1982 – 1983 Yamaha XS650S Heritage Service Manual

Description

This 160 page, 1982 – 1983 Yamaha XS650S Heritage Service Manual provides detailed service information, step-by-step repair instruction and maintenance specifications for 1982 Yamaha XS650SJ, 1983 Yamaha XS650SK Heritage motorcycles.

1982 – 1983 Yamaha XS650S Heritage Service Manual Table of contents:

General Information
MOTORCYCLE IDENTIFICATION
Frame Serial Number
Engine Serial Number
Vehicle Identification Number

SPECIAL TOOLS
For Tune-up
For Engine Service
For Chassis Service
For Electrical Components

Periodic Inspections and Adjustments
INTRODUCTION
MAINTENANCE INTERVALS CHARTS
PERIODIC MAINTENANCE EMISSION CONTROL SYSTEM
GENERAL MAINTENANCE/LUBRICATION

ENGINE
Cam Chain/Valve Clearance
Spark Plug
Crankcase Ventilation System
Fuel Line
Exhaust System
Carburetor Synchronization
Idle Speed
Engine Oil
Clutch Adjustment
Checking Ignition Timing
Compression Pressure Measurement

CHASSIS
Drive Chain Tension Check/Drive Chain Tension Adjustment
Air Filter
Front and Rear Brake
Cable Inspection and Lubrication
Brake and Change Pedals/Brake and Clutch Levers
Centerstands and Sidestands
Front Fork Oil Change
Front Fork and Rear Shock Absorber Adjustment
Steering Head Adjustment
Wheel Bearings
Fuel Petcock

ELECTRICAL
Battery
Headlight
Fuse

ENGINE REMOVAL
Preparation For Removal
Fuel Tank Removal
Removal of Other Parts
Engine Mounting Bolts and Engine Removal

ENGINE DISASSEMBLY
Cylinder and Cylinder Head
Rocker Arm Removal
Valve Removal
Piston Removal
Generator and Drive Sprocket Removal
Case Cover (Right), Primary Drive Gear and Clutch Assembly Removal
Kick Axle and Change Shaft Removal
Tachometer Gear Removal
Oil Pump Removal
Crankcase Disassembly

INSPECTION AND REPAIR
Cylinder Head Cover
Cylinder Head
Valves, Valve Guides, Valve Seats, and Valve Springs
Rocker Arms and Rocker Arm Shafts
Camshafts, Cam Chains, and Cam Sprockets
Cylinder
Piston and Piston Rings
Crankshaft and Connecting Rod
Oil Pump
Primary Drive
Clutch
Transmission
Starter
Crankcase
Bearings and Oil Seals

ENGINE ASSEMBLY AND ADJUSTMENT
Important Information
Starter Motor Unit
Shifter Transmission and Crankshaft
Crankcase Assembly
Kick Starter, Primary Drive Gear, Clutch Assembly, Oil Pump and Case Cover Right
Case Cover Left
Pistons, Cylinders and Cylinder Head
Camshaft and Chain Tensioner
Mounting the Engine

CARBURETOR
Section View and Operation
Specifications
Operation of Carburetor
Disassembly
Inspection
Assembly
Adjustment

AIR CLEANER AND CRANKCASE VENTILATION SYSTEM

Chassis
FRONT WHEEL
Removal
Front Axle Inspection
Front Wheel Inspection
Replacing The Wheel Bearings
Installing the Front Wheel

REAR WHEEL
Removal
Checking Brake Shoe Wear
Brake Drum
Brake Shoe Plate
Rear Axle Inspection
Replacing The Wheel Bearings
Rear Wheel Inspection
Installing The Rear Wheel

FRONT BRAKE
Brake Pad Replacement
Caliper Disassembly
Master Cylinder Disassembly ,
Brake Inspection and Repair
Brake Assembly

FRONT FORK
Removal and Disassembly
Inspection
Assembly

STEERING HEAD
Adjustment
Removal
Inspection
Assembly

SWING ARM
Free Play Inspection

CABLE AND FITTING
Cable Maintenance
Throttle Maintenance

Electrical
XS650SJ WIRING DIAGRAM
ELECTRIC STARTING SYSTEM
STARTING CIRCUIT OPERATION

STARTER MOTOR
Removal
Inspection and Repair

STARTER RELAY
STARTING-CIRCUIT CUT-OFF RELAY
CHARGING SYSTEM

AC GENERATOR AND VOLTAGE REGULATOR
Inspection
Battery Inspection
Stator Coil Inspection
Checking the Silicon Rectifier

IGNITION SYSTEM
Description
Operation
Troubleshooting

LIGHTING SYSTEM
Lighting Tests and Checks

HEADLIGHT RELAY/ STARTER CUT-OUT RELAY SIGNAL SYSTEM
Signal System Tests and Checks
Flasher Self-Cancelling Unit
Switches
Battery

Appendices
GENERAL SPECIFICATIONS

MAINTENANCE SPECIFICATIONS
Engine
Chassis
Electrical

TORQUE SPECIFICATIONS
GENERAL TORQUE SPECIFICATIONS
CONSUMER INFORMATION
STOPPING DISTANCE
DEFINITION OF UNITS
COLOR CODES
CONVERSION TABLE
LUBRICATION DIAGRAMS
CRANKSHAFT CONNECTING ROD/PISTON
CAM CHAIN
CYLINDER HEAD COVER CYLINDER HEAD/VALVE
TRANSMISSION
FRONT WHEEL
FRONT FORK
FRONT BRAKE CALIPER
REAR WHEEL/REAR BRAKE
ELECTRICAL COMPONENTS
WIRING DIAGRAM
CABLE ROUTING

This Official 1982-1983 Yamaha XS650S Heritage Factory Service Manual is a high quality reproduction of the original out of print manual.