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Yamaha XS650SE Shop Manual

Yamaha xs650 series motorcycles shop manual
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Summary of Contents for Yamaha XS650SE

  • Page 2 INDEX XS650E GENERAL INFORMATION PERIODIC INSPECTION AND ADJUSTMENT ENGINE OVERHAUL CARBURETION CHASSIS ELECTRICAL APPENDICES...
  • Page 3 XS650SE SUPPLEMENT (EPA) XS650E SUPPLEMENT *XS650SF USES THIS SUPPLEMENT (EPA) XS650SE SUPPLEMENT XS650SF/2F SUPPLEMENT XS650G/SG SUPPLEMENT...
  • Page 4 GENERAL INFORMATION CHAPTER 1. MACHINE IDENTIFICATION ....a ......1 l - l .

  • Page 5: General Information

    CHAPTER 1. GENERAL INFORMATION l-l. MACHINE IDENTIFICATION . Frame serial number The frame serial number is stamped on the right side of the steering head stock. Engine serial number The engine serial number is stamped on the front of the engine crank case. NOTE: The first three digits of these numbers are for model identifications;...
  • Page 6 7. Rotor puller 9. Slide hammer 8. Clutch holding tool (90890-01069) (90890-01070) 10. Drive chain cutter 11. Pocket tester 12. E lectro tester (90890-01081) (90890-03096) OTHER TOOL PARTS No. Valve guide remover 90890-01200 Valve guide installer 90890-01201 Spoke wrench 90890-05087 90890-01051 Steering nut wrench Tappet adjuster wrench...

  • Page 7: Table Of Contents

    CHAPTER 2. PERIODIC INSPECTION AND ADJUSTMENT 2-1. INTRODUCTION MAINTENANCE INTERVAL CHARTS ........4 2-2.

  • Page 8: Maintenance Interval Charts

    CHAPTER 2. PERIODIC INSPECTION AND ADJUSTMENT 2-1. INTRODUCTION This chapter includes all information necessary to perform recommended inspection and adjustments, These preventive maintenance procedures, if followed, will insure more reliable vehicle operation and a longer service life. The need for costly overhaul work will be greatly reduced. This information applies not only to vehicles already in service, but also to new vehicles that are being prepared for sale.
  • Page 9 , a_:._ Y- ,- mission oil Drive chain Control/Meter Apply thoroughly Oil filter element 12,800 Medium-weight Do not over/ Wheel bearings wheel bearing grease Yearly or . . . Light-weight Point cam lubri- very lightly A p p l y cation wicks...

  • Page 10: A. Carburetor

    b. Install the attachment and set the vacuum 2-3. ENGINE gauge. A. Carburetor c. Start motorcycle and allow it to warm up 1. Idle mixture for 2 - 3 minutes. The warm-up is com- The idle mixture is set at the factory by plete when engine responds normally to the use of special equipment.

  • Page 11: C. Engine/Transmission Oil And Filter

    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 B. Air filters a. To check the level, warm the engine up This model uses a cartridge type air filter for several minutes.

  • Page 12: D. Clutch Adjustment

    d. Remove the filter cover and oil filter 2. Mechanism adjustment securing bolt. 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.

  • Page 13: H. Exhaust System

    H. Exhaust system Remove all four tappet covers and the Check for leakage from exhaust joints and generator cover. retighten joint bolts and nuts. Turn the crankshaft to align the rotor Replace gaskets if necessary. mark with the “T” mark on the stator. This places the pistons at the top dead 2-4.

  • Page 14: D. Front Brake

    D. Front brake Refill with the same type and brand of The brake can be adjusted by simplay adjust- brake fluid; mixing fluids may result in a ing the distance that the brake lever can harmful chemical reaction and lead to travel.

  • Page 15: G. Drivechain

    FRONT REAR XS650E BASIC 104 kg@29 lb) 119 kg1262 lb) WEIGHT with oil Bridgestone or Bridgestone or Standard tire Yokohama Yokohama Tire load limit 234 kg (515 lb) 280 kg (615 lb] Cold tire pressure 20 mm (3/4 in) Normal riding 1.6 kg/cm’...
  • Page 16 8. Pour specified amount of oil into the in- prevent the formation of rust. ner tube through the upper end opening. Front fork oil: Yamaha fork oil 10 Wt Front fork oil capacity: 164 - 172 cc (5.54 - 5.82 oz) each side H.

  • Page 17: J. Lubrication Of Cables, Pivots, Etc

    Brake and change pedal shafts, and center 3. Steering fitting bolt and side stand pivots Lubricate the shafts Use steering nut wrench to loosen top and pivots with Yamaha chain and cable steering fitting nut. The top nut serves as SAE l0W/30 lube or motor oil.

  • Page 18: D. Carbon Brushes

    c. Rust or wear on the breaker arm or arm Ignition timing of right-hand cylinder shaft. must be set first. Connect timing light to d. Faulty insulation of the contact braker right-hand spark plug lead wire. assembly. Start engine. Oil or dirt on the assembly. The mark stamped on the rotor_ should To clean the points, run a point file be- line up with the stationary “F”...

  • Page 19: F. Sparkplug

    and thechassis lead is for the (-) terminal. sent on the surface of the spark plug, and Make sure the breather pipe is properly torque the spark plug properly. connected, properly routed, and is not Standard spark plug: damaged or obstructed. Champion N-7Y or NGK BP 7ES NOTE: Tightening torque:...
  • Page 20 CHAPTER 3. ENGINE OVERHAUL ENGINE REMOVAL ........3-1..A. Preparation for removal ........B. Fuel tank removal ........
  • Page 21 ENGINE ASSEMBLY AND ADJUSTMENT ......3-4. A. Shift ............B.
  • Page 22 CHAPTER 3. ENGINE OVERHAUL 31. ENGINE REMOVAL A. Preparation for removal 1. All dirt, mud, dust and foreign material should be thoroughly removed from the exterior of the engine before removal and disassembly. 2. Place machine on center stand. Star-f engine and allow it to warm up.
  • Page 23 3-2 ENGINE DISASSEMBLY C. Rocker arm removal 1. Remove rocker shaft covers. A. Governor and breaker assembly removal 2. Remove shouldered sleeves and O-rings. Remove the following parts in the order 3. Withdraw rocker shafts with the special given. tool or 6 mm bolt. 1.
  • Page 24 I. Electric starter unit removal Remove the gea r train cover, and idle gear 1 and 2. Push rod Push rod (Aluminuml Push crown Hold the clutch unit with the holding tool 10. Washer 1. Kick axle 4. Kick gear 7. Spacer (special tool), and unscrew the clutch boss 2.
  • Page 25 L. Transmission illustration Transmission 1. Main axle (13T) 1’ 1st wheel gear (32T) 2. 2nd pinion gear (17T) 2’ 2nd wheel gear (27T) 3. 3rd pinion gear (20T) 3’ 3rd wheel gear (26T) 4. 4th pinion gear (21T) 4’ 4th wheel gear (23T) (22T) 5.
  • Page 26 the stopper spring (6). 4. Remove the neutral detent unit (15-18). Release 2. Remove the bolts (1) and stopper plate(3). 5. Removecotter pins (13). and pin (12) 6. Pull out the shift cam (7). 3. Pull the guide bar (14) out. N.
  • Page 27 C. Valve, valve guide and valve seat d. Use the appropriate shouldered punch 1. Valve guide (special tool) to drive the old guide out a. If the valve guide inside diameter is be- and drive the new guide in. e, After installing the valve guide, use 8 mm yond serviceable limits, replace with an reamer (special tool) to obtain the proper oversize valve guide.
  • Page 28 width. The valve seat will have removed Lapping the valve/valve seat assembly. the bluing wherever it contacted the valve a. The valve/valve seat assembly should be lapped if (1) neither the seat nor the valve face. Measure the seat width with vernier face are severely worn, or (2) if the valve calipers.
  • Page 29 c. Another symptom of a fatigued spring is Standard size: insufficient spring pressure when com- 15.000 ~ 15.018 mm pressed. This can be checked using a valve (0.5906 ~ 0.5913 in) spring compression rate gauge. Test each spring individually. Place it in the gauge 3.
  • Page 30 4. All camshaft bearings should be removed, cleaned, dried, and the races visually checked for pits, rust spots or chatter Wear Ilmit Standard marks where the balls have dragged, If any of these conditions exists the bear- ing(s) should be replaced. G.Cam chain, sprocket and dampers 1.
  • Page 31 b. Determine piston clearance as follows: J. Piston pin 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.
  • Page 32 2. Check the clearance between outer rotor 5. Clutch springs Measure clutch spring free length. Replace and inner rotor. springs as a set if necessary. Standard clearance: Clutch spring length: 0.03 - 0.09 mm (0.0012 - 0.0035 in) 34.6 mm (1.362 in) M.
  • Page 33 11. Check to see that each gear properly 3-4. ENGINE ASSEMBLY AND ADJUST- engages its counterpart on the shaft. MENT Check the mating dogs for rounded edges, NOTE: cracks, or missing portions. Replace as All gaskets and seals should be replaced required.
  • Page 34 2. Positioning the kick clip in the groove, rotate the kick axle by kick lever l/2 turn Fit the chain over the cam sprocket, counterclockwise. 6. Apply Yamaha Bond No. 4 sealant to 3. Push the axle in. crankcase mating surface. 4. Check for correct operation.
  • Page 35 n. Pressure plate and clutch springs o. Primary drive gear Clutch screw torque: Drive gear torque: 1 .O m-kg (7 ft-lb) 9 m-kg (65 ft-lb) b. Plate 2 d. Housing e. Bearing plate f. Bearing h. Clutch boss k. Nut (usmg special tool) b =2.0 f = 2.0 g =2.0...
  • Page 36 G. Generator 2. Install pistons on rods. The arrow on the 1. Lock the crank rotation at the primary pistons must point to the front of the drive gear. engine. Reverse the generator removal sequence. NOTE: Always install new piston pin clips. H.
  • Page 37 Make sure the timing is correct. M. Cylinder heed cover 1. Install all components in the head cover. 2. Apply Yamaha No. 4 sealant to cover mating surfaces. 3. Install all head cover retaining nuts and bolts and thread them down until lightly seated.
  • Page 38 CHAPTER 4. CARBURETION ..3 6 C A R B U R E T O R ........... . 4-1.
  • Page 40 41. CARBURETOR A. Description Air flow through the venturi is controlled by a throttle slide (vacuum piston). The slide is raised and lowered by engine vacuum rather than a cable linked directly to the throttle grip. B. Specifications Main jet To inspect starter jet, remove three (3) Jet needle 5 0 2 - 3...
  • Page 41 E. Adjustments 1. Float level adjustment Measure the distance from the bottom of the float to the float bowl gasket surface. Bend the tongue on the float arm if any float level adjustment is necessary. Both floats must be at the same height. If the fuel level is too high, a rich air/fuel mix- ture will occur.
  • Page 42 CHAPTER 5. CHASSIS FRONT WHEEL ....5-1. A. Removal ....... B. Front axle inspection ... . . C. Front wheel inspection.... D. Replacing wheel bearings ..E. Installing front wheel ..... REAR WHEEL ....
  • Page 43 CHAPTER 5. CHASSIS 5-l. FRONT WHEEL a) If the run out is up and down, loosen spokes opposite the high spot and tighten A. Removal the spokes at the high spot. Remove cotter pin from front axle nut. b) If the run out is sideways, loosen the Remove the front axle nut.
  • Page 44 b. Tighten axle holder nuts. First tighten nut E. Installing rear wheel on front end of axle holder, then tighten Lightly grease lips of rear wheel oil seals. nut on rear end. 2. To install the rear wheel, reverse the removal procedure.
  • Page 46 B. Caliper disassembly Remove brake lever and spring. 1. Remove caliper brake hose. Allow caliper 4. Remove master cylinder from handlebars. assembly to drain into a container. Remove cap and drain remaining fluid. 2. Place the open hose end into the con- tainer and pump the old fluid out of the master cylinder.
  • Page 47 cap, boot bushing, piston seal, dust seal, See “Caliper Replacement Pad” procedure retaining ring. for parts to be replaced when pads are replaced. Replace piston and dust seals if damaged. Inspect master cylinder body. Replace if scratched. Clean all passages with new brake fluid.
  • Page 48 Use two wide, flat tire irons with rounded 5. Brake disc assembly edges to work the tire bead over the edge If brake disc has been removed from hub 180” of the rim, starting opposite the or is loose, tighten bolts. Use new locking tube stem.
  • Page 49 NOTE: Wear limit 3 mm (0.02 in) Be sure that all lock tabs are not cracked or broken and that they are all bent against the bolts. Constant friction and force from the chain creates wear on the sprocket teeth. If wear has progressed to the extent Slip off shown in this illustration, replace the...
  • Page 50 A. Removal and disassembly B. inspection Examine fork inner tube for scratches and NOTE: straightness. If the tube is scratched severe- For fork oil replacement only, refer to PAGE ly or bent, it should be replaced. (12) If the lips of the oil seal are worn, or the Disconnect speedometer cable.
  • Page 51 D. Reassembly Grease bearings and races with wheel bear- ing grease. 1. Bottom 2. T 5-7. STEERING HEAD A.Adjustment Install steering stem (underbracket) and (See Chapter 2-4 for Steering Head Adjust- bearings. ment.) Install bottom fitting nut. Tighten to approximately 2.0 - 2.6 m-kg (14 - 19 B.
  • Page 52 3. Operate shock absorber rod to check B. Swing arm removal damping. There should be no noticeable 1. Remove nut on swing arm pivot bolt and damping as shock extends. tap out bolt with a long aluminum or Install the shock absorber on the machine. brass rod.
  • Page 53 CHAPTER 6. ELECTRICAL STARTER ............5 0 6-1.
  • Page 54 CHAPTER 6. ELECTRICAL 6-1. STARTER sistance is less then 100 kn) replace it. A.Armature If the commutator surface is dirty, clean NOTE: with #600 grit sandpaper as shown in the Immediately after cleaning, the yoke may drawing below. show some insulation leakage. Wait for it After sanding, wash thoroughly with to thoroughly dry before checking or re-...
  • Page 56 6-2. CHARGING SYSTEM A.Charging circuit diagram 4. Load 9. Stator coil 4 . Black 2. Fuse 6. Voltage regulator IO. Relay unit 2. White 5. Sky blue 3. Main switch 7. A.C. Generator 3. Yellow (Pick up cable) 6. Field Coil 4.
  • Page 57 1. Check silicon rectifier as specified using b. If the bottoms of the cells are filled with the Yamaha Pocket Tester. corrosive material falling off the plates, the battery should be replaced. 2. The service life of a battery is usually 2 to 3 years, but lack of care as described below will shorten the life of the battery.
  • Page 58 proper rpm, nor will it advance to its a. Negligence in keeping battery topped off fullest extent. On occasion, lightweight with distilled water. grease must be applied to the weight pivot b. Battery being left discharged. pins. c. Over-charging with heavy charge. b.
  • Page 59 Standard values: Primary coil resistance: Secondary coil resistance: E. Condenser test If the contact points show excessive wear, or the spark is weak (but the ignition coil is in good condition), check the condenser. 1. Capacity test (use Electro Tester). a.
  • Page 60 operates, always check battery voltage before 6-4. SPARK PLUG proceeding further. Low battery voltage The life of a spark plug and its discoloring indicates either a faulty battery, low battery vary according to the habits of the rider. At each periodic inspection, replace burned of water, or a defective charging system.
  • Page 61 B. Reserve lighting system 1. Description: The reserve lighting system has two functions: (1) It notifies the rider that one of the head lamp filaments is inopera- tive, and (2) it switches current from the inoperative filament to the remaining functional filament.
  • Page 62 3. Circuit diagram. C. Self-canceling flasher system 1. Description The self-cancaling flasher system turns off the turn signal after a period of time or distance involved in turning or changing lanes. Generally, the signal will cancel after either 10 seconds, or 130 meters, whichever is greater.
  • Page 63 4. Inspection: If the flasher self-canceling system should become inoperative, proceed as follows: a. Pull off the 6-pin connectar from the flasher canceling unit, and operate the handle switch. If the signal operates normally in L, R, and OFF, the following are in good condition: 1) Flasher unit.
  • Page 64 CHAPTER 7. APPENDICES ..6 1 7-1. TORQUE SPECIFICATION ......... . Torque Specifications...............
  • Page 65 7-1. TORQUE SPECIFICATION The following torque specifications must be adhered to on every machine. When applying torque to multi-secured fastener components, the several studs should be tightened in gradual stages and in a pattern that will avoid warpage to the item being secured. Torque settings are for dry, clean threads.
  • Page 66 Thread dia. and Part to be tightened Tightening torque part name Delivery pipe / 10 mm union bolt 2.2 m-kg (16 ft-lb) 8mm n u t Exhaust pipe 1.5 m-kg (11 ft-lb) 1 Crankcase 1 and 2 1 8 mm bolt/nut 2.2 m-kg (16 ft-lb) Crankcase cover 1 6 mm bolt...
  • Page 67 7-2. C O N V E R S I O N T A B L E Inch Metric System Metric to Inch System Multiplier Multiplier Result Known Known (Rounded off) (Rounded off) Torque Torque 7.233 m-kg m-kg 0.13826 ft-lbs m-kg 86.80 m-kg 0.01152...
  • Page 68 7.3. SPECIFICATION A. General MODEL 1) Model (I.B.M. No.) 2) Frame I.D. and starting number DIMENSION 2,180 mm (85.8 in) 21 Overall width 835 mm (32.9 in) 3) Overall height 1,160 mm (45.7 in) 815 mm (32.1 in) 4) Seat height 1,435 mm (56.5 in) 150 mm ( 5 .
  • Page 69 Needle bearin 2) Number and type of bearing 3) Bearing dimensions 25 x 47 x 8 mm IO.984 x 1.850 x 0.315 in) Pitch/Number of links 7.774 mm IO.3060 in)/106 Sprocket ratio (Teeth) 0.009 - 0.033 mm (0.00035 - 0.00130 in) IN: 0.10 mm 10.0039 in) EX: 0.15 mm (0.0059 in) Valve head diameter “A”...
  • Page 70 IO. VALVE SPRING INNER (IN/EX): 42 mm (1.654 in) Free length OUTER (IN/EX): 42.55 mm (1.675 in) 2) Spring rate (kg/mm) INNER IIN/EX): ki = 1.43 OUTER (IN/EX): kl = 3.2 3) Installed length (Valve closed) INNER (IN/EX): 35 mm (1.378 in) OUTER (IN/EX): 37 mm (1.457 in) 4) Installed pressure (Valve closed) INNER (IN/EX): 10f 0.7 kg (22.0* 1.5 lb1...
  • Page 71 71 Clutch spring Free IengthlDuantity 34.6 mm 11.362 in)/6 pa. 0.027 - 0.081 mm fO.0011 - 0.0032 in) 0.2 mm (0.008 in) 5. TRANSMISSION Constant mesh, 5.speed forward 21 Gear ratio: Needle bearing (20x30~20 mm)10.787x1.181x0.787 in) bearing (25x52x20.6 mm)(0.984x2.047x0.811 in) Main axle (Right){ Drive axle (LeftIf Ball bearing (30x62x23.8 mm)~1.181x2.441x0.937 in)
  • Page 72 Wire diameter x winding diameter Spring constant 150 mm (5.906 in) 4) Front fork travel 35 mm (1.378 in) 5) Inner tube 0.0. 169 cc 15.71 02) 6) Front fork oil quantity and type Yamaha fork oil 1Owt or equivalent...
  • Page 73 Approx. 454 mm (17.9 in) without spring 4. REAR SUSPENSION Swing arm Oil damper, coil spring 80 mm (3.15 in) 3) Shock absorber travel 4) Shock absorber spring 201 mm (7.91 in) Set length 226 mm (8.90 in) Free length 7.5 mm x 60.5 mm 10.295 x 2.382 in) Wire diameter x winding diameter 1 mm (0.04 in)
  • Page 74 7. BRAKE Front brake Hydraulic disc type Disc size (Outside dia. x thickness) 298 mmx 7.0 mm (11.73x0.28 in) Disc wear limit 6.5 mm (0.26 in) Disc pad thickness 6.5 mm (0.26 in) Pad wear limit (Minimum thickness) 1.5 mm 10.06 in) Master cylinder inside dia.
  • Page 75 4) Voltage regulator 0.6 - 1 .O mm (0.024 - 0.039 in) core gap 0.3 - 0.4 mm (0.012 - 0.016 in) Point gap Voltage coil Resistor 5) Battery Capacitv Charging rate 1.28 at 20-C l68’F) Specific gravity 3. STARTER Bendix type HITACHI Manufacturer...
  • Page 79 Supplementary FOR XS650E MODELS AFTER ENGINE SERIAL NO. 2FO-006501...
  • Page 80 Supplementary Manual together with the Service Manual for the 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 MOTOR CO., LTD.
  • Page 81 Page numbers shown in brackets correspond to page numbers of the XS650E (LIT-1 1616-00-76) Service Manual. (Page 4-5) 2-2. Maintenance Interval Charts A. PERIODIC MAINTENANCE EMISSION CON TROL SYSTEM INITIAL BREAK-IN ITEM or 7 months 1 1 Cam Chain Check and adiust chain tension Check and adjust valve clearance when engine is cold.
  • Page 82 E. Cam chain adjustment Check/Adjust the cam chain tension as follows: Remove the cap nut. Turn the left end of the crankshaft counterclockwise. As the crankshaft is turning, check to see that the cam chain adjuster push rod is flush with the end of the bolt.
  • Page 83 6. Retighten screws. Check timing again for right cylinder. 7. Repeat procedure (steps 2-6) for left cylinder. 1. Right cylinder timing adjustment 2. Left cylinder timing adjustment (Page 15) F. Spark plug Check electrode condition and wear, insula- tor color and electrode gap. Use a wire gauge for adjusting the plug gap.
  • Page 85 XS650G/XS650SG. For complete information on service procedure, it is necessary to use this Supplementary Service Manual together with following manuals: XS650E Service Manual (LIT-1 1616-00-76) XS650SE Supplementary Service Manual (LIT-1 1616-01-08) XS650SF/2F Supplementary Service Manual (LIT-1 1616-01-65) SERVICE DEPT. INTERNATIONAL DIVISION YAMAHA MOTOR CO., LTD.
  • Page 86 Check and adjust engine idle speed, 8 ‘ Idle Speed Adjust cable free play if necessary. ‘It recommended that these Items be inspected and serwce by a Yamaha Dealer or other qualified mechanic. GENERAL MAINTENANCE/LUBRICATION 5’ Clutch Adjust free play. Check chain condition.
  • Page 87 Check specific gravity. Check breather pipe for 1 5 Batfew proper operation. Replace generator brushes Replace at initial 9,000 km (5,500 mi) ‘It is recommended that these items be inspected and serviced by a Yamaha dealer or other qualified mechanic.
  • Page 88 NEW SERVICE exactly as described. Failure to do so may be a violation of law. *SPECIAL TOOL Install the A.C.G. stator assembly to the New special tool for XS650G/XS650SG. crankcase. “TORX” socket Set the pick-up coil assembly so that the P/NO.
  • Page 89 Yamaha Motor Corporation, U.S.A., is expressly prohibited. NOTE: A special socket (90890-01308-00) is neces- sary for tightening these special bolts. The heads will shear off when the bolts have been properly torqued. 2. Timing plate pointer 7.
  • Page 90 e. Inspect the starter plunger assembly for damage. If damaged, replace. f. Float level Hold the carburetor in an upside down position. Hold the floats so the tang is just touching the float needle. Measure the distance from the top of the float to the float bowl gasket base surface without the gasket.
  • Page 91 *ELECTRICAL A. IGNITION SYSTEM protective circuit This unit consists of two pick-up coils 2. Description mounted on the generator case and a This model is equipped with a battery permanent magneto on the rotor which operated, fully transistorized breakerless is mounted to the crankshaft. When the ignition system.
  • Page 92 turned on and the crankshaft is not turned, the protective circuit stops gap until misfire occurs. (Test at various current flow to the primary coil within rpm between idle and red line.) a few seconds. When the crankshaft is Minimum spark gap: 6 mm (0.24 in) turned over, the current is turned on again by the signals generated by the pick-up coils.
  • Page 93 Minimum brush length: 7 mm (0.28 in) Generated voltage: 14.2 - 14.8V c. Rotor coil/Stator coil Check the resistance between terminals using the Yamaha Pocket Tester or other circuit tester as shown. If resistance is 14.5 14.2 - - - -...
  • Page 94 - C A U T I O N : Check the silicon rectifiers as specified The silicon rectifier can be damaged if using the Yamaha Pocket Tester or other circuit tester. Even if only one of the subjected to overcharging.
  • Page 95 *XS650SG only **XS650G only A. General 1. MODEL 1) Model (I.B.M. No.) XS650SG (3G1)/ XS650G (3GO) ‘CARDINAL RED or NEW YAMAHA BLACK “BLACK GOLD 2. DIMENSION 1) Overall length 2,120 mm (83.5 in) 2) Overall width 925 mm 136.4 in) 3) Overall height ‘1,225 mm (48.2 in)
  • Page 96 Piston skin clearance 0.050 - 0.055 mm (0.0020 - 0.0022 in) 2) Piston oversize 5. PISTON RING (Installed, top) /Installed. 2nd) 0 . 2 - 0 . 4 m m (0.008-0.016 in) (Installed, oil) 0 . 3 - 0 . 9 m m ~0.012-0.035 in) 2) Bearing size 3) Needle size Chain ICenter side)
  • Page 97 9. VALVE, VALVE SEAT AND VALVE GUIDE PCS. IN: 0.06 mm (0.0024 inI EX: 0.15 mm IO.0059 in) IN: 41 mm (1.614 in1 Valve head diameter “A” EX: 35 mm (1.378 in) Valve face width “6” IN: 2.1 mm (0.083 in) EX: 2.1 mm (0.083 ini Valve seat width “C”...
  • Page 98 0.05 mm 10.002 in) Others Wet, multiple type Inner push type, screw push system 31 Primary reduction ratio and method Thickness/Quantity 3 mm (0.118 in)/7 pcs. 2.7 mm (0.106 in) Wear limit 1.4 mm (0.055 in)/6 pa. Warp limit 0.05 mm (0.002 in) Free length/Quantity 34.6 mm Il.362 in)/6 pcs.
  • Page 99 3) Bearing: Main axle (Left) (Right) Drive axle (Left) Needle bearing (@20- $30-161 41 Oil seal type Drive axle (Left) 1 6 . S H I F T I N G M E C H A N I S M Cam drum, return type 2) Oil seal type (Change lever) 17.
  • Page 100 - - - P r e s s u r e f e e d e--Splash lubrication C. Chassis 1 F R A M E Double cradle, high tensile frame 2. STEERING SYSTEM 1 I caster 115 mm 14.53 in) 31 Number and size of balls in steering head Upper race 19 pcs.
  • Page 101 4) Shock absorber spring 226 mm (8.90 in) Free length Wire diameter x winding diameter 7.5 x 60.5 mm 10.295 x 2.382 inl Spring constant O-45 mm (O- 1.77 in) 1 mm (0.04 inl 16 mm (0.63 in) 5. FUEL TANK 11.5 lit (3.04 US gall Capacity 2.3 lit (0.61 US gall...
  • Page 102 7. BRAKE Front brake 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 (0.26 in) Disc pad thickness 11 .O mm (0.43 in) Pad wear limit 6.0 mm IO.24 in) Master cylinder inside dia.
  • Page 103 3. STARTER Bendix type Manufacturer/Model Output 0.5 kw Armature coil resistance Field coil resistance 0.0040 flO% at 2Ot (68oF) Brush size/Quantity 16 mm (0.63 in)12 per. Wear limit 4 mm (0.16 in) Spring pressure Commutator O.D./Wear limit 33mm ~1.30in)/30mm (1.18in) Mica undercut 0.7 mm IO.028 in) 2) Starter switch...

  • Page 104: Torque Specifications

    Torque Specifications Part to be tightened Thread dia. and part name Tightening torque Engine: Cylinder head and cylinder 10 mm nut 3.7 m-kg (27.0 ft-lbl Chassis: Front wheel axle 14 mm nut 10.7 m-kg (77.5 ft.lb) Front fork and axle holder 1.4 m-kg l10.0 ft.lbl Handle crown and inner tube 1.1 m-kg ( (8.0 ft.lb)
  • Page 105 Thread dia. and pan name Part to be tightened Brake disc and hub B mm bolt 1.8 m-kg 113.0 ft.lbi Caliper and support bracket 8 mm bolt 0.3 m-kg I 2.2 5 mm bolt Caliper and 0.6 m-kg 4.5 ft-lb) Caliper and bleed screw Front caliper and front fork 10 mm bolt...
  • Page 106 CONVERSION TABLES Notice The information presented represents results obtainable by skilled drivers under controlled road and vehicle conditions, and the information may not be correct under other conditions. STOPPING DISTANCE This figure indicates braking performance that can be met or exceeded by the vehicles to which it applies, without locking the wheels, under different conditions of loading and with partial failures of the braking system.
  • Page 107 not applicable and is not included) STOPPING DISTANCE IN FEET FROM 60 MPH ACCELERATION AND PASSING ABILITY This figure indicates passing times and distances that can be met or exceeded by the vehicles to which it applies, in the situations diagrammed below. The low-speed pass assumes an initial speed of 20 mph.
  • Page 113 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 114 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 115 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 116 MAINTENANCE AND LUBRICATION CHART PERIODIC MAINTENANCE EMISSION CONTROL SYSTEM...
  • Page 118 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 119 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 120 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 121 *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 122 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 123 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 124 *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 125 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 126 *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 127 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 128 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 129 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 130 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 131 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 132 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 133 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 134 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 135 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 136 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 137 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 138: Consumer Information

    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 139 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.
  • Page 141 Supplementary...
  • Page 142 FOREWORD This Supplementary Service Manual for XS650SE has been published to supplement 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 Unit: km (mi) Check tension, alignment B. LUBRICATION INTERVALS Unit: km (mi) Remarks Item Replace/Warm Engine oil engine before draining Every 400 (250) Drive chain Clean/Lube Brake pedal shaft/ Light application Change pedal shaft Yamaha chain and Control/Meter Apply thoroughly -78-...
  • Page 144 Use new fluid only fluid reserve Clean/Replace as Oil filter element required Drain completely - Yamaha Fork Oil Front forks Check specifications 20 wt. Inspect thoroughly 2,800 Medium-weight Steering bearings Pack moderately wheel bearing grease Yearly or . . .
  • Page 145 position so that its top end is approx. 12 G. Drive chain 1. Tension check footrest top end. NOTE: Secure the adjuster lock nut. Before checking and/or adjusting, rotate Loosen the brake rod adjuster lock nut rear wheel through several revolutions and and screw brake rod downward until check tension several times to find the there is noticeable free play between rod...
  • Page 146 1. Lock nut 4. Rear wheel axle nut ‘2. Adjuster 5. Cotter pin 3. Marks for align (PAGE 29 - 33) 3-4. ENGINE ASSEMBLY AND ADJUSTMENT 0. Engine Specifications should be changed as follows: Engine mounting bolt torque: Upper (U Nut) 1.8 m-kg (13.0ft-lb) M l 0 3.0 m-kg (21.5 ft-lb)
  • Page 147 (PAGE 40 - 44) 5-3. BRAKES Except for the following, the same procedure can be performed for Disassembly, Inspection and Assembly of XS650SE front and rear E. Installing front wheel brake and XS650E front brake. 4. Always secure the front wheel axle as follows: D.
  • Page 148 Check the armature and field coil for shorting and insulation. Replace arma- ture as required. A: Pad thickness 11 .O mm (0.43 in) 6: Wear limit Check the front and rear cover bearings 6.0 mm (0.24 in) for damage. If damaged, the starter C: Wear indicator assembly must be replaced.
  • Page 149 2. Troubleshooting/inspection...
  • Page 150 WHEN IS DEFECTIVE...
  • Page 151 To starter relay To A.C. Generator (PAGE 61- 62) 7-1. TORQUE SPECIFICATION The following torque specifications must be adhered to on every machine. When applying torque to multi-secured fastener components, the several studs should be tightened in gradual stages and in a pattern that will avoid warpage to the item being secured.
  • Page 152 Part to be tightened Thread dia. and part name Tightening torque Engine: Cylinder head and cylinder 10 mm nut 3.7 m-kg (27.0 ft-lb) head cover 8 mm bolt 2.1 m-ka 115.0 ft-lb) 0.9 m-kg 6.5 ft-lb) 6 mm bolt Cylinder head Cylinder head cover side 6 mm crown nut 0.9 m-kg...
  • Page 153 12mm 1.3 m-kg ft-lb) (PAGE 64 - 71) 7-3. SPECIFICATION A. General 1. MODEL XS650SE (2MO) 1) Model (I.B.M. No.) 2) Frame I.D. and starting number 2FO-100101 2FO-100101 3) Engine I.D. and starting number 2. DIMENSION 2,120 mm (83.5 in) 1) Overall length 925 mm (36.4 in)
  • Page 154 0.050 - 0.055 mm (0.0020 - 0.0022 in) 2) Piston oversize 3) Piston pin outside diameter x length 20.0 _i,,,,, mm x 61 .O _z,3 mm (0.79 _~,ooo2 In x 2.40 _E,o,,6 in) Barrel ring 1.2 mm (0.047 in) (2nd) Taper ring 1.5 mm (0.059 in) (Oil ring) With expander 2.8 mm (0.110 in)
  • Page 155 IN: 8.0 ~~:~~~ mm (0.315 Ig:Eo in) Valve stem diameter EX: 8.0 I::$“, mm (0.315 I~:~~~ in) Valve guide diameter IN: 0.020 - 0.044 mm (0.00079 - 0.00173 in) Valve stem to guide clearance EX: 0.035 - 0.059 mm (0.00138 - 0.00232 in) 10.
  • Page 156 14. CLUTCH Clutch type Wet, multiple type 2) Clutch operating mechanism Inner push type, screw push system 3) Primary reduction ratio and method 4) Primary reduction gear back lash (4 teeth) 21.45 _&6 mm (0.8445 &ooto in) 5) Friction plate Thickness/Quantity 3 mm (0.118 in)/7 pcs.
  • Page 157 5) Inner tuba O.D. 169 cc (5.72 oz) each leg 6) Front fork oil quantity and type Yamaha fork oil 20 wt or equivalent 7) Distance from the top of inner tube oil level Approx. 454 mm (17.9 in) without spring 4.
  • Page 158 Wire diameter x winding diameter 7.5 x 60.5 mm (0.295 x 2.382 in) Spring constant 5) Swing arm free play (Limit) 1 mm (0.04 in) 6) Pivot shaft - Outside diameter 16 mm (0.63 in) 5. FUEL TANK 11.5 lit (2.53 US. gal) Regular gasoline 2) Fuel grade 6.
  • Page 159 D. Electrical 1. IGNITION SYSTEM 2) ignition coil Model/Manufacturer Spark gap B mm (0.31 in) or more/300 r/min at 8V Primary winding resistance Secondary winding resistance N-7Y (CHAMPION) or BP7ES (N.G.K.) 0.7 - 0.8 mm (0.027 - 0.031 in) Spark plug gap 4) Contact breaker Manufacturer/Quantity Point gap...
  • Page 160 2) Starter switch Manufacturer HITACHI Model Amparage rating Cut-in voltage Winding resistance 3) Starter clio friction tension 2.2 - 2.5 kg (4.9 - 5.5 lb) 4. LIGHTING SYSTEM Sealed beam 2) Bulb brightness and wattage/Quantity Head light Tail/brake light Flasher light Pilot lights: Turn High beam 12v.
  • Page 165 Supplementary FOR XS650SE MODELS AFTER ENGINE SERIAL NUMBER 2FO-114241...
  • Page 166 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.
  • Page 167 3 /AI, F,lter Brake pad If necessary. Adjust free play. Yamaha chain and Apply chain lube cable lube or CHECK CHAIN TENSION AND LUBE EVERY 500 km (300 ml) t h o r o u g h l y .
  • Page 168 1 month or 7 months or 6 months or 12 months or24month ( 3 . 0 0 0 mil 12.500 ml) , , ;ynt Fork Dram completely. Yamaha fork oil Refill to speciflcatmn. Steering Ball Check bearmgs assembly Repack repack every 16,000 km grease.
  • Page 169 E. Rear brake The rear brake pedal should be so adjusted that it has a free play of 13 - 15 mm (0.51 moved to when the brake begins to be Standard tire Yokohama Yokohama effected. Loosen the adjuster lock nut (for pedal Maximum load limit 166 kg (365 Ibl 279 kg (615 lb1...
  • Page 170 L o o s e n t h e IOU W. ,, ~“, ~~, To H. Front fork oil change tighten chain tur* ‘,W 8. Pour specified amount of oil into the clockwise. To Irfn *,W inner tube through the upper end open- ing.
  • Page 171 (PAGE 29 - 33) 3-4. ENGINE ASSEMBLY AND ADJUSTMENT 0. Engine Specifications should be changed as Engine mounting bolt torCWe: 1.8 m-kg (13.0ft-lb) Upper Kl Nut) 3.0 m-kg (21.7 ft-lb) M l 0 Upper Front (U Nut) M l 0 4.6 m-kg (33.3 ft-lb) 4.1 m-kg (29.7 ft-lb) 1.
  • Page 172 Except for the following, the same procedure 4. Always secure the front wheel axle as can be performed for Disassembly, Inspection follows: and Assembly of XS650SE front and rear Specifications should be changed as brake and XS650E front brake. follows: D.
  • Page 173 for damage. If damaged, the starter A: Pad thickness assembly must be replaced. 11 .O mm (0.43 in) (PAGE 57 - 58) 6: Wear limit 6-5. LIGHTING AND SIGNAL SYSTEMS 6.0 mm IO.24 in1 B. Reserve lighting system C: Wear indicator 1.
  • Page 174 - 1 1 8 -...
  • Page 175 -119-...
  • Page 176 (PAGE 61- 62) 7-1. TORQUE SPECIFICATION The following torque specifications must be adhered to on every machine When applying torque to multi-secured fastener components, the several studs should be tightened in gradual stages and in a pattern that will avoid warpage to the item being secured.
  • Page 177 Part to be tightened Thread dia. and part name Tightening torque Delivery pipe 10 mm union bolt 2.1 m-kg (15.2 ft-lb) Exhaust pipe 8 mm nut 1.3 m-kg ( 9.4 ft.lb) Crankcase 8 mm bolt/nut 2.1 mkg (15.2 ft-lb) Kick crank boss 8 mm bolt 2.0 m-kg (14.5 ft.lb) Primary drive gear...
  • Page 178 7-3. SPECIFICATION A. General 1. M O D E L 2) Frame I.D. and starting number 3) Engine I.D. and starting number 2. D I M E N S I O N length 2,120 mm (83.5 in) Overall 925 mm (36.4 in) 2) Overall width 1,225 mm (48.2 in) 3) Overall height...
  • Page 179 Piston ring design 0.2 - 0.4 mm 10.006 - 0.016 in) (Installed. top) 0.2 - 0.4 mm (0.006- 0.016 in) (Installed, 2nd) 0.3 - 0.9 mm (0.012 - 0.035 inl (Installed. oil) 0.04 - 0.06 mm (0.0016 - 0.0031 inl 0.03 - 0.07 mm (0.0012 - 0.0026 in) Needle bearing Chain (Center side)
  • Page 180 EX: 6.0 3:;: mm (0.315 ;g:$$ in) Valve stem diameter IN: 8.0 $ti”, mm (0.315 $E inl Valve guide diameter IN: 0.020 - 0.044 mm (0.00079 - 0.00173 in) Valve stem to guide clearance EX: 0.035 - 0.059 mm IO.00138 - 0.00232 in) IN &...
  • Page 181 3 mm (0.118 in117 pcs. Wear limit 2.7 mm (0.106 in) Thickness/Quantity 1.4 mm (0.055 in)/6 pcs. Warp limit 0.05 mm (0.002 in) 7) Clutch spring 34.6 mm (1.362 in)/6 per. Free length/Quantity 0.027 - 0.081 mm (0.0011 - 0.0032 in) 8) Clutch housing radial play 9) Push rod bending limit 0.2 mm (0.008 in)
  • Page 182 100 - 150 mm (3.94 - 5.91 in) 150 mm (5.906 in) 35 mm (1.378 in) 169 cc (5.72 02) each leg Yamaha fork oil 1OWt or equivalent 7) Distance from the top of inner tube oil level without spring 4. REAR SUSPENSION...
  • Page 183 5. FUEL TANK 11 .O lit (2.9 US gal) 2) Fuel grade Regular gasoline 6. WHEEL 1) Type (Front and rear) Aluminum rim 3) Tire pressure: Up to 90 kg I198 lb) load Front: 1.6 kg/cm2 (22 psi) Rear: 2.0 kg/cm2 128 psi) 90 kg 1198 Ibjload - 204 kg (445 Ibjload Front: 2.0 kg/cm’...
  • Page 184 Primary winding resistance Secondary winding resistance 31 Spark plug N - 7 Y (C,jAMPION) or BP7ES (N.G.K.1 0.7 - 0.8 mm (0.027 - 0.031 in) Spark Plug gap HITACHI/2 pcs. 0.30 - 0.40 mm (0.012 - 0.016 in) Point gap 650 - 850 g (22.9 - 30.0 02) Point spring pressure Cam closing angle...
  • Page 185 4. LIGHTING SYSTEM Sealed beam 2) Bulb brightness and wattage/Quantity Tail/brake light Flasher light Pilot lights: Turn High beam Headlight failure Neutral Tail/brake failure Meter lights 3) Reserve lighting unit Model/Manufacturer 337-l 1720/KOITO Model/Manufacturer Maximum amparage Condenser type Model/Manufacturer Flasher frequency 85 * 10 cyclelmin.
  • Page 191 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 DIVISION YAMAHA MOTOR CO., LTD.
  • Page 192 Fuel Hose Check for leakage. Retlghten as necr- Exhaust System Replace gasket(s) tf necessary. Carburetor Adjust svnchronizaf~on of carburetors. Check and ad,ust engnr+ .dle speed. Idle Speed Adjust cable free play. GENERAL MAINTENANCE/LUBRICATION Yamaha cham and cable lube or lCWV/...
  • Page 193 1 6 0 0 mil K3,OOOmil ( 2 . 5 0 0 mi) ( 5 , 0 0 0 mil Front Fork Drawn completely. Yamaha fork oil Refill to specification. Repack repack every 16,000 km (10.000 mi). Check bearings for smooth Medium weight rotation.
  • Page 194 E. Rear brake (XS650SF only) NOTE: The rear brake pedal should be so adjusted This model is available in two types, tubeless that it has a free play of 13 - 15 mm (0.51 tire and tube-type tires. Before servicing tires, please note the following instructions.
  • Page 195 2. Before operation, always check the tire Tightening torque: surfaces for wear and/or damage; for 1.5 m-kg (1.1 ft-lb) example: cracks, glass, nails, metal fragments, stones, etc. Correct any such Aluminium wheels hazard before riding. If a tire tread Always inspect the aluminium wheels shows crosswise lines, it means that the tire is worn to its limit.
  • Page 196 deflection is approximately 20 - 30 mm (0.8 - 1.2 in). If the deflection exceeds 20 - 30 mm (0.8 - 1.2 in) adjust the chain tension. Tension adjustment Loosen the rear brake adjusting nut (XS650-2F only). Remove the cotter pin of the rear wheel axle nut with pliers.
  • Page 197 6. Retighten screws. Check timing again (PAGE 39 - 40) for right cylinder. 5-1. FRONT WHEEL 7. Repeat procedure (steps 2 - 6) for left C. Front wheel inspection (XS650SF only) cylinder. 1. Check for cracks, bends, or warpage of wheels.
  • Page 198 (PAGE 40 - 44) 5-3. BRAKES 8 0 m m (3.15 anl Except for the following, the same procedure as for the XS650E front brake can be perform- ed for the disassembly, inspection,and assem- bly of the XS650SF (front and rear brake) and the XS650-2F (front brake).
  • Page 199 (PAGE 50 - 51) NOTE: 6-1. STARTER This model has been equipped with a safety A. Armature relay so that the headlight comes on auto- Check the outer surface of the com- matically when the engine is started and the mutator.
  • Page 201 (PAGE 61 - 62) settings are for dry, clean threads. Torquing 7-1. TORQUE SPECIFICATION should always be done to the nut, never the bolt head. The following torque specifications muSt be 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 pitches may require differing torque.
  • Page 202 Torque Specifications...
  • Page 203 Part to be tightened Thread dia. and part name Tightening torque Handle crown and handlebar holder 8 mm bolt 1.8 m-kg (13.0 ft-lb) Under bracket and inner tube 8 mm nut 2.0 m-kg (14.5 ft-lb) Engine mounting 8 mm nut 1.6 m-kg (13.0 ft-lb) UPPer Engine mounting...
  • Page 204 1. OESCRIPTION Engine type Air cooled, 4.stroke. SOHC twin, parallel forward incline 653 cc (39.85 cu.in) 75 x 74 mm (2.953 x 2.913 in) 51 Compression ratio 61 Starting system. Kick and electric starter 7) Ignition system Battery ignition wet sump 2.
  • Page 205 5) Valve timing OPEN CLOSE DURATION OVERLAP Camshaft deflection limit 0.03 mm (0.0012 in) 7) Cam chain Number of links Sprocket ratio I . R O C K E R A R M A N D R O C K E R S H A F T Rocker arm inner diameter 2) Rocker arm shaft diameter 15.0 $:E mm (0.591 I~:~$ in)
  • Page 206 OUTER (IN/EX): 32.6 mm il.283 in) I N N E R (IN/EX): 6.0turns 9) idumber of windings 1) Crankshaft deflection limit 0.05 mm (0.002 in1 0.15 - 0.4 mm (0.0059 - 0.0157 in) 2) Con-rod large end clearance 66 $2 mm (2.598 I$% ini 186 j3 mm (7.323 _E,,,2 in) 26 $2: mm (1.024 Ii:% in) 26 _o,oo6 x 65 ‘;I;...
  • Page 207 3) Bearing type: Main axle (Left1 Needle bearing (@20~@30-201 Needle bearing (020.$30-161 4) Oil seal type Drive axle (Left1 SDD-40-62-9 5) Secondary reduction ratio and method 34117 ~2.0OOllChain Cam drum, return type 17. KICK STARTER Bendix type 2) Oil seal type (Kick axle) 3) Kick clip friction tension 1.2 - 1.7 kg (2.6 - 3.7 lb) 1) Air cleaner: Type/Quantity...
  • Page 208 41 Front fork travel 150 mm (5.906 in) 35 mm (1.376 in) 169 cc 15.72 oz) each leg Yamaha fork oil 1OWt or equivalent 7) Distance from the top of inner tube oil level without spring 4. REAR SUSPENSION Swing arm Oil damper.
  • Page 209 11.0 lit 12.9 US gall Capacity Regular gasoline 2) Fuel grade *Cast wheel **Spoke wheel 2) Tire size 31 Tire pressure: Front: 1.6 kg/cm’ (22 psi) Up to 90 kg (198 lb) load Rear: 2.0 kg/cm* (28 psi) Front: 2.0 kg/cm2 (28 psi1 90 kg (198 lblload - 204 kg (445 lblload Rear: 2.3 kg/cm2 (32 psi) (Maximum load)
  • Page 210 Drum brake (Leading trailing) Link rod Actuating method Brake drum I.D. 180 mm (7.09 in) Brake shoe dia. x width 180 x 30 mm (7.09 x 1.18 in) 4 mm12 mm IO.16 into.08 in) Lining thickness/wear limit Shoe spring free length 68 mm (2.68 in1 D.
  • Page 211 3. STARTER Bendix type Manufacturer HITACHI Model output 0.5 kw Armature coil resistance Field coil resistance Brush size/Ouantitv 16 mm (0.63 inIl2 Wear limit 4 mm (0.16 in) Spring pressure 800 g (28.2 011 Commutator O.D.lWear limit 33 mm (1.30 in)/31 mm 11.22 in) Mica undercut 0.7 mm 10.028 in) Manufacturer...

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