Yamaha XVS650A, Supplementary Service Manual

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Page 3: ... this Supplementa ry Service Manual together with the following manual XVS650 97 SERVICE MANUAL 4VR AE1 XVS650A 98 SUPPLEMENTARY SERVICE MANUAL 5BN4 AE1 XVS650A 2001 SUPPLEMENTARY SERVICE MANUAL 2000 by Yamaha Motor Co Ltd First Edition October 2000 All rights reserved Any reproduction or unauthorized use without the written permission of Yamaha Motor Co Ltd is expressly prohibited ...

Page 4: ...ve all its models Modifications and signifi cant changes in specifications or procedures will be forwarded to all authorized Yamaha dealers and will appear in future editions of this manual where applicable Designs and specifications are subject to change without notice IMPORTANT INFORMATION Particularly important information is distinguished in this manual by the following notations The Safety Al...

Page 5: ...lp identify parts and clarify procedure steps there are exploded diagrams at the start of each re moval and disassembly section 1 An easy to see exploded diagram 4 is provided for removal and disassembly jobs 2 Numbers 5 are given in the order of the jobs in the exploded diagram A number that is enclosed by a circle indicates a disassembly step 3 An explanation of jobs and notes is presented in an...

Page 6: ... to 16 indicate the following 9 Serviceable with engine mounted 10 Filling fluid 11 Lubricant 12 Special tool 13 Tightening torque 14 Wear limit clearance 15 Engine speed 16 Electrical data Symbols 17 to 22 in the exploded diagrams indi cate the types of lubricants and lubrication points 17 Engine oil 18 Gear oil 19 Molybdenum disulfide oil 20 Wheel bearing grease 21 Lithium soap base grease 22 Mo...

Page 7: ...UBRICATION POINTS AND LUBRICANT TYPES 7 ENGINE 7 CABLE ROUTING 8 PERIODIC INSPECTIONS AND ADJUSTMENTS 17 INTRODUCTION 17 PERIODIC MAINTENANCE LUBRICATION INTERVALS 17 REAR BRAKE ADJUSTMENT 19 SHIFT PEDAL ADJUSTMENT 21 CARBURATION 22 AIR INDUCTION SYSTEM 22 AIR INDUCTION SYSTEM DIAGRAMS 22 CHECKING THE AIR INDUCTION SYSTEM 25 CHASSIS 26 FRONT BRAKE 26 FRONT BRAKE PADS 26 FRONT BRAKE CALIPER 29 WIRI...

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Page 9: ...TION MOTORCYCLE IDENTIFICATION EB100010 VEHICLE IDENTIFICATION NUMBER The vehicle identification number 1 is stamped into the right side of the steering head MODEL LABEL The model label 1 is affixed to the frame This information will be needed to order spare parts ...

Page 10: ...and a full fuel tank 247 kg Bulb wattage quantity Headlight Tail brake light Auxiliary light Turn signal light Meter light Neutral indicator light High beam indicator light Turn indicator light Engine indicator light 12 V 60 W 55 W 1 12 V 5 W 21 W 1 12 V 4W 1 12 V 21 W 4 12 V 1 7 W 1 12 V 1 7 W 1 12 V 1 7 W 1 12 V 1 7 W 1 12 V 1 7 W 1 ...

Page 11: ...le J N Needle jet N J Pilot air jet P A J 1 Pilot outlet P O Pilot jet P J Bypass 1 B P 1 Bypass 2 B P 2 Bypass 3 B P 3 Pilot screw P S Valve seat size V S Starter jet G S 1 Starter jet G S 2 Throttle valve size Th V Fuel level F L Engine idle speed Intake vacuum CO Engine oil temperature 5BN5 20 5BNW 5BN8 30 5BNV 90 50 4CT2 2 O 4 100 0 85 20 0 8 0 8 0 8 2 1 2 1 0 17 5 0 9 140 7 5 X 8 5 mm 1 150 X...

Page 12: ...it Brake lever brake pedal Brake lever free play at pivot Brake lever free play at lever end Brake pedal position Brake pedal free play Clutch lever free play at pivot Clutch lever free play at lever end 1 X 2 mm 10 X 15 mm 108 mm 20 X 30 mm 2 X 3 mm 10 X 15 mm ...

Page 13: ...or short circuit type SH650C 11 SHINDENGEN 14 1 X 14 9 V Rectifier Model manufacturer Capacity Withstand voltage SH650C 11 SHINDENGEN 18 A 200 V Electric starter system Type Starter motor Model manufacturer I D number Output Brush overall length Commutator diameter Mica undercut Starter relay Model manufacturer Amperage rating Constant mesh type SM 13 MITSUBA SM 13 0 7 kW 10 mm 28 mm 0 7 mm MS 5F ...

Page 14: ...FICATIONS SPEC Item Standard Limit Circuit breaker Type Amperage for individual circuit MAIN HEADLIGHT SIGNALS IGNITION CARBURETOR HEATER Reserve Reserve Reserve Fuse 30 A 1 15 A 1 10 A 1 10 A 1 15 A 1 30 A 1 15 A 1 10 A 1 ...

Page 15: ... 7 LUBRICATION POINTS AND LUBRICANT TYPES SPEC EB203000 LUBRICATION POINTS AND LUBRICANT TYPES ENGINE Lubrication point Symbol Crankshaft journal Camshaft cam lobe Primary driven gear ...

Page 16: ...light lead 14 Right handlebar switch lead 15 Main switch 16 Main switch lead 17 Fuel pump lead 18 Fuel hose 1 Frame 2 Clutch cable 3 Left handlebar switch lead 4 Fuel tank breather hose 5 Speedometer cable 6 Speedometer 7 Speedometer light leads 8 Vacuum chamber air vent hose 9 Rectifier regulator EB206000 CABLE ROUTING ...

Page 17: ...lead wire through the sidestand bracket When installing wake sure not to have any extra loosening A Inside the motorcycle B Place the end of the plastic locking tie as shown C Fasten the rear brake switch lead sidestand switch lead and rectifier regulator lead with metal clamp or plastic locking tie D Pass the front flasher light leads left and right and headlight lead through the headlight cover ...

Page 18: ... vacuum chamber air vent hose through the holder AA Pass the speedometer cable through the holder AB Place the couplers behind the steeirng head P Route the sidestand switch and the lead wire under the frame boss Q Fasten the sidestand switch lead with a metal clamp R Connect the rear brake switch coupler in front of the roll over valve stay S Install the plastic locking tie immediately below the ...

Page 19: ...ay 14 Starter relay 15 Carburetor heater relay 16 Neutral switch lead 17 Pickup coil lead 18 A C magneto lead 19 Battery negative lead 20 Starter motor lead 21 Battery cover 22 Battery 23 Wire harness 24 Starting circuit cut off relay 1 Frame bracket 2 Dimmer switch 3 Self canceling turn signal relay 4 Fuse box 5 Battery positive lead 6 Spark plug lead 7 Vacuum chamber air bent hose 8 Starter cabl...

Page 20: ...s the ignition coil lead inside of the starter cable P Fasten the fuse box lead with a plastic locking tie C Fasten the self canceling turn signal relay lead and battery positive lead with a battery band D Fasten the tail brake light lead coupler and battery negative lead coupler with a clamp E Fasten the starter relay lead and fuse box lead with a plastic locking tie F To the ignition coil G The ...

Page 21: ...e frame and battery box AC Fasten the starter cable with a plastic locking tie AD Inside the motorcycle Q Fasten the battery positive lead with a battery box clamp R The carburetor heater relay should not touch the wire harness S Fasten the wire harness with a plastic locking tie T Place the end of the plastic locking tie as shown U From the engine V Pass the starter motor lead over the battery ne...

Page 22: ...and leads with a metal clamp AQ To the carburetor heater relay AR Pass the ignitor unit leads through the battery box hole AE Pass the fuel tank breather hose through the holder AF Fasten the fuel tank breather hose with a metal clamp AG Pass the speedometer cable through the front side guide AH To the battery negative lead AI To the rear fender AJ To the flasher light relay AK To the starter rela...

Page 23: ...l and spark plug lead 13 Neutral switch lead 14 Pickup coil lead 15 A C magneto lead 16 Thermo switch lead 17 Fuel tank breather hose 18 Rectifier regulator coupler 19 Wire harness 20 Throttle position sensor TPS lead 21 Frame 22 Air filter case 1 Front flasher light right 2 Throttle cables 3 Brake hose 4 Right handlebar switch lead 5 Clutch cable 6 Left handlebar switch lead 7 Front flasher light...

Page 24: ...as shown R Fasten the wire harness with a plastic locking tie S Pass the wire harness between the air filter case groove and frame G To the throttle position sensor TPS H To the carburetor I To the fuel tank J Pass the neutral switch lead pickup coil lead and A C magneto lead under the ignition coil lead thermo switch lead and throttle position sensor TPS lead K From the engine L 20 mm M Pass the ...

Page 25: ... Replace 3 Valves Check valve clearance Adjust 4 Air filter element Clean 4 Air filter element Replace 5 Clutch Check operation Adjust 6 Front brake Check operation fluid level and vehicle for fluid leakage 6 Front brake Replace brake pads Whenever worn to the limit 7 Rear brake Check operation and adjust brake pedal freeplay 7 Rear brake Replace brake shoes Whenever worn to the limit 8 Brake hose...

Page 26: ...l leakage 22 Final gear oil D Change 23 Lights signals and switches D Check operation D Adjust headlight beam D The air filter needs more frequent service if you are riding in unusually wet or dusty areas D Hydraulic brake service SRegularly check and if necessary correct the brake fluid level SEvery two years replace the internal components of the brake master cylinder and caliper and change the ...

Page 27: ... Turning in brake pedal height is decreased Turning out brake pedal height is increased Tighten the locknut Locknut 7 Nm 0 7 m kg 3 Check Brake pedal free play a Out of specification Adjust Free play brake pedal 20 30 mm 4 Adjust Brake pedal free play Adjustment steps Turn the adjuster 1 in or out until the speci fied free play is obtained Turning in brake pedal free play is decreased Turning out ...

Page 28: ... 20 REAR BRAKE ADJUSTMENT INSP ADJ 5 Adjust Brake light switch Refer to BRAKE LIGHT SWITCH ADJUST MENT ...

Page 29: ...edal rod length 168 mm 2 Adjust Shift pedal position Adjustment steps Loosen both locknuts 1 To obtain the correct pedal position turn the shift pedal rod 2 in or out Turning in shift pedal is lowered Turning out shift pedal is raised Tighten both locknuts Align the mark on the shift shaft with the center of the slit Turn in the both side of the shift pedal rod more than 4 times ...

Page 30: ...ION SYSTEM CARB A To the front cylinder head B To the rear cylinder head 1 Reed valve 2 Air cut valve 3 Air cleaner 4 Carburetor joint EB601000 CARBURATION AIR INDUCTION SYSTEM EAS00509 AIR INDUCTION SYSTEM DIAGRAMS ...

Page 31: ...d valve case to front cylinder head pipe Reed valve case to rear cylinder head hose Reed valve case to rear cylinder head hose Gasket Reed valve case to cylinder head pipe Reed valve case to cylinder head hose Vacuum hose 2 1 1 1 1 2 1 2 1 Remove the parts in the order listed 4 Nm 0 4 m kg 2 Nm 0 2 m kg AIR INDUCTION SYSTEM CARB ...

Page 32: ...er Vacuum hose 1 Air cut valve Plug Air cut valve to air cleaner hose Air cleaner Air Cleaner case Bend hose Air cut valve to reed valve hose Reed valve 1 1 1 1 1 1 1 1 1 1 1 For installation reverse the removal procedure 4 Nm 0 4 m kg 2 Nm 0 2 m kg AIR INDUCTION SYSTEM CARB ...

Page 33: ...pes Cracks damage Replace 2 Check reed valve 1 reed valve stopper reed valve seat Cracks damage Replace the reed valve 3 Measure reed valve bending a Out of specification Replace the reed valve Maximum reed valve bending 0 4 mm 1 Surface plate 4 Check air cutoff valve Cracks damage Replace 5 Check air cleaner Cracks damage Replace Clogged Clean ...

Page 34: ...aining bolt Brake caliper Brake pads Pad spring 2 1 2 1 Remove the parts in the order below For installation reverse the removal procedure Refer to BRAKE PAD REPLACEMENT 40 Nm 4 0 m kg 27 Nm 2 7 m kg 27 Nm 2 7 m kg FRONT BRAKE CHAS CHASSIS FRONT BRAKE FRONT BRAKE PADS ...

Page 35: ...aulic connection as this would require the entire brake system to be disassembled drained cleaned properly filled and bled after reassembly BRAKE PAD REPLACEMENT It is not necessary to disassemble the brake cal iper and brake hose to replace the brake pads 1 Remove Retaining bolt 1 2 Remove Brake pads 1 Install new brake pad springs when the brake pads have to be replaced Replace the brake pads as...

Page 36: ...6 m kg Install new brake pads and a new brake pad spring Install the brake caliper 3 and retaining bolt 4 Bolt brake caliper 40 Nm 4 0 m kg Retaining bolt 27 Nm 2 7 m kg 4 Check Brake fluid level Refer to BRAKE FLUID LEVEL INSPEC TION in CHAPTER 3 a LOWER level line 5 Check Brake lever operaiton Soft or spongy feeling Bleed the brake system Refer to AIR BLEEDING HYDRAULIC BRAKE SYSTEM in CHAPTER 3...

Page 37: ...pper washers Brake hose Retaining bolt Brake caliper assembly 1 1 2 1 2 1 Remove the parts in the order below Drain For installation reverse the removal procedure Refer to CALIPER INSTALLATION 7 Nm 0 7 m kg 30 Nm 3 0 m kg 6 Nm 0 6 m kg 40 Nm 4 0 m kg 27 Nm 2 7 m kg 27 Nm 2 7 m kg FRONT BRAKE CHAS FRONT BRAKE CALIPER ...

Page 38: ... ROUTING 2 Fill Brake reservoir Recommended brake fluid DOT 4 Brake fluid may damage painted surfaces or plastic parts Always clean up spilled brake fluid immediately Use only the designated quality brake fluid other brake fluids may deteriorate the rub ber seals causing leakage and poor brake performance Refill with the same type of brake fluid mix ing brake fluids may result in a harmful chemica...

Page 39: ...bleed Brake system Refer to AIR BLEEDING HYDRAULIC BRAKE SYSTEM in CHAPTER 3 4 Check Brake fluid level Brake fluid level is under the LOWER level line Fill up Refer to BRAKE FLUID LEVEL INSPEC TION in CHAPTER 3 a LOWER level line ...

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Page 41: ...ss switch 29 Dimmer switch 30 Clutch switch 31 Horn switch 32 Turn switch 33 Flasher relay 34 Horn 35 Rear brake switch 36 Tail brake light 37 Carburetor heater 38 Carburetor heater earth 39 Carburetor heater relay 40 Thermo switch 41 Carburetor heater fuse 42 Signal system fuse 43 Headlight fuse 44 Ignition fuse 45 Right handlebar switch 46 Front brake switch 47 Lights switch 48 Engine stop switc...