1985 Yamaha XS650 Service & Repair Manual

INDEX This manual has been 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

FOREWORD This Supplementary Service Manual has been prepared to introduce new service and new data for the XS650H/XS650SH. For complete information on service procedure, it is necessary to use this Supplementary Service Manual together with following manuals: ’ XS650E Service Manual (LIT-11616-00-76) I ! ’ XS650SE Supplementary Service Manual (LIT-11616-01-08) XS650SF/2F Supplementary Service Manual (LIT-11616-01-65) 1 XS650G/SG Supplementary Service Manual (LIT-1 1616-01-75) SERVICE DEPT. INTERNATIONAL DIVISION YAMAHA MOTOR CO., LTD. NOTE: This Supplementary Service Manual contains information regarding periodic maintenance to the emission control system for the XS650H/XS650SH. Please read this material carefully. NOTICE This manual was written by the Yamaha Motor Company primarily for use by Yamaha dealers and their qualified mechanics. It is not possible to put an entire mechanic’s education into one manual, so it is assumed that persons using this book to perform maintenance and 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 the correct tools is necessary to ensure that the motorcycle will operate as designed. If there is any question about a service procedure it is imperative that you contact a Yamaha dealer before continuing. Before attempting any service, check with your Yamaha dealer for any service information changes that apply to this model: This policy is intended to provide the customer with the most satisfaction from his motorcycle and to conform with federal environmental quality objectives. Yamaha Motor Company, Ltd. is continually striving to further improve all models manufactured by Yamaha. Modifications and significant changes in specifications or procedures will be forwarded to all Authorized Yamaha dealers and will, where applicable, appear in future editions of this manual. I -

Particularly important information is distinguished in this manual by the following notations: NOTE : A NOTE provides key information to make procedures 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

MAINTENANCE AND LUBRICATION CHART PERIODIC MAINTENANCE EMISSION CONTROL SYSTEM -3

*ENGINE A. IGNITION TIMING The ignition system is modified for easier maintenance. Thus, the following “ignition timing check” should be changed, Ignition timing check 1. Ignition timing is checked with a timing light by observing the position of the rotor pointer and the marks stamped on the timing plate. The timing plate is marked as follows. “ll” Firing range for No. 1 (L.H.) “T” Top Dead Center for No. 1, fL.H.1 cylinder 2. Connect the timing light to the left cylinder spark plug lead wire. 3. Start the engine and keep the engine speed as specified. Use a tachometer to check the engine speed. B. PICK-UP COIL ASSEMBLY The method of mounting the pick-up coil assembly is changed for easier service work. Thus, the followings “Pick-up coil assembly removal” and “Pick-up coil assembly reinstallation” should be changed. Pick-up coil assembly removal Remove the pick-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 timing is not adjustable. C. FUEL LEVEL The carburetor is furnished with a drain screw to provide easy access to service work. Thus, the following “Fuel level measurement” should be added. Fuel level measurement NOTE: Before checking the fuel level, note the following: 1. Place the motorcycle on a level surface. 2. Adjust the motorcycle position by plac- ing a suitable stand or a garage jack under the engine so that the carburetor is positioned vertically. 1. 2. Connect the level gauge (special tool) or a vinyl pipe of 6 mm (0.24 in) in inside diameter to the float bowl nozzle left or right side carburetor. Set the gauge as shown and loosen the drain screw. -5

3. Start the engine and stop it after a few minutes of run. This procedure is necessary to obtain the correct fuel level. NOTE: Make sure the fuel petcock is “ON” or “RES” oosition. 4. Note the fuel level and bring the gauge to the other end of the carburetor line and repeat step 3 above. Note the fuel level again and compare it with the previous gauge reading. They should be equal. If not, place a suitable size of wooden piece or the. alike under the center stand and adjust. 5. Check 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 motorcycle 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. Recheck the fuel level. D. ENGINE OIL LEVEL MEASUREMENT 1. Place the motorcycle on the center stand. Warm up the engine for several minutes. NOTE: Be sure the motorcycle is positioned straight up when checking the oil level; a slight tilt toward the side can produce false readings. -6- Y

2 With the engine stopped, check the oil level through the level window located at the lower part of the right side crankcase cover, or screw the dip stick completely out and then 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 maximum and minimum levels. If the level is lower, add sufficient oil to raise it to the proper level. l-

*CHASSIS A. REAR WHEEL REMOVAL 1. Place the motorcycle on the center stand. 2. Remove the tension bar and the brake rod from the brake shoe plate. The tension bar can be removed by removing the cotter pin and nut from the tension bar bolt. The brake rod can be removed by removing the adjuster. 1. Adjusfer 2. Brake rod 3. Tenrio” bar 3. Disconnect the drive chain. 4. Loosen the chain tension adjusting nuts and bolts on both sides. 5. Remove the axle nut cotter pin and axle nut. Discard the old pin. 6. 7. a. Remove the axle shaft and the wheel. For reassembly, follow the procedure below with care: Make sure the drive chain master link is 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 with rear wheel in this “tight chain” position. Inspect the drive chain with the center stand put up. Check the tension at the position shown in the illustration. The normal vertical 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. C. DRIVE CHAIN TENSION ADJUSTMENT 1. Loosen the rear brake adjuster. 2. Remove the cotter pin of the rear wheel axle nut with pliers.

1985 Yamaha XS650 Service & Repair Manual

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