Yamaha XS650SE Shop Manual Download

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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).

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

YAMAHA

MOTOR CO., LTD.

Summary of Contents for XS650SE

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: ...ped 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 c...

Page 6: ...acuum 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...

Page 7: ...ance 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 Whee...

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 mo...

Page 9: ...on 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 lightl...

Page 10: ...tes 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 qu...

Page 11: ...i 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 m...

Page 12: ...th 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 l...

Page 13: ...n 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...

Page 14: ...d 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 contamin...

Page 15: ...nstand 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 adjus...

Page 16: ...r 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 Yam...

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...

Page 18: ...op 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...

Page 19: ...ust 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...

Page 20: ...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 A...

Page 21: ...ifter 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...

Page 22: ...cuum 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 si...

Page 23: ...r 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 sl...

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 gea...

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 Stopp...

Page 26: ...NSPECTION 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...

Page 27: ...e 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 cylinde...

Page 28: ...ve 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...

Page 29: ...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...

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...

Page 31: ...9 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...

Page 32: ...ing 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...

Page 33: ...cks 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 fe...

Page 34: ...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 t...

Page 35: ...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...

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 cyl...

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 Go...

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: ...agm 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 star...

Page 41: ...o 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 tur...

Page 42: ...acement 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 Install...

Page 43: ...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 hig...

Page 44: ...ed 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...

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Page 46: ...emove 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...

Page 47: ...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 when...

Page 48: ...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...

Page 49: ...inst 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 l...

Page 50: ...e 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 de...

Page 51: ...es 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...

Page 52: ...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 lubr...

Page 53: ...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...

Page 54: ...ired 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...

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Page 56: ...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...

Page 57: ...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...

Page 58: ...overnor 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 a...

Page 59: ...cessive 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 defl...

Page 60: ...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 befor...

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...

Page 62: ...ever 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 ti...

Page 63: ...s 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 wi...

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...

Page 65: ...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 si...

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 k...

Page 67: ...etric 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 kml...

Page 68: ...nstalled 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 4...

Page 69: ...mensions 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...

Page 70: ...n 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...

Page 71: ...G 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...

Page 72: ...le 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...

Page 73: ...m 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...

Page 74: ...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 Quan...

Page 75: ...ufacturer 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...

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

Page 80: ...cerning 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 Supplement...

Page 81: ...p 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...

Page 82: ...ive 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 Igni...

Page 83: ...ear 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 gr...

Page 84: ..._ _ _I __ l i _ _ I l R...

Page 85: ...ls 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 MOTO...

Page 86: ...ghten 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 ne...

Page 87: ...se 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...

Page 88: ...lts 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...

Page 89: ...se 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 valv...

Page 90: ...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 l...

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...

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...

Page 93: ...ification 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 generato...

Page 94: ...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 ov...

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...

Page 96: ...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 timi...

Page 97: ...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...

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...

Page 99: ...ump 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...

Page 100: ...l 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...

Page 101: ...re 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...

Page 102: ...d 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 Hyd...

Page 103: ...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 S1...

Page 104: ...ndlebar 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 U...

Page 105: ...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 l...

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...

Page 107: ...miting 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 _____...

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Page 113: ...ombined 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 SUP...

Page 114: ...d 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 th...

Page 115: ...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...

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

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

Page 118: ...p 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 Th...

Page 119: ...k 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 remo...

Page 120: ...n 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...

Page 121: ...orrectly 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 C...

Page 122: ...tter 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 sio...

Page 123: ...G 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 depressin...

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 leve...

Page 125: ...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 i...

Page 126: ...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 Com...

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 Numb...

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 m...

Page 129: ...Quantitv 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...

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...

Page 131: ...il 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 i...

Page 132: ...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...

Page 133: ...k 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 Primar...

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 tensio...

Page 135: ...requency 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...

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...

Page 137: ...r 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 k...

Page 138: ...cm3 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 li...

Page 139: ...miting 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 PASSIN...

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Page 141: ...Supplementary...

Page 142: ...ement 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 Supplem...

Page 143: ...CE 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 sha...

Page 144: ...am 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 che...

Page 145: ...m 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 adju...

Page 146: ...hould 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 un...

Page 147: ...e 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...

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 D...

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

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

Page 151: ...l 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 pit...

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 k...

Page 153: ...ound 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 stro...

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 Camshaf...

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...

Page 156: ...e 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 p...

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...

Page 158: ...2 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...

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...

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 HITAC...

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

Page 166: ...rning 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 Sup...

Page 167: ...t 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...

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 c...

Page 169: ...e 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 13...

Page 170: ...iming 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...

Page 171: ...gth 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 m...

Page 172: ...bly 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 ins...

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 ride...

Page 174: ...R W wire to 118...

Page 175: ...119...

Page 176: ...dard 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 cyl...

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 a...

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 sys...

Page 179: ...ng 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...

Page 180: ...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...

Page 181: ...p 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...

Page 182: ...l 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 trave...

Page 183: ...ve 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...

Page 184: ...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...

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...

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Page 191: ...ing 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 T...

Page 192: ...CE 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 leak...

Page 193: ...tor 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 m...

Page 194: ...ervicing 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...

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...

Page 196: ...ole 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...

Page 197: ...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...

Page 198: ...alled 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...

Page 199: ...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 fil...

Page 200: ...1...

Page 201: ...wing 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...

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

Page 203: ...t 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...

Page 204: ...TON 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 2...

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...

Page 206: ...esslQuantitV 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...

Page 207: ...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 Bal...

Page 208: ...ront 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 Sh...

Page 209: ...ront 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 IXS6...

Page 210: ...r 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 re...

Page 211: ...l 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 Ben...

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