650SE Supplement
Contents
1. Check for battery voltage 12V R W wire to safety relay Check fuse or wiring circuit Voltage O K Voltage Check for starter relay or wiring circuit Check for voltage o R W wire to safety relay Voitage O K Check for batte voltage 12V on L B wire to safety relay Replace safety relay HEADLIGHT DOES NOT FUNCTION Check for battery voltage on L B wire to reserve unit Headlight switch or wiring circuits Voltage Check for battery voltage on L Y wire to reserve uni Unit is defective Dimmer switch or wiring circuits Check for voltage at headlight connectors High and low beam HEAD LAMP INDICATOR BULB DOES NOT GLOW Check for battery voltage on L G wire to reserve unit Reserve lighting unit is defective Voltage indicator bulb or connections bad HIGH BEAM DOES NOT LIGHT WHEN LOW BEAM IS DEFECTIVE Check for battery voltage on L G wire to reserve unit Reserve unit is defective Voltage O K Check for battery voltage at dimmer switch terminal Dimmer switch defective headlight b and dimmer switch terminal high beam terminal Voitage O K Poor ground or poor connection of head light wiring LOW BEAM DOES NOT LIGHT WHEN HIGH BEAM IS DEFECTIVE heck for batter2. within the specified lanae sq 2 rear axle cotter pin with 4 tay sra H Front fork oil change 8 Pour specified amount of oil into the inner tube through the upper end open ing Front for oil capacity 169 cc 5 72 US oz each leg PAGE 14 15 2 5 ELECTRICAL C Ignition timing 1 Point gap must be set before setting timing 2 Ignition timing is Checked with a timing light by observing the position of the stationary marks stamped on the stator and the pointer on the generator rotor 3 Advanced mark 2 15 BTDC at 1 200 r mn 1 Top dead center 3 Connect timing light to right left cylinder spark plug lead wire gnition timing of right cylinder must be set first Start the engine and keep the engine speed as specified on the label Use a tachometer for checking The rotor pointer should line up the F stamped timing mark on the stator ata specified engine speed f it does align loosen the two breaker backing plate screws breaker assembly holding screws for left cylinder and move the complete backing plate breaker assem bly for left cylinder until the point marks align Retighten screws Check timing again for right cylinder Repeat procedure steps 2 6 for left cylinder 1 Right cylinder timing adjustment 2 Left cylinder timing adjustment F Spark plug Check electrode condition and wear insulator color and electrode gap Use a wire gauge for a adjusting the
3. Insulation resistance Quantity CHARGING SYSTEM 1 AC generator Charging output Rotor coil resistance Field coil Stator coil resistance Brush length Brush wear limit 2 Rectifier Type Model Manufacturer Capacity Withstand voltage 3 Regulator Type Model Manufacturer Regulating voltage Core gap Point gap Voltage coil resistance 5 Battery Model Manufacturer Quantity Capacity Charging rate Specific gravity STARTER 1 starter motor Type Manufacturer Model output Armature coil resistance Field coil resistance Brush size Quantity Wear limit Spring pressure commutator O D Wear limit Mica undercut 2 Starter switch Manufacturer Model Amparage rating Cut in voltage Winding resistance 3 Starter clip friction tension 3 99 10 at 20 C 68 F 8 0k Q 20 at 20 C 68 F N 7Y CHAMPION or BP7ES N G K 0 7 0 8 mm 0 027 0 031 in HITACHI 2 pcs 0 30 0 40 mm 0 012 0 016 in 650 850 g 22 9 30 0 oz 93 5 0 22uF 10MX2 or more 2 pcs 1 1A 2 000 r min 5 2552 10 at 20 C 68 F 0 46Q 10 at 20 68 14 5 mm 0 571 in 7 0 mm 0 276 in 6 Element type Ful wave SB6B 17 HITACHI 12A 4 Tillil type TLIZ 80 HITACHI 14 5 0 5V 0 6 1 0 mm 0 024 0 039 in 0 3 0 4 mm 0 012 0 016 in 102 at 20 C 68 F YB14L A2 YUASA 1 pc 12V 14AH 1 4A 10 hours 1 28 at 20 C 68 F Bendix type HITACHI 5108 35 0 5 kw 0 006
4. tightest point Check and or adjust chain tension with rear wheel in this tight chain position Inspect the drive chain with both tires touching the ground and without rider 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 20 30 mm 0 87 1 2 in 2 Tension adjustment a Remove the cotter pin of the rear wheel axle nut with pliers b Loosen the rear wheel axle nut 113 c Loosen the lors To 1 tighten chain wre gt 4 7 Busters counterclockwite y wa for ward Turn ee sss ati the same amount t5 ae prt axle alignment There as side of rear and 7 te y gy use them to check for 1 Lock nut 4 Pew van 2 Adjuster 6 3 Marks for alignment d After adjusting ss 2 lock nuts and tht e a sp Insert the cotter pr ry y axle nut and bere te sy pin as shown i 6 terrace if the nut notch and tre VIO donet match tighten tr se 54 tr match CAUTION __ Always use a new ay the rear axle nut Aiten the 8 nut amp wheel f tre cotter e NOTE Excessive chain tenses gi the en gine and other vita gary Oo
5. 10 591 02097 in 15 0 7909 mm 10 591 7000055 in 0 009 0 033 mm 0 00035 0 00130 in X Y 240 48 41 mm 1 575 1 906 in 0 03 mm 10 0012 in TSUBAKIMOTO BFO5M 106L 36 18 2 000 2 pcs IN 0 10 mm 0 0039 in EX 0 15 mm 0 0059 in IN 41 mm 1 614 in EX 35 mm 1 376 in IN 2 1 mm 0 083 in EX 2 1 mm 0 083 in IN 1 3 mm 0 051 in EX 1 3 mm 0 051 in IN 1 3 mm 10 051 in EX 1 3 mm 10 051 in IN 8 0 79019 mm 0 315 700006 Valve stem diameter Valve guide diameter Valve stem to guide clearance 4 Valve face runout limit VALVE SPRING 1 Free length 2 Spring rate 3 Installed length Valve closed 4 Installed pressure Valve closed 5 Compressed length Valve open 61 Compressed pressure Valve open 7 Wire diameter 8 Winding O D 9 Number of windings CRANKSHAFT A 2 1 Crankshaft deflection limit A 2 Con rod large end clearance 3 Width of crankshaft C 0 4 Crank 1 0 5 Crank pin O D x length CONNECTING ROD 1 Big end 1 0 2 Small end I D CRANK BEARING 1 Type Right end Others 2 Oil seal type CLUTCH 1 Clutch type 2 Clutch operating mechanism 3 Primary reduction ratio and method 4 Primary reduction gear back lash 4 teeth 0 025 0 0010 EX 6 0 0 040 0 315 0 0016 in IN 8 0 10019 mm 0 315 10 000 in 019 0 0007 EX 8 0 59 010 mm 0 315 159994 IN 0 0
6. Type Disc size Outside dia X thickness Disc wear limit Disc pad thickness Pad wear limit Master cylinder inside dia Caliper cylinder inside dia Brake fluid type quantity D Electrical 1 IGNITION SYSTEM 1 Ignition timing B T D C 2 Ignition coil Model Manufacturer Spark gap 11 O lit 2 9 US gal Regular gasoline Aluminum rim 3 50519 4 130 90 16 4 Front 1 6 kg cm 22 psi Rear 2 0 kg cm 128 psi Front 2 0 kg cm 28psi Rear 2 3 kg cm 32 psi Front 2 0 kg cm 28 psi Rear 2 3 kg cm 32 psi 2 mm 0 08 in 2 mm 0 08 in 1 85 x 19 MT3 00 x 16 630322 63032 3A 63052 63042 SDD 45 56 6 SD 28 47 7 SD 35 62 9 SO 27 52 5 50HDS 103L Joint 15 875 mm 5 8in 20 30 mm 0 8 1 2 in Hydraulic disc type 298 x 7 0 mm 11 73 x 0 28 in 6 5 mm 10 26 in 11 0 mm 0 43 in 6 0 mm 0 24 in 14 0 mm 0 55 in 38 1 mm 1 50 in DOT 3 Brake fluid 38 1 cc 1 29 oz Hydraulic disc type 267 x 7 0 mm 10 5 x 0 28 in 6 5 mm 0 26 in 11 0 mm 0 43 6 0 mm 0 24 in 14 0 mm 0 55 in 38 1 mm 1 50 in DOT 3 Brake fluid 38 1 cc 1 29 oz 152 1 200 r min CM11 50B HITACHI B mm 0 31 in or more 300 r min at 8V rw w Primary winding resistance Secondary winding resistance 31 Spark plug Type Spark plug gap 4 Contact breaker Manufacturer Quantity Point gap Point spring pressure Cam closing angle 5 Condenser Capacity
7. name Tightening torque Cylinder head and cylinder 10 mm nut 3 7 m kg 26 8 ft b head cover 8 mm boit 2 1 m kg 15 2 ft lb Cylinder head cover ride 6 mm crown nut 0 9 m kg 6 5 ft lb B mm crown nut 1 3 9 4 ft lb Generator 12mm nut 3 8 127 5 ft lb Stator coil 6 mm pan head screw 0 9 m kg 6 5 ft Ib Governer 6 mm bolt Valve clearance adjustment nut 8 mm nut 2 7 m kg 19 5 ft Ib Cam chain tensioner 18 2 1 m kg 15 2 ft ib Pump cover 6 mm pan head screw 1 0 m kg 7 2 ft tb Strainer cover 6 mm bolt 1 0 m kg 7 2 ft lb Drain plug 30 mm 4 2 m kg 30 4 16 Oil filter 6 mm bolt 0 9 m kg 6 5 ft lb Part to be tightened Delivery pipe Exhaust pipe Crankcase Kick crank boss Primary drive gear Clutch boss Drive sprocket Change pedal Chassis Front wheel axle Front fork and axle holder Handle crown and inner tube Handle crown and steering shaft Handle crown and steering shaft Handle crown and handlebar holder Under bracket and inner tube Engine mounting Engine mounting Engine mounting Engine mounting Engine mounting Engine mounting Upper Upper Front Rear Rear Lower Lower Front flasher and headlight Master cylinder and brake hose Brake disc and hub Caliper and support bracket Caliper and pad Caliper and bleed screw Front caliper and front fork Master cylinder and cylinder bracket Pivot shaft Rear wh
8. plug gap If the electrodes become too worn replace it When installing the plug always clean the gasket surface wipe off any grime that might be present on the surface of the spark plug and torque the spark plug properly Standard spark plug N 7Y CHAMPION or BP7ES Spark plug gap 0 7 0 8 mm 0 028 0 031 in Spark plug tightening torque 2 0 m kg 14 5 ft Ib PAGE 22 29 33 INSPECTION AND REPAIR D Valve spring 1 Checking the valve springs d Valve spring specifications Specifications should be changed as follows 42 mm 42 55 mm 1 654 in 1 675 in 9 3 10 7 kg 16 45 18 95 kg 20 5 23 6 ib 36 3 41 8 ib Installed length 35 mm 37 mm Valve closed 1 378 in 1 457 in Compressed pressure 25 3 28 1 kg 53 5 81 5 kg Valve open 55 8 62 010 118 0 135 6 Compressed length 25 5 mm 27 5 mm Valve open 1 004 in 1 083 in Allowable tilt from 1 6 mm or 2 5 vertical 0 063 in Free length Installed pressure Valve closed PAGE 29 33 3 4 ENGINE ASSEMBLY AND ADJUSTMENT 0 Engine Specifications should be changed as follows Engine mounting bolt torque Upper U Nut M8 Upper MIO Front U Nut MIO 1 8 m kg 13 0 ft Ib 3 0 m kg 21 7 ft Ib 4 6 m kg 33 3 ft Ib Rear U Nut MIO 4 1 m kg 29 7 ft Ib Rear under U Nut MIO 4 6 m kg 33 3 ft Ib Under U Nut M10 9 0 m kg 65 1 ft lb PAGE 39 40 5 1 FRONT WH
9. reverse removal procedure taking care of following points 1 Lightly grease lip of rear wheel oil seals 2 Make sure the brake pads are installed properly and that there is an enough gap to install the rear disc 3 Install wheel assembly and axle Always use a new cotter pin on the axle nut Axle nut torque 15 0 m kg 108 5 ft lb 4 Connect drive chain 5 Adjust drive chain PAGE 40 44 5 3 BRAKES Except for the following the same procedure can be performed for Disassembly Inspection and Assembly of XS650SE front and rear brake and XS650E front brake D Brake inspection and repair Specifications should be changed as follows Wear limit 6 0 mm 0 24 in 116 A Pad thickness 11 0 mm 0 43 6 Wear limit 6 0 mm 10 24 C Wear indicator 7 Backing plate PAGE 48 5 9 REAR SHOCK ABSORBER B Inspection Specifications should be changed as follows Rear shock absorber tightening torque 3 0 m kg 21 7 ft lb 3 9 m kg 28 2 ft lb Upper Lower PAGE 50 51 8 1 STARTER A Armature 1 Check the outer surface of the com mutator If it s surface is dirty clean with No 600 grit sand paper 2 The mica insulation between com mutator segments should be 0 7 mm 0 028 in below the segment level If not scrape to proper limits with ap propriately shaped tool A hack saw blade can be ground to fit Mica under cut 0 7 mm 0 028in Commutator
10. 1 Net weight Dry 4 PERFORMANCE 1 Climbing ability 2 Minimum turning radius 3 Brakina distance B Engine 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 CYLINDER HEAD 1 Combustion chamber volume with N 7Y 2 Combustion chamber type 3 Head aasket thickness CYLINDER 1 Material 2 Bore size 3 Taper limit 4 Out of round limit PISTON 1 Piston skirt clearance 2 Piston oversize 3 Piston pin outside diameter x length XS650SE 2 0 2F0 114241 2F0 114241 2 120 mm 83 5 in 925 mm 36 4 in 1 2225 mm 48 2 in 790 mm 31 1 in 1 435 mm 56 5 in 135 mm 5 3 in 210 kg 463 Ib 26 2 500 mm 98 4 in 14 m 50 km h 45 9 ft mi h Air cooled 4 stroke SOHC twin parallel forward incline 2 0 653 139 85 cu in 75 x 74 mm 2 953 x 2 913 in 0 5 1 Kick and electric starter Battery ignition wet sump 43 6 cc 12 660 cu in Dome Swish 1 2 mm 0 047 in Aluminum alloy with cast iron sleeve 75 00 092 mm 2 9528 00008 in 0 05 mm 10 002 in 0 01 mm 0 0004 in 0 050 0 055 mm 0 0020 0 0022 in 7525 mm 75 50 mm 12 963 in 2972 I 20 0 S005 mm x 61 0 _ 75 75 76 00 2982 12992 1 0 0 3 mm 10 79 9 in 240 00116 in PISTON RING 1 Piston ring design 2 Ring end gap Instal
11. 2 000 Chain Cam drum return type SDO 14 24 6 Bendix type SD 25 35 7 1 2 1 7 kg 2 6 3 7 Dry foam rubber 2 pcs Every 8 000 km 5 000 mile BS38 MIKUNI 2 pcs 2F0 00 135 140 502 3 z 2 120 275 Preset 65 80 GS2 0 5 24 1 mm 0 94 0 04 in 1 200 rlmin Oil exchange 2 0 lit 2 1US qt Overhaul 2 5 lit 12 6 US qt Yamalube 4 cycle oil or SAE 20W 40 type SE motor oil Trochoid pump 0 10 0 18 mm 0 0039 0 0071 in 0 03 0 09 mm 0 0012 0 0035 in 0 03 0 08 mm 0 0012 0 0031 in 1 3 lit min 11 37 qt min at 1 000 r min 1 0 kg cm 114 psi 6 Lubrication chart Pressure feed Con rod Splash lubrication big end Oil main gallery Baypass Main axle and transmission Clutch C Chassis 1 FRAME 1 Frame design Double cradle high tensile frame STEERING SYSTEM 1 caster 27 2 Trail 115 mm 4 53 3 Number and size of balls in steering head upper race 19 5 1 4 in Lower race 19 pcs 1 4 in 4 Steering lock to lock 42 each L and RI FRONT SUSPENSION 1 Type Telescopic fork 2 Damper type Oil damper coil spring 3 Front fork spring Free length 482 mm 18 08 in Wire diameter x winding diameter 4x 24 5 mm 10 157 x 0 965 in Spring constant ki 0 48 kg mm 26 88 Ib in 0 100 mm 0 3 94 in k2 0 65 kg mm 36 40 Ib in 100 150 mm 3 94 5 91 in 4 Front fork travel 150 mm 5 906 in 5 In
12. 20 0 044 mm 0 00079 0 00173 in EX 0 035 0 059 mm 1O 00138 0 00232 in IN amp EX 0 03 mm 0 0012 in or less INNER IN EX 42 mm 1 654 in OUTER 1 42 55 mm 1 675 INNER 1 43 kg mm 80 1 k2 1 81 kg mm 101 4 Ib in OUTER INIEX k 3 2 kg mm 179 2 Ib i k2 4 18 kg mm 234 1Ib in INNER INIEX 35 mm 1 378 in OUTER IN EX 37 mm 1 457 in INNER 10 0 7 kg 22 0 1 5 Ib OUTER IN EX 17 7 1 25 kg 39 0 2 8 16 INNER INIEX 25 5 mm 11 004 in OUTER IN EX 27 5 mm 1 083 in INNER IN EX 27 2 1 9 kg 60 0 4 2 Ib OUTER IN EX 57 4 4 0 kg 126 5 8 8 Ib INNER IN EX 2 9 mm 0 114 in OUTER IN EX 4 2 mm 0 165 in INNER IN EX 19 4 mm 10 764 in OUTER INIEX 32 6 mm 1 283 in INNER IN EX 6 0 turns OUTER IN EX 4 25 turns 0 05 mm 0 002 in 0 15 0 4 mm 10 0059 0 0157 in 66 PEF mm 2 598 2002 0 186 9 3 mm 7 323 0 549 0 077 0 003 26 0 095 MM 1 024 0 004 in 0 01 26 _ 65 0 2 mm 1 024 _0 002 2 559 70 008 in 34 0 016 nm 1 339 9 0006 in 205988 mm 0787 10001 30 18 19 bearing 32 68 17 Rollar bearing 50 25 40 9 Wet multiple type Inner push type screw push system 72 27 2 666 spar gear 21 45 0 8445 _0 00010 5 Friction plate Thickness Quantity Wear limit 6 Clutch plate Thickness Quantity Wa
13. 3 Check the armature and field coil for shorting and insulation Replace arma ture as required Coil resistance 0 006722 at 20 C 68 F ie Armature coil Field coil 0 0042 at 20 C 68 F 4 Check the front and rear cover bearings for damage If damaged the starter assembly must be replaced PAGE 57 58 6 5 LIGHTING AND SIGNAL SYSTEMS B Reserve lighting system 1 Description The reserve lighting system has two functions 1 It notifies the rider that one of the headlight filaments is Operative and 2 it switches current from the inoperative filament to the remaining functional filament The system is connected to the headlight circuit only The reserve lighting system unit is located under the fuel tank NOTE This model has been equipped with a safety relay so that the headlight comes on auto matically when the engine is started even with the headlight switch OFF Headlight condition Headlight failure indi cator light Reserve light ing function Low beam comes on High beam comes on at low brilliance Comes on very dim Normal High beam Comes on faulty Low beam Comes on faulty 2 Troubleshooting Inspection HEADLIGHT DOES NOT COME ON WHEN ENGINE IS RUNNING WITH HANDLE BAR SWITCH OFF Check Generator or wiring circuit Check for voltage on wire to safety relay Voltage 0 K 117
14. 70 10 at 20 C 68 F 0 00492 10 at 20 C 68 F 16 mm 0 63 in 2 pcs 4 mm 0 16 in BOO g 28 202 33 mm 1 30 in 31 mm 1 22 in 0 7 mm 0 028 in HITACHI A104 70 100A 6 5V 3 52 2 2 2 5 kg 49 5 5 Ib 4 LIGHTING SYSTEM 1 Headlight type 2 Bulb brightness and wattage Quantity Headlight Tail brake light Flasher light Pilot lights Turn High beam Headlight failure Neutral Tail brake failure Meter lights 3 Reserve lighting unit Model Manufacturer 4 Horn Model Manufacturer Maximum amparage 5 Flasher relay Type Model Manufacturer Flasher frequency Capacity 6 Flasher cancelling unit Model Voltage 7 Fuse Rating Quantity 8 Light checker Model Manufacturer 129 Sealed beam 12V 50 40W x 1 PC 12V 3 32 CP 8W 27W x 1 pc 12V 32 CP 27W x 4 pcs 12V 3 4W x 2 pcs 12V 3 4W x 1 pc 12V 3 AW x 1 PC 12V 3 AW x 1 pc 12V 3 4W x 1 pc 12V 3 4W x 4 pcs 337 1 1720 KOITO CF 12 NIKKO 2 54 Condenser type 1A0 70 NIPPON DENSO 85 10 cycle min 32 CP 27W x2 3 4W EVH AC518 DC9V 16V Main Red 20A 35200 71859 KOITO 74 CABLE ROUTING DIAGRAM amc eco Speedometer Clutch wire Flasher relay Condenser Breather pipe ACG Cord Light checker Regulator wire Regulator Neutral switch lead wire Body earth Gray Orange tgnition coil H
15. EEL C Front wheel inspection 1 Check for cracks bends or warpage of wheels If a wheel is deformed or crack ed it must be replaced NOTE These aluminum wheels are not designed for use with tubeless tires 2 Check wheel run out If deflection exceeds tolerance check wheel bearing or replace wheel as required Rim run out limits Vertical 2 mm 0 08 in Lateral 2 mm 0 08 in 3 Check wheel balance Rotate wheel lightly several times and observe resting position If wheels is not statically balanced wheel will come to rest at the same po sition Install balance weight at lighter position at top as illustrated NOTE The wheel should be balanced with brake disc installed Sinn RN a Lateral E Installing front wheel 4 Always secure the front wheel axle as follows Specifications should be changed as follows Axle nut torque 10 7 77 4 ft lb Holder nut torque 1 4 m kg 10 1 ft lb PAGE 40 5 2 REAR WHEEL A Removal 1 Support machine on the center stand 2 Disconnect the drive chain Using drive chain cutter special tool NOTE The chain joint should be replaced each time the chain is cut 3 Remove the axle nut cotter pin and axle nut 4 While supporting the brake caliper pull out the rear axle 5 Remove the rear wheel assembly E Rear wheel installation When installing rear wheel
16. Speedometer 1 910 5 1 Meter light B Meter light oiv Reed switch M 1 Front stop 1 switch s 1 I 1 n i 2 E 1 l ld ii if a BP t hem fln 57 LO I Spark plug i Generator Neutral Rectifier Regulator Flasher Horn Tail brake light ce Z Se switch earth cancelling Headlight Front flasher light unit E NEL LE E BEP 557 COLOR CODE Red L W Blue White Brown Red White Blue L B Blue Black 2 Yellow UN Ios Blue Y ell ow Green Blue Green Pink Y B Yellow Black Black Br W Brown White Dark green Y R Yellow Red Chocolate L R Blue Red Sky blue W B White Biack White Green White Gray White Green Orange see Green Yellow Light green YIG Yellow Green R Y Red Yellow Main switch PARK 0 Taillight Ignition system Signaling system Headlight Regulator A C Generator
17. XobS05E Supplementary FOR XS650SE MODELS AFTER ENGINE SERIAL NUMBER 2 114241 109 De FOREWORD This Supplementary Service Manual for XS650SE has been published to supplement the Service Manual for the XS650E LIT 11616 00 76 and provides updated information for the XS650E model as well as new data concerning the XS650SE 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 NOTE This Supplementary Manual contains special information regarding periodic maintenance to the emissions control system for the XS650SE Please read this material carefully SERVICE DEPT INTERNATIONAL DIVISION YAMAHA MOTOR CO LTD Page numbers shown in brackets correspond to page numbers of the XS650E Service Manual LIT 1 1616 00 76 PAGE 4 5 2 2 MAINTENANCE INTERVALS CHARTS A PERIODIC MAINTENANCE EMISSION CONTROL SYSTEM INITIAL BREAK IN THERE AFTER EVERY 1 000 km 5 000 km 4 000 km 8 000 km or 1 month or 7 months 6 months or 12 months 600 3 000 mi 2 500 mi 5 000 mi REMARKS l Cam Chain Check and adjust chain tension 4 Check and adjust valve clearance when engine is cold i Valve Clearance Check condition Adjust point gap Replace if necessary Contact Breaker Points Ignition Timing Check and adjust ignition tim
18. be cleaned more often if the machine is operated in extremely dusty areas E Cam chain adjustment Check adjust the cam chain tension as follows 1 Remove the cap nut 2 Turn the left end of the crankshaft counterclockwise As the crankshaft is turning check to see that the cam chain adjuster push rod is flush with the end of the bolt If not turn the adjuster bolt until the push rod is flush 3 Reinstall the cap nut The cap nut acts as a lock nut for the adjuster 1 cap nut 2 Adjuster bolt 3 Push rod PAG 2 4 E 9 13 CHASSIS A Fuel petcock cleaning 1 Open the seat and remove the fuel tank securing bolt 2 Turn the petcock lever to the ON or RES position Raise the fuel tank to remove the fuel pipe 1 Fuel pipe 3 Remove the drain bolt and clean with solvent If gasket is damaged replace 1 Drai 112 fa n bolt E Rear brake 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 By turning the adjuster bolt clockwise or counterclockwise adjust the brake pedal position so that its top end is approx 12 18 mm 0 47 0 71 in below the footrest top end 3 Secure the adjuster lock nut 4 Loosen the brake rod adjuster lock nut and screw b
19. eel axle Tension bar and brake caliper Tension bar and rear arm Rear shock absorber Rear shock absorber Upper Lower Rear arm and rear arm end Front fender Neutral switch Thread dia and part name Tightening torque 10 mm union bolt 2 4 m kg 15 2 ft lb 1 3 m kg 9 4 ft lb 2 4 m kg 15 2 ft lb 8 mm nut 8 mm bolt nut 8 mm bolt 2 0 m kg 14 5 416 14 mm nut 9 0 m kg 65 1 ft lb 18 mm nut 8 0 m kg 57 9 ft tb 22 mm nut 6 5 m kg 147 0 ft Ib 6 mm bolt 1 0 m kg 7 2 ft lb 8 mm nut 2 0 m kg 14 5 ft lb 10 mm nut 4 6 m kg 33 3 ft Ib 10 mm nut 4 1 m kg 29 7 ft lb mma emm 8 mm bolt 2 0 m kg 14 5 ft Ib 1 8 m ka 113 0 ft lb 0 3 m kg 22 ft Ib 0 6 m kg 4 3 ft Ib 3 5 m kg 25 3 ft lb 0 6 m kg 4 3 ft lb 8 mm bolt 5 mm bolt 8 mm bolt 10 mm bolt 14 mm nut 6 5 m kg 47 0 ft lb 16 mm nut 15 0 m kg 108 5 ft lb 1 8 m kg 113 0 ft lb 3 2 m ka 123 1 ft lb 3 0 m kg 21 7 ft ib 3 9 m kq 28 2 ft lb 1 0 m kg 7 2 ft lb 1 0 m kg 7 2 ft lb 10 mm bolt 10 mm bolt 8 mm bolt 8 mm bolt 12mm 1 3 m kg 9 4 ft lb 121 PAGE 64 71 7 3 SPECIFICATION A General 1 MODEL 1 Model 1 8 2 Frame 1 0 and starting number 3 Engine 1 0 and starting number 2 DIMENSION 1 Overall length 2 Overall width 3 Overall height 41 Seat height 5 Wheelbase 6 Minimum ground clearance 3 WEIGHT
20. ing Check condition Adjust gap Spark Plugs Replace if necessary Check ventilation hose for cracks or damage Replace if necessary Check fuel hose for cracks or damage Replace if necessary i Crankcase Ventilation System Fuel Hose Check for leakage Retighten as necs Exhaust System sary Replace gasket s if necessary Carburetor Synchronization Adjust synchronization Of carburetors 1 Check and adjust engineidie speed Idle Speed Adjust cable free play B GENERAL MAINTENANCE LUBRICATION INITIAL BREAK IN THEREAFTEREVERY REMARKS TYPE 1 000 km 5 000 km 4 000 km 8 000 ki 16 10 1 month 7 months or6 months or 12 months 24 months 600 mi 13 000 2 500 15 000 10 000 mi Warm up engine before Yamalube 4 cycle Engine draining oil or SAE 20W 40 SE motor oil 2 Oil Filter Clean element solvent o o 3 Filter Ory type filter Clean with compressed air Brake Adjust free play Replace o 0 4 System pad if necessary 5 Adjust free play o o 0 6 Drive Chain Apply chain lube thoroughly Yamaha chain and cable lube or 10W 30 motor oil CHECK CHAIN TENSION AND LUBE EVERY 500 km 300 mi Yamaha chain and Control and Apply cable lube 7 cable lube or o Meter Cable thoroughly 10W 30 motor oil Heesr Arm A
21. led top Installed 2nd Installed oil 3 Ring groove side clearance Top 2nd BIG END BEARING 1 Type 2 Bearing size 3 Needle size CAMSHAFT 1 Cam drive type 2 Number and type of bearing 3 Bearing type 4 Cam dimensions Cam height A 39 99 t 0 05 mm 39 84 mm 1 574 0 002 in 1 569 in 40 03 0 05 mm 1 576 0 002 in 39 88 mm 1 570 in 5 Valve timing Tl EX BBDC68 6 Camshaft deflection limit 71 Cam chain Type Number of links Sprocket ratio ROCKER ARM AND ROCKER SHAFT 1 Rocker arm inner diameter 2 Rocker arm shaft diameter 3 Clearance 4 Lift ratio VALVE VALVE SEAT AND VALVE GUIDE 1 Valve per cylinder 2 Valve clearance In cold engine 3 Dimensions Valve head diameter A Valve face width B Valve seat width Valve margin thickness D Valve stem diameter 123 32 24 0 05 mm 1 269 0 002 32 30 0 05 mm 1 272 0 002 in oii ring 1 2 mm 0 047 1 5 mm 0 059 in 2 8 mm 0 110 in 0 2 0 4 mm 10 006 0 016 in 0 2 0 4 mm 0 008 0 016 in 0 3 0 9 mm 0 012 0 035 in 0 04 0 06 mm 0 0016 0 0031 in 0 03 0 07 mm 0 0012 0 0026 in Needle bearing 26 x 34 19 8 4 15 8 x 13 Chain Center side 4 bearings Ball bearings 6005 25 0 47 8 32 09 mm 7 991 mm 1 263 in 0 315 in 8 030 mm 0 316 in ATDC36 a E 15 0 0 018 mm
22. ner tube O D 35 mm 1 378 in 6 Front fork oil quantity and type 169 cc 5 7202 each leg Yamaha fork oil 10Wt or equivalent 7 Distance from the top of inner tube oil level without spring Approx 454 mm 17 9 in REAR SUSPENSION 1 Type Swing arm 2 Damper type Oil damper coil spring 3 Shock absorber travel 80 mm 3 15 in 4 Shock absorber spring Free length 226 mm 8 90 in Wire diameter x winding diameter 7 5 x 60 5 mm 10 295 x 2 382 in Spring constant ki 1 714 kg mm 96 0 lb in 07 45 mm O 1 77 in 2 244 kg mm 125 7 lb in 45 80 1 77 3 15 in 5 Swing arm free play Limit 1 mm 10 04 in 6 Pivot shaft Outside diameter 16 mm 10 63 in 5 FUEL TANK 1 Capacity 2 Fuel grade WHEEL 1 Type Front and rear 2 Tire size Front Rear 3 Tire pressure Up to 90 kg 198 b load 90 kg 1198 Ib load 204 kg 445 Ib load Maximum load High speed riding 4 Rim run out limit Front and rear Vertical Lateral 51 Rim size Front Rear 6 Bearing type Front wheel Left Right Rear wheel Left Right 7 Oil seal type Front wheel Left Right Rear wheel Left Right 8 Secondary drive chain type Type Number of links Chain pitch Chain free play BRAKE 1 Front brake Type Disc size Outside dia x thickness Disc wear limit Disc pad thickness Pad wear limit Master cylinder inside dia Caliper cylinder inside dia Brake fluid type quantity Rear brake
23. orn Flasher cancelling unit Wire harness L Speedometer cable Rectifier Battery cord Reserve lighting unit Taillight lead wire Light checker coupler Regulator coupler Battery cord Light checker Clutch wire Macuum pipe High tension cord Battery cord Starter switch Wire harness Throttle wire Clutch wire Throttle wire Front stop switch wire Handlebar switch lead wire R Handlebar switch lead wire L 75 WIRING DIAGRAM The key can be removed in this position Main switch Handlebar switch Right Handlebar switch Left ENGINE Rear stop switch stop LIGHTS I HORN swich twneh Dimmer AWE switch TURN swich Reserve lighting Light checker 11 Rear flasher light 1 1 4 RIW Tachometer Y LI ez Neutral Ll High beam rt L i WIG HH EN Meter light SE Y 1 N 4 Fiet box Tum 0 4 111 4 FH ama me S oe 5 1 Headlight ee failure Lj Ignition coil
24. pply unti new grease Pivot Shaft shows Brake pedal Yamaha chain and and change Apply lightly cable lube or V e pedal shaft 10W 30 motor oil Center and Side Stand Yamaha chain and 10 Pivots Apply lightly cable lube or 10W o Kick Crank 30 motor oil Boss Ed es REMARKS Front Fork Dram completely Oil Refill to specification Yamaha fork oil INITIAL BREAK IN THEREAFTEREVERY 10Wt or equivalent 1 000 km or 1 mon 600 mi 5 000 km 4 000 km or 7 months or 6 months 3 000 2 500 mi th 8 000 km or 12 months 5 000 mi 16 000 km or 24 month 10 000 mi Steering BalllCheck bearings assembly Medium weight 12 Bearing and for looseness Moderately wheel bearing Races repack every 16 000 km 110 000 mi Check bearings for smooth rotation Moderaltely repack every 16 000 km 10 000 mi grease Medium weight wheel bearing grease heel Bearings Check specific gravity Check breather pipe for proper operation 1 4 Battery Replace generator brushes Replace at initial 9 000 Generator km 5 500 mi 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 PAGE 7 8 2 3 ENGINE B Air filters 2 Cleaning method c The air filter element should be cleaned every 8 000 km 5 000 mi It should
25. rake rod downward until there is noticeable free play between rod and master cylinder 5 Turn in the brake rod until it lightly touches the master cylinder then turn it out by approx 1 1 5 turns for proper free play 6 Tighten the brake rod adjuster lock nut CAUTION See that the punched mark on the brake rod is not above the top surface of the adjuster lock nut in securing the brake rod adjuster lock nut 1 2 Lock nut 0 47 0 71 in 3 Lock nut 7 Free play 13 15 mm 4 Brake rod 0 51 0 59 in 5 Footrest F Wheels and tires 2 Tires Specifications should be changed as follows Adjuster bolt for pedal height 6 Pedal height 12 18 mm FRONT U XS650SE BASIC WEIGHT with oil and full fuel tank 102 kg 225 Ib 118 kg 260 Ib Bridgestone or Yokohama 3 50519 4 Bridgestone Yokohama 130 90516 4 279 kg 615 Ib Standard tire 166 kg 365 Ib Maximum load limit Cold tire pressure Up to 90 kg 198 10 load 90 kg 198 b load 204 kg 445 Ib load Maximum load High speed riding 1 6 kg cm 22 psi 2 0 kg cm 28 psi 2 0 kg cm 28 psi 2 3 kg cm 32 psi 2 0 kg cm 28 psi 2 3 kg cm 32 psi Minimum tire tread depth 0 8 mm 0 03 in 0 8 mm 0 03 in G Drive chain 1 Tension check NOTE Before checking and or adjusting rotate rear wheel through several revolutions and check tension several times to find the
26. rp limit 7 Clutch spring Free length Quantity 8 Clutch housing radial play 9 Push rod bending limit TRANSMISSION 1 Type 2 Gear ratio 1st 2nd 3rd 4th 5th 3 Bearing type Main axle Left Right Drive axle Left Right 4 Oil seal type Drive axle Left 5 Secondary reduction ratio and method SHIFTING MECHANISM 1 Type 21 Oil seal type Change lever KICK STARTER 1 Type 21 Oil seal type Kick axle 31 Kick clip friction tension INTAKE 1 Air cleaner Type Quantity 2 Cleaner cleaning interval CARBURETOR 1 Type and manufacturer Quantity 2 1 0 mark 3 Main jet MJ 4 Air jet AJ 5 Jet needle JN 6 Needle jet NJ 71 Throttle valve Th V 8 Pilot jet PJ 91 Pilot screw Turns out PS 10 starter jet GS 11 Fuel level FL 12 Idling engine speed 20 LUBRICATION 1 Engine sump oil quantity 2 Oil type and grade 3 Oil pump type 4 Trochoid pump specifications Top clearance Tip clearance Side clearance Oil pump volume 5 Bypass valve setting pressure 3 mm 0 118 in 7 pcs 2 7 mm 0 106 in 1 4 mm 0 055 in 6 pcs 0 05 mm 0 002 in 34 6 mm 1 362 in 6 pcs 0 027 0 081 mm 0 0011 0 0032 in 0 2 mm 0 008 in Constant mesh 5 speed forward 32 13 12 461 27 17 1 588 26 20 1 300 23 21 1 095 22 23 0 956 Needle bearing 20 30 20 Bal bearing 25 52 20 6 Ball bearing 30 62 23 8 Needle bearing 20 30 16 SDD 40 62 9 34 17
27. y voltage at headlight beam terminal d headlight d and dimmer switch terminal Check for battery voltage on L G wire to reserve unit Reserve unit is defective Voltage O K Poor ground or poor connection of head light wiring Voltage O K Check for battery voltage at dimmer switch terminal Dimmer switch is defective Voltage O K To starter relay To A C Generator Headlight switch LiB Reserve lighting unit Safety relay aw Light 4 checker 9 Fuse Brake tail failure indicator light 5 L b lights Meter light 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 NOTE Certain items with other than standard thread pitches may require differing torque B pe MENU Eres Bolt 6mm M6 Bmm M8 10mm M10 12mm M12 14 mm M14 16mm M16 18mm M18 20 mm M20 Torque Specifications Part to be tiahtened Thread dia and part
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