Sharp AX-700R Especificações

XS650EINDEXGENERALINFORMATIONPERIODIC INSPECTIONAND ADJUSTMENTENGINE OVERHAULCARBURETIONCHASSISELECTRICALIAPPENDICESProperty of www.SmallEngineDiscoun

1 .Throttle nap se-B. Air filtersThis model uses a cartridge type air filterelement which consists of foam rubber.1. Removala. Remove the air filter c

Property of www.SmallEngineDiscount.com - Not for Resale

Property of www.SmallEngineDiscount.com - Not for Resale

XS650ESupplementaryFOR XS650E MODELS AFTER ENGINE SERIAL NO. 2FO-006501Property of www.SmallEngineDiscount.com - Not for Resale

FOREWORDThis Supplementary Manual for XS650E has been published to supplementthe Service Manual for the XS65OE (LIT-1 1616-00-761, and provides up-dat

Page numbers shown in brackets correspond to page numbers of the XS650E (LIT-1 1616-00-76)Service Manual.(Page 4-5)2-2. Maintenance Interval ChartsA.

(Page 8)E. Cam chain adjustmentCheck/Adjust the cam chain tension asfollows:Remove the cap nut.Turn the left end of the crankshaftcounterclockwise. As

6. Retighten screws. Check timing againfor right cylinder.7. Repeat procedure (steps 2-6) for leftcylinder.-SW -_- -s-m-.-1. Right cylinder timing adj

SupplementaryFOR XS650SE MODELS AFTER ENGINE SERIAL NUMBER 2FO-114241Property of www.SmallEngineDiscount.com - Not for Resale

FOREWORDThis Supplementary Service Manual for XS650SE has been published tosupplement the Service Manual for the XS650E (LIT-11616-00-76), andprovide

Page numbers shown in brackets correspondto page numbers of the XS650E ServiceManual (LIT-1 1616-00-76).(PAGE 4 - 5)2-2. MAINTENANCE INTERVALS CHARTSA

d. Remove the filter cover and oil filtersecuring bolt.HA1. Filter securing bolt.e. Slip the filter element out and clean.f. Install the filter and fi

I II I/ INITIAL BREAK-IN 1 THEREAFTEREVERY. .- -NO. ITEM REMARKS TYPE1,000 km 5,000 km 4,000 km8,000 km 16,000 kmor 1 month or 7 months or 6 months or

E. Rear brakeThe rear brake pedal should be so adjustedthat it has a free play of 13 - 15 mm (0.51- 0.59 in) from when the brake pedal is firstmoved t

C. Loosen the IOU W. ,, ~“, ~~, Totighten chain tur* ‘,W_2, 61 @lustersclockwise. To Irfn *,Wcounterclockmw a/,,fl’ Mjustars)* U,W! for-ward. Turn ta7

1. Right cylinder timing adjustment2. Left cylinder timing adjurtmentF. Spark plugCheck electrode condition and wear, insulatorcolor and electrode gap

Balance weightE. Installing front wheel4. Always secure the front wheel axle asfollows:Specifications should be changed asfollows:(PAGE 40)5-2. REAR W

(PAGE 48)5-9. REAR SHOCK ABSORBERB. InspectionSpecifications should be changed as follows:A: Pad thickness11 .O mm (0.43 in)6: Wear limit6.0 mm IO.24

“R/W” wire to-118-Property of www.SmallEngineDiscount.com - Not for Resale

-119-Property of www.SmallEngineDiscount.com - Not for Resale

(PAGE 61- 62)7-1. TORQUE SPECIFICATIONThe following torque specifications must beadhered to on every machine When applyingtorque to multi-secured fast

Part to be tightened Thread dia. and part nameDelivery pipe 10 mm union boltExhaust pipe 8 mm nutCrankcase 8 mm bolt/nutKick crank bossPrimary drive g

1.2.3.4.Remove all four tappet covers and thegenerator cover.Turn the crankshaft to align the rotormark with the “T” mark on the stator.This places th

(PAGE 64 - 71)7-3. SPECIFICATIONA. General1.MODEL1) Model (I.&M. No.)2) Frame I.D. and starting number3) Engine I.D. and starting number2. DIMENSI

1 I Piston ring design2) Ring end gap(Installed. top)0.2 - 0.4 mm 10.006 - 0.016 in)(Installed, 2nd)0.2 - 0.4 mm (0.006- 0.016 in)(Installed. oil)0.3

Valve stem diameterEX: 6.0 3:;: mm (0.315 ;g:$$ in)Valve guide diameterIN: 8.0 $ti”, mm (0.315 $E inlEX:8.0 :~:~~~ mm (0.315 :i:“g in)Valve stem to gu

51 Friction plateThicknerslCluantityWear limit61 Clutch plateThickness/QuantityWarp limit7) Clutch springFree length/Quantity8) Clutch housing radial

6) Lubrication chart- Pressure feed----Splash lubricationI-C. Chassis1. FRAME1) Frame designDouble cradle, high tensile frame2. STEERING SYSTEM11 cast

5. FUEL TANK1) Capacity11 .O lit (2.9 US gal)2) Fuel grade Regular gasoline6. WHEEL1) Type (Front and rear) Aluminum rim2) Tire sizeIFront)3.50S19.4PR

Primary winding resistanceSecondary winding resistance31 Spark plugTVP~Spark Plug gap4) Contact breakerManufacturerlQuantitvPoint gapPoint spring pres

4. LIGHTING SYSTEM1) Headlight type2) Bulb brightness and wattage/QuantityHeadlightsTail/brake lightFlasher lightPilot lights: TurnHigh beamHeadlight

Property of www.SmallEngineDiscount.com - Not for Resale

Property of www.SmallEngineDiscount.com - Not for Resale

D. Front brakeThe brake can be adjusted by simplay adjust-ing the distance that the brake lever cantravel. (The piston in the caliper moves for-ward a

Property of www.SmallEngineDiscount.com - Not for Resale

Property of www.SmallEngineDiscount.com - Not for Resale

Property of www.SmallEngineDiscount.com - Not for Resale

FOREWORDThis Supplementary Service Manual for XS650SF/XS650-2F has beenpublished to supplement the Service Manual for the XS650E (LIT-1 1616-00-76),

Page numbers shown in brackets correspondNOTE:to page numbers of the XS650E ServiceIn the XS650E Service Manual there are a fewManual (LIT-11616-00-7

INITIAL BREAK-IN jTHEREAFTEREVERYNO.ITEMREMARKS TYPE1,000 km 5.000 km 4,000 km 8,000 km16,000 kmor 1 month or 7 months or 6 months or 12 months or24mo

E. Rear brake (XS650SF only)The rear brake pedal should be so adjustedthat it has a free play of 13 - 15 mm (0.51- 0.59 in) from when the brake pedal

Tightening torque:1.5 m-kg (1.1 ft-lb)2.a.b.Aluminium wheelsAlways inspect the aluminium wheelsbefore riding. Place the machine on thecenter stand and

2.a.b.C.d.deflection is approximately 20 - 30 mm(0.8 -1.2 in). If the deflection exceeds20- 30 mm (0.8 - 1.2 in) adjust thechain tension.Tension adjus

6. Retighten screws. Check timing againfor right cylinder.7. Repeat procedure (steps 2 - 6) for leftcylinder.1. Right cylinder timing adjustment2. Lef

FRONT REARXS650E BASICWEIGHT with oil 104 kg@29 lb) 119 kg1262 lb)md full fuel tankStandard tireBridgestone or Bridgestone orYokohama Yokohama3.50H19-

IBalance wwghf80 mm (3.15 anlII(PAGE 40)5-2. REAR WHEELA. Removal (XS650SF only)1. Support the machine on the center stand.2. Disconnect the drive cha

(PAGE 50 - 51)6-1. STARTERA. Armature1.2.Check the outer surface of the com-mutator. If its surface is dirty, cleanwith No. 600 grit sand paper.The mi

1,!Property of www.SmallEngineDiscount.com - Not for Resale

TII i’Oimmarl ii I(PAGE 61 - 62) settings are for dry, clean threads. Torquing7-1. TORQUE SPECIFICATION should always be done to the nut, never theTh

Torque SpecificationsA(Nut)-Property of www.SmallEngineDiscount.com - Not for Resale

IPart to be tightenedIThread dia. and part name1Tightening torqueHandle crown and handlebar holder8 mm boltUnder bracket and inner tube8 mm nut1.8 m-k

1.OESCRIPTION1 I Engine type Air cooled, 4.stroke. SOHC twin,parallel forward incline21 Engine model2FO31 Displacement 653 cc (39.85 cu.in)41 Bore x s

5) Valve timingOPENCLOSE DURATIONOVERLAPIN BTDC360ABDCWz3‘I”720EXBBDCE8°ATDCW284061 Camshaft deflection limit0.03 mm (0.0012 in),,.--i-J-7) Cam chainT

81 Winding0.D.9) idumber of windingslNNER (INIEX): 19.4 mm (0.764 inlOUTER (IN/EX): 32.6 mm il.283 in)INNER (IN/EX): 6.0turnsOUTER (INIEX): 4.25t”rnr1

3) Bearing type: Main axle (Left1(Right1Dr,ve axle (Left)(Right14) Oil seal type Drive axle (Left15) Secondary reduction ratio and method16. SHIFTING

b. To clean the entire chain, first removethe chain from the motorcycle, dip it insolvent and clean with stiff brush. Thentake the chain out of the so

6) Lubrication chart- Pressure feedd---Splash lubricationC. Chassis1. FRAME1) Frame designDouole cradle, high tensile frame2. STEERING SYSTEM1) Carter

5. FUEL TANK11 Capacity2) Fuel grade5. WHEEL1) Type (Front and rear)2) Tire sizeIFrOnt)(Rear)31 Tire pressure:Up to 90 kg (198 lb) load90 kg (198 lbll

31 Rear brake (XS650-2F only)TVPEActuating methodBrake drum I.D.Brake shoe dia. x widthLining thickness/wear limitShoe spring free lengthDrum brake (L

3. STARTER1) srarter motorTvpeManufacturerModeloutputArmature coil resistanceField coil resistanceBrush size/OuantitvWear limitSpring pressureCommutat

Property of www.SmallEngineDiscount.com - Not for Resale

Property of www.SmallEngineDiscount.com - Not for Resale

Property of www.SmallEngineDiscount.com - Not for Resale

Property of www.SmallEngineDiscount.com - Not for Resale

._- ..^_...“..^._I...^ ..__... l^.i ._... “..._ -.I..^-l”..RProperty of www.SmallEngineDiscount.com - Not for Resale

FOREWORDThis Supplementary Service Manual has been prepared to introduce newservice and new data for the XS650G/XS650SG. For complete informationon se

the end of the cable can be held high topour in several drops of lubricant. Withthrottle grip disassembled, coat the insidesurface of the throttle gri

MAINTENANCE AND LUBRICATION CHARTPERIODIC MAINTENANCE EMISSION CONTROL SYSTEMNO. ITEM REMARKSINITIAL BREAK-IN THEREAFTEREVERY1,000 km 5,000 km 4,000 k

15 Batfew,6e AC.GeneratorREMARKSLubricateApply lightlyYamaha chain andcable lube or 1OWl30 motor oilDram completely. Yamaha fork oilRefill to specific

~Yamaha Motor Corporation, U.S.A.. 1979 All rights reoened. Any reprinting or unauthorizeduse without the written permission of Yamaha Motor Corporati

eiYamaha Motor Corporation, U.S.A., 1979 All rights resered. Any reprinting or unauthorizeduse without the written permission of Yamaha Motor Corporat

e. Inspect the starter plunger assembly fordamage. If damaged, replace.f. Float levelHold the carburetor in an upside downposition. Hold the floats so

*ELECTRICALA. IGNITION SYSTEM1Rlneb r4irrnram1protective circuit2. DescriptionThis model is equipped with a batteryoperated, fully transistorized brea

turned on and the crankshaft is notturned, the protective circuit stopscurrent flow to the primary coil withina few seconds. When the crankshaft istur

B. CHARGING SYSTEM1. Block DiagramI.C.VoltageRegulator(with rectifier)L-2.a.1)2)3)A.C. Generator/Voltage RegulatorOutput voltage checkRemove the seat

All three stator windings must bechecked. Also test between each termi-nal and ground. A reading other thaninfinity indicates an improper groundwhich

l SPECl FICATIONA. General*XS650SG only **XS650G onlyII1. MODEL1) Model (I.B.M. No.)2) Basic colorXS650SG (3G1)/ XS650G (3GO)‘CARDINAL RED or NEW YAMA

c. Rust or wear on the breaker arm or armshaft.d. Faulty insulation of the contact brakere2.3.4.assembly.Oil or dirt on the assembly.To clean the poin

1) Piston skin clearance2) Piston oversize0.050 - 0.055 mm (0.0020 - 0.0022 in)(2.963 in) (2.972 in)31 Piston Pin outside diameter x length5. PISTON R

9. VALVE, VALVE SEAT AND VALVE GUIDE1) Valve per cylinder2) Valve clearance Iln cold engine131 DimensionsValve head diameter “A”Valve face width “6”Va

11 Crankshaft deflection limit 0.05 mm 10.002 in)2) Con-rod large end clearance(813) Width of crankshaft4) Crank pin I.D.5) Crank pin O.D. x lengthBig

3) Bearing: Main axle (Left)(Right)Drive axle (Left)(Right)41 Oil seal type Drive axle (Left)5) Secondary reduction ratio and method16. SHIFTING MECHA

61 Lubrication chart---Pressure feede--Splash lubricationC. Chassis1 FRAME1) Frame design2. STEERING SYSTEM1 I caster21 Trail31 Number and size of bal

r4) Shock absorber springFree length226 mm (8.90 in)Wire diameter x winding diameter7.5 x 60.5 mm 10.295 x 2.382 inlSpring constantkl = 1.714 kg/mm 19

7. BRAKE11 Front brakeTypeDisc size (Outside dia. x thickness)Disc wear limitDisc pad thicknessPad wear limitMaster cylinder inside dia.Caliper cylind

3. STARTER1) starter motorTypeManufacturer/ModelOutputArmature coil resistanceField coil resistanceBrush size/QuantityWear limitSpring pressureCommuta

Torque SpecificationsPart to be tightened:Thread dia. and part name Tightening torqueEngine:Cylinder head and cylinder!10 mm nut 3.7 m-kg (27.0 ft-lbl

Part to be tightened Thread dia. and pan name1 Tightening torqueBrake disc and hub B mm bolti 2.0 m-kg (14.5 ft.lb1Caliper and support bracket 8 mm bo

and thechassis lead is for the (-) terminal.Make sure the breather pipe is properlyconnected, properly routed, and is notdamaged or obstructed.NOTE:Th

CONVERSION TABLESrrNoticeThe information presented represents results obtainable by skilled drivers under controlledroad and vehicle conditions, and t

not applicable and is not included)!0 100 200 300(Feet)STOPPING DISTANCE IN FEET FROM 60 MPHACCELERATION AND PASSING ABILITYThis figure indicates pass

Property of www.SmallEngineDiscount.com - Not for Resale

Property of www.SmallEngineDiscount.com - Not for Resale

Property of www.SmallEngineDiscount.com - Not for Resale

Property of www.SmallEngineDiscount.com - Not for Resale

Property of www.SmallEngineDiscount.com - Not for Resale

INDEXThis manual has been combined with previousservice manuals to provide complete serviceinformation for: XS650H/SH.Please read and give special con

FOREWORDThis Supplementary Service Manual has been prepared to introduce newservice and new data for the XS650H/XS650SH. For complete informationon se

Particularly important information is distinguished in this manual by thefollowing notations:NOTE : A NOTE provides key information to make procedures

3-1.3-2.3-3.CHAPTER 3. ENGINE OVERHAULENGINE REMOVAL...A. Preparation for removal...

MAINTENANCE AND LUBRICATION CHARTPERIODIC MAINTENANCE EMISSION CONTROL SYSTEM-3Property of www.SmallEngineDiscount.com - Not for Resale

tccProperty of www.SmallEngineDiscount.com - Not for Resale

*ENGINEA. IGNITION TIMINGThe ignition system is modified for easiermaintenance. Thus, the following “ignitiontiming check” should be changed,Ignition

3. Start the engine and stop it after a fewminutes of run. This procedure is neces-sary to obtain the correct fuel level.NOTE:Make sure the fuel petco

2 With the engine stopped, check the oillevel through the level window located atthe lower part of the right side crankcasecover, or screw the dip sti

*CHASSISA. REAR WHEEL REMOVAL1. Place the motorcycle on the center stand.2. Remove the tension bar and the brakerod from the brake shoe plate. The ten

NOTE:The rear wheel axle nut is located on the rightside.3.4.Loosen the rear wheel axle nut.Loosen the lock nuts on each side. Totighten chain turn ch

E. REAR BRAKE LINING INSPECTIONThe specified thickness of the brake lining is 4mm (0.16 in). The lining should be replacedwhen it wears to less than 2

*ELECTRICAL ed that it can be started only when the trans-mission is in Neutral or the clutch is disengaged.STARTING CIRCUIT CUT-OFF SYSTEMThe startin

2 When the “START” button is pressed,the circuit from the main switch tothe relay - starter switch assembly -“START” (button) is closed, and thestarte

XS650SE SUPPLEMENT(EPA)XS650E SUPPLEMENT*XS650SF USES THIS SUPPLEMENT (EPA)XS650SE SUPPLEMENTIXS650SF/2F SUPPLEMENTXS650G/SG SUPPLEMENTProperty of www

3-4. ENGINE ASSEMBLY AND ADJUSTMENT...29A. Shift...29B. Transmissio

*SPECIFICATIONA. General1. MODEL1) Model (I.B.M. No.)21 Basic color‘XS650SH only**XS650H onlyXS650SH (4M4/XS650H (4N9)*CARDINAL RED or NEW YAMAHA BLAC

4. PISTON1) Piston skirt clearance2) Piston oversize3) Piston pin outside diameter x length5. PISTON RING1) Piston ring design~0.050 - 0.055 mm 10.002

9. VALVE, VALVE SEAT AND VALVE GUIDE~1) Valve per cylinder2) Valve clearance IIn cold engine)3) DimensionsValve head diameter “A”Valve face width “6”V

I. CRANKSHAFT1) Crankshaft deflection limit(A)2) Con-rod large end clearance(B)31 Width of crankshaft(Cl(D)41 Crank p,n I.D.5, Crank piln O.D. x lengt

ctL2) Gear ratio: 1st 32113 (2.461)2nd27/l 7 (1.588)3rd26/20 (1.300)4th23/21 (1.095)5th22/23 (0.956)31 Bearing: Main axle(Left1 Needle bearing (@20-$3

6) Lubrication chart- Pressure feed- -- Splash lubricationC. Chassis1. FRAME1) Frame design2. STEERfNG SYSTEM1) caster2) Trail3) Number and size of ba

4) Shock absorber springFree length~ 226 mm 03.90 in)Wire diameter x winding diameter~7.5 x 60.5 mm (0.295 x 2.382 in)Spring constant! kl = 1.714 kg/m

7. BRAKE1) Front brakeTypeDisc size (Outside dia. x thickness)Disc wear limitDisc pad thicknessPad wear limitMaster cylinder inside dia.Caliper cylind

3.4.2) RegulatorTypeI.C. typeModel/ManufacturerS8515/TOSHIBARegulating voltage14.5 ? 0.3v3) BatteryModel/Manufacturer/QuantityYB14L-AZIYUASAII PC.Capa

5) Flasher relayTypeModel/ManufacturerFlasher frequencyCapacity6) Flasher cancelling unitModelVoltage7) FuseRating/Quantity: MainHeadlightSignalIgniti

CHAPTER 3.ENGINE OVERHAUL31. ENGINE REMOVALA. Preparation for removal1. All dirt, mud, dust and foreign materialshould be thoroughly removed from thee

Torque SpecificationsPart to be tightenedEngine:Cylinder head and cylinderhead coverCylinder headCylinder head cover sideSpark plugGeneratorStator coi

Part to be tightenedBrake disc and hubCaliper and support bracketCaliper and padCaliper and bleed screwFront caliper and front forkMaster cylinder and

CONVERSION TABLESMETRIC TO INCH SYSTEMKNOWN MULTIPLIER 1 RESULTwm-kg 7.233 ~ ft-lb2m-kg 86.80i in-lb!cm-kg 0.0723, ft-lbcm-kg 0.8680i in-lbkgg g~ 2.20

FULL OPERATIONALSERVICE BRAKE(“Partial failure” information isnot applicable and is not included.)0 100 200 300 (Feet)STOPPING DISTANCE IN FEET FROM 6

Property of www.SmallEngineDiscount.com - Not for Resale

3-2 ENGINE DISASSEMBLYA. Governor and breaker assembly removalRemove the following parts in the ordergiven.1. Breaker cover2. Breaker backing plate3.

I. Electric starter unit removal1. Remove the gear train cover, and idle gear1 and 2.1.2.3.4.Push rodBallPush rod (AluminumlPush crown5. Hold the clut

L. Transmission illustration1. Main axle(13T)1’ 1st wheel gear(32T)Transmission2. 2nd pinion gear (17T)2’ 2nd wheel gear (27T)3. 3rd pinion gear (20T)

1. Release the stopper spring (6). 4. Remove the neutral detent unit (15-18). 2. Remove the bolts (1) and stopper plate(3). 5. Removecotter pins (

C. Valve, valve guide and valve seat1. Valve guidea. If the valve guide inside diameter is be-yond serviceable limits, replace with anoversize valve g

width. The valve seat will have removedthe bluing wherever it contacted the valveface. Measure the seat width with verniercalipers. It should measure

c. Another symptom of a fatigued spring isinsufficient spring pressure when com-pressed. This can be checked using a valvespring compression rate gaug

-7Q-t-AIB4. All camshaft bearings should be removed,cleaned, dried, and the races visuallychecked for pits, rust spots or chattermarks where the balls

CHAPTER 1.GENERAL INFORMATIONl-l. MACHINE IDENTIFICATION...a...1l-2.SPECIAL TOOLS...

b. Determine piston clearance as follows:Example:75.02 mm-74.97 mm=0.05 mm piston clearancec. Piston ring/ring groove fit must havecorrect clearance.

2. Check the clearance between outer rotorand inner rotor.Standard clearance:0.03 - 0.09 mm (0.0012 - 0.0035 in)M. Clutch1. Clutch housingCheck dogs o

11. Check to see that each gear properlyengages its counterpart on the shaft.Check the mating dogs for rounded edges,cracks, or missing portions. Repl

4. Make sure all bearings are positioned pro-perly as shown.1. No clearance5. Fit the chain over the cam sprocket,6. Apply Yamaha Bond No. 4 sealant t

n. Pressure plate and clutch springso. Primary drive gearClutch screw torque:IDrive gear torque:/1 .O m-kg (7 ft-lb)9 m-kg (65 ft-lb)a. Plate 1b. Plat

G. Generator1. Lock the crank rotation at the primarydrive gear.2. Reverse the generator removal sequence.H. Oil pumpReverse the oil pump removal sequ

4. Joint the chain together and revet a newlink.5. Install the cam chain tensioner, and adjustchain tension. Refer to PAGE. (8).6. Make sure the timin

CHAPTER 4. CARBURETION4-1. CARBURETOR...3 6A. Description...

Property of www.SmallEngineDiscount.com - Not for Resale

41. CARBURETORA. DescriptionAir flow through the venturi is controlled bya throttle slide (vacuum piston). The slide israised and lowered by engine va

CHAPTER 1. GENERAL INFORMATIONl-l. MACHINE IDENTIFICATION .Frame serial numberThe frame serial number is stamped on the right side of the steering hea

E. Adjustments1. Float level adjustmentMeasure the distance from the bottom ofthe float to the float bowl gasket surface.Bend the tongue on the float

5-1.5-2.5-3.5-4.5-5.5-6.5-7.5-8.5-9.5-10.CHAPTER 5. CHASSISFRONT WHEEL...A. Removal...B.Front axle inspection...

CHAPTER 5.CHASSIS5-l. FRONT WHEELA. Removal1.2.3.4.5.Remove cotter pin from front axle nut.Remove the front axle nut.Loosen the two axle holder nuts a

b. Tighten axle holder nuts. First tighten nuton front end of axle holder, then tightennut on rear end.Holder nut torque:1 .O m-kg (7 ft-lb)E. Install

Property of www.SmallEngineDiscount.com - Not for Resale

B. Caliper disassembly1. Remove caliper brake hose. Allow caliperassembly to drain into a container.2. Place the open hose end into the con-tainer and

3.4.5.6.See “Caliper Replacement Pad” procedurefor parts to be replaced when pads arereplaced.Replace piston and dust seals if damaged.Inspect master

5. Brake disc assemblyIf brake disc has been removed from hubor is loose, tighten bolts. Use new lockingwashers and bend over locking tabs afterbolts

3NOTE:Be sure that all lock tabs are not crackedor broken and that they are all bent UPagainst the bolts.Constant friction and force from thechain cre

A. Removal and disassemblyNOTE:For fork oil replacement only, refer to PAGE(12)1.2.3.4.Disconnect speedometer cable. Disconnectbrake calipers and remo

I7. Rotor puller(90890-01070)10. Drive chain cutter 11. Pocket tester(90890-01081) (90890-03096)13. Vacuum gauge(90890-03094)P8. Clutch holding tool(9

1. Bottom2. TOP5-7. STEERING HEADA.Adjustment(See Chapter 2-4 for Steering Head Adjust-ment.)B. Removal1.2.3.Remove front wheel, front forks andhandle

B. Swing arm removal1. Remove nut on swingtap out bolt with abrass rod.arm pivot bolt anddamping. There should be no noticeablelong aluminum or dampin

CHAPTER 6.ELECTRICAL6-1.STARTER...5 0A. Armature...

CHAPTER 6.ELECTRICAL6-1. STARTERA.Armature1.2.3.4.If the commutator surface is dirty, cleanwith #600 grit sandpaper as shown in thedrawing below.After

Property of www.SmallEngineDiscount.com - Not for Resale

6-2. CHARGING SYSTEMA.Charging circuit diagramL1. Rectifier 4. Load 9. Stator coil2. Fuse 6. Voltage regulator IO. Relay unit3.Main switch 7.A.C. Gene

b. Check the core and points for gap adjust-ment. If any gap is incorrect, it should beadjusted.First adjust the core gap and then1core gap 5. upper c

a. Negligence in keeping battery topped offwith distilled water.b. Battery being left discharged.c. Over-charging with heavy charge.d. Freezing.e. Fil

1. lgnmon coil 3. Orange‘2 Red/whore 4. Electra testerc. Connect fully charged battery to tester.d2.Turn on spark gap switch and increase gapuntil mi

6-4. SPARK PLUGThe life of a sparkplug and its discoloringvary according to the habits of the rider. Ateach periodic inspection, replace burned offoul

CHAPTER 2.PERIODIC INSPECTION AND ADJUSTMENT2-1. INTRODUCTION ... 2-2. MAINTENANCE INTERVAL CHARTS..

B. Reserve lighting system1. Description:The reserve lighting system has twofunctions: (1) It notifies the rider thatone of the head lamp filaments is

C. Self-canceling flasher system3. Circuit diagram.1. DescriptionThe self-cancaling flasher system turns offthe turn signal after a period of time ord

4. Inspection:If the flasher self-canceling system shouldbecome inoperative, proceed as follows:a. Pull off the 6-pin connectar from theflasher cancel

CHAPTER 7. APPENDICES7-1. TORQUE SPECIFICATION ...6 1Torque Specifications...

7-1. TORQUE SPECIFICATIONThe following torque specifications must beadhered to on every machine. When applyingtorque to multi-secured fastener compone

IPart to be tightenedIThread dia. andpart nameITightening torqueIIDelivery pipe/ 10 mm union boltI2.2 m-kg (16 ft-lb)I Exhaust pipe1 Crankcase 1 and

7-2. CONVERSION TABLEMetric to Inch SystemKnownTorquem-kgm-kgMultiplier(Rounded off)Result7.233ft.lbr86.80iwlbsDefinitionof Terms:m-kggkgkmIkm/lcckg/m

7.3. SPECIFICATIONA. General1.12.MODEL1) Model (I.B.M. No.)2) Frame I.D. and starting number3) Engine I.D. and starting numberDIMENSION1) Overall leng

r1) TypeNeedle bearin1) Cam drive type2) Number and type of bearing3) Bearing dimensions25 x 47 x 8 mm IO.984 x 1.850 x 0.315 in)TypePitch/Number of l

IO. VALVE SPRING1) Free length2) Spring rate (kg/mm)3) Installed length (Valve closed)4) Installed pressure (Valve closed)5) Compressed length (Valve

CHAPTER 2.PERIODIC INSPECTION AND ADJUSTMENT2-1. INTRODUCTIONThis chapter includes all information necessary to perform recommended inspection and adj

71 Clutch springFree IengthlDuantity34.6 mm 11.362 in)/6 pa.81 Clutch housing radial play0.027 - 0.081 mm fO.0011 - 0.0032 in)9) Push rod bending limi

3) Oil pump type4) Trochoid pump specificationsTop clearanceTip clearanceSide clearanceOil pump volume5) Bypass valve setting pressure6) Lubrication c

7) Distance from the top of inner tubeti oil level.Approx. 454 mm (17.9 in)without spring4. REAR SUSPENSION1) TypeSwing arm2) Damper typeOil damper, c

7. BRAKE1 I Front brakeTVP~Disc size (Outside dia. x thickness)Disc wear limitDisc pad thicknessPad wear limit (Minimum thickness)Master cylinder insi

4) Voltage regulatorcore gap0.6 - 1 .O mm (0.024 - 0.039 in)Point gap0.3 - 0.4 mm (0.012 - 0.016 in)Voltage coil1o.Q at 20°C (68OF)Resistor10/25R at 2

Property of www.SmallEngineDiscount.com - Not for Resale

Property of www.SmallEngineDiscount.com - Not for Resale

Property of www.SmallEngineDiscount.com - Not for Resale

SupplementaryProperty of www.SmallEngineDiscount.com - Not for Resale

FOREWORDThis Supplementary Service Manual for XS650SE has been published tosupplement the Service Manual for the XS650E (2FO-28197-10) and in-cludes c

6. LUBRICATION INTERVALS, a_:._ Y- ,-mission oilDrive chainControl/MeterApply thoroughlyOil filter elementWheel bearingsDo not over/ Medium-weight 12,

Page numbers shown in brackets correspondto page numbers of the XS650E ServiceManual (2FO-28197-10).(PAGE 4 - 5)2-2. MAINTENANCE INTERVALS CHARTSA. PE

Unit: km (mi)initial Thereafter everyItern RemarksType 400 800 1,600 3,200 1,600 3,200 6,400(250) (500) (1,000) (2.000) (1,000) (2.000) (4.000)Throttl

3.4.Secure the adjuster lock nut.Loosen the brake rod adjuster lock nutand screw brake rod downward untilthere is noticeable free play between rodand

1. Lock nut4. Rear wheel axle nut‘2. Adjuster5. Cotter pin3. Marks for align-CAUTION:Excessive chain tension will overload theengine and other vital p

NOTE:The wheel should be balanced with brake discinstalled.Balance weightE. Installing front wheel4. Always secure the front wheel axle asfollows:Spec

A6LA-A: Pad thickness11 .O mm (0.43 in)6: Wear limit6.0 mm (0.24 in)C: Wear indicatorBack plate(PAGE 48)5-9. REAR SHOCK ABSORBERB. InspectionSpecifica

2. Troubleshooting/inspectionProperty of www.SmallEngineDiscount.com - Not for Resale

LOW BEAM DOES NOTLlGHT WHEN HIGH BEAMIS DEFECTIVEProperty of www.SmallEngineDiscount.com - Not for Resale

To starter relayTo A.C. GeneratorMeter light(PAGE 61- 62)7-1. TORQUE SPECIFICATIONThe following torque specifications must beadhered to on every machi

IPart to be tightened Thread dia. and part name Tightening torqueEngine:Cylinder head and cylinderhead cover10 mm nut 3.7 m-kg (27.0 ft-lb)8 mm bolt 2

2-3. ENGINEA. Carburetor1. Idle mixtureThe idle mixture is set at the factory bythe use of special equipment. No attemptshould be made to change this

Part to be tightened Thread dia. and part name Tightening torqueIPivot shaft 14 mm nutRear wheel axle 16 mm nutTension bar and brake caliper 8 mm nutT

1. PISTON1) Ptston skirt clearance0.050 - 0.055 mm (0.0020 - 0.0022 in)2) Piston oversize7525 mm75.50 mm75.75 mm76.00 mm12.963 InII2972 In)(2 982 In)(

Valve stem diameterIN: 8.0 ~~:~~~ mm (0.315 Ig:Eo in)EX: 8.0 I::$“, mm (0.315 I~:~~~ in)Valve guide diameterEX:8.0 $iiz mm (0.315 :E:EE in)Valve stem

14. CLUTCH1) Clutch type2) Clutch operating mechanism3) Primary reduction ratio and method4) Primary reduction gear back lash (4 teeth)5) Friction pla

4) Trochoid pump specificationsTop clearanceTip clearanceSide clearanceOil pump volume5) Bypass valve setting pressure0.10 - 0.18 mm (0.0039-0.0071 in

Wire diameter x winding diameter 7.5 x 60.5 mm (0.295 x 2.382 in)Spring constantkr = 1.714 kg/mm (96.0 lb/in)/0%45mm(O-1.77in)kz = 2.244 kg/mm (125.7

D. Electrical1. IGNITION SYSTEM1) Ignition timing (B.T.D.C.)2) ignition coilModel/ManufacturerSpark gapPrimary winding resistanceSecondary winding res

2) Starter switchManufacturerModelAmparage ratingCut-in voltageWinding resistance3) Starter clio friction tension4. LIGHTING SYSTEM1) Head light type2

Property of www.SmallEngineDiscount.com - Not for Resale

Property of www.SmallEngineDiscount.com - Not for Resale