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XVS650
Yamaha XVS650 User Manual
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FRONT
WHEEL
AND
BRAKE
DISC
ICHASIAI
Order
Job
name/Part
name
O'ty
Remarks
Front
wheel
disassembly
Disassemble
the
parts
in
the
order
below.
G)
Oil
seals
1
®
Clutch
retainer
1
®
Speedometer
clutch
1
@
Oil
seal
,
®
Bearing
1
Refer
to
"FRONT
WHEEL
DISASSEM-
®
Collar
1
BL
Y/ASSEMBL
Y".
(!J
Bearing
1
For
assembly,
reverse
the
disassembly
procedure.
6-2
202
204
Table of Contents
. General Information ~
8
Default Chapter
8
Table of Contents
8
Chapter 1. General Information
16
Motorcycle Identification
16
Vehicle Identification Number
16
Model Label
16
Important Information
17
Preparation for Removal Procedures
17
Replacement Parts
17
Gaskets, Oil Seals and O-Rings
17
Bearings and Oil Seals
18
Circlips
18
Checking of Connections
19
Special Tools
20
Chapter 2. Specifications
24
General Specifications
24
Maintenance Specifications
27
Engine
27
Chassis
37
Electrical
41
General Torque Specifications
43
Lubrication Points and Lubricant Types
44
Engine
44
Chassis
45
Lubrication Diagrams
46
Cable Routing
50
Chapter 3. Periodic Inspections and Adjustments
62
Introduction
62
Periodic Maintenance/Lubrication Intervals
62
General Maintenance/Lubrication
63
Fuel Tank and Seats
65
Engine
66
Valve Clearance Adjustment
66
Carburetor Synchronization
69
Idling Speed Adjustment
71
Throttle Cable Adjustment
73
Spark Plug Inspection
73
Ignition Timing Check
75
Compression Pressure Measurement
77
Engine Oil Level Inspection
78
Engine Oil Replacement
79
Clutch Adjustment
81
Air Filter Cleaning
82
Carburetor Joint Inspection
82
Fuel Line Inspection
82
Breather Hose Inspection
83
Exhaust System Inspection
83
Chassis
84
Front Brake Adjustment
84
Rear Brake Adjustment
85
Brake Fluid Level Inspection
86
Brake Pad Inspection
87
Brake Shoe Inspection
87
Brake Light Switch Adjustment
87
Brake Hose Inspection
88
Air Bleeding (Hydraulic Brake System)
89
Shift Pedal Adjustment
89
Final Gear Oil Level Inspection
90
Final Gear Oil Replacement
91
Steering Head Inspection
91
Front Fork Inspection
93
Rear Shock Absorber Adjustment
94
Tire Inspection
94
Wheel Inspection
97
Spoke Inspection and Tightening
97
Cable Inspection and Lubrication
98
Lever and Pedal Lubrication
98
Sidestand Lubrication
98
Electrical
99
Sattery Inspection
101
Fuse Inspection
104
Headlight Beam Adjustment
106
Headlight Bulb Replacement
106
Chapter 4
108
Engine
108
Engine Removal
108
Mufflers, Brake Pedal and Side Cover
108
Cylinder Head Covers
110
Sidestand and Crankcase Cover (Left)
112
Engine Mounting Bolts
113
Shift Pedal Installation
115
Brake Pedal Installation
115
Cylinder Heads
119
Cylinder Head Inspection
119
Cylinder Head Installation
121
Rocker Arms and Camshaft
124
Rocker Arm and Camshaft Removal
125
Rocker Arm and Camshaft Inspection
125
Rocker Arm and Camshaft Installation
126
Valve and Valve Spring Removal
129
Valve and Valve Spring Inspection
129
Valve and Valve Spring Installation
133
Cylinders and Pistons
135
Piston Removal
136
Cylinder and Piston Inspection
136
Piston Ring Inspection
138
Piston Pin Inspection
139
Cylinder and Piston Installation
140
Clutch
141
Crankcase Cover (Right)
141
Clutch Removal
145
Primary Drive Gear Removal
145
Clutch Inspection
145
Push Rod Inspection
147
Primary Drive Gear Installation
147
Clutch Installation
147
Shift Shaft
150
Shift Shaft Installation
150
Oil Pump
152
Oil Pump Inspection
154
Ac Magneto and Starter Clutch
155
Stator Coil and Pickup Coil
155
Ac Magneto and Starter Clutch
156
Ac Magneto Removal
157
Starter Clutch Inspection
157
Ac Magneto Installation
158
Crankshaft and Connecting Rods
162
Crankshaft and Connecting Rods
163
Crankcase Separation
163
Crankshaft Removal
164
Crankshaft Inspection
164
Crankshaft Installation
169
Crankcase Assembly
170
Transmission
172
Shift Fork Inspection
173
Shift Cam Inspection
173
Transmission Inspection
173
Transmission Installation
175
Middle Gear
176
Middle Driven Pinion Gear
176
Middle Drive Pinion Gear
178
Middle Driven Pinion Gear Removal
179
Middle Drive Pinion Gear Removal
180
Middle Gear Inspection
181
Middle Drive Pinion Gear Installation
181
Middle Driven Pinion Gear Installation
182
Middle Drive Gear Shim Selection
185
Gear Backlash Adjustment
186
Carburetor
190
Chapter 5
194
Carburetor Assembly
194
Fuel Level Adjustment
196
Throttle Position Sensor (Tps) Inspection
197
Air Induction System (Ais) 5-1
199
Air Injection
199
Air Cut-Off Valve
199
Air Induction System Inspection
200
Front Wheel and Brake Disc
202
Chapter 6
203
FRONT WHEEL Disassembly
203
Front Wheel Inspection
204
Brake Disk Inspection
205
Front Wheel Assembly
206
Front Wheel Installation
206
Front Brake
209
Front Brake Pads
210
Brake Pad Replacement
210
Master Cylinder
214
Master Cylinder Inspection
214
MASTER CYLINDER Assembly
215
Master Cylinder Installation
215
Front Brake Caliper
217
Caliper Disassembly
218
Caliper Inspection
219
Caliper Assembly
220
Caliper Installation
220
Rear Wheel and Rear Brake
222
Muffler and Rear Brake Rod
222
Rear Wheel
223
Rear Wheel Removal
226
REAR WHEEL Disassembly
226
Rear Wheel Inspection
226
Rear Brake Inspection
227
Rear Wheel Assembly
228
REAR BRAKE Assembly
229
Rear Wheel Installation
229
Rear Wheel Static Balance Adjustment
230
Front Fork
231
FRONT FORK Disassembly
235
Front Fork Assembly
236
Front Fork Installation
239
Handlebar
242
Handlebar Inspection
243
Handlebar Installation
243
Steering Head
246
Steering Head Remoal
248
Steering Head Inspection
248
Steering Head Installation
248
Rear Shock Absorber and Swingarm
249
Handling Notes
251
Notes on Disposal
251
Rear Shock Absorber Inspection
251
Swingarm Installation
252
Rear Shock Absorber Installation
252
Swingarm Inspection
253
Shaft Drive
254
Troubleshooting
257
Final Gear Backlash Measurement
258
Final Gear Backlash Adjustment
259
Drive Shaft
260
Final Drive Gear Disassembly
262
Final Drive/Ring Gear Positioning
264
Delve SHAFT INSPECTION
268
Final Gear Case Installation
268
Chapter 7. Electrical
270
Electrical Components
270
Switch Inspection
271
Inspecting a Switch Shown in the Manual
271
Switch Continuity Inspection
272
Ignition System
275
Circuit Diagram
290
Troubleshooting
291
Circuit Diagram
299
Troubleshooting
301
Fuel Pump System
307
Fuel Pump Circuit Operation
312
Troubleshooting
314
Carburetor Heater System
314
Self·diagnosis
318
Display Order on Engine Indicator Light
318
Circuit Diagram
319
Troubleshooting
319
Troubleshooting
320
Starting Failure/Hard Starting
320
Chapter 8
320
Electrical System
320
Fuel System
320
Compression System
321
Poor Idle Speed Performance
321
Poor Medium-And High-Speed Performance
321
Table of Contents
333
General Information
334
Motorcycle Identification
334
Model Label
334
Specifications
335
General Specifications
335
Maintenance Specifications
336
Chassis
336
Cable Routing
337
Headlight Beam Adjustment
347
Headlight Bulb Replacement
348
Chassis
349
Front Fork
349
FRONT FORK Disassembly
352
Front Fork Inspection
353
Front Fork Installation
356
Steering Head
357
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Yamaha XVS650 Specifications
General
Brand
Yamaha
Model
XVS650
Category
Motorcycle
Language
English
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