INDEX XS650E GENERAL INFORMATION PERIODIC INSPECTION AND ADJUSTMENT ENGINE OVERHAUL CARBURETION CHASSIS ELECTRICAL I APPENDICES Property of www.SmallEngineDiscount.
XS650SE SUPPLEMENT (EPA) XS650E SUPPLEMENT *XS650SF USES THIS SUPPLEMENT (EPA) XS650SE SUPPLEMENT I XS650SF/2F SUPPLEMENT XS650G/SG SUPPLEMENT Property of www.SmallEngineDiscount.
CHAPTER 1. GENERAL INFORMATION l-l. MACHINE IDENTIFICATION . . . . . . . . . . . . . . . a . . . . . . . . . . . . . . . . . . . . . . . . . . .1 l-2. SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Property of www.SmallEngineDiscount.
CHAPTER 1. GENERAL INFORMATION l-l. MACHINE IDENTIFICATION . Frame serial number The frame serial number is stamped on the right side of the steering head stock. Engine serial number The engine serial number is stamped on the front of the engine crank case. NOTE: The first three digits of these numbers are for model identifications; the remaining digits are the unit production number. 1-2. SPECIAL TOOLS , 1. Cam chain cutter Parts No. (90890-01112) 2. Valve spring compressor (90890-01253) 3.
I 7. Rotor puller (90890-01070) 10. Drive chain cutter (90890-01081) P 8. Clutch holding tool (90890-01069) 11. Pocket tester (90890-03096) 9. Slide hammer (90890~;z) 12. E lectro tester (9089@0302 1) OTHER TOOL Valve guide remover Valve guide installer Spoke wrench Steering nut wrench Tappet adjuster wrench PARTS No. 90890-01200 90890-01201 90890-05087 90890-01051 .256-28137-00 13. Vacuum gauge (90890-03094) Property of www.SmallEngineDiscount.
CHAPTER 2. PERIODIC INSPECTION AND ADJUSTMENT 2-1. 2-2. 2-3. INTRODUCTION ..................................................... MAINTENANCE INTERVAL CHARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4 A. PEPIODIC MAINTENANCE ..........................................4 B. LUBRICATION INTERVALS .... ............................... .... 5 ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . 6 A.
CHAPTER 2. PERIODIC INSPECTION AND ADJUSTMENT 2-1. INTRODUCTION This chapter includes all information necessary to perform recommended inspection and adjustments, These preventive maintenance procedures, if followed, will insure more reliable vehicle operation and a longer service life. The need for costly overhaul work will be greatly reduced. This information applies not only to vehicles already in service, but also to new vehicles that are being prepared for sale.
6. LUBRICATION INTERVALS , a_:._ Y- ,- mission oil Drive chain Control/Meter Apply thoroughly Oil filter element Wheel bearings Do not over/ Yearly or . . . Point cam lubrication wicks Apply very lightly 12,800 Medium-weight wheel bearing grease Light-weight machine oil (8.000) 0 0 0 0 Property of www.SmallEngineDiscount.
2-3. ENGINE A. Carburetor 1. Idle mixture The idle mixture is set at the factory by the use of special equipment. No attempt should be made to change this adjustment by the dealer. b. Install the attachment and set the vacuum gauge. c. Start motorcycle and allow it to warm up for 2 - 3 minutes. The warm-up is complete when engine responds normally to throttle opening. d. Adjust damping valve on each vacuum gauge until the needle flutters only slightly.
mi.). It should be cleaned more often if the machine is operated in extremely dusty areas. 1 .Throttle nap se- B. Air filters This model uses a cartridge type air filter element which consists of foam rubber. 1. Removal a. Remove the air filter cover by removing the bolts. b. Pull out the springs and elements. C. Engine/transmission oil and filter 1. Oil level measurement a. To check the level, warm the engine up for several minutes. Stop the engine.
d. Remove the filter cover and oil filter securing bolt. HA 2. Mechanism adjustment a. Screw in the cable adjuster (on the lever holder) until tight. b. Screw in the adjuster (push screw) until it lightly seats against a clutch push rod. c. Back the adjuster out l/4 turn and tihgten the lock nut. d. Adjust the free play of clutch lever by turning the cable adjuster. 1. Filter securing bolt. e. Slip the filter element out and clean. f. Install the filter and filter cover. Filter torque: 1.
1. 2. 3. 4. Remove all four tappet covers and the generator cover. Turn the crankshaft to align the rotor mark with the “T” mark on the stator. This places the pistons at the top dead center and the valve clearance should be checked and adjusted at the top dead center on the compression stroke by observing when the valve adjusters have clearance. Use a feeler gauge to determine the clearance. H. Exhaust system 1. Check for leakage from exhaust joints and retighten joint bolts and nuts. 2.
D. Front brake The brake can be adjusted by simplay adjusting the distance that the brake lever can travel. (The piston in the caliper moves forward as the brake pad wears out, automatically adjusting the clearance between the brake pad and the brake disc.) 1. Adjustment a. Turn adjuster so that a brake lever end is 5 - 8 mm (0.2 - 0.3 in) before adjuster contacts master cylinder piston.
FRONT REAR XS650E BASIC WEIGHT with oil md full fuel tank 104 kg@29 lb) 119 kg1262 lb) Standard tire Bridgestone or Bridgestone or Yokohama Yokohama 3.50H19-4PR 4.OOHlB-lPR Tire load limit 234 kg (515 lb) 280 kg (615 lb] Cold tire pressure Normal riding 20 mm (3/4 in) 1.6 kg/cm’ (22 psi) With passenger 2.0 kg/cm2 or high speed (28 psi) riding With passenger 2.8 kg/cm2 (40 psi) $$xtra load Vlinimum tire :read depth 0.8 mm (0.03 in) 2.0 kg/cm2 (28 psi) 2.3 kg/cm’ (32 psi) 2.8 kg/cm2 (40 psi) 0.
b. To clean the entire chain, first remove the chain from the motorcycle, dip it in solvent and clean with stiff brush. Then take the chain out of the solvent and dry it. Immediately, lubricate the chain to prevent the formation of rust. 7. Install drain screw. NOTE: Check gasket. Replace if damaged. 8. Pour specified amount of oil into the inner tube through the upper end opening. Front fork oil: Yamaha fork oil 10 Wt H. Front fork oil change 1.
the end of the cable can be held high to pour in several drops of lubricant. With throttle grip disassembled, coat the inside surface of the throttle grip guide tube with a suitable all-purpose grease to cut down friction. 2. Meter cables Pull the inner cable out and apply cable lube throughly. c. If there is looseness in the steering head, loosen the crown pinch bolt, fork pinch bolts, and steering fitting bolt. 3.
c. Rust or wear on the breaker arm or arm shaft. d. Faulty insulation of the contact braker assembly. e Oil or dirt on the assembly. 2. To clean the points, run a point file between the points until the grey deposits and pits have been removed. Spray the points with ignition point cleaner or lacquer thinner, then snap the points shut on a white business card (or paper of hard texture) and repeatedly pull the card through until no more carbon or metal particles come off on the card.
and thechassis lead is for the (-) terminal. Make sure the breather pipe is properly connected, properly routed, and is not damaged or obstructed. NOTE: The battery must be charged before using to insure maximum performance. Failure to properly charge the battery before first use, or a low electrolyte level, will cause premature failure of the battery. Charging current: Charging hours: 1.4 Amp 10 hrs F. Spark plug The spark plug indicates how the engine is operating.
CHAPTER 3. ENGINE OVERHAUL 3-1. ENGINE REMOVAL ........................................ .... A. Preparation for removal ................................... . . . . .18 . . . . .18 . . . . .I8 . . . . .18 B. Fuel tank removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal of other parts. ................................... D. Engine mounting bolts and engine removal .................... C. 3-2. ENGINE DISASSEMBLY .................................... ..... .
3-4. ENGINE ASSEMBLY AND ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29 A. Shift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29 B. Transmission and crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29 C. Shifter assembly ................................................ . .30 D. Kick starter assembly ............................................ . .30 E.
CHAPTER 3. ENGINE OVERHAUL 31. ENGINE REMOVAL A. Preparation for removal 1. All dirt, mud, dust and foreign material should be thoroughly removed from the exterior of the engine before removal and disassembly. 2. Place machine on center stand. Star-f engine and allow it to warm up. Stop engine and drain engine/transmission oil. 8. Carburetor (to the left), and throttle cable 9. Brake pedal 10. All wires and cables connecting engine and chassis 11.
3-2 ENGINE DISASSEMBLY A. Governor and breaker assembly removal Remove the following parts in the order given. 1. Breaker cover 2. Breaker backing plate 3. Breaker housing 4. Governor cover 5. Notched plate 6. Lock nut (using punch and hammer) 7. Governor assembly C. Rocker arm removal 1. Remove rocker shaft covers. 2. Remove shouldered sleeves and O-rings. 3. Withdraw rocker shafts with the special tool or 6 mm bolt. D. Valve removal 1. Compress the valve spring and then remove both retainer locks.
I. Electric starter unit removal 1. Remove the gear train cover, and idle gear 1 and 2. 1. 2. 3. 4. 5. Push rod Ball Push rod (Aluminuml Push crown Hold the clutch unit with the holding tool (special tool), and unscrew the clutch boss lock nut. H. Kick axle and change shaft removal 1. Slip the bent sprin g off and pull the kick axle assembly out. 2. Remove circlip from left side of change shaft and pull the shaft out. 1. Kick axle 4. Kick gear 7. Spacer 8. Kickspring 5. Kickclip 2. Holder 9.
L. Transmission illustration 1. 2. 3. 4. 5. 6. Main axle 2nd pinion gear 3rd pinion gear 4th pinion gear 5th pinion gear Drive sprocket (13T) (17T) (20T) (21T) (23T) (17T) 1’ 2’ 3’ 4’ 5’ 1st wheel gear 2nd wheel gear 3rd wheel gear 4th wheel gear 5th wheel gear Transmission (32T) (27T) (26T) (23T) (22T) M. Shift drum removal 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. Bolt Lock plate stopper Plate Shaft bolt stopper Stopper spring Shift cam Bearing Shift fork (3) Shift fork (2) 11. 12. 13. 14. 15. 16. 17. 18.
1 . Release the stopper spring (6). 4. Remove the neutral detent unit (15-18). 2. Remove the bolts (1) and stopper plate(3). 5. Removecotter pins (13). and pin (12) 6. Pull out the shift cam (7). 3. Pull the guide bar (14) out. N. Crankshaft removal 1. Tap the crankshaft with a rubber hammer to loosen it, then lift it out. 2. Crankshaft illustration 1 . Crank 1(L) 14. Cam chain sprocket 2. Crank 2(R) 1 5 . Journal bearing 2 16. Circlip 17. Primary drive gear 3. Crank 2(L) 4 . Crank 2 ( R ) 5.
C. Valve, valve guide and valve seat 1. Valve guide a. If the valve guide inside diameter is beyond serviceable limits, replace with an oversize valve guide. Standard Guide diameter 1 8.010 - 8.019 mm (I.D.) (IN.EX) / (0.315 - 0.316 in) b. Measuring the clearance between valve and valve guide. 1) Insert the valve into the valve guide in the cylinder head and measure the clearance in both the X and Y axes, using a small dial gauge. d.
width. The valve seat will have removed the bluing wherever it contacted the valve face. Measure the seat width with vernier calipers. It should measure approximately 1.3 mm. Also, the seat should be uniform in contact area. If valve seat width varies, or if pits still exist, then continue to cut with the 45° cutter. Remove just enough material to achieve a satisfactory seat. Standard width I I Wear limit / c.
c. Another symptom of a fatigued spring is insufficient spring pressure when compressed. This can be checked using a valve spring compression rate gauge. Test each spring individually. Place it in the gauge and compress the spring first to the specified compressed length with the valve closed (all spring specifications can be found in the previous section, valve spring), then to length with the valve open. Note the poundage indicated on the scale at each setting.
-7 -t- Q I A B 4. All camshaft bearings should be removed, cleaned, dried, and the races visually checked for pits, rust spots or chatter marks where the balls have dragged, If any of these conditions exists the bearing(s) should be replaced. I Standard I Wear Ilmit I 1 Cylinder / outof-round G.Cam chain, sprocket and dampers 1. Cam chain Except in cases of oil starvation, the cam chain wears very little.
b. Determine piston clearance as follows: J. Piston pin 1. Apply a light film of oil to pin. install in connecting rod small end. Check for play. There should be no noticeable vertical play. If play exists, check connecting rod small end for wear. Replace pin and connecting rod as required. 2. The piston pin should have no noticeable free play in piston. If the piston pin is loose, replace the pin and/or the piston. Example: 75.02 mm -74.97 mm =0.05 mm piston clearance K. Crankshaft 1.
2. Check the clearance between outer rotor and inner rotor. 5. Clutch springs Measure clutch spring free length. Replace springs as a set if necessary. Standard clearance: 0.03 - 0.09 mm (0.0012 - 0.0035 in) M. Clutch 1. Clutch housing Check dogs on clutch housing. Look for cracks and signs of galling on edges. If damage is moderate, deburr. If severe, replace clutch housing. NOTE: Galling on the friction plate dogs of the clutch housing will cause erratic clutch operation. 2.
11. Check to see that each gear properly engages its counterpart on the shaft. Check the mating dogs for rounded edges, cracks, or missing portions. Replace as required. 0. Electric starter gears and clip spring 1. Check the gears for wear or scratches on teeth, particularly in the chamfered area of each gear. 2. The clip spring is fitted to gear (4) (Refer to PAGE 20) and slides in the groove. A too-tight or loose-fitting clip may result in improper operation.
4. Make sure all bearings are positioned properly as shown. 1. Kick clap 1. No clearance 5. Fit the chain over the cam sprocket, 6. Apply Yamaha Bond No. 4 sealant to crankcase mating surface. 7. Install bottom crankcase and nuts. Install nuts as follows: a. Use copper washers and blind nuts on bolts (1). (2), (3), (4), (12), (13). b. Tighten nuts in two stages in proper torque sequence. Start with bolt number one. 2.
n. Pressure plate and clutch springs / o. Primary drive gear I Clutch screw torque: 1 .O m-kg (7 ft-lb) a. Plate 1 b. Plate 2 C. Spacer shaft d. Housing e. Bearing plate f. Bearing g. Plate 2 h. Clutch boss i. Plane washer j. Conical spring k. Nut (usmg special tool) I. Friction plates and clutch plates m. Push rods, balls and push crw,” n. Pressure plate and clutch spring Drive gear torque: 9 m-kg (65 ft-lb) k a = 1 .o mm b =2.0 e = 1.0 f = 2.0 g =2.0 I = 2.6 i = 2.0 m d - Property of www.
G. Generator 1. Lock the crank rotation at the primary drive gear. 2. Reverse the generator removal sequence. 2. Install pistons on rods. The arrow on the pistons must point to the front of the engine. NOTE: Always install new piston pin clips. H. Oil pump Reverse the oil pump removal sequence. K. Cylinder and cylinder head Install the tensioner cushion onto crankcase. 2. Install a new cylinder base gasket. 3. Install cylinder using special tool. 4. Install the cylinder head gasket and cylinder head. 1.
4. Joint the chain together and revet a new link. 5. Install the cam chain tensioner, and adjust 6. O. Engine chain tension. Refer to PAGE. (8). Make sure the timing is correct. M. Cylinder heed cover 1. Install all components in the head cover. 2. Apply Yamaha No. 4 sealant to cover mating surfaces. 3. Install all head cover retaining nuts and bolts and thread them down until lightly seated. 4. Tighten them with torque wrench in the order given 11 1. 4 5 (M10).5.0 m-kg (36 ft-lb) N.
CHAPTER 4. CARBURETION 4-1. CARBURETOR.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..3 6 A. Description.......................................................3 6 B. Specifications.....................................................3 6 C. Disassembly.......................................................3 6 D. lnspecition.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..3 6 E.
41. CARBURETOR A. Description Air flow through the venturi is controlled by a throttle slide (vacuum piston). The slide is raised and lowered by engine vacuum rather than a cable linked directly to the throttle grip. B. Specifications Main jet Jet needle Needle jet Starter jet Fuel valve seat Pilot jet Fuel level #135 502-3 z-2 To inspect starter jet, remove three (3) screws holding the starter body to the right side of the carburetor. 6. Remove the four screws holding the float bowl cover.
E. Adjustments 1. Float level adjustment Measure the distance from the bottom of the float to the float bowl gasket surface. Bend the tongue on the float arm if any float level adjustment is necessary. Both floats must be at the same height. If the fuel level is too high, a rich air/fuel mixture will occur. If too low, a lean mixture will result. I 1. Tongue A . 24+1 m m (0.94f0.04 in1 - 3 7 - Property of www.SmallEngineDiscount.
CHAPTER 5. CHASSIS 5-1. FRONT WHEEL ................... . . . . . . . ................... . .39 A. Removal ....................... . . . . . . . ..................... 39 B. Front axle inspection . . . . . . . . . . . . . . . . . . . . ..................... 39 C. Front wheel inspection. ........... . . . . . . . ..................... 39 D. Replacing wheel bearings .......... . . . . . . . ..................... 39 Installing front wheel ............. . * . . . . . ...................
CHAPTER 5. CHASSIS 5-l. FRONT WHEEL A. Removal 1. Remove cotter pin from front axle nut. 2. Remove the front axle nut. 3. Loosen the two axle holder nuts at the bottom of the fork leg. 4. Raise the front wheel of the machine by placing suitable stand under the engine. 5. Remove the front wheel axle by simultaneously twisting and pulling out on the axle. Then remove the wheel assembly. The speedometer gear unit housing must be removed.
b. Tighten axle holder nuts. First tighten nut on front end of axle holder, then tighten nut on rear end. Holder nut torque: 1 .O m-kg (7 ft-lb) E. Installing rear wheel 1. Lightly grease lips of rear wheel oil seals. 2. To install the rear wheel, reverse the removal procedure. NOTE: Always use a new cotter pin on the axle nut. c. install a new cotter pin. Torque: Axle nut: 15 m-kg(l08 ft-lb) 5-2. REAR WHEEL F. Rear Wheel lubrication (on page 41) A. Removal 1. Place machine on center stand. 2.
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B. Caliper disassembly 1. Remove caliper brake hose. Allow caliper assembly to drain into a container. 2. Place the open hose end into the container and pump the old fluid out of the master cylinder. 3. Remove caliper support bolt and pad securing screw as in Caliper pad replacement procedure. 4. Remove caliper assembly from caliper frame. 5. Remove retaining ring and dust seal. 6. Carefully force the piston out of the caliper cylinder with compressed air. Never try to pry out the piston.
cap, boot bushing, piston seal, dust seal, retaining ring. See “Caliper Replacement Pad” procedure for parts to be replaced when pads are replaced. 3. Replace piston and dust seals if damaged. 4. Inspect master cylinder body. Replace if scratched. Clean all passages with new brake fluid. Inspect brake hoses. Replace every four years or if cracked, frayed or damaged. Check for wear and deflection of disc. 5. 6. Wear limit: 1.5 mm (0.06 in) _ I Bleed screw 1. (with 2. Bush boot 3.
Use two wide, flat tire irons with rounded edges to work the tire bead over the edge of the rim, starting 180” opposite the tube stem. Be careful not to pinch the tube as you do this. 4. After you have worked on side of the tire completely off the rim, slip the tube out. [I Be very careful not to damage the stem while pushing it back out of the rim hole. 5. Brake disc assembly If brake disc has been removed from hub or is loose, tighten bolts.
NOTE: Be sure that all lock tabs are not cracked or broken and that they are all bent U P against the bolts. 3 Wear limit 3 mm (0.02 in) Constant friction and force from the chain creates wear on the sprocket teeth. If wear has progressed to the extent shown in this illustration, replace the sprocket. Slip off 5-6. FRONT FORKS I --_w--J’ / 26. Nut u i‘ 0 /I / I 31 I 30 : d 2 126 it I 7 t - 2 7 I’ I _ _ - J Property of www.SmallEngineDiscount.
A. Removal and disassembly NOTE: For fork oil replacement only, refer to PAGE (12) 1. Disconnect speedometer cable. Disconnect brake calipers and remove front wheel. Place wooden wedge or other object into caliper assemblies to keep brake pads apart. Remove front fender. 2. Loosen pinch bolts on steering stem and crown and remove fork. Remove fork tube caps, spring stopper 3. seats, and oil drain screws. Drain fork oil. 4. Remove Allen bolt from bottom of fork assembly. Pull inner tube out of outer tube.
D. Reassembly 1. Grease bearings and races with wheel bearing grease. 1. Bottom 2. TO P 5-7. STEERING HEAD A.Adjustment (See Chapter 2-4 for Steering Head Adjustment.) Install steering stem (underbracket) and bearings. Install bottom fitting nut. Tighten to approximately 2.0 - 2.6 m-kg (14 - 19 ft-lb). Do not over-tighten. Tighten top fitting nut. Continue reassembly in reverse assembly order. When assembly is complete, check steering stem by turning it from lock to lock.
3. Operate shock absorber rod to check damping. There should be no noticeable damping as shock extends. 4. Install the shock absorber on the machine. B. Swing arm removal 1. Remove nut on swing arm pivot bolt and tap out bolt with a long aluminum or brass rod. NOTE: Carefully remove the arm while noting the location of spacing washers and shims. 1 Rear shock absorber tightening 1 Pivot bolt torque: 6.5 m-kg (47 ft-lb) 1 5-10. CABLES AND FITTINGS A.Cable maintenance 2.
CHAPTER 6. 6-1. ELECTRICAL STARTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..5 0 A. Armature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..5 0 B. Yoke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..5 0 C. Starter relay switch ............................................... .50 6-2.
I i I CHAPTER 6. ELECTRICAL i 6-1. STARTER A.Armature 1. If the commutator surface is dirty, clean with #600 grit sandpaper as shown in the drawing below. After sanding, wash thoroughly with electrical contact cleaner and dry with high-pressure air steam. 2. The mica insulation between commutator segments should be 0.5 - 0.8 mm (0.020.03 in). below the segment level. If not, scrape to proper limits with appropriately shaped tool. (A hacksaw blade can be ground to fit). 3.
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6-2. CHARGING SYSTEM A.Charging circuit diagram L 1. 2. 3. 4. Rectifier Fuse Main switch Battery 4. 6. 7. 8. Load 9. Stator coil Voltage regulator IO. Relay unit A.C. Generator Field *oil B. A.C.Generator 1. Checking method. a. Connect D.C. voltmeter to the battery terminals. Battery should be fully charged. b. Start engine. c. Accelerate engine to approximately 2,000 rpm or more and check generated voltage. Generated voltage: 14.5 + 0.5 v d.
b. Check the core and points for gap adjustment. If any gap is incorrect, it should be adjusted. Contlnultv’ Con 1 Pocket tester E l e m e n t ~~~e~t O.K. shorted1 First adjust the core gap and then RETX~ Ielement opened) 1 core gap 2. Armature 3. Lower contact 4 Point gap 5. 6. 7. 8 9 upper contact 10 Contact set 11. co11 Adjusting spring 12 Locknut Adjusttng screw Yoke Contact Spring Charging voltage output can be controlled at the regulator.
proper rpm, nor will it advance to its fullest extent. On occasion, lightweight grease must be applied to the weight pivot pins. b. Check the operation of the point cam on the shaft. It must rotate smoothly. c. Examine point cam surface. If surface is pitted or worn, the governor assembly must be replaced. a. Negligence in keeping battery topped off with distilled water. b. Battery being left discharged. c. Over-charging with heavy charge. d. Freezing. e.
Standard values: Primary coil resistance: 3.9s2 t 10% at 20°C Secondary coil resistance: 8Kn * 20% at 20°C E. Condenser test If the contact points show excessive wear, or the spark is weak (but the ignition coil is in good condition), check the condenser. 1. Capacity test (use Electro Tester). a. Calibrate capacity scale. b. Connect tester. c. Meter needle will deflect and return to center as condenser is charged. After needle stops, note reading on “p F” scale. 1. lgnmon c o i l 3 .
operates, always check battery voltage before proceeding further. Low battery voltage indicates either a faulty battery, low battery water, or a defective charging system. See section 6-2 Charging System, for checks of battery and charging system. Also check fuse condition. Replace any “open” fuses. There are individual fuses for various circuits. 1. Horn does not work: a. Check for 12V on brown wire to horn. b. Check for good grounding of horn (pink wire) when horn button is pressed. 2.
B. Reserve lighting system 1. Description: The reserve lighting system has two functions: (1) It notifies the rider that one of the head lamp filaments is inoperative, and (2) it switches current from the inoperative filament to the remaining functional filament. The system is connected to the headlight circuit only. The reserve lighting system unit is located under the fuel tank. HEADLIGHT CONDlTlON “HEAo” , lNOlC.
C. Self-canceling flasher system 1. Description The self-cancaling flasher system turns off the turn signal after a period of time or distance involved in turning or changing lanes. Generally, the signal will cancel after either 10 seconds, or 130 meters, whichever is greater. At very low speed, the function is determined by distance; at high speed, it is determined by time. At low speed, especially when changing speeds, the canceling determination is a combination of both time and distance. 2.
4. Inspection: If the flasher self-canceling system should become inoperative, proceed as follows: a. Pull off the 6-pin connectar from the flasher canceling unit, and operate the handle switch. If the signal operates normally in L, R, and OFF, the following are in good condition: 1) Flasher unit. 2) Bulb. 3) Lighting circuit. 4) Handle switch light circuit. If (1) through (4) are in good condition. the following may be faulty: 1) Flasher canceling unit. 2) Handle switch reset circuit.
CHAPTER 7. APPENDICES ..6 1 7-1. TORQUE SPECIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2. Torque Specifications............................................................... 61 CONVERSION TABLE ................................................63 Metric to Inch System .................................................63 Inch to Metric System .................................................63 Definition of Terms .........................................
7-1. TORQUE SPECIFICATION The following torque specifications must be adhered to on every machine. When applying torque to multi-secured fastener components, the several studs should be tightened in gradual stages and in a pattern that will avoid warpage to the item being secured. Torque settings are for dry, clean threads. Torquing should always be done to the nut, never the bolt head. NOTE: Certain items with other than standard thread pitches may require differing torque.
I Part to be tightened I Delivery pipe I Thread dia. and part name I / 10 mm union bolt I Tightening torque 2.2 m-kg (16 ft-lb) / 8mm n u t 1.5 m-kg (11 ft-lb) 1 Crankcase 1 and 2 1 8 mm bolt/nut 2.2 m-kg (16 ft-lb) Crankcase cover 1 6 mm bolt 1 .O m-kg (7 ft-lb) Kick crank boss 1 8 mm bolt 2.0 m-kg (14 ft-lb) Exhaust pipe 1 Clutch spring Primary drive gear 6 mm screw / I 9.0 m-kg (65 ft-lb) 6.5 m-kg (47 ft-lb) Drive sprocket 22 mm nut 5.
7-2. C O N V E R S I O N T A B L E Inch Metric System Metric to Inch System Known Multiplier (Rounded off) Known Result Torque m-kg 7.233 ft.lbr m-kg 86.80 iwlbs Multiplier (Rounded off) Result Torque ft-lbs 0.13826 m-kg in.lbs 0.01152 m-kg ft.lbr 13.831 cm.kg cm-kg in-lbs Wt. lb 0.4535 kg oz 28.352 g mpg 0.4252 km/l mph 1.609 kmlhr rn 1.609 km oz (US liq) 29.57 cc (cm” I cu. I” 16.387 cc (cm”) pt IUS liq) 0.4732 I (liter) qt (US liq) 0.9461 I (liter) 3.
7.3. SPECIFICATION A. General 1 1. MODEL 1) Model (I.B.M. No.) 2) Frame I.D. and starting number 3) Engine I.D. and starting number XS650E (2FO) 2FO-000101 ZFO-000101 2. DIMENSION 2,180 mm (85.8 in) 1) Overall length 21 Overall width 3) Overall height 835 mm (32.9 in) 1,160 mm (45.7 in) 815 mm (32.1 in) 4) Seat height 51 Wheelbase 61 Minimum ground clearance 1,435 mm (56.5 in) 150 mm ( 5 . 9 in) 3. WEIGHT 212 kg (467 lb) 26° 2,500 mm (98.4 in) 14 m @ 50 km/h (45.9 ft @ 31 mi/h) B. Engine 1.
r 1) Type Needle bearin 1) Cam drive type 2) Number and type of bearing 3) Bearing dimensions 25 x 47 x 8 mm IO.984 x 1.850 x 0.315 in) -f A 1 Type Pitch/Number of links Sprocket ratio (Teeth) TSUBAKIMOTO BFOSM 7.774 mm IO.3060 in)/106 15.0’$“‘* mm (0.591t~W07 in) 21 Rocker arm shaft diameter 15.O$:E mm lO.5911$~$ in) 31 Clearance 0.009 - 0.033 mm (0.00035 - 0.
IO. VALVE SPRING 1) Free length INNER (IN/EX): 42 mm (1.654 in) OUTER (IN/EX): 42.55 mm (1.675 in) INNER IIN/EX): ki = 1.43 kz = 1.61 OUTER (IN/EX): kl = 3.2 k> = 4.18 INNER (IN/EX): 35 mm (1.378 in) OUTER (IN/EX): 37 mm (1.457 in) INNER (IN/EX): 10f 0.7 kg (22.0* 1.5 lb1 OUTER (IN/EX): 17.7 + 1.25 kg (39.0 * 2.6 lb) INNER IIN/EX): 25.5 mm (1.004 in) OUTER (INIEXI: 27.5 mm (1.083 in) INNER IIN/EX): 27.2 * 1.9 kg (60.0 + 4.2 lb) OUTER (IN/EX): 57.4 + 4.0 kg (126.5 + 8.8 Ibl INNER (IN/EX): 2.9 mm (0.
71 Clutch spring Free IengthlDuantity 34.6 mm 11.362 in)/6 pa. 0.027 - 0.081 mm fO.0011 - 0.0032 in) 81 Clutch housing radial play 9) Push rod bending limit 0.2 mm (0.008 in) 5. TRANSMISSION 1 I Type 21 Gear ratio: Constant mesh, 5.speed forward 1st 2nd 32/13 (2.461) 27/17 11.588) 26/20 (1.300) 3rd 4th 23/21 (1.095) 5th 31 Bearing type: Main axle (Left)(l.D.xO.D.xWidth) 22/23 10.956) Needle bearing (20x30~20 mm)10.787x1.181x0.787 in) 1 Ball bearing (25x52x20.6 mm)(0.984x2.047x0.
3) Oil pump type 4) Trochoid pump specifications Top clearance Tip clearance Side clearance Oil pump volume 5) Bypass valve setting pressure Trochoid pump 0.10 - 0.18 mm IO.0039 - 0.0071 in) 0.03 - 0 . 0 9 mm 10.0012 - 0.0035 in) 0.03- 0.08 m m (0.0012 - 0.0031 in) 1.3 litlmin at 1,000 rpm/lEngine 1 . 0 kg/cm2 (14 psi) 6) Lubrication chart r C. Chassis 1. FRAME 1) Frame design Double cradle, high tensile frame 2.
7) Distance from the top of inner tubeti oil level. without spring Approx. 454 mm (17.9 in) 4. REAR SUSPENSION Swing arm 1) Type 2) Damper type Oil damper, coil spring 80 mm (3.15 in) 3) Shock absorber travel 4) Shock absorber spring Set length 201 mm (7.91 in) Free length 226 mm (8.90 in) 7.5 mm x 60.5 mm 10.295 x 2.382 in) Wire diameter x winding diameter 5) Swing arm free play (Limit) 6) Pivot shaft -Outside diameter 1 mm (0.04 in) 16 mm (0.63 in) 5. FUEL TANK 15 lit (4.
7. BRAKE 1 I Front brake Hydraulic disc type 298 mmx 7.0 mm (11.73x0.28 in) 6.5 mm (0.26 in) 6.5 mm (0.26 in) 1.5 mm 10.06 in) 14.0 mm 10.55 in) 38.18 mm 11.5 in) DOT #3 Brake fluid TVP~ Disc size (Outside dia. x thickness) Disc wear limit Disc pad thickness Pad wear limit (Minimum thickness) Master cylinder inside dia. Caliper cylinder inside dia. Brake fluid type 2) Rear brake Drum brake Leading trailing 180 mm (7.09 in) 180 x 30 mm (7.09 x 1.18 in) 412 mm 10.16lO.08 in) 68 mm (2.
4) Voltage regulator core gap Point gap Voltage coil Resistor 5) Battery ModellManufacturerMuantitv Capacitv Charging rate Specific gravity 3. STARTER 1) starter motor Tvpe Manufacturer Model output Armature coil resistance Field coil resistance Brush SizeIQuantitv Wear limit Spring pressure Commutator O.D.iWear limit Mica undercut Reduction/Ratio 2) Starter switch Manufacturer Model Amparage rating Cut-in voltage Winding resistance 3) Starter clip friction tension i.
Supplementary Property of www.SmallEngineDiscount.
FOREWORD This Supplementary Service Manual for XS650SE has been published to supplement the Service Manual for the XS650E (2FO-28197-10) and includes changes in specifications and addition to the data. For complete information on service procedures, it is necessary to use this Supplementary Service Manual together with the Service Manual for the XS650E (2FO-28197-10). Property of www.SmallEngineDiscount.
Page numbers shown in brackets correspond to page numbers of the XS650E Service Manual (2FO-28197-10). (PAGE 4 - 5) 2-2. MAINTENANCE INTERVALS CHARTS A. PERIODIC MAINTENANCE Unit: km (mi) Check tension, alignment B. LUBRICATION INTERVALS Unit: km (mi) Item Remarks Engine oil Replace/Warm engine before draining Drive chain Clean/Lube Brake pedal shaft/ Change pedal shaft Light application Control/Meter :ables Apply thoroughly Every 400 (250) Yamaha chain and Property of www.SmallEngineDiscount.
Unit: km (mi) Thereafter every initial I tern Remarks Type 400 800 1,600 3,200 3,200 6,400 1,600 (250) (500) (1,000) (2.000) (1,000) (2.000) (4.000) Throttle grip/ Housino Apply lightly Hydraulic brake fluid reserve Use new fluid only Oil filter element Clean/Replace as required Front forks Drain completely - Yamaha Fork Oil Check specifications 20 wt. Inspect thoroughly Medium-weight Pack moderately wheel bearing grease Yearly or . . .
3. 4. 5. 6. position so that its top end is approx. 12 - 18 mm (0.47 - 0.71 in) below the footrest top end. Secure the adjuster lock nut. Loosen the brake rod adjuster lock nut and screw brake rod downward until there is noticeable free play between rod and master cylinder. Turn in the brake rod until it lightly touches the master cylinder, then turn it out by approx. l-1/5 turns (for proper free play). Tighten the brake rod adjuster lock nut. G. Drive chain 1.
1. Lock nut 4. Rear wheel axle nut ‘2. Adjuster 5. Cotter pin 3. Marks for align (PAGE 29 - 33) 3-4. ENGINE ASSEMBLY AND ADJUSTMENT 0. Engine Specifications should be changed as follows: Engine mounting bolt torque: Upper (U Nut) M8 1.8 m-kg (13.0ft-lb) Upper Front (U Nut) Ml0 Ml0 3.0 m-kg (21.5 ft-lb) 4.6 m-kg (33.5 ft-lb) Rear (U Nut) Ml0 4.1 m-kg (29.
NOTE: The wheel should be balanced with brake disc installed. (PAGE 40) 5-2. REAR WHEEL A. Removal 1. Support machine on the center stand. 2. Disconnect the drive chain. Using drive chain cutter (special tool). NOTE: The chain joint should be replaced each time the chain is cut. 3. Remove the axle nut cotter pin and axle nut. 4. While supporting the brake caliper, pull out the rear axle. 5. Remove the rear wheel assembly. E.
3. Check the armature and field coil for shorting and insulation. Replace armature as required. LAA 6 A: Pad thickness 11 .O mm (0.43 in) 6: Wear limit 4. 6.0 mm (0.24 in) C: Wear indicator Check the front and rear cover bearings for damage. If damaged, the starter assembly must be replaced. (PAGE 57 - 58) 6-5. LIGHTING AND SIGNAL SYSTEMS B. Reserve lighting system 1.
2. Troubleshooting/inspection Property of www.SmallEngineDiscount.
LOW BEAM DOES NOT LlGHT WHEN HIGH BEAM IS DEFECTIVE Property of www.SmallEngineDiscount.
To starter relay To A.C. Generator Meter light (PAGE 61- 62) 7-1. TORQUE SPECIFICATION The following torque specifications must be adhered to on every machine. When applying torque to multi-secured fastener components, the several studs should be tightened in gradual stages and in a pattern that will avoid warpage to the item being secured. Torque settings are for dry, clean threads. Torquing should always be done to the nut, never the bolt head.
I Part to be tightened Thread dia. and part name Engine: Cylinder head and cylinder head cover Tightening torque 10 mm nut 8 mm bolt 3.7 m-kg (27.0 ft-lb) 2.1 m-ka 115.0 ft-lb) Cylinder head 6 mm bolt 0.9 m-kg ( 6.5 ft-lb) Cylinder head cover side 6 mm crown nut 8 m m crown nut 0.9 m-kg ( 6.5 ft-lb) 1.3 m-ka f 9.5 ft-lb) 1 Spark plug I 14 mm I 2.0 m-ka (14.5 ft-lb7 1 Generator I 12 mm nut I 3.8 m-ka (27.5 ft-lb) 1 I Stator c o i l I 6 mm pan head screw I 0.9 m-kq ( 6.
Thread dia. and part name Part to be tightened I Tightening torque Pivot shaft 14 mm nut 6.5 m-kg (47.0 ft-lb) Rear wheel axle 16 mm nut 15.0 m-kg (108.5 h-lb) Tension bar and brake caliper 8 mm nut 1.8 m-kg (13.0 ft-lb) Tension bar and rear arm 8 mm nut 3.2 m-kg (23.0 ft-lb) Rear shock absorber Upper 10 mm bolt 3.0 m-kg (21.5 ft-lb) Rear shock absorber Lower 10 mm bolt 3.9 m-kg (28.0 ft-lb) 8 mm bolt 1.0 m-kg 1 7.
1. PISTON 1) Ptston skirt clearance 0.050 - 0.055 mm (0.0020 - 0.0022 in) 2) Piston oversize 7525 mm 12.963 InI 3) Piston pin outside diameter x length 75.50 mm I2972 In) 75.75 mm (2 982 In) 76.00 mm (2992 Ill) 20.0 _i,,,,, mm x 61 .O _z,3 mm (0.79 _~,ooo2 In x 2.40 _E,o,,6 in) 5. PISTON RING 1) Piston ring design 2) Ring end gap (TOP) Barrel ring 1.2 mm (0.047 in) (2nd) (Oil ring) Taper ring 1.5 mm (0.059 in) (Installed, top) 0.2 * 0.4 mm IO.008 - 0.016 in) 0.2 - 0.4 mm (0.008 - 0.
IN: 8.0 ~~:~~~ mm (0.315 Ig:Eo in) Valve stem diameter EX: 8.0 I::$“, mm (0.315 I~:~~~ in) Valve guide diameter EX:8.0 $iiz mm (0.315 :E:EE in) IN: 0.020 - 0.044 mm (0.00079 - 0.00173 in) EX: 0.035 - 0.059 mm (0.00138 - 0.00232 in) Valve stem to guide clearance 10. VALVE SPRING 1) Free length INNER (IN/EX): 42 mm (1.654 in) OUTER (IN/EX): 42.55 mm (1.675 in) INNER (IN/EX): kr = 1.43 kg/mm (80.1 lb/in) kz = 1.81 kg/mm (101.4 lb/in OUTER (IN/EX): kr = 3.2 kg/mm (179.2 lb/in) kz = 4.18 kg/mm(234.
14. CLUTCH 1) Clutch type 2) Clutch operating mechanism 3) Primary reduction ratio and method 4) Primary reduction gear back lash (4 teeth) Wet, multiple type Inner push type, screw push system 72127 (2.666). spar Qear 21.45 _&6 mm (0.8445 &ooto in) 5) Friction plate Thickness/Quantity Wear limit 3 mm (0.118 in)/7 pcs. 2.7 mm (0.106 in) 6) Clutch plate Thickness/Quantity Warp limit 7) Clutch spring Free length/Quantity 8) Clutch housing radial play 9) Push rod bending limit 1.4 mm (0.055 in)/6 PCS. 0.
4) Trochoid pump specifications Top clearance Tip clearance Side clearance Oil pump volume 5) Bypass valve setting pressure 0.10 - 0.18 mm (0.0039 - 0.0071 in) 0.03 - 0.09 mm (0.0012 - 0.0035 in) 0.03 - 0.08 mm (0.0012 - 0.0031 in) 1.3 lit/min (1.37 qt/min) at 1,000 r/min 1.0 kg/cm’ (14 psi) 6) Lubrication chart I Oil main gallery c Oil strainer Main axle and mission j-----+q C. Chassis 1. FRAME 1) Frame design 2.
Wire diameter x winding diameter Spring constant 7.5 x 60.5 mm (0.295 x 2.382 in) kr = 1.714 kg/mm (96.0 lb/in)/ 0%45mm(O-1.77in) kz = 2.244 kg/mm (125.7 lb/in)/ 45- 80mm (1.77- 3.15in) 1 mm (0.04 in) 16 mm (0.63 in) 5) Swing arm free play (Limit) 6) Pivot shaft - Outside diameter 5. FUEL TANK 1) Capacity 2) Fuel grade 11.5 lit (2.53 US. gal) Regular gasoline 6. WHEEL 1) Type (Front and rear) 2) Tire size (Front) (Rear) 3) Tire pressure: up to 90 kg (198 lb) load Aluminum rim 3.50.
D. Electrical 1. IGNITION SYSTEM 1) Ignition timing (B.T.D.C.) 2) ignition coil Model/Manufacturer Spark gap Primary winding resistance Secondary winding resistance 3) Spark plug Type Spark plug gap 4) Contact breaker Manufacturer/Quantity Point gap Point spring pressure Cam closing angle 5) Condenser Capacity Insulation resistance Quantity 2.
2) Starter switch Manufacturer Model Amparage rating Cut-in voltage Winding resistance 3) Starter clio friction tension 4.
XS650E Supplementary FOR XS650E MODELS AFTER ENGINE SERIAL NO. 2FO-006501 Property of www.SmallEngineDiscount.
FOREWORD This Supplementary Manual for XS650E has been published to supplement the Service Manual for the XS65OE (LIT-1 1616-00-761, and provides updated information for the XS650E model as well as new data concerning the XS650E. For complete information on service procedures it is necessary to use this Supplementary Manual together with the Service Manual for the XS650E (LIT-1 1616-00-76).
Page numbers shown in brackets correspond to page numbers of the XS650E (LIT-1 1616-00-76) Service Manual. (Page 4-5) 2-2. Maintenance Interval Charts c A. PERIODIC MAINTENANCE EMISSION CON TROL SYSTEM I I NO. ITEM I 1 1 Cam Chain INITIAL BREAK-IN or 7 months Check and adiust chain tension -I Check and adjust valve clearance when engine is cold. 1 Check condition. Adjust point 0 gap. qgggik 0 0 Check and adjust ignition timing.
(Page 8) E. Cam chain adjustment Check/Adjust the cam chain tension as follows: Remove the cap nut. Turn the left end of the crankshaft counterclockwise. As the crankshaft is turning, check to see that the cam chain adjuster push rod is flush with the end of the bolt. If not, turn the adjuster bolt until the push rod is flush. Reinstall the cap nut. The cap nut acts as a lock nut for the adjuster. I a . 20530mm (0.79-1.18in) (Page 14) C. Ignition timing 1. Point gap must be set before setting timing. 2.
6. Retighten screws. Check timing again for right cylinder. 7. Repeat procedure (steps 2-6) for left cylinder. SW -_- -s-m- .- 1. Right cylinder timing adjustment 2. Left cylinder timing adjustment (Page 15) F. Spark plug Check electrode condition and wear, insulator color and electrode gap. Use a wire gauge for adjusting the plug gap. If the electrodes become too worn, replace it.
Supplementary FOR XS650SE MODELS AFTER ENGINE SERIAL NUMBER 2FO-114241 Property of www.SmallEngineDiscount.
FOREWORD This Supplementary Service Manual for XS650SE has been published to supplement the Service Manual for the XS650E (LIT-11616-00-76), and provides updated information for the XS650E model as well as new data concerning the XS650SE. For complete information on service procedures, it is necessary to use this Supplementary Service Manual together with the Service Manual for the XS650E (LIT-1 1616-00-76).
Page numbers shown in brackets correspond to page numbers of the XS650E Service Manual (LIT-1 1616-00-76). (PAGE 4 - 5) 2-2. MAINTENANCE INTERVALS CHARTS A. PERIODIC MAINTENANCE EMISSION CONTROL SYSTEM REMARKS ) Check for leakage. Retlghten as netsR e p l a c e gasket(s) of newssaw. ~ j 0 I 0 8 1 Exhaust System 9 ! I Carburetor Svnchronuatlon Ad,us, synchron,zat,o” Of carburetors.1 0 0 0 Idle Speed Check and adjust engnne Idle speed. Adlust cable free play. 0 0 0 10 sary. / 0 B.
I I NO. I ITEM I / IN. I T I .AL TYPE REMARKS B - REAK-IN 1 16,000 km 4,000 km 8,000 km 1,000 km 5,000 km or 1 month or 7 months or 6 months or 12 months or24month l5.000 mil (10,OQO mi (600 mi) ( 3 . 0 0 0 mil 12.500 ml) Yamaha fork oil 1OWt or equivalent , , ;ynt Fork Dram completely. I Refill to speciflcatmn. 0 Steering Ball Check bearmgs assembly Medwm weight ,2 Eearmg and for looseness. Moderately wheel bearing repack every 16,000 km Races grease. 110,000 rni).
E. Rear brake The rear brake pedal should be so adjusted that it has a free play of 13 - 15 mm (0.51 - 0.59 in) from when the brake pedal is first moved to when the brake begins to be effected. 1. 2. I Loosen the adjuster lock nut (for pedal height). Bridgestone or Yokohama 130/90S164PR Maximum load limit 166 kg (365 Ibl 279 kg (615 lb1 1.6 kg/cm2 (22 psi ) 2.0 kg/cm* (28 psi) 2.0 kglcmz (28 psi 1 2.3 kg/cm2 (32 psi 1 2.0 kg/cm2 (28 psi I 2.
C. L o o s e n t h e IOU W. ,, ~“, ~~, To tighten chain tur* ‘,W _ 2, 61 @lusters clockwise. To Irfn *,W ,fl’ Mjustars counterclockmw a/, )* U,W! f o r ward. Turn ta7 vqnn ?/=?I / the same amount ti FW+. rv ‘l++f,t axle alignment. (There VS. W5J”S ,,, 3ivh side H. Front fork oil change 8. Pour specified amount of oil into the inner tube through the upper end opening. of rear arm and cf TV/ #,*, 9,,,rr. uoe them to check for p--H -4; (PAGE 14 - 15) 2-5. E L E C T R I C A L C. Ignition timing 1.
(PAGE 29 - 33) 3-4. ENGINE ASSEMBLY AND ADJUSTMENT 0. Engine Specifications should be changed as 1. Right cylinder timing adjustment 2. Left cylinder timing adjurtment F. Spark plug Check electrode condition and wear, insulator color and electrode gap. Use a wire gauge for a adjusting the plug gap. If the electrodes become too worn, replace it.
(PAGE 40) 5-2. REAR WHEEL A. Removal 1. Support machine on the center stand. 2. Disconnect the drive chain. Using drive chain cutter (special tool). NOTE: The chain joint should be replaced each time the chain is cut. Remove the axle nut cotter pin and axle nut. 4. While supporting the brake caliper, pull out the rear axle. 5. Remove the rear wheel assembly. 3. E. Rear wheel installation When installing rear wheel, reverse removal procedure taking care of following points: 1.
4. Check the front and rear cover bearings for damage. If damaged, the starter assembly must be replaced. A: Pad thickness 11 .O mm (0.43 in) (PAGE 57 - 58) 6-5. LIGHTING AND SIGNAL SYSTEMS B. Reserve lighting system 1. Description: The reserve lighting system has two functions: (1) It notifies the rider that one of the headlight filaments is inoperative, and (2) it switches current from the inoperative filament to the remaining functional filament. The system is connected to the headlight circuit only.
“R/W” wire to -118- Property of www.SmallEngineDiscount.
-119- Property of www.SmallEngineDiscount.
(PAGE 61- 62) 7-1. TORQUE SPECIFICATION The following torque specifications must be adhered to on every machine When applying torque to multi-secured fastener components, the several studs should be tightened in gradual stages and in a pattern that will avoid warpage to the item being secured. Torque settings are for dry, clean threads. Torquing should always be done to the nut, never the bolt head. NOTE: Certain items with other than standard thread pitches may require differing torque.
Part to be tightened Delivery pipe Thread dia. and part name Tightening torque 10 mm union bolt 2.1 m-kg (15.2 ft-lb) Exhaust pipe 8 mm nut 1.3 m-kg ( 9.4 ft.lb) Crankcase 8 mm bolt/nut 2.1 mkg (15.2 ft-lb) Kick crank boss 8 mm bolt 2.0 m-kg (14.5 ft.lb) Primary drive gear 14 mm nut 9.0 m-kg (65.1 ft-lb) Clutch boss 18 mm nut 8.0 m.kg (57.9 ft.lb) Drive sprocket 22 mm nut 6.5 m.kg 147.0 ft-lb) 6 mm bolt Change pedal Chassis: Front wheel axle 1.0 m-kg ( 7.2 ft-lb) 14 mm nut j 10.
( P A GE 64 - 71) 7-3. SPECIFICATION A. General 1. M O D E L 1) Model (I.&M. No.) XS650S.E l2MO) 2) Frame I.D. and starting number 2FO-114241 ZFO-114241 3) Engine I.D. and starting number 2. D I M E N S I O N Overall length 2,120 mm (83.5 in) 2) Overall width 925 mm (36.4 in) 3) Overall height 1,225 mm (48.2 in) 1) 41 Seat height 5) Wheelbase 6) Minimum ground clearance 790 mm (31.1 in) 1,435 mm (56.5 in) 135 mm ( 5.3 in) 3. WEIGHT 1) Net weight (Dry) 4.
1 I Piston ring design 2) Ring end gap (Installed. top) (Installed, 2nd) (Installed. oil) 3) Ring groove side clearance (Top) 0.2 - 0.4 mm 10.006 - 0.016 in) 0.2 - 0.4 mm (0.006- 0.016 in) 0.3 - 0.9 mm (0.012 - 0.035 inl 0.04 - 0.06 mm (0.0016 - 0.0031 inl 0.03 - 0.07 mm (0.0012 - 0.0026 in) 1) Type Needle bearing 1) Cam drive type 21 Number and type of bearing 3) Bearing type Chain (Center side) 4 bearings, Ball bearings (6005) 6) Camshaft deflection limit 71 Cam chain Type Number of links 0.
Valve stem diameter EX: 6.0 3:;: mm (0.315 ;g:$$ in) Valve guide diameter IN: 8.0 $ti”, mm (0.315 $E inl EX:8.0 :~:~~~ mm (0.315 :i:“g in) IN: 0.020 - 0.044 mm (0.00079 - 0.00173 in) EX: 0.035 - 0.059 mm IO.00138 - 0.00232 in) IN & EX: 0.03 mm (0.0012 in) or less Valve stem to guide clearance 4) Valve face runout limit 10. VALVE SPRING 11 Free length INNER (IN/EX): 42 mm (1.654 in) OUTER ~(INIEX): 42.55 mm (1.675 in) INNER (INIEX): kl = 1.43 kg/mm (80.1 lb/i”) kz = 1.81 kg/mm (101.
51 Friction plate ThicknerslCluantity Wear limit 3 mm (0.118 in117 pcs. 2.7 mm (0.106 in) 61 Clutch plate Thickness/Quantity 1.4 mm (0.055 in)/6 pcs. Warp limit 7) Clutch spring 0.05 mm (0.002 in) Free length/Quantity 8) Clutch housing radial play 9) Push rod bending limit 34.6 mm (1.362 in)/6 per. 0.027 - 0.081 mm (0.0011 - 0.0032 in) 0.2 mm (0.008 in) 15. TRANSMISSION 1) Type 2) Gear ratio: Constant mesh, 5.speed forward 32/13 12.461) 27/l 7 (1.588) 26/20 (1.300) 23/21 (1.
6) Lubrication chart - Pressure feed ----Splash lubrication I- C. Chassis 1. FRAME 1) Frame design 2. STEERING SYSTEM 11 caster 2) Trail 3) Number and size of balls in steering head upper race Lower race 4) Steering lock to lock Double cradle, high tensile frame 27’ 115 mm (4.53 in) 19 pcs. l/4 in 19 pcs. l/4 in 42’ each IL and RI 3.
5. FUEL TANK 1) Capacity 2) Fuel grade 11 .O lit (2.9 US gal) Regular gasoline 6. WHEEL 1) Type (Front and rear) 2) Tire size IFront) (Rear) 3) Tire pressure: Aluminum rim 3.50S19.4PR 130/90S16-4PR Up to 90 kg I198 lb) load Front: 1.6 kg/cm2 (22 psi) Rear: 2.0 kg/cm2 128 psi) Front: 2.0 kg/cm’ (28 psi) Rear: 2.3 kg/cm2 (32 psi) Front: 2.0 kg/cm* (28 psi) 90 kg 1198 Ibjload - 204 kg (445 Ibjload (Maximum load) High speed riding Rear: 2.
Primary winding resistance Secondary winding resistance 31 Spark plug TVP~ Spark Plug gap 4) Contact breaker ManufacturerlQuantitv Point gap Point spring pressure Cam closing angle 5) Condenser Capacity Insulation resistance Quantity !. C H A R G I N G S Y S T E M 1) AC generator Charging output Rptpr coil resistance (Field coil1 Stator coil resistance Brush length Brush wear limit 2) Rectifier 3.9n ? 10% at 20°C (68°F) B.Okn + 20% at 2O’C (68°F) N - 7 Y (C,jAMPION) or BP7ES (N.G.K.1 0.7 - 0.8 mm (0.
4. LIGHTING SYSTEM 1) Headlight type 2) Bulb brightness and wattage/Quantity Headlights Tail/brake light Flasher light Pilot lights: Turn High beam Headlight failure Neutral Tail/brake failure Meter lights 3) Reserve lighting unit Sealed beam 12v. 5Ol4OW x 1 PC. 12V. 3/32 CP 18W/27Wl x 1 PC. 12V. 32 CP I27W) x 4 pcs. 12v. 3.4w x 2 pcs. 12v. 3.4w x 1 PC. 12v. 3.4w x 1 PC. 12v. 3.4w x 1 PC. 12v. 3.4w x 1 pc. 12v. 3.4w x 4 pcs.
Property of www.SmallEngineDiscount.
FOREWORD This Supplementary Service Manual for XS650SF/XS650-2F has been published to supplement the Service Manual for the XS650E (LIT-1 1616-0076), and provides updated information for the XS650E model as well as new data concerning the XS650SF/XS650-2F. For complete information on service procedures, it is necessary to use this Supplementary Service Manual together with the Service Manual for the XS650E (LIT-1 1616-00-76).
Page numbers shown in brackets correspond to page numbers of the XS650E Service Manual (LIT-11616-00-76). (PAGE 4 - 5) NOTE: In the XS650E Service Manual there are a few pages that are not arranged in order. These are pages 7, 8 and 9. They should be read in the reverse order, i.e. 9, 8 and 7. 2-2. MAINTENANCE INTERVALS CHARTS A. PERIODIC MAINTENANCE EMISSION CONTROL SYSTEM REMARKS damage. Replace If n 7 Check fuel hose for cracks or damaqe.
THEREAFTEREVERY INITIAL BREAK-IN j ITEM NO. REMARKS TYPE Front Fork Drawn completely. ” Yamaha fork oil 1OWt or equivalent Refill to specification. 011 16,000 km 1,000 km 5.000 k m 4,000 km 8,000 km or 1 month or 7 months or 6 months or 12 months or24month 1 6 0 0 mil K3,OOOmil ( 2 . 5 0 0 mi) ( 5 , 0 0 0 mil ~10,000 mi 0 Steerung Ball Check bearings assembly Medwm weight ,2 Beanng and for looseness. Moderately wheel bearing RKH repack every 16,000 km gre.%e. (10.000 mi).
E. Rear brake (XS650SF only) The rear brake pedal should be so adjusted that it has a free play of 13 - 15 mm (0.51 - 0.59 in) from when the brake pedal is first moved to when the brake begins to be effected . 1. Loosen the adjuster lock nut (for pedal height). 2. 3. 4. 5. 6. By turning the adjuster bolt clockwise or counterclockwise, adjust the brake pedal NOTE: This model is available in two types, tubeless tire and tube-type tires. Before servicing tires, please note the following instructions. 1.
Tightening torque: 1.5 m-kg (1.1 ft-lb) 2. Aluminium wheels a. Always inspect the aluminium wheels before riding. Place the machine on the center stand and check for cracks, bends or warapage of the wheels. Do not attempt even small repairs to the wheel. It must be replaced. b. Tires and wheels should be balanced whenever either one is changed or re 2. Before operation, always check the tire surfaces for wear and/or damage; for example: cracks, glass, nails, metal fragments, stones, etc.
deflection is approximately 20 - 30 mm (0.8 - 1.2 in). If the deflection exceeds 20 - 30 mm (0.8 - 1.2 in) adjust the chain tension. 2. Tension adjustment a. Loosen the rear brake adjusting nut (XS650-2F only). b. Remove the cotter pin of the rear wheel axle nut with pliers. C. Loosen the rear wheel axle nut. d. Loosen the lock nuts on each side. To tighten chain,turn chain puller adjusters clockwise. To loosen chain, turn adjusters counterclockwise and push wheel forward.
6. Retighten screws. Check timing again for right cylinder. 7. Repeat procedure (steps 2 - 6) for left cylinder. (PAGE 39 - 40) 5-1. FRONT WHEEL C. Front wheel inspection (XS650SF only) 1. Check for cracks, bends, or warpage of wheels. If a wheel is deformed or cracked, it must be replaced. 2. Check wheel run-out If deflection exceeds tolerance, check wheel bearing or replace wheel as required. Rim run-out limits (XS650SF/XS650-2F): 1. Right cylinder timing adjustment 2.
I 8 0 m m (3.15 anl (PAGE 40 - 44) 5-3. BRAKES Except for the following, the same procedure as for the XS650E front brake can be performed for the disassembly, inspection,and assembly of the XS650SF (front and rear brake) and the XS650-2F (front brake). Balance wwghf I I D. Brake inspection and repair Specifications should changed as follows: (PAGE 40) 5-2. REAR WHEEL Wear limit: 6.0 mm (0.24 in) A. Removal (XS650SF only) 1. Support the machine on the center stand. 2. Disconnect the drive chain.
(PAGE 50 - 51) 6-1. STARTER A. Armature 1. Check the outer surface of the commutator. If its surface is dirty, clean with No. 600 grit sand paper. 2. The mica insulation between commutator segments should be 0.7 mm (0.028 in) below the segment level. If not, scrape to proper limits with appropriately shaped tool. (A hack saw blade can be ground to fit.
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I I i’Oimmarl ii I T (PAGE 61 - 62) 7-1. TORQUE SPECIFICATION The following torque specifications muSt be adhered to on every machine. When applying torque to multi-secured fastener components, the several studs should be tightened in gradual stages and in a pattern that will avoid warpage to the item being secured. Torque settings are for dry, clean threads. Torquing should always be done to the nut, never the bolt head.
Torque Specifications A (Nut) Property of www.SmallEngineDiscount.
I Part to be tightened I Tightening torque Handle crown and handlebar holder 8 mm bolt Under bracket and inner tube 8 mm nut Engine mounting UPPer 8 mm nut Engine mounting upper Engine mounting Front 10 mm nut 4.6 m-kg (33.5 ft-lb) Engine mounting Rear 10 mm nut 4.1 m-kg (29.5 ft-lb) - Engine mounting Rear-Lower 10 mm nut 4.6 m-kg (33.5 ft-lb) Engine mounting Lower 10 mm nut 9.0 m-kg (65.0 ft-lb) Front flasher and headlight 8 mm nut 1.0 m-kg (7.
1. OESCRIPTION 1 I Engine type Air cooled, 4.stroke. SOHC twin, parallel forward incline 21 Engine model 2FO 653 cc (39.85 cu.in) 75 x 74 mm (2.953 x 2.913 in) 31 Displacement 41 Bore x stroke 51 Compression ratio 61 Starting system. 7) Ignition system 8.5 : I Kick and electric starter Battery ignition 81 Lubrication system wet sump 2. CYLINDER HEAD 1 I Combustion chamber volume (with N-7Yl 43.6 cc (2.660 win) Dome + Squish 21 Combustion chamber type 31 Head gasket thickness 1.2 mm (0.047 in) 3.
5) Valve timing OPEN CLOSE IN BTDC360 ABDCW z3‘I” EX BBDCE8° ATDCW 2840 DURATION OVERLAP 720 ,,.--i-J- 61 Camshaft deflection limit 0.03 mm (0.0012 in) 7) Cam chain Type Number of links Sprocket ratio TSUBAKIMOTO BF05M 106L 36/16 (2.000) I. ROCKER ARM AND ROCKER SHAFT 1) Rocker arm inner diameter (:-,: ,1 c BY 15.0+~.“‘8 mm (0.591 +z.0w7 in) 2) Rocker arm shaft diameter 15.0 $:E mm (0.591 I~:~$ in) 3) Clearance 41 Lift ratio 0.009 - 0.033 mm (0.00035 - 0.00130 in) X : Y = 40 : 46.
lNNER (INIEX): 19.4 mm (0.764 inl OUTER (IN/EX): 32.6 mm il.283 in) I N N E R (IN/EX): 6.0turns OUTER (INIEX): 4.25t”rnr 81 Winding0.D. 9) idumber of windings 1) Crankshaft deflection limit 2) Con-rod large end clearance 3) Width of crankshaft (A) 18) (a 0.05 mm (0.002 in1 0.15 - 0.4 mm (0.0059 - 0.0157 in) (D) 186 j3 mm (7.323 _E,,,2 in) 66 $2 mm (2.598 I$% ini 4) Crank pin I.D. 26 $2: mm (1.024 Ii:% in) 5) Crank pin O.D. x length 0 26 _o,oo6 x 65 ‘;I; mm (1.024 _E,wo2 x 2.559t$?J$iinl 12.
3) Bearing type: Main axle (Left1 (Right1 Dr,ve axle (Left) (Right1 4) Oil seal type Drive axle (Left1 5) Secondary reduction ratio and method Needle bearing (@20~@30-201 Ball bearing (0%052-20.61 Ball bearing l@30-062-23.8) Needle bearing (020.$30-161 SDD-40-62-9 34117 ~2.0OOllChain 16. SHIFTING MECHANISM 1) Type 21 Oil seal type (Change lever) Cam drum, return type SDO.14.24-6 17. KICK STARTER 1) TYPE 2) Oil seal type (Kick axle) 3) Kick clip friction tension Bendix type SD.25.35.7 1.2 - 1.7 kg (2.
6) Lubrication chart - Pressure feed d---Splash lubrication C. Chassis 1. FRAME 1) Frame design Douole cradle, high tensile frame 2. STEERING SYSTEM 1) Carter 21 Trail 27” 115mm (4.53 in) 3) Number and size of balls I” steering head upper race 19 pcs. 114 in Lover race 4) Steering lock to lock 19 pcs. 114 in 42” each IL and R) 3. FRONT SUSPENSION Telescopic fork 1) Type 21 Damper type Oil damper. coil spring 3) Front fork spring Free length Wire diameter x winding diameter 402 mm 118.
5. F U E L T A N K 11 Capacity 11.0 lit 12.9 US gall 2) Fuel grade Regular gasoline 5. W H E E L 1) Type (Front and rear) 2) Tire size IFrOnt) (Rear) *Cast wheel **Spoke wheel 3.50S19.4PR 130/90S16-4PR 31 Tire pressure: Front: 1.6 kg/cm’ (22 psi) Up to 90 kg (198 lb) load Rear: 2.0 kg/cm* (28 psi) Front: 2.0 kg/cm2 (28 psi1 90 kg (198 lblload - 204 kg (445 lblload (Maximum load) High speed riding Rear: 2.3 kg/cm2 (32 psi) Front: 2.0 kg/cm’ 128 psi) Rear: 2.
31 Rear brake (XS650-2F only) TVPE Actuating method Brake drum I.D. Drum brake (Leading trailing) Link rod Brake shoe dia. x width 180 x 30 mm (7.09 x 1.18 in) 4 mm12 mm IO.16 into.08 in) 180 mm (7.09 in) Lining thickness/wear limit Shoe spring free length 68 mm (2.68 in1 D. Electrical 1. IGNITION SYSTEM I) Ignition timing (B.T.D.C.) 15°/1,200 rlmin 2) Ignition coil Model/Manufacturer Spark gap CMll-50B/HITACHI Primary winding resistance 3.9R * 10% at 20°C (68°F) 8.
3. STARTER 1) srarter motor Tvpe Manufacturer Model output Armature coil resistance Field coil resistance Brush size/Ouantitv Wear limit Spring pressure Commutator O.D.lWear limit Mica undercut Bendix type HITACHI S108-35 0.5 kw 0.0067a + 10% at ZO’C (68’F) 0.004X2 + 10% at 20°C 16EaF) 16 mm (0.63 inIl2 PCS. 4 mm (0.16 in) 800 g (28.2 011 33 mm (1.30 in)/31 mm 11.22 in) 0.7 mm 10.
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FOREWORD This Supplementary Service Manual has been prepared to introduce new service and new data for the XS650G/XS650SG. For complete information on service procedure, it is necessary to use this Supplementary Service Manual together with following manuals: XS650E Service Manual (LIT-1 1616-00-76) XS650SE Supplementary Service Manual (LIT-1 1616-01-08) XS650SF/2F Supplementary Service Manual (LIT-1 1616-01-65) SERVICE DEPT. INTERNATIONAL DIVISION YAMAHA MOTOR CO., LTD.
MAINTENANCE AND LUBRICATION CHART PERIODIC MAINTENANCE EMISSION CONTROL SYSTEM THEREAFTEREVERY INITIAL BREAK-IN ITEM NO. 8,000 km 1,000 km 5,000 km 4,000 km or 1 month or 7 months or 6 months or 12 months l5.000 mil (600 mi) ( 3 , 0 0 0 mi) (2.500 mi) REMARKS 1‘ ’ Cam Chain 1 2’ Va,ve Cl e a r a n c e 1 Check and adjust valve clearance when ! engme is cold. 3 Spark Plugs 4’ Crankcase Ventilatlon System 5’ Check and adjust chain tension.
INITIAL BREAK-IN Lubricate Apply lightly Yamaha chain and cable lube or 1OWl 30 motor oil Dram completely. Refill to specification Yamaha fork oil 1Owt or equivalent 0 ,6e AC. Generator - Check specific gravity. Check breather pipe for proper operation. - Replace generator brushes Replace at initial 9,000 km (5,500 mi) 1 - I 0 0 Replace Check bearings assembly Medium weight for looseness. wheel bearing Moderately repack every grease. 16,000 km (10,000 mi).
~Yamaha Motor Corporation, U.S.A.. 1979 All rights reoened. Any reprinting or unauthorized use without the written permission of Yamaha Motor Corporation, U.S.A., is expressly prohibited. NEW SERVICE exactly as described. Failure to do so may be a violation of law. 1. Install the A.C.G. stator assembly to the crankcase. Set the pick-up coil assembly so that the 2.
eiYamaha Motor Corporation, U.S.A., 1979 All rights resered. Any reprinting or unauthorized use without the written permission of Yamaha Motor Corporation, U.S.A., is expressly prohibited. NOTE: A special socket (90890-01308-00) is necessary for tightening these special bolts. The heads will shear off when the bolts have been properly torqued. 1. Romr pointer 2. Timing plate 7. Check the ignition timing (refer to page 8. 3).
e. Inspect the starter plunger assembly for damage. If damaged, replace. f. Float level Hold the carburetor in an upside down position. Hold the floats so the tang is just touching the float needle. Measure the distance from the top of the float to the float bowl gasket base surface without the gasket. If the distance is out of the specification, correct the specification. Float level: 27.3 f 0.5 mm (1.075 * 0.02 in) To correct, carefully bend the tang on the float arm.
*ELECTRICAL A. IGNITION SYSTEM 1 Rlneb r4irrnram 1 protective circuit 2. Description This model is equipped with a battery operated, fully transistorized breakerless ignition system. By using magnetic pickup coils the need for contact breaker points is eliminated. This adds to the dependability of the system by eliminating frequent cleaning and adjustment of points and ignition timing.
turned on and the crankshaft is not turned, the protective circuit stops current flow to the primary coil within a few seconds. When the crankshaft is turned over, the current is turned on again by the signals generated by the pick-up coils. NOTE: Even though two spark plugs fire at the same time only one cylinder is on the compression stroke at a time. The other cylinder is on the exhaust stroke and the spark in that cylinder has no effect.
NOTE: B. CHARGING SYSTEM 1. Block Diagram Remove the headlight fuse (l0A) in the fuse box so that the headlight does not turn on when the engine is started. Do not turn on the signals. I.C.Voltage Regulator (with rectifier) 4) If the indicated voltage cannot reach the specification, then perform the following tests. L- 2. A.C. Generator/Voltage Regulator a. Output voltage check 1) Remove the seat and left side cover. 2) Connect a D.C. voltmeter to the battery terminals and start the engine.
A l l t h r e e stator w i n d i n g s m u s t b e checked. Also test between each terminal and ground. A reading other than infinity indicates an improper ground which must be corrected. d. Silicon rectifier Check the silicon rectifiers as specified using the Yamaha Pocket Tester or other circuit tester. Even if only one of the elements is broken, replace the voltage regulator assembly. 0 : Continuity x : Discontinuity @I -CAUTION: The silicon rectifier can be damaged if subjected to overcharging.
l SPECl FICATION *XS650SG only A. General I **XS650G only 1. MODEL 1) Model (I.B.M. No.) XS650SG (3G1)/ XS650G (3GO) 2) Basic color ‘CARDINAL RED or NEW YAMAHA BLACK “BLACK GOLD I 2. DIMENSION 1) Overall length 2,120 mm (83.5 in) 2) Overall width 925 mm 136.4 in) 3) Overall height ‘1,225 mm (48.2 in) 4) Seat height ““1,220mm (48.0 in) 790 mm (31.1 in) 1,435 mm (56.5 in1 5) Wheelbase 135 mm ( 5.3 in) 61 Minimum ground clearance 3.
1) Piston skin clearance 0.050 - 0.055 mm (0.0020 - 0.0022 in) 2) Piston oversize (2.963 in) (2.972 in) 31 Piston Pin outside diameter x length 5. PISTON RING 1) Piston ring design :$Jj 1.2mm ,O.M7 in) 21 Ring end gap +J _+&& ,.5mm ,a059 in, 2.8mrn ,cl.llO ir (Installed, top) 0.2-0.4 mm (0.008-0.016 in) /Installed. 2nd) 0 . 2 - 0 . 4 m m (0.008-0.016 in) (Installed, oil) 0 . 3 - 0 . 9 m m ~0.012-0.035 in) 11 Type 2) Bearing size @ 26 x +34 x 1 9 .
9. VALVE, VALVE SEAT AND VALVE GUIDE 2 PCS. 1) Valve per cylinder IN: 0.06 mm (0.0024 inI 2) Valve clearance Iln cold engine1 EX: 0.15 mm IO.0059 in) 31 Dimensions IN: 41 mm (1.614 in1 Valve head diameter “A” EX: 35 mm (1.378 in) Valve face width “6” IN: 2.1 mm (0.083 in) Valve seat width “C” IN: 1.3 mm (0.051 ini EX: 2.1 mm (0.083 ini EX: 1.3 mm 10.051 ini IN: 1.3 mm (0.051 inI Valve margin thickness “D” EX: 1.3 mm (0.051 ini Valve stern diameter IN: S.O_“,,,,, mm 10.315 _“,.oo,o i”’ EX: 8.
11 Crankshaft deflection limit 2) Con-rod large end clearance 0.05 mm 10.002 in) (81 3) Width of crankshaft 4) Crank pin I.D. 5) Crank pin O.D. x length Bigend I.D. 2) Small end I.D. $30.m78.19 (Ball bearing1 Others $32.@68-17 (Rollar bearing) 2) Oil seal type 1) Clutch type 2) Clutch operating mechanism 31 Primary reduction ratio and method 4) Primary reduction gear back lash (4 teeth) Wet, multiple type Inner push type, screw push system 72/27 (2.666).
3) Bearing: Main axle (Left) Needle bearing 1020.+30-20) Ball bearing ($25.$52-20.6) (Right) Drive axle (Left) Ball bearing (4 30. $662-23.8) Needle bearing (@20- $30-161 (Right) 41 Oil seal type Drive axle (Left) SDD-40.62.9 5) Secondary reduction ratio and method 34117 (2,0OO)/Chain 16. SHIFTING MECHANISM Cam drum, return type 1) Tvpe 2) Oil seal type (Change lever) SDO-14-24-6 17. KICK STARTER Bendix type 11 Type 2) Oil seal type (Kick axle) SD-25-35-7 3) Kick clip friction tension 1.
61 Lubrication chart ---Pressure e--Splash feed lubrication C. Chassis 1 FRAME 1) Frame design Double cradle, high tensile frame 2. STEERING SYSTEM 1 I caster 27’ 21 Trail 115 mm 14.53 in) 31 Number and size of balls in steering head Upper race 19 pcs. 114 in Lower race 19 pcs. 114 in 4) Steering lock to lock 42’ each /L and RI 3. FRONT SUSPENSION 1 I Type Telescopic fork ,3il damper, coil spring 21 Damper type 3) Front fork spring Free length 482 mm i 16.
r 4) Shock absorber spring 226 mm (8.90 in) Free length Wire diameter x winding diameter 7.5 x 60.5 mm 10.295 x 2.382 inl Spring constant kl = 1.714 kg/mm 196.0 lb/i”)/ O-45 mm (O- 1.77 in) k2= 2.244 kg/mm 1125.7 lbiinli 45-BOmm(1.77-3.15inl 5) Swing arm free play (Limit) 1 mm (0.04 inl 6) Pivot shaft -Outside diameter 16 mm (0.63 in) 5. FUEL TANK 1 I Capacity 11.5 lit (3.04 US gall 2) Reserve capacity 2.3 lit (0.61 US gall 3) Fuel grade Regular gasoline 6.
7. BRAKE 11 Front brake Type Disc size (Outside dia. x thickness) Disc wear limit Disc pad thickness Pad wear limit Master cylinder inside dia. Caliper cylinder inside dia. Brake flaid type I quantity 2) Rear brake lXS650SG only) Hydraulic disc type 298 x 7.0 mm (11.73 x 0.28 in) 6.5 mm (0.26 in) 11 .O mm (0.43 in) 6.0 mm IO.24 in) 14.0 mm (0.55 in) 38.1 mm (1.50 in) DOT =3 Brake fluid / 38.1 cc (1.29 oz) TVP~ Disc size (Outride dia.
3. STARTER 1) starter motor Bendix type HITACHI/S108-35 0.5 kw 0.0067R f 10% at 2o”c (68*Fl 0.0040 flO% at 2Ot (68oF) 16 mm (0.63 in)12 per. 4 mm (0.16 in) 803 g (28.2 02) 33mm ~1.30in)/30mm (1.18in) 0.7 mm IO.028 in) Type Manufacturer/Model Output Armature coil resistance Field coil resistance Brush size/Quantity Wear limit Spring pressure Commutator O.D.
Torque Specifications Part to be tightened : Cylinder head and cylinder ! Thread dia. and part name Tightening torque Engine: 10 mm nut 3.7 m-kg (27.0 ft-lbl 14 mm nut 10.7 m-kg (77.5 ft.lb) Chassis: Front wheel axle Front fork and axle holder 8 mm nut Handle crown and inner tube 8 mm nut 1 .l m-kg f( 8.0 ft.lb) Handle crown and steering shaft 8 mm nut 1.1 m-kg ( (8.0 ft.lb) Handle crown and steering shaft 14 mm bolt 5.4 m-kg (39.0 ti-lb) Handle crown and handlebar holder 8 mm bolt 1.
Thread dia. and pan name Part to be tightened 1 Tightening t o r q u e Brake disc and hub B mm bolt i 2.0 m-kg (14.5 ft.lb1 Caliper and support bracket 8 mm bolt ~1.8 m-kg 113.0 ft.lbi 5 mm bolt 0.3 m-kg I 2.2 ft-lb1 8 mm bolt 0.
CONVERSION TABLES r r Notice The information presented represents results obtainable by skilled drivers under controlled road and vehicle conditions, and the information may not be correct under other conditions. STOPPING DISTANCE This figure indicates braking performance that can be met or exceeded by the vehicles to which it applies, without locking the wheels, under different conditions of loading and with partial failures of the braking system. -185- Property of www.SmallEngineDiscount.
not applicable and is not included) 0 ! 100 200 300 (Feet) STOPPING DISTANCE IN FEET FROM 60 MPH ACCELERATION AND PASSING ABILITY This figure indicates passing times and distances that can be met or exceeded by the vehicles to which it applies, in the situations diagrammed below. The low-speed pass assumes an initial speed of 20 mph. and a limiting speed of 35 mph. This high-speed pass assumes an initial speed of 50 mph. and a limiting speed of 60 mph.
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INDEX This manual has been combined with previous service manuals to provide complete service information for: XS650H/SH. Please read and give special consideration to the “NOTICE” on the preceding page for your safety. XS650H/SH SUPPLEMENT XS650 MODELS 1978-80 Property of www.SmallEngineDiscount.
FOREWORD This Supplementary Service Manual has been prepared to introduce new service and new data for the XS650H/XS650SH. For complete information on service procedure, it is necessary to use this Supplementary Service Manual together with following manuals: ’ XS650E Service Manual (LIT-11616-00-76) ! XS650SE Supplementary Service Manual (LIT-11616-01-08) ’ XS650SF/2F Supplementary Service Manual (LIT-11616-01-65) XS650G/SG Supplementary Service Manual (LIT-1 1616-01-75) I 1 SERVICE DEPT.
Particularly important information is distinguished in this manual by the following notations: NOTE : A NOTE provides key information to make procedures easier or clearer. CAUTION: A CAUTION indicates special procedure that must be followed to avoid damage to the motorcycle. A WARNING indicates special procedures that must be folWARNING: lowed to avoid injury to a motorcycle operator or person inspecting or repairing the motorcycle. Starting Serial Number XS650H H . . . . . . . . . . . . .
MAINTENANCE AND LUBRICATION CHART PERIODIC MAINTENANCE EMISSION CONTROL SYSTEM - 3 Property of www.SmallEngineDiscount.
c t c Property of www.SmallEngineDiscount.
*ENGINE A. IGNITION TIMING The ignition system is modified for easier maintenance. Thus, the following “ignition timing check” should be changed, B. PICK-UP COIL ASSEMBLY The method of mounting the pick-up coil assembly is changed for easier service work. Thus, the followings “Pick-up coil assembly removal” and “Pick-up coil assembly reinstallation” should be changed. Pick-up coil assembly removal Ignition timing check 1.
Fuel level: 1 f 1 mm (0.04? 0.04 in) above from the carburetor mixing chamber body edge. 3. Start the engine and stop it after a few minutes of run. This procedure is necessary to obtain the correct fuel level. NOTE: Make sure the fuel petcock is “ON” or “RES” oosition. 4. Note the fuel level and bring the gauge to the other end of the carburetor line and repeat step 3 above. Note the fuel level again and compare it with the previous gauge reading. They should be equal.
2 With the engine stopped, check the oil level through the level window located at the lower part of the right side crankcase cover, or screw the dip stick completely out and then the stick in the hole. NOTE: Wait a few minutes until the oil level settles before checking. When checking engine oil level with the dip stick, let the unscrewed dip stick rest on the case threads. 1. Dip stick 2. Maximum level 3. Minimum level 3. The oil level should be between maximum and minimum levels.
*CHASSIS A. REAR WHEEL REMOVAL 1. Place the motorcycle on the center stand. 2. Remove the tension bar and the brake rod from the brake shoe plate. The tension bar can be removed by removing the cotter pin and nut from the tension bar bolt. The brake rod can be removed by removing the adjuster. b. Make sure the axle nut is properly torqued and a new cotter pin is installed. 15.0 m-kg (108.5 ft-lb) c. Adjust the drive chain. 8. DRIVE CHAIN TENSION CHECK 1. Adjusfer 2. Brake rod 3. Tenrio” bar 3.
NOTE: The rear wheel axle nut is located on the right side. 3. 4. Loosen the rear wheel axle nut. Loosen the lock nuts on each side. To tighten chain turn chain puller adjusters clockwise. To loosen chain turn adjusters counterclockwise and push wheel forward. Turn each adjuster exactly the same amount to maintain correct axle alignment. (There are marks on each side of the rear arm and on each chain puller; use them to check for proper alignment.) 6.
E. REAR BRAKE LINING INSPECTION The specified thickness of the brake lining is 4 mm (0.16 in). The lining should be replaced when it wears to less than 2 mm (0.079 in). To check, see the wear indicator position while depressing the brake pedal. Property of www.SmallEngineDiscount.
*ELECTRICAL STARTING CIRCUIT CUT-OFF SYSTEM The starting circuit cut-off system is employed. Hence, the following description. Description This model is equipped with a starting circuit cut-off switch. The starter motor is so design- ed that it can be started only when the transmission is in Neutral or the clutch is disengag ed.
2 When the “START” button is pressed, the circuit from the main switch to the relay - starter switch assembly “START” (button) is closed, and the starter switch assembly is turned on, thus causing the starter motor to start.
*SPECIFICATION A. General ‘XS650SH only **XS650H only 1. MODEL 1) Model (I.B.M. No.) XS650SH (4M4/XS650H (4N9) *CARDINAL RED or NEW YAMAHA BLACK 21 Basic color **BLACK GOLD 2. DIMENSION 1) Overall length 2.120 mm (83.5 ini 2 ) Overall width 925 mm (36.4 in) 3) Overall height 1,220 mm (48.0 in) 790 mm (31.1 ini 4) Seat height 5) Wheelbase 1,435 mm (56.5 ini 6) Minimum ground clearance 135 mm I 5.3 in) 3. WEIGHT 1) Net weight (Dry) “208 kg I459 lb) “205 kg (452 lb) 4.
4. PISTON 1) Piston skirt clearance ~ 0.050 - 0.055 mm 10.0020 - 0.0022 in) 2) Piston oversize 7 5 . 2 5 mm ~15.50 mm 75.75 mm ~2963 in, 12.972 I”/ (2.982 in, 76.00 mm 12.5xX in, , 20.0-:.005 mm x 61.0_;,3 mm 3) Piston pin outside diameter x length (0.79_&,2 in x 2.40&,,,, in) 5. PISTON RING 1) Piston ring design 1.2mm (0.047 in, 1.5mm ,0.059 in, 2.*mm IO.110 inl 2) Ring end gap 0.4 mm (0.008 - 0.016 in) 3) Ring groove side clearance (Top) 6. BIG END BEARING 11 Type $25.
9. VALVE, VALVE SEAT AND VALVE GUIDE ~ 1) Valve per cylinder 2 pcs. 2) Valve clearance IIn cold engine) IN: 0.06 mm (0.0024 in) EX: 0.15 mm (0.0059 in) 3) Dimensions Valve head diameter “A” IN: 41 mm (1.614 in) EX: 35 mm (1.378 in) Valve face width “6” Valve seat width “C” IN: 2.1 mm (0.083 in) EX: 2.1 mm (0.083 in) x $ IN: 1.3 mm (0.051 in) D EX: 1.3 mm (0.051 in) Valve margin thickness “D” B .4\----r & IN: 1.3 mm (0.051 in) EX: 1.3 mm (0.051 in) Valve stem diameter IN: 8.0_g,o,5 mm (0.
I. CRANKSHAFT 1) Crankshaft deflection limit ~0.05 mm (0.002 in) 2) Con-rod large end clearance (A) (B) 31 Width of crankshaft (Cl 66 -0.05 mm (2.598;$?,;; in) -0.10 (D) 166_;.3 mm 17.323_;,o,2 in) 41 Crank p,n I.D. 5, Crank piln O.D. x length 0.15 - 0.4 mm (0.0059 - 0.0157 in) ~26I;:;;j m m (1.024:;:;;; in) 26~&?06 x 65:;:; mm 2. CONNECTING ROD 1) Big end I.D. 34 +t016 mm ( 1.339+~.0006 in) 21 Small end I.D. 20$::85 mm 10.787:~:~o~ in) 3.
2) Gear ratio: 1st 32113 (2.461) 2nd 27/l 7 (1.588) 3rd 26/20 (1.300) 4th 23/21 (1.095) 5th 22/23 (0.956) 31 Bearing: Main axle Needle bearing (@20-$30-20) (Left1 Ball bearing ($25-e 52-20.6) (Right1 Drive axle (Left1 Ball bearing ($30.$62-23.61 Needle bearing (020.030-161 (Right1 41 Oil seal type Drive axle (Left) SDD-40-62-9 51 Secondary reduction ratio and method 34117 (Z.OOO)/Chain T 16. SHIFTING MECHANISM 1 I Type 2) Oil seal type (Change lever) L 17.
6) Lubrication chart - Pressure feed - -- Splash lubrication C. Chassis 1. FRAME 1) Frame design 2. STEERfNG Double cradle, high tensile frame SYSTEM 1) caster 27O 2) Trail 115 mm (4.53 in) 3) Number and size of balls in steering head upper race 19 pcs. l/4 in Lower race 19 pcs. l/4 in 4) Steering lock to lock 42” each (L and R) 3. FRONT SUSPENSION 1) Type Telescopic fork 2) Damper type Oil damper, coil spring 3) Front fork spring Free length 482 mm (18.
4) Shock absorber spring Free length Wire diameter x winding diameter Spring constant ~ 226 mm 03.90 in) ~ 7.5 x 60.5 mm (0.295 x 2.382 in) ! kl = 1 . 7 1 4 k g / m m (96.0 lb/in)/ 0 - 45 mm (0 - 1.77 in) k2 = 2.244 kg/mm 1125.7 lb/in)/ 45 - 80 mm (1.77 - 3.15 in) 5) Swing arm free play (Limit) 6) Pivot shaft - Outside diameter 1 mm (0.04 in) 16 mm IO.63 in1 5. FUEL TANK ~ 11.5lit(3.04USgal) 1) Capacity 2) Reserve capacity 2.3 lit IO.61 US gal) Regular gasoline 3) Fuel grade 6.
7. BRAKE 1) Front brake Type Hydraulic disc type Disc size (Outside dia. x thickness) 298 x 7.0 mm 11 1.73 x 0.28 in) Disc wear limit 6.5 mm (0.26 in1 Disc pad thickness 11.0 mm (0.43 inl Pad wear limit 6.0 mm (0.24 in1 Master cylinder inside dia. 14.0 mm (0.55 ini Caliper cylinder inside dia. 38.1 mm (1.50 in) Brake fluid type/Quantity DOT #3 Brake fluid i38.1 cc Il.29 02) 2) Rear brake Type Drum brake (Leading trailing) Actuating method Link rod Brake drum I.D. 180 mm (7.
2) Regulator I.C. type Type Model/Manufacturer S8515/TOSHIBA Regulating voltage 14.5 ? 0.3v 3) Battery Model/Manufacturer/Quantity YB14L-AZIYUASAII PC. 12V. 14AH Capacity , 1.4A 10 hours Charging rate Specific gravity ~_~..~~ 1.28 at 20°C 168°F) ..-f--.______ 3. STARTER 1 I Starter motor Type Manufacturer/Model output ~Bendix type 1 HITACHliSlOE-35 ~ 0.5kw 0.0067R * 10% at 20°C (68” Fl Armature coil resistance 0.
5) Flasher relay Type Model/Manufacturer Condenser type Flasher frequency 85 t 10 cycle/min. Capacity 32 CP (27W) x 2 + 3.4w 061300.04810/NIPPON DENS0 6) Flasher cancelling unit Model EVH-AC518 Voltage DC9V - 16V 7) Fuse Rating/Quantity: Main 20A x 1 pc. Headlight 10A x 1 pc. Signal 10A x 1 pc. Ignition 10A x 1 pc. Property of www.SmallEngineDiscount.
Torque Specifications Part to be tightened Tightening torque Thread dia. and part name Engine: Cylinder head and cylinder head cover 10 mm nut 8 mm bolt 3.7 m-kg (27.0 ft-lb) 2.1 m-kg (15.0 ft-lb) Cylinder head 6 mm bolt 0.9 m-kg ( 6.5 ft-lb) Cylinder head cover side 6 mm crown nut 8 mm crown nut 0.9 m-kg ( 6.5 ft-lb) 1.3 m-kg ( 9.5 ft-lb) Spark plug 14 mm 2.0 m-kg (14.5 ft-lb) Generator 12mm nut 3.8 m-kg (27.5 ft-lb) Stator coil 6 mm pan head screw 0.9 m-kg ( 6.
Thread dia. and part name Part to be tightened I ! Tightening torque 1 2.0 m-kg (14.5 ft-lb) Brake disc and hub 8 mm bolt Caliper and support bracket 8 mm bolt 1.8 m-kg (13.0 ft-lb) Caliper and pad 5 mm bolt 0.3 m-kg Caliper and bleed screw 8 mm bolt 0.6 m-kg ( 4.5 ft-lb) 10 mm bolt Front caliper and front fork 3.5 m-kg (25.5 ft-lb) 6 mm bolt Master cylinder and cylinder bracket ( 2.2 ft-lb) 0.6 m-kg ( 4.5 ft-lb) Pivot shaft 14 mm nut 6.5 m-kg (47.
CONVERSION TABLES r METRIC TO INCH SYSTEM KNOWN w m-kg 2 m-kg ! 0.0723 0.8680 ~ 2.205 ! 0.03527 ! kg g g ! KNOWN ~ft-lb i in-lb , ft-lb i in-lb 7.233 86.80 cm-kg I 1 RESULT MULTIPLIER cm-kg INCH TO METRIC SYSTEM MULTIPLIER ft-lb 0.13826 m-kg in-lb 0.01152 m-kg 13.831 ft-lb in-lb 1.1521 lb lb 0.4535 ~02 02 : RESULT I 28.352 cm-kg c cm-kg kg + g km/lit 2 . 3 5 2 mpg mpg 0.4252 i2 kmlhr 0 . 6 2 1 4 mph mph 1.609 kmlhr 2 km 0 . 6 2 1 4 I ! mi mi 1.
FULL OPERATIONAL SERVICE BRAKE (“Partial failure” information is not applicable and is not included.) 100 0 200 300 (Feet) STOPPING DISTANCE IN FEET FROM 60 MPH ACCELERATION AND PASSING ABILITY This figure indicates passing times and distances that can be met or exceeded by the vehicles to which it applies, in the situations diagrammed below. The low-speed pass assumes an initial speed of 20 mph. and a limiting speed of 35 mph. This high-speed pass assumes an initial speed of 50 mph.
