drag star 650 user manual

PRINTED IN JAPAN2004.05-2.6×1 CR

(E)

PRINTED ON RECYCLED PAPER YAMAHA MOTOR CO., LTD.

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

XVS650T(C)XVS650AT(C)

XVS650ATT(C)

OWNER’S MANUAL

EAU10041

U5FB15E0.book Page 1 Tuesday, May 11, 2004 3:55 AM

INTRODUCTIONEAU10080

Congratulations on your purchase of the Yamaha XVS650(C)/XVS650A(C)/XVS650AT(C). This model is the result ofYamaha’s vast experience in the production of fine sporting, touring, and pacesetting racing machines. It represents the highdegree 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 youhave any questions concerning the operation or maintenance of your motorcycle, please consult a Yamaha dealer.The design and manufacture of this Yamaha motorcycle fully comply with the emissions standards for clean air applicable atthe date of manufacture. Yamaha has met these standards without reducing the performance or economy of operation of themotorcycle. To maintain these high standards, it is important that you and your Yamaha dealer pay close attention to therecommended maintenance schedules and operating instructions contained within this manual.


IMPORTANT MANUAL INFORMATIONEAU10130

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

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 motorcycleand this manual. If you have any questions concerning this manual, please consult your Yamaha dealer.

WARNINGEWA10010

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

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

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 motor-cycle.

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

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

WARNING

CAUTION:

NOTE:


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


IMPORTANT MANUAL INFORMATION

EAU10192

XVS650T(C)/XVS650AT(C)/XVS650ATT(C)OWNER’S MANUAL

©2004 by Yamaha Motor Corporation, U.S.A.1st edition, April 2004

All rights reserved.Any reprinting or unauthorized use without the written permission of Yamaha Motor Corporation, U.S.A.

is expressly prohibited.Printed in Japan.

P/N LIT-11626-18-20

AFFIX DEALER

LABEL HERE


TABLE OF CONTENTSSAFETY INFORMATION ..................1-1

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

DESCRIPTION ..................................2-1Left view ..........................................2-1Right view........................................2-3Controls and instruments ................2-5

INSTRUMENT AND CONTROL FUNCTIONS .......................................3-1

Main switch/steering lock ................3-1Indicator and warning lights ............3-2Speedometer unit ...........................3-2Handlebar switches ........................3-3Clutch lever ....................................3-4Shift pedal (XVS650) ......................3-4Shift pedal (XVS650A/AT) ..............3-4Brake lever .....................................3-5Brake pedal ....................................3-5Fuel tank cap ..................................3-5Fuel ................................................3-6Catalytic converter ..........................3-7Fuel cock ........................................3-7Starter (choke) knob .......................3-8Seats (XVS650) ..............................3-9Seats (XVS650A/AT) ....................3-10Helmet holder ...............................3-11Storage compartment ...................3-11Adjusting the shock absorber

assembly ...................................3-12Luggage strap holders ..................3-13

Sidestand ..................................... 3-13Ignition circuit cut-off system ....... 3-14

PRE-OPERATION CHECKS ............. 4-1Pre-operation check list ................. 4-2

OPERATION AND IMPORTANT RIDING POINTS ................................ 5-1

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

Starting a warm engine .................. 5-2Shifting ........................................... 5-3Engine break-in .............................. 5-4Parking ........................................... 5-5

PERIODIC MAINTENANCE AND MINOR REPAIR................................. 6-1

PERIODIC MAINTENANCE .......... 6-1Owner’s tool kit .............................. 6-1Periodic maintenance chart for the

emission control system ............. 6-3General maintenance and

lubrication chart .......................... 6-4Removing and installing panels ..... 6-8Checking the spark plugs .............. 6-9Canister (for California only) ........ 6-10Engine oil and oil filter element .... 6-11Final gear oil ................................ 6-13Cleaning the air filter element ...... 6-14Adjusting the carburetors ............. 6-16

Adjusting the throttle cable free play ....................................6-16

Adjusting the valve clearance ...... 6-16Tires ............................................. 6-17Spoke wheels ............................... 6-19Accessories and replacement

parts .......................................... 6-19Adjusting the clutch lever

free play ....................................6-20Adjusting the brake lever

free play ....................................6-21Adjusting the brake pedal position

and free play .............................6-22Adjusting the rear brake light

switch ........................................6-23Checking the front brake pads

and rear brake shoes ................ 6-24Checking the brake fluid level ...... 6-24Changing the brake fluid .............. 6-25Checking and lubricating the

cables ....................................... 6-25Checking and lubricating the

throttle grip and cable ............... 6-26Checking and lubricating the

brake and shift pedals ............... 6-26Checking and lubricating the

brake and clutch levers .............6-26Checking and lubricating the

sidestand .................................. 6-27Checking the front fork ................. 6-27Checking the steering ..................6-28


TABLE OF CONTENTSChecking the wheel bearings .......6-28Battery ..........................................6-29Replacing the fuses ......................6-30Replacing the headlight bulb ........6-31Replacing a turn signal light bulb

or the tail/brake light bulb ..........6-32Supporting the motorcycle ............6-33Front wheel ...................................6-34Rear wheel ...................................6-35Troubleshooting ............................6-37Troubleshooting chart ...................6-38

MOTORCYCLE CARE AND STORAGE ..........................................7-1

Care ................................................7-1Storage ...........................................7-3

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

CONSUMER INFORMATION.............9-1Identification numbers ....................9-1Reporting safety defects .................9-3Motorcycle noise regulation ............9-4Maintenance record ........................9-5YAMAHA MOTOR CORPORATION,

U.S.A. STREET AND ENDURO MOTORCYCLE LIMITED WARRANTY ................................9-7

YAMAHA EXTENDED SERVICE (Y.E.S.) ........................................9-9


1-1

1

SAFETY INFORMATIONEAU10251

MOTORCYCLES ARE SINGLETRACK VEHICLES. THEIR SAFEUSE AND OPERATION ARE DEPEN-DENT UPON THE USE OF PROPERRIDING TECHNIQUES AS WELL ASTHE EXPERTISE OF THE OPERA-TOR. EVERY OPERATOR SHOULDKNOW THE FOLLOWING REQUIRE-MENTS BEFORE RIDING THISMOTORCYCLE.HE OR SHE SHOULD:

� OBTAIN THOROUGH INSTRUC-TIONS FROM A COMPETENTSOURCE ON ALL ASPECTS OFMOTORCYCLE OPERATION.

� OBSERVE THE WARNINGSAND MAINTENANCE REQUIRE-MENTS IN THE OWNER’S MAN-UAL.

� OBTAIN QUALIFIED TRAININGIN SAFE AND PROPER RIDINGTECHNIQUES.

� OBTAIN PROFESSIONAL TECH-NICAL SERVICE AS INDICATEDBY THE OWNER’S MANUAL

AND/OR WHEN MADE NECES-SARY BY MECHANICAL CONDI-TIONS.

Safe riding� Always make pre-operation

checks. Careful checks may helpprevent an accident.

� This motorcycle is designed tocarry the operator and a passen-ger.

� The failure of motorists to detectand recognize motorcycles in traf-fic is the predominating cause ofautomobile/motorcycle accidents.Many accidents have beencaused by an automobile driverwho did not see the motorcycle.Making yourself conspicuous ap-pears to be very effective in reduc-ing the chance of this type ofaccident.Therefore:• Wear a brightly colored jacket.• Use extra caution when ap-

proaching and passing throughintersections, since intersec-

tions are the most likely placesfor motorcycle accidents to oc-cur.

• Ride where other motorists cansee you. Avoid riding in anothermotorist’s blind spot.

� Many motorcycle accidents in-volve inexperienced operators. Infact, many operators who havebeen involved in accidents do noteven have a current motorcycle li-cense.• Make sure that you are qualified

and that you only lend yourmotorcycle to other qualified op-erators.

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

• We recommend that you prac-tice riding your motorcyclewhere there is no traffic until youhave become thoroughly famil-iar with the motorcycle and all ofits controls.

� Many motorcycle accidents havebeen caused by error of the motor-cycle operator. A typical errormade by the operator is veering


SAFETY INFORMATION

1-2

1

wide on a turn due to EXCESSIVESPEED or undercornering (insuffi-cient lean angle for the speed).• Always obey the speed limit and

never travel faster than warrant-ed by road and traffic conditions.

• Always signal before turning orchanging lanes. Make sure thatother motorists can see you.

� The posture of the operator andpassenger is important for propercontrol.• The operator should keep both

hands on the handlebar andboth feet on the operator foot-rests during operation to main-tain control of the motorcycle.

• The passenger should alwayshold onto the operator, seatstrap, or grab bar, if equipped,with both hands and keep bothfeet on the passenger footrests.

• Never carry a passenger unlesshe or she can firmly place bothfeet on the passenger footrests.

� Never ride under the influence ofalcohol or other drugs.

� This motorcycle is designed for on-road use only, therefore, it is notsuitable for off-road use.

Protective apparelThe majority of fatalities from motor-cycle accidents are the result of headinjuries. The use of a safety helmet isthe single most critical factor in the pre-vention or reduction of head injuries.

� Always wear an approved helmet.� Wear a face shield or goggles.

Wind in your unprotected eyescould contribute to an impairmentof vision which could delay seeinga hazard.

� The use of a jacket, heavy boots,trousers, gloves, etc., is effective inpreventing or reducing abrasionsor lacerations.

� Never wear loose-fitting clothes,otherwise they could catch on thecontrol levers, footrests, or wheelsand cause injury or an accident.

� Never touch the engine or exhaustsystem during or after operation.They become very hot and can

cause burns. Always wear protec-tive clothing that covers your legs,ankles, and feet.

� Passengers should also observethe precautions mentioned above.

ModificationsModifications made to this motorcyclenot approved by Yamaha, or the re-moval of original equipment, may ren-der the motorcycle unsafe for use andmay cause severe personal injury.Modifications may also make yourmotorcycle illegal to use.

Loading and accessoriesAdding accessories or cargo to yourmotorcycle can adversely affect stabili-ty and handling if the weight distributionof the motorcycle is changed. To avoidthe possibility of an accident, use ex-treme caution when adding cargo oraccessories to your motorcycle. Useextra care when riding a motorcyclethat has added cargo or accessories.Here are some general guidelines tofollow if loading cargo or adding acces-sories to your motorcycle:


SAFETY INFORMATION

1-3

1

LoadingThe total weight of the operator, pas-senger, accessories and cargo mustnot exceed the maximum load limit.

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

� Cargo and accessory weightshould be kept as low and close tothe motorcycle as possible. Makesure to distribute the weight asevenly as possible on both sides ofthe motorcycle to minimize imbal-ance or instability.

� Shifting weights can create a sud-den imbalance. Make sure that ac-cessories and cargo are securelyattached to the motorcycle beforeriding. Check accessory mountsand cargo restraints frequently.

� Never attach any large or heavyitems to the handlebar, front fork,or front fender. These items, in-cluding such cargo as sleepingbags, duffel bags, or tents, cancreate unstable handling or slowsteering response.

AccessoriesGenuine Yamaha accessories havebeen specifically designed for use onthis motorcycle. Since Yamaha cannottest all other accessories that may beavailable, you must personally be re-sponsible for the proper selection, in-stallation and use of non-Yamahaaccessories. Use extreme cautionwhen selecting and installing any ac-cessories.Keep the following guidelines in mind,as well as those provided under “Load-ing” when mounting accessories.

� Never install accessories or carrycargo that would impair the perfor-mance of your motorcycle. Care-fully inspect the accessory beforeusing it to make sure that it doesnot in any way reduce groundclearance or cornering clearance,

limit suspension travel, steeringtravel or control operation, or ob-scure lights or reflectors.• Accessories fitted to the handle-

bar or the front fork area cancreate instability due to improperweight distribution or aerody-namic changes. If accessoriesare added to the handlebar orfront fork area, they must be aslightweight as possible andshould be kept to a minimum.

• Bulky or large accessories mayseriously affect the stability ofthe motorcycle due to aerody-namic effects. Wind may at-tempt to lift the motorcycle, orthe motorcycle may become un-stable in cross winds. These ac-cessories may also causeinstability when passing or beingpassed by large vehicles.

• Certain accessories can dis-place the operator from his orher normal riding position. Thisimproper position limits the free-dom of movement of the opera-

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


SAFETY INFORMATION

1-4

1

tor and may limit control ability,therefore, such accessories arenot recommended.

� Use caution when adding electri-cal accessories. If electrical acces-sories exceed the capacity of themotorcycle’s electrical system, anelectric failure could result, whichcould cause a dangerous loss oflights or engine power.

Gasoline and exhaust gas� GASOLINE IS HIGHLY FLAMMA-

BLE:• Always turn the engine off when

refueling.• Take care not to spill any gaso-

line on the engine or exhaustsystem when refueling.

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

� Never start the engine or let it runfor any length of time in a closedarea. The exhaust fumes are poi-sonous and may cause loss ofconsciousness and death within ashort time. Always operate yourmotorcycle in an area that has ad-equate ventilation.

� Always turn the engine off beforeleaving the motorcycle unattendedand remove the key from the mainswitch. When parking the motor-cycle, note the following:• The engine and exhaust system

may be hot, therefore, park themotorcycle in a place where pe-destrians or children are not like-ly to touch these hot areas.

• Do not park the motorcycle on aslope or soft ground, otherwise itmay fall over.

• Do not park the motorcycle neara flammable source (e.g. a kero-sene heater, or near an openflame), otherwise it could catchfire.

� When transporting the motorcyclein another vehicle, make sure thatit is kept upright and that the fuelcock is turned to “ON” or “RES” (forvacuum type) / “OFF” (for manualtype). If it should lean over, gaso-line may leak out of the carburetoror fuel tank.

� If you should swallow any gaso-line, inhale a lot of gasoline vapor,or allow gasoline to get into your

eyes, see your doctor immediately.If any gasoline spills on your skinor clothing, immediately wash theaffected area with soap and waterand change your clothes.


SAFETY INFORMATION

1-5

1

EAU10381

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


SAFETY INFORMATION

1-6

1

1

2

3 XVS650

3 XVS650A/AT

4


SAFETY INFORMATION

1-7

1

5

6 California only

A1


DESCRIPTION

2-1

2

EAU32220

Left view

XVS650

1. Shift pedal (page 3-4)2. Fuel cock (page 3-7)3. Starter (choke) knob (page 3-8)4. Shock absorber assembly spring preload adjusting ring (page 3-12)5. Helmet holder (page 3-11)6. Owner’s tool kit (page 6-1)

7. Storage compartment (page 3-11)


DESCRIPTION

2-2

2

XVS650A/AT

1. Shift pedal (page 3-4)2. Fuel cock (page 3-7)3. Starter (choke) knob (page 3-8)4. Shock absorber assembly spring preload adjusting ring (page 3-12)5. Helmet holder (page 3-11)6. Owner’s tool kit (page 6-1)7. Storage compartment (page 3-11)


DESCRIPTION

2-3

2

EAU32230

Right view

XVS650

1. Engine oil filter element (page 6-11)2. Battery (page 6-29)3. Fuses (page 6-30)4. Main switch/steering lock (page 3-1)5. Air filter element (page 6-14)6. Brake pedal (page 3-5)


DESCRIPTION

2-4

2

XVS650A/AT

1. Engine oil filter element (page 6-11)2. Battery (page 6-29)3. Fuses (page 6-30)4. Main switch/steering lock (page 3-1)5. Air filter element (page 6-14)6. Brake pedal (page 3-5)


DESCRIPTION

2-5

2

EAU10430

Controls and instruments

1. Clutch lever (page 3-4)2. Left handlebar switches (page 3-3)3. Speedometer unit (page 3-2)4. Fuel tank cap (page 3-5)5. Right handlebar switches (page 3-3)6. Throttle grip (page 6-16)7. Brake lever (page 3-5)


INSTRUMENT AND CONTROL FUNCTIONS

3-1

3

EAU10460

Main switch/steering lock

The main switch/steering lock controlsthe ignition and lighting systems, and isused to lock the steering. The variouspositions are described below.

EAU10510

ONAll electrical systems are supplied withpower, and the headlight, meter light-ing, taillight and position lights comeon, and the engine can be started. Thekey cannot be removed.

EAU10660

OFFAll electrical systems are off. The keycan be removed.

EAU10680

LOCKThe steering is locked, and all electricalsystems are off. The key can be re-moved.

To lock the steering

1. Turn the handlebars all the way tothe left.

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

3. Remove the key.

To unlock the steering

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

WARNINGEWA10060

Never turn the key to “OFF” or“LOCK” while the vehicle is moving,otherwise the electrical systems willbe switched off, which may result inloss of control or an accident. Makesure that the vehicle is stopped be-fore turning the key to “OFF” or“LOCK”.

1. Push.2. Turn.

1. Push.2. Turn.



3-2

3

EAU11001

Indicator and warning lights

EAU11020

Turn signal indicator light “ ” This indicator light flashes when theturn signal switch is pushed to the left orright.

EAU11060

Neutral indicator light “ ” This indicator light comes on when thetransmission is in the neutral position.

EAU11080

High beam indicator light “ ” This indicator light comes on when thehigh beam of the headlight is switchedon.

EAU11500

Engine trouble warning light “ ” This warning light comes on or flasheswhen an electrical circuit monitoring theengine is defective. When this occurs,have a Yamaha dealer check the self-diagnosis system.The electrical circuit of the warning lightcan be checked by turning the key to“ON”. If the warning light does not comeon for a few seconds, then go off, havea Yamaha dealer check the electricalcircuit.

EAU11630

Speedometer unit

The speedometer unit is equipped witha speedometer, an odometer and atripmeter. The speedometer showsriding speed. The odometer shows thetotal distance traveled. The tripmetershows the distance traveled since itwas last set to zero with the reset knob.The tripmeter can be used to estimatethe distance that can be traveled with afull tank of fuel. This information will en-able you to plan future fuel stops.

1. High beam indicator light “ ”2. Turn signal indicator light “ ”3. Neutral indicator light “ ”4. Engine trouble warning light “ ”

1. Tripmeter reset knob2. Speedometer3. Odometer4. Tripmeter



3-3

3

EAU12343

Handlebar switches

Left

Right

EAU12400

Dimmer switch “ / ” Set this switch to “ ” for the highbeam and to “ ” for the low beam.

EAU12430

Turn signal switch “ / ” To signal a right-hand turn, push thisswitch to “ ”. To signal a left-handturn, push this switch to “ ”. When re-leased, the switch returns to the centerposition.Since this model is equipped with aself-canceling system, the turn signallights will self-cancel after the vehiclehas traveled both about 150 m (490 ft)and for approximately 15 seconds.However, the turn signal lights can alsobe canceled manually by pushing theswitch in after it has returned to the cen-ter position.

NOTE:The self-canceling system only oper-ates when the vehicle is moving, so thatthe turn signal lights will not self-cancelwhile you are stopped at an intersec-tion.

EAU12500

Horn switch “ ” Press this switch to sound the horn.

EAU12660

Engine stop switch “ / ” Set this switch to “ ” before startingthe engine. Set this switch to “ ” tostop the engine in case of an emergen-cy, such as when the vehicle overturnsor when the throttle cable is stuck.

EAU12710

Start switch “ ” Push this switch to crank the enginewith the starter.

CAUTION:ECA10050

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

1. Dimmer switch “ / ”2. Turn signal switch “ / ”3. Horn switch “ ”

1. Engine stop switch “ / ”2. Start switch “ ”



3-4

3

EAU12820

Clutch lever

The clutch lever is located at the lefthandlebar grip. To disengage theclutch, pull the lever toward the handle-bar grip. To engage the clutch, releasethe lever. The lever should be pulledrapidly and released slowly for smoothclutch operation.The clutch lever is equipped with aclutch switch, which is part of the igni-tion circuit cut-off system. (See page3-14.)

EAU12870

Shift pedal (XVS650)

The shift pedal is located on the leftside of the engine and is used in com-bination with the clutch lever whenshifting the gears of the 5-speed con-stant-mesh transmission equipped onthis motorcycle.

EAU12880

Shift pedal (XVS650A/AT)

The shift pedal is located on the leftside of the engine and is used in com-bination with the clutch lever whenshifting the gears of the 5-speed con-stant-mesh transmission equipped onthis motorcycle.

NOTE:Use your toes or heel to shift up andyour toes to shift down.

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



3-5

3

EAU12890

Brake lever

The brake lever is located at the righthandlebar grip. To apply the frontbrake, pull the lever toward the handle-bar grip.

EAU12941

Brake pedal

XVS650

XVS650A/AT

The brake pedal is on the right side ofthe motorcycle. To apply the rearbrake, press down on the brake pedal.

EAU13120

Fuel tank cap

To remove the fuel tank capSlide the lock cover open, insert the keyinto the lock, and then turn it 1/4 turnclockwise. The lock will be releasedand the fuel tank cap can be removed.

To install the fuel tank cap1. Insert the fuel tank cap into the

tank opening with the key insertedin the lock and with the “ ” markfacing forward.

2. Turn the key counterclockwise tothe original position, remove it, andthen close the lock cover.

1. Brake lever

1. Brake pedal

1. Brake pedal



3-6

3

NOTE:The fuel tank cap cannot be installedunless the key is in the lock. In addition,the key cannot be removed if the cap isnot properly installed and locked.

WARNINGEWA10130

Make sure that the fuel tank cap isproperly installed before riding.

EAU13210

Fuel

Make sure that there is sufficient fuel inthe tank. Fill the fuel tank to the bottomof the filler tube as shown.

WARNINGEWA10880

� Do not overfill the fuel tank, oth-erwise it may overflow when thefuel warms up and expands.

� Avoid spilling fuel on the hot en-gine.

CAUTION:ECA10070

Immediately wipe off spilled fuelwith a clean, dry, soft cloth, sincefuel may deteriorate painted surfac-es or plastic parts.

EAU13300

CAUTION:ECA11400

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

Your Yamaha engine has been de-signed to use regular unleaded gaso-line with a pump octane number[(R+M)/2] of 86 or higher, or a researchoctane number of 91 or higher. If

1. Fuel tank filler tube2. Fuel level

Recommended fuel:UNLEADED GASOLINE ONLY

Fuel tank capacity:16.0 L (4.23 US gal) (3.52 Imp.gal)

Fuel reserve amount:3.0 L (0.79 US gal) (0.66 Imp.gal)



3-7

3

knocking (or pinging) occurs, use agasoline of a different brand or premi-um unleaded fuel. Use of unleaded fuelwill extend spark plug life and reducemaintenance costs.GasoholThere are two types of gasohol: gaso-hol containing ethanol and that contain-ing methanol. Gasohol containingethanol can be used if the ethanol con-tent does not exceed 10%. Gasoholcontaining methanol is not recom-mended by Yamaha because it cancause damage to the fuel system or ve-hicle performance problems.

EAU13440

Catalytic converter This vehicle is equipped with a catalyticconverter in the muffler.

WARNINGEWA10860

The exhaust system is hot after op-eration. Make sure that the exhaustsystem has cooled down before do-ing any maintenance work.

CAUTION:ECA10700

The following precautions must beobserved to prevent a fire hazard orother damages.

� Use only unleaded gasoline.The use of leaded gasoline willcause unrepairable damage tothe catalytic converter.

� Never park the vehicle near pos-sible fire hazards such as grassor other materials that easilyburn.

� Do not allow the engine to idletoo long.

EAU13550

Fuel cock The fuel cock supplies fuel from thetank to the carburetors while also filter-ing it.The fuel cock lever positions are ex-plained as follows and shown in the il-lustrations.

OFF

With the fuel cock lever in this position,fuel will not flow. Always turn the fuelcock lever to this position when the en-gine is not running.

1. Arrow mark positioned over “OFF”



3-8

3

ON

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

RES

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

EAU13620

Starter (choke) knob “ ”

Starting a cold engine requires a richerair-fuel mixture, which is supplied bythe starter (choke).Move the knob in direction (a) to turn onthe starter (choke).Move the knob in direction (b) to turn offthe starter (choke).

CAUTION:ECA10990

Do not use the starter (choke) formore than 3 minutes as the exhaustpipe may discolor from excessiveheat. In addition, extended use ofthe starter (choke) will cause after-burning. If this occurs, turn off thestarter (choke).

1. Arrow mark positioned over “ON”

1. Arrow mark positioned over “RES”

1. Starter (choke) knob “ ”



3-9

3

EAU14180

Seats (XVS650)

Passenger seat

To remove the passenger seatRemove the nut, and then pull the pas-senger seat up.

To install the passenger seatInsert the projection on the front of thepassenger seat into the seat holder asshown, place the seat in the original po-sition, and then install the nut.

Rider seat

To remove the rider seat1. Remove the passenger seat.2. Remove the bolts, and then pull

the seat up.

To install the rider seat1. Insert the projection on the front of

the rider seat into the seat holderas shown, place the seat in theoriginal position, and then installthe bolts.

2. Install the passenger seat.

NOTE:Make sure that the seats are properlysecured before riding.

1. Nut

1. Bolt2. Seat holder3. Projection

1. Seat holder2. Projection

chapter3 Page 9 Tuesday, May 11, 2004 11:12 PM


3-10

3

EAU14190

Seats (XVS650A/AT)

Passenger seat

To remove the passenger seatRemove the bolt, and then pull the pas-senger seat up.

To install the passenger seatInsert the projections on the front of thepassenger seat into the holders asshown, place the seat in the original po-sition, and then install the bolt.

Rider seat

To remove the rider seat1. Remove the passenger seat.2. Remove the bolt, and then pull the

rider seat up.

To install the rider seat1. Insert the projection on the front of

the rider seat into the holder asshown, place the seat in the origi-nal position, and then install thebolt.

2. Install the passenger seat.

NOTE:Make sure that the seats are properlysecured before riding.

1. Bolt


1. Bolt




3-11

3

EAU14281

Helmet holder

To open the helmet holder, insert thekey into the lock, and then turn the keyas shown.To lock the helmet holder, place it in theoriginal position, and then remove thekey.

WARNINGEWA10160

Never ride with a helmet attached tothe helmet holder, since the helmetmay hit objects, causing loss of con-trol and possibly an accident.

EAU14481

Storage compartment The storage compartment is located onthe left side of the vehicle.

To open the storage compartment1. Slide the lock cover open, insert

the key into the lock, and then turnit clockwise.

2. Pull the storage compartment cov-er out as shown.

To close the storage compartment1. Place the storage compartment

cover in its original position asshown.

2. Turn the key counterclockwise, re-move it, and then close the lockcover.

1. Helmet holder2. Unlock.

1. Storage compartment cover2. Storage compartment lock cover3. Storage compartment lock

1. Storage compartment2. Storage compartment cover



3-12

3

EAU14860

Adjusting the shock absorber assembly

This shock absorber assembly isequipped with a spring preload adjust-ing ring.

CAUTION:ECA10100

Never attempt to turn an adjustingmechanism beyond the maximum orminimum settings.

Adjust the spring preload as follows.1. Remove the passenger and rider

seats. (See page 3-9.)

2. To increase the spring preload andthereby harden the suspension,turn the adjusting ring in direction(a). To decrease the spring pre-load and thereby soften the sus-pension, turn the adjusting ring indirection (b).

NOTE:� Align the appropriate notch in the

adjusting ring with the position in-dicator on the shock absorber.

� Use the special wrench and exten-sion bar included in the owner’stool kit to make the adjustment.

3. Install the passenger and riderseats.

WARNINGEWA10220

This shock absorber contains highlypressurized nitrogen gas. For prop-er handling, read and understandthe following information beforehandling the shock absorber. Themanufacturer cannot be held re-sponsible for property damage orpersonal injury that may result fromimproper handling.

� Do not tamper with or attempt toopen the gas cylinder.

� Do not subject the shock ab-sorber to an open flame or otherhigh heat sources, otherwise itmay explode due to excessivegas pressure.

� Do not deform or damage thegas cylinder in any way, as thiswill result in poor damping per-formance.

� Always have a Yamaha dealerservice the shock absorber.

1. Position indicator2. Spring preload adjusting ring3. Extension bar4. Special wrench

Spring preload setting:Minimum (soft):

1Standard:

3Maximum (hard):

7



3-13

3

EAU15150

Luggage strap holders

There is a luggage strap holder on eachpassenger footrest.

EAU15300

Sidestand The sidestand is located on the left sideof the frame. Raise the sidestand orlower it with your foot while holding thevehicle upright.

NOTE:The built-in sidestand switch is part ofthe ignition circuit cut-off system, whichcuts the ignition in certain situations.(See further down for an explanation ofthe ignition circuit cut-off system.)

WARNINGEWA10240

The vehicle must not be ridden withthe sidestand down, or if the side-stand cannot be properly moved up(or does not stay up), otherwise thesidestand could contact the groundand distract the operator, resultingin a possible loss of control.Yamaha’s ignition circuit cut-offsystem has been designed to assistthe operator in fulfilling the respon-sibility of raising the sidestand be-fore starting off. Therefore, checkthis system regularly as described

below and have a Yamaha dealer re-pair it if it does not function proper-ly.

1. Luggage strap holder



3-14

3

EAU15311

Ignition circuit cut-off system The ignition circuit cut-off system (com-prising the sidestand switch, clutchswitch and neutral switch) has the fol-lowing functions.

� It prevents starting when the trans-mission is in gear and the side-stand is up, but the clutch lever isnot pulled.

� It prevents starting when the trans-mission is in gear and the clutch le-ver is pulled, but the sidestand isstill down.

� It cuts the running engine when thetransmission is in gear and the sid-estand is moved down.

Periodically check the operation of theignition circuit cut-off system accordingto the following procedure.

WARNINGEWA10250

If a malfunction is noted, have aYamaha dealer check the system be-fore riding.



3-15

3

With the engine turned off:1. Move the sidestand down.2. Make sure that the engine stop switch is turned on.3. Turn the key on. 4. Shift the transmission into the neutral position.5. Push the start switch.Does the engine start?

With the engine still running:6. Move the sidestand up.7. Keep the clutch lever pulled.8. Shift the transmission into gear.9. Move the sidestand down.Does the engine stall?

After the engine has stalled:10. Move the sidestand up.11. Keep the clutch lever pulled.12. Push the start switch.Does the engine start?

The system is OK. The motorcycle can be ridden.

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

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

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

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

YES NO

YES NO

YES NO

NOTE:


PRE-OPERATION CHECKS

4-1

4

EAU15591

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

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

WARNINGEWA11150

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



4-2

4

EAU15602

Pre-operation check list ITEM CHECKS PAGE

Fuel• Check fuel level in fuel tank.• Refuel if necessary.• Check fuel line for leakage.

3-6

Engine oil• Check oil level in engine.• If necessary, add recommended oil to specified level.• Check vehicle for oil leakage.

6-11

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

Front brake

• Check operation.• If soft or spongy, have Yamaha dealer bleed hydraulic system.• Check lever free play.• Adjust if necessary.• Check brake pads for wear.• Replace if necessary.• Check fluid level in reservoir.• If necessary, add recommended brake fluid to specified level.• Check hydraulic system for leakage.

6-21, 6-24, 6-24

Rear brake• Check operation.• Check pedal free play.• Adjust if necessary.

6-22, 6-24

Clutch

• Check operation.• Lubricate cable if necessary.• Check lever free play.• Adjust if necessary.

6-20

Throttle grip

• Make sure that operation is smooth.• Check cable free play.• If necessary, have Yamaha dealer adjust cable free play and lubricate cable and

grip housing.

6-16, 6-26

Control cables • Make sure that operation is smooth.• Lubricate if necessary. 6-25



4-3

4

Wheels and tires

• Check for damage.• Check tire condition and tread depth.• Check air pressure.• Correct if necessary.

6-17, 6-19

Brake and shift pedals • Make sure that operation is smooth.• Lubricate pedal pivoting points if necessary. 6-26

Brake and clutch levers • Make sure that operation is smooth.• Lubricate lever pivoting points if necessary. 6-26

Sidestand • Make sure that operation is smooth.• Lubricate pivot if necessary. 6-27

Chassis fasteners • Make sure that all nuts, bolts and screws are properly tightened.• Tighten if necessary. —

Instruments, lights, signals and switches

• Check operation.• Correct if necessary. —

Sidestand switch • Check operation of ignition circuit cut-off system.• If system is defective, have Yamaha dealer check vehicle. 3-13

ITEM CHECKS PAGE


OPERATION AND IMPORTANT RIDING POINTS

5-1

5

EAU15950

WARNINGEWA10270

� Become thoroughly familiarwith all operating controls andtheir functions before riding.Consult a Yamaha dealer re-garding any control or functionthat you do not thoroughly un-derstand.

� Never start the engine or oper-ate it in a closed area for anylength of time. Exhaust fumesare poisonous, and inhalingthem can cause loss of con-sciousness and death within ashort time. Always make surethat there is adequate ventila-tion.

� Before starting out, make surethat the sidestand is up. If thesidestand is not raised com-pletely, it could contact theground and distract the opera-tor, resulting in a possible lossof control.

EAU16390

Starting and warming up a cold engine In order for the ignition circuit cut-offsystem to enable starting, one of thefollowing conditions must be met:

� The transmission is in the neutralposition.

� The transmission is in gear withthe clutch lever pulled and the sid-estand up.

WARNINGEWA10290

� Before starting the engine,check the function of the igni-tion circuit cut-off system ac-cording to the proceduredescribed on page 3-14.

� Never ride with the sidestanddown.

1. Turn the fuel cock lever to “ON”.2. Turn the key to “ON” and make

sure that the engine stop switch isset to “ ”.

3. Shift the transmission into the neu-tral position.

NOTE:When the transmission is in the neutralposition, the neutral indicator lightshould be on, otherwise have aYamaha dealer check the electrical cir-cuit.

4. Turn the starter (choke) on andcompletely close the throttle. (Seepage 3-8.)

5. Start the engine by pushing thestart switch.

NOTE:If the engine fails to start, release thestart switch, wait a few seconds, andthen try again. Each starting attemptshould be as short as possible to pre-serve the battery. Do not crank the en-gine more than 10 seconds on any oneattempt.

CAUTION:ECA11370

The engine trouble warning lightshould come on when the key isturned to “ON”, and then go off aftera few seconds. If the engine troublewarning light comes on or flashes



5-2

5

after starting, immediately stop theengine, and have a Yamaha dealercheck the self-diagnosis system.

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

CAUTION:ECA11130

For maximum engine life, alwayswarm the engine up before startingoff. Never accelerate hard when theengine is cold!

7. When the engine is warm, turn thestarter (choke) off.

NOTE:The engine is warm when it respondsnormally to the throttle with the starter(choke) turned off. To avoid the possi-bility of excessive exhaust emissions,never leave the starter (choke) on long-er than necessary. The time necessaryfor starter (choke) use depends uponthe ambient temperature. Tempera-tures above 10 °C (50 °F) require about7 seconds of starter (choke) use andtemperatures below 10 °C (50 °F) re-quire about 35 seconds with the starter

(choke) turned on, then about 2.5 min-utes with the starter (choke) in the half-way position.

EAU16640

Starting a warm engine Follow the same procedure as for start-ing a cold engine with the exceptionthat the starter (choke) is not requiredwhen the engine is warm.



5-3

5

EAU16671

Shifting

XVS650

XVS650A/AT

Shifting gears lets you control theamount of engine power available forstarting off, accelerating, climbing hills,etc.The gear positions are shown in the il-lustration.

NOTE:To shift the transmission into the neu-tral position, press the shift pedal downrepeatedly until it reaches the end of itstravel, and then slightly raise it.

CAUTION:ECA10260

� Even with the transmission inthe neutral position, do notcoast for long periods of timewith the engine off, and do nottow the motorcycle for long dis-tances. The transmission isproperly lubricated only whenthe engine is running. Inade-quate lubrication may damagethe transmission.

� Always use the clutch whilechanging gears to avoid damag-ing the engine, transmission,

and drive train, which are notdesigned to withstand theshock of forced shifting.

EAU16680

To start out and accelerate1. Pull the clutch lever to disengage

the clutch.2. Shift the transmission into first

gear. The neutral indicator lightshould go out.

3. Open the throttle gradually, and atthe same time, release the clutchlever slowly.

4. At the recommended shift pointsshown in the following table, closethe throttle, and at the same time,quickly pull the clutch lever in.

5. Shift the transmission into secondgear. (Make sure not to shift thetransmission into the neutral posi-tion.)

6. Open the throttle part way andgradually release the clutch lever.

7. Follow the same procedure whenshifting to the next higher gear.

1. Shift pedal2. Neutral position

1. Shift pedal2. Neutral position



5-4

5

NOTE:Always shift gears at the recommendedshift points.

EAU16700

To decelerate1. Apply both the front and the rear

brakes to slow the motorcycle.2. Shift the transmission into first

gear when the motorcycle reaches25 km/h (15.5 mi/h). If the engine isabout to stall or runs very roughly,pull the clutch lever in and use thebrakes to stop the motorcycle.

3. Shift the transmission into the neu-tral position when the motorcycleis almost completely stopped. Theneutral indicator light should comeon.

EAU16720

Recommended shift pointsThe recommended shift points duringacceleration and deceleration areshown in the table below.

EAU16841

Engine break-in There is never a more important periodin the life of your engine than the periodbetween 0 and 1600 km (1000 mi). Forthis reason, you should read the follow-ing material carefully.Since the engine is brand new, do notput an excessive load on it for the first1600 km (1000 mi). The various parts inthe engine wear and polish themselvesto the correct operating clearances.During this period, prolonged full-throt-tle operation or any condition that mightresult in engine overheating must beavoided.

EAU17041

0–1000 km (0–600 mi)Avoid prolonged operation above 1/3throttle.1000–1600 km (600–1000 mi)Avoid prolonged operation above 1/2throttle.

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

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



5-5

5

CAUTION:ECA10331

After 1000 km (600 mi) of operation,the engine oil and final gear oil mustbe changed, and the oil filter car-tridge or element replaced.

1600 km (1000 mi) and beyondThe vehicle can now be operated nor-mally.

CAUTION:ECA10270

If any engine trouble should occurduring the engine break-in period,immediately have a Yamaha dealercheck the vehicle.

EAU17180

Parking When parking, stop the engine, removethe key from the main switch, and thenturn the fuel cock lever to “OFF”.

WARNINGEWA10310

� Since the engine and exhaustsystem can become very hot,park in a place where pedestri-ans or children are not likely totouch them.

� Do not park on a slope or on softground, otherwise the vehiclemay overturn.

CAUTION:ECA10380

Never park in an area where thereare fire hazards such as grass orother flammable materials.


PERIODIC MAINTENANCE AND MINOR REPAIR

6-1

6

EAU17231

Safety is an obligation of the owner. Pe-riodic inspection, adjustment and lubri-cation will keep your vehicle in thesafest and most efficient condition pos-sible. The most important points ofmotorcycle inspection, adjustment, andlubrication are explained on the follow-ing pages.Maintenance, replacement, or repairof the emission control devices andsystems may be performed by anyrepair establishment or individualthat is certified (if applicable).

WARNINGEWA10320

If you are not familiar with mainte-nance work, have a Yamaha dealerdo it for you.

EAU17301

PERIODIC MAINTENANCE PROPER PERIODIC MAINTENANCEOF YOUR VEHICLE IS IMPORTANTIN ORDER TO ENJOY LONG, PLEA-SURABLE SERVICE. ESPECIALLYIMPORTANT ARE THE MAINTE-NANCE SERVICES RELATED TOEMISSIONS CONTROL. THESECONTROLS NOT ONLY FUNCTIONTO ENSURE CLEANER AIR, BUTARE ALSO VITAL TO PROPER EN-GINE OPERATION AND MAXIMUMPERFORMANCE. IN THE FOLLOW-ING PERIODIC MAINTENANCECHARTS, THE SERVICES RELATEDTO EMISSIONS CONTROL AREGROUPED SEPARATELY. THESESERVICES REQUIRE SPECIALIZEDDATA, KNOWLEDGE, AND EQUIP-MENT. YAMAHA DEALERS ARETRAINED AND EQUIPPED TO PER-FORM THESE PARTICULAR SER-VICES.

EAU17440

Owner’s tool kit

The owner’s tool kit is located inside thestorage compartment. (See page3-11.)The service information included in thismanual and the tools provided in theowner’s tool kit are intended to assistyou in the performance of preventivemaintenance and minor repairs. How-ever, additional tools such as a torquewrench may be necessary to performcertain maintenance work correctly.

NOTE:If you do not have the tools or experi-ence required for a particular job, havea Yamaha dealer perform it for you.

1. Owner’s tool kit



6-2

6

WARNINGEWA10340

Modifications not approved byYamaha may cause loss of perfor-mance, excessive emissions, andrender the vehicle unsafe for use.Consult a Yamaha dealer before at-tempting any changes.



6-3

6

EAU17600

Periodic maintenance chart for the emission control system

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

No. ITEM ROUTINE

INITIAL ODOMETER READINGS

600 mi (1000 km)

or 1 month

4000 mi (7000 km)

or 6 months

8000 mi (13000 km)

or 12 months

12000 mi (19000 km)

or 18 months

16000 mi (25000 km)

or 24 months

20000 mi (31000 km)

or 30 months

1 * Fuel line• Check fuel hoses for cracks or

damage.• Replace if necessary.

√ √ √ √ √

2 * Fuel filter • Replace. Replace.

3 Spark plugs

• Check condition.• Adjust gap and clean.• Replace every 8000 mi (13000

km) or 12 months.

√ Replace. √ Replace. √

4 * Valve clearance • Check and adjust valve clearance when engine is cold. √ √ √ √ √ √

5 * Crankcase breather system

• Check breather hose for cracks or damage.

• Replace if necessary.√ √ √ √ √

6 * Carburetor synchro-nization

• Adjust synchronization of carbu-retors. √ √ √ √ √ √

7 * Idle speed • Check and adjust engine idle speed. √ √ √ √ √

8 * Exhaust system• Check for leakage.• Tighten if necessary.• Replace gasket(s) if necessary.

√ √ √ √ √

9 *Evaporative emis-sion control system (For California only)

• Check control system for dam-age.

• Replace if necessary.√ √



6-4

6

EAU32182

General maintenance and lubrication chart

No. ITEM ROUTINE


600 mi (1000 km)

or 1 month

4000 mi (7000 km)

or 6 months

8000 mi (13000 km)

or 12 months

12000 mi (19000 km)

or 18 months

16000 mi (25000 km)

or 24 months

20000 mi (31000 km)

or 30 months

1 * Air filter element • Clean with compressed air.• Replace if necessary. √ √ √ √ √

2 * Clutch • Check operation.• Adjust or replace cable. √ √ √ √ √ √

3 * Front brake• Check operation, fluid level, and

for fluid leakage.• Replace brake pads if necessary.

√ √ √ √ √ √

4 * Rear brake• Check operation.• Adjust cable and replace brake

shoes if necessary.√ √ √ √ √ √

5 * Brake hose• Check for cracks or damage. √ √ √ √ √

• Replace. Every 4 years

6 * Wheels• Check runout, spoke tightness

and for damage.• Tighten spokes if necessary.

√ √ √ √ √

7 * Tires

• Check tread depth and for dam-age.

• Replace if necessary.• Check air pressure.• Correct if necessary.

√ √ √ √ √

8 * Wheel bearings• Check bearings for smooth oper-

ation.• Replace if necessary.

√ √ √ √ √



6-5

6

9 * Swingarm pivot bearings

• Check bearing assemblies for looseness.

• Moderately repack with lithium-soap-based grease.

√ Repack.

10 * Steering bearings

• Check bearing assemblies for looseness.

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

√ √ √ √ Repack. √

11 * Chassis fasteners• Check all chassis fitting and fas-

teners.• Correct if necessary.

√ √ √ √ √

12 Brake and clutch le-ver pivot shafts

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

13 Brake and shift ped-al pivot shafts

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

14 Sidestand pivot• Check operation.• Apply lithium-soap-based grease

(all-purpose grease) lightly.√ √ √ √ √

15 * Sidestand switch • Check operation and replace if necessary. √ √ √ √ √ √

16 * Front fork• Check operation and for oil leak-

age.• Replace if necessary.

√ √ √ √ √

17 * Shock absorber as-sembly

• Check operation and for oil leak-age.

• Replace if necessary.√ √ √ √ √

No. ITEM ROUTINE


600 mi (1000 km)

or 1 month

4000 mi (7000 km)

or 6 months

8000 mi (13000 km)

or 12 months

12000 mi (19000 km)

or 18 months

16000 mi (25000 km)

or 24 months

20000 mi (31000 km)

or 30 months



6-6

6

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

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

EAU17620

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

18 Engine oil • Change (warm engine before draining). √ √ √ √ √ √

19 Engine oil filter ele-ment • Replace. √ √ √

20 Final gear oil

• Check oil level and for oil leakage.• Change at initial 600 mi (1000

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

Change. √ √ √ Change. √

21 * Control and meter cables

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

√ √ √ √ √ √

22 * Throttle grip hous-ing and cable

• Check operation and free play.• Adjust the throttle cable free play

if necessary.• Lubricate the throttle grip housing

and cable.

√ √ √ √ √

No. ITEM ROUTINE


600 mi (1000 km)

or 1 month

4000 mi (7000 km)

or 6 months

8000 mi (13000 km)

or 12 months

12000 mi (19000 km)

or 18 months

16000 mi (25000 km)

or 24 months

20000 mi (31000 km)

or 30 months



6-7

6

� Hydraulic brake system• When disassembling the master cylinder or caliper cylinder, always replace the brake fluid. Check the brake fluid level

regularly and fill as required.• Replace the oil seals on the inner parts of the master cylinder and caliper cylinder every two years.• Replace the brake hoses every four years or if cracked or damaged.



6-8

6

EAU18771

Removing and installing panels The panels shown need to be removedto perform some of the maintenancejobs described in this chapter. Refer tothis section each time a panel needs tobe removed and installed.

XVS650

XVS650A/AT

EAU19192

Panel A

To remove the panelRemove the bolts, and then take thepanel off.

XVS650

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

XVS650A/AT

1. Panel A

1. Panel A

1. Panel B

1. Bolt

1. Bolt



6-9

6

EAU19151

Panel B

To remove the panelRemove the bolt, and then pull the pan-el off as shown.

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

EAU19543

Checking the spark plugs The spark plugs are important enginecomponents, which are easy to check.Since heat and deposits will cause anyspark plug to slowly erode, the sparkplugs should be removed and checkedin accordance with the periodic mainte-nance and lubrication chart. In addition,the condition of the spark plugs can re-veal the condition of the engine.

To remove a spark plug1. Remove the spark plug cap.

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

To check the spark plugs1. Check that the porcelain insulator

around the center electrode oneach spark plug is a medium-to-light tan (the ideal color when thevehicle is ridden normally).

2. Check that all spark plugs installedin the engine have the same color.

NOTE:If any spark plug shows a distinctly dif-ferent color, the engine could be defec-tive. Do not attempt to diagnose suchproblems yourself. Instead, have aYamaha dealer check the vehicle.

1. Bolt

1. Spark plug cap

1. Spark plug wrench



6-10

6

3. Check each spark plug for elec-trode erosion and excessive car-bon or other deposits, and replaceit if necessary.

To install a spark plug1. Measure the spark plug gap with a

wire thickness gauge and, if nec-essary, adjust the gap to specifica-tion.

2. Clean the surface of the spark pluggasket and its mating surface, andthen wipe off any grime from thespark plug threads.

3. Install the spark plug with thespark plug wrench, and then tight-en it to the specified torque.

NOTE:If a torque wrench is not available wheninstalling a spark plug, a good estimateof the correct torque is 1/4–1/2 turnpast finger tight. However, the sparkplug should be tightened to the speci-fied torque as soon as possible.

4. Install the spark plug cap.

EAU19672

Canister (for California only)

This model is equipped with a canisterto prevent the discharging of fuel vaporinto the atmosphere.

� Check each hose connection.� Check each hose and canister for

cracks or damage. Replace if dam-aged.

� Make sure the vent hose is notblocked. Clean it if necessary.

Specified spark plug:NGK/DPR7EA-9DENSO/X22EPR-U9

1. Spark plug gap

Spark plug gap:0.8–0.9 mm (0.031–0.035 in)

Tightening torque:Spark plug:

17.5 Nm (1.75 m·kgf, 13 ft·lbf)



6-11

6

EAU19742

Engine oil and oil filter element The engine oil level should be checkedbefore each ride. In addition, the oilmust be changed and the oil filter ele-ment replaced at the intervals specifiedin the periodic maintenance and lubri-cation chart.

To check the engine oil level1. Place the vehicle on a level sur-

face and hold it in an upright posi-tion.

NOTE:Make sure that the vehicle is positionedstraight up when checking the oil level.A slight tilt to the side can result in afalse reading.

2. Start the engine, warm it up forseveral minutes, and then turn itoff.

3. Wait a few minutes until the oil set-tles, and then check the oil levelthrough the check window locatedat the bottom-left side of the crank-case.

NOTE:The engine oil should be between theminimum and maximum level marks.

4. If the engine oil is at or below theminimum level mark, add sufficientoil of the recommended type toraise it to the correct level.

To change the engine oil (with orwithout oil filter element replace-ment)

1. Start the engine, warm it up forseveral minutes, and then turn itoff.

2. Place an oil pan under the engineto collect the used oil.

3. Remove the engine oil filler capand drain bolt to drain the oil fromthe crankcase.

NOTE:Skip steps 4–7 if the oil filter element isnot being replaced.

4. Remove the outer and inner oil fil-ter element covers by removingthe bolts.

1. Engine oil level check window2. Maximum level mark3. Minimum level mark4. Engine oil filler cap

1. Engine oil filler bolt2. Oil pan



6-12

6

5. Remove the oil filter element andO-ring.

6. Install a new oil filter element andthe O-ring.

7. Install the oil filter element coversby installing the bolts, and thentighten them to the specifiedtorque.

8. Install the engine oil drain bolt, andthen tighten it to the specifiedtorque.

NOTE:Check the washer for damage and re-place it if necessary.

9. Add the specified amount of therecommended oil, and then installand tighten the oil filler cap.

CAUTION:ECA11620

� In order to prevent clutch slip-page (since the engine oil alsolubricates the clutch), do notmix any chemical additives. Donot use oils with a diesel speci-fication of “CD” or oils of a high-er quality than specified. Inaddition, do not use oils labeled“ENERGY CONSERVING II” orhigher.

1. Outer oil filter element cover2. Bolt

1. Inner oil filter element cover2. Bolt

1. Oil filter element2. O-ring

Tightening torque:Oil filter element cover bolt:

10 Nm (1.0 m·kgf, 7 ft·lbf)

Tightening torque:Engine oil drain bolt:

43 Nm (4.3 m·kgf, 31 ft·lbf)

Recommended engine oil:See page 8-1.

Oil quantity:Without oil filter element replace-ment:

2.60 L (2.75 US qt) (2.29 Imp.qt)With oil filter element replacement:

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



6-13

6

� Make sure that no foreign mate-rial enters the crankcase.

10. Start the engine, and then let it idlefor several minutes while checkingit for oil leakage. If oil is leaking, im-mediately turn the engine off andcheck for the cause.

11. Turn the engine off, and thencheck the oil level and correct it ifnecessary.

EAU20022

Final gear oil The final gear case must be checkedfor oil leakage before each ride. If anyleakage is found, have a Yamaha deal-er check and repair the vehicle. In addi-tion, the final gear oil level must bechecked and the oil changed as followsat the intervals specified in the periodicmaintenance and lubrication chart.

WARNINGEWA10370

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

� Make sure that no oil gets on thetire or wheel.

To check the final gear oil level1. Place the vehicle on a level sur-


NOTE:� The final gear oil level must be

checked on a cold engine.� Make sure that the vehicle is posi-

tioned straight up when checkingthe oil level. A slight tilt to the sidecan result in a false reading.

2. Remove the oil filler bolt, and thencheck the oil level in the final gearcase.

NOTE:The oil level should be at the brim of thefiller hole.

3. If the oil is below the brim of the fill-er hole, add sufficient oil of the rec-ommended type to raise it to thecorrect level.

To change the final gear oil1. Place an oil pan under the final

gear case to collect the used oil.

1. Final gear oil drain bolt2. Final gear oil filler bolt3. Correct oil level



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2. Remove the oil filler bolt and drainbolt to drain the oil from the finalgear case.

3. Install the final gear oil drain bolt,and then tighten it to the specifiedtorque.

4. Add the recommended final gearoil to the brim of the filler hole.

NOTE:GL4 is a quality rating. Hypoid gear oilsrated GL5 or GL6 may also be used.

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

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

EAU33381

Cleaning the air filter element The air filter element should be cleanedat the intervals specified in the periodicmaintenance and lubrication chart.Clean the air filter element more fre-quently if you are riding in unusuallywet or dusty areas.

1. Remove the air filter case cover byremoving the bolts.

2. Pull the air filter element out.3. Lightly tap the air filter element to

remove most of the dust and dirt,and then blow the remaining dirtout with compressed air as shown.If the air filter element is damaged,replace it.

Tightening torque:Final gear oil drain bolt:

23 Nm (2.3 m·kgf, 17 ft·lbf)

Recommended final gear oil:SAE80 API GL-4 Hypoid gear oil

Oil quantity:0.19 L (0.20 US qt) (0.17 Imp.qt)

Tightening torque:Final gear oil filler bolt:

23 Nm (2.3 m·kgf, 17 ft·lbf)

1. Air filter case cover2. Bolt



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

CAUTION:ECA10480

� Make sure that the air filter ele-ment is properly seated in theair filter case.

� The engine should never be op-erated without the air filter ele-ment installed, otherwise thepiston(s) and/or cylinder(s) maybecome excessively worn.

5. Install the air filter case cover byaligning the match marks and in-stalling the bolts.

NOTE:If dust or water collects in the air filtercheck hose, remove the clamp from it,and then remove the plug to drain thehose.

1. Air filter element

1. Air filter element holder2. Projection3. Slot

1. Match marks

1. Air filter check hose



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EAU21270

Adjusting the carburetors The carburetors are important parts ofthe engine and emission control sys-tem, which require very sophisticatedadjustment. Therefore, all carburetoradjustments should be left to a Yamahadealer, who has the necessary profes-sional knowledge and experience.

EAU21380

Adjusting the throttle cable free play

The throttle cable free play should mea-sure 4.0–6.0 mm (0.16–0.24 in) at thethrottle grip. Periodically check thethrottle cable free play and, if neces-sary, have a Yamaha dealer adjust it.

EAU21400

Adjusting the valve clearance The valve clearance changes with use,resulting in improper air-fuel mixtureand/or engine noise. To prevent thisfrom occurring, the valve clearancemust be adjusted by a Yamaha dealerat the intervals specified in the periodicmaintenance and lubrication chart.

1. Throttle cable free play



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EAU32520

Tires To maximize the performance, durabil-ity, and safe operation of your motor-cycle, note the following pointsregarding the specified tires.

Tire air pressureThe tire air pressure should be checkedand, if necessary, adjusted before eachride.

WARNINGEWA10500

� The tire air pressure must bechecked and adjusted on coldtires (i.e., when the temperatureof the tires equals the ambienttemperature).

� The tire air pressure must be ad-justed in accordance with theriding speed and with the totalweight of rider, passenger, car-go, and accessories approvedfor this model.

WARNINGEWA10510

Proper loading of your vehicle is im-portant for several characteristics ofyour vehicle, such as handling,braking, performance and safety. Donot carry loosely packed items thatcan shift. Securely pack your heavi-est items close to the center of thevehicle, and distribute the weightevenly from side to side. Properlyadjust the suspension for your load,and check the condition and pres-sure of your tires. NEVER OVER-LOAD YOUR VEHICLE. Make surethat the total weight of the cargo, rid-er, passenger, and accessories(cowling, saddlebags, etc. if ap-proved for this model) does not ex-ceed the maximum load of the

Tire air pressure (measured on cold tires):

0–90 kg (0–198 lb):Front:

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

Rear:225 kPa (33 psi) (2.25 kgf/cm²)

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

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


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

* Total weight of rider, passenger, car-go and accessories



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vehicle. Operation of an overloadedvehicle could cause tire damage, anaccident, or even injury.

Tire inspection

Always check the tires before operatingthe motorcycle. If a tire tread showscrosswise lines (minimum tread depth),if the tire has a nail or glass fragmentsin it, or if the sidewall is cracked, con-tact a Yamaha dealer immediately andhave the tire replaced.

WARNINGEWA10560

� It is dangerous to ride with aworn-out tire. When a tire treadbegins to show crosswise lines,have a Yamaha dealer replacethe tire immediately.

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

� It is not recommended to patcha punctured tube. If unavoid-able, however, patch the tubevery carefully and replace it assoon as possible with a high-quality product.

Tire informationThis motorcycle is equipped with spokewheels and tube tires.

WARNINGEWA10460

� The front and rear tires shouldbe of the same make and de-sign, otherwise the handlingcharacteristics of the vehiclecannot be guaranteed.

� After extensive tests, only thetires listed below have been ap-proved for this model byYamaha Motor Co., Ltd.

1. Tire sidewall2. Tire wear indicator3. Tire tread depth

Minimum tire tread depth (front and rear):

1.0 mm (0.04 in)



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EAU21940

Spoke wheels To maximize the performance, durabil-ity, and safe operation of your motor-cycle, note the following pointsregarding the specified wheels.

� The wheel rims should be checkedfor cracks, bends or warpage, andthe spokes for looseness or dam-age before each ride. If any dam-age is found, have a Yamahadealer replace the wheel. Do notattempt even the smallest repair tothe wheel. A deformed or crackedwheel must be replaced.

� The wheel should be balancedwhenever either the tire or wheelhas been changed or replaced. Anunbalanced wheel can result inpoor performance, adverse han-dling characteristics, and a short-ened tire life.

� Ride at moderate speeds afterchanging a tire since the tire sur-face must first be “broken in” for itto develop its optimal characteris-tics.

EAU22011

Accessories and replacement parts

WARNINGEWA10621

This vehicle is not designed to pull atrailer or to be attached to a sidecar.The accessories or replacementparts you choose for your vehicleshould be designed specifically forthis model, and they must be se-curely mounted to maintain the in-herent stability of the originaldesign. Genuine Yamaha Parts andAccessories are designed and test-ed to be compatible with your vehi-cle. Please consider GenuineYamaha Parts and Accessories be-fore making a purchase. Use of non-Yamaha-approved accessories orreplacement parts may cause loss ofhandling stability and riding safety.Since Yamaha cannot control thequality of accessories or parts man-ufactured by other companies,Yamaha cannot be held liable for

Front tire:Size:

XVS650 100/90-19M/C 57SXVS650A 130/90-16M/C 67SXVS650AT 130/90-16M/C 67S

Manufacturer/model:XVS650 BRIDGESTONE/EXE-DRA L309XVS650A BRIDGESTONE/EXE-DRA G703XVS650AT BRIDGESTONE/EXE-DRA G703XVS650 DUNLOP/F24XVS650A DUNLOP/D404FXVS650AT DUNLOP/D404F

Rear tire:Size:

170/80-15M/C 77SManufacturer/model:

XVS650 BRIDGESTONE/EXE-DRA G546XVS650A BRIDGESTONE/EXE-DRA G702XVS650AT BRIDGESTONE/EXE-DRA G702XVS650 DUNLOP/K555XVS650A DUNLOP/D404GXVS650AT DUNLOP/D404G



6-20

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any consequences caused by theuse of items which have not beenapproved by Yamaha.

EAU22041

Adjusting the clutch lever free play

The clutch lever free play should mea-sure XVS650 10.0–15.0 mm (0.39–0.59 in)XVS650A 5.0–10.0 mm (0.20–0.39 in)XVS650AT 5.0–10.0 mm (0.20–0.39in) as shown. Periodically check theclutch lever free play and, if necessary,adjust it as follows.

1. Loosen the locknut at the clutch le-ver.

2. To increase the clutch lever freeplay, turn the adjusting bolt in di-rection (a). To decrease the clutchlever free play, turn the adjustingbolt in direction (b).

NOTE:If the specified clutch lever free playcould be obtained as described above,tighten the locknut and skip the rest ofthe procedure, otherwise proceed asfollows.

3. Fully turn the adjusting bolt at theclutch lever in direction (a) to loos-en the clutch cable.

4. Loosen the locknut at the crank-case.

1. Locknut2. Clutch lever free play adjusting bolt3. Clutch lever free play

1. Clutch lever free play adjusting nut (crank-case)

2. Locknut



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5. To increase the clutch lever freeplay, turn the adjusting nut in direc-tion (a). To decrease the clutch le-ver free play, turn the adjusting nutin direction (b).

6. Tighten the locknut at the clutch le-ver and the crankcase.

EAU22092

Adjusting the brake lever free play

The brake lever free play should mea-sure 10.0–15.0 mm (0.39–0.59 in) asshown. Periodically check the brake le-ver free play and, if necessary, adjust itas follows.

1. Loosen the locknut at the brake le-ver.

2. To increase the brake lever freeplay, turn the adjusting screw in di-rection (a). To decrease the brakelever free play, turn the adjustingscrew in direction (b).

3. Tighten the locknut.

WARNINGEWA10630

� After adjusting the brake leverfree play, check the free playand make sure that the brake isworking properly.

� A soft or spongy feeling in thebrake lever can indicate thepresence of air in the hydraulic

1. Brake lever free play

1. Locknut2. Brake lever free play adjusting screw



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system. If there is air in the hy-draulic system, have a Yamahadealer bleed the system beforeoperating the motorcycle. Air inthe hydraulic system will dimin-ish the braking performance,which may result in loss of con-trol and an accident.

EAU22231

Adjusting the brake pedal position and free play

XVS650

XVS650A/AT

WARNINGEWA10670

It is advisable to have a Yamahadealer make these adjustments.

NOTE:The brake pedal position should be ad-justed before adjusting the brake pedalfree play.

Brake pedal positionThe brake pedal should be positionedapproximately XVS650 102.0 mm(4.02 in)XVS650A 108.0 mm (4.25 in)XVS650AT 108.0 mm (4.25 in) abovethe top of the footrest as shown. Peri-odically check the brake pedal positionand, if necessary, adjust it as follows.

1. Loosen the locknut at the brakepedal.

2. To raise the brake pedal, turn theadjusting bolt in direction (a). Tolower the brake pedal, turn the ad-justing bolt in direction (b).

1. Distance between brake pedal and footrest2. Brake pedal free play

1. Distance between brake pedal and footrest2. Brake pedal free play



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3. Tighten the locknut.

WARNINGEWA11230

After adjusting the brake pedal posi-tion, the brake pedal free play mustbe adjusted.

Brake pedal free playThe brake pedal free play should mea-sure 20.0–30.0 mm (0.79–1.18 in) atthe brake pedal end. Periodically checkthe brake pedal free play and, if neces-sary, adjust it as follows.

To increase the brake pedal free play,turn the adjusting nut at the brake rod indirection (a). To decrease the brakepedal free play, turn the adjusting nut indirection (b).

EAU22270

Adjusting the rear brake light switch

The rear brake light switch, which is ac-tivated by the brake pedal, is properlyadjusted when the brake light comeson just before braking takes effect. Ifnecessary, adjust the brake light switchas follows.Turn the adjusting nut while holding therear brake light switch in place. Tomake the brake light come on earlier,turn the adjusting nut in direction (a). Tomake the brake light come on later, turnthe adjusting nut in direction (b).

1. Locknut2. Brake pedal position adjusting bolt

1. Brake pedal free play adjusting nut

1. Rear brake light switch2. Rear brake light switch adjusting nut



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EAU22380

Checking the front brake pads and rear brake shoes The front brake pads and the rear brakeshoes must be checked for wear at theintervals specified in the periodic main-tenance and lubrication chart.

EAU22430

Front brake pads

Each front brake pad is provided withwear indicator grooves, which allowyou to check the brake pad wear with-out having to disassemble the brake.To check the brake pad wear, checkthe wear indicator grooves. If a brakepad has worn to the point that the wear

indicator grooves have almost disap-peared, have a Yamaha dealer replacethe brake pads as a set.

EAU22540

Rear brake shoes

The rear brake is provided with a wearindicator, which allows you to check thebrake shoe wear without having to dis-assemble the brake. To check thebrake shoe wear, check the position ofthe wear indicator while applying thebrake. If a brake shoe has worn to thepoint that the wear indicator reachesthe wear limit line, have a Yamahadealer replace the brake shoes as aset.

EAU32342

Checking the brake fluid level

Insufficient brake fluid may allow air toenter the brake system, possibly caus-ing it to become ineffective.Before riding, check that the brake fluidis above the minimum level mark andreplenish if necessary. A low brake fluidlevel may indicate worn brake padsand/or brake system leakage. If thebrake fluid level is low, be sure to checkthe brake pads for wear and the brakesystem for leakage.Observe these precautions:

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

1. Brake pad wear indicator groove

1. Brake shoe wear limit line2. Brake shoe wear indicator

1. Minimum level mark



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� Use only the recommended qualitybrake fluid, otherwise the rubberseals may deteriorate, causingleakage and poor braking perfor-mance.

� Refill with the same type of brakefluid. Mixing fluids may result in aharmful chemical reaction andlead to poor braking performance.

� Be careful that water does not en-ter the master cylinder when refill-ing. Water will significantly lowerthe boiling point of the fluid andmay result in vapor lock.

� Brake fluid may deteriorate paint-ed surfaces or plastic parts. Al-ways clean up spilled fluidimmediately.

� As the brake pads wear, it is nor-mal for the brake fluid level to grad-ually go down. However, if thebrake fluid level goes down sud-denly, have a Yamaha dealercheck the cause.

EAU22720

Changing the brake fluid Have a Yamaha dealer change thebrake fluid at the intervals specified inthe NOTE after the periodic mainte-nance and lubrication chart. In addition,have the oil seals of the brake mastercylinder and caliper as well as thebrake hose replaced at the intervalslisted below or whenever they are dam-aged or leaking.

� Oil seals: Replace every twoyears.

� Brake hose: Replace every fouryears.

EAU23090

Checking and lubricating the cables The operation of all control cables andthe condition of the cables should bechecked before each ride, and the ca-bles and cable ends should be lubricat-ed if necessary. If a cable is damagedor does not move smoothly, have aYamaha dealer check or replace it.

WARNINGEWA10710

Damage to the outer housing of ca-bles may result in internal rustingand cause interference with cablemovement. Replace damaged ca-bles as soon as possible to preventunsafe conditions.

Recommended brake fluid:DOT 4

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



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EAU23110

Checking and lubricating the throttle grip and cable The operation of the throttle grip shouldbe checked before each ride. In addi-tion, the cable should be lubricated orreplaced at the intervals specified in theperiodic maintenance chart.

EAU23131

Checking and lubricating the brake and shift pedals

The operation of the brake and shiftpedals should be checked before eachride, and the pedal pivots should be lu-bricated if necessary.

EAU23140

Checking and lubricating the brake and clutch levers

The operation of the brake and clutchlevers should be checked before eachride, and the lever pivots should be lu-bricated if necessary.

Recommended lubricant:Lithium-soap-based grease (all-pur-pose grease)




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EAU23200

Checking and lubricating the sidestand

The operation of the sidestand shouldbe checked before each ride, and thesidestand pivot and metal-to-metalcontact surfaces should be lubricated ifnecessary.

WARNINGEWA10730

If the sidestand does not move upand down smoothly, have a Yamahadealer check or repair it.

EAU23271

Checking the front fork The condition and operation of the frontfork must be checked as follows at theintervals specified in the periodic main-tenance and lubrication chart.

To check the condition

WARNINGEWA10750

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

Check the inner tubes for scratches,damage and excessive oil leakage.

To check the operation1. Place the vehicle on a level sur-


2. While applying the front brake,push down hard on the handlebarsseveral times to check if the frontfork compresses and reboundssmoothly.

CAUTION:ECA10590

If any damage is found or the frontfork does not operate smoothly,have a Yamaha dealer check or re-pair it.




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EAU23280

Checking the steering Worn or loose steering bearings maycause danger. Therefore, the operationof the steering must be checked as fol-lows at the intervals specified in the pe-riodic maintenance and lubricationchart.

1. Place a stand under the engine toraise the front wheel off theground.

WARNINGEWA10750

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

2. Hold the lower ends of the frontfork legs and try to move them for-ward and backward. If any freeplay can be felt, have a Yamahadealer check or repair the steering.

EAU23290

Checking the wheel bearings The front and rear wheel bearings mustbe checked at the intervals specified inthe periodic maintenance and lubrica-tion chart. If there is play in the wheelhub or if the wheel does not turnsmoothly, have a Yamaha dealer checkthe wheel bearings.



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EAU23380

Battery The battery is located behind panel B.(See page 6-8.)This model is equipped with a sealed-type (MF) battery, which does not re-quire any maintenance. There is noneed to check the electrolyte or to adddistilled water.

CAUTION:ECA10620

Never attempt to remove the batterycell seals, as this would permanent-ly damage the battery.

WARNINGEWA10760

� Electrolyte is poisonous anddangerous since it contains sul-furic acid, which causes severeburns. Avoid any contact withskin, eyes or clothing and al-ways shield your eyes whenworking near batteries. In caseof contact, administer the fol-lowing FIRST AID.• EXTERNAL: Flush with plenty

of water.

• INTERNAL: Drink large quan-tities of water or milk and im-mediately call a physician.

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

� Batteries produce explosive hy-drogen gas. Therefore, keepsparks, flames, cigarettes, etc.,away from the battery and pro-vide sufficient ventilation whencharging it in an enclosedspace.

� KEEP THIS AND ALL BATTER-IES OUT OF THE REACH OFCHILDREN.

To charge the batteryHave a Yamaha dealer charge the bat-tery as soon as possible if it seems tohave discharged. Keep in mind that thebattery tends to discharge more quicklyif the vehicle is equipped with optionalelectrical accessories.

To store the battery1. If the vehicle will not be used for

more than one month, remove thebattery, fully charge it, and thenplace it in a cool, dry place.

2. If the battery will be stored for morethan two months, check it at leastonce a month and fully charge it ifnecessary.

3. Fully charge the battery before in-stallation.

4. After installation, make sure thatthe battery leads are properly con-nected to the battery terminals.

CAUTION:ECA10630

� Always keep the batterycharged. Storing a dischargedbattery can cause permanentbattery damage.

� To charge a sealed-type (MF)battery, a special (constant-volt-age) battery charger is required.Using a conventional batterycharger will damage the battery.If you do not have access to a



6-30

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sealed-type (MF) battery charg-er, have a Yamaha dealercharge your battery.

EAU23524

Replacing the fuses

The main fuse and the fuse box, whichcontains the fuses for the individual cir-cuits, are located behind panel B. (Seepage 6-8.)If a fuse is blown, replace it as follows.

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

2. Remove the blown fuse, and theninstall a new fuse of the specifiedamperage.

1. Fuse box2. Main fuse3. Spare main fuse

1. Headlight fuse2. Signaling system fuse3. Ignition fuse4. Carburetor heater fuse5. Ignitor unit fuse (for California only)6. Spare fuse7. Spare fuse (for California only)

chapter6 Page 30 Wednesday, May 12, 2004 5:08 AM


6-31

6 CAUTION:ECA10640

Do not use a fuse of a higher amper-age rating than recommended toavoid causing extensive damage tothe electrical system and possibly afire.

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

4. If the fuse immediately blowsagain, have a Yamaha dealercheck the electrical system.

EAU23792

Replacing the headlight bulb This model is equipped with a quartzbulb headlight. If the headlight bulbburns out, replace it as follows.

1. Remove the headlight unit by re-moving the screws.

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

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

Specified fuses:Main fuse:

30.0 ASignaling system fuse:

10.0 AIgnition fuse:

10.0 AHeadlight fuse:

15.0 ACarburetor heater fuse:

15.0 AIgnitor unit fuse:

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

1. Screw

1. Headlight coupler2. Headlight bulb cover

1. Headlight bulb holder



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WARNINGEWA10790

Headlight bulbs get very hot. There-fore, keep flammable products awayfrom a lit headlight bulb, and do nottouch the bulb until it has cooleddown.

4. Place a new headlight bulb into po-sition, and then secure it with thebulb holder.

CAUTION:ECA10660

Do not touch the glass part of theheadlight bulb to keep it free fromoil, otherwise the transparency ofthe glass, the luminosity of the bulb,and the bulb life will be adversely af-fected. Thoroughly clean off any dirtand fingerprints on the headlightbulb using a cloth moistened with al-cohol or thinner.

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

6. Install the headlight unit by install-ing the screws.

7. Have a Yamaha dealer adjust theheadlight beam if necessary.

EAU24281

Replacing a turn signal light bulb or the tail/brake light bulb

1. Remove the lens by removing thescrews.

XVS650

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

1. Screw

1. Screw



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XVS650A/AT

2. Remove the defective bulb bypushing it in and turning it counter-clockwise.

3. Insert a new bulb into the socket,push it in, and then turn it clock-wise until it stops.

4. Install the lens by installing thescrews.

CAUTION:ECA10680

Do not overtighten the screws, oth-erwise the lens may break.

EAU24350

Supporting the motorcycle Since this model is not equipped with acenterstand, follow these precautionswhen removing the front and rearwheel or performing other maintenancerequiring the motorcycle to stand up-right. Check that the motorcycle is in astable and level position before startingany maintenance. A strong woodenbox can be placed under the engine foradded stability.

To service the front wheel1. Stabilize the rear of the motorcycle

by using a motorcycle stand or, ifan additional motorcycle stand isnot available, by placing a jack un-der the frame in front of the rearwheel.

2. Raise the front wheel off theground by using a motorcyclestand.

To service the rear wheelRaise the rear wheel off the ground byusing a motorcycle stand or, if a motor-cycle stand is not available, by placing

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

1. Screw



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EAU24360

Front wheel

EAU24660

To remove the front wheel

WARNINGEWA10820

� It is advisable to have a Yamahadealer service the wheel.

� Securely support the motor-cycle so that there is no dangerof it falling over.

1. Disconnect the speedometer ca-ble from the front wheel.

2. Loosen the front wheel axle pinchbolt.

3. Remove the rubber cap, and thenloosen the wheel axle.

4. Lift the front wheel off the groundaccording to the procedure onpage 6-33.

5. Pull the wheel axle out, and thenremove the wheel.

CAUTION:ECA11070

Do not apply the brake after thewheel has been removed togetherwith the brake disc, otherwise thebrake pads will be forced shut.

EAU24921

To install the front wheel1. Install the speedometer gear unit

into the wheel hub so that the pro-jections mesh with the slots.

2. Lift the wheel up between the forklegs.

NOTE:Make sure that there is enough spacebetween the brake pads before insert-ing the brake disc and that the slot inthe speedometer gear unit fits over theretainer on the fork leg.

3. Insert the wheel axle.4. Lower the front wheel so that it is

on the ground.

1. Speedometer cable

1. Rubber cap2. Wheel axle3. Front wheel axle pinch bolt

1. Speedometer gear unit2. Speedometer cable3. Retainer



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5. Tighten the wheel axle and frontwheel axle pinch bolt to the speci-fied torques, and then install therubber cap.

6. While applying the front brake,push down hard on the handlebarsseveral times to check if the frontfork compresses and reboundssmoothly.

7. Connect the speedometer cable.

EAU25080

Rear wheel

EAU25141

To remove the rear wheel

WARNINGEWA10820

� It is advisable to have a Yamahadealer service the wheel.

� Securely support the motor-cycle so that there is no dangerof it falling over.

1. Loosen the axle nut.

2. Disconnect the brake torque rodfrom the brake shoe plate by re-moving the bolt and nut.

3. Loosen the brake torque rod nut atthe swingarm.

4. Remove the brake pedal free playadjusting nut, and then disconnectthe brake rod from the brake cam-shaft lever.

5. Remove panel A. (See page 6-8.)6. Remove the bolts that secure the

final gear case to the swingarm.

Tightening torques:Wheel axle:

59 Nm (5.9 m·kgf, 43 ft·lbf)Front wheel axle pinch bolt:

20 Nm (2.0 m·kgf, 14 ft·lbf)

1. Axle nut

1. Brake pedal free play adjusting nut2. Brake camshaft lever3. Brake rod4. Bolt and nut (shoe plate)5. Brake torque rod6. Nut



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7. Lift the rear wheel off the groundaccording to the procedure onpage 6-33.

8. While supporting the drive shaft,pull the rear wheel back to removethe following parts as an assem-bly: wheel, wheel axle, final gearcase, and drive shaft.

NOTE:Make sure to support the drive shaft asit is being pulled out.

EAU25511

To install the rear wheel1. Install the rear wheel, wheel axle,

final gear case, and drive shaft bypushing the wheel forward andguiding the drive shaft into the mid-dle gear universal joint.

2. Install the final gear case bolts.3. Install the brake rod onto the brake

camshaft lever, and then install thebrake pedal free play adjusting nutonto the brake rod.

4. Install the brake torque rod boltand nut at the brake shoe plate.

5. Install the panel.6. Lower the rear wheel so that it is

on the ground.

7. Tighten the axle nut, the final gearcase bolts and the brake torquerod nuts to the specified torques.

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

WARNINGEWA10660

After adjusting the brake pedal freeplay, check the operation of thebrake light.

1. Bolt2. Final gear case

1. Middle gear universal joint2. Drive shaft

Tightening torques:Axle nut:

92 Nm (9.2 m·kgf, 67 ft·lbf)Final gear case bolt:

74 Nm (7.4 m·kgf, 54 ft·lbf)Brake torque rod nut:

20 Nm (2.0 m·kgf, 14 ft·lbf)



6-37

6

EAU25850

Troubleshooting Although Yamaha motorcycles receivea thorough inspection before shipmentfrom the factory, trouble may occur dur-ing operation. Any problem in the fuel,compression, or ignition systems, forexample, can cause poor starting andloss of power.The following troubleshooting chartrepresents a quick and easy procedurefor checking these vital systems your-self. However, should your motorcyclerequire any repair, take it to a Yamahadealer, whose skilled technicians havethe necessary tools, experience, andknow-how to service the motorcycleproperly.Use only genuine Yamaha replace-ment parts. Imitation parts may look likeYamaha parts, but they are often inferi-or, have a shorter service life and canlead to expensive repair bills.



6-38

6

EAU25891

Troubleshooting chart

WARNINGEWA10840

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

Check the fuel level inthe fuel tank.

1. FuelThere is enough fuel.

There is no fuel.

Check the compression.

Supply fuel. The engine does not start. Check the compression.

Operate the electric starter.

2. CompressionThere is compression.

There is no compression.

Check the ignition.

Have a Yamaha dealercheck the vehicle.

Remove the spark plugsand check the electrodes.

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

Have a Yamaha dealer check the vehicle.

The engine does not start.Have a Yamaha dealercheck the vehicle.

The engine does not start.Check the battery.

Operate the electric starter.

4. BatteryThe engine turns over quickly.

The engine turns over slowly.

The battery is good.

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

Dry

WetOpen the throttle halfway and operatethe electric starter.


MOTORCYCLE CARE AND STORAGE

7-1

7

EAU26060

Care While the open design of a motorcyclereveals the attractiveness of the tech-nology, it also makes it more vulnera-ble. Rust and corrosion can developeven if high-quality components areused. A rusty exhaust pipe may go un-noticed on a car, however, it detractsfrom the overall appearance of a motor-cycle. Frequent and proper care doesnot only comply with the terms of thewarranty, but it will also keep yourmotorcycle looking good, extend its lifeand optimize its performance.

Before cleaning1. Cover the muffler outlets with plas-

tic bags after the engine hascooled down.

2. Make sure that all caps and coversas well as all electrical couplersand connectors, including thespark plug caps, are tightly in-stalled.

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

ucts onto seals, gaskets and wheelaxles. Always rinse the dirt and de-greaser off with water.

Cleaning

CAUTION:ECA10770

� Avoid using strong acidic wheelcleaners, especially on spokedwheels. If such products areused on hard-to-remove dirt, donot leave the cleaner on the af-fected area any longer than in-structed. Also, thoroughly rinsethe area off with water, immedi-ately dry it, and then apply a cor-rosion protection spray.

� Improper cleaning can damagewindshields, cowlings, panelsand other plastic parts. Use onlya soft, clean cloth or spongewith mild detergent and water toclean plastic.

� Do not use any harsh chemicalproducts on plastic parts. Besure to avoid using cloths orsponges which have been incontact with strong or abrasivecleaning products, solvent or

thinner, fuel (gasoline), rust re-movers or inhibitors, brake flu-id, antifreeze or electrolyte.

� Do not use high-pressure wash-ers or steam-jet cleaners sincethey cause water seepage anddeterioration in the following ar-eas: seals (of wheel and swing-arm bearings, fork and brakes),electric components (couplers,connectors, instruments,switches and lights), breatherhoses and vents.

� For motorcycles equipped witha windshield: Do not use strongcleaners or hard sponges asthey will cause dulling orscratching. Some cleaning com-pounds for plastic may leavescratches on the windshield.Test the product on a small hid-den part of the windshield tomake sure that it does not leaveany marks. If the windshield isscratched, use a quality plasticpolishing compound afterwashing.



7-2

7

After normal useRemove dirt with warm water, a milddetergent, and a soft, clean sponge,and then rinse thoroughly with cleanwater. Use a toothbrush or bottlebrushfor hard-to-reach areas. Stubborn dirtand insects will come off more easily ifthe area is covered with a wet cloth fora few minutes before cleaning.

After riding in the rain, near the sea oron salt-sprayed roadsSince sea salt or salt sprayed on roadsduring winter are extremely corrosive incombination with water, carry out thefollowing steps after each ride in therain, near the sea or on salt-sprayedroads.

NOTE:Salt sprayed on roads in the winter mayremain well into spring.

1. Clean the motorcycle with cold wa-ter and a mild detergent, after theengine has cooled down.

CAUTION:ECA10790

Do not use warm water since it in-creases the corrosive action of thesalt.

2. After drying the motorcycle, applya corrosion protection spray on allmetal, including chrome- and nick-el-plated, surfaces to prevent cor-rosion.

After cleaning1. Dry the motorcycle with a chamois

or an absorbing cloth.2. Use a chrome polish to shine

chrome, aluminum and stainless-steel parts, including the exhaustsystem. (Even the thermally in-duced discoloring of stainless-steel exhaust systems can be re-moved through polishing.)

3. To prevent corrosion, it is recom-mended to apply a corrosion pro-tection spray on all metal,including chrome- and nickel-plat-ed, surfaces.

4. Use spray oil as a universal clean-er to remove any remaining dirt.

5. Touch up minor paint damagecaused by stones, etc.

6. Wax all painted surfaces.7. Let the motorcycle dry completely

before storing or covering it.

WARNINGEWA11130

� Make sure that there is no oil orwax on the brakes or tires.

� If necessary, clean the brakediscs and brake linings with aregular brake disc cleaner or ac-etone, and wash the tires withwarm water and a mild deter-gent. Before riding at higherspeeds, test the motorcycle’sbraking performance and cor-nering behavior.

CAUTION:ECA10800

� Apply spray oil and wax spar-ingly and make sure to wipe offany excess.

� Never apply oil or wax to anyrubber and plastic parts, buttreat them with a suitable careproduct.



7-3

7

� Avoid using abrasive polishingcompounds as they will wearaway the paint.

NOTE:Consult a Yamaha dealer for advice onwhat products to use.

EAU26230

Storage

Short-termAlways store your motorcycle in a cool,dry place and, if necessary, protect itagainst dust with a porous cover.

CAUTION:ECA10810

� Storing the motorcycle in apoorly ventilated room or cover-ing it with a tarp, while it is stillwet, will allow water and humid-ity to seep in and cause rust.

� To prevent corrosion, avoiddamp cellars, stables (becauseof the presence of ammonia)and areas where strong chemi-cals are stored.

Long-termBefore storing your motorcycle for sev-eral months:

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

2. For motorcycles equipped with afuel cock that has an “OFF” posi-tion: Turn the fuel cock lever to“OFF”.

3. Drain the carburetor float cham-bers by loosening the drain bolts;this will prevent fuel deposits frombuilding up. Pour the drained fuelinto the fuel tank.

4. Fill up the fuel tank and add fuelstabilizer (if available) to preventthe fuel tank from rusting and thefuel from deteriorating.

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

and spark plugs.b. Pour a teaspoonful of engine oil

into each spark plug bore.c. Install the spark plug caps onto

the spark plugs, and then placethe spark plugs on the cylinderhead so that the electrodes aregrounded. (This will limit spark-ing during the next step.)

d. Turn the engine over severaltimes with the starter. (This willcoat the cylinder walls with oil.)

e. Remove the spark plug capsfrom the spark plugs, and theninstall the spark plugs and thespark plug caps.



7-4

7

WARNINGEWA10950

To prevent damage or injury fromsparking, make sure to ground thespark plug electrodes while turningthe engine over.

6. Lubricate all control cables and thepivoting points of all levers andpedals as well as of the side-stand/centerstand.

7. Check and, if necessary, correctthe tire air pressure, and then liftthe motorcycle so that both of itswheels are off the ground. Alterna-tively, turn the wheels a little everymonth in order to prevent the tiresfrom becoming degraded in onespot.

8. Cover the muffler outlets with plas-tic bags to prevent moisture fromentering them.

9. Remove the battery and fullycharge it. Store it in a cool, dryplace and charge it once a month.Do not store the battery in an ex-cessively cold or warm place [lessthan 0 °C (30 °F) or more than 30

°C (90 °F)]. For more informationon storing the battery, see page6-29.

NOTE:Make any necessary repairs beforestoring the motorcycle.


SPECIFICATIONS

8-1

8

Dimensions:Overall length:

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

Overall width:XVS650 880 mm (34.6 in)XVS650A 930 mm (36.6 in)XVS650AT 930 mm (36.6 in)

Overall height:XVS650 1070 mm (42.1 in)XVS650A 1105 mm (43.5 in)XVS650AT 1105 mm (43.5 in)

Seat height:XVS650 695 mm (27.4 in)XVS650A 710 mm (28.0 in)XVS650AT 710 mm (28.0 in)

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

Ground clearance:140 mm (5.51 in)

Minimum turning radius:XVS650 3100 mm (122.0 in)XVS650A 3400 mm (133.9 in)XVS650AT 3400 mm (133.9 in)

Weight:With oil and fuel:

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

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

Engine:Engine type:

Air cooled 4-stroke, SOHCCylinder arrangement:

V-type 2-cylinderDisplacement:

649.0 cm³ (39.60 cu.in)Bore × stroke:

81.0 × 63.0 mm (3.19 × 2.48 in)Compression ratio:

9.00 :1Starting system:

Electric starterLubrication system:

Wet sumpEngine oil:

Type:YAMALUBE 4, SAE10W30 or SAE20W40

Recommended engine oil grade:API service SE, SF, SG type or higher

Engine oil quantity:Without oil filter element replacement:

2.60 L (2.75 US qt) (2.29 Imp.qt)With oil filter element replacement:

2.80 L (2.96 US qt) (2.46 Imp.qt)Final gear oil:

Type:SAE80 API GL-4 Hypoid gear oil

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

Air filter:Air filter element:

Dry elementFuel:

Recommended fuel:Unleaded gasoline only

Fuel tank capacity:16.0 L (4.23 US gal) (3.52 Imp.gal)

Fuel reserve amount:3.0 L (0.79 US gal) (0.66 Imp.gal)

Carburetor:Manufacturer:

MIKUNIType x quantity:

BDS28 x 2Spark plug(s):

Manufacturer/model:NGK/DPR7EA-9

Manufacturer/model:DENSO/X22EPR-U9

Spark plug gap:0.8–0.9 mm (0.031–0.035 in)

10° 30° 50° 70° 90° 110°0° 130°F

YAMALUBE 4 (10W30)or SAE 10W30

YAMALUBE 4 (20W40)or SAE 20W40

–10° 0° 10° 20° 30° 40°–20° 50°C


SPECIFICATIONS

8-2

8

Clutch:Clutch type:

Wet, multiple-discTransmission:

Primary reduction system:Spur gear

Primary reduction ratio:68/38 (1.789)

Secondary reduction system:Shaft drive

Secondary reduction ratio:19/18 × 32/11 (3.071)

Transmission type:Constant mesh 5-speed

Operation:Left foot operation

Gear ratio:1st:

38/14 (2.714)2nd:

38/20 (1.900)3rd:

35/24 (1.458)4th:

28/24 (1.167)5th:

29/30 (0.967)Chassis:

Frame type:Double cradle

Caster angle:35.00 °

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

Front tire:Type:

With tubeSize:

XVS650 100/90-19M/C 57SXVS650A 130/90-16M/C 67SXVS650AT 130/90-16M/C 67S

Manufacturer/model:XVS650 BRIDGESTONE/EXEDRA L309XVS650A BRIDGESTONE/EXEDRA G703XVS650AT BRIDGESTONE/EXEDRA G703

Manufacturer/model:XVS650 DUNLOP/F24XVS650A DUNLOP/D404FXVS650AT DUNLOP/D404F

Rear tire:Type:

With tubeSize:

170/80-15M/C 77SManufacturer/model:

XVS650 BRIDGESTONE/EXEDRA G546XVS650A BRIDGESTONE/EXEDRA G702XVS650AT BRIDGESTONE/EXEDRA G702

Manufacturer/model:XVS650 DUNLOP/K555XVS650A DUNLOP/D404GXVS650AT DUNLOP/D404G

Loading:Maximum load:

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

Tire air pressure (measured on cold tires):

Loading condition:0–90 kg (0–198 lb)Front:

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


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


SPECIFICATIONS

8-3

8

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


Front wheel:Wheel type:

Spoke wheelRim size:

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

Rear wheel:Wheel type:

Spoke wheelRim size:

15M/C x MT3.50Front brake:

Type:Single disc brake

Operation:Right hand operation

Recommended fluid:DOT 4

Rear brake:Type:

Drum brakeOperation:

Right foot operation

Front suspension:Type:

Telescopic forkSpring/shock absorber type:

Coil spring/oil damperWheel travel:

140.0 mm (5.51 in)Rear suspension:

Type:Swingarm (monocross)

Spring/shock absorber type:Coil spring/gas-oil damper

Wheel travel:XVS650 86.0 mm (3.39 in)XVS650A 98.0 mm (3.86 in)XVS650AT 98.0 mm (3.86 in)

Electrical system:Ignition system:

Transistorized coil ignition (digital)Charging system:

A.C. magnetoBattery:

Model:GT12B-4

Voltage, capacity:12 V, 10.0 Ah

Headlight:Bulb type:

Halogen bulbBulb voltage, wattage x quantity:

Headlight:12 V, 60 W/55.0 W × 1

Tail/brake light:12 V, 8.0/27.0 W × 1

Front turn signal/position light:XVS650 12 V, 27 W/8.0 W × 2XVS650A 12 V, 23 W/8.0 W × 2XVS650AT 12 V, 23 W/8.0 W × 2

Rear turn signal light:XVS650 12 V, 27.0 W × 2XVS650A 12 V, 21.0 W × 2XVS650AT 12 V, 21.0 W × 2

Meter lighting:12 V, 1.7 W × 1

Neutral indicator light:12 V, 1.7 W × 1

High beam indicator light:12 V, 1.7 W × 1

Turn signal indicator light:12 V, 1.7 W × 1

Engine trouble warning light:12 V, 1.7 W × 1

Fuses:Main fuse:

30.0 AHeadlight fuse:

15.0 ASignaling system fuse:

10.0 AIgnition fuse:

10.0 ACarburetor heater fuse:

15.0 AIgnitor unit fuse:

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


CONSUMER INFORMATION

9-1

9

EAU26351

Identification numbers Record the key identification number,vehicle identification number and mod-el label information in the spaces pro-vided below for assistance whenordering spare parts from a Yamahadealer or for reference in case the vehi-cle is stolen.KEY IDENTIFICATION NUMBER:

VEHICLE IDENTIFICATION NUMBER:

MODEL LABEL INFORMATION:

EAU26381

Key identification number

The key identification number isstamped into the key tag. Record thisnumber in the space provided and useit for reference when ordering a newkey.

EAU26400

Vehicle identification number

The vehicle identification number isstamped into the steering head pipe.Record this number in the space pro-vided.

NOTE:The vehicle identification number isused to identify your motorcycle andmay be used to register your motor-cycle with the licensing authority in yourarea.

1. Key identification number 1. Vehicle identification number



9-2

9

EAU26470

Model label

The model label is affixed to the frameunder the rider seat. (See page 3-9.)Record the information on this label inthe space provided. This informationwill be needed when ordering spareparts from a Yamaha dealer.

1. Model label



9-3

9

EAU26550

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



9-4

9

EAU26560

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

Exhaust system• Muffler• Exhaust pipe• Silencer

Intake system• Air cleaner case• Air cleaner element• Intake duct



9-5

9

EAU26631

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

Maintenanceinterval

Date ofservice Mileage Servicing dealer

name and address Remarks

600 mi(1000 km) or

1 month4000 mi

(7000 km) or6 months8000 mi







(49000 km) or48 months



9-6

9

36000 mi(55000 km) or

54 months40000 mi

(61000 km) or60 months

Maintenanceinterval

Date ofservice Mileage Servicing dealer

name and address Remarks



9-7

9

EAU26661

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



9-8

9



9-9

9

EAU26750

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

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

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

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

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

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

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

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

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



9-10

9

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

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

Yamaha Service MarketingP.O. Box 6555Cypress, CA 906301-(866)-YES-EXTD (1-866-937-3983)


INDEXA

Accessories and replacement parts ..... 6-19Air filter element, cleaning .................... 6-14

BBattery .................................................. 6-29Brake and clutch levers,

checking and lubricating..................... 6-26Brake and shift pedals,

checking and lubricating..................... 6-26Brake fluid, changing ............................ 6-25Brake fluid level, checking .................... 6-24Brake lever ............................................. 3-5Brake lever free play, adjusting ............ 6-21Brake pads and shoes, checking.......... 6-24Brake pedal ............................................ 3-5Brake pedal position and free play,

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

Cables, checking and lubricating.......... 6-25Canister (for California only)................. 6-10Carburetors, adjustment ....................... 6-16Care........................................................ 7-1Catalytic converter.................................. 3-7Clutch lever............................................. 3-4Clutch lever free play, adjusting ........... 6-20

DDimmer switch ........................................ 3-3

EEngine break-in ...................................... 5-4Engine oil and oil filter element............. 6-11Engine, starting a warm.......................... 5-2Engine stop switch.................................. 3-3Engine trouble warning light ................... 3-2

FFinal gear oil..........................................6-13Front fork, checking...............................6-27Fuel .........................................................3-6Fuel cock.................................................3-7Fuel tank cap...........................................3-5Fuses, replacing....................................6-30

HHandlebar switches.................................3-3Headlight bulb, replacing.......................6-31Helmet holder........................................3-11High beam indicator light.........................3-2Horn switch .............................................3-3

IIdentification numbers .............................9-1Ignition circuit cut-off system.................3-14Indicator and warning lights ....................3-2

KKey identification number........................9-1

LLabels, location of ...................................1-5Luggage strap holders ..........................3-13

MMain switch/steering lock ........................3-1Maintenance and lubrication, periodic.....6-4Maintenance, emission control system ...6-3Maintenance, periodic .............................6-1Maintenance record ................................9-5Model label..............................................9-2

NNeutral indicator light ..............................3-2Noise regulation ......................................9-4

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

Parking.................................................... 5-5Part locations .......................................... 2-1Pre-operation check list .......................... 4-2

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

SSafety defects, reporting......................... 9-3Safety information................................... 1-1Seats (XVS650) ...................................... 3-9Seats (XVS650A/AT) ............................ 3-10Shifting.................................................... 5-3Shift pedal (XVS650) .............................. 3-4Shift pedal (XVS650A/AT) ...................... 3-4Shock absorber assembly, adjusting .... 3-12Sidestand.............................................. 3-13Sidestand, checking and lubricating ..... 6-27Spark plugs, checking............................. 6-9Specifications.......................................... 8-1Speedometer unit ................................... 3-2Starter (choke) knob ............................... 3-8Starting and warming up a cold

engine................................................... 5-1Start switch ............................................. 3-3Steering, checking ................................ 6-28Storage ................................................... 7-3Storage compartment ........................... 3-11Supporting the motorcycle .................... 6-33

TThrottle cable free play, adjusting......... 6-16Throttle grip and cable,

checking and lubricating ..................... 6-26Tires...................................................... 6-17Tool kit .................................................... 6-1Troubleshooting .................................... 6-37


INDEXTroubleshooting chart ........................... 6-38Turn signal indicator light ........................ 3-2Turn signal light bulb or

tail/brake light bulb, replacing ............. 6-32Turn signal switch ................................... 3-3

VValve clearance, adjusting .................... 6-16Vehicle identification number .................. 9-1

WWarranty, extended................................. 9-9Warranty, limited ..................................... 9-7Wheel bearings, checking..................... 6-28Wheel (front) ......................................... 6-34Wheel (rear) .......................................... 6-35Wheels .................................................. 6-19


PRINTED IN JAPAN2004.05-2.6×1 CR

(E)

PRINTED ON RECYCLED PAPER YAMAHA MOTOR CO., LTD.

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

XVS650T(C)XVS650AT(C)

XVS650ATT(C)

OWNER’S MANUAL

drag star 650 user manual

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