Yamaha XS650 1974-1980 Service Manual 08 ergaenzung se

Supplementary

FOREWORD

This Supplementary Service Manual for

supplement the Service Manual for the XS650E 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).

XS650SE

has been published to

(2FO-28197-10)

and in-

Page numbers shown in brackets correspond to page numbers of the Manual

(2FO-28197-10).

XS650E

Service

(PAGE 4 -

5) 2-2. MAINTENANCE INTERVALS CHARTS A. PERIODIC MAINTENANCE

Unit: km

(mi)

Check

tension, alignment

B. LUBRICATION INTERVALS

Item

Engine oil

Drive chain

Brake pedal shaft/ Change pedal shaft

Control/Meter

:ables

Remarks

Replace/Warm engine before

draining

Clean/Lube

Light application

Apply thoroughly

Yamaha chain and

Every 400

(250)

Unit: km

(mi)

-78-

tern

Remarks

Type

initial

400 800

(250) (500) (1,000) (2.000)

1,600

3,200

Thereafter every

1,600

(1,000)

3,200

(2.000) (4.000)

Unit: km (mi)

6,400

Throttle grip/ Housino

Hydraulic brake fluid reserve

Oil filter element

Front forks

Steering bearings

Speedometer gear

housinc

Rear arm pivot

shafts

Wheel bearings

Point cam

cation wicks

lubri-

Applylightly

Use new fluid only

Clean/Replace as

required Drain completely - Yamaha Fork Oil

Check specifications 20 wt.

Inspect thoroughly Pack moderately Yearly or . . .

Inspect thoroughly Pack moderately

Apply grease fully

Do not over-pack Yearly or . . .

APPLY

very lightly

Lithium

DOT No. 3

Brake fluid

Medium-weight

wheel bearing grease

Lithium base grease

Medium-weight

wheel bearing grease

Medium-weight

wheel bearing grease

Light-weight

machine oil

basegrease

check

[

1 1

check

0 0 0

check

1 (

check

2,800

(8.000)

2,800

(8,000) i

2,800

(8,000)

2,800

(8.000)

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.

(

(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.

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

Drain bolt

replace.

E. Rear brake 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 trod

15 mm (0.51

to when the brake begins to be effected.

1. Loosen the adjuster lock nut (for pedal

height).

turning the adjuster bolt clockwise or

counterclockwise, adjust the brake pedal

.J9-

position so that its top end is approx. 12

18 mm (0.47

0.71 in) below the

footrest top end.

Secure the adjuster lock nut.

3. Loosen the brake rod adjuster lock nut

4. and screw brake rod downward until

there is noticeable free play between rod and master cylinder. 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.

iifJ~~[

adjuster lock nut in securing the brake rod

G. Drive chain

1. 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 the center

stand put up. Check the tension at the position shown in the illustration. The normal vertical deflection is approximate-

ly 10

20 mm (0.4 - 0.8 in). If the deflection exceeds 20 mm (0.8 in) adjust the chain tension.

Adjuster bolt (for pedal height) 6. Pedal

2. Lock nut

Leek

nut

Brake

rod

5. Footmst

Wheels

and tires

2. Tires Specifications should follows:

Standard tire

Maximum load limit

Cold

tire

pressure:

Up to 90 kg

(198

lb)

load

kg (198

-204 kg load (Maximum

load)

High speed riding

lb)

load

(445 lb)

Bridgastone

Yokohama

3.50S19-4PR

166 kg I365

1.6

kg/cm2

(22

psi

2.0

kg/cm2

128 psi

2.0

kg/cm2

height 12-16

(0.47 -0.71 Free play 13 - 15 mm (0.51 -0.69 in)

in)

be changed as

REAR

119 kg

(262 lb)

Bridgestone

Yokohama

130/906164PR

lb)

279 kg (615

2.0

kg/cm2

(28

2.3

(32 psi)

2.3

(32 psi)

psi)

kg/cm2

lb1

a. 20 mm (0.8 in)

ml”

”

Tension adjustment

2. 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.) After adjusting, be sure to tighten the

lock nuts and the rear wheel axle nut.

Insert 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).

I.8 mm (0.03

in)

1. Lock nut ‘2. Adjuster

3. Marks for align

4. Rear wheel axle nut

5. Cotter pin

-CAUTION: 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.

H. Front fork oil change

8. Pour specified amount of oil into the

inner tube through the upper end opening.

(PAGE 29 - 33)

3-4. ENGINE ASSEMBLY AND ADJUSTMENT

0. Engine Specifications should be changed as follows:

Engine mounting bolt torque: Upper (U Nut)

Upper

Front (U Nut) Rear (U Nut) Rear - under (U Nut)

Under (U Nut) Ml0

M8 Ml0

Ml0 Ml0

Ml0

1.8 m-kg

3.0 m-kg (21.5 ft-lb)

4.6 m-kg (33.5 ft-lb)

4.1 m-kg (29.5 ft-lb)

4.6 m-kg (33.5 ft-lb)

9.0 m-kg (65.0 ft-lb)

(13.0ft-lb)

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

1. Check for cracks, bends or

warpage

of wheels. If a wheel is deformed or cracked, it must be replaced.

NOTE:

These aluminum wheels are not designed for

use with tubeless tires.

Front for oil capacity:

169 cc (5.72 US

oz)

each leg

(PAGE 22 - 29)

3-3. INSPECTION AND REPAIR

D. Valve spring

Checking the valve springs

d. Valve spring specifications

Specifications should be changed as

follows:

2. Check wheel run-out If deflection exceeds tolerance, check

wheel bearing or replace wheel as required.

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

NOTE: The wheel should be balanced with brake disc

installed.

(PAGE 40)

5-2. REAR WHEEL

A. Removal

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.

Remove the axle nut cotter pin and axle

nut.

4. While supporting the brake caliper, pull

out the rear axle.

Remove the rear wheel assembly.

E. Rear wheel installation When installing rear wheel, reverse removal procedure taking care of following points:

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

E. Installing front

wheel

4. Always secure the front wheel axle as follows: Specifications should be changed as follows:

Axle nut torque:

10.7 m-kg (77.5 ft-lb)

Holder nut torque:

1.4 m-kg (10.0 ft-lb)

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

brake and XS650E front brake.

D. Brake inspection and repair Specifications should be changed as follows:

Wear limit:

6.0 mm (0.24 in)

LA-

A: Pad thickness

11 .O mm

6: Wear limit

6.0 mm (0.24 in)

C: Wear indicator

(0.43

in)

Check the armature and field coil for

3. shorting and insulation. Replace armature as required.

Check the front and rear cover bearings

for damage. If damaged, the starter assembly must be replaced.

Back

plate

(PAGE 48) 5-9. REAR SHOCK ABSORBER B. Inspection Specifications should be changed as follows:

Rear shock absorber tightening torque:

Upper

Lower

(PAGE 50

6-1. STARTER A. Armature

1.2.Check the outer surface of the commutator. If it’s surface is dirty, clean with No. 600 grit sand paper. The mica insulation between commutator segments should be 0.7 mm

(0.028 in) below the segment level. If not, scrape to proper limits with appropriately shaped tool. (A hack saw blade can be ground to fit.)

3.0 m-kg (21.5 ft-lb)

3.9 m-kg (28.0 ft-lb)

51)

(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 fuel tank.

NOTE: This model has been equipped with a safety relay so that the headlight comes on automatically when the engine is started even with the headlight switch “OFF”.

Headlight

condition

Normal

High beam

faulty

Headlight failure

cator

Comes on (very dim)

Comes on

indi-

light

Reserve light

ing function

Low beam

comes on

Mica under cut

0.7 mm (0.026 in)

Low beam

faulty

Comes on

High beam comes on at low brilliance

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