FOREWORD This Supplementary Service Manual for XS650SF/XS650-2F has been published to supplement the Service Manual for the XS650E (LIT-1 1616-0076), and provides updated information for the XS650E model as well as new data concerning the XS650SF/XS650-2F. For complete information on service procedures, it is necessary to use this Supplementary Service Manual together with the Service Manual for the XS650E (LIT-1 1616-00-76).
Page numbers shown in brackets correspond to page numbers of the XS650E Service Manual (LIT-11616-00-76). (PAGE 4 - 5) NOTE: In the XS650E Service Manual there are a few pages that are not arranged in order. These are pages 7, 8 and 9. They should be read in the reverse order, i.e. 9, 8 and 7. 2-2. MAINTENANCE INTERVALS CHARTS A. PERIODIC MAINTENANCE EMISSION CONTROL SYSTEM REMARKS damage. Replace If n 7 Check fuel hose for cracks or damaqe.
THEREAFTEREVERY INITIAL BREAK-IN j ITEM NO. REMARKS Front Fork Drawn completely. ” Yamaha fork oil 1OWt or equivalent Refill to specification. 011 16,000 km 1,000 km 5.000 k m 4,000 km 8,000 km or 1 month or 7 months or 6 months or 12 months or24month 1 6 0 0 mil K3,OOOmil ( 2 . 5 0 0 mi) ( 5 , 0 0 0 mil ~10,000 mi TYPE 0 Steerung Ball Check bearings assembly Medwm weight ,2 Beanng and for looseness. Moderately wheel bearing RKH repack every 16,000 km gre.%e. (10.000 mi).
E. Rear brake (XS650SF only) The rear brake pedal should be so adjusted that it has a free play of 13 - 15 mm (0.51 - 0.59 in) from when the brake pedal is first moved to when the brake begins to be effected . 1. Loosen the adjuster lock nut (for pedal height). 2. 3. 4. 5. 6. By turning the adjuster bolt clockwise or counterclockwise, adjust the brake pedal NOTE: This model is available in two types, tubeless tire and tube-type tires. Before servicing tires, please note the following instructions. 1.
Tightening torque: 1.5 m-kg (1.1 ft-lb) 2. Aluminium wheels a. Always inspect the aluminium wheels before riding. Place the machine on the center stand and check for cracks, bends or warapage of the wheels. Do not attempt even small repairs to the wheel. It must be replaced. b. Tires and wheels should be balanced whenever either one is changed or re 2. Before operation, always check the tire surfaces for wear and/or damage; for example: cracks, glass, nails, metal fragments, stones, etc.
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. 2. Tension adjustment a. Loosen the rear brake adjusting nut (XS650-2F only). b. Remove the cotter pin of the rear wheel axle nut with pliers. C. Loosen the rear wheel axle nut. d. Loosen the lock nuts on each side. To tighten chain,turn chain puller adjusters clockwise. To loosen chain, turn adjusters counterclockwise and push wheel forward.
6. Retighten screws. Check timing again for right cylinder. 7. Repeat procedure (steps 2 - 6) for left cylinder. (PAGE 39 - 40) 5-1. FRONT WHEEL C. Front wheel inspection (XS650SF only) 1. Check for cracks, bends, or warpage of wheels. If a wheel is deformed or cracked, it must be replaced. 2. Check wheel run-out If deflection exceeds tolerance, check wheel bearing or replace wheel as required. Rim run-out limits (XS650SF/XS650-2F): 1. Right cylinder timing adjustment 2.
I 8 0 m m (3.15 anl (PAGE 40 - 44) 5-3. BRAKES Except for the following, the same procedure as for the XS650E front brake can be performed for the disassembly, inspection,and assembly of the XS650SF (front and rear brake) and the XS650-2F (front brake). Balance wwghf I I D. Brake inspection and repair Specifications should changed as follows: (PAGE 40) 5-2. REAR WHEEL Wear limit: 6.0 mm (0.24 in) A. Removal (XS650SF only) 1. Support the machine on the center stand. 2. Disconnect the drive chain.
(PAGE 50 - 51) 6-1. STARTER A. Armature 1. Check the outer surface of the commutator. If its surface is dirty, clean with No. 600 grit sand paper. 2. The mica insulation between commutator segments should be 0.7 mm (0.028 in) below the segment level. If not, scrape to proper limits with appropriately shaped tool. (A hack saw blade can be ground to fit.
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I I i’Oimmarl ii I T (PAGE 61 - 62) 7-1. TORQUE SPECIFICATION The following torque specifications muSt be adhered to on every machine. When applying torque to multi-secured fastener components, the several studs should be tightened in gradual stages and in a pattern that will avoid warpage to the item being secured. Torque settings are for dry, clean threads. Torquing should always be done to the nut, never the bolt head.
Torque Specifications A (Nut) -
I Part to be tightened I Tightening torque Handle crown and handlebar holder 8 mm bolt Under bracket and inner tube 8 mm nut Engine mounting UPPer 8 mm nut Engine mounting upper Engine mounting Front 10 mm nut 4.6 m-kg (33.5 ft-lb) Engine mounting Rear 10 mm nut 4.1 m-kg (29.5 ft-lb) - Engine mounting Rear-Lower 10 mm nut 4.6 m-kg (33.5 ft-lb) Engine mounting Lower 10 mm nut 9.0 m-kg (65.0 ft-lb) Front flasher and headlight 8 mm nut 1.0 m-kg (7.
1. OESCRIPTION 1 I Engine type Air cooled, 4.stroke. SOHC twin, parallel forward incline 21 Engine model 2FO 653 cc (39.85 cu.in) 75 x 74 mm (2.953 x 2.913 in) 31 Displacement 41 Bore x stroke 51 Compression ratio 61 Starting system. 7) Ignition system 8.5 : I Kick and electric starter Battery ignition 81 Lubrication system wet sump 2. CYLINDER HEAD 1 I Combustion chamber volume (with N-7Yl 43.6 cc (2.660 win) Dome + Squish 21 Combustion chamber type 31 Head gasket thickness 1.2 mm (0.047 in) 3.
5) Valve timing OPEN CLOSE IN BTDC360 ABDCW z3‘I” EX BBDCE8° ATDCW 2840 DURATION OVERLAP 720 ,,.--i-J- 61 Camshaft deflection limit 0.03 mm (0.0012 in) 7) Cam chain Type Number of links Sprocket ratio TSUBAKIMOTO BF05M 106L 36/16 (2.000) I. ROCKER ARM AND ROCKER SHAFT 1) Rocker arm inner diameter (:-,: ,1 c BY 15.0+~.“‘8 mm (0.591 +z.0w7 in) 2) Rocker arm shaft diameter 15.0 $:E mm (0.591 I~:~$ in) 3) Clearance 41 Lift ratio 0.009 - 0.033 mm (0.00035 - 0.00130 in) X : Y = 40 : 46.
lNNER (INIEX): 19.4 mm (0.764 inl OUTER (IN/EX): 32.6 mm il.283 in) I N N E R (IN/EX): 6.0turns OUTER (INIEX): 4.25t”rnr 81 Winding0.D. 9) idumber of windings 1) Crankshaft deflection limit 2) Con-rod large end clearance 3) Width of crankshaft (A) 18) (a 0.05 mm (0.002 in1 0.15 - 0.4 mm (0.0059 - 0.0157 in) (D) 186 j3 mm (7.323 _E,,,2 in) 66 $2 mm (2.598 I$% ini 4) Crank pin I.D. 26 $2: mm (1.024 Ii:% in) 5) Crank pin O.D. x length 0 26 _o,oo6 x 65 ‘;I; mm (1.024 _E,wo2 x 2.559t$?J$iinl 12.
3) Bearing type: Main axle (Left1 (Right1 Dr,ve axle (Left) (Right1 4) Oil seal type Drive axle (Left1 5) Secondary reduction ratio and method Needle bearing (@20~@30-201 Ball bearing (0%052-20.61 Ball bearing l@30-062-23.8) Needle bearing (020.$30-161 SDD-40-62-9 34117 ~2.0OOllChain 16. SHIFTING MECHANISM 1) Type 21 Oil seal type (Change lever) Cam drum, return type SDO.14.24-6 17. KICK STARTER 1) TYPE 2) Oil seal type (Kick axle) 3) Kick clip friction tension Bendix type SD.25.35.7 1.2 - 1.7 kg (2.
6) Lubrication chart - Pressure feed d---Splash lubrication C. Chassis 1. FRAME 1) Frame design Douole cradle, high tensile frame 2. STEERING SYSTEM 1) Carter 21 Trail 27” 115mm (4.53 in) 3) Number and size of balls I” steering head upper race 19 pcs. 114 in Lover race 4) Steering lock to lock 19 pcs. 114 in 42” each IL and R) 3. FRONT SUSPENSION Telescopic fork 1) Type 21 Damper type Oil damper. coil spring 3) Front fork spring Free length Wire diameter x winding diameter 402 mm 118.
5. F U E L T A N K 11 Capacity 11.0 lit 12.9 US gall 2) Fuel grade Regular gasoline 5. W H E E L 1) Type (Front and rear) 2) Tire size IFrOnt) (Rear) *Cast wheel **Spoke wheel 3.50S19.4PR 130/90S16-4PR 31 Tire pressure: Front: 1.6 kg/cm’ (22 psi) Up to 90 kg (198 lb) load Rear: 2.0 kg/cm* (28 psi) Front: 2.0 kg/cm2 (28 psi1 90 kg (198 lblload - 204 kg (445 lblload (Maximum load) High speed riding Rear: 2.3 kg/cm2 (32 psi) Front: 2.0 kg/cm’ 128 psi) Rear: 2.
31 Rear brake (XS650-2F only) TVPE Actuating method Brake drum I.D. Drum brake (Leading trailing) Link rod Brake shoe dia. x width 180 x 30 mm (7.09 x 1.18 in) 4 mm12 mm IO.16 into.08 in) 180 mm (7.09 in) Lining thickness/wear limit Shoe spring free length 68 mm (2.68 in1 D. Electrical 1. IGNITION SYSTEM I) Ignition timing (B.T.D.C.) 15°/1,200 rlmin 2) Ignition coil Model/Manufacturer Spark gap CMll-50B/HITACHI Primary winding resistance 3.9R * 10% at 20°C (68°F) 8.
3. STARTER 1) srarter motor Tvpe Manufacturer Model output Armature coil resistance Field coil resistance Brush size/Ouantitv Wear limit Spring pressure Commutator O.D.lWear limit Mica undercut Bendix type HITACHI S108-35 0.5 kw 0.0067a + 10% at ZO’C (68’F) 0.004X2 + 10% at 20°C 16EaF) 16 mm (0.63 inIl2 PCS. 4 mm (0.16 in) 800 g (28.2 011 33 mm (1.30 in)/31 mm 11.22 in) 0.7 mm 10.