Yamaha XVS650 User manual

XVS650

LIT-11616-XV-OO

YAMAHA

lIT·11616·11·16

5BN·28197·EO

XVS650AK(C)

SERVICE

MANUAL

Yamaha

Motor

Corporation, U.S.A.

First edition, August 1997

All

rights

reserved.

Any

reproduction

unauthorized use

without

the

written

permission

Yamaha

Motor

Corporation, U.S.A.

is expressly prohibited.

Printed

U.S.A.

LlT·11616·11·16

EBOO1000

NOTICE

This manual was produced by the Yamaha

Motor

Company

primarily

for

use

Yamaha

dealers and their qualified mechanics. It is

not

possible to include all the knowledge

mechanic in one manual, so

is assumed that anyone

who

uses this book

perform main-

tenance and repairs on Yamaha motorcycles has abasic understanding

the mechanical

ideas and the procedures

motorcycle repair. Repairs attempted

anyone

without

this

knowledge are likely

render the motorcycle unsafe and

unfit

for

use.

Yamaha

Motor

Company, Ltd. is continually striving to

improve

all its models. Modifications

and significant changes in specifications

procedures

will

be forwarded to all authorized

Yamaha dealers and

will

appear in future editions

this manual where applicable.

NOTE:

Designs and specifications are subject

change

without

notice.

IMPORTANT INFORMATION

Particularly

important

information is distinguished in

this

manual

the

following

notations.

The Safety Alert

Symbol

means ATTENTION! BECOME ALERT[ YOUR

SAFETY

INVOLVEDI

WARNING

NOTE:

Failure

WARNING instructions could result in severe

injury

death

the motorcycle operator, abystander

aperson inspecting or

repairing the motorcycle.

ACAUTION indicates special precautions

that

must

be taken

avoid

damage

the motorcycle.

NOTE

provides key information

make procedures easier

clearer.

EBOO2000

HOW

TO USE THIS MANUAL

MANUAL ORGANIZATION

This manual consists

chapters

for

the

main

categories

subjects. (See "Illustrated

sym~

bois")

1st title

CD:

This is the title

the

chapter

with

its

symbol

in the upper

right

corner

each

page.

2nd title

®:

This

title

indicates the section

the chapter and

only

appears on the

first

page

each section. It is located in the

upper

left

corner

the

page.

3rd title @: This

title

indicates a

sub~section

that

followed

step~by~step

procedures

accompanied

corresponding illustrations.

EXPLODED DIAGRAMS

To help

identify

parts and

clarify

procedure steps, there are exploded

diagrams

the

start

each removal and disassembly section.

1. An

easy~to-see

exploded

diagram

@is

provided

for

removal and disassembly jobs.

Numbers

®are given in the

order

the

jobs

in the exploded diagram. A

number

that

enclosed

acircle indicates adisassembly step.

An explanation

jobs and notes is presented in an easy-to-read

way

by the use

symbol

marks

The meanings

the

symbol

marks are given on

the

page.

job

instruction chart

(J)

accompanies

the

exploded diagram,

providing

the

order

jobs,

names

parts, notes in jobs, etc.

For

jobs

requiring

information,

the

step-by~step

format

supplements ®are given in

addition

the exploded

diagram

and the

job

instruction chart.

4J----+-.+--_

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011

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Qutcll___

fI_u..""..",u.._f_,

$CO<Idu....-.."".-....-,

~----..,--I

s-.lJ'

...

..........

ofltl

....

Rtf<I.1O

""NGINE

OIL

Rl:l'\AeE'

MliN'T"

CIWTeR

fl.""

"ENGlWe

REMOIII\l.·,

1 l ..70n'W'ti lit

1.$5l'1"W'ft)(\.

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1L...tS5i"1'ltft)! LSS-nwnlo1l.

4:5

JIll

3OI'fU't'iJ'J •

II~~~I~I

ISPEclo-l

II~g~1

flll

ENG

®®

ICOOll

ICARBI'ilI

(j)

ICHASI~I

IElEClol

IJ~~~

@~@[0J®~

@@®

111

®)

@ @

~~~

@®

•

III

EBOO3000

ILLUSTRATED SYMBOLS

Illustrated

symbols

®are

printed

the

top

right

each page and indicate the

subject

each chapter.

General

information

Specifications

@Periodic inspections and adjustments

@Engine

®Cooling system

®Carburetion

Chassis

®Electrical

®Troubleshooting

Illustrated

symbols

@are used

identify

the

specifications appearing in the

text.

Can

be serviced

with

engine mounted

®Filling

fluid

@Lubricant

@Special

tool

@Torque

@Wear

limit,

clearance

@Engine speed

®n,V,A

Illustrated

symbols

@in

the

exploded

diagrams

indicate

the

types

lubricants

and

lubrication

points.

Apply

engine oil

Apply

gear oil

Apply

molybdenum

disulfide

oil

®)

Apply

wheel bearing grease

Apply

lightweight

Iithium~soap

base grease

Apply

molybdenum

disulfide grease

Illustrated

symbols

®in

the

exploded

diagrams

indicate

where

apply

alocking

agent

and

when

install

new

parts ®.

Apply

locking agent (LOCTITE®)

®Replace

EBOO4000

CHAPTER

TITLES

GENERAL INFORMATION I

""-----

----1

I~~~

SPECIFICATIONS

PERIODIC

INSPECTION AND

ADJUSTMENT

ENGINE OVERHAUL

CARBURETION

CHASSIS

ELECTRICAL

TROUBLESHOOTING

SPEC

CONTENTS

CHAPTER 1.

GENERAL INFORMATION

MOTORCYCLE IDENTIFICATION

1-1

VEHICLE IDENTIFICATION NUMBER

1-1

MODEL LABEL

1-1

IMPORTANT INFORMATION 1-2

PREPARATION FOR REMOVAL PROCEDURES 1-2

REPLACEMENT PARTS 1-2

GASKETS, OIL SEALS

AND

O-RINGS 1-2

LOCK WASHERS/PLATES

AND

COITER

PINS 1-3

BEARINGS

AND

OIL SEALS 1-3

CIRCLIPS 1-3

CHECKING OF CONNECTIONS 1-4

SPECIAL TOOLS 1-5

CHAPTER

SPECIFICATIONS

GENERAL SPECIFICATIONS

2-1

MAINTENANCE SPECIFICATIONS 2-4

ENGINE 2-4

CHASSIS 2-14

ELECTRICAL 2-18

GENERAL TORQUE SPECIFICATIONS 2-20

LUBRICATION POINTS

AND

LUBRICANT TYPES 2-21

ENGINE 2-21

CHASSIS 2-22

LUBRICATION DIAGRAMS 2-23

CABLE ROUTING 2-27

GEN

INFO

SPEC

CARB

ELEC

CHAPTER

PERIODIC INSPECTIONS

AND

ADJUSTMENTS

INTRODUCTION

3-1

PERIODIC MAINTENANCE/LUBRICATION INTERVALS

3-1

GENERAL MAINTENANCE/LUBRICATION 3-2

FUEL

TANK

AND SEATS 3-4

ENGINE 3-5

VALVE CLEARANCE

ADJUSTMENT

3-5

CARBURETOR SYNCHRONIZATION 3-8

IDLING SPEED

ADJUSTMENT

3-10

THROTTLE CABLE

ADJUSTMENT

3-11

SPARK PLUG INSPECTION 3-12

IGNITION

TIMING

CHECK 3-13

COMPRESSION PRESSURE MEASUREMENT 3-15

ENGINE OIL LEVEL INSPECTION 3-17

ENGINE OIL REPLACEMENT 3-18

CLUTCH

ADJUSTMENT

3-20

AIR FILTER CLEANING 3-20

CARBURETOR

JOINT

INSPECTION 3-21

FUEL LINE INSPECTION 3-21

BREATHER HOSE INSPECTION 3-22

EXHAUST

SYSTEM INSPECTION 3-22

CHASSIS 3-23

FRONT BRAKE

ADJUSTMENT

3-23

REAR BRAKE

ADJUSTMENT

3-24

BRAKE FLUID LEVEL INSPECTION 3-25

BRAKE PAD INSPECTION 3-26

BRAKE SHOE INSPECTION 3-26

BRAKE LIGHT SWITCH

ADJUSTMENT

3-26

BRAKE HOSE INSPECTION 3-27

AIR BLEEDING (HYDRAULIC BRAKE SYSTEM) 3-27

SHIFT PEDAL

ADJUSTMENT

3-28

FINAL GEAR OIL LEVEL INSPECTION 3-29

FINAL GEAR OIL REPLACEMENT 3-30

STEERING HEAD INSPECTION 3-30

FRONT FORK INSPECTION 3-32

REAR SHOCK ABSORBER

ADJUSTMENT

3-33

TIRE INSPECTION 3-33

WHEEL INSPECTION 3-36

SPOKE INSPECTION

AND

TIGHTENING 3-36

CABLE INSPECTION

AND

LUBRICATION 3-36

LEVER

AND

PEDAL LUBRICATION 3-37

SIDESTAND LUBRICATION 3-37

ELECTRICAL 3-38

TTERY INSPECTION 3-38

FUSE INSPECTION 3-43

HEADLIGHT BEAM

ADJUSTMENT

3-45

HEADLIGHT BULB REPLACEMENT 3-45

CHAPTER

ENGINE

ENGINE REMOVAL

4-1

MUFFLERS, BRAKE PEDAL

AND

SIDE

COVER

4-1

CYLINDER HEAD

COVERS

4-3

SIDESTAND

AND

CRANKCASE

COVER

(LEFT) 4-5

ENGINE

MOUNTING

BOLTS 4-6

SHIFT PEDAL INSTALLATION 4-8

BRAKE PEDAL INSTALLATION 4-8

CYLINDER HEADS 4-9

CYLINDER HEAD REMOVAL 4-11

CYLINDER HEAD INSPECTION 4-12

CYLINDER HEAD INSTALLATION 4-14

ROCKER ARMS AND CAMSHAFT 4-17

ROCKER

ARM

AND

CAMSHAFT REMOVAL 4-18

ROCKER

ARM

AND

CAMSHAFT INSPECTION 4-18

ROCKER

ARM

AND

CAMSHAFT INSTALLATION 4-19

VALVES

AND

VALVE SPRINGS 4-21

VALVE

AND

VALVE SPRING REMOVAL 4-22

VALVE

AND

VALVE SPRING INSPECTION 4-22

VALVE

AND

VALVE SPRING INSTALLATION 4-26

CYLINDERS AND PISTONS 4-28

PISTON REMOVAL 4-29

CYLINDER

AND

PISTON INSPECTION 4-29

PISTON RING INSPECTION 4-31

PISTON PIN INSPECTION 4-32

CYLINDER

AND

PISTON INSTALLATION 4-33

CLUTCH 4-34

CRANKCASE COVER (RIGHT) 4-34

CLUTCH ASSEMBLY 4-36

CLUTCH REMOVAL 4-38

PRIMARY DRIVE GEAR REMOVAL 4-38

CLUTCH INSPECTION 4-38

PUSH ROD INSPECTION 4-40

PRIMARY

DRIVE

GEAR INSTALLATION 4-40

CLUTCH INSTALLATION 4-40

GEN

INFO

SPEC

CARB

ELEC

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