
4. Never wear loose fitting clothing. It could catch on the control levers, footrests, or wheels and cause
injury or accident.
5. 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.
6. A passenger should also observe the above precautions.

Modification
Modifications made to the motorcycle not approved by Yamaha, or the removal of original equipment,
may render your 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 machine is changed. To avoid the possibility of an accident, extreme caution
should be used if adding cargo or accessories to your motorcycle. Use extra care if riding a motorcycle
which has added cargo or accessories. Here are some general guidelines to follow if loading cargo or
adding accessories to your motorcycle:

1-3
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SAFETY INFORMATION
Loading
The total weight of the operator, passenger, accessories and cargo must not exceed the maximum
load limit of 180 kg: XVS650 / 201 kg: XVS650A.
1
When loading within these weight limits, keep the following in mind:
1. Cargo and accessory weight should be kept as low and close to the motorcycle as possible. Be sure
to distribute the weight as evenly as possible on both sides of the machine to minimize imbalance or
instability.
2. Shifting weights can create a sudden imbalance. Make sure that accessories and cargo are securely
attached to the motorcycle before riding. Recheck accessory mounts and cargo restraints frequently.
3. Never attach any large or heavy items to the handlebars, front forks, or front fender. These items, in-
cluding such cargo as sleeping bags, duffle 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 which may be available, you must personally be responsible
for the proper selection, installation and use of non-Yamaha accessories. You should use extreme
caution when selecting and installing any accessories.
Keep in mind these guidelines for mounting accessories in addition to those provided under
“LOADING”.
1. Never install accessories or carry cargo that would impair the performance of your motorcycle. Care-
fully inspect the accessory before using it to make sure it does not in any way reduce ground clear-
ance or cornering clearance, limit suspension travel, steering travel or control operation, or obscure
lights or reflectors.

1-4
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SAFETY INFORMATION
a. 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.
1 b. 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 being passed by or passing large ve-
hicles.
c. Certain accessories can displace the operator from his or her normal riding position. This improp-
er position limits the freedom of movement of the operator and may limit control ability. Therefore
such accessories are not recommended.
2. Caution must be used if adding electrical accessories. If these 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

1. GASOLINE IS HIGHLY FLAMMABLE:
a. Always turn off the engine when refueling.
b. Take care not to spill any gasoline on the engine or exhaust system when refueling.
c. Never refuel while smoking or in the vicinity of an open flame.
2. Never start the engine or let it run for any length of time in a closed area. The exhaust fumes are poi-
sonous and may cause loss of consciousness and death within a short time. Always operate your
motorcycle in an area that has adequate ventilation.
3. Always turn off the engine before leaving the motorcycle unattended and remove the ignition key.
When parking the motorcycle, note the following:

1-5
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SAFETY INFORMATION
a. The engine and exhaust system may be hot. Park the motorcycle in a place where pedestrians or
children are not likely to touch these hot areas.
b. Do not park the motorcycle on a slope or soft ground; the motorcycle may fall over.
c. Do not park the motorcycle near a flammable source, e.g. a kerosene heater, or near an open 1
flame. The motorcycle could catch fire.
4. When transporting the motorcycle in another vehicle, be sure 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.
5. If you should swallow any gasoline, inhale a lot of gasoline vapor, or allow gasoline to get in your
eyes, see your doctor immediately. If any gasoline spills on your skin or clothing, immediately wash it
off with soap and water and change your clothes.

1-6
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SAFETY INFORMATION
EAU02977

Location of the important labels

Please read the following labels carefully before operating this motorcycle.
1

1
WARNING
Before you operate this vehicle,
read the owner’s manual.
English 3HP-21568-00

4AA-22259-40

1-7
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DESCRIPTION

Left view (XVS650) ............................................................................ 2-1

Right view (XVS650) .......................................................................... 2-2
Left view (XVS650A) .......................................................................... 2-3
Right view (XVS650A)........................................................................ 2-4
2
Controls/Instruments (XVS650/XVS650A)......................................... 2-5
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DESCRIPTION
2-
EAU00026

Left view (XVS650)

1. Shift pedal (page 3-4)

2. Fuel cock (page 3-7)
3. Starter (choke) “ ” (page 3-8)
4. Rear shock absorber spring preload adjusting ring (page 3-13)
5. Helmet holder (page 3-11)
6. Storage compartment (page 3-11)
7. Tool kit (page 6-1)
2-1
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DESCRIPTION
Right view (XVS650)

8. Oil filter (page 6-10)

9. Battery (page 6-25)
10. Fuses (page 6-27)
11. Main switch (page 3-1)
12. Air filter (page 6-12)
13. Rear brake pedal (page 3-5)
2-2
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DESCRIPTION
Left view (XVS650A)

1. Shift pedal (page 3-4)

2. Fuel cock (page 3-7)
3. Starter (choke) “ ” (page 3-8)
4. Rear shock absorber spring preload adjusting ring (page 3-13)
5. Helmet holder (page 3-11)
6. Storage compartment (page 3-11)
7. Tool kit (page 6-1)

2-3
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DESCRIPTION
Right view (XVS650A)

8. Oil filter (page 6-10)

9. Battery (page 6-25)
10. Fuses (page 6-27)
11. Main switch (page 3-1)
12. Air filter (page 6-12)
13. Rear brake pedal (page 3-5)

2-4
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DESCRIPTION
Controls/Instruments (XVS650/XVS650A)

14. Clutch lever (page 3-4)

15. Left handlebar switches (page 3-3)
16. Speedometer (page 3-2)
17. Fuel tank cap (page 3-5)
18. Right handlebar switches (page 3-3)
19. Throttle grip (page 6-14)
20. Front brake lever (page 3-5)

2-5
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INSTRUMENT AND CONTROL FUNCTIONS

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

Indicator lights .................................................................................... 3-2
Speedometer...................................................................................... 3-2
Handlebar switches ............................................................................ 3-3
Clutch lever ........................................................................................ 3-4
Shift pedal .......................................................................................... 3-4
3
Front brake lever................................................................................. 3-5
Rear brake pedal................................................................................ 3-5
Fuel tank cap...................................................................................... 3-5
Fuel .................................................................................................... 3-6
Fuel cock ............................................................................................ 3-7
Starter (choke) “ ” .......................................................................... 3-8
Seats (XVS650) ................................................................................. 3-9
Seats (XVS650A) ............................................................................. 3-10
Helmet holder................................................................................... 3-11
Storage compartment ...................................................................... 3-11
Rear shock absorber adjustment ..................................................... 3-13
Luggage strap holders ..................................................................... 3-14
Sidestand ......................................................................................... 3-14
Sidestand/clutch switch operation check.......................................... 3-15
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INSTRUMENT AND CONTROL FUNCTIONS

3-
EAU00027

3
1. Push
2. Turn
EAU00029* EAU00040

Main switch/steering lock LOCK EW000016

The main switch controls the ignition The steering is locked in this position WARNING
@

and lighting systems. Its operation is and all electrical circuits are switched Never turn the key to “OFF” or
described below. off. The key can be removed in this po- “LOCK” when the motorcycle is
sition. moving. The electrical circuits will
EAU00036 To lock the steering, turn the handle- be switched off which may result in
ON bars all the way to the left. While push- loss of control or an accident. Be
Electrical circuits are switched on. The ing the key into the main switch, turn it sure the motorcycle is stopped be-
engine can be started. The key cannot from “OFF” to “LOCK” and remove it. fore turning the key to “OFF” or
be removed in this position. To release the lock, turn the key to “LOCK”.
“OFF” while pushing. @

EAU00038

OFF
All electrical circuits are switched off.
The key can be removed in this posi-
tion.

3-1
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INSTRUMENT AND CONTROL FUNCTIONS

EAU00061

Neutral indicator light “ ”

This indicator comes on when the
transmission is in neutral.

EAU00091

Engine trouble indicator light “ ”

This indicator light will come on or flash
if trouble occurs in a monitoring circuit. 3
In such a case, take the motorcycle to a
1. High beam indicator light “ ” 1. Reset knob
2. Turn indicator light “ ” Yamaha dealer to have the self-diag- 2. Speedometer
3. Neutral indicator light “ ” nostic systems checked. 3. Odometer
4. Engine trouble indicator light “ ” 4. Trip odometer
EAU00056 EAU00095

Indicator lights Speedometer

EAU00063
The speedometer shows riding speed.
High beam indicator light “ ”
This speedometer is equipped with an
This indicator comes on when the
odometer and trip odometer. The trip
headlight high beam is used.
odometer can be reset to “0” with the
EAU00057
reset knob. Use the trip odometer to
Turn indicator light “ ” estimate how far you can ride on a tank
This indicator flashes when the turn of fuel. This information will enable you
switch is moved to the left or right. to plan fuel stops in the future.

3-2
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INSTRUMENT AND CONTROL FUNCTIONS

EAU00119

Pass switch “ ”
Press the switch to operate the passing
light.

EAU00121

Dimmer switch
Turn the switch to “ ” for the high
3 beam and to “ ” for the low beam.
1. Turn signal switch EAU00129
1. Engine stop switch
2. Pass switch “ ” 2. Start switch “ ”
Horn switch “ ”
3. Dimmer switch
4. Horn switch “ ” Press the switch to sound the horn. EAU00138

Engine stop switch

EAU00118
The engine stop switch is a safety de-
Handlebar switches vice for use in an emergency such as
EAU00127

Turn signal switch when the motorcycle overturns or if

To signal a right-hand turn, push the trouble occurs in the throttle system.
switch to “ ”. To signal a left-hand Turn the switch to “ ” to start the en-
turn, push the switch to “ ”. Once the gine. In case of emergency, turn the
switch is released it will return to the switch to “ ” to stop the engine.
center position. To cancel the signal,
push the switch in after it has returned
to the center position.

3-3
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INSTRUMENT AND CONTROL FUNCTIONS

EAU00143

Start switch “ ”
The starter motor cranks the engine
when pushing the start switch.
EC000005

CAUTION:
@

See starting instructions prior to

starting the engine.
@ 3
1. Shift pedal
EAU00152 EAU00157

Clutch lever Shift pedal

The clutch lever is located on the left This motorcycle is equipped with a con-
handlebar, and the ignition circuit cut- stant-mesh 5-speed transmission.
off system is incorporated in the clutch The shift pedal is located on the left
lever holder. Pull the clutch lever to the side of the engine and is used in com-
handlebar to disengage the clutch, and bination with the clutch when shifting.
release the lever to engage the clutch.
The lever should be pulled rapidly and
released slowly for smooth clutch oper-
ation. (Refer to the engine starting pro-
cedures for a description of the ignition
circuit cut-off system.)

3-4
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INSTRUMENT AND CONTROL FUNCTIONS

EAU00158 EAU00162 EAU00167

Front brake lever Rear brake pedal Fuel tank cap

The front brake lever is located on the The rear brake pedal is on the right To open
right handlebar. Pull it toward the han- side of the motorcycle. Press down on Insert the key and turn it 1/4 turn clock-
dlebar to apply the front brake. the brake pedal to apply the rear brake. wise. The lock will be released and the
cap can be opened.

To close
Push the tank cap into position with the
key inserted. To remove the key, turn it
counterclockwise to the original posi-
tion.

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INSTRUMENT AND CONTROL FUNCTIONS

EAU00185
NOTE:
@

This tank cap cannot be closed unless CAUTION:

@

the key is in the lock. The key cannot Always wipe off spilled fuel immedi-
be removed if the cap is not locked ately with a dry and clean soft cloth.
properly. Fuel may deteriorate painted surfac-
@

EW000023 es or plastic parts.

@

@
WARNING
Be sure the cap is properly installed EAU00192 3
and locked in place before riding the 1. Filler tube Recommended fuel:
motorcycle. 2. Fuel level
@
Regular gasoline
EAU01183
For Australia:
Fuel Unleaded fuel only
Make sure there is sufficient fuel in the Fuel tank capacity:
tank. Fill the fuel tank to the bottom of Total:
the filler tube as shown in the illustra- 16 L
tion. Reserve:
EW000130
3L
@
WARNING
Do not overfill the fuel tank. Avoid
spilling fuel on the hot engine. Do
not fill the fuel tank above the bot-
tom of the filler tube or it may over-
flow when the fuel heats up later and
expands.
@

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INSTRUMENT AND CONTROL FUNCTIONS

Closed position Normal position Reserve position

3
1. Arrow mark over “OFF” 1. Arrow mark over “ON” 1. Arrow mark over “RES”
EAU02969
ON RES
Fuel cock With the fuel cock in this position, fuel This indicates reserve. If you run out of
The fuel cock supplies fuel from the flows to the carburetors. Set the fuel fuel while riding, set the fuel cock to this
tank to the carburetors while filtering it cock to this position when starting the position. Fill the tank at the first oppor-
also. engine and while riding. tunity. Be sure to set the fuel cock back
The fuel cock has three positions, to “ON” after refueling!
which should be set as shown in the il-
lustrations.

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

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INSTRUMENT AND CONTROL FUNCTIONS

ECA00038

CAUTION:
@

Do not use the starter (choke) for

more than 3 minutes as the exhaust
pipe may discolor from excessive
heat. Also, longer use of the starter
(choke) will cause afterburning. If af-
terburning occurs, turn off the 3
starter (choke).
1. Starter (choke) “ ” @

EAU02973

Starter (choke) “ ”
Starting a cold engine requires a richer
air-fuel mixture. A separate starter cir-
cuit supplies this mixture.
Move in direction a to turn on the
starter (choke).
Move in direction b to turn off the
starter (choke).

3-8
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INSTRUMENT AND CONTROL FUNCTIONS

XVS650 XVS650 XVS650

3
1. Nut 1. Bolt (× 2) 1. Seat holder
2. Seat holder 2. Projection
EAU01889
3. Projection
Seats (XVS650) To install
Passenger seat To install 1. Insert the projection on the front of
To remove Insert the projection on the front of the the seat into the seat holder and
Remove the nut and pull the seat up- seat into the seat holder and install the install the bolts.
ward. nut. 2. Install the passenger seat.

Rider seat NOTE:

@

To remove Make sure that the seats are securely

1. Remove the passenger seat. fitted.
@

2. Remove the two bolts and pull the

seat upward.

3-9
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INSTRUMENT AND CONTROL FUNCTIONS

XVS650A XVS650A XVS650A

3
1. Bolt 1. Seat holder (× 2) 1. Bolt
2. Projection (× 2)
EAU01888
Rider seat
Seats (XVS650A) To install To remove
Passenger seat Insert the projections on the front of the 1. Remove the passenger seat.
To remove seat into the holder and install the bolt. 2. Remove the bolt and pull the seat
Remove the bolt and pull the seat up- upward.
ward.

3-10
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INSTRUMENT AND CONTROL FUNCTIONS

XVS650A

3
1. Seat holder 1. Helmet holder 1. Compartment cover
2. Projection 2. Lock
EAU00260

To install Helmet holder EAU01869

1. Insert the projection on the front of To open the helmet holder, insert the Storage compartment
the seat into the holder and install key in the lock and turn it as shown. To The storage compartment is located on
the bolt. lock the helmet holder, replace the the left side of the motorcycle.
2. Install the passenger seat. holder in its original position.
EW000030

NOTE:
@ WARNING
Make sure that the seats are securely
@

Never ride with a helmet in the hel-

fitted. met holder. The helmet may hit ob-
@

jects, causing loss of control and

possibly an accident.
@

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INSTRUMENT AND CONTROL FUNCTIONS

3
1. Storage compartment

To open To close
Slide the lock cover open, insert the Place the storage compartment cover
key in the lock and turn it clockwise. in its original position as shown. Then,
Then, pull the storage compartment turn the key counterclockwise and re-
cover out as shown. move it. Close the lock cover.

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INSTRUMENT AND CONTROL FUNCTIONS

2. Use the special wrench and the EAU00315

extension bar in the owner’s tool kit @

WARNING
to turn the adjusting ring. Turn the This shock absorber contains high-
adjusting ring in direction a to in- ly pressurized nitrogen gas. Read
crease spring preload and in direc- and understand the following infor-
tion b to decrease spring preload. mation before handling the shock
Make sure that the appropriate absorber. The manufacturer cannot
3 notch in the adjusting ring is be held responsible for property
aligned with the position indicator damage or personal injury that may
1. Position indicator
2. Adjusting ring on the rear shock absorber. result from improper handling.
3. Extension bar
CI-15E ● Do not tamper with or attempt to
Stan-
4. Special wrench Soft
dard
Hard open the cylinder assembly.
EAU00299 Adjusting ● Do not subject the shock ab-
1 2 3 4 5 6 7
Rear shock absorber position sorber to an open flame or other
adjustment 3. Reinstall the seats. high heat source. This may
This shock absorber is equipped with a cause the unit to explode due to
spring preload adjuster. Adjust spring excessive gas pressure.
preload as follows: ● Do not deform or damage the
1. Remove the passenger seat and cylinder in any way. Cylinder
rider seat. (See page 3-9 for re- damage will result in poor
moval procedures.) damping performance.
● Take your shock absorber to a
Yamaha dealer for any service.
@

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INSTRUMENT AND CONTROL FUNCTIONS

EAU00330 EW000044

Sidestand WARNING
@

This model is equipped with an ignition This motorcycle must not be operat-
circuit cut-off system. The motorcycle ed with the sidestand in the down
must not be ridden when the sidestand position. If the stand is not properly
is down. The sidestand is located on retracted, it could contact the
the left side of the frame. (Refer to ground and distract the operator, re-
page 5-1 for an explanation of this sys- sulting in a possible loss of control. 3
tem.) Yamaha has designed into this
1. Luggage strap holder (× 2)
motorcycle a lockout system to as-
EAU01172
sist the operator in fulfilling the re-
Luggage strap holders sponsibility of retracting the
There is a luggage strap holder located
sidestand. Please check carefully
at each passenger footrest. the operating instructions listed be-
low and if there is any indication of a
malfunction, return the motorcycle
to a Yamaha dealer immediately for
repair.
@

3-14
 E_4xs_Functions.fm Page 15 Tuesday, November 30, 1999 2:34 PM

INSTRUMENT AND CONTROL FUNCTIONS

EAU00331

Sidestand/clutch switch ENGINE WILL STALL.

operation check
Check the operation of the sidestand
SIDESTAND SWITCH IS OK.
switch and clutch switch against the in-
formation below. EW000045
CD-11E
WARNING
TURN THE MAIN SWITCH TO “ON”
@

3 If improper operation is noted, con-

AND THE ENGINE STOP SWITCH TO
“ ”. sult a Yamaha dealer immediately.
@

TRANSMISSION IS IN GEAR AND

SIDESTAND IS UP.

PULL IN CLUTCH LEVER AND

PUSH THE START SWITCH.

ENGINE WILL START.

CLUTCH SWITCH IS OK.

SIDESTAND IS DOWN.

3-15
E_4xs_PreopTOC.fm Page 1 Tuesday, November 30, 1999 2:35 PM

PRE-OPERATION CHECKS

Pre-operation check list...................................................................... 4-1

4
 E_4xs_Preop.fm Page 1 Tuesday, November 30, 1999 2:35 PM

PRE-OPERATION CHECKS
4-
EAU01114

Owners are personally responsible for their vehicle’s condition. Your motorcycle’s vital functions can start to deteriorate
quickly and unexpectedly, even if it remains unused (for instance, if it is exposed to the elements). Any damage, fluid leak or
loss of tire pressure could have serious consequences. Therefore, it is very important that, in addition to a thorough visual in-
spection, you check the following points before each ride.
EAU00340

PRE-OPERATION CHECK LIST

ITEM CHECKS PAGE
• Check operation, free play, fluid level and vehicle for fluid leakage.
Front brake 6-18 ~ 6-22
• Fill with DOT 4 brake fluid if necessary.
• Check operation, condition and free play.
Rear brake 6-19 ~ 6-22
• Adjust if necessary.
4
• Check operation condition and free play.
Clutch 6-17 ~ 6-18
• Adjust if necessary.
• Check for smooth operation.
Throttle grip and housing 6-14, 6-23
• Lubricate if necessary.
• Check oil level.
Engine oil 6-9 ~ 6-11
• Fill with oil if necessary.
Final gear oil • Check vehicle for leakage. 6-11 ~ 6-12
• Check tire pressure, wear, damage and spoke tightness. 6-15 ~ 6-17, 6-25,
Wheels and tires
• Tighten spokes if necessary. 6-30 ~ 6-33
• Check for smooth operation.
Control and meter cable 6-22
• Lubricate if necessary.
• Check for smooth operation.
Brake and shift pedal shafts 6-23
• Lubricate if necessary.
• Check for smooth operation.
Brake and clutch lever pivots 6-23
• Lubricate if necessary.
• Check for smooth operation.
Sidestand pivot 6-24
• Lubricate if necessary.
• Make sure that all nuts, bolts and screws are properly tightened.
Chassis fasteners —
• Tighten if necessary.

4-1
E_4xs_Preop.fm Page 2 Tuesday, November 30, 1999 2:35 PM

PRE-OPERATION CHECKS
ITEM CHECKS PAGE
• Check fuel level.
Fuel 3-6
• Fill with fuel if necessary.
Lights, signals and switches • Check for proper operation. 6-28 ~ 6-29

NOTE:
Pre-operation checks should be made each time the motorcycle is used. Such an inspection can be thoroughly accom-
plished in a very short time; and the added safety it assures is more than worth the time involved.

WARNING 4
If any item in the Pre-Operation Check is not working properly, have it inspected and repaired before operating the
motorcycle.

4-2
E_4xs_Preop.fm Page 3 Tuesday, November 30, 1999 2:35 PM
E_4xs_OperationTOC.fm Page 1 Tuesday, November 30, 1999 2:35 PM

OPERATION AND IMPORTANT RIDING POINTS

Starting and warming up a cold engine.............................................. 5-1

Starting a warm engine ...................................................................... 5-4
Shifting ............................................................................................... 5-4
Tips for reducing fuel consumption .................................................... 5-5
Engine break-in .................................................................................. 5-5
Parking ............................................................................................... 5-6

5
 E_4xs_Operation.fm Page 1 Tuesday, November 30, 1999 2:36 PM

OPERATION AND IMPORTANT RIDING POINTS

5-
EAU00372

EAU00373 EAU01860

WARNING Starting and warming up a

@

● Before riding this motorcycle, cold engine

become thoroughly familiar
NOTE:
with all operating controls and @

This motorcycle is equipped with an ig-

their functions. Consult a
nition circuit cut-off system. The engine
Yamaha dealer regarding any
can be started only under one of the
control or function that you do
following conditions:
not thoroughly understand.
● The transmission is in neutral.
● Never start your engine or let it
● The sidestand is up, the transmis-
run for any length of time in a
sion is in gear and the clutch is dis-
closed area. The exhaust fumes
5 engaged.
are poisonous and can cause
The motorcycle must not be ridden
loss of consciousness and
when the sidestand is down.
death within a short time. Al- @

EW000054
ways operate your motorcycle
in an area with adequate ventila- @
WARNING
tion. Before going through the following
● Before starting out, always be steps, check the function of the
sure the sidestand is up. Failure sidestand switch and clutch switch.
to retract the sidestand com- (Refer to page 3-15.)
@

pletely can result in a serious

accident when you try to turn a
corner.
@

5-1
E_4xs_Operation.fm Page 2 Tuesday, November 30, 1999 2:36 PM

OPERATION AND IMPORTANT RIDING POINTS

CF-30E

TURN THE MAIN SWITCH TO “ON” AND THE

ENGINE STOP SWITCH TO “ ”.

IF THE TRANSMISSION IS IN NEUTRAL AND IF THE TRANSMISSION IS IN GEAR AND

SIDESTAND IS DOWN, SIDESTAND IS UP,

PUSH THE START SWITCH. PULL IN THE CLUTCH LEVER AND PUSH THE
ENGINE WILL START. START SWITCH. ENGINE WILL START.

RETRACT THE SIDESTAND AND PUT 5

TRANSMISSION IN GEAR.

MOTORCYCLE CAN BE RIDDEN. MOTORCYCLE CAN BE RIDDEN.

5-2
 E_4xs_Operation.fm Page 3 Tuesday, November 30, 1999 2:36 PM

OPERATION AND IMPORTANT RIDING POINTS

7. After warming up the engine, turn
off the starter (choke) completely.

NOTE:
@

The engine is warm when it responds

normally to the throttle with the starter
(choke) turned off.
@

1. Turn the fuel cock to “ON”. NOTE:

@

2. Turn the main switch to “ON” and If the engine fails to start, release the
5 the engine stop switch to “ ”. start switch, wait a few seconds, then
3. Shift transmission into neutral. try again. Each attempt should be as
short as possible to preserve the bat-
NOTE:
@

tery. Do not crank the engine more

When the transmission is in neutral, the
than 10 seconds on any one attempt.
neutral indicator light should be on. If @

the light does not come on, ask a 6. After starting the engine, move the
Yamaha dealer to inspect it. starter (choke) “ ”to the halfway
position.
@

4. Turn on the starter (choke) “ ”

and completely close the throttle NOTE:
@

grip. For maximum engine life, never accel-

5. Start the engine by pushing the erate hard with a cold engine!
start switch. @

5-3
E_4xs_Operation.fm Page 4 Tuesday, November 30, 1999 2:36 PM

OPERATION AND IMPORTANT RIDING POINTS

EAU01258 EC000048

Starting a warm engine CAUTION:

@

The starter (choke) is not required ● Do not coast for long periods
when the engine is warm. with the engine off, and do not
EC000046
tow the motorcycle a long dis-
CAUTION:
@ tance. Even with gears in neu-
See the “Engine break-in” section tral, the transmission is only
prior to operating the motorcycle for properly lubricated when the
the first time. engine is running. Inadequate
@

lubrication may damage the

EAU00423
transmission.
Shifting
● Always use the clutch when
The transmission lets you control the 5
changing gears. The engine,
amount of power you have available at
transmission, and driveline are
a given speed for starting, accelerating,
not designed to withstand the
climbing hills, etc. The use of the shift
shock of forced shifting and can
pedal is shown in the illustration.
be damaged by shifting without
To shift into neutral, depress the shift
using the clutch.
pedal repeatedly until it reaches the @

end of its travel, then raise the pedal

slightly.

5-4
 E_4xs_Operation.fm Page 5 Tuesday, November 30, 1999 2:36 PM

OPERATION AND IMPORTANT RIDING POINTS

EAU00424 EAU01128 EAU01171

Tips for reducing fuel Engine break-in 0 ~ 1,000 km

consumption There is never a more important period Avoid operation above 1/3 throttle.
Your motorcycle’s fuel consumption in the life of your motorcycle than the
depends to a large extent on your period between zero and 1,600 km. For 1,000 ~ 1,600 km
riding style. The following tips can help this reason we ask that you carefully Avoid cruising speeds in excess of
reduce fuel consumption: read the following material. Because 1/2 throttle.
EC000056
● Warm up the engine before riding. the engine is brand new, you must not
put an excessive load on it for the first CAUTION:
● Turn off the starter (choke) as @

soon as possible. 1,600 km. The various parts in the en- After 1,000 km of operation, be sure
● Shift up swiftly and avoid high en- gine wear and polish themselves to the to replace the engine oil, oil filter
gine speeds during acceleration. correct operating clearances. During and final gear oil.
5 ● Do not double-clutch or rev the en- this period, prolonged full throttle oper-
@

gine while shifting down and avoid ation, or any condition which might re- 1,600 km and beyond
high engine speeds with no load sult in excessive heating of the engine, Proceed with normal riding.
on the engine. must be avoided. EC000049

● Turn off the engine instead of let- CAUTION:

@

ting it idle for an extended length If any engine trouble should occur
of time, i.e. in traffic jams, at traffic during the break-in period, consult a
lights or railroad crossings. Yamaha dealer immediately.
@

5-5
E_4xs_Operation.fm Page 6 Tuesday, November 30, 1999 2:36 PM

OPERATION AND IMPORTANT RIDING POINTS

EAU00457

Parking
When parking the motorcycle, stop the
engine and remove the ignition key.
Turn the fuel cock to “OFF” whenever
stopping the engine.
EW000058

@
WARNING
The exhaust system is hot. Park the
motorcycle in a place where pedes-
trians or children are not likely to
touch the motorcycle. Do not park
the motorcycle on a slope or soft 5
ground; the motorcycle may over-
turn.
@

5-6
E_4xs_Operation.fm Page 7 Tuesday, November 30, 1999 2:36 PM
E_4xs_PeriodicTOC.fm Page 1 Tuesday, November 30, 1999 2:36 PM

PERIODIC MAINTENANCE AND MINOR REPAIR

Tool kit...................................................................6-1 Inspecting the brake fluid level ........................... 6-21

Periodic maintenance and lubrication...................6-2 Brake fluid replacement ..................................... 6-22
Panel removal and installation ..............................6-5 Cable inspection and lubrication ........................ 6-22
Panel A .................................................................6-6 Throttle cable and grip lubrication ...................... 6-23
Panel B .................................................................6-7 Brake and shift pedal lubrication ........................ 6-23
Spark plugs...........................................................6-7 Brake and clutch lever lubrication ...................... 6-23
Engine oil ..............................................................6-9 Sidestand lubrication.......................................... 6-24
Final gear oil .......................................................6-11 Front fork inspection........................................... 6-24
Air filter ...............................................................6-12 Steering inspection ............................................ 6-25
Carburetor adjustment ........................................6-13 Wheel bearings .................................................. 6-25
Idle speed adjustment ........................................6-14 Battery................................................................ 6-25
Throttle cable free play inspection ......................6-14 Fuse replacement .............................................. 6-27
6
Valve clearance adjustment ................................6-15 Headlight bulb replacement ............................... 6-28
Tires....................................................................6-15 Turn signal and taillight bulb replacement .......... 6-29
Wheels................................................................6-17 Supporting the motorcycle ................................. 6-30
Clutch lever free play adjustment........................6-17 Front wheel removal........................................... 6-31
Front brake lever free play adjustment................6-18 Front wheel installation ...................................... 6-31
Rear brake pedal height and free play Rear wheel removal ........................................... 6-32
adjustment ........................................................6-19 Rear wheel installation ....................................... 6-33
Brake light switch adjustment .............................6-20 Troubleshooting.................................................. 6-34
Checking the front brake pads and Troubleshooting chart......................................... 6-35
rear brake shoes...............................................6-21
 E_4xs_Periodic.fm Page 1 Tuesday, November 30, 1999 2:36 PM

PERIODIC MAINTENANCE AND MINOR REPAIR

6-
EAU00462

EAU00464 EAU01129 EW000062

Periodic inspection, adjustment and lu- Tool kit WARNING

brication will keep your motorcycle in The tool kit is located inside the storage
@

Modifications to this motorcycle not

the safest and most efficient condition compartment. (See page 3-11 for com- approved by Yamaha may cause
possible. Safety is an obligation of the partment opening procedures.) The loss of performance, excessive
motorcycle owner. The maintenance tools provided in the owner’s tool kit are emissions, and render it unsafe for
and lubrication schedule chart should to assist you in the performance of pe- use. Consult a Yamaha dealer be-
be considered strictly as a guide to riodic maintenance. However, some fore attempting any changes.
general maintenance and lubrication other tools such as a torque wrench are @

intervals. YOU MUST TAKE INTO also necessary to perform the mainte-
CONSIDERATION THAT WEATHER, nance correctly.
TERRAIN, GEOGRAPHICAL LOCA- The service information included in this
TIONS, AND A VARIETY OF INDIVID- manual is intended to provide you, the
UAL USES ALL TEND TO DEMAND owner, with the necessary information
6 THAT EACH OWNER ALTER THIS for completing some of your own pre-
TIME SCHEDULE TO SHORTER IN- ventive maintenance and minor re-
TERVALS TO MATCH THE ENVI- pairs.
RONMENT. The most important points
of motorcycle inspection, adjustment, NOTE:
@

and lubrication are explained in the fol- If you do not have necessary tools re-
lowing pages. quired during a service operation, take
EW000060 your motorcycle to a Yamaha dealer for
WARNING service.
@ @

If you are not familiar with motor-

cycle service, this work should be
done by a Yamaha dealer.
@

6-1
E_4xs_Periodic.fm Page 2 Tuesday, November 30, 1999 2:36 PM

PERIODIC MAINTENANCE AND MINOR REPAIR

EAU00473

PERIODIC MAINTENANCE AND LUBRICATION

CP-01E
EVERY
6,000 km 12,000 km
INITIAL or or
NO. ITEM CHECKS AND MAINTENANCE JOBS
(1,000 km) 6 months 12 months
(whichever (whichever
comes first) comes first)
• Check fuel hoses for cracks or damage.
1 * Fuel line √ √
• Replace if necessary.
• Check condition.
2 Spark plugs √ √ √
• Clean, regap or replace if necessary.
• Check valve clearance.
3 * Valves √ √ √
• Adjust if necessary.
4 Air filter • Clean or replace if necessary. √ √
• Check operation.
5 Clutch √ √ √
• Adjust or replace cable.
6
• Check operation, fluid level and vehicle for fluid leakage.
(See NOTE on page 6-4.)
6 * Front brake √ √ √
• Correct accordingly.
• Replace brake pads if necessary.
• Check operation.
7 * Rear brake √ √ √
• Adjust brake pedal free play and replace brake shoes if necessary.
• Check balance, runout, spoke tightness and for damage.
8 * Wheels √ √
• Tighten spokes and rebalance, replace if necessary.
• Check tread depth and for damage.
• Replace if necessary.
9 * Tires √ √
• Check air pressure.
• Correct if necessary.
• Check bearing for looseness or damage.
10 * Wheel bearings √ √
• Replace if necessary.

6-2
 E_4xs_Periodic.fm Page 3 Tuesday, November 30, 1999 2:36 PM

PERIODIC MAINTENANCE AND MINOR REPAIR

EVERY
6,000 km 12,000 km
INITIAL or or
NO. ITEM CHECKS AND MAINTENANCE JOBS
(1,000 km) 6 months 12 months
(whichever (whichever
comes first) comes first)
• Check swingarm pivoting point for play.
• Correct if necessary.
11 * Swingarm √ √
• Lubricate with molybdenum disulfide grease every 24,000 km
or 24 months (whichever comes first).
• Check bearing play and steering for roughness.
• Correct accordingly.
12 * Steering bearings √ √
• Lubricate with lithium soap base grease every 24,000 km
or 24 months (whichever comes first).
• Make sure that all nuts, bolts and screws are properly tightened.
13 * Chassis fasteners √ √
• Tighten if necessary.
• Check operation.
14 Sidestand √ √
• Lubricate and repair if necessary.
6 • Check operation.
15 * Sidestand switch √ √ √
• Replace if necessary.
• Check operation and for oil leakage.
16 * Front fork √ √
• Correct accordingly.
Rear shock absorber • Check operation and shock absorber for oil leakage.
17 * assembly √ √
• Replace shock absorber assembly if necessary.
• Check engine idling speed, synchronization and starter operation.
18 * Carburetors √ √ √
• Adjust if necessary.
• Check oil level and vehicle for oil leakage.
19 Engine oil • Correct if necessary. √ √ √
• Change. (Warm engine before draining.)
20 Engine oil filter element • Replace. √ √

6-3
E_4xs_Periodic.fm Page 4 Tuesday, November 30, 1999 2:36 PM

PERIODIC MAINTENANCE AND MINOR REPAIR

EVERY
6,000 km 12,000 km
INITIAL or or
NO. ITEM CHECKS AND MAINTENANCE JOBS
(1,000 km) 6 months 12 months
(whichever (whichever
comes first) comes first)
• Check oil level and vehicle for oil leakage.
21 Final gear oil • Change oil at initial 1,000 km and thereafter every 24,000 km √ √ √
or 24 months (whichever comes first).
* Since these items require special tools, data and technical skills, they should be serviced by a Yamaha dealer.

EAU02970*

NOTE:
@

● The air filter needs more frequent service if you are riding in unusually wet or dusty areas.
● Hydraulic brake system
• When disassembling the master cylinder or caliper cylinder, always replace the brake fluid. Check the brake fluid level
6
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.
@

6-4
 E_4xs_Periodic.fm Page 5 Tuesday, November 30, 1999 2:36 PM

PERIODIC MAINTENANCE AND MINOR REPAIR

XVS650 XVS650A

1. Panel A 1. Panel A 1. Panel B

EAU01122

Panel removal and installation

The panels illustrated need to be re-
moved to perform some of the mainte-
6 nance described in this chapter. Refer
to this section each time a panel has to
be removed or reinstalled.

6-5
E_4xs_Periodic.fm Page 6 Tuesday, November 30, 1999 2:36 PM

PERIODIC MAINTENANCE AND MINOR REPAIR

XVS650 XVS650A

1. Bolt (× 4) 1. Bolt (× 4)
EAU01573

Panel A
To remove
Remove the bolts.
6
To install
Place the panel in its original position
and install the bolts.

6-6
 E_4xs_Periodic.fm Page 7 Tuesday, November 30, 1999 2:36 PM

PERIODIC MAINTENANCE AND MINOR REPAIR

1. Bolt 1. Spark plug cap

EAU00491
To install EAU03053

Panel B Place the panel in its original position Spark plugs

To remove and install the bolt. Removal
Remove the bolt and pull outward on 1. Remove the spark plug caps.
6 the areas shown. 2. Use the spark plug wrench in the
tool kit to remove the spark plugs
as shown.

6-7
E_4xs_Periodic.fm Page 8 Tuesday, November 30, 1999 2:36 PM

PERIODIC MAINTENANCE AND MINOR REPAIR

Do not attempt to diagnose such prob-
lems yourself. Instead, take the motor-
cycle to a Yamaha dealer. You should
periodically remove and inspect the
spark plugs because heat and deposits
will cause any spark plug to slowly
break down and erode. If electrode ero-
sion becomes excessive, or if carbon
and other deposits are excessive, you
1. Spark plug wrench a. Spark plug gap
should replace the spark plug with the
Inspection specified plug. Installation
The spark plug is an important engine 1. Measure the electrode gap with a
component and is easy to inspect. The Specified spark plug: wire thickness gauge and, if nec-
condition of the spark plug can indicate DPR7EA-9 (NGK) or essary, adjust the gap to specifica-
the condition of the engine. Normally, X22EPR-U9 (DENSO) tion. 6
all spark plugs from the same engine
should have the same color on the Spark plug gap:
white insulator around the center elec- 0.8 ~ 0.9 mm
trode. The ideal color at this point is a
medium-to-light tan color for a motor- 2. Clean the gasket surface. Wipe off
cycle that is being ridden normally. If any grime from the threads.
one spark plug shows a distinctly differ- 3. Install the spark plug and tighten it
ent color, there could be something to the specified torque.
wrong with the engine.

6-8
 E_4xs_Periodic.fm Page 9 Tuesday, November 30, 1999 2:36 PM

PERIODIC MAINTENANCE AND MINOR REPAIR

Tightening torque:
Spark plug:
18 Nm (1.8 m·kg)

NOTE:
@

If a torque wrench is not available when

you are installing a spark plug, a good
estimate of the correct torque is 1/4 to
1/2 turn past finger tight. Have the 1. Oil level window 1. Engine oil drain bolt
spark plug tightened to the specified 2. Maximum level mark
3. Minimum level mark 2. With the engine stopped, check
torque as soon as possible.
@
EAU01326*
the oil level through the level win-
4. Install the spark plug caps. Engine oil dow located at the lower part of
Oil level inspection the left side crankcase cover.
6
1. Place the motorcycle on a level
NOTE:
place and hold it in an upright posi-
@

Wait a few minutes until the oil level

tion. Warm up the engine for sev- settles before checking.
eral minutes. @

3. The oil level should be between

NOTE:
@
the maximum and minimum
Be sure the motorcycle is positioned marks. If the level is low, fill the en-
straight up when checking the oil level. gine with sufficient oil to the speci-
A slight tilt toward the side can result in fied level.
false readings.
@

6-9
E_4xs_Periodic.fm Page 10 Tuesday, November 30, 1999 2:36 PM

PERIODIC MAINTENANCE AND MINOR REPAIR

1. Engine oil filler cap 1. Cover 1. Bolt (× 5)

2. Bolt (× 3) 2. Oil filter cover
Engine oil and oil filter element re-
placement 4. Remove the cover and the oil filter 8. Install oil filter cover and cover,
1. Warm up the engine for a few min- cover by removing the bolts. then tighten the bolts.
utes. 5. Remove the oil filter and O-ring. 9. Fill the engine with oil. Install the
2. Stop the engine. Place an oil pan 6. Reinstall the drain bolt and tighten oil filler cap and tighten it. 6
under the engine and remove the it to the specified torque.
oil filler cap. Recommended oil:
3. Remove the drain bolt and drain Tightening torque: See page 8-1.
the oil. Drain bolt: Oil quantity:
43 Nm (4.3 m·kg) Total amount:
3.2 L
7. Install a new oil filter and O-ring. Periodic oil change:
2.6 L
With oil filter replacement:
2.8 L

6-10
 E_4xs_Periodic.fm Page 11 Tuesday, November 30, 1999 2:36 PM

PERIODIC MAINTENANCE AND MINOR REPAIR

2. Remove the oil filler bolt and
check the oil level. The oil level
should be at the brim of the filler
hole. Add the recommended oil if
necessary.

Oil replacement
1. Place an oil pan under the final
gear case.
1. O-ring 1. Final gear oil drain bolt
2. Oil filter element 2. Final gear oil filler bolt 2. Remove the oil filler bolt and drain
EC000066
3. Proper level bolt to drain the oil.
EAU02943 3. Install and tighten the drain bolt to
CAUTION:
@
Final gear oil the specified torque.
● Do not put in any chemical addi- EW000066

6 tives. Engine oil also lubricates WARNING Tightening torque:

the clutch and additives could @

Do not let foreign material enter the Drain bolt:

cause clutch slippage.
final gear case. Be sure oil does not 23 Nm (2.3 m·kg)
● Be sure no foreign material en-
get on the tire or wheel.
ters the crankcase. @ 4. Fill the gear case to the brim of the
@
Oil level inspection filler hole with the recommended
10. Start the engine and warm it up for
1. Place the motorcycle on a level oil.
a few minutes. While warming up,
place and hold it in an upright posi-
check for oil leakage. If oil leakage
tion. The engine should be cool at
is found, stop the engine immedi-
ambient temperature.
ately and check for the cause.

6-11
E_4xs_Periodic.fm Page 12 Tuesday, November 30, 1999 2:36 PM

PERIODIC MAINTENANCE AND MINOR REPAIR

Final gear case capacity:
0.19 L
Recommended oil:
SAE 80 API GL-4 Hypoid gear oil
If desired, an SAE 80W90 hypoid
gear oil may be used for all condi-
tions.

NOTE:
@ 1. Case cover
“GL-4” is a quality and additive rating. 2. Screw (× 3)
3. Tap the air filter lightly to remove
Hypoid gear oils rated “GL-5” or “GL-6” EAU00586
most of the dust and dirt. Blow out
may also be used. Air filter
the remaining dirt with com-
The air filter should be cleaned at the
@

5. Install and tighten the filler bolt to pressed air as shown. If the air fil-
specified intervals. It should be cleaned 6
the specified torque. ter is damaged, replace it.
more frequently if you are riding in un-
Tightening torque: usually wet or dusty areas.
Oil filler bolt: 1. Remove the air filter case cover by
removing the screws.
23 Nm (2.3 m·kg)
2. Remove the air filter.
6. After replacing the final gear oil, be
sure to check for oil leakage.

6-12
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PERIODIC MAINTENANCE AND MINOR REPAIR

EAU00630

Carburetor adjustment
The carburetors are important parts of
the engine and require very sophisti-
cated adjustment. Most adjustments
should be left to a Yamaha dealer who
has the professional knowledge and
experience to do so. However, the idle
speed may be adjusted by the owner
1. Holder 1. Match marks as part of routine maintenance.
2. Projection EC000095
3. Slot 5. Align the match marks and install
the air filter case cover. CAUTION:
@

4. Install the air filter on the air filter EC000082 The carburetors were set at the
case as shown. CAUTION: Yamaha factory after many tests. If
@

6 ● Make sure the air filter is prop- they are changed, poor engine per-
erly seated in the air filter case. formance and damage may result.
@

● The engine should never be run

without the air filter installed.
Excessive piston and/or cylin-
der wear may result.
@

6-13
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PERIODIC MAINTENANCE AND MINOR REPAIR

EAU01168

Idle speed adjustment

NOTE:
@

A diagnostic tachometer must be used

for this procedure.
@

1. Attach the tachometer. Start the

engine and warm it up for a few
minutes at approximately 1,000 to
2,000 r/min. Occasionally rev the 1. Throttle stop screw a. Free play
engine to 4,000 to 5,000 r/min. 2. Set the idle to the specified engine EAU00635

The engine is warm when it quick- speed by adjusting the throttle Throttle cable free play
ly responds to the throttle. stop screw. Turn the screw in di- inspection
rection a to increase engine There should be a free play of 4 ~
speed and in direction b to de- 6 mm at the throttle grip. If the free play 6
crease engine speed. is incorrect, ask a Yamaha dealer to
make this adjustment.
Standard idle speed:
1,150 ~ 1,250 r/min

NOTE:
@

If the specified idle speed cannot be

obtained by performing the above ad-
justment, consult a Yamaha dealer.
@

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PERIODIC MAINTENANCE AND MINOR REPAIR

EAU00637 EAU01543* XVS650
Valve clearance adjustment Tires Maximum load* 180 kg
The correct valve clearance changes To ensure maximum performance, Cold tire pressure Front Rear
with use, resulting in improper fuel/air long service and safe operation, note 200 kPa 225 kPa
Up to 90 kg load* (2.00 kgf/cm2, (2.25 kgf/cm2,
supply or engine noise. To prevent this, the following: 2.00 bar) 2.25 bar)
the valve clearance must be adjusted 200 kPa 250 kPa
90 kg load ~
regularly. This adjustment however, Tire air pressure (2.00 kgf/cm2, (2.50 kgf/cm2,
Maximum load*
2.00 bar) 2.50 bar)
should be left to a professional Always check and adjust the tire pres-
* Load is the total weight of cargo, rider, passenger
Yamaha service technician. sure before operating the motorcycle. and accessories.
EW000082

@
WARNING XVS650A
Tire inflation pressure should be Maximum load* 201 kg
checked and adjusted when the Cold tire pressure Front Rear
temperature of the tire equals the 225 kPa 225 kPa
Up to 90 kg load* (2.25 kgf/cm2, (2.25 kgf/cm2,
6 ambient air temperature. Tire infla- 2.25 bar) 2.25 bar)
tion pressure must be adjusted ac- 225 kPa 250 kPa
90 kg load ~
cording to total weight of cargo, (2.25 kgf/cm2, (2.50 kgf/cm2,
Maximum load*
2.25 bar) 2.50 bar)
rider, passenger, and accessories
* Load is the total weight of cargo, rider, passenger
(fairing, saddlebags, etc. if approved and accessories.
for this model), and vehicle speed.
@

CE-32E

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PERIODIC MAINTENANCE AND MINOR REPAIR

EW000083 CE-10E
FRONT: XVS650

@
WARNING Manufacturer Size Type
Proper loading of your motorcycle Bridgestone 100/90-19 57S L309
is important for several characteris- Dunlop 100/90-19 57S F24

tics of your motorcycle, such as REAR: XVS650

handling, braking, performance and Manufacturer Size Type
safety. Do not carry loosely packed Bridgestone 170/80-15M/C 77S G546
items that can shift. Securely pack Dunlop 170/80-15M/C 77S K555

your heaviest items close to the CE-10E

1. Side wall FRONT: XVS650A
center of the motorcycle, and dis- 2. Wear indicator Manufacturer Size Type
tribute the weight evenly from side a. Tread depth
Bridgestone 130/90-16 67S G703
to side. Properly adjust the suspen-
Tire inspection Dunlop 130/90-16 67S D404F
sion for your load, and check the
Always check the tires before operating REAR: XVS650A
condition and pressure of your tires.
the motorcycle. If a tire tread shows Manufacturer Size Type 6
NEVER OVERLOAD YOUR MOTOR-
crosswise lines (minimum tread depth), Bridgestone 170/80-15M/C 77S G702
CYCLE. Make sure the total weight
if the tire has a nail or glass fragments Dunlop 170/80-15M/C 77S D404
of the cargo, rider, passenger, and
in it, or if the side wall is cracked, con- CE-16E
accessories (fairing, saddlebags, Minimum tire tread depth
tact a Yamaha dealer immediately and 1.0 mm
etc. if approved for this model) does (front and rear)
have the tire replaced.
not exceed the maximum load of the
motorcycle. Operation of an over- NOTE:
These limits may be different by regula-
loaded motorcycle could cause tire
damage, an accident, or even injury. tion from country to country. If so, con-
@ form to the limits specified by the
regulations of your own country.

6-16
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PERIODIC MAINTENANCE AND MINOR REPAIR

EAU00680 EAU00685

WARNING Wheels
@

● It is dangerous to ride with a To ensure maximum performance,

worn-out tire. When a tire tread long service, and safe operation, note
begins to show lines, have a the following:
Yamaha dealer replace the tire ● Always inspect the wheels before

immediately. Brakes, tires, and a ride. Check for cracks, bends or

related wheel parts replacement warpage of the wheel. Be sure the
should also be left to a Yamaha spokes are tight and undamaged.
If any abnormal condition exists in 1. Locknut
dealer. 2. Adjusting bolt
● Patching a punctured tube is a wheel, consult a Yamaha dealer. c. Free play
not recommended. If it is abso- Do not attempt even small repairs
EAU00694

lutely necessary to do so, use to the wheel. If a wheel is de- Clutch lever free play
great care and replace the tube formed or cracked, it must be re-
adjustment
6 as soon as possible with a good placed.
The clutch lever free play should be ad-
quality replacement. ● Tires and wheels should be bal-
justed to 10 ~ 15 mm.
@
anced whenever either one is
1. Loosen the locknut at the clutch le-
changed or replaced. Failure to
ver.
have a wheel balanced can result
2. Turn the adjusting bolt at the
in poor performance, adverse han-
clutch lever in direction a to in-
dling characteristics, and short-
crease free play or in direction b
ened tire life.
to decrease free play.
● Ride at moderate speeds after
3. Tighten the locknut at the clutch
changing a tire since the tire sur-
lever.
face must first be broken in for it to
develop its optimal characteristics.

6-17
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PERIODIC MAINTENANCE AND MINOR REPAIR

1. Adjusting nut a. Free play 1. Locknut

2. Locknut 2. Adjusting bolt
EAU00696

If the specified free play cannot be ob- Front brake lever free play 1. Loosen the locknut.
tained, proceed with the following adjustment 2. Turn the adjusting bolt in direction a
steps. The free play at the front brake lever to increase free play or in direction b
4. Loosen the locknut at the clutch le- should be 10 ~ 15 mm. to decrease free play. 6
ver. 3. After adjusting, tighten the locknut.
5. Turn the adjusting bolt at the
clutch lever in direction a to loos-
en the cable.
6. Loosen the locknut at the crank-
case side.
7. Turn the adjusting nut at the
crankcase in direction a to in-
crease free play or in direction b
to decrease free play.
8. Tighten the locknut at the crank-
case and the clutch lever.
6-18
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PERIODIC MAINTENANCE AND MINOR REPAIR

EW000099

@
WARNING
● Check the brake lever free play.
Be sure the brake is working
properly.
● A soft or spongy feeling in the
brake lever can indicate the
presence of air in the brake sys-
tem. This air must be removed
c. Pedal height 1. Locknut
by bleeding the brake system d. Free play 2. Adjusting bolt
before the motorcycle is operat-
ed. Air in the system will cause
EAU00711
1. Loosen the locknut.
Rear brake pedal height and 2. Turn the adjusting bolt in direction a
greatly diminished braking ca-
free play adjustment to raise pedal height or in direction b
pability and can result in loss of EW000104
6 control and an accident. Have a to lower pedal height.
WARNING 3. Tighten the locknut.
Yamaha dealer inspect and @

It is advisable to have a Yamaha

bleed the system if necessary.
@
dealer make this adjustment.
@

The brake pedal height should be ad-

justed before adjusting the brake pedal
free play.

Pedal height
The brake pedal should be positioned
approximately 85 mm above the top of
the footrest.

6-19
E_4xs_Periodic.fm Page 20 Tuesday, November 30, 1999 2:36 PM

PERIODIC MAINTENANCE AND MINOR REPAIR

1. Adjusting nut 1. Brake light switch

2. Adjusting nut
EW000105

EAU00713
WARNING
@
Brake light switch adjustment
After adjusting the pedal height, ad-
The rear brake light switch is activated
just brake pedal free play.
@
by the brake pedal and is properly ad- 6
justed when the brake light comes on
Free play just before braking takes effect. To ad-
The brake pedal free play should be just the rear brake light switch, hold the
adjusted to 20 ~ 30 mm at the brake switch body so it does not rotate while
pedal end. Turn the adjusting nut on turning the adjusting nut. Turn the ad-
the brake rod in direction a to increase justing nut in direction a to make the
free play or in direction b to decrease brake light come on earlier.
free play. Turn the adjusting nut in direction b to
make the brake light come on later.

6-20
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PERIODIC MAINTENANCE AND MINOR REPAIR

1. Wear indicator grooves 1. Wear limit line 1. Minimum level mark

2. Wear indicator
EAU00720 EAU00731

Checking the front brake pads EAU00727 Inspecting the brake fluid
Rear brake
and rear brake shoes level
Apply the brake and inspect the wear
Insufficient brake fluid may let air enter
indicator.
6 EAU01119
the brake system, possibly causing the
Front brake If the indicator reaches the wear limit
brakes to become ineffective.
Wear indicator grooves are provided line, ask a Yamaha dealer to replace
Before riding, check that the brake fluid
on each brake pad. These indicators the shoes.
is above the minimum level and replen-
allow checking of brake pad wear with-
ish when necessary.
out disassembling the brake. Inspect
Observe these precautions:
the grooves. If they have almost disap-
● When checking the fluid level,
peared, ask a Yamaha dealer to re-
make sure the top of the master
place the pads.
cylinder is level by turning the han-
dlebars.

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PERIODIC MAINTENANCE AND MINOR REPAIR

● Use only the designated quality EAU00742 EAU02962

brake fluid. Otherwise, the rubber Brake fluid replacement Cable inspection and
seals may deteriorate, causing The brake fluid should be replaced only lubrication
leakage and poor brake perfor- by trained Yamaha service personnel. EW000112

mance. Have the Yamaha dealer replace the @

WARNING
following components during periodic Damage to the outer housing of ca-
Recommended brake fluid: DOT 4 maintenance or when they are dam- bles may lead to internal rusting and
aged or leaking: interfere with the cable movement.
● Refill with the same type of brake ● oil seals (every two years) Replace damaged cables as soon as
fluid. Mixing fluids may result in a ● brake hoses (every four years) possible to prevent unsafe condi-
harmful chemical reaction and tions.
lead to poor brake performance. @

Lubricate the cables and cable ends. If

● Be careful that water does not en-
a cable does not operate smoothly, ask
ter the master cylinder when refill-
a Yamaha dealer to replace it.
ing. Water will significantly lower 6
the boiling point of the fluid and
Recommended lubricant:
may result in vapor lock.
Engine oil
● Brake fluid may deteriorate paint-
ed surfaces or plastic parts. Al-
ways clean up spilled fluid
immediately.
● Have a Yamaha dealer check the
cause if the brake fluid level goes
down.

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PERIODIC MAINTENANCE AND MINOR REPAIR

EAU00773

Throttle cable and grip

lubrication
The throttle twist grip assembly should
be greased at the time that the cable is
lubricated, since the grip must be re-
moved to get at the end of the throttle
cable. After removing the screws, hold
the end of the cable up in the air and
put in several drops of lubricant. With
the throttle grip disassembled, coat the EAU02984 EAU02985

metal surface of the grip assembly with Brake and shift pedal Brake and clutch lever
a suitable all-purpose grease. lubrication lubrication
Lubricate the pivoting parts. Lubricate the pivoting parts.
6
Recommended lubricant: Recommended lubricant:
Engine oil Engine oil

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PERIODIC MAINTENANCE AND MINOR REPAIR

3. Push down hard on the handle-
bars several times and check if the
fork rebounds smoothly.
EC000098

CAUTION:
@

If any damage or unsmooth move-

ment is found with the front fork,
consult a Yamaha dealer.
@

EAU02986 EAU02939

Sidestand lubrication Front fork inspection

Lubricate the sidestand pivoting point Visual check
and metal-to-metal contact surfaces. EW000115

Check that the sidestand moves up @

WARNING 6
and down smoothly. Securely support the motorcycle so
there is no danger of it falling over.
@

Recommended lubricant: Check for scratches or damage on the

Engine oil inner tube and excessive oil leakage
EW000113 from the front fork.

@
WARNING
If the sidestand does not move Operation check
smoothly, consult a Yamaha dealer. 1. Place the motorcycle on a level
@
place.
2. Hold the motorcycle in an upright
position and apply the front brake.

6-24
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PERIODIC MAINTENANCE AND MINOR REPAIR

EAU01144 EAU00800

Wheel bearings Battery

If there is play in the front or rear wheel This motorcycle is equipped with a
hub or if the wheel does not turn sealed-type battery. Therefore it is not
smoothly, have a Yamaha dealer in- necessary to check the electrolyte or fill
spect the wheel bearings. the battery with distilled water.
● If the battery seems to have dis-
charged, consult a Yamaha deal-
er.
● If the motorcycle is equipped with
EAU00794 optional electrical accessories, the
Steering inspection battery tends to discharge more
Periodically inspect the condition of the quickly, so be sure to recharge it
steering. Worn out or loose steering periodically.
6 bearings may be dangerous. Place a EC000101

stand under the engine to raise the CAUTION:

@

front wheel off the ground. Hold the Never try to remove the sealing caps
lower end of the front forks and try to of the battery cells. The battery will
move them forward and backward. If be damaged.
any free play can be felt, ask a Yamaha @

dealer to inspect and adjust the steer-

ing. Inspection is easier if the front
wheel is removed.
EW000115

@
WARNING
Securely support the motorcycle so
there is no danger of it falling over.
@

6-25
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PERIODIC MAINTENANCE AND MINOR REPAIR

EW000116
Battery storage
@
WARNING When the motorcycle is not used for a
Battery electrolyte is poisonous and month or longer, remove the battery,
dangerous, causing severe burns, fully charge it and store it in a cool, dry
etc. It contains sulfuric acid. Avoid place.
contact with skin, eyes or clothing. EC000102

ANTIDOTE: CAUTION:
@

● EXTERNAL: Flush with water. ● Completely recharge the bat-

● INTERNAL: Drink large quanti- tery before storing. Storing a
ties of water or milk. Follow with discharged battery can cause
milk of magnesia, beaten egg, permanent battery damage.
or vegetable oil. Call a physi- ● Use a battery charger designed
cian immediately. for a sealed-type (MF) battery.
● EYES: Flush with water for Using a conventional battery
15 minutes and get prompt charger will cause battery dam- 6
medical attention. age. If you do not have a sealed-
Batteries produce explosive gases. type battery charger, contact
Keep sparks, flame, cigarettes etc., your Yamaha dealer.
away. Ventilate when charging or ● Always make sure the connec-
using in an enclosed space. Always tions are correct when reinstall-
shield your eyes when working near ing the battery.
batteries. @

KEEP OUT OF REACH OF CHIL-

DREN.
@

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PERIODIC MAINTENANCE AND MINOR REPAIR

Specified fuses:
Main fuse: 30 A
Ignition fuse: 10 A
Signaling system fuse: 10 A
Headlight fuse: 15 A
Carburetor heater fuse: 15 A

1. Fuse block 1. Ignition fuse

2. Main fuse 2. Signaling system fuse
3. Spare fuse 3. Headlight fuse
EAU00825
4. Carburetor heater fuse
5. Spare fuse
Fuse replacement
EC000103
The fuses are located behind panel A.
6 CAUTION:
(See page 6-6 for panel removal proce- @

dures.) Do not use fuses of higher amper-

If a fuse is blown, turn off the main age rating than those recommend-
switch and the switch of the circuit in ed. Substitution of a fuse of
question. Install a new fuse of proper improper rating can cause extensive
amperage. Turn on the switches and electrical system damage and pos-
see if the electrical device operates. If sibly a fire.
@

the fuse immediately blows again, con-

sult a Yamaha dealer.

6-27
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PERIODIC MAINTENANCE AND MINOR REPAIR

EC000105

CAUTION:
@

Avoid touching the glass part of a

bulb. Keep it free from oil; other-
wise, the transparency of the glass,
life of the bulb, and luminous flux
will be adversely affected. If oil gets
on a bulb, thoroughly clean it with a
cloth moistened with alcohol or lac-
1. Screw (× 2) 1. Bulb holder
quer thinner.
EAU00833
3. Turn the bulb holder counterclock- @

Headlight bulb replacement wise to remove it and remove the

5. Install the bulb cover, connectors
This motorcycle is equipped with a and headlight unit. Ask a Yamaha
defective bulb.
quartz bulb headlight. EW000119
dealer to adjust the headlight
If the headlight bulb burns out, replace WARNING beam if necessary. 6
@

the bulb as follows: Keep flammable products and your

1. Remove the headlight unit screws. hands away from a bulb while it is
2. Remove the connectors, the head- on, as it is hot. Do not touch a bulb
light unit and then the bulb cover. until it cools down.
@

4. Put a new bulb into position and

secure it in place with the bulb
holder.

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PERIODIC MAINTENANCE AND MINOR REPAIR

XVS650 XVS650A

1. Screw (× 2) 1. Screw (× 2) 1. Screw (× 3)

EAU00855
3. Place a new bulb in the socket. EC000108

Turn signal and taillight bulb Push the bulb inward and turn it CAUTION:
@

replacement clockwise until it engages into the Do not over-tighten the screws as
1. Remove the screws and the lens. socket. the lens may break.
6 2. Push the bulb inward and turn it 4. Install the lens and the screws.
@

counterclockwise.

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PERIODIC MAINTENANCE AND MINOR REPAIR

EAU01579
Rear wheel service
Supporting the motorcycle Use a motorcycle stand or motorcycle
Since the Yamaha XVS650/XVS650A jack to elevate the motorcycle so the
has no centerstand, follow these pre- rear wheel is off the ground. Alterna-
cautions when removing the front and tively, two jacks can be placed under
rear wheel or performing other mainte- the frame or swingarm.
nance requiring the motorcycle to
stand upright. Check that the motor-
cycle is in a stable and level position
before starting any maintenance. A
strong wooden box can be placed un-
der the engine for added stability.

Front wheel service

To stabilize the rear of the motorcycle, 6
either use a motorcycle stand or place
a motorcycle jack under the frame in
front of the rear wheel to prevent it from
moving from side to side. Then use a
motorcycle stand to elevate the front
wheel off of the ground.

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PERIODIC MAINTENANCE AND MINOR REPAIR

1. Speedometer cable 1. Axle 1. Speedometer gear unit housing

2. Pinch bolt
EAU00894 EAU01394

Front wheel removal 2. Loosen the pinch bolt and wheel Front wheel installation
EW000122
axle. 1. Install the speedometer gear unit
@
WARNING 3. Elevate the front wheel by placing into the wheel hub. Make sure the
6 ● It is advisable to have a Yamaha a suitable stand under the engine. wheel hub and the speedometer
dealer service the wheel. 4. Remove the wheel axle and the gear unit are installed with the pro-
● Securely support the motor- front wheel. jections meshed into the slots.
cycle so there is no danger of it 2. Lift up the wheel between the front
falling over. NOTE:
@
fork legs and guide the brake disc
@ Do not depress the brake lever when between the brake pads. Make
1. Remove the speedometer cable the disc and caliper are separated.
from the front wheel side. @
sure the slot in the speedometer
gear unit fits over the stopper on
the front fork outer tube.
3. Install the wheel axle and let the
motorcycle down.

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PERIODIC MAINTENANCE AND MINOR REPAIR

4. Push down hard on the handle- 1. Loosen the axle nut. Do not re-
bars several times to check for move it.
proper fork operation. 2. Remove the brake torque rod bolt
5. Tighten the wheel axle to the on the brake shoe plate side.
specified torque. 3. Loosen the brake torque rod bolt
6. Install the pinch bolt and tighten it on the swingarm side.
to the specified torque. 4. Remove the brake pedal free play
adjusting nut and then the brake
Tightening torque: rod from the brake cam lever.
1. Brake pedal free play adjusting nut
Wheel axle: 2. Brake rod 5. Remove panel “A”. (See page 6-6
59 Nm (5.9 m·kg) 3. Brake torque rod bolt for removal procedures.)
Pinch bolt: 4. Brake torque rod
20 Nm (2.0 m·kg) EAU01350

Rear wheel removal

7. Install the speedometer cable. EW000122 6
@
WARNING
● It is advisable to have a Yamaha
dealer service the wheel.
● Securely support the motor-
cycle so there is no danger of it
falling over.
@

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PERIODIC MAINTENANCE AND MINOR REPAIR

3. Insert the brake rod into the brake
cam lever and install the brake
pedal free play adjusting nut.
4. Install the brake torque rod bolt
and tighten both bolts to the spec-
ified tightening torque.

Specified torque:
Brake torque rod bolts:
1. Bolt (× 4) 1. Middle drive shaft joint
2. Final gear case 2. Drive shaft 20 Nm (2.0 m·kg)
3. Axle nut
EAU01563
5. Install panel “B”.
6. Remove the bolts that secure the Rear wheel installation 6. Let the motorcycle down.
final gear case to the swingarm. 1. Install the rear wheel, axle, final 7. Tighten the axle nut to the speci-
6 7. Elevate the rear wheel off of the gear case and drive shaft as an fied tightening torque.
ground. assembly by pushing the wheel
8. Pull the wheel backward while forward and guiding the drive shaft Specified torque:
supporting the drive shaft to re- into the middle drive shaft U-joint. Axle nut:
move the wheel, axle, final gear 2. Install the bolts that secure the fi-
92 Nm (9.2 m·kg)
case and drive shaft as an assem- nal gear case to the swingarm and
bly. tighten to the specified tightening 8. Adjust the rear brake pedal free
torque. play. (See page 6-19.)

Specified torque:
Final gear case bolts:
90 Nm (9.0 m·kg)

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PERIODIC MAINTENANCE AND MINOR REPAIR

EAU01008

Troubleshooting
Although Yamaha motorcycles receive
a rigid inspection before shipment from
the factory, trouble may occur during
operation.
Any problem in the fuel, compression,
or ignition systems can cause poor
starting and loss of power. The trouble-
shooting chart describes a quick, easy
procedure for making checks.
If your motorcycle requires any repair,
bring it to a Yamaha dealer. The skilled
technicians at a Yamaha dealership
have the tools, experience, and know- 6
how to properly service your motor-
cycle. Use only genuine Yamaha parts
on your motorcycle. Imitation parts may
look like Yamaha parts, but they are of-
ten inferior. Consequently, they have a
shorter service life and can lead to ex-
pensive repair bills.

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PERIODIC MAINTENANCE AND MINOR REPAIR

EAU01297*

Troubleshooting chart
EW000125

@
WARNING
Never check the fuel system while smoking or in the vicinity of an open flame.
@

1. Fuel
Enough fuel. Go to compression check.
Check if there is fuel
in the fuel tank.
No fuel. Supply fuel. Engine doesn’t start, go to compression check.

2. Compression
There is compression. Go to ignition check.
Use the electric starter.
Ask a Yamaha dealer to
6 No compression.
inspect.

3. Ignition Wipe clean with dry cloth and correct Open throttle half-way and start
Wet.
Remove spark spark gap or replace spark plugs. the engine.
plugs and
check electrodes.
Engine doesn’t start, go to battery
Dry. Ask a Yamaha dealer to inspect.
check.

4. Battery Engine turns over

Battery good.
quickly.
Engine doesn’t start, ask a Yamaha
Use the electric starter.
dealer to inspect.
Engine turns over Check connections or
slowly. recharge.

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MOTORCYCLE CARE AND STORAGE

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

Storage............................................................................................... 7-4

7
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MOTORCYCLE CARE AND STORAGE

7-
EAU01521

Care Before cleaning Cleaning

The exposure of its technology makes 1. Cover up the muffler outlets with After normal use
a motorcycle charming but also vulner- plastic bags. Remove dirt with warm water, a neutral
able. Although high-quality compo- 2. Make sure that all caps and covers detergent and a soft clean sponge,
nents are used, they are not all rust- as well as all electrical couplers then rinse with plenty of clean water.
resistant. While a rusty exhaust pipe and connectors, including the Use a tooth or bottle brush for hard-to-
may remain unnoticed on a car, it does spark plug caps, are tightly in- reach parts. Tougher dirt and insects
look unattractive on a motorcycle. Fre- stalled. will come off more easily if the area is
quent and proper care, however, will 3. Remove extremely stubborn dirt, covered with a wet cloth for a few min-
keep your motorcycle looking good, ex- like oil burnt onto the crankcase, utes before cleaning.
tend its life and maintain its perfor- with a degreasing agent and a
mance. Moreover, the warranty states brush, but never apply such prod-
that the vehicle must be properly taken ucts onto seals, gaskets and
care of. For all these reasons, it is rec- wheel axles. Always rinse the dirt
ommended that you observe the follow- and degreaser off with water.
ing cleaning and storing precautions.
7

7-1
E_4xs_Cleaning.fm Page 2 Tuesday, November 30, 1999 2:38 PM

MOTORCYCLE CARE AND STORAGE

ECA00010
● Do not use any harsh chemical ● For motorcycles equipped with
CAUTION: products on plastic parts. Be a windshield: Do not use strong
@

● Avoid using strong acidic wheel sure to avoid using cloths or cleaners or hard sponges as
cleaners, especially on spoked sponges which have been in they will cause dulling or
wheels. If you do use such contact with strong or abrasive scratching. Some cleaning
products for hard-to-remove cleaning products, solvent or compounds for plastic may
dirt, do not leave it on any long- thinner, fuel (gasoline), rust re- leave scratches on the wind-
er than instructed, then thor- movers or inhibitors, brake flu- shield. Test the product on a
oughly rinse it off with water, id, antifreeze or electrolyte. small hidden part of the wind-
immediately dry the area and ● Do not use high-pressure wash- shield to make sure they do not
apply a corrosion protection ers or steam-jet cleaners since leave any marks. If the wind-
spray. they cause water seepage and shield is scratched, use a quali-
● Improper cleaning can damage deterioration in the following ar- ty plastic polishing compound
windshields, cowlings, panels eas: seals (of wheel bearings, after washing.
and other plastic parts. Use swingarm bearings, forks and @

only a soft, clean cloth or brakes), electric components

After riding in the rain, near the sea or
sponge with mild detergent and (couplers, connectors, instru- 7
on salt-sprayed roads
water to clean plastic. ments, switches and lights),
Since sea salt or salt sprayed on the
breather hoses and vents.
roads in the winter are extremely corro-
sive in combination with water, carry
out the following steps after each ride
in the rain, near the sea or on salt-
sprayed roads. (Salt sprayed in the
winter may remain on the roads well
into spring.)

7-2
 E_4xs_Cleaning.fm Page 3 Tuesday, November 30, 1999 2:38 PM

MOTORCYCLE CARE AND STORAGE

1. Clean your motorcycle with cold After cleaning EWA00001

water and soap after the engine 1. Dry the motorcycle with a chamois @
WARNING
has cooled down. or an absorbing cloth. Make sure that there is no oil or wax
ECA00012
2. Use a chrome polish to shine on the brakes and tires. If neces-
CAUTION: chrome, aluminum and stainless- sary, clean the brake discs and lin-
@

Do not use warm water since it in- steel parts, including the exhaust ings with a regular brake disc
creases the corrosive action of the system. (Even the thermally in- cleaner or acetone, and wash the
salt. duced discoloring of stainless- tires with warm water and mild soap.
@

steel exhaust systems can be re- Then, carefully test the motorcycle
2. Be sure to apply a corrosion pro-
moved through polishing.) for its braking performance and cor-
tection spray on all (even chrome-
3. To prevent corrosion, it is recom- nering behavior.
and nickel-plated) metal surfaces @

mended to apply a corrosion pro- ECA00013

to prevent corrosion.
tection spray on all (even chrome- CAUTION:
and nickel-plated) metal surfaces.
@

● Apply spray oil and wax spar-

4. Use spray oil as a universal clean- ingly and wipe off any excess.
er to remove any remaining dirt. ● Never apply oil or wax on rub-
7 5. Touch up minor paint damage ber and plastic parts, but treat
caused by stones, etc. them with a suitable care prod-
6. Wax all painted surfaces. uct.
7. Let the motorcycle dry completely ● Avoid using abrasive polishing
before storing it or covering it. compounds as they wear away
the paint.
@

NOTE:
@

Consult a Yamaha dealer for advice on

what products to use.
@

7-3
E_4xs_Cleaning.fm Page 4 Tuesday, November 30, 1999 2:38 PM

MOTORCYCLE CARE AND STORAGE

Storage Long-term c. Install the spark plug caps onto the
Short-term Before storing your motorcycle for sev- spark plugs and place the spark
Always store your motorcycle in a cool, eral months: plugs on the cylinder head so that
dry place and, if necessary, protect it 1. Follow all the instructions in the the electrodes are grounded. (This
against dust with a porous cover. “Care” section of this chapter. will limit sparking during the next
ECA00014 2. Drain the carburetor float cham- step.)
CAUTION: bers by loosening the drain bolts; d. Turn the engine over several times
@

● Storing the motorcycle in a this will prevent fuel deposits from with the starter. (This will coat the
poorly ventilated room or cover- building up. Pour the drained fuel cylinder walls with oil.)
ing it with a tarp while it is still into the fuel tank. e. Remove the spark plug caps from
wet will allow water and humidi- 3. Only for motorcycles equipped the spark plugs, install the spark
ty to seep in and cause rust. with a fuel cock which has an plugs and then the spark plug
● To prevent corrosion, avoid “OFF” position: Turn the fuel cock caps.
damp cellars, stables (because to “OFF”. EWA00003

of the presence of ammonia) 4. Fill up the fuel tank and add fuel @
WARNING
and areas where strong chemi- stabilizer (if available) to prevent When turning the engine over, be
cals are stored. the fuel tank from rusting and the sure to ground the spark plug elec- 7
@
fuel from deteriorating. trodes to prevent damage or injury
5. Perform the following steps to pro- from sparking.
@

tect the cylinders, piston rings, etc. 6. Lubricate all control cables and
from corrosion. the pivoting points of all levers and
a. Remove the spark plug caps and pedals as well as of the sidestand/
spark plugs. centerstand.
b. Pour a teaspoonful of engine oil
into each spark plug bore.

7-4
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MOTORCYCLE CARE AND STORAGE

7. Check and, if necessary, correct
the tire air pressure, then raise the
motorcycle so that both of its
wheels are off the ground. Alterna-
tively, turn the wheels a little every
month in order to prevent the tires
from becoming degraded in one
spot.
8. Cover up the muffler outlets with
plastic bags to prevent moisture
from entering.
9. Remove the battery and fully
charge it. Store it in a cool, dry
place and recharge it once a
month. Do not store the battery in
an excessively cold or warm place
7 (less than 0 °C or more than
30 °C). For more information, see
“Battery storage” in the chapter
“PERIODIC MAINTENANCE AND
MINOR REPAIRS”.

NOTE:
@

Make any necessary repairs before

storing the motorcycle.
@

7-5
E_4xs_SpecTOC.fm Page 1 Tuesday, November 30, 1999 2:38 PM

SPECIFICATIONS

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

HOW TO USE THE CONVERSION TABLE ....................................... 8-6

8
 E_4xs_Spec.fm Page 1 Tuesday, November 30, 1999 2:39 PM

SPECIFICATIONS
8-
EAU01038

Specifications
01E
Model XVS650/XVS650A Engine
Dimensions Engine type Air-cooled 4-stroke, SOHC
For XVS650 Cylinder arrangement V type 2-cylinder
Overall length 2,340 mm Displacement 649 cm3
Overall width 880 mm Bore × stroke 81 × 63 mm
Overall height 1,065 mm Compression ratio 9:1
Seat height 695 mm Starting system Electric starter
Wheelbase 1,610 mm Lubrication system Wet sump
Ground clearance 140 mm Engine oil
Minimum turning radius 3,100 mm Type
-20˚ -10˚ 0˚ 10˚ 20˚ 30˚ 40˚ 50˚C
For XVS650A
Overall length 2,450 mm SAE 10W/30

Overall width 930 mm SAE 10W/40

Overall height 1,105 mm SAE 15W/40
Seat height 710 mm
SAE 20W/40
Wheelbase 1,625 mm
8 SAE 20W/50
Ground clearance 145 mm
Minimum turning radius 3,400 mm Recommended engine oil
classification API Service SE, SF, SG type or
Basic weight (with oil and full higher
fuel tank)
For XVS650 227 kg
For XVS650A 242 kg

8-1
E_4xs_Spec.fm Page 2 Tuesday, November 30, 1999 2:39 PM

SPECIFICATIONS
Spark plug
CAUTION:
Type/Manufacturer DPR7EA-9 / NGK or
Be sure to use motor oils that do not contain anti-fric-
X22EPR-U9 / DENSO
tion modifiers. Passenger car motor oils (often labeled
“Energy Conserving”) contain anti-friction additives Gap 0.8 ~ 0.9 mm
which will cause clutch and/or starter clutch slippage, Clutch type Wet, multiple-disc
resulting in reduced component life and poor engine
performance. Transmission
Primary reduction system Spur gear
Quantity Primary reduction ratio 1.789
Periodic oil change 2.6 L Secondary reduction system Shaft drive
With oil filter replacement 2.8 L Secondary reduction ratio 3.071
Total amount 3.2 L Transmission type Constant mesh 5-speed
Final gear oil Operation Left foot operation
Type SAE80API “GL-4” Hypoid Gear Gear ratio
Oil
1st 2.714
Final gear case capacity 0.19 L
2nd 1.900
Air filter Dry type element
3rd 1.458
Fuel
4th 1.167
Type Regular gasoline
Unleaded fuel only (for Australia) 5th 0.967 8
Fuel tank capacity 16 L Chassis

Fuel reserve amount 3L For XVS650

Carburetor Frame type Double cradle

Type × quantity BDS28 × 2 Caster angle 35°

Manufacturer MIKUNI Trail 153 mm

8-2
 E_4xs_Spec.fm Page 3 Tuesday, November 30, 1999 2:39 PM

SPECIFICATIONS
For XVS650A For XVS650A
Frame type Double cradle Type Tube
Caster angle 35° Front
Trail 145 mm Size 130/90-16 67S
Tires Manufacturer/model Bridgestone / G703
For XVS650 Dunlop / D404F
Type Tube Rear
Front Size 170/80-15 M/C 77S
Size 100/90-19 57S Manufacturer/model Bridgestone / G702
Manufacturer/model Bridgestone / L309 Dunlop / D404
Dunlop / F24 Maximum load* 201 kg
Rear Air pressure (cold tire)
Size 170/80-15 M/C 77S Up to 90 kg load*
Manufacturer/model Bridgestone / G546 Front 225 kPa; 2.25 kgf/cm2; 2.25 bar
Dunlop / K555 Rear 225 kPa; 2.25 kgf/cm2; 2.25 bar
Maximum load* 180 kg 90 kg load ~ maximum
Air pressure (cold tire) load*
8 Front 225 kPa; 2.25 kgf/cm2; 2.25 bar
Up to 90 kg load*
Rear 250 kPa; 2.50 kgf/cm2; 2.50 bar
Front 200 kPa; 2.00 kgf/cm2; 2.00 bar
Rear 225 kPa; 2.25 kgf/cm2; 2.25 bar * Load is total weight of cargo, rider, passenger and accessories.

90 kg load ~ maximum
load*
Front 200 kPa; 2.00 kgf/cm2; 2.00 bar
Rear 250 kPa; 2.50 kgf/cm2; 2.50 bar

8-3
E_4xs_Spec.fm Page 4 Tuesday, November 30, 1999 2:39 PM

SPECIFICATIONS
Wheels Suspension
For XVS650 Front
Front Type Telescopic fork
Type Spoke Rear
Size 19 × MT2.50 Type Swingarm (monocross)
Rear Shock absorber
Type Spoke Front Coil spring / oil damper
Size 15M/C × MT3.50 Rear Coil spring / gas-oil damper,
For XVS650A spring preload adjustable
Wheel travel
Front
For XVS650
Type Spoke
Size 16 × MT3.00 Front 140 mm
Rear 86 mm
Rear
Type Spoke For XVS650A
Front 140 mm
Size 15M/C × MT3.50
Rear 98 mm
Brakes
Front Electrical
Ignition system T.C.I. (digital) 8
Type Single disc brake
Charging system
Operation Right hand operation
Fluid DOT 4 Type A.C. magneto
Standard output 14 V, 20 A @ 5,000 r/min
Rear
Battery
Type Drum brake
Operation Right foot operation Type GT12B-4
Voltage, capacity 12 V, 10 AH

8-4
 E_4xs_Spec.fm Page 5 Tuesday, November 30, 1999 2:39 PM

SPECIFICATIONS
Headlight type Quartz bulb (halogen) Fuses
Bulb voltage, wattage × quantity Main fuse 30 A
For XVS650 Ignition fuse 10 A
Headlight 12 V, 60/55 W × 1 Signaling system fuse 10 A
Licence light 12 V, 5 W × 1 Headlight fuse 15 A
Tail/brake light 12 V, 5/21 W × 1 Carburetor heater fuse 15 A
Turn signal light 12 V, 21 W × 4
Meter light 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 indicator light 12 V, 1.7 W × 1
Engine trouble indicator light 12 V, 1.7 W × 1
For XVS650A
Headlight 12 V, 60/55 W × 1
Licence light 12 V, 5 W × 1
Tail/brake light 12 V, 5/21 W × 1
Turn signal light 12 V, 21 W × 4
8
Meter light 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 indicator light 12 V, 1.7 W × 1
Engine trouble indicator light 12 V, 1.7 W × 1

8-5
E_4xs_Spec.fm Page 6 Tuesday, November 30, 1999 2:39 PM

SPECIFICATIONS
EAU01064

HOW TO USE THE CONVERSION TABLE

CS-02E
CONVERSION TABLE
All specification data in this manual are listed in SI and METRIC TO IMPERIAL
METRIC UNITS. Metric unit Multiplier Imperial unit
Use this table to convert METRIC unit data to IMPERIAL m·kg 7.233 ft·lb
m·kg 86.794 in·lb
unit data. Torque
cm·kg 0.0723 ft·lb
Ex. cm·kg 0.8679 in·lb
kg 2.205 lb
Weight
METRIC MULTIPLIER IMPERIAL g 0.03527 oz
Speed km/hr 0.6214 mph
**mm × 0.03937 = **in
km 0.6214 mi
m 3.281 ft
2 mm × 0.03937 = 0.08 in Distance m 1.094 yd
cm 0.3937 in
mm 0.03937 in
cc (cm3) 0.03527 oz (IMP liq.)
Volume / cc (cm3) 0.06102 cu·in
Capacity lt (liter) 0.8799 qt (IMP liq.)
lt (liter) 0.2199 gal (IMP liq.)
kg/mm 55.997 lb/in
Misc. kg/cm2 14.2234 psi (lb/in2)
Centigrade (°C) 9/5 + 32 Fahrenheit (°F) 8

8-6
E_4xs_Spec.fm Page 7 Tuesday, November 30, 1999 2:39 PM
E_4xs_ConsumerTOC.fm Page 1 Tuesday, November 30, 1999 2:39 PM

CONSUMER INFORMATION

Identification number records............................................................. 9-1

Key identification number ................................................................... 9-1
Vehicle identification number.............................................................. 9-1
Model label......................................................................................... 9-2
Noise regulation (For Australia).......................................................... 9-2

9
 E_4xs_Consumer.fm Page 1 Tuesday, November 30, 1999 2:39 PM

CONSUMER INFORMATION
9-
EAU01039

EAU02944

Identification number records

Record the key identification number,
vehicle identification number and mod-
el label information in the spaces pro-
vided for assistance when ordering
spare parts from a Yamaha dealer or
for reference in case the vehicle is sto-
len.
1. KEY IDENTIFICATION NUMBER: 1. Key identification number 1. Vehicle identification number
CA-02E EAU01041 EAU01043

Key identification number Vehicle identification number

The key identification number is The vehicle identification number is
stamped on the key tag. Record this stamped into the steering head pipe.
2. VEHICLE IDENTIFICATION number in the space provided and use Record this number in the space pro-
NUMBER: it for reference when obtaining a new vided.
CA-02E key.
NOTE:
@

The vehicle identification number is

used to identify your motorcycle and
may be used to register your motor-
3. MODEL LABEL INFORMATION: cycle with the licensing authority in
9 CA-01E
your state.
@

9-1
E_4xs_Consumer.fm Page 2 Tuesday, November 30, 1999 2:39 PM

CONSUMER INFORMATION
EAU01388

NOISE REGULATION
(For Australia)
TAMPERING WITH NOISE CON-
TROL SYSTEM PROHIBITED
Owners are warned that the law may
prohibit:
(a) The removal or rendering inopera-
tive by any person other than for
1. Model label
purposes of maintenance, repair
EAU01050
or replacement, of any device or
Model label element of design incorporated
The model label is affixed to the frame into any new vehicle for the pur-
under the seat. (See page 3-9 for seat pose of noise control prior to its
removal procedures.) Record the infor- sale or delivery to the ultimate pur-
mation on this label in the space pro- chaser or while it is in use; and
vided. This information will be needed (b) The use of the vehicle after such
to order spare parts from your Yamaha device or element of design has
dealer. been removed or rendered inoper-
ative by any person.
9

9-2
E_4xsIX.fm Page 1 Tuesday, November 30, 1999 2:40 PM

INDEX
10-

A F I
Air filter ..................................................6-12 Final gear oil.......................................... 6-11 Identification number records ...................9-1
Front brake lever ..................................... 3-5 Idle speed adjustment ............................6-14
B
Front brake lever free play Indicator lights..........................................3-2
Battery ...................................................6-25
adjustment .......................................... 6-18 Engine trouble indicator light...............3-2
Brake and clutch lever lubrication...........6-23
Front fork inspection .............................. 6-24 High beam indicator light ....................3-2
Brake and shift pedal lubrication ............6-23
Front wheel installation .......................... 6-31 Neutral indicator light ..........................3-2
Brake fluid replacement .........................6-22
Front wheel removal .............................. 6-31 Turn indicator light ..............................3-2
Brake light switch adjustment.................6-20
Fuel ......................................................... 3-6 Inspecting the brake fluid level ...............6-21
C Fuel cock................................................. 3-7
K
Cable inspection and lubrication ............6-22 Fuel tank cap........................................... 3-5
Key identification number .........................9-1
Carburetor adjustment ...........................6-13 Fuse replacement.................................. 6-27
Care.........................................................7-1 L
G
Checking the front brake pads and Left view (XVS650) ..................................2-1
Gasoline and exhaust gas ....................... 1-5
rear brake shoes..................................6-21 Left view (XVS650A) ................................2-3
Clutch lever..............................................3-4 H Loading and accessories .........................1-3
Clutch lever free play adjustment ...........6-17 Handlebar switches ................................. 3-3 Location of the important labels................1-7
Controls/Instruments Dimmer switch ................................... 3-3 Luggage strap holders ...........................3-14
(XVS650/XVS650A) ..............................2-5 Engine stop switch ............................. 3-3
M
Horn switch ........................................ 3-3
D Main switch/steering lock .........................3-1
Pass switch ........................................ 3-3
Dimmer switch .........................................3-3 Model label ..............................................9-2
Start switch ........................................ 3-4
Modification..............................................1-3
E Turn signal switch .............................. 3-3
Engine break-in........................................5-5 Headlight bulb replacement ................... 6-28 N
Engine oil.................................................6-9 Helmet holder ........................................ 3-11 Neutral indicator light ...............................3-2
Engine stop switch ...................................3-3 High beam indicator light ......................... 3-2 Noise regulation (For Australia)................9-2
Engine trouble indicator light ....................3-2 Horn switch ............................................. 3-3
E_4xsIX.fm Page 2 Tuesday, November 30, 1999 2:40 PM

INDEX
P Starting and warming up a cold
Panel A.................................................... 6-6 engine................................................... 5-1
Panel B.................................................... 6-7 Starting a warm engine ........................... 5-4
Panel removal and installation ................. 6-5 Start switch ............................................. 3-4
Parking .................................................... 5-6 Steering inspection................................ 6-25
Pass switch ............................................. 3-3 Storage ................................................... 7-4
Periodic maintenance and lubrication ...... 6-2 Storage compartment............................ 3-11
Pre-operation check list ........................... 4-1 Supporting the motorcycle..................... 6-30
Protective apparel.................................... 1-3 T
R Throttle cable and grip lubrication.......... 6-23
Rear brake pedal ..................................... 3-5 Throttle cable free play inspection ......... 6-14
Rear brake pedal height and free play Tips for reducing fuel consumption.......... 5-5
adjustment .......................................... 6-19 Tires...................................................... 6-15
Rear shock absorber adjustment ........... 3-13 Tool kit .................................................... 6-1
Rear wheel installation........................... 6-33 Troubleshooting .................................... 6-34
Rear wheel removal............................... 6-32 Troubleshooting chart ........................... 6-35
Right view (XVS650) ............................... 2-2 Turn indicator light................................... 3-2
Right view (XVS650A) ............................. 2-4 Turn signal and taillight bulb
replacement........................................ 6-29
S Turn signal switch ................................... 3-3
Safe riding ............................................... 1-1
Seats (XVS650)....................................... 3-9 V
Seats (XVS650A) .................................. 3-10 Valve clearance adjustment .................. 6-15
Shifting .................................................... 5-4 Vehicle identification number................... 9-1
Shift pedal ............................................... 3-4 W
Sidestand .............................................. 3-14
Wheel bearings ..................................... 6-25
Sidestand/clutch switch operation Wheels.................................................. 6-17
check .................................................. 3-15
Sidestand lubrication ............................. 6-24
Spark plugs ............................................. 6-7
Specifications .......................................... 8-1
Speedometer........................................... 3-2
Starter (choke) “ ”................................ 3-8
 YAMAHA MOTOR CO., LTD.
PRINTED ON RECYCLED PAPER PRINTED IN JAPAN
99 · 11 - 0.3 × 1 CR
(E)