XVS650AN(C) Supplementary Service Manual

XVS650AN(C) Supplementary Service Manual
FOREWORD
This Supplementary Service Manual has been prepared to introduce new service and data for the
XVS650AN(C). For complete service information procedures it is necessary to use this Supplementary Service Manual together with the following manual.
XVS650AK(C) SERVICE MANUAL: LIT-11616-11-16 (5BN-28197-E0)
XVS650AN(C)
SUPPLEMENTARY
SERVICE MANUAL
 2000 by Yamaha Motor Corporation,
U.S.A. First edition, October 2000
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.
P/N LIT-11616-14-31
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 motorcycles has a basic 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.
This model has been designed and manufactured to perform within certain specifications in regard to
performance and emissions. Proper service with the correct tools is necessary to ensure that the motorcycle will operate as designed. If there is any question about a service procedure, it is imperative that
you contact a Yamaha dealer for any service information changes that apply to this model. This policy
is intended to provide the customer with the most satisfaction from his motorcycle and to conform with
federal environmental quality objectives.
Yamaha Motor Company, Ltd. is continually striving to improve all of 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:
This Service Manual contains information regarding periodic maintenance to the emission control
system. Please read this material carefully.
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!
WARNING
CAUTION:
NOTE:
Failure to follow WARNING instructions could result in severe injury or death to
the motorcycle operator, a bystander or a person inspecting or repairing the
motorcycle.
A CAUTION indicates special precautions that must be taken to avoid damage
to the motorcycle.
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.
3
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 4 is provided for removal and disassembly jobs.
2. Numbers 5 are 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 7 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 8 are given in addition to
the exploded diagram and the job instruction chart.
2
1
6
3
8
5
4
7
EAS0009
1
2
3
SYMBOLS
The following symbols are not relevant to every
vehicle.
Symbols 1 to 8 indicate the subject of each
chapter.
4
1
2
3
4
5
6
7
8
General information
Specifications
Periodic checks and adjustments
Engine
Carburetor(-s)
Chassis
Electrical system
Troubleshooting
5
6
7
8
9
10
Symbols 9 to 16 indicate the following.
11
12
9 Serviceable with engine mounted
10 Filling fluid
11 Lubricant
12 Special tool
13 Tightening torque
14 Wear limit, clearance
15 Engine speed
16 Electrical data
13
14
15
16
17
20
23
18
19
21
22
24
Symbols 17 to 22 in the exploded diagrams indicate the types of lubricants and lubrication
points.
17
18
19
20
21
22
Engine oil
Gear oil
Molybdenum disulfide oil
Wheel bearing grease
Lithium soap base grease
Molybdenum disulfide grease
Symbols 23 to 24 in the exploded diagrams indicate the following:
23 Apply locking agent (LOCTITE)
24 Replace the part
CONTENTS
GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
MOTORCYCLE IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . .
VEHICLE IDENTIFICATION NUMBER . . . . . . . . . . . . . . . . . . . . .
MODEL LABEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1
1
1
1
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
GENERAL SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
MAINTENANCE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . .
ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHASSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ELECTRICAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
LUBRICATION POINTS AND LUBRICANT TYPES . . . . . . . . . . . . . .
ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CABLE ROUTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2
2
3
3
3
4
6
6
7
PERIODIC INSPECTION AND ADJUSTMENT . . . . . . . . . . . . . . . . . . . . 16
REAR BRAKE ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
SHIFT PEDAL ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
CARBURETION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
AIR INDUCTION SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
AIR INDUCTION SYSTEM DIAGRAMS . . . . . . . . . . . . . . . . . . . . .
CHECKING THE AIR INDUCTION SYSTEM . . . . . . . . . . . . . . . .
19
19
19
22
CHASSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FRONT BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FRONT BRAKE PADS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FRONT BRAKE CALIPER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
23
23
23
26
WIRING DIAGRAM
MOTORCYCLE IDENTIFICATION
GEN
INFO
EB100000
GENERAL INFORMATION
MOTORCYCLE IDENTIFICATION
EB100010
VEHICLE IDENTIFICATION NUMBER
The vehicle identification number 1 is stamped
into the right side of the steering head.
MODEL LABEL
The model label 1 is affixed to the frame. This
information will be needed to order spare parts.
–1–
GENERAL SPECIFICATIONS
SPECIFICATIONS
GENERAL SPECIFICATIONS
Item
Model code:
Standard
XVS650A:5BNT (For U.S.A)
5BNU (For CAL)
Dimensions:
Overall length
Overall width
Overall height
Seat height
Wheelbase
Minimum ground clearance
Minimum turning radius
2,450 mm (96.5 in)
930 mm (36.6 in)
1,105 mm (43.5 in)
710 mm (28.0 in)
1,625 mm (64.0 in)
145 mm (57.1 in)
3,400 mm (133.9 in)
Basic weight:
With oil and a full fuel tank
247 kg (544.5 lb)
Bulb wattage quantity:
Headlight
Tail/brake light
Front turn signal/position light
Rear 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 8 W/27 W 1
12 V 27 W/8 W 2
12 V 27 W 2
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
–2–
SPEC
MAINTENANCE SPECIFICATIONS
SPEC
MAINTENANCE SPECIFICATIONS
ENGINE
Item
Standard
Connecting rod:
Oil clearance
Color code (corresponding size)
0.031 X 0.055 mm (0.0012 X 0.0022 in)
1 Blue 2 Black 3 Brown 4 Green
Limit
CHASSIS
Item
Standard
Front suspension:
Front fork travel
Fork spring free length
Installed length
Spring rate
Stroke
Optional spring
Oil capacity
Oil level
Oil grade
Front brake:
Type
Disc outside diameter
140 mm (5.5 in)
332.5 mm (3.1 in)
(K1)
(K1)
thickness
287.4 mm (11.3 in)
3.43 N/mm (0.343 kg/mm, 19.2 lb/in)
0 X 140 mm (0 X 5.5 in)
No
0.507 L (17.4 US oz)
95 mm (3.74 in)
Yamaha fork oil 10 WT or equivalent
Single disk
298
5 mm (11.73
Pad thickness
inner
6.0 mm (0.24 in)
Pad thickness
outer
6.0 mm (0.24 in)
Master cylinder inside diameter
Caliper cylinder inside diameter
Caliper cylinder inside diameter
Brake fluid type
Brake lever & brake pedal:
Brake lever free play (at pivot)
Brake lever free play (at lever end)
Brake pedal position
Brake pedal free play
Clutch lever free play (at pivot)
Clutch lever free play (at lever end)
0.2 in)
Limit
325.9 mm
(12.83 in)
4.5 mm
(0.18 in)
0.8 mm
(0.03 in)
0.8 mm
(0.03 in)
14.0 mm (0.55 in)
30.2 mm (1.19 in)
33.3 mm (1.31 in)
DOT 4
1 X 2 mm (0.04 X 0.08 in)
10 X 15 mm (0.39 X 0.59 in)
108 mm (4.25 in)
20 X 30 mm (0.79 X 1.18 in)
2 X 3 mm (0.08 X 0.12 in)
10 X 15 mm (0.39 X 0.59 in)
–3–
MAINTENANCE SPECIFICATIONS
SPEC
ELECTRICAL
Item
T.C.I.:
Pickup coil resistance/color
Standard
Limit
182 X 222 Ω at 20_C (68_F)/Gray –
Black
J4T088/MITSUBISHI (U.S.A)
J4T128/MITSUBISHI (CAL)
SSS
Ignition coil:
Model/manufacturer
Minimum spark gap
Primary winding resistance
Secondary winding resistance
F6T541 /MITSUBISHI
6 mm (0.24 in)
3.6 X 4.8 Ω at 20_C (68_F)
10.7 X 14.5 kΩ at 20_C (68_F)
SSS
SSS
SSS
SSS
Voltage regulator:
Type
Model/manufacturer
No load regulated voltage
Semi-conductor, short-circuit type
SH650C-11/SHINDENGEN
14.1 X 14.9 V
SSS
SSS
SSS
Rectifier:
Model/manufacturer
Capacity
Withstand voltage
SH650C-11/SHINDENGEN
18 A
200 V
SSS
SSS
SSS
Constant mesh type
SSS
SM-13/MITSUBA
SM-13
0.7 kW
10 mm (0.39 in)
0.7 mm (0.08 in)
SSS
SSS
SSS
4 mm
(0.16 in)
27 mm
(1.06 in)
SSS
MS-5F-441 /JIDECO
180 A
SSS
SSS
Flasher relay:
Type
Model/manufacturer
Self cancelling device
Flasher frequency
Wattage
Semi transistor type
FB257H/DENSO
Yes
75 X 95 cycle/min
27 W
2 + 3.4 W
SSS
SSS
SSS
SSS
SSS
Fuel pump relay:
Model/manufacturer
G8R-30Y-Q/OMRON
SSS
T.C.I. unit model/manufacturer
Electric starter system:
Type
Starter motor:
Model/manufacturer
I.D. number
Output
Brush overall length
Commutator diameter
Mica undercut
Starter relay:
Model/manufacturer
Amperage rating
28 mm (1.10 in)
–4–
SSS
SSS
MAINTENANCE SPECIFICATIONS
Item
Circuit breaker:
Type
Amperage for individual circuit
MAIN
HEADLIGHT
SIGNALS
IGNITION
CARBURETOR HEATER
Reserve
Reserve
Reserve
SPEC
Standard
Limit
Fuse
30 A 1
15 A 1
10 A 1
10 A 1
15 A 1
30 A 1
15 A 1
10 A 1
–5–
LUBRICATION POINTS AND LUBRICANT TYPES
SPEC
EB203000
LUBRICATION POINTS AND LUBRICANT TYPES
ENGINE
Symbol
Lubrication point
Crankshaft journal
Camshaft cam lobe
Primary driven gear
–6–
CABLE ROUTING
SPEC
EB206000
CABLE ROUTING
1
2
3
4
5
6
7
8
9
Frame
Clutch cable
Left handlebar switch lead
Fuel tank breather hose
Speedometer cable
Speedometer
Speedometer light leads
Vacuum chamber air vent hose
Rectifier/ regulator
10
11
12
13
14
15
16
17
18
Sidestand switch lead
Rear brake switch lead
Horn
Headlight lead
Right handlebar switch lead
Main switch
Main switch lead
Fuel pump lead
Fuel hose
–7–
19 Spark plug lead
20 Fuel pump
CABLE ROUTING
A Inside the motorcycle.
B Place the end of the plastic locking tie as shown.
C Fasten the rear brake switch lead, sidestand switch
lead and rectifier / regulator lead with metal clamp
or plastic locking tie.
D Pass the front flasher light leads (left and right) and
headlight lead through the headlight cover hole.
E Pass the left handlebar switch lead behind the
upper bracket.
F Fasten the left handlebar switch lead with a plastic
locking tie.
G Pass the speedometer cable, speedometer light
leads and fuel tank breather hose through the fuel
tank hole.
SPEC
H To the speedometer light leads.
I Rectifier/ regulator lead should not be out over the
bracket.
J Pass the right handlebar switch lead and headlight
lead over the other harness and leads.
K Pass the clutch cable through the cable guide.
L Fasten the sidestand switch lead and rectifier /
regulator lead with a plastic locking tie.
M Install the plastic locking tie so that it is up against
the frame projection.
N To the engine.
O Pass the sidestand switch and the lead wire
through the sidestand bracket.
When installing, wake sure not to have any extra
loosening.
–8–
CABLE ROUTING
P Route the sidestand switch and the lead wire under
the frame boss.
Q Fasten the sidestand switch lead with a metal
clamp.
R Connect the rear brake switch coupler in front of the
roll over valve stay.
S Install the plastic locking tie immediately below the
cable guide bracket.
T Pass the speedometer cable through the
speedometer cable holder.
U To the rectifier / regulator.
SPEC
V Pass the rear brake switch lead between the frame
and rectifier / regulator. Do not pinch the rear brake
switch lead.
W Fasten the rear brake switch lead with a plastic
locking tie.
X To the speedometer light leads.
Y Place the rectifier / regulator coupler completely
inside the motorcycle body.
Z Pass the fuel tank breather hose and vacuum
chamber air vent hose through the holder.
AA Pass the speedometer cable through the holder.
AB Place the couplers behind the steeirng head.
–9–
CABLE ROUTING
1
2
3
4
5
6
7
8
9
10
11
12
Frame bracket
Dimmer switch
Self-canceling turn signal relay
Fuse box
Battery positive (+) lead
Spark plug lead
Vacuum chamber air bent hose
Starter cable
Right handlebar switch lead
Brake hose
Throttle cables
Thermo switch lead
13
14
15
16
17
18
19
20
21
22
23
24
Flasher light relay
Starter relay
Carburetor heater relay
Neutral switch lead
Pickup coil lead
A.C. magneto lead
Battery negative (–) lead
Starter motor lead
Battery cover
Battery
Wire harness
Starting circuit cut-off relay
–10–
SPEC
25 Fuel tank breather hose
26 Speedometer cable
27 Ignitor unit
A Pass the tail / brake light lead
between the frame bracket and
battery box. Position the mud
guard the between the edge of
the frame bracket and the
tail/ brake light lead.
B Fasten the dimmer switch lead
with a clamp.
CABLE ROUTING
C Fasten the self-canceling turn signal relay lead and
battery positive (+) lead with a battery band.
D Fasten the tail / brake light lead coupler and battery
negative (–) lead coupler with a clamp.
E Fasten the starter relay lead and fuse box lead with
a plastic locking tie.
F To the ignition coil.
G The end of the plastic locking tie should face
towards the under the handlebar.
H Fasten the right handlebar switch lead with a plastic
locking tie.
SPEC
I Pass the right handlebar switch lead behind the
upper bracket.
J Fasten the brake hose grommet with a brake hose
holder.
K Place the left handlebar switch coupler on the side
of the main switch.
L Fasten the brake hose with a brake hose holder.
M Pass the left handlebar switch lead under the main
switch.
N Fasten the spark plug lead with a metal clamp.
O Pass the ignition coil lead inside of the starter cable.
P Fasten the fuse box lead with a plastic locking tie.
–11–
CABLE ROUTING
Q Fasten the battery positive (+) lead with a battery
box clamp.
R The carburetor heater relay should not touch the
wire harness.
S Fasten the wire harness with a plastic locking tie.
T Place the end of the plastic locking tie as shown.
U From the engine.
V Pass the starter motor lead over the battery
negative (–) lead.
W Fasten the pickup coil lead, A.C. magneto lead,
neutral switch lead and starter motor lead with a
plastic locking tie.
SPEC
X Fasten the battery negative (–) lead, starter motor
lead and wire harness with a plastic locking tie.
Y Fasten the wire harness with a clamp.
Z The starting safety relay must be fixed to the
battery box after connecting the wire harness.
AA Fasten the battery negative (–) lead and
tail/ brake light lead with a clamp.
AB Pass the wire harness between the frame and
battery box.
AC Fasten the starter cable with a plastic locking tie.
AD Inside the motorcycle.
–12–
CABLE ROUTING
AE Pass the fuel tank breather hose through the
holder.
AF Fasten the fuel tank breather hose with a metal
clamp.
AG Pass the speedometer cable through the front
side guide.
AH To the battery negative (–) lead.
AI To the rear fender.
AJ To the flasher light relay.
AK To the starter relay.
AL The wire harness and leads should not touch the
rear shock absorber.
SPEC
AM Fasten the wire harness and leads with a plastic
locking tie.
AN Pass the plastic band through the frame hole.
Fasten the wire harness with a plastic band at the
point where the tape is located.
AO Fasten the wire harness and leads with a plastic
locking tie.
AP Fasten the wire harness and leads with a metal
clamp.
AQ To the carburetor heater relay.
AR Pass the ignitor unit leads through the battery box
hole.
–13–
CABLE ROUTING
1
2
3
4
5
6
7
8
9
10
11
12
Front flasher light (right)
Throttle cables
Brake hose
Right handlebar switch lead
Clutch cable
Left handlebar switch lead
Front flasher light (left)
Ignition coil
Spark plug lead
Silencer
Starter cable
Speedometer cable
Neutral switch lead
Pickup coil lead
A.C. magneto lead
Thermo switch lead
Fuel tank breather hose
Rectifier/ regulator coupler
Wire harness
Throttle position sensor (TPS)
lead
21 Frame
22 Air filter case
13
14
15
16
17
18
19
20
–14–
SPEC
A Pass the throttle cables through
the cable guide.
B Pass the left handlebar switch
lead over the right handlebar
switch lead.
C Pass the clutch cable through
the cable guide.
D Fasten the handlebar switch
leads with a plastic band.
E To the ignition coil.
F Pass the starter cable between
the ignition coil and spark plug
lead.
CABLE ROUTING
G
H
I
J
To the throttle position sensor (TPS).
To the carburetor.
To the fuel tank.
Pass the neutral switch lead, pickup coil lead and
A.C. magneto lead under the ignition coil lead,
thermo switch lead and throttle position sensor
(TPS) lead.
K From the engine.
L 20 mm (0.79 in)
M Pass the thermo switch lead inside of the silencer
breather hose.
SPEC
N Fasten the wire harness and throttle position
sensor (TPS) lead with a plastic locking tie.
O Inside the motorcycle.
P Route the wire harness and throttle position sensor
(TPS) lead so they run along the bottom of the
frame tube.
Q Place the end of the plastic locking tie as shown.
R Fasten the wire harness with a plastic locking tie.
S Pass the wire harness between the air filter case
groove and frame.
–15–
REAR BRAKE ADJUSTMENT
INSP
ADJ
PERIODIC INSPECTION AND
ADJUSTMENT
EB304012
REAR BRAKE ADJUSTMENT
1. Check:
Brake pedal height a
Out of specification Adjust.
Brake pedal height:
108 mm (4.25 in)
(above the top of the footrest)
2. Adjust:
Brake pedal height
***************************************
Adjustment steps:
Loosen the locknut 1 .
Turn the adjuster 2 in or out until the specified
pedal height is obtained.
Turning in:
brake pedal height is
decreased.
Turning out:
brake pedal height is
increased.
Tighten the locknut.
Locknut:
7 Nm (0.7 mkg, 5.1 ftlb)
***************************************
3. Check:
Brake pedal free play a
Out of specification Adjust.
Free play (brake pedal):
20 30 mm (0.79 1.18 in)
4. Adjust:
Brake pedal free play
***************************************
Adjustment steps:
Turn the adjuster 1 in or out until the specified free play is obtained.
Turning in:
brake pedal free play is
decreased.
Turning out:
brake pedal free play is
increased.
CAUTION:
Make sure that there is no brake drag after
adjusting the brake pedal height and the free
play.
–16–
***************************************
REAR BRAKE ADJUSTMENT
INSP
ADJ
5. Adjust:
Brake light switch
Refer to “BRAKE LIGHT SWITCH ADJUSTMENT”.
–17–
SHIFT PEDAL ADJUSTMENT
INSP
ADJ
EB304080
SHIFT PEDAL ADJUSTMENT
1. Check:
Shift pedal position
Check the shift pedal rod length a .
If the position is incorrect Adjust.
Shift pedal rod length:
168 mm (6.6 in)
2. Adjust:
Shift pedal position
***************************************
Adjustment steps:
Loosen both locknuts 1 .
To obtain the correct pedal position turn the
shift pedal rod 2 in or out.
Turning in:
shift pedal is lowered.
Turning out:
shift pedal is raised.
Tighten both locknuts.
***************************************
NOTE:
Align the mark on the shift shaft with the center
of the slit.
Turn in the both side of the shift pedal rod more
than 4 times.
–18–
AIR INDUCTION SYSTEM
EB601000
CARBURETION
AIR INDUCTION SYSTEM
EAS00509
AIR INDUCTION SYSTEM DIAGRAMS
1
2
3
4
Reed valve
Air cut valve
Air cleaner
Carburetor joint
A To the front cylinder head
B To the rear cylinder head
–19–
CARB
AIR INDUCTION SYSTEM
CARB
2 Nm (0.2 mkg, 1.4 ftlb)
4 Nm (0.4 mkg, 2.9 ftlb)
Order
1
2
3
4
5
6
7
8
Job/Part
Q’ty
Removing the air induction system
Reed valve case to front cylinder head
hose
Reed valve case to front cylinder head
pipe
Reed valve case to rear cylinder head
hose
Reed valve case to rear cylinder head
hose
Gasket
Reed valve case to cylinder head pipe
Reed valve case to cylinder head hose
Vacuum hose 2
–20–
Remarks
Remove the parts in the order listed.
1
1
1
1
2
1
2
1
AIR INDUCTION SYSTEM
CARB
2 Nm (0.2 mkg, 1.4 ftlb)
4 Nm (0.4 mkg, 2.9 ftlb)
Order
9
10
11
12
13
14
15
16
17
18
19
Job/Part
Q’ty
Remarks
1
1
1
1
1
1
1
1
1
1
1
Cover
Cover
Vacuum hose 1
Air cut valve
Plug
Air cut valve to air cleaner hose
Air cleaner
Air Cleaner case
Bend hose
Air cut valve to reed valve hose
Reed valve
For installation, reverse the removal
procedure.
–21–
AIR INDUCTION SYSTEM
CARB
EAS00510
CHECKING THE AIR INDUCTION SYSTEM
1. Check:
hoses
Loose connection Connect properly.
Cracks/damage Replace.
pipes
Cracks/damage Replace.
2. Check:
reed valve 1
reed valve stopper
reed valve seat
Cracks/damage Replace the reed valve.
3. Measure:
reed valve bending a
Out of specification Replace the reed
valve.
Maximum reed valve bending
0.4 mm (0.016 in)
1 Surface plate
4. Check:
air cutoff valve
Cracks/damage Replace.
5. Check:
air cleaner
Cracks/damage Replace.
Clogged Clean.
–22–
FRONT BRAKE
CHAS
CHASSIS
FRONT BRAKE
FRONT BRAKE PADS
40 Nm (4.0 mkg, 28.9 ftlb)
27 Nm (2.7 mkg, 19.5 ftlb)
27 Nm (2.7 mkg, 19.5 ftlb)
Order
1
2
3
4
Job/Part
Q’ty
Remarks
Remove the parts in the order below.
Front brake pad removal
Retaining bolt
Brake caliper
Brake pads
Pad spring
2
1
2
1
Refer to “BRAKE PAD
REPLACEMENT”.
For installation, reverse the removal
procedure.
–23–
FRONT BRAKE
CHAS
CAUTION:
Disc brake components rarely require disassembly. DO NOT:
disassemble components unless absolutely necessary;
use solvents on internal brake components;
use spent brake fluid for cleaning; (use
only clean brake fluid)
allow brake fluid to come in contact with
the eyes, as this may cause eye injury;
splash brake fluid onto painted surfaces or
plastic parts, as this may cause damage;
disconnect any hydraulic connection, as
this would require the entire brake system
to be disassembled, drained, cleaned,
properly filled and bled after reassembly.
BRAKE PAD REPLACEMENT
NOTE:
It is not necessary to disassemble the brake caliper and brake hose to replace the brake pads.
1. Remove:
Retaining bolt 1
2. Remove:
Brake pads 1
NOTE:
Install new brake pad springs when the brake
pads have to be replaced.
Replace the brake pads as a set if either is
found to be worn to the wear limit.
3. Install:
Brake pads
Brake pads spring
***************************************
Installation steps:
Connect a suitable hose 1 tightely to the
brake caliper bleed screw 2 . Put the other
end of this hose into an open container.
–24–
FRONT BRAKE
CHAS
Loosen the brake caliper bleed screw and
using a finger push the caliper pistons into
the brake caliper.
Tighten the brake caliper bleed screw 2 .
Brake caliper bleed screw:
6 Nm (0.6 mkg, 4.3 ftlb)
Install new brake pads and a new brake pad
spring.
Install the brake caliper 3 and retaining bolt
4.
Bolt (brake caliper):
40 Nm (4.0 mkg, 28.9 ftlb)
Retaining bolt:
27 Nm (2.7 mkg, 19.5 ftlb)
***************************************
4. Check
Brake fluid level
Refer to “BRAKE FLUID LEVEL INSPECTION” in CHAPTER 3.
a “LOWER” level line
5. Check:
Brake lever operaiton
Soft or spongy feeling Bleed the brake
system.
Refer to “AIR BLEEDING (HYDRAULIC
BRAKE SYSTEM)” in CHAPTER 3.
–25–
FRONT BRAKE
CHAS
FRONT BRAKE CALIPER
7 Nm (0.7 mkg, 5.1 ftlb)
30 Nm (3.0 mkg, 21.7 ftlb)
6 Nm (0.6 mkg, 4.3 ftlb)
40 Nm (4.0 mkg, 28.9 ftlb)
27 Nm (2.7 mkg,
19.5 ftlb)
27 Nm (2.7 mkg, 19.5 ftlb)
Order
1
2
3
4
5
6
Job/Part
Q’ty
Remarks
Remove the parts in the order below.
Drain
Front brake caliper removal
Brake fluid
Brake hose holder
Union bolts
Copper washers
Brake hose
Retaining bolt
Brake caliper assembly
1
1
2
1
2
1
Refer to “CALIPER INSTALLATION”.
For installation, reverse the removal
procedure.
–26–
CHAS
FRONT BRAKE
CALIPER INSTALLATION
1. Install:
Brake caliper 1
Retaining bolt 2
27 Nm (2.7 mkg, 19.5 ftlb)
Brake hose 3
Copper washers 4 New
Union bolt 5
30 Nm (3.0 mkg, 21.7 ftlb)
CAUTION:
When installing the brake hose on the brake
caliper, make sure that the brake pipe
touches the projection a on the brake caliper.
WARNING
Proper brake hose routing is essential to insure safe motorcycle operation. Refer to
“CABLE ROUTING”.
2. Fill:
Brake reservoir
Recommended brake fluid:
DOT 4
CAUTION:
Brake fluid may damage painted surfaces or
plastic parts. Always clean up spilled brake
fluid immediately.
WARNING
Use only the designated quality brake fluid:
other brake fluids may deteriorate the rubber seals, causing leakage and poor brake
performance.
Refill with the same type of brake fluid: mixing brake fluids may result in a harmful
chemical reaction and lead to poor brake
performance.
Be careful that water does not enter the
master cylinder when refilling. Water will
significantly lower the boiling point of the
brake fluid and may result in vapor lock.
–27–
FRONT BRAKE
CHAS
3. Air bleed
Brake system
Refer to “AIR BLEEDING (HYDRAULIC
BRAKE SYSTEM)” in CHAPTER 3.
4. Check:
Brake fluid level
Brake fluid level is under the “LOWER” level
line Fill up.
Refer to “BRAKE FLUID LEVEL INSPECTION” in CHAPTER 3.
a “LOWER” level line
–28–
XVS650AN(C) WIRING DIAGRAM
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
COLOR CODE
B . . . . . Black
Br . . . . Brown
Ch . . . Chocolate
Dg . . . Dark green
G . . . . Green
Gy . . . Gray
L .....
Lg . . . .
O ....
P .....
R.....
Sb . . . .
Blue
Light green
Orange
Pink
Red
Sky blue
W ....
Y .....
B/L . . .
B/W . .
B/Y . . .
Br/B . .
White
Yellow
Black/Blue
Black/White
Black/Yellow
Brown/Black
Br/L . .
Br/W .
Br/Y . .
G/Y . .
L/B . . .
L/R . . .
Brown/Blue
Brown/White
Brown/Yellow
Green/Yellow
Blue/Black
Blue/Red
L/W . .
L/Y . . .
R/B . . .
R/W . .
R/Y . . .
Blue/White
Blue/Yellow
Red/Black
Red/White
Red/Yellow
A.C. magneto
Rectifier/ regulator
Main switch
Battery
Main fuse
Starter relay
Starter motor
Relay unit
Fuel pump
Sidestand switch
Throttle position sensor (TPS)
Ignitor unit
Ignition coil
Spark plug
Pickup coil
Neutral switch
Meter assembly
Engine indicator light
Neutral indicator light
Meter light
High beam indicator light
Turn indicator light
Rear turn signal
Front turn signal
Headlight
Left handlebar switch
Dimmer switch
Horn switch
Clutch switch
Turn switch
Flasher relay
Horn
Rear brake switch
Tail/ brake light
Carburetor heater
Carburetor heater earth
Carburetor heater relay
Thermo switch
Carburetor heater fuse
Signal system fuse
Headlight fuse
Ignition fuse
Right handlebar switch
Front brake switch
Engine stop switch
Start switch
PRINTED IN U.S.A.
99 S 11 - 0.4 1
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