Yamaha XS650SF Service manual

FOREWORD
This Supplementary Service Manual for XS650SF/XS650-2F has been
published to supplement the Service Manual for the XS650E (LIT-1 1616-0076), 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).
(PAGE 4 - 5)
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
reverse order, i.e. 9, 8 and 7.
2-2. MAINTENANCE INTERVALS CHARTS
A. PERIODIC MAINTENANCE EMISSION CONTROL SYSTEM
REMARKS
damage. Replace If n
7
Check fuel hose for cracks or damaqe.
Replace If necessary
Fuel Hose
0
0
8
Exhaust System
Check for leakage. Retlghten as necrsaw. Replace gasket(s) tf necessary. )
0
C
z
9
Carburetor
Svnchronlzataon
Adjust svnchronizaf~on
0
0
0
Idle Speed
Check and ad,ust engnr+ .dle speed.
Adjust cable free play.
0
0
0
10
B. GENERAL
of carburetors.
MAINTENANCE/LUBRICATION
Yamaha cham and
cable lube or lCWV/
‘XS65OSF onlv
THEREAFTEREVERY
INITIAL BREAK-IN j
ITEM
NO.
REMARKS
Front Fork Drawn completely.
”
Yamaha fork oil
1OWt or equivalent
Refill to specification.
011
16,000 km
1,000 km 5.000 k m
4,000 km
8,000 km
or 1 month or 7 months or 6 months or 12 months or24month
1 6 0 0 mil K3,OOOmil ( 2 . 5 0 0 mi) ( 5 , 0 0 0 mil
~10,000 mi
TYPE
0
Steerung Ball Check bearings assembly
Medwm weight
,2 Beanng and for looseness. Moderately wheel bearing
RKH
repack every 16,000 km
gre.%e.
(10.000 mi).
Check bearings for smooth
Medium weight
,3 W h e e l
rotation. Moderaltelv
wheel bearing
Bearings
repsk eVeV 16,ooO km
gresre.
(10,000 mil.
1 4 l8attew
,5 A . C .
Generator
1
Check specific gravitv.
Check breather D~DC for
proper operatio;l:
Replace generator brushes.
Replace at initial 9,000
km (5.500 mi)
i
-
0
3
0
G
IO
IO
Repack
Repack
I
0
_
(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.
(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.
E. Cam chain adjustment
Check/adjust thecam chain tension as follows:
1. 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
Fuel PIP
3. Remove the drain bolt and clean with
solvent If gasket is damaged, replace.
hnlt.
1. Locknut
1.
2. Gasket
- 138-
E. Rear brake (XS650SF only)
The rear brake pedal should be so adjusted
that it has a free play of 13 - 15 mm (0.51
- 0.59 in) from when the brake pedal is first
moved to when the brake begins to be
effected .
1. Loosen the adjuster lock nut (for pedal
height).
2.
3.
4.
5.
6.
By turning the adjuster bolt clockwise or
counterclockwise, adjust the brake pedal
NOTE:
This model is available in two types, tubeless
tire and tube-type tires. Before servicing tires,
please note the following instructions.
1. Tubeless tire
a. The identification marks are fitted on
the tire sidewall and wheel spoke for
tubeless tires as shown.
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.
Loosen the brake rod adjuster lock nut
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.
-WARNING:
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.
Failure to allow proper seating may cause
tire failure resulting in serious injury to the
machine and rider.
I-
I
i
1. Adjuster bolt (for pedal height) 6. Pedal height 12 - 18 ml- ”
(0.47 - 0 . 7 1 in)
2. Lock nut
7. Free play 13 - 15 mm
3. Lock nut
(0.51 -0.59 in)
4. Brake rod
5. Footrest
F. Wheels and tires
Tubeless tires and aluminium wheels
(XS650SF only)
-139-
b. 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:
1.5 m-kg (1.1 ft-lb)
2. Aluminium wheels
a. 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.
b. Tires and wheels should be balanced
whenever either one is changed or re
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.
placed. Failure to have a wheel assembly
balanced can result in poor performance, adverse handling characteristics, and shortened tire life.
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
“XS650-2F only
BASIC WEIGHT
Nith oil and full
fuel tank
l 102 kg (226 lb) ‘118 kg (260 lb
“100 kg (221 lb) l *116 kg (256 lb
standard tire
Bridgestone or
Yokohama
3.5OS194PR
Bridgestone or
Yokohama
13OBOS184PR
vlsximum load limit
166 kg I365 lb)
279 kg (615 lb1
1.6 kg/cm2
(22 psi 1
2.0 kg/cm=
(28 psi1
2.0 kg/cm2
(28 psi I
2.3 kg/cm2
2.0 kg/cm2
(28 psi)
2.3 kg/cm2
132 psi)
Zold tire presswe:
UP to 90 kg
(198 lb) load
9Okg1198Ib)load
5 206 kg (453 lb)
load (Maximum
load)
High speed riding
Minimum tire
wad depth
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 both tires
touching the ground and without rider.
Check the tension at the position shown
in the illustration, The normal vertical
132 Psi)
0.8 mm (0.03 in) 0.8 mm (0.03 in)
. . 20-30 mm (0.8- 1.2 in)
- 140-
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.
2. Tension adjustment
a. Loosen the rear brake adjusting nut
(XS650-2F only).
b. Remove the cotter pin of the rear wheel
axle nut with pliers.
C. Loosen the rear wheel axle nut.
d.
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.
4. Roar whal ale nut
1. Locknut
2. Adjuster
5. Cotter pin
3. Marks for alignment
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).
1. Top dead canter
3. Advanced mark
2. 15’ ETDC at 1,200 rlmn
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-
Connect timing light to right (left)
cylinder spark plug lead wire. Ignition
timing of right cylinder must be set first.
4. Start the engine and keep the engine
speed as specified on the label. Use a
tachometer for checking.
5. The rotor pointer should line up the “F”
stamped timing mark on the stator at a
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.
3.
6. Retighten screws. Check timing again
for right cylinder.
7. Repeat procedure (steps 2 - 6) for left
cylinder.
(PAGE 39 - 40)
5-1. FRONT WHEEL
C. Front wheel inspection (XS650SF only)
1. Check for cracks, 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):
1. Right cylinder timing adjustment
2. Left cylinder timing adjustment
3.
F. Spark plug
Check electrode condition and wear, insulator
color, and electrode gap. Use a wire gauge for
If the electrodes
adjusting the plug gap.
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.
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.
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 29 - 33)
3-4. ENGINE ASSEMBLY AND ADJUSTMENT
0. Engine
Specifications should be changed as
follows:
Engine mounting bolt
Upper (U Nut)
Upper
Front (U Nut)
Rear (U Nut)
Rear - under
torque:
1.8 m-kg (13.0
M8
Ml0
3.0 m-kg (215
Ml0
4.6 m-kg (33.5
Ml0
4.1 m-kg (29.5
ft-lb)
ft-lbl
ft-lb)
ft-lb)
(U Nut)
Ml0
Under (U Nut)
Ml0
Check wheel balance
Rotate wheel lightly several times and
observe resting position.
4.6 m-kg (33.5 h-lb)
9.0 m-kg (65.0 ft-lb)
-142-
I
8 0 m m (3.15 anl
(PAGE 40 - 44)
5-3. BRAKES
Except for the following, the same procedure
as for the XS650E front brake can be performed for the disassembly, inspection,and assembly of the XS650SF (front and rear brake)
and the XS650-2F (front brake).
Balance wwghf
I
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D. Brake inspection and repair
Specifications should changed as follows:
(PAGE 40)
5-2. REAR WHEEL
Wear limit:
6.0 mm (0.24 in)
A. Removal (XS650SF only)
1. Support the machine on the center stand.
2. Disconnect the drive chain. Using the
drive chain cutter (special tool).
NOTE: __
The chain joint should be replaced each time
the chain is cut.
3.
4.
5.
A, P a d thickness
1 1 . 0 m m ( 0 . 4 3 In)
Remove the axle nut cotter pin and the
axle nut.
While supporting the brake caliper, pull
out the rear axle.
Remove the rear wheel assembly.
6: Wear limit
6.0 mm 10.24 1n1
C. Wear
E. Installing rear wheel (XS650SF only)
When installing rear wheel, reverse removal
procedure taking care of following points:
1. Lightly grease lip of rear wheel oil seals.
2. Make sure the brake pads are installed
properly and that there is a sufficient
gap to install the rear disc.
3. Install the wheel assembly and the axle.
Always use a new cotter pin on the axle
nut.
Axle nut torque:
15.0 m-kg (108.5 ft-lb)
i
mdlcator
(PAGE 44)
5-4. WHEELS, TIRES, TUBE (XS650SF Tubeless tire model)
Refer to “Tubeless tire and Aluminium Wheel
Manual” for tubeless tire and wheel service.
I
4. Connect the drive chain.
5. Adjust the drive chain.
- 143-
(PAGE 50 - 51)
6-1. STARTER
A. Armature
1. Check the outer surface of the commutator. If its surface is dirty, clean
with No. 600 grit sand paper.
2. 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.)
NOTE:
This model has been equipped with a safety
relay so that the headlight comes on automatically when the engine is started and the
light stays on until the main switch is turned
to “OFF” even if the engine stalls.
Headlight
condition
Normal
Headlight
failure indicator light
Comes on
, (very dim)
Low beam
comes on
Mica under cut
0 . 7 m m (0.028 an)
n
High beam
comes on at
low brilliance
I
I
2. Troubleshooting/Inspection
Commutator
3. Check the armature and field coil for
shorting and insulation. Replace armature as required.
“ Y ” w i r e to safety
Coil resistance
Armature coil
1 Field coil
0.0067R at 20°C 168°F)
1 0.004R a t 2O’C (68°F)
Reserve lighting function
1
4. Check the front and rear cover bearings
for damage. If damaged, the starter
assembly must be replaced.
(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 inoperative, 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 seat.
- 144 -
1
,!
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i’Oimmarl
ii
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T
(PAGE 61 - 62)
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.
-146-
NOTE:
Certain items with other than standard thread
pitches may require differing torque.
Torque Specifications
A
(Nut)
-
I
Part to be tightened
I
Tightening torque
Handle crown and handlebar holder
8 mm bolt
Under bracket and inner tube
8 mm nut
Engine mounting
UPPer
8 mm nut
Engine mounting
upper
Engine mounting
Front
10 mm nut
4.6 m-kg (33.5 ft-lb)
Engine mounting
Rear
10 mm nut
4.1 m-kg (29.5 ft-lb) -
Engine mounting
Rear-Lower
10 mm nut
4.6 m-kg (33.5 ft-lb)
Engine mounting
Lower
10 mm nut
9.0 m-kg (65.0 ft-lb)
Front flasher and headlight
8 mm nut
1.0 m-kg (7.2 ft-lb)
I
Master cylinder and brake hose
Caliper and support bracket
I
Caliper and pad
I
Caliper and bleed screw
Front caliper and front fork
Master cylinder and cylinder bracket
Pivot shaft
1.8 m-kg (13.0 ft-lb)
I
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10 mm nut
8 mm bolt
2.0 m-kg (14.5 ft-lb)
1.8 m-kg (13.0 ft-lb)
5 m m bolt
0.3 m-kg
8 mm bolt
1
6 mm bolt
I
14 mm nut
Tension bar and rear arm
1
(21.5 ft-lb)
8 mm bolt
I
1 (2.2 ft-lb)
0.6 m-kg
(4.5 ft-lb)
3.5 m-kg (25.5 ft-lb)
0.6 m-kg
I
16 mm nut
Tension bar and brake caliper (plate)
3.0 m-kg
2.6 m-ka (19.0 ft-lb)
10 mm bolt
Rear wheel axle
2.0 m-kg (14.5 ft-lb)
1.6 m-kg (13.0 ft-lb)
10 mm union bolt
Brake disc and hub
I
1
Thread dia. and part name
6.5 m-kg
(4.5 ft-lb)
(47.0 ft-lb)
15.0 m-kg (106.5 ft-lb)
8 mm nut
1.6 m-kg (13.0 ft-lb)
8 mm nut
3.2 m-kg
(23.0 ft-lb)
Rear shock absorber
Upper
10mm bolt
3.0 m-kg (21.5 ft-lb)
Rear shock absorber
Lower
10 mm bolt
3.9 m-kg (28.0 ft-lb)
Rear arm and rear arm end
8 mm bolt
Front fender
8 mm bolt
Neutral switch
I
12mm
1.0 m-kg
(7.2 ft-lb)
1.0 m-kg
(7.2 ft-lb)
1.3 m-kg
(9.5 ft-lb)
( P A G E 6 4 - 71)
7.3. S P E C I F I C A T I O N
A.
‘XS65OSF only
General
1. MODEL
1) Model (I.B.M. No.)
2) Frame I.D. and starting number
31 Engine I.D. and startinq number
2. DIMENSION
1) Overall length
2) Overall width
31 Overall height
4) Seat height
5) Wheelbase
6) Minimum ground clearance
3. WEIGHT
1) Net weight (Dry)
4.
PERFORMANCE
1) Climbing ability
2) Minimum turning radius
!
- 14; 6-
“XS65O.2F only
XS650SF (2MO)/XS650-2F
(3NO)
2FO-150101/2FO-250101
2F0.150101/2F@250101
2,120 mm (63.5 in)
925 mm 136.4 in)
* 1,225 mm (48.2 in) “1,220 mm (46.0 in)
790 mm (31.1 in)
1,435 mm (56.5 in)
135 mm
( 5.3 in)
‘210 kg (463 lb) “205 kg (452 lb)
26’
2,500 mm 196.4 in)
I
1. OESCRIPTION
1 I Engine type
Air cooled, 4.stroke. SOHC twin,
parallel forward incline
21 Engine model
2FO
653 cc (39.85 cu.in)
75 x 74 mm (2.953 x 2.913 in)
31 Displacement
41 Bore x stroke
51 Compression ratio
61 Starting system.
7) Ignition system
8.5 : I
Kick and electric starter
Battery ignition
81 Lubrication system
wet sump
2. CYLINDER HEAD
1 I Combustion chamber volume (with N-7Yl
43.6 cc (2.660 win)
Dome + Squish
21 Combustion chamber type
31 Head gasket thickness
1.2 mm (0.047 in)
3. CYLINDER
Aluminum alloy with cast iron sleeve
1 I Material
2) Bore size
~ ~~~~~~l”,,o~~irj:.9528 +~.Ooos
in)
31 Taper limit
41 Out of round limit
0.01 mm (0.0004 in)
I
1. PISTON
1) Piston skirt clearance
21 Piston oversize
0.050 - 0.055 mm ~0.0020 - 0.0022 in)
7 5 . 2 5 mm 75.50 mm 75.75 ml-n 76.00 m m
12 963 i n , 12972 in, 12982 in, 12992 InI
3) Piston pin outside diameter x length
20.0 _;,, mm x 61 .o -:.a mm
IO.79 &,,,, in x 2.40 -&II 16 j”)
5. PISTON RING
11 Piston ring design
TOI,
2nd
Oil ring
-@
-I%
-+.a%
1.2 mm 10.047 in) 1.5 mm 10.059 in, 2.8 mm 10.110 II
21 Ring end gap
3) Ring groove side clearance
IInstalled. top)
ilnrtalled. 2nd)
0.2 - 0.4 mm (0.008 - 0.016 in)
0.2 - 0.4 mm (0.008 - 0.016 in)
(Installed. oil)
(Top)
(2nd)
0.3 - 0.9 mm (0.012 - 0.035 in1
0.04 - 0.08 mm (0.0016 - 0.0031 in)
0.03 - 0.07 mm (0.0012 - 0.0028 in)
6. BIG END BEARING
1) Tvpe
2) Bearing size
Needle bearing
@26x @34x19.8
31 Needle size
@4x ~15.6x13
7. CAMSHAFT
1 I Cam drive type
21 Number and type of bearing
31 Bearing type
41 Cam dimensions
Chain (Center side)
4 bearings, Ball bearings (6W5)
Q25-647-8
5) Valve timing
OPEN
CLOSE
IN
BTDC360
ABDCW
z3‘I”
EX
BBDCE8°
ATDCW
2840
DURATION
OVERLAP
720
,,.--i-J-
61 Camshaft deflection limit
0.03 mm (0.0012 in)
7) Cam chain
Type
Number of links
Sprocket ratio
TSUBAKIMOTO BF05M
106L
36/16 (2.000)
I. ROCKER ARM AND ROCKER SHAFT
1) Rocker arm inner diameter
(:-,:
,1
c BY
15.0+~.“‘8 mm (0.591 +z.0w7 in)
2) Rocker arm shaft diameter
15.0 $:E mm (0.591 I~:~$ in)
3) Clearance
41 Lift ratio
0.009 - 0.033 mm (0.00035 - 0.00130 in)
X : Y = 40 : 46.41 mm (1.575 : 1.906 in)
3. V A L V E , V A L V E S E A T A N D V A L V E G U I D E
1) Valve per cylinder
2) Valve clearance (In cold engine)
2 pcs.
IN: 0.06 mm (0.0024 in)
EX: 0.15 mm (0.0059 in)
31 Dimensions
Valve head diameter “A”
IN: 41 mm (1.614 in)
Valve face width “6”
:;:: ;yl $y07;3i3ifn))
Valve seat width “C”
EX: 2.1 mm (0.063 in)
IN: 1.3 mm (0.051 in)
EX: 1.3 mm (0.051 in)
Valve margin thickness “D”
n
y$JJ_$
T
D
I-_A~~_
IN: 1.3 mm (0.051 in)
EX: 1.3 mm (0.051 in)
IN: 8.0 7:::: m m ( 0 . 3 1 5 I::‘0 in)
Valve stem diameter
Valve stem diameter
EX: 6.0 I;:$; mm (0.315 1;::;; in)
Valve guide diameter
IN: 6.0 :t:z:‘, m m ( 0 . 3 1 5 :,“I= inI
E x : 6 . 0 ;;:j;; m m ( 0 . 3 1 5 :E:z in)
IN: 0.020 - 0.044 mm (0.00079 - 0.00173 in)
EX: 0.035 - 0.059 mm (0.00136 - 0.00232 in1
IN & EX: 0.03 mm (0.0012 in) or less
Valve stem to guide clearance
4) Valve face runout limit
I. V A L V E S P R I N G
1) Free length
I N N E R (IN/EX): 4 2 m m ( 1 . 6 5 4 i n )
O U T E R (IN/EX): 42.55 mm (1.675 in)
I N N E R (INIEX): kl = 1.43 kg/mm (80.1 lb/in)
kz = 1.61 kg/mm (101.4 lb/in)
O U T E R (INIEXI: kl = 3.2 kg/mm (179.2 lb/in1
kz = 4.16 kg/mm(234.1 lb/in)
INNER (INIEX): 35 mm (1.378 in)
O U T E R (IN/EX): 37 mm (1.457 in)
I N N E R (IN/EX): 10 +-0.7 kg (22.0 t 1.5 lb)
O U T E R (lN/EX): 17.7 i 1.25 kg (39.0 i 2.6 lb)
INNER (INIEX): 25.5 mm (1.004 in)
O U T E R (IN/EX): 27.5mm (1.063 in)
I N N E R (IN/EX): 27.2 ? 1.9 kg (60.0 * 4.2 lb)
O U T E R (IN/EX): 57.4 k4.0 kg (126.5 + 8.6 Ibl
2) Spring rate
3) Installed length (Valve closed)
4) Installed pressure (Valve closed)
5) Compressed length (Valve open)
6) Compressed prerrure (Valve open)
- 150-
lNNER (INIEX): 19.4 mm (0.764 inl
OUTER (IN/EX): 32.6 mm il.283 in)
I N N E R (IN/EX): 6.0turns
OUTER (INIEX): 4.25t”rnr
81 Winding0.D.
9) idumber of windings
1) Crankshaft deflection limit
2) Con-rod large end clearance
3) Width of crankshaft
(A)
18)
(a
0.05 mm (0.002 in1
0.15 - 0.4 mm (0.0059 - 0.0157 in)
(D)
186 j3 mm (7.323 _E,,,2 in)
66 $2 mm (2.598 I$% ini
4) Crank pin I.D.
26 $2: mm (1.024 Ii:% in)
5) Crank pin O.D. x length
0
26 _o,oo6
x 65 ‘;I; mm
(1.024 _E,wo2 x 2.559t$?J$iinl
12. CONNECTING ROD
1) Big end I.D.
34 +$‘16 mm (1.339 +z,” in)
2) Small end I.D.
20:~:~:~ mm (0.787 $$$A in1
13. CRANK BEARING
1) Type Right end
Others
2) Oil seal type
$3Q@78-19 (Ball bearing)
@32-G68.17 (Rollar bearing)
SD-25-40-9
14. CLUTCH
1) Clutch type
2) Clutch operating mechanism
3) Primary reduction ratio and method
4) Primary reduction gear back lash (4 teeth)
5) Friction plate
ThicknessIQuantitv
Wear limit
6) Clutch plate
ThicknesslQuantitV
Warp limit
7) Clutch spring
Free length/Quantity
8) Clutch housing radial Play
9) Push rod bending limit
15. TRANSMISSION
1) Tvpe
2) Gear ratio:
1st
2nd
3rd
4th
5th
Wet, multiple type
Inner push type. screw push system
72127 (2.6661. spar gear
21.45 &x6 mm (0.8445 _~,oooto in)
3 mm (0.118 in)/7 pcs.
2.7 mm (0.106 in1
1.4 mm (0.055 in)/6 pcx
0.05 mm (0.002 in\
:
34.6 mm (1.362 in)/6 pcs.
0.027 - 0.081 mm (0.0011 - 0.0032 in)
0.2 mm (0.008 in)
Constant mesh. 5.speed forward
32/13 (2.4611
27/17 (1.588)
26/20’ ( 1 . 3 0 0 1
’ 23/21 1 1 . 0 9 5 )
22/23 (0.956)
-151-
3) Bearing type: Main axle (Left1
(Right1
Dr,ve axle (Left)
(Right1
4) Oil seal type Drive axle (Left1
5) Secondary reduction ratio and method
Needle bearing (@20~@30-201
Ball bearing (0%052-20.61
Ball bearing l@30-062-23.8)
Needle bearing (020.$30-161
SDD-40-62-9
34117 ~2.0OOllChain
16. SHIFTING MECHANISM
1) Type
21 Oil seal type (Change lever)
Cam drum, return type
SDO.14.24-6
17. KICK STARTER
1) TYPE
2) Oil seal type (Kick axle)
3) Kick clip friction tension
Bendix type
SD.25.35.7
1.2 - 1.7 kg (2.6 - 3.7 lb)
18. IFITAKE
1) Air cleaner: Type/Quantity
2) Cleaner cleaning interval
Dry. foam rubber/2 pa.
Every 6,000 km (5.000 mile)
19. CARBURETOR
1) Type and manufactureriDuantitY
2) I.D. mark
31 Main jet
(MJI
4) Air jet
(AJ)
5) Jet needle
(JNI
61 Needle jet
(NJ1
7) Throttle valve
(Th.VI
6) Pilot jet
IPJ)
9) Pilot screw (Turns out) (PSI
101 Starter jet
IGS)
11) Fuel level
(FL1
12) Idling engine speed
ES36 MIKUNl/Z pcs.
ZFO-00
#135
#140
502.3
z-2
#120
r127.5
Preset
GS, : #80, GSz : 0.5
24 + 1 mm (0.94 to.04 in)
1,200 rlmin
20. LUBRICATION
11 Engine sump oil quantity
31 Oil pump type
Oil exchange: 2.0 lit 12.1 US qt)
Overhaul: 2.5 lit (2.6 US qtl
Yamalube 4~cycle oil or SAE 2OWl40 type
“SE” motor oil
Trochoid pump
4) Trochoid pump specifications
Top clearance
Tip clearance
Side clearance
Oil pump volume
51 Bvoass valve settina pressure
0.10- 0.16 mm IO.0039 -0.0071 in)
0.03 - 0.09 mm 10.0012 - 0.0035 in)
0.03 - 0.08 mm (0.0012 - 0.0031 in1
1.3 litlmin (1.37 qtlmin) at 1,000 rImin
1.0 kg/cm’ (14 psi)
21 Oil type and grade
- 152-
6) Lubrication chart
- Pressure feed
d---Splash
lubrication
C. Chassis
1. FRAME
1) Frame design
Douole cradle, high tensile frame
2. STEERING SYSTEM
1) Carter
21 Trail
27”
115mm (4.53 in)
3) Number and size of balls I” steering head
upper race
19 pcs. 114 in
Lover race
4) Steering lock to lock
19 pcs. 114 in
42” each IL and R)
3. FRONT SUSPENSION
Telescopic fork
1) Type
21 Damper type
Oil damper. coil spring
3) Front fork spring
Free length
Wire diameter x winding diameter
402 mm 118.98 in)
4 x 24.5 mm 10.157 x 0.965 in)
Spring constant
kl = 0.46 kg/mm i26.66 lb/in)/
0 - 100 mm IO - 3.94 in)
kg = 0.65 kg/mm (36.40 lb/in)/
100 - 150 mm (3.94 - 5.91 in)
41 Front fork travel
150 mm (5.906 in)
35 mm (1.376 in)
5) Inner tube O.D.
6) Front fork oil quantity and type
169 cc 15.72 oz) each leg
Yamaha fork oil 1OWt or equivalent
7) Distance from the top of inner tube oil level
Approx. 454 mm 117.9 in1
without spring
4. REAR SUSPENSION
Swing arm
11 Type
2) Damper type
3) Shock absorber travel
Oil damper. coil spring
I30 mm 13.15 in)
4) Shock absorber spring
Free length
226 mm 18.90 in)
7.5 x 60.5 mm (0.295 x 2.362 in)
kl = 1.714 kg/mm (96.0 lb/in)/
O- 45 mm 10 - 1.77 in)
k2 = 2.244 kg/mm (125.7 lb/in)/
Wire diameter x winding diameter
Spring constant
5) Swing arm free play (Limit)
6) Pivot shaft -Outside diameter
1
- 15:3-
45-6Omm (1.77-3,15in)
1 mm IO.04 in)
16 mm (0.63 in)
5. F U E L T A N K
11 Capacity
11.0 lit 12.9 US gall
2) Fuel grade
Regular gasoline
5. W H E E L
1) Type (Front and rear)
2) Tire size
IFrOnt)
(Rear)
*Cast wheel **Spoke wheel
3.50S19.4PR
130/90S16-4PR
31 Tire pressure:
Front: 1.6 kg/cm’ (22 psi)
Up to 90 kg (198 lb) load
Rear: 2.0 kg/cm* (28 psi)
Front: 2.0 kg/cm2 (28 psi1
90 kg (198 lblload - 204 kg (445 lblload
(Maximum load)
High speed riding
Rear: 2.3 kg/cm2 (32 psi)
Front: 2.0 kg/cm’ 128 psi)
Rear: 2.3 kg/cm* (32 psi)
4) Rim run out limit (Front and rear)
Vertical
Lateral
5) Rim size
2 mm (0.08 in)
2 mm (0.08 in)
IFront)
(Rear)
6) Bearing type
Front wheel (Left)
(Right)
Rear wheel
1.85 x 19
‘MT3.00 x 16 “2.75 x 1 6
‘ 6 3 0 2 2 2 “86303
‘63022
“B6303RS
63042
63052
(Left)
(Right)
71 Oil seal type
Front wheel (Left)
Rear wheel
SDD-45-56-6
SD.22.42-7
SD.35.62-9
(Right)
(Left)
SO-27-52-5
(Right)
8) Secondary drive chain type
50HDS
Type
Number of links
Chain pitch
Chain free play
103L + Joint
15.875 mm 15/E in1
20 - 30 mm (0.8 - 1.2 in)
7. BRAKE
1) Front brake
Hydraulic disc type
298x 7.0 mm 111.73 x 0.28 in)
6.5 mm 10.26 in)
Type
Disc size (Outside dia. x thickness)
Disc wear limit
Disc pad thickness
11.0 mm (0.43 in)
6.0 mm (0.24 in)
14.0 mm (0.55 in)
Pad wear limit
Master cylinder inside dia.
Caliper cylinder inside dia.
38.1 mm 11.50 in)
DOT #3 Brake fluid I3B.l cc (1.29 01)
Brake fluid type I quantity
2) Rear brake IXS65OSF only)
Hydraulic disc type
Type
Disc sire (Outride dia. x thickness)
267 x 7.0 mm (10.5 x 0.28 in)
6.5 mm IO.26 in)
Disc wear limit
Disc pad thickness
11.0 mm 10.43 in)
Pad wear limit
Master cylinder inside dia.
6.0 mm (0.24 in)
14.0 mm (0.55 in)
Caliper cylinder inside dia.
38.1 mm (1.50 in)
DOT #3 Brake fluid / 38.1 cc (1.29 ozl
Brake fluid type / quantitv
-154-
31 Rear brake (XS650-2F only)
TVPE
Actuating method
Brake drum I.D.
Drum brake (Leading trailing)
Link rod
Brake shoe dia. x width
180 x 30 mm (7.09 x 1.18 in)
4 mm12 mm IO.16 into.08 in)
180 mm (7.09 in)
Lining thickness/wear limit
Shoe spring free length
68 mm (2.68 in1
D. Electrical
1. IGNITION SYSTEM
I) Ignition timing (B.T.D.C.)
15°/1,200 rlmin
2) Ignition coil
Model/Manufacturer
Spark gap
CMll-50B/HITACHI
Primary winding resistance
3.9R * 10% at 20°C (68°F)
8.0kR * 20% at 2O’C (68°F)
6 mm (0.24 in) or mare at 500 r/min
Secondary winding resistance
3) Spark plug
N-7Y (CHAMPION) or BP7ES (N.G.K.)
TVP~
Spark Plug gap
4) Contact breaker
0.7 - 0.8 mm 10.027 - 0.031 in)
HITACHI/2 pcs.
0.30- 0.40 mm (0.012- 0.016 in)
Manufacturerlouantity
Point gap
Point spring pressure
650 - 850 g 122.9 - 30.0 02)
93O r 5O
Cam closing angle
51 Condenser
Capacity
Insulation resistance
Quantity
0.22/~F
1OMR o r m o r e
2 per.
2. CHARGING SYSTEM
1) AC generator
14V 1 lAf2.000 rImin
Charging output
Rotor coil resistance (Field coil)
Stator coil resistance
5.25a 5 10% at 2O’C 168°F)
0.46a ? 10% at 2O’C (68’Fl
14.5 mm (0.571 in)
Brush length
Brush wear limit
2) Rectifier
7.0 mm (0.276 in)
B-Element type (Full wave)
Tvpe
Model/Manufacturer
Capacity
SBGB.l7/HITACHI
12A
Withstand voltage
4oov
31 Regulator
TVP~
Model/Manufacturer
Regulating voltage
Tillil type
TLIZSO/HITACHl
Core gap
0.6 - 1.0 mm (0.024 - 0.039 in)
0.3 - 0.4 mm (0.012 - 0.016 in)
14.5 + 0.5v
Point gap
Voltage coil resistance
10R at 20°C (68OF)
5) Battery
Model/Manufacturer/~uantity
Ytl14L.A2/YUASA/l PC.
12V. 14AH
1.4A 10 hours
Capacity
Charging rate
Specific gravity
1.28 at 20-c (68°F)
- 1 5 5 -
.
3. STARTER
1) srarter motor
Tvpe
Manufacturer
Model
output
Armature coil resistance
Field coil resistance
Brush size/Ouantitv
Wear limit
Spring pressure
Commutator O.D.lWear limit
Mica undercut
Bendix type
HITACHI
S108-35
0.5 kw
0.0067a + 10% at ZO’C (68’F)
0.004X2 + 10% at 20°C 16EaF)
16 mm (0.63 inIl2 PCS.
4 mm (0.16 in)
800 g (28.2 011
33 mm (1.30 in)/31 mm 11.22 in)
0.7 mm 10.028 in)
2) Starter switch
Manufacturer
Model
Amparage rating
Cut-in voltage
Winding resistance
3) Starter clip friction tension
HITACHI
Al04-70
1OOA
6.5V
3.5R
2.2 - 2.5 kg (4.9 - 5.5 lb)
4. LIGHTING SYSTEM
1) Headlight type
2) Bulb brightness and wattage/Quantitv
Headlight
Tail/brake light
Flasher light
Pilot lights: Turn
High beam
Headlight failure
Neutral
Tail/brake failure
Meter lights
3, Reserve lighting “nit
Sealed beam
12v. 5014ow x 1 PC.
12V. 3/32 CP (8Wi27WI Y 1
12V. 32 CP (27Wl x 4 PCS.
12v 3.4w x 1 PC.
12v. 3.4w x 1 PC.
12v. 3.4w x 1 PC.
12V. 3.4W x 1 PC.
12v. 3.4w x 1 PC.
12v. 3.4w x 4 PCS.
337.11720iKOITO
Model/Manufacturer
4) Horn
Model/Manufacturer
Maximum amparage
5) Flasher relay
Tvpe
Model/Manufacturer
Flasher frequency
Capacitv
6) Flasher cancelling unit
Model
Voltage
7) Fuse
Rating/Quantity
8) Light checker
Model
Manufacturer
CF.lZ/NIKKO
2.5A
Condenser type
lAO.70/NIPPON DENS0
85 + 10 cvcleimin.
32 CP (27WI x 2 + 3.4W
EVH-AC518
DCSV - 16V
Main (Red): 20A
35200.71859
KOITO
- 156-
PC