650H/SH Supplement
Contents
1. 4X Pressure feed Splash lubrication strainer Double cradle high tensile frame 27 115 mm 4 53 in 19 pcs 1 4 in 19 pcs 1 4 in 42 each L and R Telescopic fork Oil damper coil spring 482 mm 18 98 in 4 x 24 5 mm 10 157 x 0 965 in ki 0 48 kg mm 126 88 lb in 0 100 mm 0 3 94 k2 0 65 kg mm 136 40 Ib in 100 150 mm 3 94 5 91 in 150 mm 5 906 in 35 mm 1 378 in 169 cc 5 7202 each leg Yamaha fork oil 1Owt or equivalent Approx 454 mm 17 9 in 4 REAR SUSPENSION 1 Type 2 Damper type 3 Shock absorber travel Swing arm Oil damper coil spring 80 mm 3 15 in 4 Shock absorber spring Free length Wire diameter x winding diameter Spring constant 5 Swing arm free play Limit 6 Pivot shaft Outside diameter 226 mm 8 90 7 5 60 5 mm 0 295 x 2 382 in lki 1 714 kg mm 96 0 Ib in 0 45 mm 0 1 77 in k2 2 244 kg mm 1125 7 Ib in 45 80 mm 1 77 3 15 in 1 mm 0 04 in 16 mm 10 63 in 5 FUEL TANK 1 Capacity 11 5 lit 3 04 US gal 2 Reserve capacity 2 3 lit 10 61 US gal 3 Fuel grade Regular gasoline 6 WHEEL 1 Type Front and rear Cast wheel Spoke wheel 2 Tire size Front 3 50819 4PR Tubeless tire Tube type tire Rear 130 90 16 67S Tubeless tire Tube type tire 3 Tire pressure Up 1090 kg 198 b load 90 kg 198 Ib loa2. Yamaha chain and cable lube or SAE i Center and i Side Stand Pivots and Kick Crank Boss Lubricate Appiy chain lube lightly 10W 30 motor oil Front Fork Drain completely Yamaha fork oil Refill to specification 10wt or equivalent Check bearings assembly Steering for looseness i k Bearings Moderately repack every bearing Repat 16 000 km 10 000 mi 9rease i Medium weight Wheel Check bearings for Bearings smooth rotation Check specific gravity Battery Check breather pipe for proper operation Replace generator brushes Replace at initial 9 000 km 5 500 mi and there after every 8 000 km 5 000 mi A C Generator t is recommended that these items be inspected and serviced by a Yamaha dealer or other qualified mechanic ENGINE A IGNITION TIMING The ignition system is modified for easier maintenance Thus the following ignition timing check should be changed Ignition timing check 1 Ignition timing is checked with a timing light by observing the position of the rotor pointer and the marks stamped on the timing plate The timing plate is marked as follows n Firing range for No 1 L H cylinder T Top Dead Center for No 1 L H cylinder 2 Connect the timing light to the left cy
3. 0 033 mm 0 00035 0 00130 in 4 Lift ratio X Y 40 48 41 mm 1 575 1 906 in 14 9 VALVE VALVE SEAT AND VALVE GUIDE 1 Valve per cylinder 2 pes 2 Valve clearance In 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 EX 2 1 mm 0 083 in Valve seat width IN 1 3 mm 0 051 in p EX 1 3 mm 0 051 in aa Valve margin thickness D IN 1 3 mm 0 051 in EX 1 3 mm 0 051 in Valve stem diameter IN 8 0 mm 0 315 0 0 0 015 0 0010 1 d 0 025 0 0010 EX 8 0 5040 mm 0 315 0016 in Valve guide diameter IN 8020015 0 315 EX 80059078 mm 0 315 22 000 in Valve stem to guide clearance IN 0 010 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 amp EX 0 03 mm 10 0012 in or less 0 VALVE SPRING 1 Free length INNER IN EX 42 mm 1 654 in OUTER UN EX 42 55 mm 1 675 2 Spring rate INNER 1 43 kg mm 180 1 Ib in k2 1 81 kg mm 1101 4 Ib in OUTER IN EX k1 3 2 kg mm 179 2 Ib in k2 4 18 kg mm 234 1 Ib in 3 Installed length Valve closed INNER IN EX 35 mm 11 378 in OUTER IN EX 37 mm 11 457 in 41 Installed pressure Valve closed INNER IN EX 10 0 7 kg 22 0 1 5 Ib
4. OUTER IN EX 17 7 1 25 kg 39 0 2 8 Ib 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 1 9 kg 60 0 4 2 Ib OUTER IN EX 57 4 14 0 kg 126 5 8 8 Ib 7 Wire diameter INNER IN EX 2 9 mm 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 OUTER IN EX 32 6 mm 1 283 in 91 Number of windings INNER IN EX 6 0 turns OUTER tN EX 4 25 turns I CRANKSHAFT ME 1 Crankshaft deflection limit 2 Con rod large end clearance 3 Width of crankshaft C D 41 Crank pin I D 5 Crank pin O D x length 0 05 mm 0 002 0 15 0 4 mm 0 0059 0 0157 in 66 0 05 mm 2 598 0 002 in 0 10 0 004 186 0 mm 7 323 85 in 26 001 mm 1 024 26 926 x65193 mm 1 024 9 2 559 in 2 CONNECTING ROD 1 Big end I D 2 Small end I D 34 0 016 mm 1 339 0 0006 in 0 028 0 0011 20 0 787 90006 3 CRANK BEARING 1 Type Right end Others 2 Oil seal type i 30 78 79 Ball bearing 032 668 17 Rollar bearing SD 25 40 9 4 CLUTCH 1 Clutch type 2 Clutch operating mechanism 3 Primary reduction ratio and method 4 Primary reduction gear back lash 4 teeth 5 Friction plate Thickness Quantity Wear limit 6 Clutch plate Thickness Quantity Warp limit 7 Clutch
5. amp YAMAHA Suplemeniary Service LIT 11616 02 30 4N3 28197 10 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 TE 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 XS650SE Supplementary Service Manual LIT 11616 01 08 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 LTD XS650E Service Manual LIT 11616 00 76 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 proced
6. and part name Tightening torque Engine Cylinder head and cylinder head cover Cylinder head 10 mm nut 8 mm bolt 6 mm bolt 3 7 m kg 27 0 ft lb 2 1 m kg 15 0 ft lb 0 9 m kg 6 5 ft lb Cylinder head cover side 6 mm crown nut 8 mm crown nut 0 9 m kg 6 5 ft lb 1 3 m kg 9 5 ft Ib Spark plug 14 mm 2 0 m kg 14 5 ft lb Generator Stator coil 12mm nut 6 mm pan head screw 3 8 m kg 27 5 ft Ib 0 9 m kg 6 5 ft Ib Governer 6 mm bolt 0 8 m kg 6 0 ft Ib Valve clearance adjustment nut 8 mm nut 2 7 m kg 19 5 ft Ib Cam chain tensioner 18 mm cap 2 1 m kg 15 0 ft Ib Pump cover 6 mm pan head screw 1 0 m kg 7 2 ft Ib Strainer cover 6 mm bolt 1 0 m kg 7 2 ft Ib Drain plug 30 mm bolt 4 2 m kg 30 5 ft lb Oil filter 6 mm bolt 0 9 m kg 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 Drive sprocket Change pedal 18 mm nut 22 mm nut 6 mm bolt 8 0 m kg 58 0 ft lb 6 5 m kg 47 0 ft lb 1 0 m kg 7 2 ft Ib Chassis Front wheel axle Front fork and axle holder Handle crown and inner tube 14 mm nut 8
7. spring Free length Quantity 8 Clutch housing radial play 9 Push rod bending limit 5 TRANSMISSION 1 Wet multiple type Inner push type screw push system 72 27 2 666 spar gear 0 0 i 121 45 5925 mm 0 8445 3 mm 0 118 in 7 pes 2 7 mm 0 106 in 1 4 mm 0 055 in 6 pcs 0 05 mm 0 002 in 34 6 mm 1 362 in 6 Pcs 0 027 0 081 mm 0 0011 0 0032 in 0 2 mm 0 008 in Constant mesh 5 speed forward 2 Gear ratio 1st 2nd 3rd 4th 5th 3 Bearing Main axle Left Right Drive axle Left Right 41 Oil seal type Drive axle Left 5 Secondary reduction ratio and method 16 SHIFTING MECHANISM 1 Type 2 Oil seal type Change lever 32113 2 461 27 17 1 588 26 20 1 300 23 21 1 095 22 23 0 956 Needle bearing 20 9 30 20 Ball bearing 25 52 20 6 Ball bearing 30 9 62 23 8 Needle bearing 20 9 30 16 SDD 40 62 9 34117 2 000 Chain Cam drum return type SDO 14 24 6 17 KICK STARTER 1 Type 2 Oil seal type Kick axle 3 Kick clip friction tension 18 INTAKE 1 Air cleaner Type Quantity 2 Cleaner cleaning interval Bendix type SD 25 35 7 1 2 1 7 kg 2 6 3 7 b Dry foam rubber 2 pcs Every 6 000 km 5 000 mile CARBURETOR 1 Type and manufacturer Quantity 2 LD mark 3 Main jet M J 4 Air jet A J 5 Jet needle J N 61 Needle j
8. 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 LOAD FULL OPERATIONAL LIGHT 173 6 XS650H 174 XS650SH SERVICE BRAKE Partial failure information is MAXIMUM 182 XS650H 182 56505 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 TOTAL PASSING TIME SECONDS LOW SPEED PASS 55 ft CONSTANT 20 MPH TRUCK INITIAL SPEED 50 MPH LIMITING SPEED 80 MPH TOTAL PASSING DISTANCE FEET TOTAL PASSING TIME SECONDS HIGH SPEED PASS SUMMARY Low speed pass 353 3 feet 7 2 seconds XS650H 357 0 feet 7 3 seconds XS650SH D High speed pass 944 0 feet 9 27 seconds XS650H a 945 5 feet 9 3 seconds XS650SH i XS650H XS650SH WIRING DIAGRAM Main switch Starter switch Handlebar switch right Safety relay Frontbrake Rear brak
9. the rear wheel axle nut 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 engine and other vital parts keep the ten sion within the specified limits Also replace the rear axle cotter pin with a new one 7 In the final step adjust the play in the brake pedal D REAR BRAKE ADJUSTMENT 1 Pedal height 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 4 After adjusting the pedal height the brake pedal free play should be adjusted 2 Free play Turn the adjuster on the brake rod clockwise or counterclockwise to pro vide the brake pedal end with a free play of 20 30 mm 0 79 1 18 in T 5 A CJ i 1 Adjuster bolt for pedal height 2 Lock nut 3 Footrest 4 Pedal height 12 18 mm 0 47 0 71 in 5 Free play 20 30 mm 0 79 1 18 1 Adjuster 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 indic
10. turned on while the transmission is in neutral the starting circuit cut off relay circuit is closed and the relay is actuated 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 SPECIFICATION A General 1 MODEL 1 Model I B M No 21 Basic color XS650SH only XS650H only XS650SH 4M4 XS650H 4N9 CARDINAL RED or NEW YAMAHA BLACK BLACK GOLD 2 DIMENSION 1 Overall length 2 Overall width 3 Overall height 2 120 mm 83 5 i
11. 0 km 16 000 km or 1 month or 7 months or 6 months or 12 months 24 montt 600 mi 3 000 mi 2 500 mi 5 000 mi 10 000 mi HUM Misit Y amalube 4 cycie 1 Warm up engine before oil or SAE 20W 40 o ooa SE motor oil 2 Filter Clean element in solvent Dry type filter Clean i 3 with compressed air 2 Adjust free play Replace 4 Brake pads front brake only _ System or shoes rear brake only if necessary 5 Clutch Adjust free play Check chain condition Yamaha chain and 6 Drive Chain Adjust and tubricate cable lube or EVERY 500 km 300 mi chain thoroughly 10W 30 motor oil 7 Control Apply cable lube amaha chain and o Meter Cable thoroughly 10W 30 motor 8 Rear Arm Apply until new grease Lithium soap Pivot Shaft shows base grease Brake Pedal Yamaha chain and Lubricate 9 and Change cable lube or e Pedal Shaft PPlv chain lube lightly 10 30 motor Brake Clutch Yamaha chain and Lever Pivot Apply chain tube lightly cable lube or Shafts 10W 30 motor oil INITIAL BREAK IN THEREAFTER EVERY TUE REMARKS 1 000 km 5 000 4 000 8 000 km 16 000 km 1 month or 7 months 6 months or 12 months or 24 months 600 mi 3 000 mi 2 500 mi 5 000 mi 1 10 000 mi
12. 06722 10 at 20 C 68 F 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 11 18 in Mica undercut 0 7 mm 10 028 in 21 Starter switch Manufacturer HITACHI Model A10470 Amperage rating 100A Cut in voltage 6 5V Winding resistance 3 52 3 Starter clip friction tension 2 2 2 5 4 9 5 5 Ib LIGHTING SYSTEM 1 Headlight type Sealed beam 2 Bulb brightness and wattage Quantity Headlight 12v 50 40W x 1 PC Tail Brake light 12V 3132 CP 8W 27W x 2 pcs Flasher light 12V 32 CP 27W x 4 pcs License light 12V 3 8W x 2 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 Meter lights 12v 3 4w x 2 PCS 3 Reserve lighting unit Model Manufacturer i 337 1 1720 KOITO 4 Horn 12 SF 12 NIKKO 2 5 0 5A Model Manufacturer Maximum amperage 1 XS650SH only XS650H only DI 5 Flasher relay Type Model Manufacturer Flasher frequency Capacity 6 Flasher cancelling unit Model Voltage 7 Fuse Rating Quantity Main Headlight Signal Ignition Condenser type 061300 04810 NIPPON DENSO 85 10 cycle min 32 CP 27W x 2 3 4w EVH AC518 DC9V 16V 20A x 1 pc 10A x 1 pc 10A x 1 Torque Specifications Part to be tightened Thread dia
13. W DISTANCE 2 352 0 6214 0 6214 3281 094 3937 0 039 mi ft Yd in 3 7 in FLOW DISTANCE 0 4252 1 609 1 609 0 3048 0 9141 2 54 25 4 km lit km hr km m m cm mm cc cm3 cc cm3 lit liter lit liter lit liter CAPACITY VUL 0 03382 0 06102 2 1134 1 057 0 2642 oz US liq Cu in pt US liq qt US liq gal USliq kg mm kg cm MISC Centigrade 56 007 14 2234 C 9 5 C 32 DEFINITION OF Ib in psi Ib in2 Fahrenheit 9F TERMS US liq cu in pt US liq qt US gal US 29 57 16 387 0 4732 0 9461 3 785 cc cm cc cm3 lit liter lit liter lit liter MISC CAPACITY Ib in psi Ib in2 i Fahrenheit F 0 017855 0 07031 5 9 F 32 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 cm volume or capacity kg mm Kilogram s per millimeter usualiy spring compression rate kg cm per square centimeter pressure CONSUMER INFORMATION kg mm kg cm Centigrade C 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
14. ark plug Type Spark plug gap Hydraulic disc type 298 x 7 0 mm 11 1 73 x 0 28 in 6 5 mm 0 26 in 11 0 mm 0 43 6 0 mm 0 24 in 14 0 mm 0 55 in 38 1 mm 1 50 in DOT 3 Brake fluid 38 1 cc 11 29 02 Drum brake Leading trailing Link rod 180 mm 7 09 in 180 x 30 mm 17 09 x 1 18 in 4 mm 2 mm 10 16 in 0 08 in 68 mm 2 68 in 15 1 200 r min as 3 200 r min at 41 1 5 40 35 30 25 20 Advance degree at rotor shaft 15 1 900 100 r min at 16 T 0 1 2 3 Engine speed x 103 r min 12 09 6 mm 0 24 or more at 500 r min 2 592 10 at 20 C 68 F 11kQ 20 at 20 C 68 F N 7Y CHAMPION or BP7ES N G K 0 7 0 8 mm 0 027 0 031 in 2 CHARGING SYSTEM 1 A C generator Charging output Rotor coil resistance Field coil Stator coil resistance Brush length Brush wear limit 14V 16Ai5 000 r min 5 252 10 at 20 C 68 0 460 10 at 20 C 68 F 14 5 mm 0 571 in 7 0 mm 0 276 in unii 2 Regulator Type 10 type Model Manufacturer 8515 TOSHIBA Regulating voltage 14 5 0 3V 3 Battery Model Manufacturer Quantity YB14L A2 YUASA 1 Capacity 12V 14AH Charging rate 1 44 10 hours Specific gravity 1 28 at 20 C 68 F STARTER 1 Starter motor Type Bendix type Manufacturer Model HITACHI S108 35 output O 5kw Armature coil resistance 0 0
15. ator position while depressing the brake pedal 1 Wear limit 2 Wear indicator ELECTRICAL STARTING CIRCUIT CUT OFF SYSTEM The starting circuit cut off system is employ ed Hence the following description Description This model is equipped with a starting circuit cut off switch The starter motor is so design ed that it can be started only when the trans mission is in Neutral or the clutch is disengag ed Accordingly the starter motor will not start when the transmission is shifted into any position other than neutral unless the clutch lever is pulled in e START button Engine stop switch Neutrai switch Sb Br Battery Main switch Br Neutral indicator tight Starting circuit cut off switch LW COLOR CODE Y Yellow G Green B Black Br brown Sb Sky blue R W Red White B Y Black Yeliow L B Blue Black Battery Starter motor Function of the Diode in the Relay When the transmission is in a position other than Neutral Turning on the clutch lever switch Clutch is disengaged by pulling the clutch lever makes the safety relay to turn on In this case the diode interrupts the flow of current from the main switch to the neutral indicator light and to the relay and thus the light will not come on Operation a When the transmission is in Neutral Neutral switch ON Clutch lever switch OFF or ON When the main switch is
16. ct 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 D Level gauge 2 Drain screw 3 Start the engine and stop it after a few minutes of run This procedure is neces sary to obtain the correct fuel level NOTE _ Make sure the fuel petcock is ON or RES oosition 4 Note the fuel level and bring the gauge to the other end of the carburetor line and repeat step 3 above Note the fuel level again and compare it with the 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 5 Check the fuel level one by one The level should be in the specified range Fuel level 1 1 0 04 0 04 in above from the carburetor mixing chamber body edge 1 Fuel level 6 If the fuel level is incorrect remove the carburetor assembly from the motor cycle and check the fuel valve s and float assembly s for damage 7 If no damage is found correct the fuel level by slightly bending the float arm tang Recheck the fuel level Tang D ENGINE OIL LEVEL MEASUREMENT 1 Place the motorcycle on the center stand Warm up the engine for several minutes NOTE Be sure the motorcycle is positioned straight up when checking the oil level a slight tilt to
17. d 206 kg 453 Ib load Maximum load High speed riding 4 Rim run out limit Front and rear Vertical Lateral Rim Size Front Rear 6 Bearing type 5 Left Right Left Right Front wheel Rear wheel 7 Oil seal type Front wheel Left Right Left Right 8 Secondary drive chain type Type Number of links Chain pitch Rear wheel Chain free play XS650SH XS650H Front 1 6 kg cm 122 psi Rear 2 0 kg cm 28 psi Front 2 0 kg cm2 28 psi Rear 2 3 kg cm 32 psi Front 2 0 kg cm 28 psi Rear 2 3 kg cm 32 psi 2 mm 0 08 in 2 mm 0 08 in MT1 85x 19 1 85 x 19 MT3 00 x 16 2 75 x 16 6630322 66303 863032 B6303RS 63057 663042 SDD 45 56 6 SD 28 47 7 SD 22 42 7 SD 35 62 9 SO 27 52 5 50HDS 103L Joint 15 875 mm 5 8 in 20 30 mm 0 8 1 2 in Total weight of accessories etc excepting motorcycle 19 7 BRAKE 1 Front brake Type Disc size Outside dia x thickness Disc wear limit Disc pad thickness Pad wear limit Master cylinder inside dia Caliper cylinder inside dia Brake fluid type Quantity Rear brake Type Actuating method Brake drum 1 0 Brake shoe dia x width Lining thickness wear limit Shoe spring free length D Electrical 1 IGNITION SYSTEM 1 Ignition timing B T D C 2 Ignition coil Model Manufacturer Spark gap Primary winding resistance Secondary winding resistance 3 Sp
18. e light switch light switch START ENGINE STOP switch Switch alee os x ane Front flasher light RI OFF v OFF fore p Reserve lighting Dg Fuse box 5 removed in this Bw r Tachometer S E SERIA Relay Roer flasher fight Meter light can be tockea in this position y Lem O High beam IL IGNITION G Y gr L 8 Y RAW RW LR 15 Pitot box R Riv nw RIY 8 v R w Turn sb i m Neutra B T _ Headlight S22 mm D A D E H failure ES C i E 7 Tail Brake 3 po 3 m fess a cerca Sor H3 pues Ss es ee ee Il 1 ee 22 e t t i ft mn H m 1 6 a po a 52 ci S zo 2 teo eoe Ee i EE i LE ill Speedometer B Ju Qe e BL Meter il WG hal PH ids switch 8 8 Rear flasher tight L Front flasher light L Dg Dark green Br Brown L W Blue White Ch Chocolate Oo Orange Br W Brown White HOAN TURN witen CUM 12 lgnitor unit Black t Blue Y G Yellow Gr
19. een Hendlebar switch left es C generator Neutral switch Y Yellow p Pink B W Black White Lg Light green L B Blue Black W G White Green G Green R W Red White White Red W White Red Yellow G Y Green Yellow Sb Sky blue L Y Blue Yellow Y R Yellow Red R Red L G Blue Green Y B Yellow Black
20. et N J 7 Throttle valve Th V 8 Pilot jet P J 9 Pilot screw Turnsout P S 101 starter jet G S 11 Fuel level F L 12 Idling engine speed BS34 MIKUNI 2 pcs 3G 1 00 3132 5 85 5 12 135 42 5 Preset 30 27 3 0 5 mm 1 075 0 020 in 1 200 r min 20 LUBRICATION 1 Engine sump oil quantity 2 Oil type and grade 31 Oil pump type 4 Trochoid pump specifications Top clearance Tip clearance Side clearance Oil pump volume Oil exchange 2 0 lit 2 1 US qt Overhaul 2 5 lit 2 6 US qt Yamalube 4 cycle oil or SAE 20W 40 type SE motor oil Trochoid pump 0 10 0 18 mm 0 0039 0 0071 in 0 03 0 09 mm 0 0012 0 0035 in 0 03 0 08 mm 0 0012 0 0031 in 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 Camshaft C Chassis 1 FRAME 1 Frame design Crankshaft Oil main gallery Bypass valve Oil filter Main axle and transmission 2 STEERING SYSTEM 1 caster 2 Trail 3 Number and size of balls in steering head upper race Lower race 4 Steering lock to lock 3 FRONT SUSPENSION 1 Type 2 Damper type 3 Front fork spring Free length Wire diameter x winding diameter Spring constant 41 Front fork travel 51 Inner tube O D 6 Front fork oil quantity and type a 7 Distance from the top of inner tube oil level without spring
21. iston ring design ET 1 2mm 0 047 1 5mm 0 059 2 8 mm 0 110 in 2 Ring gap Installed top 0 2 0 4 mm 0 008 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 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 dies es Ee EN 6 BIG END BEARING 1 Type Needle bearing 2 Bearing size 26 34 19 8 3 Needle size 4 15 8 x 13 7 CAMSHAFT 1 Cam drive type Chain Center side 2 Number and type of bearing 4 bearings Ball bearings 6005 3 Bearing type 25 47 8 4 Cam dimensions neigh A Lim m une 39 99 0 05mm 39 84 32 24 0 05 mm 32 09 7 99 mm 1 524 0 002 in 1 569 in 1 269 0 002 1 263 in 0 315 in 40 03 0 05 mm 39 88 32 30 0 05 mm 32 15 mm 8 03 mm 1 576 0 002 1 570 in 1 272 0 002 in 1 266 in 0 316 in 5 Valve timing OPEN CLOSE DURATION OVERLAP BTDC 35 ABDC 69 284 d 20 BBDC 67 37 284 6 Camshaft deflection limit 0 03 mm 0 0012 in 7 Cam chain A Type TSUBAKIMOTO BF05M P Number of links i 106L Sprocket ratio 36 18 2 000 B 3 ROCKER ARM AND ROCKET SHAFT 1 Rocker arm inner diameter 15 070918 mm 0 591 79 0007 in 2 Rocker arm shaft diameter 15 0 0008 mm 0 591 20003818 3 Clearance 0 009
22. linder spark plug lead wire 3 Start the engine and keep the engine speed as specified Use a tachometer to check the engine speed Specified engine speed 1 200 r min 4 The rotor pointer should be within the limits of on the timing plate If it exceeds the limits or does not steady check the timing plate for tight ness and or ignition system for damage NOTE Ignition timing is not adjustable 2 Timing plate 1 Rotor pointer B PICK UP COIL ASSEMBLY The method of mounting the pick up coil assembly is changed for easier service work Thus the followings Pick up coil assembly removal and Pick up coil assembly reinstal lation should be changed Pick up coil assembly removal Remove the pick up coil securing screws and remove the pick up coil assembly Pick up coil assembly reinstallation Install the pick up coil assembly on to the stator assembly C FUEL LEVEL The carburetor is furnished with a drain screw to provide easy access to service work Thus the following Fuel level measurement should be added Fuel level measurement NOTE Before checking the fuel level note the follow 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 Conne
23. mm nut 8 mm nut 10 7 m kg 77 5 ft lb 1 4 m kg 10 0 ft Ib 1 1 m kg 8 0 ft Ib Handle crown and steering shaft 8 mm nut 1 1 m kg 8 0 ft Ib Handle crown and steering shaft Handle crown and handlebar holder Under bracket and inner tube Engine mounting Upper 14 mm bolt 8 mm bolt 8 mm nut 8 mm nut 5 4 m kg 39 0 ft Ib 1 8 m kg 13 0 ft Ib 2 0 m kg 14 5 ft Ib 1 8 m kg 13 0 ft Ib Engine mounting Upper 10 mm nut 3 0 m kg 21 5 ft Ib Engine mounting Front Engine mounting Rear 10 mm nut 10 mm nut 4 6 m kg 33 5 ft Ib 4 1 m kg 29 5 ft Ib Engine mounting Rear Lower Engine mounting Lower 10 mm nut 9 0 m kg 65 0 ft Ib Front flasher and headlight 10 mm nut 8 mm nut 4 6 m kg 33 5 ft Ib 1 0 m kg 7 2 ft Ib Master cylinder and brake hose 10 mm union bolt 23 2 6 m kg 19 0 ft lb 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 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 b
24. n 925 mm 36 4 in 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 tn 3 WEIGHT 1 Net weight Dry 208 kg 45910 205 kg 452 Ib 4 PERFORMANCE 1 Climbing ability 26 2 Minimum turning radius B Engine 1 DESCRIPTION 1 Engine type 2 Engine model 3 Displacement 4 Bore x stroke 5 Compression ratio 6 Starting system 7 Ignition System 8 CYLINDER HEAD 1 Combustion chamber volume with N 7Y 2 Combustion chamber type 3 Head gasket thickness Lubrication system 2 500 mm 198 4 in Air cooled 4 stroke SOHC twin parallel forward incline 4M4 4N9 653 cc 39 85 cu in 75 x 74 mm 2 953 x 2 913 in 8 7 1 Kick and electric starter Battery ignition Full transistor ignition wet sump 42 5 cc 2 59 cu in Dome Squish 1 2 mm 10 047 in CYLINDER 1 Material 2 Bore size 3 Taper limit Aluminum alloy with cast iron sleeve 75 00 0 02 mm 2 9528 9008 in 005 mm 0 002 ij 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 75 25 mm i 75 50 mm 75 75 mm 76 00 mm 2 963 in 2 972 in 2 982 in 2 992 in A 0 0 3 Piston pin outside diameter x length 20 0 MM 61 0 54 mm 0 0 0 79 o 999 240 5 944g in 5 PISTON RING Top 2nd Oil ring 1 P
25. properly torqued and a new cotter pin is installed Axle nut torque 15 0 m kg 108 5 ft Ib c Adjust the drive chain B DRIVE CHAIN TENSION CHECK NOTE Before checking and or adjusting rotate rear wheel through several revolutions and check tension several times to find the tightest point Check and or adjust chain tension with rear wheel in this tight chain position a 20 30 mm 0 8 1 2 in Inspect the drive chain with the center stand put up 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 C DRIVE CHAIN TENSION ADJUSTMENT 1 Loosen the rear brake adjuster 2 Remove the cotter pin of the rear wheel axle nut with pliers 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 same amount to maintain correct axle alignment There are marks on each side of the rear arm and on each chain puller use them to check for proper alignment 1 Lock nut 2 Adjuster 3 Marks for align 4 Rear wheel axle nut 5 Cotter pin 5 After adjusting be sure to tighten the lock nuts and
26. rake 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 t 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 1 6 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 B Standard tightening torque Bolt 24 CONVERSION TABLES METRIC TO INCH SYSTEM INCH TO METRIC SYSTEM KNOWN MULTIPLIER RESULT KNOWN MULTIPLIER i E RESULT m kg m kg cm kg TORQUE cm kg 7 233 86 80 0 0723 0 8680 ft Ib in Ib ft Ib in Ib TORQUE 1 ft lb in Ib ft Ib in Ib 0 13826 0 01152 13 831 1 1521 m kg m kg cm kg cm kg WT e g 2 205 0 03527 Ib o2 WT 0 4535 i 28 352 kg g km lit km hr FLO
27. ures 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 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 WARNING indicates special procedures that must be fol lowed to avoid injury to a motorc
28. ward the side can produce false readings 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 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 Ur 1 Adjuster 2 Brake rod 3 Tension bar 3 Disconnect the drive chain 4 Loosen the chain tension adjusting nuts and bolts on both sides 5 Remove the axle nut cotter pin and axle nut Discard the old pin 1 Cotter pin 2 Axle nut 6 Remove the axle shaft and the wheel 7 For reassembly follow the procedure below with care a Make sure the drive chain master link is correctly installed with rounded end in direction of chain travel Turning direction b Make sure the axle nut is
29. ycle operator or person inspecting or repairing the motorcycle Starting Serial Number XS650H 4N9 000101 MAINTENANCE AND LUBRICATION CHART PERIODIC MAINTENANCE EMISSION CONTROL SYSTEM INITIAL BREAK IN THEREAFTER EVERY REMARKS 1 000 km 5 000 km 4 000 km 8 000 km or 1 month or 7 months or 6 months or 12 months 600 mi 3 000 mi 2 500 5 000 mi Cam Chain Check and adjust chain tension Check and adjust valve clearance when Valve Clearance Mes engine is cold Check condition Adjust gap Clean Spark Plugs Replace after initial 13 000 km 18 mos and thereafter every 12 000 km 18 mos Crankcase Venti Check ventilation hose for cracks or lation System damage Replace if necessary Check fuei hose and vacuum pipe for Fuel Hose cracks or damage Replace if necessary Check for leakage Retighten as Exhaust System necessary Replace gasket s if necessary Carburetor Synchronization Adjust synchronization of carburetors Check and adjust engine idle speed idle Speed Adjust cable free play if necessary It is recommended that these items be inspected and service by a Yamaha Dealer or other qualified mechanic GENERAL MAINTENANCE LUBRICATION INITIAL BREAK IN THEREAFTER EVERY NO ITEM REMARKS TYPE 1 000 km 5 000 km 4 000 km 8 00
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