XVS650AN(C) Supplementary Service Manual
Contents
1. Euer e eO Si M P db PAR di l EM 4 E AN A QA Ye oo er Walla LAZA LI JT 224 aye ye A j M au WO ses 8 ki a ge 710 der CABLE ROUTING SPEC v Fasten the battery negative lead starter motor lead and wire harness with a plastic locking tie Fasten the wire harness with a clamp The starting safety relay must be fixed to the battery box after connecting the wire harness Fasten the battery negative lead and tail brake light lead with a clamp Pass the wire harness between the frame and battery box Fasten the starter cable with a plastic locking tie Inside the motorcycle Z KY LA NS PAS A 12 CABLE ROUTING SPEC v Pass the fuel tank breather hose through the Fasten the wire harness and leads with a plastic holder locking tie Fasten the fuel tank breather hose with a metal Pass the plastic band through the frame hole clamp Fasten the wire harness with a plastic band at the Pass the speedometer cable through the front point where the tape is located side guide Fasten the wire harness and leads with a plastic To the battery negative lead locking tie To the rear fender Fasten the wire harness and leads with a metal To the flasher light relay clamp To the starter relay To the carburetor heater relay The wire harness and leads2. FRONT BRAKE CHAS FRONT BRAKE CALIPER 40 Nm 4 0 mekg 28 9 ftelb W127 Nm 2 7 mekg 19 5 ftelb Front brake caliper removal Remove the parts in the order below Brake fluid Drain Brake hose holder Union bolts Copper washers Brake hose Refer to CALIPER INSTALLATION Retaining bolt Brake caliper assembly For installation reverse the removal procedure 26 07 FRONT BRAKE CHAS CALIPER INSTALLATION 1 Install e Brake caliper 1 Retaining bolt 2 e Brake hose 3 Copper washers 4 e Union bolt S 30 Nm 3 0 mekg 21 7 ft lb CAUTION When installing the brake hose on the brake caliper make sure that the brake pipe touches the projection 8 on the brake cali per WARNING Proper brake hose routing is essential to in sure safe motorcycle operation Refer to CABLE ROUTING 2 Fill e Brake reservoir Recommended brake fluid DOT 4 CAUTION Brake fluid may damage painted surfaces or plastic parts Always clean up spilled brake fluid immediately A WARNING e Use only the designated quality brake fluid other brake fluids may deteriorate the rub ber seals causing leakage and poor brake performance Refill with the same type of brake fluid mix ing brake fluids may result in a harmful chemical reaction and lead to poor brake performance e careful that water does not enter the master cylinder when refilling Water will sign
3. INGUIN eget seen ee ee pe ae Bes aoe ee 6 CABLE ROUTING ESS scenes ns cames eases 7 PERIODIC INSPECTION AND ADJUSTMENT 16 REAR BRAKE ADJUSTMENT 16 SHIFT PEDAL ADJUSTMENT 18 CARBURETION 19 AIR INDUCTION SYSTEM sc aces qe de mene 19 AIR INDUCTION SYSTEM DIAGRAMS 19 CHECKING THE AIR INDUCTION SYSTEM 22 CHASSIS 4E rHPTPPIT 23 PRON BRANE cae 23 FRONT BRAKE PADS 23 FRONT BRAKE CALIPER cathe ame be fa 26 WIRING DIAGRAM MOTORCYCLE IDENTIFICATION REN d EB100000 GENERAL INFORMATION MOTORCYCLE IDENTIFICATION VEHICLE IDENTIFICATION NUMBER The vehicle identification number 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 GENERAL SPECIFICATIONS SPEC ye SPECIFICATIONS GENERAL SPECIFICATIONS Item Standard Model code XVS650A 5BNT For U S A 5BNU For CAL Dimensions Overall length 2 450 mm 96 5 in Overall width 930 mm 36 6 in Overall height 1 105 mm 43 5 in Seat height 710 mm 28 0 in Wheelbase 1 625 mm 64 0 in Minimum ground clearance 145 mm 57 1 in Minimum turning radius 3 400 mm 133 9 in Basic weight With oil and a full fu
4. W Brown White Li ses Ch Chocolate O Orange B L Black Blue Br Y Brown Yellow R B Dg Dark green Paati Pink B W Black White G Y Green Yellow R W G Green Fe Red B Y Black Yellow L B Blue Black R Y Gy Gray Sb Sky blue Br B Brown Black L R Blue Red MAIN HARNESS CORD TAIL LIGH MAIN HARNESS CARB HEATER Blue White Blue Yellow Red Black Red White Red Yellow 1 A C magneto Rectifier regulator 3 Main switch 4 Battery 5 Main fuse 6 Starter relay 7 Starter motor Relay unit 9 Fuel pump Sidestand switch 11 Throttle position sensor TPS 4 Ignitor unit 13 Ignition coil Spark plug 15 Pickup coil Neutral switch 17 Meter assembly Engine indicator light Neutral indicator light 60 Meter light 61 High beam indicator light 62 Turn indicator light 63 Rear turn signal 62 Front turn signal 65 Headlight 66 Left handlebar switch 67 Dimmer switch Horn switch 69 Clutch switch Turn switch Gi Flasher relay 62 Horn 63 Rear brake switch Tail brake light 65 Carburetor heater Carburetor heater earth 67 Carburetor heater relay Thermo switch Carburetor heater fuse Signal system fuse Headlight fuse 2 Ignition fuse Right handlebar switch Front brake switch Engine stop switch Start switch YAMAHA YAMAHA MOTOR CO LTD 2500 SHINGAI IWATA SHIZUOKA JAPAN PRINTED IN U S A
5. amp YAMAHA AVSGODAN 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 Supplementa ry 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 itis assumed that anyone who uses this book to perform maintenance and repairs on Yamaha mo torcycles 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 mo torcycle will operate as designed If the
6. m ANT 2 7 A Ini N th A mi PAZ gt 2 zB gt lt TF Fy eee 14 CABLE ROUTING ye To the throttle position sensor TPS Fasten the wire harness and throttle position To the carburetor sensor TPS lead with a plastic locking tie To the fuel tank O Inside the motorcycle Pass the neutral switch lead pickup coil lead and P Route the wire harness and throttle position sensor A C magneto lead under the ignition coil lead TPS lead so they run along the bottom of the thermo switch lead and throttle position sensor frame tube TPS lead Q Place the end of the plastic locking tie as shown From the engine R Fasten the wire harness with a plastic locking tie 20 mm 0 79 in Pass the wire harness between the air filter case Pass the thermo switch lead inside of the silencer groove and frame breather hose e u 4 LP j 4 di 9 LA gt Ss ACT Y a amp N ANT ee G ROME sen n 7 M T F E Ceet etd NG a mU S l UA Lon ER NS w 5 V f A 15 INSP REAR BRAKE ADJUSTMENT PERIODIC INSPECTION AND ADJUSTMENT REAR BRAKE ADJUSTMENT 1 Check e Brake pedal height Out of specification Adjust Brake pedal height 108 mm 4 25 in above the top of the footrest 2 Adjust e Brake pedal
7. main categories of subjects See Illustrated symbols 1st title This is the title of the chapter with its symbol in the upper right comer of each page 2nd title 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 3rd title G This title indicates a sub section that is followed by step by step procedures accompa nied by corresponding illustrations EXPLODED DIAGRAMS To help identify parts and clarify procedure steps there are exploded diagrams at the start of each re moval and disassembly section 1 An easy to see exploded diagram 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 Ajob instruction chart 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 4 CLUTCH CLUTCH REMOVAL CRANKCASE COVER RIGHT SUS BIS 1 Straighten Lock washer tab 2 Loosen Nut clutch boss D NOTE L L
8. pump relay Model manufacturer G8R 30Y Q OMRON MAINTENANCE SPECIFICATIONS SPEC v Standard Circuit breaker Type Amperage for individual circuit MAIN HEADLIGHT SIGNALS IGNITION CARBURETOR HEATER Heserve Heserve Heserve _5 LUBRICATION POINTS AND LUBRICANT TYPES SPEC ye EB203000 LUBRICATION POINTS AND LUBRICANT TYPES ENGINE Lubrication point Symbol Crankshaft journal Primary driven gear 6 EB206000 CABLE ROUTING 1 Frame 2 Clutch cable 3 Left handlebar switch lead 4 Fuel tank breather hose 5 Speedometer cable 6 Speedometer 7 Speedometer light leads Vacuum chamber air vent hose 9 Rectifier regulator CABLE ROUTING SPEC v Spark plug lead 60 Fuel pump Sidestand switch lead 11 Rear brake switch lead 2 Horn 3 Headlight lead Right handlebar switch lead 5 Main switch Main switch lead 12 Fuel pump lead Fuel hose Inside the motorcycle Place the end of the plastic locking tie as shown 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 Pass the left handlebar switch lead behind the upper bracket Fasten the left handlebar switch lead with a plastic locking tie Pass the speedometer cable speedometer light leads and fuel tank breather hose th
9. should not touch the Pass the ignitor unit leads through the battery box rear shock absorber hole AL a 7 e e ap CASEY A SRE Ve 2 a m lidi n an M BAN am 4 S em gt A ki CARTE l e TW Li rj TL Je AN f X ga s D G n P 0 i Li mi pou 3 aO m eS au ig a 110mm X j c d 119 CABLE ROUTING v 1 Front flasher light right 13 Neutral switch lead Pass the throttle cables through 2 Throttle cables Pickup coil lead the cable guide 8 Brake hose 5 A C magneto lead Pass the left handlebar switch 4 Right handlebar switch lead Thermo switch lead lead over the right handlebar 5 Clutch cable 12 Fuel tank breather hose switch lead 6 Left handlebar switch lead Rectifier regulator coupler Pass the clutch cable through 7 Front flasher light left Wire harness the cable guide Ignition coil 0 Throttle position sensor TPS D Fasten the handlebar switch 9 Spark plug lead lead leads with a plastic band Silencer Gi Frame To the ignition coil 11 Starter cable 62 Air filter case Pass the starter cable between 12 Speedometer cable the ignition coil and spark plug lead w amp D p 2 RE 26 eec 4 g a 3 D X pa
10. G THE AIR INDUCTION SYSTEM 1 Check ehoses Loose connection Connect properly Cracks damage Replace e pipes Cracks damage Replace 2 Check reed valve 1 ereed valve stopper O e reed valve seat Cracks damage Replace the reed valve 3 Measure ereed valve bending 8 Out of specification Replace the reed valve E I e X Maximum reed valve bending D 0 4 mm 0 016 in 1 Surface plate 4 Check eair cutoff valve Cracks damage Replace 5 Check eair cleaner Cracks damage Replace Clogged Clean _99_ FRONT BRAKE CHAS CHASSIS FRONT BRAKE FRONT BRAKE PADS iv 0 CKO Uf W 27 Nm 2 7 19 5 ft lb Front brake pad removal Remove the parts in the order below Retaining bolt Brake caliper Refer to BRAKE PAD Brake pads REPLACEMENT Pad spring For installation reverse the removal procedure DA 24 FRoNTBRAKE CHAS CAUTION Disc brake components rarely require disas sembly DO NOT edisassemble components unless abso lutely necessary euse solvents on internal brake compo nents 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 e splash brake fluid onto painted surfaces or plastic parts as this may cause damage e disconnect any hydraulic connection as this would require the entire brake system to be d
11. arp limit clutch plate Less than 0 2 mm EAS0009 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 s 6 Chassis 7 Electrical system Troubleshooting Symbols 9 to 09 indicate the following 9 Serviceable with engine mounted Filling fluid 11 Lubricant 12 Special tool 3 Tightening torque Wear limit clearance 15 Engine speed Electrical data Symbols 47 to 2 in the exploded diagrams indi cate the types of lubricants and lubrication points 12 Engine oil Gear oil Molybdenum disulfide oil 0 Wheel bearing grease Lithium soap base grease 62 Molybdenum disulfide grease Symbols 3 to 62 in the exploded diagrams indi cate the following 63 Apply locking agent LOCTITE Replace the part CONTENTS GENERAL INFORMATION MOTORCYCLE IDENTIFICATION ai oso ay 1 VEHICLE IDENTIFICATION NUMBER 1 MODEL LABEL sw 524 PRSE EUER ce pe 1 SPECIFICATIONS 2 GENERAL SPECIFICATIONS x5 3753 4 4 3 908 17 5 9 a inik Ec rn meds 2 MAINTENANCE SPECIFICATIONS 3 E NOINE 3 Salt rmm 3 ELEC AIGA LUBRICATION POINTS AND LUBRICANT TYPES 6
12. e through the holder Pass the speedometer cable through the holder Place the couplers behind the steeirng head CABLE ROUTING ye 1 Frame bracket 13 Flasher light relay 65 Fuel tank breather hose 2 Dimmer switch Starter relay C Speedometer cable 3 Self canceling turn signal relay 43 Carburetor heater relay 67 Ignitor unit 4 Fuse box Neutral switch lead 5 Battery positive lead 12 Pickup coil lead Pass the tail brake light lead 6 Spark plug lead A C magneto lead between the frame bracket and 7 Vacuum chamber air bent hose Battery negative lead battery box Position the mud Starter cable 69 Starter motor lead guard the between the edge of 9 Right handlebar switch lead Battery cover the frame bracket and the Brake hose 62 Battery tail brake light lead 11 Throttle cables 63 Wire harness Fasten the dimmer switch lead 2 Thermo switch lead 62 Starting circuit cut off relay with a clamp e Io CA Ni yo AN Nan ooo m ALO avi YONN avt GO 10mm TIN X 4 c d 10 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 Fasten the starter relay lead and fuse box lead with a plastic locking tie To the ignition coil The end of the pla
13. eTo obtain the correct pedal position turn the shift pedal rod in or out shift pedal is lowered shift pedal is raised e Tighten both locknuts XKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKYEK NOTE _ Align the mark on the shift shaft with the center of the slit e Turn in the both side of the shift pedal rod more than 4 times AIR INDUCTION SYSTEM CARB CARBURETION EB601000 AIR INDUCTION SYSTEM AIR INDUCTION SYSTEM DIAGRAMS 1 Reed valve To the front cylinder head 2 Air cut valve To the rear cylinder head 3 Air cleaner 4 Carburetor joint O 10 AIR INDUCTION SYSTEM CARB 2 Nm 0 2 mekg 1 4 ftelb Removing the air induction system Remove the parts in the order listed 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 AIR INDUCTION SYSTEM CARB 2 Nm 0 2 mekg 1 4 ftelb 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 td For installation reverse the removal procedure Jj AIR INDUCTION SYSTEM CARB EAS00510 CHECKIN
14. el tank 247 kg 544 5 Ib Bulb wattage x quantity Headlight 12 V 60 W 55 W x 1 Tail brake light 12 8 W 27 W x 1 Front turn signal position light 12V27 W 8W 2 Rear turn signal light 12V27W x2 Meter light 12V 1 7W x 1 Neutral indicator light 12V 1 7W x 1 High beam indicator light 12V 1 7W x 1 Turn indicator light 12V 1 7W x 1 Engine indicator light 12V 1 7W x 1 MAINTENANCE SPECIFICATIONS SPEC ye MAINTENANCE SPECIFICATIONS ENGINE Connecting rod Dil clearance Standard 0 031 0 055 mm 0 0012 0 0022 in Color code corresponding size CHASSIS 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 x thickness Pad thickness inner Pad thickness outer Master cylinder inside diameter Caliper cylinder inside diameter Caliper cylinder inside diameter Brake fluid type Brake lever amp 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 CD Blue Black Brown Green Standard 140 mm 5 5 in 332 5 mm 3 1 in 325 9 mm 12 83 in 287 4 mm 11 3 in 3 43 N mm 0 343 kg mm 19 2 Ib in 140 mm 0 5 5 in No 0 507 L 17 4 US oz 95 mm 3 74 in Yamaha fork oil 10 WT or equivalent S
15. height kkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkk Adjustment steps e Loosen the locknut 1 e Turn the adjuster in or out until the specified pedal height is obtained Turnina in brake pedal height is urning in decreased Turning out brake pedal height is increased e Tighten the locknut NS A Ne A Locknut A ELE SS kkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkk 3 Check e Brake pedal free play a Out of specification Adjust X Free play brake pedal 20 x 30 mm 0 79 x 1 18 in 4 Adjust Brake pedal free play KKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKK K Adjustment steps Turn the adjuster 1 in or out until the speci fied free play is obtained Turning in brake pedal free play is decreased 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 ET UM KKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKK E 16 INSP REAR BRAKE ADJUSTMENT 5 Adjust Brake light switch Refer to BRAKE LIGHT SWITCH ADJUST MENT 17 18 INSP SHIFT PEDAL ADJUSTMENT EB304080 SHIFT PEDAL ADJUSTMENT 1 Check e Shift pedal position Check the shift pedal rod length If the position is incorrect Adjust X Shift pedal rod length 168 mm 6 6 in 2 Adjust e Shift pedal position KKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKE Adjustment steps Loosen both locknuts 1
16. ificantly lower the boiling point of the brake fluid and may result in vapor lock FRONT BRAKE CHAS 3 Air bleed e Brake system Refer to AIR BLEEDING HYDRAULIC BRAKE SYSTEM in CHAPTER 3 4 Check e Brake fluid level Brake fluid level is under the LOWER level line Fill up Refer to BRAKE FLUID LEVEL INSPEC TION in CHAPTER 3 a LOWER level line 28 XVS650AN C WIRING DIAGRAM ea a a ieee ee EO et 1 1 8 A E L_OFF i L BJL Y 1 RED RED Br L BLUE poco coo oe ee ee ee OO Oe DEUS REN 1 Bu fer rele BLACK BLACK T co Lssesesesesiil o A MA A AN 52757 V BW a an Gato te e zapi S gt BLACK BLACK BLACK gt 88 Ch e Bh 1 29 amp EE ei D EE ee waly penc Dg d chalp B Sb sels ew 6 etan BLUE BLUE OO to O0 ON EE BAM 29 ete IB VR roo oe ZN 1 nu 1 LI BLUE 1 D 4 z a E 5 E E a ae 3 Bd KO E AE ist st 87 amp b SL LELE de 97 i COLOR CODE Black Blue W White Br L Brown Blue L W Br Brown Lg Light green pat Yellow Br
17. ingle disk 298 x 5 mm 11 73 x 0 2 in 6 0 mm 0 24 in 6 0 mm 0 24 in 14 0 mm 0 55 in 30 2 mm 1 19 in 33 3 mm 1 31 in DOT 4 1 2mm 0 04 0 08 in 10 15 mm 0 39 0 59 in 108 mm 4 25 in 20 30 mm 0 79 1 18 in 2 3mm 0 08 0 12 in 10 15 mm 0 39 0 59 in MAINTENANCE SPECIFICATIONS SPEC ELECTRICAL Sandara LOT Pickup coil resistance color 182 222 Q at 20 C 68 F Gray Black T C l unit model manufacturer J4T088 MITSUBISHI U S A J4T128 MITSUBISHI CAL Ignition coil Model manufacturer F6T541 MITSUBISHI Minimum spark gap 6 mm 0 24 in Primary winding resistance 3 6 4 8 Q at 20 C 68 F Secondary winding resistance 10 7 14 5 kQ at 20 C 68 F Voltage regulator Type Semi conductor short circuit type Model manufacturer SH650C 11 SHINDENGEN No load regulated voltage 14 1 149 V Rectifier Model manufacturer SH650C 11 SHINDENGEN Capacity 18 A Withstand voltage 200 V Electric starter system Type Constant mesh type Starter motor Model manufacturer SM 13 MITSUBA D number SM 13 Output 0 7 KW Brush overall length 10 mm 0 39 in Commutator diameter 28 mm 1 10 in Mica undercut 0 7 mm 0 08 in Starter relay Model manufacturer MS 5F 441 JIDECO Amperage rating 180A Flasher relay Type Semi transistor type Model manufacturer FB257H DENSO Self cancelling device Yes Flasher frequency 75 95 cycle min Wattage 2 W x 2 3 4W Fuel
18. isassembled drained cleaned properly filled and bled after reassembly BRAKE PAD REPLACEMENT NOTE Itis not necessary to disassemble the brake cal iper and brake hose to replace the brake pads 1 Remove Retaining bolt 1 2 Remove e Brake pads 1 NOTE e Install new brake pad springs when the brake pads have to be replaced e Replace the brake pads as a set if either is found to be worn to the wear limit 3 Install e Brake pads e Brake pads spring kkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkk Installation steps e Connect a suitable hose 1 tightely to the brake caliper bleed screw Put the other end of this hose into an open container FRONT BRAKE CHAS e Loosen the brake caliper bleed screw and using a finger push the caliper pistons into the brake caliper e Tighten the brake caliper bleed screw Brake caliper bleed screw 6 Nm 0 6 mekg 4 3 ftelb e Install new brake pads and a new brake pad spring e Install the brake caliper 3 and retaining bolt Bolt brake caliper 40 Nm 4 0 mekg 28 9 ftelb Retaining bolt 27 Nm 2 7 mekg 19 5 ftelb KKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKK K 4 Check e Brake fluid level Refer to BRAKE FLUID LEVEL INSPEC TION in CHAPTER 3 LOWER level line 5 Check e Brake lever operaiton Soft or spongy feeling Bleed the brake system Refer to AIR BLEEDING HYDRAULIC BRAKE SYSTEM in CHAPTER 3 25
19. oosen the nut clutch boss D while hold ing the clutch boss 2 with the clutch holding tool 3 21 Clutch holding tool NP 90890 04086 PRIMARY DRIVE GEAR REMOVAL 1 Straighten Lock washer tab 2 Loosen Nut primary drive gear D NOTE Place a copper plate 2 between the teeth of the primary drive gear 3 and primary driven gear to lock them CLUTCH INSPECTION 1 Inspect Friction plates Wear damage Replace the friction plates as a set 2 Measure Friction plate thickness Out of specification Replace the fric Job name Part name 1 Remarks tion plates as a set Crankcase cover right removal Remove the parts in the order below Measure at four places Stand the motorcycle on a level surface Thickness friction plate A WARNING 2 9 3 1mm Securely support the motorcycle so Wan limit 2 mm there is no danger of it falling over 3 Inspect Engine oil Refer to ENGINE OIL REPLACE die MENT in CHAPTER 3 Damage Replace the clutch plates as Muffler assembly 1 2 a set Brake pedal link Refer to ENGINE REMOVAL N 4 Measure Oil filter cover plate Clutch plate warpage Oil filter cover L 70 mm x 1 65 mm x 1 25 mm x 3 Out of specification Replace the O ring clutch plates as a set Oil filter Use a surface plate and a feeler gauge Crankcase cover right L 65 mm x 1 55 mm x 1 45 mm x 4 30 mm x 4 Ms W
20. re 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 sig nificant 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 e This Service Manual contains information regarding periodic maintenance to the emission control system Please read this material carefully e Designs and specifications are subject to change without notice IMPORTANT INFORMATION Particularly important information is distinguished in this manual by the following notations A The Safety Alert Symbol means ATTENTION BECOME ALERT YOUR SAFETY IS INVOLVED A WARNING 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 CAUTION 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 EB002000 HOW TO USE THIS MANUAL MANUAL ORGANIZATION This manual consists of chapters for the
21. rough the fuel tank hole 45 Ne yi Ys S NVA YA SIT RE E 7 CABLE ROUTING v To the speedometer light leads Rectifier regulator lead should not be out over the bracket Pass the right handlebar switch lead and headlight lead over the other harness and leads Pass the clutch cable through the cable guide Fasten the sidestand switch lead and rectifier regulator lead with a plastic locking tie Install the plastic locking tie so that it is up against the frame projection 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 P Route the sidestand switch and the lead wire under the frame boss IQ Fasten the sidestand switch lead with a metal clamp Connect the rear brake switch coupler in front of the roll over valve stay Install the plastic locking tie immediately below the cable guide bracket Pass the speedometer speedometer cable holder To the rectifier regulator cable through the CABLE ROUTING ye Pass the rear brake switch lead between the frame and rectifier regulator Do not pinch the rear brake switch lead M Fasten the rear brake switch lead with a plastic locking tie To the speedometer light leads Place the rectifier regulator coupler completely inside the motorcycle body Pass the fuel tank breather hose and vacuum chamber air vent hos
22. stic locking tie should face towards the under the handlebar Fasten the right handlebar switch lead with a plastic locking tie 30m P D 5 fs TA p he d Pis 1 Q Vi nn af gt NS N RES WAA ap ETIN KON e ie 2 A pP PA L zd IL 4 Bim V i AN B Z f CABLE ROUTING SPEC v Pass the right handlebar switch lead behind the upper bracket Fasten the brake hose grommet with a brake hose holder Place the left handlebar switch coupler on the side of the main switch Fasten the brake hose with a brake hose holder Pass the left handlebar switch lead under the main switch Fasten the spark plug lead with a metal clamp O Pass the ignition coil lead inside of the starter cable Fasten the fuse box lead with a plastic locking tie 8 Lx LIN 7 A N EVA pu S EN KAN dE ASM RE ap lt i i am M a 2 G Q Fasten the battery positive lead with a battery box clamp R The carburetor heater relay should not touch the wire harness Fasten the wire harness with a plastic locking tie Place the end of the plastic locking tie as shown From the engine Pass the starter motor lead over the battery negative lead M Fasten the pickup coil lead A C magneto lead neutral switch lead and starter motor lead with a plastic locking tie
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