Yamaha XS650 Series Shop Manual Download

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3-4. ENGINE ASSEMBLY AND ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . .

A. Shift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

B. Transmission and crankshaft

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

C. Shifter assembly

D. Kick starter assembly

E. Electric-starter gear assembly

Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

G. Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

H . Oil pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Right-hand crankcase cover

J. Piston . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

K. Cylinder and cylinder head.

L. Camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

M. Cylinder head cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

N. Governor and breaker assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

0. Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Summary of Contents for XS650 Series

Page 1: ......

Page 2: ...XS650E INDEX GENERAL INFORMATION PERIODIC INSPECTION AND ADJUSTMENT ENGINE OVERHAUL CARBURETION CHASSIS ELECTRICAL I APPENDICES ...

Page 3: ...XS650SE SUPPLEMENT EPA XS650E SUPPLEMENT XS650SF USES THIS SUPPLEMENT EPA XS650SE SUPPLEMENT I XS650SF 2F SUPPLEMENT XS650G SG SUPPLEMENT ...

Page 4: ...CHAPTER 1 GENERAL INFORMATION l l MACHINE IDENTIFICATION a 1 l 2 SPECIAL TOOLS ...

Page 5: ...mped 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 c 2 Valve spring compressor 90890 01253 3 Valve guide reamer 90890 01211 J 4 Valve seat cutter set 5 Piston ring compressors 6 Piston support plate 90890 01179 90890 01066 ...

Page 6: ...Vacuum gauge 90890 03094 P 8 Clutch holding tool 90890 01069 9 Slide hammer 90890 z 12 E lectro tester 9089 0302 1 OTHER TOOL PARTS No Valve guide remover 90890 01200 Valve guide installer 90890 01201 Spoke wrench 90890 05087 Steering nut wrench 90890 01051 Tappet adjuster wrench 256 28137 00 2 ...

Page 7: ...rance adjustment 8 G Crankcase ventilation system 9 H Exhaust system 9 2 4 CHASSIS 9 A B C D E F G H I J Fuel petcock cleaning 9 Fuel petcock disassembly 9 Fuel hose 9 Front brake 10 Rear brake lO Wheels and tires 10 Drivechain 11 Front fork oil change 12 Steering head 12 Lubrication of cables pivots etc I3 2 5 ELECTRICAL 13 A Contact breaker point adjustment 13 B Contact breaker point maintenance...

Page 8: ... the chart to avoid damage A PERIODIC MAINTENANCE Periodic inspection adjustment and lubri and most efficient condition Safety is an ob cation will keep your motorcycle in the safest ligation of the motorcycle owner Item Remarks Unit km mi initial Thereafter every 400 800 1 600 3 200 1 600 3 200 6 400 2 5 0 500 1 0 0 0 2 000 1 000 2 000 4 0 0 0 Cylinder 1 Check compression I IOI I lo Valves 1 Chec...

Page 9: ...ion oil Drive chain Control Meter Apply thoroughly Oil filter element Wheel bearings Do not over Medium weight 12 800 Yearly or wheel bearing grease 8 000 Point cam lubri cation wicks Apply very lightly Light weight machine oil 0 0 0 0 5 ...

Page 10: ...utes The warm up is com plete when engine responds normally to throttle opening d Adjust damping valve on each vacuum e f gauge until the needle flutters only slightly The gauge needles must respond quickly to rapid opening of the throttle Both gauge will indicate the same reading if the carburetors are synchronized Turn the synchronizing screw until the gauge readings are the same 1 Synchronizing...

Page 11: ...mi It should be cleaned more often if the machine is operated in extremely dusty areas 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 With the engine stopped screw the dip stick completely out and then rest the stick in the hole 1 Oil leuel dip stick b 2 NOTE When checking engine oil level with the dip stick ...

Page 12: ...gth adjuster either in or out until proper lever free play is achieved 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 c 1 Adjuster 2 Lock nut E Cam cha...

Page 13: ...en joint bolts and nuts 2 Replace gaskets if necessary 2 4 CHASSIS A Fuel petcock cleaning 1 Turn the petcock lever to the ON or RES position Remove the fuel pipe 2 Remove the drain cover and clean it with solvent 1 RES position 2 Drain cover B Fuel petcock disassembly If the fuel petcock is leaking or excessively contaminated it should be removed from the fuel tank and inspected 1 2 3 4 5 Remove ...

Page 14: ...nd poor brake performance Refill with the same type and brand of brake fluid mixing fluids may result in a harmful chemical reaction and lead to poor performance Be careful that water or other contamina tion does not enter the master cylinder when refilling Water will significantly lower the boiling point and may result in vapor lock E Rear brake 1 Adjust rear brake pedal play to suit pro viding a...

Page 15: ...instand erected Check the tension at the position shown in the illustration The normal ver tical deflection is approximately 20 mm 3 4 in 20 mm 3 4 in 2 Tension adjustment a Loosen the rear brake adjuster b Remove the cotter pin of the rear wheel axle nut c Loosen the rear wheel axle nut d Loosen the adjuster lock nuts on each side e To tighten chain turn chain puller ad juster clockwise Turn each...

Page 16: ...er outer tubes to pump out re maining oil 7 Install drain screw NOTE Check gasket Replace if damaged 8 Pour specified amount of oil into the in ner tube through the upper end opening Front fork oil Yamaha fork oil 10 Wt I Front fork oil capacity 164 172 cc 5 54 5 82 oz each side 9 After filling slowly pump the outer tubes up and down to distribute the oil 10 Inspect O ring on fork cap bolts and re...

Page 17: ... 1 Throttle cable and grip The throttle twist grip assembly should be greasedat the time that the cable is lubri cated since the grip must be removed to get at the end of the throttle cable Two screws clamp the throttle housing to the handlebar Once these two are removed 3 Rear arm pivot shaft Apply grease to grease nipple on top of pivot with low pressure hand operated gun Apply until fresh greas...

Page 18: ...Top dead center 2 15 BT0C11 200 rpm 3 Advanced mark _ 2 3 4 5 6 7 Ignition timing of right hand cylinder must be set first Connect timing light to right hand spark plug lead wire Start engine The mark stamped on the rotor_ should line up with the stationary F timing mark If it does not align loosen two breaker backing plate screws and move the complete backing plate until the mark on the rotor and...

Page 19: ...must be a medium tan color If it is not check carburetion timing and ignition adjust ments 3 The spark plug must be removed and checked Check electrode wear insulator color and electrode gap Spark plug gap 0 7 0 8 mm 0 028 0 031 in Engine heat and combustion chamber de posits will cause any spark plug to slowly break down and erode If the electrodes finally become too worn or if for any reason you...

Page 20: ...r unit removal J Oil pump removal K Crankcase disassembly L Transmission illustration M Shift drum removal N Crank shaft removal 18 18 18 I8 18 19 19 19 19 19 19 19 19 20 20 20 20 21 21 22 INSPECTION AND REPAIR 22 A B C D E F G H I J K L M N 0 P Q R Cyinder head cover 22 Cylinderhead 22 Valve valve guide and valve seat 23 Valvespring 2 4 Rocker arm and rocker shaft 25 Cam shaft wear 2 5 Cam chain ...

Page 21: ...hifter assembly 30 D Kick starter assembly 30 E Electric starter gear assembly 30 F Clutch 30 G Generator 32 H Oil pump p 32 I Right hand crankcase cover 32 J Piston 32 K Cylinder and cylinder head 32 L Camshaft 32 M Cylinder head cover 33 N Governor and breaker assembly 33 0 Engine 33 ...

Page 22: ...acuum pipes from petcock 2 Lift seat and remove fuel tank holding bolt Remove fuel tank C Removal of other parts Remove the following parts in the order given 1 Exhaust pipes 2 Horn as a unit 3 Both side footrests 4 Change pedal and drive chain guide 5 Left hand crank case cover and clutch cable 6 Side covers 7 Air cleaner assembly and ventilation hoses 8 Carburetor to the left and throttle cable ...

Page 23: ...er NOTE It is advisable to remove the stator and rotor after finding the place of the master link pins Refer to item F Generator 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 2 3 Compress the valve spring and then re move both retainer locks Remove the compressor and lift off t...

Page 24: ... panhead screw 10 gear 2 axle assembly out 6 shaft 2 5 and gear 1 4 2 Remove circlip from left side of change 4 Remove the circlip 11 and gear as shaft and pull the shaft out sembly 7 8 9 5 Starter gears illustration D 2 1 Absorber Idlegear 1 6 7 Gear Starter 3 wheel 3 ldlegear 2 T g Y 3 9 Gear 4 4 Gear 1 10 Panhead screw 5 Shaft 2 11 T Circlip 6 Gear 2 J Oil pump removal K Crankcase disassembly 1...

Page 25: ... 4 4th pinion gear 21T 4 4th wheel gear 23T 5 5th pinion gear 23T 5 5th wheel gear 22T 6 Drive sprocket 17T M Shift drum removal 11 Shiftfork 1 12 Pin 13 Cotter pin 14 Guide bar 15 Cam stopper 16 Stopper spring 17 Gasket 18 Stopper bolt 1 Bolt 2 Lock plate 3 stopper Plate 4 Shaft bolt 5 stopper 6 Stopper spring 7 Shift cam 8 Bearing 9 Shift fork 3 10 Shift fork 2 ...

Page 26: ...INSPECTION AND REPAIR A Cylinder head cover Place head cover on a surface plate There should be no warpage Correct by re surfacing as follows Place 400 or 600 grit wet sandpaper on surface plate and re surface head cover using a figure eight sanding pattern Rotate head cover several times to avoid removing too much material from one side B Cylinder head 1 Remove spark plugs 2 Removevalves 3 Using ...

Page 27: ...he old guide out and drive the new guide in e After installing the valve guide use 8 mm f 2 a I L reamer special tool to obtain the proper valve clearance After fitting the valve guide into the cylinder head be sure to grind the valve seat and perform valve lapping The valve must be replaced with a new one Grinding the valve seat The valve seat is subject to severe wear similar to valve face Whene...

Page 28: ...lve and valve seat are evenly polished Clean off the coarse compound then follow the same procedure with fine com pound _ Valve leakage check Continue lapping until the valve face shows a complete and smooth surface all the way around Clean off the compound material Apply bluing dye to the valve face and rotate the valve face for full seat contact which is indicated by a shiny sur face all around ...

Page 29: ...m pump and passages checked Standard shaft diameter 14 985 14 991 mm 0 5900 0 5902 in rocker 4 Standard clearance between the shaft and hole should be 0 009 0 033 mm 0 00035 0 00130 in If measure ment shows more than 0 1 mm 0 0004 in clearance replace either or both parts as necessary F Camshaft wear 1 2 3 The cam lobe metal surface may have a blue discoloration due to excessive fric tion The meta...

Page 30: ... H Cylinder 1 Inspect the cylinder walls for scratches If vertical scratches are evident the cylinder wall should be rebored or the cylinder should be replaced 2 Measure cylinder wall wear as shown If wear is excessive compression pressure will decrease Rebore the cylinder wall and replace the piston and piston rings Cylinder wear should be measured at three depths with a cylinder bore gauge See i...

Page 31: ...79 0 016 in 0 039 in Oil control 0 2 0 9 mm Visual Rails 0 0079 0 0354 in inspection J Piston pin 1 2 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 con necting rod as required The piston pin should have no noticeable free play in piston If the pis...

Page 32: ...ring free length Replace springs as a set if necessary Clutch spring length 34 6 mm 1 362 in N Transmission 1 2 3 4 5 6 7 Inspect each shift fork for signs of galling on gear contact surfaces Check for bend ing Make sure each fork slides freely on its guide bar Roll the guide bar across a surface plate If bar is bent replace Check the shift cam grooves for signs of wear or damage If any profile ha...

Page 33: ...acks or other damage 2 Clean all oil passages and blow out with compressed air R Bearings and oil seals 1 2 After cleaning and lubricating bearings rotate inner race with a finger If rough spots are felt replace the bearing Check oil seal lips for damage and wear Replace as required 3 4 ENGINE ASSEMBLY AND ADJUST MENT NOTE 1 2 3 All gaskets and seals should be replaced when an engine is overhauled...

Page 34: ...l Adjust them by adjuster if necessary 1 Adjuster 2 A B D Kick starter assembly 1 Partially insert the assembly until the re turn spring can be slipped over its anchor point 1 Kick clap 2 Positioning the kick clip in the groove rotate the kick axle by kick lever l 2 turn counterclockwise 3 Push the axle in 4 Check for correct operation E Electric starter gear assembly Install the unit as shown Ref...

Page 35: ...m kg 65 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 k m a 1 o mm b 2 0 e 1 0 f 2 0 g 2 0 I 2 6 i 2 0 d ...

Page 36: ... TO P 2 2nd 3 Expander 4 spacer upper 5 spacer lower 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 K Cylinder and cylinder head 1 2 3 4 L 1 2 Install the tensioner cushion onto crank case Install a new cylinder base gasket Install cylinder using special tool Install the cylinder head gasket and cylinder head NOTE T...

Page 37: ... 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 N Governor and breaker assembly Reverse the governor and breaker removal sequence NOTE Before inserting the governor rod supportive bearings should be lubricated with molyb denum disulfide O Engine 11 1 ...

Page 38: ...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 Adjustments 37 ...

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Page 40: ...ragm piston valve Note that there is tab on the rubber diaphragm There are matching recesses in the carburetor body for the diaphragm tab 8 To inspect starter jet remove three 3 screws holding the starter body to the right side of the carburetor Remove the four screws holding the float bowl cover Remove float bowl cover The main jet is located under a cover in the float bowl Pull out float pivot p...

Page 41: ...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 mix ture will occur If too low a lean mixture will result I 1 Tongue A 24 1 m m 0 94f0 04 in1 3 7 ...

Page 42: ...lacement 40 B Caliper disassembly 42 C Master cylinder disassembly 42 D Brake inspection and repair 42 E Brake reassembly 43 WHEELS TIRES TUBES 44 A Wheel inspection 44 B Tire tube removal 44 C Installation 44 REAR WHEEL SPROCKET 44 FRONT FORKS 4 5 A Removal and disassembly 46 6 Inspection 4 6 C Assembly 4 6 STEERING HEAD 4 7 A Adjustment 4 7 B Removal 4 7 C Inspection 4 7 D Reassembly 4 7 SWING A...

Page 43: ...n out is up and down loosen spokes opposite the high spot and tighten the spokes at the high spot b If the run out is sideways loosen the spokes at the high spot and tighten the spokes opposite the high spot D Replacing wheel bearings If the bearings allow play in the wheel hub or if wheel does not turn smoothly replace the bearings as follows 1 2 3 Clean the outside of the wheel hub Drive the bea...

Page 44: ...ned and then properly filled and bled upon reassembly CAUTION 2 3 4 5 6 Loosen the chain tension adjusting nuts and bolts on both right and left sides Remove the rear axle cotter pin and nut Remove the right hand chain adjuster and distance collar Remove the rear brake plate Lean the machine to the left and remove the rear wheel assembly B Rear axle inspection See front Wheel Axle Inspection Proce...

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Page 46: ...Remove piston seal 3 Remove brake lever and spring 4 Remove master cylinder from handlebars Remove cap and drain remaining fluid h 1 1 Snap ring 2 Cylinder CUP IFI 3 Piston 4 Shim 5 Piston cup 6 Spacer 7 Return spring D Brake inspection and repair Pad s c r e w 3 sntm 2 Shim 4 Pads C Master cylinder disassembly 1 Remove brake hose 2 Remove front brake switch Recommended Brake Component Replace men...

Page 47: ...e disc E Brake reassembly All internal parts should be cleaned in new brake fluid Internal parts should be lubricated with brake fluid when installed Caliper reassembly Replace the following parts whenever a caliper is disassembled bleed screw and cap boot bushing piston seal dust seal retaining ring I _ 1 Bleed screw with cap 4 Dust seal 2 Bush boot 5 Retaining ring 3 Piston seal a Install piston...

Page 48: ...l air is out of tube separate tire bead from rim both sides by stepping on tire with your foot 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 Be very careful not to damage the stem ...

Page 49: ...ainst the bolts 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 5 6 FRONT FORKS Wear limit 3 mm 0 02 in Slip off 26 Nut _w J I ii 0 u2 I 31 I 3 0 I d it 7 I t 2 7 I 126 I _ _ J 45 ...

Page 50: ...be for scratches and straightness If the tube is scratched severe ly or bent it should be replaced If the lips of the oil seal are worn or the oil seal is leaking replace it Check the outer tube for dents If any dent causes the inner tube to hang up during operation the outer tube should be replaced Check the free length of the springs Spring free length 482 mm 18 98 in Check the O ring on the top...

Page 51: ...ces and bearings 4 Install bearings in races Spin bearings If the bearings hang up or are not smooth in their operation in the races replace bear ings and races D Reassembly 1 Grease bearings and races with wheel bear ing grease 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 Co...

Page 52: ...S A Cable maintenance NOTE See maintenance and lubrication intervals charts Cable maintenance is primarily con cerned with preventing deterioration through rust and weathering and providing proper lubrication to allow the cable to move freely within its housing Cable removal is straight forward and uncomplicated Removal will not be discussed within this section WARNING Cable routing is very import...

Page 53: ...D Checking silicon rectifier 53 E Battery 5 3 6 3 IGNITION SYSTEM 5 4 A Ignition circuit diagram 54 B Governor assembly 54 C Sparkgaptest 54 D Ignitioncoil 5 4 E Condensertest 5 5 6 4 SPARK PLUG 5 6 A How to Read a spark plug condition 56 B Inspection 5 6 65 LIGHTING AND SIGNAL SYSTEMS 56 A Lighting tests and checks 56 B Reserve lighting system 57 C Self cancelling flasher system 58 ...

Page 54: ...uired check the condition of the cover bearings armature electrical properties starter amperage draw and rpm and finally carbon brushes B Yoke 1 2 If the yoke area is dirty clean with clean solvent and dry with high pressure air Yoke coil resistance is 0 05 ohm The coil should be show zero ohm resist ance if it shows more than zero ohm replace it If the yoke shows leakage to ground re sistance is ...

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Page 56: ...k the coil connections If the coil connections are good then the coil is broken inside and it should be replaced Field coil resistance Green Black 5 25R 2 10 at 20 C Stator coil resistance W 1 W2 W2 W3 W3 W 1 0 46 Q f 10 at 20 C 1 Stator coil 4 Black 2 White 5 Sky blue 3 Yellow Pick up cable 6 Field Coil C Voltage regulator The regulator s function is to pass a control led amount of current throug...

Page 57: ...5 V DC D Checking silicon rectifier 1 Check silicon rectifier as specified using the Yamaha Pocket Tester Contlnultv Con 1 Pocket tester Element e t O K shorted1 RETX Ielement opened 1 Wh te 2 White 3 White 4 IBlack 5 fRedI Even if only one element is broken re place assembly CAUTION The silicon rectifier can be damaged if subjected to overcharging Special care should be taken to avoid a short cir...

Page 58: ...Governor assembly 1 Inspection a Both weights must pivot smoothly or ignition advance will not occur at the 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 repl...

Page 59: ...xcessive 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 2 a b Condenser capacity 0 22 1F 2 10 Insulation test Connect ohmmeter as shown n x 1 000 or more Resista...

Page 60: ...S A Lighting tests and checks The battery provides power for operation of the horn tail light stop light neutral light and flasher light If none of the above 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 A...

Page 61: ... filaments is inopera tive 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 HEAo lNOlC 4TOR i RESERVE LIGHTING CONDlTlON YT F NCTlON L J Voltage on W wring circuits ...

Page 62: ...hever 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 combina tion of both time and distance 2 Operation The handle switch has three positions L left OFF and R right The switch lever will return to the OFF position after being pushed to L or R but the signal will...

Page 63: ...es on the wire harness side Turn the speedometer shaft If the tester needle swings back and forth four times between 0 and m the speedo meter sensor circuit is in good condition If not the sensor or wire harness may be inoperative c Pull off the 6 pin connector from the flasher canceling unit Check if there is continuity between the yellow red lead wire on the wire harness side and the chassis If ...

Page 64: ... Torque Specifications 61 7 2 CONVERSION TABLE 63 Metric to Inch System 63 Inch to Metric System 63 Definition of Terms 63 7 3 SPEClFlCATlON 64 A General 64 B Engine 64 C Chassis 66 D Electrical 70 7 4 CABLE ROUTING DIAGRAM 72 7 5 CIRCUIT DIAGRAM 7 4 ...

Page 65: ...1 3 5 4 0 12 mm Ml21 i 4 0 4 5 14 mm Ml41 600 700 1 Part to be tightened I Thread dia and part name I Tightening torque Engine Cylinder head and cylinder head cover Cylinder head Cylinder head cover side Spark plug Generator I 10mm nut 8 mm bolt 6 mm bolt 6 mm crown nut 8 mm crown nut l 14 mm 1 2 m m n u t 3 8 m kg 27 ft lb 2 2 m kg 16 ft lb 1 O m kg 7 ft lb 1 O m kg 7 ft lb 1 1 5 m kg 10 ft lb i ...

Page 66: ... Primary drive gear 14 mm nut I 9 0 m kg 65 ft lb I Clutch boss Drive sprocket Change pedal Chassis Front wheel shaft 18 mm nut 22 mm nut 6 mm bolt 14 mm nut 6 5 m kg 47 ft lb 5 0 m kg 36 ft lb 1 O m kg 7 ft lb 8 5 m kg 61 ft lb i Outer tube and axle holder 1 8 m m n u t I 1 5 m kg 11 ft lb I r Handle crown and inner tube 8 m m n u t I 1 O m kg 7 ft lb I 1 Handle crown and steering shaft I 8 m m n...

Page 67: ...Metric System Known Torque ft lbs in lbs ft lbr Multiplier Rounded off Result 0 13826 m kg 0 01152 m kg 13 831 cm kg in lbs Wt cm kg lb 0 4535 kg oz 28 352 g Flow Distance mpg 0 4252 km l mph 1 609 kmlhr rn 1 609 km Vol Capacity 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 gal US liq 3 765 I liter Misc Cubic centimer s cm3 Volume or capacity Kilogram...

Page 68: ...Installed 2nd Installed oil 3 Ring groove side clearance TOP 2nd XS650E 2FO 2FO 000101 ZFO 000101 2 180 mm 85 8 in 835 mm 32 9 in 1 160 mm 45 7 in 815 mm 32 1 in 1 435 mm 56 5 in 150 mm 5 9 in 212 kg 467 lb 26 2 500 mm 98 4 in 14 m 50 km h 45 9 ft 31 mi h Air cooled 4 stroke SOHC twin parallel forward incline 2F0 653 cc 39 85 cu in 75 x 74 mm 2 953 x 2 913 in 8 5 1 Kick and electric starter Batter...

Page 69: ...imensions Valve head diameter A Valve face width 6 Valve seat width C Valve margin thickness D IN 0 10 mm 10 0039 in EX 0 15 mm 0 0059 in IN 41 mm Il 614 in1 EX 35 mm 1 378 in IN 2 1 mm 10 083 in EX 2 1 mm 0 083 in1 IN 1 3 mm 0 051 inl EX 1 3 mm 0 051 in IN 1 3 mm 0 051 in EX 1 3 mm 0 051 in Valve stem diameter Valve guide diameter Valve stem to guide clearance 4 Valve face runout limit IN 8 0 mm ...

Page 70: ...on limit A 2 Conwd large end clearance B 3 Width of crankshaft C 0 4 Crank pin I D 5 Crank pin O D x length 12 CONNECTING ROD 1 Big end I D 2 Small end I D 13 CRANK BEARING 11 Size Right end I D x O D x Width Others I D x O D x Width 2 Oil seal type size I D x O D x Width 14 CLUTCH 1 Clutch type 2 Clutch operating mechanism 3 Primary reduction ratio and method 4 Primary reduction gear back lash To...

Page 71: ...NG MECHANISM 1 Type Cam drum return type 2 Oil seal type Change lever I Dx0 D x Width SDO 14x24 6 mm 10 551x0 945x0 236 in 7 KICK STARTER 1 I Type Bendix type 2 Oil seal type Kick axle I D xO D x Width SD 25x35 7 mm 0 984x1 378x0 276 in 31 Kick clip friction tension 1 2 1 7 kg 2 6 3 7 lb 8 INTAKE 1 Air cleaner Type Quantity Dry foam rubber Z pcs 2 Cleaner cleaning interval Every 1 600 km Il 000 mi...

Page 72: ...ile frame 2 STEERING SYSTEM 1 caster 2 Trail 27 115 mm 4 53 inl 3 Number and size of balls in steering head upper race Lower race 4 Steering lock to lock 19 pcs l 4 in 19 pcs 114 in 42 each IL and RI 3 FRONT SUSPENSION 1 I Type 2 Damper type 3 Front fork spring Free length Telescopic fork Oil damper coil spring Wire diameter x winding diameter Spring constant 4 Front fork travel 5 Inner tube 0 0 6...

Page 73: ...um run 2 Tire size Front 3 50H19 4PR Rear 4 00H18 4PR 31 Tire pressure Normal riding Front 1 6 kg cm 22 psi Rear 2 0 kg cm2 28 psi Refer to PAGE 10 4 Rim run out limit Front and rear Vertical 2 mm 0 08 in1 Lateral 2 mm 0 08 in 5 Rim size Front 1 85 19 in Rear 2 1518 in 6 Bearing type Front wheel Left 6303RS Front wheel Right 6303RS Rear wheel Left 63052 Rear wheel Right 63042 7 Oil seal type Front...

Page 74: ...e Secondary winding resistance 31 Spark plug Tvw Spark plug gap 4 Contact breaker Manufacturer Quantity Point gap Point spring pressure Cam closing angle 5 Condenser Capacity Insulation resistance Quantity 2 CHARGING SYSTEM 1 AC generator Charging output Rotor coil resistance Field coil Stator coil resistance Brush length Brush wear limit 2 Rectifier Tvw Model Manufacturer Capacity Withstand volta...

Page 75: ...nufacturer HITACHI Model A 104 70 Amparage rating 1OOA Cut in voltage 6 5V Winding resistance 3 523 3 Starter clip friction tension 2 2 2 5 kg 4 9 5 5 lb i LIGHTING SYSTEM 1 Head light type Sealed beam 2 Bulb brightness and wattagelQuantitv Head light wattage 12v 50 4OW x 1 PC Tail Stoplight wattage OI and wattage 3132 cp 12V 8 27W 1 pa s Flasher light wattage ss and wattage 32 cp 12V 27W x 4 pcs ...

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Page 79: ...XS650E Supplementary FOR XS650E MODELS AFTER ENGINE SERIAL NO 2FO 006501 ...

Page 80: ...ncerning 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 NOTE This Supplementary Manual contains special information regarding periodic maintenance to the emissions control system for the XS650E Please read this material carefully SERVICE DEPT INTERNATIONAL DIVISION YAMAHA MO...

Page 81: ...ap qgggik Check and adjust ignition timing INITIAL BREAK IN or 7 months 0 0 I 0 0 Crankcase Ventilation I 6 I Svstem I PI loI I _ I _ 1 Check fuel hose for cracks or damage 1 I A I I f l I I r el nose Replae if necessary a P L _I c _ 1 Check for leakage Ratighten as nacs 1 n I n IrIm U r rlll sary Replace gasket sl if necessaw 9 Carburetor Synchronization Adjust synchronization of carburetors 0 Ch...

Page 82: ...rive and driven sprockets The normal vertical deflec tion is approximately 20 _ 30 mm 0 79 w 1 18 in a 20530mm 0 79 1 18in Page 14 C Ignition timing 1 Point gap must be set before setting timing 2 Ignition timing is checked with a timing light by observing the position of the stationary marks stamped on the stator and the pointer on the generator rotor 1 Top dead center 2 19 BTDC l ZOO rlmin 3 Adv...

Page 83: ...wear insula tor color and electrode gap Use a wire gauge for adjusting the plug gap If the electrodes become too worn replace it When installing the plug always clean the gasket surface wipe off any grime that might be present on the surface of the spark plug and torque the spark plug properly Standard spark plug N 7Y CHAMPION or BP7ES NGK Spark plug gap 0 7 0 8 mm 0 028 0 031 in Spark plug tighte...

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Page 85: ...als 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 NOTE This Supplementary Service Manual contains information regarding periodic maintenance to the emission control system for the XS650G XS650SG Please read this material carefully Starting ...

Page 86: ...lghten as necessary Replace gasket s if necessary 0 0 7 Carburetor Synchron zat on Adjust synchronization of carburetors 0 0 8 Idle Speed Check and adjust engine idle speed Adjust cable free play if necessary 0 0 It IS recommended that these Items be inspected and serwce by a Yamaha Dealer or other qualified mechanic GENERAL MAINTENANCE LUBRICATION 5 Clutch Adjust free play 0 0 0 Check chain condi...

Page 87: ...ase 16 000 km 10 000 mi Check bearings for wnooth rotation Check specific gravity Check breather pipe for proper operation Replace generator brushes Replace at initial 9 000 1 km 5 500 mi INITIAL BREAK IN 1 THEREAFTEREVERY I 1 000 km i 5 M o km 1 4 000 km r 1 monthior 7 months or 6 month 600 mi 13 000 mi l2 5OOmil E 0 0 0 0 0 0 0 0 0 Replace Repack ii It is recommended that these items be inspecte...

Page 88: ...olts and adhesive It is necessary to replace the A C G stator assembly with a new one if the pick up coil is damaged C IGNITION TIMING ADJUSTMENT If the A C G stator assembly is replaced with a new one the following adjustment and treatment are necessary It is mandatory that these procedures be followed carefully and exactly as described Failure to do so may be a violation of law 1 2 Install the A...

Page 89: ...ese special bolts The heads will shear off when the bolts have been properly torqued D CARBURETOR 1 Specifications Main jet Jet needle Needle jet Starter jet Float level Pilot jet Pilot screw Fuel valve seat Engine idle speed 132 5 5HX12 Y O 30 27 3 0 5 mm 1 075 r 0 020 in 42 5 Preset 2 0 mm 0 079 in 1 200 r min 1 2 Inspection And Correction a Examine the carburetor body and fuel passages If conta...

Page 90: ...g 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 specifi cation Float level 27 3 f 0 5 mm 1 075 0 02 in To correct carefully bend the tang on the float arm Both floats must be at the same height I Float height 26 8 27 8mm 1 055 1 095 in1 1 1 169 ...

Page 91: ... using magnetic pick up coils and a transistor control box TCI in place of contact breaker points a Pick up unit 1 Pick up unit This unit consists of two pick up coils mounted on the generator case and a permanent magneto on the rotor which is mounted to the crankshaft When the magneto passes through these pickup coils the signals are generated at the pick up coils and forwarded to the ignitor uni...

Page 92: ... the Electro Tester If the ignition sys tem will fire across a sufficient gap the engine ignition system can be considered good If not proceed with individual component tests until the problem is found 1 Warm up engine thoroughly so that all electrical components are at operating temperature 2 Stop the engine and connect the tester as shown 3 Start the engine and increase the spark gap until misfi...

Page 93: ...cification then perform the fol lowing tests C A U T I O N Never disconnect the wires from the battery while the generator is in operation If the battery is disconnected the voltage across the generator terminals will increase damag ing the semiconductors b Brush Check the brush length Replace brush if at or near limits Check the brush spring pressure by comparing it with a new spring Replace the ...

Page 94: ...n replace the voltage regulator assembly w White U V W Brown White U White IV White IW Black B 0 Continuity x Discontinuity I L 173 C A U T I O N The silicon rectifier can be damaged if subjected to overcharging Special care should be taken to avoid a short circuit and or incorrect connection of the positive and negative leads at the battery Never connect the rectifier directly to the battery to m...

Page 95: ... lb 26 2 500 mm 98 4 in B Engine 1 DESCRIPTION 1 Engine type 2 Engine model 3 Displacement 4 Bore x stroke 5 Compression ratio 61 Starting system 7 Ignition system 81 Lubrication system 2 CYLINDER HEAD Air cooled 4 stroke SOHC twin parallel forward incline 2FO 653 cc 39 85 cu in 75 x 74 mm 2 953 x 2 913 in 8 7 1 Kick and electric starter Battery ignition Full transistor ignition Wet rump 1 Combust...

Page 96: ...0 035 in 11 Type 2 Bearing size 3 Needle size 26 x 34 x 19 8 1 Cam drive type 21 Number and type of bearing 3 Bearing type 4 Cam dimensions Chain ICenter side 4 bearings Ball bearings 6005 5 Valve timing 6 Camshaft deflection limit 7 Cam chain Tvpe Number of links Sprocket ratio 0 03 mm 0 0012 in TSUBAKIMOTO BF05M 8 ROCKERARMANO ROCKETSHAFT 11 Rocker arm inner diameter 2 Rocker arm shaft diameter ...

Page 97: ...m 10 051 ini IN 1 3 mm 0 051 inI EX 1 3 mm 0 051 ini IN S O_ mm 10 315_ oo o i EX 8 0 0 mm 0 315 in IN E O mm 0 315 47 inl EX 8 0 9b mm 10 315 in IN 0 010 0 034 mm 10 00079 0 00173 in EX 0 035 0 059 mm 0 00136 0 00232 in IN EX 0 03 mm 10 0012 in or less INNER INIEXI 42 mm 1 654 in OUTER IN EXI 42 55 mm 1 675 in INNER IN EXl kl 1 43 kg mm 80 1 lb in k 1 81 kg mm 101 4 lb in OUTER IN EX k 3 2 kg mm ...

Page 98: ... teeth Wet multiple type Inner push type screw push system 72 27 2 666 spar gear 5 Friction plate Thickness Quantity Wear limit 6 Clutch plate ThicknessKluantity Warp limit 7 Clutch spring Free length Quantity 8 Clutch housing radial play 9 Push rod bending limit 15 TRANSMISSION 1 Type 2 Gear ratio 1st 2nd 3rd 4th 5th 3 mm 0 118 in 7 pcs 2 7 mm 0 106 in 1 4 mm 0 055 in 6 pa 0 05 mm 0 002 in 34 6 m...

Page 99: ...rump oil quantity 2 Oil type and grade 3 Oil pump type 4 Trochoid pump specifications Top clearance Tip clearance Side clearance Oil pump volume 5 Bypass valve rening pressure Needle bearing 1020 30 20 Ball bearing 25 52 20 6 Ball bearing 4 30 662 23 8 Needle bearing 20 30 161 SDD 40 62 9 34117 2 0OO Chain Cam drum return type SDO 14 24 6 Bendix type SD 25 35 7 1 2 1 7 kg 2 6 3 7 lb Dry foam rubbe...

Page 100: ...il quantity and type 7 Distance from the top of inner tube oil level without spring 4 REAR SUSPENSION 1 Type 2 Damper type 3 Shock absorber travel 17 Telescopic fork 3il damper coil spring I I I 9 482 mm i 16 96 in 4 x 24 5 mm 0 157 x 0 965 in I 0 46 kg mm 26 88 lb in O 100 mm O 3 94 in CZ 0 65 kg mm 136 40 lb in lOO 150 mm 3 94 5 91 in 150 mm 5 906 in 35 mm 1 378 in 169 cc 15 72 02 each leg t ama...

Page 101: ...ure Up to 90 kg 198 lb load Front 1 6 kg cm 122 psi Rear 2 0 kg cm2 28 psi 90 kg 198 lb load 206 kg 453 lb load Front 2 0 kg cm2 I28 psi Maximum load Rear 2 3 kg cm2 32 psi High speed riding Front 2 0 kg cm 28 psi Rear 2 3 kg cm 32 psi 4 Rim run out limit Front and rear Vertical 2 mm 0 08 in Lateral 2 mm 0 08 in 51 Rim size Front MT1 85 x 19 1 85x 1 9 Rear MT3 00 x 16 2 75 x 16 6 Bearing type Fron...

Page 102: ...ld coil Stator coil resistance Brush length Brush wear limit 2 Regulator TVP Model Manufacturer Regulating voltage 3 Battery Model Manufacturer Quantity Capacity Charging rate Specific gravity 18 l 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 Hydraulic disc type 267 x 7 0 mm 10 5 x ...

Page 103: ...m amperage 5 Flasher relay TVP Model Manufacturer Flasher frequency Capacity 6 Flasher cancelling unit Model Voltage 7 Fuse Rating Quantity Main Head light Signal Ignition vrccnc 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 HITACHI A10470 1OOA 6 5V 3 552 2 2 2 5 kg 4 9 5...

Page 104: ...andlebar holder Under bracket and inner tube 8 mm nut 14 mm bolt 8 mm bolt 8 mm nut 1 1 m kg 8 0ft lb 5 4 m kg 39 0 ti lb 1 8 m kg 13 0 ft lb 2 0 m kg 14 5 ft lb Engine mounting Upper Engine mounting Upper Engine mounting Front Engine mounting Rear Engine mounting Rear Lower Engine mounting Lower Front flasher and headlight Master cylinder and brake hose 8 mm nut 10 mm nut 10 mm nut 10 mm nut 10 m...

Page 105: ...3 0 ft lb Tension bar and rear arm B mm nut i 3 2 m kg 23 0 R lb1 Rear shock absorber Upper Rear shock absorber Lower Rear arm and rear arm end Front fender Neutral switch 10 mm bolt 3 0 m kg 21 5 ft lb1 10 mm bolt i 3 3 m kg 28 0 ti lb1 8 mm bolt I 1 0 m kg I 7 2 ti lb1 8mm b o l t 12mm General Torque Specifications tighten multi fastener assemblies in a criss This chart specifies torque for stan...

Page 106: ... 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 ...

Page 107: ...imiting speed of 35 mph This high speed pass assumes an initial speed of 50 mph and a limiting speed of 60 mph LOWSPEED PASS t TOTAL PASSING DISTANCE FEET TOTAL PASSING TIME 5EC0N0S 1 __ 4 i J cf _________ 0 55 ff CONSTANT 20 MPH TRUCK HIGHSPEED PASS TOTAL PASSING DISTANCE FEET TOTAL PASSING TIME SECONDS Ilc 3 y coff ____________ a oott 55 ff CONSTANT 50 MPH TRVCK SUMMARY Low speed pass ___ 357 fe...

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Page 113: ...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 ...

Page 114: ...nd repairs on Yamaha motorcycles have a basic understanding of the mechanical concepts and procedures inherent to motorcycle repair technology Without such know ledge attempted repairs or service to this model may render it unfit for use and or unsafe This model has been designed and manufactured to perform within certain specifications in regard to performance and emissions Proper service with th...

Page 115: ...s easier or clearer CAUTION A CAUTION indicates special procedure that must be fol lowed to avoid damage to the motorcycle WARNING A WARNING indicates special procedures that must be fol lowed to avoid injury to a motorcycle operator or person inspecting or repairing the motorcycle Starting Serial Number XS650H H 4N9 000101 XS650SH H __ 4M4 000101 ...

Page 116: ...MAINTENANCE AND LUBRICATION CHART PERIODIC MAINTENANCE EMISSION CONTROL SYSTEM 3 ...

Page 117: ...t c c ...

Page 118: ...up coil securing screws and remove the pick up coil assembly Pick up coil assembly reinstallation Install the pick up coil assembly on to the stator assembly _ L 4 Specified engine speed 1 200 r min The rotor pointer should be within the limits of fl on the timing plate If it exceeds the limits or does not steady check the timing plate for tight ness and or ignition system for damage NOTE Ignition...

Page 119: ...ck the fuel level one by one The level should be in the specified range Fuel level 1 f 1 mm 0 04 0 04 in above from the carburetor mixing chamber body edge YL___ A 6 If the fuel level is incorrect remove the carburetor assembly from the motor cycle and check the fuel valve s and float assembly s for damage 7 If no damage is found correct the fuel level by slightly bending the float arm tang Rechec...

Page 120: ...en 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 maxi mum and minimum levels If the level is lower add sufficient oil to raise it to the proper level l ...

Page 121: ...correctly installed with rounded end in direction of chain travel 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 NOTE Before checking and or adjusting rotate rear wheel through several revolutions and check tension several times to find the tightest point Check and or adjust chain tension wit...

Page 122: ...otter pin if the nut notch and the cotter pin hole do not match tighten the nut 1 slightly to match C A U T I O N Excessive chain tension will overload the engine and other vital parts keep the ten sion within the specified limits Also replace the rear axle cotter pin with a new one 7 In the final step adjust the play in the brake pedal D REAR BRAKE ADJUSTMENT 1 a b C Pedal height Loosen the adjus...

Page 123: ...NG 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 ...

Page 124: ... G Green B Black Br brown Sb B blue R W Red White B Y Black Yeliow L B Blue Black Function of the Diode in the Relay When the transmission is in a position other than Neutral Turning on the clutch lever switch Clutch is disengaged by pulling the clutch lever makes the safety relay to turn on In this case the diode interrupts the flow of current from the main switch to the neutral indicator light a...

Page 125: ...t off is kept open the relay is not actuated and it is impossible to turn on the starter switch assembly by pushing the START button As a result the starter motor does not run c When the clutch lever is disengaged by pulling in the clutch lever while the transmission is in a position other than neutral Neutral switch OFF Clutch lever switch ON Since the clutch lever switch is on while the neutral ...

Page 126: ...2 500 mm 198 4 in B Engine L 1 DESCRIPTION 1 Engine type 2 Engine model 3 Displacement 4 Bore x stroke 5 Compression ratio 6 Starting system 7 Ignition System 8 Lubrication system 2 CYLINDER HEAD 1 Combustion chamber volume with N 7Y Air cooled 4 stroke SOHC twin parallel forward incline 4M4 4N9 653 cc 39 85 cu inl 75 x 74 mm 2 953 x 2 913 in 8 7 1 Kick and electric starter Battery ignition Full t...

Page 127: ... 5mm 0 059 in 2 mm IO 110 inl 0 4 mm 0 008 0 016 in 3 Ring groove side clearance Top 6 BIG END BEARING 11 Type 31 Bearing type 4 Cam dimensions 25 47 8 6 Camshaft deflection limit 7 Cam chain Type Number of links Sprocket ratio 8 ROCKER ARM AND ROCKET SHAFT i 0 03 mm 0 0012 in TSUBAKIMOTO BF05M i 106L 36 18 2 0 0 0 1 Rocker arm inner diameter 15 0 y8 mm 0 591 oW7 in 2 Rocker arm shaft diameter 15 ...

Page 128: ... in EX 2 1 mm 0 083 in x B IN 1 3 mm 0 051 in D IN 8 0_g o 5 mm 0 315_ 0 in EX 8 0 42 mm 10 315I in IN E O mm 0 315 z gi in EX S O mm 0 315 z Ez in IN O OlO 0 034 mm 0 00079 0 00173 in EX 0 035 0 059 mm 10 00138 0 00232 in IN EX 0 03 mm 10 0012 in or less INNER IN EX 42 mm 1 654 in OUTER IN EX 42 55 mm 1 675 in INNER IN EX kl 1 43 kg mm 180 1 lb in kz 1 81 kg mm 1101 4 lb in OUTER IN EX kl 3 2 kg ...

Page 129: ...lQuantitv Warp limit 7 Clutch spring Free length Quantity 8 Clutch housing radial plav 9 Push rod bending limit 5 TRANSMISSION 11 Tvoe 0 05 mm 0 002 in 0 15 0 4 mm 0 0059 0 0157 in 66 0 05 mm 2 598 in 0 10 166_ 3 mm 17 323_ o 2 in 26I j m m 1 024 in 26 06 x 65 mm 34 t016 mm 1 339 0006 in 20 85 mm 10 787 o in 030 78 9 Ball bearing 032 068 17 Rollar bearing SD 25 40 9 Wet multiple type Inner push ty...

Page 130: ... Needle jet 7 Throttle valve 8 Pilot jet 9l Pilot screw Turns out 101 starter jet 11 I Fuel level 12 Idling engine speed 20 LUBRICATION 1 Engine sump oil quantity 2 Oil type and grade 31 Oil pump type 4 Trochoid pump specifications Top clearance Tip clearance Side clearance Oil pump volume 5 Bypass valve setting pressure M J 1 1A J l J N N J Th V P J 1 P S 1 IG S F L Cam drum return type SDO 14 24...

Page 131: ...oil quantity and type Double cradle high tensile frame 27O 115 mm 4 53 in 19 pcs l 4 in 19 pcs l 4 in 42 each L and R Telescopic fork Oil damper coil spring 482 mm 18 99 in 4 x 24 5 mm IO 157 x 0 965 in kl 0 48 kg mm 126 88 Iblinll 0 100 mm 0 3 94 in k2 0 65 kg mm 136 40 lb in loo 150 mm 3 94 5 91 in 150 mm 5 906 in 35 mm 1 378 in 169 cc 5 72 oz each leg Yamaha fork oil 1Owt or equivalent Approx 4...

Page 132: ...g 198 Ibl load Front 1 6 kg cm 122 psi Rear 2 0 kg cm2 I28 psi1 90 kg 198 lb load 206 kg 453 lb load Front 2 0 kg cm2 28 psi Maximum load Rear 2 3 kg cm 32 psi High speed riding Front 2 0 kg cm I28 psi Rear 2 3 kg cm I32 psi 4 Rim run out limit Front and rear Vertical 2 mm 0 08 in Lateral 2 mm 0 08 in 5 Rim Size Front MT1 85 x 19 1 85 x 19 Rear MT3 00 x 16 2 75 x 16 6 Bearing type Front wheel t Le...

Page 133: ...nk rod 180 mm 7 09 ini 180 Y 30 mm 17 09 x 1 18 in 4 mm12 mm IO 16 1nI0 08 in 68 mm 2 68 inl 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 15 1 200 rimin 0 I 2 3 tnqine roeed x 101 r m n CM12 OS HITACHI 6 mm 0 24 in or more at 500 rimin 2 5a 10 at 20 C 68...

Page 134: ... 30 in 30 mm Il 18 in Mica undercut 0 7 mm 10 028 inl 21 Starter switch Manufacturer HITACHI Model A10470 Amperage rating 1OOA Cut in voltage 6 5V Winding resistance 3 5R 3 Starter clip friction tension 2 2 2 5kg 4 9 5 5lbl LIGHTING SYSTEM 1 Headlight type Sealed beam 2 Bulb brightness and wattage Quantity Headlight 12v 5014ow x 1 PC Tail Brake light 12V 3132 CP 18W 27W x 2 PCS Flasher light 12V 3...

Page 135: ...frequency Capacity 6 Flasher cancelling unit Model Voltage 7 Fuse Rating Quantity Main Headlight Signal Ignition Condenser type 061300 04810 NIPPON DENS0 85 t 10 cycle min 32 CP 27W x 2 3 4w EVH AC518 DC9V 16V 20A x 1 pc 10A x 1 pc 10Ax1pc 10A x 1 pc ...

Page 136: ... m kg 6 5 ft lb 6 mm crown nut 0 9 m kg 6 5 ft lb 8 mm crown nut 1 3 m kg 9 5 ft lb 14 mm 2 0 m kg 14 5 ft lb 12mm nut 3 8 m kg 27 5 ft lb 6 mm pan head screw 0 9 m kg 6 5 ft lb 6 mm bolt 0 8 m kg 6 0 ft lb 8 mm nut 2 7 m kg 19 5 ft lb 18 mm cap 2 1 m kg 15 0 ft lb 6 mm pan head screw 1 0 m kg 7 2 ft lb 6 mm bolt 1 0 m kg 7 2 ft lb 30 mm bolt 4 2 m kg 30 5 ft lb 6 mm bolt 0 9 m kg I 6 5 ft lb 10 m...

Page 137: ...ar shock absorber Lower 10 mm bolt Rear arm and rear arm end 8 mm bolt Front fender 8 mm bolt Neutral switch I 12mm 3 0 m kg 21 5 ft lb 3 9 m kg 28 0 ft lb 1 0 m kg 7 2 ft lb 1 0 m kg 7 2 ft lb 1 3 m kg 9 5 ft lb General Torque Specifications tighten multi fastener assemblies in a criss This chart specifies torque for standard cross fashion in progressive stages until full fasteners with standard ...

Page 138: ...fcm3 0 4732 lit liter 0 9461 lit liter 3 785 lit tlrter 0 017855 kg mm 0 07031 kg cm2 5 91OF 32 Centrgrade C INCH TO METRIC SYSTEM I ft lb in lb ft lb in lb mpg mph mi ft Yd in 02 US liq cu in pt US liq qt US liq gal US liq lb in psi tIb in2 1 Fahrenheit OF m kg g kg lit km lit cc kg mm kg cm2 Meter kilogram s usually torque Gram s Kilogram s 1 000 grams liter s Kilometer s per liter fuel consumpt...

Page 139: ...imiting speed of 35 mph This high speed pass assumes an initial speed of 50 mph and a limiting speed of 80 mph LOW SPEED PASS HIGH SPEED PASS T INITIAL SPEED 20 MPH LIMITING SPEED 35 MPH t TOTAL PASSING DISTANCE FEET TOTAL PASSING TIME SECONDS 1 d _ __ l 4 l 4 40ft djj_ _ a40ft 55 ft CONSTANT 20 MPH TRUCK INITIAL SPEED 50 MPH LIMITING SPEED 80 MPH I TOTAL PASSING DISTANCE FEET TOTAL PASSING TIME S...

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Page 142: ...lement the Service Manual for the XS650E 2FO 28197 10 and in cludes 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 ...

Page 143: ...NCE INTERVALS CHARTS A PERIODIC MAINTENANCE Unit km mi Check tension alignment B LUBRICATION INTERVALS Item Engine oil Remarks Replace Warm engine before draining Drive chain Clean Lube Brake pedal shaft Change pedal shaft Light application Control Meter ables Apply thoroughly Unit km mi Every 400 250 Yamaha chain and 78 ...

Page 144: ...cam lubri APPLY very lightly Light weight machine oil 0 0 0 0 cation wicks NOTE Brake fluid replacement 1 When disassembling the master cylinder or caliper cylinder replace the brake fluid Normally check the brake fluid level and add the fluid as required 2 On the inner parts of the master cylinder and caliper cylinder replace the oil seals every two years 3 Replace the brake hoses every four year...

Page 145: ...mm 0 03 in G Drive chain 1 Tension check NOTE Before checking and or adjusting rotate rear wheel through several revolutions and check tension several times to find the tightest point Check and or adjust chain tension with rear wheel in this tight chain position Inspect the drive chain with the center stand put up Check the tension at the position shown in the illustration The normal vertical defl...

Page 146: ...should be changed as follows Engine mounting bolt torque Upper U Nut M8 1 8 m kg 13 0ft lb Upper M l 0 3 0 m kg 21 5 ft lb Front U Nut Ml0 4 6 m kg 33 5 ft lb Rear U Nut Ml0 4 1 m kg 29 5 ft lb Rear under U Nut Ml0 4 6 m kg 33 5 ft lb Under U Nut M l 0 9 0 m kg 65 0 ft lb PAGE 39 40 5 1 FRONT WHEEL C Front wheel inspection 1 Check for cracks bends or warpage of wheels If a wheel is deformed or cra...

Page 147: ...he brake caliper pull out the rear axle 5 Remove the rear wheel assembly E Rear wheel installation When installing rear wheel reverse removal procedure taking care of following points 1 Lightly grease lip of rear wheel oil seals 2 Make sure the brake pads are installed properly and that there is an enough gap to install the rear disc 3 Install wheel assembly and axle Always use a new cotter pin on...

Page 148: ... the front and rear cover bearings for damage If damaged the starter assembly must be replaced 83 Mica under cut 0 7 mm 0 026 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 in operative and 2 it switches current from the inoperative filament to the rem...

Page 149: ...2 Troubleshooting inspection ...

Page 150: ...LOW BEAM DOES NOT LlGHT WHEN HIGH BEAM IS DEFECTIVE ...

Page 151: ...ll 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 Torque Specifications A Nut 10 mm 12mm 14 mm 17mm 19 mm 22 mm 24 mm 27 mm B Bolt 6 m m M6 B m m M8 10mm Ml0 1 2 m m M12 14mm M14 1 6 m m Ml6 18mm Ml8 2 0 m m M20 Sta...

Page 152: ... lb 9 0 m kg 65 0 ft lb 8 0 m kg 58 0 ft lb 6 5 m kg 47 0 ft lb 1 O m kg 7 0 ft lb Chassis Front wheel axle Front fork and axle holder Handle crown and inner tube 14 mm nut 8 mm nut 8 mm nut 1 10 7 m ko 77 5 ft lb 1 4 m kg 10 0 ft lb 1 l m kg 8 0 ft lb I Handle crown and steering shaft I 8 mm nut I 1 1 m kg 8 0 ft lb I Handle crown and steering shaft Handle crown and handle holder 14 mm bolt 8 mm ...

Page 153: ...round clearance 3 WEIGHT 1 Net weight Dry 4 PERFORMANCE 1 Climbing ability 2 Minimum turning radius 3 Braking distance B Engine 1 DESCRIPTION I 1 Engine type 2 Engine model 3 Displacement 4 Bore x stroke 5 Compression ratio 6 Starting system 7 Ignition system 8 Lubrication system 2 CYLINDER HEAD 1 Combustion chamber volume with N 7Y I 2 Combustion chamber We 3 Head gasket thickness 3 CYLINDER 1 Ma...

Page 154: ... 012 0 035 in 3 Ring groove side clearance Top 0 04 0 08 mm 0 0016 0 0031 in 0 03 0 07 m m 0 0012 0 0028 in 1 Type Chain Center side 2 Number and type of bearing 4 bearings Ball bearings 6005 6 Camshaft deflection limit 0 03 mm 0 0012 in 7 Cam chain Type TSUBAKIMOTO BF05M Number of links 1 Rocker arm inner diameter 15 0 i mm 0 591 E 07 in 2 Rocker arm shaft diameter 9 VALVE VALVE SEAT AND VALVE GU...

Page 155: ... Valve open INNER INIEX 25 5 mm 1 004 in OUTER IN EX 27 5 mm 1 083 in 6 Compressed pressure Valve open INNER IN EX 27 2 f 1 9 kg 60 0 f 4 2 lb OUTER IN EX 57 4 4 0 kg 126 5 8 8 lb 7 Wire diameter INNER IN EX 2 9 mm 0 114 in OUTER IN EX 4 2 mm 0 165 in 8 Winding D D INNER IN EX 19 4 mm 0 764 in OUTER IN EX 32 6 mm 1 283 in 9 Number of windings INNER IN EX 6 0 turns OUTER IN EX 4 25 turns 1 Cranksha...

Page 156: ...le jet NJ 7 Throttle valve Th V 8 Pilot jet PJ 9 Pilot screw Turns out PS 10 Starter jet GS 11 Fuel level FL 12 Idling engine speed 20 LUBRICATION 1 Engine sump oil quantiD 2 Oil type and grade 3 Oil pump type Wet multiple type Inner push type screw push system 72127 2 666 spar Qear 21 45 _ 6 mm 0 8445 ooto in 3 mm 0 118 in 7 pcs 2 7 mm 0 106 in 1 4 mm 0 055 in 6 PCS 0 05 mm 0 002 in 34 6 mm 1 362...

Page 157: ... each L and R 3 FRONT SUSPENSION 1 Type 2 Damper type 3 Front fork spring Free length Wire diameter x winding diameter Spring constant Telescopic fork Oil damper coil spring 482 mm 18 98 in 4 x 24 5 mm 0 157 x 0 965 in kt 0 48 kg mm 26 88 lb in 4 Front fork travel 5 Inner tuba O D 6 Front fork oil quantity and type 7 Distance from the top of inner tube oil level without spring 4 REAR SUSPENSION 1 ...

Page 158: ...22 Front wheel Right 63032132 Rear wheel Left 63052 Rear wheel Right 63042 7 Oil seal type Front wheel 1 Left SDD 45 56 6 Front wheel Right SD 28 47 7 Rear wheel Left SD 35 62 9 Rear wheel Right SO 27 52 5 8 Secondary drive chain type Type 50HDS Number of links 103L Joint Chain pitch 15 875 mm 5 E in Chain free play 20 mm 314 in 7 BRAKE 1 Front brake Tvw Hydraulic disc type Disc size Outside dia x...

Page 159: ... Type Manufacturer Model output Armature coil resistance Field coil resistance Brush size Quantity Wear limit Spring pressure Commutator O D Mlear limit Mica undercut 15 1 200 r min CMll SOB HITACHI B mm 0 31 in or more 300 r min at 8V 3 9 Q 10 at 20 C 68 F B OkR r 20 at 20 C 6B F N 7Y CHAMPION or BP7ES N G K 0 7 0 8 mm 0 027 0 031 in HITACHI 2 pcs 0 30 0 40 mm 0 012 0 016 in 650 850 g 22 9 30 0 o...

Page 160: ... Manufacturer Maximum amparage 5 Flasher relay Type Model Manufacturer Flasher frequency Capacity 6 Flasher cancelling unit Model Voltage 7 Fuse Rating Quantity 8 Light checker Model Manufacturer HITACHI A104 70 1OOA 6 5V 3 5a 2 2 2 5 kg 4 9 5 5 lb Sealed beam 12v 50 4ow x 1 PC 12V 3132 CP W 27W x 1 PC 12V 32 CP 27W 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 ...

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Page 165: ...Supplementary FOR XS650SE MODELS AFTER ENGINE SERIAL NUMBER 2FO 114241 ...

Page 166: ...erning 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 NOTE This Supplementary Manual contains special information regarding periodic maintenance to the emissions control system for the XS650SE Please read this material carefully SERVICE DEPT INTERNATIONAL DlVlSION Y...

Page 167: ...ot Shaft REMARKS TYPE INITIAL BREAK IN T H E R E A F T E R E V E R Y 1 000 km 5 000 km 4 000 km km km or 1 month or 7 months or6 months or 12 months or 24 months 600 muI 13 000 mil 12 500 ml 8 000 I 1 6 0 0 0 1 5 0 0 0 mll l10 000 ma I I I I I Warm up engine before Yamalube 4 cycle drammg 011 or SAE 2OW 40 0 0 0 SE motor oil _ Clean element in solvent 0 0 Dry type filter Clean wth compressed air c...

Page 168: ... 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 PAGE 7 8 2 3 ENGINE B Air filters 2 Cleaning method c The air filter element should be cleaned every 8 000 km 5 000 mi It should be cleaned more often if the machine is operated in extremely dusty areas E Cam chain adjustment Check adjust the cam chain tension as follows 1 Remove the ca...

Page 169: ...ee play 13 15 mm 4 Brake rod 0 51 0 59 in 5 Footrest F Wheels and tires 2 Tires Specifications should be changed as follows I Bridwstone or Bridgestone or Standard tire Yokohama Yokohama 3 50SlQ lPR 130 90S164PR Up to 90 kg 198 lb load 90 kg 198 lb load 204 kg 445 lb load Maximum load1 1 6 kg cm2 22 psi 2 0 kglcmz 28 psi 1 2 0 kg cm 28 psi 2 3 kg cm2 32 psi 1 High speed riding 2 0 kg cm2 2 3 kg cm...

Page 170: ...timing 2 Ignition timing is be set before setting checked with a timing light by observing the position of the stationary marks stamped on the stator 1 Too dead center 3 Advanced mark 2 15 3 5 6 7 BTDC at 1 200 rlmn Connect timing light to right left cylinder spark plug lead wire Ignition timing of right cylinder must be set first Start the engine and keep the engine speed as specified on the labe...

Page 171: ...ngth 25 5 mm 27 5 mm Waive open 1 0 l in 1 083 in Allowable tilt from 1 6 mm or 2 5 vertical 0 063 in PAGE 29 33 3 4 ENGINE ASSEMBLY AND ADJUSTMENT 0 Engine Specifications should be changed as Engine mounting bolt torCWe Upper Kl Nut M8 1 8 m kg 13 0ft lb Upper Ml0 3 0 m kg 21 7 ft lb Front U Nut Ml0 4 6 m kg 33 3 ft lb Rear U Nut Ml0 4 1 m kg 29 7 ft lb Rear under U Nut Ml0 4 6 m kg 33 3 ft lb Un...

Page 172: ...mbly E Rear wheel installation When installing rear wheel reverse removal procedure taking care of following points 1 2 3 4 5 Lightly grease lip of rear wheel oil seals Make sure the brake pads are installed properly and that there is an enough gap to install the rear disc Install wheel assembly and axle Always use a new cotter pin on the axle nut ji Connect drive chain Adjust drive chain PAGE 40 ...

Page 173: ... If damaged the starter assembly must be replaced 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 in operative and 2 it switches current from the inoperative filament to the remaining functional filament The system is connected to the headlight circuit onl...

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Page 175: ... 119 ...

Page 176: ...ndard tightenins torque m kg ft lb 1 o 7 2 2 0 15 4 0 29 4 5 33 5 0 36 6 5 47 7 0 50 8 0 58 I Part to be tiahtened I Thread dia and part name I T i g h t e n i n g torque 1 Engine Cylinder head and cylinder head cover Cylinder head Cylinder head cover ride 1Omm nut 3 7 m kg 26 6 ft lb 8 mm bolt 2 1 m kg 15 2 ft lb 6 mm bolt 0 9 m kg 6 5 ft lb 6 mm crown nut 0 9 m kg 1 6 5 ft lb B mm crown nut 1 3 ...

Page 177: ... 7 ft lb Engine mounting Front 10 mm nut 4 6 m kg 33 3 ft lb Engine mounting Rear Engine mounting ReaVLOVJer Engine mounting LOWW Front flasher and headlight Master cylinder and brake hose Brake disc and hub Caliwr and surxaort bracket 10 mm nut 10 mm nut 10 mm nut 8 mm nut 10 mm union bolt 8 mm bolt 8 mm bolt Caliper and pad Caliper and bleed screw Front caliper and front fork Master cylinder and...

Page 178: ... forward incline 21 Engine model 2FO 3 Displacement 653 cc 139 85 cu in 4 Bore x stroke 75 x 74 mm 2 953 x 2 913 in 5 Compression ratio 0 5 1 61 Starting rvrtem Kick and electric starter 7 Ignition system Battery ignition 8 Lubrication system wet rump 2 CYLINDER HEAD 1 Combustion chamber volume with N 7Y 43 6 cc 12 660 win 2 Combustion chamber tvPe Dome Swish 31 Head oasket thickness 1 2 mm 0 047 ...

Page 179: ...ing type 6 Camshaft deflection limit 0 03 mm 10 0012 in 71 Cam chain Type TSUBAKIMOTO BF06M Number of links 1 Rocker arm inner diameter 15 0 8 mm IO 591 t Mx17 in 2 Rocker arm shaft diameter 15 0 z r5 mm IO 591 I in 3 Clearance 0 009 0 033 mm 0 00035 0 00130 in1 1 Valve per cylinder 2 Valve clearance In cold engine IN 0 10 mm 0 0039 in EX 0 15 mm 0 0059 in 31 Dimensions Valve head diameter A IN 41...

Page 180: ...2 f 1 9 kg 60 0 f 4 2 lb OUTER IIN EX 57 4 e4 0 kg 126 5 t 8 8 lb 7 Wire diameter INNER IN EX 2 9 mm 0 114 in OUTER IN EX 4 2 mm 0 165 in 8 Winding0 D INNER IN EX 19 4 mm IO 764 in OUTER INIEX 32 6 mm 1 283 in 9 Number of windings INNER lIN EXl 6 0 turns OUTER llN EX 4 25 turns 11 CRANKSHAFT PYo 1 Crankshaft deflection limit A 0 05 mm 0 002 in 2 Con rod large end clearance 6 0 15 0 4 mm 10 0059 0 ...

Page 181: ...mp oil quantiw 2 Oil type and grade 3 Oil pump type 4 Trochoid pump specifications Top clearance Tip clearance Side clearance Oil pump volume 5 Bvpass valve setting pressure 3 mm 0 118 in117 pcs 2 7 mm 0 106 in 1 4 mm 0 055 in 6 pcs 0 05 mm 0 002 in 34 6 mm 1 362 in 6 per 0 027 0 081 mm 0 0011 0 0032 in 0 2 mm 0 008 in Constant mesh 5 speed forward 32 13 12 461 27 l 7 1 588 26 20 1 300 23 21 1 095...

Page 182: ...ll 4 Front fork travel 5 Inner tube O D 6 Front fork oil quantitv and type 7 Distance from the top of inner tube oil level without spring 4 REAR SUSPENSION 1 I Type 2 Damper type 3 Shock absorber travel 4 Shock absorber spring Free length Wire diameter x winding diameter Spring constant 5 Swing arm free play Limit 6 Pivot shaft Outside diameter 0 100 mm IO 3 94 in kz 0 65 kg mm 36 40 lb in 100 150...

Page 183: ...ive chain type Type 50HDS Number of links 103L Joint Chain pitch 15 875 mm 5 8 in Chain free play 20 30 mm 0 8 1 2 in 7 BRAKE 1 Front brake TVP Hydraulic disc type Disc size Outside dia x thickness 298 x 7 0 mm 11 73 x 0 28 in Disc wear limit 6 5 mm 10 26 inl Disc pad thickness 11 0 mm 0 43 inl Pad wear limit 6 0 mm 0 24 in Master cylinder inside dia 14 0 mm 0 55 in Caliper cylinder inside dia 38 ...

Page 184: ...r limit Spring pressure commutator O O iWear limit Mica undercut 2 Starter switch Manufacturer Model Amparage rating Cut in voltage Winding resistance 3 Starter clip friction tension 3 9n 10 at 20 C 68 F B Okn 20 at 2O C 68 F N 7Y C jAMPION or BP7ES N G K 1 0 7 0 8 mm 0 027 0 031 in HITACHI 2 pcs 0 30 0 40 mm 0 012 0 016 in 650 850 g 22 9 30 0 02 93 5O 0 22uF 10Mfi or more 2 PCS 14V 1 lAl2 000 rlm...

Page 185: ... relay Type Model Manufacturer Flasher frequency Capacity 61 Flasher cancelling unit Model voltage 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 337 l 1720 KOITO CF lZ NIKKO 2 5A Condenser type IAO 70INIPPON DENS0 85 10 cyclelmin 32 CP 27WI x 2 3 4W EVH AC518 DCSV 16...

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Page 191: ...ning 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 NOTE This Supplementary Manual contains special information regarding periodic maintenance to the emissions control system for the XS650SE Please read this material carefully SERVICE DEPT INTERNATIONAL DIV...

Page 192: ...NCE INTERVALS CHARTS A PERIODIC MAINTENANCE EMISSION CONTROL SYSTEM REMARKS damage Replace If n 7 Fuel Hose Check fuel hose for cracks or damaqe Replace If necessary 0 0 8 Exhaust System Check for leakage Retlghten as necr saw Replace gasket s tf necessary 0 C z 9 Carburetor Svnchronlzataon Adjust svnchronizaf on of carburetors 0 0 0 10 Idle Speed Check and ad ust engnr dle speed Adjust cable free...

Page 193: ...ator Replace at initial 9 000 0 _ km 5 500 mi PAGE 7 8 2 3 ENGINE B Air filters 2 Cleaning method c The air filter element should be cleaned specified intervals It should be cleaned more often if the machine is operated in extremely dusty areas E Cam chain adjustment Check adjust thecam chain tension as follows 1 Remove the cap nut and loosen the lock nut 2 Turn the left end of the crankshaft coun...

Page 194: ...servicing tires please note the following instructions 1 Tubeless tire a The identification marks are fitted on the tire sidewall and wheel spoke for tubeless tires as shown I WARNING Do not attempt to use tubeless tires on a wheel designed for use only with tube type tires Tire failure and personal injury may result from sudden deflation Tube type wheel Tube type Only Tubeless type wheel Tube typ...

Page 195: ... tire Yokohama Yokohama 3 5OS194PR 13OBOS184PR vlsximum load limit 166 kg I365 lb 279 kg 615 lb1 Zold tire presswe UP to 90 kg 1 6 kg cm2 2 0 kg cm 198 lb load 22 psi 1 28 psi1 9Okg1198Ib load 5 206 kg 453 lb load Maximum 2 0 kg cm2 2 3 kg cm2 28 psi I 132 Psi load High speed riding 2 0 kg cm2 2 3 kg cm2 28 psi 132 psi Minimum tire wad depth 0 8 mm 0 03 in 0 8 mm 0 03 in 2 Before operation always ...

Page 196: ...hole do not match tighten the nut slightly to match NOTE Excessive chain tension will overload the en gine and other vital parts keep the tension within the specified limits Also replace the rear axle cotter pin with a new one g In the final step adjust the play in the brake pedal XS650 2F only PAGE 14 15 2 5 ELECTRICAL C Ignition timing 1 Point gap must be set before setting timing 2 Ignition tim...

Page 197: ...0 Engine Specifications should be changed as follows Engine mounting bolt torque Upper U Nut M8 1 8 m kg 13 0 ft lb Upper Ml0 3 0 m kg 215 ft lbl Front U Nut Ml0 4 6 m kg 33 5 ft lb Rear U Nut Ml0 4 1 m kg 29 5 ft lb Rear under U Nut Ml0 4 6 m kg 33 5 h lb Under U Nut Ml0 9 0 m kg 65 0 ft lb PAGE 39 40 5 1 FRONT WHEEL C Front wheel inspection XS650SF only 1 Check for cracks bends or warpage of whe...

Page 198: ...talled properly and that there is a sufficient gap to install the rear disc 3 Install the wheel assembly and the axle Always use a new cotter pin on the axle nut Axle nut torque I 15 0 m kg i 108 5 ft lb 4 Connect the drive chain 5 Adjust the drive chain PAGE 40 44 5 3 BRAKES Except for the following the same procedure as for the XS650E front brake can be perform ed for the disassembly inspection ...

Page 199: ...y must be replaced 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 in operative 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 u...

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Page 201: ...owing torque specifications muSt be bolt head adhered to on every machine When applying NOTE torque to multi secured fastener components Certain items with other than standard thread the several studs should be tightened in gradual stages and in a pattern that will avoid pitches may require differing torque warpage to the item being secured Torque 146 ...

Page 202: ...Torque Specifications A Nut ...

Page 203: ...lt 6 mm bolt 3 5 m kg 25 5 ft lb 0 6 m kg 4 5 ft lb I Pivot shaft I 14 mm nut I 6 5 m kg 47 0 ft lb Rear wheel axle Tension bar and brake caliper plate 1 16 mm nut 8 mm nut 15 0 m kg 106 5 ft lb 1 6 m kg 13 0 ft lb Tension bar and rear arm Rear shock absorber Upper 8 mm nut 10mm bolt 3 2 m kg 23 0 ft lb 3 0 m kg 21 5 ft lb Rear shock absorber Lower Rear arm and rear arm end 10 mm bolt 8 mm bolt 3 ...

Page 204: ...STON I 1 Piston skirt clearance 0 050 0 055 mm 0 0020 0 0022 in 21 Piston oversize 75 25 mm 75 50 mm 75 75 ml n 76 00 m m 12 963 i n 12972 in 12982 in 12992 InI 3 Piston pin outside diameter x length 20 0 _ mm x 61 o a mm IO 79 in x 2 40 II 16 j 5 PISTON RING 11 Piston ring design TOI 2nd Oil ring I a 1 2 mm 10 047 in 1 5 mm 10 059 in 2 8 mm 10 110 II 21 Ring end gap IInstalled top 0 2 0 4 mm 0 00...

Page 205: ... mm 0 051 in EX 1 3 mm 0 051 in Valve stem diameter Valve stem diameter Valve guide diameter IN 8 0 7 mm 0 315 I 0 in EX 6 0 I mm 0 315 1 in IN 6 0 t z m m 0 3 1 5 I inI Ex 6 0 j mm 0 315 E z in Valve stem to guide clearance 4 Valve face runout limit I VALVE SPRING 1 Free length 2 Spring rate IN 0 020 0 044 mm 0 00079 0 00173 in EX 0 035 0 059 mm 0 00136 0 00232 in1 IN EX 0 03 mm 0 0012 in or less...

Page 206: ...nesslQuantitV Warp limit 7 Clutch spring Free length Quantity 8 Clutch housing radial Play 9 Push rod bending limit 0 05 mm 0 002 in1 0 15 0 4 mm 0 0059 0 0157 in 66 2 mm 2 598 I ini 186 j3 mm 7 323 _E 2 in 26 2 mm 1 024 Ii in 0 26 _o oo6 x 65 I mm 1 024 _E wo2 x 2 559t J iinl 34 16 mm 1 339 z in 20 mm 0 787 A in1 3Q 78 19 Ball bearing 32 G68 17 Rollar bearing SD 25 40 9 Wet multiple type Inner pu...

Page 207: ...l quantity 21 Oil type and grade 31 Oil pump type 4 Trochoid pump specifications Top clearance Tip clearance Side clearance Oil pump volume 51 Bvoass valve settina pressure 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 Cam drum return type SDO 14 24 6 Bendix type SD 25 35 7 1 2 1 7 kg 2 6 3 7 lb Dry foam rubber...

Page 208: ...Front fork travel 5 Inner tube O D 6 Front fork oil quantity and type 7 Distance from the top of inner tube oil level without spring 4 REAR SUSPENSION 11 Type 2 Damper type 3 Shock absorber travel 4 Shock absorber spring Free length Wire diameter x winding diameter Spring constant 5 Swing arm free play Limit 6 Pivot shaft Outside diameter 15 1 3 0 100 mm IO 3 94 in kg 0 65 kg mm 36 40 lb in 100 15...

Page 209: ...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 fluid type I quantity 2 Rear brake IXS65OSF only Type Disc sire Outride dia x thickness Disc wear limit Disc pad thickness Pad wear limit Master cylinder inside dia Caliper cylinder inside dia Brake fluid type quantitv 2 mm 0 08 in 2 mm 0...

Page 210: ...or coil resistance Brush length Brush wear limit 2 Rectifier Tvpe Model Manufacturer Capacity Withstand voltage 31 Regulator TVP Model Manufacturer Regulating voltage Core gap Point gap Voltage coil resistance 5 Battery Model Manufacturer uantity Capacity Charging rate Specific gravity 15 1 200 rlmin CMll 50B HITACHI 6 mm 0 24 in or mare at 500 r min 3 9R 10 at 20 C 68 F 8 0kR 20 at 2O C 68 F N 7Y...

Page 211: ...el Manufacturer Maximum amparage 5 Flasher relay Tvpe Model Manufacturer Flasher frequency Capacitv 6 Flasher cancelling unit Model Voltage 7 Fuse Rating Quantity 8 Light checker Model Manufacturer 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 10 028 in HITACHI Al04 70 1OOA 6 ...

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