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Yamaha XVS650 Service Manual

Motorcycle.

Also See for XVS650

Owner's manual - 108 pages
Supplementary service manual - 47 pages
Owner's manual - 119 pages

Most useful pages: More

SELF·DIAGNOSIS Display order on engine indicator light

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Table of Contents

8
Table of Contents
- 16
  Chapter 1. General Information
  - 16
    Motorcycle Identification
    - 16
      Vehicle Identification Number
    - 16
      Model Label
  - 17
    Important Information
    - 17
      Preparation for Removal Procedures
    - 17
      Replacement Parts
    - 17
      Gaskets, Oil Seals and O-rings
    - 18
      Bearings and Oil Seals
    - 18
      Circlips
  - 19
    Checking of Connections
  - 20
    Special Tools
- 24
  Chapter 2. Specifications
  - 24
    General Specifications
  - 27
    Maintenance Specifications
    - 27
      Engine
    - 37
      Chassis
    - 41
      Electrical
  - 43
    General Torque Specifications
  - 44
    Lubrication Points and Lubricant Types
    - 44
      Engine
    - 45
      Chassis
  - 46
    Lubrication Diagrams
  - 50
    Cable Routing
- 62
  Chapter 3. Periodic Inspections and Adjustments
  - 62
    Introduction
  - 62
    Periodic Maintenance/lubrication Intervals
  - 63
    General Maintenance/lubrication
  - 65
    Fuel Tank and Seats
  - 66
    Engine
    - 66
      Valve Clearance Adjustment
    - 69
      Carburetor Synchronization
    - 71
      Idling Speed Adjustment
    - 73
      Throttle Cable Adjustment
    - 73
      Spark Plug Inspection
    - 75
      Ignition Timing Check
    - 77
      Compression Pressure Measurement
    - 78
      Engine Oil Level Inspection
    - 79
      Engine Oil Replacement
    - 81
      Clutch Adjustment
    - 82
      Air Filter Cleaning
    - 82
      Carburetor Joint Inspection
    - 82
      Fuel Line Inspection
    - 83
      Breather Hose Inspection
    - 83
      Exhaust System Inspection
  - 84
    Chassis
    - 84
      Front Brake Adjustment
    - 85
      Rear Brake Adjustment
    - 86
      Brake Fluid Level Inspection
    - 87
      Brake Pad Inspection
    - 87
      Brake Shoe Inspection
    - 87
      Brake Light Switch Adjustment
    - 88
      Brake Hose Inspection
    - 89
      Air Bleeding (hydraulic Brake System)
    - 89
      Shift Pedal Adjustment
    - 90
      Final Gear Oil Level Inspection
    - 91
      Final Gear Oil Replacement
    - 91
      Steering Head Inspection
    - 93
      Front Fork Inspection
    - 94
      Rear Shock Absorber Adjustment
    - 94
      Tire Inspection
    - 97
      Wheel Inspection
    - 97
      Spoke Inspection and Tightening
    - 98
      Cable Inspection and Lubrication
    - 98
      Lever and Pedal Lubrication
    - 98
      Sidestand Lubrication
  - 99
    Electrical
    - 101
      Sattery Inspection
    - 104
      Fuse Inspection
    - 106
      Headlight Beam Adjustment
    - 106
      Headlight Bulb Replacement
- 108
  Chapter 4 .
  - 108
    Engine
  - 108
    Engine Removal
    - 108
      Mufflers, Brake Pedal and Side Cover
    - 110
      Cylinder Head Covers
    - 112
      Sidestand and Crankcase Cover (left)
    - 113
      Engine Mounting Bolts
    - 115
      Shift Pedal Installation
    - 115
      Brake Pedal Installation
  - 119
    Cylinder Heads
    - 119
      Cylinder Head Inspection
    - 121
      Cylinder Head Installation
  - 124
    Rocker Arms and Camshaft
  - 135
    Cylinders and Pistons
    - 136
      Piston Removal
    - 136
      Cylinder and Piston Inspection
    - 138
      Piston Ring Inspection
    - 139
      Piston Pin Inspection
    - 140
      Cylinder and Piston Installation
  - 141
    Clutch
    - 141
      Crankcase Cover (right)
    - 145
      Clutch Removal
    - 145
      Primary Drive Gear Removal
    - 145
      Clutch Inspection
    - 147
      Push Rod Inspection
    - 147
      Primary Drive Gear Installation
    - 147
      Clutch Installation
  - 150
    Shift Shaft
    - 150
      Shift Shaft Installation
  - 152
    Oil Pump
    - 154
      Oil Pump Inspection
  - 155
    Ac Magneto and Starter Clutch
    - 155
      Stator Coil and Pickup Coil
    - 156
      Ac Magneto and Starter Clutch
    - 157
      Ac Magneto Removal
    - 157
      Starter Clutch Inspection
    - 158
      Ac Magneto Installation
  - 162
    Crankshaft and Connecting Rods
    - 163
      Crankshaft and Connecting Rods
    - 163
      Crankcase Separation
    - 164
      Crankshaft Removal
    - 164
      Crankshaft Inspection
    - 169
      Crankshaft Installation
    - 170
      Crankcase Assembly
  - 172
    Transmission
    - 173
      Shift Fork Inspection
    - 173
      Shift Cam Inspection
    - 173
      Transmission Inspection
    - 175
      Transmission Installation
  - 176
    Middle Gear
    - 176
      Middle Driven Pinion Gear
    - 178
      Middle Drive Pinion Gear
    - 179
      Middle Driven Pinion Gear Removal
    - 180
      Middle Drive Pinion Gear Removal
    - 181
      Middle Gear Inspection
    - 181
      Middle Drive Pinion Gear Installation
    - 182
      Middle Driven Pinion Gear Installation
    - 185
      Middle Drive Gear Shim Selection
    - 186
      Gear Backlash Adjustment
  - 190
    Carburetor
    - 194
      Carburetor Assembly
    - 196
      Fuel Level Adjustment
    - 197
      Throttle Position Sensor (tps) Inspection
  - 199
    Air Induction System (ais) 5-1
    - 199
      Air Injection
    - 199
      Air Cut-off Valve
    - 200
      Air Induction System Inspection
- 202
  Chapter 6 .
  - 202
    Front Wheel and Brake Disc
    - 203
      FRONT WHEEL DiSASSEMBLy
    - 204
      Front Wheel Inspection
    - 205
      Brake Disk Inspection
    - 206
      Front Wheel Assembly
    - 206
      Front Wheel Installation
  - 209
    Front Brake
    - 210
      Front Brake Pads
    - 210
      Brake Pad Replacement
    - 214
      Master Cylinder
    - 214
      Master Cylinder Inspection
    - 215
      MASTER CYLINDER ASSEMBLy
    - 215
      Master Cylinder Installation
    - 217
      Front Brake Caliper
    - 218
      Caliper Disassembly
    - 219
      Caliper Inspection
    - 220
      Caliper Assembly
    - 220
      Caliper Installation
  - 222
    Rear Wheel and Rear Brake
    - 222
      Muffler and Rear Brake Rod
    - 223
      Rear Wheel
    - 226
      Rear Wheel Removal
    - 226
      REAR WHEEL DiSASSEMBLy
    - 226
      Rear Wheel Inspection
    - 227
      Rear Brake Inspection
    - 228
      Rear Wheel Assembly
    - 229
      REAR BRAKE ASSEMBLy
    - 229
      Rear Wheel Installation
    - 230
      Rear Wheel Static Balance Adjustment
  - 231
    Front Fork
    - 235
      FRONT FORK DiSASSEMBLy
    - 236
      Front Fork Assembly
    - 239
      Front Fork Installation
  - 242
    Handlebar
    - 243
      Handlebar Inspection
    - 243
      Handlebar Installation
  - 246
    Steering Head
    - 248
      Steering Head Remoal
    - 248
      Steering Head Inspection
    - 248
      Steering Head Installation
  - 249
    Rear Shock Absorber and Swingarm
    - 251
      Handling Notes
    - 251
      Notes On Disposal
    - 251
      Rear Shock Absorber Inspection
    - 252
      Swingarm Installation
    - 252
      Rear Shock Absorber Installation
    - 253
      Swingarm Inspection
  - 254
    Shaft Drive
    - 257
      Troubleshooting
    - 258
      Final Gear Backlash Measurement
    - 259
      Final Gear Backlash Adjustment
    - 260
      Drive Shaft
    - 262
      Final Drive Gear Disassembly
    - 264
      Final Drive/ring Gear Positioning
    - 268
      DElVE SHAFT INSPECTION
    - 268
      Final Gear Case Installation
- 270
  Chapter 7. Electrical
  - 270
    Electrical Components
  - 271
    Switch Inspection
    - 271
      Inspecting a Switch Shown in the Manual
    - 272
      Switch Continuity Inspection
  - 275
    Ignition System
    - 290
      Circuit Diagram
    - 291
      Troubleshooting
    - 299
      Circuit Diagram
    - 301
      Troubleshooting
  - 307
    Fuel Pump System
    - 312
      Fuel Pump Circuit Operation
    - 314
      Troubleshooting
  - 314
    Carburetor Heater System
    - 318
      Self·diagnosis
    - 318
      Display Order On Engine Indicator Light
    - 319
      Circuit Diagram
    - 319
      Troubleshooting
    - 320
      Troubleshooting
- 320
  Chapter 8 .
  - 320
    Starting Failure/hard Starting
    - 320
      Fuel System
    - 320
      Electrical System
    - 321
      Compression System
  - 321
    Poor Idle Speed Performance
  - 321
    Poor Medium-and High-speed Performance
333
Table of Contents
- 334
  General Information
  - 334
    Motorcycle Identification
    - 334
      Model Label
- 335
  Specifications
  - 335
    General Specifications
  - 336
    Maintenance Specifications
    - 336
      Chassis
  - 337
    Cable Routing
    - 347
      Headlight Beam Adjustment
    - 348
      Headlight Bulb Replacement
- 349
  Chassis
  - 349
    Front Fork
    - 352
      FRONT FORK DiSASSEMBLy
    - 353
      Front Fork Inspection
    - 356
      Front Fork Installation
  - 357
    Steering Head

H

XVS650

LIT-11616-XV-OO

Table of Contents

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Chapters

Table of Contents

8
Table of Contents
- 16
  Chapter 1. General Information
  - 16
    Motorcycle Identification
    - 16
      Vehicle Identification Number
    - 16
      Model Label
  - 17
    Important Information
    - 17
      Preparation for Removal Procedures
    - 17
      Replacement Parts
    - 17
      Gaskets, Oil Seals and O-rings
    - 18
      Bearings and Oil Seals
    - 18
      Circlips
  - 19
    Checking of Connections
  - 20
    Special Tools
- 24
  Chapter 2. Specifications
  - 24
    General Specifications
  - 27
    Maintenance Specifications
    - 27
      Engine
    - 37
      Chassis
    - 41
      Electrical
  - 43
    General Torque Specifications
  - 44
    Lubrication Points and Lubricant Types
    - 44
      Engine
    - 45
      Chassis
  - 46
    Lubrication Diagrams
  - 50
    Cable Routing
- 62
  Chapter 3. Periodic Inspections and Adjustments
  - 62
    Introduction
  - 62
    Periodic Maintenance/lubrication Intervals
  - 63
    General Maintenance/lubrication
  - 65
    Fuel Tank and Seats
  - 66
    Engine
    - 66
      Valve Clearance Adjustment
    - 69
      Carburetor Synchronization
    - 71
      Idling Speed Adjustment
    - 73
      Throttle Cable Adjustment
    - 73
      Spark Plug Inspection
    - 75
      Ignition Timing Check
    - 77
      Compression Pressure Measurement
    - 78
      Engine Oil Level Inspection
    - 79
      Engine Oil Replacement
    - 81
      Clutch Adjustment
    - 82
      Air Filter Cleaning
    - 82
      Carburetor Joint Inspection
    - 82
      Fuel Line Inspection
    - 83
      Breather Hose Inspection
    - 83
      Exhaust System Inspection
  - 84
    Chassis
    - 84
      Front Brake Adjustment
    - 85
      Rear Brake Adjustment
    - 86
      Brake Fluid Level Inspection
    - 87
      Brake Pad Inspection
    - 87
      Brake Shoe Inspection
    - 87
      Brake Light Switch Adjustment
    - 88
      Brake Hose Inspection
    - 89
      Air Bleeding (hydraulic Brake System)
    - 89
      Shift Pedal Adjustment
    - 90
      Final Gear Oil Level Inspection
    - 91
      Final Gear Oil Replacement
    - 91
      Steering Head Inspection
    - 93
      Front Fork Inspection
    - 94
      Rear Shock Absorber Adjustment
    - 94
      Tire Inspection
    - 97
      Wheel Inspection
    - 97
      Spoke Inspection and Tightening
    - 98
      Cable Inspection and Lubrication
    - 98
      Lever and Pedal Lubrication
    - 98
      Sidestand Lubrication
  - 99
    Electrical
    - 101
      Sattery Inspection
    - 104
      Fuse Inspection
    - 106
      Headlight Beam Adjustment
    - 106
      Headlight Bulb Replacement
- 108
  Chapter 4 .
  - 108
    Engine
  - 108
    Engine Removal
    - 108
      Mufflers, Brake Pedal and Side Cover
    - 110
      Cylinder Head Covers
    - 112
      Sidestand and Crankcase Cover (left)
    - 113
      Engine Mounting Bolts
    - 115
      Shift Pedal Installation
    - 115
      Brake Pedal Installation
  - 119
    Cylinder Heads
    - 119
      Cylinder Head Inspection
    - 121
      Cylinder Head Installation
  - 124
    Rocker Arms and Camshaft
  - 135
    Cylinders and Pistons
    - 136
      Piston Removal
    - 136
      Cylinder and Piston Inspection
    - 138
      Piston Ring Inspection
    - 139
      Piston Pin Inspection
    - 140
      Cylinder and Piston Installation
  - 141
    Clutch
    - 141
      Crankcase Cover (right)
    - 145
      Clutch Removal
    - 145
      Primary Drive Gear Removal
    - 145
      Clutch Inspection
    - 147
      Push Rod Inspection
    - 147
      Primary Drive Gear Installation
    - 147
      Clutch Installation
  - 150
    Shift Shaft
    - 150
      Shift Shaft Installation
  - 152
    Oil Pump
    - 154
      Oil Pump Inspection
  - 155
    Ac Magneto and Starter Clutch
    - 155
      Stator Coil and Pickup Coil
    - 156
      Ac Magneto and Starter Clutch
    - 157
      Ac Magneto Removal
    - 157
      Starter Clutch Inspection
    - 158
      Ac Magneto Installation
  - 162
    Crankshaft and Connecting Rods
    - 163
      Crankshaft and Connecting Rods
    - 163
      Crankcase Separation
    - 164
      Crankshaft Removal
    - 164
      Crankshaft Inspection
    - 169
      Crankshaft Installation
    - 170
      Crankcase Assembly
  - 172
    Transmission
    - 173
      Shift Fork Inspection
    - 173
      Shift Cam Inspection
    - 173
      Transmission Inspection
    - 175
      Transmission Installation
  - 176
    Middle Gear
    - 176
      Middle Driven Pinion Gear
    - 178
      Middle Drive Pinion Gear
    - 179
      Middle Driven Pinion Gear Removal
    - 180
      Middle Drive Pinion Gear Removal
    - 181
      Middle Gear Inspection
    - 181
      Middle Drive Pinion Gear Installation
    - 182
      Middle Driven Pinion Gear Installation
    - 185
      Middle Drive Gear Shim Selection
    - 186
      Gear Backlash Adjustment
  - 190
    Carburetor
    - 194
      Carburetor Assembly
    - 196
      Fuel Level Adjustment
    - 197
      Throttle Position Sensor (tps) Inspection
  - 199
    Air Induction System (ais) 5-1
    - 199
      Air Injection
    - 199
      Air Cut-off Valve
    - 200
      Air Induction System Inspection
- 202
  Chapter 6 .
  - 202
    Front Wheel and Brake Disc
    - 203
      FRONT WHEEL DiSASSEMBLy
    - 204
      Front Wheel Inspection
    - 205
      Brake Disk Inspection
    - 206
      Front Wheel Assembly
    - 206
      Front Wheel Installation
  - 209
    Front Brake
    - 210
      Front Brake Pads
    - 210
      Brake Pad Replacement
    - 214
      Master Cylinder
    - 214
      Master Cylinder Inspection
    - 215
      MASTER CYLINDER ASSEMBLy
    - 215
      Master Cylinder Installation
    - 217
      Front Brake Caliper
    - 218
      Caliper Disassembly
    - 219
      Caliper Inspection
    - 220
      Caliper Assembly
    - 220
      Caliper Installation
  - 222
    Rear Wheel and Rear Brake
    - 222
      Muffler and Rear Brake Rod
    - 223
      Rear Wheel
    - 226
      Rear Wheel Removal
    - 226
      REAR WHEEL DiSASSEMBLy
    - 226
      Rear Wheel Inspection
    - 227
      Rear Brake Inspection
    - 228
      Rear Wheel Assembly
    - 229
      REAR BRAKE ASSEMBLy
    - 229
      Rear Wheel Installation
    - 230
      Rear Wheel Static Balance Adjustment
  - 231
    Front Fork
    - 235
      FRONT FORK DiSASSEMBLy
    - 236
      Front Fork Assembly
    - 239
      Front Fork Installation
  - 242
    Handlebar
    - 243
      Handlebar Inspection
    - 243
      Handlebar Installation
  - 246
    Steering Head
    - 248
      Steering Head Remoal
    - 248
      Steering Head Inspection
    - 248
      Steering Head Installation
  - 249
    Rear Shock Absorber and Swingarm
    - 251
      Handling Notes
    - 251
      Notes On Disposal
    - 251
      Rear Shock Absorber Inspection
    - 252
      Swingarm Installation
    - 252
      Rear Shock Absorber Installation
    - 253
      Swingarm Inspection
  - 254
    Shaft Drive
    - 257
      Troubleshooting
    - 258
      Final Gear Backlash Measurement
    - 259
      Final Gear Backlash Adjustment
    - 260
      Drive Shaft
    - 262
      Final Drive Gear Disassembly
    - 264
      Final Drive/ring Gear Positioning
    - 268
      DElVE SHAFT INSPECTION
    - 268
      Final Gear Case Installation
- 270
  Chapter 7. Electrical
  - 270
    Electrical Components
  - 271
    Switch Inspection
    - 271
      Inspecting a Switch Shown in the Manual
    - 272
      Switch Continuity Inspection
  - 275
    Ignition System
    - 290
      Circuit Diagram
    - 291
      Troubleshooting
    - 299
      Circuit Diagram
    - 301
      Troubleshooting
  - 307
    Fuel Pump System
    - 312
      Fuel Pump Circuit Operation
    - 314
      Troubleshooting
  - 314
    Carburetor Heater System
    - 318
      Self·diagnosis
    - 318
      Display Order On Engine Indicator Light
    - 319
      Circuit Diagram
    - 319
      Troubleshooting
    - 320
      Troubleshooting
- 320
  Chapter 8 .
  - 320
    Starting Failure/hard Starting
    - 320
      Fuel System
    - 320
      Electrical System
    - 321
      Compression System
  - 321
    Poor Idle Speed Performance
  - 321
    Poor Medium-and High-speed Performance
333
Table of Contents
- 334
  General Information
  - 334
    Motorcycle Identification
    - 334
      Model Label
- 335
  Specifications
  - 335
    General Specifications
  - 336
    Maintenance Specifications
    - 336
      Chassis
  - 337
    Cable Routing
    - 347
      Headlight Beam Adjustment
    - 348
      Headlight Bulb Replacement
- 349
  Chassis
  - 349
    Front Fork
    - 352
      FRONT FORK DiSASSEMBLy
    - 353
      Front Fork Inspection
    - 356
      Front Fork Installation
  - 357
    Steering Head

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