Yamaha XVS650A User Manual

FOREWORD

This Supplementary Service Manual has been prepared to introduce new service and data for the XVS650A 2004. For complete service information procedures it is necessary to use this Supplementary Service Manual together with the following manual.

XVS650 ’97 SERVICE MANUAL: 4VR-AE1

XVS650A ’98 SUPPLEMENTARY SERVICE MANUAL: 5BN4-AE1

XVS650A 2001 SUPPLEMENTARY SERVICE MANUAL: 5BN4-AE2

XVS650A 2004

SUPPLEMENTARY

SERVICE MANUAL

E2003 by Yamaha Motor Co., Ltd.

First Edition, October 2003

Any reproduction or unauthorized use

without the written permission of

Yamaha Motor Co., Ltd. is expressly prohibited.

EAS00002

NOTICE

This manual was produced by the Yamaha Motor Company, Ltd. 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. Therefore, anyone who uses this book to perform maintenance and repairs on Yamaha vehicles should have a basic understanding of mechanics and the techniques to repair these types of vehicles. Repair and maintenance work attempted by anyone without this knowledge is likely to render the vehicle unsafe and unfit for use.

Yamaha Motor Company, Ltd. is continually striving to improve all 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:

Designs and specifications are subject to change without notice.

EAS00004

IMPORTANT INFORMATION

Particularly important information is distinguished in this manual by the following.

The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR SAFETY IS INVOLVED!

WARNING

CAUTION:

NOTE: A NOTE provides key information to make procedures easier or clearer.

Failure to follow WARNING instructions could result in severe injury or death the motorcycle operator, a bystander or a person checking or repairing the motorcycle.

A CAUTION indicates special precautions that must be taken to avoid damage to the motorcycle.

EB002000

HOW TO USE THIS MANUAL

MANUAL ORGANIZATION

This manual consists of chapters for the main categories of subjects. (See “Illustrated symbols”) 1st title 2nd title

3rd title

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

2. Numbers

3. An explanation of jobs and notes is presented in an easy-to-read way by the use of symbol marks

4. A job instruction chart

5. For jobs requiring more information, the step-by-step format supplements

: This is the title of the chapter with its symbol in the upper right comer of each page.

: 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.

: This title indicates a sub-section that is followed by step-by-step procedures accompa-

nied by corresponding illustrations.

is provided for removal and disassembly jobs.

are given in the order of the jobs in the exploded diagram. A number that is enclosed by

a circle indicates a disassembly step.

. The meanings of the symbol marks are given on the next page.

accompanies the exploded diagram, providing the order of jobs, names of

parts, notes in jobs, etc.

the exploded diagram and the job instruction chart.

are given in addition to

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SYMBOLS

The following symbols are not relevant to every vehicle. Symbols

chapter.

General information

Specifications

Periodic inspections and adjustments

Engine

Carburation

Chassis

Electrical

Troubleshooting

to 8 indicate the subject of each

18 19

Symbols 9 to 16 indicate the following.

Serviceable with engine mounted

Filling fluid

Lubricant

Special tool

Tightening torque

Wear limit, clearance

Engine speed

Electrical data

Symbols 17 to 22 in the exploded diagrams indicate the types of lubricants and lubrication points.

23 24

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:

Apply locking agent (LOCTITE)

Replace the part

CONTENTS

SPECIFICATIONS

GENERAL SPECIFICATIONS 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ENGINE SPECIFICATIONS 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CHASSIS SPECIFICATIONS 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ELECTRICAL SPECIFICATIONS 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CABLE ROUTING 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PERIODIC INSPECTIONS AND ADJUSTMENTS

INTRODUCTION 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PERIODIC MAINTENANCE / LUBRICATION INTERVALS 18. . . . . . . . . .

ENGINE

ENGINE REMOVAL 20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SIDESTAND AND CRANKCASE COVER (LEFT) 20. . . . . . . . . . . . . .

CARBURETION

CARBURETOR 21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ELECTRICAL

SWITCH INSPECTION 24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SWITCH CONTINUITY INSPECTION 24. . . . . . . . . . . . . . . . . . . . . . . .

CHECKING THE LED 26. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

IMMOBILIZER SYSTEM 27. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SYSTEM DIAGRAM 27. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CIRCUIT DIAGRAM 28. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

GENERAL INFORMATION 29. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

KEY ID REGISTRATION METHOD 30. . . . . . . . . . . . . . . . . . . . . . . . . . .

SELF-DIAGNOSIS ERROR CODE INDICATION 32. . . . . . . . . . . . . . .

TROUBLESHOOTING 33. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CHECKING THE IMMOBILIZER SYSTEM 34. . . . . . . . . . . . . . . . . . . .

REPLACEMENT PARTS ON TROUBLES 36. . . . . . . . . . . . . . . . . . . . .

XVS650A 2004 WIRING DIAGRAM

GENERAL SPECIFICATIONS/ENGINE SPECIFICATIONS

SPECIFICATIONS

GENERAL SPECIFICATIONS

Item Standard Limit

SPEC

Model code 5SCE/5SCK

Dimensions

Overall length Overall width Overall height Seat height Wheelbase Minimum ground clearance Minimum turning radius

Weight

Wet (with oil and a full fuel tank) Maximum load (except motorcycle)

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) 140 mm (5.5 in) 3,500 mm (137.8 in)

249 kg (549 lb) 198 kg (437 lb)

ENGINE SPECIFICATIONS

Item Standard Limit

Carburetor

I.D. mark

Main jet (M.J) Main air jet (M.A.J) Jet needle (J.N) Needle jet (N.J) Pilot air jet (P.A.J.1) Pilot outlet (P.O) Pilot jet (P.J) Bypass 1 (B.P.1) Bypass 2 (B.P.2) Bypass 3 (B.P.3) Pilot screw (P.S) Valve seat size (V.S) Starter jet (G.S.1) Strater jet (G.S.2) Throttle valve size (Th. V) Fuel level (F.L) Engine idle speed Intake vacuum Engine oil temperature

5SCE 00 (5SCE) 5SCK 10 (5SCK) #91.3 #50 4CT5-2 O-4M #100

0.85 #20

0.8

0.8 2-1/ 2

1.0 #17.5

0.9 #140

7.5 X 8.5 mm (0.30 X 0.33 in) 1,150 X 1,250 r/ min

29.3 kPa (0.30 kg/ cm 80 X 90 _C (176 X 194 _F)

, 220 mmHg)

SSS

SSS SSS SSS SSS SSS SSS SSS

SSS SSS

SSS SSS SSS SSS SSS SSS SSS SSS SSS SSS SSS SSS SSS SSS SSS SSS SSS SSS SSS SSS SSS

–1–

CHASSIS SPECIFICATIONS

Item Standard Limit

Front wheel

Wheel type Rim

Size

Material Wheel travel Wheel runout

Max. radial wheel runout

Max. lateral wheel runout

Rear wheel

Wheel type Rim

Size

Material Wheel travel Wheel runout

Max. radial wheel runout

Max. lateral wheel runout

CHASSIS SPECIFICATIONS

Spoke wheel

16 M/ C MT3.00 Steel 140 mm (5.51 in)

SSS SSS

Spoke wheel

15 M/ C MT3.50 Steel 98 mm (3.86 in)

SSS SSS

SPEC

SSS

SSS SSS SSS

1 mm (0.04 in)

0.5 mm (0.02 in)

SSS

SSS SSS SSS

1mm (0.04 in)

0.5 mm (0.02 in)

Front tire

Tire type Size Model (manufacturer)

Tire pressure (cold)

0 X 90 kg (0 X 198 lb)

90 X 198 kg (198 X 437 lb) Min. tire tread depth

Rear tire

Tire type Size Model (manufacturer)

Tire pressure (cold)

0 X 90 kg (0 X 198 lb)

90 X 198 kg (198 X 437 lb) Min. tire tread depth

With tube 130/ 90-16M/C 67S G703 (BRIDGESTONE) D404F (DUNLOP)

225 kPa (2.25 kgf/cm 225 kPa (2.25 kgf/cm

SSS

With tube 170/ 180-15M/C 77S G702 (BRIDGESTONE) D404G (DUNLOP)

225 kPa (2.25 kgf/cm 250 kPa (2.5 kgf/ cm

SSS

, 2.25 bar, 33 psi)

, 2.5 bar, 36 psi)

SSS SSS SSS SSS

SSS SSS

1.6 mm (0.06 in)

SSS SSS SSS SSS

SSS SSS

1.6 mm (0.06 in)

–2–

CHASSIS SPECIFICATIONS/

ELECTRICAL SPECIFICATIONS

Item Standard Limit

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)

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) 5 X 10 mm (0.20 X 0.39 in)

ELECTRICAL SPECIFICATIONS

Item Standard Limit

T.C.I.

Pickup coil resistance/ color

T.C.I. unit model/ manufacturer

Headlight relay

Model (manufacture) Coil resistance

189 X 231 Ω at 20_C (68_F)/ GrayBlack J4T150/ MITSUBISHI (5SCE) J4T151/ MITSUBISHI (5SCK)

ACA12115-1 (MATSUSHITA) 72 X 88 Ω at 20_C (68_F)

SPEC

SSS SSS SSS SSS SSS SSS

SSS

SSS SSS

Thermo switch

Model (manufacture)

Fuel pump relay

Model/ manufacturer

Circuit breaker

Type Amperage for individual circuit

MAIN

HEADLIGHT

SIGNALS

IGNITION

PARKING LIGHT

CARBURETOR HEATER

Reserve

Indicatior light

Immobilizer system indicator light

5FU (NIPPON THERMOSTAT)

UC-Z61B/ MITSUBISHI

Fuse

30 A 1 15 A 1 10 A 1 10 A 1 10 A 1 15 A 1 30 A 1 15 A 1 10 A 1 5 A 1

LED 1

SSS

SSS SSS SSS SSS SSS SSS SSS SSS SSS SSS

SSS

–3–

CABLE ROUTING

SPEC

1 Clutch cable 2 Fuel tank breather hose 3 Left handlebar switch lead 4 Speedometer 5 Speedometer lead 6 Speed sensor 7 Rectifier/ regulator 8 Rear brake light switch lead 9 Speedometer cable

10 Sidestand switch lead 11 Horn 12 Head pipe cover 13 Headlight lead 14 Right handlebar switch lead 15 Vacuum chamber air vent hose 16 Frame 17 Immobilizer 18 Main switch lead

19 Immobilizer lead 20 Fuel pump and ignition coil

bracket

21 Spark plug lead 22 Fuel hose 23 Fuel pump lead 24 Rectifier/ regulator lead 25 Sheet 1 26 Flap

–4–

CABLE ROUTING

SPEC

A Pass the front turn signal light leads (left and right)

through the hole of headlight cover from rear side.

B Pass the left handle bar switch lead through behind

the handle ber upper bracket so that there is no slack.

C Fasten the left handlebar switch lead to the handle-

bar with a band.

D To install the fuel tank, make sure to install the fuel

tank breather hose so that it is not bent too much.

E Pass the harness and fuel breather hose to be con-

nected to the speedometer cable and speedometer lead through the hole of fuel tank.

F Pass the harness to be connected to the speedom-

eter lead through under the wire harness.

G Rectifier / regulator lead should not be positioned

higher than the bracket.

H To the engine

I A.C. magneto lead (from the engine)

J Pickup coil lead (from the engine)

K Harness to be connected to the speed sensor (to

the wire harness)

L Push in the coupler inside of the engine lead and

crank case after the coupler is connected so that it does not come out.

–5–

CABLE ROUTING

SPEC

M Pass the speed sensor lead through inside of the

engine lead.

N Pass the side stand switch lead through inside of

the side stand bracket and install so that there is no adverse slack.

O Hold the side stand switch lead with a plastic clamp.

Any direction of the plastic clamp opening can be accepted.

P Pass the sidestand switch lead through under the

frame boss.

Q Fasten the rear brake light switch lead, sidestand

switch lead and rectifier/ regulator lead to the frame with a band.

R Position the band immediately under the T stud. S Position the band immediately under the frame

boss.

T Pass the speedometer cable through the holder on

the front fender.

U Fasten the rear brake light switch lead, side stand

switch lead and rectifier/ regulator lead to the frame with a band. They should not contact with the cylinder head cover during routing.

–6–

CABLE ROUTING

SPEC

V Position the right handle bar switch lead and head

light switch lead at the outer position of all harnesses and leads behind the frame head pipe. Particularly, the right handle bar switch lead should be positioned at the outermost section.

W Do not cross the handle bar switch lead and head

light lead at the out side of the head pipe cover. X Inside the frame Y Position of cutting section Z Harness to be connected to the speedometer lead

AA Pass the harness and fuel breather hose to be

connected to the speedometer cable and speedometer lead through the hole of fuel tank.

BB Pass the speedometer cable through the holder

of the frame.

CC Pass the fuel tank beather hose and carburetor

air vent hose through the holder of the frame.

DD Allocate the couplers for all leads behind the

frame head pipe at the rear section.

EE Allocate the coupler to be connected to the rectifi-

er/ regulator lead inside of the vehicle body and make it not to come out.

FF Pass the flap through the hole of fuel tank stay

and install. (for both right and left sides)

GG Install the sheet 1 so that the lower edge is hidden

by the frame.

–7–

+ 32 hidden pages