Yamaha XVS650 Manual

FOREWORD
This Supplementary Service Manual has been prepared to introduce new service and data for the
XVS6502001.ForcompleteserviceinformationproceduresitisnecessarytousethisSupplementary
Service Manual together with the following manual.
XVS650 ’97 SERVICE MANUAL: 4VR-AE1
XVS650 ’98 SUPPLEMENTARY SERVICE MANUAL: 4VR-AE2
XVS650 2001
SUPPLEMENTARY
SERVICE MANUAL
2000 by Yamaha Motor Co., Ltd.
First Edition, October 2000
All rights reserved. Any reproduction or
unauthorized use without the written
permission of Yamaha Motor Co., Ltd.
is expressly prohibited.

NOTE:
WARNING
CAUTION:
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 maintenance and repairs on Yamaha mo-
torcycleshas abasic understandingof themechanical ideasand theprocedures ofmotorcycle repair.
Repairs attempted by anyone without this knowledge are likely to render the motorcycle unsafe and
unfit for use.
YamahaMotorCompany,Ltd.iscontinuallystrivingtoimproveallitsmodels.Modificationsandsignifi-
cant changes in specifications or procedures will be forwarded to all authorized Yamaha dealers and
will appear in future editions of this manual where applicable.
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!
FailuretofollowWARNINGinstructions could result insevereinjuryordeathto
the motorcycle operator, a bystander or a person inspecting or repairing the
motorcycle.
ACAUTION indicates special precautions that must betaken toavoid damage
to the motorcycle.
NOTE: A NOTE provides key information to make procedures easier or clearer.

1
26
3
5
4
7
8
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. It is located in the upper left comer of the page.
3rd title 3: This title indicates a sub-section that is followed by step-by-step procedures accompa-
nied by corresponding illustrations.
EXPLODED DIAGRAMS
To help identify parts and clarify procedure steps, there are exploded diagrams at the start of each re-
moval and disassembly section.
1. An easy-to-see exploded diagram 4is provided for removal and disassembly jobs.
2. Numbers 5aregivenintheorderofthejobsintheexplodeddiagram.Anumberthatisenclosedby
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. Ajobinstructionchart 7accompaniestheexplodeddiagram,providingthe order of jobs,namesof
parts, notes in jobs, etc.
5. Forjobsrequiringmoreinformation,thestep-by-stepformatsupplements 8aregiveninadditionto
the exploded diagram and the job instruction chart.

1
3
5
7
9
11
13
15
17
2
4
8
10
12
14
6
20
23 24
18 19
21 22
16
EAS0009
SYMBOLS
The following symbols are not relevant to every
vehicle.
Symbols 1to 8indicate the subject of each
chapter.
1General information
2Specifications
3Periodic checks and adjustments
4Engine
5Carburetor(-s)
6Chassis
7Electrical system
8Troubleshooting
Symbols 9to 16 indicate the following.
9Serviceable with engine mounted
10 Filling fluid
11 Lubricant
12 Special tool
13 Tightening torque
14 Wear limit, clearance
15 Engine speed
16 Electrical data
Symbols 17 to 22 intheexplodeddiagramsindi-
cate the types of lubricants and lubrication
points.
17 Engine oil
18 Gear oil
19 Molybdenum disulfide oil
20 Wheel bearing grease
21 Lithium soap base grease
22 Molybdenum disulfide grease
Symbols 23 to 24 intheexplodeddiagramsindi-
cate the following:
23 Apply locking agent (LOCTITE)
24 Replace the part

CONTENTS
GENERAL INFORMATION 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
MOTORCYCLE IDENTIFICATION 1. . . . . . . . . . . . . . . . . . . . . . . . . . . .
VEHICLE IDENTIFICATION NUMBER 1. . . . . . . . . . . . . . . . . . . . .
MODEL LABEL 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SPECIFICATIONS 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
GENERAL SPECIFICATIONS 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
MAINTENANCE SPECIFICATIONS 3. . . . . . . . . . . . . . . . . . . . . . . . . . .
ENGINE 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHASSIS 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ELECTRICAL 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
LUBRICATION POINTS AND LUBRICANT TYPES 7. . . . . . . . . . . . . .
ENGINE 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CABLE ROUTING 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PERIODIC INSPECTIONS AND ADJUSTMENTS 18. . . . . . . . . . . . . . . . . .
INTRODUCTION 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PERIODIC MAINTENANCE/LUBRICATION INTERVALS 18. . . . . . . .
SHIFT PEDAL ADJUSTMENT 20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
HEADLIGHT BEAM ADJUSTMENT 21. . . . . . . . . . . . . . . . . . . . . . . . . . .
CARBURATION 22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
AIR INDUCTION SYSTEM 22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
AIR INDUCTION SYSTEM DIAGRAMS 22. . . . . . . . . . . . . . . . . . . . .
CHECKING THE AIR INDUCTION SYSTEM 25. . . . . . . . . . . . . . . .
CHASSIS 26. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FRONT BRAKE 26. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FRONT BRAKE PADS 26. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FRONT BRAKE CALIPER 29. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FRONT FORK 32. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FRONT FORK INSPECTION 35. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FRONT FORK ASSEMBLY 35. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
WIRING DIAGRAM

–1–
MOTORCYCLE IDENTIFICATION GEN
INFO
EB100000
GENERAL INFORMATION
MOTORCYCLE IDENTIFICATION
EB100010
VEHICLE IDENTIFICATION NUMBER
Thevehicleidentificationnumber 1isstamped
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.

–2–
GENERAL SPECIFICATIONS SPEC
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
Tail/brake light
Auxiliary light
Turn signal light
Meter light
Neutral indicator light
High beam indicator light
Turn indicator light
Engine indicator light
12 V 60 W/55 W 1
12 V 5 W/21 W 1
12 V 4W 1
12 V 21 W 4
12 V 1.7 W 1
12 V 1.7 W 1
12 V 1.7 W 1
12 V 1.7 W 1
12 V 1.7 W 1

–3–
MAINTENANCE SPECIFICATIONS SPEC
1 2 3 4
MAINTENANCE SPECIFICATIONS
ENGINE
Item Standard Limit
Connecting rod:
Oil clearance
Color code (corresponding size) 0.031 X0.055 mm
Blue Black Brown Green


Carburetor:
I.D. mark
Main jet (M.J)
Main air jet (M.A.J)
Jet needle (J.N)
Needle jet (N.J)
Pilot air jet (P.A.J.1)
Pilot outlet (P.O)
Pilot jet (P.J)
Bypass 1 (B.P.1)
Bypass 2 (B.P.2)
Bypass 3 (B.P.3)
Pilot screw (P.S)
Valve seat size (V.S)
Starter jet (G.S.1)
Starter jet (G.S.2)
Throttle valve size (Th.V)
Fuel level (F.L)
Engine idle speed
Intake vacuum
CO%
Engine oil temperature
5BN5 20 (4XRD)
5BN8 30 (4VRD)
#90
#50
4CT2-2
O-4
#100
0.85
#20
0.8
0.8
0.8
2-1/2
1.0
#17.5
0.9
#140
7.5 X8.5 mm
1,150 X1,250 r/min
29.0 kPa (0.29 kg/cm2, 220 mmHg)
3 X4%
80 X90C























–4–
MAINTENANCE SPECIFICATIONS SPEC
CHASSIS
Item Standard Limit
Front suspension:
Front fork travel
Fork spring free length
Installed length
Spring rate (K1)
Stroke (K1)
Optional spring
Oil capacity
Oil level
Oil grade
140 mm
303 mm
258 mm
3.5 N/mm (0.35 kg/mm)
0 X140 mm
No
0.462 L
110 mm
Fork oil 10W or equivalent

292 mm







Front brake:
Type
Disc outside diameter thickness
Pad thickness inner
Pad thickness outer
Master cylinder inside diameter
Caliper cylinder inside diameter
Caliper cylinder inside diameter
Brake fluid type
Single disk
298 5 mm
6.0 mm
6.0 mm
14.0 mm
30.2 mm
33.3 mm
DOT 4

4.5 mm
0.8 mm
0.8 mm





–5–
MAINTENANCE SPECIFICATIONS SPEC
ELECTRICAL
Item Standard Limit
T.C.I.:
Pickup coil resistance/color
T.C.I. unit model/manufacturer 182 X222 Ωat 20C/Gray – Black
J4T097/MITSUBISHI


Ignition coil:
Model/manufacturer
Minimum spark gap
Primary winding resistance
Secondary winding resistance
F6T541/MITSUBISHI
6 mm
3.6 X4.8 Ωat 20C
10.7 X14.5 kΩat 20C




Voltage regulator:
Type
Model/manufacturer
No load regulated voltage
Semi-conductor, short-circuit type
SH650C-11/SHINDENGEN
14.1 X14.9 V



Rectifier:
Model/manufacturer
Capacity
Withstand voltage
SH650C-11/SHINDENGEN
18 A
200 V



Electric starter system:
Type
Starter motor:
Model/manufacturer
I.D. number
Output
Brush overall length
Commutator diameter
Mica undercut
Starter relay:
Model/manufacturer
Amperage rating
Constant mesh type
SM-13/MITSUBA
SM-13
0.7 kW
10 mm
28 mm
0.7 mm
MS-5F-441/JIDECO
180 A




4 mm
27 mm



Flasher relay:
Type
Model/manufacturer
Self cancelling device
Flasher frequency
Wattage
Full transistor type
FE246BH/DENSO
No
75 X95 cycle/min
21 W 2 + 3.4 W





Fuel pump relay:
Model/manufacturer G8R-30Y-Q/OMRON 

–6–
MAINTENANCE SPECIFICATIONS SPEC
Item Standard Limit
Circuit breaker:
Type
Amperage for individual circuit
MAIN
HEADLIGHT
SIGNALS
IGNITION
CARBURETOR HEATER
Reserve
Reserve
Reserve
Fuse
30 A 1
15 A 1
10 A 1
10 A 1
15 A 1
30 A 1
15 A 1
10 A 1










–7–
LUBRICATION POINTS AND LUBRICANT TYPES SPEC
EB203000
LUBRICATION POINTS AND LUBRICANT TYPES
ENGINE
Lubrication point Symbol
Crankshaft journal
Camshaft cam lobe
Primary driven gear

–8–
CABLE ROUTING SPEC
19 Spark plug lead
20 Fuel pump
10 Sidestand switch lead
11 Rear brake switch lead
12 Horn
13 Headlight lead
14 Right handlebar switch lead
15 Main switch
16 Main switch lead
17 Fuel pump lead
18 Fuel hose
1Frame
2Clutch cable
3Left handlebar switch lead
4Fuel tank breather hose
5Speedometer cable
6Speedometer
7Speedometer light leads
8Vacuum chamber air vent hose
9Rectifier/regulator
EB206000
CABLE ROUTING

–9–
H To the speedometer light leads.
I Rectifier/regulator lead should not be out over the
bracket.
J Pass the right handlebar switch lead and headlight
lead over the other harness and leads.
K Pass the clutch cable through the cable guide.
L Fasten the sidestand switch lead and rectifier/
regulator lead with a plastic locking tie.
M Install the plastic locking tie so that it is up against
the frame projection.
N To the engine.
O Thesidestandswitchleadshouldnottouchtheshift
rod.
A Inside the motorcycle.
B Place the end of the plastic locking tie as shown.
C Fastentherearbrakeswitchlead,sidestandswitch
lead and rectifier/regulator lead with metal clamp
or plastic locking tie.
D Passthe front flasherlightleads (left and right)and
headlight lead through the headlight cover hole.
E Pass the left handlebar switch lead behind the
upper bracket.
F Fasten the left handlebar switch lead with a plastic
locking tie.
G Pass the speedometer cable, speedometer light
leads and fuel tank breather hose through the fuel
tank hole.
CABLE ROUTING SPEC

–10–
V Fasten the rear brake switch lead with a plastic
locking tie.
W To the speedometer light leads.
X Place the rectifier/regulator coupler completely
inside the motorcycle body.
Y Pass the fuel tank breather hose and vacuum
chamber air vent hose through the holder.
Z Pass the speedometer cable through the holder.
AA Place the couplers behind the steeirng head.
P Fasten the sidestand switch lead with a metal
clamp.
Q Connecttherearbrakeswitchcouplerinfrontofthe
roll over valve stay.
R Install the plastic locking tie immediately below the
cable guide bracket.
S Pass the speedometer cable through the
speedometer cable holder.
T To the rectifier/regulator.
U Passthe rear brake switch lead between the frame
and rectifier/regulator. Do not pinch the rear brake
switch lead.
CABLE ROUTING SPEC

–11–
25 Fuel tank breather hose
26 Speedometer cable
27 Ignitor unit
A Pass the tail/brake light lead
between the frame bracket and
battery box. Position the mud
guard the between the edge of
the frame bracket and the
tail/brake light lead.
B Fasten the dimmer switch lead
with a clamp.
13 Flasher light relay
14 Starter relay
15 Carburetor heater relay
16 Neutral switch lead
17 Pickup coil lead
18 A.C. magneto lead
19 Battery negative (–) lead
20 Starter motor lead
21 Battery cover
22 Battery
23 Wire harness
24 Starting circuit cut-off relay
1Frame bracket
2Dimmer switch
3Self-canceling turn signal relay
4Fuse box
5Battery positive (+) lead
6Spark plug lead
7Vacuum chamber air bent hose
8Starter cable
9Right handlebar switch lead
10 Brake hose
11 Throttle cables
12 Thermo switch lead
CABLE ROUTING SPEC

–12–
I Pass the right handlebar switch lead behind the
upper bracket.
J Cross the throttle cable in front of the guide wire.
K Fasten the brake hose grommet with a brake hose
holder.
L Place the left handlebar switch coupler on the side
of the main switch.
M Fasten the brake hose with a brake hose holder.
N Pass the left handlebar switch lead under the main
switch.
C Fastentheself-canceling turnsignalrelay leadand
battery positive (+) lead with a battery band.
D Fasten the tail/brake light lead coupler and battery
negative (–) lead coupler with a clamp.
E Fastenthe starterrelay leadandfuseboxlead with
a plastic locking tie.
F To the ignition coil.
G The end of the plastic locking tie should face
towards the under the handlebar.
H Fastentherighthandlebarswitchleadwithaplastic
locking tie.
CABLE ROUTING SPEC