Yamaha XVS650 '97 Manual

FOREWORD
This Supplementary Service Manual has been prepared to introduce new service and data
for the XVS650 ’97. 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 ’97
SUPPLEMENTARY
SERVICE MANUAL
1997 by Yamaha Motor Co., Ltd.
First Edition, January 1997
All rights reserved. Any reproduction or
unauthorized use without the written
permission of Yamaha Motor Co., Ltd.
is expressly prohibited.

EB001000
NOTICE
This manual was produced by the Yamaha Motor Company primarily for use by Yamaha
dealers and their qualified mechanics. 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 main-
tenance and repairs on Yamaha motorcycles has a basic understanding of the mechanical
ideas and the procedures of motorcycle repair. Repairs attempted by anyone without this
knowledge are likely to 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 or procedures will be forwarded to all authorized
Yamaha dealers and will appear in future editions of this manual where applicable.
NOTE:
Designs and specifications are subject to change without notice.
IMPORTANT INFORMATION
Particularly important information is distinguished in this manual by the following notations.
The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR
SAFETY IS INVOLVED!
Failure to follow WARNING instructions could result in severe injury or
death to the motorcycle operator, a bystander or a person inspecting or
repairing the motorcycle.
A CAUTION indicates special precautions that must be taken to avoid
damage to the motorcycle.
A NOTE provides key information to make procedures easier or clearer.
WARNING
CAUTION:
NOTE:

EB002000
HOW TO USE THIS MANUAL
MANUAL ORGANIZATION
This manual consists of chapters for the main categories of subjects. (See “Illustrated sym-
bols”)
1st title 1: This is the title of the chapter with its symbol in the upper right corner of each
page.
2nd title 2: This title indicates the section of the chapter and only appears on the first page of
each section. It is located in the upper left corner of the page.
3rd title 3: This title indicates a sub-section that is followed by step-by-step procedures
accompanied by corresponding illustrations.
EXPLODED DIAGRAMS
To help identify parts and clarify procedure steps, there are exploded diagrams at the start of
each removal and disassembly section.
1. An easy-to-see exploded diagram 4is provided for removal and disassembly jobs.
2. Numbers 5are given in the order of the jobs in the exploded diagram. A number that is
enclosed by a circle indicates a disassembly step.
3. An explanation of jobs and notes is presented in an easy-to-read way by the use of symbol
marks 6. The meanings of the symbol marks are given on the next page.
4. A job instruction chart 7accompanies the exploded diagram, providing the order of jobs,
names of parts, notes in jobs, etc.
5. For jobs requiring more information, the step-by-step format supplements 8are given in
addition to the exploded diagram and the job instruction chart.

EB003000
ILLUSTRATED SYMBOLS
Illustrated symbols 1to 9are printed on
the top right of each page and indicate the
subject of each chapter.
1General information
2Specifications
3Periodic inspections and adjustments
4Engine
5Cooling system
6Carburetion
7Chassis
8Electrical
9Troubleshooting
Illustrated symbols 0to Gare used to
identify the specifications appearing in the
text.
0Can be serviced with engine mounted
AFilling fluid
BLubricant
CSpecial tool
DTorque
EWear limit, clearance
FEngine speed
GΩ, V, A
Illustrated symbols Hto Min the exploded
diagrams indicate the types of lubricants
and lubrication points.
HApply engine oil
IApply gear oil
JApply molybdenum disulfide oil
KApply wheel bearing grease
LApply lightweight lithium-soap base grease
MApply molybdenum disulfide grease
Illustrated symbols Nto Oin the exploded
diagrams indicate where to apply a locking
agent Nand when to install new parts O.
NApply locking agent (LOCTITE)
OReplace
12
34
56
78
90
AB
CD
EFG
HIJ
KLM
NO
GEN
INFO
SPEC
INSP
ADJ ENG
COOL CARB
CHAS
–+
ELEC
TRBL
SHTG
T
R
.
.
GM
E
BLS M
LT
New

CONTENTS
GENERAL INFORMATION .............................................................................. 1
MOTORCYCLE IDENTIFICATION............................................................ 1
VEHICLE IDENTIFICATION NUMBER ............................................... 1
MODEL LABEL..................................................................................... 1
SPECIFICATIONS............................................................................................. 2
GENERAL SPECIFICATIONS ................................................................... 2
MAINTENANCE SPECIFICATIONS ......................................................... 3
ENGINE ................................................................................................ 3
ELECTRICAL......................................................................................... 3
CHASSIS .............................................................................................. 4
CABLE ROUTING ..................................................................................... 5
CARBURETION ................................................................................................ 7
AIR INDUCTION SYSTEM (AIS) <For CH, A> ........................................ 7
AIR INJECTION.................................................................................... 7
AIR CUT-OFF VALVE........................................................................... 7
AIR INDUCTION SYSTEM INSPECTION............................................ 8

– 1 –
GEN
INFO
MOTORCYCLE IDENTIFICATION
EB100000
GENERAL INFORMATION
MOTORCYCLE IDENTIFICATION
VEHICLE IDENTIFICATION NUMBER
EB100010
The vehicle identification number 1is
stamped into the right side of the steering
head.
MODEL LABEL
The model label 1is affixed to the frame.
This information will be needed to order
spare parts.

GENERAL SPECIFICATIONS SPEC
– 2 –
SPECIFICATIONS
GENERAL SPECIFICATIONS
Model Standard
Model XVS650
Model code: 4XP1/2 (CH, A)
4XR1/2 (D, F, NL, GB, E)
Basic weight (with oil and a full fuel tank): 227 kg (D, F, NL, GB, E)
229 kg (CH, A)

MAINTENANCE SPECIFICATIONS SPEC
– 3 –
MAINTENANCE SPECIFICATIONS
ENGINE
ELECTRICAL
Item Standard Limit
Carburetor:
I. D. mark 4XR 00 (D, F, NL, GB, E) 4XP 00 (CH, A) ----
Main jet (M.J) #90 ←----
Main air jet (M.A.J) #50 ←----
Jet needle (J.N) 4CZ11-3 4CT2-2 ----
Needle jet (N.J) O-6 O-4 ----
Pilot air jet (P.A.J.1) #100 ←----
Pilot outlet (P.O) 0.85 ←----
Pilot jet (P.J) #20 ←----
Bypass 1 (B.P.1) 0.8 ←----
Bypass 2 (B.P.2) 0.8 ←----
Bypass 3 (B.P.3) 0.8 ←----
Pilot screw (P.S) 2 2-1/2 ----
Valve seat size (V.S) 1.0 ←----
Starter jet (G.S.1) #17.5 ←----
Starter jet (G.S.2) 0.9 ←----
Throttle valve size (Th.V) #140 ←----
Fuel level (F.L) 7.5 ~ 8.5 mm ←----
Engine idle speed 1,150 ~ 1,250 r/min ←----
Intake vacuum 29.3 kPa
(0.29 kg/cm2, 220 mmHg) ←----
Item Standard Limit
T.C.I.:
Pickup coil resistance / color 182 ~ 222 Ωat 20˚C / Gray – Black ----
T.C.I. unit model / manufacturer J4T079 / MITSUBISHI (D, F, NL, GB, E)
J4T082 / MITSUBISHI (CH, A)
----
----
Voltage regulator:
Type Semi-conductor, short-circuit type ----
Model / manufacturer SH650D-11 / SHINDENGEN ----
No load regulated voltage 14.1 ~ 14.9 V ----
Rectifier:
Model / manufacturer SH650D-11 / SHINDENGEN ----
Capacity 25 A ----
Withstand voltage 240 V ----
Circuit breaker:
Type Fuse ----
Amperage for individual circuit
MAIN 30 A ×1 ----
HEAD LIGHT 15 A ×1 ----
SIGNALS 10 A ×1 ----
IGNITION 10 A ×1 ----
CARBURETOR HEATER 15 A ×1 ----

MAINTENANCE SPECIFICATIONS SPEC
– 4 –
CHASSIS
Tightening torques
Reserve 30 A ×1 ----
Reserve 15 A ×1 ----
Reserve 10 A ×1 ----
Part to be tightened Thread size
Tightening
torque Remarks
Nm m·kg
Brake pedal M6 8 0.8
Item Standard Limit

– 5 –
SPEC
CABLE ROUTING
CABLE ROUTING
1Thermo switch
2Spark plug lead
3Fuel tank breather hose
4Carburetor
5Fuel filter
6Fuel cock
7Fuel hose
8Fuel pump
9Ignition coil
ÅPosition the spark plug lead in front of the fuel tank.
ıPass the fuel tank breather hose through the hose
guide.
ÇPass the fuel hose through the hose guide.
ÎFasten the fuel hose.
‰To the engine
ÏPosition the hose clip tabs inward.
ÌPosition the hose clip tabs downward.

– 6 –
SPEC
CABLE ROUTING
1Fuel tank breather hose
2Carburetor
3Fuel hose
4Fuel filter
5Spark plug lead
6Fuel pump lead
7Fuel pump
8Rollover valve
9Ignition coil
ÅTo the rollover valve
ıTo the engine
ÇFrom the fuel cock
ÎPosition the hose clip tabs downward.
‰From the fuel tank
ÏThe longer stem on the rollover valve faces up.
ÌThe tabs on both hose clips should face in the
same direction.

– 7 –
CARB
AIR INDUCTION SYSTEM (AIS) <For CH, A>
CARBURETION
EB601000
AIR INDUCTION SYSTEM (AIS)
<For CH, A>
AIR INJECTION
This system burns the unburned exhaust
gases by injecting fresh air (secondary air)
at the exhaust port. This is to reduce the
output of the hydrocarbons.
When there is negative pressure around the
exhaust port, the reed valve opens and the
secondary air flows into the exhaust port.
The required temperature for burning the
unburned exhaust gases is approximately
600˚ to 700˚C.
AIR CUT-OFF VALVE
The air cut-off valve is operated by intake
gas pressure through the diaphram. Nor-
mally, this valve is opened in order to allow
fresh air to flow into the exhaust port.
When the throttle is rapidly closed, nega-
tive pressure is generated and the valve
closes in order to prevent after-burning.
VIEW 1. (NO FLOW)
When decelerating (the throttle closes), the
valve will close.
VIEW 2. (FLOW)
During normal operation the valve is open.
ÅFrom the air filter
ıTo the reed valve
ÇTo the carburetor joint

– 8 –
CARB
AIR INDUCTION SYSTEM (AIS) <For CH, A>
1Reed valve
2Air filter
3Air cut-off valve
4Carburetor joint (front cylinder)
ÅFrom the air cut-off valve
ıTo the front cylinder head
ÇTo the rear cylinder head
ÎTo the carburetor joint
AIR INDUCTION SYSTEM INSPECTION
1.Inspect:
●Hose connections
Poor connections →Properly connect.
●Hoses
●Reed valves
●Air cut-off valve
●Air filter
Cracks/damage →Replace.
Clogged →Clean.
UP
B
1
ı
Å
Ç
C
ı
Ç
ı
Î
Ç
A
1
23
C
B
Ç
ı
2
4
3
A