Yamaha XVS6501997 Manuals

Manuals and User Guides for Yamaha XVS6501997. We have 1 Yamaha XVS6501997 manual available for free PDF download: Service Manual

Yamaha XVS6501997 Service Manual

Yamaha XVS6501997 Service Manual (327 pages)

Brand: Yamaha | Category: Motorcycle | Size: 6.61 MB

Table of Contents

Section 1

9
- Important Information
  4
- How to Use this Manual
  5
- Table of Contents
  9
- Chapter 1
  11
- Motorcycle Identification
  11
- Important Information
  12
  - Lock Washers/Plates and Cotter Pins
    13
- Checking of Connections
  14
- Special Tools
  15
Section 2

19
- Specifications Spec
  19
- Chapter 2. Specifications
  21
- General Specifications
  21
- Maintenance Specifications
  24
  - Engine
    24
  - Chassis
    33
  - Electrical
    37
- General Torque Specifications
  39
- Lubrication Points and Lubricant Types
  40
  - Engine
    40
  - Chassis
    41
- Lubrication Diagrams
  42
- Cable Routing
  46
Table of Contents

55
- Chapter 3
  57
- Introduction
  57
- Periodic Inspections and Adjustments
  57
- Periodic Maintenance/Lubrication Intervals
  57
- Fuel Tank and Seats
  59
- Engine
  60
  - Valve Clearance Adjustment
    60
  - Carburetor Synchronization
    63
  - Idling Speed Adjustment
    65
  - Throttle Cable Adjustment
    66
  - Spark Plug Inspection
    67
  - Ignition Timing Check
    68
  - Compression Pressure Measurement
    70
  - Engine Oil Level Inspection
    72
  - Engine Oil Replacement
    73
  - Clutch Adjustment
    75
  - Air Filter Cleaning
    75
  - Carburetor Joint Inspection
    76
  - Fuel Line Inspection
    76
  - Breather Hose Inspection
    77
  - Exhaust System Inspection
    77
- Chassis
  78
  - Front Brake Adjustment
    78
  - Rear Brake Adjustment
    79
  - Brake Fluid Level Inspection
    80
  - Brake Pad Inspection
    81
  - Brake Shoe Inspection
    81
  - Brake Light Switch Adjustment
    81
  - Brake Hose Inspection
    82
  - Air Bleeding (Hydraulic Brake System)
    82
  - Shift Pedal Adjustment
    83
  - Final Gear Oil Level Inspection
    84
  - Final Gear Oil Replacement
    85
  - Steering Head Inspection
    85
  - Front Fork Inspection
    87
  - Rear Shock Absorber Adjustment
    88
  - Tire Inspection
    88
  - Wheel Inspection
    91
  - Spoke Inspection and Tightening
    91
  - Cable Inspection and Lubrication
    91
  - Lever and Pedal Lubrication
    92
  - Sidestand Lubrication
    92
- Electrical
  93
  - Battery Inspection
    93
  - Fuse Inspection
    98
  - Headlight Beam Adjustment
    100
  - Headlight Bulb Replacement
    100
Insp Adj

103
- Chapter 4. Engine
  105
- Engine Removal
  105
  - Mufflers, Brake Pedal and Side Cover
    105
  - Cylinder Head Covers
    107
  - Sidestand and Crankcase Cover (Left)
    109
  - Engine Mounting Bolts
    110
  - Shift Pedal Installation
    112
  - Brake Pedal Installation
    112
- Cylinder Heads
  113
  - Cylinder Head Removal
    115
  - Cylinder Head Inspection
    116
  - Cylinder Head Installation
    118
- Rocker Arms and Camshaft
  121
- Valves and Valve Springs
  125
- Cylinders and Pistons
  132
  - Piston Removal
    133
  - Cylinder and Piston Inspection
    133
  - Piston Ring Inspection
    135
  - Piston Pin Inspection
    136
  - Cylinder and Piston Installation
    137
- Clutch
  138
  - Crankcase Cover (Right)
    138
  - Clutch Assembly
    140
  - Clutch Removal
    142
  - Primary Drive Gear Removal
    142
  - Clutch Inspection
    142
  - Push Rod Inspection
    144
  - Primary Drive Gear Installation
    144
  - Clutch Installation
    144
- Shift Shaft
  146
  - Shift Shaft Inspection
    147
  - Shift Shaft Installation
    147
- Oil Pump
  149
  - Oil Pump Inspection
    151
- Ac Magneto and Starter Clutch
  152
  - Stator Coil and Pickup Coil
    152
  - Ac Magneto and Starter Clutch
    153
  - Ac Magneto Removal
    154
  - Starter Clutch Inspection
    154
  - Ac Magneto Installation
    155
- Crankshaft and Connecting Rods Crankcase
  157
  - Crankcase Separation
    160
  - Crankshaft Removal
    161
  - Crankshaft Inspection
    161
  - Crankshaft Installation
    166
  - Crankcase Assembly
    167
- Transmission
  169
  - Shift Fork Inspection
    170
  - Shift Cam Inspection
    170
  - Transmission Inspection
    170
  - Transmission Installation
    172
- Middle Gear
  173
  - Middle Driven Pinion Gear
    173
  - Middle Drive Pinion Gear
    175
  - Middle Driven Pinion Gear Removal
    176
  - Middle Drive Pinion Gear Removal
    177
  - Middle Gear Inspection
    178
  - Middle Drive Pinion Gear Installation
    178
  - Middle Driven Pinion Gear Installation
    179
  - Middle Drive Gear Shim Selection
    182
  - Gear Backlash Adjustment
    183
Carburetor

187
- Carburetor
  189
  - Carburetor Inspection
    192
  - Carburetor Assembly
    193
  - Fuel Level Adjustment
    195
  - Throttle Position Sensor (Tps) Inspection
    196
- Chapter 5. Carburetion
  189
Chassis Chas

199
- Chapter 6. Chassis
  201
- Front Wheel and Brake Disc
  201
  - Front Wheel Disassembly
    203
  - Front Wheel Inspection
    203
  - Brake Disk Inspection
    204
  - Front Wheel Assembly
    205
  - Front Wheel Installation
    205
  - Front Wheel Static Balance Adjustment
    206
- Front Brake
  208
  - Front Brake Pads
    208
  - Brake Pad Replacement
    209
  - Master Cylinder
    211
  - Master Cylinder Inspection
    213
  - Master Cylinder Assembly
    213
  - Master Cylinder Installation
    214
  - Front Brake Caliper
    216
  - Caliper Disassembly
    218
  - Caliper Inspection
    218
  - Caliper Assembly
    219
  - Caliper Installation
    219
- Rear Wheel and Rear Brake
  221
  - Muffler and Rear Brake Rod
    221
  - Rear Wheel
    222
  - Rear Wheel Removal
    225
  - Rear Wheel Disassembly
    225
  - Rear Wheel Inspection
    225
  - Rear Brake Inspection
    226
  - Rear Wheel Assembly
    227
  - Rear Brake Assembly
    228
  - Rear Wheel Installation
    228
  - Rear Wheel Static Balance Adjustment
    229
- Front Fork
  230
  - Front Fork Disassembly
    233
  - Front Fork Inspection
    234
  - Front Fork Assembly
    234
  - Front Fork Installation
    237
- Handlebar
  238
  - Handlebar Inspection
    240
  - Handlebar Installation
    240
- Steering Head
  243
  - Steering Head Remoal
    245
  - Steering Head Inspection
    245
  - Steering Head Installation
    245
- Rear Shock Absorber and Swingarm
  246
  - Handling Notes
    248
  - Notes on Disposal
    248
  - Rear Shock Absorber Inspection
    248
  - Swingarm Inspection
    249
  - Swingarm Installation
    250
  - Rear Shock Absorber Installation
    250
- Shaft Drive
  251
  - Troubleshooting
    251
  - Final Gear Backlash Measurement
    255
  - Final Gear Backlash Adjustment
    256
  - Drive Shaft
    257
  - Final Gear
    258
  - Final Drive Gear Disassembly
    259
  - Final Drive Roller Bearing Removal and Reassembly
    259
  - Final Drive/Ring Gear Positioning
    261
  - Deive Shaft Inspection
    265
  - Final Gear Case Installation
    265
Table of Contents

267
- Chapter 7. Electrical
  269
- Electrical Components
  269
- Switch Inspection
  270
  - Inspecting a Switch Shown in the Manual
    270
  - Switch Continuity Inspection
    271
- Ignition System
  273
  - Circuit Diagram
    273
  - Troubleshooting
    274
- Electric Starting System
  279
  - Circuit Diagram
    279
  - Starting Circuit Operation
    280
  - Troubleshooting
    281
  - Starter Motor
    285
  - Starter Motor Inspection
    286
  - Starter Motor Assembly
    287
- Charging System
  289
  - Circuit Diagram
    289
  - Troubleshooting
    290
- Lighting System
  292
  - Circuit Diagram
    292
  - Troubleshooting
    293
  - Lighting System Check
    295
- Signal System
  298
  - Circuit Diagram
    298
  - Troubleshooting
    300
  - Signal System Check
    302
- Fuel Pump System
  306
  - Circuit Diagram
    306
  - Fuel Pump Circuit Operation
    307
  - Troubleshooting
    308
  - Fuel Pump Test
    311
- Carburetor Heater System
  312
  - Circuit Diagram
    312
  - Troubleshooting
    313
Trbl Shtg

319
- Chapter 8. Troubleshooting
  321
- Starting Failure/Hard Starting
  321
  - Fuel System
    321
  - Electrical System
    321
  - Compression System
    322
- Poor Idle Speed Performance
  322
- Poor Medium-And High-Speed Performance
  322
- Clutch Slipping/Dragging
  323
  - Clutch Slipping
    323
  - Clutch Dragging
    323
- Faulty Gear Shifting
  323
  - Hard Shifting
    323
  - Shift Pedal Does Not Move
    323
  - Jumps-Out-Of Gear
    323
- Faulty Brake
  324
- Faulty Brake Poor Braking Effect
  324
- Front Fork Oil Leakage and Front Fork Malfunction
  324
  - Oil Leakage
    324
- Overheating
  324
- Faulty Lighting and Signal Systems
  325
  - Headlight Does Not Light
    325
  - Bulb Burnt out
    325
  - Flasher Does Not Light
    325
  - Flasher Blinks Slowly
    325
  - Flasher Remains Lit
    325
  - Flasher Blinks Quickly
    325
  - Horn Does Not Sound
    325
- Unstable Handling
  325

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