Yamaha XS650 1974-1980 Service Manual 11 ergaenzung sf2f

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 to page numbers of the XS650E Service Manual (LIT-11616-00-76).

NOTE:

In the XS650E Service Manual there are a few pages that are not arranged in order. These are pages 7, 8 and 9. They should be read in the

(PAGE 4

reverse order,

i.e. 9,

2-2. MAINTENANCE INTERVALS CHARTS A. PERIODIC MAINTENANCE EMISSION CONTROL SYSTEM

REMARKS

8 and 7.

damage.

Fuel Hose

Exhaust System Carburetor

Svnchronlzataon

Idle Speed

GENERAL MAINTENANCE/LUBRICATION

Check

Replace If necessary

Check for leakage.

saw.

Adjust Check and

Adjust cable free play.

Replace If

fuel

Replace gasket(s) tf necessary.

svnchronizaf~on

hose for cracks or

Retlghten as

of carburetors.

ad,ust engnr+ .dle

damaqe.

speed.

necr-

0 0

)

C 0 0

0 0 0

‘XS65OSF

onlv

Yamaha

cham

cable lube or

and

lCWV/

NO.

Front Fork

” 011

Steerung Ball

,2 Beanng

RKH

Wheel

Bearings

l8attew

A.C.

Generator

ITEM

Check bearings assembly

and for looseness. Moderately wheel bearing

REMARKS TYPE

Drawn

completely.

Refill to specification.

repack every 16,000 km (10.000 mi).

Check bearings for smooth rotation. Moderaltelv

repsk eVeV 16,ooO

(10,000 Check specific

Check breather

proper Replace generator brushes.

Replace at initial 9,000 km (5.500 mi)

mil.

operatio;l:

gravitv.

D~DC

for

Yamaha fork oil

1OWt

or equivalent

Medwm weight

gre.%e.

Medium weight wheel bearing

gresre.

INITIAL BREAK-IN

1,000 km 5.000 km 4,000 km 8,000 km

or 1 month or 7 months or 6 months or 12 months

1600 mil

K3,OOOmil

(2.500 mi) (5,000 mil

0 3

THEREAFTEREVERY

16,000 km

or24month

~10,000 mi

Repack

(PAGE 7 - 8) 2-3. ENGINE B. Air filters

2. Cleaning method c. The air filter element should be cleaned

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

E. Cam chain adjustment

Check/adjust thecam chain tension as follows:

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.

3. Secure the lock nut and tighten the cap

hnlt.

(PAGE 9 - 13)

2-4. 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. Fuel

PIP

3. Remove the drain bolt and clean with solvent If gasket is damaged, replace.

1. Locknut

2. Gasket

138-

E. Rear brake

(XS650SF

only) The rear brake pedal should be so adjusted that it has a free play of 13

0.59 in) from when the brake pedal is first

15 mm (0.51

moved to when the brake begins to be effected .

1. Loosen the adjuster lock nut (for pedal height).

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.

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).

Tighten the brake rod adjuster lock nut.

NOTE: This model is available in two types, tubeless

tire and tube-type tires. Before servicing tires,

please note the following instructions.

Tubeless tire

a. The identification marks are fitted on

the tire sidewall and wheel spoke for

tubeless tires as shown.

Pedal

(for

pedal

Adjuster bolt

2.Lock nut

3. Lock nut

4. Brake rod

5. Footrest

height)

7. Free play 13

height

-0.71

(0.47

(0.51 -0.59 in)

F. Wheels and tires

Tubeless tires and aluminium wheels

(XS650SF only)

12 -18

in)

15 mm

-WARNING:

I-

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. After installing a tire, ride conservatively to allow the tire to seat itself on the properly.

ml-

Failure to allow proper seating may cause

”

tire failure resulting in serious injury to the machine and rider.

After repairing or replacing a tire, check

to be sure the valve stem lock nut is securely fastened. If not, torque it as specified.

-139-

Tightening torque:

1.5 m-kg (1.1 ft-lb)

Aluminium wheels

2. Always inspect the aluminium wheels

before riding. Place the machine on the center stand and check for cracks, bends

or warapage of the wheels. Do not attempt even small repairs to the wheel. It must be replaced. 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.

2. Before operation, always check the tire surfaces for wear and/or damage; for example: cracks, glass, nails, metal fragments, stones, etc. Correct any such hazard before riding. If a tire tread shows crosswise lines, it means that the

tire is worn to its limit. Reolace the tire.

Tire pressure

(XS650SF/XS650-2F)

To insure maximum performance and long

service, note the following:

1. Always maintain proper air pressure as described in the chart. Check tire pressure daily, before riding, and adjust as necessary.

‘XS65OSF Only

BASIC WEIGHT

Nith

oil and full

fuel

tank “100 kg

standard

tire

vlsximum Zold tire presswe:

UP to 90 kg

(198

9Okg1198Ib)load 5

206 kg (453 lb) load (Maximum load)

High

speed

Minimum

wad

depth

“XS650-2F only

load limit

lb)

load

riding

tire

102 kg (226

Bridgestone

Yokohama

3.5OS194PR

166 kg I365

1.6

(22

2.0

(28

2.0

(28 psi)

0.8 mm (0.03

lb)

(221 lb)

lb)

kg/cm2

psi 1

kg/cm2

psi

kg/cm2

in)

‘118 kg (260 lb

*116 kg (256 lb

Bridgestone

Yokohama

13OBOS184PR

279 kg

2.0

2.3

(615 lb1

kg/cm=

(28 psi1

kg/cm2

132 Psi)

2.3

kg/cm2

132

psi)

0.8 mm (0.03 in)

G. 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.

Inspect the drive chain with both tires touching the ground and without rider. Check the tension at the position shown

in the illustration, The normal vertical

- 140-

. .

20-30

(0.8-

1.2 in)

deflection is approximately 20 - 30 mm

(0.8

1.2

in). If the deflection exceeds 20- 30 mm (0.8 - 1.2 in) adjust the chain tension.

Tension adjustment

2. a.

Loosen the rear brake adjusting nut

(XS650-2F only).

Remove the cotter pin of the rear wheel

axle nut with pliers.

Loosen the rear wheel axle nut.

Loosen the lock nuts on each side. To tighten chain,turn chain puller adjusters clockwise. To loosen chain, turn adjusters counterclockwise and push wheel forward. Turn each adjuster exactly the same amount to maintain correct axle alignment. (There are marks on each side of rear arm and on each chain puller; use them to check for proper alignment.)

g. In the final step, adjust the play in the

brake pedal (XS650-2F only).

(PAGE 14

15)

2-5. ELECTRICAL

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

and the pointer on the generator rotor.

Roar whal ale

1. Locknut

2. Adjuster 5. Cotter pin

3. Marks for

alignment

nut

e. After adjusting, be sure to tighten the

lock nuts and the rear wheel axle nut.

f. Inset-t the cotter pin into the rear wheel

axle nut and bend the end of the cotter pin as shown in the illustration (if the nut notch and the cotter pin hole do not match, tighten the nut slightly to match).

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

-141-

1. Top

dead

canter

2. 15’

ETDC

at 1,200

Connect timing light to right (left)

3. Advanced mark

rlmn

cylinder spark plug lead wire. Ignition timing of right cylinder must be set first. Start the engine and keep the engine

4. speed as specified on the label. Use a tachometer for checking.

The rotor pointer should line up the “F” stamped timing mark on the 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 assembly for left cylinder) until the point marks align.

stator

at a

6. Retighten screws. Check timing again for right cylinder.

7. Repeat procedure (steps 2

6) for left

cylinder.

1. Right cylinder timing adjustment

2. Left cylinder timing adjustment

F. Spark plug Check electrode condition and wear, insulator 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)

(PAGE 39 - 40) 5-1. FRONT WHEEL C. Front wheel inspection

1. Check for cracks,

(XS650SF

only)

bends, or warpage

of wheels. If a wheel is deformed or cracked, 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):

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 position. install balance weight at lighter position (at top) as illustrated.

NOTE: The wheel should be balanced with brake disc

installed.

(PAGE 29 3-4.

ENGINE ASSEMBLY AND ADJUSTMENT

33)

0. Engine Specifications should be changed as follows:

Engine mounting bolt torque:

Upper (U Nut)

Upper

Front

Nut)

Rear

Nut)

Rear - under

Under

Nut)

Ml0

Ml0 Ml0

Ml0

1.8 m-kg (13.0 ft-lb)

3.0 m-kg (215

ft-lbl

4.6 m-kg (33.5 ft-lb)

4.1 m-kg (29.5 ft-lb)

4.6 m-kg (33.5 h-lb)

9.0

m-kg

(65.0 ft-lb)

-142-

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