Yamaha DRAG STAR XVS650 (1997) [135/360] Cylinders and pistons

Содержание

• Service mandai 2
• Xvs650akœ 2
• Yamaha 2
• Caution 4
• Important information 4
• Notice 4
• How to use this manual 5
• Illustrated symbols 6
• Carburetion 7
• Chapter titles 7
• Chassis 7
• Electrical 7
• Engine overhaul 7
• General information 7
• Periodic inspection and adjustment 7
• Specifications 7
• Troubleshooting 7
• Chapter 2 8
• Contents chapter 1 8
• Gen info 8
• General information 8
• Insp adj 8
• Specifications 8
• Chapter 3 9
• Periodic inspections and adjustments 9
• Chapter 4 10
• Engine 10
• Carburetion 11
• Chapter 5 11
• Chapter 6 12
• Chassis 12
• Chapter 7 electrical 13
• Chapter 8 14
• Gen info 14
• Insp adj 14
• Troubleshooting 14
• Gen info 16
• General information 16
• Motorcycle identification 16
• Gen info 17
• Important information 17
• Caution ________________________ 18
• Gen info 18
• Important information 18
• Checking of connections 19
• Gen info 19
• Gen info 20
• Special tools 20
• Special tools fo 22
• General specifications 24
• Spec ü 24
• Specifications 24
• General specifications 25
• General specifications 26
• Maintenance specifications 27
• Spec ü 27
• Maintenance specifications 28
• Maintenance specifications 29
• Maintenance specifications 30
• Maintenance specifications 31
• Maintenance specifications 32
• Maintenance specifications spec ü 33
• Maintenance specifications spec 0 34
• Maintenance specifications 35
• Spec ü 35
• Maintenance specifications 36
• Maintenance specifications 37
• Maintenance specifications 38
• Maintenance specifications 39
• Spec q 39
• Maintenance specifications 40
• Spec ü 40
• Maintenance specifications 41
• Maintenance specifications 42
• General torque specifications 43
• Lubrication points and lubricant types 44
• Spec 0 44
• Lubrication points and lubricant types 45
• Spec u 45
• Lubrication diagrams 46
• Spec u 46
• Lubrication diagrams spec u 47
• Lubrication diagrams 48
• Spec 0 48
• Lubrication diagrams 49
• Spec ü 49
• Cable routing 50
• Cable routing 51
• Cable routing 52
• Spec u 52
• Cable routing 53
• Spec o 53
• Cable routing 54
• Cable routing 55
• Spec u 55
• Cable routing 56
• Spec u 56
• Cable routing 57
• Spec u 57
• Cable routing 58
• Spec q 58
• Cable routing 59
• Cable routing 60
• Spec u 60
• Cable routing 61
• Introduction 62
• Introduction periodic maintenance nsp fob 62
• Items marked with an asterisk require special tools data and technical skills for servicing take the motorcycle to a yamaha dealer or refer to the service manual when servicing these items 62
• Lubrication intervals 62
• Periodic inspections and adjustments 62
• Periodic maintenance lubrication intervals 62
• This chapter includes all information necessary to perform recommended inspections and adjustments these preventive maintenance procedures if followed will ensure more reli able vehicle operation and a longer service life the need for costly overhaul work will be greatly reduced this information applies to vehicles already in service as well as to new vehicles that are being prepared for sale all service technicians should be familiar with this entire chapter 62
• General maintenance lubrication 63
• Insp adj 63
• Items marked with an asterisk require special tools data and technical skills for servicing take the motorcycle to a yamaha dealer or refer to the service manual when servicing these items 63
• General maintenance lubrication 64
• Insp adj 64
• Fuel tank and seats 65
• Insp adj 65
• Engine 66
• Insp adj 66
• Valve clearance adjustment 66
• Insp fol 67
• Valve clearance adjustment 67
• Insp fob adj 68
• Valve clearance adjustment 68
• Valve clearance adjustment i sp îab carburetor synchronization 69
• Carburetor synchronization 70
• Insp to 70
• Idling speed adjustment 71
• Insp adj 71
• Adj xv 72
• Idling speed adjustment 72
• Throttle cable adjustment 72
• Caution ________________________ 73
• Spark plug inspection 73
• Throttle cable adjustment nsp fob 73
• Insp adj 74
• Spark plug inspection ignition timing check 74
• Ignition timing check 75
• Insp fob adj 75
• Caution ________________________ 76
• Compression pressure measurement 76
• Insp fob adj 76
• Compression pressure measurement 77
• Insp ad 77
• Engine oil level inspection 78
• Insp adj 78
• _______________ 78
• Engine oil replacement 79
• Insp adj 79
• Engine oil replacement 80
• Caution ________________________ 81
• Clutch adjustment air filter cleaning 81
• Insp adj 81
• Air filter cleaning carburetor joint sp à ab 82
• Inspection fuel line inspection 82
• J sîv 82
• Breather hose inspection 83
• Exhaust system inspection 83
• Sp idl 83
• Caution ________________________ 84
• Chassis 84
• Front brake adjustment 84
• Insp 4ob adj 84
• Caution ________________________ 85
• Insp go adj 85
• Rear brake adjustment 85
• Brake fluid level inspection 86
• Caution ________________________ 86
• Rear brake adjustment nsp fob 86
• Brake light switch adjustment 87
• Brake pad inspection brake shoe inspection insp gob 87
• J sjç 87
• Air bleeding hydraulic brake system 88
• Brake hose inspection 88
• Sp inb 88
• Air bleeding hydraulic brake system 89
• Shift pedal adjustment 89
• Sp ink 89
• Final gear oil level inspection 90
• Shift pedal adjustment nsp inb 90
• Final gear oil replacement nsp îal 91
• Steering head inspection adj wl 91
• Insp lol 92
• Steering head inspection 92
• Front fork inspection adj sîv 93
• Sp fob 93
• Steering head inspection 93
• Caution ________________________ 94
• Rear shock absorber adjustment nsp fob 94
• Tire inspection 94
• Insp adj 95
• Tire inspection 95
• Insp fol 96
• Tire inspection 96
• Tightening cable inspection and lubrication dj 97
• Wheel inspection spoke inspection and isp fob 97
• Cable inspection and lubrication lever and nsp fob 98
• Pedal lubrication sidestand lubrication 98
• Battery inspection 99
• Caution ________________________ 99
• Electrical 99
• Insp adj 99
• Battery inspection 100
• Caution ________________________ 100
• Insp fob adj wv 100
• Battery inspection 101
• Caution ________________________ 101
• Insp adj 101
• Battery inspection 103
• Insp adj 103
• Battery inspection nsp ini 104
• Caution ________________________ 104
• Fuse inspection 104
• Fuse inspection 105
• Insp adj 105
• Headlight beam adjustment nsp fob headlight bulb replacement dj 106
• Adj 1v 107
• Caution ________________________ 107
• Headlight bulb replacement 107
• Insp fol 107
• Engine 108
• Engine removal 108
• Engine removal 109
• Engine removal 110
• Engine removal 111
• Engine removal 112
• Engine removal 113
• Engine removal 114
• Engine removal 115
• Cylinder heads 116
• Cylinder heads 117
• Cylinder heads 118
• Cylinder heads 119
• Cylinder heads 120
• Cylinder heads 121
• Cylinder heads 122
• Cylinder heads 123
• Rocker arms and camshaft 124
• Rocker arms and camshaft 125
• Rocker arms and camshaft 126
• Rocker arms and camshaft 127
• Valves amd valve springs 128
• Valves and valve springs 128
• Valves and valve springs 129
• Valves and valve springs 130
• Valves and valve springs 131
• Caution ______________ 132
• Valves and valve springs 132
• Valves and valve springs 133
• Caution ___________________ 134
• Valves and valve springs 134
• Cylinders and pistons 135
• Caution ________________________ 136
• Cylinders and pistons 136
• C a 2c 137
• Cylinders and pistons 137
• Cylinders and pistons 138
• Cylinders and pistons 139
• Cylinders and pistons 140
• Clutch 141
• Clutch 142
• Clutch 144
• Clutch 145
• Clutch 146
• Clutch 147
• Clutch 148
• Shift shaft 149
• Shift shaft 150
• Shift shaft 151
• Oil pump 152
• Oil pump 153
• Oil pump 154
• Ac magneto and starter clutch 155
• Ac magneto and starter clutch 156
• Ac magneto and starter clutch 157
• Ac magneto and starter clutch 158
• Ac magneto and starter clutch 159
• Crankshaft and connecting rods 160
• Crankshaft and connecting rods 161
• Crankshaft and connecting rods 162
• Caution _________________________ 163
• Crankshaft and connecting rods 163
• Crankshaft and connecting rods 164
• Caution ___________________ 165
• Crankshaft and connecting rods 165
• Caution ________________________ 166
• Crankshaft and connecting rods 166
• Caution _________________________ 167
• Crankshaft and connecting rods 167
• Caution ________________________ 168
• Crankshaft and connecting rods 168
• Crankshaft and connecting rods 169
• Caution _________________________ 170
• Crankshaft and connecting rods 170
• Crankshaft and connecting rods 171
• Transmission 172
• Transmission 173
• Transmission 174
• Transmission 175
• Middle gear 176
• Middle gear 177
• Middle gear 178
• Caution _________________________ 179
• Middle gear 179
• Caution _________________________ 180
• Middle gear 180
• Middle gear 181
• Caution ________________________ 182
• Middle gear 182
• Caution _________________________ 183
• Middle gear 183
• Caution _________________________ 184
• Middle gear 184
• Middle gear 185
• Middle gear 186
• Caution ________________________ 187
• Middle gear 187
• Caution _________________________ 188
• Middle gear 188
• Middle gear 189
• Carburetion 190
• Carburetor 190
• Carburetor 191
• Carburetor 192
• Carburetor 193
• Carburetor 194
• Caution ________________________ 194
• Carburetor 195
• Carburetor 196
• Carburetor 197
• Carburetor 198
• Air induction system ais 199
• Air induction system ais 200
• Chassis 202
• Front wheel and brake disc 202
• Front wheel and brake disc 203
• Front wheel and brake disc 204
• Front wheel and brake disc 205
• Caution ________________________ 206
• Front wheel and brake disc 206
• Front wheel and brake disc 207
• Front wheel and brake disc 208
• Front brake 209
• Caution ________________________ 210
• Front brake 210
• Front brake 211
• Front brake 212
• Front brake 213
• Front brake 214
• Caution ________________________ 215
• Front brake 215
• Caution ___________________ 216
• Front brake 216
• Front brake 217
• Front brake 218
• Front brake 219
• Front brake 220
• Caution ________________________ 221
• Front brake 221
• Rear wheel and rear brake 222
• Rear wheel and rear brake 223
• Rear wheel and rear brake 224
• Rear wheel and rear brake 225
• Rear wheel and rear brake 226
• Rear wheel and rear brake 227
• Caution ________________________ 228
• Rear wheel and rear brake 229
• Rear wheel and rear brake 230
• Front fork 231
• Front fork 232
• Front fork 233
• Front fork 234
• Caution ________________________ 235
• Front fork 235
• Front fork 236
• Caution ________________________ 237
• Front for 237
• Caution ________________________ 238
• Front fork 238
• Front fork 239
• Front fork 240
• Handlebar 241
• Handlebar 242
• Caution ___________________ 243
• Handlebar 243
• Caution ________________________ 244
• Handlebar 244
• Handlebar 245
• Steering head 246
• Steering head 247
• Caution ________________________ 248
• Steering head 248
• Rear shock absorber and swingarm 249
• Rear shock absorber and swingarm 250
• Rear shock absorber and swingarm 251
• Rear shock absorber and swingarm 252
• Rear shock absorber and swingarm 253
• Shaft drive 254
• Caution ________________________ 255
• Shaft drive 255
• Shaft drive 257
• Shaft drive 258
• Shaft drive 259
• Shaft drive 260
• Shaft drive 261
• Caution ________________________ 262
• Shaft drive 262
• Shaft drive 263
• Shaft drive 264
• Shaft drive 265
• Caution ________________________ 266
• Shaft drive 266
• Shaft drive 267
• Shaft drive 268
• Electrical 270
• Electrical components 270
• Switch inspection 271
• Switch inspection elec 271
• Switch inspection 273
• Ignition system elec 275
• Ignition system 276
• Ignition system 277
• Electric starting system 281
• Electric starting system 282
• Electric starting system 284
• Electric starting system 287
• Electric starting system 288
• Electric starting system 289
• Charging system 292
• Lighting system 293
• Trr ill 293
• Lighting system 297
• Lighting system 298
• Signal system 300
• Signal system 302
• Signal system 304
• Signal system 306
• L j o 8 307
• Fuel pump system 310
• Fuel pump system 311
• Carburetor heater system 315
• Carburetor heater system 316
• Self diagnosis 318
• Starting failure hard starting 320
• Trbl o shtg f 320
• Troubleshooting 320
• Poor idle speed performance 321
• Poor medium and high speed performance 321
• Clutch slipping dragging 322
• Clutch slipping dragging shtg 322
• Faulty gear shifting 322
• Faulty gear shifting trbl o 322
• Faulty brake 323
• Front fork oil leakage and front fork malfunction 323
• Leakage and front fork malfunction 323
• Overheating 323
• Overheating faulty brake front fork oil 323
• Trbl o 323
• Faulty lighting and signal systems 324
• Trbl o 324
• Unstable handling 324
• Xvs650ak c wiring diagram 325
• Xvs650kici 328
• Foreword 329
• Caution 330
• Important information 330
• Notice 330
• How to use this manual 331
• Illustrated symbols 332
• Contents 333
• Gen info 334
• General information 334
• Motorcycle identification 334
• General specifications 335
• Spec ü 335
• Specifications 335
• Maintenance specifications 336
• Cable routing 337
• Spec o 337
• Cable routing 338
• Cable routing 339
• Cable routing 340
• Cable routing 341
• Spec u 341
• Cable routing 342
• Spec o 342
• Cable routing 343
• Spec o 343
• Cable routing 344
• Cable routing 345
• Spec o 345
• Fuel tank and seats 346
• Insp fo 346
• Periodic inspection and adjustments 346
• Headlight beam adjustment nsp inb headlight bulb replacement 347
• Caution ___________________ 348
• Headlight bulb replacement 348
• Insp lot 348
• Chassis 349
• Front fork 349
• Front fork 350
• Front fork 351
• Caution ___________________ 352
• Front fork 352
• Front fork 353
• Caution ___________________ 354
• Front fork 354
• Caution i__________________ 355
• Front fork 355
• Front fork 356
• Steering head 357
• Steering head 358
• Genuine yamaha 360

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CYLINDERS AND PISTONS CYLINDERS AND PISTONS Order Job name Part name Q ty 1 Cylinder and piston removal Cylinder heads Timing chain guide 2 Cylinder O ring 1 1 3 4 5 6 7 O ring collar Dowel pins Cylinder gasket Piston pin clips Piston pin Piston Piston ring set 1 1 2 1 2 1 8 9 1 1 1 Remarks Remove the parts in the order below Refer to CYLINDER HEADS The up mark should face towards the cylinder head Refer to CYLINDER AND PISTON INSTALLATION Refer to PISTON REMOVAL CYLINDER AND PISTON INSTALLATION For installation reverse the removal procedure 4 28