1978 – 1981 Yamaha XS650 Service Manual

Description

This 230 page, 1978 – 1981 Yamaha XS650 Service Manual is a reproduction of the original, out of print manual. It provides detailed service information, step-by-step repair instruction and maintenance specifications for 1978 – 1981 Yamaha XS 650 motorcycles. This 1978 – 1981 Yamaha XS650 manual has been combined with previous Yamaha XS 650 service manuals to provide complete service information for: XS650H/SH models. This 1978 – 1981 Yamaha XS650 Service Manual has been written by Yamaha Motor Company for use by Authorized Yamaha Dealers and their qualified mechanics. In light of this purpose it has been assumed that certain basic mechanical precepts and procedures inherent to Yamaha motorcycles are already known and understood by the reader. Without such basic knowledge, repairs or service to this 1978 – 1981 Yamaha XS650 may render the motorcycle unsafe, and for this reason we must advise that all repairs and/or service be performed by an Authorized Yamaha Dealer who is in possession of the requisite basic product knowledge.

1978 – 1981 Yamaha XS650 Service Manual Table of Contents

GENERAL INFORMATION

PERIODIC INSPECTION AND ADJUSTMENT
INTRODUCTION

MAINTENANCE INTERVAL CHARTS
A PERIODIC MAINTENANCE
B LUBRICATION INTERVALS

ENGINE
A Carburetor
B Air filters
C Engine/Transmission oil and filter
D Clutch adjustment
E Cam chain adjustment
F Valve clearance adjustment
G Crankcase ventilation system
H Exhaust system

CHASSIS
A Fuel petcock cleaning
B Fuel petcock disassembly
C Fuel hose
D Front brake
E Rear brake
F Wheels and tires
G Drive chain
H Front fork oil change
I Steering head
J Lubrication of cables, pivots, etc

ELECTRICAL
A Contact breaker point adjustment
B Contact breaker point maintenance
C Ignition timing
D Carbon brushes
E Battery
F Spark plug
G Headlight

ENGINE OVERHAUL
ENGINE REMOVAL
A Preparation for removal
B Fuel tank removal
C Removal of other parts
D Engine mounting bolts and engine removal

ENGINE DISASSEMBLY
A Governor and breaker assembly removal
B Cylinder head and cylinder removal
C Rocker arm removal
D Valve removal
E Piston removal
F Generator removal
G Primary drive gear and clutch assembly removal
H Kick axle and change shaft removal
I Electric starter unit removal
J Oil pump removal
K Crankcase disassembly
L Transmission illustration
M Shift drum removal
N, Crank shaft removal

INSPECTION AND REPAIR
A Cylinder head cover
B Cylinder head
C Valve, valve guide and valve seat
D Valve spring
E Rocker arm and rocker shaft
F Cam 1 shaft wear
G Cam chain, sprocket and dampers
H Cylinder
I Piston and rings
J Piston pin
K Crankshaft
L Oil pump
M Clutch
N Transmission
O Electric starter gears and clip spring
P Kick starter
Q Crankcase and oil passages
R Bearings and oil seals

CARBURETION
Description
Specifications
Disassembly
Inspection
Adjustments

CHASSIS
FRONT WHEEL
A Removal
B Front axle inspection
C Front wheel inspection
D Replacing wheel bearings
E Installing front wheel

REAR WHEEL
A Removal
B Rear axle inspection
C Replacing wheel bearings
D Rear wheel inspection
E Installing rear wheel
F Rear wheel illustration

BRAKES
A Caliper pad replacement
B Caliper disassembly
C Master cylinder disassembly
D Brake inspection and repair
E Brake reassembly

WHEELS, TIRES, TUBES
A Wheel inspection
B Tire, tube removal
C Installation

REAR WHEEL SPROCKET

FRONT FORKS
A Removal and disassembly
B Inspection
C Assembly

STEERING HEAD
A Adjustment
B Removal
C Inspection
D Reassembly

SWING ARM
A Inspection
B Swing arm removal
C Swing arm lubrication

REAR SHOCK ABSORBER
A Removal
B Inspection

CABLES AND FITTINGS
A Cable maintenance
B Throttle maintenance

ELECTRICAL
STARTER
A Armature
B Yoke
C Starter relay switch

CHARGING SYSTEM
A Charging circuit diagram
B AC Generator
C Voltage regulator
D Checking silicon rectifier
E Battery

IGNITION SYSTEM
A Ignition circuit diagram
B Governor assembly
C Spark gap test
D Ignition coil
E Condenser test

SPARK PLUG
A How to “Read” a spark plug (condition)
B Inspection

LIGHTING AND SIGNAL SYSTEMS
A Lighting tests and checks
B Reserve lighting system
C Self-cancelling flasher system

APPENDICES

including XS650E, XS650SE, XS650SF, XS6502F, XS650G, XS650SG, XS650H, and XS650SH.