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

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.

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.

23 24

18 19

21 22

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

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