Yamaha XS650H 1978 Supplementary Service Manual
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Yamaha XS650H 1978 Supplementary Service Manual

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Summary of Contents for Yamaha XS650H 1978

  • Page 2 INDEX This manual has been combined with previous service manuals to provide complete service information for: XS650H/SH. Please read and give special consideration to the “NOTICE” on the preceding page for your safety. XS650H/SH SUPPLEMENT XS650 MODELS 1978-80...
  • Page 3 XS650H/XS650SH. Please read this material carefully. NOTICE This manual was written by the Yamaha Motor Company primarily for use by Yamaha dealers and their qualified mechanics. It is not possible to put an entire mechanic’s education into one manual, so it is assumed that...
  • Page 4 Particularly important information is distinguished in this manual by the following notations: NOTE : A NOTE provides key information to make procedures easier or clearer. CAUTION: A CAUTION indicates special procedure that must be fol- lowed to avoid damage to the motorcycle. A WARNING indicates special procedures that must be fol- WARNING: lowed to avoid injury to a motorcycle operator or person...

  • Page 5: Periodic Maintenance Emission Control System

    MAINTENANCE AND LUBRICATION CHART PERIODIC MAINTENANCE EMISSION CONTROL SYSTEM...

  • Page 7: Fuel Level

    B. PICK-UP COIL ASSEMBLY The method of mounting the pick-up coil *ENGINE assembly is changed for easier service work. Thus, the followings “Pick-up coil assembly A. IGNITION TIMING removal” and “Pick-up coil assembly reinstal- The ignition system is modified for easier lation”...
  • Page 8 Fuel level: 1 f 1 mm (0.04? 0.04 in) above from the carburetor mixing chamber body edge. 3. Start the engine and stop it after a few minutes of run. This procedure is neces- sary to obtain the correct fuel level. NOTE: 6.
  • Page 9 With the engine stopped, check the oil level through the level window located at the lower part of the right side crankcase cover, or screw the dip stick completely out and then the stick in the hole. NOTE: Wait a few minutes until the oil level settles before checking.

  • Page 10: Drive Chain Tension Check

    *CHASSIS A. REAR WHEEL REMOVAL Place the motorcycle on the center stand. 2. Remove the tension bar and the brake rod from the brake shoe plate. The ten- sion bar can be removed by removing the cotter pin and nut from the tension bar bolt.

  • Page 11: Rear Brake Adjustment

    NOTE: The rear wheel axle nut is located on the right side. Loosen the rear wheel axle nut. Loosen the lock nuts on each side. To tighten chain turn chain puller adjusters clockwise. To loosen chain turn adjus- ters counterclockwise and push wheel forward.
  • Page 12 E. REAR BRAKE LINING INSPECTION The specified thickness of the brake lining is 4 mm (0.16 in). The lining should be replaced when it wears to less than 2 mm (0.079 in). To check, see the wear indicator position while depressing the brake pedal.
  • Page 13 *ELECTRICAL ed that it can be started only when the trans- mission is in Neutral or the clutch is disengag STARTING CIRCUIT CUT-OFF SYSTEM The starting circuit cut-off system is employ- ed. Hence, the following description. Accordingly, the starter motor will not start when the transmission is shifted into any Description position other than neutral, unless the clutch...
  • Page 14 the circuit from the main switch to the relay - starter switch assembly - “START” (button) is closed, and the starter switch assembly is turned on, thus causing the starter motor to start. b) When the clutch lever is released while the transmission is in position other than neutral: Neutral...
  • Page 15 *SPECIFICATION A. General ‘XS650SH only **XS650H only 1. MODEL 1) Model (I.B.M. No.) XS650SH (4M4/XS650H (4N9) *CARDINAL RED or NEW YAMAHA BLACK 21 Basic color **BLACK GOLD 2. DIMENSION 1) Overall length 2.120 mm (83.5 ini 2 ) Overall width 925 mm (36.4 in)
  • Page 16 4. PISTON 0.050 - 0.055 mm 10.0020 - 0.0022 in) 1) Piston skirt clearance 2) Piston oversize 7 5 . 2 5 mm 3) Piston pin outside diameter x length 5 . P I S T O N R I N G 1) Piston ring design 1.2mm (0.047 in, 1.5mm ,0.059 in,...

  • Page 17: Valve Spring

    9. VALVE, VALVE SEAT AND VALVE GUIDE 1) Valve per cylinder 2 pcs. 2) Valve clearance IIn cold engine) IN: 0.06 mm (0.0024 in) EX: 0.15 mm (0.0059 in) 3) Dimensions Valve head diameter “A” IN: 41 mm (1.614 in) EX: 35 mm (1.378 in) Valve face width “6”...

  • Page 18: Connecting Rod

    I. CRANKSHAFT 1) Crankshaft deflection limit 0.15 - 0.4 mm (0.0059 - 0.0157 in) 2) Con-rod large end clearance 66 -0.05 mm (2.598;$?,;; in) 41 Crank p,n I.D. 5, Crank piln O.D. x length 2. CONNECTING ROD 1) Big end I.D. 34 +t016 mm 3.
  • Page 19 Gear ratio: 1st 32113 (2.461) 26/20 (1.300) 23/21 (1.095) 22/23 (0.956) Needle bearing (@20-$30-20) Ball bearing ($25-e 52-20.6) Drive axle (Left1 Ball bearing ($30.$62-23.61 Needle bearing (020.030-161 41 Oil seal type Drive axle (Left) SDD-40-62-9 34117 (Z.OOO)/Chain Cam drum, return type Type SDO-14-24-6 2) Oil seal type (Change lever)
  • Page 20 51 Inner tube O.D. 169 cc (5.72 oz) each leg 6) Front fork oil quantity and type Yamaha fork oil 1Owt or equivalent 7) Distance from the top of inner tube oil level Approx. 454 mm (17.9 in) without spring 4.
  • Page 21 4) Shock absorber spring Free length 226 mm 03.90 in) Wire diameter x winding diameter 7.5 x 60.5 mm (0.295 x 2.382 in) Spring constant 0 - 45 mm (0 - 1.77 in) 45 - 80 mm (1.77 - 3.15 in) 5) Swing arm free play (Limit) 1 mm (0.04 in) 6) Pivot shaft - Outside diameter...
  • Page 22 7. BRAKE 1) Front brake type Hydraulic disc Type 298 x 7.0 mm 11 1.73 x 0.28 in) Disc size (Outside dia. x thickness) Disc wear limit 6.5 mm (0.26 in1 Disc pad thickness 11.0 mm (0.43 inl Pad wear limit 6.0 mm (0.24 in1 Master cylinder inside dia.

  • Page 23: Lighting System

    Regulator I.C. type T y p e S8515/TOSHIBA Model/Manufacturer 14.5 ? 0.3v Regulating voltage 3) Battery Model/Manufacturer/Quantity 12V. 14AH Capacity 1.4A 10 hours Charging rate 1.28 at 20°C 168°F) Specific gravity STARTER Bendix type Type Manufacturer/Model 0.5kw output Armature coil resistance 0.0049 ? 10% at 20°C (68°F) Field coil resistance 16 mm (0.63 in)/2 pcs.
  • Page 24 5) Flasher relay Condenser type Type Model/Manufacturer 85 t 10 cycle/min. Flasher frequency 32 CP (27W) x 2 + 3.4w Capacity 6) Flasher cancelling unit Model EVH-AC518 DC9V - 16V Voltage 7) Fuse Rating/Quantity: 20A x 1 pc. Main 10A x 1 pc. Headlight Signal Ignition...
  • Page 25 Torque Specifications Part to be tightened Thread dia. and part name Tightening torque Engine: Cylinder head and cylinder 3.7 m-kg (27.0 ft-lb) 10 mm nut head cover 8 mm bolt 2.1 m-kg (15.0 ft-lb) Cylinder head 6 mm bolt 0.9 m-kg ( 6.5 ft-lb) Cylinder head cover side 6 mm crown nut 0.9 m-kg...
  • Page 26 Thread dia. and part name Tightening torque Part to be tightened 8 mm bolt 2.0 m-kg (14.5 ft-lb) Brake disc and hub 8 mm bolt 1.8 m-kg (13.0 ft-lb) Caliper and support bracket Caliper and pad 5 mm bolt 0.3 m-kg 2.2 ft-lb) Caliper and bleed screw 8 mm bolt...

  • Page 27: Conversion Tables

    CONVERSION TABLES METRIC TO INCH SYSTEM INCH TO METRIC SYSTEM KNOWN M U L T I P L I E R 1 R E S U L T M U L T I P L I E R KNOWN R E S U L T m-kg 7.233 ft-lb...
  • Page 28 FULL OPERATIONAL SERVICE BRAKE (“Partial failure” information is not applicable and is not included.) 3 0 0 (Feet) STOPPING DISTANCE IN FEET FROM 60 MPH ACCELERATION AND PASSING ABILITY This figure indicates passing times and distances that can be met or exceeded by the vehicles to which it applies, in the situations diagrammed below.

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Xs650h 1979Xs650g 1978Xs650g 1979Xs650sh 1978Xs650h 1980Xs650sh 1980 ... Show all

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