Yamaha XS650 1974-1980 Service Manual 05 fahrwerk

5-1.

5-2.

5-3.

5-4.

5-5. 5-6.

5-7.

5-8.

5-9.

5-10.

CHAPTER 5. CHASSIS

FRONT WHEEL A. Removal B.

Front axle inspection

Front wheel inspection. D. Replacing wheel bearings E.

Installing front wheel REAR WHEEL

Removal

Rear axle inspection

Replacing wheel bearings

Rear wheel inspection

Installing rear wheel

Rear wheel illustration

BRAKES A. Caliper pad replacement B. Caliper disassembly. C.

Master cylinder disassembly D. Brake inspection and repair E.

Brake reassembly WHEELS, TIRES, TUBES A. Wheel inspection B. Tire, tube removal C.

Installation

REAR WHEEL SPROCKET

FRONT FORKS

A. Removal and disassembly

Inspection C. Assembly STEERING HEAD A. Adjustment

Removal.........................................................4

D. Reassembly

SWING

A. Inspection B. Swing arm removal

Swing arm lubrication

REAR SHOCK ABSORBER

A. Removal ..........................................................

B. Inspection CABLES AND FITTINGS A. Cablemaintenance

B. Throttle maintenance

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Inspection

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CHAPTER 5.

CHASSIS

5-l. FRONT WHEEL A. Removal

Remove cotter pin from front axle nut.

Remove the front axle nut.

Loosen the two axle holder nuts at

the bottom of the fork leg.

Raise the front wheel of the machine by

placing suitable stand under the engine.

Remove the front wheel axle by simul-

taneously twisting and pulling out on the axle. Then remove the wheel assembly. The speedometer

be removed.

gear unit housing must

a) If the run out is up and down, loosen

spokes opposite the high spot and tighten the spokes at the high spot.

b) If the run out is sideways, loosen the

spokes at the high spot, and tighten the spokes opposite the high spot.

Replacing wheel bearings

If the bearings allow play in the wheel hub or if wheel does not turn smoothly, replace the

bearings as follows:

Clean the outside of the wheel hub.

1. Drive the bearing out by pushing the

2. 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. To install the wheel bearing, reverse the

3. above sequence. Be sure to grease the bearing before installation. Use a socket that matches the outside race of the bearing 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.

C. Front wheel inspection

1. A rim can develop (1) running the wheel into an object and

bending the outer rim, or (2) one or more spokes loosening.

Check for on a stand (or, if the wheel is attached to a motorcycle, it can be blocked up and held in place). Use some device to measure

or detect movement then slowly spin the wheel and note the amount of rim out”. It should not exceed 2 mm(0.08 in).

3. If all the spokes are tight, and the rim shows no obvious signs of damage, and yet run out is still excessive, do

ing:

warpage

warpage.

by mounting the wheel

It is due to

“run-

the follow-

E. Installing front wheel When installing front wheel, reverse the removal procedure. Note the following points:

Lightly grease lips of front wheel oil seals and gear teeth of speedometer drive and driven gears. Use lightweight lithium soap base grease. Make sure there is enough gap between

2. disc pads. Check for proper engagement of the boss

3. on the outer fork tube with the locating slot on speedometer gear unit housing.

Always secure the front wheel axle as follows:

Tighten the front axle nut.

Axle nut torque:

8.5 m-kg (61 ft-lb)

b. Tighten axle holder nuts. First tighten nut

on front end of axle holder, then tighten nut on rear end.

Holder nut torque:

1 .O m-kg (7 ft-lb)

c. install a new cotter pin.

5-2. REAR WHEEL

Installing rear wheel

Lightly grease lips of rear wheel oil seals.

2. To install the rear wheel, reverse the removal procedure.

NOTE: Always use a new cotter pin on the axle nut.

Torque:

Axle nut: 15 m-kg(l08 ft-lb)

A. Removal

1. Place machine on center stand.

Disconnect the tension bar, and the brake

rod from the rear shoe plate. Pay strict attention to the presence and location of the tension bar lock washer and cotter key. These are safety parts and must be

included during assembly.

Loosen the chain tension adjusting nuts

and bolts on both right and left sides.

Remove the rear axle cotter pin and nut.

Remove the right-hand chain adjuster and

distance collar.

Remove the rear brake plate.

Lean the machine to the left and remove

the rear wheel assembly.

F. Rear Wheel lubrication (on page

41)

5-3. BRAKES

CAUTION: Disc brake components rarely require disassembly. Do not disassembly components unless absolutely necessary. If any hydraulic connection in the system is opened, the entire system should be disassembled, drained,

cleaned and then properly filled and bled

upon reassembly.

CAUTION:

DO not use solvents on brake internal components. 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-

faces.

A.Caliper pad replacement

1. It

is not necessary to disassemble the

brake fluid hoses to replace the brake pads.

Remove the caliper suppdrt bolt.*

3. Remove the

phillips

screw that holds the

brake pads.

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 (See Front Wheel, Inspection Procedures.)

Caliper

2. Pad screw

wppcm

bolt

Pull caliper cylinder off caliper frame.

5. Install new brake pads. Replace pads as a set.

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