XVS65AWV

XVS65ATV

For California (04 Model)

XVS650ASC

XVS650ATSC

SUPPLEMENTARY

SERVICE MANUAL

5BN-28197-E2

LIT-11616-19-81

XVS65AWV/XVS65ATV

XVS650ASC/XVS650ATSC

SUPPLEMENTARY

SERVICE MANUAL

© 2005 by Yamaha Motor

Corporation, U.S.A.

First Edition, October 2005

All rights reserved. Any reproduction or

unauthorized use without the written

permission of Yamaha Motor

Corporation, U.S.A. is expressly

prohidited. Printed in U.S.A.

P/ N LIT-11616-19-81

XVS650AK(C) SERVICE MANUAL: LIT-11616-11-16 (5BN-28197-E0)

XVS650AN(C) SUPPLEMENTARY SERVICE MANUAL: LIT-11616-14-31 (5BN-28197-E1)

EAS00001

FOREWORD

This Supplementary Service Manual has been prepared to introduce new service and data for the

XVS650A. For complete service information procedures it is necessary to use this Supplementary

Service Manual together with the following manual.

EAS00003

NOTICE

This manual was produced by the Yamaha Motor Company, Ltd. primarily for use by Yamaha deal-

ers and their qualified mechanics. It is not possible to include all the knowledge of a mechanic in

one manual. There fore, 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.

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

vehicle 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 vehicle 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 deal-

ers and will appear in future editions of this manual where applicable.

This Service Manual contains information regarding periodic maintenance to the emission control

system. Please read this material carefully.

NOTE:

Designs and specifications are subject to change without notice.

EAS00005

IMPORTANT MANUAL INFORMATION

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

Q

The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR

SAFETY IS INVOLVED!

w

Failure to follow WARNING instructions could result in severe injury or death

to the motorcycle operator, a bystander or a person checking or repairing

the motorcycle.

cC

A CAUTION indicates special precautions that must be taken to avoid

damage to the motorcycle.

NOTE:

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

EAS00007

HOW TO USE THIS MANUAL

This manual is intended as a handy, easy-to-read reference book for the mechanic. Comprehensive

explanations of all installation, removal, disassembly, assembly, repair and check procedures are

laid out with the individual steps in sequential order.

1 The manual is divided into chapters. An abbreviation and symbol in the upper right corner of

each page indicate the current chapter.

Refer to "SYMBOLS".

2 Each chapter is divided into sections. The current section title is shown at the top of each page,

except in Chapter 3 ("PERIODIC CHECKS AND ADJUSTMENTS"), where the sub-section title(s)

appears.

3 Sub-section titles appear in smaller print than the section title.

4 To help identify parts and clarify procedure steps, there are exploded diagrams at the start of

each removal and disassembly section.

5 Numbers are given in the order of the jobs in the exploded diagram. A circled number indicates

a disassembly step.

6 Symbols indicate parts to be lubricated or replaced.

Refer to "SYMBOLS".

7 A job instruction chart accompanies the exploded diagram, providing the order of jobs, names of

parts, notes in jobs, etc.

8 Jobs requiring more information (such as special tools and technical data) are described sequen-

tially.

1

2

6

3

5

4

7

8

EB003000

ILLUSTRATED SYMBOLS

The following symbols are not relevant to every

vehicle.

Symbols 1 to 8 indicate the subject of each

chapter.

1 General information

2 Specifications

3 Periodic checks and adjustments

4 Engine

5 Carburetor

6 Chassis

7 Electrical system

8 Troubleshooting

Symbols 9 to y indicate the following.

9 Serviceable with engine mounted

0 Filling fluid

q Lubricant

w Special tool

e Tightening torque

r Wear limit, clearance

t Engine speed

y Electrical data

Symbols u to s in the exploded diagrams indi-

cate the types of lubricants and lubrication

points.

u Engine oil

i Gear oil

o Molybdenum-disulfide oil

p Wheel-bearing grease

a Lithium-soap-based grease

s Molybdenum-disulfide grease

Symbols d to f in the exploded diagrams indi-

cate the following.

d Apply locking agent (LOCTITE^®)

f Replace the part

CONTENTS

SPECIFICATIONS

GENERAL SPECIFICATIONS ……………………………………………… 1

MAINTENANCE SPECIFICATIONS

……………………………………… 2

ENGINE …………………………………………………………………… 2

CHASSIS …………………………………………………………………… 3

ELECTRICAL ……………………………………………………………… 4

CABLE ROUTING …………………………………………………………… 6

PERIODIC CHECKS AND ADJUSTMENTS

INTRODUCTION

…………………………………………………………… 14

PERIODIC MAINTENANCE CHART FOR EMISSION CONTROL

SYSTEM ……………………………………………………………………… 14

CARBURETOR

CARBURETOR ……………………………………………………………… 17

CHECKING THE FUEL CUT SOLENOID …………………………… 19

CHASSIS

FRONT WHEEL AND BRAKE DISC …………………………………… 19A

ELECTRICAL

LIGHTING SYSTEM ………………………………………………………… 20

CIRCUIT DIAGRAM

…………………………………………………… 20

TROUBLE SHOOTING ………………………………………………… 21

CARBURETOR HEATER SYSTEM ……………………………………… 23

CIRCUIT DIAGRAM

…………………………………………………… 23

TROUBLE SHOOTING ………………………………………………… 24

SELF-DIAGNOSIS

………………………………………………………… 27

TROUBLE SHOOTING ………………………………………………… 29

XVS65AWV/XVS65ATV/XVS650ASC/XVS650ATSC

WIRING DIAGRAM (for US and CAL)

SPEC

–1–

GENERAL SPECIFICATIONS

SPECIFICATIONS

GENERAL SPECIFICATIONS

Item

Standard

Model code:

XVS650ASC :

5SCL (For CAL)

XVS650ATC :

5SCP (For CAL)

XVS650ATSC : 5SCM (For CAL)

XVS650ATTC : 5SCU (For CAL)

XVS65AVC :

4CT5 (For CAL)

XVS65ATV :

4C54 (For U.S.A.)

XVS65ATVC :

4C55 (For CAL)

XVS65AV :

5SCY (For U.S.A.)

Dimensions:

Overall length

2450 mm (96.5 in)

Overall width

930 mm (36.6 in)

Overall height

1105 mm (43.5 in)

Seat height

710 mm (28.0 in)

Wheelbase

1625 mm (64.0 in)

Ground clearance

140 mm (5.51 in)

Minimum turning radius

3400 mm (133.9 in)

Basic weight:

With oil and fuel

XVS650ASC/XVS650ATC/XVS650ATSC

XVS650ATTC/XVS65AVC/XVS65ATVC :

249.0 kg (549 lb)

XVS65ATV/XVS65AV :

247.0 kg (545 lb)

Maximum load

XVS650ASC/XVS650ATSC :

194 kg (428 lb)

XVS650ATC/XVS650ATTC/XVS65AVC/

XVS65ATVC :

198 kg (437 lb)

XVS65AVC/XVS65AV :

200 kg (441 lb)

SPEC

–2–

MAINTENANCE SPECIFICATIONS

MAINTENANCE SPECIFICATIONS

ENGINE

Item

Standard

Limit

Fuel pump:

Pump type

Electrical

•••

Model/manufacturer

UC-Z61B/MITSUBISHI

•••

Maximum consumption amperage

0.8 A

•••

Output pressure

8.3–12.3 kPa (1.2–1.8 psi)

•••

(0.08–0.12 kgf/cm²)

Carburetor:

Type × quantity

BDS28 × 2

•••

Manufacturer

MIKUNI

•••

ID mark

5SCL 20

•••

Main jet

#91.3

•••

Main air jet

#50

•••

Jet needle

4CT3-1

•••

Needle jet

O-4

•••

Pilot air jet 1

#100

•••

Pilot outlet

0.85

•••

Pilot jet

#20

•••

Bypass 1

0.8

•••

Bypass 2

0.8

•••

Bypass 3

0.8

•••

Valve seat size

1

•••

Starter jet 1

#17.5

•••

Starter jet 2

0.9

•••

Throttle valve size

#140

•••

Fuel level A (using fuel level gauge)

7.5–8.5 mm (0.30–0.33 in)

•••

SPEC

–3–

MAINTENANCE SPECIFICATIONS

CHASSIS

Item

Standard

Limit

Front wheel:

Wheel type

Spoke wheel

•••

Rim size

16M/C × MT3.00

•••

Rim material

Steel

•••

Wheel travel

140.0 mm (5.51 in)

•••

Radial wheel runout limit

•••

1.0 mm

(0.04 in)

Lateral wheel runout limit

•••

0.5 mm

(0.02 in)

Front tire:

Size

130/90-16M/C 67S

•••

Manufacturer/model

BRIDGESTONE/EXEDRA G703

•••

Manufacturer/model

DUNLOP/D404F

•••

Wear limit (front)

•••

0.8 mm

(0.03 in)

Rear tire:

Size

170/80-15M/C 77S

•••

Manufacturer/model

BRIDGESTONE/EXEDRA G702

•••

Manufacturer/model

DUNLOP/D404G

•••

Wear limit (rear)

•••

0.8 mm

(0.03 in)

SPEC

–4–

MAINTENANCE SPECIFICATIONS

ELECTRICAL

Item

Standard

Limit

TCI:

Pickup coil resistance

189–231 ΩGray–Black

•••

TCI unit model/manufacturer

J4T153/MITSUBISHI

•••

Battery:

Model

GT12B-4

•••

Voltage, capacity

12 V, 10.0 Ah

•••

Specific gravity

1.32

•••

Manufacturer

GS YUASA

•••

Ten hour rate amperage

1.00 A

•••

Bulb voltage, wattage × quantity:

Headlight

12 V, 60 W/55.0 W × 1

•••

Tail/brake light

12 V, 8.0 W/27.0 W × 1

•••

Front turn signal/position light

XVS650ASC/XVS650ATSC :

12 V, 27 W/8.0 W × 2

•••

XVS650ATC/XVS650ATTC/XVS65AV :

12 V, 23 W/8.0 W × 2

•••

Rear turn signal light

XVS650ASC/XVS650ATSC :

12 V, 27.0 W × 2

•••

XVS650ATC/XVS650ATTC/XVS65AV :

12 V, 21.0 W × 2

•••

Meter lighting

12 V, 1.7 W × 1

•••

Turn signal relay:

Relay type

Semi transistor

•••

Model/manufacturer

FB257H/DENSO

•••

Built-in, self-canceling device

Yes

•••

Turn signal blinking frequency

75.0–95.0 cycles/min

•••

Wattage

23(21) W × 2 + 3.4 W

•••

Starting circuit cut-off relay:

Model/manufacturer

G8R-30Y-U0/OMRON

•••

Coil resistance

162–198 Ω

•••

Headlight relay:

Model/manufacturer

ACA12115-1/MATSUSHITA

•••

Coil resistance

72–88 Ω

•••

Fuel pump relay:

Model/manufacturer

G8R-30Y-U0/OMRON

•••

Coil resistance

162–198 Ω

•••

Thermostat switch:

Model/manufacturer

5FU/NIPPON THERMOSTAT

•••

SPEC

–5–

MAINTENANCE SPECIFICATIONS

Item

Standard

Limit

Fuses:

Main fuse

30.0 A

•••

Headlight fuse

15.0 A

•••

Signaling system fuse

10.0 A

•••

Ignition fuse

10.0 A

•••

Carburetor heater fuse

15.0 A

•••

Ignitor unit fuse

5.0 A

•••

Reserve fuse

30.0 A

•••

Reserve fuse

15.0 A

•••

Reserve fuse

10.0 A

•••

Reserve fuse

5.0 A

•••

SPEC

CABLE ROUTING

–6–

1 Frame

2 Clutch cable

3 Left handlebar switch lead

4 Fuel tank breather hose

5 Speedometer cable

6 Speedometer

7 Speedometer light leads

8 Vacuum chamber air vent hose

9 Rectifier/regulator lead

0 A.C. magneto lead

q Pickup coil lead

w Rectifier/regulator

e Rear brake switch lead

r Sidestand switch lead

t Horn

y Head pipe cover

u Headlight lead

i Right handlebar switch lead

o Flap

p Sheet1

å

å

∫

ç

∂

´

ƒ

©

˙

ˆ

∆

˚

¬

¬

µ

˜

ø

π

œ

®

∫

B

A

C

E

E

C

D

A

A-A

C-C

Installing the flap

E-E

B

D

ƒ

†

¨

√

≈

∑

∑

ß

2

3 4

5 6

7

8

9

0

q

w

e

t

r

y

u

i

1

1

4

5

9

w

e

r

o

o

p

p

EB206000

CABLE ROUTING

SPEC

–7–

CABLE ROUTING

A Inside the motorcycle.

B Place the end of the plastic

locking tie as shown.

C Pass the front flasher light leads

(left and right) and headlight

lead through the headlight

cover hole.

D Pass the left handlebar switch

lead behind the upper bracket.

E Fasten the left handlebar switch

lead with a plastic locking tie.

F Pass the speedometer cable,

speedometer light leads and

fuel tank breather hose through

the fuel tank hole.

G Rectifier/regulator lead should

not be out over the bracket.

H Pass the right handlebar switch

lead and headlight lead over the

other

harness

and

leads.

Especially, place the right han-

dlebar switch lead at most out

side.

I Fasten the sidestand switch

lead and rectifier/regulator lead

with a plastic locking tie (do not

touch the engine head cover).

J Fasten the leads with a plastic

locking tie at under the frame

boss.

K To the engine.

L From the engine.

M Pass the sidestand switch lead

through inside of the sidestand

bracket. The lead should not

slack.

N The sidestand switch lead

should not touch the shift rod.

O Fasten the sidestand switch

lead with a metal clamp.

P Fasten the rear brake switch

lead, sidestand switch lead and

rectifier/regurator lead with a

plastic locking tie.

å

å

∫

ç

∂

´

ƒ

©

˙

ˆ

∆

˚

¬

¬

µ

˜

ø

π

œ

®

∫

B

A

C

E

E

C

D

A

A-A

C-C

Installing the flap

E-E

B

D

ƒ

†

¨

√

≈

∑

∑

ß

2

3 4

5 6

7

8

9

0

q

w

e

t

r

y

u

i

1

1

4

5

9

w

e

r

o

o

p

p

SPEC

–8–

CABLE ROUTING

Q Fasten the leads with a plastic

locking tie at bottom of the T

stud.

R Pass the speedometer cable

through the speedometer cable

holder.

S Do not cross the handlebar

switch lead and headlight lead

in outside of the head pipe

cover.

T Pass the rear brake switch lead

between the frame and rectifi-

er/regulator. Do not pinch the

rear brake switch lead.

U Fasten the rear brake switch

lead with a plastic locking tie.

V Pass the tank stay through the

flap hole. (right side and left

side) Also, place the all cou-

plers in bottom of the flap.

W Place the sheet1 so that the

edge of the frame should not

expose.

X Install the sheet1 to hide the

bottom of the sheet 1 in the

frame.

å

å

∫

ç

∂

´

ƒ

©

˙

ˆ

∆

˚

¬

¬

µ

˜

ø

π

œ

®

∫

B

A

C

E

E

C

D

A

A-A

C-C

Installing the flap

E-E

B

D

ƒ

†

¨

√

≈

∑

∑

ß

2

3 4

5 6

7

8

9

0

q

w

e

t

r

y

u

i

1

1

4

5

9

w

e

r

o

o

p

p