FOREWORD

This Supplementary Service Manual has been prepared to introduce new service and data for theXVS650AN(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)SUPPLEMENTARYSERVICE 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 ofYamaha Motor Corporation, U.S.A.

is expressly prohibited.Printed in U.S.A.

P/N LIT-11616-14-31

NOTE:

WARNING

CAUTION:

EB001000

NOTICEThis manual was produced by the Yamaha Motor Company primarily for use by Yamaha dealers andtheir 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 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 andunfit for use.This model has been designed and manufactured to perform within certain specifications in regard toperformance and emissions. Proper service with the correct tools is necessary to ensure that the mo-torcycle will operate as designed. If there is any question about a service procedure, it is imperative thatyou contact a Yamaha dealer for any service information changes that apply to this model. This policyis intended to provide the customer with the most satisfaction from his motorcycle and to conform withfederal 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 dealersand will appear in future editions of this manual where applicable.

This Service Manual contains information regarding periodic maintenance to the emission controlsystem. Please read this material carefully.

Designs and specifications are subject to change without notice.

IMPORTANT INFORMATIONParticularly important information is distinguished in this manual by the following notations.

The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOURSAFETY IS INVOLVED!

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

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

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

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3

5

4

7

8

EB002000

HOW TO USE THIS MANUALMANUAL ORGANIZATIONThis 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.3rd title 3 : This title indicates a sub-section that is followed by step-by-step procedures accompa-

nied by corresponding illustrations.

EXPLODED DIAGRAMSTo 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 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.

1

3

5

7

9

11

13

15

17

2

4

8

10

12

14

6

20

23 24

18 19

21 22

16

EAS0009

SYMBOLSThe following symbols are not relevant to everyvehicle.Symbols 1 to 8 indicate the subject of eachchapter.

1 General information2 Specifications3 Periodic checks and adjustments4 Engine5 Carburetor(-s)6 Chassis7 Electrical system8 Troubleshooting

Symbols 9 to 16 indicate the following.

9 Serviceable with engine mounted10 Filling fluid11 Lubricant12 Special tool13 Tightening torque14 Wear limit, clearance15 Engine speed16 Electrical data

Symbols 17 to 22 in the exploded diagrams indi-cate the types of lubricants and lubricationpoints.

17 Engine oil18 Gear oil19 Molybdenum disulfide oil20 Wheel bearing grease21 Lithium soap base grease22 Molybdenum disulfide grease

Symbols 23 to 24 in the exploded diagrams indi-cate the following:

23 Apply locking agent (LOCTITE )24 Replace the part

CONTENTS

GENERAL INFORMATION 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MOTORCYCLE IDENTIFICATION 1. . . . . . . . . . . . . . . . . . . . . . . . . . . .

VEHICLE IDENTIFICATION NUMBER 1. . . . . . . . . . . . . . . . . . . . . MODEL LABEL 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SPECIFICATIONS 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . GENERAL SPECIFICATIONS 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MAINTENANCE SPECIFICATIONS 3. . . . . . . . . . . . . . . . . . . . . . . . . . .

ENGINE 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHASSIS 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ELECTRICAL 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

LUBRICATION POINTS AND LUBRICANT TYPES 6. . . . . . . . . . . . . . ENGINE 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CABLE ROUTING 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PERIODIC INSPECTION AND ADJUSTMENT 16. . . . . . . . . . . . . . . . . . . . REAR BRAKE ADJUSTMENT 16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SHIFT PEDAL ADJUSTMENT 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CARBURETION 19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AIR INDUCTION SYSTEM 19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

AIR INDUCTION SYSTEM DIAGRAMS 19. . . . . . . . . . . . . . . . . . . . . CHECKING THE AIR INDUCTION SYSTEM 22. . . . . . . . . . . . . . . .

CHASSIS 23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FRONT BRAKE 23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

FRONT BRAKE PADS 23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FRONT BRAKE CALIPER 26. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

WIRING DIAGRAM

–1–

MOTORCYCLE IDENTIFICATIONGENINFO

EB100000

GENERAL INFORMATIONMOTORCYCLE IDENTIFICATIONEB100010

VEHICLE IDENTIFICATION NUMBERThe vehicle identification number 1 is stampedinto the right side of the steering head.

MODEL LABELThe model label 1 is affixed to the frame. Thisinformation will be needed to order spare parts.

–2–

GENERAL SPECIFICATIONS SPEC

SPECIFICATIONS

GENERAL SPECIFICATIONS

Item Standard

Model code: XVS650A:5BNT (For U.S.A)5BNU (For CAL)

Dimensions:Overall lengthOverall widthOverall heightSeat heightWheelbaseMinimum ground clearanceMinimum 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:HeadlightTail /brake lightFront turn signal/position lightRear turn signal lightMeter lightNeutral indicator lightHigh beam indicator lightTurn indicator lightEngine indicator light

12 V 60 W/55 W 112 V 8 W/27 W 112 V 27 W/8 W 212 V 27 W 212 V 1.7 W 112 V 1.7 W 112 V 1.7 W 112 V 1.7 W 112 V 1.7 W 1

–3–

MAINTENANCE SPECIFICATIONS SPEC

1 2 3 4

MAINTENANCE SPECIFICATIONSENGINE

Item Standard Limit

Connecting rod:Oil clearanceColor code (corresponding size)

0.031 0.055 mm (0.0012 0.0022 in) Blue Black Brown Green

CHASSIS

Item Standard Limit

Front suspension:Front fork travelFork spring free length

Installed lengthSpring rate (K1)Stroke (K1)Optional springOil capacityOil levelOil grade

140 mm (5.5 in)332.5 mm (3.1 in)

287.4 mm (11.3 in)3.43 N/mm (0.343 kg/mm, 19.2 lb/ in)0 140 mm (0 5.5 in)No0.507 L (17.4 US oz)95 mm (3.74 in)Yamaha fork oil 10 WT or equivalent

325.9 mm(12.83 in)

Front brake:TypeDisc outside diameter thickness

Pad thickness inner

Pad thickness outer

Master cylinder inside diameterCaliper cylinder inside diameterCaliper cylinder inside diameterBrake fluid type

Single disk298 5 mm (11.73 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

4.5 mm(0.18 in)0.8 mm(0.03 in)0.8 mm(0.03 in)

Brake lever & brake pedal:Brake lever free play (at pivot)Brake lever free play (at lever end)Brake pedal positionBrake pedal free playClutch lever free play (at pivot)Clutch lever free play (at lever end)

1 2 mm (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 3 mm (0.08 0.12 in)10 15 mm (0.39 0.59 in)

–4–

MAINTENANCE SPECIFICATIONS SPEC

ELECTRICAL

Item Standard Limit

T.C.I.:Pickup coil resistance/color

T.C.I. unit model/manufacturer

182 222 Ω at 20C (68F)/Gray –BlackJ4T088/MITSUBISHI (U.S.A)J4T128/MITSUBISHI (CAL)

Ignition coil:Model/manufacturerMinimum spark gapPrimary winding resistanceSecondary winding resistance

F6T541/MITSUBISHI6 mm (0.24 in)3.6 4.8 Ω at 20C (68F)10.7 14.5 kΩ at 20C (68F)

Voltage regulator:TypeModel/manufacturerNo load regulated voltage

Semi-conductor, short-circuit typeSH650C-11/SHINDENGEN14.1 14.9 V

Rectifier:Model/manufacturerCapacityWithstand voltage

SH650C-11/SHINDENGEN18 A200 V

Electric starter system:TypeStarter motor:Model/manufacturerI.D. numberOutputBrush overall length

Commutator diameter

Mica undercutStarter relay:Model/manufacturerAmperage rating

Constant mesh type

SM-13/MITSUBASM-130.7 kW10 mm (0.39 in)

28 mm (1.10 in)

0.7 mm (0.08 in)

MS-5F-441/JIDECO180 A

4 mm(0.16 in)27 mm(1.06 in)

Flasher relay:TypeModel/manufacturerSelf cancelling deviceFlasher frequencyWattage

Semi transistor typeFB257H/DENSOYes75 95 cycle/min27 W 2 + 3.4 W

Fuel pump relay:Model/manufacturer G8R-30Y-Q/OMRON

–5–

MAINTENANCE SPECIFICATIONS SPEC

Item Standard Limit

Circuit breaker:TypeAmperage for individual circuitMAINHEADLIGHTSIGNALSIGNITIONCARBURETOR HEATERReserveReserveReserve

Fuse

30 A 115 A 110 A 110 A 115 A 130 A 115 A 110 A 1

–6–

LUBRICATION POINTS AND LUBRICANT TYPES SPEC

EB203000

LUBRICATION POINTS AND LUBRICANT TYPESENGINE

Lubrication point Symbol

Crankshaft journal

Camshaft cam lobe

Primary driven gear

–7–

CABLE ROUTING SPEC

19 Spark plug lead20 Fuel pump

10 Sidestand switch lead11 Rear brake switch lead12 Horn13 Headlight lead14 Right handlebar switch lead15 Main switch16 Main switch lead17 Fuel pump lead18 Fuel hose

1 Frame2 Clutch cable3 Left handlebar switch lead4 Fuel tank breather hose5 Speedometer cable6 Speedometer7 Speedometer light leads8 Vacuum chamber air vent hose9 Rectifier / regulator

EB206000

CABLE ROUTING

–8–

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 extraloosening.

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 clampor plastic locking tie.

D Pass the front flasher light leads (left and right) andheadlight lead through the headlight cover hole.

E Pass the left handlebar switch lead behind theupper bracket.

F Fasten the left handlebar switch lead with a plasticlocking tie.

G Pass the speedometer cable, speedometer lightleads and fuel tank breather hose through the fueltank hole.

CABLE ROUTING SPEC

–9–

V Pass the rear brake switch lead between the frameand rectifier / regulator. Do not pinch the rear brakeswitch lead.

W Fasten the rear brake switch lead with a plasticlocking 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.

P Route the sidestand switch and the lead wire underthe frame boss.

Q Fasten the sidestand switch lead with a metalclamp.

R Connect the rear brake switch coupler in front of theroll over valve stay.

S Install the plastic locking tie immediately below thecable guide bracket.

T Pass the speedometer cable through thespeedometer cable holder.

U To the rectifier / regulator.

CABLE ROUTING SPEC

–10–

25 Fuel tank breather hose26 Speedometer cable27 Ignitor unit

A Pass the tail /brake light leadbetween the frame bracket andbattery box. Position the mudguard the between the edge ofthe frame bracket and thetail /brake light lead.

B Fasten the dimmer switch leadwith a clamp.

13 Flasher light relay14 Starter relay15 Carburetor heater relay16 Neutral switch lead17 Pickup coil lead18 A.C. magneto lead19 Battery negative (–) lead20 Starter motor lead21 Battery cover22 Battery23 Wire harness24 Starting circuit cut-off relay

1 Frame bracket2 Dimmer switch3 Self-canceling turn signal relay4 Fuse box5 Battery positive (+) lead6 Spark plug lead7 Vacuum chamber air bent hose8 Starter cable9 Right handlebar switch lead10 Brake hose11 Throttle cables12 Thermo switch lead

CABLE ROUTING SPEC

–11–

I Pass the right handlebar switch lead behind theupper bracket.

J Fasten the brake hose grommet with a brake hoseholder.

K Place the left handlebar switch coupler on the sideof 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.

C Fasten the self-canceling turn signal relay lead andbattery positive (+) lead with a battery band.

D Fasten the tail /brake light lead coupler and batterynegative (–) lead coupler with a clamp.

E Fasten the starter relay lead and fuse box lead witha 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.

CABLE ROUTING SPEC

–12–

X Fasten the battery negative (–) lead, starter motorlead 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.

Q Fasten the battery positive (+) lead with a batterybox clamp.

R The carburetor heater relay should not touch thewire 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 aplastic locking tie.

CABLE ROUTING SPEC

–13–

AM Fasten the wire harness and leads with a plasticlocking tie.

AN Pass the plastic band through the frame hole.Fasten the wire harness with a plastic band at thepoint where the tape is located.

AO Fasten the wire harness and leads with a plasticlocking tie.

AP Fasten the wire harness and leads with a metalclamp.

AQ To the carburetor heater relay.AR Pass the ignitor unit leads through the battery box

hole.

AE Pass the fuel tank breather hose through theholder.

AF Fasten the fuel tank breather hose with a metalclamp.

AG Pass the speedometer cable through the frontside 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.

CABLE ROUTING SPEC

–14–

A Pass the throttle cables throughthe cable guide.

B Pass the left handlebar switchlead over the right handlebarswitch lead.

C Pass the clutch cable throughthe cable guide.

D Fasten the handlebar switchleads with a plastic band.

E To the ignition coil.F Pass the starter cable between

the ignition coil and spark pluglead.

13 Neutral switch lead14 Pickup coil lead15 A.C. magneto lead16 Thermo switch lead17 Fuel tank breather hose18 Rectifier / regulator coupler19 Wire harness20 Throttle position sensor (TPS)

lead21 Frame22 Air filter case

1 Front flasher light (right)2 Throttle cables3 Brake hose4 Right handlebar switch lead5 Clutch cable6 Left handlebar switch lead7 Front flasher light (left)8 Ignition coil9 Spark plug lead10 Silencer11 Starter cable12 Speedometer cable

CABLE ROUTING SPEC

–15–

N Fasten the wire harness and throttle positionsensor (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 theframe 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.

G To the throttle position sensor (TPS).H To the carburetor.I To the fuel tank.J 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.

CABLE ROUTING SPEC

–16–

REAR BRAKE ADJUSTMENTINSPADJ

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CAUTION:

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PERIODIC INSPECTION ANDADJUSTMENT

EB304012

REAR BRAKE ADJUSTMENT1. Check:Brake pedal height aOut 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 specifiedpedal height is obtained.

Turning in:brake pedal height isdecreased.

Turning out:brake pedal height isincreased.

Tighten the locknut.

Locknut:7 Nm (0.7 mkg, 5.1 ft lb)

3. Check:Brake pedal free play aOut 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 speci-fied free play is obtained.

Turning in:brake pedal free play isdecreased.

Turning out:brake pedal free play isincreased.

Make sure that there is no brake drag afteradjusting the brake pedal height and the freeplay.

–17–

REAR BRAKE ADJUSTMENTINSPADJ

5. Adjust:Brake light switchRefer to “BRAKE LIGHT SWITCH ADJUST-MENT”.

–18–

SHIFT PEDAL ADJUSTMENTINSPADJ

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***************************************NOTE:

EB304080

SHIFT PEDAL ADJUSTMENT1. Check:Shift pedal positionCheck 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 theshift pedal rod 2 in or out.

Turning in: shift pedal is lowered.

Turning out: shift pedal is raised.

Tighten both locknuts.

Align the mark on the shift shaft with the centerof the slit.

Turn in the both side of the shift pedal rod morethan 4 times.

–19–

AIR INDUCTION SYSTEM CARB

A To the front cylinder headB To the rear cylinder head

1 Reed valve2 Air cut valve3 Air cleaner4 Carburetor joint

EB601000

CARBURETION

AIR INDUCTION SYSTEMEAS00509

AIR INDUCTION SYSTEM DIAGRAMS

–20–

Order Job/Part Q’ty Remarks

1

2

3

4

5678

Removing the air induction systemReed valve case to front cylinder headhoseReed valve case to front cylinder headpipeReed valve case to rear cylinder headhoseReed valve case to rear cylinder headhoseGasketReed valve case to cylinder head pipeReed valve case to cylinder head hoseVacuum hose 2

1

1

1

1

2121

Remove the parts in the order listed.

2 Nm (0.2 mkg, 1.4 ft lb)

4 Nm (0.4 mkg, 2.9 ft lb)

AIR INDUCTION SYSTEM CARB

–21–

Order Job/Part Q’ty Remarks

910111213141516171819

CoverCoverVacuum hose 1Air cut valvePlugAir cut valve to air cleaner hoseAir cleanerAir Cleaner caseBend hoseAir cut valve to reed valve hoseReed valve

11111111111

For installation, reverse the removalprocedure.

2 Nm (0.2 mkg, 1.4 ft lb)

4 Nm (0.4 mkg, 2.9 ft lb)

AIR INDUCTION SYSTEM CARB

–22–

AIR INDUCTION SYSTEM CARB

EAS00510

CHECKING THE AIR INDUCTION SYSTEM1. Check:hosesLoose connection Connect properly.Cracks/damage Replace.

pipesCracks/damage Replace.

2. Check: reed valve 1 reed valve stopper reed valve seatCracks/damage Replace the reed valve.

3. Measure: reed valve bending aOut of specification Replace the reedvalve.

Maximum reed valve bending0.4 mm (0.016 in)

1 Surface plate

4. Check:air cutoff valveCracks/damage Replace.

5. Check:air cleanerCracks/damage Replace.Clogged Clean.

–23–

Order Job/Part Q’ty Remarks

1234

Front brake pad removalRetaining boltBrake caliperBrake padsPad spring

2121

Remove the parts in the order below.

For installation, reverse the removalprocedure.

Refer to “BRAKE PADREPLACEMENT”.

40 Nm (4.0 mkg, 28.9 ft lb)

27 Nm (2.7 mkg, 19.5 ft lb)

27 Nm (2.7 mkg, 19.5 ft lb)

FRONT BRAKE CHAS

CHASSISFRONT BRAKEFRONT BRAKE PADS

–24–

FRONT BRAKE CHAS

CAUTION:

NOTE:

NOTE:

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Disc brake components rarely require disas-sembly. DO NOT:disassemble components unless abso-lutely necessary;

use solvents on internal brake compo-nents;

use spent brake fluid for cleaning; (useonly clean brake fluid)

allow brake fluid to come in contact withthe eyes, as this may cause eye injury;

splash brake fluid onto painted surfaces orplastic parts, as this may cause damage;

disconnect any hydraulic connection, asthis would require the entire brake systemto be disassembled, drained, cleaned,properly filled and bled after reassembly.

BRAKE PAD REPLACEMENT

It is not necessary to disassemble the brake cal-iper and brake hose to replace the brake pads.

1. Remove:Retaining bolt 1

2. Remove:Brake pads 1

Install new brake pad springs when the brakepads have to be replaced.

Replace the brake pads as a set if either isfound to be worn to the wear limit.

3. Install:Brake padsBrake pads spring

Installation steps: Connect a suitable hose 1 tightely to the

brake caliper bleed screw 2 . Put the otherend of this hose into an open container.

–25–

FRONT BRAKE CHAS

***************************************

Loosen the brake caliper bleed screw andusing a finger push the caliper pistons intothe brake caliper.

Tighten the brake caliper bleed screw 2 .

Brake caliper bleed screw:6 Nm (0.6 mkg, 4.3 ft lb)

Install new brake pads and a new brake padspring.

Install the brake caliper 3 and retaining bolt4 .

Bolt (brake caliper):40 Nm (4.0 mkg, 28.9 ft lb)

Retaining bolt:27 Nm (2.7 mkg, 19.5 ft lb)

4. CheckBrake fluid levelRefer to “BRAKE FLUID LEVEL INSPEC-TION” in CHAPTER 3.a “LOWER” level line

5. Check:Brake lever operaitonSoft or spongy feeling Bleed the brakesystem.Refer to “AIR BLEEDING (HYDRAULICBRAKE SYSTEM)” in CHAPTER 3.

–26–

Order Job/Part Q’ty Remarks

123456

Front brake caliper removalBrake fluidBrake hose holderUnion boltsCopper washersBrake hoseRetaining boltBrake caliper assembly

112121

Remove the parts in the order below.Drain

For installation, reverse the removalprocedure.

Refer to “CALIPER INSTALLATION”.

7 Nm (0.7 mkg, 5.1 ft lb)

30 Nm (3.0 mkg, 21.7 ft lb)

40 Nm (4.0 mkg, 28.9 ft lb)

27 Nm (2.7 mkg, 19.5 ft lb)

6 Nm (0.6 mkg, 4.3 ft lb)

27 Nm (2.7 mkg,19.5 ftlb)

FRONT BRAKE CHAS

FRONT BRAKE CALIPER

–27–

FRONT BRAKE CHAS

27 Nm (2.7 mkg, 19.5 ft lb)

30 Nm (3.0 mkg, 21.7 ft lb)

CAUTION:

WARNING

CAUTION:

WARNING

CALIPER INSTALLATION1. Install:Brake caliper 1Retaining bolt 2

Brake hose 3Copper washers 4 NewUnion bolt 5

When installing the brake hose on the brakecaliper, make sure that the brake pipetouches the projection a on the brake cali-per.

Proper brake hose routing is essential to in-sure safe motorcycle operation. Refer to“CABLE ROUTING”.

2. Fill:Brake reservoir

Recommended brake fluid:DOT 4

Brake fluid may damage painted surfaces orplastic parts. Always clean up spilled brakefluid immediately.

Use only the designated quality brake fluid:other brake fluids may deteriorate the rub-ber seals, causing leakage and poor brakeperformance.

Refill with the same type of brake fluid: mix-ing brake fluids may result in a harmfulchemical reaction and lead to poor brakeperformance.

Be careful that water does not enter themaster cylinder when refilling. Water willsignificantly lower the boiling point of thebrake fluid and may result in vapor lock.

–28–

FRONT BRAKE CHAS

3. Air bleedBrake systemRefer to “AIR BLEEDING (HYDRAULICBRAKE SYSTEM)” in CHAPTER 3.

4. Check:Brake fluid levelBrake fluid level is under the “LOWER” levelline Fill up.Refer to “BRAKE FLUID LEVEL INSPEC-TION” in CHAPTER 3.a “LOWER” level line

COLOR CODEB Black. . . . . Br Brown. . . . Ch Chocolate. . . Dg Dark green. . . G Green. . . . Gy Gray. . .

1 A.C. magneto2 Rectifier / regulator3 Main switch4 Battery5 Main fuse6 Starter relay7 Starter motor8 Relay unit9 Fuel pump10 Sidestand switch11 Throttle position sensor (TPS)12 Ignitor unit13 Ignition coil14 Spark plug15 Pickup coil16 Neutral switch17 Meter assembly18 Engine indicator light19 Neutral indicator light20 Meter light21 High beam indicator light22 Turn indicator light23 Rear turn signal24 Front turn signal25 Headlight26 Left handlebar switch27 Dimmer switch28 Horn switch29 Clutch switch30 Turn switch31 Flasher relay32 Horn33 Rear brake switch34 Tail /brake light35 Carburetor heater36 Carburetor heater earth37 Carburetor heater relay38 Thermo switch39 Carburetor heater fuse40 Signal system fuse41 Headlight fuse42 Ignition fuse43 Right handlebar switch44 Front brake switch45 Engine stop switch46 Start switch

L Blue. . . . . Lg Light green. . . . O Orange. . . . P Pink. . . . . R Red. . . . . Sb Sky blue. . . .

W White. . . . Y Yellow. . . . . B/L Black/Blue. . . B/W Black/White. . B/Y Black/Yellow. . . Br/B Brown/Black. .

Br/L Brown/Blue. . Br/W Brown/White. Br/Y Brown/Yellow. . G/Y Green/Yellow. . L/B Blue/Black. . . L/R Blue/Red. . .

L/W Blue/White. . L/Y Blue/Yellow. . . R/B Red/Black. . . R/W Red/White. . R/Y Red/Yellow. . .

XVS650AN(C) WIRING DIAGRAM

PRINTED IN U.S.A.99 S 11 - 0.4 1