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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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
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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
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GEN
INFO
SPEC
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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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GEN
INFO
SPEC
CARB
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