Yamaha XS650SE Installationsanleitung

XS650E

INDEX

GENERAL

INFORMATION

PERIODIC INSPECTION

AND ADJUSTMENT

ENGINE OVERHAUL

CARBURETION

CHASSIS

ELECTRICAL

APPENDICES

XS650SE

SUPPLEMENT

(EPA)

XS650E

SUPPLEMENT

*XS650SF USES THIS SUPPLEMENT (EPA)

XS650SE

SUPPLEMENT

XS650SF/2F

SUPPLEMENT

XS650G/SG

SUPPLEMENT

CHAPTER 1. GENERAL INFORMATION

l-l. MACHINE IDENTIFICATION ...............

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

l-2. SPECIAL TOOLS ..................................................... .

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)

2. Valve spring compressor

(90890-01253)

3. Valve guide reamer

(90890-01211)

Valve seat cutter set

5. Piston ring compressors 6. Piston support plate

(90890-01179) (90890-01066) (90890-01067)

7. Rotor puller

(90890-01070)

10. Drive chain cutter 11. Pocket tester

(90890-01081) (90890-03096)

13. Vacuum gauge

(90890-03094)

8. Clutch holding tool

(90890-01069)

9. Slide hammer

(90890~;z)

12. E lectro tester

(9089@0302

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-

CHAPTER 2.

PERIODIC INSPECTION AND ADJUSTMENT

2-1.

INTRODUCTION

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

2-2.

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

A. PEPIODIC MAINTENANCE

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

B. LUBRICATION INTERVALS

....

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

2-3.

ENGINE

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

......6

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

Air filten ........................................................

Engine/Transmission oil and filter

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

D. Clutch adjustment

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

Cam chain adjustment

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

F. Valve clearance adjustment

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

G. Crankcase ventilation system

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

H. Exhaust system

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

2-4.

CHASSIS

..............................................................9

Fuel petcock cleaning

................................................. 9

Fuel petcock disassembly

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

Fuel hose

...........................................................9

Front brake

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

Rear brake

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

..lO

Wheels and tires

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

Drivechain

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

Front fork oil change

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

.12

Steering head

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

Lubrication of cables, pivots, etc

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

....I3

2-5.

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

A.Contact breaker point adjustment

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

.13

Contact breaker point maintenance

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

lgnition timing

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

Carbon brushes

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

Battery

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

Sparkplug

.......................................................... 15

Headlight

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

-3-

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

(250)

(500)

(1,000) (2.000)

(1,000)

(2.000)

(4,000)

Cylinder

Check

compression

IOI

Valves

Check/Adjust valve clearance

0101

Cam chain

(

Check/Adjust chain tension

I I I

Spark

pluqs

inspect/Clean or replace as required

loI

Air filter

Dry type

Clean/Replace as required

‘0

;

Carburetor

| Check

operation/Adjust as required

’

Brake system Check/Adjust as required

Repair as

(complete) required

0 0

/Adjust free

play

Wheel

andtires

Checkpressure/Wear/Balance 0~

0 0

;

Fuel petcocks Clean/Flush tank as required 0

Battery Top-up/Check specific gravity and 0~breather

pipe

Ignition timing

| Adjust/Clean

or replace parts as required 1

o/oj

Lights/Signals

Check operation/Replace as required

0 0

/o/o

Fittings/Fasteners

| Tighten

before each trip and/or

lo~o/olo/

Generator

brushes |

Check brush wear/Replace if necessary

I ~I I I

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

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.

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

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.

Standard idle rpm:

1,200 rpm

-6-

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