XS650E

INDEX
GENERAL
INFORMATION

PERIODIC INSPECTION
AND ADJUSTMENT

ENGINE OVERHAUL

CARBURETION

CHASSIS

ELECTRICAL
I
APPENDICES
XS650SE SUPPLEMENT

(EPA)
XS650E SUPPLEMENT

*XS650SF USES THIS SUPPLEMENT (EPA)

XS650SE SUPPLEMENT
I
XS650SF/2F SUPPLEMENT

XS650G/SG SUPPLEMENT
 CHAPTER 1. GENERAL INFORMATION

l-l. MACHINE IDENTIFICATION . . . . . . . . . . . . . . . a . . . . . . . . . . . . . . . . . . . . . . . . . . .1

l-2. SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
 CHAPTER 1. GENERAL INFORMATION

l-l. MACHINE IDENTIFICATION .

Frame serial number
The frame serial number is stamped on the right side of the steering head stock.

Engine serial number

The engine serial number is stamped on the front of the engine crank case.

NOTE:
The first three digits of these numbers are for model identifications; the remaining digits are the
unit production number.

1-2. SPECIAL TOOLS

, J

1. Cam chain cutter 2. Valve spring compressor 3. Valve guide reamer

Parts No. (90890-01112) (90890-01253) (90890-01211)

4. Valve seat cutter set 5. Piston ring compressors 6. Piston support plate
(90890-01179) (90890-01066) (90890-01067)
I
7. Rotor puller
(90890-01070)
P
8. Clutch holding tool
(90890-01069)
9. Slide hammer
(90890~;z)

10. Drive chain cutter 11. Pocket tester 12. E lectro tester
(90890-01081) (90890-03096) (9089@0302 1)

OTHER TOOL PARTS No.

Valve guide remover 90890-01200
Valve guide installer 90890-01201
Spoke wrench 90890-05087
Steering nut wrench 90890-01051
Tappet adjuster wrench .256-28137-00

13. Vacuum gauge

(90890-03094)

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 CHAPTER 2.
PERIODIC INSPECTION AND ADJUSTMENT
2-1. INTRODUCTION .....................................................
2-2. MAINTENANCE INTERVAL CHARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
A. PEPIODIC MAINTENANCE ..........................................4
B. LUBRICATION INTERVALS .... ............................... .... 5
2-3. ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . 6
A. Carburetor.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
B. Air filten . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
C. Engine/Transmission oil and filter ......................................7
D. Clutch adjustment ..................................................6
E. Cam chain adjustment .............................................. .8
F. Valve clearance adjustment ...........................................8
G. Crankcase ventilation system ..........................................9
H. Exhaust system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
2-4. CHASSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
A. Fuel petcock cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 9
B. Fuel petcock disassembly .............................................9
C. Fuel hose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
D. Front brake ......................................................10
E. Rear brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..lO
F. Wheels and tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
G. Drivechain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
H. Front fork oil change .............................................. .12
I. Steering head .....................................................12
J. Lubrication of cables, pivots, etc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .....I3
2-5. ELECTRICAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ... . . . . . . . . . . . . . . . . . . 13
A. Contact breaker point adjustment .....................................13
B. Contact breaker point maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
C. lgnition timing.............................................................. 14
D. Carbon brushes................................................................ 14
E. Battery.................................................................... 14
F. Sparkplug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..... 15
G. Headlight.................................................................. 15

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 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. Any service technician performing
preparation work should be familiar with this entire chapter.

2-2. MAINTENANCE INTERVALS CHARTS

The following charts should be considered strictly as a guide to general maintenance and lubrication intervals.
You must take into consideration that weather, terrain, geographical location, and a variety of individual uses
all tend to alter this time schedule. For example, if the motorcycle is continually operated in an area of high
humidity, then all parts must be lubricated much more frequently than shown on the chart to avoid damage
caused by water to metal parts,

A.PERIODIC MAINTENANCE
Periodic inspection, adjustment and lubri- and most efficient condition. Safety is an ob-
cation will keep your motorcycle in the safest ligation of the motorcycle owner.

Unit: km (mi
initial Thereafter every
Item Remarks 400 800 1,600 3,200 1,600 3,200 6,400
( 2 5 0 ) (500) ( 1 , 0 0 0 ) (2.000) (1,000) (2.000) ( 4 , 0 0 0 )

Cylinder 1 Check compression I ! IOI I lo

Valves 1 Check/Adjust valve clearance I I 0101 I lo
Cam chain ( Check/Adjust chain tension I lo I I I I lo
Spark pluqs I inspect/Clean or replace as required loI : lo 1 IO I
Air filter / Dry type - Clean/Replace as required 1
I
: ‘0 I I 0 ; I
Carburetor | Check operation/Adjust as required I i 0 ’ 0 10 ~
Brake system Check/Adjust as required - Repair as
i 0 0
(complete) required

/Adjust free play I io I I 0 I I 0 I

Wheel and tires Check pressure/Wear/Balance 0 ~ 0 0 ; I 0 I
Fuel petcocks Clean/Flush tank as required 0 0 ~ I 0 I

~1 0 0 1,o i 0
Top-up/Check specific gravity and
Battery
breather pipe 0

Ignition timing | Adjust/Clean or replace parts as required 1 io o/oj IO I

Lights/Signals / Check operation/Replace as required / 0 ! 0 0 /o/o I
Fittings/Fasteners | Tighten before each trip and/or lo lo~o/olo/
Generator brushes | Check brush wear/Replace if necessary 1 I ~ I I I lo
6. LUBRICATION INTERVALS
, a_:._ Y- ,-

mission oil

Drive chain

Control/Meter
Apply thoroughly

Oil filter element

Do not over/ Medium-weight 12,800

Wheel bearings
Yearly or . . . wheel bearing grease (8.000)
Point cam lubri- Light-weight
cation wicks
Apply very lightly machine oil 0 0 0 0

-5
2-3. ENGINE b. Install the attachment and set the vacuum
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. No attempt
throttle opening.
should be made to change this adjustment
d. Adjust damping valve on each vacuum
by the dealer.
gauge until the needle flutters only
slightly. The gauge needles must respond
quickly to rapid opening of the throttle.
e. Both gauge will indicate the same reading
if the carburetors are synchronized.
f. Turn the synchronizing screw until the
gauge readings are the same.

1. Do not adjust
2. Throttle
Turn the throttle grip to see if it operates
properly and if the play is normal. Make
certain the throttle snaps closed when
released.
1. Synchronizing screw

g. After adjustment, firmly tighten the plug

screws.
NOTE:
Check gasket. Replace if damaged.

4. Idle speed adjustment.

NOTE:
1. 5 - 8 mm (0.2 - 0.3 in) Carburetors must be synchronized before
3. Synchronization setting final idle speed.
NOTE:
Ignition timing and valve clearances must a. Start the engine and warm it up for a few
be set properly before synchronizing minutes.
carburetors. b. Set the engine idle speed to specified rpm
by turning the throttle stop screw in to
Procedure:
increase the engine speed and back off the
a. Turn fuel petcocks to “PRIME”, and
screw to decrease the engine speed.
remove the plug screws for the adapter
Use a tachometer for checking and adjust-
attachment holes in the carburetor body.
ing the engine speed.
I Standard idle rpm:
1,200 rpm I

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 mi.). It should be cleaned more often if
the machine is operated in extremely
dusty areas.

1 .Throttle nap se- 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. Stop the engine.
element which consists of foam rubber.
With the engine stopped, screw the dip
1. Removal
stick completely out and then rest the
a. Remove the air filter cover by removing
stick in the hole.
the bolts.
b. Pull out the springs and elements.

1. Oil leuel dip stick

NOTE:
When checking engine oil level with the
2. Cleaning method
dip stick, position the machine straight up
a. Tap the element lightly to remove most of
and on main stand.
the dust and dirt; then blow out the re-
maining dirt with compressed air through b. The dip stick has a minimum and a maxi-
the inner surface of the element. If mum mark. The oil level should be
element is damaged, replace. between the two. If the level is low, add
sufficient oil to raise it to the proper level.
2. Oil replacement and filter cleaning
a. Start the engine. Allow it to warm up for
2-3 minutes. Stop the engine.
b. Place an oil pan under the engine.
c. Remove the drain plugs and drain the oil.

b. Reassemble by reversing the removal pro-

cedure. Check whether the element is
seated completely against the case.
c. The air filter element should be cleaned
once a month or every 1,600 km(l,000
1. drain plugs
-7
 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.

HA
c. Back the adjuster out l/4 turn and
tihgten the lock nut.
d. Adjust the free play of clutch lever by
turning the cable adjuster.

1. Filter securing bolt.

e. Slip the filter element out and clean.

f. Install the filter and filter cover.
/ Filter torque:
I 1.0 m-ko f7 f&lb)
g. Reinstall the drain plugs. (Make sure it is
tight.) c
1, Adjuster 2. Lock nut
Drain plug torque: E. Cam chain adjustment
/ 4.4 m-kg (32 ft-lb) The cam chain becomes stretched with use,
h. Add oil through the dip stick hole. resulting in improper valve timing and engine
r noise. To prevent this the cam chain ten-
Oil quantity:
sioner must be adjusted regularly.
2.0 lit (2.1 qt): periodic oil change
2.5 lit (2.6 qt): engine overhauling
Recommended oil:

I Yamalube 4-cycle oil or SAE

20W/40 type “SE” motor oil

D. Clutch adjustment
This model has a clutch cable length adjuster
and a clutch mechanism adjuster. Normally,
once the mechanism is properly adjusted, the
only adjustment required is maintenance of
free play at the clutch handle lever. Remove the cap nut.
1. Free play adjustment Turn the adjuster bolt in until the push
Loosen the handle lever adjuster lock nut. rod (inside the adjuster bolt) is flush with
Next, turn the length adjuster either in or the end of the adjuster bolt.
out until proper lever free play is achieved. NOTE:
The push rod will not come out beyond a
certain limit even if the adjuster bolt con-
tinues to be screwed in.

Reinstall the cap nut.

Valve clearance adjustment

NOTE:
Valve clearance must be measured with
1 . 2-3mm (0.08-0.12inl
the engine at room temperature.
2. Lock nut
3. Adjuster
1. Remove all four tappet covers and the H. Exhaust system
generator cover. 1. Check for leakage from exhaust joints and
2. Turn the crankshaft to align the rotor retighten joint bolts and nuts.
mark with the “T” mark on the stator. 2. Replace gaskets if necessary.
3. This places the pistons at the top dead
center and the valve clearance should be 2-4. CHASSIS
checked and adjusted at the top dead A. Fuel petcock cleaning
center on the compression stroke by 1. Turn the petcock lever to the “ON” or
observing when the valve adjusters have “RES” position. Remove the fuel pipe.
clearance. 2. Remove the drain cover and clean it with
4. Use a feeler gauge to determine the solvent.
clearance.

Exhaust valve clearance (cold):

Intake valve clearance (cold):

1 “RES” position
2. Drain cover

B. Fuel petcock disassembly

If the fuel petcock is leaking or excessively
contaminated, it should be removed from the
fuel tank and inspected.
1. Remove fuel tank and position it so that
5. Loosen the valve adjuster lock nut. Turn fuel will not spill when the petcock is
the adjuster in or out to obtain the removed.
correct clearance. Hold the adjuster to 2. Remove petcock and inspect filter screen.
prevent it from moving and throughly Clean or replace filter if seriously con-
tighten the lock nut. taminated.
6. Recheck the clearance after tightening. 3. Remove screws on front and rear of pet-
cock and remove plate, gaskets, lever and
G. Crankcase ventilation system diaphragm.
1. Check ventilation hose for cracks or 4. Inspect all components and replace any
damage. that are damaged. If the diaphragm is in
2. Replace it if necessary. any way damaged, or the petcock body
gasket surfaces scratched or corroded, the
petcock assembly must be replaced. If
there is abrasive damage to any com-
ponent, the fuel tank must be drained and
flushed.
5. Reassemble petcock and install on fuel
tank.

C. Fuel hose
1. Check fuel hose for cracks or damage.
1, Ventilation hose 2. Replace it if necessary.
2. Fuel pipe

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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. (The piston in the caliper moves for- poor performance.
ward as the brake pad wears out, automati- Be careful that water or other contamina-
cally adjusting the clearance between the tion does not enter the master cylinder
brake pad and the brake disc.) when refilling. Water will significantly
1. Adjustment lower the boiling point and may result in
a. Turn adjuster so that a brake lever end is vapor lock.
5 - 8 mm (0.2 - 0.3 in) before adjuster
contacts master cylinder piston. E. Rear brake
1. Adjust rear brake pedal play to suit, pro-
viding a minimum of 20 - 30 mm (0.8 -
1.2 in) freeplay. Turn the adjuster on the
rear brake rod in or out until brake pedal
free play is suitable.
NOTE:
Rear brake pedal adjustment must be
checked anytime chain is adjusted or rear
wheel is removed and then reinstalled.
1 . 5-8mmI0.2-0.3inl
2. Lock nut
3. Adjuster

2. Brake pad check

1. Adjuster

F. Wheels and tires

1. Wheels
1, Indicator cap a. Check each spoke for tightness.
To check, open the wear indicator cap
NOTE:
and if any pad is worn to the red line, re-
If loose spokes are found, tighten and
place pads.
repeat rim runout check.
3. Check the brake fluid level
Insufficient brake fluid may allow air to 2. Tires
enter the brake system, possibly causing a. Important notice
the brake to become ineffective. Check Proper loading of XS650E is important
the brake fluid level and replenish when for the handling, braking, and other
necessary and observe these precautions: performance and safety characteristics.
a. Use only the designated quality brake NEVER OVERLOAD THE M O T O R -
fluid; otherwise, the rubber seals may de- CYCLE.
teriorate, causing leakage and poor brake
WARNING: Never overload the motor-
performance.
cycle beyond specified tire limits. Opera-
Recommended brake fluid:
DOT No. 3 Brake fluid
 FRONT REAR
XS650E BASIC
WEIGHT with oil 104 kg@29 lb) 119 kg1262 lb)
md full fuel tank

Bridgestone or Bridgestone or
Standard tire Yokohama Yokohama
3.50H19-4PR 4.OOHlB-lPR

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’ 2.0 kg/cm2
(22 psi) (28 psi) 2. Tension adjustment
With passenger 2.0 kg/cm2 2.3 kg/cm’ a. Loosen the rear brake adjuster.
or high speed (28 psi) (32 psi) b. Remove the cotter pin of the rear wheel
riding
2.8 kg/cm2 axle nut.
With passenger 2.8 kg/cm2
(40 psi) (40 psi) c. Loosen the rear wheel axle nut.
$$xtra load
d. Loosen the adjuster lock nuts on each
Vlinimum tire 0.8 mm 0.8 mm side.
:read depth (0.03 in) (0.03 in)
e. To tighten chain turn chain puller ad-
juster clockwise.
Make sure the total weight of the motorcycle with Turn each bolt exactly the same amount
accessories, rider(s) etc., does not exceed the tire
to maintain correct axle alignment.
limits.
There are marks on each side of rear arm
b. Check the tire wear and on each chain puller; use them to
If a tire tread shows cross wise lines, it check for proper alignment.
means that the tire is worn to its limit.
Replace the tire.

1. Alignment marks
2. Rear axle nut
3. Adjuster
c. Check the wheel damage and check the 4. Lock nut
tightness of spokes. 5. Cotter pin

G. Drive chain f. After adjusting be sure to tighten the lock

1. Tension check nuts and the rear wheel axle nut.
a. Inspect the drive chain with mainstand g. Install a new cotter pin and bend the end
erected. Check the tension at the position over.
shown in the illustration. The normal ver- h. In the final step, adjust the play in the
tical deflection is approximately 20 mm brake pedal and stoplight switch free play.
(3/4 in). 3. Lubrication
a. First, remove dirt and mud from the chain
with a brush or cloth and then spray the
lubricant between both rows of side plates
and on all center rollers.

-,I -
 b. To clean the entire chain, first remove 7. Install drain screw.
the chain from the motorcycle, dip it in NOTE:
solvent and clean with stiff brush. Then
Check gasket. Replace if damaged.
take the chain out of the solvent and dry
it. Immediately, lubricate the chain to 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 I

Front fork oil capacity:

164 - 172 cc (5.54 - 5.82 oz)
H. Front fork oil change each side
1. Raise the front wheel off the floor with a 9. After filling, slowly pump the outer tubes
suitable frame stand. up and down to distribute the oil.
2. Loosen the fork pinch bolts. 10. Inspect O-ring on fork cap bolts and re-
3. Remove the rubber cap from the top of place if damaged.
each fork.

6
1. O-ring
1. Pinch bolt 2. CSP
4. Loosen the cap bolt (adjuster unit). 11. Install fork cap bolts.
5. Remove drain screw from each outer tube 12. Tighten pinch bolts.
with open container under each drain hole.

I Tightening torque:

Fork cap bolt

m-kg
5.0
ft-lb
36
I

Pinch bolt 1.0 7

I. Steering head
1. adjustment
The steering assembly should be checked
periodically for looseness.
1. Dr
ean
iS
cr
ew Do this as follows:
rCAUTION: a. Raise front end of machine so that there
Do not allow oil to contact disc brake is no weight on the front wheel.
components. b. Grasp bottom of forks and gently rock
fork assembly backward and forward,
6. After most oil has drained, slowly raise
checking for looseness in the steering
and lower outer tubes to pump out re
assembly bearings.
maining oil.

- I2 -
 the end of the cable can be held high to
pour in several drops of lubricant. With
throttle grip disassembled, coat the inside
surface of the throttle grip guide tube
with a suitable all-purpose grease to cut
down friction.
2. Meter cables
Pull the inner cable out and apply cable
lube throughly.

c. If there is looseness in the steering head,

loosen the crown pinch bolt, fork pinch
bolts, and steering fitting bolt.

3. Rear arm pivot shaft

Apply grease to grease nipple on top of
pivot with low pressure hand operated
gun. Apply until fresh grease appears at
both ends of pivot shaft.

Recommended lube:
Medium-weight wheel bearing grease
1. Crown pinch bolt
2. Fork pinch bolt 4. Brake and change pedal shafts, and center
3. Steering fitting bolt
and side stand pivots Lubricate the shafts
d. Use steering nut wrench to loosen top and pivots with Yamaha chain and cable
steering fitting nut. The top nut serves as lube or SAE l0W/30 motor oil.
a lock nut. 5. Wheel bearings
e. Tighten the lower steering fitting nut until Refer to PAGE 39.
the steering head is tight, but does not
2-5. ELECTRICAL
bind when forks are turned.
f. Retighten the top steering fitting bolt, A. Contact breaker point adjustment
crown pinch bolts and fork pinch bolts, in 1. Remove breaker point cover.
that order. 2. Check contact breaker point gap (at
largest gap) with clean feeler gauge.
g. Recheck steering adjustment to make sure
there is no binding when the forks are
moved from lock to lock. If necessary, Contact breaker gap:
repeat adjustment procedure. 0.3 - 0.4 mm (0.012 - 0.016 in)
2. Lubrication
Refer to PAGE 47. If necessary, adjust by loosening securing
screws and moving the adjustable contact
J. Lubrication of cables, pivots, etc. point.
1. Throttle cable and grip 3. Tighten adjusting screws and recheck
The throttle twist grip assembly should be breaker point gap.
greased at the time that the cable is lubri-
cated since the grip must be removed to B. Contact breaker point maintenance
get at the end of the throttle cable. Two 1. The contact breaker should be checked
screws clamp the throttle housing to the for the following:
handlebar. Once these two are removed, a. Wear of the bakelite cam heel
b. Damage of contact point surfaces
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 c. Rust or wear on the breaker arm or arm 2. 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. 3. Start engine.
e Oil or dirt on the assembly. 4. The mark stamped on the rotor_ should
2. To clean the points, run a point file be- line up with the stationary “F” timing
tween the points until the grey deposits mark. If it does not align, loosen two
and pits have been removed. Spray the breaker backing plate screws and move
points with ignition point cleaner or the complete backing plate until the mark
lacquer thinner, then snap the points shut on the rotor and the “F” mark align.
on a white business card (or paper of hard 5. Retighten screws. Check timing again for
texture) and repeatedly pull the card the right-hand cylinder.
through until no more carbon or metal 6. Rev the engine to above 3,500 rpm.
particles come off on the card. (The card Check whether the mark on the rotor is in
may be dipped in lacquer thinner or other the vicinity of the stationary “full ad-
cleaner to facilitate this procedure.) vance” mark.
3. Point replacement should be necessary 7. Repeat procedure (steps 2-6) for another
when the points become severely pitted, if cylinder.
the heel is broken or worn unevenly, or if
the points become shorted or show faulty
operation.

NOTE:
New points must be cleaned and adjusted.

4. Add a few drops of light-weight machine

oil onto the felt rubbing pad after each
point adjustment to lubricate the point
cam surface. Do not over oil. 1. Rlghf cylinder timing adfustment
2. Left cylinder timmg adjustment

C. Ignition timing
D. Carbon brushes
NOTE:
Visually inspect the carbon brush holder
Point gap must be set before setting timing.
brushes for obvious breakage or wear.
Standard brush length is 14.5 mm(0.571 in).
1. Ignition timing is checked with a timing
Wear limit is 7.0 mm (0.276 in) and
light by observing the position of the
marked there.
stationary marks stamped on the stator
and the pointer on the generator.
E. Battery
A poorly maintained battery will deteriorate
quickly. The battery fluid should be checked
at least once a month.
1. The level should be between the upper
and lower level marks. Use only distilled
water for refilling. Normal tap water con-
tains minerals which are harmful to a
battery; therefore, refill only with dis-
tilled water.
1. Top dead center 2. Always make sure the connections are
2 . 15’ BT0C11.200 rpm
correct when installing the battery. The
3. Advanced mark
magnet relay lead is for the (+) terminal
_ 14 -
 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
damaged or obstructed. Standard spark plug:
Champion N-7Y or NGK BP 7ES
NOTE:
Tightening torque:
The battery must be charged before using
2.0 m-kg (14 ft-lb)
to insure maximum performance. Failure
to properly charge the battery before first
G. Headlight
use, or a low electrolyte level, will cause
1. Headlight beam adjustment.
premature failure of the battery.
When necessary, adjust the headlight
beam as follows:
Charging current: 1.4 Amp
a. Adjust horizontally by tightening or
Charging hours: 10 hrs
loosening the adjust screw.
To adjust to the right:
F. Spark plug
Tighten the screw
The spark plug indicates how the engine is
To adjust to the left:
operating. If the engine is operating correctly,
Loosen the screw
and the machine is being ridden properly, the
tip of the white insulator around the positive b. Adjust vertically as follows:
electrode of the spark plug will be a medium 1) Loosen adjusting screw and adjust ver-
tan color. If the insulator is very dark brown tically by moving the headlight body.
1. If the insulator is very dark brown or 2) Retighten the screw.
black color, then a plug with a hotter heat
range might be required. This situation is
quite common during the engine break-in
period.
2. If the insulator tip shows a very light tan
or white color or is actually pure white
and glazed, or if electrodes show signs of
melting, then a spark plug with a colder
heat range is required. Remember, the
insulator area surrounding the positive
1. Vertical adjustment
electrode of the spark plug must be a 2. Horizontal adjustment
medium tan color. If it is not, check
carburetion, timing and ignition adjust- 2. Replacing the headlight bulb.
ments.
3. The spark plug must be removed and
checked. Check electrode wear, insulator
color, and electrode gap.
Spark plug gap:
_-_._
0.7 - 0.8 mm (0.028 - 0.031 in) _ --

Engine heat and combustion chamber de-

posits will cause any spark plug to slowly
break down and erode. If the electrodes
finally become too worn, or if for any reason a. Loosen bolts and replace bulb.
you believe the spark plug is not functioning b. After installing, adjust headlight beam.
correctly, replace it. When installing the plug, NOTE:
always clean the gasket surface, use a new Take care not to damage the headlight. It
gasket, wipe off any grime that might be pre- is very fragile.
- 15 -
 CHAPTER 3. ENGINE OVERHAUL

3-1. ENGINE REMOVAL ........................................ .... .18

A. Preparation for removal ................................... . . . . .18
B. Fuel tank removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18
C. Removal of other parts. ................................... . . . . .I8
D. Engine mounting bolts and engine removal .................... . . . . .18
3-2. ENGINE DISASSEMBLY .................................... ..... .19
A. Governor and breaker assembly removal ........ . . . . . . . . . . . . . . . . . . . . . 19
B. Cylinder head and cylinder removal ............ . . . . . . . . . . . . . . . . . . . . . 19
C. Rocker arm removal ........................ . . . . . . . . . . . . . . . . . . . . . 19
D. Valve removal ............................. . . . . . . . . . . . . . . . . . . . . . 19
E. Piston removal ............................ . . . . . . . . . . . . . . . . . . . . . 19
F. Generator removal ......................... . . . . . . . . . . . . . . . . . . . . . 19
G. Primary drive gear and clutch assembly removal ... . . . . . . . . . . . . . . . . . . . . . 19
H. Kick axle and change shaft removal ............ . . . . . . . . . . . . . . . . . . . . .20
I. Electric starter unit removal .................. . . . . . . . . . . . . . . . . . . . . . 20
J. Oil pump removal. ......................... . . . . . . . . . . . . . . . . . . . . . 20
K. Crankcase disassembly ...................... ..................... 20
L. Transmission illustration .................... . . . . . . . . . . . . . . . . . . . . . 21
M. Shift drum removal ........................ . . . . . . . . . . . . . . . . . . . . . 21
N. Crank shaft removal ........................ . . . . . . . . . . . . . . . . . . . . . 22
3-3. INSPECTION AND REPAIR
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22
A. Cyinder head cover. ............................................... .22
B. Cylinderhead.....................................................22
C. Valve, valve guide and valve seat. ......................................23
D. Valvespring.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..2 4
E. Rocker arm and rocker shaft ........................................ .25
F. Cam shaft wear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..2 5
G. Cam chain, sprocket and dampers .....................................26
H. Cylinder.........................................................2 6
I. Piston and rings .................................................. .26
J. Pistonpin........................................................27
K. Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..2 7
L. Oil pump
p ...................................................... ..2 7
M. Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..2 8
N. Transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..2 8
0 . Electric starter gears and clip spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29
P. Kickstarter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..2 9
Q. Crankcase and oil passages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29
R. Bearings and oil seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
3-4. ENGINE ASSEMBLY AND ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29
A. Shift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29
B. Transmission and crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29
C. Shifter assembly ................................................ . .30
D. Kick starter assembly ............................................ . .30
E. Electric-starter gear assembly ...................................... . .30
F. Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . -30
G. Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32
H. Oil pumpp ..................................................... . .32
I. Right-hand crankcase cover ....................................... . .32
J. Piston . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32
K. Cylinder and cylinder head. ....................................... . .32
L. Camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32
M. Cylinder head cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . * -33
N. Governor and breaker assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . * *33
0. Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33
 CHAPTER 3.
ENGINE OVERHAUL
31. ENGINE REMOVAL
A. Preparation for removal
1. All dirt, mud, dust and foreign material
should be thoroughly removed from the
exterior of the engine before removal and
disassembly.
2. Place machine on center stand. Star-f
engine and allow it to warm up. Stop
engine and drain engine/transmission oil.

8. Carburetor (to the left), and throttle cable

9. Brake pedal
10. All wires and cables connecting engine
and chassis
11. Top center engine mounting brackets
(Remove only four bolts for easier re-
assembly)

B. Fuel tank removal

1. Turn fuel petcocks to “on” (there is no
“off” position - fuel will not flow from a
petcock on the “on” position unless the
engine is operating). Disconnect fuel pipes
and vacuum pipes from petcock.
T ..--
2. Lift seat and remove fuel tank holding
bolt. Remove fuel tank. 12. Drive chain (with special tool)

D. Engine mounting bolts and engine removal

C. Removal of other parts 1. Remove mounting bolts in the order as
Remove the following parts in the order given.
1. Exhaust pipes
2. Horn (as a unit)
3. Both side footrests
4. Change pedal and drive chain guide
5. Left-hand crank case cover and clutch
cable.
6. Side covers
7. Air cleaner assembly and ventilation
hoses.

2. Remove the engine to the right.

 3-2 ENGINE DISASSEMBLY C. Rocker arm removal
A. Governor and breaker assembly removal 1. Remove rocker shaft covers.
Remove the following parts in the order 2. Remove shouldered sleeves and O-rings.
given. 3. Withdraw rocker shafts with the special
1. Breaker cover tool or 6 mm bolt.
2. Breaker backing plate
D. Valve removal
3. Breaker housing
4. Governor cover 1. Compress the valve spring and then re-
move both retainer locks.
5. Notched plate
6. Lock nut (using punch and hammer) Remove the compressor and lift off the
7. Governor assembly retainer and springs.
2. Remove valve stem seals.
3. Remove valves.
NOTE:
Deburr any deformed valve stem end. Use
an oil stone to smooth the stem end. This
will help prevent damage to the valve
guide during valve removal.

E. Piston removal
Remove piston pin clips, piston pins and
pistons.
8. Breaker shaft (to the point side)
9. Dowel pin
F. Generator removal
10. Advance unit housing
1. Remove the stator.
B. Cylinder head and cylinder removal 2. Remove the securing nut and lock washer.
1. Remove the oil delivery and pipe fitting 3. Mount the rotor puller (special tool) onto
attached to the crankcase. Note place
the rotor and pull the rotor off.
ment of copper gaskets.
2. Remove all tappet covers.
3. Remove spark plugs.
4. Remove four cylinder head cover holding
bolts, three cylinder head holding bolts
and eight cylinder head holding nuts.
5. Remove the head cover. It may be nec-
essary to tap each lightly with a soft
hammer.
6. Remove the camshaft as follows.
i .’ ~eca9coio7oj
a. Remove tensioner adjusting bolt to make
the chain tension loose. G. Primary drive gear and clutch assembly re-
b. Push out the master link pins with the moval
cam chain cutter. 1. Remove the crankcase cover (right).
c. Tie each end of the camchain with a wire 2. Loosen the drive gear securing nut by first
to prevent it from falling into the crank- placing a rag folded into many layers be-
case. tween the teeth of gears to lock them.
7. Remove the cylinder head and cylinder. 3. Remove six clutch spring screws and pre-
NOTE: ssure plate.
It is advisable to remove the stator and 4. Remove clutch plates, friction plates,
rotor after finding the place of the master push crown, two push rods and two balls.
link pins. Refer to item “F. Generator
-19-
removal.”
 I. Electric starter unit removal
1. Remove the gear train cover, and idle gear
1 and 2.

1. Push rod
2. Ball
3. Push rod (Aluminuml
4. Push crown

5. Hold the clutch unit with the holding tool

1. Kick axle 4. Kick gear 7. Spacer 10. Washer
(special tool), and unscrew the clutch boss 2. Holder 5. Kickclip 8. Kickspring 11. Circlip
lock nut. 3. Clip 6. Shim 9. Spring wide

2. Remove the four mounting bolts and

H. Kick axle and change shaft removal motor.
1. Slip the bent sprin
g off and pull the kick 3. Remove the panhead screw (10), gear 2
axle assembly out. (6). shaft 2 (5), and gear 1 (4).
2. Remove circlip from left side of change 4. Remove the circlip (11), and gear as-
shaft and pull the shaft out. sembly (7) (8) (9).
5. Starter gears illustration

D 2. 1. Absorber Idlegear 1 6. 7. Gear Starter 3 wheel

3. ldlegear 2 9. Gear 4
T g 4. Gear 1 10. Panhead screw
5. Shaft 2 11. Circlip
T Y 3 6. Gear 2

J. Oil pump removal K.Crankcase disassembly

1. Remove the tachometer drive gear, oil 1. Loosen all case securing bolts and nuts
pump driven gear, and key. l/4 turn at a time to avoid case warpage,
2. Remove the three Phillips screws. and remove them.
3. Remove the pump unit. 2. Use a soft rubber hammer to carefully
separate the crankcases.

- 20 -
L. Transmission illustration

1. Main axle (13T) 1’ 1st wheel gear (32T) Transmission

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)
5. 5th pinion gear (23T) 5’ 5th wheel gear (22T)
6. Drive sprocket (17T)

M. Shift drum removal

1. Bolt 11. Shiftfork (1)

2. Lock plate 12. Pin
3. stopper Plate 13. Cotter pin
4. Shaft bolt 14. Guide bar
5. stopper 15. Cam stopper
6. Stopper spring 16. Stopper spring
7. Shift cam 17. Gasket
8. Bearing 18. Stopper bolt
9. Shift fork (3)
10. Shift fork (2)
1 . Release the stopper spring (6). 4. Remove the neutral detent unit (15-18).
2. Remove the bolts (1) and stopper plate(3). 5. Removecotter pins (13). and pin (12)
3. Pull the guide bar (14) out. 6. Pull out the shift cam (7).

N. Crankshaft removal
1. Tap the crankshaft with a rubber hammer
to loosen it, then lift it out.
2. Crankshaft illustration

1 . Crank 1(L) 14. Cam chain sprocket

2. Crank 2(R) 15. Journal bearing 2
3. Crank 2(L) 16. Circlip
4 . Crank 2 ( R ) 17. Primary drive gear
5. Woodruff key 18. Plate washer
6 . Connecting rod 19. Drive gear
7. Big end bearing 20. Dowel pin
8. Crank pin washer 21. Oil seal
9, 10 Crank pin 22. Spring washer
11. Crankshim 23. Nut
12. Journal bearing 1 2 4 . Key
25. Dowel pin

3-3. INSPECTION AND REPAIR 3. Using a rounded scraper, remove carbon

A.Cylinder head cover deposits from combustion chamber. Take
Place head cover on a surface plate. There care t o avoid damaging spark plug threads
and valve seats. Do not use a sharp
should be no warpage. Correct by re-surfacing
instrument. Avoid scratching the alumi-
as follows:
num.
Place #400 or #600 grit wet sandpaper on
4. Place on a surface plate. There should be
surface plate and re-surface head cover using
no warpage. Correct b y re-surfacing as
a figure-eight sanding pattern. Rotate head
follows:
cover several times t o avoid removing too
Place #400 or #600 grit wet sandpaper
much material from one side.
on surface plate and re-surface head using
a figure-eight sanding pattern. Rotate
B. Cylinder head
head several times t o avoid removing too
1. Remove spark plugs.
much material from one side.
2. Remove valves.

22
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.
yond serviceable limits, replace with an e, After installing the valve guide, use 8 mm
oversize valve guide. reamer (special tool) to obtain the proper
valve clearance.
Standard f. After fitting the valve guide into the
Guide diameter 1 8.010 - 8.019 mm cylinder head, be sure to grind the valve
(I.D.) (IN.EX) / (0.315 - 0.316 in) seat, and perform valve lapping. The valve
must be replaced with a new one.
b. Measuring the clearance between valve 2. Grinding the valve seat.
and valve guide. a. The valve seat is subject to severe wear
1) Insert the valve into the valve guide in similar to valve face. Whenever the valve
the cylinder head and measure the face is resurfaced, the valve seat should
clearance in both the X and Y axes, also be re-surfaced at a 45° angle. In
using a small dial gauge. addition, if a new valve guide has been
installed (without any valve repair), the
valve seat should be checked to guarantee
complete sealing between the valve face
and seat.
CAUTION :
If the valve seat is obviously pitted or 1
worn, it should be cleaned with a valve
seat cutter. Use the 45° cutter, and
when twisting the cutter, keep an even
1. Dial gauge
2 . 1 0 m m IO.4 i n )
I downward pressure to prevent chatter
L marks.
If cutting section “A” of the valve seat,
2) If the measured clearance is greater
use the 8R cutter (radius cutter). If
than 0.10 mm (0.0039 in) for the
cutting section “B”, use the 45° cutter.
inlet valve or 0.12 mm (0.0047 in) for
the exhaust valve, both the valve and
valve guide should be replaced. The
replacement valve guide should be one
that is oversize.

Valve guide oversize:

Part No. Size (0.D.)

256-l 1133-l 1 (IN) 15.1 mm (0.594 in)
256-l 1133-21 15.2 mm (0.598 in)
256-l 1134-l 1 (EX) 15.1 mm (0.594 in)
b. Measure valve seat width. Apply mecha-
256-l 1134-21 15.2 mm (0.598 in)
nic’s bluing dye (such as Dykem) to the
valve face, apply a very small amount of
c. To ease guide removal and reinstallation, fie grinding compound around the surface
and to maintain the correct interference of the valve seat, insert the valve into
fit, heat the head to 100°C. Use an oven position, and spin the valve quickly back
to avoid any possibility of head warpage and forth. Lift the valve, clean off all
due to uneven heating. grinding compound, and check valve seat

- 23
 width. The valve seat will have removed 3. Lapping the valve/valve seat assembly.
the bluing wherever it contacted the valve a. The valve/valve seat assembly should be
face. Measure the seat width with vernier lapped if (1) neither the seat nor the valve
calipers. It should measure approximately face are severely worn, or (2) if the valve
1.3 mm. Also, the seat should be uniform face and valve seat have been resurfaced
in contact area. If valve seat width varies, and now require a final light grinding
or if pits still exist, then continue to cut operation for perfect sealing.
with the 45° cutter. Remove just enough Apply a small amount of coarse lapping
material to achieve a satisfactory seat. compound to valve face. Insert the valve
into the head. Rotate the valve until the
Standard width Wear limit
valve and valve seat are evenly polished.
Clean off the coarse compound, then
I I / I
follow the same procedure with fine com-
c. If the valve seat is uniform around the pound.
perimeter of the valve face, but is too Continue lapping until the valve face
wide or not centered on the valve face, it shows a complete and smooth surface all
must be altered. Use either the 8R, 45°
the way around. Clean off the compound
or 25° cutters to correct the improper
material. Apply bluing dye to the valve
seat location in the manner described
face and rotate the valve face for full seat
below:
contact which is indicated by a shiny sur-
1) If the valve face shows that the valve face all around the valve face where the
seat is centered on the valve face, but
bluing has been rubbed away.
too wide, then lightly use both the 8R
_. Valve leakage check
and the 25° cutters to reduce the seat
After all work has been performed on the
width to 1.3 m m .
valve and valve seat, and all head parts
2) If the seat shows to be in the middle have been assembled, check for proper
of the valve face, but too narrow, use
valve/valve seat sealing by pouring solvent
the 45° cutter until the width equals
into each of the intake ports, then the
1.3 mm.
exhaust ports. There should be no leakage
3) If the seat is too narrow and right up past the seat. If fluid leaks, disassemble
near the valve margin, then first use and continue to lap with fine lapping
the 8R cutter and then the 45° cutter compound. Clean all parts thoroughly,
to get the correct seat width. reassemble and check again with solvent.
4) If the seat is too narrow and down Repeat this procedure as often as neces-
near the bottom edge of the valve sary to obtain a satisfactory seal.
face, then first use the 25° cutter and
then the 45° cutter. D. Valve spring
I I ’ I 1. Checking the valve springs
a. This engine uses two springs of different
sizes to prevent valve float or surging. The
chart below shows the basic value
characteristics.
b. Even though the spring is constructed of
durable spring steel, it gradually loses
some of it’s tension. This is evidenced by
a gradual shortening of free length. Use a
vernier caliper to measure spring free
length. If the free length of any spring has
decreased more than 2 mm (0.08 in) from
its specification, replace it.
24 ~
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. The shaft has been hardened and it should
and compress the spring first to the
not wear excessively. If a groove has
specified compressed length with the valve
developed in this surface that can be felt,
closed (all spring specifications can be
or if it shows a blue discoloration, then
found in the previous section, valve
the shaft should be replaced and the
spring), then to length with the valve
lubrication system (pump and passages)
open. Note the poundage indicated on the
checked.
scale at each setting. Use this procedure
with outer springs, then the inner spring.
Standard shaft diameter:
NOTE: 14.985 ~14.991 mm
All valve springs must be installed with (0.5900 ~ 0.5902 in)
greater pitch upward as shown.
4. Standard clearance between the rocker
shaft and hole should be 0.009 ~ 0.033
mm (0.00035 ~ 0.00130 in). If measure-
ment shows more than 0.1 mm (0.0004
in) clearance, replace either or both parts
as necessary.

F. Camshaft wear
1. The cam lobe metal surface may have a
blue discoloration due to excessive fric-
tion. The metal surface could also start to
flake off or become pitted. This is due to
1. Larger patch
poor lubrication, incorrect clearances
2. Smaller pitch
(from poor adjustment or valve bounce),
d. Valve spring specifications or due to normal wear.
2. If any of the above wear conditions are
readily visible, the camshaft should be re-
placed. Also, the corresponding rocker
arm contacting surface should be checked
for similar wear and replaced if obvious
Ivalve closed) (1.457 ml (1.378 m) wear is noted.
Compressed 53.5 - 61.5 kg 25.5 - 29.0 kg / 3. Even though the cam lobe surface appears
to be in satisfactory condition, the lobes
should be measured with a micrometer.
Cam lobe wear can occur without scarring
the surface. If this wear exceeds a pre-
determined amount, valve timing and lift
E. Rocker arm and rocker shaft. are affected. Replace the camshaft if wear
1. The rocker arm usually wears at two exceeds the limits listed below.
locations: (1) at the rocker shaft hole, (2) Cam Lift (A) Width (6)
Standard Value Wear Llmtt Standard Value Wear Llmat
at the cam lobe contacting surface.
39.99+0.05 mm 39 84 mm 32.24kO.05 mm 32.09 mm
2. Measure the rocker shaft hole in the Intake
(1.574+0.002 in1 IO.569 1n1 ‘II 269f0.002 In) (1.263 m)
rocker arm. Exhaust 40 03_+0.05 mm 139.88 mm 32.30+0.05 mm 32.15 mm
11.576+0.002 1n1 i11.570 in) 11.272+0 002 in1 (1.266 in)
- 25
 -7
Q
I
-t-
B
A

4. All camshaft bearings should be removed,

cleaned, dried, and the races visually
checked for pits, rust spots or chatter
marks where the balls have dragged, If
any of these conditions exists the bear-
I I Standard Wear Ilmit I

ing(s) should be replaced.

1 Cylinder
G.Cam chain, sprocket and dampers / outof-round
1. Cam chain
If the cylinder wall is worn more than
Except in cases of oil starvation, the cam
chain wears very little. If the cam chain wear limit, it should be rebored.
has stretched excessively and it is difficult
to keep the proper cam chain tension, the I. Piston and piston rings
chain should be replaced. 1. Piston
2. Cam sprockets a. Measure the outside diameter of the
Check cam sprockets for obvious wear. piston at the piston skirt.
3. Cam chain dampers Measurement should be made at a point
Inspect the two vertical (slipper-type) 10 mm (0.394 in) above the bottom edge
dampers for excessive wear. Any that of the piston. Place the micrometer at
shows excessive wear should be replaced. right angles to the piston pin.
Worn dampers may indicate an impro-
Standard: 74.96, 74.97 mm
perly adjusted or worn-out cam chain,
(2.951, 2.952 in)
Oversize 1: 75.25 mm (2.963 in)
H. Cylinder
Oversize 2: 75.50 mm (2.972 in)
1. Inspect the cylinder walls for scratches. If
Oversize 3: 75.75 mm (2.982 in)
vertical scratches are evident, the cylinder
Oversize 4: 76.00 mm (2.992 in)
wall should be rebored or the cylinder
should be replaced.
2. Measure cylinder wall wear as shown. If
wear is excessive, compression pressure
will decrease. Rebore the cylinder wall
and replace the piston and piston rings.
Cylinder wear should be measured at
three depths with a cylinder bore gauge.
(See illustration.)

26
b. Determine piston clearance as follows: J. Piston pin
1. Apply a light film of oil to pin. install in
connecting rod small end. Check for play.
There should be no noticeable vertical
play. If play exists, check connecting rod
small end for wear. Replace pin and con-
Example: necting rod as required.
75.02 mm 2. The piston pin should have no noticeable
-74.97 mm free play in piston. If the piston pin is
loose, replace the pin and/or the piston.
=0.05 mm piston clearance

K. Crankshaft
c. Piston ring/ring groove fit must have
1. Main bearing and big end bearing visually
correct clearance. If the piston and ring
inspect all friction surfaces for obvious
have already been used, the ring must be
pits, scratches, chatter marks, or rust. Re-
removed and the ring groove cleaned of
place it if necessary.
carbon. The rings should then be rein
2. Small end play(A)
stalled. Use a feeler gauge to measure the
gap between the ring and the land.
Maximum allowable tolerance:
2.0 mm (0.079 in)

;I 3. Big end side clearance(B)

(0.0016Q.0031 in1 1 0 . 0 0 1 2 - 0 . 0 0 2 8 i n )

Standard clearance:
2. Piston ring 0.15 - 0.4 mm (0.0059 - 0.016 in)
a. The oversize top and middle ring sizes are
stamped on top of the ring.
4. Crankshaft run out(C)
Mount the crankshaft in V-blocks and
check for run out using a dial gauge.

1’
1 Run out limit: 0.05 mm (0.002 in)

b. Push the ring into the bore and check end

gap clearance with a feeler gauge.

NOTE:
The end gap on the expander spacer of
the oil control ring is unmeasureable. If
oil control ring rails show excessive gap,
all three components should be replaced.

Standard Limit
L. Oil pump
Topl2nd 0.2 7 0.4 mm 1.0 mm
1. Check the clearance between housing and
ring (0.0079 - 0.016 in) (0.039 in)
outer rotor.
Oil control 0.2 - 0.9 mm Visual
(Rails) (0.0079 - 0.0354 in) inspection Standard clearance:
0.10 - 0.18 mm (0.0039 - 0.0071 in)

- 27 -
2. Check the clearance between outer rotor 5. Clutch springs
and inner rotor. Measure clutch spring free length. Replace
springs as a set if necessary.
Standard clearance:
0.03 - 0.09 mm (0.0012 - 0.0035 in) Clutch spring length:
34.6 mm (1.362 in)

M. Clutch
N. Transmission
1. Clutch housing
1. Inspect each shift fork for signs of galling
Check dogs on clutch housing. Look for
on gear contact surfaces. Check for bend-
cracks and signs of galling on edges. If
ing. Make sure each fork slides freely on
damage is moderate, deburr. If severe, re-
its guide bar.
place clutch housing.
2. Roll the guide bar across a surface plate.
NOTE: If bar is bent, replace.
Galling on the friction plate dogs of the 3. Check the shift cam grooves for signs of
clutch housing will cause erratic clutch wear or damage. If any profile has ex-
operation. cessive wear and/or damage, replace cam.
4. Check the cam followers on each shift
2. Clutch boss fork for wear. The follower should fit
Check splines on clutch boss for galling. If snugly into its seat in the shift fork, but
damage is slight to moderate, deburr. If it should not be overly tight. Check the ends
is severe, replace clutch boss. that ride in the grooves in the shift cam. If
NOTE: they are worn or damaged, replace
Galling on clutch plate splines will cause followers.
erratic clutch operation. 5. Check shift cam dowel pins and side plate
for looseness, damage or wear. Replace as
3. Friction and clutch plates required.
Check clutch steel plates and friction 6. Check the shift cam stopper plate and cir-
plates for heat damage. Measure friction clip and stopper for wear. Replace as re-
plate thickness at 3 or 4 points. Measure quired.
clutch plates for warpage. Replace clutch 7. Check the transmission shafts using a
plate or friction plates as a set if any is centering device and dial gauge. If any
faulty or beyond wear limits. shaft is bent beyond specified limit, re-
place shaft.
Standard Wear limit

Friction plate
thickness
3.0 mm
(0.118 inl
2.7 mm
(0.106 in) I Maximum run-out:
0.03 mm (0.001 in) I

Clutch plate - 0.05 mm 8. Carefully inspect each gear. Look for

warp limit (0.002 in)
signs of obvious heat damage (blue dis-
coloration). Check the gear teeth for signs
4. Clutch push rod
of pitting, galling or other extreme wear.
Check ends of clutch push rod for inden-
Replace as required.
tation. If severe, clutch adjustment may
9. Check to see that each gear moves freely
be difficult. Check for looseness of the
on its shaft.
steel ends of the push rod. If ends are
10. Check to see that all washers and clips are
loose or indented, replace push rod.
properly installed and undamaged. Re-
place bent or loose clips and bent washers.
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
1) All gaskets and seals should be replaced
required.
when an engine is overhauled. All gasket
surfaces must be cleaned.
0. Electric starter gears and clip spring
2) Properly oil all mating engine and trans-
1. Check the gears for wear or scratches on
mission parts during assembly.
teeth, particularly in the chamfered area
3) All circlips should be inspected before
of each gear.
assembly. Replace distorted circlips.
2. The clip spring is fitted to gear (4) (Refer
Always replace cotter pins and piston pin
to PAGE 20) and slides in the groove. A clips after one use.
too-tight or loose-fitting clip may result in
improper operation. If too loose, bend the
A. Shift
clip so that the friction increases, or re-
(Refer to PAGE 21)
place clip.
Install shift forks, shift cam, guide pin, cotter
Friction tension: pin, guide bar, stoper plate and detent. Apply
2.2 - 2.5 kg (4.9 - 5.5 lb) LOCK-TITE to eccentric bolt.
NOTE:
P. Kick starter Check for smooth and complete shifting after
1. Kick gears installing transmission.
Check the kick gears for wear or scratches
on teeth, particularly in the chamfered
area of each gear.
2. Kick clip spring
The kick clip is fitted to kick gear and
slides in the groove. A too-tight or loose-
fitting clip may result in improper ope-
ration. If too loose, bend the kick clip so
that the friction increases, or replace clip.

Friction tension:
1.2 - 1.7 kg (2.0 - 3.7 lb)
B. Transmission and crankshaft
Q. Crankcases and oil passages 1. Rotate shift cam to neutral position.
1. Check crankcases for cracks or other 2. Install the transmission, bearings and seals
damage. onto the upper case.
2. Clean all oil passages and blow out with 3. Install crankshaft, seal and bearings.
compressed air. NOTE:
Fit each bearing over each locating pin
R. Bearings and oil seals and push the crankshaft into position by
1. After cleaning and lubricating bearings,
hand. Each bearing has line or punch
rotate inner race with a finger. If rough
mark which indicates the position of
spots are felt, replace the bearing. mating surface.
2. Check oil seal lips for damage and wear.
Replace as required.

- 29 -
4. Make sure all bearings are positioned pro-
perly as shown.

1. Kick clap
2. Positioning the kick clip in the groove,
1. No clearance rotate the kick axle by kick lever l/2 turn
5. 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.
7. Install bottom crankcase and nuts. Install
nuts as follows: E. Electric-starter gear assembly
a. Use copper washers and blind nuts on Install the unit as shown.
bolts (1). (2), (3), (4), (12), (13). (Refer to PAGE 20, if necessary.)
b. Tighten nuts in two stages in proper tor-
que sequence. Start with bolt number one.

Crankcase torque:
2.2 m-kg (16 ft-lb)

NOTE:
Before installing crankcase, make sure
electric starter shaft 2 and gear 1 (PAGE 20)
is installed.
! ‘*-)]I
1. Clip

F. Clutch
C. Shifter assembly 1. Install the following parts in the order
1. Install shift shaft. Install circlip (E-clip) given.
on left side of crankcases. a. Plate 1, t = 1 mm (0.039 in)
2. Make sure distances A and B are equal. b. Plate 2, t = 2 mm (0.079 in)
Adjust them by adjuster if necessary. c. Spacer shaft
d. Housing
e. Bearing plate, t = 1 mm (0.039 in)
f. Bearing
g. Plate 2, t = 2 mm (0.079 in)
h. Clutch boss
i. Plane washer, t = 2.6 mm (0.102 in)
j. Conical spring
k. Nut (using special tool)

Clutch lock nut torque:

1. Adjuster 2 . A=B
6.5 m-kg (47 ft-lb)
D. Kick starter assembly
1. Partially insert the assembly until the re-
I. Friction plates and clutch plates
turn spring can be slipped over its anchor
m. Push rods, balls and push crown
point.
- 30 -
 n. Pressure plate and clutch springs o. Primary drive gear
I
Clutch screw torque: Drive gear torque:
/ 1 .O m-kg (7 ft-lb) 9 m-kg (65 ft-lb)

a. Plate 1
b. Plate 2
C. Spacer shaft k
d. Housing
e. Bearing plate
f. Bearing
g. Plate 2
h. Clutch boss
i. Plane washer
j. Conical spring
k. Nut (usmg special tool)
I. Friction plates and clutch plates
m. Push rods, balls and push crw,”
n. Pressure plate and clutch spring

a = 1 .o mm
b =2.0
e = 1.0
f = 2.0
g =2.0
I = 2.6
m i = 2.0

d -
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.
2. Reverse the generator removal sequence.
NOTE:
Always install new piston pin clips.
H. Oil pump
Reverse the oil pump removal sequence.
K. Cylinder and cylinder head
1. Install the tensioner cushion onto crank-
case.
2. Install a new cylinder base gasket.
3. Install cylinder using special tool.
4. Install the cylinder head gasket and
cylinder head.

NOTE:
The assembly of the cylinder head is the
I. Right-hand crankcase cover reverse of the disassembly procedure.
Install valve springs with tighter windings
While properly engaging oil pump gear, install
(smaller pitch) down,
new case cover gasket and right-hand crank-
case cover. Tighten holding screws gradually
L. Camshaft t
until proper torque is reached.
1. Rotate the piston to TDC.
2. Install the, chain onto the camshaft with
Crankcase cover holding screw torque:
no slack in the cam chain on the front
1.0 m-kg (7 ft-lb)
portion (opposite side from the tensioner).

J. Piston
1, Position piston rings as shown.

NOTE:
1) Make sure ends of oil ring expanders
are not overlapped.
2) Manufacturer’s marks or numbers
stamped on the rings are on the top
side of the rings. Coat pistons and rings
1. Center
well with oil. 2. No clearance

3. Position the groove in the left side of the

cam sprocket so that it lines up with the
sprocket centers.
ii! ‘1.

1. TO P
2. 2nd
3. Expander
4. spacer upper
5. spacer lower

- 32 -
4. Joint the chain together and revet a new O. Engine
link.
5. Install the cam chain tensioner, and adjust
chain tension. Refer to PAGE. (8).
6. Make sure the timing is correct.

M. Cylinder heed cover

1. Install all components in the head cover.
2. Apply Yamaha No. 4 sealant to cover
mating surfaces.
3. Install all head cover retaining nuts and
bolts and thread them down until lightly
seated.
4. Tighten them with torque wrench in the
order given

11 1. 4 5 (M10).5.0 m-kg (36 ft-lb)

N. Governor and breaker assembly

Reverse the governor and breaker removal
sequence.
NOTE:
Before inserting the governor rod, supportive
bearings should be lubricated with molyb-
denum disulfide.
 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
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 #135

Jet needle 502-3 5. To inspect starter jet, remove three (3)
Needle jet z-2 screws holding the starter body to the right
Starter jet #a0 side of the carburetor.
Fuel valve seat 2mm 6. Remove the four screws holding the float
Pilot jet #27.5 bowl cover. Remove float bowl cover. The
Fuel level 24*1 mm(0.94+0.04 in)
main jet is located under a cover in the
(above gasket surface)
float bowl.
NOTE: 7. Pull out float pivot pin. Remove the float
The low speed mixture screw settings are assembly. Be careful not to lose the float
adjusted at the factory with the use of special- valve needle located under the float level
ized equipment. Do not attempt to change adjustment tongue. Remove the needle
these settings. jet.
8. Reassemble in reverse order. Pay close
C. Disassembly attention to the installation of the
1. Prepare to separate carburetors (separa- vacuum piston diaphragm.
tion not necessary if only float level
adjustment or throttle value inspection is D. Inspection
to be done). Remove starter lever. Loosen 1. Examine carburetor body and fuel passage-
starter lever securing screws and remove s. If contaminated, wash carburetor in
starter lever rod. petroleum-based solvent. Do not use
2. Remove upper and lower brackets. Note caustic carburetor cleaning solutions.
position of synchronizing screws for Blow out all passages and jets with com-
guidance in reassembly. Separate car- pressed air.
buretors. 2. Examine condition of floats. If floats are
3. Remove vacuum chamber cover. Remove leaking or damaged, they should be re-
the spring, needle fitting clip, needle, placed.
and diaphragm (piston valve). 3. Inspect inlet needle valve and seat for
4. Note that there is tab on the rubber wear or contamination. Replace these
diaphragm. There are matching recesses components as a set.
in the carburetor body for the diaphragm 4. Inspect piston valve and rubber dia-
tab. phragm. If the piston is scratched or the
diaphragm is torn, the assembly must be
replaced.

- 36 -
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. If too low, a lean mixture
will result.

1. Tongue A . 24+1 m m (0.94f0.04 in1

- 3 7 -
 CHAPTER 5. CHASSIS
5-1. FRONT WHEEL ................... . . . . . . . ................... . .39
A. Removal ....................... . . . . . . . ..................... 39
B. Front axle inspection . . . . . . . . . . . . . . . . . . . . ..................... 39
C. Front wheel inspection. ........... . . . . . . . ..................... 39
D. Replacing wheel bearings .......... . . . . . . . ..................... 39
E. Installing front wheel ............. . * . . . . . ..................... 39

5-2. REAR WHEEL .................... . . . . . . . ..................... 40

A. Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . * .40

B. Rear axle inspection ...................................... . . . . . .40

C. Replacing wheel bearings .................................. . . . . . .40

D. Rear wheel inspection .................................... . . . . . -40

E. Installing rear wheel ...................................... . . . . . .40

F. Rear wheel illustration .................................... . . . . . .40

5-3. BRAKES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..4 0

A. Caliper pad replacement .............................................40
B. Caliper disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .42
C. Master cylinder disassembly ..........................................42
D. Brake inspection and repair ..........................................42
E. Brake reassembly ..................................................43
5-4. WHEELS, TIRES, TUBES ......................................... .. .44
A. Wheel inspection ..................................................44
B. Tire, tube removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .44
C. Installation .......................................................44
5-5. REAR WHEEL SPROCKET ............................................44
5-6. FRONT FORKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..4 5
A. Removal and disassembly ............................................46
6. Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..4 6
C. Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..4 6

5-7. STEERING HEAD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..~.......4 7

A. Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..4 7
B. Removal.........................................................4 7
C. Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..4 7
D. Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..4 7
5-8. SWING ARM........................................................4 7
A. Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..4 7
B. Swing arm removal .................................................4.8
C. Swing arm lubrication ..............................................48
5-9. REAR SHOCK ABSORBER ............................................48
A. Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
B. Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-10. CABLES AND FITTINGS .............................................48
A. Cablemaintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...48
B. Throttle maintenance ...............................................48
- 38 -
 CHAPTER 5.
CHASSIS
5-l. FRONT WHEEL a) If the run out is up and down, loosen
A. Removal spokes opposite the high spot and tighten
1. Remove cotter pin from front axle nut. the spokes at the high spot.
2. Remove the front axle nut. b) If the run out is sideways, loosen the
3. Loosen the two axle holder nuts at spokes at the high spot, and tighten
the bottom of the fork leg. the spokes opposite the high spot.
4. Raise the front wheel of the machine by
placing suitable stand under the engine. D. Replacing wheel bearings
5. Remove the front wheel axle by simul- If the bearings allow play in the wheel hub or
if wheel does not turn smoothly, replace the
taneously twisting and pulling out on the
axle. Then remove the wheel assembly. bearings as follows:
1. Clean the outside of the wheel hub.
The speedometer gear unit housing must
be removed. 2. Drive the bearing out by pushing the
spacer aside and tapping around the
perimeter of the bearing inner race with a
soft metal drift pin and hammer. The
spacer “floats” between the bearings. Both
bearings can be removed in this manner.
3. To install the wheel bearing, reverse the
above sequence. Be sure to grease the
bearing before installation. Use a socket
that matches the outside race of the bear-
ing as a tool to drive in the bearing.

B. Front axle inspection

Remove any corrosion from axle with emery
cloth. Place the axle on a surface plate and
check for bends. If bent, replace axle.
E. Installing front wheel
When installing front wheel, reverse the re-
C. Front wheel inspection
moval procedure. Note the following points:
1. A rim can develop warpage. It is due to
1. Lightly grease lips of front wheel oil seals
(1) running the wheel into an object and
and gear teeth of speedometer drive and
bending the outer rim, or (2) one or more
driven gears. Use lightweight lithium soap
spokes loosening.
base grease.
2. Check for warpage by mounting the wheel
2. Make sure there is enough gap between
on a stand (or, if the wheel is attached to
disc pads.
a motorcycle, it can be blocked up and
3. Check for proper engagement of the boss
held in place). Use some device to measure
on the outer fork tube with the locating
or detect movement then slowly spin the
slot on speedometer gear unit housing.
wheel and note the amount of rim “run-
4. Always secure the front wheel axle as
out”. It should not exceed 2 mm(0.08 in). ,
follows:
3. If all the spokes are tight, and the rim
a Tighten the front axle nut.
shows no obvious signs of damage, and
yet run out is still excessive, do the follow-
Axle nut torque:
ing:
8.5 m-kg (61 ft-lb)
J
 b. Tighten axle holder nuts. First tighten nut E. Installing rear wheel
on front end of axle holder, then tighten 1. Lightly grease lips of rear wheel oil seals.
nut on rear end. 2. To install the rear wheel, reverse the
removal procedure.
Holder nut torque: NOTE:
1 .O m-kg (7 ft-lb) Always use a new cotter pin on the axle
nut.
c. install a new cotter pin.
Torque:
5-2. REAR WHEEL Axle nut: 15 m-kg(l08 ft-lb)

A. Removal F. Rear Wheel lubrication (on page 41)

1. Place machine on center stand. 5-3. BRAKES
2. Disconnect the tension bar, and the brake CAUTION:
rod from the rear shoe plate. Pay strict Disc brake components rarely require dis-
attention to the presence and location of assembly. Do not disassembly components
the tension bar lock washer and cotter unless absolutely necessary. If any hydraulic
key. These are safety parts and must be connection in the system is opened, the entire
included during assembly. system should be disassembled, drained,
cleaned and then properly filled and bled
upon reassembly.
CAUTION:
D O not use solvents on brake internal com-
ponents. Solvents will cause seals to swell and
distort. Use only clean brake fluid for clean-
ing. Use care with brake fluid. Brake fluid is
injurious to eyes and will damage painted sur-
L
faces.

2. Loosen the chain tension adjusting nuts A.Caliper pad replacement

and bolts on both right and left sides. 1. It is not necessary to disassemble the
3. Remove the rear axle cotter pin and nut. brake fluid hoses to replace the brake
4. Remove the right-hand chain adjuster and pads.
distance collar. 2. Remove the caliper suppdrt bolt.*
5. Remove the rear brake plate. 3. Remove the phillips screw that holds the
6. Lean the machine to the left and remove brake pads.
the rear wheel assembly.

B. Rear axle inspection

(See front Wheel, Axle Inspection Procedure.)

C. Replacing wheel bearings

Rear wheel bearing replacement is similar to
the procedure for the front wheel.

D. Rear wheel inspection 1. Caliper wppcm bolt

2. Pad screw
(See Front Wheel, Inspection Procedures.)
4. Pull caliper cylinder off caliper frame.
5. Install new brake pads. Replace pads as a
set.

-40 -
B. Caliper disassembly 3. 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.
3. Remove caliper support bolt and pad se-
curing screw as in Caliper pad replacement
procedure.
4. Remove caliper assembly from caliper
frame.
5. Remove retaining ring and dust seal. & h%;& 1 & &
6. Carefully force the piston out of the cali-
1. Snap ring
per cylinder with compressed air. Never 2. Cylinder CUP IFI)
try to pry out the piston. 3. Piston
4. Shim
5. Piston cup
6. Spacer
7. Return spring
that piston does not cause injury as it is
expelled from the cylinder.
7. Remove piston seal. D.Brake inspection and repair

Recommended Brake Component Replace-

ment Schedule:
Brake pads . . . . . . . . . . . . . . . .As required
Piston seal, dust seal . . . . . Every two years
Brake hoses . . . . . . . . . .Every four years
Brake fluid . . . . . . . . . . Replace only when
brakes are disassembled

1. Replace caliper piston if it is scratched.

2. Replace any brake pad worn beyond
limits.
Pad s c r e w 3. sntm
4. Pads.
Replace brake pads as a set. _
2. Shim

A
C. Master cylinder disassembly
1. Remove brake hose.
A : Pad thickness
2. Remove front brake switch.
6. : Wear limit (1.5 mm)
C : Wear indicator(red line)
C

?
Pad
l_ \
Back plate
 See “Caliper Replacement Pad” procedure cap, boot bushing, piston seal, dust seal,
for parts to be replaced when pads are retaining ring.
replaced.

3. Replace piston and dust seals if damaged.

4. Inspect master cylinder body. Replace if
scratched. Clean all passages with new
brake fluid.
5. Inspect brake hoses. Replace every four
years or if cracked, frayed or damaged.
6. Check for wear and deflection of disc.

Wear limit:
_
1.5 mm (0.06 in) I
1. Bleed screw (with cap) 4. Dust seal
2. Bush boot 5. Retaining ring
3. Piston seal

a. Install piston seal and piston. Place caliper

cylinder into caliper frame.
b. Install pad spring and retainer. Install dust
seal and clip.
c. Install pad spring and pads.
d. Install support bolt and remount caliper
on brackets.

1. Dial gauge
1. Mounting bolt a
Maximum deflection: 0.15 mm(0.006 in)
Mounting bolt torque:
Minimum disc thickness: 6.5 mm(0.26 in)
3.5 m-kg (25 ft-lb)

If disc is worn beyond minimum thickness

3. Attach brake hoses.
or deflection exceeds specified amount,
4. Master cylinder reassembly
replace disc.
Reassemble master cylinder.

E. Brake reassembly
All internal parts should be cleaned in
new brake fluid. Internal parts should be
lubricated with brake fluid when installed.
2. Caliper reassembly
Replace the following parts whenever a
caliper is disassembled: bleed screw and
 Use two wide, flat tire irons with rounded
5. Brake disc assembly 3.
edges to work the tire bead over the edge
If brake disc has been removed from hub
of the rim, starting 180” opposite the
or is loose, tighten bolts. Use new locking
tube stem. Be careful not to pinch the
washers and bend over locking tabs after
tube as you do this.
bolts are tightened.
4. After you have worked on side of the tire
completely off the rim, slip the tube out.
[I Be very careful not to damage the stem
while pushing it back out of the rim hole.
6. Air bleeding NOTE: __
-CAUTION:
If you are changing the tire itself, then
If the brake system is disassembled or if
finish the removal by working the second
any brake hose has been loosened or re-
bead off the rim.
moved, the brake system must be bled to
remove air from the brake fluid. If the
C. Installation
brake fluid level is very low or brake
Reinstall the tire and tube by reversing the
operation is incorrect, bleed the brake
disassembly procedure. After the tube has
system.
been installed, but before the tire has been
a. Add proper brake fluid to the reservoir. completely slipped onto the rim, put a small
Install the diaphragm, being careful not amount of air into the tube. This removes any
to spill or overflow the reservoir. creases that might exist. Release the air and
b. Connect the clear plastic tube tightly to continue with reassembly. After the tire has
the caliper bleed screw. Put the end of the been completely slipped onto the rim, make
tube into a container. sure the stem comes out of the hole in the rim
C. Slowly apply the brake lever several times. at a right angle to the rim. Finally inflate the
Pull in lever. Hold lever in “on” position. tire. Refer to PAGE (10).
Loosen bleed screw. Allow the lever to
travel slowly toward its limit. When the Front Tire Rear Tire
limit is reached, tighten bleed screw. INormal riding 1.6 kg/cm* (22 psi) 2.0kg/cm2 (29psij
d. Continue step C until all air bubbles are
removed from system. NOTE:
NOTE: Make sure the wheel is balanced every time
If bleeding is difficult, it may be necessary the tire is replaced. (Refer to “Front wheel
to let the brake system stabilize for a few inspection”.)
hours. Repeat bleeding procedure.

5-5. REAR WHEEL SPROCKET

5-4. WHEELS, TIRES, TUBES
A. Wheel inspection 1. Bend the lock washer ears flat.
Wheels should be inspected frequently. Wheel 2. Remove the sprocket mounting bolts.
run-out is discussed in Chapter 5-1. Check the lock washer and bolt for
damage. If the lock washer is not bent
B. Tire, tube removal over the hexagon bolt head, or is broken,
1. Remove valve cap, valve core and valve or the bolt is loose, the sprocket can come
stem lock nut. loose.
2. When all air is out of tube, separate tire
bead from rim (both sides) by stepping on
tire with your foot.
 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 U P
against the bolts.

3 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
sprocket.

5-6. FRONT FORKS

--_w--J’ I

26. Nut

-45 -
u
i‘
t
-

126
:

2
7

7
0

d
31
30

_ _ - J
I
I’
I
2

it
I
I
/
/I
A. Removal and disassembly B. inspection
1. Examine fork inner tube for scratches and
NOTE:
For fork oil replacement only, refer to PAGE straightness. If the tube is scratched severe-
(12) ly or bent, it should be replaced.
2. If the lips of the oil seal are worn, or the
1. Disconnect speedometer cable. Disconnect
oil seal is leaking, replace it.
brake calipers and remove front wheel.
3. Check the outer tube for dents. If any
Place wooden wedge or other object into
dent causes the inner tube to “hang up”
caliper assemblies to keep brake pads
during operation, the outer tube should
apart. Remove front fender.
be replaced.
2. Loosen pinch bolts on steering stem and
4. Check the free length of the springs.
crown and remove fork.
3. Remove fork tube caps, spring stopper
Spring free length:
seats, and oil drain screws. Drain fork oil.
482 mm (18.98 in)
4. Remove Allen bolt from bottom of fork
assembly. Pull inner tube out of outer
5. Check the O-ring on the top spring seat. If
tube.
damaged, replace O-ring.

6
5. To remove fork seal, pull off dust cover. 1. O-ring

Remove spring clip over oil seal. Pry out

C. Assembly
oil seal, being careful to not damage the
1. Make sure all components are clean before
fork tube.
assembly.
2. Apply oil to the fork seal and install the
seal spacer and seal by pressing in with a
large socket. Install retaining clip.
3. Install inner tube into outer tube. Install
dust cover. Install and tighten Allen bolt
and washer. Assembly procedure is the
reverse of the disassembly procedure.

NOTE:
When installing fork springs, the greater
pitch should be at the bottom.
 D. Reassembly
1. Grease bearings and races with wheel bear-
ing grease.

1. Bottom
2. TO P
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. Removal ft-lb). Do not over-tighten. Tighten top
1. Remove front wheel, front forks and fitting nut.
handle bars. Continue reassembly in reverse assembly
2. Remove front brake pipe junction. order.
3. Loosen steering stem (underbracket) When assembly is complete, check steer-
pinch bolt. Remove stem bolt and washer. ing stem by turning it from lock to lock.
If threr is any binding or looseness, re-
adjust steering stem tightness.

Under bracket.

5-8. SWING ARM

A. Inspection
1. Crown Dlnch bolt 2. Fork pinch bolt 1. Free play inspection
3. Steering fitting bolt
4. Remove steering crown. Remove rear wheel and shock absorbers.
5. Remove top fitting nut. Use proper Grasp the swing arm and move it from
spanner. side to side as shown. There should be no
6. Support steering stem (underbracket) and noticeable side play.
remove bottom fitting nut.
7. Remove bearings.

C. Inspection
1. Wash bearings in solvent.
2. inspect bearings for pitting or other
damage. Replace bearings if pitted or
damaged. Replace races when bearings are
replaced.
3. Clean and inspect bearing races. If races
are damaged, replace races and bearings. I
1
Swing arm freeplay: 1 mm (0.4 in) II
4. Install bearings in races. Spin bearings. If 2. If freeplay is excessive, remove swing arm
the bearings hang up or are not smooth in and replace swing arm bushing.
their operation in the races, replace bear- 47 -
ings and races.
B. Swing arm removal 3. Operate shock absorber rod to check
1. Remove nut on swing arm pivot bolt and damping. There should be no noticeable
tap out bolt with a long aluminum or damping as shock extends.
brass rod. 4. Install the shock absorber on the machine.

NOTE: Rear shock absorber tightening

Carefully remove the arm while noting the
location of spacing washers and shims. 1

1 Pivot bolt torque: 6.5 m-kg (47 ft-lb) 1

5-10. CABLES AND FITTINGS

2. Tap out old bushing from each side of A.Cable maintenance

pivot using the long rod. NOTE:
3. Install new bushings using a press. See maintenance and lubrication intervals
NOTE: charts. Cable maintenance is primarily con-
If tapping on bushing, bushing may be cerned with preventing deterioration through
broken. rust and weathering and providing proper
lubrication to allow the cable to move freely
within its housing. Cable removal is straight-
C. Swing arm lubrication forward and uncomplicated. Removal will not
1. Apply grease to grease fitting on top of be discussed within this section.
pivot with low pressure hand operated
gun. Apply until fresh grease appears at WARNING:
both ends of pivot shaft. Cable routing is very important. For details of ~
cable routing, see the table routing diagrams!
Recommended lubricant: at the end of the manual. Improperly routed, /
Medium-weight grease assembled or adjusted cables may make the
vehicle unsafe for operation.
2. Wipe off excess grease. 1. Remove the cable.
2. Check for free movement of cable within
its housing. If movement is obstructed,
check for fraying or kinking of cable
strands. If damage is evident, replace the
cable assembly.
3. To lubricate cable, hold in vertical posi-
tion. Apply lubricant to uppermost end of
cable. Leave in vertical position until
lubricant appears at bottom. Allow excess
1. Grease fitting to drain and reinstall.
5-9. REAR SHOCK ABSORBER NOTE:
Choice of lubricant depends upon con-
A. Removal
ditions and preferences. However, a semi-
Remove one (1) rear shock absorber at a time,
drying chain and cable lubricant will
inspect and reinstall before removing the
probably perform adequately under most
other.
conditions.

B. Inspection B. Throttle maintenance

1. Check the rod. If it is bent or damaged, 1. Remove Phillips head screws from throttle
replace the shock absorber. housing assembly and separate two halves
2. Check for oil leakage. If oil leakage is of housing.
evident, replace the shock absorber. 2. Disconnect cable end from throttle grip
48 - assembly and remove grip assembly.
 CHAPTER 6. ELECTRICAL

6-1. STARTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..5 0

A. Armature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..5 0
B. Yoke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..5 0
C. Starter relay switch ............................................... .50
6-2. CHARGING SYSTEM.................................................52
A. Charging circuit diagram. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .52
B. A.C.Generator....................................................52
C. Voltage regulator ................................................. .52
D. Checking silicon rectifier ........................................... .53
E. Battery..........................................................53
6-3. IGNITION SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..5 4
A. Ignition circuit diagram ............................................ .54
B. Governor assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .54
C. Sparkgaptest.....................................................5 4
D. Ignitioncoil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..5 4
E. Condensertest....................................................5 5
6-4. SPARK PLUG.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..5 6
A. How to “Read” a spark plug (condition) ............................... .56
B. Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..5 6
65. LIGHTING AND SIGNAL SYSTEMS ................................... .56
A. Lighting tests and checks ........................................... .56
B. Reserve lighting system ............................................ .57
C. Self-cancelling flasher system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .58
 I
i

I
CHAPTER 6. i

ELECTRICAL
6-1. STARTER
A.Armature sistance is less then 100 kn) replace it.
1. 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-
electrical contact cleaner and dry with installing.
high-pressure air steam.
2. The mica insulation between commutator
C. Starter relay switch
segments should be 0.5 - 0.8 mm (0.02-
1. Inspection
0.03 in). below the segment level. If not,
a. Disconnect starter relay leads at the relay.
scrape to proper limits with appropriately
b. Connect pocket tester leads to the relay
shaped tool. (A hacksaw blade can be
terminals (ohm x 1 scale).
ground to fit).
c. Turn ignition ON (“1” position) and
3. Each commutator segment should show
zero ohm resistance to the others and at engine stop switch to “RUN”.
least 3Ma resistance to the core. If there d. Push starter button. The relay should
is less than 3MR resistance to the core, or click once and the scale should read zero
one of segments is open, replace the ohm. If the relay clicks but the scale does
armature. not read zero, the relay must be replaced.
In addition, the armature can be placed
on a “growler” (testing device) and
checked magnetically for internal shorts.
Follow manufacturer’s test recommenda-
tions.
4. If the commutator surface shows heavy
scoring, it can be turned down on a lathe
or commutator turning machine. Check
the specification chart for minimum
allowable commutator diameter. Recut 1. Starter button “ON”
the mica after. e. If the relay does not click, check the wires
from the starter button and the battery
NOTE:
Should turning be required, check the (red/white, blue/white). Turn ignition off.
Use (ohm x 1) scale on tester. The re-
condition of the cover bearings, armature
electrical properties starter amperage draw sistance between these wires should be no
and rpm and, finally, carbon brushes. more than 3.5n. If there is more re-
sistance, the relay should be replaced.
B. Yoke
1. If the yoke area is dirty, clean with clean
solvent and dry with high-pressure air.
2. Yoke coil resistance is 0.05 ohm.
The coil should be show zero ohm resist-
ance, if it shows more than zero ohm,
replace it.
If the yoke shows leakage to ground (re-

- 50 -
6-2. CHARGING SYSTEM
A.Charging circuit diagram

L
1. Rectifier 4. Load 9. Stator coil
2. Fuse 6. Voltage regulator IO. Relay unit 1, Stator coil 4 . Black
3. Main switch 7. A.C. Generator 2. White 5. Sky blue
4. Battery 8. Field *oil 3. Yellow (Pick up cable) 6. Field Coil

B. A.C.Generator
C. Voltage regulator
1. Checking method.
The regulator’s function is to pass a control-
a. Connect D.C. voltmeter to the battery
led amount of current through the field
terminals. Battery should be fully charged.
windings which creates a magnetic field that
b. Start engine.
produces a charging voltage in the three stator
c. Accelerate engine to approximately 2,000
windings.
rpm or more and check generated voltage.
1. When adjusting the regulator, a D.C.
Generated voltage: voltmeter, ammeter, and tachometer are
14.5 + 0.5 v necessary. They are connected as illustrat-
ed, and adjustment should be made in the
d. If the indicated voltage cannot be reach- following sequence:
ed, then perform the tests in step 2.

NOTE:
/
Never disconnect wires from the battery
/ii\
while the generator is in operation. If the
battery is disconnected, the voltage across
the generator terminals will increase,
damaging the diodes.
2. Resistance test of field coil and statorcoil.
Check the resistance between terminals. If
resistance is out of specification, coil is
broken. Check the coil connections. If the L
A . Ammeter 1 Rectifier 4. AC. Generator
coil connections are good, then the coil is V . Voltmeter 2. Battery 6. Field coil
broken inside and it should be replaced. 3. voltage regulator 6. Stator coil

a. Remove the regulator from the frame, and

Field coil resistance:
check the contact points. If the point
(Green-Black)
surfaces are rough, they should be
5.25R 2 10% at 20°C
Stator coil resistance: smoothed with sand paper (#500 or
#600). After sandpapering, throughly
(W 1 -W2, W2-W3, W3-W 1)
clean contact points with contact point
0.46.Q f 10% at 20°C
cleaner.

- 52 -
 b. Check the core and points for gap adjust- Contlnultv’ Con

ment. If any gap is incorrect, it should be

1 Pocket tester
adjusted. RETX~
E l e m e n t ~~~e~t
Ielement
O.K.
shorted1 opened)
First adjust the core gap and then

core gap 5. upper contact 9 Locknut

2. Armature 6. Contact set 10 Adjusttng screw
3. Lower contact 7. co11 11. Yoke
4 Point gap 8 Adjusting spring 12 Contact Spring
1 Wh,te
2 White
3 White
C. Charging voltage output can be controlled
4 IBlack)
at the regulator. Inside the housing is a 5 fRedI
screw that pushes against a flat spring
steel plate. This iJ the adjusting screw. Even if only one element is broken, re-
d. Before starting engine, disconnect wire place assembly.
connector (coupler) containing 5 wires CAUTION:
from rectifier (1 red, 1 black, 3 white). /The silicon rectifier can be damaged if
Remove the RED wire from the con- : subjected to overcharging. Special care
nector. Connect pocket tester (DC20V) should be taken to avoid a short circuit,
red tester lead (+) to red wire from re- and/or incorrect connection of the posi-
ctifier. Connect tester black ( - ) to good I tive and negative leads at the battery.
ground. Start engine. Tester should / Never connect the rectifier directly to the
indicate 14.5 - 15 V (DC). battery to make a continuity check.

E. Battery
1. Checking
a. If battery sulfation (white accumulation)
occurs on plates due to lack of battery
D. Checking silicon rectifier
electrolyte, the battery should be replaced.
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.

- 53
 a. Negligence in keeping battery topped off proper rpm, nor will it advance to its
with distilled water. fullest extent. On occasion, lightweight
b. Battery being left discharged. grease must be applied to the weight pivot
c. Over-charging with heavy charge. pins.
d. Freezing. b. Check the operation of the point cam on
e. Filling with water or sulfuric acid contain- the shaft. It must rotate smoothly.
ing impurities. c. Examine point cam surface. If surface is
f. Improper charging voltage or current on pitted or worn, the governor assembly
new battery. must be replaced.

Battery 12V. 14AH

C. Spark gap test
Electrolyre Specific gravity: 1 .2B The entire ignition system can be checked for
lnitnl charging current 1.4 amp misfire and weak spark using the Electro
(new battery) Tester. If the ignition system will fire across a
Rechargmg current , 1.4 amp until specific sufficient gap, the engine ignition system can
gravity reaches 1.28
be considered good. If not, proceed with
Refill fluid Distilled water
It0 maximum level line) individual component tests until the problem
Refill period Check once per month is found.
(or more often. as required) 1. Warm up engine throughly so that all
3. If the motorcycle is not to be used for a electrical components are at operating
long time, remove the battery and have it temperature.
stored. The following instructions should 2. Stop engine and connect tester as shown.
be observed ::
a. Recharge the battery periodically.
b. Store the battery in a cool, dry place.
C. Recharge the battery before reinstallation.

6-3. IGNITION SYSTEM

A. Ignition circuit diagram

2. Plug wre from coil

3. Spark plug

1.
2.
3.
w
Ignition coil
Spark plug
Engine stop switch
5.
6.
7.
Fuse (ZOA)
Battery
Condenser
J 3. Start engine and increase spark gap until
misfire occurs. (Test at various rpm’s
between idle and red line.)

Minimum spark gap:

6 mm (0.24 in)
4. Main switch 8. Contact breaker

D. Ignition coil
B. Governor assembly 1. Coil spark gap test.
1. Inspection a. Remove fuel tank and disconnect ignition
a. Both weights must pivot smoothly or coil from wire harness and spark plug.
ignition advance will not occur at the b. Connect Electro Tester as shown.

- 54 -
 Standard values:
Primary coil resistance:
3.9s2 t 10% at 20°C
Secondary coil resistance:
8Kn * 20% at 20°C

E. Condenser test
If the contact points show excessive wear, or
the spark is weak (but the ignition coil is in
good condition), check the condenser.
1. Capacity test (use Electro Tester).
a. Calibrate capacity scale.
b. Connect tester.
c. Meter needle will deflect and return to
center as condenser is charged. After
needle stops, note reading on “p F” scale.
1. lgnmon c o i l 3 . O r a n g e
‘ 2 Red/whore 4. Electra tester Condenser capacity:
c. Connect fully charged battery to tester. 0.22/.1F 2 10%
d Turn on spark gap switch and increase gap
until misfire occurs. 2. Insulation test.
a. Connect ohmmeter as shown (n x 1,000
111 or more).
b. Resistance reading should be m or at lease
3MR. If less, replace.
2. Direct current resistance test.
Use a pocket tester or equivalent ohm-
meter to determine resistance and con-
tinuity of primary and secondary coil
windings.

--- 0
-0

Condenser
2 Battery

After this measurement, the condenser

tive lead wire to the condenser case.

1. Primary coil resistance value 4. Redlwhne

2. Secondary coil resistance value 5. Orange
3. Ignition coil 6. Ohmmeter &? x 1)

- 55
6-4. SPARK PLUG operates, always check battery voltage before
The life of a spark plug and its discoloring proceeding further. Low battery voltage
vary according to the habits of the rider. At indicates either a faulty battery, low battery
each periodic inspection, replace burned of water, or a defective charging system. See
fouled plugs with suitable ones determined section 6-2 Charging System, for checks of
by the color and condition of the bad plugs. battery and charging system. Also check fuse
One machine may be ridden only in urban condition. Replace any “open” fuses. There
areas at low speeds; another may be ridden are individual fuses for various circuits.
for hours at high speed. Confirm what the 1. Horn does not work:
present plugs indicate by asking the rider how a. Check for 12V on brown wire to horn.
long and how fast he rides. Recommend a b. Check for good grounding of horn (pink
hot, standard, or cold plug type accordingly. wire) when horn button is pressed.
It is actually economical to install new plugs 2. Stop light does not work:
often since it will tend to keep the engine in a. Check bulb.
good condition and prevent excessive fuel b. Check for 12V on yellow wire to stop
consumption. light.
c. Check for 12V on brown wire to each
A. How to “Read” a spark plug (condition) stop light switch (front brake and rear
1. Best condition: When the porcelain brake switches).
around the center electrode is a light tan 3. Tail light does not work:
color. a. Check bulb.
2. If the electrodes and porcelain are black b. Check for 12V on blue wire.
and somewhat oily, replace the plug with c. Check for ground on black wire to tail/
a hotter type for low speed riding. stop light assembly.
3. If the porcelain is burned or glazed white 4. Flasher light(s) do not work:
and/or the electrodes are partially burned a. Check bulb.
away, replace the plug with a colder type b. Right circuit:
for high speed riding. 1) Check for 12V on dark green wire to
light.
B. inspection 2) Check for ground on black wire to
Instruct the rider to: light assembly.
1. Inspect and clean the spark plug every c. Left circuit:
3,200 km. (2,000 mil) 1) Check for 12V on dark brown wire to
2. Clean the electrodes of carbon and adjust light.
the electrode gap. 2) Check for ground on black wire to
3. Be sure to use the proper reach plug as a light assembly.
replacement to avoid overheating, fouling d. Right and left circuits do not work:
or piston damage. 1) Check for 12V on brown/white wire
to flasher switch on left handlebar.
Spark plug type: N-7Y (Champion) or 2) Check for 12V on brown wire to
BP7ES (NGK) flasher relay.
3) Replace flasher relay.
Spark plug gap: 0.7 - 0.8 mm I
(0.027 - 0.031 in) 4) Replace flasher switch.
e. Check flasher self-canceling system.
6-5. LIGHTING AND SIGNAL SYSTEMS (Refer to flasher self-canceling system.)
5. Neutral light does not work:
A. Lighting tests and checks
a. Check bulb.
The battery provides power for operation of
b. Check for 12V on sky blue wire to neutral
the horn, tail light, stop light, neutral light,
switch.
and flasher light. If none of the above
c. Replace neutral switch.
56
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.
The system is connected to the headlight
circuit only. The reserve lighting system
unit is located under the fuel tank.
HEADLIGHT “HEAo”
lNOlC.4TOR i
RESERVE LIGHTING
CONDlTlON , ,~:YT / F”NCTlON

L J

Voltage on “W”
wring circuits
C. Self-canceling flasher system 3. Circuit diagram.
1. Description
The self-cancaling flasher system turns off
the turn signal after a period of time or
distance involved in turning or changing
lanes. Generally, the signal will cancel
after either 10 seconds, or 130 meters,
whichever is greater. At very low speed,
the function is determined by distance; at
high speed, it is determined by time. At low
speed, especially when changing speeds,
the canceling determination is a combina-
tion of both time and distance.
2. Operation:
The handle switch has three positions:
L (left), OFF, and R (right). The switch
lever will return to the “OFF” position
after being p u s h e d to L or R, but the
signal will function. By pushing the lever
in, the signal may be cancelled manually,

- 58 -
4. Inspection:
If the flasher self-canceling system should
become inoperative, proceed as follows:
a. Pull off the 6-pin connectar from the
flasher canceling unit, and operate the
handle switch. If the signal operates
normally in L, R, and OFF, the following
are in good condition:
1) Flasher unit.
2) Bulb.
3) Lighting circuit.
4) Handle switch light circuit.
If (1) through (4) are in good condition.
the following may be faulty:
1) Flasher canceling unit.
2) Handle switch reset circuit.
3) Speedometer sensor circuit.
b. Pull off the 6-pin connector from the
flasher canceling unit, and connect a
tester (a x 100 range) across the white/
green and the black lead wires on the wire
harness side. Turn the speedometer shaft.
If the tester needle swings back and forth,
four times between 0 and m, the speedo-
meter sensor circuit is in good condition.
If not, the sensor or wire harness may be
inoperative.
c. Pull off the 6-pin connector from the
flasher canceling unit. Check if there is
continuity between the yellow/red lead
wire on the wire harness side and the
chassis.

If the test needle does not swing as

indicated above, check the handle switch
circuit and wire harness.
d. If no defect is found with the above
three check-ups and the flasher canceling
system is still inoperative, replace the
flasher canceling unit.
e. If the signal ftashes only when the
handle switch lever is turned to L or R
and it turns off immediately when the
handle switch lever returns to center,
replace the flasher canceling unit.

_ 59 -
 CHAPTER 7. APPENDICES

7-1. TORQUE SPECIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..6 1

Torque Specifications............................................................... 61
7-2. CONVERSION TABLE ................................................63
Metric to Inch System .................................................63
Inch to Metric System .................................................63
Definition of Terms ...................................................63
7-3. SPEClFlCATlON........................................................................64
A. General...................................................................64
B. Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . .. 64
C. Chassis.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. ..66
D. Electrical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..70
7-4. CABLE ROUTING DIAGRAM ......................................... .72
7-5. CIRCUIT DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..7 4
7-1. TORQUE SPECIFICATION
The following torque specifications must be
adhered to on every machine. When applying
torque to multi-secured fastener components,
the several studs should be tightened in
gradual stages and in a pattern that will avoid
warpage to the item being secured. Torque
settings are for dry, clean threads. Torquing
should always be done to the nut, never the
bolt head.

NOTE:
Certain items with other than standard thread
pitches may require differing torque.

Torque Specifications

1
l-
A Ia I Standard tightening torque
INut) (Bk m-kg ft-lb
~ in-lb

10mm 6 mm (M6) i 1.0 7 85

12mm 8mm fM8) I 2.0 175
14 mm 10 mm (Ml01 ; 3.5 - 4.0 300 - 350
17 mm 12 mm (Ml21 i 4.0 - 4.5 350 - 400
19mm 14 mm (Ml41 400 - 440
22 mm 480 - 570
24 mm

27 mm 600 - 700

Thread dia. and

Part to be tightened Tightening torque
I part name I
I
Engine:
Cylinder head and cylinder ~10mm n u t 3.8 m-kg (27 ft-lb)
head cover ~8 mm bolt 2.2 m-kg (16 ft-lb)

Cylinder head ) 6 mm bolt 1 .O m-kg ( 7 ft-lb)

Cylinder head cover side 6 mm crown nut 1 .O m-kg ( 7 ft-lb) 1
8 mm crown nut 1.5 m-kg (10 ft-lb) i
l 14 mm
I 2.0 m-kg (14 ft.lb)
Spark plug
/
Generator ~1 2 m m n u t I 4.0 m-kg (29 ft-lb)

Stator coil ~6 mm pan headscrew / 1.0 m-kg ( 7 ft-lb) I

Governer ~6 m m b o l t I 0.8 m-kg ((6 ft-lb) I
Valve clearance adjustment nut / 8 mm nut I 2.7 m-kg (20 ft-lb) I
/ 18mmcap 2.2 m-kg (16 f t.lb) 1,
Cam chain tensioner cover I I
Pump cover 6 mm pan head screw ! 1 .O m-kg ( 7 ft-lb)
Strainer cover 6 mm bolt 1.0 m-kg ((7 ft-lb)

Drain plug i 30 mm bolt 4.4 m-kg (32 ft.lb)

Filter cover 1 6 mm bolt 1.0 m-kg ((7 ft-lb)

_~___
Oil filter 1 16 mm bolt 1 .O m-kg 1(7 ft-lb)
I Part to be tightened
I Thread dia. and
part name I
Tightening torque
I
I Delivery pipe / 10 mm union bolt I 2.2 m-kg (16 ft-lb) I
Exhaust pipe / 8mm n u t 1.5 m-kg (11 ft-lb)
1 Crankcase 1 and 2 1 8 mm bolt/nut 2.2 m-kg (16 ft-lb)
Crankcase cover 1 6 mm bolt 1 .O m-kg (7 ft-lb)
Kick crank boss 1 8 mm bolt 2.0 m-kg (14 ft-lb)

1 Clutch spring 6 mm screw 1 .O m-kg (7 ft-lb)

Primary drive gear / 14 mm nut I 9.0 m-kg (65 ft-lb) I
Clutch boss 18 mm nut 6.5 m-kg (47 ft-lb)
Drive sprocket 22 mm nut 5.0 m-kg (36 ft-lb)
Change pedal 6 mm bolt 1 .O m-kg (7 ft-lb)

Chassis:
Front wheel shaft 14 mm nut 8.5 m-kg (61 ft-lb)

i-
Outer~~ tube and axle holder 1 8mm nut I 1.5 m-kg (11 ft-lb) I
r Handle crown and inner tube / 8mm nut I 1 .O m-kg (7 ft-lb) I
1 Handle crown and steering shaft I 8mmnut I 1.0 m-kg (7 ft-lb) I
1 Handle crown and steering shaft / 14 mm bolt I 5.5 m-kg (40 ft-lb) I
I Handle crown and handle holder / 8 mm bolt I 2.5 m-kg (18 ft-lb) I
7-2. C O N V E R S I O N T A B L E

Metric to Inch System Inch Metric System

Multiplier Multiplier
Known Result Known Result
(Rounded off) (Rounded off)
Torque Torque
m-kg 7.233 ft.lbr
ft-lbs 0.13826 m-kg
m-kg 86.80 iwlbs
in.lbs 0.01152 m-kg
ft.lbr 13.831 cm.kg
in-lbs cm-kg
Wt.
lb 0.4535 kg
oz 28.352 g
Flow/Distance
mpg 0.4252 km/l

mph 1.609 kmlhr

rn 1.609 km

Vol./Capacity
oz (US liq) 29.57 cc (cm” I
cu. I” 16.387 cc (cm”)
pt IUS liq) 0.4732 I (liter)
qt (US liq) 0.9461 I (liter)
gal (US liq) 3.765 I (liter)
Misc.

Definition of Terms:
m-kg Meter-kilograms: Usually torque.
g Gram(s).
kg Kilogram(s): 1,000 grams.
km Kilometer(s).
I Liter(s).
km/l Kilometer(s) per liter: Mileage.
cc Cubic centimer(s) (cm3): Volume or capacity.
kg/mm Kilogram(s) per millimeter: Usually spring cqmpress~pn rate,
kg/cm’ Kilogram(s) per square centimeter: Pressure.

63
7.3. SPECIFICATION
A. General

1
1. MODEL
1) Model (I.B.M. No.) XS650E (2FO)
2) Frame I.D. and starting number 2FO-000101
3) Engine I.D. and starting number ZFO-000101

2. DIMENSION
1) Overall length 2,180 mm (85.8 in)
21 Overall width 835 mm (32.9 in)
3) Overall height 1,160 mm (45.7 in)
4) Seat height 815 mm (32.1 in)
51 Wheelbase 1,435 mm (56.5 in)
61 Minimum ground clearance 150 mm ( 5 . 9 in)

3. WEIGHT
212 kg (467 lb)

26°
2,500 mm (98.4 in)
14 m @ 50 km/h (45.9 ft @ 31 mi/h)

B. Engine

1. DESCRIPTION
1) Engine type Air cooled, 4-stroke. SOHC twin. parallel forward
incline
2) Engine model 2F0
3) Displacement 653 cc (39.85 cu.in)
4) Bore x stroke 75 x 74 mm (2.953 x 2.913 in)
5) Compression ratio 8.5 :: 1
61 Starting system Kick and electric starter
7) Ignition system Battery ignition
8) Lubrication system Wet sump

2. C Y L I N D E R H E A D
1) Combustion chamber volume (with N-7Y) 44.18 cc (2.696 cu.in)
2) Combustion chamber type Dome + Squish
3) Head gasket thickness 1.2 mm (0.047 in)

3. C Y L I N D E R
1) Material Aluminum alloy with cast iron sleeve
2) Bore size 75.00f~.02 mm (2.9528+~Ooo8 in)
3) Taper limit 0.05 mm (0.002 in)
4) Out of round limit 0.01 mm (0.0004 in)

4. PISTON
1) Piston skirt clearance 0.050 ~ 0.055 mm (0.0020 ~ 0.0022 in1
21 Piston oversize 75.25 mm 75.50 mm 75.75 mm 76.00 mm
12.963 inl 12.972 in, 12.982 in, l2.992 in1
3) Piston pin outside diameter x length 20.0_~,005mm x 61.0 & mm

(0.79mg,M)02 in x 2.40 -to115 in)

5. PISTON RING
1) Piston ring design ITOP) 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)
2) Ring end gap (Installed. top 0.2 - 0.4 mm 10.008 - 0.016 in)
(Installed. 2nd 0.2 - 0.4 mm (0.008 - 0.016 in)
(Installed, oil) 0.3 - 0.9 mm (0.012 - 0.036 in)
3) Ring groove side clearance (TOP) 0.04 - 0.08 mm (0.0016 - 0.0031 in)
(2nd) 0.03 - 0.07 mm (0.0012 - 0.0028 in)
r 1) Type Needle bearin

1) Cam drive type

2) Number and type of bearing
3) Bearing dimensions
25 x 47 x 8 mm IO.984 x 1.850 x 0.315 in)

-f
A

1
Type TSUBAKIMOTO BFOSM
Pitch/Number of links 7.774 mm IO.3060 in)/106
Sprocket ratio (Teeth)

15.0’$“‘* mm (0.591t~W07 in)

21 Rocker arm shaft diameter 15.O$:E mm lO.5911$~$ in)
31 Clearance 0.009 - 0.033 mm (0.00035 - 0.00130 in)
in)

alve per cy inder

2) Valve clearance (In cold engine) IN: 0.10 mm 10.0039 in)
EX: 0.15 mm (0.0059 in)
3) Dimensions
Valve head diameter “A” IN: 41 mm Il.614 in1
EX: 35 mm (1.378 in)
Valve face width “6” IN: 2.1 mm 10.083 in)
EX: 2.1 mm (0.083 in1
Valve seat width “C” IN: 1.3 mm (0.051 inl
EX: 1.3 mm (0.051 in)
Valve margin thickness “D” IN: 1.3 mm (0.051 in)
EX: 1.3 mm (0.051 in)

I N : 8.0;~:~~~ m m (0.315~~:~ in)

Valve stem diameter
EX: 8.OI~:~~ mm (0.315;~:$~~ in)
Valve guide diameter IN: 8.0 $ii”, mm 10.315 I::= in)
E X : S.O:~:$~ mm 10.315:z:“d in)
Valve stem to guide clearance IN: 0.020 _ 0.044 mm 10.00079 - 0.00173 in)
EX: 0.035 - 0.059 mm (0.00138 - 0.00232 in)
4) Valve face runout limit IN & EX: 0.03 mm (0.0012 in) or less
IO. VALVE SPRING
1) Free length INNER (IN/EX): 42 mm (1.654 in)
OUTER (IN/EX): 42.55 mm (1.675 in)
2) Spring rate (kg/mm) INNER IIN/EX): ki = 1.43
kz = 1.61
OUTER (IN/EX): kl = 3.2
k> = 4.18
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
OUTER (IN/EX): 17.7 + 1.25 kg (39.0 * 2.6 lb)
5) Compressed length (Valve open) INNER IIN/EX): 25.5 mm (1.004 in)
OUTER (INIEXI: 27.5 mm (1.083 in)
6) Compressed pressure (Valve open) INNER IIN/EX): 27.2 * 1.9 kg (60.0 + 4.2 lb)
OUTER (IN/EX): 57.4 + 4.0 kg (126.5 + 8.8 Ibl
7) Wire diameter INNER (IN/EX): 2.9 mm (0.114 in)
OUTER (IN/EX): 4.2 mm 10.165 in)
8) Winding O.D. INNER (IN/EX): 19.4 mm (0.764 in)
OUTER (IN/EXI: 32.6 mm (1.283 in)
9) Number of windings INNER (IN/EX): 6.0 turns
OUTER (IN/EX): 4.25 turns
Il. CRANKSHAFT

1) Crankshaft deflection limit (A) 0.05 mm (0.002 in)

2) Conwd large end clearance (B) 0.15 - 0.4 mm 10.0059 - 0.0157 in)
3) Width of crankshaft 0 002 in)
66$$ mm 12.5981rJ:po4
(C)
0) 166_& mm (7.323_&,t2 in)
4) Crank pin I.D. 26:g:‘d: mm (1.024:$$: in)
5) Crank pin O.D. x length 262., x 65::;: mm (1.024_&,,2 x 2.559-q:% in)

12. CONNECTING ROD

1) Big end I.D. 34+t016 mm (1.339+$oM)6 in)
2) Small end I.D. 2O:g:j:g mm (0.787$“$jM in)
13. CRANK BEARING
11 Size Right end I.D. x O.D. x Width 30 x 70 x 19 mm (1.16 x 3.07 x 0.75 in)
Others I.D. x O.D. x Width 32 x 68 x 17 mm (1.26 x 2.69 x 0.67 in)
2) Oil seal type/size (I.D. x O.D. x Width) SD25 x 40 x 9.0 mm (0.984 x 1.575 x 0.354 in)
14. CLUTCH
1) Clutch type Wet, multiple type
2) Clutch operating mechanism Inner push type, screw push system
3) Primary reduction ratio and method 72127 (2.666). spar gear
4) Primary reduction gear back lash
Tolerance 0.05 - 0.08 mm (0.0020 - 0.0031 in)
5) Friction plate
Thickness/Quantity 3 mm (0.118 in)/7 pcs.
Wear limit 2.7 mm (0.106 in1
6) Clutch plate
Thickness/Quantity 1.4 mm 10.055 in)/6 pcs.
Warp limit 0.05 mm (0.002 in)

-6.5 -
 71 Clutch spring
Free IengthlDuantity 34.6 mm 11.362 in)/6 pa.
81 Clutch housing radial play 0.027 - 0.081 mm fO.0011 - 0.0032 in)
9) Push rod bending limit 0.2 mm (0.008 in)

5. TRANSMISSION
1 I Type Constant mesh, 5.speed forward
21 Gear ratio: 1st 32/13 (2.461)
2nd 27/17 11.588)
3rd 26/20 (1.300)
4th 23/21 (1.095)
5th 22/23 10.956)
31 Bearing type: Main axle (Left)(l.D.xO.D.xWidth) Needle bearing (20x30~20 mm)10.787x1.181x0.787 in)
Main axle (Right){ ” 1 Ball bearing (25x52x20.6 mm)(0.984x2.047x0.811 in)
Drive axle (LeftIf ” ) Ball bearing (30x62x23.8 mm)~1.181x2.441x0.937 in)
Drive axle lRight)( ” 1 Needle bearing lZOx3Ox16 mml~0.787x1.181x0.630 in)
4) Oil seal type Drive axle (Left)( ” j S D D (40x62x9 mm)(1.575x2.441x0.354 in)
51 Secondary reduction ratio and method 34117 (2.0). chain

6. SHIFTING MECHANISM
1) Type Cam drum, return type
2) Oil seal type (Change lever) I.Dx0.D.x Width SDO-14x24~6 mm 10.551x0.945x0.236 in)
7. KICK STARTER
1 I Type Bendix type
2) Oil seal type (Kick axle) I.D.xO.D.x Width SD-25x35~7 mm (0.984x1.378x0.276 in)
31 Kick clip friction tension 1.2 - 1.7 kg (2.6 - 3.7 lb)
8. INTAKE
1) Air cleaner: Type/Quantity Dry, foam rubber/Z pcs.
2) Cleaner cleaning interval Every 1,600 km Il.000 mile)
9. CARBURETOR
1) Type and manufacturer/Quantity 6538 MIKUNIR pcs.
2) I.D. mark ZFOOO
3) Main jet (MJ) #135
4) Air jet IAJ) #140
5) Jet needle (JN) 502.3
6) Needle jet (NJ) z-2
7) Throttle valve ITh.VJ #120
8) Pilot jet (PJ) #27.5
9) Pilot screw (Turns out) (PS) 2%
101 starter jet (GS) GS1 : #80. GSz : 0 . 5
11) Fuel level (FL) 24 t 1 mm (0.94 f 0.04 in)
121 Vacuum synchronization Same readings
13) Idling engine speed 1,200 rpm
0. LUBRICATION
1) Engine sump oil Quantity Oil exchange: 2.0 lit (2.1 qt)
Overhaul : 2.5 lit (2.6 qt)
2) Oil type and grade Yamalube 4.cycle oil or SAE 2OWJ40
“SE” motor oil
 3) Oil pump type Trochoid pump
4) Trochoid pump specifications
Top clearance 0.10 - 0.18 mm IO.0039 - 0.0071 in)
Tip clearance 0.03 - 0 . 0 9 mm 10.0012 - 0.0035 in)
Side clearance 0.03- 0.08 m m (0.0012 - 0.0031 in)
Oil pump volume 1.3 litlmin at 1,000 rpm/lEngine
5) Bypass valve setting pressure 1 . 0 kg/cm2 (14 psi)
6) Lubrication chart

C. Chassis

1. FRAME
1) Frame design Double cradle, high tensile frame

2. STEERING SYSTEM
1) caster 27”
2) Trail 115 mm (4.53 inl
3) Number and size of balls in steering head
upper race 19 pcs. l/4 in
Lower race 19 pcs. 114 in
4) Steering lock to lock 42’ each IL and RI

3. FRONT SUSPENSION
1 I Type Telescopic fork
2) Damper type Oil damper, coil spring
3) Front fork spring
Free length 482 2 6 mm 118.98 * 0.24 in)
Wire diameter x winding diameter 4 mm x 24.5 mm 10.157 x 0.965 in)
Spring constant
4) Front fork travel 150 mm (5.906 in)
5) Inner tube 0.0. 35 mm (1.378 in)
6) Front fork oil quantity and type 169 cc 15.71 02)
Yamaha fork oil 1Owt or equivalent
 7) Distance from the top of inner tubeti oil level. Approx. 454 mm (17.9 in)
without spring
4. REAR SUSPENSION
1) Type Swing arm
2) Damper type Oil damper, coil spring
3) Shock absorber travel 80 mm (3.15 in)
4) Shock absorber spring
Set length 201 mm (7.91 in)
Free length 226 mm (8.90 in)
Wire diameter x winding diameter 7.5 mm x 60.5 mm 10.295 x 2.382 in)
5) Swing arm free play (Limit) 1 mm (0.04 in)
6) Pivot shaft -Outside diameter 16 mm (0.63 in)

5. FUEL TANK
1) Capacity 15 lit (4.0 USgal)
21 Fuel grade Regular gasoline (90 octane)

6. WHEEL
1) Type (Front and rear) Aluminum run
2) Tire size (Front) 3.50H19.4PR
(Rear) 4.00H18.4PR
31 Tire pressure:
Normal riding (Front) 1.6 kg/cm’ (22 psi)
(Rear) 2.0 kg/cm2 (28 psi) Refer to PAGE 10
4) Rim run out limit (Front and rear)
Vertical 2 mm (0.08 in1
Lateral 2 mm (0.08 in)
5) Rim size (Front) 1.85-19 in
(Rear) 2.1518 in
6) Bearing type
Front wheel (Left) 6303RS
Front wheel (Right) 6303RS
Rear wheel (Left) 63052
Rear wheel (Right) 63042
7) Oil seal type
Front wheel (Lettl I.D.xO.D.x Width SD0 45x56~6 mm (1.771x2.205x0.236 in)
Front wheel (Right) ” SD 28x47~7 mm (1.102x1.850x0.276 in1
Rear wheel (Left) ” SD 35x62x9 mm (1.378x2.441x0.354 in)
Rear wheel (Right) ” SO 27x52x5mm (1.063x2.047x0.197 in)
8) Secondary drive chain type
Type 50HDS
Number of links 103L + Joint
Chain pitch 15.875 mm (518 in1
Chain free play 20 mm (314 in)
 7. BRAKE
1 I Front brake
TVP~ 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. 14.0 mm 10.55 in)
Caliper cylinder inside dia. 38.18 mm 11.5 in)
Brake fluid type DOT #3 Brake fluid
2) Rear brake
Tvpe Drum brake
Actuating method Leading trailing
Brake drum I.D. 180 mm (7.09 in)
Brake shoe dia. x width 180 x 30 mm (7.09 x 1.18 in)
Lining thickness/wear limit 412 mm 10.16lO.08 in)
Shoe spring free length 68 mm (2.68 in)

D. Electrical

1. IGNITION SYSTEM
1) Ignition timing (B.T.D.C.) 15”/1,200 rpm
2) Ignition coil
Model/Manufacturer CM1 I-5OBIHITACHI
Spark gap 6 mm (0.24 in) or more1500 rpm
Primary winding resistance 3.9.Q + 10% at 20°C (68OF)
Secondary winding resistance Fl.Okn? 20% at 20°C 168’F)
31 Spark plug
Tvw NGK BP 7ES. CHAMPION N-7Y
Spark plug gap 0.7 - 0.8 mm 10.027 - 0.031 inl
4) Contact breaker
Manufacturer/Quantity HITACHI/2 PCS .
Point gap 0.30 - 0.40 mm 10.012 - 0.016 inl
Point spring pressure 750 f 100 g
Cam closing angle 93O f 5O
5) Condenser
Capacity 0.22 /IF
Insulation resistance 10 M!J or more
Quantity 2 pcs.
2. CHARGING SYSTEM
1) AC generator
Charging output 14 V 1 lA12.000 rpm
Rotor coil resistance (Field coil) 5.2522 f 10% at 20°C (68°F)
Stator coil resistance 0.4622 * 10% at 2O’C 168°F)
Brush length 14.5 mm IO.571 in)
Brush wear limit 7.0 mm 10.276 in)
2) Rectifier
Tvw B-Element type (Full wave)
Model/Manufacturer SBGB-17/HITACHI
Capacity 12A
Withstand voltage 400v
3) Regulator
Tvpe Tillil type
Model/Manufacturer TLlZ-BOIHITACHI
Regulating voltage 14.5 t 0.5 v

- 70
 4) Voltage regulator
core gap 0.6 - 1 .O mm (0.024 - 0.039 in)
Point gap 0.3 - 0.4 mm (0.012 - 0.016 in)
Voltage coil 1o.Q at 20°C (68OF)
Resistor 10/25R at 20°C (68-F)
5) Battery
ModellManufacturerMuantitv Y814L.AZ/YUASA/l
Capacitv 12V. 14AH
Charging rate 1.4A 10 hours
Specific gravity 1.28 at 20-C l68’F)
3. STARTER
1) starter motor
Tvpe Bendix type
Manufacturer HITACHI
Model SlOB-35
output 0.5 kw
Armature coil resistance 0.0067a + 10% at 2O’C 168’F)
Field coil resistance 0.004a + 10% at 2o”c 168OF)
Brush SizeIQuantitv 16 mm (0.63 in)/2 PCS.
Wear limit 4 mm (0.16 in)
Spring pressure 800 g (28.2 02)
Commutator O.D.iWear limit 33 mm (1.30 in)/31 mm 11.22 in)
Mica undercut 0.7 mm (0.028 in)
Reduction/Ratio 19.654 (36/7 x 24126 x 23/14 x 63/25)
2) Starter switch
Manufacturer HITACHI
Model A 104.70
Amparage rating 1OOA
Cut-in voltage 6.5V
Winding resistance 3.523
3) Starter clip friction tension 2.2 - 2.5 kg (4.9 - 5.5 lb)
i. LIGHTING SYSTEM
1) Head light type Sealed beam
2) Bulb brightness and wattagelQuantitv
Head light wattage 12v. 50/4OW x 1 PC.
Tail/Stoplight wattage OI and wattage 3132 cp, ( 12V. 8/27W) 1 pa.-s.
Flasher light wattage ss and wattage 32 cp. (12V. 27W) x 4 pcs.
Meter light wattage 12v. 3.4W x 4 pcs.
Neutral light wattage 12v. 3.4w x 1 pa.
Flasher pilot light wattage 12v. 3.4W x 2 per.
12v. 3.4w x 1 PC.
High beam indicator light wattage 12v. 3.4w x 1 PC.
3) Reserve lighting unit Model/Manufacturer 337.11720/KOITO
4) Horn
Model/Manufacturer CF.12/NIKKO
Maximum amparage 2.5A
5) Flasher relay
TVP~ Condenser type
Model/Manufacturer lAO-70IND
Flasher frequency 85*10 cvclelmin.
Capacitv 32 cp, l27W) x 2 + 3.4 W
6) Flasher cancelling Unit
Model EVH-AC518
Voltage DCSV - 16V
7) Fuse
Rating/Quantity Main (Red): 2OA
 XS650E
Supplementary
FOR XS650E MODELS AFTER ENGINE SERIAL NO. 2FO-006501
 FOREWORD
This Supplementary Manual for XS650E has been published to supplement
the Service Manual for the XS65OE (LIT-1 1616-00-761, and provides up-
dated information for the XS650E model as well as new data concerning the
XS650E. For complete information on service procedures it is necessary to
use this Supplementary Manual together with the Service Manual for the
XS650E (LIT-1 1616-00-76).
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 numbers shown in brackets correspond to page numbers of the XS650E (LIT-1 1616-00-76)
Service Manual.
(Page 4-5)
2-2. Maintenance Interval Charts

c
A. PERIODIC MAINTENANCE EMISSION CON TROL SYSTEM

I I
INITIAL BREAK-IN
NO. ITEM
or 7 months
I
1 1 Cam Chain Check and adiust chain tension

-I
Check and adjust valve clearance 0
when engine is cold.
1 Check condition. Adjust point gap.
0

qgggik
Check and adjust ignition timing. 0
0

I 6 I Svstem
Crankcase Ventilation
I1 PI loI
I _I I -r”el* ,,_~~
nose
1 Check fuel hose for cracks or damage. I A I I f-l I
Replae if necessary.

a P”L ^.._I c .,_. ^-

-IrIm”,, U*r,rlll
1 Check for leakage. Ratighten as nacs- 1 n I n
sary. Replace gasket(sl if necessaw.
Carburetor
9 Adjust synchronization of carburetors. 0
Synchronization
Check and adjust engine idle speed.
Adjust cable free play.

B. GENERAL MAINTENANCE/LUBRICATION
-I-

AND LUBE EVERY 500 km 300m,

Medium .wght wheel

(Page 8)
E. Cam chain adjustment
Check/Adjust the cam chain tension as
follows:
Remove the cap nut.
Turn the left end of the crankshaft
counterclockwise. As the crankshaft is
turning, check to see that the cam chain
adjuster push rod is flush with the end of
the bolt. If not, turn the adjuster bolt
a . 20530mm (0.79-1.18in)
until the push rod is flush.
Reinstall the cap nut. The cap nut acts (Page 14)
as a lock nut for the adjuster. C. Ignition timing
1. Point gap must be set before setting
timing.
2. Ignition timing is checked with a timing
light by observing the position of the
I stationary marks stamped on the stator
and the pointer on the generator rotor.

+-
1. Cap nut 2. Adjuster bolt 3. Push rod

(Page 9)
B. Air filters
2. Cleaning method
C. The air filter element should be cleaned
every 8,000 km (5,000 mi). It should be 1. Top dead center
cleaned more often if the machine is 2. 19 BTDC/l,ZOO rlmin
operated in extremely dusty areas. 3. Advanced mark

3. Connect timing light to right (left)

cylinder spark plug lead wire. Ignition
(Page 11)
timing of right cylinder must be set first.
G. Drive chain
4. Start the engine and keep the engine
1. Tension check
speed as specified on the label. Use a
Inspect the drive chain with both tires
tachometer for checking.
touching the ground. Check the tension
5. The rotor pointer should line up the “F”
halfway between drive and driven
stamped timing mark on the stator at
sprockets. The normal vertical deflec-
a specified engine speed. If it does not
tion is approximately 20 _ 30 mm (0.79
align, loosen the two breaker backing
w 1.18 in)
plate screws (breaker assembly holding
screws for left cylinder) and move the
complete backing plate (breaker assem-
bly for left cylinder) until the point
marks align.

r
-106-
 6. Retighten screws. Check timing again
for right cylinder.
7. Repeat procedure (steps 2-6) for left
cylinder.
- SW -_- -s-m- .-

1. Right cylinder timing adjustment

2. Left cylinder timing adjustment

(Page 15)
F. Spark plug
Check electrode condition and wear, insula-
tor color and electrode gap. Use a wire gauge
for adjusting the plug gap. If the electrodes
become too worn, replace it. When installing
the plug, always clean the gasket surface, wipe
off any grime that might be present on the
surface of the spark plug, and torque the
spark plug properly.

Standard spark plug:

N-7Y (CHAMPION) or BP7ES (NGK)
Spark plug gap:
0.7 - 0.8 mm (0.028 - 0.031 in)
Spark plug tightening torque:
2.0 m-kg (14.5 ft-lb)

- 107-
. _ - ..^_. ..“.. ^._I...^ ..__... l^.i ._... “..._ -.I. .^-l”..
R
 FOREWORD
This Supplementary Service Manual has been prepared to introduce new
service and new data for the XS650G/XS650SG. For complete information
on service procedure, it is necessary to use this Supplementary Service
Manual together with following manuals:

XS650E Service Manual (LIT-1 1616-00-76)

XS650SE Supplementary Service Manual (LIT-1 1616-01-08)
XS650SF/2F Supplementary Service Manual (LIT-1 1616-01-65)

SERVICE DEPT.
INTERNATIONAL DIVISION
YAMAHA MOTOR CO., LTD.
NOTE:
This Supplementary Service Manual contains information regarding periodic
maintenance to the emission control system for the XS650G/XS650SG.
Please read this material carefully.

Starting Serial Number

XS650G G . . . . . . . . . . . . . . 3G1-000101

XS650SG
G . . . . . . . . . . . . 2F0-200101
 MAINTENANCE AND LUBRICATION CHART
PERIODIC MAINTENANCE EMISSION CONTROL SYSTEM
INITIAL BREAK-IN THEREAFTEREVERY

NO. ITEM 1,000 km 5,000 km 4,000 km 8,000 km

REMARKS
or 1 month or 7 months or 6 months or 12 months
(600 mi) ( 3 , 0 0 0 mi) (2.500 mi) l5.000 mil

1‘ ’ Cam Chain 1 Check and adjust chain tension. CJ 0 0

2’ Va,ve Cl e a r a n c e 1 Check and adjust valve clearance when 0 0 0

! engme is cold.
Replace every
3 Check condition. Adjust gap. 12,000 km or
Spark Plugs 0 0
Replace after initial 13,000 km. 18 months
(7,500 mi)

4’ Crankcase Venti- ’ Check ventilation hose for cracks or 0 0

latlon System damage. Replace if necessary.
Check fuel hose for cracks or damage. 0 0
5’ Fuel Hose
Replace if necessary.
Check for leakage. Retlghten as 0 0
6’ Exhaust System
necessary. Replace gasket(s) if necessary.
Carburetor 0 0
7’ Adjust synchronization of carburetors.
Synchron,zat,on

Check and adjust engine idle speed, 0 0

8‘ Idle Speed
Adjust cable free play if necessary.

‘It IS recommended that these Items be inspected and serwce by a Yamaha Dealer or other qualified mechanic.

GENERAL MAINTENANCE/LUBRICATION

5’ Clutch Adjust free play. - 0 0 0

Check chain condition. Yamaha chain and

6 Drive Chain Adjust and lubricate cable lube or CHECK CHAIN TENSION AND LUBE EVERY 500 km (300 mi).
chain thoroughly. lOW/30 motor oil
Yamaha chain and
, Control and Apply cable lube 0 Q 0
cable lube or
Meter Cable thoroughly.
lOW/30 motor oil

6 Rear Arm Apply until new grease - 0

Pwot Shaft shows.
Brake Pedal Yamaha chain and
9 and Change Apply lightly cable lube or 0 0
Pedal Shaft lOW130 motor oil

Brake/Clutch Yamaha chain and

IO Lever Pwot Apply lightly cable lube or 0 0
Shafts lOWl30 motor oil

-165-

i ,
 INITIAL BREAK-IN 1 THEREAFTEREVERY
I
1,000 km i 5,M)o km 4,000 km
1
REMARKS
r 1 monthior 7 months or 6 month! E 0
(600 mi) / 13,000 mi) l2,5OOmil ,

Yamaha chain and

Lubricate
cable lube or 1OWl 0 0
Apply lightly 30 motor oil

Dram completely. Yamaha fork oil Replace

Refill to specification 1Owt or equivalent

Check bearings assembly Medium weight

for looseness. wheel bearing 0 0
Repack
Moderately repack every grease.
16,000 km (10,000 mi).

Check bearings for - 0 0

wnooth rotation.
Check specific gravity.
1 5 Batfew Check breather pipe for - 0 0
proper operation. +
Replace generator brushes
,6e AC. Replace at initial 9,000 - ii-+--
Generator km (5,500 mi) 1

‘It is recommended that these items be inspected and serviced by a Yamaha dealer or other qualified mechanic.
“XS650G onlv

-166-
 ~Yamaha Motor Corporation, U.S.A.. 1979 All rights reoened. Any reprinting or unauthorized
use without the written permission of Yamaha Motor Corporation, U.S.A., is expressly prohibited.

NEW SERVICE exactly as described. Failure to do so may be

a violation of law.
*SPECIAL TOOL
1. Install the A.C.G. stator assembly to the
New special tool for XS650G/XS650SG.
crankcase.
“TORX” socket
2. Set the pick-up coil assembly so that the
P/NO. 90890-01308-00
upper bolt (special bolt) comes in the
center of the oblong hole in the upper
pick-up plate and lightly tighten the
special bolts (upper and lower).

This socket is used to tighten the pick-up coil

securing bolts (special bolts) and to shear off
the bolt head.
*ENGINE 3. Remove the breaker cover.
A. IGNITION TIMING CHECK 4. Install the dial gauge in the left cylinder
Ignition timing adjustment is required only to set the timing plate.
when the pick-up coil is replaced. NOTE:
1. Connect the timing light to the left Put the gauge needle through the plug hole as
cylinder spark plug lead wire. normal to the piston head as possible.
2. Start the engine and keep the engine Do not let the needle contact the plug hole.
speed as specified. Use a tachometer to
check the engine speed.

Specified engine speed: 1,200 r/min

I

3. The rotor pointer should line up with

the “F” stamped timing mark on the
timing plate. If it does not align or
steady, check the crankshaft bearing
and/or woodruff key for damage.

5. Rotate the engine in a counterclockwise

B. PICK-UP COIL ASSEMBLY
direction until top dead center is found.
The pick-up plate assembly is permanently
6. With the engine at top dead center,
mounted to the stator housing with special
loosen the screw on the timing plate and
bolts and adhesive. It is necessary to replace
align the “T” mark on the timing plate
the A.C.G. stator assembly with a new one if
with the rotor pointer.
the pick-up coil is damaged.
Recheck the top dead center and align-
ment of the “T” mark and pointer.
C. IGNITION TIMING ADJUSTMENT
When all are aligned, tighten the screw.
If the A.C.G. stator assembly is replaced with
a new one, the following adjustment and
treatment are necessary. It is mandatory that
these procedures be followed carefully and

- 167 -
 eiYamaha Motor Corporation, U.S.A., 1979 All rights resered. Any reprinting or unauthorized
use without the written permission of Yamaha Motor Corporation, U.S.A., is expressly prohibited.

NOTE:
A special socket (90890-01308-00) is neces-
sary for tightening these special bolts. The
heads will shear off when the bolts have been
properly torqued.

1. Romr pointer 2. Timing plate

7. Check the ignition timing (refer to page

3).
8. If the ignition timing is incorrect, loosen
the special bolts and move the pick-up
plate until the “F” and pointer marks
align.
D. CARBURETOR
1. Specifications

Main jet # 132.5 1

Jet needle 5HX12
Needle jet Y-O
Starter jet # 30
Float level 27.3 + 0.5 mm
(1.075 ?r 0.020 in)
Pilot jet # 42.5
Pilot screw Preset
9. After the ignition timing is properly Fuel valve seat 2.0 mm (0.079 in)
adjusted, tighten the lower special bolt Engine idle speed 1,200 r/min
until the head shears off.
2. Inspection And Correction
a. Examine the carburetor body and fuel
passages. If contaminated, remove all
component pieces, wash the carburetor
in a petroleum-based solvent. Blow out
all passages and jets with compressed air.
-CAUTION: .
Do not use caustic carburetor cleaning
solutions.

b. Examine the condition of the floats. If

1. “TORX” socket
the floats are damaged, they should be
10. Back off the upper special bolt 3 or 4 replaced.
turns and apply a liberal amount of an C. Inspect the inlet needle valve and seat
epoxy adhesive around the bolt thread. for wear or contamination. Replace
Retighten the bolt until the head shears these components as a set if required.
off. d. Inspect the vacuum piston and rubber
diaphragm. If the piston is scratched or
the diaphragm is torn, the assembly must
be replaced.
-168-
e. Inspect the starter plunger assembly for
damage. If damaged, replace.

f. Float level
Hold the carburetor in an upside down
position. Hold the floats so the tang is
just touching the float needle. Measure
the distance from the top of the float to
the float bowl gasket base surface
without the gasket. If the distance is out
of the specification, correct the specifi-
cation.

Float level: 27.3 f 0.5 mm

(1.075 * 0.02 in)

To correct, carefully bend the tang on

the float arm. Both floats must be at the
same height.

I
Float height
26.8-27.8mm
(1.055 - 1.095 in1

- 169-
*ELECTRICAL
A. IGNITION SYSTEM
1 Rlneb r4irrnram
1

protective circuit

2. Description This unit consists of two pick-up coils

This model is equipped with a battery mounted on the generator case and a
operated, fully transistorized breakerless permanent magneto on the rotor which
ignition system. By using magnetic pick- is mounted to the crankshaft. When the
up coils the need for contact breaker magneto passes through these pickup
points is eliminated. This adds to the coils, the signals are generated at the
dependability of the system by eliminat- pick-up coils and forwarded to the
ing frequent cleaning and adjustment of ignitor unit as a signal.
points and ignition timing. This TCI The full ignition advance is determined
unit incorporates an automatic advance by the distance (or angle) between two
circuit controlled by signals generated by pick-up coils.
the pick-up coils. This adds to the b. lgnitor unit
dependability of the system by eliminat-
ing the mechanic advancer. This TCI
system consists of two main units; a
pick-up unit and an ignitor unit.
3. Operation
The TCI functions on the same principle
as a conventional DC ignition system
with the exception of using magnetic
pick-up coils and a transistor control box
(TCI) in place of contact breaker points.
1. lgnitor unit (T.C.I. unit)
a. Pick-up unit
This unit has such functions of wave
form, duty control, switching, and elec-
trical ignition advance. The ignition
timing is advanced electrically using two
signals from the pick-up coils.
The duty control circuit is provided to
control the on time period of the pri-
mary ignition current to reduce the
electrical consumption. This unit also
incorporates a protective circuit for the
1. Pick-up unit ignition coil. If the ignition switch is
- 170-
 turned on and the crankshaft is not 3) Start the engine and increase the spark
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
turned over, the current is turned on Minimum spark gap: 6 mm (0.24 in)
again by the signals generated by the
pick-up coils.
Do not run engine In neutral above 6,000
NOTE:
r/min for more than 1 or 2 seconds.
Even though two spark plugs fire at the same
time only one cylinder is on the compression b. If the ignition system should become
stroke at a time. The other cylinder is on the inoperative, the following troubleshoot-
exhaust stroke and the spark in that cylinder ing aids will be useful.
has no effect.

-CAUTION:
Do not run the engine without any spark
plug cap(s) in place. Due to the high sec- &
OK
ondary voltage, it is possible to damage the I
&
internal insulation of the secondary coil. Check battery for ‘““y”“““bm
voltage and specific grawy
4. Troubleshooting/Inspection specific gravity
a. The entire ignition system can be
checked for misfire and weak spark using
L
OK

the Electro Tester. If the ignition sys- +

tem will fire across a sufficient gap, the Check fuse and fuse Weak cpnnectmn
connections or open cwcuit t,on or replace
engine ignition system can be considered
good. If not, proceed with individual
component tests until the problem is
found.
1) Warm up engine thoroughly so that all Check resistance of
electrical components are at operating
temperature.
2) Stop the engine and connect the tester Primary: 2.5 .Q 2
as shown.

Check pick-up
coils for resistance
Pick-up coil:
7 0 0 R f 20%
I

-171-
 B. CHARGING SYSTEM NOTE:
1. Block Diagram Remove the headlight fuse (l0A) in the fuse
box so that the headlight does not turn on
I.C.Voltage when the engine is started. Do not turn on
Regulator
(with rectifier) the signals.

4) If the indicated voltage cannot reach

the specification, then perform the fol-
lowing tests.
-CAUTION:
Never disconnect the wires from the battery
while the generator is in operation. If the
battery is disconnected, the voltage across
the generator terminals will increase, damag
L-
ing the semiconductors.
2. A.C. Generator/Voltage Regulator
a. Output voltage check b. Brush
1) Remove the seat and left side cover. Check the brush length. Replace brush
2) Connect a D.C. voltmeter to the battery if at, or near, limits. Check the brush
terminals and start the engine. spring pressure by comparing it with a
3) Accelerate the engine to approximately new spring. Replace the old spring if it
2,000 r/min or more and check the gener- is weak.
ated voltage.
Minimum brush length: 7 mm (0.28 in)
, Generated voltage: 14.2 - 14.8V I

c. Rotor coil/Stator coil

Check the resistance between terminals
Vt using the Yamaha Pocket Tester or other
14.8 ______--__--- _ _ _ _ _ _ _ circuit tester as shown. If resistance is
14.5
14.2 - - - - -------_
r - - - - - out of specification, check the coil
VI connections. If the coil connections are
8 good, then the coil is broken inside and
z
it should be replaced.
2
r Rotor coil resistance (Green-Brown):
I
I
I
5.3s2 * 10% at 2OC (68°F)
0 *
Approx. 2,000 r/mm Stator coil resistance (White-White):
Engine revolutions 0.46s2 + 10% at 20°C (68°F)

- 172-

4
 A l l t h r e e stator w i n d i n g s m u s t b e
checked. Also test between each termi-
nal and ground. A reading other than
infinity indicates an improper ground
which must be corrected.

0 : Continuity
x : Discontinuity @I
d. Silicon rectifier
Check the silicon rectifiers as specified -CAUTION:
using the Yamaha Pocket Tester or other The silicon rectifier can be damaged if
circuit tester. Even if only one of the subjected to overcharging. Special care
elements is broken, replace the voltage should be taken to avoid a short circuit
regulator assembly. and/or incorrect connection of the positive
and negative leads at the battery. Never
connect the rectifier directly to the battery
to make a continuity check.
L

e. If the above inspection reveals that the

regulator is faulty, it cannot be adjusted
and must be replaced.

w White U,V,W Brown

White(U)
White IV)
White IW)

Black (B)

- 173-
 l SPECl FICATION
A. General *XS650SG only **XS650G only

I
1. MODEL
1) Model (I.B.M. No.) XS650SG (3G1)/ XS650G (3GO)
2) Basic color ‘CARDINAL RED or NEW YAMAHA BLACK
I “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) ““1,220mm (48.0 in)
4) Seat height 790 mm (31.1 in)
5) Wheelbase 1,435 mm (56.5 in1
61 Minimum ground clearance 135 mm ( 5.3 in)

3. WEIGHT
1) Net weight (Dry) ‘210 kg (463 lb) “205 kg (452 lb)

4. PERFORMANCE
1) Climbing ability 26’
2) Minimum turning radius 2,500 mm (98.4 in)

B. Engine

1. DESCRIPTION
1) Engine type Air cooled. 4-stroke, SOHC twin,
parallel forward incline
2) Engine model 2FO
3) Displacement 653 cc (39.85 cu.in)
4) Bore x stroke 75 x 74 mm (2.953 x 2.913 in)
5) Compression ratio 8.7 : 1
61 Starting system Kick and electric starter
7) Ignition system Battery ignition (Full transistor ignition)
81 Lubrication system Wet rump

2. CYLINDER HEAD
1) Combustion chamber volume (with N-7Y) 42.5 cc (2.59 cu.inl
2) Combustion chamber type Dome + Squish
3) Head gasket thickness 1.2 mm IO.047 in)

3. CYLINDER
1) Material Aluminum alloy with cast iron sleeve
2) Bore size 75.00+p mm (2.9528 2.oo8 in1

3) Taper limit 0.05 mm (0.002 in)

4) Out of round limit 0.01 mm (0.0004 in)

- 174-

-
 1) Piston skin clearance 0.050 - 0.055 mm (0.0020 - 0.0022 in)
2) Piston oversize
(2.963 in) (2.972 in)

31 Piston Pin outside diameter x length

5. PISTON RING
1) Piston ring design :$Jj +J _+&&

1.2mm ,O.M7 in) ,.5mm ,a059 in, 2.8mrn ,cl.llO ir

21 Ring end gap (Installed, top) 0.2-0.4 mm (0.008-0.016 in)
/Installed. 2nd) 0 . 2 - 0 . 4 m m (0.008-0.016 in)
(Installed, oil) 0 . 3 - 0 . 9 m m ~0.012-0.035 in)

11 Type
2) Bearing size @ 26 x +34 x 1 9 . 8
3) Needle size

1) Cam drive type Chain ICenter side)

21 Number and type of bearing 4 bearings, Ball bearings (6005)
3) Bearing type
4) Cam dimensions

5) Valve timing

6) Camshaft deflection limit 0.03 mm (0.0012 in)

7) Cam chain
Tvpe TSUBAKIMOTO BF05M
Number of links
Sprocket ratio

8. ROCKERARMANO ROCKETSHAFT
11 Rocker arm inner diameter 15.0+$0’8 mm (0.591+~‘W07 in)

2) Rocker arm shaft diameter 15.0$$~ mm 10.591 I~:“$~5~ in)

31 Clearance 0.009 -0.033 mm (0.00035-0.00130 in)

41 Lift ratio X : Y =40 : 48.41 mm (1.575 : 1.906 in1

- 1 7 5 -
9. VALVE, VALVE SEAT AND VALVE GUIDE
1) Valve per cylinder 2 PCS.
2) Valve clearance Iln cold engine1 IN: 0.06 mm (0.0024 inI
EX: 0.15 mm IO.0059 in)
31 Dimensions
Valve head diameter “A” IN: 41 mm (1.614 in1
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” IN: 1.3 mm (0.051 ini
EX: 1.3 mm 10.051 ini
Valve margin thickness “D” IN: 1.3 mm (0.051 inI
EX: 1.3 mm (0.051 ini

Valve stern diameter IN: S.O_“,,,,, mm 10.315 _“,.oo,o i”’

EX: 8.0-~~~$0 mm (0.315~~:~~~ in)

Valve guide diameter IN: E.O$~~~ mm (0.315:$?47 inl

EX: 8.0;,,9b” mm 10.315$~~ in)

Valve stern to guide clearance IN: 0.010-0.034 mm 10.00079- 0.00173 in)

EX: 0.035- 0.059 mm ~0.00136-0.00232 in)
4) Valve face funout limit IN & EX: 0.03 mm 10.0012 in) or less

10. VALVE SPRING

1) Free length INNER (INIEXI: 42 mm (1.654 in)
OUTER(IN/EXI: 42.55 mm (1.675 in)
2) Spring rate INNER (IN/EXl: kl= 1.43 kg/mm (80.1 lb/in)
k*= 1.81 kg/mm (101.4 lb/in)
OUTER(IN/EX): k != 3.2 kg/mm (179.2 lb/in)
kz= 4.18 kg/mm (234.1 lb/in)
3) Installed length (Valve closed) INNER (INIEXI: 35 mm 11.378 in)
OUTER(IN/EXl: 37 mm 11.457 in)
41 Installed pressure (Valve closed) INNER (IN/EX): 10 + 0.7 kg i22.0? 1.5 lb)
OUTER(IN/EX): 17.7 t1.25 kg (39.0 + 2.8 lb)
5) Compressed length (Valve open) INNER (IN/EXI: ‘25.5 mm 11.004 in)
OUTER(IN/EXl: 27.5 mm (1.083 in)
61 Compressed pressure (Valve open) INNER (INIEX): 27.2 il.9 kg (60.0+ 4.2 lb)
OUTER(IN/EX): 57.4 + 4.0 kg (126.52 8.8 lb)
7) Wire diameter INNER (IN/EXl: 2.9 mm (0.114 in)
OUTER(IN/EXl: 4.2 mm (0.165 in)
8) Winding 00. INNER (IN/EX): 19.4 mm (0.764 inl
OUTER(IN/EX): 32.6 mm (1.283 in)
91 Number of windings INNER (INIEXI: 6.0 turns
OUTER(IN/EX): 4.25 turns

-176-
 11 Crankshaft deflection limit 0.05 mm 10.002 in)
2) Con-rod large end clearance (81
3) Width of crankshaft

4) Crank pin I.D.

5) Crank pin O.D. x length

Bigend I.D.
2) Small end I.D.

$30.m78.19 (Ball bearing1

Others $32.@68-17 (Rollar bearing)
2) Oil seal type

1) Clutch type Wet, multiple type

2) Clutch operating mechanism Inner push type, screw push system
31 Primary reduction ratio and method 72/27 (2.666). spar gear
4) Primary reduction gear back lash (4 teeth)

5) Friction plate
Thickness/Quantity 3 mm (0.118 in)/7 pcs.
Wear limit 2.7 mm (0.106 in)
6) Clutch plate
ThicknessKluantity 1.4 mm (0.055 in)/6 pa.
Warp limit 0.05 mm (0.002 in)
7) Clutch spring
Free length/Quantity 34.6 mm Il.362 in)/6 pcs.
8) Clutch housing radial play 0.027-0.081 mm (O.OOll- 0.0032 in)
9) Push rod bending limit 0.2 mm 10.008 in)
15. TRANSMISSION
1) Type Constant mesh, 5.speed forward
2) Gear ratio: 1st 32/13 12.461)
2nd 27/17 (1.588)
3rd 26120 ( 1.300)
4th 23/21 (1.095)
5th 22/23 (0.956)

- 177-
 3) Bearing: Main axle (Left) Needle bearing 1020.+30-20)
(Right) Ball bearing ($25.$52-20.6)
Drive axle (Left) Ball bearing (4 30. $662-23.8)
(Right) Needle bearing (@20- $30-161
41 Oil seal type Drive axle (Left) SDD-40.62.9
5) Secondary reduction ratio and method 34117 (2,0OO)/Chain

16. SHIFTING MECHANISM

1) Tvpe Cam drum, return type
2) Oil seal type (Change lever) SDO-14-24-6

17. KICK STARTER

11 Type Bendix type
2) Oil seal type (Kick axle) SD-25-35-7
3) Kick clip friction tension 1.2 - 1.7 kg (2.6 - 3.7 lb)

18. INTAKE
1) Air cleaner: Type/Quantity Dry. foam rubber/2 pa.
2) Cleaner cleaning interval Every 8,000 km 15.000 mile)

19. CARBURETOR
1) Type and manufacturer/Quantity 8534MIKUNI12 per.
2) I.D. mark 3GlM)
3) Main jet (M.J.) gl32.5
4) Air jet (A.J.) #85
5) Jet needle (J.N.1 5HX12
6) Needle jet (N.J.) Y.0
7) Throttle valve 1Th.V) #135
8) Pilot jet (P.J.) #42.5
9) Pilot screw (Turns out) (P.S.1 Preset
10) starter jet (G.S.1 #30
11) Fuel level (F.L.1 27.3 ? 0.5 mm 11.075 + 0.020 in)
12) Idling engine speed 1,200 rlmin

20. LUBRICATION
1) Engine rump oil quantity Oil exchange: 2.0 lit 12.1 US qt)
Overiwl: 2.5 lit (2.6 US qt)
2) Oil type and grade Yarn&be 4.cycle oil or SAE 2OW/40 type
“SE” motpr oil
3) Oil pump type Trochoid pump
4) Trochoid pump specifications
Top clearance O.lO- 0.18 mm (0.0039- 0.0071 in)
Tip clearance 0.03- 0.09 mm 10.0012- 0.0035 in)
Side clearance 0.03- 0.08 mm (0.0012-0.0031 in)
Oil pump volume 1.3 litlmin (1.37 qtlmin) at 1,000 rlmin
5) Bypass valve rening pressure 1.0 kg/cm’114 psi)

- 178-
 61 Lubrication chart

---Pressure feed

e--Splash lubrication

C. Chassis

1 FRAME
1) Frame design Double cradle, high tensile frame

2. STEERING SYSTEM
1 I caster 27’
21 Trail 115 mm 14.53 in)
31 Number and size of balls in steering head
Upper race 19 pcs. 114 in
Lower race 19 pcs. 114 in
4) Steering lock to lock 42’ each /L and RI

3. FRONT SUSPENSION
1 I Type Telescopic fork
21 Damper type ,3il damper, coil spring
3) Front fork spring
Free length 482 mm i 16.96 in)
Wire diameter x winding diameter 4 x 24.5 mm (0.157 x 0.965 in)
Spring constant I <I = 0.46 kg/mm (26.88 lb/in)/
O- 100 mm (O- 3.94 in)
ICZ= 0.65 kg/mm 136.40 lb/in)/
lOO- 150 mm (3.94-5.91 in)
4) Front fork travel 150 mm (5.906 in)
5) Inner tube O.D. 35 mm (1.378 in)
6) Front fork oil quantity and type 169 cc 15.72 02) each leg
t’amaha fork oil 1Owt or equivalent
7) Distance from the top of inner tube oil level
without spring I 4pprox. 454 mm (17.9 in)

4. REAR SUSPENSION
1) Type <swing arm

2) Damper type Oil damper, coil spring

3) Shock absorber travel 80mm (3.15 in)

- 17 9-
r 4) Shock absorber spring
Free length 226 mm (8.90 in)
Wire diameter x winding diameter 7.5 x 60.5 mm 10.295 x 2.382 inl
Spring constant kl = 1.714 kg/mm 196.0 lb/i”)/
O-45 mm (O- 1.77 in)
k2= 2.244 kg/mm 1125.7 lbiinli
45-BOmm(1.77-3.15inl
5) Swing arm free play (Limit) 1 mm (0.04 inl
6) Pivot shaft -Outside diameter 16 mm (0.63 in)

5. FUEL TANK
1 I Capacity 11.5 lit (3.04 US gall
2) Reserve capacity 2.3 lit (0.61 US gall
3) Fuel grade Regular gasoline

6. WHEEL
1) Type (Front and rear) *Cast wheel **Spoke wheel
21 Tire size (Front) 3.50S194PR “Tubeless tire “Tube~type t
(Rear) 130/90S164PR *Tubeless tire “Tube-type t
3) Tire pressure:
Up to 90 kg (198 lb) load”*’ Front: 1.6 kg/cm’ 122 psi)
Rear: 2.0 kg/cm2 (28 psi)
90 kg (198 lb) load-206 kg (453 lb) load”’ Front: 2.0 kg/cm2 I28 psi)
(Maximum load) Rear: 2 . 3 kg/cm2 (32 psi)
High speed riding Front: 2.0 kg/cm’ (28 psi)
Rear: 2.3 kg/cm’ (32 psi)
4) Rim run out limit (Front and rear)
Vertical 2 mm (0.08 in)
Lateral 2 mm (0.08 in)
51 Rim size (Front) “MT1.85 x 1 9 “‘1.85x 1 9
(Rear) ‘MT3.00 x 16 ‘“2.75 x 16
6) Bearing type
Front wheel (Left) ‘630222 ““86303
(Right) ‘63022 “B6303RS
Rear wheel (Left) 63042
63052
7) Oil seal type ‘Right’
Front wheel (Left) SDD45-56.6
(Right) SD-22-42-7
Rear wheel (Left) SD-35-62-9
(Right) SO-27.52-5
8) Secondary drive chain type
Tvpe SOHDS
Number of links 103L + Joint
Chain pitch 15.875 mm (5/8 in1
Chain free play 20 - 30 mm (0.8 - 1.2 in)
1 . , ^ ^_ ^^ ^
: XxiD”Sti
I.
: XS650G
.f.
: Total weight of accessories, etc., excepting motorcycle.

- 180-
 7. BRAKE
11 Front brake
Type 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. 14.0 mm (0.55 in)
Caliper cylinder inside dia. 38.1 mm (1.50 in)
Brake flaid type I quantity DOT =3 Brake fluid / 38.1 cc (1.29 oz)
2) Rear brake lXS650SG only)
TVP~ Hydraulic disc type
Disc size (Outride dia. x thickness) 267 x 7.0 mm (10.5 x 0.28 in1
Disc wear limit 6.5 mm (0.26 in)
Disc pad thickness 11 .O mm (0.43 in)
Pad wear limit 6.0 mm 10.24 in)
Master cylinder inside dia. 14.0 mm (0.55 in)
Caliper cylinder inside dia. 38.1 mm 11.50 in)
Brake fluid type/quantity DOT =3 Brake fluid / 38.1 cc (1.29 oz)
3) Rear brake (XS650G only)
TVP~ 3rum brake (Leading trailing)
Actuating method Link rod
Brake drum I.D. 180 mm (7.09 in)
Brake shoe dia. x width 180 x 30 mm (7.09 x 1.18 in)
Lining thickness I wear limit I mm/2 mm (0.16 in/O.08 in)
Shoe spring free length $8 mm (2.68 in)

D. Electrical

1. IGNITION SYSTEM
1) Ignition timing IB.T.D.C.l 15”11.200rimin
2) Ignition coil
Model/Manufacturer CM12-08AIHITACHI
Spark gap 6 mm 10.24 in) or more at 500 rlmin
Primary winding resistance 2.5R 2 10% at 20°C (68oF)
Secondary winding resistance 13kQ * 20% at 2O’C (68OF)
31 Spark plug
TVP~ N-7Y (CHAMPION) or EIP7ES (N.G.K.)
Spark plug gap 0.7 - 0.8 mm (0.027-0.031 in)
2. CHARGING SYSTEM
1) A.C. generator
Charging output 14V 16Al5.000 rimin
Rotor coil resistance (Field coil) 5.25R ? 10% at 20°C (68=‘F)
Stator coil resistance 0.46fi ? 10% at 20°C (6BOF)
Brush length 14.5 mm (0.571 in)
Brush wear limit 7.0 mm (0.276 in)
2) Regulator
TVP~ I.C. type
Model/Manufacturer S8515,‘TOSHIBA
Regulating voltage 14.5 * 0.3v
3) Battery
Model/Manufacturer/Quantity YB14L.A2/YUASA/l pc.
Capacity 12V. 14AH
Charging rate 1.4A 10 hours
Specific gravity 1.28 at 2O’C (68’F)

- 18 l-
 3. STARTER
1) starter motor
Type Bendix type
Manufacturer/Model HITACHI/S108-35
Output 0.5 kw
Armature coil resistance 0.0067R f 10% at 2o”c (68*Fl
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 803 g (28.2 02)
Commutator O.D./Wear limit 33mm ~1.30in)/30mm (1.18in)
Mica undercut 0.7 mm IO.028 in)
2) Starter switch
Manufacturer HITACHI
Model A10470
Amperage rating 1OOA
Cut-in voltage 6.5V
Winding resistance 3.552
3) Starter clip friction tension 2.2 - 2.5 kg (4.9 - 5.5 lb)
4. LIGHTING SYSTEM
11 Headlight type Sealed beam
2) Bulb brightness and wattage/Quantity
Headlight 12v. 50/4ow x 1 PC.
Tail/Brake light 12V. 3/32 CP (8Wi27W) x lpc.
Flasher light 12V. 32 CP 127W) x 4 pcs.
* License light 12v. 3.8w x 2 pa.
Pilot lights: Turn 12v. 3.4w x 1 pc.
High beam 12v. 3.4w x 1 pc.
Headlight failure 12v. 3.4w x 1 PC.
Neutral 12v. 3.4w x 1 pc.
**Tail/brake failure 12v. 3.4w x 1 pc.
Meter lights 12v. 3.4w x 4 PCs.
3) Reserve lighting unit
Model/Manufacturer 337.11720/KOITO
4) Horn
Model/Manufacturer CF-lZ/NIKKO
Maximum amperage 2.5 + 0.5A
5) Flasher relay
TVP~ Condenser type
Model/Manufacturer 061300048101NIPPON DENS0
Flasher frequency 85 ? 10 cyclelmin.
Capacity 32 CP (27W) x 2 + 3.4W
6) Flasher cancelling unit
Model EVH-AC518
Voltage DCSV - 16V
7) Fuse
Rating/Quantity:
Main 20A x 1 PC.
Head light 10A x 1 pc.
Signal 10Axlpc.
Ignition 10A x 1 pc.
I)
vrccnc,-.
AJO3”3U only.
.f
: XS650G only.
- 182-
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 8 mm nut 1.4 m-kg l10.0 ft.lbl
Handle crown and inner tube 8 mm nut 1 .l m-kg f( 8.0 ft.lb)

Handle crown and steering shaft 8 mm nut 1.1 m-kg ( (8.0 ft.lb)

Handle crown and steering shaft 14 mm bolt 5.4 m-kg (39.0 ti-lb)

Handle crown and handlebar holder 8 mm bolt 1.8 m-kg (13.0 ft-lb)
Under bracket and inner tube 8 mm nut 2.0 m-kg (14.5 ft.lb)

Engine mounting Upper 8 mm nut 1.8 m-kg (13.0 ft.lb)

Engine mounting Upper 10 mm nut 3.0 m-kg (21.5 ft-lb)

Engine mounting Front 10 mm nut 4.6 m-kg (33.5 ft.lb1

Engine mounting Rear 10 mm nut 4.1 m-kg (29.5 ft.lb)

Engine mounting Rear-Lower 10 mm nut 4.6 m-kg (33.5 ft.lb)

Engine mounting Lower 10 mm nut 9.0 m-kg (65.0 Wlbl

Front flasher and headlight 8 mm nut 1.0 m-kg ( (7.2 ft~lbi

_
Master cylinder and brake hose 10 mm union bolt / 2.6 m-kg (19.0 ft-lb)

- lB3-
 Part to be tightened Thread dia. and pan name 1 Tightening t o r q u e
Brake disc and hub B mm bolt i 2.0 m-kg (14.5 ft.lb1

Caliper and support bracket 8 mm bolt ~1.8 m-kg 113.0 ft.lbi

Caliper and pad I 5 mm bolt 0.3 m-kg I 2.2 ft-lb1
Caliper and bleed screw 8 mm bolt 0.6 m-kg ( 4.5 ft-lb)
Front caliper and front fork 10 mm bolt 3.5 m-kg (25.5 ft-lb)

Master cylinder and cylinder bracket : 6 mm bolt 0.6 m-kg I 4.5 ft-lb)
Pivot shaft 14 mm nut 6.5 m-kg (47.0 ft-lb)

Rear wheel axle 16 mm nut 115.0 m-kg (108.5 ft-lb)

Tension bar and brake caliper (plate) ! 8 mm nut 1.8 m-kg (13.0 ft-lb)

Tension bar and rear arm B mm nut i 3.2 m-kg (23.0 R-lb1
Rear shock absorber Upper 10 mm bolt : 3.0 m-kg (21.5 ft-lb1
Rear shock absorber Lower ~ 10 mm bolt i 3.3 m-kg (28.0 ti-lb1

Rear arm and rear arm end 8 mm bolt - I 1.0 m~kg I 7.2 ti-lb1
Front fender ~ 8mm b o l t ~~-~~~~~??~~# ~~’
Neutral switch 12mm

General Torque Specifications tighten multi-fastener assemblies in a criss-

This chart specifies torque for standard cross fashion, in progressive stages, until full
fasteners with standard I.S.O. pitch threads. torque is reached. Unless otherwise specified,
Torque specifications for special components torque specifications call for clean, dry
or assemblies are included in the applicable threads. Components should be at room
sections this book. To avoid warpage, temperature.
CONVERSION TABLES
r r

Notice
The information presented represents results obtainable by skilled drivers under controlled
road and vehicle conditions, and the information may not be correct under other conditions.

STOPPING DISTANCE
This figure indicates braking performance that can be met or exceeded by the vehicles to which
it applies, without locking the wheels, under different conditions of loading and with partial
failures of the braking system.

-185-
 not applicable and is not included)

0 100 200 300 (Feet)

!
STOPPING DISTANCE IN FEET FROM 60 MPH

ACCELERATION AND PASSING ABILITY

This figure indicates passing times and distances that can be met or exceeded by the vehicles to
which it applies, in the situations diagrammed below. The low-speed pass assumes an initial
speed of 20 mph. and a limiting speed of 35 mph. This high-speed pass assumes an initial speed
of 50 mph. and a limiting speed of 60 mph.

TOTAL PASSING DISTANCE, FEET

LOWSPEED PASS
t- TOTAL PASSING TIME. .5EC0N0S
+-------------__--4 1
i---J
~cf~~_________*~~0~
55 ff CONSTANT 20 MPH
TRUCK

TOTAL PASSING DISTANCE. FEET

TOTAL PASSING TIME. SECONDS
HIGHSPEED PASS +----------------------,-y
Ilc-3
,coff ~____________--a ,oott
55 ff CONSTANT 50 MPH
TRVCK

SUMMARY

Low-speed pass ___............... 357 feet: 7.3 seconds XS65OSG

352.3 feet: 7.14 seconds XS650G
High-speed pass . . . . . . . . . . . .._.. 945.5 feet: 9.3 seconds XS650SG
931.8 feet: 9.0 seconds XS650G

- 186-
 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

 FOREWORD

This Supplementary Service Manual has been prepared to introduce new

service and new data for the XS650H/XS650SH. For complete information
on service procedure, it is necessary to use this Supplementary Service
Manual together with following manuals:

I
’ XS650E Service Manual (LIT-11616-00-76)
! XS650SE Supplementary Service Manual (LIT-11616-01-08) 1
’ XS650SF/2F Supplementary Service Manual (LIT-11616-01-65)
XS650G/SG Supplementary Service Manual (LIT-1 1616-01-75)

SERVICE DEPT.
INTERNATIONAL DIVISION
YAMAHA MOTOR CO., LTD.

NOTE:
This Supplementary Service Manual contains information regarding periodic
maintenance to the emission control system for the 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
persons using this book to perform maintenance and repairs on Yamaha
motorcycles have a basic understanding of the mechanical concepts and
procedures inherent to motorcycle repair technology. Without such know-
ledge, attempted repairs or service to this model may render it unfit for use
and/or unsafe.

This model has been designed and manufactured to perform within certain
specifications in regard to performance and emissions. Proper service with
the correct tools is necessary to ensure that the motorcycle will operate as
designed. If there is any question about a service procedure it is imperative
that you contact a Yamaha dealer before continuing. Before attempting any
service, check with your Yamaha dealer for any service information changes
that apply to this model: This policy is intended to provide the customer
with the most satisfaction from his motorcycle and to conform with federal
environmental quality objectives.

Yamaha Motor Company, Ltd. is continually striving to further improve all

models manufactured by Yamaha. Modifications and significant changes in
specifications or procedures will be forwarded to all Authorized Yamaha
dealers and will, where applicable, appear in future editions of this manual.

I -
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.
WARNING: A WARNING indicates special procedures that must be fol-
lowed to avoid injury to a motorcycle operator or person
inspecting or repairing the motorcycle.

Starting Serial Number

XS650H H . . . . . . . . . . . . . 4N9-000101

XS650SH
H . . . . . . . . ..__. 4M4-000101
 MAINTENANCE AND LUBRICATION CHART
PERIODIC MAINTENANCE EMISSION CONTROL SYSTEM

- 3
 c
t
c
 B. PICK-UP COIL ASSEMBLY
The method of mounting the pick-up coil
*ENGINE
assembly is changed for easier service work.
A. IGNITION TIMING Thus, the followings “Pick-up coil assembly
The ignition system is modified for easier removal” and “Pick-up coil assembly reinstal-
maintenance. Thus, the following “ignition lation” should be changed.
timing check” should be changed,
Pick-up coil assembly removal
Ignition timing check Remove the pick-up coil securing screws and
1. Ignition timing is checked with a timing remove the pick-up coil assembly.
light by observing the position of the
rotor pointer and the marks stamped on
the timing plate.
The timing plate is marked as follows.
“ll” Firing range for No. 1 (L.H.)

“T” Top Dead Center for No. 1,

fL.H.1 cylinder
2. Connect the timing light to the left
cylinder spark plug lead wire.
3. Start the engine and keep the engine Pick-up coil assembly reinstallation
speed as specified. Use a tachometer to Install the pick-up coil assembly on to the
check the engine speed. stator assembly.

Specified engine speed: C. FUEL LEVEL

1,200 r/min The carburetor is furnished with a drain screw
L_ to provide easy access to service work. Thus,
4. The rotor pointer should be within the following “Fuel level measurement”
the limits of ” fl ” on the timing plate. should be added.
If it exceeds the limits or does not
steady, check the timing plate for tight- Fuel level measurement
ness and/or ignition system for damage. NOTE:
NOTE: Before checking the fuel level, note the follow-
Ignition timing is not adjustable. ing:
1. Place the motorcycle on a level surface.
2. Adjust the motorcycle position by plac-
ing a suitable stand or a garage jack
under the engine so that the carburetor
is positioned vertically.

1. Connect the level gauge (special tool) or

a vinyl pipe of 6 mm (0.24 in) in inside
diameter to the float bowl nozzle left or
right side carburetor.
2. Set the gauge as shown and loosen the
drain screw.

-5
 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.
YL___-A
NOTE:
Make sure the fuel petcock is “ON” or “RES” 6. If the fuel level is incorrect, remove the
oosition. carburetor assembly from the motor-
cycle and check the fuel valve(s) and
4. Note the fuel level and bring the gauge float assembly(s) for damage.
to the other end of the carburetor line 7. If no damage is found, correct the fuel
and repeat step 3 above. Note the fuel level by slightly bending the float arm
level again and compare it with the tang. Recheck the fuel level.
previous gauge reading. They should be
equal. If not, place a suitable size of
wooden piece or the. alike under the
center stand and adjust.

D. ENGINE OIL LEVEL MEASUREMENT

1. Place the motorcycle on the center stand.
Warm up the engine for several minutes.
5. Check the fuel level one by one. The
level should be in the specified range. NOTE:
Be sure the motorcycle is positioned straight
up when checking the oil level; a slight tilt
toward the side can produce false readings.

-6-

Y
 2 With the engine stopped, check the oil
level through the level window located at
the lower part of the right side crankcase
cover, or screw the dip stick completely
out and then the stick in the hole.
NOTE:
Wait a few minutes until the oil level settles
before checking. When checking engine oil
level with the dip stick, let the unscrewed dip
stick rest on the case threads.

1. Dip stick 2. Maximum level 3. Minimum level

3. The oil level should be between maxi-

mum and minimum levels. If the level
is lower, add sufficient oil to raise it to
the proper level.

l-
*CHASSIS

A. REAR WHEEL REMOVAL

1. Place the motorcycle on the center stand.
2. Remove the tension bar and the brake
rod from the brake shoe plate. The ten-
sion bar can be removed by removing the
cotter pin and nut from the tension bar
bolt. The brake rod can be removed by
removing the adjuster.
b. Make sure the axle nut is properly
torqued and a new cotter pin is installed.

15.0 m-kg (108.5 ft-lb)

c. Adjust the drive chain.

8. DRIVE CHAIN TENSION CHECK

NOTE:
1. Adjusfer 2. Brake rod 3. Tenrio” bar Before checking and/or adjusting, rotate rear
wheel through several revolutions and check
3. Disconnect the drive chain.
tension several times to find the tightest
4. Loosen the chain tension adjusting nuts
point. Check and/or adjust chain tension
and bolts on both sides.
with rear wheel in this “tight chain” position.
5. Remove the axle nut cotter pin and axle
nut. Discard the old pin.

Inspect the drive chain with the center stand

6. Remove the axle shaft and the wheel.
put up. Check the tension at the position
7. For reassembly, follow the procedure
shown in the illustration. The normal vertical
below with care:
deflection is approximately 20 - 30 mm (0.8
a. Make sure the drive chain master link is
- 1.2 in). If the deflection exceeds 20 - 30
correctly installed with rounded end in
mm (0.8 - 1.2 in) adjust the chain tension.
direction of chain travel.

C. DRIVE CHAIN TENSION ADJUSTMENT

1. Loosen the rear brake adjuster.
2. Remove the cotter pin of the rear wheel
axle nut with pliers.
NOTE:
The rear wheel axle nut is located on the right
side.

3. Loosen the rear wheel axle nut.

4. 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. Turn each adjuster exactly the 7. In the final step, adjust the play in the
same amount to maintain correct axle brake pedal.
alignment. (There are marks on each
side of the rear arm and on each chain D. REAR BRAKE ADJUSTMENT
puller; use them to check for proper 1. Pedal height
alignment.) a. Loosen the adjuster lock nut (for pedal
height).
b By turning the adjuster bolt clockwise
or counterclockwise, adjust the brake
pedal position so that its top end is
approx. 12 - 18 mm (0.47 - 0.71 in)
below the footrest top end.
C Secure the adjuster lock nut.

-WARNING: -
After adjusting the pedal height, the brake
1. LO& nut
2. Adj”rter
pedal free play should be adjusted.
3. Marks for align
4. near wheel axle nut
2. Free play
5. cotter pin
Turn the adjuster on the brake rod
clockwise or counterclockwise to pro-
5. After adjusting, be sure to tighten the
vide the brake pedal end with a free play
lock nuts and the rear wheel axle nut.
of 20- 30 mm (0.79 - 1.18 in).
6. Insert the cotter pin into the rear wheel
axle nut and bend the end of the cotter
pin (if the nut notch and the cotter pin
hole do not match, tighten the nut
slightly to match).

-CAUTION:
Excessive chain tension will overload the 1
engine and other vital parts; keep the ten-
sion within the specified limits. Also,
replace the rear axle cotter pin with a new
one.

9
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.
*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
ed.
The starting circuit cut-off system is employ-
ed. Hence, the following description.
Accordingly, the starter motor will not start
Description when the transmission is shifted into any
This model is equipped with a starting circuit position other than neutral, unless the clutch
cut-off switch. The starter motor is so design- lever is pulled in

COLOR CODE
Y Yellow
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 Operation

When the transmission is in a position other a) When the transmission is in Neutral:
than Neutral: Neutral switch ON
Turning on the clutch lever switch (Clutch is Clutch lever switch OFF or ON
disengaged by pulling the clutch lever) makes o When the main switch is turned on
the safety relay to turn on. while the transmission is in neutral the
In this case, the diode interrupts the flow of starting circuit cut-off relay circuit is
current from the main switch to the neutral closed and the relay is actuated.
indicator light and to the relay, and thus the
light will not come on.
 2 When the “START” button is pressed,
the circuit from the main switch to
the relay - starter switch assembly -
“START” (button) is closed, and the
starter switch assembly is turned on,
thus causing the starter motor to start.
b) When the clutch lever is released while
the transmission is in position other than
neutral:
Neutral switch OFF
Clutch lever switch OFF
- Since the starting circuit cut-off is
kept open, the relay is not actuated,
and it is impossible to turn on the
starter switch assembly by pushing the
“START” button.
As a result, the starter motor does not
run.
c) When the clutch lever is disengaged by
pulling in the clutch lever while the
transmission is in a position other than
neutral:
Neutral switch OFF
Clutch lever switch ON
Since the clutch lever switch is on while
the neutral switch is off, the following
circuit - main switch - starting circuit
cut off relay - clutch lever switch is
closed and the relay is actuated.
The subsequent operation is the same as
a).

-lZ-
*SPECIFICATION
A. General ‘XS650SH only **XS650H only

1. MODEL
1) Model (I.B.M. No.) XS650SH (4M4/XS650H (4N9)
21 Basic color *CARDINAL RED or NEW YAMAHA BLACK
**BLACK GOLD
2. DIMENSION
1) Overall length 2.120 mm (83.5 ini
2 ) Overall width 925 mm (36.4 in)
3) Overall height 1,220 mm (48.0 in)
4) Seat height 790 mm (31.1 ini
5) Wheelbase 1,435 mm (56.5 ini
6) Minimum ground clearance 135 mm I 5.3 in)

3. WEIGHT
1) Net weight (Dry) “208 kg I459 lb) “205 kg (452 lb)
4. PERFORMANCE
1) Climbing ability 26’
2) Minimum turning radius ~2,500 mm 198.4 in/

B. Engine

1. DESCRIPTION
1) Engine type Air cooled, 4.stroke. SOHC twin.
parallel forward incline
2) Engine model *4M4 **4N9
3) Displacement 653 cc (39.85 cu.inl
4) Bore x stroke 75 x 74 mm (2.953 x 2.913 in)
5) Compression ratio 8.7 : 1
6) Starting system Kick and electric starter
7) Ignition System Battery ignition (Full transistor ignition)
8) Lubrication system wet sump

2. CYLINDER HEAD
1) Combustion chamber volume (with N-7Y) 42.5 cc (2.59 win)
21 Combustion chamber type Dome + Squish
3) Head gasket thickness 1.2 mm IO.047 in)

3. CYLINDER
1) Material Aluminum alloy with cast iron sleeve

2) Bore size 75.00+~‘* mm i2.9528t~~oo8 in)

3) Taper limit ~0.05 mm (0.002 in)

L ~ 0.01 mm (0.0004 in)

4) Out of round limit
4. PISTON
1) Piston skirt clearance ~ 0.050 - 0.055 mm 10.0020 - 0.0022 in)
2) Piston oversize 7 5 . 2 5 mm ~15.50 mm 75.75 mm 76.00 mm
~2963 in, 12.972 I”/ (2.982 in, 12.5xX in, ,

3) Piston pin outside diameter x length 20.0-:.005 mm x 61.0_;,3 mm

(0.79_&,2 in x 2.40&,,,, in)

5. PISTON RING
1) Piston ring design

1.2mm (0.047 in, 1.5mm ,0.059 in, 2.*mm IO.110 inl

2) Ring end gap
0.4 mm (0.008 - 0.016 in)

3) Ring groove side clearance (Top)

6. BIG END BEARING

11 Type

31 Bearing type $25.$47-8

4) Cam dimensions

6) Camshaft deflection limit i 0.03 mm (0.0012 in)

7) Cam chain
Type ~ TSUBAKIMOTO BF05M
Number of links i 106L
Sprocket ratio ~36/18 ( 2 . 0 0 0 )
8. ROCKER ARM AND ROCKET SHAFT
1) Rocker arm inner diameter 15.0+y8 mm (0.591+~oW7 in)

2) Rocker arm shaft diameter 15.07~:~~ m m (0.591~$~“,~ in)

3) Clearance 0.009 - 0.033 mm (0.00035- 0.00130 in1

4) Lift ratio X : Y = 40 : 48.41 mm (1.575 : 1.906 in)

l4-

Y
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” IN: 2.1 mm (0.083 in)
x B
EX: 2.1 mm (0.083 in) $
Valve seat width “C” IN: 1.3 mm (0.051 in) D
.4\----r
&
EX: 1.3 mm (0.051 in)
Valve margin thickness “D” IN: 1.3 mm (0.051 in)
EX: 1.3 mm (0.051 in)
Valve stem diameter IN: 8.0_g,o,5 mm (0.315_&,,0 in)

EX:8.0~~:~42~ mm 10.315I~:~~~ in)

Valve guide diameter IN: E.O:~:~~“, mm (0.315 :z:gi in)

EX: S.O:$~~~ mm (0.315 z:Ez in)

Valve stem to guide clearance IN: O.OlO- 0.034 mm (0.00079- 0.00173 in)
EX: 0.035 - 0.059 mm 10.00138 - 0.00232 in)
4) Valve face runout limit IN & EX: 0.03 mm 10.0012 in) or less

0. VALVE SPRING
1) Free length INNER (IN/EX): 42 mm (1.654 in)
OUTER(IN/EX): 42.55 mm (1.675 in)
21 Spring rate INNER (IN/EX): kl = 1.43 kg/mm 180.1 lb/in)
kz = 1.81 kg/mm 1101.4 lb/in)
OUTER(IN/EX): kl = 3.2 kg/mm (179.2 lb/in)
k2 = 4.18 kg/mm (234.1 lb/in)
3) Installed length (Valve closed) INNER (INIEXI: 35 mm 11.378 in)
OUTER(IN/EX): 37 mm 11.457 in)
41 Installed pressure (Valve closed) INNER (IN/EX): 10 f 0.7 kg (22.0 f 1.5 lb)
OUTER(IN/EX): 17.7 + 1.25 kg (39.0 f 2.8 lb)
5) Compressed length (Valve open) INNER (IN/EX): 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)
OUTERIIN/EX): 57.4 f4.0 kg (126.5 f 8.8 lb)
7) Wire diameter INNER (IN/EX): 2.9mm (0.114 in)
OUTER(IN/EX): 4.2 mm (0.165 in)
8) Winding O.D. INNER (IN/EX): 19.4 mm (0.764 in)
OUTERIIN/EX): 32.6 mm (1.283 in)
91 Number of windings INNER IINIEXI: 6.0 turns
OUTER(IN/EXI: 4.25 turns
I. CRANKSHAFT

1) Crankshaft deflection limit (A) ~0.05 mm (0.002 in)

2) Con-rod large end clearance (B) 0.15 - 0.4 mm (0.0059 - 0.0157 in)

31 Width of crankshaft (Cl 66 -0.05 mm (2.598;$?,;; in)

-0.10

(D) 166_;.3 mm 17.323_;,o,2 in)

41 Crank p,n I.D. ~26I;:;;j m m (1.024:;:;;; in)

5, Crank piln O.D. x length 26~&?06 x 65:;:; mm

2. CONNECTING ROD
1) Big end I.D. 34 +t016 mm ( 1.339+~.0006 in)

21 Small end I.D. 20$::85 mm 10.787:~:~o~ in)

3. CRANK BEARING
1) Type Right end ~030.$78.:9 (Ball bearing)
Others 032.068.17 (Rollar b e a r i n g )
2) Oil seal fvpe SD-25-40-9

4. CLUTCH
1) Clutch type ! Wet. multiple type
2) Clutch operating mechanism Inner push type. screw push sfstem
3) Primarv reduction ratio and method 72/27 (2.6661, spar gear

4) Primary reduction gear back lash (4 teeth) ~21.45_E,025 m m ~0.8445_~,o~,o in)

I
51 Friction plate
Thickness/Quantity I 3 mm (0.118 in)/7 pcs.
Wear limit 2.7 mm (0.106 in)
6) Clutch plate
ThicknerslQuantitv 1.4 mm (0.055 in)/6 PCS.
Warp limit 0.05 mm (0.002 in1
7) Clutch spring
Free length/Quantity 34.6 mm (1.362 in)/6 PCS.

8) Clutch housing radial plav 0.027 - 0.081 mm (0.0011 - 0.0032 in)

9) Push rod bending limit ~ 0.2 mm (0.008 in)
5. TRANSMISSION
11 Tvoe Constant mesh, 5-speed forward

-16-
 2) Gear ratio: 1st 32113 (2.461)
2nd 27/l 7 (1.588)
3rd 26/20 (1.300)
4th 23/21 (1.095)
5th 22/23 (0.956)
31 Bearing: Main axle (Left1 Needle bearing (@20-$30-20)
(Right1 Ball bearing ($25-e 52-20.6)
Drive axle (Left1 Ball bearing ($30.$62-23.61
(Right1 Needle bearing (020.030-161
41 Oil seal type Drive axle (Left) SDD-40-62-9
51 Secondary reduction ratio and method 34117 (Z.OOO)/Chain

16. SHIFTING MECHANISM

1 I Type
T Cam drum, return type
2) Oil seal type (Change lever)

17. KICK STARTER

L SDO-14-24-6

1) Type Bendix type

2) Oil seal type (Kick axle) SD-25-35-7
31 Kick clip friction tension
c 18. INTAKE _ 1.2 - 1.7 kg (2.6 - 3.7 lb)

1) Air cleaner: Type/Quantity Dry. foam rubber/2 pcs.

2) Cleaner cleaning interval Every 6,000 km (5,000 mile)
i
t19. CARBURETOR
1) Type and manufacturer/Quantity BS34 MIKUNl/2 pcs.
21 I.D. mark 3G l-00
3) Main jet (M.J.1 #132.5
4) Air jet 1A.J.l #85
5) Jet needle (J.N.) 5HX12
61 Needle jet (N.J.) Y-O
7) Throttle valve (Th.V.) #135
8) Pilot jet (P.J.1 #42.5
9l Pilot screw (Turns out) (P.S.1 Preset
101 starter jet IG.S.) #30
11 I Fuel level (F.L.) 27.3 + 0.5 mm (1.075? 0.020 in)
12) Idling engine speed 1.200 rlmin

20. LUBRICATION
1) Engine sump oil quantity Oil exchange: 2.0 lit (2.1 US qt)
Overhaul: 2.5 lit (2.6 US qt)
2) Oil type and grade Yamalube 4-cycle oil or SAE 2OW/40 type
“SE” motor oil
31 Oil pump type Trochoid pump
4) Trochoid pump specifications
Top clearance 0.10 - 0.18 mm (0.0039 - 0.0071 in)
Tip clearance 0.03 - 0.09 mm (0.0012 - 0.0035 in)
Side clearance 0.03 - 0.08 mm (0.0012 - 0.0031 in)
Oil pump volume 1.3 litlmin (1.37 qtlminl at 1,000 rlmin

L 5) Bypass valve setting pressure 1.0 kg/cm’ (14 psi)

- 17-
 6) Lubrication chart
- Pressure feed

- -- Splash lubrication

C. Chassis

1. FRAME
1) Frame design Double cradle, high tensile frame

2. STEERfNG SYSTEM
1) caster 27O
2) Trail 115 mm (4.53 in)
3) Number and size of balls in steering head
upper race 19 pcs. l/4 in
Lower race 19 pcs. l/4 in
4) Steering lock to lock 42” each (L and R)

3. FRONT SUSPENSION
1) Type Telescopic fork

2) Damper type Oil damper, coil spring

3) Front fork spring
Free length 482 mm (18.99 in)
Wire diameter x winding diameter 4 x 24.5 mm IO.157 x 0.965 in)
Spring constant kl = 0.48 kg/mm 126.88 Iblinll
0 - 100 mm (0 - 3.94 in)
k2 = 0.65 kg/mm 136.40 lb/in)/
loo- 150 mm (3.94 - 5.91 in)
41 Front fork travel 150 mm (5.906 in)
51 Inner tube O.D. 35 mm (1.378 in)
6) Front fork oil quantity and type 169 cc (5.72 oz) each leg
Yamaha fork oil 1Owt or equivalent
7) Distance from the top of inner tube oil level
without spring Approx. 454 mm (17.9 in)

4. REAR SUSPENSION
1) Type Swing arm
2) Damper type Oil damper, coil spring
3) Shock absorber travel 80 mm (3.15 in)
 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 ! kl = 1 . 7 1 4 k g / m m (96.0 lb/in)/
0 - 45 mm (0 - 1.77 in)
k2 = 2.244 kg/mm 1125.7 lb/in)/
45 - 80 mm (1.77 - 3.15 in)
5) Swing arm free play (Limit) 1 mm (0.04 in)
6) Pivot shaft - Outside diameter 16 mm IO.63 in1

5. FUEL TANK
1) Capacity ~ 11.5lit(3.04USgal)
2) Reserve capacity 2.3 lit IO.61 US gal)
3) Fuel grade Regular gasoline

6. WHEEL
1) Type (Front and rear) ~ ‘Cast wheel ** Spoke wheel
2) Tire size (Front) ~ 3.50S19.4PR ‘Tubeless tire “Tube-type tire
IRear) ~ 130/90-16 675 *Tubeless tire **Tube-type tire
3) Tire pressure:
Up to90 kg (198 Ibl load”” 1.6 kg/cm’ 122 psi)
~ Front:
~Rear: 2.0 kg/cm2 I28 psi1
90 kg (198 lb) load - 206 kg (453 lb) load”’ ~Front: 2.0 kg/cm2 (28 p s i )
(Maximum load) Rear: 2.3 kg/cm’ (32 psi)
High speed riding Front: 2.0 kg/cm’ I28 psi)
Rear: 2.3 kg/cm’ I32 psi)
4) Rim run out limit (Front and rear)
Vertical 2 mm (0.08 in)
Lateral 2 mm (0.08 in)
5) Rim Size (Front) “MT1.85 x 19 “ 1 . 8 5 x 19
(Rear) “MT3.00 x 16 “ 2 . 7 5 x 16
6) Bearing type
Front wheel t Left) ‘6630322 “66303
(Right) ‘863032 “86303RS
Rear wheel I Left) 663052
(Right) 663042
7) Oil seal type
Front wheel (Left) SDD-45-56-6
(Right) ‘SD-28-47-7 *“SD-22-42-7
Rear wheel I Left) SD-35-62-9
(Right) SO-27-52-5
8) Secondary drive chain type
Tvpe SOHDS
Number of links 103L + Joint
Chain pitch 15.875 mm (518 in)
Chain free play 20 - 30 mm IO.8 - 1.2 in)

+ : XS650SH
f”
: XS650H
f..
: Total weight of accessories. etc.. excepting motorcycle.

-19-
 7. BRAKE
1) Front brake
Type Hydraulic disc type
Disc size (Outside dia. x thickness) 298 x 7.0 mm 11 1.73 x 0.28 in)
Disc wear limit 6.5 mm (0.26 in1
Disc pad thickness 11.0 mm (0.43 inl
Pad wear limit 6.0 mm (0.24 in1
Master cylinder inside dia. 14.0 mm (0.55 ini
Caliper cylinder inside dia. 38.1 mm (1.50 in)
Brake fluid type/Quantity DOT #3 Brake fluid i38.1 cc Il.29 02)
2) Rear brake
Type Drum brake (Leading trailing)
Actuating method Link rod
Brake drum I.D. 180 mm (7.09 ini
Brake shoe dia. x width 180 Y 30 mm 17.09 x 1.18 in)
Lining thickness/wear limit 4 mm12 mm IO.16 1nI0.08 in)
Shoe spring free length 68 mm (2.68 inl

D. Electrical

1. IGNITION SYSTEM
1) Ignition timing (B.T.D.C.) 15”/1,200 rimin

0 I 2 3
2) Ignition coil
tnqine roeed ,x 101 r,m,n,
Model/Manufacturer CM12-OS/HITACHI
Spark gap 6 mm (0.24 in) or more at 500 rimin
Primary winding resistance 2.5a * 10% at 20” C (68” F)
Secondary winding resistance 1lkQ + 20% at 2O’C (68” Fl
3) Spark plug
Type N-7Y (CHAMPION) or BP7ES (N.G.K.)
Spark plug gap 0.7 - 0.8 mm (0.027 - 0.031 in)

2. CHARGING SYSTEM
11 A.C. generator
Charging output 14V 16Ai5.000 rlmin
Rotor coil resistance (Field coil) 5.25a + 10% at 20” C (68” Fl
Stator coil resistance 0.46a f 10% at 203C (68’F)
Brush length 14.5 mm (0.571 in)
Brush wear limit 7.0 mm (0.276 ini
 2) Regulator
Type I.C. type
Model/Manufacturer S8515/TOSHIBA
Regulating voltage 14.5 ? 0.3v
3) Battery
Model/Manufacturer/Quantity YB14L-AZIYUASAII PC.

Capacity 12V. 14AH

Charging rate , 1.4A 10 hours
Specific gravity 1.28 at 20°C 168°F)
~_~..~~ ..-f--.______
3. STARTER
1 I Starter motor
Type ~Bendix type
Manufacturer/Model 1 HITACHliSlOE-35
output ~ 0.5kw
Armature coil resistance 0.0067R * 10% at 20°C (68” Fl
Field coil resistance 0.0049 ? 10% at 20°C (68°F)
Brush size/Quantitv ~ 16 mm (0.63 in)/2 pcs.
Wear limit 4 mm 10.16 in)
Spring pressure BOO g (28.2 oz)
Commutator O.D./Wear limit ~ 33 mm (1.30 in)/30 mm Il.18 in)
Mica undercut 0.7 mm 10.028 inl
21 Starter switch
Manufacturer , HITACHI
Model A10470
Amperage rating , 1OOA
Cut-in voltage ~ 6.5V
Winding resistance ! 3.5R
3) Starter clip friction tension ( 2.2-2.5kg(4.9-5.5lbl

4. LIGHTING SYSTEM
1) Headlight type Sealed beam
2) Bulb brightness and wattage/Quantity
Headlight 12v. 5014ow x 1 PC.
Tail/Brake light , 12V. 3132 CP 18W/27W) x 2 PCS.
Flasher light 12V. 32 CP (27W) x 4 pcs.
License light 12V. 3.8W x 2 P C S.

Pilot lights: Turn 12v. 3.4w x 1 PC.

High beam 12v. 3.4w x 1 PC.
Headlight failure 12v. 3.4w x 1 PC.
Neutral 12v. 3.4w x 1 PC.
Meter lights 12v. 3.4w x 2 PCS.
3) Reserve lighting unit
Model/Manufacturer i 337-l 1720/KOlTO
4) Horn
Model/Manufacturer ~ ‘CF.12 “SF-12INIKKO
Maximum amperage j 2.5+0.5A

* : XS650SH o n l y
fl
: XS650H only

-2l-
5) Flasher relay
Type Condenser type
Model/Manufacturer 061300.04810/NIPPON DENS0
Flasher frequency 85 t 10 cycle/min.
Capacity 32 CP (27W) x 2 + 3.4w
6) Flasher cancelling unit
Model EVH-AC518
Voltage DC9V - 16V
7) Fuse
Rating/Quantity: Main 20A x 1 pc.
Headlight 10A x 1 pc.
Signal 10A x 1 pc.
Ignition 10A x 1 pc.
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-lb)
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 ( 6.5 ft-lb)
8 mm crown nut 1.3 m-kg ( 9.5 ft-lb)
Spark plug 14 mm 2.0 m-kg (14.5 ft-lb)
Generator 12mm nut 3.8 m-kg (27.5 ft-lb)
Stator coil 6 mm pan head screw 0.9 m-kg ( 6.5 ft-lb)
Governer 6 mm bolt 0.8 m-kg ( 6.0 ft-lb)
Valve clearance adjustment nut 8 mm nut 2.7 m-kg (19.5 ft-lb)
Cam chain tensioner 18 mm cap 2.1 m-kg (15.0 ft-lb)
Pump cover 6 mm pan head screw 1.0 m-kg ( 7.2 ft-lb)
Strainer cover 6 mm bolt 1.0 m-kg (7.2 ft-lb)
Drain plug 30 mm bolt 4.2 m-kg (30.5 ft-lb)
Oil filter 6 mm bolt 0.9 m-kg I 6.5 ft-lb)
Delivery pipe 10 mm union bolt 2.1 m-kg (15.0 ft-lb)
Exhaust pipe 8 mm nut 1.3 m-kg ( 9.5 ft-lb)
Crankcase 8 mm bolt/nut 2.1 m-kg (15.0 ft-lb)
Kick crank boss 8 mm bolt 2.0 m-kg (14.5 ft-lb)
Primary drive gear 14 mm nut 9.0 m-kg (65.0 ft-lb)
Clutch boss 18 mm nut 8.0 m-kg (58.0 ft-lb)
Drive sprocket 22 mm nut 6.5 m-kg (47.0 ft-lb)
Change pedal 6 mm bolt I 1.0 m-kg ( 7.2 ft-lb)
Chassis:
Front wheel axle 14 mm nut 10.7 m-kg (77.5 ft-lb)
Front fork and axle holder 8 mm nut 1.4 m-kg (10.0 ft-lb)
Handle crown and inner tube 8 mm nut 1.1 m-kg ( 8.0 ft-lb)
Handle crown and steering shaft 8 mm nut 1.1 m-kg ( 8.0 ft-lb)
Handle crown and steering shaft 14 mm bolt 5.4 m-kg (39.0 ft-lb)
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 Upper 8 mm nut 1.8 m-kg (13.0 ft-lb)
Engine mounting Upper 10 mm nut 3.0 m-kg (21.5 ft-lb)
Engine mounting Front 10 mm nut 4.6 m-kg (33.5 ft-lb)
I
Engine mounting Rear 10 mm nut 4.1 m-kg (29.5 ft-lb)
Engine mounting Rear-Lower 10 mm nut 4.6 m-kg (33.5 ft-lb)
Engine mounting Lower 10 mm nut 9.0 m-kg (65.0 ft-lb)
Front flasher and headlight 8 mm nut 1.0 m-kg ( 7.2 ft-lb)
Master cylinder and brake hose 10 mm union bolt 2.6 m-kg (19.0 ft-lb)

-23-
 I
Part to be tightened Thread dia. and part name ! Tightening torque

Brake disc and hub 8 mm bolt 2.0 m-kg (14.5 ft-lb)

1
Caliper and support bracket 8 mm bolt 1.8 m-kg (13.0 ft-lb)

Caliper and pad 5 mm bolt 0.3 m-kg ( 2.2 ft-lb)

Caliper and bleed screw 8 mm bolt 0.6 m-kg ( 4.5 ft-lb)

Front caliper and front fork 10 mm bolt 3.5 m-kg (25.5 ft-lb)

Master cylinder and cylinder bracket 6 mm bolt 0.6 m-kg ( 4.5 ft-lb)
Pivot shaft 14 mm nut 6.5 m-kg (47.0 ft-lb)

Rear wheel axle 16 mm nut 15.0 m-kg (108.5 ft-lb)

Tension bar and brake caliper (plate) 8 mm nut 1.8 m-kg (13.0 ft-lb)

Tension bar and rear arm 8 mm nut 3.2 m-kg (23.0 ft-lb)

Rear shock absorber Upper 10 mm bolt 3.0 m-kg (21.5 ft-lb)

Rear shock absorber Lower 10 mm bolt 3.9 m-kg (28.0 ft-lb)

Rear arm and rear arm end 8 mm bolt 1.0 m-kg (7.2 ft-lb)

Front fender 8 mm bolt 1.0 m-kg ( 7.2 ft-lb)

Neutral switch I 12mm 1.3 m-kg ( 9.5 ft-lb)

General Torque Specifications tighten multi-fastener assemblies in a criss-

This chart specifies torque for standard cross fashion, in progressive stages, until full
fasteners with standard I.S.O. pitch threads. torque is reached. Unless otherwise specified,
Torque specifications for special components torque specifications call for clean, dry
or assemblies are included in the applicable threads. Components should be at room
sections of this book. To avoid warpage, temperature.
r

A B Standard tightening torque

(Nut) (Bolt) m-kg ft-lb
IOmm 6mm 0.6 4.5
12mm 8mm 1.5 11
14 mm 10mm 3.0 22
17mm 12mm 5.5 40
19mm 14 mm 8.5 61
22 mm 16mm 13.0 94

- 2 4 -
CONVERSION TABLES

METRIC TO INCH SYSTEM r INCH TO METRIC SYSTEM

I
KNOWN MULTIPLIER 1 RESULT KNOWN ! MULTIPLIER RESULT

w m-kg 7.233 ~ft-lb ft-lb 0.13826 m-kg

2 m-kg 86.80 i in-lb in-lb 0.01152 m-kg

cm-kg 0.0723 , ft-lb ft-lb 13.831 cm-kg
!
cm-kg 0.8680 i in-lb in-lb 1.1521 cm-kg
c
kg ~ 2.205 lb lb 0.4535 kg
g g ! 0.03527 ~02 02 I 28.352 g
! : +
w
km/lit 2 . 3 5 2 mpg mpg 0.4252 km/lit
kmlhr 0 . 6 2 1 4 mph mph 1.609 kmlhr
i2
2 km 0 . 6 2 1 4 I mi mi 1.609 km
‘”
n:m
~ 3.281 ! ft ft 0.3048 m

2 m 1 . 0 9 4 I vd Yd 0.9141 m
-I cm 0 . 3 9 3 7 j in in 2.54 cm
LL
mm ~ 0 . 0 3 9 3 71 in in 25.4
I L mm

cc fcm3) 02 (US liq) 02 (US liq) 29.57 cc (cm3 1

$1 cc (cm3) ~ :::::; cu.in cu.in 16.387 cc fcm3)
.,Q lit (liter) 2.1134 pt f US liq) pt (US liq) 0.4732 lit (liter)
<z / lit (liter) 1.057 qt (US liq) ! qt (US liq) 0.9461 lit (liter)
> lit (liter) ,
i
0.2642 1 gal (US liq)

/ lb/in
c gal (US liq) 3.785 lit tlrter)

1
k g / m m 56.007 lb/in 0.017855 kg/mm
”
z kg/cm2 14.2234 ~psi (Ib/in2) psi tIb/in2) 1 0.07031 kg/cm2
I Centigrade f°C) 1 9/5f°C) + 32 Fahrenheit (OFI Fahrenheit (OF) 5/91OF) - 32 Centrgrade (‘C)
I

DEFINITION OF TERMS:

m-kg = Meter-kilogram(s) (usually torque)

g = Gram(s)

kg Kilogram(s) (1,000 grams)

lit = liter(s)
km/lit = Kilometer(s) per liter (fuel consumption1

cc = Cubic centimeter(s) (cm31 (volume or capacityI

kg/mm ; Kilogram(s) per millimeter u u spring compression rate)

kg/cm2 = Kilogram(s) per square centimeter (pressure)

CONSUMER INFORMATION

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.

-25-
 FULL OPERATIONAL
SERVICE BRAKE
(“Partial failure” information is
not applicable and is not included.)
0 100 200 300 (Feet)

STOPPING DISTANCE IN FEET FROM 60 MPH

ACCELERATION AND PASSING ABILITY

This figure indicates passing times and distances that can be met or exceeded by the vehicles to
which it applies, in the situations diagrammed below. The low-speed pass assumes an initial
speed of 20 mph. and a limiting speed of 35 mph. This high-speed pass assumes an initial speed
of 50 mph. and a limiting speed of 80 mph.

INITIAL SPEED: 20 MPH LIMITING SPEED: 35 MPH

TOTAL PASSING DISTANCE, FEET

t--- TOTAL PASSING TIME, SECONDS ‘1

LOW-SPEED PASS
d----_--__---------@$
l-4djj_-_ ------- +al-4
40ft 40ft
55 ft CONSTANT 20 MPH
TRUCK

T INITIAL SPEED: 50 MPH LIMITING SPEED: 80 MPH

TOTAL PASSING DISTANCE, FEET

I- TOTAL PASSING TIME, SECONDS
HIGH-SPEED PASS

55 it CONSTANT 50 MPH
TRUCK

SUMMARY
Low-speed pass . . . . . . . . . . . . . . . . 353.3 feet: 7.2 seconds XS650H
357.0 feet: 7.3 seconds XS650SH
High-speed pass . . . . . . . . . . . . . . . . 944.0 feet: 9.27 seconds XS650H
945.5 feet: 9.3 seconds XS650SH

-26-
Supplementary
 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 numbers shown in brackets correspond
to page numbers of the XS650E Service
Manual (2FO-28197-10).

(PAGE 4 - 5)
2-2. MAINTENANCE INTERVALS CHARTS
A. PERIODIC MAINTENANCE
Unit: km (mi)

Check tension, alignment

B. LUBRICATION INTERVALS
Unit: km (mi)

Item Remarks

Replace/Warm
Engine oil engine before
draining

Drive chain Clean/Lube Every 400 (250)

Brake pedal shaft/

Light application
Change pedal shaft
Yamaha chain and
Control/Meter
Apply thoroughly
:ables

-78-
 Unit: km (mi)
initial Thereafter every
I tern Remarks Type 400 800 1,600 3,200 1,600 3,200 6,400
(250) (500) (1,000) (2.000) (1,000) (2.000) (4.000)
Throttle grip/ (
Housino Apply lightly 1 Lithium basegrease 1 [ 1 1 0 1 ( 0 1

Hydraulic brake DOT No. 3

Use new fluid only Brake fluid check check check check check
fluid reserve
Clean/Replace as - 0 0
Oil filter element 0
required
Drain completely - Yamaha Fork Oil 0
Front forks 0
Check specifications 20 wt.
Inspect thoroughly i 2,800
Medium-weight
Steering bearings Pack moderately
wheel bearing grease (8.000)
Yearly or . . .
Speedometer gear Inspect thoroughly i 2,800
Lithium base grease
housinc Pack moderately I
(8,000)
Rear arm pivot Medium-weight i 2,800
Apply grease fully
shafts wheel bearing grease (8,000)
Do not over-pack Medium-weight i 2,800
Wheel bearings
Yearly or . . . wheel bearing grease (8.000)
Point cam lubri- Light-weight
APPLY very lightly machine oil 0 0 0 0
cation wicks

NOTE :
Brake fluid replacement:
1. When disassembling the master cylinder or caliper cylinder, replace the brake fluid. Normally check the
brake fluid level and add the fluid as required.
2. On the inner parts of the master cylinder and caliper cylinder, replace the oil seals every two years.
3. Replace the brake hoses every four years, or if cracked or damaged.

3. Remove the drain bolt and clean with

solvent. If gasket is damaged, replace.

(PAGE 7,10 - 13)

24. CHASSIS
A. Fuel petcock cleaning
1. Open the seat and remove the fuel tank
securing bolt.
2. Turn the petcock lever to the “ON” or
“RES” position. Raise the fuel tank to
remove the fuel pipe. 1. Drain bolt
E. Rear brake
The rear brake pedal should be so adjusted
that it has a free play of 13 - 15 mm (0.51
- 0.59 in) from when the brake pedal is trod
to when the brake begins to be effected.
1. Loosen the adjuster lock nut (for pedal
height).
2. By turning the adjuster bolt clockwise or
counterclockwise, adjust the brake pedal
.J9-
 position so that its top end is approx. 12 G. Drive chain
- 18 mm (0.47 - 0.71 in) below the 1. Tension check
footrest top end.
NOTE:
3. Secure the adjuster lock nut.
Before checking and/or adjusting, rotate
4. 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
tightest point. Check and/or adjust chain
and master cylinder.
tension with rear wheel in this “tight chain”
5. Turn in the brake rod until it lightly
position.
touches the master cylinder, then turn it
out by approx. l-1/5 turns (for proper
Inspect the drive chain with the center
free play).
stand put up. Check the tension at the
6. Tighten the brake rod adjuster lock nut.
position shown in the illustration. The
normal vertical deflection is approximate-

iifJ~~[
adjuster lock nut in securing the brake rod
ly 10 - 20 mm (0.4 - 0.8 in). If the
deflection exceeds 20 mm (0.8 in) adjust
the chain tension.

a. 20 mm (0.8 in)
Adjuster bolt (for pedal height) 6. Pedal height 12-16 I ml” ”
2. Lock nut (0.47 -0.71 in)
3. Leek nut 7. Free play 13 - 15 mm 2. Tension adjustment
4. Brake rod (0.51 -0.69 in) a. Remove the cotter pin of the rear wheel
5. Footmst axle nut with pliers.
F. Wheels and tires b. Loosen the rear wheel axle nut.
2. Tires C. Loosen the lock nuts on each side. To
Specifications should be changed as tighten chain turn chain puller adjusters
follows: clockwise. To loosen chain turn adjusters
REAR counterclockwise and push wheel for-
ward. Turn each adjuster exactly the
119 kg (262 lb) same amount to maintain correct axle
alignment. (There are marks on each side
Bridgastone or Bridgestone or
Standard tire Yokohama Yokohama of rear arm and on each chain puller; use
3.50S19-4PR 130/906164PR them to check for proper alignment.)
Maximum load limit 166 kg I365 lb) 279 kg (615 lb1 d. After adjusting, be sure to tighten the
Cold tire pressure: lock nuts and the rear wheel axle nut.
Up to 90 kg 1.6 kg/cm2 2.0 kg/cm2
(198 lb) load (22 psi 1 (28 psi)
e. Insert the cotter pin into the rear wheel
90 kg (198 lb) load axle nut and bend the end of the cotter
-204 kg (445 lb) 2.0 kg/cm2 2.3 kg/cm2 pin as shown in the illustration (if the
load (Maximum 128 psi 1 (32 psi)
load)
nut notch and the cotter pin hole do not
High speed riding 2.0 kg/cm2 2.3 kg/cm2 match, tighten the nut slightly to match).
(32 psi)

I.8 mm (0.03 in)

80 -
1. Lock nut 4. Rear wheel axle nut
‘2. Adjuster 5. Cotter pin
3. Marks for align

(PAGE 29 - 33)
3-4. ENGINE ASSEMBLY AND ADJUSTMENT
0. Engine
Specifications should be changed as
follows:
Engine mounting bolt torque:
Upper (U Nut) M8 1.8 m-kg (13.0ft-lb)
Upper Ml0 3.0 m-kg (21.5 ft-lb)
Front (U Nut) Ml0 4.6 m-kg (33.5 ft-lb)
Rear (U Nut) Ml0 4.1 m-kg (29.5 ft-lb)
Rear - under (U Nut)
Ml0 4.6 m-kg (33.5 ft-lb)
-CAUTION:
Under (U Nut) Ml0 9.0 m-kg (65.0 ft-lb)
Excessive chain tension will overload the
engine and other vital parts; keep the
(PAGE 39 - 40)
tension within the specified limits. Also,
5-1. FRONT WHEEL
replace the rear axle cotter pin with a new
C. Front wheel inspection
one.
1. Check for cracks, bends or warpage of
wheels. If a wheel is deformed or crack-
H. Front fork oil change ed, it must be replaced.
8. Pour specified amount of oil into the NOTE:
inner tube through the upper end open- These aluminum wheels are not designed for
ing. use with tubeless tires.

Front for oil capacity: 2. Check wheel run-out

169 cc (5.72 US oz) each leg If deflection exceeds tolerance, check
wheel bearing or replace wheel as required.
(PAGE 22 - 29)
3-3. INSPECTION AND REPAIR
D. Valve spring ti
1. Checking the valve springs
d. Valve spring specifications
Specifications should be changed as 3. Check wheel balance
follows: Rotate wheel lightly several times and
observe resting position.
If wheels is not statically balanced,
wheel will come to rest at the same po-
sition. Install balance weight at lighter
position (at top) as illustrated.
- 81 -
NOTE: (PAGE 40)
The wheel should be balanced with brake disc 5-2. REAR WHEEL
installed. A. Removal
1. Support machine on the center stand.
2. Disconnect the drive chain. Using drive
chain cutter (special tool).
NOTE:
The chain joint should be replaced each time
the chain is cut.

3. Remove the axle nut cotter pin and axle

nut.
4. While supporting the brake caliper, pull
out the rear axle.
5. Remove the rear wheel assembly.

E. Rear wheel installation

When installing rear wheel, reverse removal
procedure taking care of following points:
1, Lightly grease lip of rear wheel oil seals.
2. Make sure the brake pads are installed
properly and that there is an enough gap
to install the rear disc.
3. Install wheel assembly and axle. Always
use a new cotter pin on the axle nut.

Balance weight )I

4. Connect drive chain.

5. Adjust drive chain.

(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. Brake inspection and repair
Specifications should be changed as Specifications should be changed as follows:
follows:
Wear limit:
Axle nut torque: 6.0 mm (0.24 in)
10.7 m-kg (77.5 ft-lb)
Holder nut torque:
1.4 m-kg (10.0 ft-lb)

- 82 -
 3. Check the armature and field coil for
shorting and insulation. Replace arma-

LA-
A ture as required.
6

A: Pad thickness
11 .O mm (0.43 in)
6: Wear limit
4. Check the front and rear cover bearings
6.0 mm (0.24 in)
C: Wear indicator
for damage. If damaged, the starter
assembly must be replaced.

(PAGE 57 - 58)
Back plate
6-5. LIGHTING AND SIGNAL SYSTEMS
B. Reserve lighting system
1. Description:
The reserve lighting system has two
( P A G E 48)
functions: (1) It notifies the rider that
5-9. REAR SHOCK ABSORBER
one of the headlight filaments is in-
B. Inspection
operative, and (2) it switches current
Specifications should be changed as follows:
from the inoperative filament to the
remaining functional filament.
Rear shock absorber tightening torque:
The system is connected to the headlight
Upper 3.0 m-kg (21.5 ft-lb)
circuit only. The reserve lighting system
Lower 3.9 m-kg (28.0 ft-lb)
unit is located under the fuel tank.
NOTE:
(PAGE 50 - 51) This model has been equipped with a safety
6-1. STARTER relay so that the headlight comes on auto-
A. Armature matically when the engine is started even
1. Check the outer surface of the com- with the headlight switch “OFF”.
mutator. If it’s surface is dirty, clean
with No. 600 grit sand paper. Headlight Headlight Reserve light
2. The mica insulation between com- condition failure indi- ing function
mutator segments should be 0.7 mm cator light
(0.028 in) below the segment level. If Normal Comes on -
not, scrape to proper limits with ap- (very dim)
propriately shaped tool. (A hack saw High beam Comes on Low beam
blade can be ground to fit.) faulty comes on
Low beam Comes on High beam
Mica under cut faulty comes on at
0.7 mm (0.026 in)
low brilliance

- 83 -
2. Troubleshooting/inspection
 LOW BEAM DOES NOT
LlGHT WHEN HIGH BEAM
IS DEFECTIVE
 To starter relay To A.C. Generator

Meter light

(PAGE 61- 62)

7-1. TORQUE SPECIFICATION
The following torque specifications must be
adhered to on every machine. When applying
torque to multi-secured fastener components,
the several studs should be tightened in
gradual stages and in a pattern that will avoid
warpage to the item being secured. Torque
settings are for dry, clean threads. Torquing
should always be done to the nut, never the
bolt head.
NOTE:
Certain items with other than standard thread
pitches may require differing torque.

Torque Specifications
Standard tightening torque
A B
(Nut) (Bolt) m-kg ft-I b

10 mm 6 m m (M6) 1.0 7.2

12mm B m m (M8) 2.0 15

14 mm 10mm (Ml0) 4.0 29

17mm 1 2 m m (M12) 4.5 33

19 mm 14mm (M14) 5.0 36

22 mm 1 6 m m (Ml6) 6.5 47

24 mm 18mm (Ml8) 7.0 50

27 mm 2 0 m m (M20) 8.0 58
I Engine:
Part to be tightened Thread dia. and part name Tightening torque

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)
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 ( 6.5 ft-lb)
8 m m crown nut 1.3 m-ka f 9.5 ft-lb)
1 Spark plug I 14 mm I 2.0 m-ka (14.5 ft-lb7
1 Generator I 12 mm nut I 3.8 m-ka (27.5 ft-lb) 1
I Stator c o i l I 6 mm pan head screw I 0.9 m-kq ( 6.5 ft-lb) 1
I Governer I 6 mm bolt I 0.8 m-ks ( 6.0 ft-lb) I
Valve clearance adjustment nut 8 mm nut 2.7 m-kg (19.5 ft-lb)
Cam chain tensioner 18 mm cap 2.1 m-kg (15.0 ft-lb)
I Pump cover I 6 mm pan head screw I 1 .O m-kg ( 7.0 ft-lb) I
I Strainer cover I 6 mm bolt I 1.0 m-kg ( 7.0 ft-lb) ~ 1
I Drain plug I 30 mm bolt I 4.2 m-kg (30.5 ft-lb) I
I Oil filter I 6 mm bolt I 0.9 m-kg ( 6.5 ft-lb) I
I Delivery pipe I 10 mm union bolt I 2.1 m-kg (15.0 ft-lb) I
Exhaust pipe 8 mm nut 1.3 m-kg ( 9.5 ft-lb)
Crankcase 8 mm bolt/nut 2.1 m-kg (15.0 ft-lb)
Kick crank boss 8 mm bolt 2.0 m-kg (14.5 ft-lb)
Primary drive gear 14 mm nut 9.0 m-kg (65.0 ft-lb)
Clutch boss 18mm nut 8.0 m-kg (58.0 ft-lb)
Drive sprocket 22 mm nut 6.5 m-kg (47.0 ft-lb)
Change pedal 6 mm bolt 1 .O m-kg ( 7.0 ft-lb)
Chassis:
Front wheel axle 14 mm nut 1 10.7 m-ko (77.5 ft-lb)
Front fork and axle holder 8 mm nut 1.4 m-kg (10.0 ft-lb)
Handle crown and inner tube 8 mm nut 1 .l m-kg ( 8.0 ft-lb)
I Handle crown and steering shaft I 8 mm nut I 1.1 m-kg ( 8.0 ft-lb) I
Handle crown and steering shaft 14 mm bolt 5.4 m-kg (39.0 ft-lb)
Handle crown and handle holder 8 mm bolt 1.8 m-kg (13.0 ft-lb)
1:id’,
I Under bracket and inner tube I 8 mm nut I 2.0 m-kg (14.6 ft-lb) ) ;

I Engine mounting Upper I 8 mm nut I 1.8 m-kg (13.0 ft-lb) I /I/;

I Engine mounting Upper I 10 mm nut I 3.0 m-kg (21.5 ft-lbl I j. :
r Engine mounting Front I 10 mm nut I 4.6 m-kg (33.5 ft-lb) I
Engine mounting Rear 10 mm nut 4.1 m-kg (29.5 ft-lb)
Engine mounting Rear-Lower 10 mm nut 4.6 m-kg (33.5 ft-lb)
Engine mounting Lower 10 mm nut 9.0 m-kg (65.0 ft-lb)
Front flasher and headlight 8 mm nut 1 .O m-kg ( 7.0 ft-lb)
Master cylinder and brake hose 10 mm union bolt 2.6 m-kg (19.0 ft-lb)
Brake disc and hub 8 mm bolt 2.0 m-kg (14.5 h-lb)
Caliper and support bracket 8 mm bolt 1.8 m-kg (13.0 ft-lb)
Caliper and pad 5 mm bolt 0.3 m-kg ( 2.0 h-lb)
Caliper and bleed screw 8 mm bolt 0.6 m-kg ( 4.5 ft-lb)
Front caliper and front fork 10 mm bolt 3.5 m-kg (25.5 ft-lb)
Master cylinder and cylinder bracket 6 mm bolt 0.6 m-kg ( 4.5 ft-lb)
- 87 -
 Part to be tightened Thread dia. and part name Tightening torque
I
Pivot shaft 14 mm nut 6.5 m-kg (47.0 ft-lb)
Rear wheel axle 16 mm nut 15.0 m-kg (108.5 h-lb)
Tension bar and brake caliper 8 mm nut 1.8 m-kg (13.0 ft-lb)
Tension bar and rear arm 8 mm nut 3.2 m-kg (23.0 ft-lb)
Rear shock absorber Upper 10 mm bolt 3.0 m-kg (21.5 ft-lb)
Rear shock absorber Lower 10 mm bolt 3.9 m-kg (28.0 ft-lb)
Rear arm and rear arm end 8 mm bolt 1.0 m-kg 1 7.0 ft-lb1
I Front fender I 8 mm bolt I 1 .O m-kg ( 7.0 ft-lb)

I Neutral switch 12mm 1.3 m-kg ( 9.5 ft-lb)

(PAGE 64 - 71)
7-3. SPECIFICATION
A. General
_
1. MODEL
1) Model (I.B.M. No.) XS650SE (2MO)
2) Frame I.D. and starting number 2FO-100101
3) Engine I.D. and starting number 2FO-100101

2. DIMENSION
1) Overall length 2,120 mm (83.5 in)
2) Overall width 925 mm (36.4 in)
3) Overall height 1,220 mm (48.0 in)
4) Seat height 790 mm (31.1 in)
5) Wheelbase 1,435 mm (56.5 in)
6) Minimum ground clearance 135 mm ( 5.3 in)

3. WEIGHT
1) Net weight (Dry) 210 kg (463 lb)

4. PERFORMANCE
1) Climbing ability 26’
2) Minimum turning radius 2,500 mm (98.4 in)
3) Braking distance 14 m @ 50 km/h (45.9 ft Q 31 mi/h)

B. Engine
-I-
1. DESCRIPTION

I 1) Engine type

2) Engine model
Air cooled, 4-stroke, SOHC twin,
parallel forward incline
2F0
3) Displacement 653 cc (39.85 cu.in)
4) Bore x stroke 75 x 74 mm (2.953 x 2.913 in)
5) Compression ratio 8.5 : 1
6) Starting system Kick and electric starter
7) Ignition system Battery ignition
8)) Lubrication system Wet sump
2. CYLINDER HEAD
1) Combustion chamber volume (with N-7Y) 43.6 cc (2.660 cu.in)
2) Combustion chamber We Dome + Squish
I 3) Head gasket thickness 1.2 mm (0.047 in)
3. CYLINDER
1) Material Aluminum alloy with cast iron sleeve
2) Bore size 75.00 +y mm (2.9528 2”” in)
3) Taper limit 0.05 mm (0.002 in)

1 4) Out of round limit

-88-
0.01 mm (0.0004 in)
1. PISTON
1) Ptston skirt clearance 0.050 - 0.055 mm (0.0020 - 0.0022 in)
2) Piston oversize 7525 mm 75.50 mm 75.75 mm 76.00 mm
12.963 InI I2972 In) (2 982 In) (2992 Ill)

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)

5. PISTON RING
1) Piston ring design (TOP) 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)
2) Ring end gap (Installed, top) 0.2 * 0.4 mm IO.008 - 0.016 in)
(Installed, 2nd) 0.2 - 0.4 mm (0.008 - 0.016 in)
(Installed, oil) 0.3 - 0.9 mm (0.012 - 0.035 in)
3) Ring groove side clearance (Top) 0.04 - 0.08 mm (0.0016 - 0.0031 in)
0.03 - 0.07 m m (0.0012 - 0.0028 in)

1) Type

Chain (Center side)

2) Number and type of bearing 4 bearings, Ball bearings (6005)

6) Camshaft deflection limit 0.03 mm (0.0012 in)

7) Cam chain
Type TSUBAKIMOTO BF05M
Number of links

1) Rocker arm inner diameter 15.0+i.“‘* mm (0.591 +E”)07 in)

2) Rocker arm shaft diameter

9. VALVE,VALVE SEAT AND VALVE GUIDE

1) Valve per cylinder
2) Valve clearance (In cold engine) IN: 0.10 mm (0.0039 in)
EX: 0.15 mm (0.0059 in1
3) Dimensions
Valve head diameter “A” IN: 41 mm (1.614 in)
EX: 35 mm (1.378 in) C ’
% \ ‘\Y
Valve face width “B” IN: 2.1 mm (0.083 in) )J( 1%
_zzzT
EX: 2.1 mm (0.083 in) T
Valve seat width “C” IN: 1.3mm (0.051 in) D A_~_ 1,
L--
EX: 1.3 mm (0.051 in)
- 89 -
 Valve stem diameter IN: 8.0 ~~:~~~ mm (0.315 Ig:Eo in)

EX: 8.0 I::$“, mm (0.315 I~:~~~ in)

Valve guide diameter

EX:8.0 $iiz mm (0.315 :E:EE in)

Valve stem to guide clearance IN: 0.020 - 0.044 mm (0.00079 - 0.00173 in)
EX: 0.035 - 0.059 mm (0.00138 - 0.00232 in)

10. VALVE SPRING

1) Free length INNER (IN/EX): 42 mm (1.654 in)
OUTER (IN/EX): 42.55 mm (1.675 in)
2) Spring rate INNER (IN/EX): kr = 1.43 kg/mm (80.1 lb/in)
kz = 1.81 kg/mm (101.4 lb/in
OUTER (IN/EX): kr = 3.2 kg/mm (179.2 lb/in)
kz = 4.18 kg/mm(234.1 lb/in)
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): 10 kO.7 kg (22.0 -t 1.5 lb)
OUTER (IN/EX): 17.7 + 1.25 kg (39.0 f 2.8 lb)
5) Compressed length (Valve open) INNER (INIEX): 25.5 mm (1.004 in)
OUTER (IN/EX): 27.5 mm (1.083 in)
6) Compressed pressure (Valve open) INNER (IN/EX): 27.2 f 1.9 kg (60.0 f 4.2 lb)
OUTER (IN/EX): 57.4 +4.0 kg (126.5 * 8.8 lb)
7) Wire diameter INNER (IN/EX): 2.9 mm (0.114 in)
OUTER (IN/EX): 4.2 mm (0.165 in)
8) Winding D.D. INNER (IN/EX): 19.4 mm (0.764 in)
OUTER (IN/EX): 32.6 mm (1.283 in)
9) Number of windings INNER (IN/EX): 6.0 turns
OUTER (IN/EX): 4.25 turns

1) Crankshaft deflection limit (A) 0.05 mm (0.002 in)

2) Con-rod large end clearance (6) 0.15 - 0.4 mm (0.0059 - 0.0157 in)
3) Width of crankshaft (C) 663.2 mm (2.598 1E.g in)

(D) 186 -:.a mm (7.323 _E.o,g in)

4) Crank pin I.D. 26 ::“A: mm (1.024 _i:“d in)
0
5) Crank pin O.D. x length 28 _o.M)6 x 65 TX:: mm
(1.024 _&,os x 2.559z:zin)
12. CONNECTING ROD
1) Big end I.D. 34 +tol’ mm (1.339 +i.0°06 in)

2) Small end I.D. 20 $‘z”, mm (0.787 ~~:~~~ in)

13. CRANK BEARING

1) Type Right end @30-$78-19
Others @32-@68-17
2) Oil seal type SD-2540-9
_ on -
14. CLUTCH
1) Clutch type Wet, multiple type
2) Clutch operating mechanism Inner push type, screw push system
3) Primary reduction ratio and method 72127 (2.666). spar Qear
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.
Wear limit 2.7 mm (0.106 in)

6) Clutch plate
Thickness/Quantity 1.4 mm (0.055 in)/6 PCS.
Warp limit 0.05 mm (0.002 in)
7) Clutch spring
Free length/Quantity 34.6 mm (1.362 in)/6 PCS.
8) Clutch housing radial play 0.027 N 0.061 mm (0.0011 - 0.0032 in)
9) Push rod bending limit 0.2 mm (0.006 in)
15. TRANSMISSION
1) Type Constant mesh, 5-speed forward
2) Gear ratio: 1st 32/13 (2.461)
2nd 27117 (1.588)
3rd 26/20 (1.300)
4th 23/21 (1.095)
6th 22123 (0.966)
3) Bearing type: Main axle (Left) Needle bearing ( @20-$30-20)
Main axle (Right) Ball bearing (r#~25-$52-20.6)
Drive axle (Left) Ball bearing (@30-#62-23.8)
Drive axle (Right) Needle bearing (#20-#30-16)
4) Oil seal type Drive axle (Left) SDD-40-62-9
5) Secondary reduction ratio and method 34117 (2.0OO)/Chain
16. SHIFTING MECHANISM
1) Tvpe Cam drum, return type
2) Oil seal type (Change lever) SDO-14-24-6
17. KICK STARTER
1) Tvpe Bendix type
2) Oil seal type (Kick axle) SD-25-35-7
3) Kick clip friction tension 1.2 - 1.7 kg (2.6 - 3.7 lb)
18. INTAKE
1) Air cleaner: Type/Quantity Dry. foam rubber/2 pcs.
2) Cleaner cleaning interval Every 1,600 km (1,000 mile)
19. CARBURETOR
1) Type and manufacturer/Quantity BS38 MIKUNIR pcs.
2) I.D. mark 2FOOO
3) Main jet (MJ) #135
4) Air jet (AJ) #140
5) Jet needle (JN) 502-3
6) Needle jet (NJ) Z-2
7) Throttle valve (Th.V) #120
8) Pilot jet (PJ) #27.5
9) Pilot screw (Turns out) (PS) Preset
10) Starter jet (GS) GSr : #80, GSz : 0.5
11) Fuel level (FL) 24 f 1 mm (0.94 *O&l in)
12) Idling engine speed 1,200 rlmin
20. LUBRICATION
1) Engine sump oil quantiD/ Oil exchange: 2.0 lit (2.1 qt)
Overhaul: 2.5 lit (2.6 qt)
2) Oil type and grade Yamaluba 4-cycle oil or SAE 2OW/40 type
“SE” motor oil
3) Oil pump type Trochoid pump

-91 -
 4) Trochoid pump specifications
Top clearance 0.10 - 0.18 mm (0.0039 - 0.0071 in)
Tip clearance 0.03 - 0.09 mm (0.0012 - 0.0035 in)
Side clearance 0.03 - 0.08 mm (0.0012 - 0.0031 in)
Oil pump volume 1.3 lit/min (1.37 qt/min) at 1,000 r/min
5) Bypass valve setting pressure 1.0 kg/cm’ (14 psi)

6) Lubrication chart

I Oil main gallery c

Oil strainer

Main axle and mission j-----+q

C. Chassis

1. FRAME
1) Frame design Double cradle, high tensile frame
2. STEERING SYSTEM
1) Caster 27”
2) Trail 115 mm (4.53 in)
3) Number and size of balls in steering head
Upper race 19 PCS. l/4 in
Lower race 19 PCS. l/4 in
4) Steering lock to lock 42” each (L and R)
3. FRONT SUSPENSION
1) Type Telescopic fork
2) Damper type Oil damper, coil spring
3) Front fork spring
Free length 482 mm (18.98 in)
Wire diameter x winding diameter 4 x 24.5 mm (0.157 x 0.965 in)
Spring constant kt = 0.48 kg/mm (26.88 lb/in)/
0 - 100 mm (0 - 3.94 in)
kz = 0.65 kg/mm (36.40 lb/in)/
100 - 150 mm (3.94 - 5.91 in)
4) Front fork travel 150 mm (5.906 in)
5) Inner tuba O.D. 35 mm (1.378 in)
6) Front fork oil quantity and type 169 cc (5.72 oz) each leg
Yamaha fork oil 20 wt or equivalent
7) Distance from the top of inner tube oil level
without spring Approx. 454 mm (17.9 in)
4. REAR SUSPENSION
1) Tvpe Swing arm
2) Damper type Oil damper, coil spring
3) Shock absorber travel 80 mm (3.15 in)
4) Shock absorber spring
Free length 226 mm (8.90 in)
 Wire diameter x winding diameter 7.5 x 60.5 mm (0.295 x 2.382 in)
Spring constant kr = 1.714 kg/mm (96.0 lb/in)/
0%45mm(O-1.77in)
kz = 2.244 kg/mm (125.7 lb/in)/
45- 80mm (1.77- 3.15in)
5) Swing arm free play (Limit) 1 mm (0.04 in)
6) Pivot shaft - Outside diameter 16 mm (0.63 in)

5. FUEL TANK
1) Capacity 11.5 lit (2.53 US. gal)
2) Fuel grade Regular gasoline
6. WHEEL
1) Type (Front and rear) Aluminum rim
2) Tire size (Front) 3.50.S19-4PR
(Rear) 130/9OS 16-4P R
3) Tire pressure:
up to 90 kg (198 lb) load Front: 1.6 kg/cm’ (22 psi)
Rear: 2.0 kg/cm2 (28 psi)
90 kg (198 Ib)load - 204 kg (445 Ib)load Front: 2.0 kg/cm2 (28 psi)
(Maximum load) Rear: 2.3 kg/cm2 (32 psi)
High speed riding Front: 2.0 kg/cm’ (28 psi)
Rear: 2.3 kg/cm’ (32 psi)
4) Rim run out limit (Front and rear)
Vertical 2 mm (0.08 in)
Lateral 2 mm (0.08 in)
5) Rim size (Front) 1.85 x 19
(Rear) MT390 x 16
6) Bearing type
Front wheel (Left) 630322
Front wheel (Right) 63032132
Rear wheel (Left) 63052
Rear wheel (Right) 63042
7) Oil seal type
Front wheel 1 Left) SDD-45-56-6
Front wheel (Right) SD-28-47-7
Rear wheel (Left) SD-35-62-9
Rear wheel (Right) SO-27-52-5
8) Secondary drive chain type
Type 50HDS
Number of links 103L + Joint
Chain pitch 15.875 mm (5/E in)
Chain free play 20 mm (314 in)

7. BRAKE
1) Front brake
Tvw Hydraulic disc type
Disc size (Outside dia. x 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 (0.24 in)
Master cylinder inside dia. 14.0 mm (0.55 in)
Caliper cylinder inside dia. 38.1 mm (1.50 in)
Brake fluid type / quantiD/ DOT #3 Brake fluid / 38.1 cc (1.29 02)
2) Rear brake
Type Hydraulic disc type
Disc size (Outside dia. x thickness) 267 x 7.0 mm (10.5 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 (0.24 in)
Master cylinder inside dia. 14.0 mm (0.55 in)
Caliper cylinder inside dia. 38.1 mm (1.50 in)
Brake fluid type / quantity DOT #3 Brake fluid / 38.1 cc (1.29 02)
_a?_
D. Electrical

1. IGNITION SYSTEM
1) Ignition timing (B.T.D.C.) 15’/1,200 r/min
2) ignition coil
Model/Manufacturer CMll-SOB/HITACHI
Spark gap B mm (0.31 in) or more/300 r/min at 8V
Primary winding resistance 3.9!Q + 10% at 20°C (68°F)
Secondary winding resistance B.OkR ?r 20% at 20°C (6B°F)
3) Spark plug
Type N-7Y (CHAMPION) or BP7ES (N.G.K.)
Spark plug gap 0.7 - 0.8 mm (0.027 - 0.031 in)
4) Contact breaker
Manufacturer/Quantity HITACHI/2 pcs.
Point gap 0.30 - 0.40 mm (0.012 - 0.016 in)
Point spring pressure 650 - 850 g (22.9 - 30.0 oz)
Cam closing angle 93” -+ 5”
5) Condenser
Capacity 0.22pF
Insulation resistance lOMa or more
Quantity 2 PCS.
2. CHARGING SYSTEM
1) AC generator
Charging output 14V 1 lAI2.000 r/min
Rotor coil resistance (Field coil) 5.2552 f 10% at 20°C (6B’F)
Stator coil resistance 0.46SJI * 10% at 20°C (68°F)
Brush length 14.5 mm (0.571 in)
Brush wear limit 7.0 mm (0.276 in)
2) Rectifier
Type 6-Element type (Full wave)
Model/Manufacturer SBGB-17/H ITACH I
Capacity 12A
Withstand voltage 4oov
3) Regulator
Type Tillil type
Model/Manufacturer TLIZSO/HlTACHI
Regulating voltage 14.5 f 0.5v
Core gap 0.6 - 1.0 mm (0.024 - 0.039 in)
Point gap 0.3 - 0.4 mm (0.012 - 0.016 in)
Voltage coil resistance 1051 at 2O’C (66’F)
5) Battery
Model/Manufacturer/Quantity YB14L-A2/YUASAIl pc.
Capacity 12V, 14AH
Charging rate 1.4A 10 hours
Specific gravity 1.28 at 2O’C (66’F)
3. STARTER
1) Starter motor
Type Bendix type
Manufacturer HITACHI
Model s108-35
output 0.5 kw
Armature coil resistance 0.006752 f 10% at 20°C &F)
Field coil resistance 0.00451 f 10% at 2O’C (68’F)
Brush size/Quantity 16 mm (0.63 in)/2 PCS.
Wear limit 4 mm (0.16 in)
Spring pressure 800 g (28.2 oz)
Commutator O.D.Mlear limit 33 mm (1.30 in)/31 mm (1.22 in)
Mica undercut 0.7 mm (0.028 in)
 2) Starter switch
Manufacturer HITACHI
Model A104-70
Amparage rating 1OOA
Cut-in voltage 6.5V
Winding resistance 3.5a
3) Starter clio friction tension 2.2 - 2.5 kg (4.9 - 5.5 lb)
4. LIGHTING SYSTEM
1) Head light type Sealed beam
2) Bulb brightness and wattage/Quantity
Head light 12v. 50/4ow x 1 PC.
Tail/brake light 12V, 3132 CP @W/27W) x 1 P C.

Flasher light 12V. 32 CP (27W) x 4 PCS.

Pilot lights: Turn 12v, 3.4w x 2 PCS.
High beam 12v. 3.4w x 1 PC.
Headlight failure 12v. 3.4w x 1 pc.
Neutral 12v. 3.4w x 1 pc.
Tail/brake failure 12v, 3.4w x 1 PC.
Meter lights 12v, 3.4w x 4 PCS.
3) Reserve lighting unit Model/Manufacturer 337-l 1720/KOITO
4) Horn
Model/Manufacturer CF-12/NIKKO
Maximum amparage 2.5A
5) Flasher relay
Type Condenser type
Model/Manufacturer lAO-70/NIPPON DENS0
Flasher frequency 85 + 10 cycle/min.
Capacity 32 CP (27W) x 2 + 3.4W
6) Flasher cancelling unit
Model EVH-AC518
Voltage DCSV - 16V
7) Fuse
Rating/Quantity Main (Red): 20A
8) Light checker
Model 35200-7 1859
Manufacturer KOITO
 Supplementary
FOR XS650SE MODELS AFTER ENGINE SERIAL NUMBER 2FO-114241
 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.
 Page numbers shown in brackets correspond
to page numbers of the XS650E Service
Manual (LIT-1 1616-00-76).

(PAGE 4 - 5)
2-2. MAINTENANCE INTERVALS CHARTS
A. PERIODIC MAINTENANCE EMISSION CONTROL SYSTEM

REMARKS

8 1 Exhaust System
) Check for leakage. Retlghten as nets- ~ 0 j 0 I 0
sary.R e p l a c e gasket(s) of newssaw. /
9
! Carburetor
Ad,us, synchron,zat,o” Of carburetors.1 0 0 0
I Svnchronuatlon

10 Idle Speed
Check and adjust engnne Idle speed. 0 0 0
Adlust cable free play.

B. GENERAL MAINTENANCE/LUBRICATION
INITIAL BREAK-IN THEREAFTEREVERY

REMARKS TYPE 1,000 km 5.000 km 4.000 km 8,000 km I---- 1 6 , 0km

00
VO. ITEM or 1 month or 7 months or6 months or 12 months or 24 months
(600 muI 13,000 mil 12,500 ml) 1 5 , 0 0 0 mll l10.000 ma)
I I , I I I

Warm-up engine before Yamalube 4.cycle

drammg. 011 or SAE 2OW/40 0 0 0
“SE” motor oil _
Clean element in solvent. 0 0

3 /AI, F,lter Dry type filter Clean c 0

wth compressed air

Brake Adjust free play. Replace 0 0 0

4 System pad If necessary.

Tp”tch Adjust free play. 0 0 0

Yamaha chain and
Apply chain lube cable lube or
6 Drwe Chaan CHECK CHAIN TENSION AND LUBE EVERY 500 km (300 ml)
thoroughly.
low/30 motor 011
Yamaha chsln and
, Control a n d Apply cable lube cable lube or 0 0 0
Meter Cable thoroughly
lOWl30 motor oil
B Rear Arm Apply untel new grease 0
-t
Pwot Shaft shows
Yamaha chain and
Apply Ilghtly. cable lube or cj i’
low/30 mcltor 011

-lll-
I I I I / IN. I T I .-
AL - REAK-IN 1
B THEREAFTEREVERY

1,000 km 5,000 km 4,000 km 8,000 km 16,000 km

NO. ITEM REMARKS TYPE
or 1 month or 7 months or 6 months or 12 months or24month
(600 mi) ( 3 . 0 0 0 mil 12.500 ml) l5.000 mil (10,OQO mi

, , ;ynt Fork Dram completely. Yamaha fork oil 0

I Refill to speciflcatmn. 1OWt or equivalent
Steering Ball Check bearmgs assembly Medwm weight
,2 Eearmg and for looseness. Moderately wheel bearing 0 0 Repack
Races repack every 16,000 km grease.
110,000 rni).
Check bearmgs for smooth
Medium weight
,3 W h e e l rotation. Moderaltelv 0 0
wheel bearmg Repack
Bearings repack every 16,000 km
~lO,C00 mil. grease.

Check specific gravity.

1 4 Battery Check breather pipe for 0 0
proper operation.

Replace generator brushes.

,5 A . C . - 0
Replace at initial 9.000
Generator
km 16.500 mi)

In the XS650E Service Manual there are a few (PAGE 9 - 13)

pages that are not arranged in order. These 2-4. CHASSIS
are pages 7, 8 and 9. They should be read in A. Fuel petcock cleaning
the reverse order, i.e. 9,8 and 7. 1. Open the seat and remove the fuel tank
securing bolt.
(PAGE 7 - 8) 2. Turn the petcock lever to the “ON” or
2-3. ENGINE “RES” position. Raise the fuel tank to
B. Air filters remove the fuel pipe.
2. Cleaning method
c. The air filter element should be cleaned
every 8,000 km (5,000 mi). It should be
cleaned more often if the machine is
operated in extremely dusty areas.

E. Cam chain adjustment

Check/adjust the cam chain tension as follows:
1. Remove the cap nut.
2. Turn the left end of the crankshaft
counterclockwise. As the crankshaft is 1. Fuel pipe
turning, check to see that the cam chain
adjuster push rod is flush with the end of 3. Remove the drain bolt and clean with
the bolt. If not, turn the adjuster bolt solvent. If gasket is damaged, replace.
until the push rod is flush.
3. Reinstall the cap nut. The cap nut acts
as a lock nut for the adjuster.

1. Drain bolt

_/-------/ j ,:
_/--- R
1. cap nut 2. Adjuster bolt 3. Push rod
E. Rear brake
The rear brake pedal should be so adjusted
that it has a free play of 13 - 15 mm (0.51
- 0.59 in) from when the brake pedal is first
moved to when the brake begins to be
effected.
I Standard tire
Bridwstone or
Yokohama
3.50SlQ-lPR
Bridgestone or
Yokohama
130/90S164PR
1. Loosen the adjuster lock nut (for pedal Maximum load limit 166 kg (365 Ibl 279 kg (615 lb1
height). Cold tire oressure: 1
Up to 90 kg 1.6 kg/cm2 2.0 kg/cm*
2. By turning the adjuster bolt clockwise or (198 lb) load (22 psi ) (28 psi)
counterclockwise, adjust the brake pedal 90 kg (198 lb) load
- 204 kg (445 lb) 2.0 kglcmz 2.3 kg/cm2
position so that its top end is approx. 12 load (Maximum (28 psi 1 (32 psi 1
- 18 mm (0.47 - 0.71 in) below the load1

footrest top end. High speed riding 2.0 kg/cm2 2.3 kg/cm2
(28 psi I (32 psi I
3. Secure the adjuster lock nut.
4. Loosen the brake rod adjuster lock nut
and screw brake rod downward until
I Minimum tire
tread depth
0.8 mm (0.03 in) 0.8 mm (0.03 in)

there is noticeable free play between rod G. Drive chain

and master cylinder. 1. Tension check
5. Turn in the brake rod until it lightly
NOTE:
touches the master cylinder, then turn it
Before checking and/or adjusting, rotate
out by approx. 1-1/5 turns (for proper
rear wheel through several revolutions and
free play).
check tension several times to find the
6. Tighten the brake rod adjuster lock nut.
tightest point. Check and/or adjust chain
- CAUTION: tension with rear wheel in this “tight chain”
See that the punched mark on the brake position.
rod is not above the top surface of the
adjuster lock nut in securing the brake rod Inspect the drive chain with both tires
adjuster lock nut. touching the ground and without rider.
Check the tension at the position shown
in the illustration. The normal vertical
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.

4
1. Adjuster bolt (for pedal height) 6. Pedal height 12 - 18 mm
2. Lock nut (0.47 - 0 . 7 1 in)
3. Lock nut 7. Free play 13 - 15 mm
4. Brake rod (0.51 -0.59 in)
5. Footrest

F. Wheels and tires

2. Tension adjustment
2. Tires
a. Remove the cotter pin of the rear wheel
Specifications should be changed as
axle nut with pliers.
follows:
b. Loosen the rear wheel axle nut.
-113-
C. L o o s e n t h e IOU W. ,, ~“, ~~, To
H. Front fork oil change
tighten chain tur* ‘,W _
2, 61 @lusters 8. Pour specified amount of oil into the
clockwise. To Irfn *,W
,fl’ Mjustars inner tube through the upper end open-
counterclockmw a/,
)* U,W! f o r - ing.
ward. Turn ta7 vqnn
?/=?I / the
same amount ti FW+.
rv ‘l++f,t axle
alignment. (There VS. W5J”S ,,, 3ivh side
of rear arm and cf TV/ #,*, 9,,,rr. uoe
them to check for p--H -4;
(PAGE 14 - 15)
2-5. E L E C T R I C A L
C. Ignition timing
1. Point gap must be set before setting
timing.
2. Ignition timing is checked with a timing
light by observing the position of the
stationary marks stamped on the stator

2. Adjuster 6. bewp+ - - -
3. Marks for alipnant
d. After adjusting, 8~ ,..,+ .,
c ‘j’t#ten the

1. Too dead center 3. Advanced mark

2.15” BTDC at 1,200 rlmn
CAUTION:-. .*,_
3. Connect timing light to right (left)
cylinder spark plug lead wire. Ignition
timing of right cylinder must be set first.
NOTE: 4. Start the engine and keep the engine
-I_ speed as specified on the label. Use a
Excessive chain tense ~1) ,,W,M the en_
gine and other vita, m tachometer for checking.
’ ‘W tlu: ternion The rotor pointer should line up the “F”
within the specifti iir& h, ,~~ the 5.
rear axle cotter pin * * + k stamped timing mark on the stator at a
specified engine speed. If it does not
-‘-- “_ align, loosen the two breaker backing
plate screws (breaker assembly holding
screws for left cylinder) and move the
complete backing plate (breaker assem-
bly for left cylinder) until the point
marks align.
6. Retighten screws. Check timing again
for right cylinder.
7. Repeat procedure (steps 2 - 6) for left
cylinder.

-114-

.
 (PAGE 29 - 33)
3-4. ENGINE ASSEMBLY AND ADJUSTMENT
0. Engine
Specifications should be changed as

Engine mounting bolt torCWe:

Upper Kl Nut) M8 1.8 m-kg (13.0ft-lb)
Upper M l 0 3.0 m-kg (21.7 ft-lb)
Front (U Nut) Ml0 4.6 m-kg (33.3 ft-lb)
1. Right cylinder timing adjustment Rear (U Nut) Ml0 4.1 m-kg (29.7 ft-lb)
2. Left cylinder timing adjurtment Rear - under (U Nut)
F. Spark plug Ml0 4.6 m-kg (33.3 ft-lb)
Check electrode condition and wear, insulator Under (U Nut) Ml0 9.0 m-kg (65.1 ft-lb)
color and electrode gap. Use a wire gauge for
a adjusting the plug gap. If the electrodes
become too worn, replace it. (PAGE 39 - 40)
When installing the plug, always clean the 5-1. FRONT WHEEL
gasket surface, wipe off any grime that might C. Front wheel inspection
be present on the surface of the spark plug, 1. Check for cracks, bends or warpage of
and torque the spark plug properly. wheels. If a wheel is deformed or crack-
ed, it must be replaced.
Standard spark plug:
N-7Y (CHAMPION) or BP7ES (NGK) NOTE:
Spark plug gap: These aluminum wheels are not designed for
0.7 - 0.8 mm (0.028 - 0.031 in) use with tubeless tires.
Spark plug tightening torque:
2.0 m-kg (14.5 ft-lb)
2. Check wheel run-out
If deflection exceeds tolerance, check
(PAGE 22 - 29) wheel bearing or replace wheel as required.
33. INSPECTION AND REPAIR
D. Valve spring
1. Checking the valve springs
d. Valve spring specifications
Specifications should be changed a s
follows:
3. Check wheel balance
Rotate wheel lightly several times and
observe resting position.
If wheels is not statically balanced,
wheel will come to rest at the same po-
Installed length 35 mm 37 mm sition. Install balance weight at lighter
(Valve closad) (1.378 in) (1.457 in) position (at top) as illustrated.
compraued press”re 25.3-28.1 kg 53.5-81.5 kg
Waive openl (55.8-82.0 lb1 (118.0 -135.6 lb) NOTE:
Compressed length 25.5 mm 27.5 mm The wheel should be balanced with brake disc
Waive open) (1.0&l in) (1.083 in)
installed.
Allowable tilt from 1.6 mm or 2.5’ -
vertical (0.063 in)

- 115-
 (PAGE 40)
5-2. REAR WHEEL
A. Removal
1. Support machine on the center stand.
2. Disconnect the drive chain. Using drive
chain cutter (special tool).
NOTE:
The chain joint should be replaced each time
the chain is cut.

3. Remove the axle nut cotter pin and axle

nut.
4. While supporting the brake caliper, pull
out the rear axle.
5. Remove the rear wheel assembly.

E. Rear wheel installation

When installing rear wheel, reverse removal
procedure taking care of following points:
1. Lightly grease lip of rear wheel oil seals.
2. Make sure the brake pads are installed
properly and that there is an enough gap
to install the rear disc.
3. Install wheel assembly and axle. Always
Balance weight
use a new cotter pin on the axle nut.

ji

4. Connect drive chain.

5. Adjust drive chain.

(PAGE 40 - 44)
5-3. BRAKES
E. Installing front wheel 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. Brake inspection and repair
Specifications should be changed as follows:

Wear limit:
6.0 mm (0.24 in)

- 116-
 4. Check the front and rear cover bearings
for damage. If damaged, the starter
A: Pad thickness
assembly must be replaced.
11 .O mm (0.43 in)
6: Wear limit (PAGE 57 - 58)
6.0 mm IO.24 in1 6-5. LIGHTING AND SIGNAL SYSTEMS
C: Wear indicator B. Reserve lighting system
1. Description:
The reserve lighting system has two
-Backing plate
functions: (1) It notifies the rider that
/ L-J one of the headlight filaments is in-
Pad
operative, and (2) it switches current
( PAGE 4 8 ) from the inoperative filament to the
5-9. REAR SHOCK ABSORBER remaining functional filament.
B. Inspection The system is connected to the headlight
Specifications should be changed as follows: circuit only. The reserve lighting system
unit is located under the fuel tank.
Rear shock absorber tightening torque: NOTE:
This model has been equipped with a safety
relay so that the headlight comes on auto-
matically when the engine is started even
(PAGE 50 - 51) with the headlight switch “OFF”.
8-1. STARTER
Headlight Headlight Reserve light-
A. Armature
condition failure indi- ing function
1. Check the outer surface of the com-
mutator. If it’s surface is dirty, clean cator light
with No. 600 grit sand paper. Normal Comes on -
2. The mica insulation between com- (very dim)
mutator segments should be 0.7 mm High beam Comes on Low beam
(0.028 in) below the segment level. If faulty comes on
not, scrape to proper limits with ap-
Low beam Comes on High beam
propriately shaped tool. (A hack saw
faulty comes on at
blade can be ground to fit.)
low brilliance
2. Troubleshooting/Inspection
Mica under cut
0.7 mm (0.026 inl

HEADLIGHT DOES NOT

COME ON WHEN ENGINE
IS RUNNING WITH HANDLE
BAR SWITCH OFF

I
Commutator

3. Check the armature and field coil for

shorting and insulation. Replace arma- 1 “ohage 0K
ture as required.
-117-
“R/W” wire to

-118-
-119-
(PAGE 61- 62)
7-1. TORQUE SPECIFICATION
The following torque specifications must be
adhered to on every machine When applying
torque to multi-secured fastener components,
the several studs should be tightened in
gradual stages and in a pattern that will avoid
warpage to the item being secured. Torque
settings are for dry, clean threads. Torquing
should always be done to the nut, never the
bolt head.
NOTE:
Certain items with other than standard thread
pitches may require differing torque.

Torque Specifications

B Standard tightenins torque

(Bolt) m-kg ft.lb

10mm 6mm (M61 1 .o 7.2

12mm Bmm (MB) 2.0 15

14 mm 10mm (Ml01 4.0 29

17mm 12mm (M12) 4.5 33

19mm 14 mm (Ml41 5.0 36

22 mm 16mm (M16) 6.5 47

24 mm 18mm (MlBl 7.0 50

27 mm 20 mm (M20) 8.0 58

I Part to be tiahtened I Thread dia. and part name I T i g h t e n i n g torque 1

Engine:
Cylinder head and cylinder 1Omm nut 3.7 m-kg (26.6 ft.lb)
head cover 8 mm bolt 2.1 m-kg (15.2 ft.lb)
Cylinder head 6 mm bolt 0.9 m-kg ( 6.5 ft-lb)
Cylinder head cover ride 6 mm crown nut 0.9 m-kg 1 6.5 ft.lb)
B mm crown nut 1.3 m-ka 1 9.4 ft.lbl

Spark plug 14 mm 2.0 m-kg (14.5 ft.lb)

GeW?rat0r I 12mm nut I 3.8 m-kg 127.5 ft.lb)

Stator coil 6 mm pan head screw 0.9 m-kg ( 6.5 ft.lb)

GLXWner 6 mm bolt 0.8 m-kg ( 5.8 ft-lb)
Valve clearance adiustmenf nut 8 mm nut

Cam chain tensioner I 18 mm cap

Pump cover 6 mm pan head screw 1.0 m-kg ( 7.2 ti-lb)
Strainer cover 6 mm bolt 1.0 m-kg ( 7.2 ft.lb)
Drain plug 30 mm bolt 4.2 m-kg (30.4 ft.lb)

Oil filter 6 mm bolt 0.9 m-kg ( 6.5 ft.lb)

 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 14 mm nut 9.0 m-kg (65.1 ft-lb)
Clutch boss 18 mm nut 8.0 m.kg (57.9 ft.lb)
Drive sprocket 22 mm nut 6.5 m.kg 147.0 ft-lb)
Change pedal 6 mm bolt 1.0 m-kg ( 7.2 ft-lb)
Chassis:
Front wheel axle 14 mm nut j 10.7 m-kg (77.4 ft.lb)
Front fork and axle holder 8 mm nut I 1.4 m-ka_ 110.1 ft.lb\
Handle crown and inner tube 8 mm nut 1 . 1 m.kg ( 8.0ft-lb)
Handle crown and steering shaft 8 mm nut 1.1 m.kg ( 8.0 ft.lb)
Handle crown and steering shaft 14 mm bolt 5.4 m-kg 139.1 ft-lb)
Handle crown and handlebar holder 8 mm bolt 1.8 m-kg (13.0 ft-lbl
Under bracket and inner tube 8 mm nut 2.0 m-kg (14.5 ft.lb)
Engine mounting Upper 8mm nut 1.8 m-kg I 5.8 ft-lb)
Engine mounting UPPer 10 mm nut 3.0 m-kg (21.7 ft.lb)
Engine mounting Front 10 mm nut 4.6 m-kg (33.3 ft-lb)
Engine mounting Rear 10 mm nut 4.1 m-kg (29.7 ft.lb)
Engine mounting ReaVLOVJer 10 mm nut 4.6 m-kg (33.3 ft-lb)
Engine mounting LOWW 10 mm nut 9.0 m-kg (65.1 ft-lb)
Front flasher and headlight 8 mm nut 1.0 m.kg ( 7.2 ft.lb)
Master cylinder and brake hose 10 mm union bolt 2.6 m-kg (18.8 ft.lb)
Brake disc and hub 8 mm bolt 2.0 m-kg (14.5 ft-lb)
Caliwr and surxaort bracket 8 mm bolt 1.8 m-ka 113.0 ft.lb)
Caliper and pad 5 mm bolt 0.3 m-kg ( 2.2 ft.lb)
Caliper and bleed screw 8 mm bolt 0.6 m-kg ( 4.3 ft.lb)
Front caliper and front fork 10 mm bolt 3.5 m-kg (25.3 ft.lb)
Master cylinder and cylinder bracket 6 mm bolt 0.6 m-kg ( 4.3 ft.lb)
Pivot shaft 14 mm nut 6.5 m-kg (47.0 ft.lb)
Rear wheel axle 16 mm nut 15.0 m-kg (108.5 ft-lb)
Tension bar and brake caliper 8 mm nut 1.8 m-kg 113.0 ft-lb)
Tension bar and rear arm 8 mm nut 3.2 m-ka 123.1 ft.lbi
Rear shock absorber UPPer 10 mm bolt 3.0 m-kg (21.7 ft.lbl
Rear shock absorber LOWW 10 mm bolt 3.9 m:ks (28.2 ft.lb1
Rear arm and rear arm end 8 mm bolt 1.0 m-kg ( 7.2 ft-lb)
Front fender 8 mm bolt 1.0 m-kg ( 7.2 ft.lb)
Neutral switch 12mm 1.3 m-kg ( 9.4 ft.lb)

-121-

;
v c
( P A GE 64 - 71)
7-3. SPECIFICATION
A. General
1. M O D E L
1) Model (I.&M. No.) XS650S.E l2MO)
2) Frame I.D. and starting number 2FO-114241
3) Engine I.D. and starting number ZFO-114241

2. D I M E N S I O N
1) Overall length 2,120 mm (83.5 in)
2) Overall width 925 mm (36.4 in)
3) Overall height 1,225 mm (48.2 in)
41 Seat height 790 mm (31.1 in)
5) Wheelbase 1,435 mm (56.5 in)
6) Minimum ground clearance 135 mm ( 5.3 in)

3. WEIGHT
1) Net weight (Dry) 210 kg (463 lb)

4. PERFORMANCE
1) Climbing ability 26’
2) Minimum turning radius 2,500 mm (98.4 in)
31 Brakina distance 14 m @ 50 km/h (45.9 ft @ 31 mi/h)

B. Engine
1. D E S C R I P T I O N
11 Engine type Air cooled, 4.stroke, SOHC twin,
parallel forward incline
21 Engine model 2FO
3) Displacement 653 cc 139.85 cu.in)
4) Bore x stroke 75 x 74 mm (2.953 x 2.913 in)
5) Compression ratio 0.5 : 1
61 Starting rvrtem Kick and electric starter
7) Ignition system Battery ignition
8) Lubrication system wet rump
2. C Y L I N D E R H E A D
1) Combustion chamber volume (with N-7Y) 43.6 cc 12.660 win)
2) Combustion chamber tvPe Dome + Swish
31 Head oasket thickness 1.2 mm (0.047 in)
3. CYLINDER
1 I Material Aluminum alloy with cast iron sleeve
2) Bore size 7 5 . 0 0 $.Oz mm (2.952B*~.0°08 in)
3) Taper limit 0.05 mm 10.002 in)
4) Out of round limit 0.01 mm (0.0004 in)
4. PISTON
1) Piston skirt clearance 0.050 - 0.055 mm (0.0020 + 0.0022 in)
21 Piston oversize 7525 mm 7560 mm 75.75 mm 78.00 mrn
12.963 I”) 12972 I”, 12982 I”) 12992 I”,

3) Piston pin outside diameter x length 20.0 _&,, mm x 61 .O _0,3

O mm
0
10.79 _o,oo,,2 in x 2.40 _$,,,, in)
1 I Piston ring design

2) Ring end gap (Installed. top) 0.2 - 0.4 mm 10.006 - 0.016 in)
(Installed, 2nd) 0.2 - 0.4 mm (0.006- 0.016 in)
(Installed. oil) 0.3 - 0.9 mm (0.012 - 0.035 inl
3) Ring groove side clearance (Top) 0.04 - 0.06 mm (0.0016 - 0.0031 inl
0.03 - 0.07 mm (0.0012 - 0.0026 in)

1) Type Needle bearing

1) Cam drive type Chain (Center side)

21 Number and type of bearing 4 bearings, Ball bearings (6005)
3) Bearing type

6) Camshaft deflection limit 0.03 mm 10.0012 in)

71 Cam chain
Type TSUBAKIMOTO BF06M
Number of links

1) Rocker arm inner diameter 15.0+~.“‘8 mm IO.591 +t.Mx17 in)

2) Rocker arm shaft diameter 15.0 :z:r5 mm IO.591 I$=$ in)

3) Clearance 0.009 - 0.033 mm (0.00035 - 0.00130 in1

1) Valve per cylinder

2) Valve clearance (In cold engine) IN: 0.10 mm (0.0039 in)
EX: 0.15 mm (0.0059 in)
31 Dimensions
Valve head diameter “A” IN: 41 mm (1.614 in)
EX: 35 mm (1.376 in) c
Valve face width “B”

Valve seat width “C” IN: 1.3 mm (0.051 in)

EX: 1.3 mm (0.051 inl
Valve margin thickness “D” IN: 1.3 mm IO.051 in)
EX: 1.3 mm IO.051 in)

- 123-
 Valve stem diameter EX: 6.0 3:;: mm (0.315 ;g:$$ in)

Valve guide diameter IN: 8.0 $ti”, mm (0.315 $E inl

EX:8.0 :~:~~~ mm (0.315 :i:“g in)

Valve stem to guide clearance IN: 0.020 - 0.044 mm (0.00079 - 0.00173 in)
EX: 0.035 - 0.059 mm IO.00138 - 0.00232 in)
4) Valve face runout limit IN & EX: 0.03 mm (0.0012 in) or less
10. VALVE SPRING
11 Free length INNER (IN/EX): 42 mm (1.654 in)
OUTER ~(INIEX): 42.55 mm (1.675 in)
2) Spring rate INNER (INIEX): kl = 1.43 kg/mm (80.1 lb/i”)
kz = 1.81 kg/mm (101.4 lb/in
OUTER (INIEX): kl = 3.2 kg/mm (179.2 lb/i”)
k2 = 4.18 kglmm(234.1 lb/in)
3) Installed length IValve closed1 INNER (INIEX): 35 mm (1.378 in)
OUTER (IN/EX): 37 mm (1.457 in)
4) Installed pressure (Valve closed) INNER (INIEX): 10 to.7 kg (22.0 * 1.5 lb)
OUTER (IN/EX): 17.7 f 1.25 kg (39.0 * 2.8 lb1
5) Compressed length (Valve open) INNER (INIEX): 25.5 mm Il.004 in1
OUTER (IN/EX): 27.5 mm (1.083 in)
61 Compressed prestw? (Valve Open) INNER (IN/EXI: 27.2 f 1.9 kg (60.0 f 4.2 lb)
OUTER IIN/EX): 57.4 e4.0 kg (126.5 t 8.8 lb)
7) Wire diameter INNER (IN/EX): 2.9 mm (0.114 in)
OUTER (IN/EX): 4.2 mm (0.165 in)
8) Winding0.D. INNER (IN/EX): 19.4 mm IO.764 in)
OUTER (INIEX): 32.6 mm (1.283 in)
9) Number of windings INNER lIN/EXl: 6.0 turns
OUTER llN/EX): 4.25 turns
11. CRANKSHAFT

PYo /
1) Crankshaft deflection limit (A) 0.05 mm (0.002 in)
2) Con-rod large end clearance (6) 0.15- 0.4 mm 10.0059” 0.0157 in)
3) Width of crankshaft IC) 66 2:$ mm (2.598 1::’ in)

(D) 186 -;.3 mm (7.323 &,,2 in)

4) Crank pin I.D. 26 I$‘dg mm (1.024 1::’ in)

5) Crank pin O.D. x length 26 j.M)6 x 65 _*;:; mm

(1.024 _&,,2 x 2.559+z:zinl
12. CONNECTING ROD
1) Big end I.D. 34+t”16 mm (1.339 +~Ooo6 in)

2) Small end I.D. 20$$85 mm (0.787 :i:gA in)

13. CRANK BEARING

1) Type Right end $30$78-19 (Ball bearing)
Others 432.$68-17 (Rollar bearing)
2) Oil seal type SD-25-40-9
14. CLUTCH
11 Clutch type Wet, multiple type
21 Clutch operating mechanism Inner push type. screw push system
3) Primary reduction ratio and method 72/27 (2.666). spar gear
4) Primary reduction gear back lash (4 twthl 0
21.45 _-0,-,25mm (0.8445 j.m,o in)
_,o*_
 51 Friction plate
ThicknerslCluantity 3 mm (0.118 in117 pcs.
Wear limit 2.7 mm (0.106 in)
61 Clutch plate
Thickness/Quantity 1.4 mm (0.055 in)/6 pcs.
Warp limit 0.05 mm (0.002 in)
7) Clutch spring
Free length/Quantity 34.6 mm (1.362 in)/6 per.
8) Clutch housing radial play 0.027 - 0.081 mm (0.0011 - 0.0032 in)
9) Push rod bending limit 0.2 mm (0.008 in)

15. TRANSMISSION
1) Type Constant mesh, 5.speed forward
2) Gear ratio: 1st 32/13 12.461)
2nd 27/l 7 (1.588)
3rd 26/20 (1.300)
4th 23/21 (1.095)
5th 22/23 (0.956)
3) Bearing type: Main axle (Left) Needle bearing ($20. $30.20)
(Right) Ball bearing I@ 25.$52-20.6) ,
Drive axle (Left) Ball bearing ($30. $62.23.8)
(Right) Needle bearing (@20-$30.16)
4) Oil seal type Drive axle (Left) SDD-40-62-9
5) Secondary reduction ratio and method 34117 (2.0OO)/Chain
16. SHIFTING MECHANISM
1) Type Cam drum, return type
21 Oil seal type (Change lever) SDO-14-24-6
17. KICK STARTER
1) Tvpe Bendix type
21 Oil seal type (Kick axle) SD-25-35-7
31 Kick clip friction tension 1.2 - 1.7 kg (2.6 - 3.7 lb)
18. INTAKE
1) Air cleaner: Type/Quantity Dry, foam rubber12 pcs.
2) Cleaner cleaning interval Every 8.000 km (5.000 mile)
19. CARBURETOR
1) Type and manufacturerlQuantity ES38 MIKUNII2 pcs.
2) I.D. mark 2FO-00
3) Main jet (MJ) #135
4) Air jet (AJ) #140
5) Jet needle IJN) 502.3
6) Needle jet (NJ) z-2
71 Throttle valve (Th.V) #120
8) Pilot jet IPJ) #27.5
91 Pilot screw (Turns out) (PS) Preset
10) starter jet (GS) GS, : #80, GS> : 0.5
11) Fuel level IFL) 24 + 1 mm (0.94 to.04 in)
12) Idling engine speed 1.200 rlmin
20. LUBRICATION
1) Engine sump oil quantiw Oil exchange: 2.0 lit (2.1 US qt)
Overhaul: 2.5 lit 12.6 USqtl
2) Oil type and grade Yamalube 4.cycle oil or SAE 2OWl40 twe
“SE” motor oil
3) Oil pump type Trochoid pump

4) Trochoid pump specifications

Top clearance O.lO- 0.18 mm (0.0039 -0.0071 in)
Tip clearance 0.03 - 0.09 mm (0.0012 - 0.0035 in)
Side clearance 0.03 - 0.08 mm (0.0012 - 0.0031 in)
Oil pump volume 1.3 litlmin Il.37 qtlmin) at 1,000 rlmin
5) Bvpass valve setting pressure 1.0 kg/cm’ 114 psi)
.I_
 6) Lubrication chart
- Pressure feed
----Splash lubrication

I-

C. Chassis
1. FRAME
1) Frame design Double cradle, high tensile frame

2. STEERING SYSTEM
11 caster 27’
2) Trail 115 mm (4.53 in)
3) Number and size of balls in steering head
upper race 19 pcs. l/4 in
Lower race 19 pcs. l/4 in
4) Steering lock to lock 42’ each IL and RI

3. FRONT SUSPENSION
1) Type Telescopic fork
21 Damper type Oil damper, coil spring
3) Front fork spring
Free length 482 mm (18.08 in)
Wire diameter x winding diameter 4 x 24.5 mm IO.157 x 0.965 in)
Spring constant kl = 0.48 kg/mm (26.88 lblinll
0 - 100 mm IO - 3.94 in)
kz = 0.65 kg/mm (36.40 lb/in)/
100 - 150 mm (3.94 - 5.91 in)
4) Front fork travel 150 mm (5.906 in)
5) Inner tube O.D. 35 mm (1.378 in)
6) Front fork oil quantitv and type 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 Approx. 454 mm (17.9 in)

4. REAR SUSPENSION
1 I Type Swing arm
2) Damper type Oil damper, coil spring
3) Shock absorber travel 80 mm (3.15 inl
4) Shock absorber spring
Free length 226 mm (8.90 in)
Wire diameter x winding diameter 7.5 x 60.5 mm 10.295 x 2.382 in)
Spring constant kl = 1.714 kg/mm (96.0 lb/in)/
0 - 45 mm IO - 1.77 in)
kz = 2.244 kg/mm (125.7 lb/in)/
45” 80mm (1.77- 3.15 in)
5) Swing arm free play (Limit) 1 mm 10.04 in)
6) Pivot shaft - Outside diameter 16 mm IO.63 in)
 5. FUEL TANK
1) Capacity 11 .O lit (2.9 US gal)
2) Fuel grade Regular gasoline

6. WHEEL
1) Type (Front and rear) Aluminum rim
2) Tire size IFront) 3.50S19.4PR
(Rear) 130/90S16-4PR
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’ (28 psi)
(Maximum load) Rear: 2.3 kg/cm2 (32 psi)
High speed riding Front: 2.0 kg/cm* (28 psi)
Rear: 2.3 kg/cm’ (32 psi)
41 Rim run out limit (Front and rear)
Vertical 2 mm (0.08 in)
Lateral 2 mm (0.08 in)
51 Rim size (Front) 1.85 x 19
(Rear1 MT300 x 16
6) Bearing type
Front wheel (Left) 630322
(Right) 6303213A
Rear wheel (Left) 63052
(Right) 63042
7) Oil seal type
Front wheel (Left) SDD-45-56-6
(Right1 SD-28-47-7
Rear wheel (Left) SD-35-62-9
(Right) 50-27-52-5
8) Secondary drive chain type
Type 50HDS
Number of links 103L + Joint
Chain pitch 15.875 mm (5/8 in)
Chain free play 20 - 30 mm (0.8 - 1.2 in)
7. BRAKE
1) Front brake
TVP~ Hydraulic disc type
Disc size (Outside dia. x thickness) 298 x 7.0 mm (11.73 x 0.28 in)
Disc wear limit 6.5 mm 10.26 inl
Disc pad thickness 11.0 mm (0.43 inl
Pad wear limit 6.0 mm (0.24 in)
Master cylinder inside dia. 14.0 mm (0.55 in)
Caliper cylinder inside dia. 38.1 mm (1.50 in)
Brake fluid type I quantity DOT #3 Brake fluid I38.1 cc (1.29 ozl
21 Rear brake
TVP~ Hydraulic disc type
Disc size (Outside dia. x thickness) 267 Y 7.0 mm (10.5 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 (0.24 in)
Master cylinder inside dia. 14.0 mm (0.55 in)
Caliper cylinder inside dia. 38.1 mm (1.50 in)
Brake fluid type I quantity DOT #3 Brake fluid / 38.1 cc (1.29 02)

D. Electrical

1. IGNITION SYSTEM
1) Ignition timing (8.T.D.C.) 15°/1.200 rlmin
2) Ignition coil
Model/Manufacturer CM1 1.508/HITACHI

- 127-
 Primary winding resistance 3.9n ? 10% at 20°C (68°F)
Secondary winding resistance B.Okn + 20% at 2O’C (68°F)
31 Spark plug
TVP~ N - 7 Y (C,jAMPION) or BP7ES (N.G.K.1
Spark Plug gap 0.7 - 0.8 mm (0.027 - 0.031 in)
4) Contact breaker
ManufacturerlQuantitv HITACHI/2 pcs.
Point gap 0.30 - 0.40 mm (0.012 - 0.016 in)
Point spring pressure 650 - 850 g (22.9 - 30.0 02)
Cam closing angle 9 3 ” * 5O
5) Condenser
Capacity 0.22uF
Insulation resistance 10Mfi or more
Quantity 2 PCS.
!. C H A R G I N G S Y S T E M
1) AC generator
Charging output 14V 1 lAl2.000 rlmin
Rptpr coil resistance (Field coil1 5.2552 f 10% at 2O’C 168OF)
Stator coil resistance 0.46a i 10% at 2O’C (6B’F)
Brush length 14.5 mm (0.571 in)
Brush wear limit 7.0 mm (0.276 in)
2) Rectifier
TVP~ 6.Elementtype /Full wave)
Model/Manufacturer SBGB-17/HITACHI
Capacity 12A
Withstand voltage 4oov
3) Regulator
TVP~ Tillil type
Model/Manufacturer TLIZ-BO/HITACHI
Regulating voltage 14.5 + 0.5v
Core gap 0.6 - 1 .O mm (0.024 - 0.039 in)
Point gap 0.3- 0.4 mm (0.012- 0.016 in)
Voltage coil resistance 1On at 2O’C (6B’FI
51 Battery
ModellManufacturerlQuantity YBl4L.A2/YUASA/ 1 PC.
Capacity 12V. 14AH
Charging rate 1.4A 10 hours
Specific gravity 1.28 at 2oDc (6BOF)
3. STARTER
1) starter mcItOr
Tvpe Bendix type
Manufacturer HITACHI
Model 5108.35
output 0.5 kw
Armature coil resistance 0.0067R f. 10% at 2O’C (68’F)
Field coil resistance o.oo4a ? 10% at 2o”c (68°F)
Brush size/Quantity 16 mm (0.63 in)12 PCS.
Wear limit 4 mm (0.16 in)
Spring pressure BOO g 128.2 02)
commutator O.O.iWear limit 33 mm (1.30 in)/31 mm (1.22 in)
Mica undercut 0.7 mm (0.028 in)

2) Starter switch
Manufacturer HITACHI
Model AlO4-70
Amparage rating 1OOA
Cut.in voltage 6.5V
Winding resistance 3.5a
3) Starter clip friction tension 2.2 - 2.5 kg (4.9 - 5.5 lb)
 4. LIGHTING SYSTEM
1) Headlight type Sealed beam
2) Bulb brightness and wattage/Quantity
Headlights 12v. 5Ol4OW x 1 PC.
Tail/brake light 12V. 3/32 CP 18W/27Wl x 1 PC.
Flasher light 12V. 32 CP I27W) x 4 pcs.
Pilot lights: Turn 12v. 3.4w x 2 pcs.
High beam 12v. 3.4w x 1 PC.
Headlight failure 12v. 3.4w x 1 PC.
Neutral 12v. 3.4w x 1 PC.
Tail/brake failure 12v. 3.4w x 1 pc.
Meter lights 12v. 3.4w x 4 pcs.
3) Reserve lighting unit
Model/Manufacturer 337-l 1720/KOITO
4) Horn
Model/Manufacturer CF.lZ/NIKKO
Maximum amparage 2.5A
51 Flasher relay
Type Condenser type
Model/Manufacturer IAO-70INIPPON DENS0
Flasher frequency 85 * 10 cyclelmin.
Capacity 32 CP (27WI x 2 + 3.4W
61 Flasher cancelling unit
Model EVH-AC518
voltage DCSV - 16V

I 7) Fuse
Rating/Quantity
8) Light checker
Main (Red): 20A

Model 35200.71859
Manufacturer KQITO

_ 129-

t
 FOREWORD
This Supplementary Service Manual for XS650SF/XS650-2F has been
published to supplement the Service Manual for the XS650E (LIT-1 1616-00-
76), and provides updated information for the XS650E model as well as new
data concerning the XS650SF/XS650-2F. For complete information on
service procedures, it is necessary to use this Supplementary Service Manual
together with the Service Manual for the XS650E (LIT-1 1616-00-76).

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.

-136-
Page numbers shown in brackets correspond NOTE:
to page numbers of the XS650E Service In the XS650E Service Manual there are a few
Manual (LIT-11616-00-76). pages that are not arranged in order. These are
pages 7, 8 and 9. They should be read in the
(PAGE 4 - 5) reverse order, i.e. 9, 8 and 7.
2-2. MAINTENANCE INTERVALS CHARTS
A. PERIODIC MAINTENANCE EMISSION CONTROL SYSTEM

REMARKS

damage. Replace If n
Check fuel hose for cracks or damaqe. 0 0
7 Fuel Hose
Replace If necessary

8 Exhaust System
Check for leakage. Retlghten as necr- 0 C z
saw. Replace gasket(s) tf necessary. )
Carburetor 0 0
9 Adjust svnchronizaf~on of carburetors. 0
Svnchronlzataon
Check and ad,ust engnr+ .dle speed. 0 0 0
10 Idle Speed
Adjust cable free play.

B. GENERAL MAINTENANCE/LUBRICATION ‘XS65OSF onlv

Yamaha cham and

cable lube or lCWV/
 INITIAL BREAK-IN j THEREAFTEREVERY

NO. ITEM REMARKS TYPE 1,000 km 5.000 k m 4,000 km 8,000 km 16,000 km

or 1 month or 7 months or 6 months or 12 months or24month
1 6 0 0 mil K3,OOOmil ( 2 . 5 0 0 mi) ( 5 , 0 0 0 mil ~10,000 mi

Front Fork Drawn completely. Yamaha fork oil 0

” 011 Refill to specification. 1OWt or equivalent
Steerung Ball Check bearings assembly Medwm weight
,2 Beanng and for looseness. Moderately wheel bearing 0 3
Repack
RKH repack every 16,000 km gre.%e.
(10.000 mi).
Check bearings for smooth
Medium weight
,3 W h e e l rotation. Moderaltelv 0 G
Bearings wheel bearing Repack
repsk eVeV 16,ooO km
(10,000 mil. gresre.
Check specific gravitv.
1 4 l8attew 1 Check breather D~DC for i - IO IO I
proper operatio;l:
Replace generator brushes.
,5 A . C . _ 0
Replace at initial 9,000
Generator
km (5.500 mi)

(PAGE 7 - 8) (PAGE 9 - 13)

2-3. ENGINE 2-4. CHASSIS
B. Air filters A. Fuel petcock cleaning
2. Cleaning method 1. Open the seat and remove the fuel tank
c. The air filter element should be cleaned securing bolt.
specified intervals. It should be cleaned 2. Turn the petcock lever to the “ON” or
more often if the machine is operated in “RES” position. Raise the fuel tank to
extremely dusty areas. remove the fuel pipe.

E. Cam chain adjustment

Check/adjust thecam chain tension as follows:
1. Remove the cap nut and loosen the lock
nut.
2. Turn the left end of the crankshaft
counterclockwise. As the crankshaft is
turning, check to see that the cam chain
adjuster push rod is flush with the end of
the bolt. If not, turn the adjuster bolt
until the push rod is flush. 1. Fuel PIP
3. Secure the lock nut and tighten the cap
hnlt. 3. Remove the drain bolt and clean with
solvent If gasket is damaged, replace.

1. Locknut 2. Gasket

- 138-
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,
- 0.59 in) from when the brake pedal is first please note the following instructions.
moved to when the brake begins to be
effected . 1. Tubeless tire
1. Loosen the adjuster lock nut (for pedal a. The identification marks are fitted on
height). the tire sidewall and wheel spoke for
2. By turning the adjuster bolt clockwise or tubeless tires as shown.
counterclockwise, adjust the brake pedal
position so that its top end is approx. 12
- 18 mm (0.47 - 0.71 in) below the
footrest top end.
3. Secure the adjuster lock nut.
4. Loosen the brake rod adjuster lock nut
and screw brake rod downward until
there is noticeable free play between rod
and master cylinder.
5. Turn in the brake rod until it lightly
touches the master cylinder, then turn it
out by approx. l-1/5 turns (for proper
free play).
6. Tighten the brake rod adjuster lock nut.

I--WARNING:
Do not attempt to use tubeless tires on a
wheel designed for use only with tube-type
tires. Tire failure and personal injury may
result from sudden deflation.
‘Tube-type wheel : Tube-type Only
“Tubeless-type wheel : Tube-type or Tube
less tires
When using tube-type tires, be sure to
install the proper tube also.
I After installing a tire, ride conservatively to
allow the tire to seat itself on the properly.
Failure to allow proper seating may cause
i
1. Adjuster bolt (for pedal height) 6. Pedal height 12 - 18 ml- ” tire failure resulting in serious injury to the
2. Lock nut (0.47 - 0 . 7 1 in)
machine and rider.
3. Lock nut 7. Free play 13 - 15 mm
4. Brake rod (0.51 -0.59 in)
5. Footrest b. After repairing or replacing a tire, check
to be sure the valve stem lock nut is
F. Wheels and tires securely fastened. If not, torque it as
specified.
Tubeless tires and aluminium wheels
(XS650SF only)

-139-
 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
2. Aluminium wheels hazard before riding. If a tire tread
a. Always inspect the aluminium wheels shows crosswise lines, it means that the
before riding. Place the machine on the tire is worn to its limit. Reolace the tire.
center stand and check for cracks, bends
or warapage of the wheels. Do not at-
tempt even small repairs to the wheel. It
must be replaced.
b. Tires and wheels should be balanced
whenever either one is changed or re
placed. Failure to have a wheel assembly
balanced can result in poor perfo-
rmance, adverse handling character-
istics, and shortened tire life.

Tire pressure (XS650SF/XS650-2F)

To insure maximum performance and long
service, note the following: G. Drive chain
1. Always maintain proper air pressure as 1. Tension check
described in the chart. Check tire pres-
NOTE:
sure daily, before riding, and adjust as
Before checking and/or adjusting, rotate
necessary.
rear wheel through several revolutions and
check tension several times to find the
tightest point. Check and/or adjust chain
‘XS65OSF Only “XS650-2F only
tension with rear wheel in this “tight chain”
position.
BASIC WEIGHT
Nith oil and full l 102 kg (226 lb) ‘118 kg (260 lb
Inspect the drive chain with both tires
fuel tank “100 kg (221 lb) l *116 kg (256 lb
touching the ground and without rider.
Bridgestone or Bridgestone or
standard tire Yokohama Yokohama Check the tension at the position shown
3.5OS194PR 13OBOS184PR in the illustration, The normal vertical
vlsximum load limit 166 kg I365 lb) 279 kg (615 lb1
Zold tire presswe:
UP to 90 kg 1.6 kg/cm2 2.0 kg/cm=
(198 lb) load (22 psi 1 (28 psi1
9Okg1198Ib)load
5 206 kg (453 lb) 2.0 kg/cm2 2.3 kg/cm2
load (Maximum (28 psi I 132 Psi)
load)
High speed riding 2.0 kg/cm2 2.3 kg/cm2
(28 psi) 132 psi)
Minimum tire
0.8 mm (0.03 in) 0.8 mm (0.03 in)
wad depth

. . 20-30 mm (0.8- 1.2 in)

- 140-
 deflection is approximately 20 - 30 mm
(0.8 - 1.2 in). If the deflection exceeds
20 - 30 mm (0.8 - 1.2 in) adjust the
chain tension.
2. Tension adjustment
a. Loosen the rear brake adjusting nut
(XS650-2F only).
b. Remove the cotter pin of the rear wheel
axle nut with pliers.
C. Loosen the rear wheel axle nut.

d. Loosen the lock nuts on each side. To g. In the final step, adjust the play in the
tighten chain,turn chain puller adjusters brake pedal (XS650-2F only).
clockwise. To loosen chain, turn adjusters
counterclockwise and push wheel for- (PAGE 14 - 15)
ward. Turn each adjuster exactly the 2-5. ELECTRICAL
same amount to maintain correct axle C. Ignition timing
alignment. (There are marks on each side 1. Point gap must be set before setting
of rear arm and on each chain puller; use timing.
them to check for proper alignment.) 2. Ignition timing is checked with a timing
light by observing the position of the
stationary marks stamped on the stator
and the pointer on the generator rotor.

1. Locknut 4. Roar whal ale nut

2. Adjuster 5. Cotter pin
3. Marks for alignment

e. After adjusting, be sure to tighten the 1. Top dead canter 3. Advanced mark
lock nuts and the rear wheel axle nut. 2. 15’ ETDC at 1,200 rlmn
f. Inset-t the cotter pin into the rear wheel
3. Connect timing light to right (left)
axle nut and bend the end of the cotter
cylinder spark plug lead wire. Ignition
pin as shown in the illustration (if the
timing of right cylinder must be set first.
nut notch and the cotter pin hole do not
4. Start the engine and keep the engine
match, tighten the nut slightly to match).
speed as specified on the label. Use a
tachometer for checking.
5. The rotor pointer should line up the “F”
stamped timing mark on the stator at a
specified engine speed. If it does not
NOTE: align, loosen the two breaker backing
Excessive chain tension will overload the en- plate screws (breaker assembly holding
gine and other vital parts, keep the tension screws for left cylinder) and move the
within the specified limits. Also, replace the complete backing plate (breaker assem-
rear axle cotter pin with a new one. bly for left cylinder) until the point
marks align.
-141-
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. If a wheel is deformed or crack-
ed, it must be replaced.
2. Check wheel run-out
If deflection exceeds tolerance, check
wheel bearing or replace wheel as required.

Rim run-out limits (XS650SF/XS650-2F):

1. Right cylinder timing adjustment

2. Left cylinder timing adjustment 3. Check wheel balance
F. Spark plug Rotate wheel lightly several times and
Check electrode condition and wear, insulator observe resting position.
color, and electrode gap. Use a wire gauge for If wheels is not statically balanced,
adjusting the plug gap. If the electrodes wheel will come to rest at the same po-
become too worn, replace it. sition. install balance weight at lighter
When installing the plug, always clean the position (at top) as illustrated.
gasket surface, wipe off any grime that might
be present on the surface of the spark plug, NOTE:
and torque the spark plug properly. The wheel should be balanced with brake disc
installed.
Standard spark plug:
N-7Y (CHAMPION) or BP7ES (NGK)
Spark plug gap:
0.7 - 0.8 mm (0.028 - 0.031 in)
Spark plug tightening torque:
2.0 m-kg (14.5 ft-lb)

(PAGE 29 - 33)
3-4. ENGINE ASSEMBLY AND ADJUSTMENT
0. Engine
Specifications should be changed as
follows:

Engine mounting bolt torque:

Upper (U Nut) M8 1.8 m-kg (13.0 ft-lb)
Upper Ml0 3.0 m-kg (215 ft-lbl
Front (U Nut) Ml0 4.6 m-kg (33.5 ft-lb)
Rear (U Nut) Ml0 4.1 m-kg (29.5 ft-lb)
Rear - under (U Nut)
Ml0 4.6 m-kg (33.5 h-lb)
Under (U Nut) Ml0 9.0 m-kg (65.0 ft-lb)

-142-
 (PAGE 40 - 44)
I 8 0 m m (3.15 anl
Balance wwghf
5-3. BRAKES
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).

D. Brake inspection and repair

I I Specifications should changed as follows:
(PAGE 40)
Wear limit:
5-2. REAR WHEEL
6.0 mm (0.24 in)
A. Removal (XS650SF only)
1. Support the machine on the center stand.
2. Disconnect the drive chain. Using the
drive chain cutter (special tool).
NOTE: __
The chain joint should be replaced each time
the chain is cut.

A, P a d thickness
3. Remove the axle nut cotter pin and the 1 1 . 0 m m ( 0 . 4 3 In)
axle nut. 6: Wear limit
4. While supporting the brake caliper, pull 6.0 mm 10.24 1n1
out the rear axle. C. Wear mdlcator

5. Remove the rear wheel assembly.

E. Installing rear wheel (XS650SF only)

When installing rear wheel, reverse removal
procedure taking care of following points:
1. Lightly grease lip of rear wheel oil seals.
2. Make sure the brake pads are installed (PAGE 44)
properly and that there is a sufficient
5-4. WHEELS, TIRES, TUBE (XS650SF -
gap to install the rear disc.
Tubeless tire model)
3. Install the wheel assembly and the axle. Refer to “Tubeless tire and Aluminium Wheel
Always use a new cotter pin on the axle Manual” for tubeless tire and wheel service.
nut.

Axle nut torque: I

15.0 m-kg (108.5 ft-lb)
i
4. Connect the drive chain.
5. Adjust the drive chain.

- 143-
(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-
1. Check the outer surface of the com- matically when the engine is started and the
mutator. If its surface is dirty, clean light stays on until the main switch is turned
with No. 600 grit sand paper. to “OFF” even if the engine stalls.
2. The mica insulation between com-
mutator segments should be 0.7 mm Headlight Headlight Reserve light-
(0.028 in) below the segment level. If condition failure indi- ing function
not, scrape to proper limits with ap- cator light
propriately shaped tool. (A hack saw
Normal Comes on
blade can be ground to fit.)
, (very dim)
Low beam
Mica under cut
0 . 7 m m (0.028 an)
comes on

n
I High beam
comes on at
low brilliance
2. Troubleshooting/Inspection
I
Commutator

3. Check the armature and field coil for

shorting and insulation. Replace arma-
ture as required.

Coil resistance “ Y ” w i r e to safety

Armature coil 0.0067R at 20°C 168°F)

1 Field coil 1 0.004R a t 2O’C (68°F) 1

4. Check the front and rear cover bearings

for damage. If damaged, the starter
assembly must be replaced.
(PAGE 57 - 58)
6-5. LIGHTING AND SIGNAL SYSTEMS
B. Reserve lighting system
1. Description:
The reserve lighting system has two
functions: (1) It notifies the rider that
one of the headlight filaments is in-
operative, and (2) it switches current
from the inoperative filament to the
remaining functional filament.
The system is connected to the headlight
circuit only. The reserve lighting system
unit is located under the seat.

- 144 -
1

,!
 I I i’Oimmarl ii I

(PAGE 61 - 62) settings are for dry, clean threads. Torquing

7-1. TORQUE SPECIFICATION should always be done to the nut, never the
The following torque specifications muSt be bolt head.
adhered to on every machine. When applying NOTE:
torque to multi-secured fastener components, Certain items with other than standard thread
the several studs should be tightened in pitches may require differing torque.
gradual stages and in a pattern that will avoid
warpage to the item being secured. Torque

-146-
 Torque Specifications

A
(Nut)

-
 I Part to be tightened I Thread dia. and part name 1 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 I 2.0 m-kg (14.5 ft-lb)
Engine mounting UPPer 8 mm nut 1.6 m-kg (13.0 ft-lb)
Engine mounting upper I 10 mm nut I 3.0 m-kg (21.5 ft-lb)
Engine mounting Front 10 mm nut 4.6 m-kg (33.5 ft-lb)
Engine mounting Rear 10 mm nut 4.1 m-kg (29.5 ft-lb) -
Engine mounting Rear-Lower 10 mm nut 4.6 m-kg (33.5 ft-lb)
Engine mounting Lower 10 mm nut 9.0 m-kg (65.0 ft-lb)
Front flasher and headlight 8 mm nut 1.0 m-kg (7.2 ft-lb)
Master cylinder and brake hose 10 mm union bolt 2.6 m-ka (19.0 ft-lb) I

Brake disc and hub 8 mm bolt 2.0 m-kg (14.5 ft-lb)

Caliper and support bracket I 8 mm bolt 1.8 m-kg (13.0 ft-lb)
Caliper and pad 5 m m bolt 0.3 m-kg 1 (2.2 ft-lb)
Caliper and bleed screw I 8 mm bolt I 0.6 m-kg (4.5 ft-lb)
Front caliper and front fork 10 mm bolt 3.5 m-kg (25.5 ft-lb)
Master cylinder and cylinder bracket 1 6 mm bolt 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 16 mm nut 15.0 m-kg (106.5 ft-lb)
Tension bar and brake caliper (plate) 1 8 mm nut 1.6 m-kg (13.0 ft-lb)
Tension bar and rear arm 8 mm nut 3.2 m-kg (23.0 ft-lb)
Rear shock absorber Upper 10mm bolt 3.0 m-kg (21.5 ft-lb)

Rear shock absorber Lower 10 mm bolt 3.9 m-kg (28.0 ft-lb)

Rear arm and rear arm end 8 mm bolt I 1.0 m-kg (7.2 ft-lb)
Front fender 8 mm bolt 1.0 m-kg (7.2 ft-lb)
Neutral switch 12mm 1.3 m-kg (9.5 ft-lb)

( P A G E 6 4 - 71)
7.3. S P E C I F I C A T I O N
‘XS65OSF only “XS65O.2F only
A. General
1. MODEL

!
1) Model (I.B.M. No.) XS650SF (2MO)/XS650-2F (3NO)
2) Frame I.D. and starting number 2FO-150101/2FO-250101
31 Engine I.D. and startinq number 2F0.150101/2F@250101

2. DIMENSION
1) Overall length 2,120 mm (63.5 in)
2) Overall width 925 mm 136.4 in)
31 Overall height * 1,225 mm (48.2 in) “1,220 mm (46.0 in)
4) Seat height 790 mm (31.1 in)
5) Wheelbase 1,435 mm (56.5 in)
6) Minimum ground clearance 135 mm ( 5.3 in)
3. WEIGHT
1) Net weight (Dry) ‘210 kg (463 lb) “205 kg (452 lb)

4. PERFORMANCE
1) Climbing ability 26’
2) Minimum turning radius 2,500 mm 196.4 in)

- 14; 6-
1. OESCRIPTION
1 I Engine type Air cooled, 4.stroke. SOHC twin,
parallel forward incline
21 Engine model 2FO
31 Displacement 653 cc (39.85 cu.in)
41 Bore x stroke 75 x 74 mm (2.953 x 2.913 in)
51 Compression ratio 8.5 : I
61 Starting system. Kick and electric starter
7) Ignition system Battery ignition
81 Lubrication system wet sump
2. CYLINDER HEAD
1 I Combustion chamber volume (with N-7Yl 43.6 cc (2.660 win)
21 Combustion chamber type Dome + Squish
31 Head gasket thickness 1.2 mm (0.047 in)
3. CYLINDER
1 I Material Aluminum alloy with cast iron sleeve

2) Bore size ~ ~~~~~~l”,,o~~irj:.9528 +~.Ooos in)

31 Taper limit
41 Out of round limit 0.01 mm (0.0004 in)
1. PISTON I
1) Piston skirt clearance 0.050 - 0.055 mm ~0.0020 - 0.0022 in)
21 Piston oversize 7 5 . 2 5 mm 75.50 mm 75.75 ml-n 76.00 m m
12 963 i n , 12972 in, 12982 in, 12992 InI

3) Piston pin outside diameter x length 20.0 _;,, mm x 61 .o -:.a mm

IO.79 &,,,, in x 2.40 -&II 16 j”)

5. PISTON RING
TOI, 2nd Oil ring
11 Piston ring design
-@ -I% -+.a%
1.2 mm 10.047 in) 1.5 mm 10.059 in, 2.8 mm 10.110 II
21 Ring end gap IInstalled. top) 0.2 - 0.4 mm (0.008 - 0.016 in)
ilnrtalled. 2nd) 0.2 - 0.4 mm (0.008 - 0.016 in)
(Installed. oil) 0.3 - 0.9 mm (0.012 - 0.035 in1
3) Ring groove side clearance (Top) 0.04 - 0.08 mm (0.0016 - 0.0031 in)
(2nd) 0.03 - 0.07 mm (0.0012 - 0.0028 in)
6. BIG END BEARING
1) Tvpe Needle bearing
2) Bearing size @26x @34x19.8
31 Needle size @4x ~15.6x13
7. CAMSHAFT
1 I Cam drive type Chain (Center side)
21 Number and type of bearing 4 bearings, Ball bearings (6W5)
31 Bearing type Q25-647-8
41 Cam dimensions
 5) Valve timing
OPEN CLOSE DURATION OVERLAP
IN BTDC360 ABDCW z3‘I”
720
EX BBDCE8° ATDCW 2840
,,.--i-J-
61 Camshaft deflection limit 0.03 mm (0.0012 in)
7) Cam chain
Type TSUBAKIMOTO BF05M (:-,:
,1
Number of links 106L
c BY
Sprocket ratio 36/16 (2.000)
I. ROCKER ARM AND ROCKER SHAFT
1) Rocker arm inner diameter 15.0+~.“‘8 mm (0.591 +z.0w7 in)

2) Rocker arm shaft diameter 15.0 $:E mm (0.591 I~:~$ in)

3) Clearance 0.009 - 0.033 mm (0.00035 - 0.00130 in)
41 Lift ratio X : Y = 40 : 46.41 mm (1.575 : 1.906 in)
3. V A L V E , V A L V E S E A T A N D V A L V E G U I D E
1) Valve per cylinder 2 pcs.
2) Valve clearance (In cold engine) IN: 0.06 mm (0.0024 in)
EX: 0.15 mm (0.0059 in)
31 Dimensions
Valve head diameter “A” IN: 41 mm (1.614 in)
n
Valve face width “6” :;:: ;yl $y07;3i3ifn)) y$JJ_$
EX: 2.1 mm (0.063 in) T
Valve seat width “C” IN: 1.3 mm (0.051 in) D
I-_A~~_
EX: 1.3 mm (0.051 in)
Valve margin thickness “D” IN: 1.3 mm (0.051 in)
EX: 1.3 mm (0.051 in)

Valve stem diameter IN: 8.0 7:::: m m ( 0 . 3 1 5 I::‘0 in)

Valve stem diameter EX: 6.0 I;:$; mm (0.315 1;::;; in)

Valve guide diameter IN: 6.0 :t:z:‘, m m ( 0 . 3 1 5 :,“I= inI

E x : 6 . 0 ;;:j;; m m ( 0 . 3 1 5 :E:z in)

Valve stem to guide clearance IN: 0.020 - 0.044 mm (0.00079 - 0.00173 in)
EX: 0.035 - 0.059 mm (0.00136 - 0.00232 in1
4) Valve face runout limit IN & EX: 0.03 mm (0.0012 in) or less
I. V A L V E S P R I N G
1) Free length I N N E R (IN/EX): 4 2 m m ( 1 . 6 5 4 i n )
O U T E R (IN/EX): 42.55 mm (1.675 in)
2) Spring rate I N N E R (INIEX): kl = 1.43 kg/mm (80.1 lb/in)
kz = 1.61 kg/mm (101.4 lb/in)
O U T E R (INIEXI: kl = 3.2 kg/mm (179.2 lb/in1
kz = 4.16 kg/mm(234.1 lb/in)
3) Installed length (Valve closed) INNER (INIEX): 35 mm (1.378 in)
O U T E R (IN/EX): 37 mm (1.457 in)
4) Installed pressure (Valve closed) I N N E R (IN/EX): 10 +-0.7 kg (22.0 t 1.5 lb)
O U T E R (lN/EX): 17.7 i 1.25 kg (39.0 i 2.6 lb)
5) Compressed length (Valve open) INNER (INIEX): 25.5 mm (1.004 in)
O U T E R (IN/EX): 27.5mm (1.063 in)
6) Compressed prerrure (Valve open) I N N E R (IN/EX): 27.2 ? 1.9 kg (60.0 * 4.2 lb)
O U T E R (IN/EX): 57.4 k4.0 kg (126.5 + 8.6 Ibl

- 150-
 81 Winding0.D. lNNER (INIEX): 19.4 mm (0.764 inl
OUTER (IN/EX): 32.6 mm il.283 in)
9) idumber of windings I N N E R (IN/EX): 6.0turns
OUTER (INIEX): 4.25t”rnr

1) Crankshaft deflection limit (A) 0.05 mm (0.002 in1

2) Con-rod large end clearance 18) 0.15 - 0.4 mm (0.0059 - 0.0157 in)
3) Width of crankshaft (a 66 $2 mm (2.598 I$% ini

(D) 186 j3 mm (7.323 _E,,,2 in)

4) Crank pin I.D. 26 $2: mm (1.024 Ii:% in)

5) Crank pin O.D. x length 0

26 _o,oo6 x 65 ‘;I; mm
(1.024 _E,wo2 x 2.559t$?J$iinl
12. CONNECTING ROD
1) Big end I.D. 34 +$‘16 mm (1.339 +z,” in)

2) Small end I.D. 20:~:~:~ mm (0.787 $$$A in1

13. CRANK BEARING

1) Type Right end $3Q@78-19 (Ball bearing)
Others @32-G68.17 (Rollar bearing)
2) Oil seal type SD-25-40-9
14. CLUTCH
1) Clutch type Wet, multiple type
2) Clutch operating mechanism Inner push type. screw push system
3) Primary reduction ratio and method 72127 (2.6661. spar gear
4) Primary reduction gear back lash (4 teeth) 21.45 &x6 mm (0.8445 _~,oooto in)
5) Friction plate
ThicknessIQuantitv 3 mm (0.118 in)/7 pcs.
Wear limit 2.7 mm (0.106 in1
6) Clutch plate
ThicknesslQuantitV 1.4 mm (0.055 in)/6 pcx
Warp limit 0.05 mm (0.002 in\
7) Clutch spring
Free length/Quantity 34.6 mm (1.362 in)/6 pcs.
8) Clutch housing radial Play : 0.027 - 0.081 mm (0.0011 - 0.0032 in)
9) Push rod bending limit 0.2 mm (0.008 in)

15. TRANSMISSION
1) Tvpe Constant mesh. 5.speed forward
2) Gear ratio: 1st 32/13 (2.4611
2nd 27/17 (1.588)
3rd 26/20’ ( 1 . 3 0 0 1
4th ’ 23/21 1 1 . 0 9 5 )
5th 22/23 (0.956)

-151-
 3) Bearing type: Main axle (Left1 Needle bearing (@20~@30-201
(Right1 Ball bearing (0%052-20.61
Dr,ve axle (Left) Ball bearing l@30-062-23.8)
(Right1 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
16. SHIFTING MECHANISM
1) Type Cam drum, return type
21 Oil seal type (Change lever) SDO.14.24-6
17. KICK STARTER
1) TYPE Bendix type
2) Oil seal type (Kick axle) SD.25.35.7
3) Kick clip friction tension 1.2 - 1.7 kg (2.6 - 3.7 lb)
18. IFITAKE
1) Air cleaner: Type/Quantity Dry. foam rubber/2 pa.
2) Cleaner cleaning interval Every 6,000 km (5.000 mile)
19. CARBURETOR
1) Type and manufactureriDuantitY ES36 MIKUNl/Z pcs.
2) I.D. mark ZFO-00
31 Main jet (MJI #135
4) Air jet (AJ) #140
5) Jet needle (JNI 502.3
61 Needle jet (NJ1 z-2
7) Throttle valve (Th.VI #120
6) Pilot jet IPJ) r127.5
9) Pilot screw (Turns out) (PSI Preset
101 Starter jet IGS) GS, : #80, GSz : 0.5
11) Fuel level (FL1 24 + 1 mm (0.94 to.04 in)
12) Idling engine speed 1,200 rlmin
20. LUBRICATION
11 Engine sump oil quantity Oil exchange: 2.0 lit 12.1 US qt)
Overhaul: 2.5 lit (2.6 US qtl
21 Oil type and grade Yamalube 4~cycle oil or SAE 2OWl40 type
“SE” motor oil
31 Oil pump type Trochoid pump
4) Trochoid pump specifications
Top clearance 0.10- 0.16 mm IO.0039 -0.0071 in)
Tip clearance 0.03 - 0.09 mm 10.0012 - 0.0035 in)
Side clearance 0.03 - 0.08 mm (0.0012 - 0.0031 in1
Oil pump volume 1.3 litlmin (1.37 qtlmin) at 1,000 rImin
51 Bvoass valve settina pressure 1.0 kg/cm’ (14 psi)

- 152-
 6) Lubrication chart
- Pressure feed

d---Splash lubrication

C. Chassis

1. FRAME
1) Frame design Douole cradle, high tensile frame

2. STEERING SYSTEM
1) Carter 27”
21 Trail 115mm (4.53 in)
3) Number and size of balls I” steering head
upper race 19 pcs. 114 in
Lover race 19 pcs. 114 in
4) Steering lock to lock 42” each IL and R)

3. FRONT SUSPENSION
1) Type Telescopic fork
21 Damper type Oil damper. coil spring
3) Front fork spring
Free length 402 mm 118.98 in)
Wire diameter x winding diameter 4 x 24.5 mm 10.157 x 0.965 in)
Spring constant kl = 0.46 kg/mm i26.66 lb/in)/
0 - 100 mm IO - 3.94 in)
kg = 0.65 kg/mm (36.40 lb/in)/
100 - 150 mm (3.94 - 5.91 in)
41 Front fork travel 150 mm (5.906 in)
5) Inner tube O.D. 35 mm (1.376 in)
6) Front fork oil quantity and type 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 Approx. 454 mm 117.9 in1

4. REAR SUSPENSION
11 Type Swing arm
2) Damper type Oil damper. coil spring
3) Shock absorber travel I30 mm 13.15 in)
4) Shock absorber spring
Free length 226 mm 18.90 in)
Wire diameter x winding diameter 7.5 x 60.5 mm (0.295 x 2.362 in)
Spring constant kl = 1.714 kg/mm (96.0 lb/in)/
O- 45 mm 10 - 1.77 in)
k2 = 2.244 kg/mm (125.7 lb/in)/
45-6Omm (1.77-3,15in)
5) Swing arm free play (Limit) 1 mm IO.04 in)
6) Pivot shaft -Outside diameter 1
- 15:3-
16 mm (0.63 in)
5. F U E L T A N K
11 Capacity 11.0 lit 12.9 US gall
2) Fuel grade Regular gasoline

5. W H E E L
1) Type (Front and rear) *Cast wheel **Spoke wheel
2) Tire size IFrOnt) 3.50S19.4PR
(Rear) 130/90S16-4PR
31 Tire pressure:
Up to 90 kg (198 lb) load Front: 1.6 kg/cm’ (22 psi)
Rear: 2.0 kg/cm* (28 psi)
90 kg (198 lblload - 204 kg (445 lblload Front: 2.0 kg/cm2 (28 psi1
(Maximum load) Rear: 2.3 kg/cm2 (32 psi)
High speed riding Front: 2.0 kg/cm’ 128 psi)
Rear: 2.3 kg/cm* (32 psi)
4) Rim run out limit (Front and rear)
Vertical 2 mm (0.08 in)
Lateral 2 mm (0.08 in)
5) Rim size IFront) 1.85 x 19
(Rear) ‘MT3.00 x 16 “2.75 x 1 6
6) Bearing type
Front wheel (Left) ‘ 6 3 0 2 2 2 “86303
(Right) ‘63022 “B6303RS
Rear wheel (Left) 63042
(Right) 63052
71 Oil seal type
Front wheel (Left) SDD-45-56-6
(Right) SD.22.42-7
Rear wheel (Left) SD.35.62-9
(Right) SO-27-52-5
8) Secondary drive chain type
Type 50HDS
Number of links 103L + Joint
Chain pitch 15.875 mm 15/E in1
Chain free play 20 - 30 mm (0.8 - 1.2 in)

7. BRAKE
1) Front brake
Type Hydraulic disc type
Disc size (Outside dia. x thickness) 298x 7.0 mm 111.73 x 0.28 in)
Disc wear limit 6.5 mm 10.26 in)
Disc pad thickness 11.0 mm (0.43 in)
Pad wear limit 6.0 mm (0.24 in)
Master cylinder inside dia. 14.0 mm (0.55 in)
Caliper cylinder inside dia. 38.1 mm 11.50 in)
Brake fluid type I quantity DOT #3 Brake fluid I3B.l cc (1.29 01)
2) Rear brake IXS65OSF only)
Type Hydraulic disc type
Disc sire (Outride dia. x thickness) 267 x 7.0 mm (10.5 x 0.28 in)
Disc wear limit 6.5 mm IO.26 in)
Disc pad thickness 11.0 mm 10.43 in)
Pad wear limit 6.0 mm (0.24 in)
Master cylinder inside dia. 14.0 mm (0.55 in)
Caliper cylinder inside dia. 38.1 mm (1.50 in)
Brake fluid type / quantitv DOT #3 Brake fluid / 38.1 cc (1.29 ozl

-154-
 31 Rear brake (XS650-2F only)
TVPE Drum brake (Leading trailing)
Actuating method Link rod
Brake drum I.D. 180 mm (7.09 in)
Brake shoe dia. x width 180 x 30 mm (7.09 x 1.18 in)
Lining thickness/wear limit 4 mm12 mm IO.16 into.08 in)
Shoe spring free length 68 mm (2.68 in1

D. Electrical
1. IGNITION SYSTEM
I) Ignition timing (B.T.D.C.) 15°/1,200 rlmin
2) Ignition coil
Model/Manufacturer CMll-50B/HITACHI
Spark gap 6 mm (0.24 in) or mare at 500 r/min
Primary winding resistance 3.9R * 10% at 20°C (68°F)
Secondary winding resistance 8.0kR * 20% at 2O’C (68°F)
3) Spark plug
TVP~ N-7Y (CHAMPION) or BP7ES (N.G.K.)
Spark Plug gap 0.7 - 0.8 mm 10.027 - 0.031 in)
4) Contact breaker
Manufacturerlouantity HITACHI/2 pcs.
Point gap 0.30- 0.40 mm (0.012- 0.016 in)
Point spring pressure 650 - 850 g 122.9 - 30.0 02)
Cam closing angle 93O r 5O
51 Condenser
Capacity 0.22/~F
Insulation resistance 1OMR o r m o r e
Quantity 2 per.

2. CHARGING SYSTEM
1) AC generator
Charging output 14V 1 lAf2.000 rImin
Rotor coil resistance (Field coil) 5.25a 5 10% at 2O’C 168°F)
Stator coil resistance 0.46a ? 10% at 2O’C (68’Fl
Brush length 14.5 mm (0.571 in)
Brush wear limit 7.0 mm (0.276 in)
2) Rectifier
Tvpe B-Element type (Full wave)
Model/Manufacturer SBGB.l7/HITACHI
Capacity 12A
Withstand voltage 4oov
31 Regulator
TVP~ Tillil type
Model/Manufacturer TLIZSO/HITACHl
Regulating voltage 14.5 + 0.5v
Core gap 0.6 - 1.0 mm (0.024 - 0.039 in)
Point gap 0.3 - 0.4 mm (0.012 - 0.016 in)
Voltage coil resistance 10R at 20°C (68OF)
5) Battery
Model/Manufacturer/~uantity Ytl14L.A2/YUASA/l PC.
Capacity 12V. 14AH
Charging rate 1.4A 10 hours
Specific gravity 1.28 at 20-c (68°F)

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3. STARTER
1) srarter motor
Tvpe Bendix type
Manufacturer HITACHI
Model S108-35
output 0.5 kw
Armature coil resistance 0.0067a + 10% at ZO’C (68’F)
Field coil resistance 0.004X2 + 10% at 20°C 16EaF)
Brush size/Ouantitv 16 mm (0.63 inIl2 PCS.
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)
2) Starter switch
Manufacturer HITACHI
Model Al04-70
Amparage rating 1OOA
Cut-in voltage 6.5V
Winding resistance 3.5R
3) Starter clip friction tension 2.2 - 2.5 kg (4.9 - 5.5 lb)

4. LIGHTING SYSTEM
1) Headlight type Sealed beam
2) Bulb brightness and wattage/Quantitv
Headlight 12v. 5014ow x 1 PC.
Tail/brake light 12V. 3/32 CP (8Wi27WI Y 1 PC

Flasher light 12V. 32 CP (27Wl x 4 PCS.

Pilot lights: Turn 12v 3.4w x 1 PC.
High beam 12v. 3.4w x 1 PC.
Headlight failure 12v. 3.4w x 1 PC.
Neutral 12V. 3.4W x 1 PC.
Tail/brake failure 12v. 3.4w x 1 PC.
Meter lights 12v. 3.4w x 4 PCS.
3, Reserve lighting “nit
Model/Manufacturer 337.11720iKOITO
4) Horn
Model/Manufacturer CF.lZ/NIKKO
Maximum amparage 2.5A
5) Flasher relay
Tvpe Condenser type
Model/Manufacturer lAO.70/NIPPON DENS0
Flasher frequency 85 + 10 cvcleimin.
Capacitv 32 CP (27WI x 2 + 3.4W
6) Flasher cancelling unit
Model EVH-AC518
Voltage DCSV - 16V
7) Fuse
Rating/Quantity Main (Red): 20A
8) Light checker
Model 35200.71859
Manufacturer KOITO

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