Yamaha XVS650 User manual

H
XVS650
LIT-11616-XV-OO

YAMAHA
lIT·11616·11·16
5BN·28197·EO

XVS650AK(C)
SERVICE MANUAL
©1997
by Yamaha Motor Corporation, U.S.A.
First edition, August 1997
All
rights reserved. Any reproduction or
unauthorized use without the written
permission of Yamaha Motor Corporation, U.S.A.
is expressly prohibited.
Printed
in U.S.A.
LlT·11616·11·16

EBOO1000
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 abasic 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 INVOLVEDI
A. WARNING
NOTE:
Failure to follow WARNING instructions could result in severe injury or
death
to the motorcycle operator, abystander or aperson inspecting or
repairing the motorcycle.
ACAUTION indicates special precautions
that must be taken to avoid
damage
to the motorcycle.
A
NOTE provides key information to make procedures easier or clearer.

EBOO2000
HOW TO USE THIS MANUAL
MANUAL ORGANIZATION
This manual consists of chapters for the main categories of subjects. (See "Illustrated sym~
bois")
1st title CD: This is the title of the chapter with its symbol in the upper right corner of each
page.
2nd title
®: 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 @: 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 @is provided for removal and disassembly jobs.
2. Numbers ®are given in the order of the jobs in the exploded diagram. A number that is
enclosed
by acircle indicates adisassembly step.
3. An explanation of jobs and notes is presented in an easy-to-read way by the use of symbol
marks @. The meanings of the symbol marks are given on the next page.
4. A job instruction chart (J) accompanies 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 ®are given in
addition
to the exploded diagram and the job instruction chart.
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EBOO3000
ILLUSTRATED SYMBOLS
Illustrated symbols CD to ®are printed on
the
top right of each page and indicate the
subject
of each chapter.
CD General information
Specifications
@Periodic inspections and adjustments
@Engine
®Cooling system
®Carburetion
CV Chassis
®Electrical
®Troubleshooting
Illustrated symbols @> to @are used to
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 @) to @in the exploded
diagrams indicate the types of 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 @ to ®in the exploded
diagrams indicate where to apply alocking
agent @ and when to install new parts ®.
@ Apply locking agent (LOCTITE®)
®Replace

EBOO4000
CHAPTER TITLES
GENERAL INFORMATION I ~D
""----- ----1 I~~~
SPECIFICATIONS
PERIODIC INSPECTION AND
ADJUSTMENT
ENGINE OVERHAUL
CARBURETION
CHASSIS
ELECTRICAL
TROUBLESHOOTING
~
SPEC
o

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 2.
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
o
ELEC

CHAPTER 3.
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
SA TTERY INSPECTION 3-38
FUSE INSPECTION 3-43
HEADLIGHT BEAM
ADJUSTMENT 3-45
HEADLIGHT BULB REPLACEMENT 3-45
CHAPTER 4.
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
~
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SPEC
CARB
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SHIFT SHAFT 4-42
SHIFT SHAFT INSPECTION 4-43
SHIFT SHAFT INSTALLATION 4-43
OIL
PUMP 4-45
OIL PUMP INSPECTION 4-47
AC
MAGNETO AND STARTER CLUTCH 4-48
STATOR COIL
AND PICKUP COIL 4-48
AC MAGNETO
AND STARTER CLUTCH 4-49
AC MAGNETO REMOVAL 4-50
STARTER CLUTCH INSPECTION 4-50
AC MAGNETO INSTALLATION
4-51
CRANKSHAFT AND CONNECTING RODS 4-53
CRANKCASE
~ 4-53
CRANKSHAFT
AND CONNECTING RODS 4-55
CRANKCASE SEPARATION 4-56
CRANKSHAFT REMOVAL 4-57
CRANKSHAFT INSPECTION 4-57
CRANKSHAFT INSTALLATION 4-62
CRANKCASE ASSEMBLY 4-63
TRANSMISSION 4-65
SHIFT FORK INSPECTION 4-66
SHIFT CAM INSPECTION 4-66
TRANSMISSION INSPECTION 4-66
TRANSMISSION INSTALLATION 4-68
MIDDLE GEAR 4-69
MIDDLE DRIVEN PINION GEAR 4-69
MIDDLE DRIVE PINION GEAR
4-71
MIDDLE DRIVEN PINION GEAR REMOVAL 4-72
MIDDLE DRIVE PINION GEAR REMOVAL 4-73
MIDDLE GEAR INSPECTION 4-74
MIDDLE DRIVE PINION GEAR INSTALLATION 4-74
MIDDLE DRIVEN PINION GEAR INSTALLATION 4-75
MIDDLE DRIVE GEAR
SHIM SELECTION 4-78
GEAR BACKLASH
ADJUSTMENT 4-79
CHAPTER 5.
CARBURETION
CARBURETOR 5-1
CARBURETOR INSPECTION 5-4
CARBURETOR ASSEMBLY 5-5
FUEL LEVEL
ADJUSTMENT 5-7
THROTTLE POSITION SENSOR (TPS) INSPECTION
AND ADJUSTMENT 5-8

?
•
o
~
GEN
INFO
ELEC
SPEC
TRBL
SHTG
CARB
CHAPTER 6.
CHASSIS
AIR INDUCTION SYSTEM (AIS) 5-1 0
AIR INJECTION 5-10
AIR CUT-OFF VALVE 5-10
AIR INDUCTION SYSTEM INSPECTION 5-11
REAR WHEEL
AND REAR BRAKE 6-21
MUFFLER
AND REAR BRAKE ROD 6-21
REAR WHEEL 6-22
REAR WHEEL REMOVAL 6-25
REAR WHEEL
DiSASSEMBLy 6-25
REAR WHEEL INSPECTION 6-25
REAR BRAKE INSPECTION 6-26
REAR WHEEL ASSEMBLY 6-27
REAR BRAKE ASSEMBLy 6-28
REAR WHEEL INSTALLATION 6-28
REAR WHEEL STATIC BALANCE
ADJUSTMENT 6-29
FRONT WHEEL AND BRAKE DISC 6-1
FRONT WHEEL DiSASSEMBLy 6-3
FRONT WHEEL INSPECTION 6-3
BRAKE DISK INSPECTION 6-4
FRONT WHEEL ASSEMBLY 6-5
FRONT WHEEL INSTALLATION 6-5
FRONT WHEEL STATIC BALANCE
ADJUSTMENT 6-6
FRONT BRAKE 6-8
FRONT BRAKE PADS 6-8
BRAKE PAD REPLACEMENT 6-9
MASTER CYLINDER 6-11
MASTER CYLINDER INSPECTION 6-13
MASTER CYLINDER
ASSEMBLy 6-13
MASTER CYLINDER INSTALLATION 6-14
FRONT BRAKE CALIPER 6-16
CALIPER DISASSEMBLY 6-18
CALIPER INSPECTION 6-18
CALIPER ASSEMBLY 6-19
CALIPER INSTALLATION 6-19
FRONT FORK 6-30
FRONT FORK
DiSASSEMBLy 6-34
FRONT FORK INSPECTION 6-35
FRONT FORK ASSEMBLY6-35
FRONT FORK INSTALLATION 6-38
HANDLEBAR 6-40

HANDLEBAR INSPECTION 6-42
HANDLEBAR INSTALLATION 6-42
STEERING HEAD 6-45
STEERING HEAD REMOAL 6-47
STEERING HEAD INSPECTION 6-47
STEERING HEAD INSTALLATION 6-47
REAR SHOCK ABSORBER
AND SWINGARM 6-48
HANDLING NOTES 6-50
NOTES ON DISPOSAL 6-50
REAR SHOCK ABSORBER INSPECTION 6-50
SWINGARM INSTALLATION 6-51
REAR SHOCK ABSORBER INSTALLATION 6-51
SWINGARM INSPECTION 6-52
SHAFT DRIVE 6-53
TROUBLESHOOTING 6-53
FINAL GEAR BACKLASH MEASUREMENT 6-57
FINAL GEAR BACKLASH
ADJUSTMENT 6-58
DR IVE SHAFT 6-59
FI NAL GEAR 6-60
FINAL DRIVE GEAR DISASSEMBLY 6-61
FINAL DRIVE ROLLER BEARING REMOVAL
AND REASSEMBLY .6-61
FINAL DRIVE/RING GEAR POSITIONING 6-63
DElVE SHAFT INSPECTION 6-67
FINAL GEAR CASE INSTALLATION 6-67
CHAPTER 7.
ELECTRICAL
ELECTRICAL COMPONENTS 7-1
SWITCH INSPECTION 7-2
SWITCH INSPECTION 7-2
INSPECTING ASWITCH SHOWN IN THE
MANUAL 7-2
SWITCH CONTINUITY INSPECTION 7-3
IGNITION SYSTEM 7-5
CIRCUIT DIAGRAM 7-5
TROUBLESHOOTING 7-6
ELECTRIC STARTING SYSTEM 7-11
CIRCUIT DIAGRAM 7-11
STARTING CIRCUIT OPERATION 7-12
TROUBLESHOOTING 7-13

STARTER MOTOR 7-17
STARTER MOTOR INSPECTION 7-18
STARTER MOTOR
ASSEMBLy 7-19
CHARGING SYSTEM 7-21
CIRCUIT DIAGRAM 7-21
TROUBLESHOOTING 7-22
LIGHTING SYSTEM 7-24
CIRCUIT DIAGRAM 7-24
TROUBLESHOOTING 7-25
LIGHTING SYSTEM CHECK 7-27
SIGNAL SYSTEM 7-30
CIRCUIT DIAGRAM 7-30
TROUBLESHOOTING 7-32
SIGNAL SYSTEM CHECK 7-34
FUEL
PUMP SYSTEM 7-38
CIRCUIT DIAGRAM 7-38
FUEL
PUMP CIRCUIT OPERATION 7-39
TROUBLESHOOTING 7-40
FUEL PUMP TEST 7-43
CARBURETOR HEATER
SYSTEM 7-44
CIRCUIT DIAGRAM 7-44
TROUBLESHOOTING 7-45
SELF-DIAGNOSIS 7-49
TROUBLESHOOTING 7-50
CHAPTER 8.
TROUBLESHOOTING
STARTING FAILURE/HARD STARTING 8-'
FUEL SYSTEM 8-1
ELECTRICAL SYSTEM 8-1
COMPRESSION SYSTEM 8-2
POOR IDLE SPEED PERFORMANCE 8-2
POOR IDLE SPEED PERFORMANCE 8-2
POOR
MEDIUM-AND HIGH-SPEED PERFORMANCE 8-2
POOR
MEDIUM-AND HIGH-SPEED PERFORMANCE 8-2
~
GEN
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FAULTY GEAR SHIFTING 8-3
HARD SHI
FTI NG 8-3
SHIFT PEDAL DOES
NOT MOVE 8-3
JUMPS-OUT-OF GEAR 8-3
CLUTCH SLIPPING/DRAGGING 8-3
CLUTCH SLIPPING 8-3
CLUTCH DRAGGING 8-3
OVERHEATING 8-4
OVERHEATING 8-4
FAUL
TV BRAKE 8-4
POOR BRAKING EFFECT 8-4
FRONT FORK OIL LEAKAGE
AND FRONT FORK MALFUNCTION 8-4
MALFUNCTION 8-4
OIL LEAKAGE 8-4
UNSTABLE HANDLING 8-5
UNSTABLE HANDLING 8-5
FAULTY LIGHTING
AND SIGNAL SYSTEMS 8-5
HEADLIGHT DOES
NOT LIGHT 8-5
BULB BURNT
OUT 8-5
FLASHER DOES
NOT LIGHT 8-5
FLASHER BLINKS SLOWLY 8-5
FLASHER REMAINS LIT 8-5
FLASHER BLINKS
QUiCKLy 8-5
HORN DOES
NOT SOUND 8-5
XVS650AK(C) WIRING
DIAGRAM

MOTORCYCLE IDENTIFICATION II~~~ I ~ I
EB100000
GENERAL INFORMATION
MOTORCYCLE IDENTIFICATION
EB100010
VEHICLE IDENTIFICATION NUMBER
The vehicle identification number CD is 0
stamped into the right side of the steering
head.
MODEL LABEL
The model label CD is affixed to the frame.
This information
will be needed to order
spare parts.
1 - 1

IMPORTANT INFORMATION I ~~~ I~I
EB101000
IMPORTANT INFORMATION
PREPARATION FOR REMOVAL
PROCEDURES
1.Remove all dirt, mud, dust and foreign
material before removal and disassembly.
300-008
300-016
1 - 2
2.Use propertools and cleaning equipment.
Refer to the "SPECIAL TOOLS" section.
3.When disassembling the machine, always
keep mated parts together. This includes
gears, cylinders, pistons and other parts
that have been
"mated" through normal
wear. Mated parts
must always be reused
or replaced as an assembly.
4.During machine disassembly, clean all
parts and place them in trays in the order
of disassembly. This will speed up assem-
bly and
allow for the correct installation of
all parts.
5.Keep all parts
away from any source of
fire.
ES101010
REPLACEMENT PARTS
1.Use only genuine Yamaha parts for all
replacements. Use
oil and grease recom-
mended by Yamaha
for all lubrication
jobs. Other brands
may be similar in func-
tion and appearance, but
inferior in qual-
ity.
E8101020
GASKETS, OIL SEALS AND O-RINGS
1.Replace all gaskets, seals and a-rings
when overhauling the engine. All gasket
surfaces, oil seal lips and
a-rings must be
cleaned.
2.Properly
oil all mating parts and bearings
during reassembly.
Apply grease to the
oil seal lips.

IMPORTANT INFORMATION II~~~ I~I
EB101030
LOCK WASHERS/PLATES AND COTTER
PINS
1.Replace all lock washers/plates CD and
cotter pins after removal. Bend lock tabs
along the bolt or nut flats after the bolt or
nut has been tightened to specification.
300·000
EB101040
BEARINGS AND OIL SEALS
1.1nstall bearings and oil seals so that the
manufacturer's marks or numbers are vis-
ible. When
installing oil seals, apply a
light coating of lightweight lithium base
grease
to the seal lips. Oil bearings liber-
ally when installing, if appropriate.
<D Oil seal
300·003
Do not use compressed air to spin the bear-
ings dry. This will damage the bearing sur-
faces.
<D Bearing
300-002
EB101050
CIRCLIPS
1.Check all circlips carefully before reas-
sembly.
Always replace piston pin clips
after one use. Replace distorted circlips.
When installing acirclip CD, make sure
that the sharp-edged corner ®is posi-
tioned opposite the thrust @ it receives.
See sectional
view .
..... 300_.00_1....@Shaft

CHECKING OF CONNECTIONS I ~~~ I ~ I
EB801000
CHECKING OF CONNECTIONS
Check the connectors for stains, rust, mois-
ture, etc.
1.Disconnect:
•Connector
2.Check:
•Connector
Moisture
-? Dry each terminal with an air
blower.
Stains/rust
-? Connect and disconnect the
terminals several times.
3.Check:
•Connector leads
Looseness......, Bend up the pin CD and con-
nect the terminals.
4.Connect:
•Connector terminals
NOTE: _
The two terminals "click" together.
5.Check:
•Continuity (using apocket tester)
NOTE: _
•If there is no continuity, clean the termi-
nals.
•When checking the
wire harness be sure
to perform steps 1
to 3.
•As aquick remedy, use acontact revital-
izer available at
most part stores.
•Check the connector
with apocket tester
as shown.
1-4

SPECIAL TOOLS II~~~ I ~ I
EB102001
SPECIAL TOOLS
The following special tools are necessary for complete and accurate tune-up and assembly.
Use
only the appropriate special tools; this will help prevent damage caused by the use of
inappropriate tools or improvised techniques. Special tools may differ by shape and part
number from country to country. In such acase, two types are provided.
When placing an order, refer
to the list provided below to avoid any mistakes.
P/N.YM-, YU-
For US, CDN
YS-, YK- ACC-
P/N.90890-
Except
for US, CON
Tool No.
Weight
YU-1083-3
90890-01084
Bolt
YU-1083-2
90890-01085
YM-01231
90890-01231
YU-01304
90890-01304
Tool name I How to use
Slide hammer bolt / weight
These tools are used to remove the
rocker arm shaft.
Final gear backlash band
This tool is needed when measuring
final gear backlash.
Piston pin
puller
This tool is used to remove the pis-
ton pin.
Illustration
YM-01312-A
90890-01312
T-handle
YM-01326
90890-01326
Holder
YM-01388
90890-01388
Puller
YU-33270
90890-01362
Adapter
YM-33282
90890-04089
Weight
YM-33963
90890-01367
Adapter
YM-8020
90890-01381
Fuel level gauge
This gauge is used to measure the
fuel level in the float chamber.
T-handle I
damper rod holder
These tools are needed to loosen and
tighten the damper rod holding bolt.
Flywheel
puller /adapter
These
tools are needed to remove
the rotor.
Fork seal driver weight Iadapter
These
tools are needed when install-
ing the slide metal, oil seal and dust
seal into the fork.
1-5