Yamaha xvs650 Supplementary Service Manual
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Yamaha xvs650 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 XVS650 2001. For complete service information procedures it is necessary to use this Supplementary Service Manual together with the following manual. XVS650 ’97 SERVICE MANUAL: 4VR-AE1 XVS650 ’98 SUPPLEMENTARY SERVICE MANUAL: 4VR-AE2...

  • Page 4: Important Information

    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: How To Use This Manual

    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: XVS650: 4VRD, 4XRD Basic weight: With oil and a full fuel tank 233 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 (4XRD) 5BN8 30 (4VRD) Main jet (M.J) Main air jet (M.A.J) Jet needle (J.N)

  • Page 12: Chassis

    SPEC MAINTENANCE SPECIFICATIONS CHASSIS Item Standard Limit Front suspension: Front fork travel 140 mm Fork spring free length 303 mm 292 mm Installed length 258 mm Spring rate (K1) 3.5 N/mm (0.35 kg/mm) 0 X 140 mm Stroke (K1) Optional spring Oil capacity 0.462 L Oil level...

  • 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 J4T097/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 Fasten the sidestand switch lead with a metal V Fasten the rear brake switch lead with a plastic clamp. locking tie. Q Connect the rear brake switch coupler in front of the W To the speedometer light leads. roll over valve stay.
  • 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 Cross the throttle cable in front of the guide wire.
  • Page 21 SPEC CABLE ROUTING O Fasten the spark plug lead with a metal clamp. X Fasten the pickup coil lead, A.C. magneto lead, P Pass the ignition coil lead inside of the starter cable. neutral switch lead and starter motor lead with a Q Fasten the fuse box lead with a plastic locking tie.
  • Page 22 SPEC CABLE ROUTING AD Fasten the starter cable with a plastic locking tie. AM The wire harness and leads should not touch the AE Inside the motorcycle. rear shock absorber. AF Pass the fuel tank breather hose through the AN Fasten the wire harness and leads with a plastic holder.
  • Page 23 SPEC CABLE ROUTING AS Pass the ignitor unit leads through the battery box hole. –15–...
  • Page 24 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 25 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 26: 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 27 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 eakage. Final gear oil Final gear oil D Change.

  • Page 28: 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: 156.6 mm 2. Adjust: S Shift pedal position *************************************** Adjustment steps: S Loosen both locknuts 1 .

  • Page 29: Headlight Beam Adjustment

    INSP HEADLIGHT BEAM ADJUSTMENT EB305020 HEADLIGHT BEAM ADJUSTMENT 1. Adjust: S headlight beam (vertically) a. Turn the adjusting screw 1 in direction a or ! Headlight beam is Direction raised. ! Headlight beam is Direction Lowered. *************************************** 2. Adjust: S headlight beam (horizontally) a.

  • 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) 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) 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 40: Front Fork

    CHAS FRONT FORK FRONT FORK 20 Nm (2.0 mSkg) 23 Nm (2.3 mSkg) 7 Nm (0.7 mSkg) 30 Nm (3.0 mSkg) 10 Nm (1.0 mSkg) 40 Nm (4.0 mSkg) Order Job/Part Q’ty Remarks Front fork removal Remove the parts in the order below. Front wheel Refer to “FRONT WHEEL”.
  • Page 41 CHAS FRONT FORK 23 Nm (2.3 mSkg) 30 Nm (3.0 mSkg) Order Job/Part Q’ty Remarks Front fork disassembly Disassemblel the parts in the order below. Cap bolt O-ring Spacer collar Refer to “FRONT FORK ASSEMBLY”. Spring seat Fork spring Dust seal Retaining clip Damper rod bolt Refer to “FRONT FORK...
  • Page 42 CHAS FRONT FORK 23 Nm (2.3 mSkg) 30 Nm (3.0 mSkg) Order Job/Part Q’ty Remarks Seal spacer Slide metal Inner tube/piston metal Refer to “FRONT FORK ASSEMBLY”. Oil lock piece Outer tube For assembly, reverse the disassembly procedure. –34–...

  • Page 43: Front Fork Inspection

    CHAS FORNT FORK EB703030 FRONT FORK INSPECTION 1. Check: S Inner tube 1 S Outer tube 2 Scratches/bends/damage ! Replace. WARNING Do not attempt to straighten a bent inner tube as this may dangerously weaken the tube. 2. Measure: S Fork spring length a Over the specified limit ! Replace.
  • Page 44 CHAS FRONT FORK 1. Install: S Damper rod 1 S Rebound spring S Oil lock piece 2 S Inner tube 3 CAUTION: Allow the damper rod to slide slowly down the inner tube until it protrudes from the bot- tom, being careful not to damage the inner tube.
  • Page 45 CHAS FRONT FROK 6. Install: S Slide metal 1 S Seal spacer Use the fork seal driver weight 2 and the adapter 3 . 7. Install: S Oil seal 1 Use the fork seal driver weight 2 and the adapter 3 . Fork seal driver weight: 90890-01367 Adapter:...
  • Page 46 CHAS FRONT FORK 10. Fill: S Fork oil Each fork: 0.462 L (462 cm Fork oil 10W or equivalent. After filling up, slowly pump the fork up and down to distribute the fork oil. Oil level a : 110 mm (from the top of the inner tube fully compressed and without the fork spring)
  • Page 47 XVS650 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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