Yamaha XS650 1974-1980 Service Manual 07 anhaenge

CHAPTER 7. APPENDICES

7-1.

7-2.

7-3.

7-4. 7-5.

TORQUE SPECIFICATION Torque Specifications CONVERSION TABLE

Metric to Inch System

Inch to Metric System Definition of Terms

SPEClFlCATlON.........

A. General

B.

Engine

C.

Chassis.. D. Electrical CABLE ROUTING DIAGRAM

CIRCUIT DIAGRAM

...................................................................

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........................................................

......................................................

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...............................................................

...............................................

..........................................

...... 64

.........................................

..6 1

61

.63

.63 .63

.63

64

...66

..70

.72

..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

A

l-

INut)

10mm 12mm 14 mm 17 mm 19mm

22 mm 24 mm 27 mm

Part to be tightened

Ia

(Bk

6 mm (M6) 8mm fM8)

10mm 12mm 14mm

(Ml01 (Ml21 (Ml41

Engine:

Cylinder head and cylinder head cover

Cylinder head Cylinder head cover side

Spark plug Generator

Stator

coil Governer Valve clearance adjustment nut Cam chain tensioner cover Pump cover

Strainer cover

I

m-kg

i I ;

i

I

~ ~ 8 mm bolt

)

6 mm bolt 6 mm crown nut

~ 12 mm nut ~ 6 mm pan headscrew ~ 6mmbolt

/ 8

/ 18mmcap

1.0

2.0

3.5

-

4.0

-

4.5

Thread dia. and

part name

10mm

nut

8 mm crown nut

l

14 mm

mm nut

6 mm pan head screw 6mmbolt

Standard tightening torque

ft-lb

7

I

I /

I

/ I

I

2.2 m-kg

!

~

175 300 350 - 400 400 - 440 480 - 570

600 - 700

Tightening

3.8 m-kg (27 ft-lb)

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

1.5 m-kg

2.0 m-kg (14

4.0 m-kg (29 ft-lb)

1.0 m-kg ( 7 ft-lb)

0.8 m-kg ((6 ft-lb)

2.7 m-kg

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

1.0

m-kg ((7

torque

(16

ft-lb)

(10

ft-lb)

ft.lb)

(20

ft-lb)

(16 f t.lb)

ft-lb)

in-lb

85

-

350

1

i

I

1,

Drain plug Filter

cover

Oil filter

i 30 mm bolt

1

6mmbolt

1

16

mmbolt

4.4 m-kg (32

1.0

m-kg ((7

_~___

1 .Om-kg 1(7

ft.lb)

ft-lb)

I

Delivery pipe

I

Exhaust 1

Crankcase 1 and 2

Crankcase

Kick crank

1

Clutch spring

Primary drive gear

Clutch boss Drive sprocket Change pedal

Chassis:

Front wheel shaft Outer tube and axle holder

i-

Handle crown and inner tube

r

1

Handle crown and

1

Handle crown and steering shaft

I

Handle crown and handle holder

Part to be tightened

pipe

cover

boss

~~

steering

shaft

Thread dia. and

I

/

10 mm union bolt

/

8mm

1

8 mm bolt/nut

1

6 mm bolt 1

8 mm bolt

/

14 mm nut

1

8mm nut

/

8mm nut

I

8mmnut

/ /

part name

nut

6 mm screw

18 mm nut

22 mm nut

6 mm bolt

14 mm nut

14 mm bolt

8 mm bolt

I I

I

I I I I I

Tightening torque

2.2 m-kg (16 ft-lb)

1.5 m-kg

2.2 m-kg (16 ft-lb) 1 .O m-kg (7 ft-lb)

2.0 m-kg (14 ft-lb) 1 .O m-kg (7 ft-lb)

9.0 m-kg (65 ft-lb)

6.5 m-kg (47 ft-lb)

5.0 m-kg (36 ft-lb)

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

8.5 m-kg

1.5 m-kg

1 .O m-kg

1.0 m-kg (7 ft-lb)

5.5 m-kg (40 ft-lb)

2.5 m-kg (18 ft-lb)

(11

ft-lb)

(61

ft-lb)

(1

1 ft-lb)

(7 ft-lb)

I I

I

I I I

I

7-2.

CONVERSION TABLE

Known

Torque

m-kg m-kg

Metric to Inch System

Multiplier

(Rounded

7.233

86.80

off)

ft.lbr

iwlbs

Result

Known

Torque

ft-lbs

in.lbs

ft.lbr

in-lbs

Wt.

lb

oz

Flow/Distance

mpg mph

rn

Inch Metric System

Multiplier

(Rounded off)

0.13826

0.01152

13.831

0.4535

28.352

0.4252

1.609

Result

m-kg m-kg

cm.kg

cm-kg

kg

g

km/l kmlhr

km

Definition m-kg

g kg

km

I

km/l cc kg/mm

kg/cm’

of Terms:

Meter-kilograms: Usually torque. Gram(s).

Kilogram(s): 1,000 Kilometer(s). Liter(s). Kilometer(s) per liter: Mileage.

Cubic centimer(s) (cm3): Volume or capacity.

Kilogram(s) per millimeter: Usually spring Kilogram(s) per square centimeter: Pressure.

grams.

Vol./Capacity

oz

(US liq)

cu.

I”

pt

IUS

qt

(US

gal (US

Misc.

cqmpress~pn

liq)

rate,

29.57

16.387

0.4732

0.9461

3.765

cc (cm” cc (cm”)

I

(liter) I (liter)

I

(liter)

I

63

7.3. SPECIFICATION A. General

MODEL

1.

1) Model

2) Frame I.D. and starting number

3)

Engine I.D. and starting number

DIMENSION

2.

1)

Overall length

21 Overall width

3) Overall height

4) Seat height

1

51

Wheelbase

61

Minimum ground clearance

3. WEIGHT

Engine

B.

1.

DESCRIPTION

1)

Engine type

2)

Engine model

3) Displacement

4) Bore

5) Compression ratio

61

Starting

7)

Ignition system

8) Lubrication system

2.

CYLINDER HEAD

1)

Combustion chamber volume (with

2)

Combustion chamber type

3) Head gasket thickness

3.

CYLINDER

1)

Material

2)

Bore size

3)

Taper limit

4) Out of round limit

4. PISTON

1)

Piston skirt clearance

21 Piston oversize

3)

Piston pin outside diameter x length

5.

PISTON RING

1)

Piston ring design

2) Ring end gap

3)

Ring groove side clearance

(I.B.M.

x

stroke

system

No.)

N-7Y)

ITOP) (2nd)

(Oil

ring)

(Installed. top (Installed. 2nd (Installed, oil)

(TOP) (2nd)

XS650E 2FO-000101 ZFO-000101

2,180 mm (85.8 in)

1,160 mm (45.7 in)

1,435 mm (56.5

212 kg (467

26° 2,500 mm (98.4

14 m @ 50 km/h (45.9 ft @ 31

Air cooled, 4-stroke. SOHC

incline 2F0 653 cc (39.85 cu.in)

75

8.5 :: 1 Kick and electric starter Battery ignition Wet sump

44.18 cc (2.696 Dome +

1.2 mm (0.047 in)

Aluminum alloy with cast iron sleeve

75.00f~.02

0.05 mm (0.002 in)

0.01 mm (0.0004 in)

0.050

20.0_~,005mm x

(0.79mg,M)02 in x 2.40

Barrel ring 1.2 mm (0.047 in) Taper ring 1.5 mm (0.059 in) With expander 2.8 mm (0.110 in)

0.2

0.2 - 0.4 mm (0.008 - 0.016 in)

0.3

0.04

0.03

(2FO)

835 mm (32.9

815 mm (32.1 in)

150

mm( 5.9 in)

x

74 mm (2.953 x 2.913

Squish

~

0.055 mm (0.0020~ 0.0022

75.25 mm 75.50 mm 75.75 mm

12.963

inl

-

0.4 mm 10.008 - 0.016

-

0.9 mm (0.012 - 0.036 in)

-

0.08 mm (0.0016 - 0.0031 in)

-

0.07 mm (0.0012 - 0.0028

in)

lb)

in)

cu.in)

mm

(2.9528+~Ooo8

12.972 in, 12.982

61.0

& mm

-to115 in)

mi/h)

twin.

parallel forward

in)

in,

in)

in1

76.00 mm

l2.992

in1

Yamaha XS650 1974-1980 Service Manual 07 anhaenge

Specifications and Main Features

Frequently Asked Questions

User Manual