Archive for the ‘Manual – Other’ Category

XS650: Engine Nuts n Bolts   Leave a comment

Been thinking about tarting one of the old girls up a little. Nuts n Bolts. But which?

Alu?

Stainless Steel?

Titanium?

Phillips Screw type?

Hex socket(Allen key)?

Hex Head?

Race Spec?

Not racing so I dont need them drilled. Weight isn’t really a factor so I can’t justify the expense of Titanium. Aluminium? Stainless steel?

Pro Bolt has an interesting selection. Outlets in the UK, USA, Australia, Germany, Denmark, France, South Africa.

 

1 .. aluminium, hex socket – allen key … gold, silver, red, purple, orange, grey, black, blue

aluminium, hex socket – allen key … gold, silver, red, purple, orange, grey, black, blue

 

2 .. stainless steel … hex socket - tapered head (allen key)

stainless steel … hex socket – tapered head (allen key)

 

3 .. stainless steel ... flanged head hex bolt

stainless steel … flanged head hex bolt

 

4 .. Titanium … race spec – drilled ... flanged head hex bolt ... silver, purple, gold, blue

Titanium … race spec – drilled … flanged head hex bolt … silver, purple, gold, blue

 

5 .. aluminium … race spec – drilled ... hex bolt

aluminium … race spec – drilled … hex bolt

 

6 .. titanium banjo bolt - single ... 10mm - hex socket (allen key)

titanium banjo bolt – single … 10mm – hex socket (allen key)

 

 

Next problem. List of required items. Went through an old engine. Put this list together…Haven’t checked it right through so may not be 100% correct. XS650E.

5.0 x 0.8mm
   Alternator Cover

2

5 X 10 Hex socket
   Carb Top

8

5 x 16 Phillips

Washer

8

5mm Plain
6.0 x 1.0mm
HEAD:
   Breather Box

4

4

6×60(large)

6×25(small)

Hex Socket
   Points/ATU Cover

4

6 x 20
   Bolt

1

6 x 35 Hex Bolt

Washer

   1 6mm Plain
   Tri. Tappet Cover

9

6mm Crown Nut

Washer

9

6mm Plain
BARREL:
   Cam Chain Adj

4

6 x 18 Hex Bolt
   .. with shoulder

2

6 x 19 Hex Bolt

Washer

6

6mm Plain
   Front Guide

2

2

6x20M10-special Hex Bolt

Washer

Washer

2

2

6mm/11mm Copper-Plain
   Carb Boot

4

6 x 20 Hex Socket
CRANKCASE:
   Starter Cover

6

6 x 25 Hex Socket
   Oil Sump Cover

6

6 x 25 Hex Socket
   Gear Lever

1

6 x 20 Hex Bolt
ALTERNATOR  SIDECASE:

4

6 x 25 Hex Socket
   Bolt

2

6 x 40 Hex Socket
CLUTCH  SIDECASE:

4

6 x 75 Hex Socket
   Bolt

1

6 x 40 Hex Socket
   Bolt

7

6 x 25 Hex Socket
8.0 x 1.25mm
HEAD:
   Squ. Tappet Cover

4

8mm Crown Nut
   Bolt

4

8 x 60 Hex Bolt
   Bolt

2

8 x 35 Hex Bolt

Washer

10

8mm Plain
CRANKCASE:
   Bolt

2

8 x 75 Hex Bolt
   Bolt

1

8 x 55 Hex Bolt
   Bolt

1

8 x 90 Hex Bolt
   Nut

8

8mm Short Open
   Nut

6

8mm Long Crown

Washer

12

8mm Plain
Kickstart

1

8 x 30 Hex Bolt
Starter

2

8 x 35 Hex Bolt
Starter

2

8 x 35 Hex Bolt-flank

Washer

4

8mm Plain

Washer

4

8mm Spring
10 x 1.25mm
HEAD:

8

10mm Crown Nut

Washer

8

22×10.5x4mm Copper/Brass Plain
Banjo Bolts ..Oil

2

10mm Single

Washer

4

10mm Copper Plain
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Posted February 29, 2012 by xscafe in Manual - Other, Motor - Cases

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XS650: XS1B Motor Schematic   Leave a comment

It’s a better machine. The way it should be. When you know how they’re built. Traditional and tough.

Simply the best!

 

XS1B graphic … motor schematic for the Yamaha 50th

XS1B graphic … motor schematic for the Yamaha 50th

Posted February 11, 2012 by xscafe in Frame - Design, Manaul - Literature, Manual - Other, Motor - Cases

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XS650: Model, Year, Model code, Engine Number   Leave a comment

I made this list up some years ago. This version is arranged in Model Code numeric sequence. This code is found on the steering stem ID/VIN plate and Registration Papers. This is not necessarily the same as the first 3 places of the Engine Number.

MODEL       YEAR       MODEL CODE          ENGINE NUMBER

XS-B            75-76                 533                        447-500101

I’m sure it’s not complete. May include errors. If you have a machine with a model code not listed here let me know.

 

… by model code – page 01

 

… model codes – page 02

 

Or here listed by Engine Number.

… by engine number – page 01

 

by engine number – page 02

 

As you can see, there are questions. (???)

… my original tables included these model code/engine number combinations … they are not however confirmed by Yamaha … if you have a machine covered by one of these please let me know and I will reinclude it in the above tables

 

Have a Model Code that’s not listed here? Let me know.

I wish to get an idea of production runs. The engine numbers in the above tables are arranged so … 447-300101 to (400000). I have the start number for each model. Yamaha have given the absolute end number-these are in brackets. Not necessarily the real end number. Where I know this I have entered it without brackets … 2F0-000101 to 006141. The information is from Yamaha Publication #12100-100E1.

I’m looking for approximate end numbers. If you want you could leave me your model and engine number. No Name. No address. When left in the comment box below no one will see it.

XS650: OU/OW72 Heads   1 comment

Was discussing XS650 heads earlier. The major limitation to developing horsepower in our beloved engines (developing hp is a different topic to actually reliably and effectively getting it to the rear wheel).

Design limitations are found in exhaust port shape and cross sectional area-too large. Inlet ports could be smaller and would be better inclined downwards. The ‘Yamaha Racing Tips’ manual produced in 73 also recommends pocket porting-careful removal of material around the valve seats.

 

XS750(650) Racing Special

XS750(650) Racing Special

 

XS750(650) Racing Special

XS750(650) Racing Special .. valve springs

 

The legendary dirt track battles between Yamaha and HD highlighted these limitations to the extent that for the ’76 season USYamaha brought in Tim Witham. The OW72 (I have seen these called OU72 and OW72-this would indicate 2 separate programmes-as far as I know this was a 1 off so I will, for continuity, use OW72) was developed. Didn’t stop the Harleys. Kenny Roberts lost the AMA Grand National Championship to Gary Scott. Time was short. Frames not properly set up. Shell Thuets eye for detail and reliability was missing too.

Still, from Roberts: ‘Best thing I ever rode’

Surprizingly Yamaha Japan had accepted Withams challenge to produce a new head. Probably as an R&D exercise for future 4 stroke engines. Kept King Kenny happy too. The head was cast totally different to the production ones. To accomodate the steeper valve angles ( racing: 56° production: 76° … inlet: OW72 – 43mm, prod’n – 41mm; exhaust: OW72 – 37mm, prod’n – 35mm) the heads were higher and the rockers shorter, enabling a lower rocker cover. Overall engine height was the same. Interchangeable with production motors.

The heads arrived from Japan in dribs and drabs. No ports, guides, valves, springs, cams. The engines had larger crankpins, improved pistons, rods,  gearboxes, clutches and deeper sumps. I can imagine the stress. Modern business practice could learn a thing or two from this about networked local sourcing for local consumption.

 

OW72 Head vs OEM .. OEM left … OW72 head, right … note, OW72: larger cooling fins, inlet ports 5mm wider apart

OW72 Head vs OEM .. OEM left … OW72 head, right … note, OW72: larger cooling fins, inlet ports 5mm wider apart

 

XS1 rockerbox sitting on an OW72 head

XS1 rockerbox sitting on an OW72 head

 

OW72 vs OEM rocker .. shorter due to the altered valve angle and head configuration

OW72 vs OEM rocker .. shorter due to the altered valve angle and head configuration

 

Racing combustion chambers were hemispherical, aluminiun, with steel valve seat inserts. Production heads had a steel cap cast into the alu and valve seats were cut directly into this.

 

OW72 - no steel cap - alu combustion chamber with steel valve seat inserts

OW72 – no steel cap – alu combustion chamber with steel valve seat inserts

 

OW72 inserts direct in alu head

OW72 inserts direct in alu head

 

XS1 heads showing the steel cap containing the combustion chamber ... valve seats are cut directly into this

XS1 heads showing the steel cap containing the combustion chamber … valve seats are cut directly into this

OW72 inlet port

inlet port

 

OW72 inlet port

inlet port

 

OW72 exhaust port

exhaust port

 

Cycle World wrote an article about the development of these motors in their Aug 76 issue.

Original consensus is that 25 of these were produced. AMA homolugation rules required 1 complete bike and 24 engines and transmissions.

‘In order to be approved, a motorcycle must be a standard catalogued production model, one complete motorcycle produced, race ready, and at least 24 identical engines and transmissions must be available for inspection and purchase within the United States.’

There seems to be more (?). There is some confusion about this. It seems that Don Vesco produced some tuned heads back in the 70’s based on production heads and TRD valves. 650 Central sells your production heads CNC machined to tuner Lillies’ racing specs (these are your remanufactured production heads NOT ‘Yamaha’ racing heads).

70 hp motors appear to be relatively reliable. 75 hp motors not so.

I have seen several other attempts to address this problem, including homemade cast heads and machined billet heads. Of course, head modifications increasing available hp will expose shortcomings in other parts of the drive train, namely crankcases, crankshafts, clutches……………..How deep are your pockets?

Posted September 13, 2011 by xscafe in Frame - Design, Manaul - Literature, Manual - Other, Motor - Head

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XS650: Shell Service Guide   Leave a comment

Shell Marketing getting in on the action. 11/75.

 

shell service guide

shell service guide

 

 

shell XS500 ... XS650

XS500 … XS650

 

 

XS650 shell service guide

XS650: Warranty Claim Info   Leave a comment

This was interesting. The grounds for warranty claims. And what was not covered. Also the accepted Labour Allocations.

For times follow column K.

 

… will turn this into a pdf and reload …

Posted March 15, 2011 by xscafe in Manual - Other, Manual - Workshop

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XS650: Nuts and Bolts from 1975   Leave a comment

This may be interesting to restorers and others with an attention to detail…

Nuts

Bolts

Old – New X reference … Nuts

Old – New X reference … BoltsNew – Old X reference … Nuts

New – Old X reference … Bolts

 

… will turn this into a pdf and reload …

Posted March 15, 2011 by xscafe in Manual - Other

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