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XS650E

INDEX

GENERAL

INFORMATION

PERIODIC INSPECTION

AND ADJUSTMENT

ENGINE OVERHAUL

CARBURETION

CHASSIS

ELECTRICAL

I

APPENDICES

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XS650SE SUPPLEMENT

(EPA)

XS650E SUPPLEMENT

*XS650SF USES THIS SUPPLEMENT (EPA)

XS650SE SUPPLEMENT

I

XS650SF/2F SUPPLEMENT

XS650G/SG SUPPLEMENT

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CHAPTER 1.

GENERAL INFORMATION

l-l.

MACHINE IDENTIFICATION

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

a . . . . . . . . . . . . . . . . . . . . . . . . . .

.1

l-2.

SPECIAL TOOLS

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

.

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CHAPTER 1.

GENERAL INFORMATION

l-l. MACHINE IDENTIFICATION

.

Frame serial number

The frame serial number is stamped on the right side of the steering head stock.

Engine serial number

The engine serial number is stamped on the front of the engine crank case.

NOTE:

The first three digits of these numbers are for model identifications; the remaining digits are the

unit production number.

1-2. SPECIAL TOOLS

1. Cam chain cutter

Parts No. (90890-01112)

c

2. Valve spring compressor

(90890-01253)

,

3. Valve guide reamer

(90890-01211)

J

4. Valve seat cutter set

5. Piston ring compressors

6. Piston support plate

(90890-01179)

(90890-01066)

(90890-01067)

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I

7. Rotor puller

(90890-01070)

10. Drive chain cutter

11. Pocket tester

(90890-01081)

(90890-03096)

13. Vacuum gauge

(90890-03094)

P

8. Clutch holding tool

(90890-01069)

9. Slide hammer

(90890~;z)

12. E lectro tester

(9089@0302 1)

OTHER TOOL

PARTS No.

Valve guide remover

90890-01200

Valve guide installer

90890-01201

Spoke wrench

90890-05087

Steering nut wrench

90890-01051

Tappet adjuster wrench

.256-28137-00

-2-

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CHAPTER 2.

PERIODIC INSPECTION AND ADJUSTMENT

2-1.

INTRODUCTION

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

2-2.

MAINTENANCE INTERVAL CHARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

.4

A. PEPIODIC MAINTENANCE

.........................................^.4

B. LUBRICATION INTERVALS

....

............................... .... 5

2-3.

ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . 6

A. Carburetor.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

B. Air filten . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

.7

C. Engine/Transmission oil and filter

.....................................^.7

D. Clutch adjustment

..................................................6

E.

Cam chain adjustment

..............................................^.8

F. Valve clearance adjustment

...........................................8

G. Crankcase ventilation system

.........................................^.9

H. Exhaust system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9

2-4.

CHASSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

A.

B.

C.

D.

E.

F.

G.

H.

I.

J.

Fuel petcock cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 9

Fuel petcock disassembly

............................................^.9

Fuel hose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Front brake

......................................................10

Rear brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

..lO

Wheels and tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10

Drivechain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

11

Front fork oil change

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

.12

Steering head

.....................................................12

Lubrication of cables, pivots, etc. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

....I3

2-5.

ELECTRICAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ... . . . . . . . . . . . . . . . . . . 13

A. Contact breaker point adjustment

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

.13

B.

Contact breaker point maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

C. lgnition timing.............................................................. 14

D. Carbon brushes................................................................ 14

E. Battery.................................................................... 14

F. Sparkplug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..... 15

G.

Headlight.................................................................. 15

-3-

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CHAPTER 2.

PERIODIC INSPECTION AND ADJUSTMENT

2-1. INTRODUCTION

This chapter includes all information necessary to perform recommended inspection and adjustments, These

preventive maintenance procedures, if followed, will insure more reliable vehicle operation and a longer service

life. The need for costly overhaul work will be greatly reduced. This information applies not only to vehicles

already in service, but also to new vehicles that are being prepared for sale. Any service technician performing

preparation work should be familiar with this entire chapter.

2-2. MAINTENANCE INTERVALS CHARTS

The following charts should be considered strictly as a guide to general maintenance and lubrication intervals.

You must take into consideration that weather, terrain, geographical location, and a variety of individual uses

all tend to alter this time schedule. For example, if the motorcycle is continually operated in an area of high

humidity, then all parts must be lubricated much more frequently than shown

caused by water to metal parts,

on the chart to avoid damage

A.PERIODIC MAINTENANCE

Periodic inspection,

adjustment and lubri-

and most efficient condition. Safety is an ob-

cation will keep your motorcycle in the safest

ligation of the motorcycle owner.

Item

Remarks

Unit: km (mi

initial

Thereafter every

400

800

1,600

3,200

1,600

3,200

6,400

( 2 5 0 ) (500) ( 1 , 0 0 0 ) (2.000)

(1,000)

(2.000) ( 4 , 0 0 0 )

Cylinder

1 Check compression

I

!

IOI

I

lo

Valves

1 Check/Adjust valve clearance

I

I

0101

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lo

Cam chain

( Check/Adjust chain tension

I

lo

I

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Spark pluqs

I inspect/Clean or replace as required

loI

:

lo

1

IO

I

Air filter

/ Dry type

- Clean/Replace as required

1

I

:

‘0

I

I

0

;

I

Carburetor

| Check operation/Adjust as required

I

i

0

’

0

10

~

Brake system

Check/Adjust as required

- Repair as

(complete)

required

i

0

0

/Adjust free play

I

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I

0

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I

0

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Wheel and tires

Check pressure/Wear/Balance

0

~

0

0

;

I

0

I

Fuel petcocks

Clean/Flush tank as required

0

0

~

I

0

I

Battery

Top-up/Check specific gravity and

0

~

breather pipe

0

0

1

1

,o

i

0

Ignition timing

| Adjust/Clean or replace parts as required

1

io

o/oj

IO I

Lights/Signals

/ Check operation/Replace as required

/

0

!

0

0

/o/o

I

Fittings/Fasteners | Tighten before each trip and/or

lo

lo~o/olo/

Generator brushes | Check brush wear/Replace if necessary

1

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6. LUBRICATION INTERVALS

,

a_:._

Y-

,-

mission oil

Drive chain

Control/Meter

Apply thoroughly

Oil filter element

Wheel bearings

Do not over/

Medium-weight

12,800

Yearly or . . .

wheel bearing grease

(8.000)

Point cam lubri-

cation wicks

Apply very lightly

Light-weight

machine

oil

0

0

0

0

-5

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2-3. ENGINE

A. Carburetor

1. Idle mixture

The idle mixture is set at the factory by

the use of special equipment. No attempt

should be made to change this adjustment

by the dealer.

1. Do not adjust

2. Throttle

Turn the throttle grip to see if it operates

properly and if the play is normal. Make

certain the throttle snaps closed when

released.

1. 5

- 8 mm

(0.2

- 0.3 in)

3. Synchronization

NOTE:

Ignition timing and valve clearances must

be set properly before synchronizing

carburetors.

Procedure:

a. Turn fuel petcocks to “PRIME”, and

remove the plug screws for the adapter

attachment holes in the carburetor body.

b. Install the attachment and set the vacuum

gauge.

c. Start motorcycle and allow it to warm up

for 2

- 3 minutes. The warm-up is com-

plete when engine responds normally to

throttle opening.

d. Adjust damping valve on each vacuum

e.

f.

gauge until the needle flutters only

slightly. The gauge needles must respond

quickly to rapid opening of the throttle.

Both gauge will indicate the same reading

if the carburetors are synchronized.

Turn the synchronizing screw until the

gauge readings are the same.

1. Synchronizing screw

g. After adjustment, firmly tighten the plug

screws.

NOTE:

Check gasket. Replace if damaged.

4. Idle speed adjustment.

NOTE:

Carburetors must be synchronized before

setting final idle speed.

a. Start the engine and warm it up for a few

minutes.

b. Set the engine idle speed to specified rpm

by turning the throttle stop screw in to

increase the engine speed and back off the

screw to decrease the engine speed.

Use a tachometer for checking and adjust-

ing the engine speed.

I

Standard idle rpm:

1,200 rpm

I

-6-

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1

.Throttle

nap

se-

B. Air filters

This model uses a cartridge type air filter

element which consists of foam rubber.

1. Removal

a. Remove the air filter cover by removing

the bolts.

b. Pull out the springs and elements.

2.

a.

Cleaning method

Tap the element lightly to remove most of

the dust and dirt; then blow out the re-

maining dirt with compressed air through

the inner surface of the element. If

element is damaged, replace.

b. Reassemble by reversing the removal pro-

cedure. Check whether the element is

seated completely against the case.

c. The air filter element should be cleaned

once a month or every 1,600 km(l,000

mi.). It should be cleaned more often if

the machine is operated in extremely

dusty areas.

C. Engine/transmission oil and filter

1. Oil level measurement

a. To check the level, warm the engine up

for several minutes. Stop the engine.

With the engine stopped, screw the dip

stick completely out and then rest the

stick in the hole.

1. Oil

leuel

dip

stick

b.

2.

NOTE:

When checking engine oil level with the

dip stick, position the machine straight up

and on main stand.

The dip stick has a minimum and a maxi-

mum mark. The oil level should be

between the two. If the level is low, add

sufficient oil to raise it to the proper level.

Oil replacement and filter cleaning

a. Start the engine. Allow it to warm up for

2-3 minutes. Stop the engine.

b. Place an oil pan under the engine.

c. Remove the drain plugs and drain the oil.

1.

drain plugs

-7

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d. Remove the filter cover and oil filter

securing bolt.

HA

1. Filter securing bolt.

e. Slip the filter element out and clean.

f. Install the filter and filter cover.

/

Filter torque:

I

1.0 m-ko

f7

f&lb)

g. Reinstall the drain plugs. (Make sure it is

tight.)

/

Drain plug torque:

4.4 m-kg (32 ft-lb)

h. Add oil through the dip stick hole.

r

I

Oil quantity:

2.0 lit (2.1 qt): periodic oil change

2.5 lit (2.6 qt): engine overhauling

Recommended oil:

Yamalube 4-cycle oil or SAE

20W/40 type “SE” motor oil

D. Clutch adjustment

This model has a clutch cable length adjuster

and a clutch mechanism adjuster. Normally,

once the mechanism is properly adjusted, the

only adjustment required is maintenance of

free play at the clutch handle lever.

1. Free play adjustment

Loosen the handle lever adjuster lock nut.

Next, turn the length adjuster either in or

out until proper lever free play is achieved.

2. Mechanism adjustment

a. Screw in the cable adjuster (on the lever

holder) until tight.

b. Screw in the adjuster (push screw) until it

lightly seats against a clutch push rod.

c. Back the adjuster out l/4 turn and

tihgten the lock nut.

d. Adjust the free play of clutch lever by

turning the cable adjuster.

c

1, Adjuster

2. Lock nut

E. Cam chain adjustment

The cam chain becomes stretched with use,

resulting in improper valve timing and engine

noise. To prevent this the cam chain ten-

sioner must be adjusted regularly.

Remove the cap nut.

Turn the adjuster bolt in until the push

rod (inside the adjuster bolt) is flush with

the end of the adjuster bolt.

NOTE:

The push rod will not come out beyond a

certain limit even if the adjuster bolt con-

tinues to be screwed in.

Reinstall the cap nut.

Valve clearance adjustment

NOTE:

Valve clearance must be measured with

the engine at room temperature.

1.

2-3mm

(0.08-0.12inl

2. Lock nut

3. Adjuster

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1.

2.

3.

4.

Remove all four tappet covers and the

generator cover.

Turn the crankshaft to align the rotor

mark with the “T” mark on the stator.

This places the pistons at the top dead

center and the valve clearance should be

checked and adjusted at the top dead

center on the compression stroke by

observing when the valve adjusters have

clearance.

Use a feeler gauge to determine the

clearance.

Exhaust valve clearance (cold):

Intake valve clearance (cold):

5. Loosen the valve adjuster lock nut. Turn

the adjuster in or out to obtain the

correct clearance. Hold the adjuster to

prevent it from moving and throughly

tighten the lock nut.

6.

Recheck the clearance after tightening.

G. Crankcase ventilation system

1. Check ventilation hose for cracks or

damage.

2. Replace it if necessary.

1, Ventilation hose

2. Fuel pipe

H. Exhaust system

1.

Check for leakage from exhaust joints and

retighten joint bolts and nuts.

2.

Replace gaskets if necessary.

2-4. CHASSIS

A. Fuel petcock cleaning

1. Turn the petcock lever to the “ON” or

“RES” position. Remove the fuel pipe.

2.

Remove the drain cover and clean it with

solvent.

1 “RES” position

2. Drain cover

B. Fuel petcock disassembly

If the fuel petcock is leaking or excessively

contaminated, it should be removed from the

fuel tank and inspected.

1.

2.

3.

4.

5.

Remove fuel tank and position it so that

fuel will not spill when the petcock is

removed.

Remove petcock and inspect filter screen.

Clean or replace filter if seriously con-

taminated.

Remove screws on front and rear of pet-

cock and remove plate, gaskets, lever and

diaphragm.

Inspect all components and replace any

that are damaged. If the diaphragm is in

any way damaged, or the petcock body

gasket surfaces scratched or corroded, the

petcock assembly must be replaced. If

there is abrasive damage to any com-

ponent, the fuel tank must be drained and

flushed.

Reassemble petcock and install on fuel

tank.

C. Fuel hose

1.

Check fuel hose for cracks or damage.

2. Replace it if necessary.

-9-

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D. Front brake

The brake can be adjusted by simplay adjust-

ing the distance that the brake lever can

travel. (The piston in the caliper moves for-

ward as the brake pad wears out, automati-

cally adjusting the clearance between the

brake pad and the brake disc.)

1.

a.

Adjustment

Turn adjuster so that a brake lever end is

5

- 8 mm (0.2

- 0.3 in) before adjuster

contacts master cylinder piston.

1.

5-8mmI0.2-0.3inl

2. Lock

nut

3. Adjuster

2. Brake pad check

1, Indicator cap

To check, open the wear indicator cap

and if any pad is worn to the red line, re-

place pads.

3. Check the brake fluid level

Insufficient brake fluid may allow air to

enter the brake system, possibly causing

the brake to become ineffective. Check

the brake fluid level and replenish when

necessary and observe these precautions:

a. Use only the designated quality brake

fluid; otherwise, the rubber seals may de-

teriorate, causing leakage and poor brake

performance.

Refill with the same type and brand of

brake fluid; mixing fluids may result in a

harmful chemical reaction and lead to

poor performance.

Be careful that water or other contamina-

tion does not enter the master cylinder

when refilling. Water will significantly

lower the boiling point and may result in

vapor lock.

E. Rear brake

1. Adjust rear brake pedal play to suit, pro-

viding a minimum of 20

- 30 mm (0.8

-

1.2 in) freeplay. Turn the adjuster on the

rear brake rod in or out until brake pedal

free play is suitable.

NOTE:

Rear brake pedal adjustment must be

checked anytime chain is adjusted or rear

wheel is removed and then reinstalled.

1. Adjuster

F. Wheels and tires

1.

a.

2.

a.

Recommended brake fluid:

DOT No. 3 Brake fluid

Wheels

Check each spoke for tightness.

NOTE:

If loose spokes are found, tighten and

repeat rim runout check.

Tires

Important notice

Proper loading of

XS650E is important

for the handling, braking, and other

performance and safety characteristics.

NEVER OVERLOAD THE M O T O R -

CYCLE.

WARNING: Never overload the motor-

cycle beyond specified tire limits. Opera-

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FRONT

REAR

XS650E BASIC

WEIGHT with oil

104

kg@29

lb) 119

kg1262

lb)

md full fuel tank

Standard tire

Bridgestone or Bridgestone or

Yokohama

Yokohama

3.50H19-4PR

4.OOHlB-lPR

Tire load limit

234 kg

(515

lb) 280 kg (615 lb]

Cold tire pressure

Normal riding

1.6

kg/cm’

2.0

kg/cm2

(22 psi)

(28 psi)

With passenger 2.0

kg/cm2

2.3

kg/cm’

or high speed

riding

(28 psi)

(32 psi)

With passenger 2.8

kg/cm2

2.8

kg/cm2

$$xtra

load

(40 psi)

(40 psi)

Vlinimum tire

0.8 mm

0.8 mm

:read depth

(0.03 in)

(0.03 in)

Make sure the total weight of the motorcycle with

accessories, rider(s) etc., does not exceed the tire

limits.

b. Check the tire wear

If a tire tread shows cross wise lines, it

means that the tire is worn to its limit.

Replace the tire.

c. Check the wheel damage and check the

tightness of spokes.

G. Drive chain

1. Tension check

a. Inspect the drive chain with mainstand

erected. Check the tension at the position

shown in the illustration. The normal ver-

tical deflection is approximately 20 mm

(3/4 in).

20 mm (3/4 in)

2. Tension adjustment

a. Loosen the rear brake adjuster.

b. Remove the cotter pin of the rear wheel

axle nut.

c. Loosen the rear wheel axle nut.

d. Loosen the adjuster lock nuts on each

side.

e. To tighten chain turn chain puller ad-

juster clockwise.

Turn each bolt 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.

1. Alignment marks

2. Rear axle nut

3. Adjuster

4. Lock nut

5. Cotter pin

f. After adjusting be sure to tighten the lock

nuts and the rear wheel axle nut.

g. Install a new cotter pin and bend the end

over.

h. In the final step, adjust the play in the

3.

a.

brake pedal and stoplight switch free play.

Lubrication

First, remove dirt and mud from the chain

with a brush or cloth and then spray the

lubricant between both rows of side plates

and on all center rollers.

-,I

-

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