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.
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26
3
5
4
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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.
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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
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