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 All rights reserved.
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.
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The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR |
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SAFETY IS INVOLVED! |
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WARNING |
Failure to follow WARNING instructions could result in severe injury or death to |
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the motorcycle operator, a bystander or a person checking or repairing the mo- |
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torcycle. |
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A CAUTION indicates special precautions that must be taken to avoid damage |
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CAUTION: |
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to the motorcycle. |
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NOTE: |
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A NOTE provides key information to make procedures easier or clearer. |
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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 |
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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- |
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nied 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
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5
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24 |
EAS0009
SYMBOLS
The following symbols are not relevant to every vehicle.
Symbols 1 to 8 indicate the subject of each chapter.
1General information
2Specifications
3Periodic inspections and adjustments
4Engine
5Carburation
6Chassis
7Electrical
8Troubleshooting
Symbols 9 to 16 indicate the following.
9 Serviceable with engine mounted
10Filling fluid
11Lubricant
12Special tool
13Tightening torque
14Wear limit, clearance
15Engine speed
16Electrical data
Symbols 17 to 22 in the exploded diagrams indicate the types of lubricants and lubrication points.
17Engine oil
18Gear oil
19Molybdenum disulfide oil
20Wheel bearing grease
21Lithium soap base grease
22Molybdenum disulfide grease
Symbols 23 to 24 in the exploded diagrams indicate the following:
23Apply locking agent (LOCTITE )
24Replace the part
CONTENTS |
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SPECIFICATIONS |
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GENERAL SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . |
1 |
ENGINE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . |
1 |
CHASSIS SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . |
2 |
ELECTRICAL SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . |
3 |
CABLE ROUTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . |
4 |
PERIODIC INSPECTIONS AND ADJUSTMENTS |
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INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . |
18 |
PERIODIC MAINTENANCE/LUBRICATION INTERVALS . . . . . . . . . . |
18 |
ENGINE |
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ENGINE REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . |
20 |
SIDESTAND AND CRANKCASE COVER (LEFT) . . . . . . . . . . . . . . |
20 |
CARBURETION |
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CARBURETOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . |
21 |
ELECTRICAL |
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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 |
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GENERAL SPECIFICATIONS/ENGINE SPECIFICATIONS |
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SPEC |
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SPECIFICATIONS |
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GENERAL SPECIFICATIONS |
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Item |
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Standard |
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Limit |
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Model code |
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5SCE/5SCK |
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SSS |
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Dimensions |
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Overall length |
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2,450 mm (96.5 in) |
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Overall width |
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930 mm (36.6 in) |
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SSS |
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Overall height |
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1,105 mm (43.5 in) |
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SSS |
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Seat height |
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710 mm (28.0 in) |
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SSS |
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Wheelbase |
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1,625 mm (64.0 in) |
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SSS |
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Minimum ground clearance |
140 mm (5.5 in) |
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SSS |
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Minimum turning radius |
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3,500 mm (137.8 in) |
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SSS |
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Weight |
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Wet (with oil and a full fuel tank) |
249 kg (549 lb) |
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SSS |
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Maximum load (except motorcycle) |
198 kg (437 lb) |
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SSS |
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ENGINE SPECIFICATIONS |
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Item |
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Standard |
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Limit |
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Carburetor |
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I.D. mark |
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5SCE 00 (5SCE) |
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SSS |
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5SCK 10 (5SCK) |
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SSS |
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Main jet |
(M.J) |
#91.3 |
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SSS |
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Main air jet |
(M.A.J) |
#50 |
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SSS |
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Jet needle |
(J.N) |
4CT5-2 |
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SSS |
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Needle jet |
(N.J) |
O-4M |
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SSS |
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Pilot air jet |
(P.A.J.1) |
#100 |
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SSS |
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Pilot outlet |
(P.O) |
0.85 |
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SSS |
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Pilot jet |
(P.J) |
#20 |
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SSS |
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Bypass 1 |
(B.P.1) |
0.8 |
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SSS |
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Bypass 2 |
(B.P.2) |
0.8 |
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SSS |
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Bypass 3 |
(B.P.3) |
0.8 |
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SSS |
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Pilot screw |
(P.S) |
2-1/2 |
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SSS |
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Valve seat size |
(V.S) |
1.0 |
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SSS |
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Starter jet |
(G.S.1) |
#17.5 |
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SSS |
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Strater jet |
(G.S.2) |
0.9 |
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SSS |
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Throttle valve size |
(Th. V) |
#140 |
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SSS |
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Fuel level |
(F.L) |
7.5 X 8.5 mm (0.30 X 0.33 in) |
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SSS |
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Engine idle speed |
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1,150 X 1,250 r/min |
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SSS |
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Intake vacuum |
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29.3 kPa (0.30 kg/cm2, 220 mmHg) |
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SSS |
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Engine oil temperature |
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80 X 90 _C (176 X 194 _F) |
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SSS |
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–1–
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CHASSIS SPECIFICATIONS |
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SPEC |
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CHASSIS SPECIFICATIONS |
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Item |
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Standard |
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Limit |
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Front wheel |
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Wheel type |
Spoke wheel |
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SSS |
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Rim |
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Size |
16 M/C |
MT3.00 |
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SSS |
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Material |
Steel |
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SSS |
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Wheel travel |
140 mm (5.51 in) |
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SSS |
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Wheel runout |
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Max. radial wheel runout |
SSS |
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1 mm (0.04 in) |
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Max. lateral wheel runout |
SSS |
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0.5 mm (0.02 in) |
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Rear wheel |
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Wheel type |
Spoke wheel |
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SSS |
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Rim |
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Size |
15 M/C |
MT3.50 |
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SSS |
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Material |
Steel |
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SSS |
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Wheel travel |
98 mm (3.86 in) |
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SSS |
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Wheel runout |
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Max. radial wheel runout |
SSS |
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1mm (0.04 in) |
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Max. lateral wheel runout |
SSS |
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0.5 mm (0.02 in) |
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Front tire |
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Tire type |
With tube |
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SSS |
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Size |
130/90-16M/C 67S |
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SSS |
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Model (manufacturer) |
G703 (BRIDGESTONE) |
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SSS |
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D404F (DUNLOP) |
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SSS |
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Tire pressure (cold) |
225 kPa (2.25 kgf/cm2, 2.25 bar, 33 psi) |
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0 X 90 kg (0 X 198 lb) |
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SSS |
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90 X 198 kg (198 X 437 lb) |
225 kPa (2.25 kgf/cm2, 2.25 bar, 33 psi) |
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Min. tire tread depth |
SSS |
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1.6 mm (0.06 in) |
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Rear tire |
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Tire type |
With tube |
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SSS |
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Size |
170/180-15M/C 77S |
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SSS |
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Model (manufacturer) |
G702 (BRIDGESTONE) |
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SSS |
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D404G (DUNLOP) |
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SSS |
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Tire pressure (cold) |
225 kPa (2.25 kgf/cm2, 2.25 bar, 33 psi) |
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0 X 90 kg (0 X 198 lb) |
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SSS |
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90 X 198 kg (198 X 437 lb) |
250 kPa (2.5 kgf/cm2, 2.5 bar, 36 psi) |
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Min. tire tread depth |
SSS |
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1.6 mm (0.06 in) |
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–2–
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CHASSIS SPECIFICATIONS/ |
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SPEC |
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ELECTRICAL SPECIFICATIONS |
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Item |
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Standard |
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Limit |
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Brake lever & brake pedal: |
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Brake lever free play (at pivot) |
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1 X 2 mm (0.04 X 0.08 in) |
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SSS |
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Brake lever free play (at lever end) |
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10 X 15 mm (0.39 X 0.59 in) |
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SSS |
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Brake pedal position |
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108 mm (4.25 in) |
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SSS |
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Brake pedal free play |
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20 X 30 mm (0.79 X 1.18 in) |
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SSS |
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Clutch lever free play (at pivot) |
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2 X 3 mm (0.08 X 0.12 in) |
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SSS |
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Clutch lever free play (at lever end) |
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5 X 10 mm (0.20 X 0.39 in) |
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SSS |
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ELECTRICAL SPECIFICATIONS |
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Item |
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Standard |
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Limit |
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T.C.I. |
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189 X 231 Ω at 20_C (68_F)/Gray- |
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Pickup coil resistance/color |
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SSS |
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Black |
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T.C.I. unit model/manufacturer |
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J4T150/MITSUBISHI (5SCE) |
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SSS |
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J4T151/MITSUBISHI (5SCK) |
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SSS |
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Headlight relay |
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Model (manufacture) |
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ACA12115-1 (MATSUSHITA) |
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SSS |
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Coil resistance |
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72 X 88 Ω at 20_C (68_F) |
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SSS |
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Thermo switch |
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Model (manufacture) |
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5FU (NIPPON THERMOSTAT) |
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SSS |
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Fuel pump relay |
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Model/manufacturer |
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UC-Z61B/MITSUBISHI |
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SSS |
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Circuit breaker |
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Type |
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Fuse |
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SSS |
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Amperage for individual circuit |
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MAIN |
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30 A |
1 |
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SSS |
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HEADLIGHT |
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15 A |
1 |
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SSS |
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SIGNALS |
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10 A |
1 |
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SSS |
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IGNITION |
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10 A |
1 |
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SSS |
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PARKING LIGHT |
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10 A |
1 |
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SSS |
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CARBURETOR HEATER |
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15 A |
1 |
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SSS |
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Reserve |
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30 A |
1 |
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SSS |
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Reserve |
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15 A |
1 |
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SSS |
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Reserve |
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10 A |
1 |
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SSS |
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Reserve |
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5 A |
1 |
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SSS |
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Indicatior light |
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Immobilizer system indicator light |
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LED |
1 |
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SSS |
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–3–
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CABLE ROUTING |
SPEC |
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CABLE ROUTING |
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1 |
Clutch cable |
10 |
Sidestand switch lead |
19 |
Immobilizer lead |
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2 |
Fuel tank breather hose |
11 Horn |
20 |
Fuel pump and ignition coil |
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3 |
Left handlebar switch lead |
12 |
Head pipe cover |
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bracket |
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4 |
Speedometer |
13 |
Headlight lead |
21 |
Spark plug lead |
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5 |
Speedometer lead |
14 |
Right handlebar switch lead |
22 |
Fuel hose |
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6 |
Speed sensor |
15 |
Vacuum chamber air vent hose |
23 |
Fuel pump lead |
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7 |
Rectifier/regulator |
16 |
Frame |
24 |
Rectifier/regulator lead |
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8 |
Rear brake light switch lead |
17 |
Immobilizer |
25 |
Sheet 1 |
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9 |
Speedometer cable |
18 |
Main switch lead |
26 |
Flap |
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–4–
APass the front turn signal light leads (left and right) through the hole of headlight cover from rear side.
BPass the left handle bar switch lead through behind the handle ber upper bracket so that there is no slack.
CFasten the left handlebar switch lead to the handlebar with a band.
DTo install the fuel tank, make sure to install the fuel tank breather hose so that it is not bent too much.
EPass the harness and fuel breather hose to be connected to the speedometer cable and speedometer lead through the hole of fuel tank.
CABLE ROUTING SPEC
FPass the harness to be connected to the speedometer lead through under the wire harness.
G Rectifier/regulator lead should not be positioned
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higher than the bracket. |
H To the engine |
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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 |
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the wire harness) |
LPush in the coupler inside of the engine lead and crank case after the coupler is connected so that it does not come out.
–5–
MPass the speed sensor lead through inside of the engine lead.
NPass the side stand switch lead through inside of the side stand bracket and install so that there is no adverse slack.
OHold the side stand switch lead with a plastic clamp. Any direction of the plastic clamp opening can be accepted.
PPass the sidestand switch lead through under the frame boss.
QFasten the rear brake light switch lead, sidestand switch lead and rectifier/regulator lead to the frame with a band.
CABLE ROUTING SPEC
RPosition the band immediately under the T stud.
SPosition the band immediately under the frame boss.
TPass the speedometer cable through the holder on the front fender.
UFasten 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–
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CABLE ROUTING |
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SPEC |
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V Position the right handle bar switch lead and head |
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Pass the speedometer cable through the holder |
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BB |
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light switch lead at the outer position of all |
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of the frame. |
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harnesses and leads behind the frame head pipe. |
CC |
Pass the fuel tank beather hose and carburetor |
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Particularly, the right handle bar switch lead should |
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air vent hose through the holder of the frame. |
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be positioned at the outermost section. |
DD |
Allocate the couplers for all leads behind the |
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W Do not cross the handle bar switch lead and head |
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frame head pipe at the rear section. |
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light lead at the out side of the head pipe cover. |
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Allocate the coupler to be connected to the rectifi- |
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EE |
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X Inside the frame |
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er/regulator lead inside of the vehicle body and |
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Y |
Position of cutting section |
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make it not to come out. |
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Z |
Harness to be connected to the speedometer lead |
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Pass the flap through the hole of fuel tank stay |
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FF |
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Pass the harness and fuel breather hose to be |
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and install. (for both right and left sides) |
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AA |
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connected to the speedometer cable and |
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Install the sheet 1 so that the lower edge is hidden |
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GG |
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speedometer lead through the hole of fuel tank. |
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by the frame. |
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–7–
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