YAMAHA XS750 XS850 Service Repair Manual

SPECI F ICAT IONS A. GENERAL SPECIFICATIONS Basic color Dimensions: Overall length Overal I width Overall height Seat height Wheelbase Minimum ground clearance Caster (steering head angle) TraiI Weight: Net Engine: Type Bore x stroke x cylinders Displacement Compression ratio Compression pressure (warm engine) Lubr i cation : Lubrication system Delivery pump type Carburetion: Manufacture Type, I.D. No., Quantity Rated venturi size Air filter Ignition: Type Spark plug Charging Type Manufacture, I.D. No. Maximum output Battery type Battery dimensions Regulator Rectifier Starting Primary drive Type Teeth, ratio Clutch Crystal Silver 2180mm (85.8 in.) 835mm (32.9 in.) 1150mm (45.3 in.) 810mm (31.9 in.) 1465mm (57.7 in.) 145mm (5.7 in.) 27° 110mm (4.3 in.) 229 kg (505 Ibs.) ________~~ D.O.H.C., air-cooled, triple 68mm x 68.6mm x 3 747cc 8.5: 1 142 Ibs in² (±14 Ibs in²) Pressure lubricated, wet sump Trocoid Mikuni BS34, constant velocity, 1J701, 3 pcs. 34mm Dry foam rubber Battery/coi I NGK BP-7ES, Champion N-7Y Three- phase, regulated alternator Hitachi LD120-02 14.5 Volt/l8 amp 12 volt 14amp-hour 134 x 166 x 89mm Hitachi TL1Z-80 Stanley DE-4404, Silicon, full wave Transmission coupled kick Mitsuba Electric SM-224C Hy-Vo silent chain 45/27 1.666 Wet, multiple disc.

Transmission: Teeth, ratio, overall 1st 2nd 3rd 4th 5th Secondary Drive: Transmission 0utput : Type, teeth, ratio Middle gear case Type, teeth, ratio Final gear case Type, teeth, ratio Chassis: Frame Suspension: Front (type, travel) Rear (type, travel) Front Rear Brakes: Front Rear Fuel tank Wheels: Front Rear Tires: Constant mesh, 5- speed, drum shifter 32/13 2.461 13.285 27/17 1.588 8.636 26/20 1.300 7.069 1 1.095 5.955 22/23 0.956 5.201 Shaft drive Spur gear, 34/32, 1.063 Bevel gear, 19/18, 1.056 Bevel gear, 32/11, 2.909 Tubular steel double cradle Telescopic fork, 175mm (6.9 in.) Swing arm, 75mm (3.0 in.) 3.25 H 19 Bridgestone 4.00 H 18 Bridgestone Dual hydraulic disc Single hydraulic disc US gal.) Regular leaded or unleaded 1.85 x 19 Cast Aluminum 2.15 x 18 Cast Aluminum B. MAINTENANCE SPECIFICATIONS 1. Engine Engine Oil Capacity Oil and filter change Oil change R ecommended Iubricant : If temperature does not go below If temperature does not go above (3.7 (3.4 US qt.) (3.0 US qt.) SAE SE motor oil SAE SE motor oil

Middle gear case capacity: Final Gear case capacity Recommended I ubr i cant If temperature does not go below 5°C (40°F) If temperature does not go above A I I weather 15°C (60°F) A Exhaust B C 375cc ( 13 oz.) 300cc (100 oz.) SAE 90 Hypoid gear oil, G L -4 SAE 80 Hypoid gear oil, GL - 4 SAE 80W90 Hypoid gear oil, GL- 4 8.018mmm ------------- 28.285 ±0.05mm 28.13mm 36.303 ± 0.05mm 36.15mm Cranking pressure (at sea level) Maximum difference between cylinders Free length 10 ± 1 kg/cm² (142 ± 14 psi) 1 .0 kg/cm² (14 psi) INTAKE/EXHAUST 35.6mm Camshafts I Wire diameter Number of windings 2.8mm 7.75 Valve stem run- out maximum Valve seat width standard/maximum .03mm (.0012 in.) 1.3mm (.050 in.) / 2.0mm (.080 in.) Wear I imit Camshaft bearing surface diameter 24.97~24.98mm (0.9830~0.9835 in.) Camshaft-to-cap clearance : Standard Maximum Camshaft runout limit .020~.054mm (.0008~.002 in.) .160mm (.006in.) 0.1mm (.004 in) I Valves I INNER OUTER INTAKE/EXHAUST 39.9mm ALLOWABLE TILT FROM VERTICAL OUTER I OUTER Spring rate (kg/mm) K1 1.84 K2 2.36 K1 3.32 K2 4.18 Installed length (valve closed) Installed pressure (valve closed) 34.5mm 31.5mm 1 7.5 ± 0.75kg 17.5 ± 1.2kg Compressed length (valve open) 23.0mm 26.0mm 3.9mm 6.4 INTAKE EXHAUST DIRECTION OF WINDINGS (TOP TO BOTTOM) Winding O.D. 15+ 0.3mm 0 21.6 0 - 0.3mm I I 1

"B" "C" seat width "D" margin thickness Stem diameter (O.D.) Guide diameter (I.D.) CI earance (Cold engine) " A" head diameter 0.1 6~ 0.20m m 36 + 0.2 1.3 ±0.15mm 1.2 ± 0.2mm 7 + .010mm -.025mm 7 + .019mm -.010mm I "B" face width 2.26 ± 0.57mm " B" face width "C" seat width "D" margin thickness Stem diameter (O.D.) 2.26 ± 0.57mm 1.3 ± 0.15mm 1.2 ± 0.2mm 7 +.025mm -.040 mm I Stem-to-guide clearance I 0.020~0.041mm I EXHAUST CIea rance (Cold engine) 0.2 1 ~0.25mm " A" head diameter 31 + 0.2mm Guide diameter (I.D.) 7 + .019mm St em-t o-guide clearance 0.035~0.059mm Cylinder and Piston Cylinder material Cylinder liner Standard bore sizehtandard Cylindertaper limit Cylinder out- of-round limit Piston clearancehtandard maximum maximum Piston Rings Design End gap (installed) Side clearance Aluminum Pressed in; special cast iron 68.00~68.02mm / (2.677~2.678 in.) 68.10mm (2.681) 0.05mm (.002 in.) 0.01mm (.0004 in.) 0.050~0.055mm / (.0020~.0022 in.) 0.1mm (.004 in.) Oil 0.04-0.08mm 0.03-0.07mm -0.4mm -0.4mm 0.2~0.9mm

Crankshaft and Connecting Rods: Main bearing oil clearance Rod bearing oil clearance Main journal run-out (maximun) Oil Pump Housing-to-outer rotor clearance Outer rotor-to-inner rotor clearance Clutch Friction plate thickness standard minimum Clutch plate warp maximum Clutch spring length standard minimum Clutch push rod run-out maximum Clutch lever freeplay (endof lever) Transmission shaft run-out maximum Middle gear case lash 0.022~0.044mm (.0009~.0017 in.) 0.032~0.054mm (.0013~.0021 in.) 0.03mm (.0012 in.) ,090~.015mm (.0035~.0059 in.) .03 ~.09mm (.0011~.0035 in.) 3.0mm (0.12 in.) 2.8mm (0.11 in.) 0.05mm (.002 in) 42.8mm (1.685 in.) 41.5mm (1.634 in.) 0.4mm (.016in.) 13~26mm (0.5~1.0 in) .08mm (.001 in.) 0.1 ~0.2mm (.004~.008 in.) 2. Carburetion I Manufacturer Model, I. D. No. Main jet Needle jet Pilot jet Starter jet Jet needles / Clip position Mikuni BS34,1J701 No. 145 Y-2 No. 17.5 No. 45 4H11/3 Float level Pilot screw Air jet, Main Air jet, Pilot Throttle valve Inlet valve size Engine idle speed 26.5 ±2.5mm (from gasket surf 2¼ turns 1 .0mm 1.6mm No. 140 2.0mm 1050 ~ 1150 r.p.m.

3. Chassis Ignition timing retarded adva nced advance starts Wheels and Tires Rim run-out, vertical Rim run-out, horizontal Tire pressure, front, normal riding High speed or with passenger Tire pressure, rear, normal riding High speed or with passenger Brakes Recommendedfluid Pad thickness wear limit Brake disc maximum deflection Brake disc minimum thickness Front brake freeplay (end of lever) Rear brake freeplay (end of pedal) Minimum boiling point 10° @ 1100 rpm 38.5° ± 1.5°@ 2,900 rpm 1550 + 200 rpm 0 Front forks Spring (upper) free length Spring (lower) free length Spring rate (0 ~100 mm travel) Fork oil capacity (each side) preload length preload length (100~175mm travel) Rear shock absorbers Spring free length Spring preload length Spring rate (0~45mm travel) (45~75mm travel) 2.0mm (.080 in.) l.0mm (.040 in.) 1.8 (26 p.s.i.) 2.0 kg/cm2 (28 p.s.i.) 2.0 kg/cm2 (28 p.s.i.) 2.3 kg/cm2 (33 p.s.i.) DOT No. 3 240°C (464°F) 5.5mm (0.18 in.) 0.15mm (.006 in.) 6.5mm (0.26 in.) 5.0~10.0mm (0.2~0.4 in.) 5.0~10.0mm (0.2~0.4 in.) 55.8mm (2.2 in.) 50.8mm (2.0 in.) 448.3mm (17.65 in.) 423.3mm (16.67 in.) 0.5 kg/mm (28 Ibs/in.) 0.6 kg/mm (33.6 Ibs./in.) 170cc (5.75 US fl. oz.) 253mm (9.95 in.) 228 mm (9.0 in.) 1.9 kg/mm (106 Ibs./in.) 2.6 kg/mm (145 Ibs./in.) Spark plug Electrode gap NGK BP-7ES or Champion N-7Y 0.7~ 0.8mm (.028~.032 in) Spark plug cap resistance I 5.0 K ohms Contact point gap Spring tension 0.3~0.4mm (.012 ~.016 in) 750 ± 1 00g (26.5 ± 3.5 oz) Condenser capacity Insulation resistance 0.22μF ± 10% 10 M ohms or more Ignition coil type Spark gap 6V 12V Primary resistance (20°C) Secondary resistance (20°C) Hitach i CM11-52A 6mm @ 100 rpm 7mm @ 5,000 rpm 4.0 ± 0.4 ohms 11.0 ± 1.1K ohms

Starter motor type Armature coil resistance (2O°C) Field coil resistance (2O°C) Brush length standard minimum Brush spring pressure Armature mica undercut Battery type Charging rate Generator type No load voltage Field (inner) coil resistance(20°C) Stator (outer) coil resistance (20°C) Regulator type Regulated vo I t age Core gap Yoke gap Point gap Starter relay switch Cut-in voltage Winding resistance (20°C) Lighting Headlight Ta iIIight/stopI ight License light Flasher Iight Flasher pilot light Meter Iights High beam indicator light Oil pressure warning light Neutral light Mitsuba SM-224C 0.007 ohms 0.01 ohms 12.5mm (0.5 in) 5.5mm (0.22 in) 620 ± 60g (22.0 ± 2.0 oz) 0.5 ~ 0.8mm (0.02 ~ 0.03 in) Yuasa YB 14L 1.4 amps for 10 hours Hitachi Ld 120-02 14.5 ± 0.5V 0.48 ± 0.05 ohms 4.04 ± 0.4 ohms Hitachi TLIZ - 80 14.5 ± 0.5V 0.6 ~ 1 .0mm (.024 ~.040 in) 0.9mm (.035 in) 0.3 ~ 0.4mm (.012 ~.016 in) Hitachi A104-70 6.5 V 3.5 ohms Sealed beam 12V50/40W 12V 8/27W (two bulbs) 12V 27W (four bulbs) 12V 3.4W (two bulbs) 12V 3.4W (two bulbs) 12v 3.4w 12v 3.4w 12v 3.4w 12v 8W

C. Torque Specifications Spark plug Cam cap nut Rod cap Starter clutch bolt I Engine 1.5 ~ 2.5 m-kg (11.0 ~18.0 ft-lbs.) 0.8 ~ 1 .O m-kg (6.0 ~ 7.0 ft-lbs.) 3.8 m-kg (27 ft-lbs.) 2.8 ~ 3.2 m-kg (20 ~ 23 ft-lbs.) Shift cam locating bolt Detent assembly 1.3 ~ 2.1 m-kg (9 ~ 15 ft-lbs.) 4.0 ~ 4.5 m-kg (29 ~ 32 ft-lbs.) Transmission bearing caps Crankcase bolts 8mm 1.8 ~ 2.2 m-kg (13 ~ 16 ft-lbs.) 2.0 rn-kg (14 ft-lbs.) 1 0mm Clutch holding nut Clutch spring screws 3.7 m-kg (27 ft -lbs.) 8 m-kg (58 ft-lbs) 0.8 ~ 1.O m-kg (6.0 ~ 7.0 ft-lbs.) Middle gear case mounting screws Rotor holding bolt 2.0 ~ 2.5 m-kg (14 ~ 18 ft -lbs.) 3.0 ~ 4.0 m-kg (22 ~ 29 ft-lbs.) Bearing housing bolt Oil pipe union bolt 12mm I 8.0 ~ 11.0 m-kg (58 ~ 80 ft-lbs.) 2.0 ~ 2.4 m-kg (14 ~ 17 ft-lbs.) 2.0 ~ 2.2 m-kg (14 ~ 16 ft-lbs.) Oil pump drive gear nut Crankshaft turning nut Cylinder head 8mm 8.0 ~ 12.0 m-kg (58 ~ 87 ft-lbs.) 1.5 ~ 2.9 m-kg (11 ~ 21 ft-lbs.) 2.0 m-kg (14 ft-lbs.) I 1 1 0mm Cylinder holding nuts 3.5 m-kg (25 ft -lbs.) 2.0 m-kg (14 ft-lbs.) Camshaft cap nuts Engine mounting bolts 10mm 1 .O m-kg (7 ft-lbs.) 5.0 ~ 6.0 m-kg (36 ~ 43 ft-lbs.) Engine oil drain plug Oil filter mounting bolt Middle gear drain plug Front axle nut Front axle holder nuts Rear axle nut Rear axle pinch bolt Chassis 3.9 ~ 4.7 m-kg (28 ~ 34 ft-lbs.) 3.0 ~ 3.4 m-kg (22 ~ 25 ft-lbs.) 3.9 ~ 4.7 m-kg (28 ~ 34 ft-lbs.) 7.0 ~ 10.0 m-kg (50 ~ 72 ft-lbs.) 1.3 ~ 2.3 m-kg (9 ~ 17 ft-lbs.) 12.0 ~ 18.0 m-kg (87 ~ 130 ft-lbs.) 0.45 ~ 0.75 m-kg (3.0 ~ 5.0 ft-lbs.) Brakes Caliper support bolt Caliper mounting bolt Brake hose union bolt Disc mounting bolt Front fork pinch bolt Steering stem top bolt Swing arm pivot lock nut Rear shock absorber nut 1.5 ~ 2.0 m-kg (11 ~ 15 ft-lbs.) 4.5 ~ 5.0 m-kg (28 ~ 35 ft-lbs.) 2.3 ~ 2.8 m-kg (16 ~ 20 ft-lbs.) 1.7 ~ 2.2 m-kg (12 ~ 16 ft-lbs.) 1.3 ~ 2.3 m-kg (9 ~ 17 ft-lbs.) 6.6 ~ 10.5 m-kg (48 ~ 76 ft-lbs.) 8.0 ~ 10.0 m-kg (58 ~ 72 ft-lbs.) 2.3 ~ 3.7 m-kg (20 ~ 27 ft-lbs.)

Components should be room temperature. 500 - 600

YAMAHA XS750 XS850 Service Repair Manual

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