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Yamaha xvs650a Supplementary Service Manual

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  • Page 3 FOREWORD This Supplementary Service Manual has been prepared to introduce new service and data for the XVS650A 2001. For complete service information procedures it is necessary to use this Supplementa- ry Service Manual together with the following manual. XVS650 ’97 SERVICE MANUAL: 4VR-AE1 XVS650A ’98 SUPPLEMENTARY SERVICE MANUAL: 5BN4-AE1...
  • Page 4 It is not possible to include all the knowledge of a mechanic in one manual, so it is assumed that anyone who uses this book to perform maintenance and repairs on Yamaha mo- torcycles has a basic understanding of the mechanical ideas and the procedures of motorcycle repair.
  • Page 5 EB002000 HOW TO USE THIS MANUAL MANUAL ORGANIZATION This manual consists of chapters for the main categories of subjects. (See “Illustrated symbols”) 1st title 1 : This is the title of the chapter with its symbol in the upper right comer of each page. 2nd title 2 : This title indicates the section of the chapter and only appears on the first page of each section.
  • Page 6 EAS0009 SYMBOLS The following symbols are not relevant to every vehicle. Symbols 1 to 8 indicate the subject of each chapter. 1 General information 2 Specifications 3 Periodic checks and adjustments 4 Engine 5 Carburetor(-s) 6 Chassis 7 Electrical system 8 Troubleshooting Symbols 9 to indicate the following.

  • Page 7: Table Of Contents

    CONTENTS GENERAL INFORMATION ........MOTORCYCLE IDENTIFICATION .

  • Page 9: General Information

    MOTORCYCLE IDENTIFICATION INFO EB100000 GENERAL INFORMATION 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. –1–...

  • Page 10: Specifications

    SPEC GENERAL SPECIFICATIONS SPECIFICATIONS GENERAL SPECIFICATIONS Item Standard Model code: XVS650A: 5BNV, 5BNW Basic weight: With oil and a full fuel tank 247 kg Bulb wattage quantity: Headlight 12 V 60 W/55 W Tail/brake light 12 V 5 W/21 W...

  • Page 11: Maintenance Specifications

    SPEC MAINTENANCE SPECIFICATIONS MAINTENANCE SPECIFICATIONS ENGINE Item Standard Limit Connecting rod: 0.031 X 0.055 mm Oil clearance Color code (corresponding size) Blue Black Brown Green Carburetor: I.D. mark 5BN5 20 (5BNW) 5BN8 30 (5BNV) Main jet (M.J) Main air jet (M.A.J) Jet needle (J.N)

  • Page 12: Chassis

    SPEC MAINTENANCE SPECIFICATIONS CHASSIS Item Standard Limit Brake lever & brake pedal: 1 X 2 mm Brake lever free play (at pivot) 10 X 15 mm Brake lever free play (at lever end) Brake pedal position 108 mm 20 X 30 mm Brake pedal free play 2 X 3 mm Clutch lever free play (at pivot)

  • Page 13: Electrical

    SPEC MAINTENANCE SPECIFICATIONS ELECTRICAL Item Standard Limit T.C.I.: 182 X 222 Ω at 20_C/Gray – Black Pickup coil resistance/color T.C.I. unit model/manufacturer J4T094/MITSUBISHI Ignition coil: Model/manufacturer F6T541 /MITSUBISHI Minimum spark gap 6 mm 3.6 X 4.8 Ω at 20_C Primary winding resistance 10.7 X 14.5 kΩ...
  • Page 14 SPEC MAINTENANCE SPECIFICATIONS Item Standard Limit Circuit breaker: Type Fuse Amperage for individual circuit MAIN 30 A HEADLIGHT 15 A SIGNALS 10 A IGNITION 10 A CARBURETOR HEATER 15 A Reserve 30 A Reserve 15 A Reserve 10 A –6–...

  • Page 15: Lubrication Points And Lubricant Types

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

  • Page 16: Cable Routing

    SPEC CABLE ROUTING EB206000 CABLE ROUTING Frame Sidestand switch lead Spark plug lead Clutch cable Rear brake switch lead Fuel pump Left handlebar switch lead Horn Fuel tank breather hose Headlight lead Speedometer cable Right handlebar switch lead Speedometer Main switch Speedometer light leads Main switch lead Vacuum chamber air vent hose...
  • Page 17 SPEC CABLE ROUTING A Inside the motorcycle. H To the speedometer light leads. B Place the end of the plastic locking tie as shown. I Rectifier/ regulator lead should not be out over the C Fasten the rear brake switch lead, sidestand switch bracket.
  • Page 18 SPEC CABLE ROUTING P Route the sidestand switch and the lead wire under V Pass the rear brake switch lead between the frame the frame boss. and rectifier / regulator. Do not pinch the rear brake Q Fasten the sidestand switch lead with a metal switch lead.
  • Page 19 SPEC CABLE ROUTING Frame bracket Flasher light relay Fuel tank breather hose Dimmer switch Starter relay Speedometer cable Self-canceling turn signal relay Carburetor heater relay Ignitor unit Fuse box Neutral switch lead Battery positive (+) lead Pickup coil lead A Pass the tail / brake light lead Spark plug lead A.C.
  • Page 20 SPEC CABLE ROUTING C Fasten the self-canceling turn signal relay lead and I Pass the right handlebar switch lead behind the battery positive (+) lead with a battery band. upper bracket. D Fasten the tail / brake light lead coupler and battery J Fasten the brake hose grommet with a brake hose negative (–) lead coupler with a clamp.
  • Page 21 SPEC CABLE ROUTING Q Fasten the battery positive (+) lead with a battery X Fasten the battery negative (–) lead, starter motor box clamp. lead and wire harness with a plastic locking tie. R The carburetor heater relay should not touch the Y Fasten the wire harness with a clamp.
  • Page 22 SPEC CABLE ROUTING AE Pass the fuel tank breather hose through the AM Fasten the wire harness and leads with a plastic holder. locking tie. AF Fasten the fuel tank breather hose with a metal AN Pass the plastic band through the frame hole. clamp.
  • Page 23 SPEC CABLE ROUTING Front flasher light (right) Neutral switch lead A Pass the throttle cables through Throttle cables Pickup coil lead the cable guide. Brake hose A.C. magneto lead B Pass the left handlebar switch Right handlebar switch lead Thermo switch lead lead over the right handlebar Clutch cable Fuel tank breather hose...
  • Page 24 SPEC CABLE ROUTING G To the throttle position sensor (TPS). N Fasten the wire harness and throttle position H To the carburetor. sensor (TPS) lead with a plastic locking tie. I To the fuel tank. O Inside the motorcycle. J Pass the neutral switch lead, pickup coil lead and P Route the wire harness and throttle position sensor A.C.

  • Page 25: Periodic Inspections And Adjustments

    D The annual checks must be performed every year, except if a kilometer-based maintenance is performed instead. D From 50,000 km, repeat the maintenance intervals starting from 10,000 km. D Items marked with an asterisk should be performed by a Yamaha dealer as they require special tools, data and technical skills. EB301000...
  • Page 26 INSP PERIODIC MAINTENANCE/LUBRICATION INTERVALS ODOMETER READING (x 1,000 km) ANNUAL ITEM ITEM CHECKS OR MAINTENANCE JOB CHECKS OR MAINTENANCE JOB CHECK Engine oil filter D Replace. element D Check oil level and vehicle for oil leakage. Final gear oil Final gear oil D Change.

  • Page 27: Rear Brake Adjustment

    INSP REAR BRAKE ADJUSTMENT EB304012 REAR BRAKE ADJUSTMENT 1. Check: S Brake pedal height a Out of specification ! Adjust. Brake pedal height: 108 mm (above the top of the footrest) 2. Adjust: S Brake pedal height *************************************** Adjustment steps: S Loosen the locknut 1 .
  • Page 28 INSP REAR BRAKE ADJUSTMENT 5. Adjust: S Brake light switch Refer to “BRAKE LIGHT SWITCH ADJUST- MENT”. –20–...

  • Page 29: Shift Pedal Adjustment

    INSP SHIFT PEDAL ADJUSTMENT EB304080 SHIFT PEDAL ADJUSTMENT 1. Check: S Shift pedal position Check the shift pedal rod length a . If the position is incorrect ! Adjust. Shift pedal rod length: 168 mm 2. Adjust: S Shift pedal position *************************************** Adjustment steps: S Loosen both locknuts 1 .

  • Page 30: Carburation

    CARB AIR INDUCTION SYSTEM EB601000 CARBURATION AIR INDUCTION SYSTEM EAS00509 AIR INDUCTION SYSTEM DIAGRAMS Reed valve A To the front cylinder head Air cut valve B To the rear cylinder head Air cleaner Carburetor joint –22–...
  • Page 31 CARB AIR INDUCTION SYSTEM 2 Nm (0.2 mSkg) 4 Nm (0.4 mSkg) Order Job/Part Q’ty Remarks Removing the air induction system Remove the parts in the order listed. Reed valve case to front cylinder head hose Reed valve case to front cylinder head pipe Reed valve case to rear cylinder head hose...
  • Page 32 CARB AIR INDUCTION SYSTEM 2 Nm (0.2 mSkg) 4 Nm (0.4 mSkg) Order Job/Part Q’ty Remarks Cover Cover 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 For installation, reverse the removal procedure.

  • Page 33: Checking The Air Induction System

    CARB AIR INDUCTION SYSTEM EAS00510 CHECKING THE AIR INDUCTION SYSTEM 1. Check: S hoses Loose connection ! Connect properly. Cracks/damage ! Replace. S pipes Cracks/damage ! Replace. 2. Check: S reed valve 1 S reed valve stopper S reed valve seat Cracks/damage ! Replace the reed valve.

  • Page 34: Chassis

    CHAS FRONT BRAKE CHASSIS FRONT BRAKE FRONT BRAKE PADS 40 Nm (4.0 mSkg) 27 Nm (2.7 mSkg) 27 Nm (2.7 mSkg) Order Job/Part Q’ty Remarks Front brake pad removal Remove the parts in the order below. Retaining bolt Brake caliper Refer to “BRAKE PAD Brake pads REPLACEMENT”.
  • Page 35 CHAS FRONT BRAKE CAUTION: Disc brake components rarely require dis- assembly. DO NOT: S disassemble components unless abso- lutely necessary; S use solvents on internal brake compo- nents; S use spent brake fluid for cleaning; (use only clean brake fluid) S allow brake fluid to come in contact with the eyes, as this may cause eye injury;...
  • Page 36 CHAS FRONT BRAKE S Loosen the brake caliper bleed screw and using a finger push the caliper pistons into the brake caliper. S Tighten the brake caliper bleed screw 2 . Brake caliper bleed screw: 6 Nm (0.6 mSkg) S Install new brake pads and a new brake pad spring.

  • Page 37: Front Brake Caliper

    CHAS FRONT BRAKE FRONT BRAKE CALIPER 7 Nm (0.7 mSkg) 30 Nm (3.0 mSkg) 6 Nm (0.6 mSkg) 40 Nm (4.0 mSkg) 27 Nm (2.7 mSkg) 27 Nm (2.7 mSkg) Order Job/Part Q’ty Remarks Front brake caliper removal Remove the parts in the order below. Brake fluid Drain Brake hose holder...
  • Page 38 CHAS FRONT BRAKE CALIPER INSTALLATION 1. Install: S Brake caliper 1 S Retaining bolt 2 27 Nm (2.7 mSkg) S Brake hose 3 S Copper washers 4 S Union bolt 5 30 Nm (3.0 mSkg) CAUTION: When installing the brake hose on the brake caliper, make sure that the brake pipe touches the projection a on the brake cali- per.
  • Page 39 CHAS FRONT BRAKE 3. Air bleed S Brake system Refer to “AIR BLEEDING (HYDRAULIC BRAKE SYSTEM)” in CHAPTER 3. 4. Check: S Brake fluid level Brake fluid level is under the “LOWER” level line ! Fill up. Refer to “BRAKE FLUID LEVEL INSPEC- TION”...
  • Page 41 XVS650A 2001 WIRING DIAGRAM 1 A.C. magneto 2 Rectifier/ regulator 3 Main switch 4 Battery 5 Main fuse 6 Starter relay 7 Starter motor 8 Relay unit 9 Fuel pump Sidestand switch Throttle position sensor (TPS) Ignitor unit Ignition coil...

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