Yamaha XS650G 1978, Supplementary Service Manual

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Page 2: ...combined with previous service manuals to provide complete service information for XS650H SH Please read and give special consideration to the NOTICE on the preceding page for your safety XS650H SH SUPPLEMENT XS650 MODELS 1978 80 ...

Page 3: ...nd repairs on Yamaha motorcycles have a basic understanding of the mechanical concepts and procedures inherent to motorcycle repair technology Without such know ledge attempted repairs or service to this model may render it unfit for use and or unsafe This model has been designed and manufactured to perform within certain specifications in regard to performance and emissions Proper service with th...

Page 4: ...s easier or clearer CAUTION A CAUTION indicates special procedure that must be fol lowed to avoid damage to the motorcycle WARNING A WARNING indicates special procedures that must be fol lowed to avoid injury to a motorcycle operator or person inspecting or repairing the motorcycle Starting Serial Number XS650H H 4N9 000101 XS650SH H __ 4M4 000101 ...

Page 5: ...MAINTENANCE AND LUBRICATION CHART PERIODIC MAINTENANCE EMISSION CONTROL SYSTEM 3 ...

Page 6: ...t c c ...

Page 7: ...up coil securing screws and remove the pick up coil assembly Pick up coil assembly reinstallation Install the pick up coil assembly on to the stator assembly _ L 4 Specified engine speed 1 200 r min The rotor pointer should be within the limits of fl on the timing plate If it exceeds the limits or does not steady check the timing plate for tight ness and or ignition system for damage NOTE Ignition...

Page 8: ...ck the fuel level one by one The level should be in the specified range Fuel level 1 f 1 mm 0 04 0 04 in above from the carburetor mixing chamber body edge YL___ A 6 If the fuel level is incorrect remove the carburetor assembly from the motor cycle and check the fuel valve s and float assembly s for damage 7 If no damage is found correct the fuel level by slightly bending the float arm tang Rechec...

Page 9: ...en the stick in the hole NOTE Wait a few minutes until the oil level settles before checking When checking engine oil level with the dip stick let the unscrewed dip stick rest on the case threads 1 Dip stick 2 Maximum level 3 Minimum level 3 The oil level should be between maxi mum and minimum levels If the level is lower add sufficient oil to raise it to the proper level l ...

Page 10: ...correctly installed with rounded end in direction of chain travel b Make sure the axle nut is properly torqued and a new cotter pin is installed 15 0 m kg 108 5 ft lb c Adjust the drive chain 8 DRIVE CHAIN 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 wit...

Page 11: ...otter pin if the nut notch and the cotter pin hole do not match tighten the nut 1 slightly to match C A U T I O N Excessive chain tension will overload the engine and other vital parts keep the ten sion within the specified limits Also replace the rear axle cotter pin with a new one 7 In the final step adjust the play in the brake pedal D REAR BRAKE ADJUSTMENT 1 a b C Pedal height Loosen the adjus...

Page 12: ...NG INSPECTION The specified thickness of the brake lining is 4 mm 0 16 in The lining should be replaced when it wears to less than 2 mm 0 079 in To check see the wear indicator position while depressing the brake pedal ...

Page 13: ... G Green B Black Br brown Sb B blue R W Red White B Y Black Yeliow L B Blue Black Function of the Diode in the Relay When the transmission is in a position other than Neutral Turning on the clutch lever switch Clutch is disengaged by pulling the clutch lever makes the safety relay to turn on In this case the diode interrupts the flow of current from the main switch to the neutral indicator light a...

Page 14: ...t off is kept open the relay is not actuated and it is impossible to turn on the starter switch assembly by pushing the START button As a result the starter motor does not run c When the clutch lever is disengaged by pulling in the clutch lever while the transmission is in a position other than neutral Neutral switch OFF Clutch lever switch ON Since the clutch lever switch is on while the neutral ...

Page 15: ...2 500 mm 198 4 in B Engine L 1 DESCRIPTION 1 Engine type 2 Engine model 3 Displacement 4 Bore x stroke 5 Compression ratio 6 Starting system 7 Ignition System 8 Lubrication system 2 CYLINDER HEAD 1 Combustion chamber volume with N 7Y Air cooled 4 stroke SOHC twin parallel forward incline 4M4 4N9 653 cc 39 85 cu inl 75 x 74 mm 2 953 x 2 913 in 8 7 1 Kick and electric starter Battery ignition Full t...

Page 16: ... 5mm 0 059 in 2 mm IO 110 inl 0 4 mm 0 008 0 016 in 3 Ring groove side clearance Top 6 BIG END BEARING 11 Type 31 Bearing type 4 Cam dimensions 25 47 8 6 Camshaft deflection limit 7 Cam chain Type Number of links Sprocket ratio 8 ROCKER ARM AND ROCKET SHAFT i 0 03 mm 0 0012 in TSUBAKIMOTO BF05M i 106L 36 18 2 0 0 0 1 Rocker arm inner diameter 15 0 y8 mm 0 591 oW7 in 2 Rocker arm shaft diameter 15 ...

Page 17: ... in EX 2 1 mm 0 083 in x B IN 1 3 mm 0 051 in D IN 8 0_g o 5 mm 0 315_ 0 in EX 8 0 42 mm 10 315I in IN E O mm 0 315 z gi in EX S O mm 0 315 z Ez in IN O OlO 0 034 mm 0 00079 0 00173 in EX 0 035 0 059 mm 10 00138 0 00232 in IN EX 0 03 mm 10 0012 in or less INNER IN EX 42 mm 1 654 in OUTER IN EX 42 55 mm 1 675 in INNER IN EX kl 1 43 kg mm 180 1 lb in kz 1 81 kg mm 1101 4 lb in OUTER IN EX kl 3 2 kg ...

Page 18: ...lQuantitv Warp limit 7 Clutch spring Free length Quantity 8 Clutch housing radial plav 9 Push rod bending limit 5 TRANSMISSION 11 Tvoe 0 05 mm 0 002 in 0 15 0 4 mm 0 0059 0 0157 in 66 0 05 mm 2 598 in 0 10 166_ 3 mm 17 323_ o 2 in 26I j m m 1 024 in 26 06 x 65 mm 34 t016 mm 1 339 0006 in 20 85 mm 10 787 o in 030 78 9 Ball bearing 032 068 17 Rollar bearing SD 25 40 9 Wet multiple type Inner push ty...

Page 19: ... Needle jet 7 Throttle valve 8 Pilot jet 9l Pilot screw Turns out 101 starter jet 11 I Fuel level 12 Idling engine speed 20 LUBRICATION 1 Engine sump oil quantity 2 Oil type and grade 31 Oil pump type 4 Trochoid pump specifications Top clearance Tip clearance Side clearance Oil pump volume 5 Bypass valve setting pressure M J 1 1A J l J N N J Th V P J 1 P S 1 IG S F L Cam drum return type SDO 14 24...

Page 20: ...oil quantity and type Double cradle high tensile frame 27O 115 mm 4 53 in 19 pcs l 4 in 19 pcs l 4 in 42 each L and R Telescopic fork Oil damper coil spring 482 mm 18 99 in 4 x 24 5 mm IO 157 x 0 965 in kl 0 48 kg mm 126 88 Iblinll 0 100 mm 0 3 94 in k2 0 65 kg mm 136 40 lb in loo 150 mm 3 94 5 91 in 150 mm 5 906 in 35 mm 1 378 in 169 cc 5 72 oz each leg Yamaha fork oil 1Owt or equivalent Approx 4...

Page 21: ...g 198 Ibl load Front 1 6 kg cm 122 psi Rear 2 0 kg cm2 I28 psi1 90 kg 198 lb load 206 kg 453 lb load Front 2 0 kg cm2 28 psi Maximum load Rear 2 3 kg cm 32 psi High speed riding Front 2 0 kg cm I28 psi Rear 2 3 kg cm I32 psi 4 Rim run out limit Front and rear Vertical 2 mm 0 08 in Lateral 2 mm 0 08 in 5 Rim Size Front MT1 85 x 19 1 85 x 19 Rear MT3 00 x 16 2 75 x 16 6 Bearing type Front wheel t Le...

Page 22: ...nk rod 180 mm 7 09 ini 180 Y 30 mm 17 09 x 1 18 in 4 mm12 mm IO 16 1nI0 08 in 68 mm 2 68 inl D Electrical 1 IGNITION SYSTEM 1 Ignition timing B T D C 2 Ignition coil Model Manufacturer Spark gap Primary winding resistance Secondary winding resistance 3 Spark plug Type Spark plug gap 15 1 200 rimin 0 I 2 3 tnqine roeed x 101 r m n CM12 OS HITACHI 6 mm 0 24 in or more at 500 rimin 2 5a 10 at 20 C 68...

Page 23: ... 30 in 30 mm Il 18 in Mica undercut 0 7 mm 10 028 inl 21 Starter switch Manufacturer HITACHI Model A10470 Amperage rating 1OOA Cut in voltage 6 5V Winding resistance 3 5R 3 Starter clip friction tension 2 2 2 5kg 4 9 5 5lbl LIGHTING SYSTEM 1 Headlight type Sealed beam 2 Bulb brightness and wattage Quantity Headlight 12v 5014ow x 1 PC Tail Brake light 12V 3132 CP 18W 27W x 2 PCS Flasher light 12V 3...

Page 24: ...frequency Capacity 6 Flasher cancelling unit Model Voltage 7 Fuse Rating Quantity Main Headlight Signal Ignition Condenser type 061300 04810 NIPPON DENS0 85 t 10 cycle min 32 CP 27W x 2 3 4w EVH AC518 DC9V 16V 20A x 1 pc 10A x 1 pc 10Ax1pc 10A x 1 pc ...

Page 25: ... m kg 6 5 ft lb 6 mm crown nut 0 9 m kg 6 5 ft lb 8 mm crown nut 1 3 m kg 9 5 ft lb 14 mm 2 0 m kg 14 5 ft lb 12mm nut 3 8 m kg 27 5 ft lb 6 mm pan head screw 0 9 m kg 6 5 ft lb 6 mm bolt 0 8 m kg 6 0 ft lb 8 mm nut 2 7 m kg 19 5 ft lb 18 mm cap 2 1 m kg 15 0 ft lb 6 mm pan head screw 1 0 m kg 7 2 ft lb 6 mm bolt 1 0 m kg 7 2 ft lb 30 mm bolt 4 2 m kg 30 5 ft lb 6 mm bolt 0 9 m kg I 6 5 ft lb 10 m...

Page 26: ...ar shock absorber Lower 10 mm bolt Rear arm and rear arm end 8 mm bolt Front fender 8 mm bolt Neutral switch I 12mm 3 0 m kg 21 5 ft lb 3 9 m kg 28 0 ft lb 1 0 m kg 7 2 ft lb 1 0 m kg 7 2 ft lb 1 3 m kg 9 5 ft lb General Torque Specifications tighten multi fastener assemblies in a criss This chart specifies torque for standard cross fashion in progressive stages until full fasteners with standard ...

Page 27: ...fcm3 0 4732 lit liter 0 9461 lit liter 3 785 lit tlrter 0 017855 kg mm 0 07031 kg cm2 5 91OF 32 Centrgrade C INCH TO METRIC SYSTEM I ft lb in lb ft lb in lb mpg mph mi ft Yd in 02 US liq cu in pt US liq qt US liq gal US liq lb in psi tIb in2 1 Fahrenheit OF m kg g kg lit km lit cc kg mm kg cm2 Meter kilogram s usually torque Gram s Kilogram s 1 000 grams liter s Kilometer s per liter fuel consumpt...

Page 28: ...imiting speed of 35 mph This high speed pass assumes an initial speed of 50 mph and a limiting speed of 80 mph LOW SPEED PASS HIGH SPEED PASS T INITIAL SPEED 20 MPH LIMITING SPEED 35 MPH t TOTAL PASSING DISTANCE FEET TOTAL PASSING TIME SECONDS 1 d _ __ l 4 l 4 40ft djj_ _ a40ft 55 ft CONSTANT 20 MPH TRUCK INITIAL SPEED 50 MPH LIMITING SPEED 80 MPH I TOTAL PASSING DISTANCE FEET TOTAL PASSING TIME S...

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