Yamaha XS850G Owner's Manual

XS850G

OWNER’S MANUAL

1ST

PRINTING, JULY 1979

ALL RIGHTS RESERVED,

BY YAMAHA MOTOR COMPANY

LIMITED, JAPAN

PRINTED IN JAPAN

P/N LIT-l 1626-01-79

PLEASE READ THIS MANUAL CAREFULLY AND COMPLETELY
BEFORE OPERATING THIS MOTORCYCLE.
DO NOT ATTEMPT TO OPERATE THIS MOTORCYCLE UNTIL

YOU HAVE ATTAINED A SATISFACTORY KNOWLEDGE OF ITS

CONTROLS AND OPERATING FEATURES AND HAVE BEEN

TRAINED IN SAFE AND PROPER RIDING TECHNIQUES.

REGULAR INSPECTIONS AND CAREFUL MAINTENANCE ARE
REQUIRED IN ADDITION TO RIDING SKILL IN ORDER TO
ENJOY THE CAPABILITIES AND RELIABILITY OF THIS MOTOR-

CYCLE SAFELY.

Particularly important information is distinguished in this manual by the fol­lowing notations:
NOTE:

CAUTION:

WARNING:

A NOTE provides key information to make procedures

easier or clearer.

A CAUTION indicates special procedures that must be fol-

lowed to avoid damage to the motorcycle.

A WARNING indicates special procedures that must be fol-

lowed to avoid injury to a motorcycle operator or person in-

specting or repairing the motorcycle.

NOTE:
This manual should be considered a permanent part of this motorcycle and
should remain with it even if the motorcycle is subsequently sold.

-SAFETY WARNINGS:
1,

Traffic regulations vary from state to state. Study the regulations

in your state before riding this motorcycle.

2.

This motorcycle is designed for on-road use only. It is not suita-

ble for off-road use.

3. GASOLINE IS HIGHLY FLAMMABLE:

*

Always turn off the engine when refuelling.

*

Take care not to spill any gasoline on the engine or exhaust

pipe(s)/muffler(s)

when refuelling.

*

Never refuel while smoking or in the vicinity of an open flame.

4.

If you should swallow some gasoline, or inhale a lot of gasoline

vapor, or allow some gasoline to get in your

eye(s), see your
doctor immediately. If any gasoline spills on your skin or cloth­ing, immediately wash it with soap and water and change your
clothes.

5.

*

*

6.

7.

6.

Always turn off the engine before leaving the motorcycle unat­tended and do not forget to remove the ignition key. When park­ing the motorcycle, note the following:
The engine and exhaust

pipe(s)/muffler(s)

may be hot. Park the
motorcycle in a place where pedestrians or children are not like­ly to touch the motorcycle.
Do not park the motorcycle on a slope or soft ground; the motor­cycle may overturn.
When transporting the motorcycle in another vehicle, be sure it
is kept upright and that the fuel petcock(s) is turned to the “ON”
or “RES” position (for vacuum

type)/“OFF”

position (for manual
type). If it should lean over, gasoline may leak out of the car­bretor or fuel tank.
Never start your engine or let it run for any length of time in a
closed area. The exhaust fumes are poisonous and may cause
loss of consciousness and death within a short time. Always
operate your motorcycle in en area with adequate ventilation.
Always wear a helmet, gloves, trousers (tapered around the cuff

and ankle so they do not flap), and a brightly colored jacket.

INTRODUCTION

Congratulations on your purchase of the
Yamaha

XS850G.

This model represents the
product of many years of Yamaha experience
in the production of fine sporting. touring,

and pacesetting racing machines. You can
now appreciate the high degree of crafts­manship and reliability that have made
Yamaha a leader in these fields.
This manual will provide the owner with a
good basic understanding of the operation
and basic maintenance of this vehicle. If you
have any questions regarding the operation
or maintenance of your motorcycle. please
consult

your Yamaha dealer.

-NOTICE:
Some data in this manual may become
outdated due to improvements made to

this model in the future. If there is any
question concerning this manual, con­sult your nearby Yamaha dealer.

This Yamaha Motorcycle in its design and
manufacture fully complies with the emis­sions standards for clean air applicable at
the date of manufacture. Yamaha has met
these standards without

reducing the

motorcycle’s performance or economy of
operation. To maintain these high standards.
it is important that you and your dealer pay
close

attention to

the

recommended
maintenance schedules and operating in­structions contained within this manual.

SERVICE DEPT.

INTERNATIONAL DIVISION

YAMAHA MOTOR CO., LTD.

CONTENTS

LOCATION OF THE “CAUTION AND

SPECIFICATION LABELS”

,.,.,.......................

1

DESCRIPTION

..,,,...........................................~

2

MACHINE IDENTIFICATION

3

CONTROL FUNCTIONS4

PRE-OPERATION CHECKS

..,,......................

15

OPERATION AND IMPORTANT
RIDING POINTS 24

PERIODIC MAINTENANCE AND
MINOR REPAIR

.,.......,,,,,,.,..,.,.,......................

30

CLEANING AND STORAGE

.,.......................

72
MISCELLANEOUS 75
SPECIFICATIONS 77

WARRANTY INFORMATION 80

MAINTENANCE RECORD 81

WIRING DIAGRAM 83

RIGHT SIDE

DESCRIPTION

INSTRUMENTS

LEFT SIDE

MACHINE

IDENTIFICATION

Frame serial number
The frame serial number is stamped into the
right side of the steering head pipe.

Engine serial number

The engine serial number is stamped into the
elevated part of the right rear section of the

engine.

NOTE:
The first three digits of these numbers are for

model identification; the remaining digits are
the unit production number. These identifica­tion numbers are used to register Your

motorcycle with the licensing authority in
your state as well as with the manufacturer.

Keep a record of these numbers for reference
when ordering parts from Your Yamaha deal­er. In case of theft, the authorities will need
these numbers and Your model name for
identification.

ON:

RES:

With the lever in this position fuel
flows if the engine is running but stops
if the engine is not running.

This indicates “RESERVE”. If you run
out of fuel while riding, move the lever
to

“PRI”

and switch to “RES” posi­tion after starting the engine. Then, fill
the tank at the first opportunity.

NOTE:
In the “ON” and

“RES”

positions the petcock

works on pressure from the engine turning

over. If the line connecting the petcock to the
carburetor intake manifold is not connected
or has a leak the petcock will not function
properly.

PRI: This indicates “PRIME”. With the fuel

petcock in this position fuel flows
whether the engine is running or not. If
the fuel tank is completely empty, refill
the tank, prime the carburetor in this

position, and then switch to the “ON”
position after starting the engine.

Starter (CHOKE)

When cold, the engine requires a richer fuel

mixture for starting. A separate starter circuit,
which is controlled by the starter, supplies
this mixture.

The starter on this model is a

2-position

type

as follows:

1.

Pull the starter fully up.

-When starting a cold engine.

2.

Push back the starter half-way.

-When warming up the engine.

NOTE:

Refer to “Starting and warming up a cold
engine” for proper operation.

Steering lock
To lock the steering, turn the handlebars fully

to the right, insert the key into the steering

lock and turn the key about

l/8

turn coun-

terclockwise. Then push the key in and turn it

about

l/8

turn clockwise. After checking if

the lock is engaged, remove the key from the

lock. To release the lock. reverse the above

steps.

Seat lock
To open the seat lock insert the key in the
lock and turn it counterclockwise and pull the
lever backwards.

In reinstalling the seat. insert the lobes on
the seat front into the receptacles on the
frame, then push down the seat at the end.
After making sure the seat is securely fitted,
turn the key clockwise to the center position

to lock.

Helmet holder
To open the helmet holder. insert the key in
the lock and turn it clockwise.
To lock the helmet holder, replace the holder
in the original position.

Never ride with a helmet in the helmet
holder. It could interfere with rear wheel
movement, causing loss of control and
possibly an accident.

Side cover (Left and Right)

To remove the right side cover, pull out the

bottom of the cover. To reinstall the cover.
make sure the top of the cover is securely

seated on the hinge hooks, then push the
bottom of the cover into its snap fitting.

-12-

Front forks
The front forks of this model are

pneumome­chanical; namely, a combination air and me­chanical coil spring in the inner tube provides
suspension best suited to the motorcycle’s
load

(ex:

optional accessories etc.) and riding
conditions by the adjustment of the air pres­sure. Refer to page 54 for proper adjustment
procedures.

Always adjust the fork preload to the
same position on each side. Uneven ad-

::::::b::

justment can cause poor handling and

Rear shock absorber

The spring preload and the damping force
can be adjusted to suit motorcycle load (ex:
optional accessories etc.) and riding condi­tions. Refer to page 54 for proper adjustment
procedures.

-I3-

An optional heavy duty rear shock absor­ber spring is available for this model.

Please ask your nearby Yamaha dealer for

further details.

Kick starter

To start the engine. rotate the kick crank.

push down lightly with foot until gears
engage, and then kick forcefully. This model
cannot be started unless the transmission is
in neutral.

* Heavy duty rear shock absorber

spring: P/No.

3J2-22212-A0

i

PRE-OPERATION CHECKS (DAILY)

Before using this motorcycle check the following points:

No.

Item

Routine

Page

Check operation, free play and fluid.

1.

Brakes (Front and Rear)

Top-up with DOT.

#3

brake fluid 16.44

if necessary.

2. Clutch

3. Engine oil
4 Middle/final Gear Oil

5. Throttle

6. Battery

7. Lights/Signals

8. Wheels/Tires

9. Fittings/Fasteners

Check operation. condition and free play.
Adjust if necessary.

Check engine oil

level.

add oil if necessary.
Check for leakage visually.
Check for smooth operation.

Adjust if necessary.

Check

fluid level. top-up with

distilled water if necessary.
Check operation.
Check tire pressure. wear damage.
Check all chassis fittings and fasteners.

Adjust. if necessary.

17.49

17.38

18.40

17.50

23.58

22
18

37

-15-

Pre-operation checks should be made each time the motorcycle is used. Such an inspection
can be accomplished in a very short time, and the added safety it assures is more than worth
the time involved.

. . . . .._.._ -.

1. The engine, exhaust pipe(s), and muffler(s) will be vary hot after the engine has
been run. Be careful not to touch them or to allow any clothing item to contact
them during inspection

or

repair.

2. If any item in the PRE-OPERATION CHECK is not working properly, have it in­spected and repaired before operating the motorcycle.

Brakes (See page 44 for more detail)

1.

Brake lever and brake pedal
Check for correct play in the front brake
lever and rear brake pedal. Make sure

they are working properly. Check the

brakes at low speed shortly after start­ing out.

-16-

-WARNING:
A soft, spongy feeling in the brake lever
(and/or brake pedal) indicates a failure
in the brake system. Do not operate the
motorcycle until the failure in the brake

system is corrected. Ask your Yamaha
dealer or other qualified mechanic for

immediate repairs. A soft, spongy feel-

ing could indicate a hazardous condition
in the brake system.

leakage could indicate a hazardous con­dition in the brake system.

Clutch (See page

49

for more detail)
Check for correct play in the clutch lever and
make sure the lever operates properly.
If the play is incorrect, make an adjustment,

Throttle grip (See page 50 for more detail)
Turn the throttle grip to see if it operates
properly and if the play is normal. Make
certain the throttle springs closed when re­leased.

Engine oil (See page 38 for more detail)
Make sure the engine oil is at the specified
level. Add oil as necessary.

I

1

Recommended oil:

I

Middle gear/Final gear oil (See page 40 for
more detail)
Make sure the middle gear/final gear oil is at

the specified level. Add oil as necessary.

If desired, an SAE

80W/90

hypoid gear oil

may be used for all conditions.

NOTE:

“GL-4” is a quality and additive rating. “GL-

5” or “GL-6” rated hypoid gear oils may also
be used.

TUBELESS TIRES AND ALUMINUM
WHEELS
This motorcycle is equipped with aluminum
wheels designed to be compatible with
either tube or tubeless tires.
Tubeless tires are installed as standard
equipment.

Do not attempt to use tubeless tires on
a wheel designed for use only with tube-
type tires. Tire failure and personal in-

jury may results from sudden deflation.

Tubeless-type Wheel

--t

Tube-type

rWARNING:-

When using tube-type tires be sure to

install the proper tube also.

To insure maximum performance, long ser­vice, and safe operation, note the following
precautions:

1.

2.

3.

Always maintain proper air pressure as
described in the Chart on page 21.
Check tire pressure. before riding. adjust
as necessary.

Before operation, always check the tire
surfaces for wear and/or damage: look
for cracks, glass, nails, metal frag-

ments, stones, etc. Correct any such
hazard before riding.

-19-

4. Always inspect the aluminum wheels
before a ride. Place the motorcycle on
the center stand and check for cracks,
bends or

warpage

of the wheels. If any
abnormal condition exists in a wheel,
consult your Yamaha dealer or other
qualified mechanic. Do not attempt
even small repairs to the wheel. If a
wheel is deformed or cracked, it must
be replaced.

5. Tires and wheels should be balanced
whenever either one is changed or re­placed. Failure to have a wheel assem­bly balanced can result in poor perform­ance, adverse handling characteristics,
and shortened tire life.

6. After installing a tire, ride conservatively
to allow the tire to seat itself on the rim
properly. Failure to allow proper seating
may cause tire failure resulting in
damage to the motorcycle and injury to
the rider.

7. After repairing or replacing a tire, check
to be sure the valve stem lock nut is
securely fastened. If not, torque it as
specified.

Tightening torque: 0.15 m-kg (1

.1

ft-lb)

The standard equipment tires originally fitted
to the

XS850G

are suited to normal riding
and touring. They are not suited for sustained
high speed running or racing and must not be
used for such purposes. Consider your riding
skill, road and weather conditions, and cor­rect weight distribution when loading your
motorcycle. Securely pack your heaviest
items close to the center of the motorcycle.

-WARNING:

1. This motorcycle is not designed to
pull a trailer or to be attached to a
sidecar. The accessories you choose
for your motorcycle should be de­signed specifically for it and should

be securely mounted in such a
fashion as to maintain the inherent
stability of the original design as

much as possible. Yamaha has a full

line of sport and touring accessories
designed specifically for this motor­cycle. Please consider them before

making a purchase. Use of non-ap-

proved accessories may cause loss
of handling stability and riding safe­ty. Consult your Yamaha dealer or

other qualified mechanic regarding
the consequences of using such

items.

2. Proper loading of your motorcycle is
important for the handling, braking,

I

and other performance and safety
characteristics of your motorcycle.

NEVER OVERLOAD YOUR MO­TORCYCLE. Make sure the total
weight of the accessories, and etc.,
does not exceed the maximum load

limites. Operation of an overloaded

motorcycle could cause tire damage,
an accident, and injury.

If a tire tread shows crosswise lines, it means

that the tire is worn to its limit. Replace the
tire.

-WARNING:
It is dangerous to ride with a worn-out

tire. When a tire tread begins to show
lines. Have Your Yamaha dealer or other
qualified mechanic replace the tire im­mediately. Brake pad replacement, tire,
and related wheel parts replacement

should be left to a Yamaha Service
Technician or other qualified mechanic.

If you must change your own tire, be
sure to use proper tools and procedures
as described in the Tubeless Tire and
Wheel Manual available from Your
Yamaha dealer.

Fittings/Fasteners
Always check the tightness of chassis fittings
and fasteners before a ride. Use the chart on
page 37 to find the correct torque.

Lights and signals
Check the headlight, flasher lights, taillight,

brake light, meter lights and all the indicator
lights to make sure they are in working con-

dition.

-22-

Switches

Check the operation of the headlight switch,

turn switch, brake light switch, horn button,

main switch, etc.

Battery (See page 58 for more detail)

Check fluid level and top-up if necessary.

Use only

distilled

water if refilling is neces-

sary.

Fuel
Make sure there is sufficient fuel in the tank.

-23-