Yamaha XVS6501997 User manual

EB000000
XVS650
SERVICE MANUAL
1996 by Yamaha Motor Co.Ltd.
First edition, September 1996
All rights reserved. Any reproduction or
unauthorized use without the written
permission of Yamaha Motor Co., Ltd.
is expressly prohibited.

NOTE:
CAUTION:
EB001000 NOTICE
This manual was produced by the Yamaha Motor Company primarily for useby 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-
torcycleshasabasicunderstandingof the mechanicalideasand the proceduresofmotorcycle 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!
FailuretofollowWARNINGinstructionscouldresultinsevereinjuryordeathto
the motorcycle operator, a bystander or a person inspecting or repairing the
motorcycle.
ACAUTION indicatesspecialprecautions thatmustbe takentoavoid damage
to the motorcycle.
NOTE: A NOTE provides key information to make procedures easier or clearer.

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26
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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 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 accompa-
nied 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. Forjobsrequiring more information, the step-by-step formatsupplements 8aregiven in addition
to the exploded diagram and the job instruction chart.

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3
5
7
9
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18
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4
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10
12
14
16
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21
24 25
17
19 20
22 23
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 10 to 17 are used to identify
the specifications appearing in the text.
10 Can be serviced with engine mounted
11 Filling fluid
12 Lubricant
13 Special tool
14 Torque
15 Wear limit, clearance
16 Engine speed
17 Ω, V, A
Illustratedsymbols 18 to 23 in theexplodeddia-
grams indicate the types of lubricants and lu-
brication points.
18 Apply engine oil
19 Apply gear oil
20 Apply molybdenum disulfide oil
21 Apply wheel bearing grease
22 Apply lightweight lithium-soap base grease
23 Apply molybdenum disulfide grease
Illustratedsymbols 24 to 25 in theexplodeddia-
grams indicate where to apply locking agent 24
and when to install new parts 25.
24 Apply locking agent (LOCTITE))
25 Replace

GENERAL INFORMATION
SPECIFICATIONS
PERIODIC INSPECTION AND
ADJUSTMENTS
ENGINE OVERHAUL
CARBURETION
CHASSIS
ELECTRICAL
TROUBLESHOOTING
GEN
INFO 1
SPEC 2
INSP
ADJ 3
ENG 4
CARB 5
CHAS 6
ELEC 7
TRBL
SHTG 8
E004000 CHAPTER TITLES

GEN
INFO
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 COTTER PINS 1-3. . . . . . . . . . . . . . . .
BEARINGS AND OIL SEALS 1-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CIRCLIPS 1-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING OF CONNECTIONS 1-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SPECIAL TOOLS 1-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

GEN
INFO

1-1
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.

1-2
IMPORTANT INFORMATION GEN
INFO
EB101000
IMPORTANT INFORMATION
PREPARATION FOR REMOVAL
PROCEDURES
1. Remove all dirt, mud, dust and foreign ma-
terial before removal and disassembly.
2. Use proper tools 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
partsandplace them in trays in the order of
disassembly. This will speed up assembly
and allow for the correct installation of all
parts.
5. Keepallpartsaway from any source of fire.
EB101010
REPLACEMENT PARTS
1. Use only genuine Yamaha parts for all re-
placements. Use oil and grease recom-
mended by Yamaha for all lubrication jobs.
Otherbrandsmaybesimilarinfunctionand
appearance, but inferior in quality.
EB101020
GASKETS, OIL SEALS AND O-RINGS
1. Replace all gaskets, seals and O-rings
when overhauling the engine. All gasket
surfaces, oil seal lips and O-rings must be
cleaned.
2. Properly oil all mating parts and bearings
during reassembly. Apply grease to the oil
seal lips.

1-3
IMPORTANT INFORMATION GEN
INFO
CAUTION:
EB101030
LOCK WASHERS/PLATES AND COTTER
PINS
1. Replace all lock washers/plates 1and
cotter pins after removal. Bend lock tabs
alongtheboltornutflatsaftertheboltornut
has been tightened to specification.
EB101040
BEARINGS AND OIL SEALS
1. Install 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 liberally when
installing, if appropriate.
1Oil seal
Do not use compressed air to spin the bear-
ings dry. This will damage the bearing sur-
faces.
1Bearing
EB101050
CIRCLIPS
1. Check all circlips carefully before reas-
sembly. Always replace piston pin clips af-
ter one use. Replace distorted circlips.
When installing a circlip 1, make surethat
thesharp-edgedcorner 2ispositionedop-
positethethrust 3itreceives.Seesection-
al view.
4Shaft

1-4
CHECKING OF CONNECTIONS GEN
INFO
NOTE:
NOTE:
EB801000
CHECKING OF CONNECTIONS
Checktheconnectors for stains, rust, moisture,
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Bendupthepin 1andcon-
nect the terminals.
4. Connect:
Connector terminals
The two terminals “click” together.
5. Check:
Continuity (using a pocket tester)
If there is no continuity, clean the terminals.
When checking the wire harness be sure to
perform steps 1 to 3.
As a quick remedy, use a contact revitalizer
available at most part stores.
Check the connector with a pocket tester as
shown.

1-5
SPECIAL TOOLS GEN
INFO
EB102001
SPECIAL TOOLS
The following special tools are necessary for complete and accurate tune-up and assembly. Use only
theappropriatespecialtools;this willhelp preventdamage causedby theuse ofinappropriate toolsor
improvised techniques. Special tools may differ by shape and part number from country to country. In
such a case, two types are provided.
When placing an order, refer to the list provided below to avoid any mistakes.
Tool No. Tool name/How to use Illustration
Weight
90890-01084
Bolt
90890-01085
Slide hammer bolt/weight
These tools are used to remove the
rocker arm shaft.
90890-01231
Final gear backlash band
This tool is needed when measuring
final gear backlash.
90890-01304
Piston pin puller
This tool is used to remove the
piston pin.
90890-01312
Fuel level gauge
This gauge is used to measure the
fuel level in the float chamber.
T-handle
90890-01326
Holder
90890-01388
T-handle/damper rod holder
These tools are needed to loosen and
tighten the damper rod holding bolt.
Puller
90890-01362
Adapter
90890-04089
Flywheel puller/adapter
These tools are needed to remove
the rotor.
Weight
90890-01367
Adapter
90890-01381
Fork seal driver weight/adapter
These tools are needed when installing
the slide metal, oil seal and dust seal into
the fork.
90890-01403
Ring nut wrench
This tool is needed to loosen and tighten
the steering stem ring nut.

1-6
SPECIAL TOOLS GEN
INFO
Tool No. Tool name/How to use Illustration
90890-01701
Sheave holder
This tool is needed to hold the rotor
when removing or installing the rotor
bolt.
90890-03081
Compression gauge set
These tools are needed to measure
engine compression.
90890-03094
Vacuum gauge
This gauge is needed for carburetor
synchronization.
90890-03112
Pocket tester
This instrument is needed for checking
the electrical system.
90890-03113
Engine tachometer
This tool is needed for observing
engine rpm.
90890-03141
Timing light
This tool is necessary for checking
ignition timing.
90890-04018
Valve guide remover & installer
This tool is needed to remove and
install the valve guide.
90890-04019
Valve spring compressor
This tool is needed to remove and
install the valve assemblies.
90890-04050
Bearing retainer wrench
This tool is needed when removing or
installing the final drive shaft bearing.

1-7
SPECIAL TOOLS GEN
INFO
Tool No. Tool name/How to use Illustration
90890-04057
Bearing retainer wrench
This tool is needed when removing or
installing the middle driven shaft
bearing.
Driver
90890-04058
Installer/
remover
90890-04074
Middle driven shaft bearing driver
Plain bearing installer/remover
These tools are needed when removing
or installing the main journal bearing.
90890-04062
Universal joint holder
This tool is needed when removing or
installing the driven pinion gear nut.
90890-04080
Middle gear backlash tool
This tool is needed for the gear backlash
adjustment.
90890-04086
Clutch holding tool
This tool is needed to hold the clutch
when removing or installing the clutch
boss nut.
90890-04090
Damper spring compressor
This tool is needed when removing or
installing the damper spring.
90890-06754
Ignition checker
This instrument is necessary for checking
the ignition system components.
90890-85505
Yamaha bond No.1215
This sealant (bond) is used on crankcase
mating surfaces, etc.

GEN
INFO

SPEC
CHAPTER 2.
SPECIFICATIONS
GENERAL SPECIFICATIONS 2-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
MAINTENANCE SPECIFICATIONS 2-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ENGINE 2-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHASSIS 2-13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ELECTRICAL 2-17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
GENERAL TORQUE SPECIFICATIONS 2-19. . . . . . . . . . . . . . . . . . . . . . . . . .
LUBRICATION POINTS AND LUBRICANT TYPES 2-20. . . . . . . . . . . . . . . .
ENGINE 2-20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHASSIS 2-21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
LUBRICATION DIAGRAMS 2-22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CABLE ROUTING 2-26. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SPEC