Yamaha XS650SG Motorcycle Manuals

Manuals and User Guides for Yamaha XS650SG Motorcycle. We have 1 Yamaha XS650SG Motorcycle manual available for free PDF download: Shop Manual

Yamaha XS650SG Shop Manual

Yamaha XS650SG Shop Manual (215 pages)

Yamaha XS650 Series Motorcycles Shop manual

Brand: Yamaha | Category: Motorcycle | Size: 6.83 MB

Table of Contents

Index
2
General Information
4
Engine Serial Number
5
Frame Serial Number
5
General Information
5
Machine Identification
5
Special Tools
5
Table of Contents
7
Periodic Inspection and Adjustment
7
Chapter 2. Periodic Inspection and Adjustment

8
- Introduction
  8
- Engine
  10
  - Carburetor
    10
    
    Idle Mixture
    10
    
    Synchronization
    10
    
    Air Filters
    11
    
    Cleaning Method
    11
  - Engine/Transmission Oil and Filter
    11
  - Oil Level Measurement
    11
  - Clutch Adjustment
    12
  - Cam Chain Adjustment
    12
  - Mechanism Adjustment
    12
  - Valve Clearance Adjustment
    12
- Chassis
  13
  - Crankcase Ventilation System
    13
  - Fuel Petcock Cleaning
    13
  - Fuel Petcock Disassembly
    13
  - Exhaust System
    13
  - Fuel Hose
    13
  - Front Brake
    14
  - Rear Brake
    14
  - Brake Pad Check
    14
  - Wheels and Tires
    14
    
    Check the Tire Wear
    15
    
    Drive Chain
    15
    
    Tension Adjustment
    15
  - Front Fork Oil Change
    16
  - Steering Head
    16
- Electrical
  17
  - Contact Breaker Point Adjustment
    17
  - Contact Breaker Point Maintenance
    17
  - Lubrication of Cables, Pivots, Etc.
    17
  - Battery
    18
  - Carbon Brushes
    18
  - Headlight
    19
    
    Spark Plug
    19
    
    Engine Overhaul
    20
Chapter 3. Engine Overhaul

22
- Engine Mounting Bolts and Engine Removal
  22
- Engine Removal
  22
- Fuel Tank Removal
  22
- Preparation for Removal
  22
- Removal of Other Parts
  22
- Cylinder Head and Cylinder Removal
  23
- Engine Disassembly
  23
- Generator Removal
  23
- Governor and Breaker Assembly Removal
  23
- Piston Removal
  23
- Primary Drive Gear and Clutch Assembly Removal
  23
- Rocker Arm Removal
  23
- Valve Removal
  23
- Crankcase Disassembly
  24
- Electric Starter Unit Removal
  24
- Kick Axle and Change Shaft Removal
  24
- Oil Pump Removal
  24
- Shift Drum Removal
  25
- Transmission Illustration
  25
  - Crankshaft Illustration
    26
  - Inspection and Repair
    26
- Crankshaft Removal
  26
  - Cylinder Head Cover
    26
  - Measuring the Clearance between Valve and Valve Guide
    27
  - Valve, Valve Guide and Valve Seat
    27
    
    Lapping the Valve/Valve Seat Assembly
    28
    
    Valve Leakage Check
    28
    
    Valve Spring
    28
  - Camshaft Wear
    29
  - Rocker Arm and Rocker Shaft
    29
  - Valve Spring Specifications
    29
  - Cam Chain, Sprocket and Dampers
    30
  - Cylinder
    30
  - Piston and Piston Rings
    30
  - Crankshaft
    31
  - Oil Pump
    31
    
    Piston Pin
    31
    
    Piston Ring
    31
    
    Small End Play
    31
    
    Clutch Boss
    32
    
    Clutch Housing
    32
    
    Clutch Push Rod
    32
    
    Clutch Springs
    32
  - Transmission
    32
  - Bearings and Oil Seals
    33
  - Crankcase and Oil Passages
    33
    
    Engine Assembly and Adjustment
    33
    
    Kick Clip Spring
    33
    
    Kick Gears
    33
    
    Kick Starter
    33
    
    Clutch
    34
    
    Electric-Starter Gear Assembly
    34
    
    Kick Starter Assembly
    34
    
    Shifter Assembly
    34
    
    Generator
    36
    
    Oil Pump
    36
    
    Piston
    36
    
    Right-Hand Crankcase Cover
    36
    
    Cylinder Heed Cover
    37
    
    Governor and Breaker Assembly
    37
    
    Carburetion
    38
    
    Float System
    39
  - C a R B U R E T O
    40
  - Idle System
    39
  - Main Metering System
    39
  - Starter System
    39
Chapter 4 . Carburetion

40
- Description
  40
- Specifications
  40
- Disassembly
  40
- Float Level Adjustment
  41
Chapter 5. Chassis

43
- Front Axle Inspection
  43
- Front Wheel Inspection
  43
- Installing Front Wheel
  43
- Removal
  43
- Replacing Wheel Bearings
  43
- Brakes
  44
- Caliper Pad Replacement
  44
- Installing Rear Wheel
  44
- Rear Axle Inspection
  44
- Rear Wheel Inspection
  44
- Removal
  44
- Replacing Wheel Bearings
  44
- Brake Inspection and Repair
  46
- Caliper Disassembly
  46
- Master Cylinder Disassembly
  46
- Brake Reassembly
  47
  - Air Bleeding
    48
  - Installation
    48
  - Tire, Tube Removal
    48
  - Wheel Inspection
    48
  - Front Forks
    49
  - Assembly
    50
  - Inspection
    50
  - Removal and Disassembly
    50
  - Adjustment
    51
  - Inspection
    51
  - Reassembly
    51
  - Removal
    51
  - Steering Head
    51
  - Swing Arm
    51
  - Cablemaintenance
    52
  - Cables and Fittings
    52
  - Inspection
    52
  - Rear Shock Absorber
    52
  - Swing Arm Lubrication
    52
  - Swing Arm Removal
    52
  - Throttle Maintenance
    52
  - Armature
    54
  - Starter Relay Switch
    54
  - Yoke
    54
- Brake Disc Assembly
  48
- Rear Wheel Sprocket
  48
- Wheels, Tires, Tubes
  48
Chapter 6. Electrical

54
- Starting Motor
  55
- A.C.generator
  56
- Charging Circuit Diagram
  56
- Charging System
  56
- Voltage Regulator
  56
- Battery
  57
- Checking Silicon Rectifier
  57
- Governor Assembly
  58
- Ignition Circuit Diagram
  58
- Ignition System
  58
  - Spark Gap Test
    58
  - Condenser Test
    59
  - Insulation Test
    59
  - Lighting and Signal Systems
    60
  - Lighting Tests and Checks
    60
  - Spark Plug
    60
- How to "Read" a Spark Plug (Condition)
  60
CHAPTER 7 Appendices

64
- Torque Specification
  65
- Conversion Table
  67
- Metric to Inch System
  67
- Inch to Metric System
  67
- Definition of Terms
  67
- General
  68
- Engine
  68
  - Cable Routing Diagram
    76
  - Circuit Diagram
    78
  - Xs650E
    79
  - General Maintenance/Lubrication
    81
  - Maintenance Interval Charts
    81
  - Periodic Maintenance Emission con Trol System
    81
  - Xs650G
    84
  - Xs650Sg
    84
  - Ignition Timing Adjustment
    88
  - Ignition Timing Check
    88
  - Pick-Up Coil Assembly
    88
  - Ignition System Block Diagram
    91
  - Chassis
    104
    
    Torque Specifications
    104
    
    Color Code
    108
    
    Wiring Diagram
    108
    
    Cable Routing XS650G/XS650SG
    110
    
    Xs650H
    112
    
    Xs650Sh
    112
  - Electrical
    124
  - Consumer Information
    138
  - Xs650Se
    141
  - Xd650Sf
    190
  - Xs650-2F
    190

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